Generac Power Systems 004700-00 manual

Owner’ s Man ual and Installation Instructions Air -cooled Recreational V ehic le Generators • Model: 004700-0 QUIETP A CT 40G This manual should remain with the unit.[...]

I NTRODUCTION Thank you for purchasing this model of the QUIETP ACT product line by Generac P ower Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. R EAD THIS MAN UAL THOROUGHL Y If any portion of this manual is not understood, con- tact the nearest Authorized Service Dealer for starting , o[...]

T able of Contents Recreational V ehicle Generator 1 Part I – Owner’s Manual Introduction ...................................... Inside Front Cover Read This Manual Thoroughly ................................ IFC Contents ................................................................. IFC Operation and Maintenance ............................[...]

2 Study these SAFETY RULES carefully before install- ing, operating or servicing this equipment. Become familiar with this manual and with the unit. The gen- erator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or p[...]

3 • When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued. • Inspect the generator regularly , and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement. • Before performing any maintenance on the gen- erator , disconnect its batt[...]

4 1. Generator Air Intake 2. Engine Start/Stop Switch 3. F use 4. Optional Remote P anel Receptacle (Side V iew) 5. Generator AC Output Leads (Side V iew) 6. F uel Primer Switch 7. Circuit Breaker 8. Starter Contactor 9. F uel Inlet 10. F uel Pump (Behind Access P anel) 11. F uel Filter (Side V iew) 12. Oil Filter 13. Oil Drain Cap 14. Oil Dipstick[...]

5 Section 1 – General Information Recreational V ehicle Generator 1.2 GEN ER A T OR AP P LICAB I LIT Y These generators have been designed and manufac- tured for supplying electrical power for recreational vehicles. Do not modify the generator or use it for any application other than for what it was designed. If there are any questions pertaining[...]

6 Section 1 – General Information Recreational V ehicle Generator  The manufacturer does not r ecommend using any gasoline containing alcohol (such as “gaso- hol”). If using any gasoline containing alcohol, it must not contain more than 10 per cent ethanol, and it must be removed fr om the generator dur - ing storage. Do NOT use any gasoli[...]

7 Section 2 – Operation Recreational V ehicle Generator 2.1 GEN ER A T OR CONTROL P AN EL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control Panel PRI ME FUEL STO P START 30A C. B . FUS E CONTROL CENTER 7. 5 A 2.1.1 F UEL PRIME R Before starting a cold engine (if it has not been starte[...]

8 Section 2 – Operation Recreational V ehicle Generator 2.4.2 ENGI NE L UB R ICA TION Have the engine crankcase properly serviced with the recommended oil before starting . Refer to Section 1.5.4, and Sections 3.1 and 3.2 for oil servicing proce - dures and recommendations.  Any attempt to crank or start the engine before it has been properly [...]

9 Section 2 – Operation Recreational V ehicle Generator 2.6 S T OP P I NG TH E GEN ER A T OR 1. T urn 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 [...]

10 Section 2 – Operation Recreational V ehicle Generator 2.9.3 F IELD 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 2.3). During engine cranking only , a positive DC (battery) voltage is delivered th[...]

11 Section 3 – Maintenance Recreational V ehicle Generator 2.1 0.4 OPER A TION I N H IGH GR AS S OR B RUSH Never operate the generator while the vehicle 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 ex[...]

12 Section 3 – Maintenance Recreational V ehicle Generator • Change the engine oil filter after the first 25 hours of operation, and every 100 operating hours there - after . T o change the oil and/or oil filter , proceed as follows (see Figure 3.1): 1. R un the engine until it is thoroughly warmed up (at least five minutes) then shut OFF the e[...]

Section 3 – Maintenance Recreational V ehicle Generator 3.4 CLEAN AI R I NT AKE 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 muf- fler periodically and remove all grass, leaves, dirt, etc., from this area. Figur[...]

14 3.8 CLEAN I NG TH E GEN ER A T OR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dirt, corrosive vapors, road splash, etc. P ermitting 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 remai[...]

15 3.1 0 MA JOR SERVICE MAN U AL T o obtain a service manual for the generator , contact the nearest Authorized Service Dealer . Make sure to identify the MODEL NUMBER and SERIES. 3.1 1 EXERCISI NG TH E GEN ER A T OR The manufacturer recommends that the generator be started and operated at least once every seven days. Let the unit run for at least [...]

16 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 — T ightening Jam Nut 3.1 4 RV GENER A T OR SERVI[...]

P ART I I – I NS T ALL A TION I NS TR UCTIONS D ANGER ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!![...]

18 NO TICE T O I NST ALLER These Installation Instructions have been published by the manufacturer to aid in the installation of the products described in this manual. The manufac- turer assumes that installation personnel are familiar with the procedures for installing such products, or similar products manufactured. The manufacturer also assumes [...]

19  ELE CTR ICAL HA Z AR DS  • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. A void 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 work[...]

20 1.1 P U R POSE AN D S COPE OF TH E MAN U AL 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 conti[...]

21 Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-G) Section 1 – General Information Recreational V ehicle Generator REF . 749.8 [ 29 1/2"] 342.2 [ 13 1/2"] REF . 483.1 [ 19"] HOT AIR EXHAUST T AIL PIPE EXIT OIL DRAIN AIR INT AKE AC OUTPUT HARNESS REMOTE P ANEL CONNECTOR BA TTER Y CONNECTIONS FUEL FIL TER 48.1 [ 1[...]

22 2.1 L OCA TION AN D SU P PORT 2.1.1 GEN ERA T OR L OCA TION 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 rein- force. Many recreational vehicles have been factory equipped with an [...]

23 • The installer must make certain that the selected location will permit adequate cooling and ventilat - ing airflow to be supplied. 2.1.4 GEN ERA T OR R ES TRAI NT Use four 5/16"-18 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing . These bolts must pass through (a) the generator mounti[...]

24 • 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. • If flexible metal conduit is used, it must be sealed internally at the end where it terminates inside the compartmen[...]

25 • 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 2.7 – T ypical Noise Abatement 2.2.5 COMP ARTM ENT F L OOR CUT OUTS Provide openings in the generator compartment for the following items (Figure 1.2): • Engine e[...]

26 2.3 C OOLI NG AN D VENTI L A TI NG AI R It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. W ithout sufficient airflow , the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also may cause fire and personal injur[...]

27 2.4.1 F UEL T AN K 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 regula- tions. If the generator is to share the vehicle engine&apo[...]

28 2.5.1 SP AR K AR REST OR This spark arrestor assembly meets code and stan- dard requirements of the U .S. F orest Service. Use only mufflers and parts approved by the manufactur - er . 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 lia[...]

29 • W iring 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. 2.6.1 ELECTRICAL J U NCTION BOX Install an approved, square electrical ju[...]

30 2.6.5 IS OLA T IN G D IFFE REN T PO WER SOURCES Connections from the junction box must terminate in a double -pole, double -throw transfer switch (Figure 2.14). An alternate method for isolating different power sources is by using an isolating receptacle (Figure 2.15). Whichever method is used, be certain that both power sources are NOT connecte[...]

31 2.6.7 GROU ND F AUL T CI RCU IT I NTERR U PTERS The National Electrical Code (NFP A 70, 551-7) requires that ground fault circuit interrupters (GFCIs) be installed on all external and some internal electri- cal receptacles. Contact the dealer for recommenda- tions. 2.7 B A T TER Y INST ALL A TION 2.7 .1 REC OMM EN DED BA T TER Y Install a batter[...]

32 2.8.1 R EMO TE ST ART/ST OP P AN EL A remote mounted Start/Stop panel (Figure 2.18) is available that allows the user to start and stop the generator engine conveniently from inside the vehicle. The remote panel includes a Start/Stop switch, hour - meter , generator run lamp, a fuel prime switch, and a wire harness. The hourmeter should be used [...]

33 Section 3 – Post-installation Start-up Adjustments Recreational V ehicle Generator 3.5 I NS T ALL A TION CH ECKLIS T L OCA TION AN D SU P PORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GEN ERA T OR COMP ARTM ENT ❑ Compartment construction is proper . ❑ Holes/Openings are v[...]

34 Appendix 1 – Notes Recreational V ehicle Generator[...]

35 Appendix 2 – T roubleshooting Recreational V ehicle Generator TROU B LE SHOO TI NG GU I DE Problem Cause Correction The engine will not crank. 1. F use blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary . 3. Defective engine Start/Stop 3. Replace Start/Stop switch. switch 4. Defectiv[...]

RED BLUE ORANGE BROWN 7 7 YELLOW WHITE 15 BA TTERY CHARGE WINDING NEUTRAL CONNECTION GREEN BY CUSTOMER WHITE T2 FIELD 120V 30A 44 0F 0N 0K 22P DPE WINDING 2 CB3 6 ELECTRONIC REGULA TOR VOLT AGE 2A 0N 0N R1 POWER WINDING 22S 11S 77 55 BLACK FUEL PRIME 11P 4 4 T1 4 CB1 REMOTE P ANEL (OPTIONAL) 33 4 66 ST ART HM L1 1 STOP 8 A 4 1 8 5 14 18 0 17 BLK 14[...]

37 Appendix 3 — Electrical Data Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D 0 CONN. 2 PIN# 0 90 14 14 CH 18A 90 85 LOP CS 0 18 RED 18 85 17 18A 85 PCB J1-7 J1-9 J1-12 J1-11 J1-10 J1-8 J1-15 J1-14 J1-13 J1-2 J1-5 J1-4 J1-3 J1-1 J2 J1-6 J3 18 1 FS 14 2 3 18 18A 18 CONN. 1 PIN# 0 0 FP 90 14 2 1 2A[...]

38 23 46 42 55 37 17 2 54 34 32 31 33 55 50 55 16 40 56 T O CARB 12 57 21 13 43 15 21 52 41 3 48 9 21 21 27 28 55 58 36 21 35 42 41 21 18 1 53 21 51 39 23 22 6 10 47 8 24 22 20 15 21 11 14 44 25 49 7 21 24 26 41 21 38 59 45 5 4 30 19 Appendix 4 — Exploded Views and P arts Lists Recreational V ehicle Generator Enclosure – Drawing No. 0D835 2-G[...]

39 ITEM P ART NO . QTY . DESCRIPTION 1 0D6822 1 TRA Y , ENCLOSURE 2 0D6942 1 P ANEL, ENCLOSURE SIDE 3 0D6939 1 P ANEL, REAR DIVIDER 4 0D6943 1 P ANEL, ENCLOSURE ROOF 5 0D6941 1 P ANEL, ENCLOSURE BACK 6 0D6940 1 P ANEL, FRONT DIVIDER 7 0D6945 1 COMP ARTMENT , AIR INT AKE 8 0D6944 1 P ANEL, ENCLOSURE DOOR 9 0D8254 1 SHIELD , MUFFLER 10 0C5644 2 SLIDE[...]

40 Appendix 4 — Exploded Views and P arts Lists Recreational V ehicle Generator Generator – Drawing No. 0D835 3-H 22 1 8 2 1 2 5 3 24 25 4 7 8 9 24 38 2 8 1 8 3 7 1 8 2 3 2 2 1 2 21 15 2 1 8 21 2 1 8 2 8 10 3 5 26 27 11 2 12 2 1 3 2 3 3 6 39 2 17 1 8 1 8 16 14 2 9 1 0 3 4 3 0 3 2 42 3 1 2 9 33[...]

41 Appendix 4 — Exploded Views and P arts Lists Recreational V ehicle Generator Generator – Drawing No. 0D835 3-H ITEM P ART NO . QTY . DESCRIPTION 1 050322 1 SCREW IHHC 5/16"-24 X 9-3/4" 2 022129 22 W ASHER LOCK M8-5/16" 3 049451 1 W ASHER FLA T .406" I.D . X 1.62" O .D . 4 0C8096A 1 F AN, 8" CUR VE BLADE, 16.5MM [...]

42 1 0 11 12 1 3 3 1 1 5 1 21 2 0 2 4 17 1 8 17 3 5 6 5 4 3 14 2 8 22 1 9 7 25 27 24 2 3 9 1 6 2 3 2 6 17 5 3 0 3 5 8 3 7 3 6 2 9 39 38 Appendix 4 — Exploded Views and P arts Lists Recreational V ehicle Generator Control Panel – Drawing No. 0D83 54-E[...]

43 Appendix 4 — Exploded Views and P arts Lists Recreational V ehicle Generator Control Panel – Drawing No. 0D83 54-E ITEM P ART NO . QTY . DESCRIPTION 1 0830490 1 REGULA TOR VOL T AGE 2 075210A 1 TERMINAL BLOCK 3 092234 1 CONTROLLER P .C.B. 4 065795 1 BA TTER Y CHARGER RECTIFIER 5 023484F 1 BUSHING SNAP 1" 6 023484R 1 BUSHING SNAP 1-1/4&q[...]

44 Appendix 4 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0D8355-S P art 1 44 55 38 43 42 41 39 9 60 62 59 61 37 63 56 57 58 9 33 9 40 20 20 54 53 52 9 45 21 23 22 14 19 34 29 32 25 24 26 27 31 8 13 15 15 6 35 30 36 28 4 5 10 11 12 7 9 3 1 16 17 16 2[...]

45 Appendix 4 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0D8355-S P art 1 ITEM P ART NO . QTY . DESCRIPTION 1 0D8433 1 GU ARD , F AN 2 0C1069 10 SCREW , HHTT M6-1.0 X 8mm 3 090695F 1 BLOWER HOUSING 4 081810 1 NUT , HEX M16-1.5 5 083312 1 W ASHER, M16 CONICAL 6 0D8400 1 ASSEMBL Y CHOKE SOL[...]

46 Appendix 4 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0D8355-S P art 2 20 36 50 43 42 45 44 46 25 26 48 24 22 23 31 30 32 17 28 13 4 29 38 37 40 39 21 51 15 35 16 5 33 41 49 34 27 14 19 18 1 35 8 1 52 7 2 6 47 11 13 7 3 10 10 12 9[...]

47 Appendix 4 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0D8355-S P art 2 ITEM P ART NO . QTY . DESCRIPTION N/A 0E8804 1 LONG BLOCK ASSEMBL Y 1 078621 1 CONNECTING ROD ASSEMBL Y 2 076389 1 PIST ON PIN 3 088411 1 PIST ON RING SET 4 0A8897B 1 GEAR COVER ASSEMBL Y 5 077168 5 M8 x 56mm HEAD B[...]

48 CALI FOR N IA AND F EDER AL EM ISSION C ONTROL W AR R ANT Y ST A TEM ENT Y OU R W ARR ANT Y RIGHTS AN D OBLIGA TIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EP A), together with Generac P ower Systems, Inc. (Generac), are pleased to explain the Emission Control System W arranty on your new[...]

49 EM IS SION CONTROL S Y STEM W AR R ANT Y Emission Control System W arranty (ECS W arranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS W arranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purcha[...]

Part No. 0D8351 Revision R (02/22/06) Printed in U.S.A. Appendix 5 – W arranty Recreational V ehicle Generator GENERA C PO WER SYSTEMS’ THREE-YEAR LIMITED W ARRANTY FOR GU ARDIAN RECREA TIONAL VEHICLE GENERA T ORS NO TE: ALL UNITS MUST BE INST ALLED BY GENERAC PO WER SYSTEMS AUTHORIZED SER VICE F ACILITIES. F or a period of 3 (three) years of o[...]