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Generac Power Systems 004614-1 Installation And Owner's Manual

Liquid-cooled recreational vehicle generator
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®
POWER SYSTEMS, INC.
Owner's Manual and

Installation Instructions

Liquid-cooled Recreational Vehicle Generator
• Model: 004614-1
QUIETPACT™ 65D

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Summary of Contents for Generac Power Systems 004614-1

  • Page 1: Installation Instructions

    ® POWER SYSTEMS, INC. Owner’s Manual and Installation Instructions Liquid-cooled Recreational Vehicle Generator • Model: 004614-1 QUIETPACT™ 65D...

  • Page 2: Introduction

    This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views, and lists of repair parts for generator model number 004614-1. In addition, the latter portion of this manual contains information necessary for the proper installation of these generators.

  • Page 3: Table Of Contents

    Testing Under Load ...34 Installation Checklist ...35 Appendix 1 – Troubleshooting...36 Appendix 2 – Electrical Data ...37 Appendix 3 – Exploded Views and Parts Lists ...40 Appendix 4 - Notes...62 Appendix 5 – Warranty ...64 Generac Power Systems, Inc. ®...

  • Page 4: Safety Rules

    Many accidents are caused by failing to follow simple and fundamental rules or precautions. Generac cannot possibly anticipate every possible cir cumstance that might involve a hazard. The warn- ings in this manual, and on tags and decals affixed to the unit, are, therefore, not all-inclusive.

  • Page 5: Fire Hazards

    Inspect the unit’s fuel system fre- quently and correct any leaks immediately. Before placing this equipment into service, the fuel supply lines must be properly installed, purged, and leak- tested according to applicable fuel-gas codes. Generac Safety Rules Power Systems, Inc. ®...

  • Page 6: Section 1 - General Information

    1. Model Number ____________________ 3. kW Rating__________________________ Generac Power Systems, Inc. ® 2. Serial Number __________________ 4. Rated Voltage __________________ Model: 004614-1 QUIETPACT™ 65D 1. 2-Pole, 30-amp Circuit Breaker 2. Hourmeter 3. Oil Fill Opening and Plug 4. Oil Dipstick 5.

  • Page 7: Generator Applicability

    Also, appropriate care should be taken in applica- tions where extremely low ambient temperatures are possible, to ensure the temperature of the diesel fuel is not allowed to fall below levels where “gelling” could occur. Generac NOTE: Power Systems, Inc. ®...

  • Page 8: Fuel Consumption

    1.5.2 FUEL CONSUMPTION (GAL/HR) Model No Load QUIETPACT™ 65D 0.28 (004614-1) 1.5.3 ENGINE OIL REQUIREMENTS Use a high-quality detergent oil with American Petroleum Institute (API) classification “For Service CC.” Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE vis-...

  • Page 9: Section 2 - Operation

    2.3.1 INSTALLATION Generator installation must have been properly com- pleted so that it complies with all applicable codes, standards, and regulations and with the manufactur- er's recommendations. Generac NOTE: NOTE: Power Systems, Inc. ®...

  • Page 10: Engine Lubrication

    Close windows, doors, and other openings in the vehicle that, if open, might permit exhaust gases to enter the vehicle. Generac Power Systems, Inc. ® The generator engine releases DEADLY carbon monoxide gas through its exhaust system. This...

  • Page 11: Stopping The Generator

    This normally-open (N.O.) thermostatic switch has a sensing tip that is immersed in captive coolant. Should the coolant temperature exceed approximate- ly 115° C (240° F), the switch contacts close, and the engine shuts down automatically. Generac Power Systems, Inc. ®...

  • Page 12: Overspeed Shutdown

    2.8.2 25-HOUR CHECK-UP After the 25-hour break-in period, contact a Generac Authorized Service Dealer for the following mainte- nance, for which the vehicle owner is responsible for all charges: •...

  • Page 13: Operation In High Grass Or Brush

    8. Screw the new filter on by hand, until its gasket lightly contacts the oil filter adapter. Then, tight- en the filter an additional 3/4 to one turn. Generac OIL DIPSTICK (PANEL TRANSPARENT FOR VIEWING PURPOSES.

  • Page 14: Servicing The Engine Air Filter

    See the “Service Schedule,” Section 3.13 (Page 16), for recommended air cleaner maintenance. SPARK ARRESTOR MUFFLER The exhaust muffler supplied with the QUIETPACT™ 65D is a spark arrestor type. Generac exhaust muf- flers for recreational vehicle generators do not have a 12 Generac Power Systems, Inc.

  • Page 15: Cleaning The Generator

    Once each year, have the generator cleaned and inspected by a Generac Authorized Service Dealer. Service technicians will use dry, low-pressure air to clean internal windings. Parts inside the control con- sole should be cleaned and inspected at this time, as well.

  • Page 16: Cooling System

    Generac Authorized Service Dealer. 3.11 EXERCISING THE GENERATOR Generac recommends that you start and operate the generator at least once every seven days. Let the unit run for at least 30 minutes to “exercise” the engine. If you cannot exercise the generator every seven days, and it is to be out of service longer than 30 days, see Section 3.12.

  • Page 17: Return To Service

    7. Apply electrical loads to at least 50 percent of the unit’s rated wattage capacity. 8. When the engine is thoroughly warmed up, shut it down. 9. Your generator is now ready for service. Section 3 – Maintenance QUIETPACT™ 65D Recreational Vehicle Generator Generac Power Systems, Inc. 15 ®...

  • Page 18: Service Schedule

    Section 3 – Maintenance QUIETPACT™ 65D Recreational Vehicle Generator 3.13 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by your nearest Generac Authorized Service Dealer. SYSTEM/COMPONENT X = Action R = Replace/Adjust as Needed * = To Be Completed by a Generac Authorized Service Dealer.

  • Page 19: Part Ii - Installation Instructions

    PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

  • Page 20: Safety Rules

    (a) use of common hand tools, (b) use of special Generac tools, and (c) use of any tools and/or equipment from other suppliers. Generac cannot possibly know of, nor advise the...
  • Page 21 There must be no possibility of fuel vapors enter- ing the vehicle interior. • You are required to install an approved, flexible, nonconductive fuel line between the generator fuel connection point and the rigid fuel lines. Generac Safety Rules Power Systems, Inc. 19 ®...

  • Page 22: Section 1 - General Information

    Boulevard, Rexdale, Ontario, Canada, M9W 1R3. EQUIPMENT DESCRIPTION Instructions and information in this section pertain to Generac liquid-cooled generators, designed specifically for installing in recreational vehicles. The QUIET- PACT™ 65D operates 230-volt, single-phase, 50-Hertz, AC electrical loads that require up to 28.2 amps at 230 volts.
  • Page 23 Section 1 – General Information QUIETPACT™ 65D Recreational Vehicle Generator Major Features and Dimensions — Drawing No. D2650-A Figure 1.2 – Major Features and Dimensions Generac Power Systems, Inc. 21 ®...

  • Page 24: Section 2 - Installation

    The fol- lowing general rules apply: • Vehicle construction MUST be capable of support- ing the weight of the generator. 22 Generac Power Systems, Inc. ® • Whether the generator is mounted above the hori- zontal support tubing or suspended below the tub- ing, the supporting frame used must be structural- ly sound.

  • Page 25: Generator Restraint

    • If the compartment is lined with galvanized steel, it may be constructed of any material. Generac rec- ommends that the compartment be constructed of 1/2-inch thick plywood (not strandboard), with the...

  • Page 26: Sound Insulating Materials

    One excellent insulating material is a 1- inch (25 mm) thick fiberglass having a 2-pound den- sity. When fiberglass is used, its coated side should face toward the compartment interior. 24 Generac Power Systems, Inc. ® Do not install sound insulation or any absorbent material on the compartment floor interior.

  • Page 27: Compartment Floor Cutouts

    • Generator cooling air inlet and front service door • Four holes for passage of generator mounting bolts. See Section 2.1.4 (Page 23) • Rear service door. Fuel lines and exhaust piping must not pene- trate into the vehicle living area. Generac Power Systems, Inc. 25 ®...

  • Page 28: Cooling And Ventilating Air

    (see Figure 2.7). Figure 2.7 – Airflow Through Engine/Generator 26 Generac Power Systems, Inc. ® 2.3.2 COOLING AIR INLET OPENINGS...

  • Page 29: Compensating For Restrictions

    187.5 square inches (1,218.75 cm QUIETPACT™ 65D Recreational Vehicle Generator 2.3.4 TESTING THE INSTALLATION 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.

  • Page 30: Fuel Tank

    If the generator is to share the vehicle’s engine tank, separate fuel pickup tubes are required for the engine and the generator. Generac recommends that you make the fuel pickup tube 2 to 3 inches (51 to 76 mm) shorter than the vehicle’s engine pickup tube.

  • Page 31: Exhaust System

    • Use enough exhaust system hangers to prevent any part of the system from being dislocated. • Use exhaust system parts recommended by Generac. Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person(s) installing such unauthorized parts.

  • Page 32: Electrical Connections

    Flexible metal conduit is NOT vapor-tight along its entire length. 30 Generac Power Systems, Inc. ® • From the junction box, route power supply wires...

  • Page 33: Conduit

    NOTE: 2.6.5 POWER SUPPLY CORD 2.6.6 GROUND FAULT CIRCUIT INTERRUPTERS 2.6.7 ISOLATING DIFFERENT POWER SOURCES Generac Power Systems, Inc. 31 ®...

  • Page 34: Battery Installation

    NOTE: If the battery is to be used to power other vehicle accessories, as well as to start the generator, you may need a battery with a larger capacity. 32 Generac Power Systems, Inc. ® 2.7.2 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage, which causes starting problems.

  • Page 35: Battery Compartment

    Installation of such a panel will per- mit you to start and stop the generator engine from any convenient location inside the vehicle. Figure 2.20 – Remote Panel Plug-in Receptacle Generac WIRE #18 (STOP) WIRE #150 (PREHEAT)

  • Page 36: Remote Start/Stop Connections

    The generator engine is equipped with a high coolant temperature switch. The switch has normal- ly open (N.O.) contacts. When the engine coolant temperature is too high, switch contacts close, and the engine shuts down automatically. GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLING.

  • Page 37: Installation Checklist

    ❑ Check that remote start/stop panels (if used) are installed properly. ❑ Check that all other options and accessories (if used) are installed properly. POST INSTALLATION TESTS ❑ Check that all tests are completed properly. ____________________________________________________ ______________________________________________________ ________________________________________________ CHECKS Generac Power Systems, Inc. 35 ®...

  • Page 38: Appendix 1 - Troubleshooting

    2. Check cooling system for leaks. 3. Disconnect Remote Harness Check/Replace Start/Stop Switch 4. Replace pressure switch. 5. Replace temperature switch. 6. Contact a Generac Authorized Service Dealer 7. Replace control board. 1. Replace switch. 2. Reconnect or close wire.

  • Page 39: Appendix 2 - Electrical Data

    Appendix 2 — Electrical Data QUIETPACT™ 65D Recreational Vehicle Generator Electrical Schematic – Drawing No. - 0D5037-A Generac Power Systems, Inc. 37 ®...
  • Page 40 Appendix 2 — Electrical Data QUIETPACT™ 65D Recreational Vehicle Generator Wiring Diagram – Drawing No. 0D5036-A 38 Generac ® Power Systems, Inc.
  • Page 41 Appendix 2 — Electrical Data QUIETPACT™ 65D Recreational Vehicle Generator Wiring Diagram – Drawing No. 0D5036-A Generac ® Power Systems, Inc. 39...

  • Page 42: Appendix 3 - Exploded Views And Parts Lists

    Appendix 3 — Exploded Views and Parts Lists QUIETPACT™ 65D Recreational Vehicle Generator Engine, Alternator Drive and Starter Assembly – Drawing No. 0D5057-A 40 Generac Power Systems, Inc. ®...
  • Page 43 ¼" SPECIAL LOCK WASHER M8 FLANGE NUT TAPTITE, M6-1.0 X 8MM ENGINE, 1.0L DIESEL WASHER, FLAT M12 CLAMP, VINYL COATED, ¾" HHCS M12-1.25 X 25MM TENSIONER, SE-F18-4.5" ½"-13 X1-3/4" HHCS ½"-13 FLANGE NUT FLAT WASHER, 5/16" Generac Power Systems, Inc. 41 ®...
  • Page 44 0C6722 PLATE, CLEANOUT 042907 HHCS M8-1.25 X 16 022129 WASHER, SPLIT LK- M8 022097 WASHER, SPLIT LK -1/4-M6 42 Generac Power Systems, Inc. ® ITEM PART NO. QTY. DESCRIPTION 043146 HHCS M6-1.00 X 10 0C7561 CARRIAGE BOLT 3/8 -16 X 55MM...
  • Page 45 DECAL, MAX HOT / MIN COOLANT DECAL, WARNING RV SUPPORT, COOLANT TANK NUT, HEX M6-1.0 FOAM, AIR DUCT FACE FOAM, AIR DUCT SIDE DECAL, UNIT WASHER, SPLIT LOCK ¼" - M6 DECAL, ENGINE DATA DECAL, CSA APPROVAL Generac Power Systems, Inc. 43 ®...
  • Page 46 Appendix 3 — Exploded Views and Parts Lists QUIETPACT™ 65D Recreational Vehicle Generator Cooling System – Drawing No. D2360 44 Generac Power Systems, Inc. ®...
  • Page 47 Hose 5/16" SAE-20R4 Clamp, Vinyl Coated 1-5/8" Cap, Radiator Pressure Clamp, Vinyl Coated 1-1/16" Gasket, Radiator Base Clamp, Vinyl Coated 1-½" Nut, Hex M8-1.25 Bracket, Support ½"-13 x 1-¾" HHCS Tensioner ½"-13 Flange Nut Generac Power Systems, Inc. 45 ®...
  • Page 48 WASHER, FLAT M5 0D2021B HARNESS 0C3992 M4-0.7 X 16 HHCS TAPTITE 0C7022 DECAL, CUSTOMER CONNECTION 46 Generac Power Systems, Inc. ® 25 26 ITEM PART NO. QTY. A/R = AS REQUIRED * NOT SHOWN REFER TO WIRING DIAGRAM C4946 DESCRIPTION...
  • Page 49 0C5105 022145 039253 043107 035586 042909 042907 022145 0709390357 075673 Generac DESCRIPTION WASHER, SPLIT LK -M8 NUT, HEX M8-1.25 CRIMPTITE, ¼"-20 X 5/8" BRACKET, SUPPORT WASHER, FLAT - M8 HHCS M8-1.25 X 20 HHCS M8-1.25 X 25 HOSE CLAMP #20 HHCS M8-1.25 X 30...
  • Page 50 047411 HHCS M6-1.00 x 16 0C7968 Hex Nut 3/8-16 Brass 022237 Washer Split Lk 3/8 075763 Boot, Battery Cable 48 Generac Power Systems, Inc. ® ITEM PART NO. QTY. DESCRIPTION 075763A Boot, Battery Cable 0C7413 Grommet 3/8 I/D x 1 GD 022127 Hex Nut ¼...
  • Page 51 HOSE CLAMP SIZE #16 M4-0.7 X 16 HHCS TAPTITE WASHER, FLAT #6 GROMMET GASKET, ENGINE CONTROL BOX CIRCUIT BREAKER, 30A, 2 POLE NUT, HEX M6-1.0 PHMS M5-0.8 X 12 FLATWASHER, #8 WASHER, SPLIT LOCK 1/4”-M6 Generac Power Systems, Inc. 49 ®...
  • Page 52 ITEM PART NO. QTY. DESCRIPTION 0709390232 CAMSHAFT ASSEMBLY 0709390233 CAMSHAFT GEAR 0709390195 0709390234 GEAR 0709390235 SPACER 0709390236 BALL BEARING 0709390237 SLIDER 50 Generac Power Systems, Inc. ® ITEM PART NO. QTY. DESCRIPTION 0709390238 PLATE 0709390239 TACHOMETER SHAFT 0709390240 BOLT 0709390241 BOLT 0709390242 GASKET...
  • Page 53 0709390119 0709390120 0709390121 0709390131 0709390123 0709390124 0709390125 0709390126 0709390127 0709390128 0709390129 0709390130 MM = MILLIMETER U.S. = UNDERSIZE Generac DESCRIPTION DOWEL PIN SPRING PIN STUD STUD STUD SNAP RING OIL SEAL DRAIN COCK CONNECTOR OIL FILTER TAPPET PUSH ROD RELIEF VALVE O-RING Power Systems, Inc.
  • Page 54 VALVE GUIDE SEAL (INTAKE) 0709390154 SPRING 0709390155 RETAINER 0709390156 0709390157 0709390158 CYLINDER HEAD GASKET, 1.2MM THICK 0709390159 CYLINDER HEAD GASKET, 1.3MM THICK 52 Generac Power Systems, Inc. ® ITEM PART NO. QTY. DESCRIPTION 0709390160 BOLT 0709390161 BOLT 0709390162 LIFTING EYE 0709390163 BOLT...
  • Page 55 070939-223 070939-224 070939-225 070939-230 070939-231 U.S. - UNDERSIZE O.S. - OVERSIZE AR - AS REQUIRED MM - MILLIMETER Generac DESCRIPTION STANDARD PISTON RING SET PISTON RING SET-0.5MM O.S. PISTON RING SET-1.0MM O.S. PISTON PIN SNAP RING CONNECTING ROD ASSEMBLY BUSHING...
  • Page 56 THRUST WASHER 0709390253 ROTOR 0709390254 OIL PUMP COVER 0709390255 0.10MM SHIM 0709390532 0.15MM SHIM 0709390533 0.20MM SHIM 0709390258 0.50MM SHIM 54 Generac Power Systems, Inc. ® ITEM PART NO. QTY. DESCRIPTION 0709390259 SPRING 0709390260 COLLAR 0709390261 SNAP RING 0709390262 FRONT PLATE...
  • Page 57 Appendix 3 — Exploded Views and Parts Lists QUIETPACT™ 65D Recreational Vehicle Generator 1.0 Liter Diesel Rocker Arm Assembly – Drawing No. 075683-A ITEM PART NO. QTY. 070939-176 070939-177 070939-178 070939-179 070939-180 070939-181 DESCRIPTION ROCKER ARM SHAFT SPRING SCREW SPRING,PIN STUD Generac Power Systems, Inc. 55 ®...
  • Page 58 INSERT 0709390324 0709390325 INJECTOR 0709390326 TUBING 0709390327 TUBING 0709390328 TUBING 0709390329 TUBING 0709390330 CLAMP 56 Generac Power Systems, Inc. ® ITEM PART NO. QTY. DESCRIPTION 0709390331 BOLT 0709390332 GLOW PLUG 0709390333 CONNECTOR 0709390334 GASKET 0709390335 COVER (ALL MODELS EXCEPT 04270 &...
  • Page 59 068736 074823 074819 0709390651 0709290662 0709390663 028414A * -QTY 1 (MODEL 04270 & 04614) AR - AS REQUIRED Generac DESCRIPTION 275MM HOSE, 3/16" SAE 30R2 240MM HOSE, 3/16" SAE 30R2 HOSE CLAMP FUEL BLEED FITTING FUEL BLEED GASKET HOLLOW BOLT BANJO FITTING 1/8"...
  • Page 60 Appendix 3 — Exploded Views and Parts Lists QUIETPACT™ 65D Recreational Vehicle Generator 1.0 Liter Diesel Timing and Governor – Drawing No. 082067-B 58 Generac Power Systems, Inc. ®...
  • Page 61 SCREW HHC M8-1.25 X 60 G8.8 (MODEL 04270 & 04614) SCREW HHC M8-1.25 X 65 G8.8 (MODEL 04270 & 04614) NUT HEX M8-1.25 G8 (MODEL 04270 & 04614) WASHER LOCK M8-5/16 (MODEL 04270 & 04614) Generac Power Systems, Inc. 59 ®...
  • Page 62 097843 O-RING (ALL MODELS EXCEPT 04270 & 04614) 070939-145 BOLT 070939-146 DIPSTICK (ALL MODELS EXCEPT 04270 & 04614) 070939-183 ROCKER COVER GASKET 60 Generac Power Systems, Inc. ® ITEM PART NO. QTY. DESCRIPTION 070939-184 ROCKER COVER 070939-185 OIL STOPPER 070939-186...
  • Page 63 Appendix 3 — Exploded Views and Parts Lists QUIETPACT™ 65D Recreational Vehicle Generator 1.0 Liter Diesel Water Pump – Drawing No. 82962 ITEM PART NO. QTY. 0709390272 0709390273 0709390274 0709390275 0709390247 0709390284 Generac DESCRIPTION GASKET BOLT BOLT PULLEY BOLT Power Systems, Inc. 61 ®...

  • Page 64: Appendix 4 - Notes

    Appendix 4 – Notes QUIETPACT™ 65D Recreational Vehicle Generator 62 Generac Power Systems, Inc. ®...
  • Page 65 Appendix 4 – Notes QUIETPACT™ 65D Recreational Vehicle Generator Generac Power Systems, Inc. 63 ®...

  • Page 66: Appendix 5 - Warranty

    GENERAC and ISM recommend that you retain the original purchase documentation and all receipts covering maintenance on your engine, but GENERAC and ISM cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 67 GENERAC. Add-on or modified parts may not be used for maintenance or war- ranty repairs. Such use will be grounds for disallowing a warranty claim, and GENERAC will not be liable to warrant fail- ures of warranted parts caused by the use of an add-on or modified part.
  • Page 68 NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (three) years or 2,000 (two thousand) hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection, and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

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