Generac 004709-0 manual

This manual should remain with the unit. Air -cooled R ecreational V ehicle Generators Quietpact 40G Models: 004709-0, 005852-0 Owner's Manual and Installation Instructions[...]

P ar t – Owner’s Manual Introduction ............................................................................. 1 Read This Manual Thoroughly ......................................................... 1 Contents ......................................................................................... 1 Operation and Maintenance ..............[...]

INTRODUCTION Thank you for purchasing this model by Generac P ower Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. READ T HIS MANUAL THOROUGHL Y If any por tion of this manual is not understood, contact the near - est Authorized Ser vice Dealer for star ting, operating and ser vicing proced[...]

2 Study these SAFETY RULES carefully before installing, operating or ser vicing 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 r ules or p[...]

3 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 r unning. Ensure all appropriate covers, guards and bar - riers are in place before operating the generator . If work must be done a[...]

4 1. Generator Air Intake 2. Engine Star t/Stop Switch 3. Fuse 4. Optional Remote P anel Receptacle (Side View) 5. Generator AC Output Leads (Side View) 6. Fuel P rimer Switch 7. Circuit Breaker 8. Star ter Contactor 9. Fuel Inlet 10. Fuel Pump (Behind Access P anel) 11. Fuel Filter (Side View) 12. Oil Filter 13. Oil Drain Cap 14. Oil Dipstick 15. [...]

5 1.2 GENERA TOR APPLICABILITY These generators have been designed and manufactured for sup- plying 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 per taining to its application, contact an Authorized Ser vice Dealer . Do not use t[...]

6 n The manufacturer does not recommend using any gasoline containing alcohol (such as “gasohol”). If using any gasoline contain- ing 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 frequ[...]

7 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-per - meation fuel line is used to supply the generator with gasoline. Contact the California Air Resource Board or the Environmental protection agency [...]

8 n Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure. 2.4.3 FUEL SUPPL Y The engine must have an adequate supply of proper fuel to oper - ate. Before star ting it, check that sufficient fuel is available. NOTE: Depending on the installation, the generator may have[...]

9 2.7.1 LETTING THE ENGINE ST ABILIZE 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 appli- ances. If electrical loads are applied at reduced operating speeds, such loads imposed on the engine when sufficient power i[...]

10 Figure 2.4 – Solid State Voltage Regulator The voltage regulator also incorporates a “voltage surge protection circuit.” This circuit prevents troublesome surges in the generator AC output voltage. V oltage surge is a common cause of damage to electronic equipment. 2.10 ADDITIONAL INFORMA TION 2.10.1 ATTENTION REQUIRED AFTER SUBMERSION If [...]

11 9. Install and tighten the oil fill cap and the dipstick before oper - ating the engine. 10. Star t the engine and check for leaks. NOTE: Check the oil level and fill to the “FULL ” mark after checking for leaks. The filter will retain some oil. 3.3 MAINT AINING THE ENGINE AIR CLEANER 3.3.1 CLEANING THE FOAM PRECLEANER Clean and re-oil the f[...]

12 3.4 CLEAN AIR INT AKE Clean all foreign material from the air intake (Figure 3.3) at least once ever y 100 hours of operation. Clean more of ten if neces- sar y . Inspect the area around the generator exhaust muffler periodically and remove all grass, leaves, dir t, etc., from this area. Figure 3.3 – Cleaning Air Intake USTC USTC 3.5 CHECKING [...]

Figure 3.6 - Spark Arrestor RET AINING SCREW P/N 056892 SP ARK ARRRESTOR SCREEN P/N 089680 T AILPIPE P/N 0E0683 3.8 CLEANING THE GENERA TOR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dir t, corrosive vapors, road splash, etc. P er mitting dir t and moisture to accumulate on generator windings will [...]

14 • 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 [...]

15 2. When valve clearance is cor rect, 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. Af ter tightening the jam nut, recheck valve clearance to make sure it did not change (Figure 3.8). Figure 3.8 — Tightening Jam Nut CRO W'S FOO T 3.14 RV[...]

16 Notes[...]

P ART II – INST ALLA TION INSTRUCTIONS ONL Y QU ALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A T TEMPT INST ALLA TION![...]

18 NOTICE TO INST ALLER These Installation Instructions have been published by the manu- facturer to aid in the installation of the products described in this manual. The manufacturer assumes that installation personnel are familiar with the procedures for installing such products, or similar products manufactured. The manufacturer also assumes tha[...]

19 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 r unning. Ensure all appropriate covers, guards and bar - riers are in place before operating the generator . If work must be done [...]

20 1.1 PURPOSE AND SCOPE OF THE MANU 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 seri- ous consideration to all information and instr uctions in the manual, both for safety and for continued[...]

21 Figure 1.2 – Major F eatures and Dimensions (Drawing No. 0D8716-K) General Information[...]

22 2.1 L OCA TION AND SUPPORT 2.1.1 GENERA TOR 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 reinforce. Many recreational vehicles have been factor y equipped with an area f[...]

23 Figure 2.3 – T ypical Generator Restraint 2.2 GENERA TOR COMP ARTMENTS Whether the generator set is being installed inside a compar tment specifically manufactured to house a generator or inside a com- par tment that the installer constr ucts, the compar tment must meet cer tain specifications as outlined in the following sections: 2.2.1 COMP [...]

24 Figure 2.6 – T ypes of Lock Seams Af ter the compar tment has been metal lined and vapor • sealed, line the compar tment interior walls and ceiling with an approved, nonflammable sound insulating material (see "Sound Insulating Materials").  Do not install any flammable material directly above or around the compartment. Heat,[...]

25 Figure 2.8 – Compartment Floor Cutout (Drawing 0G3723-A) Installation[...]

26 n Fuel lines and exhaust piping must not pen- etrate into the vehicle living area. 2.3 COOLING AND VENTILA TING 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 air flow , the engine/generator quickly over heats. Such overheating can ca[...]

27 2.4.1 FUEL T ANK 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 constr ucted, installed and restrained so they comply with applicable codes, standards and regulations. If the generator is to share the vehicle engine's[...]

28 Figure 2.11 - Spark Arrestor RET AINING SCREW P/N 056892 SP ARK ARRREST OR SCREEN P/N 089680 T AILPIPE P/N 0E0683 Figure 2.12 — Spark Arrestor Installation 40 [1.58"] 5.5 [7/32"] DRILL BOTT OM SIDE ONL Y 27.4 [1.08"] I.D . 2.5.2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches (76 mm) between • exhaust system pa[...]

29 From the junction box, route power supply wires through • approved conduit to either (a) double-pole, double-throw trans- fer 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 [...]

30 Figure 2.14 – T ransfer Switch Isolation Method Figure 2.15 – Installation With Isolation Receptacle Installation[...]

31 2.7.2 BA TTERY CABLES Using batter y cables that are too long or too small in diameter may cause a drop in voltage, which causes star ting problems. For the best cold weather star ting, the voltage drop between batter y terminals and the generator connection point should not exceed 0.12 volts per 100 amperes of cranking current. These generators[...]

32 3.1 POST INST ALLA TION TESTS The air -cooled generator set was factor y tested and adjusted. It should not be required to adjust the unit any fur ther except under special circumstances. n Do not make any unnecessary adjustments. Factory settings are correct for most appli- cations. When making adjustments, however , be careful to avoid overspe[...]

33 3.5 INST ALLA TION CHECKLIST L OCA TION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly suppor ted. ❑ Generator is properly restrained. GENERA TOR COMP ARTMENT ❑ Compar tment constr uction is proper . ❑ Holes/Openings are vapor -sealed. ❑ Compar tment size is cor rect. ❑ Compar tment is vapor-sealed. ❑ Sound [...]

TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace as necessar y . batter y cables. 3. Defective engine Star t/Stop switch 3. Replace Star t/Stop switch. 4. Defective star ter contactor 4. Replace contactor . 5. Defective star ter moto[...]

Generac ® Pow er Systems, Inc. 35 35 Notes[...]

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 AG E 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 1[...]

37 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 2 17 18 4 16 CB3 66 0 56 14 15 90 0 90 16 56 IM1 18A HTO SP1 85 13 14A 15 18 15 66 77 14 15 14 15 0 0 2 14 14A 14 F1 66 BCR 15 [...]

38 Exploded Views & P arts Lists Enclosure Drawing No. 0D8352-N[...]

39 ITEM P ART NO. QTY . DESCRIPTION 1 0D6822 1 TRA Y , ENCL OSURE 2 0D6942 1 P ANEL, ENCL OSURE SIDE 3 0D6939 1 P ANEL, REAR DIVIDER 4 0D6943 1 P ANEL, ENCL OSURE ROOF 5 0D6941 1 P ANEL, ENCL OSURE BACK 0D6941A 1 P ANEL, ENCL OSURE BACK, EXTERNAL POR T (04709 ONL Y) 6 0D6940 1 P ANEL, FRONT DIVIDER 0D6940A 1 P ANEL, FRONT DIVIDER, EXTERNAL POR T (0[...]

40 Exploded Views & P arts Lists Generator Drawing No. 0D8353-M[...]

41 ITEM P ART NO . QTY . DESCRIPTION 1 029092 1 SCREW IHHC 5/16”-24 X 11-1/4” G5 2 022129 22 WASHER L OCK M8-5/16” 3 049451 1 WASHER FLA T .406” I.D. X 1.62” O .D. 4 0C8096A 1 F AN, 8" CURVE BLADE, 16.5MM I.D. 5 0D8120 4 SCREW IHHC M8-1.25 X 260MM 6 066849 2 SCREW HHTT M5-0.8 X 16 7 066386 1 ASSEMBL Y , BRUSH HOLDER 8 0D4217 1 CARRIE[...]

42 Exploded Views & P arts Lists Control P anel Drawing No. 0D8354-H[...]

43 ITEM P ART NO . QTY . DESCRIPTION 1 0F9719 1 REGULA TOR VOL T AGE 2 075210A 1 TERMINAL BL OCK 3 092234 1 CONTROLLER P .C.B. 4 065795 1 BA TTERY CHARGER RECTIFIER 5 023484F 1 BUSHING SNAP 1” 023484F 2 BUSHING SNAP 1” (04709 ONL Y) 6 023484R 1 BUSHING SNAP 1-1/4” 7 075234 1 RESISTOR, 1 OHM 25W 8 057159 1 CIRCUIT BREAKER 2.0 Amp (60Hz) 054502[...]

44 Exploded Views & P arts Lists GN-220 H/SH Engine Drawing No. 0D8355-AG P art 1[...]

45 ITEM P ART NO. QTY . DESCRIPTION 1 0D8433 1 GUARD, F AN 2 0C1069 10 SCREW , HHT T M6-1.0 X 8MM 0C1069 11 (04709 ONL Y) 3 090965F 1 BL OWER HOUSING 0G6468 1 BL OWER HOUSING 220RV (04709 ONL Y) 4 081810 1 NUT , HEX M16-1.5 5 083312 1 WASHER , M16 CONICAL 6 0D8400 1 ASSEMBL Y CHOKE SOLENOID BRACKET 7 0C8917A 1 FL YWHEEL, WITH RING GEAR 8 0C8798A 1 [...]

46 Exploded Views & P arts Lists GN-220 H/SH Engine Drawing No. 0D8355-AG P art 2[...]

47 ITEM P ART NO . QTY . DESCRIPTION N/A 0E8804 1 L ONG BL OCK AS SEMBL Y 1 078621 1 CONNECTING ROD ASSEMBL Y 2 076389 1 PISTON PIN 3 0G4379 1 PISTON RING SET DIA 75 PLA TEAU HONED 4 0A8897B 1 GEAR COVER AS SEMBL Y 5 077168 5 M8 X 56MM HEAD BOL T 6 0G4331 1 PISTON, COA TED DIA 75 7 076390 2 PIN RET AINER RING 8 0G5827 1 ASSY , CR ANKSHAFT GH220 T A[...]

48 CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY ST A TEMENT Y OUR WARRANTY RIGHTS AND 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 Warranty on your new engine.* New util[...]

49 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 EC S W ar ranty P eriod shall begin on the date the new engine or equip- ment is purchased by/delivered to its original, end-use purchaser/o[...]

Part No. 0D8351 Revision AA (06/02/10) Printed in U .S.A. W arranty GENERAC POWER SYSTEMS’ THREE- YEAR LIMITED W ARRANTY FOR RECREA TIONAL VEHICLE GENERA TORS PURCHASED IN THE U .S.A . AND CANADA NOTE: ALL UNITS MUST BE INST ALLED BY GENERAC POWER SYSTEMS A UTHORIZED SERVICE F ACILITIES. For a period of 3 (three) years of operation from the date [...]