Generac Power Systems 004701-0 manual

Owner’ s Man ual and Installation Instructions Air -cooled Recreational V ehic le Generators • Model: 004701-0 QUIETP A CT 40LP This manual should remain with the unit.[...]

I NTRODUCTION Thank you for purchasing this model by Generac P ower Systems Inc. It has been designed and manu- factured 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 , operating and servicing procedur[...]

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 Owner’s Manual and with the unit. The generator 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 ru[...]

3 • Adequate, unobstructed flow of cooling and ven- tilating air is critical to correct generator opera- tion and is required to expel toxic fumes and fuel vapors from the generator compartment. W ithout sufficient cooling airflow , the engine/generator quickly overheats, which causes serious damage to the generator . Do not alter the installatio[...]

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. LP Regulator/Solenoid 12. Oil Filter 13. Oil Drain Cap 14. Oil Dipstick 15.[...]

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 1.5.3 ENGI N E OIL R EQ UIRE MEN T S Use only high quality detergent oil rated with American P etroleum Institute (API) Service Classification SF , SG or SH. The recommended oil weights include the following: • During summer months: SAE 30. An acceptable substitute is SAE 10W -30. • During winter months: SAE 5W -30. DO NOT USE SAE 10- W40. Cr[...]

7 Section 2 – Operation Recreational V ehicle Generator 2.1.4 MAI N BR EAKER The main breaker protects the generator’s AC out - put circuit against overload and provides a method of turning OFF the generator’s 120-volt AC output to the vehicle circuits. This generator has a 30-amp breaker . 2.2 OPTIONAL R EMO TE S T ART/ST OP P AN EL A remote[...]

8 Section 2 – Operation Recreational V ehicle Generator T o start the generator from either the generator con- trol panel or from the optional remote panel, proceed as follows: 1. T urn OFF electrical loads using the means pro - vided in the vehicle (such as a main line circuit breaker or transfer switch). NOTE: If starting from the generator con[...]

9 Section 2 – Operation Recreational V ehicle Generator 2.8.2 H IGH TEM PER A TU R E SWIT CH This switch (Figure 2.2), which has normally open (N .O .) contacts, is mounted near the oil filter . The contacts close if the temperature should exceed approximately 284º F (140º C), initiating an engine shutdown. Figure 2.2 – Low Oil Pressure and H[...]

10 2.9.2 25-HOUR CHECK-U P After the 25-hour break -in period, contact an Authorized Service Dealer for the following main- tenance. The vehicle owner is responsible for any charges: • Change the engine crankcase oil and oil filter . • Check the oil level. • Inspect the cooling and ventilation openings. • Check the engine carburetor adjustm[...]

11 Section 3 – Maintenance Recreational V ehicle Generator 4. If necessary , remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dip - stick “F ull” mark. DO NOT FILL ABOVE THE “FULL ” MARK.  Never operate the engine with the oil level below the “Add” mark on the dipstick. Doing this could damage the[...]

12 Section 3 – Maintenance Recreational V ehicle Generator 3.3.2 CLEAN ING OR R EP L ACING TH E P AP ER F I L TER Once each year or every 100 hours of operation (whichever comes first), clean or replace the paper filter . The new replacement filter must be flame retardant. Service the paper filter more frequently if operating the generator in ext[...]

Section 3 – Maintenance Recreational V ehicle Generator Figure 3.5 - Spark Arrestor RET AINING SCREW P/N 056892 SP ARK ARRRESTOR SCREEN P/N 089680 T AILPIPE P/N 0E0683 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 ermittin[...]

14 • Where electr olyte 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 bicar - bonate of soda solution[...]

15 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 3.7). Figure 3.7 — T ightening Jam Nut 3.1 3 RV GEN ER A T OR SERV[...]

16 Section 4 – Notes Recreational V ehicle Generator[...]

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. 0F4610) Section 1 – General Information Recreational V ehicle Generator 3 42. 2 [1 3 1/2"] 77 8 . 9 [ 3 0 11/16" ] REF. FR O NT D OO R A CC E SS F OR ALL RE Q UIRED MAINTENANC E REM O TE PANE L CO NNE C T OR 500 . 2 [ 1 9 11/16" ] REF. A C OU TP UT HARNE SS H O T AI R EXH[...]

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 2.2 GEN ER A T OR C OM P ARTM ENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compartment that the installer constructs, the compartment must meet certain spec- ifications as outlined in the following sections: 2.2.1 COMP ARTM ENT SIZE Plan the compartment size car[...]

24 Figure 2.5 – T ypes of Lock Seams D ANGER  Do not install any flammable material directly above or around the compartment. Heat, trans- ferred thr ough the compartment structure, may be sufficient to ignite, char or discolor seat cush- ions, fiberboard and other flammable materials. Use approved nonflammable insulating materi- als in high t[...]

25 Section 2 – Installation Recreational V ehicle Generator Figure 2.7 – Compartment Floor Cutout (Drawing 0G3723-A)[...]

26 D ANGER  Fuel lines and exhaust piping must not pen- etrate into the vehicle living area. 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 ov[...]

27 Figure 2.9 – T ypical Propane Gas Fuel System 2.4.2 SOME I M PORT 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 reduces the possibility of leakage[...]

28 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 propor - tional to airflow through t[...]

29 2.5.1 SP AR K ARR ES T 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 li[...]

30 • 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 JU NCTION BOX Install an approved, square electrical jun[...]

31 Section 2 – Installation Recreational V ehicle Generator Figure 2.14 – T ransfer Switch Isolation Method Figure 2.15 – Installation With Isolation Receptacle[...]

32 2.6.6 POWER SUP P L Y CORD The power supply cord must comply with all appli- cable codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected. 2.6.7 GROU ND F AU L T CI RCUIT I NTERR U PTERS The National Electrical Code (NFP A 70, 551-7) requires that a ground fault circuit interrupters (G[...]

33 Section 3 – Post-installation Start-up Adjustments Recreational V ehicle Generator Figure 2.17 – Remote Panel Plug-in Receptacle 12.00" 14 0 17 1 5 1 8 14A 1 3 2 5 4 6 0 14 17 1 8 14A 1 5 1 5 17 14A 1 8 14 0 N o. WIRE WIRE CO L OR RED YELL OW O RAN GE WHITE BL UE BR O W N 12.0 ( 305 ) LENGTH ( mm ) 12.0 ( 305 ) 12.0 ( 305 ) 12.0 ( 305 )[...]

34 6. T urn off all electrical loads by setting the gener- ator’s main circuit breakers to their “OFF” (or open) position. 7. Let the unit run at no -load for a few minutes to stabilize internal engine/generator temperatures. Then, shut down the engine. NOTE: The generator set was thoroughly tested and adjusted at the factory before shipping [...]

35 Section 3 – Post-installation Start-up Adjustments Recreational V ehicle Generator 3.5 I NS T ALL A TION CH E CKLIST 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[...]

36 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. Defective starter contactor 4. Replace contactor . 5. Defective starter [...]

37 Section 5 – Notes Recreational V ehicle Generator[...]

RED BLUE ORANGE BROWN 7 7 YELLOW WHITE 15 BA TTERY CHARGE WINDING NEUTRAL CONNECTION GREEN BY CU S TOMER 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 22 S 11 S 77 55 BLACK FUEL PRIME 11P 4 4 T1 4 CB1 REMOTE P ANEL (OPTIONAL) 33 4 66 S TA R T HM L1 1 S TOP 8 A 4 1 8 5 14 18 0 17[...]

39 Section 6 — 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 C S 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 F S 14 2 3 18 18A 18 CONN. 1 PIN# 0 0 FP 90 14 2 1 2[...]

40 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator Enclosure – Drawing No. 0F4589-B[...]

41 ITEM P ART NO . QTY . DESCRIPTION 1 0F3916 1 TRA Y , ENCLO S URE 2 0D6942 1 P ANEL, ENCLO S URE S IDE 3 0D6939 1 P ANEL, REAR DIVIDER 4 0F3920 1 P ANEL, ENCLO S URE ROOF 5 0F3917 1 P ANEL, ENCLO S URE BACK 6 0F3918 1 P ANEL, FRONT DIVIDER 7 0F3919 1 COMP ARTMENT , AIR INT AKE 8 0G7329 1 P ANEL, ENCLO S URE DOOR 9 0D8254 1 S HIELD , MUFFLER 10 0C[...]

42 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator Generator – Drawing No. 0F4590-C[...]

43 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator Generator – Drawing No. 0F4590-C ITEM P ART NO . QTY . DESCRIPTION 1 029092 1 S CREW IHHC 5/16”-24 X 11-1/4” G5 2 022129 22 W A S HER LOCK M8-5/16” 3 049451 1 W A S HER FLA T .406” I.D . X 1.62” O .D . 4 0C8096A 1 F AN, 8" CUR VE BLADE, 16.5MM I.D . 5 [...]

44 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator Control Panel – Drawing No. 0F45 9 1 -A[...]

45 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator Control Panel – Drawing No. 0F45 9 1 -A ITEM P ART NO . QTY . DESCRIPTION 1 0F9719 1 REGULA TOR V OL T AGE 2 075210A 1 TERMINAL BLOCK 3 092234 1 CONTROLLER P .C.B. 4 065795 1 BA TTERY CHARGER RECTIFIER 5 023484F 2 BU S HING S NAP 1” 6 023484R 1 BU S HING S NAP 1-1/[...]

46 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0F57 9 1-G P art 1[...]

47 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0F57 9 1-G P art 1 ITEM P ART NO . QTY . DESCRIPTION 1 0D8433 1 GUARD , F AN 2 0C1069 10 S CREW , HHTT M6-1.0 X 8mm 11 (04701-1 ONL Y) 3 090695F 1 BLOWER HOU S ING 0G6468 1 BLO WER HOU S ING (04701-1 ONL Y) 4 081810 1 NUT , HEX M16-1[...]

48 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0F57 9 1-G P art 2[...]

49 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0F57 9 1-G P art 2 ITEM P ART NO . QTY . DESCRIPTION N/A 0F5800 1 LONG BLOCK A SS EMBL Y 220 RV LP 1 078621 1 CONNECTING ROD A SS EMBL Y 2 076389 1 PI S T ON PIN 3 0G4379 1 RING S ET , PI S TON DIA 75 4 0A8897B 1 GEAR CO VER A SS EMB[...]

50 9 14 12 11 1 8 1 6 1 3 1 5 17 1 9 2 3 21 2 0 22 2 5 24 2 6 8 1 0 4 6 5 3 2 1 7 Section 7 — Exploded Views and P arts Lists Recreational V ehicle Generator Regulator – Drawing No. 0F58 1 9[...]

51 ITEM P ART NO . QTY . DESCRIPTION 1 0D5694 1 CA S TING, TWIN REGULA TOR HOU S ING 2 0F4795 4 S CREW PPHM S EM S M4-0.7 X 10 3 0F5022 1 S OLENOID COIL, 12VDC 4 0C6070 1 S PRING- S OLENOID PLUNGER 5 0C4680 1 PLUNGER LP REG. A SS Y 6 0C4647 1 GA S KET , S OLENOID 7 0C4643 1 INLET , TWIN REGULA TOR NO HOLE 8 0D3973 1 PLUG, EXP AN S ION 16MM TWINREG [...]

52 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[...]

53 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. 0F4594 Revision D (10/22/07) Printed in U.S.A. Section 8 – 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 op[...]