Generac Power Systems 004701-0 Owner's Manual
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Generac Power Systems 004701-0 Owner's Manual

Generac Power Systems 004701-0 Owner's Manual

Air-cooled recreational vehicle generator
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Owner's Manual and

Installation Instructions

Air-cooled Recreational
Vehicle Generators
• Model: 004701-0
QUIETPACT 40LP
This manual should remain with the unit.

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Summary of Contents for Generac Power Systems 004701-0

  • Page 1: Installation Instructions

    Owner’s Manual and Installation Instructions Air-cooled Recreational Vehicle Generators • Model: 004701-0 QUIETPACT 40LP This manual should remain with the unit.

  • Page 2: Introduction

    This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views and lists of repair parts for generator model numbers 004701-0. In addition, the latter portion of this manual contains information necessary for the proper installation of these generators.

  • Page 3: Table Of Contents

    Part I – Owner’s Manual Introduction ...Inside Front Cover Read This Manual Thoroughly ... IFC Contents ... IFC Operation and Maintenance ... IFC How to Obtain Service ... IFC Authorized Service Dealer Locator Number ... IFC Safety Rules ...2 Section 1 – General Information ...4 1.1 Generator Identification ...

  • Page 4: Safety Rules

    Safety Rules Recreational Vehicle Generator  SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment. ...

  • Page 5: Fire Hazards

    • 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. Without sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to the generator.

  • Page 6: Section 1 - General Information

    Section 1 – General Information Recreational Vehicle Generator GENERATOR IDENTIFICATION Please record the following information from the generator DATA LABEL or information decal. 1. Model Number _____________________ 3. kW Rating _________________________ 1. Generator Air Intake 2. Engine Start/Stop Switch 3. Fuse 4.

  • Page 7: Generator Applicability

    32°F (0°C). For that reason, a higher ratio of propane is desired in the gas mixure when temperatures drop below freezing. 1.5.2 FUEL CONSUMPTION Model 1/2 Load 004701-0 0.55 Fuel consumption is in gal/hr. Full Load 0.73...

  • Page 8: Section 2 - Operation

    Section 2 – Operation Recreational Vehicle Generator 1.5.3 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum 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.

  • Page 9: Optional Remote Start/Stop Panel

    2.1.4 MAIN BREAKER 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. OPTIONAL REMOTE START/STOP PANEL A remote mounted Start/Stop Panel is available that allows starting and stopping the generator engine conveniently from inside the vehicle.

  • Page 10: Stopping The Generator

    Section 2 – Operation Recreational Vehicle Generator To start the generator from either the generator con- trol panel or from the optional remote panel, proceed as follows: 1. Turn OFF electrical loads using the means pro- vided in the vehicle (such as a main line circuit breaker or transfer switch).

  • Page 11: Additional Information

    2.8.2 HIGH TEMPERATURE SWITCH 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 High Temperature Switches High Temperature Switch Low Oil Pressure...

  • Page 12: Section 3 - Maintenance

    Section 3 – Maintenance Recreational Vehicle Generator 2.9.2 25-HOUR CHECK-UP 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. •...

  • Page 13: Changing The Engine Oil And/Or Oil Filter

    4. If necessary, remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dip- stick “Full” mark. DO NOT FILL ABOVE THE “FULL ” MARK.  Never operate the engine with the oil level below the “Add”...

  • Page 14: Clean Air Intake

    Section 3 – Maintenance Recreational Vehicle Generator 3.3.2 CLEANING OR REPLACING THE PAPER FILTER 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 extremely dusty or dirty conditions.

  • Page 15: Cleaning The Generator

    Figure 3.5 - Spark Arrestor TAILPIPE P/N 0E0683 SPARK ARRRESTOR SCREEN P/N 089680 RETAINING SCREW P/N 056892 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and mois- ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings.

  • Page 16: Major Service Manual

    Section 3 – Maintenance Recreational Vehicle Generator • 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.

  • Page 17: Rv Generator Service Interval

    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).

  • Page 18: Section 4 - Notes

    Section 4 – Notes Recreational Vehicle Generator...

  • Page 19: Part Ii - Installation Instructions

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

  • Page 20: Safety Rules

    Safety Rules Recreational Vehicle Generator  DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installa- tion must comply with the manufacturer’s instructions and recommendations.
  • Page 21  ELECTRICAL HAZARDS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. Avoid 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.

  • Page 22: Section 1 - General Information

    Section 1 – General Information Recreational Vehicle Generator PURPOSE AND SCOPE OF THE MANUAL 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 continued reliable operation of the equipment.
  • Page 23 Section 1 – General Information Recreational Vehicle Generator Figure 1.2 – Major Features and Dimensions (Drawing No. 0F4610)

  • Page 24: Section 2 - Installation

    Section 2 – Installation Recreational Vehicle Generator LOCATION AND SUPPORT 2.1.1 GENERATOR LOCATION 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.

  • Page 25: Generator Compartments

    GENERATOR COMPARTMENTS 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 COMPARTMENT SIZE Plan the compartment size carefully.
  • Page 26 Section 2 – Installation Recreational Vehicle Generator Figure 2.5 – Types of Lock Seams DANGER  Do not install any flammable material directly above or around the compartment. Heat, trans- ferred through the compartment structure, may be sufficient to ignite, char or discolor seat cush- ions, fiberboard and other flammable materials.
  • Page 27 Section 2 – Installation Recreational Vehicle Generator Figure 2.7 – Compartment Floor Cutout (Drawing 0G3723-A)

  • Page 28: Cooling And Ventilating Air

    Section 2 – Installation Recreational Vehicle Generator DANGER  Fuel lines and exhaust piping must not pen- etrate into the vehicle living area. COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set.
  • Page 29 Figure 2.9 – Typical Propane Gas Fuel System 2.4.2 SOME IMPORTANT CONSIDERATIONS 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.

  • Page 30: Exhaust System

    Section 2 – Installation Recreational Vehicle Generator 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.

  • Page 31: Electrical Connections

    2.5.1 SPARK ARRESTOR This spark arrestor assembly meets code and stan- dard requirements of the U.S. Forest 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 liable for any damage, injury or warranty expense that might be caused by such unapproved installation...
  • Page 32 Section 2 – Installation Recreational Vehicle Generator • Wiring 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.
  • Page 33 Section 2 – Installation Recreational Vehicle Generator Figure 2.14 – Transfer Switch Isolation Method Figure 2.15 – Installation With Isolation Receptacle...

  • Page 34: Battery Installation

    Section 2 – Installation Recreational Vehicle Generator 2.6.6 POWER SUPPLY 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 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code (NFPA 70, 551-7)

  • Page 35: Section 3 - Post-Installation Start-Up Adjustments

    Figure 2.17 – Remote Panel Plug-in Receptacle 12.00" WIRE WIRE LENGTH (mm) COLOR WHITE 12.0 (305) 12.0 (305) ORANGE 12.0 (305) YELLOW 12.0 (305) BROWN 12.0 (305) BLUE 12.0 (305) P/N: 0D9099-B 2.8.1 REMOTE START/STOP PANEL 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.

  • Page 36: Testing Under Load

    Section 3 – Post-installation Start-up Adjustments Recreational Vehicle Generator 6. Turn 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.

  • Page 37: Installation Checklist

    INSTALLATION CHECKLIST LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GENERATOR COMPARTMENT ❑ Compartment construction is proper. ❑ Holes/Openings are vapor-sealed. ❑ Compartment size is correct. ❑ Compartment is vapor-sealed. ❑...

  • Page 38: Section 4 - Troubleshooting

    Section 4 – Troubleshooting Recreational Vehicle Generator TROUBLESHOOTING GUIDE Problem The engine will not crank. The engine cranks but will not start. The engine starts hard and runs rough. The engine starts, but shuts down when the Start/Stop switch is released. The Start/Stop switch is set to Stop, but the engine continues to run.

  • Page 39: Section 5 - Notes

    Section 5 – Notes Recreational Vehicle Generator...

  • Page 40: Section 6 - Electrical Data

    Section 6 — Electrical Data Recreational Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D BATTERY CHARGE WINDING WHITE GREEN NEUTRAL CONNECTION BY CUSTOMER BATTERY J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 (START) J1-7 (STOP) J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14...
  • Page 41 SUPPLIED BY CUSTOMER BATTERY J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 PCB J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 CONN. 1 PIN# CONN. 2 PIN# Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D SUPPLIED BY CUSTOMER 6 2A FILTER MTG SCREW Section 6 —...

  • Page 42: Section 7 - Exploded Views And Parts Lists

    Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generator Enclosure – Drawing No. 0F4589-B...
  • Page 43 ITEM PART NO. 0F3916 0D6942 0D6939 0F3920 0F3917 0F3918 0F3919 0G7329 0D8254 0C5644 0A1495 0E1742A 047290 048031E 0D8628B 047411 022473 023484S 022097 086729 0D3700 022129 022259 075763A 0D7293 064113 0C7561 0A4456 049813 022237 022131 0C5443 0C7423 029451 074908 0D8717 0D9020 0742600144 0E0724 0G4933...
  • Page 44 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generator Generator – Drawing No. 0F4590-C...
  • Page 45 ITEM PART NO. 029092 022129 049451 0C8096A 0D8120 066849 066386 0D4217 073159 0D4484H 0D4430H 0D4216 048614 0F9533 022131 027028 0D6832 022145 030231 0C3168 022259 0C8565 0D8048 083512 0D6831 029451 0D6918 0D2558 087680 0D7530 0D9723 0D4511 0D8451 022097 0G3671 090388 0G3671 081105 089476 022531...
  • Page 46 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generator Control Panel – Drawing No. 0F4591-A...
  • Page 47 ITEM PART NO. 0F9719 075210A 092234 065795 023484F 023484R 075234 057159 054502 087798 092113 032300 0A9611 090145 0E2314 0A1658 075235 047411 049226 051716 075476 022264 051715 0A2053 022473 022097 049813 055440 049815 038750 051714 0D8794 025105 028739 0D8308 0F5025 023484S 043182 031879 Section 7 —...
  • Page 48 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generator GN-220 H/SH Engine – Drawing No. 0F5791-G Part 1...
  • Page 49 ITEM PART NO. QTY. DESCRIPTION 0D8433 GUARD, FAN 0C1069 SCREW, HHTT M6-1.0 X 8mm (04701-1 ONLY) 090695F BLOWER HOUSING 0G6468 BLOWER HOUSING (04701-1 ONLY) 081810 NUT, HEX M16-1.5 083312 WASHER, M16 CONICAL 0D8400 ASSEMBLY, CHOKE SOLENOID BRACKET 0C8917D FLYWHEEL, WITH RING GEAR 0C8798A BACKPLATE, ELECTRIC START 045756...
  • Page 50 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generator GN-220 H/SH Engine – Drawing No. 0F5791-G Part 2...
  • Page 51 ITEM PART NO. 0F5800 078621 076389 0G4379 0A8897B 077168 0G4331 076390 0G5827 078658 0F0967 089213E 0A7637 0E3811 0D1303 078645 0A7811 072683A 0F0687 089096 088156 0A8822 078691 0A5772 0A5776 074908 078606 076361 0D2414 099922 0C3733 0C4390 084186 083192 0E0057 078699B 021705B 0C3590 0C3591 0D9853A...
  • Page 52 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generator Regulator – Drawing No. 0F5819...
  • Page 53 ITEM PART NO. 0D5694 0F4795 0F5022 0C6070 0C4680 0C4647 0C4643 0D3973 0D7020A 026073 0D3308 070728 0C5764 0C4643A 0C5764 0C5968 0C5759 0C5761 0C6069 0C6731 0C6067 0C4706 0C6068 0C5762 045764 0C5760K Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generator Regulator –...

  • Page 54: Section 8 - Warranty

    Warranty (ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period.
  • Page 55 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 ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
  • Page 56 NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (three) years of operation from the date of original sale, 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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