Related Manuals for Generac Power Systems 004709-0
Summary of Contents for Generac Power Systems 004709-0
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Page 1: Installation Instructions
Owner’s Manual and Installation Instructions Air-cooled Recreational Vehicle Generators Model: 004709-0 QUIETPACT 40G This manual should remain with the unit. -
Page 2: Introduction
INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc. This model is designed and man- ufactured to supply electrical power for recreational vehicles. READ T HIS MANUAL THOROUGHLY If any portion of this manual is not understood, con- tact the nearest Authorized Service Dealer for starting, operating and servicing procedures. -
Page 3: Table Of Contents
Part – 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 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 in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment. ... -
Page 5: Electrical Hazards
• When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued. • Inspect the generator regularly, and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement. •... -
Page 6: Section 1 - General Information
13. Oil Drain Cap 14. Oil Dipstick 15. Air Filter (Behind Access Panel) 16. Oil Fill 17. Spark Plug 18 External Vacuum Port (model 004709-0 only) CONTROL CENTER C . B . S T A R T F U E L... -
Page 7: Generator Applicability
GENERATOR APPLICABILITY 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 to its application, contact an Authorized Service Dealer. -
Page 8: Fuel Consumption
1.5.2 FUEL CONSUMPTION Model No Load 1/2 Load 004709-0 0.24 Fuel consumption is in gal/hr. 1.5.3 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum Institute (API) Service Classification SF , SG or SH. -
Page 9: Section 2 - Operation
GENERATOR CONTROL PANEL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control Panel CONTROL CENTER S T A R T F U E L S T O P P R I M E F U S E 7. -
Page 10: Starting The Generator
Section 2 – Operation Recreational Vehicle Generator 2.4.2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommended oil before starting. Refer to sections "Engine Oil Requiremtents", "Checking the Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter" for oil servicing procedures and recommendations. -
Page 11: Stopping The Generator
STOPPING THE GENERATOR 1. Turn 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 temperatures. 3. Place the Start/Stop switch in its STOP position. APPLYING LOADS TO GENERATOR When applying electrical loads to the generator, observe these guidelines:... -
Page 12: Field Boost
Section 2 – Operation Recreational Vehicle Generator 2.9.3 FIELD 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, a positive DC (battery) voltage is delivered through the diode, resistor, brushes and slip rings, to the generator rotor. -
Page 13: Section 3 - Maintenance Recreational Vehicle Generator
CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements, see “Engine Oil Requirements”. Check the engine crankcase oil level at least every eight hours of operation, or before each use. To check the engine oil level, proceed as follows (see Figure 3.1): 1. -
Page 14: Maintaining The Engine Air Cleaner
Section 3 – Maintenance Recreational Vehicle Generator NOTE: Check the oil level and fill to the “FULL ” mark after checking for leaks. The filter will retain some oil. MAINTAINING THE ENGINE AIR CLEANER 3.3.1 CLEANING THE FOAM PRECLEANER Clean and re-oil the foam precleaner every three months or every 25 hours of operation, whichever occurs first. -
Page 15: Fuel Filter
Figure 3.4 – Setting the Spark Plug Gap Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end. If nec- essary, re-form the wire terminal to obtain a tight fit. FUEL FILTER Remove and replace the fuel filter (Figure 3.5) once each year or every 400 hours of operation, whichever comes first. -
Page 16: Battery Maintenance
Section 3 – Maintenance Recreational Vehicle Generator BATTERY MAINTENANCE All lead-acid batteries will discharge when not in use. The generator battery should be inspected as follows: 3.9.1 WEEKLY • Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. •... -
Page 17: Return To Service
4. Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase. 5. Remove the spark plug and pour two or three tablespoons of clean, fresh engine oil into the spark plug threaded openings. Reinstall and tighten the spark plug. -
Page 18: Section 4 - Notes Recreational Vehicle Generator
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, installation 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.
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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. 0D8716-J)
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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 Restraint
Figure 2.2 – Typical Suspended Mounting System GENERATOR MOUNTING HOLES FOR 5/16" - 18 BOLTS (6 PLACES) 2.1.4 GENERATOR RESTRAINT Use four 5/16"-18 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing. These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compartment is used) and (c) the support- ing framework (Figure 2.3). -
Page 26: Sound Insulating Materials
Section 2 – Installation Recreational Vehicle Generator • If constructing a compartment, line the exterior (underside) of the compartment floor with 26- gauge galvanized steel. • All seams, splices and joints of the compartment walls (unless vapor tight by design) should be caulked to prevent poisonous, flammable or explo- sive vapors from entering the vehicle interior. -
Page 27: Compartment Floor Cutouts
Figure 2.7 – Typical Noise Abatement • Line the compartment interior walls and floor, as well as the underside of the floor, with 26-gauge galvanized steel. • Vapor seal all compartment seams and joints. • Over the galvanized steel lining, install a combi- nation of acoustical materials as mentioned in "Sound Insulating Materials". - Page 28 Section 2 – Installation Recreational Vehicle Generator Figure 2.8 – Compartment Floor Cutout (Drawing 0G3723-A)
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Page 29: Testing The Installation
2.3.2 TESTING THE INSTALLATION The manufacturer recommends testing the installa- tion to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, enlarge the air openings. Never place a unit into service until absolutely certain that cooling and ventilation is adequate. -
Page 30: Exhaust System
Section 2 – Installation Recreational Vehicle Generator 2.4.2.2 Flexible Fuel Line Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines. This prevents breaking of the line caused by vibration, shifting, settling or movement. The follow- ing rules apply: •... -
Page 31: Exhaust System Safety
2.5.2 EXHAUST SYSTEM SAFETY • Maintain a clearance of at least 3 inches (76 mm) between exhaust system parts and any combus- tible material (such as wood, felt, cotton, organic fibers or other like material). If the 3-inch (76 mm) clearance cannont be maintained, locate, insulate or shield the exhaust part(s) so that the tempera- ture of any combustible material is not raised... -
Page 32: Isolating Different Power Sources
Section 2 – Installation Recreational Vehicle Generator Figure 2.13 – Generator AC Output Leads 483.1 BATTERY CONNECTIONS Do NOT connect electrical loads in excess of any circuit breaker rating or problems will develop with circuit breaker tripping, which causes a loss of AC output. -
Page 33: Ground Fault Circuit Interrupters
Figure 2.15 – Installation With Isolation Receptacle 2.6.7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code (NFPA 70, 551-7) requires that ground fault circuit interrupters (GFCIs) be installed on all external and some internal electri- cal receptacles. Contact the dealer for recommenda- tions. -
Page 34: Battery Cable Connections
Section 2 – Installation Recreational Vehicle Generator 2.7.3 BATTERY CABLE CONNECTIONS 1. Connect the battery cable from the battery post or terminal indicated by a POSITIVE, POS or (+) to the lug on the starter contactor (Figure 2.16). NOTE: Check to be sure the battery cable boot for the starter cable has been installed. -
Page 35: Section 3 - Post-Installation Start-Up Adjustments
POST INSTALLATION TESTS The air-cooled generator set was factory tested and adjusted. It should not be required to adjust the unit any further except under special circumstances. Do not make any unnecessary adjustments. Factory settings are correct for most applica- tions. -
Page 36: Installation Checklist
Section 3 – Post-Installation Start-up Adjustments Recreational Vehicle Generator 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. ❑... -
Page 37: Troubleshooting Guide
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 38: Section 5 - Electrical Data Recreational Vehicle Generator Electrical Schematic And Wiring Diagram - Drawing No. 0D8063-D
Section 5 — 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 39 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 5 —...
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Page 40: Section 6 - Exploded Views And Parts Lists Recreational Vehicle Generator Enclosure - Drawing No. 0D8352-K
Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Enclosure – Drawing No. 0D8352-K... - Page 41 ITEM PART NO. QTY. DESCRIPTION 0D6822 TRAY, ENCLOSURE 0D6942 PANEL, ENCLOSURE SIDE 0D6939 PANEL, REAR DIVIDER 0D6943 PANEL, ENCLOSURE ROOF 0D6941 PANEL, ENCLOSURE BACK 0D6941A PANEL, ENCLOSURE BACK, EXTERNAL PORT (04709 ONLY) 0D6940 PANEL, FRONT DIVIDER 0D6940A PANEL, FRONT DIVIDER, EXTERNAL PORT (04709 ONLY) 0D6945 COMPARTMENT, AIR INTAKE...
- Page 42 Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Generator – Drawing No. 0D8353-L...
- Page 43 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 0D7441 081105 089476 022531...
- Page 44 Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Control Panel – Drawing No. 0D8354-H...
- Page 45 ITEM PART NO. 0F9719 075210A 092234 065795 023484F 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 0D8418 023484S 043182 031879...
- Page 46 Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator GN-220 H/SH Engine – Drawing No. 0D8355-AA Part 1...
- Page 47 ITEM PART NO. QTY. DESCRIPTION 0D8433 GUARD, FAN 0C1069 SCREW, HHTT M6-1.0 X 8mm 0C1069 (04709 ONLY) 090965F BLOWER HOUSING 0G6468 BLOWER HOUSING 220RV (04709 ONLY) 081810 NUT, HEX M16-1.5 083312 WASHER, M16 CONICAL 0D8400 ASSEMBLY CHOKE SOLENOID BRACKET 0C8917A FLYWHEEL, WITH RING GEAR 0C8798A BACKPLATE, ELECTRIC START...
- Page 48 Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator GN-220 H/SH Engine – Drawing No. 0D8355-AA Part 2...
- Page 49 ITEM PART NO. 0E8804 078621 076389 0G4379 0A8897B 077168 0G4331 076390 0G5827 078658 0F0967 089213E 0A7637 0E3811 0D1303 078645 0A7811 072683A 0A9878 089096 088156 0A8822 078691 0A5772 0A5776 074908 078606 076361 0D2414 099922 0C3733 0C4390 084186 083192 0E0057 078699B 021705B 0C3590 0C3591 0D9853A...
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Page 50: Section 7 - Warranty Recreational Vehicle Generator
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 51: Emission Control System Warranty
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 52: Generac Power Systems' Three-Year Limited Warranty For Guardian Recreational Vehicle Generators
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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