Generac Power Systems 004700-0 manual

GENERA C OHVI POW ERED GENERA C OHVI I N DUSTR IAL ENG INE QUIETPA CT 40G RV S E RVI CE L O CAT O R: 1.8 00.333.1322 G E N E R A C P o w e r S y s t e m s , I n c - W h i t e w a t e r , W I ® ® Owner’ s Man ual and Installation Instructions Air -cooled Recreational V ehic le Generator s • Model: 004700-0 QUIETP A CT 40G This manual should re[...]

Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the PRIMEP 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 you do not understand any portion of this manual, contact Generac or your near[...]

T able of Contents QUI ETP ACT 40G Recreational V ehicle Generator Generac ® Pow er Systems, Inc. 1 P ar t I – Owner’s Manual Introduction ......................................Inside Front Cover Read This Manual Thoroughly ....................................IFC Contents ......................................................................IF[...]

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 main- tained. Many accidents are caused by failing to follow s[...]

Generac ® Pow er Systems, Inc. 3 • When working on this equipment, remain alert at all times. Never work on the equipment when you are physically or mentally fatigued. • Inspect the generator regularly , and contact your nearest Generac Authorized Service Dealer immedi- ately for parts needing repair or replacement. • Before performing any m[...]

4 Generac ® Pow er Systems, Inc. 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[...]

Generac ® Pow er Systems, Inc. 5 Section 1 – General Information QUI ETP ACT 40G 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. Y ou should not modify the generator or use it for any application other than for wh[...]

6 Generac ® Pow er Systems, Inc. Section 1 – General Information QUI ETP ACT 40G Recreational V ehicle Generator Generac does not recommend using any gasoline containing alcohol (such as “gasohol”). If you use any gasoline containing alcohol, it must not contain more than 10 per cent ethanol, and it must be removed fr om the generator during[...]

Generac ® Pow er Systems, Inc. 7 Section 2 – Operation QUI ETP ACT 40G Recreational V ehicle Generator 2.1 GENER 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 2.1.1 F U EL PRIMER Before starting a cold engine (if it has not been start- ed in more than[...]

8 Generac ® Pow er Systems, Inc. Section 2 – Operation QUI ETP ACT 40G Recreational V ehicle Generator 2.4.2 ENGI N E L U BR ICA TION Have the engine crankcase properly serviced with the recommended oil before starting . Refer to Section 1.5.4 (P age 6) and Sections 3.1 and 3.2 (P age 12) for oil ser- vicing procedures and recommendations. Any a[...]

Generac ® Pow er Systems, Inc. 9 Section 2 – Operation QUI ETP ACT 40G 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 temp[...]

10 Generac ® Pow er Systems, Inc. Section 2 – Operation QUI ETP ACT 40G Recreational V ehicle Generator 2.9.3 F I ELD 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 [...]

Generac ® Pow er Systems, Inc. 11 Section 3 – Maintenance QUI ETP ACT 40G 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[...]

12 Generac ® Pow er Systems, Inc. Section 3 – Maintenance QUI ETP ACT 40G 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. Run the engine until it is thoroughly warmed [...]

Section 3 – Maintenance QUI ETP ACT 40G 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 [...]

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

Generac ® Pow er Systems, Inc. 15 3.1 0 MA JOR SERVICE MAN UAL T o obtain a service manual for your generator , con- tact Generac or your nearest Generac Authorized Service Dealer or , go to www .generac.com. Make sure to identify your MODEL NUMBER and SERIES. 3.1 1 EXERCISI NG TH E GENER A T OR Generac recommends that you start and operate the ge[...]

16 Generac ® Pow er Systems, Inc. 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 tight- ening the jam nut, recheck valve clearance to make sure it did not change (Figure 3.8). Figure 3.8 — T ightening J[...]

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[...]

18 Generac ® Pow er Systems, Inc. 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 installing such products, or similar prod- ucts that Generac manufactures. G[...]

Generac ® Pow er Systems, Inc. 19 ELE CTR ICAL HA ZAR 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 t[...]

20 Generac ® Pow er Systems, Inc. 1.1 P U R POSE AN D SC OP E 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 manu[...]

Generac ® Pow er Systems, Inc. 21 Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-C) Section 1 – General Information QUI ETP ACT 40G Recreational V ehicle Generator b y Generac Power S y stems Inc. GU ARDIAN 7 4 9 . 8 3 42.2 483 .1 H O T AI R E XHA US T TAIL PIPE EXIT O IL DRAIN AIR INTAKE AC OU TP U T H ARNE SS R EM O TE PANEL [...]

22 Generac ® Pow er Systems, Inc. 2.1 L OCA TION AN D SU P PORT 2.1.1 GEN ER A 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 reinforce. Many recreational vehicles have[...]

Generac ® Pow er Systems, Inc. 23 2.1.4 GEN ER A T OR R ES TR AI NT 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[...]

24 Generac ® Pow er Systems, Inc. • If flexible metal conduit is used, it must be sealed internally at the end where it terminates inside the compartment ’s electrical junction box. NOTE: Flexible metal conduit, due to its unique con- struction, is NOT vapor tight along its entire length. • Seams and joints of the galvanized steel (whether u[...]

Generac ® Pow er Systems, Inc. 25 Figure 2.7 – T ypical Noise Abatement 2.2.5 COMP ARTM ENT F L OOR CUT OUTS Y ou must provide openings in the generator compart- ment for the following items (Figure 1.2, page 21): • Engine exhaust and cooling air outlets • Generator cooling air inlet • F our holes for passage of generator mounting bolts. S[...]

26 Generac ® Pow er Systems, Inc. 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 air- flow , the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also[...]

Generac ® Pow er Systems, Inc. 27 2.4.1 F U EL T AN K 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 ge[...]

28 Generac ® Pow er Systems, Inc. 2.5.1 SP AR K AR R E ST 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 Generac. Any person(s) installing an unapproved muffler , or an unapproved exhaust system part, or modifying an exhaust system in any way that might c[...]

Generac ® Pow er Systems, Inc. 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 a[...]

30 Generac ® Pow er Systems, Inc. 2.6.5 ISOLA TI NG D IFFERE NT PO WE R 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 you use, you must be certain t[...]

Generac ® Pow er Systems, Inc. 31 2.6.7 GROU N D F AU L T CI RCUIT I NTERR U PTERS The National Electrical Code (NFP A 70, 551-7) 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. 2.7 B A T TER Y I NS T ALL A TION [...]

32 Generac ® Pow er Systems, Inc. 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, hourmeter , generator run lamp and a wire harness. The hourmeter should b[...]

Generac ® Pow er Systems, Inc. 33 Section 3 – Post-installation Start-up Adjustments QUI ETP ACT 40G Recreational V ehicle Generator 3.5 I NS T ALL A TION CH ECKLIS T L OCA TION AN D SU PPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GEN ERA T OR COMP ARTM ENT ❑ Compartment co[...]

34 Generac ® Pow er Systems, Inc. Appendix 1 – Notes QUI ETP ACT 40G Recreational V ehicle Generator[...]

Generac ® Pow er Systems, Inc. 35 Appendix 2 – T roubleshooting QUI ETP ACT 40G Recreational V ehicle Generator TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION 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[...]

4 66 4 5 5 1 55 8 8 77 1 1A 1 A BATTERY CHARGE WINDING 120V 30A DPE WINDING VOLTAGE REGULATOR POWER WINDING ELECTRONIC BY CUSTOMER NEUTRAL CONNECTION WHITE T2 GREEN 0F FIELD CB3 0N 0K 2 2A 22P 44 22S 0N 0N R1 55 4 BLACK 6 4 T1 4 11S CB1 11P 33 HM START STOP 4 L1 16 BATTERY 14 15 77 BCR 66 J1-14 J1-15 J1-12 J1-13 15 15 J1-9 J1-10 J1-11 J1-6 J1-7 J1-[...]

Generac ® Pow er Systems, Inc. 37 Appendix 3 — Electrical Data QUI ETP ACT 40G Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-A 18A 85 18 18 4 J1-9 CB3 J1-14 J1-15 J1-13 J1-10 J1-11 J1-12 18 18 66 16 85 0 J2 PCB J1-7 J1-8 J1-5 J1-6 J1-2 J1-3 J1-4 J1-1 J3 14 17 17 18A 56 90 15 16 CUSTOMER SUPPLIED B[...]

38 Generac ® Pow er Systems, Inc. 22 39 2 3 2 0 21 24 11 12 43 41 2 21 3 2 9 2 8 27 21 1 9 8 1 0 21 6 7 21 2 6 2 5 36 37 4 5 1 6 55 34 33 3 1 2 9 1 9 30 22 2 3 24 42 42 47 4 5 4 6 59 44 1 3 38 49 50 17 21 21 21 1 5 T O C AR B 51 1 8 14 52 21 53 54 2 9 21 4 0 56 57 58 Appendix 4 — Exploded Views and P ar ts Lists QUI ETP ACT 40G Recreational V eh[...]

Generac ® Pow er Systems, Inc. 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 SH[...]

40 Generac ® Pow er Systems, Inc. Appendix 4 — Exploded Views and P ar ts Lists QUI ETP ACT 40G Recreational V ehicle Generator Generator – Drawing No. 0D835 3-F 9 1 4 3 6 7 5 2 8 10 11 12 2 18 6 36 18 19 17 20 4 1 21 2 18 23 18 2 21 21 2 18 21 2 18 23 24 25 26 27 28 29 30 3 1 3 2 33 3 4 29 24 35 38 3 7 2 15 22 14 21 39 40 18 42 18[...]

Generac ® Pow er Systems, Inc. 41 Appendix 4 — Exploded Views and P ar ts Lists QUI ETP ACT 40G Recreational V ehicle Generator Generator – Drawing No. 0D835 3-F 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 [...]

42 Generac ® Pow er Systems, Inc. 1 11 12 1 3 31 1 5 1 21 2 0 2 4 17 1 8 17 3 5 6 25 24 2 3 14 2 8 22 1 9 7 25 27 24 23 9 1 6 2 3 2 6 17 25 30 35 8 37 36 2 9 39 38 Appendix 4 — Exploded Views and P ar ts Lists QUI ETP ACT 40G Recreational V ehicle Generator Control Panel – Drawing No. 0D83 54-C[...]

Generac ® Pow er Systems, Inc. 43 Appendix 4 — Exploded Views and P ar ts Lists QUI ETP ACT 40G Recreational V ehicle Generator Control Panel – Drawing No. 0D83 54-C ITEM P ART NO . QTY . DESCRIPTION 1 0830490 1 REGULA T OR V OL T AGE 2 075210A 1 TERMINAL BLOCK 3 0922340 1 CONTROLLER P .C.B . 4 065795 1 BA TTER Y CHARGER RECTIFIER 5 023484F 1 [...]

44 Generac ® Pow er Systems, Inc. Appendix 4 — Exploded Views and P ar ts Lists QUI ETP ACT 40G Recreational V ehicle Generator GN-22 0 H/SH Eng ine – Drawing No. 0D835 5-C Par t 1 1 2 3 5 9 8 7 18 15 16 17 6 15 10 11 12 13 14 19 20 20 21 22 23 24 25 26 27 28 29 3 2 3 1 30 36 35 9 33 3 7 45 44 4 1 42 43 9 38 39 40 9 55 5 2 53 5 4 56 6 5 7 58 5[...]

Generac ® Pow er Systems, Inc. 45 Appendix 4 — Exploded Views and P ar ts Lists QUI ETP ACT 40G Recreational V ehicle Generator GN-22 0 H/SH Eng ine – Drawing No. 0D835 5-C Par t 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 BLO WER HOUSING 4 081810 1 NUT , HEX M16-1.5 5 083312 1[...]

46 Generac ® Pow er Systems, Inc. Appendix 4 — Exploded Views and P ar ts Lists QUI ETP ACT 40G Recreational V ehicle Generator GN-22 0 H/SH Eng ine – Drawing No. 0D835 5-C Par t 2 26 43 42 44 45 23 22 24 25 48 30 17 13 28 4 18 40 3 7 36 46 39 38 21 29 16 35 33 15 20 3 2 3 1 3 4 5 41 49 14 27 35 8 1 47 5 1 1 2 7 19 1 2 3 9 13 11 10 6 7 50 5 2[...]

Generac ® Pow er Systems, Inc. 47 Appendix 4 — Exploded Views and P ar ts Lists QUI ETP ACT 40G Recreational V ehicle Generator GN-22 0 H/SH Eng ine – Drawing No. 0D835 5-C Par t 2 ITEM P ART NO . QTY . DESCRIPTION N/A 0C8925 1 LONG BLOCK ASSEMBL Y 1 078621 1 CONNECTING ROD ASSEMBL Y 2 076389 1 PISTON PIN 3 088411 1 PISTON RING SET 4 0A8897B 1[...]

48 Generac ® Pow er Systems, Inc. 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 AR RANT Y R IGHTS AND OB LIGA 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 Con[...]

Generac ® Pow er Systems, Inc. 49 EM IS SION CONTROL SY 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 [...]

Part No. 0D8351 Re vision C (08/07/02) Printed in U.S.A. Appendix 5 – W arranty QUI ETP ACT 40G Recreational V ehicle Generator GEN ERAC PO WER S YS TEMS’ TH R EE- YEAR LI MITED W AR R ANT Y FOR R E CR EA TIONAL VEH ICLE GEN ER A T ORS NOTE: ALL UNITS MUST BE INST ALLED BY GENERAC POWER SYSTEMS AUTHORIZED SER VICE F ACILITIES. F or a period of [...]