Generac 004702-0, 004703-0, 004704-0, 004705-0, 004706-0 User Manual

...
4 (1)

Owner’s Manual

Air-cooled Recreational

Vehicle Generators

QUIETPACT 55, 65 and 75

• Models: 004702-0, 004703-0 004704-0, 004705-0 004706-0, & 004707-0

QUIETPACT 55G

POWERED BY GUARDIAN 760cc OHVI V-TWIN

This manual should remain with the unit.

INTRODUCTION

READ THIS MANUAL THOROUGHLY

If you do not understand any portion of this manual, contact Generac or your nearest Generac Authorized Service Dealer for starting, operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

DANGER

After this heading, you can read instructions that, if not strictly complied with, will result in personal injury, including death, and property damage.

After this heading, you can read instructions that, if not strictly complied with, may result in personal injury or property damage.

After this heading, you can read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, you can read explanatory statements that require special emphasis.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents.

Four commonly used safety symbols accompany the Danger, Warning and Caution blocks. The type of information each indicates follows:

This symbol points out important safety infor- ! mation that, if not followed, could endanger

personal safety and/or property of you and others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

The operator (driver) is responsible for proper and safe use of the vehicle and its equipment, and the safety of all vehicle occupants. We strongly recommend that the operator read this manual and thoroughly understand all instructions before using this equipment. We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator. This prepares them if they need to operate the equipment in an emergency.

CONTENTS

This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views and lists of repair parts for generator model numbers 004702-0, 004703-0, 004704-0, 004705-0, 004706-0, and 004707-0. In addition, the latter portion of this manual contains information necessary for the proper installation of these generators.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by a Generac Authorized Service Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum. See your Generac Authorized Service Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

When your generator requires servicing or repairs, simply contact a Generac Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all of your service needs.

When contacting a Generac Authorized Service Dealer or the factory about parts and service, always supply the complete model number and serial number of your unit as given on its data decal, which is located on your generator.

Model No. ____________ Serial No. ______________

AUTHORIZED SERVICE

DEALER LOCATION

To locate the GENERAC AUTHORIZED SERVICE

DEALER nearest you, please call this number:

1-800-333-1322

ONLY DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

Generac® Power Systems, Inc.

Table of Contents

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

Part I — Operating Instructions

 

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

4

1.2

Generator ..................................................Applicability

5

1.3

Installation ....................................................................

5

1.4

Safety

............................................................................

5

1.5

Generator ..................................AC Connection System

5

1.6

Specifications ................................................................

6

 

1.6.1

Fuel ..............................................Requirements

6

 

1.6.2

Engine ....................................Oil Requirements

6

 

1.6.3

Generator ......................................Specifications

6

 

1.6.4

Engine ..........................................Specifications

7

 

1.6.5

Emissions ............................Compliance Period

7

Section 2 – Operation ................................................................

7

2.1

Generator ................................................Control Panel

7

 

2.1.1

Fuel ..........................................................Primer

7

 

2.1.2

Start/Stop ................................................Switch

7

 

2.1.3

15 ........................................................Amp Fuse

7

 

2.1.4

Line ......................................................Breakers

7

2.2

Optional ..................................Remote Start/Stop Panel

8

2.3

Automatic ..........................................................Choke

8

 

2.3.1

Choke ..................................................Solenoid

8

 

2.3.2

Prechoke..............................................................

8

2.4

Before ............................................Starting the Engine

8

 

2.4.1

Installation..............................................................

8

 

2.4.2

Engine ................................................Lubrication

8

 

2.4.3

Fuel ............................................................Supply

8

 

2.4.4

Cooling ....................................and Ventilating Air

8

 

2.4.5

Engine ..............................................Exhaust Gas

8

2.5

Starting ..................................................the Generator

9

2.6

Stopping ..................................................the Generator

9

2.7

Applying ........................................Loads to Generator

9

 

2.7.1

Letting ................................the Engine Stabilize

9

 

2.7.2

Do ........................Not Overload the Generator

10

2.8

Protection ......................................................Systems

10

 

2.8.1

Low ....................................Oil Pressure Switch

10

 

2.8.2

High ..................................Temperature Switch

10

 

2.8.3

Field ........................................................Boost

10

 

2.8.4

Overvoltage ......................................Protection

11

 

2.8.5

25 ....................................-Hour Break-in Period

11

 

2.8.6

25 ..............................................-Hour Checkup

11

 

2.8.7

Operation ....................in High Grass or Brush

11

Section 3 – Maintenance ........................................................

11

3.1

Checking ......................................the Engine Oil Level

11

3.2

Changing ....................the Engine Oil and/or Oil Filter

12

3.3

Maintaining ............................the Engine Air Cleaner

12

 

3.3.1

Cleaning ............................the Foam Precleaner

12

3.4

Checking ..................................the Engine Spark Plug

13

3.5

Fuel Filter ..........................................(Gasoline Only)

13

3.6

Clean Spark ..................................................Arrestor

13

3.7

Cleaning ................................................the Generator

14

3.8

Battery ....................................................Maintenance

14

 

3.8.1

Weekly ..............................................................

14

 

3.8.2

Every ..............................................Six Months

14

3.9

Major Service ..................................................Manual

15

3.10

Drive Belt ....................................................................

15

3.11

Exercising ............................................the Generator

15

3.12

Out of ............................................Service Procedure

15

 

3.12.1 ....................................

15

 

3.12.2 ............................................

15

3.13

RV Generator ......................................Service Interval

15

Section 4 – Notes......................................................................

16

Part II — Installation Instructions ........................................

17

Safety Rules................................................................................

18

Section 5 — General Information..........................................

20

5.1

Purpose and Scope of the Installation Instructions......

20

5.2

Safety

..........................................................................

20

5.3

Standards Booklets ....................................................

20

5.4

Equipment Description................................................

20

5.5

Generator Engine Operating Speed..............................

20

5.6

Generator AC Connection System................................

20

 

Major Features and Dimensions ..................................

21

Section 6 — Installation ..........................................................

22

6.1

Location and Support ..................................................

22

 

6.1.1

Generator Location............................................

22

 

6.1.2

Generator Support ............................................

22

 

6.1.3

Suspended Mounting ........................................

23

 

6.1.4

Generator Restraint ..........................................

23

6.2

Generator Compartments ............................................

23

 

6.2.1

Compartment Size ............................................

23

 

6.2.2

Compartment Construction ..............................

23

 

6.2.3

Sound Insulating Materials................................

24

 

6.2.4

Acoustics ..........................................................

25

 

6.2.5

Compartment Floor Cutouts..............................

25

6.3

Cooling and Ventilating Air ..........................................

25

 

6.3.1

Generator Airflow ..............................................

25

 

6.3.2

Testing the Installation ......................................

26

6.4

Gasoline Fuel System ..................................................

26

 

6.4.1

Fuel Tank ..........................................................

27

 

6.4.2

Generator Fuel Supply Line ..............................

27

6.5

LP Gas Fuel System ....................................................

27

 

6.5.1

LP Fuel Consumption ........................................

27

 

6.5.2

Parts Not Included in Fuel System ....................

27

 

6.5.3

Some Important Considerations........................

28

 

6.5.4

Vapor Withdrawal ..............................................

28

 

6.5.5

Primary Regulator..............................................

28

 

6.5.6

Gaseous Carburetion ........................................

28

 

6.5.7

Fuel Supply Lines ..............................................

29

 

6.5.8

Excess Flow Valve ..............................................

29

 

6.5.9

Leakage Tests ....................................................

29

6.6

Exhaust System ..........................................................

29

 

6.6.1

Mufflers and Spark Arrestors............................

30

 

6.6.2

Exhaust System Safety ......................................

30

6.7

Electrical Connections ................................................

30

 

6.7.1

Electrical Junction Box ....................................

30

 

6.7.2

Wiring ................................................................

31

 

6.7.3

Generator AC Connections ................................

31

 

6.7.4

Conduit..............................................................

31

 

6.7.5

Isolating Different Power Sources ......................

31

 

6.7.6

Power Supply Cord............................................

31

 

6.7.7

Ground Fault Circuit Interrupters ....................

32

6.8

Battery Installation ......................................................

32

 

6.8.1

Recommended Battery ......................................

32

 

6.8.2

Battery Cables ..................................................

32

 

6.8.3

Battery Cable Connections ................................

32

 

6.8.4

Battery Compartment ........................................

32

6.9

Optional Accessories....................................................

34

 

6.9.1

Remote Panel Models ........................................

34

Section 7 — Post Installation ................................................

34

7.1

Post Installation Tests ..................................................

34

7.2

Before Initial Start-up ..................................................

34

7.3

Initial Start ..................................................................

34

7.4

Testing Under Load......................................................

35

7.5

Installation Checklist ..................................................

35

Section 8 – Troubleshooting ..................................................

36

8.1

Troubleshooting Guide ................................................

36

Section 9 – Notes......................................................................

37

Section 10 – Electrical Data ..................................................

38

Section 11 – Exploded Views and Parts Lists....................

40

Section 12 – Warranty ............................................................

52

 

 

Generac® Power Systems, Inc.

1

Safety Rules

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

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.

!WARNING: !

The engine exhaust from this product contains chemicals known to the state

of California to cause cancer, birth defects or other reproductive harm.

!

WARNING:

!

 

 

 

This product contains or emits chemicals

 

 

known to the state of California to cause

 

cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit, are, therefore, not all-inclusive. If you use a procedure, work method or operating technique Generac does not specifically recommend, you must satisfy yourself that it is safe for you and others. You also must make sure the procedure, work method or operating technique that you choose does not render the generator unsafe.

DANGER

Despite the safe design of this generator,

!operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to operate or maintain this equipment.

Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot

!during operation. Exercise care near running generators.

! GENERAL HAZARDS !

• For safety reasons, Generac recommends that the installation, initial start-up and maintenance of this equipment is carried out by a Generac Authorized Service Dealer.

The generator engine releases DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED. SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a) inability to think coherently, (b) nausea, (c) vomiting, (d) twitching muscles, (e) throbbing temples, (f) dizziness, (g) headaches, (h) weakness, and (i) sleepiness. IF YOU EXPERIENCE ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET MEDICAL HELP. Shut down the generator and do not operate it until it has been inspected and repaired.

Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector. The exhaust system must be installed in accordance with the genset installation manual. Make sure there is ample fresh air when operating the genset in a confined area.

Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation 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. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator.

When working on this equipment, remain alert at all times. Never work on the equipment when you are physically or mentally fatigued.

Inspect the generator regularly, and contact your nearest Generac Authorized Service Dealer immediately for parts needing repair or replacement.

2 Generac® Power Systems, Inc.

Safety Rules

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

ELECTRICAL HAZARDS

The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

FIRE HAZARDS

For fire safety, the generator must be installed and maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.

Keep a fire extinguisher in the vehicle at all times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system. Keep the extinguisher properly charged and be familiar with its use. If you have any question pertaining to fire extinguishers, consult your local fire department.

During installation onto the vehicle, have the generator properly grounded (bonded) either by solid mounting to the vehicle frame or chassis, or by means of an approved bonding conductor. DO NOT disconnect the bonding conductor, if so equipped. DO NOT reconnect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 American Wire Gauge (AWG) copper wire minimum.

In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE. Do not permit smoking, open flame, sparks or any source of heat in the vicinity while handling gasoline. Comply with all laws governing the storage and handling of gasoline.

This generator may use liquid propane (LP) gas as a fuel. LP gas is highly EXPLOSIVE. The gas is heavier than air and tends to settle in low areas where even the slightest spark can ignite the gas and cause an explosion.

Generac® Power Systems, Inc. 3

Section 1 – General Information

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

1.1GENERATOR 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 __________________________

 

 

 

 

 

16

4

2

 

 

 

 

5

8

 

10

14

P A N E L

3

11, 15 (Behind Access Panel)

17

13

12

1

 

 

 

19

7

6

9, 18

REFERENCE NUMBER IDENTIFICATION

1.

Generator Air Intake Screen

11.

Fuel Pump (Behind access panel.)

2.

Data Plate

12.

Oil Filter

3.

Engine Start/Stop Switch

13.

Oil Drain Plug

4.

7.5 amp Fuse

14.

Oil Dipstick and Filler Tube

5.

Circuit Breaker

15.

Air Filter (Behind access panel.)

6.

Optional Remote Panel Receptacle

16.

Spark Plugs

7.

Generator AC Output Leads

17.

Exhaust Outlet

8.

Starter Contactor

18.

Fuel Filter

9.

Fuel Inlet

19.

LP Fuel Inlet

10.

Fuel Primer Switch

 

 

4 Generac® Power Systems, Inc.

Section 1 – General Information

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

1.2GENERATOR APPLICABILITY

These generators have been designed and manufactured for supplying electrical power for recreational vehicles. You should 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, write or call the factory. Do not use the unit until you have been advised by competent authority.

DANGER

For fire safety, the generator must have been properly installed in compliance with ANSI

119.2-1975/NFPA 501C-1974, “Standard for Recreational Vehicles, Part III – Installation of Electrical Systems.” The generator also must have been installed in strict compliance with the manufacturer’s detailed installation instructions. After installation, do nothing that might render the unit in noncompliance with such codes, standards and instructions.

You can use your generator set to supply electrical power for operating one of the following electrical loads:

QUIETPACT 55G & LP: 120 and/or 240 volts, single phase, 60 Hz electrical loads. These loads can require up to 5500 watts (5.5 kW) of total power, but cannot exceed 45.8 AC amperes of current at 120 volts or exceed 22.9 AC amperes at 240 volts.

QUIETPACT 65G & LP: 120 and/or 240 volts, single phase, 60 Hz electrical loads. These loads can require up to 6500 watts (6.5 kW) of total power, but cannot exceed 54.1 AC amperes of current at 120 volts or exceed 27 AC amperes at 240 volts.

QUIETPACT 75G & LP: 120 and/or 240 volts, single phase, 60 Hz electrical loads. These loads can require up to 7500 watts (7.5 kW) of total power, but cannot exceed 62.5 AC amperes of current at 120 volts or exceed 31.2 AC amperes at 240 volts.

Do not overload the generator. Some installa-

!tions may require that electrical loads be alternated to avoid overloading. Applying excessively high electrical loads may damage the generator and may shorten its life. Add up the rated watts of all electrical lighting, appliance, tool and motor loads the generator will power at one time. This total should not be greater than the wattage capacity of the generator. If an electrical device nameplate gives only volts and amps, multiply volts times amps to obtain watts (volts x amps = watts). Some electric motors require more watts of power (or amps of current) for starting than for continuous operation.

1.3INSTALLATION

This Owner’s Manual has been prepared under the assumption that a competent, qualified technician installed the generator into a recreational vehicle. We also assume the installer complied with all applicable codes, standards and regulations pertaining to installation.

An INSTALLATION MANUAL was shipped with the generator. That Manual contains manufacturer’s instructions and recommendations for installing the unit into an industrial vehicle. After installation, installers should forward the Installation Manual to Owners/Operators for their information.

Owners/Operators have the responsibility to make sure that nothing is done that might render the installation unsafe or in non-compliance with applicable codes, standards and instructions.

1.4SAFETY

Before using the generator set, carefully read GENERAL SAFETY RULES inside the cover. Comply with these RULES to prevent accidents and damage to equipment and/or property. Generac suggests copying and posting the GENERAL SAFETY RULES to potential operators of this equipment.

1.5GENERATOR AC CONNECTION

SYSTEM

These air-cooled generator sets are equipped with dual stator AC power windings. These two stator windings supply electrical power to customer electrical loads by means of a dual 2-wire connection system.

Generators may be installed to provide the following outputs:

1.120 VAC loads only — one load with a maximum total wattage requirement equal to the generator’s rated power output (in watts), and 120V across the generator output terminals. Figure 1.1, page 6, shows the generator lead wire connections for 120VAC ONLY.

2.120/240 VAC loads — one load with a maximum total wattage requirement equal to the generator’s rated power output, and 240V across the generator output terminals; or two seperate loads, each with a maximum total wattage requirement equal to half of the generator’s rated power output (in watts), and 120V across the generator output terminals. Figure 1.2, page 6, shows the generator lead wire connections for 120/240 VAC loads. Also refer to section 2.1.4 Line Breakers for circuit breaker ratings.

This procedure should be done by a Generac Authorized Service Dealer or other qualified installer.

Generac® Power Systems, Inc. 5

Section 1 – General Information

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

Figure 1.1 – Connection for 120 Volts Only

Figure 1.2 - Connection for 120/240 Volts

T1

RED

CB1

T2

WHITE

CB2 T3

BLACK

STATOR WINDINGS GROUNDED NEUTRAL

1.6SPECIFICATIONS

1.6.1 FUEL REQUIREMENTS (GASOLINE)

This generator is equipped with a gasoline fuel system as standard equipment. Specific installations may provide either a separate fuel tank for the generator, or the generator may “share” the vehicle engine’s fuel tank.

1.6.1.1

Fuel Consumption (gph/lbs.ph)

 

 

 

 

 

 

 

 

Model

10% Load

50% Load

100% Load

 

 

QuietPact 55G

0.51

0.73

0.97

 

 

QuietPact 65G

0.51

0.76

1.07

 

 

QuietPact 75G

0.51

0.80

1.28

 

 

 

 

 

 

 

NOTE

Some installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine’s pickup tube. Such an arrangement causes the generator engine to “run out of gas” while adequate fuel for the vehicle remains in the tank.

To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator. Leaded REGULAR grade gasoline is an acceptable substitute.

NOTE:

Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits.

Generac does not recommend using any

!gasoline containing alcohol (such as “gasohol”). If you use any gasoline containing alcohol, it must not contain more than 10 percent ethanol, and it must be removed from the generator during storage. Do NOT use any gasoline containing methanol. If you use gasoline with alcohol, inspect more frequently for fuel leaks and other abnormalities.

1.6.2 ENGINE OIL REQUIREMENTS

Use only high quality detergent oil classified “For Service SF” and with an oil viscosity rating of SAE 10W-30 oil. Do not pour in any additives to the recommended oil. Engine crankcase capacity is 1.8 liters or 1.9 quarts with oil filter change. See Section 3.2 on page 11 for oil level check and filing procedures.

 

 

1.6.3

GENERATOR SPECIFICATIONS

 

 

 

 

 

SERIES

QP55G

QP55LP

QP65G

 

QP65LP

QP75G

QP75LP

 

 

Rotor RPM

3600

3600

3600

 

3600

3600

3600

 

 

Rotor Poles

2

2

2

 

2

2

2

 

 

Engine RPM

2200

2200

2571

 

2571

2571

2571

 

 

Rated Max. Continuous AC Output Watts*

5500

5500

6500

 

6500

7500

7500

 

 

Voltage*

120

120

120

 

120

120

120

 

 

Rated Max. Continuous Current Amps (240V)

45.8 (22.9)

45.8 (22.9)

54.1 (27.0)

 

54.1 (27.0)

62.5 (31.2)

62.5 (31.2)

 

 

Phase

1

1

1

 

1

1

1

 

 

Frequency

60 Hertz

60 Hertz

60 Hertz

 

60 Hertz

60 Hertz

60 Hertz

 

 

Battery Charging Current (Max.)

2 amps

2 amps

2 amps

 

2 amps

2 amps

2 amps

 

 

Weight

326 lbs.

329 lbs.

328 lbs.

 

331 lbs.

330 lbs.

333 lbs.

 

 

Length

33.7 in.

33.7 in.

33.7 in.

 

33.7 in.

33.7 in.

33.7 in.

 

 

Width

22.2 in.

22.2 in.

22.2 in.

 

22.2 in.

22.2 in.

22.2 in.

 

 

Height

19.6 in.

19.6 in.

19.6 in.

 

19.6 in.

19.6 in.

19.6 in.

 

 

 

 

 

 

 

 

 

 

 

* All units are reconnectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output

6 Generac® Power Systems, Inc.

Section 2 – Operation

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

1.6.4

ENGINE SPECIFICATIONS

Type of Engine

 

QUIETPACT 55/65/75 ................................................

GT-760

Cooling Method ........................................................

Air-cooled

Rated Horsepower

 

QUIETPACT 55..............................................

27 at 3600 rpm

QUIETPACT 65..............................................

27 at 3600 rpm

QUIETPACT 75..............................................

27 at 3600 rpm

Displacement

 

QUIETPACT 55/65/75....................................................

760cc

Compression Ratio........................................................

8.6 to 1

Cylinder Block ..........................

Aluminum w/Cast Iron Sleeve

Type of Governor ..............................

Mechanical, Fixed Speed

Engine Governor Speed

 

QUIETPACT 55 ......................................................

2200 rpm

QUIETPACT 65/75..................................................

2571 rpm

Air Cleaner

........................Paper Element w/Foam Precleaner

Starter ........................................................

 

12-volt DC Electric

Ignition System ......................

Solid-state w/Flywheel Magneto

Recommended Spark Plug

 

Champion ..................................................................

 

RC12YC

AC....................................................................................

 

R45S

Fram Autolite ......................................................................

65

Spark Plug Gap........................................

0.030 inch (0.8 mm)

Recommended Min. Battery............

400 Cold Cranking Amps

1.6.5 EMISSIONS COMPLIANCE PERIOD

For nonhandled engines the Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal emission requirements.

For engines less than 225 cc displacement, Category C=125 hours, B=250 hours, and A=500 hours.

For engines of 225 cc or more, Category C=250 hours, B=500 hours, and A=1000 hours.

2.1GENERATOR CONTROL PANEL

The following features are mounted on the generator control panel (Figure 2.1):

2.1.1 FUEL PRIMER

Before starting a cold engine (if it has not been started in more than two weeks), you must press this switch for approximately ten seconds to bring fuel from the tank to the fuel pump. This rocker type switch springs back into its original position when you release it.

2.1.2 START/STOP SWITCH

To crank and start the engine, hold this switch in the START position. Release the switch when the engine starts. To stop an operating engine, press and hold the switch in the STOP position until the engine shuts off. The switch center position is the RUN position.

2.1.3 7.5 AMP FUSE

The fuse protects the engine’s DC control circuit against electrical overload. If the fuse element has melted open due to overloading, the engine cannot be cranked. If you must replace the fuse, use only an identical 7.5 amp replacement fuse.

2.1.4 LINE BREAKERS

Protects generator’s AC output circiut against overload, i.e., prevents unit from exceeding wattage/amperage capacity. The circuit breaker ratings are as follows:

 

Model

Circuit Breaker 1

Circuit Breaker 2

240 Volt

 

 

QuietPact 55

30A

20A

25A 2P

 

 

QuietPact 65

30A

30A

30A 2P

 

 

QuietPact 75

35A

35A

35A 2P

 

 

 

 

 

 

 

NOTE:

If this generator has been reconnected for dual voltage AC output (120/240 volts), you can install line breakers having an amperage rating that is different than that stated above. The replacement line breakers consist of two separate breakers with a connecting piece between the breaker handles (so that both breakers will operate at the same time). If the unit is reconnected for dual voltage, it is no longer RVIA or CSA listed.

Figure 2.1 – Typical Control Panel

CONTROL CENTER

 

 

C

R

U T

 

 

 

B R E A K E R

 

 

 

C

R

U T

 

 

 

B R

A K E R

 

F

S E

S T A R T

F U E L

REV. B

0E0580

7

5 A

 

 

 

 

 

 

 

IF GENERATOR DOES NOT START.

S T O P

P R M E

 

REMOVE AND INSPECT FUSE.

(SEE OWNER'S MANUAL TROUBLE SHOOTING GUIDE.)

PRESS PRIME SWITCH FOR 10 SECONDS

BEFORE STARTING. WHEN STARTING, DO NOT PRESS

START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT.

Generac® Power Systems, Inc. 7

Section 2 – Operation

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

2.2OPTIONAL REMOTE

START/STOP PANEL

A remote mounted Start/Stop Panel (Figure 2.2) is available that allows you to start and stop the generator engine conveniently from inside the vehicle. The remote panel includes a Start/Stop switch, hourmeter, generator run lamp and a wire harness.

Figure 2.2 — Optional Remote Panel

(Models 004057 and 004184)

2.3AUTOMATIC CHOKE

This engine is equipped with an automatic choke that consists of two main components: a choke solenoid and prechoke.

2.3.1 CHOKE SOLENOID

During engine cranking (Start/Stop switch at START), a solid-state choke module signals the choke solenoid to activate and cycle (choke on/choke off) until the engine starts. The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking. When the engine starts, the choke stops cycling.

2.3.2 PRECHOKE

The choke system also has a temperature-sensitive metal strip that adjusts choke valve angle according to ambient temperatures (i.e., in cold ambient temperatures, choke valve closes more). Once the engine starts, an element heats the temperature-sensitive strip to a normal operating condition, opening the choke valve. This may take about three minutes in cooler weather.

2.4.1 INSTALLATION

Generator installation must have been properly completed so it complies with all applicable codes, standards and regulations and with the manufacturer's recommendations.

2.4.2 ENGINE LUBRICATION

Have the engine crankcase properly serviced with the recommended oil before starting. Refer to Section 1.6.3 (Page 6) and Sections 3.1 and 3.2 (Page 11) for oil servicing procedures and recommendations.

Any attempt to crank or start the engine before

!you have properly serviced it with the recommended oil may result in an engine failure.

2.4.3 FUEL SUPPLY

The engine must have an adequate supply of proper fuel to operate. Before starting it, check that sufficient fuel is available.

NOTE:

Depending on the installation, the generator may have either a separate fuel tank, or it may “share” the vehicle engine’s fuel tank.

2.4.4 COOLING AND VENTILATING AIR

Air inlet and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. Without sufficient cooling and ventilating airflow, the engine/generator quickly overheats, which causes it to shut down and may damage the generator.

2.4.5 ENGINE EXHAUST GAS

Before starting the generator engine, you should be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals. Close windows, doors and other openings in the vehicle that, if open, might permit exhaust gases to enter the vehicle.

2.4BEFORE STARTING THE ENGINE

NOTE:

Instructions and information in this manual assume the generator has been properly installed, connected, serviced, tested and adjusted by a qualified installation technician or installation contractor.

8 Generac® Power Systems, Inc.

Section 2 – Operation

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

DANGER

The generator engine releases DEADLY carbon

!monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED. SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a) inability to think coherently, (b) nausea, (c) vomiting, (d) twitching muscles, (e) throbbing temples, (f) dizziness, (g) headaches, (h) weakness, and (i) sleepiness. IF

YOU EXPERIENCE ANY OF THESE SYMPTOMS,

MOVE INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET MEDICAL HELP. Shut down the generator and do not operate it until it has been inspected and repaired.

2.If you have not started the engine in more than two weeks, press the Fuel Pump Primer switch and hold it for about 10 seconds. However, if the engine is warm, skip Step 2.

3.To crank and start the engine, hold the start/stop switch at START. Release the switch when the engine starts.

If the engine does not start after it has been

!cranking for 15 seconds, release the Start/Stop switch and wait 1 minute before trying again. Holding the switch for longer than 15 seconds can damage the starter motor.

4.Let the engine run at no-load for a few minutes to stabilize and warm up.

5.Turn ON electrical loads using the means provided (such as a main circuit breaker or transfer switch).

DANGER

Never sleep in the vehicle while the genset is

!running unless the vehicle has a working carbon monoxide detector. The exhaust system must be installed in accordance with the genset installation manual. Make sure there is ample fresh air when operating the genset in a confined area.

2.5STARTING THE GENERATOR

NOTE:

Read the vehicle manufacturer’s instructions. The owner/operator should become familiar with the vehicle in which this generator is installed. Differences exist between vehicles. For example, some vehicles may use a transfer switch to isolate dockside power from the generator, while other vehicles may use an isolating receptacle. Some vehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads.

To crank and start the generator engine, proceed as follows:

1.Turn OFF electrical loads using the means provided in your vehicle (such as a main line circuit breaker or transfer switch).

NOTE:

If starting from the generator control panel, turn OFF loads by setting the generator’s main circuit breaker to the OFF (or open) position. If starting from a remote panel, turn OFF loads using the means provided in the vehicle (such as a main circuit breaker). Electrical load circuits will be turned ON after the generator has started, stabilized and warmed up.

2.6STOPPING 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. The engine will come to a complete stop.

2.7APPLYING LOADS TO GENERATOR

When applying electrical loads to the generator, observe these guidelines:

Before applying electrical loads, let the generator stabilize and warm up for a minute or two.

DO NOT overload the generator.

2.7.1 LETTING THE ENGINE STABILIZE

The generator supplies correct rated voltage only at the proper governed speed. Some electrical appliances may be extremely sensitive to voltage. Incorrect voltages can damage such appliances.

If electrical loads are applied at reduced operating speeds, such loads imposed on the engine when sufficient power is not available may shorten engine life. Never turn ON electrical loads until after the generator engine has started and stabilized at no-load.

Generac® Power Systems, Inc. 9

Section 2 – Operation

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

2.7.2 DO NOT OVERLOAD THE GENERATOR

 

2.8.2 HIGH TEMPERATURE SWITCH

You can read the rated wattage/amperage capacity of your generator on the generator data decal (see Section 1.1 on Page 4).

Applying electrical loads in excess of the unit’s rated capacity will cause the engine/generator to automatically shut down.

To avoid overloading, add up the wattage of all connected electrical lighting, appliance, tool and motor loads. This total should not be greater than the generator’s rated wattage capacity.

Most lighting, appliance, tool and motor loads indicate their required watts on their nameplate or data plate. For light bulbs, simply note the wattage rating of the bulb.

If a load does not show its rated wattage, multiply that load’s rated VOLTS times AMPS to obtain WATTS.

Induction type motors (such as those that run the vehicle’s 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. First, figure the watts needed to start electric motors in the system. To that figure, add the running wattages of other items that will be operated by the generator.

Do not apply heavy electrical loads for the first two or three hours of operation.

2.8PROTECTION SYSTEMS

2.8.1 LOW OIL PRESSURE SWITCH

This switch (Figure 2.3) has normally closed (N.C.) contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below a preset level, switch contacts close, and the engine automatically shuts down. The unit should not be restarted until oil is added.

This switch (Figure 2.3), which has normally open (N.O.) contacts, is mounted near the oil filter. The contacts close if the temperature should exceed approximately 270º F (132º C) for gasoline models, and 284° F (140° C) for LP models, initiating an engine shutdown.

Figure 2.3 – Low Oil Pressure and

High Temperature Switches

2.8.3 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 2.4). During engine cranking only, a positive DC (battery) voltage is delivered through a diode, resistor, brushes, slip rings, and the generator rotor. Application of this voltage to the rotor “flashes the field” whenever it is started. Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce “pickup” voltage in the stator windings.

Figure 2.4 – Field Boost Circuit

10 Generac® Power Systems, Inc.

Section 3 – Maintenance

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

2.8.4 OVERVOLTAGE PROTECTION

A solid-state voltage regulator (Figure 2.5) controls the generator’s AC output voltage. This regulator supplies an excitation current to the rotor. By regulating the rotor’s excitation current, the strength of its magnetic field is regulated and, in turn, the voltage delivered to connected electrical loads is controlled. When the AC frequency is 60 Hertz, voltage is regulated at 115 volts.

Figure 2.5 – Solid State Voltage Regulator

The voltage regulator also incorporates a “voltage surge protection circuit.” This circuit prevents troublesome surges in the generator AC output voltage. Voltage surge is a common cause of damage to electronic equipment.

2.8.5 25-HOUR BREAK-IN PERIOD

The first 25 hours of operation is the break-in period for the generator. Properly breaking in the generator is essential to minimize fuel consumption and provide maximum engine performance. During this 25hour break-in period, follow this procedure:

Run the unit at varying electrical loads to help seat the engine piston rings properly.

Check the engine oil level frequently. Add oil if needed. It is normal for the generator engine to consume more oil than is normal until the piston rings have properly seated.

For the 75-hour operation following the break-in period, avoid light electrical loads. Load the generator at 50 percent (or more) of its rated wattage capacity. Repeated light loads during these 75 hours can cause improper seating of engine piston rings, resulting in blowby and high oil consumption.

After operating the unit for 25 hours, complete the tasks recommended under Section 2.8.6.

2.8.6 25-HOUR CHECK-UP

After the 25-hour break-in period, contact a Generac Authorized Service Dealer for the following maintenance. (The vehicle owner is responsible for any charges relating to normal unit maintenance.)

Change the engine crankcase oil and oil filter.

Check all fluid levels.

Inspect the cooling and ventilation openings.

Check the engine ignition system.

Inspect the entire electrical system.

Inspect the engine exhaust system.

2.8.7 OPERATION IN HIGH GRASS

OR BRUSH

Never operate the generator while the vehicle is parked over high grass, weeds, brush, leaves or any other combustible substance. Such materials can ignite and burn from the heat of the exhaust system. The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down.

3.1CHECKING THE ENGINE OIL

LEVEL

For oil capacities and requirements, see “Engine Oil Requirements,” Section 1.6.2 (Page 6). Check the engine crankcase oil level at least every eight hours of operation, or before you use it. To check the engine oil level, proceed as follows (see Figure 3.1):

1.Be sure the generator is as level as possible.

2.Remove the dipstick and wipe it dry with a clean, lint-free cloth.

3.Install and tighten the dipstick cap; then, remove it again. The oil level should be at the dipstick “Full” mark.

4.If necessary, remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dipstick “Full” mark. DO NOT FILL ABOVE THE “FULL” MARK.

Never operate the engine with the oil level

!below the “Add” mark on the dipstick. Doing this could damage the engine.

5.Install and tighten the oil fill cap and the dipstick before operating the engine.

Generac® Power Systems, Inc. 11

Generac 004702-0, 004703-0, 004704-0, 004705-0, 004706-0 User Manual

Section 3 – Maintenance

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

3.2CHANGING THE ENGINE OIL

AND/OR OIL FILTER

Change the engine oil after the first 25 hours of operation (after the 25-hour break-in period, see Section 2.8.5, Page 10). Thereafter, change the oil every 100 operating hours. Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures.

Change the engine oil filter after the first 25 hours of operation, and every 100 operating hours thereafter.

To change the oil and/or oil filter, proceed as follows:

1.Run the engine until it is thoroughly warmed up (at least five minutes) then shut OFF the engine.

2.With the engine still warm from running, remove the oil drain plug (Figure 3.1). Drain the oil into a suitable container.

Figure 3.1 — Oil Dipstick/Fill Tube and

Location of Oil Drain Plug

Oil Dipstick

9. Start the engine and check for leaks.

Figure 3.2 — Engine Oil Filter

NOTE:

Check the oil level and fill to the “FULL” mark after checking for leaks. The filter will retain some oil.

Oil Drain Hose

3.After the oil has drained, replace the oil drain plug. (If only changing the oil, go to step 7.)

4.With the oil drained, remove the old oil filter by turning it counterclockwise (Figure 3.2).

5.Apply a light coating of clean engine oil to the gasket of the new filter.

6.Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter. Then, tighten the filter an additional 3/4 to one turn.

7.Remove the dipstick and fill crankcase with the proper type and amount of recommended oil (see Section 1.6.2, Page 6). The engine crankcase can hold about 1.8 liters or 1.9 quarts with oil filter change. DO NOT FILL ABOVE THE “FULL” MARK.

8.Install and tighten the dipstick before operating the engine.

3.3MAINTAINING 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. Service the foam precleaner more frequently if operating the generator in extremely dusty or dirty conditions. Use the following procedure (Figure 3.3):

1.Turn the knob counterclockwise to loosen.

2.Remove the cover, foam precleaner and paper filter.

3.Remove the foam precleaner from the cover.

4.Wash the foam precleaner in liquid detergent and water.

5.Wrap the foam precleaner in a clean cloth and gently squeeze it dry.

6.Saturate the foam precleaner in clean engine oil. Gently squeeze it in a clean cloth to remove excess oil and to distribute oil (DO NOT TWIST).

7.Install the foam precleaner into the cover, followed by the paper filter. Tabs at edges of paper filter must lock into slots on cover.

8.Install the cover, foam precleaner and paper filter.

9.Replace knob to retain the filter in place.

12 Generac® Power Systems, Inc.

Section 3 – Maintenance

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

Figure 3.3 – Engine Air Cleaner

Figure 3.5 – Fuel Filter

Flat

Wing

FUEL FILTER

Washer

Nut

 

 

TO FUEL PUMP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

Offset S

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x Compartment

CUSTOMER FUEL CONNECTION

Wing

Nut

3.4CHECKING THE ENGINE

SPARK PLUG

Clean the spark plug and reset the spark plug gap every 100 hours of operation.

1.Clean the area around the base of the spark plug to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plug to clean.

2.Remove the spark plug and check the condition. Replace the spark plug if worn or if reuse is questionable.

3.Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.030 inch (0.76 mm) by carefully bending the ground electrode (Figure 3.4).

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 necessary, re-form the wire terminal to obtain a tight fit.

3.5FUEL FILTER (GASOLINE ONLY)

Remove and replace the fuel filter (Figure 3.5) once each year or every 400 hours of operation, whichever comes first.

3.6CLEAN SPARK ARRESTOR

The engine exhaust muffler has a spark arrestor screen. Inspect and clean the screen every 50 hours of operation or once each year, whichever comes first.

NOTE:

If you use your generator on any forest-covered, brush-covered or grass-covered unimproved land, it must equipped with a spark arrestor. The spark arrestor must be maintained in good condition by the owner/operator.

Clean and inspect the spark arrestor as follows:

Remove the screen retaining bracket by removing the screw.

Slide the spark arrestor screen out from the tail pipe.

Inspect screen and replace if torn, perforated or otherwise damaged. DO NOT USE a defective screen. If screen is not damaged, clean it with commercial solvent.

Replace the screen and the retaining bracket.

Figure 3.6 - Spark Arrestor

TAILPIPE

P/N 0E0907

RETAINER

P/N 0D5133A

SPARK ARRRESTOR

SCREEN P/N 0D5133

RETAINING

SCREW P/N 045764

Generac® Power Systems, Inc. 13

Section 3 – Maintenance

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

3.7CLEANING 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 moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings.

When moisture is allowed to remain in contact with windings, some of the moisture will be retained in voids and cracks in the insulation. This causes a reduced insulation resistance and will eventually cause problems. Dirt will make the problem worse, since dirt tends to hold moisture in contact with windings. Salt (as from sea air) also will worsen the problem since it tends to absorb moisture from the air. Salt and moisture, when combined, form a good electrical conductor.

Do NOT use a forceful spray of water to clean

!the generator. Water will enter the generator interior and cause problems, and may also contaminate the generator fuel system.

3.8BATTERY MAINTENANCE

All lead-acid batteries will discharge when not in use. The generator battery should be inspected as follows:

3.8.1 WEEKLY

Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.

Check the battery fluid level of unsealed batteries and, if necessary, fill with Distilled Water Only. Do not use tap water in batteries.

3.8.2 EVERY SIX MONTHS

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 precautions. Keep unauthorized personnel away from batteries.

Damage will result if the battery connections are made in reverse.

DANGER

Do not dispose of the battery in a fire. The battery is capable of exploding. Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks, or any spark producing tools or equipment near the battery. Discharge static electricity from your body before touching the battery by first touching a grounded metal surface.

A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when working on batteries:

Remove watches, rings or other metal objects;

Use tools with insulated handles;

Wear rubber gloves and boots;

Do not lay tools or metal parts on top of the battery;

Disconnect any charging source prior to connecting or disconnecting battery terminals; and

Do not use any jumper cables or booster battery to crank and start the generator engine. If any battery has discharged, remove it for recharging.

Do not open or mutilate the battery. Released

!electrolyte has been known to be harmful to the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

!harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:

Wear full eye protection and protective clothing;

Where electrolyte contacts the skin, wash it off immediately with water;

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. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

14 Generac® Power Systems, Inc.

Section 3 – Maintenance

QUIETPACT 55, 65, and 75 Recreational Vehicle Generators

3.9 MAJOR SERVICE MANUAL

3.12.2 RETURN TO SERVICE

To obtain a service manual for your generator, contact your nearest Generac Authorized Service Dealer. Make sure to identify your MODEL NUMBER and SERIES. Manuals can be obtained from the internet website (www.generac.com) or a service dealer.

3.10 DRIVE BELT

The engine drives the generator rotor by means of a pulley and drive belt arrangement. Drive belt tension was properly adjusted before the unit was shipped from the factory. If you suspect that drive belt tension is incorrect, contact a 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.

3.12 OUT OF SERVICE PROCEDURE

3.12.1 REMOVAL FROM SERVICE

If you cannot exercise the generator every seven days, and it is to be out of service longer than 30 days, prepare the generator for storage as follows:

1.Start the engine and let it warm up.

2.Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down.

3.While the engine is still warm from running, drain the oil completely. Refill the crankcase with SAE 5W-30 oil having API classification “For Service SF.”

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.

6.Remove the battery and store it in a cool, dry room on a wooden board. Never store the battery on any concrete or earthen floor.

7.Clean and wipe the entire generator.

To return the unit to service after storage, proceed as follows:

1.Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see Section 1.5.4, Page 6). If necessary, drain and refill with the proper oil.

2.Check the state of the battery. Fill all cells of unsealed batteries to the proper level with distilled water. DO NOT USE TAP WATER IN THE BATTERY. Recharge the battery to 100 percent state of charge, or, if defective, replace the battery.

3.Clean and wipe the entire generator.

4.Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly.

5.Turn OFF all electrical loads. Add fuel if necessary and then start the engine.

6.Allow the unit to warm up thoroughly.

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.

3.13 RV GENERATOR SERVICE INTERVAL

QUIETPACT 55/65/75:

50 Hours ................................

 

Clean Spark Arrestor

1st 50 Hours,

 

 

then every 500 Hours

................Adjust Valve Lash

100 Hours..........................

 

Change Engine Oil/Filter

100 Hours ..................................

 

Clean Air Pre-filter

100 Hours ................................

 

Inspect Spark Plugs

250 Hours ............

Replace Paper Air Filter Element

400 Hours ..................................

 

Replace Fuel Filter

500 Hours................................

 

Replace Spark Plugs

Generac® Power Systems, Inc. 15

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