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Generac Power Systems 004702-0, 004703-0, 004704-0, 004705-0, 004706-0, 004707-0 manual

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Table of contents for the manual

  • Page 1

    P O WERED BY GU ARDIAN 7 60cc O HVI V-TWI N QU IETPA CT IND US TRIA L 55 G Owner’ s Man ual Air -cooled Recreational V ehic le Generators QUIETP A CT 55, 65 and 75 • Models: 004702-0, 004703-0 004704-0, 004705-0 004706-0, & 004707-0 This manual should remain with the unit.[...]

  • Page 2

    Generac ® Pow er Systems, Inc. I NTRODUCTION R EAD THIS MAN UAL THOROUGHL Y 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, W ARNING, CA UTIO[...]

  • Page 3

    T able of Contents QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators Generac ® Pow er Systems, Inc. 1 Part I — Operating Instructions Introduction ..................................................Inside Front Cover Read This Manual Thoroughly ..........................................IFC Contents .....................................[...]

  • Page 4

    2 Generac ® Pow er Systems, Inc. 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 sim[...]

  • Page 5

    Generac ® Pow er Systems, Inc. 3 • 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 NEGA TIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step. Stepping on the [...]

  • Page 6

    4 Generac ® Pow er Systems, Inc. Section 1 – General Information QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators Please recor d the following information from the generator DA T A DECAL or information decal. 1. Model Number ____________________ 2. Serial Number __________________ 3. kW Rating __________________________ 4. Rated V ol[...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 Section 1 – General Information QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 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. Y ou should not modify the generator or use it for any application othe[...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. Section 1 – General Information QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators Figure 1.1 – Connection for 120 V olts Only Figure 1.2 - Connection for 120/240 V olts 1.6 SP E CI F ICA TIONS 1.6.1 F UEL R EQ UIRE ME NT S ( G A S OL INE) This generator is equipped with a gasoline fuel system as stan[...]

  • Page 9

    Generac ® Pow er Systems, Inc. 7 Section 2 – Operation QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 1.6.4 ENGI NE SP ECIF ICA TIONS T ype of Engine QUIETP ACT 55/65/75 ................................................GT -760 Cooling Method ........................................................Air - cooled Rated Horsepower QUIETP[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. Section 2 – Operation QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 2.2 OPTIONAL R EMO TE S T ART/ST OP P AN EL A remote mounted Start/Stop P anel (F igure 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 St[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 Section 2 – Operation QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators The generator engine releases DEADL Y carbon monoxide gas through its exhaust system. This dangerous gas, if br eathed in sufficient concen- trations, can cause unconsciousness or even death. Never operate the generator set with th[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. Section 2 – Operation QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 2.7 .2 DO NO T O VER L O AD TH E GEN ER A T OR Y ou can read the rated wattage/amperage capacity of your generator on the generator data decal (see Section 1.1 on P age 4). Applying electrical loads in excess of the unit ’s rate[...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 Section 3 – Maintenance QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 2.8.4 OVERV OL T AGE PRO TE CTION 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 [...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. Section 3 – Maintenance QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 3.2 CHANGI NG TH E ENGI N E OI L AN D/OR OI L F I L TER • Change the engine oil after the first 25 hours of operation (after the 25-hour break -in period, see Section 2.8.5, P age 10). Thereafter , change the oil every 100 ope[...]

  • Page 15

    Section 3 – Maintenance QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators Figure 3.3 – Engine Air Cleaner 3.4 CH E CKI NG TH E ENGI N E SP AR K P L UG 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 [...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. 3.7 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. W[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 3.9 MA JOR SERVICE MAN U AL T o 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 . 3.1 0 DR IVE B EL T The engine drive[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. Section 4 – Notes QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators[...]

  • Page 19

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

  • Page 20

    18 Generac ® Pow er Systems, Inc. Safety Rules QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators NO TICE T O I NST ALLER 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 in[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 Safety Rules QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle 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 t[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. 5.1 P U R POSE AN D S COPE OF TH E I NS T ALL A TION I NSTRUCTIONS 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 in[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Figure 5.2 - Major Features and Dimensions (Drawing No. 0E1058-A) Section 5 – General Information QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators A 5 4 5 5 74.7 95 . 5 T YP. 183 . 5 2 2 6 . 5 8 21.2 233 .2 469 195 . 8 83 4. 9 5 7 5 1 6 .2 TYP. 469 . 8 TYP. 495 5 2 6 .2 70 . 8 3 44. 6 45 ˚ 305 . 9 5[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. Figure 5.3 - Connection for 120/240 V olts • The AC connection system on all air - cooled PRIMEP ACT series generators uses a GROUNDED neutral. • A separate green ground wire is connected to the recreational vehicle’s junction box. • Loads connected across T1 (Red) to T2 (White), and T3 (Black) to T2 (Whit[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 6.1.3 SUSP ENDED MOU NTI NG 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 for the generator . One typ- ical suspended mounting s[...]

  • Page 26

    24 Generac ® Pow er Systems, Inc. Figure 6.5 – T ypical Compartment Construction • If constructing a compartment, line the exterior (underside) of the compartment floor with 26- gauge galvanized steel. • All seams, splices and joints of the compartment walls (unless vapor tight by design) should be caulked to prevent poisonous, flammable or [...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 Section 6 – Installation QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 6.2.4 AC OUS TIC S F or 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 u[...]

  • Page 28

    26 Generac ® Pow er Systems, Inc. 6.3.2 TES TING TH E I NST ALL A TION 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 cer[...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 F actory 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 a[...]

  • Page 30

    28 Generac ® Pow er Systems, Inc. Figure 6.15 – T ypical Propane Gas Fuel System 6.5.3 SOME I MPORT ANT CONSIDER A TIONS When installing an LP gas system, consider seriously the following items: • All fittings, lines, hoses and clamps must be tight and free of leaks. Apply a pipe sealant to threads when assembling threaded connections. This re[...]

  • Page 31

    Generac ® Pow er Systems, Inc. 29 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- ment of the regulator valve. The more the regulator valve opens, the greater the gas flow that is propo[...]

  • Page 32

    30 Generac ® Pow er Systems, Inc. 6.6.1 MUFF LERS AN D SP AR K AR R ES T ORS This muffler meets code and standard requirements of the U .S. F orest 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 cau[...]

  • Page 33

    Generac ® Pow er Systems, Inc. 31 6 .7 .2 W IRING • W iring should be of stranded copper to reduce the chance that vibration may cause breakage. • W ire gauge size should be large enough to handle at least 115 percent of the installed generator's rated maximum current. • If neutral conductors are used, they must be the same size as othe[...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. Section 6 – Installation QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 6.7 .7 GROU ND F AUL T CI RCU IT I NTERR U PTERS The National Electrical Code (NFP A 70, article 551) requires that you install ground fault circuit inter- rupters (GFCIs) on all external and some internal electrical receptacle[...]

  • Page 35

    Generac ® Pow er Systems, Inc. 33 Section 6 – Installation QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators Figure 6.18 — T ransfer Switch Isolation Method P O WERED BY GU ARDIAN 7 60 cc O HVI V-TWI N QU IETPA CT INDUSTRIAL 55 G Figure 6.19 — Installation With Isolation Receptacle P O WERED BY GU ARDIAN 7 60cc O HVI V-TWI N QU IE[...]

  • Page 36

    34 Generac ® Pow er Systems, Inc. 6.9 OPTIONAL A C CE S S OR I E S A plug-in receptacle (F igure 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 fr[...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 7 .4 TE STING U N DER L O AD 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 a[...]

  • Page 38

    36 Generac ® Pow er Systems, Inc. Section 8 – T roubleshooting QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 8.1 TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION Engine won’t crank. 1. 7.5 amp fuse blo wn. 1. Replace blo wn fuse. 2. Loose, or corroded or def ectiv e 2. Tighten, clean or replace, batter y cable(s). as [...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 Section 9 – Notes QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators[...]

  • Page 40

    38 Generac ® Pow er Systems, Inc. Section 1 0 — Electrical Data QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators V - Twin – Drawing No. 0E1 05 7 -B 1 20V 35A - Q P75 D PE WINDIN G VO LTA G E R E GU LAT O R E LE C TR O NI C 1 20V 20A - Q P55 B Y CUS T O MER N E U TRAL CO NNE C TI O N T2 G REEN 0 F FIELD C B 3 0 N 0 K 2 2A 22P 44 2 2[...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 Section 1 0 — Electrical Data QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators V - Twin – Drawing No. 0E1 05 7 -B 18 A 85 18 18 4 C B 3 J 1-1 5 2 2A 18 66 16 0 J3 14 17 18 A 56 90 15 16 CUS T O MER SU PPLIED BY 11P RED B LA C K IM2 S P1 18 A 18 18 18 A H T O 14 15 15 F1 1 3 14A 14 0 B 14 TC S W2 18[...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. 1 3 2 4 6 3 4 7 9 3 8 5 1 0 1 1 1 2 1 3 3 2 1 1 5 14 3 2 1 6 17 2 0 1 8 1 9 2 3 4 4 2 3 2 2 21 2 5 2 6 27 2 8 4 5 30 1 0 31 32 33 34 35 36 6 37 3 39 40 41 42 4 3 44 4 6 52 47 4 8 4 9 50 51 2 6 52 57 56 55 53 54 50 53 58 8 59 60 61 A " " A " T O C ARB . " B " B Section 1 1 — Exploded V ie[...]

  • Page 43

    Generac ® Pow er Systems, Inc. 41 Section 1 1 — Exploded V iews and Parts Lists QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators Base & Pulley – Drawing No. 0E1 32 3-A ITEM P ART NO . QTY . DESCRIPTION 1 0E0196 1 FRAME, 760 ENGINE 2 022129 12 W ASHER LOCK M8-5/16 3 022145 15 W ASHER FLA T 5/16-M8 ZINC 4 022259 6 NUT HEX 5/16-18[...]

  • Page 44

    42 Generac ® Pow er Systems, Inc. VIEW " A" VIEW " A" T ARTE R G R OU N D T O EN G IN E G R OU ND T O CO NT. PANE L 1 2 42 4 5 6 7 5 8 1 0 5 11 4 0 6 14 1 5 1 6 12 2 2 1 3 19 9 5 17 6 5 1 8 2 2 0 21 2 2 9 2 3 24 25 2 6 27 2 8 2 9 30 31 32 33 3 34 35 36 30 31 30 37 38 41 3 44 4 3 5 47 38 4 8 4 6 5 4 0 48 Section 1 1 — Exploded[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 0D8827 1 P ANEL, ENCLOSURE ROOF 2 0A7215 22 SCREW SW 1/4-20X5/8 N W A JS500 3 029451 11.5 FT . T APE ELEC UL FOAM 1/8 X 1/2" 4 0D8825 1 P ANEL, SIDE AND BACK ENCLOSURE 5 0D3700 14 NUT FLANGE M6-1.0 NYLOK (GASOLINE ONL Y) 0D3700 17 NUT FLANGE M6-1.0 NYLOK (LP ONL Y) 6 090388[...]

  • Page 46

    44 Generac ® Pow er Systems, Inc. 1 2 3 5 6 7 7 8 9 11 12 1 14 1 5 17 1 8 1 1 8 2 0 21 22 2 3 4 2 6 27 2 8 2 9 30 31 32 33 36 35 37 38 3 9 39 4 0 41 6 42 4 3 44 45 5 4 6 4 4 8 4 9 50 56 57 52 53 54 55 58 5 60 62 63 64 65 66 67 69 7 0 7 73 74 7 5 77 78 8 79 7 80 81 82 83 84 85 87 91 1 92 2 2 94 4 5 96 97 98 99 100 0 1 01 66 102 1 04 66 1 03 1 05 1 [...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 ITEM P ART NO . QTY . DESCRIPTION 1 045756 15 SCREW HHTT M6-1.0 X 10 YC 2 0D1131 1 GU ARD ,F AN 12KW HSB 3 0C3022G 1 HOUSING, BLO WER V -TWIN R V 4 0C9763 4 NUT ,GROMMET 1/4 PLUG 5 0D9782 1 HOSE, BREA THER 6 0C3034 1 NUT HEX M24-2.0 G8 YEL CHR 7 0C3033 1 W ASHER,BELLEVILLE 25MM BOL T 8 051754 2 SCREW HHC M8-1.25 X[...]

  • Page 48

    46 Generac ® Pow er Systems, Inc. 1 2 3 4 5 6 7 8 9 9 1 0 11 12 2 1 3 14 4 1 5 1 6 17 1 8 1 9 2 0 21 22 2 3 24 5 2 5 2 6 27 7 28,2 30 31 32 33 34 35 36 37 39 4 0 41 42 4 3 44 4 45 5 4 6 39 40 37 36 35 47 4 9 50 8 51 52 7 53 54 55 56 5 59 60 39 61 62 63 8 7 64 65 66 8 7 67 Section 1 1 — Exploded V iews and Parts Lists QUI ETP ACT 55, 65, and 7 5 [...]

  • Page 49

    Generac ® Pow er Systems, Inc. 47 ITEM P ART NO . QTY . DESCRIPTION 1 0C2375 2 SCREW HHC M8-1.25 X 90 G8.8 2 022145 2 W ASHER FLA T 5/16-M8 ZINC 3 029459 2 TENSION SPRING 4 075215 2 W ASHER, SPRING CENTER 5 052858 6 NUT LOCK FL M8-1.25 6 047411 7 SCREW HHC M6-1.0 X 16 G8.8 7 022097 13 W ASHER LOCK M6-1/4 8 022473 10 W ASHER FLA T 1/4-M6 ZINC 9 080[...]

  • Page 50

    48 Generac ® Pow er Systems, Inc. Section 1 1 — Exploded V iews and Parts Lists QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 7 60 V - Twin Engine – Drawing No. 0E1 0 1 4-B 54 53 42 4 8 4 5 4 6 4 7 4 3 56 58 50 4 9 59 61 60 2 0 2 3 51 4 0 41 39 30 31 2 9 3 38 37 21 35 36 33 34 33 2 8 27 9 1 6 44 2 7 17 1 8 1 9 22 1 2 1 5A 1 5B 1[...]

  • Page 51

    Generac ® Pow er Systems, Inc. 49 ITEM P ART NO . QTY . DESCRIPTION 1 0C5730A 1 ASSEMBL Y , CRANKCASE R V 2 0C3008 1 SEAL, 38 I.D . CRANKCASE 3 090388 6 SCREW , HHTT M6-1.0 X 12mm 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER CO VER 6 0C3003 3 SEP ARA T OR, OIL BREA THER 7 0D8067A 1 ASSEMBL Y , HEAD #1 8 0C2981C 1 CO VER, ROCKER 9[...]

  • Page 52

    50 Generac ® Pow er Systems, Inc. 5 6 4 3 2 7 8 1 1 0 9 11 12 1 3 14 1 5 1 9 21 22 2 3 2 4 2 5 2 6 1 6 17 1 8 2 0 27 Section 1 1 — Exploded V iews and Parts Lists QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators LP Regulator – Drawing No. 0E1 53 0[...]

  • Page 53

    Generac ® Pow er Systems, Inc. 51 ITEM P ART NO . QTY . DESCRIPTION 1 0D5694 1 CASTING, TWIN REGULA TOR HOUSING 2 075475 4 SCREW PPHM M4-0.7 X 10 3 022264 4 W ASHER LOCK #8-M4 4 043180 4 W ASHER FLA T M4 5 0C5765 1 SOLENOID , TWIN REGULA TOR 6 0C6070 1 SPRING-SOLENOID PLUNGER 7 0C4680 1 PLUNGER LP REG. ASSY 8 0C4647 1 GASKET , SOLENOID 9 0C4643 1 [...]

  • Page 54

    52 Generac ® Pow er Systems, Inc. Section 1 2 – W arranty QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators 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 AND OB LIGA TIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EP A), togethe[...]

  • Page 55

    Generac ® Pow er Systems, Inc. 53 Section 1 2 – W arranty QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators EM IS SION CONTROL S Y STEM W AR R ANTY 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 arrant[...]

  • Page 56

    Part No. 0E1015 Revision B (08/30/02) Printed in U.S.A. Section 1 2 – W arranty QUI ETP ACT 55, 65, and 7 5 Recreational V ehicle Generators GENER AC PO WER SY S TEMS’ TH REE- YEAR LIM ITED W ARR ANT Y FOR RECREA TIONAL VEH ICLE GEN ERA T ORS NOTE: ALL UNITS MUST BE INST ALLED BY GENERAC POWER SYSTEMS AUTHORIZED SER VICE F ACILITIES. F or a per[...]