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
Models: 004709-0, 005852-0 Owner's Manual and Installation Instructions Air-cooled Recreational Vehicle Generators Quietpact 40G This manual should remain with the unit. -
Page 2: Table Of Contents
Table of Contents Part – Owner’s Manual Part II – Installation Instructions Introduction ................1 Safety Rules ................. 18 Read This Manual Thoroughly ............1 Notice to Installer ................18 Contents ..................1 General Information .............. 20 Operation and Maintenance .............1 Purpose and Scope of the Manual .........20 How to Obtain Service ..............1 Safety ...................20 Authorized Service Dealer Locator Number ...........1... -
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: General Information
15. Air Filter (Behind Access Panel) 7. Circuit Breaker 16. Oil Fill 8. Starter Contactor 17. Spark Plug 9. Fuel Inlet 18 Evaporative Port (model 004709-0 only) 14,16 CONTROL CENTER C . B . S T A R T F U E L... -
Page 7: Generator Applicability
General Information GENERATOR APPLICABILITY GENERATOR AC These generators have been designed and manufactured for sup- CONNECTION SYSTEM plying electrical power for recreational vehicles. Do not modify the This generator set is equipped with dual stator AC power windings. generator or use it for any application other than for what it was These two-stator windings supply electrical power to customer designed. - Page 8 Length ................749.8 mm (29.52 in.) Model No Load 1/2 Load Full Load Width ................483.1 mm (19.02 in.) 004709-0 0.24 0.35 0.55 Height ................342.2 mm (13.47 in.) Fuel consumption is in gal/hr. * Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambient temperature, altitude, engine condition, etc..
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Page 9: Operation
Operation OPTIONAL REMOTE This generator is not legal for sale in the state of California unless all CARB evaporative emission requirements are adhered to, and START/STOP PANEL is not legal for sale in any other state unless certified low-per- meation fuel line is used to supply the generator with gasoline. A remote mounted Start/Stop Panel is available that allows start- Contact the California Air Resource Board or the Environmental ing and stopping the generator engine conveniently from inside... -
Page 10: Starting The Generator
Operation STARTING THE GENERATOR NOTE: Any attempt to crank or start the engine Read the vehicle manufacturer’s instructions. The owner/ before it has been properly serviced with the operator should become familiar with the vehicle in which this recommended oil may result in an engine generator is installed. -
Page 11: Do Not Overload The Generator
Operation 2.7.1 LETTING THE ENGINE STABILIZE Figure 2.2 – Low Oil Pressure and High Temperature Switches The generator supplies correct rated voltage only at the proper governed speed. Some electrical appliances may be extremely High Temperature Switch sensitive to voltage. Incorrect voltages can damage such appli- ances. -
Page 12: 2.10 Additional Information
Maintenance CHECKING THE ENGINE OIL Figure 2.4 – Solid State Voltage Regulator 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, pro- ceed as follows (see Figure 3.1): Be sure the generator is as level as possible. -
Page 13: Maintaining The Engine Air Cleaner
GENERAC OHVI INDUSTRIAL ENGINE 0˚F TO 80˚F 10W-30 -20˚F TO 50˚F 5W-30 QUIETPACT 40G WHEN SERVICE OR PARTS ARE NEEDED IN THE USA OR CANADA, CONTACT THE GENERAC SERVICE LOCATOR AT 1-800-333-1322. RV SERVICE LOCATOR: 1.800.333.1322 Oil Drain Oil Filter Oil Dipstick/Oil Fill Figure 3.2 –... -
Page 14: Clean Air Intake
Maintenance CLEAN AIR INTAKE Clean all foreign material from the air intake (Figure 3.3) at least Sparking can occur if the wire terminal does once every 100 hours of operation. Clean more often if neces- not fit firmly on the spark plug terminal end. sary. -
Page 15: Cleaning The Generator
Maintenance 3.9.2 EVERY SIX MONTHS Figure 3.6 - Spark Arrestor • Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer. Note: Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precau- TAILPIPE tions. -
Page 16: 3.10 Major Service Manual
Maintenance 3.12.2 RETURN TO SERVICE • Where electrolyte contacts the eyes, flush thoroughly and immediately with water and To return the unit to service after storage, proceed as follows: seek medical attention; and Check the tag on the engine for oil viscosity and classification. •... -
Page 17: Rv Generator Service Interval
Maintenance 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 3.8). -
Page 18: Notes
Notes... -
Page 19: Part Ii - Installation Instructions
PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! -
Page 20: 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 21: Fire Hazards
Safety Rules ELECTRICAL HAZARDS FIRE HAZARDS • The generator covered by this manual produces dangerous • For fire safety, the generator must be installed and maintained electrical voltages and can cause fatal electrical shock. Avoid properly. Installation always must comply with applicable contact with bare wires, terminals, connections, etc., while the codes, standards, laws and regulations. -
Page 22: General Information
General Information PURPOSE AND SCOPE EQUIPMENT DESCRIPTION Instructions and information in this section pertain to air-cooled OF THE MANUAL generators. This generator is designed specifically for installing in These Installation Instructions have been prepared especially for recreational vehicles. This generator operates 120-volts, single- the purpose of familiarizing installers and owners of the applicable phase, 60-Hertz, AC electrical loads that require 30.0 amps. - Page 23 General Information Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-K)
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Page 24: Installation
Installation LOCATION AND SUPPORT • If the generator cannot be bolted directly to the supporting frame or support tubing, consider using additional tubing, angle brackets or other supports to give the supporting frame 2.1.1 GENERATOR LOCATION sufficient strength. The most desirable location for the generator set is between the vehicle's main frame members. -
Page 25: Generator Compartments
Installation Figure 2.3 – Typical Generator Restraint • If the compartment is lined with galvanized steel, it may be constructed of any material. The manufacturer recommends that the compartment be constructed of 1/2-inch thick plywood (not strandboard), with the floor made of a double thickness of 1/2-inch plywood with the grain of the wood at cross section for added strength (Figure 2.5). - Page 26 Installation Figure 2.6 – Types of Lock Seams NOTE: Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compart- ment. In addition to the effective use of sound insulating materials, construction of a special noise abatement compartment might be considered to reduce noise levels.
- Page 27 Installation Figure 2.8 – Compartment Floor Cutout (Drawing 0G3723-A)
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Page 28: Cooling And Ventilating Air
5W-30 a suction fan, draws air that is heated from a hot engine into a collec- QUIETPACT 40G WHEN SERVICE OR PARTS ARE NEEDED IN THE USA OR CANADA, CONTACT THE GENERAC SERVICE LOCATOR AT 1-800-333-1322. RV SERVICE LOCATOR: 1.800.333.1322 tor compartment at the left side of the unit. -
Page 29: Exhaust System
Installation EXHAUST SYSTEM 2.4.1 FUEL TANK The generator exhaust system must be safely and properly Either the generator must share the vehicle engine's fuel tank, installed. Only approved mufflers and other exhaust system parts or install a separate fuel tank for the generator set. All fuel tanks must be used. -
Page 30: Electrical Connections
Installation Figure 2.11 - Spark Arrestor • Do not terminate the exhaust system under any opening, win- dow or vent that can be opened or is not permanently sealed from the vehicle interior. • Exhaust piping must be large enough to prevent excessive back pressure on the generator engine. -
Page 31: Battery Installation
Installation 2.6.4 CONDUIT • From the junction box, route power supply wires through approved conduit to either (a) double-pole, double-throw trans- Route the connections between the generator and the junction box fer switch, or (b) approved isolation receptacle. Connecting to through approved, flexible conduit. - Page 32 Installation Figure 2.14 – Transfer Switch Isolation Method Figure 2.15 – Installation With Isolation Receptacle...
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Page 33: Optional Accessories
Installation 2.7.2 BATTERY CABLES 2.7.4 BATTERY COMPARTMENT Using battery cables that are too long or too small in diameter Install the generator battery in its own, vented compartment. Place may cause a drop in voltage, which causes starting problems. For the battery compartment away from any source of heat, sparks the best cold weather starting, the voltage drop between battery or flame. -
Page 34: Post-Installation Start-Up Adjustments
Post Installation Start-up Adjustments POST INSTALLATION TESTS Let the engine warm up for about five minutes to allow internal temperatures to stabilize. The air-cooled generator set was factory tested and adjusted. It Carefully inspect the engine/generator for fuel, oil and exhaust should not be required to adjust the unit any further except under system leaks. -
Page 35: 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 36: Troubleshooting
Troubleshooting TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace as necessary. battery cables. 3. Defective engine Start/Stop switch 3. Replace Start/Stop switch. 4. -
Page 37: Notes
Notes Generac ® Power Systems, Inc. 35 35... -
Page 38: Electrical Data
Electrical Data Electrical Schematic/Wiring Diagram Drawing No. 0D8063-D 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 REMOTE J1-14 PANEL CONNECTOR J1-15 4 1 A BATTERY CHARGE WINDING STOP START POWER WINDING FUEL PRIME ELECTRONIC REMOTE PANEL... - Page 39 Electrical Data Electrical Schematic/Wiring Diagram Drawing No. 0D8063-D SUPPLIED BY CUSTOMER SUPPLIED BY CUSTOMER BATTERY 6 2A ELECTRONIC VOLTAGE REGULATOR STATOR J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 PCB J1-7 J1-8 CLOSEST TO BEARING J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 FIELD CONN.
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Page 40: Exploded Views And Parts Lists
Exploded Views & Parts Lists Enclosure Drawing No. 0D8352-N... - Page 41 Exploded Views & Parts Lists Enclosure Drawing No. 0D8352-N ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0D6822 TRAY, ENCLOSURE 022237 WASHER LOCK 3/8” 0D6942 PANEL, ENCLOSURE SIDE 022131 WASHER FLAT 3/8-M10” 0D6939 PANEL, REAR DIVIDER 0C5443 BLOCK, TERMINAL BATTERY POST 0D6943 PANEL, ENCLOSURE ROOF 0C7423...
- Page 42 Exploded Views & Parts Lists Generator Drawing No. 0D8353-M...
- Page 43 Exploded Views & Parts Lists Generator Drawing No. 0D8353-M ITEM PART NO. QTY. DESCRIPTION 029092 SCREW IHHC 5/16”-24 X 11-1/4” G5 022129 WASHER LOCK M8-5/16” 049451 WASHER FLAT .406” I.D. X 1.62” O.D. 0C8096A FAN, 8" CURVE BLADE, 16.5MM I.D. 0D8120 SCREW IHHC M8-1.25 X 260MM 066849...
- Page 44 Exploded Views & Parts Lists Control Panel Drawing No. 0D8354-H...
- Page 45 Exploded Views & Parts Lists Control Panel Drawing No. 0D8354-H ITEM PART NO. QTY. DESCRIPTION 0F9719 REGULATOR VOLTAGE 075210A TERMINAL BLOCK 092234 CONTROLLER P .C.B. 065795 BATTERY CHARGER RECTIFIER 023484F BUSHING SNAP 1” 023484F BUSHING SNAP 1” (04709 ONLY) 023484R BUSHING SNAP 1-1/4”...
- Page 46 Exploded Views & Parts Lists GN-220 H/SH Engine Drawing No. 0D8355-AG Part 1...
- Page 47 Exploded Views & Parts Lists GN-220 H/SH Engine Drawing No. 0D8355-AG Part 1 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0D8433 GUARD, FAN 091638A SPRING, GOVERNOR 0C1069 SCREW, HHTT M6-1.0 X 8MM 0G7967 SCREW, HHTT 5/16” X ½” SEMI- 0C1069 (04709 ONLY) GIMLET...
- Page 48 Exploded Views & Parts Lists GN-220 H/SH Engine Drawing No. 0D8355-AG Part 2...
- Page 49 Exploded Views & Parts Lists GN-220 H/SH Engine Drawing No. 0D8355-AG Part 2 ITEM PART NO. QTY. DESCRIPTION 0E8804 LONG BLOCK ASSEMBLY 078621 CONNECTING ROD ASSEMBLY 076389 PISTON PIN 0G4379 PISTON RING SET DIA 75 PLATEAU HONED 0A8897B GEAR COVER ASSEMBLY 077168 M8 X 56MM HEAD BOLT 0G4331...
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Page 50: Warranty
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. -
Page 51: Emission Control System Warranty
(1) Any warranted, emissions-related parts that are 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. - Page 52 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.