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Generac 004583-0 Portable Generator User Manual

1. SUPPLIED BY CUSTOMER 12V BATTERY SM O O SUPPLIED BY CUSTOMER f 13 SC 16 11S 4 OK 6 2A TOS ELECTRONIC 4 VOLTAGE 16 16 O REGULATOR 22S 13 SCR 13 A B El El 2A 0 16 BH 0 J3 us 15 J2 14 J1 1 56 J1 2 O 90 J1 3 O 2A n J1 4 O 18A J1 5 O 11S J1 6 O 17 17 PCB J1 7 O 17 ma sra O CLOSEST TO BEARING J1 9 O1 4 J1 10 O 66 A J1 11 OH 85 90 a J1 12 O 0 J1 13 O 16 2A 14 i EEn E i C FIELD oF 3 CB3 gt 77 22P 2 BCR k 44 55 2A END 66 11
2. 38 Section 11 Exploded Views and Parts Lists 40 d INPEAU ULM 52 Generac Power Systems Inc AFETY RULE d veo Safety Rules QUIETPACT 55 65 and 75 Recreational Vehicle Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe A WARNING A The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm A WARNING A This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions Generac cannot possibly anticipate every possible circumstance 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 you use a procedure work method or operating tech nique Generac does not specifically recommend you must satisfy yourself that it is safe for you and others You also must make sure the procedure work method or operating technique that you choose does not render the
3. CONTROL CENTER START 0E0580 REV B PRIM E PRESS PRIME SWITCH FOR 10 SECOND BEFORE STARTING WHEN STARTING DO NOT PRESS START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT Generac Power Systems Inc 7 OPERATION Section 2 Operation 15 QUIETPACT 55 65 and 75 Recreational Vehicle Generators 2 2 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel Figure 2 2 is available that allows you to start and stop the gener ator engine conveniently from inside the vehicle The remote panel includes a Start Stop switch hourme ter generator run lamp and a wire harness Figure 2 2 Optional Remote Panel Models 004057 and 004184 E c MOBILE CE 2 5 AUTOMATIC CHOKE This engine is equipped with an automatic choke that consists of two main components a choke solenoid and prechoke 2 5 1 CHOKE SOLENOID During engine cranking Start Stop switch at START a solid state choke module signals the choke solenoid to activate and cycle choke on choke off until the engine starts The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking When the engine starts the choke stops cycling 2 3 2 PRECHOKE The choke system also has a
4. GUARDIAN by by Generac Power Systems Inc Power Systems Inc RY Owner s Manual Air cooled Recreational Vehicle Generators QUIETPACT 55 65 and 75 e Models 004702 0 004703 0 004704 0 004705 0 004706 0 amp 004707 0 This manual should remain with the unit INTRODUCTION READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual contact Generac or your nearest Generac Authorized Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or care lessly Observe them carefully Their definitions are as follows A Da A After this heading you can read instructions that if not strictly complied with will result in personal injury including death and property damage WARNING amp After this heading you can read instructions that if not strictly complied with may result in person al injury or property damage caution amp After this heading you can read instructions that if not strictly complied with could result in dam age to equipment and or property NOTE After this heading you can read explanatory statements that require special emphasis These safety warnings cannot elimin
5. INSTALLATION Hh Section 6 Installation Line T1 red to T2 white is protected against over load by a circuit breaker CB1 Use this line to neu tral connection separately to operate 120 volt single phase 60 Hertz AC loads Line T3 black to T2 white also is protected against overload by a circuit breaker CB2 Use this line to neutral connection separately to operate similar loads However be sure the total unit load does not exceed the maximum rat ing of the generator The neutral line T2 white on all units is a grounded neutral caution amp Do NOT connect electrical loads in excess of any circuit breaker rating or you will develop problems with circuit breaker tripping which causes a loss of AC output Also do NOT exceed the generator s rated wattage capacity Add the watts or amperes of all lighting appli ance tool and motor loads the generator will operate at one time This total should be less than the unit s rated wattage amperage capaci ty 6 7 4 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The following general rules apply Cut wiring to the required length and allow extra wire for junction box connections e Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation Route conduit so it does not interfere with genera tor movement e If you use metallic conduit vapor sea
6. NUT FLG 5 16 18 LOCK SCREW HHC 3 8 24 X 2 1 4 G8 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC SCREW TAP R 10 32 X 9 1 BLOWER HOUSING GTV760 RV SCREW HHC 3 8 24 X 1 G5 WASHER LOCK 3 8 WASHER FLAT 406ID X 1 620D SET BLOWER HOUSING GASKET BELT V RIB 4LX42 5 BUSHING SNAP GASOLINE ONLY PLUG PLASTIC 0 687 LP ONLY STUD M6 1 0 OFFSET ELEMENT AIR FILTER PRECLEANER AIR GTH990 GASOLINE FILTER GASKET RV GASOLINE ONLY FILTER GASKET RV LP ONLY WASHER FLAT 281 ID X 1 25 0D NUT WING M6 1 0 NUT FLANGE M6 1 0 NYLOK GASOLINE ONLY NUT FLANGE M6 1 0 NYLOK LP ONLY FILTER FUEL 1 8P 5 16H GASOLINE ONLY ASSEMBLY NON SHTOFF FUEL PUMP GASOLINE ONLY ASSEMBLY RV V TWIN FUEL LINE GASOLINE ONLY GROMMET 38 1 DIA CROSS SLIT GASOLINE ONLY PLUG PLASTIC 1 50 LP ONLY WASHER LOCK SPECIAL 1 4 SCREEN SPARK ARRESTOR RETAINER SPARK ARREST SCREEN SCREW HHTT M4 0 7 X 8 BP Generac Power Systems Inc 41 Qi As Section 11 Exploded Views and Parts Lists QUIETPACT 55 65 and 75 Recreational Vehicle Generators Ko Enclosure Drawing No 0E1011 B 4190 oe GROUND TO CONT PANEL pcc T p 33 E 1g 2f 30 3 HF 26 34 lt P TO STARTER U 25 307 Ye DN 35 1j c a V 30 4 42 Generac Power Systems Inc Section 11 Exploded Views and Parts Lists Qi us QUIETPACT 55 65 and 75 Recreationa
7. e throb bing temples f dizziness g headaches h weakness and i sleepiness IF YOU EXPERI ENCE ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PER SIST GET MEDICAL HELP Shut down the gener ator and do not operate it until it has been inspect ed 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 Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or per mit 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 you are physically or mentally fatigued e Inspect the generator regularly and contact your nearest Generac Authorized Service Dealer imme diately fo
8. ment of the regulator valve The more the regulator valve opens the greater the gas flow that is propor tional to airflow through the generator The following facts about the secondary regulator must be emphasized The regulator must be sensitive to venturi throat pressure changes throughout the operating range The regulator must be properly adjusted so it will stop the flow of gas when the engine is not running no air flow through the carburetor The slightest airflow and vacuum in the venturi throat should move the regulator valve off its seat and permit gas to flow 6 5 7 FUEL SUPPLY LINES LP gas lines must be accessible but protected against possible damage Do NOT connect electrical wiring to any LP 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 nonmetallic nonorganic and nonconductive It must be approved for use with LP gas A N A A Gaseous fuel lines between the tank and the 3 secondary regulator are under a positive pres sure about 11 inches water column Gas pres sure at the outlet side of the secondary regula tor however is a negative pressure and can draw flame inside a line or fitting and cause an explosion 6
9. po BRP BRB BB Pp HH S S P HSH SH pP SH BS BS BS Sa SS ko ss ss ROO PO SBS SS eS es a a pm aa PO a o PARTS ib ies O DESCRIPTION BRACKET CHOKE LP ONLY RHMS 4 40 X 5 16SEMS SPRING CHOKE RETURN WRAP VALLEY UPPER SPCC WRAPPER UPR 1 W M8 WELD NUT WRAP VALLEY GTV760 RV SPCC WRAPPER UPR 2 W M8 WELD NUT ASSY GROUND WIRE GV990 INSULATOR ASM IGN ASSY IGNITION COIL GT760 RV WASHER LOCK M6 1 4 SCREW HHTT M6 1 0 X 25 BP O RING 59 92 X 66 98 X 3 53MM O RING 21 89 X 27 13 X 2 62MM KEY WOODRFF 4 X 19D ADPTR OIL PAD FLARE TUBE ENGINE OIL RETURN TUBE ENGINE OIL OUT O RING 20 35 X 23 91 X 1 78MM BOLT OIL ADAPTOR WRAP CYL 2 GTV760 RV SPCC INTAKE TUBE 1 25 X 20 GA HOSE CLMP BAND 1 5 8 BOOT INTAKE AIRBOX BOOT CARB ADAPTOR BOLT CARB MOUNT M6 X 1 0 85LG ADAPTER AIR INTAKE CARB GASKET CARB TO ADAPTOR CARBURETOR GT 760 GASOLINE ONLY CARBURETOR GT 760 LP ONLY GASKET CARB TO INTAKE MANIFOLD GASKET INTAKE PORT GT990 MANIFOLD INTAKE 760 RV SCREW SHC M8 1 25 X 30 G12 9 WASHER FLAT M8 SS WASHER LOCK M8 SS BARBED STR 1 4NPT X 3 8 W VS CLAMP HOSE 15 5 62 62 HOSE 3 8 IDX6 L 300F COOLER OIL GV 990 DUCT OIL CLR GTV760 RV SPCC PLASTITE 1 4 15 X 34 SCREW PPHM 10 32 X 3 8 SCREW HHTT 44 40 X Ya PLATE THROTTLE WASHER LOCK 10 NUT HEX 10 32 STEEL SCREW HHC M6 1 0 X 12 G8 8 WASHER FLAT M6 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHTT M5 0 8 X 8 BP CLAMP HOSE 8 53
10. 1 00 LP ONLY HOSE 1 2 ID LP ONLY SCREW PPHM M4 0 7 X 16 GASOLINE ONLY CLIP J VINYL COAT 375 ID GASOLINE ONLY WASHER FLAT 8 GASOLINE ONLY WASHER LOCK 8 GASOLINE ONLY NUT HEX M4 0 7 G8 YC GASOLINE ONLY SCREW HHTT M6 1 0 X 16 YC CLAMP VINYL 1 06 X 406 LP ONLY WASHER FLAT 1 4 M6 LP ONLY SCREW HHTT M6 1 0 X 12 LP ONLY Generac Power Systems Inc 45 i As Section 11 Exploded Views and Parts Lists QUIETPACT 55 65 and 75 Recreational Vehicle Generators Ko Control Panel Drawing No 0E1013 A S NON NEON E NON A N NJ NON NN ON KOON NN N ON XN N YON N NS N Se ON NOS NR MEN ES N SON f RON 46 Generac Power Systems Inc Section 11 Exploded Views and Parts Lists PARTS Ce LISTS QUIETPACT 55 65 and 75 Recreational Vehicle Generators Control Panel Drawing No 0E1013 A O ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0C2375 2 SCREW HHC M8 1 25 X 90 G8 8 34 054502 1 CIRCUIT BREAKER 3 X 1 2 022145 2 WASHER FLAT 5 16 M8 ZINC 35 031879 4 WASHER FLAT 4 ZINC 3 029459 2 TENSION SPRING 36 043182 4 WASHER LOCK M3 4 075215 2 WASHER SPRING CENTER 37 051714 4 NUT HEX M3 0 5 G8 YEL CHR 5 052858 6 NUT LOCK FL M8 1 25 38 092234 1 ASSY POTTED RV CNTL 6 047411 7 SCREW HHC M6 1 0 X 16 G8 8 39 049226 5 WASHER LOCK M5 7 022097 13 WASHER LOCK M6 1 4 40 051716 3 NUT HEX M5 0 8 G8 YEL CH
11. 25 mm 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 30 Generac Power Systems Inc QUIETPACT 55 65 and 75 Recreational Vehicle Generators e 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 that can be opened or is not permanently sealed from the vehicle interior e Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all applicable codes standards and regula tions 6 7 ELECTRICAL CONNECTIONS Be sure to read Section 5 6 o
12. Generac Power Systems Inc 53 Section 12 Warranty WARRANTY QUIETPACT 55 65 and 75 Recreational Vehicle Generators GENERAC POWER SYSTEMS THREE YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS NOTE ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES For a period of 3 three years or 2 000 two thousand hours of operation from the date of original sale whichever occurs first Generac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspec tion 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 trans portation 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 This warranty is effective only upon Generac s receipt from the original purchaser owner of a completed Warranty Registration Card This card is the only valid registration identification and must be presented at time of request for warranty service Claims wi
13. LP Regulator Drawing No 0E1530 DESCRIPTION CASTING TWIN REGULATOR HOUSING SCREW PPHM M4 0 7 X 10 WASHER LOCK 8 M4 WASHER FLAT M4 SOLENOID TWIN REGULATOR SPRING SOLENOID PLUNGER PLUNGER LP REG ASSY GASKET SOLENOID INLET TWIN REGULATOR NO HOLE PLUG EXPANSION 16MM TWINREG BARBED STR 1 2 X 1 2NPT W VS PLUG STD PIPE 1 8 STEEL SQ HD WASHER FLAT 3 2MM ID X 10MM OD SCREW PFILHM M3 0 5 X 5 SPRING REGULATOR 45N M 32MM 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 age LISTS Generac Power Systems Inc 51 Section 12 Warranty WARRANTY QUIETPACT 55 65 and 75 Recreational Vehicle Generators 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
14. Phase 6 Hertz 11 y 15 Behind Access Panel REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake Screen 11 Fuel Pump Behind access panel 2 Data Plate 12 Oil Filter 3 Engine Start Stop Switch 13 Oil Drain Plug 4 7 5 amp Fuse 14 Oil Dipstick and Filler Tube 5 Circuit Breaker 15 Air Filter Behind access panel 6 Optional Remote Panel Receptacle 16 Spark Plugs 7 Generator AC Output Leads 17 Exhaust Outlet 8 Starter Contactor 18 Fuel Filter 9 FuelInlet 19 LP Fuel Inlet 10 Fuel Primer Switch e Generac Power Systems Inc 1 2 GENERATOR APPLICABILITY These generators have been designed and manufac tured for supplying electrical power for recreational vehicles You should not modify the generator or use it for any application other than for what it was designed If there are any questions pertaining to its application write or call the factory Do not use the unit until you have been advised by competent authority A DIG A For fire safety the generator must have been fo properly installed in compliance with 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 instruc tions After installation do nothing that
15. VEHICLE AC DISTRIBUTION PANEL Generac Power Systems Inc 33 INSTALLATION TED Section 7 Post Installation 6 9 OPTIONAL ACCESSORIES A plug in receptacle Figure 6 22 is provided on the generator set above the muffler enclosure Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit you to start and stop the genera tor engine from any convenient location inside the vehicle Figure 6 22 Remote Panel Plug in Receptacle a VO A 0 Oo 00 e 00 12 00 WIRE WIRE No Coton LENGTH mm FUNCTION 0 WHITE 12 0 305 GROUND 14 RED 12 0 305 ENGINE RUN SIGNAL 15 ORANGE 12 0 305 12 VDC 17 YELLOW 12 0 305 START 18 BROWN 12 0 305 STOP 14A BLUE 12 0 305 PRIME P N 0D9099 B 6 9 1 REMOTE PANEL MODELS 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 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 7 1 POST INSTALLATION TESTS The air cooled generator set was factory tested and adjusted You should not be required to adjust the unit any further except under
16. separate fuel pickup tubes are required for the engine and the generator Generac recommends that you make the fuel pickup tube 2 to 3 inches 51 to 76 mm shorter than the vehicle engine s pickup tube This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods caution amp A Do NOT tee the generator fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not run ning generator operation may drain the vehi cle engine supply line making it difficult to start the vehicle engine 6 4 2 GENERATOR FUEL SUPPLY LINE 6 4 2 1 Rigid Fuel Lines Those lines used to supply fuel from a tank to the generator must comply with applicable codes stan dards and regulations The following general rules apply to rigid fuel lines Rigid lines should be of annealed seamless drawn aluminum or steel e Lines and fittings must comply with SAE J512E Standard Automotive Fittings or with ANSI B126 26 latest edition Route the fuel line so that at least 2 inches 51 mm of clearance is maintained between the line and any exhaust system parts Do not attach electrical wiring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so if they leak fuel does not drip onto any electrical
17. unsealed batteries to the proper level with distilled water DO NOT USE TAP WATER IN THE BAT TERY Recharge the battery to 100 percent state of charge or if defective replace the battery 3 Clean and wipe the entire generator 4 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 5 Turn OFF all electrical loads Add fuel if neces sary and then start the engine 6 Allow the unit to warm up thoroughly 7 Apply electrical loads to at least 5O percent of the units rated wattage capacity 8 When the engine is thoroughly warmed up shut it down 9 Your generator is now ready for service 3 13 RV GENERATOR SERVICE INTERVAL QUIETPACT 55 65 75 DO TOUS oc da ddr DIE Clean Spark Arrestor lst 50 Hours then every 500 Hours Adjust Valve Lash LOO SHOUTS id Change Engine Oil Filter LOO QUES dia Clean Air Pre filter LOO QUES beciwesotvenioseiedexbouoaavels Inspect Spark Plugs 250 Hours Replace Paper Air Filter Element TOO EIOUES ie Replace Fuel Filter DOO HOTS 1i dtt eines Replace Spark Plugs Generac Power Systems Inc 15 NOTES Section 4 Notes QUIETPACT 55 65 and 75 Recreational Vehicle Generators 16 Generac Power Systems Inc PART Il INSTALLATION INSTRUCTIONS AFETY RULE d veo Safety Rules QUIETPACT 55 65 and 75 Recreational Vehicle Generators DANGER For fire safety installation of a generator int
18. 67 cubic feet per hour If an existing primary gas regulator does not have a sufficient flow capacity for the generator and other gas appliances in the circuit a install a pri mary regulator with adequate flow rate or b install a separate regulator only and rated at least 67 cubic feet per hour The inlet side of any pri mary regulator that supplies the generator must connect directly to a gas pressure tank Do NOT tee the generator line into a gas circuit feeding other areas 6 5 6 GASEOUS CARBURETION LP gas vapors should be supplied to the secondary regulator inlet at about 11 inches water column pos itive pressure The engine pistons draw air in during the intake stroke Figure 6 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 glow through the carburetor Figure 6 16 LP Gas Carburetion Diagram AIR GAS AT FLOW POSITIVE Y E PRESSURE LOW PRESSURE REUS AREA QUIETPACT 55 65 and 75 Recreational Vehicle Generators The greater the airflow through the carburetor ven turi the lower the pressure at the venturi throat The lower the pressure at the venturi throat the greater the diaphragm movement and the greater the move
19. Arrestors 30 6 6 2 Exhaust System Safety esee 30 6 7 Electrical Connections meterte XE senati ie 30 6 7 1 Electrical Junction Box eese 30 Dor d WIEN erotica 31 6 7 3 Generator AC Connections sesese 31 DTE CODO atenta 31 6 7 5 Isolating Different Power Sources 31 6 7 06 Power Supply COt easco serere eoe baa ab n re x Ee aRUS 31 6 7 7 Ground Fault Circuit Interrupters 32 6 8 Battery Installation asin ise 32 6 8 1 Recommended Battery oooocccncncncncncncnncnnnnnnnono 32 66 2 Battery Cables 25 91 pir reiciaiata 32 6 8 3 Battery Cable Connections sss 32 6 8 4 Battery Compartment eeeeeeeeeeee 32 6 9 Optional ACCeSSOF S ince cirea rotor eae REIP SP n eas E Ee ERIS 34 6 9 1 Remote Panel Models ccsteciievscceerscesedasestevesascaseies 34 Section 7 Post Installation 34 7 1 Post Installation TES Sui ricerca 34 7 2 Belore Initial Star up cumbias Ee VUES EROS 34 7 3 Mal toic P 34 TA Vesting Under L098ta eorr t aeree rh io 35 7 5 Installation Checklist 255 eceioeoio o Shire aevi pao ciclo 35 Section 8 Troubleshooting 36 8 1 Troubleshootin Guide eran 36 Section 9 NOteS canica 37 Section 10 Electrical Data
20. 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 Page 29 A Da A Use only approved components in the fuel sup ply system All components must be properly installed in accordance with applicable codes Improper installation or use of unauthorized components may result in fire or an explosion Follow approved methods to test the system for leaks No leakage is permitted Do not allow fuel vapors to enter the vehicle interior Generac Power Systems Inc 27 INSTALLATION TED Section 6 Installation Figure 6 15 Typical Propane Gas Fuel System CARBURETOR REGULATOR ta i UEL F LOCKOFF SOLENOID tts 9 les 2 EA y LJ VAPOR i WIDTHDRAWAL TANK 6 5 5 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system consider seriously the following items e All fittings lines hoses and clamps must be tight and free of leaks Apply a pipe sealant to threads when assembling threaded connections This reduces the possibility of leakage Test the entire fuel system for leaks using approved test methods Optimum gas pressure at the inlet to the gaseous fuel solenoid valve and secondary regulator is 11 inches water column The installer s fuel supply con
21. TO STUD V T RV 34 0A4456 1 WASHER LOCK SPECIAL 3 8 35 0D8502 1 NEUTRAL CONNETCTOR UL 36 0E0593 1 STUD 1 4 20 TO 5 16 18 37 0742600148 1 WIRE ASM BATT POS QP RV 38 022129 2 WASHER LOCK M8 5 16 GASOLINE ONLY 022129 4 WASHER LOCK M8 5 16 LP ONLY 39 022259 2 NUT HEX 5 16 18 STEEL 40 045756 8 SCREW HHTT M6 1 0 X 10 YC 41 0A2115 1 WASHER NYLON 250 42 029451A 6 5 FT TAPE 1 2 X 1 16 CLOSED CELL 43 0E1534A 1 PLUG PLASTIC 1 50 GASOLINE ONLY 44 0A5606 1 ELBOW 90DEG 3 8X3 4 LP ONLY 45 0E1528 1 BRACKET LP REGULATOR MOUNTING LP ONLY 46 041495 2 SCREW HHTT M4 0 7 X 10 BP LP ONLY 47 042907 2 SCREW HHC M8 1 25 X 16 G8 8 LP ONLY 48 022145 1 WASHER FLAT 5 16 M8 ZINC GASOLINE ONLY 022145 3 WASHER FLAT 5 16 M8 ZINC LP ONLY 49 0D8979A 1 PANEL AIR IN DUCT Generac Power Systems Inc 43 i us Section 11 Exploded Views and Parts Lists QUIETPACT 55 65 and 75 Recreational Vehicle Generators Ko Sheet Metal Drawing No 0E1012 B TO LP REGULATOR 10 1 s E N 11 UL QC M La c A 106 114 y d 107 115 116 44 Generac Power Systems Inc ITEM PART NO QTY CO 0 JJ O O1 WP 27 28 29 30 31 32 33 34 39 36 37 38 045756 0D1131 003022G 009763 0D9782 003034 003033 051754 0A5992 003032 003031 0C3725A 0C3016A 023484F 0D9679A 0D9708 0D9681A 056893 072347 0E0998 0D8384 0437
22. a liner or for 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 6 6 Installer constructed compartments typically utilize a standard lap joint 24 Generac Power Systems Inc QUIETPACT 55 65 and 75 Recreational Vehicle Generators Figure 6 6 Types of Lock Seams FOLD LOCKED STANDING DOUBLE LOCK DOUBLE SEAM oa rT GORDON SEAM LOCK SEAM STANDARD LAP JOINT e After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material See Section 6 2 3 A Da A Do not install any flammable material directly above or around the compartment Heat transferred through the compartment structure may be sufficient to ignite char or discolor seat cushions fiberboard and other flammable materials You may need to use approved nonflammable insulating materials in high temperature areas 6 2 5 SOUND INSULATING MATERIALS Once installers have determined that a compartment is properly constructed and metal lined they can add acoustical material This may include additional sealant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a nonflam mable type One excellent insulating material is a 1 inch 25 mm thick fiberglass havi
23. generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline Fuel lines must be properly installed and fastened and free of leaks There must be no possibility of gasoline vapors entering the vehi cle interior You are required to install an approved flexible nonconductive fuel line between the generator fuel connection point and rigid fuel lines If the generator is equipped with a liquid propane LP gas fuel system install the unit so it complies with all codes standards and regulations pertain ing to such systems LP gas is highly explosive The gas tends to settle in low areas where even the slightest spark can ignite it and cause an explo sion Do not allow gas vapors to enter the vehicle Generac Power Systems Inc 19 5 1 PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product s installation requirements Give serious consideration to all information and instructions in the manual both for safety and for continued reliable operation of the equipment Because of the different recreational vehicle models and the variations between the models it wo
24. generator unsafe A MAA A A Despite the safe design of this generator operating this equipment imprudently neglect ing its maintenance or being careless can cause possible injury or death Permit only responsi ble and capable persons to operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator 1 Parts of the generator are rotating and or hot during operation Exercise care near running generators 2 Generac Power Systems Inc operation be copied and posted in potential hazard areas of the recreational vehicle A Safety should be stressed to all operators and potential operators of this equipment GENERAL HAZARDS e For safety reasons Generac recommends that the installation initial startup and mainte nance of this equipment is carried out by a Generac Authorized Service Dealer 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
25. might render the unit in noncompliance with such codes standards and instructions You can use your generator set to supply electrical power for operating one of the following electrical loads e QUIETPACT 55G amp LP 120 and or 240 volts sin gle phase 60 Hz electrical loads These loads can require up to 5500 watts 5 5 kW of total power but cannot exceed 45 8 AC amperes of current at 120 volts or exceed 22 9 AC amperes at 240 volts e QUIETPACT 65G amp LP 120 and or 240 volts sin gle phase 60 Hz electrical loads These loads can require up to 6500 watts 6 5 kW of total power but cannot exceed 54 1 AC amperes of current at 120 volts or exceed 27 AC amperes at 240 volts QUIETPACT 75G amp LP 120 and or 240 volts sin gle phase 60 Hz electrical loads These loads can require up to 7500 watts 7 5 kW of total power but cannot exceed 62 5 AC amperes of current at 120 volts or exceed 31 2 AC amperes at 240 volts caution amp A Do not overload the generator Some installa tions may require that electrical loads be alter nated to avoid overloading Applying excessive ly high electrical loads may damage the genera tor 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
26. 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 531 90 Part No OE1015 Revision B O8 30 02 Printed in U S A
27. not endangered by the method procedure or technique selected Information illustrations specifications etc con tained in these Installation Instructions are based on the latest information available at the time of publi cation Every effort has been expended to be sure that such data is both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time without prior notice A DI A A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator 1 Parts of the generator are rotating and or hot during operation Exercise care near running generators 18 Generac Power Systems Inc GENERAL HAZARDS e For safety reasons Generac recommends that the installation initial startup and mainte nance of this equipment is carried out by a Generac Authorized Service Dealer 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 vehicl
28. 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 prob lem 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 mu
29. provided there has been no abuse neglect unapproved modification or improp er maintenance of your engine Your emission control system may include parts such as the carburetor ignition and exhaust systems Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications
30. temperature sensitive metal strip that adjusts choke valve angle according to ambient temperatures i e in cold ambient tem peratures choke valve closes more Once the engine starts an element heats the temperature sensitive strip to a normal operating condition opening the choke valve This may take about three minutes in cooler weather 2 4 BEFORE STARTING THE ENGINE NOTE Instructions and information in this manual assume the generator has been properly installed connected serviced tested and adjusted by a qualified installation technician or installation contractor 8 Generac Power Systems Inc 2 4 1 INSTALLATION Generator installation must have been properly com pleted so it complies with all applicable codes stan dards and regulations and with the manufacturer s recommendations 2 4 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommended oil before starting Refer to Section 1 6 3 Page 6 and Sections 3 1 and 3 2 Page 11 for oil servicing procedures and recommendations caution amp 1 Any attempt to crank or start the engine before you have properly serviced it with the recom mended oil may result in an engine failure 2 4 5 FUEL SUPPLY The engine must have an adequate supply of proper fuel to operate Before starting it check that sufficient fuel is available NOTE Depending on the installation the generator may have either a sep
31. 083049 1 ASY POTTED REG W FIN 25 090145 1 CIRCUIT BREAKER 30 X 1 5 5 amp 6 5 KW 62 089047 2 SPACER 25 X 43 X 55 ST ZNC ONLY 63 075234 1 RESISTOR WW LUG 1R 5 25W 0E1529 1 CIRCUIT BREAKER 35 X 1 7 5 KW ONLY 64 0A2053 1 SCREW HHC M6 1 0 X 65 G8 8 26 090144 1 CIRCUIT BREAKER 20 X 1 5 5 KW ONLY 65 058000K 2 NUTTRIC M5 X 8 090145 1 CIRCUIT BREAKER 30 X 1 6 5 KW ONLY 66 0D8941 1 COMPARTMENT AIR BOX 0E1529 1 CIRCUIT BREAKER 35 X 1 7 5 KW ONLY 67 029451A 2 3FT TAPE 1 2 X 1 16 CLOSED CELL 27 025105 4 SCREW RHM 6 32 X 1 4 SIMS 68 0E0583 1 WIRE HARNESS QP RV GASOLINE 28 0A9611 1 FUSE7 5 AMP ONLY NOT SHOWN 29 032300 1 HOLDER FUSE 0E1812 1 WIRE HARNESS QP RV LP ONLY NOT 30 092113 1 SWITCH SPDT ON MOM ON SHOWN 31 087798 1 SWITCH 6A SPDT 69 0E1375 1 WIRE ASS Y STARTER TO C PNL NOT 32 055440 2 SCREW HHC M5 0 8 X 25 G8 8 SHOWN 33 0D9377 1 PANEL TOP CONTROL Generac Power Systems Inc 47 i As Section 11 Exploded Views and Parts Lists 7 QUIETPACT 55 65 and 75 Recreational Vehicle Generators Ko 760 V Twin Engine Drawing No 0E1014 B 63 64 43 Generac Power Systems Inc ITEM PART NO QTY 00 1o05 0 1 WP 0C5730A 003008 090388 005372 003005 003003 0D8067A 002981C 071983 005848 021533 071980 0D4041 002983 0C2985A
32. 0C2985B 0D4042 0A7811 002977 005943 0D4122A 0D3961 002978 093873 021374 002994 002997 002995 002996 003011 003009 003010 050873A 6 3 1 4 2 2 2 1 1 2 1 1 1 1 1 1 2 2 3 3 1 1 1 1 2 2 2 1 Section 11 Exploded Views and Parts Lists QUIETPACT 55 65 and 75 Recreational Vehicle Generators PARTS Ce LISTS 760 V Twin Engine Drawing No 0E1014 B O DESCRIPTION ASSEMBLY CRANKCASE RV SEAL 38 I D CRANKCASE SCREW HHTT M6 1 0 X 12mm ASSEMBLY BREATHER GASKET BREATHER COVER SEPARATOR OIL BREATHER ASSEMBLY HEAD 1 COVER ROCKER RETAINER PISTON PIN 20 PISTON HC SET PISTON RING 90mm PIN PISTON D20 ASSEMBLY CAMSHAFT amp GEAR SHAFT GOVERNOR ROLLER BEARING GOVERNOR PLATE ROLLER BEARING GOVERNOR ASSEMBLY GOVERNOR GEAR SPOOL GOVERNOR MACHINED GASKET CRANK CASE SEAL OIL PASSAGE ASSEMBLY CRANKSHAFT ASSEMBLY CONNECTING ROD GASKET HEAD WASHER LOCK RIB M6 SCREW SHC M6 1 0 X 30mm SCREEN OIL PICKUP COVER GEROTOR GEROTOR INNER GEROTOR OUTER COVER OIL RELIEF SPRING OIL RELIEF BALL 1 2D OIL RELIEF 1 4 NPT PIPE PLUG ITEM PART NO QTY 002991 0D1667A 002988 002992 005732 002993 003007 0D9756 003006 0C8566 002982 093064 002979 086515 0D2274 0D3867 078672 005371 0D5326 0D5354 0D5313 0D6023 0D6024 002976 0D8067B 002229 086516 0D9853D 083897 003017 022129 061906 2 1 1 1 1 1 1 1 MOARRRPRRN
33. 35A QP75 MODEL CB2 CIRCUIT BREAKER 20A QP55 MODEL CIRCUIT BREAKER 30A QP65 MODEL 99 CIRCUIT BREAKER 35A QP75 MODEL R1 CB3 CIRCUIT BREAKER 2 5A QP55 MODEL ON CIRCUIT BREAKER 3 0A QP65 amp QP75 MODELS CH CHOKE HEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY F1 FUSE 7 5A FP FUEL PUMP OR LPG SHUT OFF VALVE POWER WINDING A FS FUEL SOLENOID 33 GT TERMINAL GROUND HM METER HOUR OPTIONAL p ON 998 118 HTO SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP 11P IM1 IGNITION MAGNETO 1 CYL 22P IM2 IGNITION MAGNETO 2 CYL O o L1 LIGHT RUN OPTIONAL ELECTRONIC CBi REMOTE PANEL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE VOLTAGE O PCB ENGINE CONTROLLER REGULATOR R1 RESISTOR 1 OHM 25W OK RED SC STARTER CONTACTOR DES SCR STARTER CONTACTOR RELAY DA SM STARTER MOTOR d T7 SW1 SWITCH START STOP BLACK SW SWITCH FUEL PRIMER M CBS SP1 SPARK PLUG 1 CYL 9 4 T1 SP2 SPARK PLUG 2 CYL 2 6 T3 TC TERMINAL CONN 4 TAB AA gt CONNECTOR BPE WINDING DEE ks a 77 FIELD WHITE 120V 20A QP55 PLAGI GREEN gt 120V 30A QP65 a T2 120V 35A QP75 RED 120V 30A QP55 amp QP65 120V 35A QP75 i NEUTRAL CONNECTION BY CUSTOMER 38 Generac Power Systems Inc Section 10 Electrical Data QUIETPACT 55 65 and 75 Recreational Vehicle Generators EEC ACAL V Twin Drawing No 0E1057 B DATA A
34. 5 8 EXCESS FLOW VALVE LP 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 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 INSTALLATION TED Section 6 Installation 6 5 9 LEAKAGE TESTS Do not place the generator into service until you have properly tested the gas system for leaks To test the system you need a separate source of 12 volts DC to open the gaseous fuel solenoid valve The leak test must comply fully with NFPA Paragraph 318 All connections hoses valve regula tors fittings and other fuel system parts must be tested under gas or air pressure of not less than 90 psi 620 kPa while using soap and water or an equivalent solution to check for leaks Other approved methods of testing for leaks may be used if appropriate DO NOT USE ANY FLAME TO TEST FOR LEAKS 6 6 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 NE A A Th
35. 55 65 and 75 Recreational Vehicle Generators Figure 6 8 Compartment Floor Cutout HOT AIR EXHAUST TAILPIPE LOCATION 9 25 4 T VIEW FROM TOP n 469 8 516 2 TYP TYP 526 2 305 9 344 6 AIR INTAKE PRA Di FUEL INLET 574 7 3 8 16 WELDNUTS 8 PLACES 834 9 FRONT NOTE ALL AIR INTAKES AND EXHAUST OUTLETS MUST BE KEPT CLEAR OF ANY OBSTRUCTIONS ALL OPEN AREA IS REQUIRED FOR COOLING 6 3 2 TESTING THE INSTALLATION Generac recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of overheating you will need to enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is ade quate NOTE You must test the installation especially if you bring in air from below the generator set 6 4 GASOLINE FUEL SYSTEM A DIG A Gasoline is highly flammable and its vapors are explosive Comply with all codes standards and regulations pertaining to gasoline fuel systems used in recreational vehicle generators Properly install and maintain the fuel system and keep it entirely free of leaks Gasoline vapors must not enter the vehicle interior 26 Generac Power Systems Inc The installation of a gasoline fuel system Figure 6 14 for a recreational
36. 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 2 Air Induction System including 1 1 Gasoline carburetor assembly and its a Intake pipe manifold internal components if so equipped b Air cleaner a Fuel filter if so equipped 3 Ignition System including b Carburetor gaskets a Spark plug c Fuel pump if so equipped b Ignition module 1 2 LPG carburetion assembly and its 4 Catalytic Muffler Assembly if so equipped including internal components if so equipped a Muffler gasket a Fuel controller if so equipped b Exhaust manifold b Mixer and its gaskets if so equipped 5 Crankcase Breather Assembly including c Carburetor and its gaskets if so equipped a Breather connection tube d Primary gas regulator if so equipped e LP liquid vaporizer if so equipped 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
37. 90A 0D3083 0E0361A 0E0393 0C2824 0C2824 065852 075246 0A4456 0A2311 070185 0A8584 0A5360 043182 0C1085 0E1497 075281 0D9399 0D9513 0E1498 0D1366 0D9395 077075 0A7094 0D8590 0D8591 045770 049226 051713 0D9402 077091 082025 0E1247 055173 022129 022145 0D9403 0E1246 15 MD D D Aa N T a N poo _ _h L tt c c py NO NO Pp Section 11 Exploded Views and Parts Lists QUIETPACT 55 65 and 75 Recreational Vehicle Generators Sheet Metal Drawing No 0E1012 B DESCRIPTION SCREW HHTT M6 1 0 X 10 YC GUARD FAN 12KW HSB HOUSING BLOWER V TWIN RV NUT GROMMET 1 4 PLUG HOSE BREATHER NUT HEX M24 2 0 G8 YEL CHR WASHER BELLEVILLE 25MM BOLT SCREW HHC M8 1 25 X 12 G8 8 WASHER SHAKEPROOF INT M8 SS PLATE FAN GV 990 FAN NYLON GV 990 FLYWHEEL ASSY GT 990 PLATE BACKING GT990 W OIL COOL BUSHING SNAP SB 1000 12 WRAP CRANKCASE GTV760 RV SPCC GT760 VERTICAL SHAFT RV ENGINE WRAP CYL 1 GTV760 RV SPCC SCREW CRIMPTITE 10 24 X 14 SPARK PLUG CLAMP VINYL 9 5 O D TUBE TUBE OIL DRAIN amp CHECK BARBED EL 90 3 8NPT X 3 8 VS ASSEMBLY OIL DRAIN HOSE OIL DRAIN DIPSTICK TUBE VTW ASSEMBLY CAP amp DIP STICK SCREW TAP R 410 32 X 9 16 GASOLINE ONLY SCREW TAP R 40 32 X 9 16 LP ONLY SPRING CLIP HOLDER 37 62 SCREW HHTT 3 8 16 X 1 1 4 CZ WASHER LOCK SPECIAL 3 8 SCREW SWAGE 1 4 20 X 1 Z YC FILTER OIL D 69X64 LG SWITCH OI
38. ABOVE THE FULL MARK 8 Install and tighten the dipstick before operating the engine 12 Generac Power Systems Inc QUIETPACT 55 65 and 75 Recreational Vehicle Generators 9 Start the engine and check for leaks Figure 3 2 Engine Oil Filter ENGINE OIL FILTER TWIST COUNTER CLOCKWISE TO LOOSEN NOTE Check the oil level and fill to the FULL mark after checking for leaks The filter will retain some oil 5 5 MAINTAINING THE ENGINE AIR CLEANER 3 3 1 CLEANING THE FOAM PRECLEANER Clean and re oil the foam precleaner every three months or every 25 hours of operation whichever occurs first Service the foam precleaner more fre quently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 3 1 Turn the knob counterclockwise to loosen 2 Remove the cover foam precleaner and paper fil ter 3 Remove the foam precleaner from the cover 4 Wash the foam precleaner in liquid detergent and water 5 Wrap the foam precleaner in a clean cloth and gently squeeze it dry 6 Saturate the foam precleaner in clean engine oil Gently squeeze it in a clean cloth to remove excess oil and to distribute oil DO NOT TWIST 7 Install the foam precleaner into the cover fol lowed by the paper filter Tabs at edges of paper filter must lock into slots on cover 8 Install the cover foam precleaner and paper filter 9 Replace knob to retain t
39. C TO poli Rosa uU 27 at 3600 rpm Displacement OUIETPACT 55 59 79 auEbERe pablo as 760cc Compression RO asar abad 8 6 to 1 Cylinder Block Aluminum w Cast Iron Sleeve Type Of Governor Mechanical Fixed Speed Engine Governor Speed QUETTAC T GO loc 2200 rpm OUISIPAGT OS apra 2571 rpm Air Cleaner Paper Element w Foam Precleaner UAL VEL C 12 volt DC Electric Ignition System Solid state w Flywheel Magneto Recommended Spark Plug Sido RC12YC pn R455 Pratt AAO en sia 65 Spark PING Gap esris n 0 030 inch 0 8 mm Recommended Min Battery 400 Cold Cranking Amps 1 6 5 EMISSIONS COMPLIANCE PERIOD For nonhandled engines the Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal emission requirements e For engines less than 225 cc displacement Category C 125 hours B 250 hours and A 500 hours For engines of 225 cc or more Category C 250 hours B 500 hours and A 1000 hours 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 2 1 1 FUEL PRIMER Before starting a cold engine if it has not been start ed in more than two weeks you must press this switch for approximately ten seconds to bring fu
40. Generators DX A Do not dispose of the battery in a fire The 3 battery is capable of exploding Storage batter ies give off explosive hydrogen gas This gas can form an explosive mixture around the bat tery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery Discharge static electricity from your body before touch ing the battery by first touching a grounded metal surface A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries e Remove watches rings or other metal objects e Use tools with insulated handles e Wear rubber gloves and boots e Do not lay tools or metal parts on top of the battery e Disconnect any charging source prior to connecting or disconnecting battery terminals and e Do not use any jumper cables or booster battery to crank and start the generator engine If any battery has discharged remove it for recharging bh WARNING amp 1 Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic A The electrolyte is a dilute sulfuric acid th
41. ION LED Section 6 Installation 6 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a gen erator or inside a compartment that the installer con structs the compartment MUST meet certain specifi cations as outlined in the following sections 6 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a mini mum clearance of 1 2 inch 13 mm on the front and top 1 inch 25 mm on the sides and 1 2 inch 13 mm from the back for air circulation AFTER the compartment has been lined with metal and sound insulation Figure 6 4 NOTE Refer to Figure 5 2 Major Features and Dimensions on Page 21 Figure 6 4 Clearances Plywood Compartment 1 2 Clearance on Top 1 Clearance in Back 1 Each Side Insulation Y l l l l l l l l l l l l y 6 2 2 COMPARTMENT CONSTRUCTION The generator compartment should be either con structed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum s low melting point e If the compartment is lined with galvanized steel it may be constructed of any material Generac rec ommends that the compartment be constructed of 1 2 inch thick plywood not strandboard with the floor made of a double thickness of 1 2 inch ply wood with the grain of the wood at cro
42. IS NUMBER QUIETPACT 55 65 and 75 Recreational Vehicle Generators Part Operating Instructions Introduction ennnen nne Inside Front Cover Read This Manual Thoroughly eere IFC ecu gd Eeee IFC Operation and Maintenance io cero trie rerit ete tenir IFC How to Obtain Service nvidia IFC Authorized Service Dealer Locator Number IFC Sate FS reve 2 Section 1 General Information 4 1 1 Generator Identification sionistas dad antena creanis 4 1 2 Generator Applicability vaci n aldeas 5 1 3 eo irs d rena ON sunt rotondas ns 5 1 4 cilc MEM T O O roams oh EN EA EEE 5 1 5 Generator AC Connection SysteM ooccccncncncccncncnnnnnncnonono 5 1 6 DCCC A ONS nordeste eui a assdnisvq UU dd 6 1 6 1 Fuel Requirements sitos 6 1 6 2 Engine Oil Requirements occoccccncnncncnncnoccnnnenos 6 1 6 3 Generator Specifications eeeeeeeeeees 6 LGA Engine Speciliealiotns osten eno bre orina ree dene 7 1 6 5 Emissions Compliance Period 7 Section 2 Operation eee 7 2 4 Generator Control Panel o ede tote reve arcas 7 A E E m ne en ee 7 2 1 2 Start Stop Switch ausrraisada oc maaniescaeeands 7 21 3 19 Amp socio 7 2 1 4 Line Breaker tocas oda era cnica 7 2 2 Optional Remote Start
43. L PRESSURE HOBBS SUPPORT OIL FLTR FLARE WASHER LOCK M3 SCREW PPHM M3 0 5 X 8 SWITCH OIL HIGH TEMP GASOLINE ONLY SWITCH OIL HIGH TEMP LP ONLY ASSEMBLY GOVERNOR LEVER SPRING GOV 5 5 KW amp 5 0 KW 50HZ ONLY SPRING GOV 6 5 7 5 KW amp 7 0 KW 50HZ ONLY BUSHING GOVERNOR ROD ROD GOVERNOR BOOT CHOKE SOLENOID GASOLINE ONLY RHMS 4 40 X 1 4 SEMS GASOLINE ONLY ASSY B METAL HEATER GASOLINE ONLY SOLENOID CHOKE GASOLINE ONLY SCREW HHC M5 0 8 X 10 G8 8 WASHER LOCK M5 WASHER FLAT M5 LINKAGE CHOKE SOLENOID BELLCRNK GASOLINE ONLY COTTER PIN GASOLINE ONLY NUT LOCK HEX M5 0 8 SS NYL INS ASSEMBLY GOV ADJUSTMENT SCREW HHC M8 1 25 X 20 G10 9 WASHER LOCK M8 5 16 WASHER FLAT 5 16 M8 ZINC LINKAGE CHOKE BELLCRANK CARB ASSEMBLY CHOKE BRACKET GASOLINE ONLY ITEM PART NO QTY 57 58 99 60 61 62 63 64 65 66 67 68 69 70 71 109 110 111 112 113 114 115 116 0D9400 0A7095 0D9404 0D9801A 0C3018A 0D9680A 0D1143A 003053 085011 0D9852 022097 092079 001546 001547 082774 0A5358 0D9312 0D9314 001557 0A9028 0D9682A 0D9270 048031A 0D9269 0E0142 078643B 0D9219 0E0573 0D8807 0E1217 0E0572 003043 0D8836 049821 070008 070006 035461A 040173 009806 003026 0D9683A 009764 036933 0E0246 0D9394 022152 022158 043116 049811 047411 066849B 05 822 074994 075476 082121A 038150 022264 051715 0D6029 055934D 022473 090388 no DO ON Po Po BP aa R
44. LY IF SYMP TOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired A DIE A A Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installa tion manual Make sure there is ample fresh air when operating the genset in a confined area 2 5 STARTING THE GENERATOR NOTE Read the vehicle manufacturer s instructions The owner operator should become familiar with the vehicle in which this generator is installed Differences exist between vehicles For example some vehicles may use a transfer switch to isolate dockside power from the generator while other vehicles may use an isolating receptacle Some vehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads To crank and start the generator engine proceed as follows 1 Turn OFF electrical loads using the means pro vided in your vehicle such as a main line circuit breaker or transfer switch NOTE If starting from the generator control panel turn OFF loads by setting the generator s main circuit breaker to the OFF or open position If starting from a remote panel turn OFF loads using the means provided in the vehicle such as a main cir cuit breaker Electrical load circuits will be turned ON after the gene
45. MAP ROM HAH HOS n5 ho no B BP Pp DESCRIPTION E RING GOVERNOR ARM ARM GOVERNOR THRUST WASHER GOVERNOR BUSHING GOVERNOR LOWER ASSEMBLY SUMP WITH SLEEVE SEAL GOVERNOR SHAFT SEAL 42 1 D CRANKSHAFT CONNECTOR 3 8NPT TO INVTD FLR 3 80D SCREW HHFC M10 1 5 X 55mm SCREW HHFC M6 1 0 X 20mm COVER ROCKER WITH OIL FILL ASSEMBLY OIL FILL CAP GASKET VALVE COVER KEEPER VALVE SPRING RETAINER VALVE SPRING SPRING VALVE SEAL VALVE STEM D7 WASHER VALVE SPRING NUT JAM ROCKER ARM PIVOT ROCKER ARM ROCKER ARM STUD ROCKER ARM M8 1 0 x 57mm PLATE PUSH ROD GUIDE SCREW HHFC M8 1 25 X 65mm ASSEMBLY HEAD 2 VALVE INTAKE VALVE EXHAUST PUSHROD 147 TAPPET SOLID STARTER V TWIN ENGINE WASHER LOCK M8 SCREW HHC M8 1 25 X 85mm Generac Power Systems Inc 49 i us Section 11 Exploded Views and Parts Lists QUIETPACT 55 65 and 75 Recreational Vehicle Generators Ko LP Regulator Drawing No 0E1530 50 Generac Power Systems Inc ITEM CON OOF WP PART NO 0D5694 075475 022264 043180 005765 006070 004680 004647 004643 0D3973 0C6606 026073 0D3308 070728 005764 0C4643A 06066 05968 005759 005761 0C6069 006731 06067 004706 06068 005762 045764 QTY OOD c c S c c c c c 5 NO DSO KS Si c c A p Pp o Section 11 Exploded Views and Parts Lists QUIETPACT 55 65 and 75 Recreational Vehicle Generators
46. NECTION 3 6 CLEAN SPARK ARRESTOR The engine exhaust muffler has a spark arrestor screen Inspect and clean the screen every 50 hours of operation or once each year whichever comes first NOTE If you use your generator on any forest covered brush covered or grass covered unimproved land it must equipped with a spark arrestor The spark arrestor must be maintained in good condition by the owner operator Clean and inspect the spark arrestor as follows e Remove the screen retaining bracket by removing the screw e Slide the spark arrestor screen out from the tail pipe Inspect screen and replace if torn perforated or otherwise damaged DO NOT USE a defective screen If screen is not damaged clean it with com mercial solvent Replace the screen and the retaining bracket Figure 3 6 Spark Arrestor TAILPIPE P N 0E0907 RETAINER Co gt i SPARK ARRRESTOR SCREEN P N 0D5133 RETAINING SCREW P N 045764 Generac Power Systems Inc 13 MAINTENANCE LD Section 3 Maintenance 3 7 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids
47. No AC output voltage 1 Main breaker s open 1 Close main breaker s 2 Transfer switch if so equipped is 2 Reset transfer switch set to wrong position 3 Failure in vehicle electrical system 3 See vehicle manual 4 Generator component failure 4 Contact an authorized service facility 36 Generac Power Systems Inc Section 9 Notes NOTES QUIETPACT 55 65 and 75 Recreational Vehicle Generators Generac Power Systems Inc 37 Section 10 Electrical Data QUIETPACT 55 65 and 75 Recreational Vehicle Generators a as o V Twin Drawing No 0E1057 B A BATTERY RED 10 BLK SC 13 RED 16 13 16 SCR 14 14A 14 Ja 2 56 Ja gt 90 J1 3 gt 16 Ji 4 gt 18A J1 5 gt 18A J 6 gt 17 Lo SW1 W172 M o erop Jia gt Ji 9 gt 4 14A J1 10 gt 66 disti 85 J1 12 gt 0 J1 13 7 66 REMOTE J1 14 gt 18 i PANEL J1 15 3 i8 pa CONNECTOR ol 1 1 47 2 2 14 14 3 3 15 18 4 4H 14A 15 Z Z wu LLI BCR 14A Goa IESE 120907 66 2ctmmoemsSs 15 m o LEGEND n 18 14 17 O BCR BATTERY CHARGE RECTIFIER CB1 CIRCUIT BREAKER 30A QP55 amp QP65 MODELS BATTERY CHARGE WINDING CIRCUIT BREAKER
48. OH4 SNOLLO3NNOO i AHdallvg i dAL EL I i os B e HOLO3NNOO b d J3NVd SLOWSY ez 7 B nO o 1370 7303 Y v16v SS3NHVH LNdLNO OV O g S 02L 8 958 I v 06 j 6 p88 ied j Lv G INOS La Gps FZZ Si e i id spere ET l fi i pHi i z 9z J 8 02 db ys 52 o o NM me MN LW Tf af 13 INI 13N3 6 S0 9 vbe rd ONIOOO HOS GAYINOAY SI Vauv NadO m uw 1 nM AL us TIY SNOLLONHLSEO ANY JO HV3T10 1d3 38 LSNW ia 1 i i SLY1LAO LSAVHX3 ANY S3MVLNI HIV TIV 3 LON i T Y dO NOY3 MIA NOILLWIO1 3dld llv L 1SNVHX3 HIV LOH 21 Generac Power Systems Inc INSTALLATION Hh Section 6 Installation Figure 5 3 Connection for 120 240 Volts T1 RED A 120 VAC T2 Y 240 WHITE A VAC T3 Y STATOR WINDINGS GROUNDED NEUTRAL The AC connection system on all air cooled PRIMEPACT series generators uses a GROUNDED neutral A separate green ground wire is connected to the recreational vehicle s junction box e Loads connected across T1 Red to T2 White and T3 Black to T2 White must not exceed rat ings for your specific generator see Section 1 6 3 NOTE Do NOT connect loads in excess of circuit breaker ratings 6 1 LOCATION AND SUPPORT 6 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 u
49. P R1 17 33 ON 66 15 OK OF OY m O 18A 18 0 0 OF CONN 1 E 0 85 18 DN 0 0 E o CUNG 0 O cs 90 90 14 4 O 14A 23 14 14 O CH 14 14 e E z L 14 i o 12 33 14 TC S A rn REMOTE M PINE 15 l Swi O PANEL T E oe oc is CONNECTOR 0B 11P T2 T2 FS FP e m 0 11P dd E 13 18 3t E 14A 15 CB2 BLACK 4 18 18 18A Si TA 85 B 85 i gt HTO WHITE E 13 T 2 GREEN CUSTOMER AC CONNECTION T NEUTRAL CONNECTION BLACK 2 A BY CUSTOMER WHITE RED SP1 Generac Power Systems Inc 39 Section 11 Exploded Views and Parts Lists QUIETPACT 55 65 and 75 Recreational Vehicle Generators Base Pulley Drawing No 0E1323 A TO CARB 40 Generac Power Systems Inc ITEM PART NO QTY CON DOF WP 2 28 29 30 0E0196 022129 022145 022259 007758 003168 002417 077603 0E0588 029451 0D8912 0E0571 0D8911 043107 0D9021 096289 0D8940 070006 070008 040976 056893 023897 0E1078 004138 043116 022097 022097 022473 001751 0C1753B 073106B 075224A 075224B 1 12 15 6 po A 1 5 FT Po PO 0 A A A SH S N PO p Section 11 Exploded Views and Parts Lists QUIETPACT 55 65 and 75 Recreational Vehicle Generators Base amp Pulley Drawing No 0E1323 A DESCRIPTION FRAME 760 ENGINE WASHER LOCK M8 5 16 WA
50. QUIREMENTS GASOLINE This generator is equipped with a gasoline fuel system as standard equipment Specific installations may pro vide either a separate fuel tank for the generator or the generator may share the vehicle engine s fuel tank QUIETPACT 55 65 and 75 Recreational Vehicle Generators 4 1 6 1 1 Fuel Consumption gph Ibs ph 1096 Load 5096 Load QuietPact 55G 10096 Load QuietPact 65G 0 51 0 76 QuietPact 75G 0 51 0 80 NOTE Some installations using a shared fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine s pickup tube Such an arrangement causes the generator engine to run out of gas while adequate fuel for the vehicle remains in the tank To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator Leaded REGULAR grade gasoline is an acceptable substitute NOTE Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits caution amp Generac does not recommend using any A gasoline containing alcohol such as gasohol If you use any gasoline containing alcohol it must not contain more than 10 percent ethanol and it must be removed from the generator during storage Do NOT use any gasoline containing methanol If you use gasoline with alcohol inspect more frequently for fuel leaks and other abnormalities 1 6 2 ENGINE OIL REQUIREMENTS Use only high qualit
51. R 8 022473 10 WASHER FLAT 1 4 M6 ZINC 41 023484R 2 BUSHING SNAP 9 080925 8 WASHER NYLON 404 42 0D3700 1 NUT FLANGE M6 1 0 NYLOK 10 0D9921 4 STANDOFF 1 2 HEX 43 0D9378 1 PANEL BOTTOM CONTROL 11 066849 2 SCREWHHTT M5 0 8 X 16 44 052619 1 SCREW HHC M5 0 8 X 20 G8 8 12 066386 1 ASSY BRUSH HOLDER 45 075476 2 SCREW PPHM M4 0 7 X 16 13 0C9674 1 BEARING CARRIER UP 46 065795 1 RECTIFIER BATTERY CHARGE 14 0E0363H 1 STATOR ASSEMBLY 5 5 KW ONLY 47 0C2174 1 RELAY 12V 25A SPST 0E0364H 1 STATOR ASSEMBLY 6 5 KW ONLY 48 092120 4 NUTLOCKTRIC M6 X 1 0 Y ZNC 0E0362H 1 STATOR ASSEMBLY 7 5 KW ONLY 49 049721 2 SCREW HHC M6 1 0 X 35 G8 8 BLK 15 073159 1 BEARING BALL 50 0A1658 2 WASHER LOCK SPECIAL 1 4 16 077005H 1 ROTOR ASSEMBLY 5 5 KW ONLY 51 074260 146 1 WIRE ASM GRD STD CONN 077004H 1 ROTOR ASSEMBLY 6 5 KW ONLY 52 049813 4 NUT HEX M6 X 1 0 G8 YEL CHR 073163H 1 ROTOR ASSEMBLY 7 5 KW ONLY 53 023484D 1 BUSHING SNAP 17 031971 1 BEARING 54 074260 151 1 GROUND WIRE C PNL TO STUD V T RV 18 077006 4 STUDRV STATOR DIC 55 084867 1 RUBBER U CHANNEL 19 0C9675 1 BEARING CARRIER LOW 56 043181 2 SCREW PHM M3 0 5 X 10MM 20 0A5351 1 NYLON SLIDE 57 075210A 1 BLOCK 1 POSITION 21 073146 2 SLIDE NYLON 58 022264 2 WASHER LOCK 8 M4 22 0C1878 SUPPORT SLIDE 59 051715 2 NUT HEX M4 0 7 G8 YEL CHR 23 075242 4 SPRING GEN MOUNT 60 007605 2 SCREW HHC M5 0 8 X 60 G8 8 24 075237 4 WASHER SPRING CENTER 61
52. Recharge or replace battery 4 Defective Start Stop switch 4 Replace switch 5 Defective starter contactor 5 Replace starter contactor 6 Defective starter motor 6 Replace starter motor 7 Defective Engine Control Board 7 Contact an authorized service dealer Engine cranks won t start 1 Out of fuel 1 Refill fuel tank 2 Fuel shutoff valve is closed 2 Open fuel shutoff valve s 3 Fuel pump not operating 3 Repair or replace pump 4 Automatic choke not operating properly 4 Repair replace or adjust 5 Engine is flooded 5 Wait 5 10 minutes try again 6 Fuel filter is clogged 6 Replace filter if clogged 7 Engine spark plugs defective 7 Clean regap or replace as needed 8 Bad ignition magneto on engine 8 Replace if defective 9 Bad carburetor 9 Adjust repair or replace 10 Dirty air cleaner 10 Clean or replace as needed Engine starts hard runs rough 1 Dirty engine air cleaner 1 Cleanor replace as needed 2 Automatic choke is sticking 2 Free choke linkage as needed 3 Defective spark plugs 3 Clean regap or replace 4 Defective ignition magneto 4 Replace it if defective Engine starts then shuts down 1 Engine oil level is low 1 Add oil as needed 2 Bad low oil pressure switch 2 Replace if bad 3 Defective high temp switch 3 Replace if bad 4 Water in fuel 4 Drain fuel tank and refill 5 Defective remote harness 5 Disconnect remote harness Contact authorised service facility
53. S OR BRUSH bh WARNING amp Never operate the generator while the vehicle AN is parked over high grass weeds brush leaves or any other combustible substance Such materials can ignite and burn from the heat of the exhaust system The generator exhaust system becomes extremely hot dur ing operation and remains hot for a long time after it has shut down 3 1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements see Engine Oil Requirements Section 1 6 2 Page 6 Check the engine crankcase oil level at least every eight hours of operation or before you use it To check the engine oil level proceed as follows see Figure 3 1 1 Be sure the generator is as level as possible 2 Remove the dipstick and wipe it dry with a clean lint free cloth 3 Install and tighten the dipstick cap then remove it again The oil level should be at the dipstick Full mark 4 If necessary remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dip stick Full mark DO NOT FILL ABOVE THE FULL MARK caution amp Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 5 Install and tighten the oil fill cap and the dipstick before operating the engine Generac Power Systems Inc 11 MAINTENANCE LD Section 3 Maintenance 5 2 CHANGING THE ENGINE OIL AND OR OIL FILTER Change
54. SHER FLAT 5 16 M8 ZINC NUT HEX 5 16 18 STEEL VIB MNT 1 5 X 1 38 X 5 16 18 WASHER LOCK SPECIAL 5 16 EARTH STRAP SCREW HHC 5 16 18 X 3 5 SPC SPACER SAFETY BOLT 375 LD TAPE ELEC UL FOAM 1 8 X DUCT AIR OUT GASKET AIR OUT DUCT BRACKET MUFFLER SUPPORT SCREW HHC M8 1 25 X 25 68 8 MUFFLER GTV760 RV CLAMP EXHAUST 1 25 MANIFOLD EXHAUST WASHER LOCK M8 SS WASHER FLAT M8 SS SCREW SHC M8 1 25 X 20 G12 9 SCREW CRIMPTITE 10 24 X 14 WASHER FLAT 10 ZINC GASKET EXH BASE GTV760 RV GASKET EXHAUST PORT SCREW HHC M6 1 0 X 12 G8 8 5 5 KW ONLY WASHER LOCK M6 1 4 5 5 KW ONLY WASHER LOCK M6 1 4 6 5 amp 7 5 KW ONLY WASHER FLAT 1 4 M6 ZINC 5 5 KW ONLY FAN NYLON 7 DIA 5 5 KW ONLY PULLEY ALTERNATOR 2200 RPM 5 5 KW ONLY PULLEY ALTERNATOR 2500 RPM 6 5 amp 7 5 KW ONLY PULLEY ENGINE 2100 RPM 5 5 KW ONLY PULLEY ENGINE 2500 RPM 6 5 amp 7 5 KW ONLY ITEM PART NO QTY 94 55 56 9 0E0586 0D7176 0E1334 0D8824 081105 073118 046526 022131 002824 0E1077 042633 022237 049451 001441 001112 023484E 0E1534 0D7530 0D9723 0D4511 0D8981 0D8981 0D8451 087680 0D3700 0D3700 087769 0E0570 0D9919 0E1330 0E1534A 0A1658 0D5133 0D5133A 045764 O po D c c c i bo i ll jo S IA d PARTS ib ies O DESCRIPTION GASKET BOTTOM AIR OUT QPRV WASHER SELF LOCKING 1 DIA 12GA SCREEN BOTTOM AIR OUT TRAY V TWIN RV
55. Stop Panel 8 2 9 Automate CHOKE ion cba 8 2 9 CHOKE Solenoid iii 8 2 0 2 A O 8 24 Before Starting the Engine 45 diia 8 PAS ISA AO anta tin 8 21 2 Engine LUDFICALON usina 8 23 MEL SUDDIV sab a a AA OE 8 2 4 4 Cooling and Ventilating Air esses 8 24 9 Engine Exhaust GaS inicia 8 2 5 Stal tre the Generator sumida 9 2 6 stopping the Generator animada 9 2 7 Applying Loads to Generator eene 9 2 7 1 Letting the Engine Stabilize 9 2 7 2 Do Not Overload the Generator 10 2 8 PrOUICCUOD Ste asadas ci 10 2 8 1 Low Oil Pressure Switch eee 10 2 8 2 High Temperature Switch usse 10 28 0 Bield BOOST road 10 2 5 4 Overvoltase Protectioll 1 2 edite dn ar 11 2 8 5 25 Hour Break in Period 11 2 8 6 25 Honr Checkup noir abdo DI Dim S ie DUUM 11 2 8 7 Operation in High Grass or Brush 11 Section 3 Maintenance eee ennnen nne 11 3 1 Checking the Engine Oil Level eet 11 3 2 Changing the Engine Oil and or Oil Filter 12 3 3 Maintaining the Engine Air Cleaner 12 3 3 1 Cleaning the Foam Precleaner 12 3 4 Checking the Engine Spark Plug sss 13 3 5 Fuel Filter G
56. UAL 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 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
57. YSTEM Q Exhaust system complies with all applicable codes Q Exhaust system is properly and safely installed ELECTRICAL CONNECTIONS Q Connections comply with local code requirements and all National Electrical Codes Q Junction box is properly installed O Wiring meets all standards U All connections are correct Q Conduit is properly installed and sealed Q Generator is properly bonded to the vehicle BATTERY INSTALLATION Q Recommended battery is installed Recommended cables are installed Cables are clean and tight Cables are connected properly Proper ventilation is provided DL OC UCIALU Terminals are coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES Q Check that remote start stop panels if used are installed properly Q Check that hourmeter kit if used is installed properly Q Check that any other options and accessories if used are installed properly POST INSTALLATION TESTS Q Check that all tests are completed properly Generac Power Systems Inc 35 TROUBLESHOOTING 8 1 PROBLEM Engine won t crank Section 8 Troubleshooting QUIETPACT 55 65 and 75 Recreational Vehicle Generators TROUBLESHOOTING GUIDE CAUSE 1 7 5 amp fuse blown 2 Loose or corroded or defective battery cable s CORRECTION Replace blown fuse Tighten clean or replace as necessary 3 Battery is discharged or defective 3
58. and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor caution amp A Do NOT use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also cont aminate the generator fuel system 3 8 BATTERY MAINTENANCE All lead acid batteries will discharge when not in use The generator battery should be inspected as follows 3 8 1 WEEKLY Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary Check the battery fluid level of unsealed batteries and if necessary fill with Distilled Water Only Do not use tap water in batteries 3 8 2 EVERY SIX MONTHS Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer NOTE Servicing of the battery is to be performed or supervised by personnel knowledgeable of batter ies and the required precautions Keep unautho rized personnel away from batteries Damage will result if the battery connections are made in reverse 14 Generac Power Systems Inc QUIETPACT 55 65 and 75 Recreational Vehicle
59. arate fuel tank or it may share the vehicle engine s fuel tank 2 4 4 COOLING AND VENTILATING AIR Air inlet and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation Without sufficient cooling and ventilating airflow the engine generator quickly over heats which causes it to shut down and may damage the generator 2 4 5 ENGINE EXHAUST GAS Before starting the generator engine you should be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals Close windows doors and other openings in the vehi cle that if open might permit exhaust gases to enter the vehicle OPERATION Section 2 Operation QUIETPACT 55 65 and 75 Recreational Vehicle Generators 15 DX A A The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concen trations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOX IDE POISONING ARE a inability to think coher ently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weakness and i sleepiness IF YOU EXPERIENCE ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATE
60. asoline Only sesiones 13 3 6 Clean Spark Arrestor uoocisesdener po ui or in eni eA Gus DEUM 13 3 7 Cleaning the Gener LOT iuucociinsesct oe papud du dd unite etia di auarus d 14 3 8 Battery Mte ndliCe seour ireti 14 S NM ME iconos 14 9 0 2 Every Sik MODLDDS easier 14 3 9 Major Service Manual ous orci deti e iEn gens e gau Ed nar anepEs 15 o0 DENCIA enmaai uds 15 3 11 Exercising the Generator ejincocuccoras ariadna 15 9 12 Out OF Service Procedure asirios 15 3 12 1 Removal From Service 22 2 porter ire epe dus derer ors 15 9 12 2 IReLUEI LO SEP VICE miseria iris 15 3 13 RV Generator Service Interval cesses 15 Section 4 NOTES unicidad 16 Table of Contents TABLE OF CONTENTS Part II Installation Instructions 17 Sate y RUGS T 18 Section 5 General Information 20 5 1 Purpose and Scope of the Installation Instructions 20 5 2 ER ECON ny o o m 20 5 3 standards Booklets 55 arre RE Ears S ur RE No rbn Rio UEM 20 5 4 Equipment Descrip asia do 20 5 5 Generator Engine Operating Speed 20 5 6 Generator AC Connection System eeesss 20 Major Features and Dimensions 21 Section 6 Installation 22 6 1 Location and SUD POE cire eate riti trece H
61. at is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed e Wear full eye protection and protective clothing e Where electrolyte contacts the skin wash it off immediately with water e Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and e Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried QUIETPACT 55 65 and 75 Recreational Vehicle Generators 3 9 MAJOR SERVICE MANUAL To obtain a service manual for your generator con tact your nearest Generac Authorized Service Dealer Make sure to identify your MODEL NUMBER and SERIES Manuals can be obtained from the internet website www generac com or a service dealer 3 10 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement Drive belt tension was properly adjusted before the unit was shipped from the factory If you suspect that drive belt tension is incorrect contact a Generac Authorized Service Dealer 3 11 EXERCISING THE GENERATOR Generac recommends that you start and operate the generator at least
62. ate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the Danger Warning and Caution blocks The type of information each indicates follows A This symbol points out important safety infor mation that if not followed could endanger personal safety and or property of you and others A This symbol points out potential explosion 3 hazard This symbol points out potential fire hazard A This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator driver is responsible for proper and safe use of the vehicle and its equipment and the safety of all vehicle occupants We strongly recom mend that the operator read this manual and thor oughly understand all instructions before using this equipment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for generator model numbers 004702 0 004703 0 004704 0 004705 0 004706 0 and 004707 0 In addition the latter por tion of this manual contains information necessary for the proper installation of th
63. available same as Item 1 3 ANSI C1 1975 and ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI A119 2 NFPA 501C available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 avail able from the State of California Documents Section PO Box 1015 North Highlands CA 95660 20 Generac Power Systems Inc Section 5 General Information QUIETPACT 55 65 and 75 Recreational Vehicle Generators 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 5 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to Generac air cooled generators These generators are designed specifically for installing in recreational vehicles They operate 120 volt single phase 60 Hertz AC electrical loads 5 5 GENERATOR ENGINE OPERATING SPEED The generator s revolving field rotor is driven by a single cylinder four cycle engine through a pulley and drive belt arrangement The generator supplies 120 volts AC at 60 Hertz when the rotor is operating at 3 600 rpm The drive belt arrangement allows the engine to operate at a lower speed than the rotor 5 6 GENERATOR AC CONNECTION SYSTEM These air cooled generator sets are equipped with dual sta
64. cable 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 c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted fo
65. e 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 YOU EXPERI ENCE ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PER SIST GET MEDICAL HELP Shut down the gener ator and do not operate it until it has been inspect ed 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 Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or per mit even partial blockage of ventilation provisions as this can seriously affect safe operation of the ge
66. e generator engine gives off 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 vomiting c twitching muscles d throbbing temples e dizziness f headaches g weakness and h sleepiness IF YOU FEEL ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Do not operate the generator until its exhaust system has been inspected and properly repaired caution amp A 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 Generac Power Systems Inc 29 INSTALLATION TED Section 6 Installation 6 6 1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U S Forest Service Use only mufflers and parts approved by Generac Any person s installing an unapproved muffler or an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable for any dam age injury or warranty exp
67. el from the tank to the fuel pump This rocker type switch springs back into its original position when you release it 2 1 2 START STOP SWITCH To crank and start the engine hold this switch in the START position Release the switch when the engine starts To stop an operating engine press and hold the switch in the STOP position until the engine shuts off The switch center position is the RUN position 2 1 3 7 5 AMP FUSE The fuse protects the engine s DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine cannot be cranked If you must replace the fuse use only an identical 7 5 amp replacement fuse 2 1 4 LINE BREAKERS Protects generators AC output circiut against overload i e prevents unit from exceeding wattage amperage capacity The circuit breaker rat ings are as follows Circuit Breaker 1 Circuit Breaker 2 QuietPact 55 20A QuietPact 65 30A 30A QuietPact 75 35A 35A NOTE If this generator has been reconnected for dual voltage AC output 120 240 volts you can install line breakers having an amperage rating that is different than that stated above The replacement line breakers consist of two separate breakers with a connecting piece between the breaker handles so that both breakers will operate at the same time If the unit is reconnected for dual voltage it is no longer RVIA or CSA listed Figure 2 1 Typical Control Panel
68. ense that might be caused by such unapproved installation or modification Failure to provide and maintain a spark arrestor may be in violation of the law If this generator is used on any forest covered brush covered or grass covered unimproved land you must provide a spark arrestor The vehicle owner or operator must maintain this device in good condition In the state of California the preceding is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands When installing replacing the tailpipe or spark arrestor components verify that the tailpipe has a hole to securely fasten the spark arrestor compo nents see Figure 6 17 Use only Generac supplied hardware Substitution of parts may cause damage to the screen or a loose fit to the tailpipe Figure 6 17 Spark Arrestor Installation j 38 1 o O D 85 9 64 DRILL 24 0 95 BOT OM SIDE ONLY 6 6 2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any com bustible material such as wood felt cotton organic fibers or other like material If you cannot maintain the 3 inch 76 mm clearance 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 temperature Extend the exhaust system at least 1 inch
69. erator 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 accident caused by electric shock imme diately 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 nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards 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 established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fire exti
70. erned speed Some electrical appli ances may be extremely sensitive to voltage Incorrect voltages can damage such appliances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when suf ficient power is not available may shorten engine life Never turn ON electrical loads until after the genera tor engine has started and stabilized at no load Generac Power Systems Inc 9 OPERATION Section 2 Operation 15 QUIETPACT 55 65 and 75 Recreational Vehicle Generators 2 7 2 DO NOT OVERLOAD THE GENERATOR You can read the rated wattage amperage capacity of your generator on the generator data decal see Section 1 1 on Page 4 Applying electrical loads in excess of the unit s rated capacity will cause the engine generator to automati cally shut down To avoid overloading add up the wattage of all con nected electrical lighting appliance tool and motor loads This total should not be greater than the gen erator s rated wattage capacity Most lighting appliance tool and motor loads indi cate their required watts on their nameplate or data plate For light bulbs simply note the wattage rating of the bulb If a load does not show its rated wattage multiply that load s rated VOLTS times AMPS to obtain WATTS Induction type motors such as those that run the vehicle s furnace fan refrigerator air conditioner etc need about 2 1 2 times more watts of power for s
71. ese generators OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safe ty checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Authorized Service Dealer Normal maintenance ser vice and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum See your Generac Authorized Service Dealer for service aids and acces sories HOW TO OBTAIN SERVICE When your generator requires servicing or repairs simply contact a Generac Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all of your service needs When contacting a Generac Authorized Service Dealer or the factory about parts and service always supply the complete model number and serial num ber of your unit as given on its data decal which is located on your generator Model No Serial No AUTHORIZED SERVICE DEALER LOCATION To locate the GENERAC AUTHORIZED SERVICE DEALER nearest you please call this number 1 800 333 1322 ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT TH
72. 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 combina tion of acoustical materials as mentioned in Section 6 2 3 A Da A To prevent fire or explosion do not install any insulation or other absorbent materials on the interior or underside of the compartment floor e Seal all compartment door edges to prevent noise leakage around the door perimeter Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 inch 25 mm thick fiberglass with a 2 pound density Figure 6 7 Typical Noise Abatement PLYWOOD PLYWOQ EXTERIOR 5 8 OR 3 4 THICK NUN METAL MATERIAL SESS 7 uy M f Ss A LO ES an PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION INSTALLATION LD Section 6 Installation 6 2 5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compart ment for the following items Figure 6 8 Page 26 Engine exhaust and cooling air outlets Generator cooling air inlet e Four holes for passage of generator mounting bolts See Section 6 1 4 Page 23 A DIE A 1 Fuel lines and exhaust piping must not pene trate into the vehicle living area 6 3 COOLING AND VENTILATING AIR It is absolutely essential that an adequa
73. h 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 6 1 The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the generator below the horizontal support tubing by means of suit able structurally sound metal framework The fol lowing general rules apply Vehicle construction MUST be capable of support ing the weight of the generator Whether the generator is mounted above the hori zontal support tubing or suspended below the tub ing the supporting frame used must be structural ly sound e If the generator cannot be bolted directly to the supporting frame or support tubing consider using additional tubing angle brackets or other supports to give the supporting frame sufficient strength Figure 6 1 Typical Horizontal Support Frame SUPPORT TUBING QUIETPACT 55 65 and 75 Recreational Vehicle Generators 6 1 3 SUSPENDED MOUNTING If you are going to suspend the generator below the horizontal support tubing the suspension method you use with the vehicle frame members must a be able to support the weight of the generator AND b provide sufficient restraint f
74. he filter in place QUIETPACT 55 65 and 75 Recreational Vehicle Generators Figure 3 3 Engine Air Cleaner Flat Wing Washer Nut Precleaner Air Filter Offset Stud Lock Washer Gasket M i Airbox Compartment p el Wing p gt a Nut ud 3 4 CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and com mercial solvent Do not blast the spark plug to clean 2 Remove the spark plug and check the condition Replace the spark plug if worn or if reuse is ques tionable 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 030 inch 0 76 mm by carefully bending the ground electrode Figure 3 4 Figure 3 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 030 inch 0 76 mm NC caution amp A Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end If necessary re form the wire terminal to obtain a tight fit 3 5 FUEL FILTER GASOLINE ONLY Remove and replace the fuel filter Figure 3 5 once each year or every 400 hours of operation whichever comes first MAINTENANCE 2D Section 3 Maintenance Figure 3 5 Fuel Filter ida TO FUEL PUMP CUSTOMER FUEL CON
75. hours of operation is the break in period for the generator Properly breaking in the generator is essential to minimize fuel consumption and pro vide maximum engine performance During this 25 hour break in period follow this procedure e Run the unit at varying electrical loads to help seat the engine piston rings properly Check the engine oil level frequently Add oil if needed It is normal for the generator engine to consume more oil than is normal until the piston rings have properly seated For the 75 hour operation following the break in period avoid light electrical loads Load the generator at 50 percent or more of its rated wattage capacity Repeated light loads during these 75 hours can cause improper seating of engine pis ton rings resulting in blowby and high oil con sumption e After operating the unit for 25 hours complete the tasks recommended under Section 2 8 6 MAINTENANCE 2D Section 3 Maintenance 2 8 6 25 HOUR CHECK UP After the 25 hour break in period contact a Generac Authorized Service Dealer for the following mainte nance The vehicle owner is responsible for any charges relating to normal unit maintenance Change the engine crankcase oil and oil filter Check all fluid levels e Inspect the cooling and ventilation openings Check the engine ignition system Inspect the entire electrical system Inspect the engine exhaust system 2 8 7 OPERATION IN HIGH GRAS
76. is o bixv eel aiye 22 6 1 1 Generator Location cesses 22 6 1 2 Generator Support semis geh Er ERE x Exe ed EE URNA 22 6 1 3 Suspended Mounting eere 23 6 1 4 Generator Restraint eeeeeeeesse 23 6 2 Generator Compartments cesses 23 6 2 1 Compartiment SIZE iecore ere tddi 23 6 2 2 Compartment Construction 23 6 2 3 Sound Insulating Materials 24 DIA ACOUSUOS sesion 25 6 2 5 Compartment Floor Cutouts 25 6 3 Cooling and Ventilating Air eese 25 6 9 1 Generator AIrlIOW 25i eire totae ern nkra Erani 25 6 3 2 Testing the Installation esee 26 6 4 Gasoline Fuel SySUetlk dossier hospi rad 26 AS 27 6 4 2 Generator Fuel Supply Line 27 6 5 LP Gas Fuel SVSICPIE estirar 27 6 5 1 LP Fuel Consutmptloh eroe o tado ern rea esa SRiG 27 6 5 2 Parts Not Included in Fuel System 27 6 5 3 Some Important Considerations 28 6 5 4 Vapor Withdrawal cities 28 6 5 5 Primary Regulator eee 28 6 5 6 Gaseous Carburetion eese 28 6 5 7 Fuel Supply Lines eds bite than ioi pero E ESPSRUA 29 6 5 8 Excess Flow Valve esnansstisinlen ainia 29 0 5 9 Leakage Pests eo riora sp iban 29 6 6 PXNAUSU SVSUCIM A 29 6 6 1 Mufflers and Spark
77. l Vehicle Generators Enclosure Drawing No OE1011 B O ITEM PART NO QTY DESCRIPTION 1 0D8827 1 PANEL ENCLOSURE ROOF 2 0A7215 22 SCREW SW 1 4 20X5 8 N WA JS500 3 029451 11 5 FT TAPE ELEC UL FOAM 1 8 X 1 2 4 0D8825 1 PANEL SIDE AND BACK ENCLOSURE 5 0D3700 14 NUT FLANGE M6 1 0 NYLOK GASOLINE ONLY 0D3700 17 NUT FLANGE M6 1 0 NYLOK LP ONLY 6 090388 8 SCREW HHTT M6 1 0 X 12 YC 7 0D8979 1 PANEL AIR IN DUCT BASE 8 0D8960 1 PANEL CUSTOMER CONNECTION 9 023484D 1 BUSHING SNAP SB 875 11 10 0E0594 1 COVER RV AIR CLEANER BOX 11 064113 1 STUD WINGNUT M6 1 0 X 20MM NY 12 0E0575 1 FOAM SEALING STRIP 1 X 12FT 13 0D8980 1 PANEL AIR IN DUCT BACK 14 0E1376 1 BAFFLE V TWIN RV SHORT 15 0E1377 1 BAFFLE V TWIN RV LONG 16 0D8628 3 5 FOAM AIR OUT COMPARTMENT 17 0D8910 1 PANEL MUFFLER SHIELD 18 0D8826 1 PANEL ENCLOSURE SIDE 19 0D9162 1 PANEL FRONT amp SIDE ENCLOSURE 20 0C5644 2 SLIDE LATCH FLUSH 21 0D8828 1 PANEL ENCLOSURE DOOR 22 0E0585 1 FOAM PANEL DOOR 1 2 THK QP RV 23 0E1486 1 HARNESS AC OUTPUT 5 5 6 5 amp 7 5 KW ONLY 0E1774 1 HARNESS AC OUTPUT 5 0 amp 7 0 KW 50 Hz ONLY 24 0D9099 1 CUST CONN 4KW RV REMOTE 25 074908 4 SCREW HHTT M5 0 8 X 10 BP 26 022473 1 WASHER FLAT 1 4 M6 ZINC 27 022097 1 WASHER LOCK M6 1 4 28 022507 1 SCREW HHC 1 4 20 X 1 2 G5 29 0742600149 1 WIRE ASM BATT NEG QP RV 30 0C7968 4 NUT HEX JAM 3 8 16 BRASS 31 022237 2 WASHER LOCK 3 8 32 007423 1 STUD 3 8 16 X 2 1 4 BRASS 33 0742600151 1 GND WIRE C PNL
78. l the end of the conduit where it enters the junction box Do this because flexible metallic conduit is not vapor proof along its entire length 6 7 5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 6 19 Page 33 An alternate method for isolating dif ferent power sources is by using an isolating recepta cle Figure 6 20 Page 33 Whichever method you use you must be certain that both power sources are NOT connected at the same time 6 7 6 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 See page 33 for illustration Generac Power Systems Inc 31 INSTALLATION TED Section 6 Installation 6 7 7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code NFPA 70 article 551 requires that you install ground fault circuit inter rupters GFCIs on all external and some internal electrical receptacles Contact your manufacturer or dealer for recommendations 6 8 BATTERY INSTALLATION 6 8 1 RECOMMENDED BATTERY Install a battery that meets the following require ments e The battery must be a 12 volt automotive type storage battery e For prevailing ambient temperatures above 32 F O C use a battery rated 70 amp hours and capa ble of delivering 400 cold c
79. le from the battery post indicated by a NEGATIVE NEG or to the frame ground connection Figure 6 21 3 Connect cables so the connectors are clean and tight Figure 6 21 Connecting Battery Cables Q 6 6 WwW Positive Cable Battery Negative Cable O Chassis Ground 6 8 4 BATTERY COMPARTMENT Install the generator battery in its own vented com partment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage Section 6 Installation INSTALLATION e y QUIETPACT 55 65 and 75 Recreational Vehicle Generators Figure 6 18 Transfer Switch Isolation Method 2ND AIR FROM 20 AMP CONDITIONER HACR BREAKER JUNCTION BOX VEHICLE FLEXIBLE mtus CONDUIT B E TN VEHICLE AC amp DISTRIBUTION DOUBLE PANEL 6 THROW gt SWITCHING 30 AMP MAIN BREAKER G DEVICE HACR BREAKERS FOR AIR CONDITIONERS EN GFCI BREAKERS POWER SUPPLY CORD Figure 6 19 Installation With Isolation Receptacle DOCKSIDE POWER RECEPTACLE JUNCTION e BOX FLEXIBLE CONDUIT oT power SUPPLY CORD
80. ll not be accepted without presentation of the Warranty Registration Card 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 e Rotor Stator Computer Control Board if applicable with regard to the generator Cylinder Block Cylinder Head Crankshatt 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 Generac s SUPER SERVICE INFORMATION MAN
81. maximum current If neutral conductors are used they must be the same size as other leg wires Route power supply conductors from generator AC output leads T1 red T2 white T3 black and the green ground wire through approved flexible conduit to the electrical junction box on the com partment wall e If flexible metal conduit is used between the gener ator and the compartment junction box the con duit end that terminates the compartment junction box must be vapor sealed Flexible metal conduit is NOT vapor tight along its entire length From the junction box route power supply wires through approved conduit to either a double pole double throw transfer switch or b approved isolation receptacle Connecting to a transfer switch or isolation receptacle must pre vent vehicle electrical circuits from being connect ed to two different power supplies at the same time such as generator and dockside power e Conductors must be rated 221 F 105 C or must be of a larger conductor size 6 7 3 GENERATOR AC CONNECTIONS Generator AC output leads T1 red T2 white and T3 black come out of the generator as shown in Figure 6 18 Leads T1 red and T3 black are hot while T2 white is the grounded neutral lead There is also a green lead that connects to ground in the junction box of the recreational vehicle Figure 6 18 Generator AC Output Leads To
82. multiply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of cur rent for starting than for continuous operation Section 1 General Information QUIETPACT 55 65 and 75 Recreational Vehicle Generators GENERAL INFORMATION 1 3 INSTALLATION This Owner s Manual has been prepared under the assumption that a competent qualified technician installed the generator into a recreational vehicle We also assume the installer complied with all applicable codes standards and regulations pertaining to instal lation An INSTALLATION MANUAL was shipped with the generator That Manual contains manufacturer s instructions and recommendations for installing the unit into an industrial vehicle After installation installers should forward the Installation Manual to Owners Operators for their information Owners Operators have the responsibility to make sure that nothing is done that might render the instal lation unsafe or in non compliance with applicable codes standards and instructions 1 4 SAFETY Before using the generator set carefully read GEN ERAL SAFETY RULES inside the cover Comply with these RULES to prevent accidents and damage to equipment and or property Generac suggests copy ing and posting the GENERAL SAFETY RULES to potential operators of this equipment 1 5 GENERATOR AC CONNECTION SYSTEM These air cooled generator sets are equipped with dual
83. n Page 20 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 Electrical Code NFPA 70 and state and local codes apply e Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent damage from road shock Wiring must be of adequate size have approved insulative qualities and be properly supported Conduit and wire openings into the generator com partment if used must be vapor sealed to prevent entry of flammable explosive or poisonous gases into the vehicle 6 7 1 ELECTRICAL JUNCTION BOX Install an approved square electrical junction box with a blank cover on the interior or exterior wall of the area you plan to install the generator NOT on the generator Route the generators AC output leads into this junction box through approved flexible con duit This is the point of first termination for genera tor AC output leads QUIETPACT 55 65 and 75 Recreational Vehicle Generators 6 7 2 WIRING Wiring should be of stranded copper to reduce the chance that vibration may cause breakage Wire gauge size should be large enough to handle at least 115 percent of the installed generator s rated
84. n working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS e For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations 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 you have any question per taining to fire extinguishers consult your local fire department ZA EXPLOSION HAZARDS 4 Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the
85. nection 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 Usea length of approved flexible fuel hose between the gaseous fuel solenoid valve and rigid gas pip ing The flexible line should be at least 6 inches longer than necessary 6 5 4 VAPOR WITHDRAWAL LP gas is stored in pressure tanks as a liquid The gas systems used with these generators 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 generator with any liquid with drawal type system ee Generac Power Systems Inc QUIETPACT 55 65 and 75 Recreational Vehicle Generators 6 5 5 PRIMARY REGULATOR Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regula tor Mount the primary regulator at the gas tank out let or in the supply line from the gas tank The fol lowing rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inch es water column Do NOT exceed 14 inches water column The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommended MINIMUM gas flow rate for all air cooled PRIMEPACT series generators is
86. nerator When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental start up Disconnect the cable from the bat tery post indicated by a NEGATIVE NEG or first Reconnect that cable last AFETY RULE Safety Rules 2 aia QUIETPACT 55 65 and 75 Recreational Vehicle Generators 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 You might seriously injure yourself or damage the equipment ELECTRICAL HAZARDS 4 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 Ensure all appropriate covers guards and barriers are in place before operating the generator If you must work 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 in
87. ng a 2 pound den sity When fiberglass is used its coated side should face toward the compartment interior A DNI A 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 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 QUIETPACT 55 65 and 75 Recreational Vehicle Generators 6 2 4 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement com partment NOTE Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compartment In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise levels Such a compartment might be constructed as follows Figure 6 7 Use 5 8 inch thick or 3 4 inch thick plywood in the compartment Construct the compartment floor of a double thick ness of 5 8 inch or 3 4 inch plywood Line the compartment interior walls and
88. nguisher 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 you have any question pertaining to fire extinguishers consult your local fire department EXPLOSION HAZARDS 4 Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline This generator may use liquid propane LP gas as a fuel LP gas is highly EXPLOSIVE The gas is heavier than air and tends to settle in low areas where even the slightest spark can ignite the gas and cause an explosion Generac Power Systems Inc 3 Section 1 General Information QUIETPACT 55 65 and 75 Recreational Vehicle Generators 1 1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage 5
89. nits must be installed on the side of the vehicle and are difficult to reinforce Many recreational vehicles have been factory equipped with an area for the generator set 5ome 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 frame work that is part of the recreational vehicle as out lined in Section 6 1 2 The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from under neath the supporting framework The location must provide easy access to frequent ly serviced components such as filters oil drains spark plugs and other common maintenance parts ee Generac Power Systems Inc QUIETPACT 55 65 and 75 Recreational Vehicle Generators The location must provide sufficient room to allow minimum clearances as outlined in Section 6 2 If sound insulation is to be used on the compartment walls and ceiling the minimum recommended applies to the space between the generator and such insulation The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense 6 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 whic
90. o a recreational vehicle must comply strictly with article 551 NFPA 70 ANSI C1 1975 AND ANSI A119 2 1975 NFPA 501C Standard for Recreational Vehicles Part 3 Installation of Electrical Systems In addition installation must comply with the manufacturer s instructions and recommendations NOTICE TO INSTALLER These Installation Instructions have been published by Generac to aid in the installation of the products described in this manual Generac assumes that installation personnel are familiar with the proce dures for installing such products or similar prod ucts that Generac manufactures Generac also assumes that personnel have been trained in the rec ommended installation procedures for these prod ucts and that such training includes a use of com mon hand tools b use of special Generac tools and c use of any tools and or equipment from other sup pliers Generac cannot possibly know of and 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 product s safety is
91. once every seven days Let the unit run for at least 30 minutes to exercise the engine 3 12 OUT OF SERVICE PROCEDURE 3 12 1 REMOVAL FROM SERVICE If you cannot exercise the generator every seven days and it is to be out of service longer than 30 days pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 5W 30 oil having API classification For Service SF 4 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase o Remove the spark plug and pour two or three tablespoons of clean fresh engine oil into the spark plug threaded openings Reinstall and tighten the spark plug 6 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor 7 Clean and wipe the entire generator MAINTENANCE LD Section 3 Maintenance 3 12 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Check the tag on the engine for oil viscosity and classification Verify that the correct recommend ed oil is used in the engine see Section 1 5 4 Page 6 If necessary drain and refill with the proper oil 2 Check the state of the battery Fill all cells of
92. or exhaust system parts Use nonferrous metal straps without sharp edges to secure fuel lines INSTALLATION TED Section 6 Installation 6 4 2 2 Flexible Fuel Line Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines This prevents breaking of the line caused by vibration shifting settling or movement The follow ing rules apply e The flexible hose must comply with SAE J30B Standard for Fuel and Oil Hose It must be approved for use with gasoline The hose should be at least 6 inches 152 mm longer than is needed to prevent the hose from rupturing if the generator shifts or settles 6 5 LP GAS FUEL SYSTEM A DIG A A LP gas is highly EXPLOSIVE The gas is heavier than air and tends to settle in low areas Even the slightest spark can ignite it and cause and explosion Only competent qualified people should be allowed to install test adjust or ser vice an LP gas fuel system Install the optional fuel system in compliance with applicable codes standards and regulations After the installation do not do anything that might ren der the system in noncompliance with applica ble codes and standards The LP powered range of generators are fitted with a nonadjustable factory set system These systems are tamper proof to meet 1997 California Air Resources Board requirements for engine emission 6 5 1 LP FUEL CONSUMPTION Ib hour 6 5 2
93. or the generator One typ ical suspended mounting system is shown in Figure 6 2 The location of a suspended mounting system must be carefully planned keeping the following gen eral 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 gen erator is adequately protected road test the installa tion through mud water and slush Figure 6 2 Typical Suspended Mounting System The installer must make certain that the selected location will permit adequate cooling and ventilat ing airflow to be supplied 6 1 4 GENERATOR RESTRAINT Use four 3 8 16 hardened steel bolts Grade 5 to fas ten the generator to the supporting frame or the sup port tubing These bolts must pass through a the gen erator mounting base b the compartment floor if a compartment is used and c the supporting frame work Figure 6 3 All bolts must be long enough so that when tight at least three threads are visible past the retaining lock nuts Refer to Section 6 2 for the location of the generator mounting holes Figure 6 3 Typical Generator Restraint METAL LINED Ya INCH THICK METAL LINED VEHICLE BOTTOM INSTALLAT
94. r parts needing repair or replacement AFETY RULE Safety Rules 2 aia QUIETPACT 55 65 and 75 Recreational Vehicle Generators Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental start up Disconnect the cable from the bat tery post indicated by a NEGATIVE NEG or first 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 ZA ELECTRICAL HAZARDS 4 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 Ensure all appropriate covers guards and barriers are in place before operating the generator If you must work 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 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 gen
95. r 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 responsi ble 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
96. ranking amperes e For prevailing ambient temperatures below 32 F O C use a battery rated 95 amp hours and capa ble of delivering 400 cold cranking amperes NOTE If the battery is to be used to power other vehicle accessories as well as start the generator you may need a battery with a larger capacity 6 8 2 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes starting problems For the best cold weather starting the voltage drop between battery terminals and the generator connection point should not exceed 0 12 volts per 100 amperes of cranking current PRIMEPACT generators are rated at about 100 DC amperes of cranking current Select battery cables based on a cable length and b prevailing ambient temperatures Generally the longer the cable and the colder the weather the larg er the cable size must be as shown in the chart CABLE LENGTH in Feet meters CABLE SIZE 16 to 20 4 5 to 6 For warm weather use No 2 cable up to 20 feet 32 Generac Power Systems Inc QUIETPACT 55 65 and 75 Recreational Vehicle Generators 6 8 3 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or to the lug on the starter contactor Figure 6 21 NOTE Check to be sure the battery cable boot for the starter cable has been installed 2 Connect the battery cab
97. ranking only a positive DC battery voltage is deliv ered through a diode resistor brushes slip rings and the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Figure 2 4 Field Boost Circuit CONTROLLER CIRCUIT CLOSEST TO BOARD BEARING QUIETPACT 55 65 and 75 Recreational Vehicle Generators 2 8 4 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 5 controls the generator s AC output voltage This regulator sup plies an excitation current to the rotor By regulating the rotor s excitation current the strength of its mag netic field is regulated and in turn the voltage deliv ered to connected electrical loads is controlled When the AC frequency is 60 Hertz voltage is regulated at 115 volts Figure 2 5 Solid State Voltage Regulator Q e p SENSING C 4 TO ROTOR m E 0 DIRECT CURRENT CORP FROM STATOR TS EXCITATION WINDING ALTERNATING CURRENT NN Q The voltage regulator also incorporates a voltage surge protection circuit This circuit prevents trou blesome surges in the generator AC output voltage Voltage surge is a common cause of damage to elec tronic equipment 2 8 5 25 HOUR BREAK IN PERIOD The first 25
98. rator has started stabi lized and warmed up 2 If you have not started the engine in more than two weeks press the Fuel Pump Primer switch and hold it for about 10 seconds However if the engine is warm skip Step 2 3 To crank and start the engine hold the start stop switch at START Release the switch when the engine starts caution amp A If the engine does not start after it has been cranking for 15 seconds release the Start Stop switch and wait 1 minute before trying again Holding the switch for longer than 15 seconds can damage the starter motor 4 Let the engine run at no load for a few minutes to stabilize and warm up 5 Turn ON electrical loads using the means provided such as a main circuit breaker or transfer switch 2 6 STOPPING THE GENERATOR Turn OFF all electrical loads using the means provided such as a main circuit breaker or transfer switch 2 Let generator run at no load for a few minutes to stabilize internal engine generator temperatures 3 Place the Start Stop switch in its STOP position The engine will come to a complete stop 2 7 APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Before applying electrical loads let the generator stabilize and warm up for a minute or two DO NOT overload the generator 2 7 1 LETTING THE ENGINE STABILIZE The generator supplies correct rated voltage only at the proper gov
99. re more cranking for initial starting since the fuel lines have to be primed use of the primer switch will shorten this time 3 Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load See Section 7 4 Run the unit at least 30 minutes with loads applied 6 Turn off all electrical loads by setting the genera tor s main circuit breakers to their OFF or open position 7 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine NOTE The generator set was thoroughly tested and adjusted at the factory before shipping No addi tional adjustment should be necessary Only qual ified service technicians who have been trained should perform adjustments outlined in this man ual QUIETPACT 55 65 and 75 Recreational Vehicle Generators 7 4 TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 per cent of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling airflow is available You m
100. special circumstances WARNING 4 A 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 34 Generac Power Systems Inc QUIETPACT 55 65 and 75 Recreational Vehicle Generators 7 2 BEFORE INITIAL START UP Before starting complete the following 1 Check the engine crankcase oil level and if nec essary fill to the dipstick FULL mark cross hatched area with the recommended oil Do not fill above the 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 A NE A If a liquid propane LP gas fuel system has been installed it must be properly tested for leaks before operating the system in compli ance with ANSI A119 2 NFPA 501C No leakage is permitted You must be sure no gasoline fuel vapors enter the vehicle interior 7 5 INITIAL START When you are absolutely certain that the unit has been properly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s main circuit breakers to their OFF or open position 2 Refer to Part I Section 2 5 Starting the Generator Page 8 for cranking and starting instructions The engine may requi
101. ss section for added strength Figure 6 5 Generac Power Systems Inc 23 INSTALLATION TED Section 6 Installation Figure 6 5 Typical Compartment Construction CROSS SECTION VIEW METAL LINING FIREPROOF SOUND INSULATION METAL LINING VAPOR SEALED AT ALL TIMES METAL LINING PLYWOOD e If constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel e All seams splices and joints of the compartment walls unless vapor tight by design should be caulked to prevent poisonous flammable or explo sive vapors from entering the vehicle interior NOTE Caulking must be done so that the caulking mate rial will stay in place permanently Pressing such materials as putty tape onto joints and seams is not acceptable A high quality silicone rubber base sealant is recommended Holes and openings made in the compartment walls to allow for the passage of electrical conduit conductors hoses cables etc into the vehicle liv ing area must be sealed vapor tight with silicone rubber base sealant e If flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartments electrical junction box NOTE Flexible metal conduit due to its unique con struction is NOT vapor tight along its entire length e Seams and joints of the galvanized steel whether used as
102. st 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 fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 5e Generac Power Systems Inc Section 12 Warranty QUIETPACT 55 65 and 75 Recreational Vehicle Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1997 and later model year engines a Applicability This warranty shall apply to 1997 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall contin ue 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 appli
103. stallation 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 If the vehicle electrical circuits can be powered by any other source of electricity such as a dockside power receptacle there must be no possibility of connecting the different power sources to the vehi cle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operating Failure to isolate the vehicle circuits from the dock side power supply when the generator is running may result in damage to the generator or serious injury or death to dockside utility power workers due to backfeed of electrical energy In case of accident caused by electric shock imme diately 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 nonconducting implement such as a rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry whe
104. stator AC power windings These two stator windings supply electrical power to customer electri cal loads by means of a dual 2 wire connection sys tem Generators may be installed to provide the following outputs 1 120 VAC loads only one load with a maximum total wattage requirement equal to the generator s rated power output in watts and 120V across the generator output terminals Figure 1 1 page 6 shows the generator lead wire connections for 120VAC ONLY 2 120 240 VAC loads one load with a maximum total wattage requirement equal to the generator s rated power output and 240V across the genera tor output terminals or two seperate loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120V across the generator output ter minals Figure 1 2 page 6 shows the generator lead wire connections for 120 240 VAC loads Also refer to section 2 1 4 Line Breakers for cir cuit breaker ratings This procedure should be done by a Generac Authorized Service Dealer or other qualified installer Generac Power Systems Inc 5 Section 1 General Information GENERAL INFORMATION 120V STATOR POWER WINDINGS T2 WHITE T2 WHITE GROUNDED NEUTRAL Figure 1 2 Connection for 120 240 Volts T1 RED A 120 VAC T2 Y 240 WHITE A VAC 120 VAC 3 Y STATOR WINDINGS GROUNDED NEUTRAL 1 6 SPECIFICATIONS 1 6 1 FUEL RE
105. tarting than for running for a few seconds during motor starting Be sure to allow for this when connecting electrical loads to the generator First figure the watts needed to start electric motors in the system To that figure add the run ning wattages of other items that will be operated by the generator Do not apply heavy electrical loads for the first two or three hours of operation 2 8 PROTECTION SYSTEMS 2 8 1 LOW OIL PRESSURE SWITCH This switch Figure 2 3 has normally closed N C contacts that are held open by engine oil pressure during cranking and operating Should oil pressure drop below a preset level switch contacts close and the engine automatically shuts down The unit should not be restarted until oil is added 10 Generac Power Systems Inc 2 8 2 HIGH TEMPERATURE SWITCH This switch Figure 2 3 which has normally open N O contacts is mounted near the oil filter The contacts close if the temperature should exceed approximately 270 F 132 C for gasoline models and 284 F 140 C for LP models initiating an engine shutdown Figure 2 3 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE ENGINE OIL OIL PRESSURE FILTER SWITCH 2 8 5 FIELD BOOST The Controller Circuit Board houses a field boost diode and resistor that are not part of the automatic choke circuit These two components are part of a field boost circuit Figure 2 4 During engine c
106. te 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 also may 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 also must provide for a path for exhausting the cooling air to the exterior of a com partment if so equipped A DX A 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 6 3 1 GENERATOR AIRFLOW Engine operation drives cooling fans for the two stage cooling air system A pressure fan draws cooling air into the top of the generator Figure 6 9 This airflow cools the engine generator and electronic compo nents The second part of the cooling system a suc tion fan draws air that is heated from a hot engine into a collector pan at the base of the unit This heat ed air although cooler than exhaust muffler is then deflected out the bottom toward the ground Figure 6 9 Airflow Through Engine Generator g M tJ Y NN Generac Power Systems Inc 25 INSTALLATION TED Section 6 Installation QUIETPACT
107. the engine oil after the first 25 hours of operation after the 25 hour break in period see Section 2 8 5 Page 10 Thereafter change the oil every 100 operating hours Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures Change the engine oil filter after the first 25 hours of operation and every 100 operating hours there after To change the oil and or oil filter proceed as follows 1 Run the engine until it is thoroughly warmed up at least five minutes then shut OFF the engine 2 With the engine still warm from running remove the oil drain plug Figure 3 1 Drain the oil into a suitable container Figure 3 1 Oil Dipstick Fill Tube and Location of Oil Drain Plug Cil Dipstick 9 Q 3 C Oil Drain Hose 3 After the oil has drained replace the oil drain plug If only changing the oil go to step 7 4 With the oil drained remove the old oil filter by turning it counterclockwise Figure 3 2 5 Apply a light coating of clean engine oil to the gas ket of the new filter 6 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tight en the filter an additional 3 4 to one turn 7 Remove the dipstick and fill crankcase with the proper type and amount of recommended oil see Section 1 6 2 Page 6 The engine crankcase can hold about 1 8 liters or 1 9 quarts with oil filter change DO NOT FILL
108. tor AC power windings These two stator windings supply electrical power to customer electrical loads by means of a dual 2 wire connection system Generators may be installed to provide the following outputs 1 120 VAC loads only one load with a maximum total wattage requirement equal to the generator s rated power output in watts and 120V across the generator output terminals See Fig 5 1 below 2 120 240 VAC loads one load with a maximum total wattage requirement equal to the generator s rated power output and 240 V across the generator output terminals or two seperate loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120 V across the generator output terminals See Fig 5 3 on page 22 Figure 5 1 Connection for 120 Volts Only 120V 120V STATOR POWER WINDINGS T2 WHITE T2 WHITE GROUNDED NEUTRAL Section 5 General Information QUIETPACT 55 65 and 75 Recreational Vehicle Generators t cc LLI Z LLI o Figure 5 2 Major Features and Dimensions Drawing No 0E1058 A L ELS ozy JONYNILNIYN d38 NO34 TIY is si HOJ SS320V HOOd LN
109. uld be extremely difficult if not impractical to provide detailed instructions for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all applicable codes standards and regulations pertain ing to the installation and use of this product If any portion of this manual appears to be in conflict with such codes standards or regulations the applicable codes standards or regulations must take prece dence over the manual 5 2 SAFETY Before handling installing operating or servicing this equipment carefully read the Notice to Installer and Safety Rules on Pages 18 and 19 Comply with all safety rules to prevent death personal injury or damage to equipment and or property Stress safety to all installers operators and service technicians who work on this equipment 5 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 Standard 501C Standard for Recreational Vehicles available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 NFPA 70 NFPA Handbook of the National Electric Code
110. ust not allow the unit to overheat during prolonged operation NOTE The generator engine is equipped with a high tem perature switch The switch has normally open N O contacts When the engine temperature is too high switch contacts close and the engine shuts down automatically GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLINC 7 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT Q Generator is properly located Q Generator is properly supported Q Generator is properly restrained GENERATOR COMPARTMENT Q Compartment construction is proper Q Holes Openings are vapor sealed Q Compartment size is correct Q Compartment is vapor sealed Q Sound insulation is correct Q Floor cutouts are properly completed COOLING AND VENTILATING AIR U Airflow is adequate A Air inlet opening is correct Q Compensate for restrictions Q Check that installation has been tested GASOLINE FUEL SYSTEM Q Fuel tank complies with all applicable codes Q Fuel system is properly installed and checked for leaks DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER INSTALLATION LED Section 7 Post Installation OPTIONAL LP GAS FUEL SYSTEM Q Fuel system is properly installed and checked for leaks Q Pressure at regulator inlet is correct Q Rated flow of primary regulator is correct Q All parts are properly installed Q Fuel system is properly tested adjusted EXHAUST S
111. vehicle generator set must comply with applicable codes standards and regula tions The entire fuel system must be completely free of leaks There must be no possibility of gasoline vapors entering the vehicle interior Figure 6 14 Generator Fuel System Ltt Fuel Pump n IW m Behind Access E ta m Ld 3 no Cover eS J A MERE Fuel Filter a a i Side of Unit a Fuel Line QUIETPACT 55 65 and 75 Recreational Vehicle Generators Factory installed generator fuel system components include a fuel filter b 12 volt DC electric pump c engine carburetor and d interconnecting lines and fittings Connect a fuel supply line to the fuel filter inlet Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines 6 4 1 FUEL TANK Either the generator must share the vehicle engine s fuel tank or you must install a separate fuel tank for the generator set All fuel tanks installed on the vehi cle must be constructed installed and restrained so they comply with applicable codes standards and regulations If the generator is to share the vehicle engine s tank
112. y detergent oil classified For Service SF and with an oil viscosity rating of SAE 10W 30 oil Do not pour in any additives to the rec ommended oil Engine crankcase capacity is 1 8 liters or 1 9 quarts with oil filter change See Section 3 2 on page 11 for oil level check and filing proce dures 4 1 6 3 GENERATOR SPECIFICATIONS SERIES Rotor RPM Rotor Poles Engine RPM Rated Max Continuous AC Output Watts Voltage Rated Max Continuous Current Amps 240V 45 8 22 9 45 8 22 9 Phase Frequenc Battery Charging Current Max 60 Hertz 60 Hertz 60 Hertz 60 Hertz 2 amps 2 amps Weight 328 lbs 331 lbs Length 33 7 in 33 7 in Width 22 2 in 22 2 in Height 19 6 in 19 6 in QP65LP QP75LP 3600 3600 3600 2 2571 2571 7500 7500 120 120 625 312 62 5 31 2 1 60 Hertz 2 amps 333 Ibs 33 7 in 22 2 in 86 in 20 1 6500 04 1 27 0 04 1 27 0 1 1 NO No o All units are reconnectable to 120 and or 240 volts dual voltage output Units are not listed per RVIA ANSI when reconnected for dual voltage output 6 Generac Power Systems Inc OPERATION Section 2 Operation QUIETPACT 55 65 and 75 Recreational Vehicle Generators 15 1 6 4 ENGINE SPECIFICATIONS Type of Engine OUIETPAGT 59 05 75 in GT 760 COOS MEWO sorcisoe Dio lloro islas oie Air cooled Rated Horsepower QUIE TPAC DOO tute FUR NU ODER PE 27 at 3600 rpm QUIE TPAC T DO oou RUE SUUM MU UU iE 27 at 3600 rpm OUIETFPA

Generac 004583-0 Portable Generator User Manual

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