Related Manuals for Generac Power Systems 004703-1
Summary of Contents for Generac Power Systems 004703-1
- Page 1 Models: 004703-1, 004705-1, 004706-1, 004707-1, 005750-0. 005854-0, 005858-0, 005859-0, 005860-0 Owner's Manual Air-cooled Recreational Vehicle Generators Quietpact 55, 65 and 75 ® This manual should remain with the unit.
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Page 2: Table Of Contents
Table of Contents Part I — Operating Instructions Part II — Installation Instructions Introduction ................1 Safety Rules ................20 Read This Manual Thoroughly ............1 Notice to Installer .................20 Contents ..................1 Section 1 — General Information ........22 Operation and Maintenance ............1 How to Obtain Service ..............1 Purpose and Scope of the Installation Instructions....22 Authorized Service Dealer Locator Number ......... -
Page 3: Introduction
The operator (driver) is responsible for proper and safe use of the vehicle and its equipment, and the safety of all vehicle occupants. Thank you for purchasing this model by Generac Power Systems We strongly recommend that the operator read this manual and Inc. -
Page 4: Safety Rules
Safety Rules SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment. Study these SAFETY RULES carefully before installing, operating •... -
Page 5: Explosion Hazards
Safety Rules EXPLOSION HAZARDS ELECTRICAL HAZARDS • Do not smoke around the generator. Wipe up any fuel or oil spills • The generator covered by this manual produces dangerous immediately. Ensure that no combustible materials are left in the electrical voltages and can cause fatal electrical shock. Avoid generator compartment, or on or near the generator, as FIRE or contact with bare wires, terminals, connections, etc., while the EXPLOSION may result. -
Page 6: Section 1 - General Information
General Information GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal. 1. Model Number _____________________ 2. Serial Number __________________ 3. kW Rating _________________________ 4. Rated Voltage __________________ 5. Phase _____________________________ 6. Hertz __________________________ CONTROL CENTER C IR C U IT B R E A K E R C IR C U IT... -
Page 7: Generator Applicability
General Information GENERATOR APPLICABILITY INSTALLATION These generators have been designed and manufactured for sup- This Owner’s Manual has been prepared under the assumption plying electrical power for recreational vehicles. DO NOT modify that a competent, qualified technician installed the generator into the generator or use it for any application other than for what it a recreational vehicle. -
Page 8: Specifications
General Information 120/240 VAC loads — one load with a maximum total watt- age requirement equal to the generator’s rated power output, and 240V across the generator output terminals; or two sep- The manufacturer does not recommend using any gasoline containing alcohol (such as erate loads, each with a maximum total wattage requirement “gasohol”). -
Page 9: Evaporative Emissions Information
General Information 1.6.4 GENERATOR SPECIFICATIONS SERIES QP55LP QP65LP QP75G QP75LP Rotor RPM 3600 3600 3600 3600 Rotor Poles Engine RPM 2200 2571 2571 2571 Rated Max. Continuous AC Output Watts*/** 5500 6500 7500 7500 Voltage* Rated Max. Continuous Current Amps (240V)** 45.8 (22.9) 54.1 (27.0) 62.5 (31.2) -
Page 10: Exhaust Emissions Information (Propane)
Operation GENERATOR CONTROL PANEL The Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for The following features are mounted on the generator control panel which the engine has been shown to meet Federal and California (Figure 2.1): emission requirements. -
Page 11: Optional Remote Start/Stop Panel
Operation 2.4.2 ENGINE LUBRICATION NOTE: If this generator has been reconnected for dual voltage AC out- Have the engine crankcase properly serviced with the recommend- put (120/240 volts), install line breakers having an amperage ed oil before starting. Refer to sections "Engine Specifications", rating that is different than that stated above. -
Page 12: Starting The Generator
Operation Adequate, unobstructed flow of cooling and ventilating air is critical for expelling toxic car- bon monoxide gas and fuel vapors from the If the engine does not start after it has been generator compartment and for proper genera- cranking for 15 seconds, release the Start/Stop tor operation. -
Page 13: Protection Systems
Operation • Induction type motors (such as those that run the vehicle’s Figure 2.4 – Field Boost Circuit furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2 times more watts of power for starting than for running (for a few seconds during motor starting). Be sure to allow for this when connecting electrical loads to the generator. -
Page 14: Section 3 - Maintenance
Maintenance CHECKING THE ENGINE OIL Figure 3.1 — Oil Dipstick/Fill Tube and Location of Oil Drain Plug LEVEL For oil capacities and requirements, see the “Engine Oil Oil Dipstick Requirements” section. Check the engine crankcase oil level at least every eight hours of operation, or before it is used. To check the engine oil level, proceed as follows (see Figure 3.1): Be sure the generator is as level as possible. -
Page 15: Maintaining The Engine Air Cleaner
Maintenance MAINTAINING THE ENGINE Remove the Air Box Cover by pulling up and left to clear the three locating tabs. AIR CLEANER Turn the exterior steel wing nut on the left side of the Air Box Compartment counterclockwise and remove. 3.3.1 CLEANING THE FOAM PRECLEANER Pull the Air Filter Assembly to the right and out of the front of the compartment. -
Page 16: Fuel Filter (Gasoline Only)
Maintenance CLEANING THE GENERATOR Keep the generator set as clean and dry as possible. Protect the Sparking can occur if the wire terminal does unit against excessive dust, dirt, corrosive vapors, road splash, not fit firmly on the spark plug terminal end. If etc. -
Page 17: Adjusting Valve Clearance
Maintenance ADJUSTING VALVE CLEARANCE After the first six (6) months of operation, check the valve clear- Do not dispose of the battery in a fire. The ance in the engine, adjust if necessary. battery is capable of exploding. Stored batteries give off explosive hydrogen gas. -
Page 18: 3.10 Major Service Manual
Maintenance When valve clearance is correct, hold the pivot ball stud in place Attach a tag to the engine indicating the viscosity and clas- sification of the oil in the crankcase. with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. -
Page 19: Section 4 - Notes
Notes... - Page 20 Notes...
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Page 21: Part Ii - Installation Instructions
PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! -
Page 22: Safety Rules
Safety Rules 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, installation must comply with the manufacturer’s instructions and recommendations. -
Page 23: Fire Hazards
Safety Rules • Do not operate the generator if the exhaust system is leaking or FIRE HAZARDS has been damaged or if you have experienced carbon monoxide poisoning symptoms during use. Shut down the generator and do not operate it until it has been inspected and/or repaired. •... -
Page 24: Section 1 - General Information
General Information PURPOSE AND SCOPE OF THE EQUIPMENT DESCRIPTION Instructions and information in this section pertain to air-cooled INSTALLATION INSTRUCTIONS generators. These generators are designed specifically for install- These Installation Instructions have been prepared especially for ing in recreational vehicles. They operate 120-volt, single-phase, the purpose of familiarizing installers and owners of the applicable 60-Hertz, AC electrical loads. -
Page 25: Major Features And Dimensions
General Information Figure 1.2 - Major Features and Dimensions (Drawing No. 0E1058-H) -
Page 26: Section 2 - Installation
Installation Figure 1.3 - Connection for 120/240 Volts clearances as outlined in "Generator Compartments". If sound insulation is to be used on the compartment walls and ceiling, the minimum recommended applies to the space between the generator and such insulation. •... -
Page 27: Generator Compartments
Installation GENERATOR COMPARTMENTS 2.1.3 SUSPENDED MOUNTING Whether the generator set is being installed inside a compartment If planning to suspend the generator below the horizontal sup- specifically manufactured to house a generator or inside a compart- port tubing, the suspension method to use with the vehicle frame ment that the installer constructs, the compartment MUST meet members must (a) be able to support the weight of the generator certain specifications as outlined in the following sections:... - Page 28 Installation Figure 2.5 – Typical Compartment Construction Figure 2.6 – Types of Lock Seams Do not install any flammable material directly above or around the compartment. Heat, transferred through the compartment structure, may be sufficient to ignite, char or discolor seat cushions, fiberboard and other flammable materials.
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Page 29: Cooling And Ventilating Air
Installation 2.2.4 ACOUSTICS 2.2.5 COMPARTMENT FLOOR CUTOUTS For additional noise abatement, the installer may wish to consider Provide openings in the generator compartment for the following the following: items (Figure 2.8): • Using special sound insulating materials. • Engine exhaust and cooling air outlets •... - Page 30 Installation Figure 2.8 — Compartment Floor Cutout (Drawing 0G3529-A)
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Page 31: Gasoline Fuel System
Installation 2.3.2 TESTING THE INSTALLATION If the generator is to share the vehicle engine's tank, separate fuel pickup tubes are required for the engine and the generator. The manufacturer recommends testing the installation to be sure The manufacturer recommends that the fuel pickup tube be two adequate cooling airflow is available to the unit before placing the to three inches (51 to 76 mm) shorter than the vehicle engine's unit into service. -
Page 32: Lp Gas Fuel System
Installation LP GAS FUEL SYSTEM 2.5.2 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system, consider seriously the following items: LP gas is highly EXPLOSIVE. The gas is heavier • All fittings, lines, hoses and clamps must be tight and free of than air and tends to settle in low areas. -
Page 33: Exhaust System
Installation 2.5.5 GASEOUS CARBURETION LP gas vapors should be supplied to the secondary regulator inlet Gaseous fuel lines between the tank and the at about 11 inches water column (positive pressure). The engine secondary regulator are under a positive pres- pistons draw air in during the intake stroke (Figure 2.12). - Page 34 Installation Adequate, unobstructed flow of cooling and Figure 2.13 — Spark Arrestor Installation ventilating air is critical for expelling toxic car- bon monoxide gas and fuel vapors from the generator compartment and for proper genera- tor operation. Without sufficient cooling airflow, deadly carbon monoxide gas can accumulate O.D.
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Page 35: Electrical Connections
Installation ELECTRICAL CONNECTIONS 2.7.3 GENERATOR AC CONNECTIONS The following general rules apply to electrical connections in a Generator AC output leads T1 (red), T2 (white) and T3 (black) recreational vehicle: come out of the generator as shown in Figure 2.14. Leads T1 (red) and T3 (black) are “hot,”... -
Page 36: Battery Installation
Installation 2.7.4 CONDUIT 2.8.2 BATTERY CABLES Route the connections between the generator and the junction box Using battery cables that are too long or too small in diameter may through approved, flexible conduit. The following general rules cause a drop in voltage, which causes starting problems. For the apply: best cold weather starting, the voltage drop between battery ter- minals and the generator connection point should not exceed 0.12... - Page 37 Installation Figure 2.15 — Transfer Switch Isolation Method QUIETPACT POWERED BY GUARDIAN 760cc OHVI V-TWIN INDUSTRIAL Figure 2.16 — Installation With Isolation Receptacle QUIETPACT POWERED BY GUARDIAN 760cc OHVI V-TWIN INDUSTRIAL...
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Page 38: Optional Accessories
Post Installation Start-up Adjustments POST INSTALLATION TESTS 2.8.4 BATTERY COMPARTMENT The air-cooled generator set was factory tested and adjusted. It Install the generator battery in its own, vented compartment. Place should not be necessary to adjust the unit any further except under the battery compartment away from any source of heat, sparks special circumstances. -
Page 39: Testing Under Load
Post Installation Start-up Adjustments NOTE: The generator set was thoroughly tested and adjusted at the factory before shipping. No additional adjustment should be necessary. Only qualified service technicians who have been trained should perform adjustments outlined in this manual. TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 percent of the unit's rated wattage/amperage capacity. -
Page 40: Installation Checklist
Post Installation Start-up Adjustments INSTALLATION CHECKLIST EXHAUST SYSTEM ❑ Exhaust system complies with all applicable codes. LOCATION AND SUPPORT ❑ Exhaust system is properly and safely installed. ❑ Generator is properly located. ❑ Generator is properly supported. ELECTRICAL CONNECTIONS ❑ Generator is properly restrained. ❑... -
Page 41: Section 4 - Troubleshooting
Troubleshooting TROUBLESHOOTING GUIDE Problem Cause Correction Engine won’t crank. 1. 7.5 amp fuse blown. Replace blown fuse. 2. Loose, or corroded or defective Tighten, clean or replace, battery cable(s). as necessary. 3. Battery is discharged or defective. Recharge or replace battery. 4. -
Page 42: Section 5 - Electrical Data
Electrical Data Electrical Schematic - V-twin - Drawing No. 0E1057-F... - Page 43 Electrical Data Electrical Schematic - V-twin - Drawing No. 0E1057-F...
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Page 44: Section 6 - Exploded Views And Parts Lists
Exploded Views & Parts Lists Base & Pulley Drawing No. 0E1323-H... - Page 45 Exploded Views & Parts Lists Base & Pulley Drawing No. 0E1323-H ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E0196 FRAME, 760 ENGINE 0E0586 GASKET, BOTTOM AIR OUT QPRV 022129 WASHER LOCK M8-5/16 0D7176 WASHER SELF LOCKING 1"DIA 12GA 022145 WASHER FLAT 5/16-M8 ZINC 0E1334...
- Page 46 Exploded Views & Parts Lists Enclosure Drawing No. 0G7865-C...
- Page 47 Exploded Views & Parts Lists Enclosure Drawing No. 0G7865-C ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0D8827 PANEL, ENCLOSURE ROOF 0C7423 STUD 3/8-16 X 2-1/4 BRASS 0G4933 SCREW SWT 1/4-20 X 5/8 W/W 0742600151 GND WIRE C/PNL TO STUD V-T RV 029451 11.5 FT.
- Page 48 Exploded Views & Parts Lists Engine Accessories Drawing No. 0G7866-E...
- Page 49 Exploded Views & Parts Lists Engine Accessories Drawing No. 0G7866-E ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 045756 SCREW HHTT M6-1.0 X 10 YC 0D9404 SPRING, CHOKE RETURN 0D1131 GUARD,FAN 12KW HSB 0D9801A WRAP , VALLEY UPPER SPCC 0F1169G HOUSING, BLOWER V-TWIN RV 0C3018A...
- Page 50 Exploded Views & Parts Lists Control Panel Drawing No. 0E1013-B...
- Page 51 Exploded Views & Parts Lists Control Panel Drawing No. 0E1013-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C2375 SCREW HHC M8-1.25 X 90 G8.8 054502 CIRCUIT BREAKER 3 X 1 022145 WASHER FLAT 5/16-M8 ZINC 031879 WASHER FLAT #4 ZINC 029459 TENSION SPRING 043182...
- Page 52 Exploded Views & Parts Lists 760 V-twin Engine Drawing No. 0F1997-C...
- Page 53 Exploded Views & Parts Lists 760 V-twin Engine Drawing No. 0F1997-C ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C5730A ASSEMBLY, CRANKCASE RV 0C2991 E-RING, GOVERNOR ARM 0E9843 SEAL, 38 I.D. CRANKCASE 0D1667A ARM, GOVERNOR 090388 SCREW, HHTT M6-1.0 X 12mm 0C2988 THRUST WASHER, GOVERNOR 0C5372...
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Page 54: Section 7 - Warranty
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. Note that this warranty shall not apply to any incidental, consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replace- ment of the defective part(s). -
Page 55: Emission Control System Warranty
(1) Any warranted part that is not scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. - 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.