Generac Power Systems 004270-1 User Manual

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, V V 1

POV\/EPI SYSTEIVIS. II\IC

Owner’s Manual and

Installation Instructions

Liquid-cooled Recreational Vehicle Generator

• Model: 004270-1

QUIETPACT™ 75D

INTRODUCTION

Thank you for purchasing this model of the
QUIETPACT™ product line by Generac Power
Systems, Inc. This model is designed and manufac
tured to supply electrical power for recreational vehi
cles.

4 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, WARN
ING, CAUTION, and NOTE blocks are used to alert
you to special instructions about a particular oper

ation that may be hazardous if performed incorrect
ly or carelessly. Observe them carefully. Their defin
itions are as follows:

DANGER

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

-------

M. WARNING ik

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

■“—M. CAUTION -------------------------

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 compli

ance with the special instructions while performing the

service are essential for preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING, and CAUTION blocks. Here are

the types of information indicated by each symbol:

____________

--------------

The operator (i.e., the driver) is responsible for the
proper and safe use of the vehicle and its equipment,
and for the safety of all vehicle occupants. Before
using this equipment, we strongly recommend that
the operator read this manual and thoroughly under
stand all instructions. We also strongly recommend
instructing other occupants in the vehicle to properly
start and operate the generator. This prepares them to
operate the equipment in case of an emergency.

^ CONTENTS

_________________ ______________

This manual contains pertinent owner’s information,
including warranty, electrical diagrams, exploded
views, and lists of repair parts for generator model
number 004270-1. 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 main
tenance service and replacement of parts are the
responsibilities of the owner/operator and, as such,
are not considered defects in materials or work
manship 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
minimize problems and operating expenses. 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 num
ber of your unit, as given on its data decal, which is
located on your generator.

_

This symbol points out important safety informa

A

tion that, if not followed, could endanger personal
safety and/or property to self and Others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock

A

hazard.

Generac* Power Systems, Inc.

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.

Table of Contents

QUIETPACT“ 75D Recreational Vehicle Generator

Part 1 ■" Owner's Manual

Introduction

Read This Manual Thoroughly ........................................IFC

Contents ...........................................................................IFC

Operation and Maintenance .............................................IFC

How to Obtain Service
Authorized Service Dealer Locator Number

Safety Rules ........................................................... 2

Section 1 - General Information

1.1 Generator Identification

1.2 Generator Applicability

1.3 Safety.............................................................................5

1.4 Generator AC Connection System

1.5 Specifications ...............................................................5

Section 2 - Operation....................................................7

2.1 Generator Control Panel

2.2 Optional Remote StarCStop

2.3 Before Starting the Engine............................................7

2.4 Starting the Generator

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

2.6 Applying Loads to Generator

2.7 Protection Systems .......................................................9

2.8 Additional Information

Section 3 - Maintenance

3.1 Checking the Engine Oil Level

3.2 Changing the Engine Oil and/or Oil Filter

3.3 Servicing the Engine Air Filter...................................12

3.4 Spark Arrestor Muffler

3.5 Cleaning the Generator ..............................................13

3.6 Battery Maintenance ..................................................13

3.7 Cooling System ..........................................................14

3.8 Engine Coolant ...........................................................14

3.9 Major Service Manual

3.10 Drive Belt ...................................................................14

3.11 Exercising the Generator

3.12 Out-of-Service Procedure

3.13 Service Schedule.........................................................16

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

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

.Inside Front Cover

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

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

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

IFC
IFC

4

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

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

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

1.5.1 Fuel Requirements

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

1.5.2 Fuel Consumption..........................................6

1.5.3 Engine Oil Requirements

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

1.5.4 Coolant ..........................................................6

1.5.5 Engine............................................................6

1.5.6 Generator

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

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

2.1.1 Hourmeter.................................................... 7

2.1.2 StarhStop Switch

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

2.1.3 Fuse................................................................7

2.1.4 Line Breaker

2.1.5 Preheat Switch

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

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

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

2.3.1 Installation

2.3.2 Engine Lubrication

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

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

2.3.3 Fuel Supply ...................................................8

2.3.4 Coolant Level

2.3.5 Cooling and Ventilating Air

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

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

2.3.6 Engine Exhaust Gas..................................... 8

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

9

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

2.6.1 Letting the Engine Stabilize

2.6.2 Do Not Overload the Generator

2.7.1 Low Oil Pressure Switch

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

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

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

2.7.2 High Coolant Temperature Switch.................9

2.7.3 Overspeed Shutdown...................................10

2.7.4 Overvoltage Protection................................10

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

2.8.1 25-Hour Break-in Period

2.8.2 25-Hour Check-up

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

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

.10

2.8.3 Attention Required After Submersion ........10

2.8.4 Operation in High Grass or Brush

2.8.5 Effects of Moisture and Dirt

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

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

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

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

11

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

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

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

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

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

3.12.1 Removal From Service

3.12.2 Return to Service

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

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

7

8
9

10
10

11
11

11

12

14
14

14
14

15

4
5

5
5
6

6
7
7
7

7

7

8
8

8

9
9

9

11

Part 11 - Instailation instructions

Safety Rules.................................................................18

Section 1 - General Information

1.1 Purpose and Scope of the Manual

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

....

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

20

20

1.2 Safety...........................................................................20

1.3 Standards Booklets......................................................20

1.4 Equipment Description................................................20

1.5 Generator Engine Operating Speed.............................20

1.6 Generator AC Connection System..............................20

Section 2 - Installation................................................22

2.1 Location and Support

2.1.1 Generator Location

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

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

22
22

2.1.2 Generator Support .......................................22

2.1.3 Suspended Mounting

2.1.4 Generator Restraint

2.2 Generator Compartments

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

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

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

22
23
23

2.2.1 Compartment Construction..........................23

2.2.2 Sound Insulating Materials

2.2.3 Acoustics

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

2.2.4 Compartment Floor Cutouts

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

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

24
24
25

2.3 Cooling and Ventilating Air .......................................26

2.3.1 Generator Airflow .......................................26

2.3.2 Cooling Air Inlet Openings

2.3.3 Compensating for Restrictions

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

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

26
27

2.3.4 Testing the Installation............................... 27

2.4 Diesel Fuel System......................................................27

2.4.1 Fuel Tank

2.4.2 Generator Fuel Supply Lines

2.4.3 Generator Fuel Return Lines

2.5 Exhaust System

2.5.1 Muffler and Spark Arrestor

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

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

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

.......................28

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

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

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

28
28

29

29

2.6 Electrical Connections..................................................30

2.6.1 Electrical Junction Box

2.6.2 Wiring

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

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

30

2.6.3 Generator AC Connections .........................30

2.6.4 Conduit.........................................................32

2.6.5 Power Supply Cord .....................................32

2.6.6 Groxmd Fault Circuit Interrupters...............32

2.6.7 Isolating Different Power Sources ..............32

2.7 Battery Installation .....................................................33

2.7.1 Recommended Battery.................................33

2.7.2 Battery Cables..............................................33

2.7.3 Battery Cable Cormections..........................33

2.7.4 Battery Compartment

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

33

2.8 Optional Accessories...................................................34

2.8.1 Remote Star VS top Connections

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

34

Section 3 - Post-installation Startup

Checks.............................................-

.......

3.1 Post Installation Tests ..................................................35

3.2 Before Initial Startup...................................................35

3.3 Initial Start ..................................................................35

3.4 Testing Under Load

3.5 Installation Checklist

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

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

35
36

Appendix 1 - Troubleshooting................................. 37

Appendix 2 - Notes
Appendix 3 - Electrical Data

Appendix 4 - Exploded Views and Parts Lists
Appendix 5 - Notes

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

.38-39

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

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

40

......

63

Appendix 5 - Warranty................................................64

29

30

35

44

Generac* Power Systems, Inc.

SAFETY RULES

Safety Rules

QUIETPACT™ 75D 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. Mmk

The engine exhaust fumes contain carbon monox

WARNING:

The engine exhaust from this product

contains 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 reli
ably 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 cir
cumstance that might involve a hazard. The warn
ings 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 that Generac does not specifically recom
mend, 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,

A

operating this equipment imprudently, neglect
ing its maintenance, or being careless can cause
possible injury or death. Permit only responsi
ble and capable persons to operate and main
tain this equipment.

Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.

Potentially lethal voltages are generated by

A

these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.

A

GENERAL HAZARDS

For safety reasons, Generac recommends
that the installation, initial startup, and mainte
nance of this equipment be performed by a

Generac Authorized Service Dealer.

ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. Thus, the exhaust
system must be installed properly, in strict com
pliance with applicable codes and standards.
Following installation, you must do nothing that
might render the system unsafe or in noncompli
ance with such codes and standards. The genera
tor compartment must be completely vapor-sealed
from the vehicle interior. There must be no possi

bility of exhaust fumes entering the vehicle interi

or. Never operate this equipment with a leaking or
defective exhaust system.

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 venti

lating 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 seriously damages the
generator. Do not alter the installation or permit
even partial blockage of ventilation provisions, as
this can also seriously affect the 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 imme
diately for parts needing repair or replacement.

Before performing any maintenance on the genera

tor, disconnect its battery cables to prevent acci
dental startup. First, disconnect the cable from the
battery post, indicated by a NEGATIVE, NEG, or
(-). Reconnect this cable last.

Never use the generator, or any of its parts, as a

step. Stepping on the unit can stress and break
parts, resulting in dangerous operating conditions
due to leaking exhaust gases, fuel leakage, oil leak
age, etc.

Never insert any tool or other object through open

ings in the generator interior, even if the unit is not
running. You might seriously injure yourself or
damage the equipment.

Generac* Power Systems, Inc.

Safety Rules

QUIETPACT“ 75D Recreational Vehicle Generator

SAFETY RULES

A

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.
Before operating the generator, ensure all appro
priate covers, guards, and barriers are in place . 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.

• During installation onto the vehicle, have the gen
erator 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 conduc
tor 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 an 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 nonconduct
ing implement, such as, a dry 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 equip
ment. Jewelry can conduct electricity, resulting in
electric shock, or may get caught in moving com
ponents, causing, injury.

A

A

FIRE HAZARDS

For fire safety, the generator must be installed and

maintained properly. Installation must always
comply with NFPA 70 (latest edition), “National
Electrical Code”, Article 551, and NFPA 1192 (lat
est edition), “Standard for Recreational Vehicles”,
along with all applicable codes, standards, laws,
and regulations. Adhere strictly to local, state, and
federal electrical and building codes. Comply with
regulations the Occupational Safety and Health

Administration (OSHA) has established. Also,

ensure that the generator is installed in accor
dance with the manufacturer’s instructions and
recommendations. After proper installation, do
nothing that might alter the installation and render
the unit in noncompliance with the aforemen
tioned 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 sys
tem. 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.

A

A EXPLOSION HAZARDS A

Do not smoke around the generator. Wipe off any

fuel or oil spills immediately. Ensure that no com
bustible material is left in the generator compart
ment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround
ing the generator clean and free of debris.

All fuel types are potentially FLAMMABLE and/or

EXPLOSrVT^ and should be handled with care.
Comply with all laws regulating the storage and
handling of fuels. Inspect the unit’s fuel system fre
quently and correct any leaks immediately. Before

placing this equipment into service, the fuel supply

lines must be properly installed, purged, and leak­tested according to applicable fuel-gas codes.

Generac® Power Systems, Inc.

GENERAL

INFORMATION

Section 1 - General Information

QUIETPACT™ 75D Recreational Vehicle Generator

1.1 GENERATOR IDENTIFICATION

Please record the following information from the generator DATA DECAL or information decal,
located below the user control panel.

1. Model Number

3. kW Rating.

22

FRONT VIEW

_________________________

15 12 3

_____

2. Serial Number

______________

Rated Voltage

_____________________

Model: 04270-0 QUIETPACT“ 75D

1. 2-Pole, 35-amp Circuit
Breaker

2. Hourmeter

3. Oil Fill Opening and Plug

4. Oil Dipstick

5. Engine Start/Stop Switch

6. 14-amp Fuse

7. Engine Preheat Switch

8. Fuel Filter

9. Air Filter

10. Oil Filter

11. Starter Motor

12. Preheat Contactor

13. Starter Contactor

14. Radiator

15. Coolant Recovery Tank

16. Muffler

17. Battery Connections

18. Fuel Connections

19. Alternator

20. Fuel Pump

21. Centrifugal Cooling Fan
and Housing

22. Alternator Drive Belt

23. Alternator Drive Belt

Tensioner

24. Coohng Fan Drive Belt

25. Cooling Fan Drive Belt

Tensioner

26. Engine

REARVIEW

Generac* Power Systems, Inc.

Section 1 - General Information

QUIETPACT” 75D Recreational Vehicle Generator

GENERAL

INFORMATION

1.2 GENERATOR APPLICABILITY

These generators have been designed and manufac
tured for supplying electrical power to recreational vehi

cles. You should neither modify the generator nor 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 a competent authority.

DANGER

For fire safety, the generator must have been

A

properly installed in compliance with NFPA 70 (lat

est edition), "National Electrical Code", Article
551, and NFPA 1192 (latest edition), "Standard for
Recreational Vehicles". 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, stan
dards, and Instructions.

You can use this generator to supply electrical power for

operating 120/240-volt, single-phase, 60-Hertz, AC elec

trical loads. These loads can require up to 7,500 watts

(7.5 kW) of power, but cannot exceed 62.5 AC amps of

current at 120 volts, or 31.2 AC amps at 240 volts.

1.4 GENERATOR AC CONNECTION SYSTEM

This generator is equipped with dual-stator AC power
windings. These two-stator windings supply electrical
power to customer electrical loads by means of a dual,
two-wire connection system. Note, however, that the
neutral is grounded.

The generator may have been installed so that it powers

120- and/or 240-volt AC electrical loads (Figure 1.1). It
can be rewired to connect 120-volt AC electrical loads
only. This procedure should be done by a Generac
Authorized Service Dealer or other qualified installer.
Refer to the installation portion of this manual for more
information.

Figure 1.1 - Connections for 120/240 Dual Voltage

NEUTRA^ <BLACK)

mm

•

-------

M. CAUTION Mr—

Do not overload the generator. Some installations

A

may require that electrical loads be alternated to

avoid overloading. Applying excessively high elec
trical loads may damage the generator and short
en its life. Add up the rated watts of all electrical

lighting, appliance, tool, and motor loads the gen

erator 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 opera
tion.

1.3 SAFETY

Before attempting to use the generator set, carefully
read the “Safety Rules” section of this manual. Comply
strictly with these rules to prevent accidents and dam
age to equipment and/or property. We suggest copying
and posting the “Safety Rules” in potential hazard areas
of the vehicle. Stress safety to all operators and poten
tial operators of this equipment.

-?

^"TJUUUULT^ GROUNDED ^JLiJLiJL^

NEUTRAL

1.5

SPECIFICATIONS

♦ 1.5.1 FUEL REQUIREMENTS

The generator is equipped with a diesel fuel system. Use
clean, fresh No. ID or No. 2D diesel fuel with minimum
Cetane number of 40. The diesel fuel must also conform
to American Society of Testing and Materials (ASTM)
specifications. Never use any dirty or contaminated fuel.
When adding fuel, DO NOT overfill the tank. Allow room
at the top of the tank for fuel expansion. Depending on
the installation, the generator may have either a sepa
rate fuel tank or “share” the vehicle’s engine fuel tank.

NOTE:

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

Also, appropriate care should be taken in applica
tions where extremely low ambient temperatures are
possible, to ensure the temperature of the diesel fuel
is not allowed to fall below levels where “gelling”
could occur

Generac® Power Systems, Inc.

GENERAL

INFORMATION

Section 1 - General Information

QUIETPACT™ 75D Recreational Vehicle Generator

♦ 1.5.2 FUEL CONSUMPTION (GÄL/HR)

Mode!

^gUIETMCT™^D

No Load Half Load Full Load

0^28

(145

0778

(004270-0)

♦ 1.5.5 ENGINE OIL REQUIREMENTS________________

Use a high-quality detergent oil with American Petroleum
Institute (API) classification “For Service CC.” Detergent
oils keep the engine cleaner and reduce carbon deposits.
Use oh having the following SAE viscosity rating, based on
the ambient temperature range anticipated before the next

Temperature Oil Grade (Recommended)

Above 100“ F (38° C) SAE 15W-40* or SAE 40

40° to 100° F (4.4° to 38° C)

Below 40° F (4.4° C)

SAE 10W-30 or SAE 30

SAE 5W-20 or 5W-30

♦ - in units from the factory

Crankcase and oil filter capacity is approximately 3.5 L
or 3.7 U.S. quarts. Do NOT use special additives. See
Sections 3.1 and 3.2 (Page 12) for oil level checking and
changing procedures.

^ 1.5.4 COOLANT_______________________________

Use a 50:50 mixture that is half low silicate, ethylene
glycol base antifreeze and half soft water. Use only soft
water and only low silicate antifreeze. If desired, you
may add a high-quality rust inhibitor to the recom
mended coolant mixture. When adding coolant, always
add the recommended 50-50 mixture.

DANGER

Do not remove the radiator pressure cap while

A

the engine is hot; otherwise, serious burns from
boiling liquid or steam could result.

Ethylene glycol base antifreeze is poisonous. Do

A

not use your mouth to siphon coolant from the
radiator, recovery bottle, or any container. Wash
your hands thoroughly after handling. Never
store used antifreeze in an open container
because animals are attracted to the smell and
taste of antifreeze, even though it is poisonous to
them.

-------

Jk CAUTION Jk

Do not use any chromate base rust inhibitor with
ethylene glycol base antifreeze; or else, chromium
hydroxide ("green slime") will form and cause
overheating. Engines that have been operated

with a chromate base rust inhibitor must be

chemically cleaned before adding ethylene glycol
base antifreeze. Using any high-silicate antifreeze
boosters or additives will also cause overheating.
We also recommend that you DO NOT use any
soluble oil inhibitor for this equipment.

----------------

A 1.5.5 ENGINE

__________

___________________

Type of Engine............................................................ISM Diesel

Cylinder Arrangement ....................................................3, in-line

Displacement...................................................

Bore

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

Stroke

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

Compression Ratio
Combustion Chamber Type
Rated Horsepower
Cylinder Block
Number of Main Bearings

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

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

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

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

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

58.2 in^. (954 cc)

2.95 in. (75 mm)

2.83 in. (72 mm)

Pre -Combustion
13 @ 1,950 rpm

Cast Iron

Number of Teeth on Flywheel................................................104

Type of Governor

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

Mechanical, Fixed Speed

Fuel Filter..............................Full Flow Spin-On (Part # 69858)

Oil Filter

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

PuU Flow with Bypass Valve

(Part # 126-70939)
Oil Pressure
Type of Cooling System

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

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

Pressurized, Closed Recovery

29-71 psi

Cooling Method......................................................Liquid-cooled

Type of Cooling Fan
Coohng System Capacity

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

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

1.4 U.S. gals (5.3 L)

Centrifugal Puller

Air Cleaner..............................Disposable Filter (Part # C4880)

Starter.............................................................12-volt DC Electric

_

Recommended Battery.......................70 Ah, 360 Cold-cranking

Amps (Minimrtm ratings)

Maximum Cranking Current

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

220 Amps

Groimd Polarity................................................................Negative

A 1.5.6 GENERATOR

Rated Maximum Continuous AC Output at...

85“ F (29° C) Ambient

100° F (38° C) Ambient
120° F (49° C) Ambient

Rated Voltage

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

Rated Maximum Continuous AC Current at...

7,500 Watts

120 Volts......................................................................62.5 Amps

240 Volts......................................................................31.2 Amps

7.000 Watts

120 Volts......................................................................58.3 Amps

240 Volts......................................................................29.2 Amps

6.000 Watts

120 Volts......................................................................50.0 Amps

240 Volts......................................................................25.0 Amps

Phase....................................................................................Single

Rotor Speed at No Load

Number of Rotor Poles.................................................................2

Engine RPM

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

Rated AC Frequency
Battery Charge Voltage
Batteiy Charge Current

Weight........................................................................486 Pounds

Length........................................................36.6 inches (929 mm)

Width

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

Height .......................................................22.3 inches (567 mm)

*A11 units are reconnectable to 120-volt-only AC output.

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

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

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

7,500 Watts (7.5 kW)
.7,000 Watts (7.0 kW)
6,000 Watts (6.0 kW)

120/240 Volts AC*

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

3,780 rpm

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

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

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

14 Volts DC

2 Amps (max)

23.8 inches (604 mm)

23-to-l

4

1,950

60 Hz

Generac* Power Systems, Inc.

Section 2 - Operation

QUIETPACT™ 75D Recreational Vehicle Generator

OPERATION

6d

2.1 GENERATOR CONTROL PANEL

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

Figure 2.1 - Generator Control Panel

LINE
BREAKER

NOTE: PANEL SHOWN WITHOUT WEATHER-SEAL BOOTS.

4 2.1.1 HOURMETER

This indicates the length of time the engine/generator
has operated, in hours and tenths of hours. Use
the hourmeter to ensure that the periodic mainte
nance tasks for your generator are completed on a
timely basis.

♦ 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’s center position is the RUN position.

♦ 2.1.3 FUSE

The 14-amp fuse protects the engine’s DC control cir
cuit against electrical overload. If the fuse element
has melted open due to overloading, the engine can
not be cranked. If you must replace the fuse, use only
an identical replacement (i.e., SFE-14).

--------

ik CAUTION

If a fuse element melts, you should find the

A

cause of the overload before replacing the fuse.

A

FUSE

PREHEAT

^ 2.1.4 LINE BREAKER

The line (i.e., main) breaker protects the generator’s
AC output circuit against overload and provides a
method of turning OFF the generator’s 120/240-volt
AC output to the vehicle circuits. The QUIETPACT™
75D has two 35-amp breakers.

NOTE:

Refer to Section 1.4, “Generator AC Connection
System,” (Page 5). Individual installations will dif
fer. If an overload occurs, the dual breakers will
open the ungrounded (i.e., hot) stator leads (11
and 44 in Figure 1.1, Page 5). When the generator
has been connected for 120 volts only (Figure

2.16, Page 31], the line breakers will operate inde
pendently on the ungrounded (i.e., hot) stator
leads (11 and 33 in Figure 2.16, Page 31).

A 2.1.5 PREHEAT SWITCH

_____________________

The diesel engine is equipped with glow plugs, one
for each cylinder. When you press the preheat switch,
the glow plugs heat the engine combustion chamber,
allowing for quicker starts when the engine is cold.
Pressing the preheat switch also operates the fuel
pump.

2.2 OPTIONAL REMOTE START/STOP

This generator is equipped with a plug-in connector
that can be interfaced with an optional remote panel
provided inside the vehicle. This option allows you to
start and stop the generator conveniently from with
in the vehicle. Refer to Part II - Installation
Instructions, Section 2.8, for details on the remote
start/stop option.

2.3 BEFORE 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.

♦ 2.3.1

INSTALLATION

Generator installation must have been properly com
pleted so that it complies with all applicable codes,
standards, and regulations and with the manufactur
er's recommendations.

_________________________

Generac* Power Systems, Inc.

OPERATION

6i>

Section 2 - Operation

QUIETPACT™ 75D Recreational Vehicle Generator

♦ 23.2 ENGINE LUBRICATION

Before starting the engine, have the engine crankcase

properly serviced with the recommended oil. Refer to
Section 1.5.3 (Page 6) and Sections 3.1 and 3.2 (Page

12) for oil servicing procedures and

recommendations.

-------

ik CAUTION M

Any attempt to crank or start the engine before

A

you have properly serviced it with the recom

mended oil may result in an engine failure.

4 233 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 “share” the
vehicle’s engine fuel tank.

Some installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter
than the vehicle’s engine pickup tube. Such an

arrangement causes the generator engine to “run
out of fuel”, while adequate fuel for the vehicle
engine remains in the tank.

# 23.4 COOLANT LEVEL

Check the engine coolant level prior to initial use and
at recommended intervals. Refer to Section 1.5.4,
“Coolant” (Page 6), and Section 3.8, “Engine Coolant”

(Page 14), for procedures and recommendations.

» 23.5 COOLING AND VENTILATING AIR

Air inlet and outlet openings in the generator com
partment must be open and unobstructed for con
tinued proper operation. Without sufficient cooling
and ventilating airflow, the engine/generator may

overheat, causing engine shutdown and damage to

the generator.

♦ 2.3.6 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.

DANGER

The generator engine releases DEADLY carbon

A

monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concen

trations, 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 MONOX

IDE POISONING ARE (a) inability to think coher
ently, (b) vomiting, (c) twitching muscles, (d)
throbbing temples, (e) dizziness, (f) headaches,
(g) weakness, and (h) sleepiness. IF YOU FEEL
ANY OF THESE SYMPTOMS, MOVE INTO FRESH
AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP.

2.4 STARTING 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 start the generator from either the generator con
trol panel or from the optional remote panel, proceed
as follows:

1. Turn OFF electrical loads using the means pro
vided in 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-line
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, stabi
lized, and warmed up.

2. If the engine is cold, press the Preheat switch for
a maximum of 15 to 30 seconds.

3. While pressing the Preheat switch to crank the

engine, hold the engine Start/Stop switch in the
START position. When the engine starts, release
the switches.

Generac® Power Systems, Inc.

Section 2 - Operation

QUIETPACT™ 75D Recreational Vehicle Generator

OPERATION

Òi>

-------

Mk CAUTION Jk----------------

If the engine does not start after it has been

^ cranking for 15 seconds, release the Start/Stop

switch, wait 15 seconds, and try 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.

Turn ON electrical loads, using the means

5.
provided in your vehicle (such as, a main-line cir

cuit breaker or transfer switch).

2.5 STOPPING THE GENERATOR

1. Turn OFF all electrical loads, using the means
provided in your vehicle (such as, a main-line cir
cuit breaker or transfer switch).

2. Let the generator run at no-load for a few minutes,
to stabilize internal engine generator temperatures.

-

------

m CAUTION Mk

Do not stop the engine/generator immediately

A

after running under load. This can overheat
and damage the engine and/or generator.

3. Press and hold the Start/Stop switch in the STOP
position, until the engine shuts off.

----------------

2.6 APPLYING 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.

4^ 2.6.1 LETTING THE ENGINE STABILIZE

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

Electrical loads applied on the engine 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 no­load.

• 2.6.2 DQ NOT OVERLOAD THE GENERATOR

You can read the rated wattage/amperage capacity of
your generator on the generator data decal located
below the user control panel.

Applying electrical loads in excess of the unit’s rated
capacity may trip the line breaker or cause the

engine/generator to shut down.

To avoid overloading, add up the wattage of all con
nected electrical lighting, appliance, tool, and motor

loads. This total should not be greater than the gen
erator’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 time more watts of power for
starting than for running (for a few seconds during
motor starting). Be sure to allow for this when con
necting electrical loads to the generator. First, cal
culate 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.

• For the first two or three hours of operation, do not
apply electrical loads over 75 percent of the unit’s
rating.

2.7 PROTEaiON SYSTEMS

The engine has several safety switches that cause
it to automatically shut down, under the following

conditions: low oil pressure, high coolant tempera
ture, and engine overspeed. See Figure 2.2 (Page 10)
for the location of these devices. If automatic shut
down does occur, refer to “Troubleshooting Guide’’,
on page 37.

• 2.7.1 LOW OIL PRESSURE SWITCH

This switch is normally closed (N.C.) but is held open
by engine oil pressure during engine running. Should
operating oil pressure drop below approximately 10
psi, the switch contacts close, and the engine shuts
down automatically.

____________

• 2.7.2 HIGH COOLANT TEMPERATURE SWITCH

This normally-open (N.O.) thermostatic switch has a
sensing tip that is immersed in captive coolant.
Should the coolant temperature exceed approximate
ly 115° C (240° F), the switch contacts close, and the
engine shuts down automatically.

Generac* Power Systems, Inc.

OPERATION

Section 2 - Operation

QUIETPACT™ 75D Recreational Vehicle Generator

Figure 2.2 - Engine Protective Devices

HIGH COOLANT

LOW OIL

PRESSURE

TEMPERATURE

SWITCH

# 2.7.5 OVERSPEEO SHUTDOWN_______________

A DC control circuit board senses engine speed from

the frequency of the alternator AC output. Should the
alternator output frequency exceed approximately 72
Hertz (4,320 alternator rpm), circuit board action
initiates an automatic engine shutdown.

♦ 2.7.4 OVERVOLTAGE PROTEOiON

A solid-state voltage regulator (Figure 2.3) controls

the generator’s AC output voltage. This regulator sup
plies an excitation current to the rotor. By regulating
the rotor’s excitation current, the strength of its mag
netic field is regulated and, in turn, the voltage deliv
ered to connected electrical loads is controlled. When
the AC frequency is 60 Hertz, voltage is regulated at

120 volts (voltage-to-frequency ratio is 2-to-l).

Figure 2.3 - Solid-state Voltage Regulator

SENSING
(ALTERNATING CURKNT]

TO ROTOR
(DIRECT CURRENT)

FROM STATOR
EXCITATION mNDING
(AUERNATINSCURieiT)

The voltage regulator also incorporates a “voltage

surge protection circuit.” This circuit prevents trou
blesome surges in the generator AC output voltage.
Voltage surge is a common cause of damage to elec
tronic equipment.

2.8 ADDITIONAL INFORMATION

• 2.8.1 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 oil consumption and maxi
mize engine performance. During this 25-hour break-

in period, observe the following rules:

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

• After operating the unit for 25 hours, complete the
tasks recommended under Section 2.8.2 (Page

11).

• For the next 75 hours of 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 pis
ton rings, resulting in blowby and high oil con
sumption.

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

• 2.8.2 25-HQUR CHECK-UP

___________________

After the 25-hour break-in period, contact a Generac
Authorized Service Dealer for the following mainte
nance, for which the vehicle owner is responsible for
all charges;

• Change the engine crankcase oil and oil filter.

• Check all fluid levels (engine coolant, fuel,
battery electrolyte fluid).

• Visually inspect the unit for any leaks or loose
hardware.

• Inspect the exhaust tailpipe for any leaks or
damage.

• 2.33 AHENTION REQUIRED
AFTER SUBMERSIOM__________________

If the recreational vehicle generator has been sub
merged in water, it MUST NOT be started and oper
ated. Following any submersion in water, have a
Generac Authorized Service Dealer thoroughly clean
and dry the generator.

____________

i O Generac* Power Systems, Inc.

Section 3 - Maintenance

QUIETPACP* 750 Recreational Vehicle Generator

MAINTENANCE

# 2.8.4 OPERATION IN HIGH GRASS

______ _

OR BRUSH

__________________________

Never operate the generator while the vehicle is
parked over high grass, weeds, brush, leaves, or
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.

2.8.5 EFFEaS OF MOISTURE AND DIRT

Keep the generator set as clean and dry as possible.
Protect the unit against excessive dust, dirt, corrosive

vapors, road splash, etc. Permitting dirt and mois

ture to accumulate on generator windings will have
an adverse effect on the insulation resistance of those

windings.
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 reduces insu

lation resistance and will eventually cause problems.
Dirt will make the problem worse, since it tends to
hold moisture in contact with windings. Salt (as from
sea air) will also worsen the problem, since it tends
to absorb moisture from the air. Salt and moisture,

when combined, form a good electrical conductor.

3.1 CHECKING THE ENGINE OIL

LEVEL

After the 25-hour break-in period, check the engine

crankcase oil level every eight hours of operation, or
at least once daily, before using the generator. For oil
capacities and requirements, see “Engine Oil
Requirements,” Section 1.5.3 (Page 6). To check the
engine oil level, proceed as follows (see Figure 3.1):

Be sure the generator is as leveled as possible.

1.

Remove the dipstick, and wipe it dry with a clean,

2.

lint-free cloth.
Install the dipstick, and fully seat the T-handle;

3.
then, remove it again. The oil level should be at
the dipstick “Full” mark.

If necessary, remove the oil fill plug and slowly

4.
add oil until it reaches the dipstick “FULU mark.
DO NOT FILL ABOVE THE “FULL’ MARK.

-------

ik CAUTION Mk

Never operate the engine with the oil level

A

below the "ADD" mark on the dipstick. Doing

this could damage the engine.

5. Install the oil-fill plug and the dipstick before
operating the engine.

----------------

Figure 3.1 - Oil Maintenance Features

OIL FILL
OPENING AND PLUG

OIL DIPSTICK

{PANEL TRANSPARENT

3.2 CHANGING THE ENGINE OIL

AND/OR OIL FILTER

Change the engine oil and oil filter after the first 25
hours of operation (after the 25-hour break-in peri
od, see Section 2.8.1, Page 10). See the “Service
Schedule,” Section 3.13 (Page 16), for subsequent oil
and filter changes. Change the oil more frequently, if
operating consistently under heavy load or at high
ambient temperatures.

To change the oil and/or oil filter, proceed as
follows (see Figure 3.1):

Run the engine until it is thoroughly warmed up

1.

(for at least five minutes) then shut OFF
the engine.
Immediately after the engine shuts OFF, remove

2.

the front service door, located beneath the unit,
by retracting the two latches and pivoting the
door downward.

Remove the air filter (see Section 3.3).

3.
Remove the oil-drain plug and drain the oil into a

4.
suitable container. Removing the oil-fill plug will
allow the crankcase to drain faster.

After the oil has drained, replace the oil-drain

5.

plug.

Go to step 9 if changing oil only.
With the oil drained, remove the old oil filter by

6.

turning it counterclockwise.

Apply a light coating of clean engine oil to the gas

7.
ket of the new filter.

Screw the new filter on by hand, until its gasket

8.

hghtly contacts the oil filter adapter. Then, tight
en the filter an additional 3/4 to one turn.

Generac® Power Systems, Inc. 1

1

MAINTENANCE

Section 3 - Maintenance

QUIETPACT™ 75D Recreational Vehicle Generator

9. Remove the dipstick, and wipe it dry with a clean,
lint-free cloth. This will be used later to check the
oil level.

10. Remove the oil-fill plug, and slowly add the prop
er type and amount of recommended oil (see
Section 1.5.3, Page 6). Periodically use the dip
stick to check the oil level and continue to fill the
crankcase until the oil reaches the dipstick
“FULL’ mark. DO NOT FILL ABOVR THE “FULL’
MARK.

11. Install the oil-fill plug and the dipstick.

12. Reinstall the air filter.

13. Reattach the front service door; make sure the
latches are fully engaged.

14. Start the engine, and check for leaks.

NOTE:

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

3.3 SERVICING THE ENGINE

AIR FILTER

To access the engine air filter (Figure 3.2, Page 13),
remove the front service door, located beneath the
unit, by retracting the two latches and pivoting the
door downward. Loosen the hose clamp at the base
of the air filter and remove the filter. Place the hose
clamp on the new filter and install it, making sure it
is positioned properly before reattaching the service
door. Make sure the service door latches are fully
engaged.

spark arrestor screen, but are of the more efficient
“toroid” or “swirl” t5Tpe. To remove carbon and com
bustion deposits from the muffler, proceed as follows
(see Figure 3.3):

1. Place the unit above a noncombustable surface,
and ensure that the generator exhaust piping is
cool.

2. Remove the two screws holding the spark
arrestor access plate to the rear floor pan.

3. Remove the spark arrestor access plate and gasket.

4. Remove the hex pipe cap from the end of the
spark arrestor cleanout pipe.

5. Thread on a 3/8” NPT pipe coupling and pipe
nipple to extend the cleanout pipe at least 10
inches (250 mm) below the rear floor pan; addi
tional piping may be added to direct the muffler
exhaust away from the cooling air discharge flow
beneath the unit.

6. Start and run the engine for approximately 15
minutes.

7. Shut down the engine, and allow the piping to
cool.

8. Remove the 3/8” NPT coupling and piping.

9. Apply a graphite-base, anti-seize compound to
the cleanout pipe threads.

10. Reinstall the hex pipe cap, spark arrestor access
plate, gasket, and two screws.

--------

Ml warning M

The exhaust system of this product gets extreme

A

ly hot and remains hot after shutdown. High
grass, weeds, brush, leaves, etc., must remain

clear of the exhaust. Such materials may ignite
and burn from the heat of the exhaust system.

----------------------

Figure 3.2 - Engine Air Filter

(PANEL TRANSPARENT

See the “Service Schedule,” Section 3.13 (Page 16),
for recommended air cleaner maintenance.

3.4 SPARK ARRESTOR MUFFLER

The exhaust muffler supplied with the QUIETPACT™
75D is a spark arrestor type. Generac exhaust muf
flers for recreational vehicle generators do not have a

1

a Generac*

Power Systems,

Inc.

----A WARNING A

Failure to provide and maintain a spark arrestor
may be in violation of the law. If this generator

is used on any forest-covered, brush-covered,
or grass-covered unimproved land, the vehicle
owner or operator must maintain the spark
arrestor in good condition, in the state of
California, the preceding is required by law
(Section 4442 of the California Public Resources
Code). Other states may have similar laws.

Federal laws apply on federal lands.

-------

Æ WARNING Æ

Be sure to reinstall the hex pipe cap tightly to the

A

spark arrestor cleanout pipe. Vibration could cause
a loose cap to fall out, resulting in hot engine
exhaust being drawn through the centrifugal cool

ing fan and out beneath the unit. This could result

in damage to the generator or in discharge of hot

exhaust sparks beneath the unit.

-----

--------------

Section 3 - Maintenance

QUIETPACT“ 75D Recreational Vehicle Generator

MAINTENANCE

Figure 3.3 - Spark Arrestor

Muffler Maintenance

3.5 CLEANING THE GENERATOR

Keep your generator as clean and as dry as possible.
Dirt and moisture that accumulate on internal gener
ator windings have adversely affect insulation resis
tance.

Periodically, clean the generator’s exterior surfaces.
A soft brush may be used to loosen caked-on dirt.
You can use a vacuum system or dry, low-pressure air
to remove any accumulations of dirt. The generator is
housed inside an all-weather enclosure; clean the
enclosure with a soft, damp cloth or with sponge and
water.

Once each year, have the generator cleaned and
inspected by a Generac Authorized Service Dealer.
Service technicians will use dry, low-pressure air to
clean internal windings. Parts inside the control con
sole should be cleaned and inspected at this time, as
well.

Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.

------

Mk OiUTiofsi Jk

Do NOT use a forceful spray of water to clean

A

the generator. Water will enter the generator

interior and cause problems, and may also
contaminate the generator fuel system.

--------------

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

• Have the state of charge and condition checked by
a Generac Authorized Service Dealer.

NOTE:

Servicing of the battery is to be performed or
supervised by knowledgeable personnel, accord
ing to the required precautions. Keep unautho
rized 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 batter
ies release 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 explo
sion. 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 tool or equip
ment near the battery. Discharge static electrici

ty from your body before touching the battery

by first touching a grounded metal surface.

A battery presents a risk of electrical shock and

A

high short-circuit current. The following precau
tions are to be observed when working on bat
teries:

• Remove watches, rings, and 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 connect
ing, or disconnecting, battery terminals; and

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

-A WARNING A-

3.6 BATTERY MAINTENANCE

All lead-acid batteries will discharge when not in use.
The generator battery should be inspected per the
“Service Schedule,” Section 3.13 (Page 16). The fol
lowing procedure should be used for inspection:

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

Do not open or mutilate the battery. Released

A

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

A

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;

• Immediately wash with water ail skin areas that

Generac® Power Systems, Inc. 1 3

MAINTENANCE

Section 3 - Maintenance

QUIETPACT™ 75D Recreational Vehicle Generator

come into contact with the electrolyte.

• If the electrolyte contacts the eyes, immediately

flush eyes thoroughly with water, and seek med

ical attention.

• 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) of water. The bicar
bonate 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.

3.7 COOLING SYSTEM

Air intake and outlet openings in the generator com
partment must be open and unobstructed for contin
ued proper operation. Avoid obstructions, such as,
high grass, weeds, brush, leaves, and snow.

Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down.

3.8 ENGINE COOLANT

Check the coolant level in the coolant recovery tank
at least once daily or prior to use. Add the recom
mended coolant mixture (see Section 1.5.4, Page 6),
as necessary: the tank should be kept within the lev
els indicated on the adjacent decal. If desired, you
may add a high-quality rust inhibitor to the recom
mended 50-50 coolant mixture. If added consistently,
the recommended mixture will protect the unit
against freezing temperatures.

Periodically remove the radiator pressure cap, locat
ed behind the access cover above the user control
panel, to make sure the coolant recovery system is
functioning properly. Coolant should be at the bottom
of the radiator filler neck. If the coolant level is low,
inspect the gasket in the radiator pressure cap.
Replace the cap, if necessary. To have the pressure
cap tested, contact a Generac Authorized Service
Dealer. Inspect both the cooling system and coolant
recovery system for leaks.

DANGER

Do not remove the radiator pressure cap while

the engine is hot; otherwise, serious burns
from boiling liquid or steam could result.

Ethylene glycol base antifreeze is poisonous.

Do not use your mouth to siphon coolant from
the radiator, recovery bottle, or any container.
Wash your hands thoroughly after handling.

Never store used antifreeze in an open contain

er because animals are attracted to the smell

and taste of antifreeze, even though it is poiso

nous to them.

-------

-Jà CAUTION Jk

Do not use any chromate base rust inhibitor

A

with ethylene glycol base antifreeze; other
wise, chromium hydroxide ("green slime") will
form and cause overheating. Engines that have

been operated with a chromate base rust
inhibitor must be chemically cleaned before

adding ethylene glycol base antifreeze. Using
any high-silicate antifreeze boosters or addi
tives will also cause overheating. We also rec
ommend that you DO NOT use any soluble oil

inhibitor for this equipment.

---------------

-

3.9 MAJOR SERVICE MANUAL

To obtain a service manual for your generator, con
tact Generac or your nearest Generac Authorized
Service Dealer. Make sure to identify your MODEL
NUMBER and SERIES.

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. If you cannot exercise the generator every
seven days, and it is to be out of service longer than
30 days, see Section 3.12.

3.12 OUT-OF-SERVICE PROCEDURE

♦ 3.12.1 REMOVAL FROM SERVICE

Prepare the generator for storage as follows:

1. Start the engine and let it run until it is thor
oughly warmed up (at least five minutes), then
shut off the engine.

2. While the engine is still warm from running,
drain the oil completely (see Section 3.2, Page

12). Refill the crankcase with the recommended

oil (see Section 1.5.3, Page 6).

3. Attach a tag to the engine, indicating the viscosity
and classification of the oil in the crankcase.

4. 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.

5. Clean and wipe the entire generator.

______________

1 4 Generac* Power Systems, Inc.

QUIETPACT™ 75D Recreational Vehicle Generator

♦ 3.12.2 RETURN TO SERVICE

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 1.5.3, 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 incor
rectly.

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.

Section 3 - Maintenance

MAINTENANCE

Generac* Power Systems, Inc. 1 5

Section 3 - Maintenance

MAINTENANCE

QUIETPACT™ 75D Recreational Vehicle Generator

3.13 SERVICE SCHEDULE

be performed by your nearest Generac Authorized Service Dealer.

SYSTEM/COMPONENT

X = Action

R = Replace/Adjnst as Needed

* = To Be Completed by a

Generac Authorizeci
Service Dealer.

FUEL

Fuel level

Fuel lines and connections*

Fuel Filter*

LUBRICATION

Oil level
Oil

Oil Filter

Oil line leakage*

COOLING

Engine cooling system*

Coolant level

Coolant*

Enclosure louvers

EXHAUST

Exhaust system
Retorque Exhaust Manifold*
Clean out Muffler/Spark Arrestor

BATTERY

Electrolyte fluid level
Charge and condition

FAN/ALTERNATOR BELTS

Tension and condition* | X

ENGINE

Retorque cylinder head*

Retorque intake manifold*

Starter motor*
Air filter

Compression*
Valve clearance*

Governor*

Safety devices*

Injection system*

GENERAL

Overall condition

Exercise system

COMPLETE TUNE-UP*

ATTENTION: It is recommended that all service work

PROCEDURE

Inspect Change

Clean D - Daily W = Weekly

X

X

X

X

X

X

X

X

X

X

X

X

X
X

X

X
X

R X

R

X
X
X
X

R EVERY 500 H
X
X

R EVERY 750 H
X R
X
X

R EVERY 750 H

R EVERY 750 H

X X AFTER 25-H BREAK-IN, W

X

X X Y

FREQUENCY

M = Monthly Y = Yearly
H = Hours

AFTER 25-H BREAK-IN,

D / BEFORE USE

AFTER 25-H BREAK-IN,

EVERY 250 H / 6 M
EVERY 250 H / 6 M

EVERY 8 H/D

AFTER 25-H BREAK-IN,

EVERY 250 H / 6 M

AFTER 25-H BREAK-IN,

EVERY 250 H / 6 M

EVERY 100H

AFTER 25-H BREAK-IN,

EVERY 100 H/M

AFTER 25-H BREAK-IN,

D / BEFORE USE

EVERY 500 H / Y

EVERY 250 H / 6 M

EVERY 100 H/M

EVERY 750 H

EVERY 150 H/Y

AFTER 25-H BREAK-IN, W

W, EVERY 250 H / 6 M

1 EVERY 750 H

EVERY 750 H
EVERY 750 H
EVERY 750 H

EVERY 750 H

EVERY 750 H

W

1 в Generac® Power Systems, Inc.

PART II -

INSTALLATION

INSTRUaiONS

DANGER

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

SAFETY RULES

Safety Rules

QUIETPACT™ 75D Recreational Vehicle Generator

DANGER: For Jire safety, installation of a generator into a recreational vehicle must comply

strictly with NFPA 70 (latest edition), “National Electrical Code”, Article 551, and NFPA 1192

(latest edition), “Standardfor Recreational Vehicles”. In addition, installation must comply with

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the manufacturer’s instructions and recommendations.

NOTICE TO INSTALLER

These Installation Instructions have been published
by Generac to aid in the installation of the products

described in this manual. Generac assumes that
installation personnel are familiar with the procedures
for installing such products, or similar products that

Generac manufactures. Generac also assumes that

personnel have been trained in the recommended

installation procedures for these products and that

such training includes (a) use of common hand tools,

(b) use of special Generac tools, and (c) use of any

tools and/or equipment from other suppliers.

Generac cannot possibly know of, nor advise the

recreational vehicle trade of, all conceivable methods,

procedures, or techniques by which to perform an

installation. Nor can Generac anticipate every possi

ble hazard that might result from each installation

method, procedure, or technique. Generac has not

undertaken any such wide evaluation. Therefore,

people who use a method, procedure, or technique

that Generac does not specifically recommend must

first completely satisfy themselves that their safety,

the safety of the vehicle's occupants, and the prod

uct's safety are not endangered by the method, pro

cedure, or technique selected.

Information, illustrations, specifications, etc., con

tained in these Installation Instructions are based on

the latest information available at the time of publi

cation. Every effort has been expended to be sure that

such data are both accurate and current. However,

the manufacturer reserves the right to change, alter,

or otherwise improve this product at any time, with
out prior notice.

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.
Parts of the generator are rotating and/or hot

during operation. Exercise care near running
generators.

Potentially lethal voltages are generated by

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these machines. Ensure ail steps are taken to

render the machine safe before attempting to

work on the generator.

M. GENERAL HAZARDS ^

• For safety reasons, Generac recommends
that the installation, initial startup, and mainte
nance of this equipment is carried out by a
Generac Authorized Service Dealer.

• The engine exhaust fumes contain carbon monox
ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust sys
tem must be installed properly, in strict compli
ance with applicable codes and standards.
Following installation, you must do nothing that
might render the system unsafe or in noncompli
ance with such codes and standards. The genera
tor compartment must be completely vapor-sealed
from the vehicle interior. There must be no possi
bility of exhaust fumes entering the vehicle interi
or. Never operate this equipment with a leaking or
defective exhaust system.

• 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 ven
tilating air is critical to correct generator oper
ation and is required to expel toxic fumes and
fuel vapors from the generator compartment.

Without sufficient cooling airflow, the
engine/generator quickly overheats, which caus
es 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.

• Before performing any maintenance on the genera

tor, disconnect its battery cables to prevent acci
dental startup. First, disconnect the cable from the
battery post, indicated by a NEGATIVE, NEG, or

(-). 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 con
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.

• Never insert any tool or other object through open

ings in the generator interior, even if the unit is not
running. You might seriously injure yourself or
damage the equipment.

1 S Generac* Power Systems, Inc.

Safety Rules

QUIETPACT" 75D Recreational Vehicle Generator

SAFETY RULES

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ELECTRICAL HAZARDS

The generator covered by this manual produces

dangerous electrical voltages that 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 barri

ers 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.
During installation onto the vehicle, properly

ground (bond) the generator either by solid mount
ing to the vehicle frame or chassis, or by means of
an approved bonding conductor. DO NOT connect
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.

If the vehicle electrical circuits can be powered by

any other source of electricity (such as, a “dockside”
power receptacle), there must be no possibility of
connecting the different power sources to the vehi
cle’s circuits at the same time. The dockside (utility)
power source must be positively isolated from the
vehicle’s circuits whenever the generator is operat
ing. Failure to isolate the vehicle’s circuits from the
dockside power supply when the generator is run
ning may result in damage to the generator or in
serious injury or death to dockside (utility) power
workers due to backfeed of electrical energy.

In case of an 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 noncon
ducting implement, such as, a rope or board, to
free the victim from the live conductor. If the vic
tim is unconscious, apply first aid, and get
immediate medical help.

Never wear jewelry when working on this equip
ment. Jewelry can conduct electricity, resulting in
electric shock, or may get caught in moving com
ponents, causing injury.

A

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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 estab

lished. 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 noncom
pliance with the aforementioned codes, stan

dards, 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 per
taining to fire extinguishers, consult your local fire
department.

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no com
bustible materials are left in the generator com

partment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surround
ing the generator clean and free from debris.

All fuel types are potentially FLAMMABLE and/or

EXPLOSr\^ and should be handled with care.
Comply with all laws regulating the storage and han
dling of fuels.

Fuel supply lines must be properly installed, purged

and leak-tested according to applicable fuel-gas
codes, before placing this equipment into service.
There must be no possibility of fuel vapors enter
ing the vehicle interior.

You are required to install an approved, flexible,

nonconductive fuel line between the generator fuel
connection point and the rigid fuel lines.

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Generac* Power Systems, Inc. 1 3