Models: 004709-0, 005852-0 Owner's Manual and Installation Instructions Air-cooled Recreational Vehicle Generators Quietpact 40G This manual should remain with the unit.
Table of Contents Part – Owner’s Manual Part II – Installation Instructions Introduction............................................................................. 1 Safety Rules ......................................................................... 18 Read This Manual Thoroughly .........................................................1 Notice to Installer ..............................................................................18 Contents ...................................................
Introduction INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.
Safety Rules THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to n SAVE all operators and potential operators of this equipment. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this manual and with the unit.
Safety Rules ELECTRICAL HAZARDS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.
General Information 1.1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal. 1. 2. 3. 4. 5. 6. 7. 8. 9. 1. Model Number ____________________ 2. Serial Number _________________ 3. kW Rating _________________________ 4.
General Information 1.2 GENERATOR APPLICABILITY These generators have been designed and manufactured for supplying electrical power for recreational vehicles. Do not modify the generator or use it for any application other than for what it was designed. If there are any questions pertaining to its application, contact an Authorized Service Dealer. Do not use the unit until advised by a competent authority. For fire safety, the generator must have been properly installed in compliance with ANSI 119.
General Information 1.5.5 GENERATOR The manufacturer does not recommend using any gasoline containing alcohol (such as “gasohol”). If using 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 using gasoline with alcohol, inspect more frequently for fuel leaks and other abnormalities. n 1.5.2 FUEL CONSUMPTION Model 004709-0 No Load 1/2 Load Full Load 0.24 0.35 0.
Operation This generator is not legal for sale in the state of California unless all CARB evaporative emission requirements are adhered to, and is not legal for sale in any other state unless certified low-permeation fuel line is used to supply the generator with gasoline. Contact the California Air Resource Board or the Environmental protection agency for further information. CARB regulations can be found in 13 CCR §§2750 – 2773; EPA regulations can be found in 40 CFR Part 90. 2.
Operation 2.5 Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure. n 2.4.3 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 separate fuel tank, or it may “share” the vehicle engine’s fuel tank. 2.4.
Operation 2.7.1 LETTING THE ENGINE STABILIZE The generator supplies correct rated voltage only at the proper governed speed. Some electrical appliances 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 sufficient power is not available may shorten engine life. Never turn ON electrical loads until after the generator engine has started and stabilized at no-load. 2.
Maintenance Figure 2.4 – Solid State Voltage Regulator 3.1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements, see “Engine Oil Requirements”. Check the engine crankcase oil level at least every eight hours of operation, or before each use. To check the engine oil level, proceed as follows (see Figure 3.1): 1. 2. 3. 4. The voltage regulator also incorporates a “voltage surge protection circuit.” This circuit prevents troublesome surges in the generator AC output voltage.
Maintenance Figure 3.1 – Oil Maintenance Features CONTROL CENTER C .B . 3 0 A F U E L S T A R T S T O P P R IM E FUS E 7.5 A S E R V IC E A C C E S S P A N E L AIR FILTER LOCATED BEHIND PANEL. MAINTENANCE SCHEDULE OIL LEVEL: CHECK DAILY AIR FILTER: CLEAN PREFILTER EVERY 100 HOURS. * REPLACE ELEMENT EVERY 250 HOURS. * OIL & OIL FILTER: CHANGE EVERY 100 HOURS. (OR ANNUALLY) * * GENERAC OHVI POWERED GEN ER A C To Re I INSPECT & CLEAN PLUGS EVERY 100 HOURS. REPLACE PLUGS EVERY 500 HOURS.
Maintenance 3.4 CLEAN AIR INTAKE Clean all foreign material from the air intake (Figure 3.3) at least once every 100 hours of operation. Clean more often if necessary. Inspect the area around the generator exhaust muffler periodically and remove all grass, leaves, dirt, etc., from this area. Figure 3.3 – Cleaning Air Intake can occur if the wire terminal does not fit firmly on the spark plug terminal end. nSparking If necessary, re-form the wire terminal to obtain a tight fit. 3.
Maintenance Figure 3.6 - Spark Arrestor 3.9.2 EVERY SIX MONTHS • Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer. Note: Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. TAILPIPE P/N 0E0683 Damage will result if the battery connections are made in reverse.
Maintenance • Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention; and • 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 bicarbonate 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. 3.
Maintenance 2. When valve clearance is correct, hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut with a crows foot. Tighten the jam nut to 65-85 inch-pounds torque. After tightening the jam nut, recheck valve clearance to make sure it did not change (Figure 3.8). Figure 3.8 — Tightening Jam Nut CROW'S FOOT 3.14 RV GENERATOR SERVICE INTERVAL 50 Hours ....................................................Clean Spark Arrestor 100 Hours .......................................
Notes 16
PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
Safety Rules For fire safety, installation of a generator into a recreational vehicle must comply strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational n DANGER: Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the manufacturer’s instructions and recommendations.
Safety Rules ELECTRICAL HAZARDS FIRE HAZARDS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.
General Information 1.1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to all information and instructions in the manual, both for safety and for continued reliable operation of the equipment.
General Information Figure 1.2 – Major Features and Dimensions (Drawing No.
Installation 2.1 LOCATION AND SUPPORT 2.1.1 GENERATOR LOCATION The most desirable location for the generator set is between the vehicle's main frame members. However, this is seldom possible. Most units must be installed on the side of the vehicle and are difficult to reinforce. • If the generator cannot be bolted directly to the supporting frame or support tubing, consider using additional tubing, angle brackets or other supports to give the supporting frame sufficient strength. Figure 2.
Installation Figure 2.3 – Typical Generator Restraint • If the compartment is lined with galvanized steel, it may be constructed of any material. The manufacturer recommends 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 plywood with the grain of the wood at cross section for added strength (Figure 2.5). Figure 2.5 – Typical Compartment Construction 2.
Installation Figure 2.6 – Types of Lock Seams 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 2.7): • Use 5/8-inch thick or 3/4-inch thick plywood in the compartment.
Installation Figure 2.
Installation 2.3.2 TESTING THE INSTALLATION Fuel lines and exhaust piping must not penetrate into the vehicle living area. n 2.3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. Without sufficient airflow, the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also may cause fire and personal injury.
Installation 2.4.1 FUEL TANK Either the generator must share the vehicle engine's fuel tank, or install a separate fuel tank for the generator set. All fuel tanks installed on the vehicle 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, separate fuel pickup tubes are required for the engine and the generator.
Installation Figure 2.11 - Spark Arrestor TAILPIPE P/N 0E0683 SPARK ARRRESTOR SCREEN P/N 089680 RETAINING SCREW P/N 056892 Figure 2.12 — Spark Arrestor Installation 27.4 [1.08"] I.D. 40 [1.58"] 5.5 [7/32"] DRILL BOTTOM SIDE ONLY 2.5.2 EXHAUST SYSTEM SAFETY • Maintain a clearance of at least 3 inches (76 mm) between exhaust system parts and any combustible material (such as wood, felt, cotton, organic fibers or other like material).
Installation • 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 prevent vehicle electrical circuits from being connected to two different power supplies at the same time (such as generator and dockside power). • Conductors must be rated 221° F (105° C) or must be of a larger conductor size. 2.6.
Installation Figure 2.14 – Transfer Switch Isolation Method Figure 2.
Installation 2.7.2 BATTERY CABLES 2.7.4 BATTERY COMPARTMENT 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. Install the generator battery in its own, vented compartment. Place the battery compartment away from any source of heat, sparks or flame.
Post Installation Start-up Adjustments 3.1 POST INSTALLATION TESTS The air-cooled generator set was factory tested and adjusted. It should not be required to adjust the unit any further except under special circumstances. 3. 4. 5. not make any unnecessary adjustments. Factory settings are correct for most applinDo cations. When making adjustments, however, be careful to avoid overspeeding the engine. 3.2 BEFORE INITIAL START-UP Before starting, complete the following: 1. 2.
Post Installation Start-up Adjustments 3.5 INSTALLATION CHECKLIST EXHAUST SYSTEM ❑ Exhaust system complies with all applicable codes. LOCATION AND SUPPORT ❑ Exhaust system is properly and safely installed. ❑ Generator is properly located. ❑ Generator is properly supported. ELECTRICAL CONNECTIONS ❑ Generator is properly restrained. ❑ Connections comply with local code requirements and all National Electrical Codes. GENERATOR COMPARTMENT ❑ Junction box is properly installed.
Troubleshooting TROUBLESHOOTING GUIDE Problem The engine will not crank. Cause 1. Fuse blown 2. Loose, corroded or defective battery cables. 3. Defective engine Start/Stop switch 4. Defective starter contactor 5. Defective starter motor 6. Low or defective battery Correction 1. Replace fuse. 2. Tighten, clean or replace as necessary. 3. 4. 5. 6. Replace Start/Stop switch. Replace contactor. Replace starter motor. Charge or replace battery. The engine cranks but will not start. 1. Out of fuel 2.
Notes Generac® Power Systems, Inc.
Electrical Data Electrical Schematic/Wiring Diagram Drawing No.
Electrical Data Electrical Schematic/Wiring Diagram Drawing No.
Exploded Views & Parts Lists 38 Enclosure Drawing No.
Exploded Views & Parts Lists Enclosure Drawing No. 0D8352-N ITEM PART NO. QTY.
Exploded Views & Parts Lists 40 Generator Drawing No.
Exploded Views & Parts Lists Generator Drawing No. 0D8353-M ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 PART NO. QTY. DESCRIPTION 029092 022129 049451 0C8096A 0D8120 066849 066386 0D4217 073159 0D4484H 0D4430H 0D4216 048614 0F9533 022131 027028 0D6832 022145 030231 0C3168 022259 0C8565 0D8048 083512 0D6831 029451 0D6918 0D2558 087680 0D7530 0D9723 1 22 1 1 4 2 1 1 1 1 1 1 4 1 4 4 1 18 3 1 10 2 4 6 1 2.
Exploded Views & Parts Lists 42 Control Panel Drawing No.
Exploded Views & Parts Lists Control Panel Drawing No. 0D8354-H ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 PART NO. 0F9719 075210A 092234 065795 023484F 023484F 023484R 075234 057159 054502 087798 092113 032300 0A9611 090145 0E2314 0A1658 075235 047411 049226 051716 075476 022264 051715 0A2053 022473 022097 049813 055440 049815 038750 051714 0D8794 025105 028739 0D8308 0D8418 023484S 043182 031879 0D6575D 0A9973 QTY.
Exploded Views & Parts Lists 44 GN-220 H/SH Engine Drawing No.
Exploded Views & Parts Lists GN-220 H/SH Engine Drawing No. 0D8355-AG Part 1 ITEM PART NO. QTY. DESCRIPTION 0D8433 0C1069 0C1069 090965F 0G6468 1 10 11 1 1 4 5 6 081810 083312 0D8400 1 1 1 7 8 9 10 11 12 13 14 15 16 17 0C8917A 0C8798A 045756 082774 022129 081990 0D9004A 0E7585 1 1 9 1 2 2 1 1 GUARD, FAN SCREW, HHTT M6-1.0 X 8MM (04709 ONLY) BLOWER HOUSING BLOWER HOUSING 220RV (04709 ONLY) NUT, HEX M16-1.
Exploded Views & Parts Lists 46 GN-220 H/SH Engine Drawing No.
GN-220 H/SH Engine Drawing No. 0D8355-AG Part 2 ITEM PART NO.
Warranty 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.
Warranty EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Warranty GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS PURCHASED IN THE U.S.A. AND CANADA NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (three) years of operation from the date of original sale, Generac Power Systems, Inc.
