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

A

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

A

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

A

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

A

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.

A

A

Generac* Power Systems, Inc. 1 3

GENERAL

INFORMATION

Section 1 - General Information

QUIETPACT" 75D Recreational Vehicle Generator

1.1 PURPOSE AND SCOPE

OF THE MANUAL

These Installation Instructions have been prepared

especially for the purpose of familiarizing installers
and owners of the applicable equipment with the
product's installation requirements. Give serious
consideration to all information and instructions in
the manual, both for safety and for continued reliable
operation of the equipment.

Because of the different recreational vehicle models
and the variations between the models, it would be
extremely difficult, if not impractical, to provide
detailed instructions for every possible installation.
For that reason, instructions and illustrations in this
manual are general in nature. Illustrations are not
intended to serve as detailed installation blueprints.

The installation should comply strictly with all
applicable codes, standards, and regulations pertain
ing to the installation and use of this product. If any
portion of this manual appears to be in conflict with
such codes, standards, or regulations, the applicable

codes, standards, or regulations must take prece
dence over the manual.

1.2 SAFETY

Before handling, installing, operating, or servicing

this equipment, carefully read the “Notice to
Installer” and “Safety Rules” on Pages 18 and 19.
Comply with all safety rules to prevent death, per
sonal injury, or damage to equipment and/or proper
ty. Stress safety to all installers, operators, and ser

vice technicians who work on this equipment.

Canadian Standards Association, Housing and
Constructions Materials Section, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada, M9W 1R3.

1.4 EQUIPMENT DESCRIPTION

Instructions and information in this section pertain to
Generac liquid-cooled generators, designed specifically
for installing in recreational vehicles. The QUIETPACT
75D operates 120/240-volt, single-phase, 60-Hertz, AC
electrical loads that require up to 62.5 amps at 120
volts or 31.2 amps at 240 volts.

1.5 GENERATOR ENGINE

OPERATING SPEED

The generator’s two-pole revolving field (rotor) is dri

ven by a three-cylinder, 1.0-liter diesel engine. The

generator supplies 120/240 volts AC at 60 Hertz,

when the rotor is operating at 3,600 rpm. Engine

speed is held nearly constant by a mechanical, fixed
speed governor at 1,950 rpm.

1.6 GENERATOR AC

CONNECTION SYSTEM

The generator is equipped with dual stator power
windings, as shown in Figure 1.1.

Figure 1.1 - Connections for 120/240 Dual

Voltage

CRED> neutral ( BLACK)

1.3 STANDARDS BOOKLETS

Installation, use, and servicing of this equipment
should comply strictly with published standards, as

well as the manufacturer's recommendations. The

following standards booklets (latest revision) are
available from the sources indicated:

NFPA 1192, “Standard for Recreational Vehicles”

1.

(replaces ANSI A119.2/NFPA 501C), available
from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

NFPA 70, “NFPA Handbook of the National
Electric Code,” available same as Item 1.

ANSI/RVLA EGS-1, “Engine Generator Sets for

Recreational Vehicle Safety Requirements”, ava­ialable from the Recreational Vehicle Industry
Association, 1896 Preston White Drive, Reston,
VA 22090.

California Administrative Code, Title 25, avail

4.
able from the State of California, Documents
Section, PO. Box 1015, North Highlands,
CA 95660.

CSA Electrical Bulletin 946, available from the

5.

20 Generac® Power Systems, Inc.

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• The AC connection system uses a GROUNDED
neutral. A separate green ground wire is connected
to the recreational vehicle’s junction box.

• For this QUIETPACT™ unit, each stator winding can
support 120-volt, 60-Hertz, AC electrical output
(3,600 rpm). When the two stator windings are con
nected in series, the unit can generate an output of
240 volts AC.

NOTE:

Do NOT connect loads in excess of circuit

breaker ratings.

Section 1 - Generai Information

QUIETPACT“ 75D Recreational Vehicle Generator

Major Features and Dimensions — Drawing No. D2650

Figure 1.2 - Major Features and Dimensions

GENERAL

INFORMATION

INSTALLATION

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

2.1 LOCATION AND SUPPORT

• 2.1.1 GENERATOR LOCATION

The most desirable location for the generator set is
between the vehicle's main frame members.

Many recreational vehicles have been factory­equipped with an area for the generator set. Some
may even have a generator compartment provided by
the vehicle manufacturer.

Plan the generator location based on the following:

• The generator set must be installed on a frame
work that is part of the recreational vehicle, as out
lined in Section 2.1.2.

• The location must provide an access opening that
is large enough to permit generator removal

(unless the generator is to be removed from under

neath the supporting framework).

• The location must provide easy access to frequent
ly serviced components, such as, filters, oil drains,
and other common maintenance parts.

• The location must provide sufficient room to
allow minimum clearances for air circulation. If
sound insulation is to be used on the compart
ment walls and ceiling, the minimum recom
mended clearance applies to the space between
the generator and such insulation.

• The location must provide adequate cooling and
ventilating airflow for the generator, without a great
deal of work and expense.

_______________

• Whether the generator is mounted above the hori
zontal support tubing or suspended below the tub
ing, the supporting frame used must be structural
ly sound.

• If the generator cannot be bolted directly to
the supporting frame or support tubing, consider
using additional tubing, angle brackets
or other supports to give the supporting frame suf
ficient strength.

4 2.1.3 SUSPENDED MOUNTING

__________ ______

If you are going to suspend the generator below the
horizontal support tubing, the suspension method
you use with the vehicle frame members must (a) be
able to support the weight of the generator AND (b)
provide sufficient restraint for the generator. One t3rp­ical suspended mounting system is shown in Figure

2.1. The location of a suspended mounting system
must be carefully planned, keeping the following gen
eral rules in mind:

• Protect the generator against road splash and debris.
Baffles or splash guards may be required to protect
certain areas of the generator. To make sure the gen
erator is adequately protected, road-test the installa
tion through mud, water, and slush.

Figure 2.1 - Typical Suspended Mounting System

4 2.1.2 GENERATOR SUPPORT

___________

_ _

The generator must be securely attached to a metal
framework that has been affixed to the vehicle frame
structure by bolting or welding. The metal framework
on which the generator will rest, and which will restrain
the generator set, should consist of at least two hori
zontal beams. These beams should consist of (a) 1-1/2­inch square, 11-gauge steel tubing OR (b) 1-1/2-inch,

11-gauge angle iron.

The generator can be installed so that it sits on top of
the horizontal support tubing, if the vehicle design
permits. Another method is to suspend the generator
below the horizontal support tubing by means of suit

able, structurally-sound metal framework. The fol
lowing general rules apply:

• Vehicle construction MUST be capable of support
ing the weight of the generator.

22 Generac* Power Systems, Inc.

SUPPORT
BRACES

The installer must make certain that the selected

location will permit adequate cooling and ventilat
ing airflow.

Section 2 - Installation

QUIETPACF“ 75D Recreational Vehicle Generator

INSTALLATION

♦ 2.1.4 GENERATOR RESTRAINT

________________

Use four 3/8"-16 hardened steel bolts (Grade 5) to fas

ten the generator to the supporting frame or the sup

port tubing. These bolts must pass through (a) the gen

erator mounting base, (b) the compartment floor (if a

compartment is used), and (c) the supporting frame
work (Figure 2.2). All bolts must be long enough so
that, when tight, they engage at least 3/8” of an inch [9.5
millimeters]. Refer to Section 2.2 for the location of the
generator mounting holes.

Figure 2.2 - Typical Generator Restraint

METAL LINED

1/2 INCH THICK

2.2 GENERATOR COMPARTMENTS

Whether the generator set is being installed inside a

compartment specifically manufactured to house a gen
erator or inside a compartment that the installer con
structs, the compartment MUST meet certain specifi

cations, as outlined in the following sections:

» 2.2.1 COMPARTIVIENT CONSIRUaiON

• The generator compartment should be either
constructed of, or lined with, 26-gauge galva
nized steel.

NOTE:

Aluminum is NOT an acceptable alternative
to galvanized steel due to aluminum’s low
melting point.

• If the compartment is lined with galvanized steel, it
may be constructed of any material. Generac rec
ommends that the compartment be constructed of

1/2-inch thick plywood (not strandboard), with the
floor made of a double thickness of 1/2-inch ply
wood, having the grain of the wood at cross section
for added strength (Figure 2.3).

Figure 2.3 - Typical Compartment Construction

CROSS-SECTiONVlEW METALLISING

• If constructing a compartment, line the exterior
(underside) of the compartment floor with 26-

gauge galvanized steel.

• All seams, splices, and joints of the compartment

walls (unless vapor-tight by design) should
be caulked to prevent poisonous, flammable, or
explosive vapors from entering the vehicle interior.

NOTE:

Caulking must be done so that the caulking materi
al will stay in place permanently. Pressing materials
such as, putty tape, onto joints and seams is NOT
acceptable. A high-quality silicone rubber base
sealant is recommended.

• Holes and openings made in the compartment
walls to allow for the passage of electrical conduit,
conductors, hoses, cables, etc., into the vehicle liv
ing area must be sealed vapor-tight with silicone
rubber base sealant.

• If a flexible metal conduit is used, it must be sealed
internally at the end, where it terminates inside
the compartment’s electrical junction box.

NOTE:

Flexible metal conduit, due to its unique con
struction, is NOT vapor-tight along its entire

length.

Generac* Power Systems, Inc. 23

INSTALLATION

Section 2 - Installation

QUIETPACT“ 75D Recreational Vehicle Generator

Seams and joints of the galvanized steel (whether

used as a liner or for the compartment itself) must
be lapped and mechanically secured. Such seams
may be manufactured, welded, bolted, riveted, or
screwed. Manufactured lock seams are shown in
Figure 2.4. Installer-constructed compartments
typically utilize a standard lap joint.

Figure 2.4 - Types of Lock Seams

ЮШ LOCKED STANDING

GORDON SEAM

Ч ДГ

I

■ ■ OFF SET

DOUBLE LOCK

I

DOUBLE

SEAM

ACME LOCK

LOCK SEAM

T

STANDABO LAP JOINT

After the compartment has been metal -lined and

vapor-sealed, line the compartment interior walls
and ceiling with an approved, nonflammable
sound-insulating material. See Section 2.2.2.

DANGER

Do not install any flammable material directly
above or around the compartment. Heat,
transferred through the compartment structure,
may be sufficient to ignite, char, or discolor
seat cushions, fiberboard, and other flammable
materials. You may need to use approved,
nonflammable insulating materials in high
temperature areas.

♦ 2.2.2 SOUND INSULATiNG IViATERIALS

Once installers have determined that a compartment
is properly constructed and metal-lined, they can add
acoustical material. This may include additional
sealant or insulating material, to reflect noise away
from the vehicle interior.

Sound insulating materials should be of a nonflam
mable type. One excellent insulating material is a 1­inch (25 mm) thick fiberglass having a 2-pound den
sity. When fiberglass is used, its coated side should
face toward the compartment interior.

шЁЁшт

A Do not install sound insulation or any

absorbent material on the compartment floor

interior. Such materials will become soaked

with combustible or explosive vapors and

liquids and will become a fire hazard.

Using a combination of sound-insulating materials
can often reduce noise more effectively than a sin

gle material. For example, a sheet of lead or visco

elastic material, along with a layer of other acousti
cal material, is more effective than when a single

material is used.

• 2.2.3 ACOUSTICS

For additional noise abatement, the installer may
wish to consider the following:

• Using special sound-insulating materials.

• Construction of a special noise abatement
compartment.

NOTE:

Any method used to reduce noise must not
adversely affect the flow of cooling and ventilating
air into, or out of, the compartment.

In addition to the effective use of sound insulating
materials, construction of a special noise abatement
compartment might be considered to reduce noise
levels. Such a compartment might be constructed as
follows (Figure 2.5, Page 25):

• Use 5/8-inch thick or 3/4-inch thick plywood in the
compartment.

• Construct the compartment floor of a double thick
ness of 5/8-inch or 3/4-inch plywood.

• Line the compartment’s interior walls and floor, as
well as the underside of the floor, with 26-gauge
galvanized steel.

• Vapor-seal all compartment seams and joints.

• Over the galvanized steel lining, install a combina
tion of acoustical materials, as mentioned in
Section 2.2.2.

DANGER

To prevent fire or explosion, do not install any

^

insulation, or other absorbent materials, on the
interior or underside of the compartment floor.

Seal all compartment door edges to prevent noise

leakage around the door perimeter.

Line the compartment door interior (except for air

openings) with suitable, fireproof sound insulation
(such as, 1-inch (25 mm) thick fiberglass with a 2­pound density).

24 Generac* Power Systems, Inc.

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

INSTALLATION

Figure 2.5 - Typical Noise Abatement

Figure 2.6 - Compartment Floor Cutout

• 2.2.4 COMPARTMENT FLOOR CUTOUTS

You must provide openings in the generator compart

ment for the following items (Figure 2.6):

• Engine exhaust and cooling air outlets

• Generator cooling air inlet and front service door

• Four holes for passage of generator mounting
bolts. See Section 2.1.4 (Page 23)

• Rear service door.

DANGER

Fuel lines and exhaust piping must not pene
trate into the vehicle living area.

NOTE: FDR A FULL SIZE TEMPLATE, CONTACT GENERAC
SERVICE DEPARTMENT AT: 1-262-544-4811

Generac* Power Systems, Inc. 25

INSTALLATION

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

2.3 COOLING AND VENTILATING AIR

It is absolutely essential that an adequate flow of air
for cooling, ventilation, and engine combustion be
supplied to the generator set. Without sufficient air
flow, the engine/generator quickly overheats. Such
overheating can cause serious operating difficulties
and also may cause fire and personal injury. The
installer must make sure that sufficient air is avail
able to the generator for cooling, ventilating, and
combustion. The installer also must provide a path
for exhausting the cooling air to the exterior of a com
partment, if so equipped.

DANGER

Never use discharged cooling air for heating or
permit such air to enter the vehicle interior. This

air contains deadly carbon monoxide gas and
other poisonous, flammable, or explosive gases.

♦ 2.5.1 GENERATOR AIRFLOW

This unit uses an impellar fan located on the alterna

tor drive pulley to cool the alternator’s internal com
ponents. Air is drawn through the alternator and
expelled radially behind the drive pulley. An engine­driven centrifugal blower draws in cooling air

through air inlet openings, moves that air around the

engine/generator and across the radiator, then dis

charges that air out the bottom (see Figure 2.7).

__________________

♦ 23.2 COQLiNG AIR INLET OPENINGS

_____________

The minimum size of the air inlet opening, whether
the generator is housed in a conventional compart
ment or not, is at least 150 square inches

(975 cm^) (see Figure 2.8). This rule applies whether

inlet air is brought in through an opening in the com
partment door, an opening in the vehicle skirt,
through ductwork, or by any other means.

NOTE:

Screening, louvers, or expanded metal that cover air
openings restrict airflow. You must compensate for

this by making the actual air opening proportion

ately larger. See Section 2.3.3 (Page 27).

Figure 2.8 - Air Inlet in Compartment Door

150 SQUARE INCHES
UNRESTRICTED
MINIMUM OPENING

Figure 2.7 - Airflow Through Engine/Generator

When the unit is installed on a suspended mounting

system, one of several different methods of supplying
airflow may be used as follows:

• Provide a door in the vehicle skirt having an air
inlet opening (Figure 2.9).

Figure 2.9 - Suspended Mount: Inlet Door

Use ductwork (Figure 2.10, Page 27). The installer

must be sure air is available to the
sides of the generator for proper air intake.

Provide an opening in the vehicle skirt and space

around the generator for cooling airflow (Figure

2.11, Page 27). Recommended clearance around
all sides of the generator is at least
2 inches (50 mm).

26 Generac* Power Systems, Inc.

Section 2 - Installation

QUIETPACr™ 75D Recreational Vehicle Generator

INSTALLATION

Figure 2.10 - Air Inlet Using Ductwork

ANTI-SPLASH

Figure 2.11 - Air Inlet in Vehicle Skirt

4 2.3.4 TESTING THE INSTALLATION______________

Generac recommends testing the installation to be
sure adequate cooling airflow is available to the
unit, before placing the unit into service. If the unit
shows signs of overheating, you will need to
enlarge the air openings. Never place a unit into
service until absolutely certain that cooling and

ventilation is adequate.

NOTE:

You must test the installation, especially if you

bring in air from below the generator set.

2.4 DIESEL FUEL SYSTEM

The installation of a diesel fuel system (Figure 2.12)
for a recreational vehicle generator set must comply
with applicable codes, standards, and regulations.
The entire fuel system must be completely free of

leaks. There must be no possibility of fuel vapors
entering the vehicle interior.

Figure 2.12 - Generator Fuel System

♦ 2.5.3 COiVIPEfMSATIfSIG FOR RESTRICTIONS

Materials, such as, screening, louvers, or expanded
metal, can restrict the free flow of air. Compensate for
this restriction by making the actual air opening pro
portionately larger.

Some materials may offer only a 60 percent “free air
inlet area.” Other more efficient materials may pro

vide up to a 90 percent free air inlet area. The per

centage of free air inlet opening is usually available
from the material’s supplier or manufacturer.

To determine the actual air inlet opening size
required, divide 150 square inches (975 cm“)by
the percentage of free air inlet area for the mater
ial you will use.

For example: If you plan to use screening with an 80

percent free air inlet area, divide 150 (975) by 0.8,
which results in 187.5 square inches (1,218.75 cm9­Minimum actual size of air inlet opening in this case is

187.5 square inches (1,218.75 cm^).

DANGER

All fuel types are potentially FLAMMABLE
and/or EXPLOSIVE and should be handled
with care. Comply with all laws regulating the
storage and handling of fuels. Properly install
and maintain the fuel system, and keep it
entirely free of leaks. Fuel vapors must
not enter the vehicle interior.

Generac* Power Systems, Inc.

S~7

INSTALLATION

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

Because diesel fuels are less volatile than gasoline or
gaseous fuels, they are considered safer from the stand
point of storage and handling. As a result, installers
may tend to be careless in their installation practices,
which can result in poor engine performance. For
example, a poorly tightened fuel line may not show any
signs of leakage; however, air can be drawn into the
loose connection and cause problems. Air that is
trapped in the diesel fuel system results in hard start
ing and rough engine operation.

Dirt that enters the fuel system also may cause prob
lems. Lines and piping must be properly installed
and tightened to prevent dirt from entering. Diesel
fuel must be kept clean.

Factory-installed generator fuel system components
include (a) a fuel filter, (b) a 12-volt DC electric pump,
(cj an injection pump, and (d) interconnecting lines
and fittings. Connect a fuel supply line to the supply
fitting and a return line from the fuel return fitting
back to the tank.

NOTE:

Fuel supply and return fittings located on the gen
erator are 1/8” NPT.

Use a length of approved flexible fuel hose between
the fuel connection fittings and rigid fuel lines (see
Sections 2.4.2 and 2.4.3).

♦ 2.4J FUEL TANK

Either the generator must share the vehicle’s
engine fuel tank, or you must install a separate fuel

tank for the generator set. All fuel tanks installed

on the vehicle must be constructed, installed, and

restrained so they comply with applicable codes,
standards, and regulations.

If the generator is to share the vehicle’s engine

tank, separate fuel pickup tubes are required for
the engine and the generator. Generac recommends
that you make the fuel pickup tube 2 to 3 inches
(51 to 76 mm) shorter than the vehicle’s engine
pickup tube. This prevents the generator from
depleting the entire fuel supply during prolonged

generator operating periods.

-------

Mk CAUTION M----------------

Do NOT tee the generator fuel supply line into
the vehicle engine fuel supply line. If this is
done, the generator will be starved of fuel
when both engines are operating at the same
time. Also, while the vehicle engine is not run

ning, generator operation may drain the vehi
cle engine supply line, making it difficult to
start the vehicle engine.

• 2.4.2 GENERATOR FUEL SUPPLY LINES

^ 2.4.2.1 Rigid Fuel Lines

Those lines used to supply fuel from a tank to the
generator must comply with applicable codes, stan
dards, and regulations. The following general rules
apply to rigid fuel lines:

• Rigid lines should be of annealed, seamless, drawn
aluminum, or steel.

• Lines and fittings must comply with SAE J512E
“Standard Automotive Fittings,” or with ANSI

B126.26 (latest edition).

• Route the fuel line so that at least 2 inches (51 mm)
of clearance is maintained between the line and
any exhaust system parts.

• Do not attach electrical wiring to fuel lines. Route

the wiring so it cannot come into contact with any
fuel line.

• Route fuel lines so that, if they leak, fuel does not

drip onto any electrical or exhaust system parts.

• Use nonferrous metal straps without sharp edges

to secure fuel lines.

• Fuel system components must be accessible, but

protected from abrasion, chafing, road damage,
and kinking.

^ 2.4.2.2 Flexible Fuel Line

Use a length of approved flexible fuel hose between
the generator fuel supply fitting and rigid fuel lines.
This prevents breaking of the line caused by vibra

tion, shifting, settling, or movement. The following

rules apply:

• The flexible hose must comply with SAE J30B,
“Standard for Fuel and Oil Hose.” It must be
approved for use with diesel fuel.

• The hose should be at least 6 inches (152 mm)
longer than is needed, to prevent the hose from
rupturing if the generator shifts or settles.

4 2.43 GENERATOR FUEL RETURN LINES

The same general rules that apply to fuel supply lines
also apply to fuel return lines.

NOTE:

Locate the diesel fuel return line at least 12 inches
from the tank fuel pickup tubes to prevent air bub
bles from entering the fuel supply lines.

SB

Generac* Power Systems, Inc.

Section 2 - Installation

QUIETPACF“ 75D Recreational Vehicle Generator

INSTALLATION

2.5 EXHAUST SYSTEM

The generator exhaust system must be safely and
properly installed. Only approved exhaust system
parts must be used. A properly installed exhaust sys
tem must be vapor-tight, quiet, and completely safe.

DANGER

The generator engine gives off DEADLY carbon

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. Do not operate the generator
until its exhaust system has been inspected and
property repaired.

A

• 25.2 EXHAUST SYSTEM SAFETY

________________

• Maintain a clearance of at least 3 inches (76 mm)
between exhaust system parts and any com
bustible material (such as, wood, felt, cotton,
organic fibers, or other like material). If you can
not maintain the 3-inch (76 mm) clearance, locate,
insulate, or shield the exhaust part(s) so that the
temperature of any combustible material is not
raised to more than 117° F (65° C) above the
ambient air temperature.

• Terminate the exhaust tailpipe at least 3 feet (91
cm) from the vehicle’s fuel filler cap and at least

2 inches (51 mm) past the outer edge of the vehi
cle. Do not terminate the exhaust system under
the vehicle.

• Terminate the exhaust tailpipe such that exhaust
gases will not be drawn back into the generator
compartment and recirculated.

• Fuel and oil must NOT be able to drip onto any
exhaust system part.

Figure 2.13 - Typical Exhaust System

------

m CAUTION A—

Never tee the generator engine exhaust pipe

A

into the vehicle engine exhaust piping. This
causes excessive back pressure on the genera
tor engine. Also, water from one engine can
damage the other engine.

♦ 2.5.1 MUFFLER AND SPARK ARRESTOR

The exhaust muffler supplied with the QUIETPACT ™

75D is a spark arrestor type that meets code and
standard requirements of the U.S. Forest Service.
Any person!s) installing an unapproved muffler, or an
unapproved exhaust system part, or modiiying an
exhaust system in any way that might cause a hazard,
is liable for any damage, injury, or warranty expense
that might be caused by such unapproved installation
or modification.

MUFFLER PERMANENTLY
MOUNTED INSIDE
ENCLOSURE

TAILPIPE MUST EXTEND 2 INCHES

BEYOND THE COACH BODYWORK

If there is any possibility of the tailpipe or muffler

being damaged, protect these damage-prone
areas by means of a protective device (such as, a
skid bar).

Install the generator exhaust system according to

safe automotive practices.

Use enough exhaust system hangers to prevent any

part of the system from being dislocated.

Generac® Power Systems, Inc. S3

INSTALLATION

Section 2 - Installation

QUIETPACT“ 75D Recreational Vehicle Generator

• Use exhaust system parts recommended by
Generac. Using unapproved exhaust mufflers and
exhaust system parts is the responsibility of the
person!s) installing such unauthorized parts.

• Do not terminate the exhaust system under any
opening, window, or vent that can be opened or is
not permanently sealed from the vehicle interior.

• Exhaust piping must be large enough to prevent
excessive back pressure on the generator engine.

• Never tee the generator engine exhaust pipe into
the vehicle engine exhaust piping. This causes
excessive back pressure on the generator engine.
Also, water from one engine can damage the
other engine.

• Plan exhaust system installation carefully.
Comply with all applicable codes, standards, and
regulations.

2.6 ELECTRICAL CONNECTIONS

Be sure to read Section 1.6 on Page 20.

The following general rules apply to electrical con
nections in a recreational vehicle:

• Qualified electricians who are familiar with applic

able codes, standards, and regulations should
install electrical wiring.

• The wiring should comply with codes, standards,

and regulations. The National Electrical Code
(NFPA 70), and state and local codes apply.

• Switches and circuit breakers should be of a type

approved for use in recreational vehicles and must

be mounted and installed to prevent damage from

road shock.

• Wiring must be of adequate size, have approved

insulative qualities, and be properly supported.

® Conduit and wire openings into the generator com

partment (if used) must be vapor-sealed to prevent
entry of flammable, explosive, or poisonous gases
into the vehicle.

• If neutral conductors are used, they must be the
same size as other leg wires.

• Route power supply conductors from generator AC
output leads T1 (red), T2 (white), T3 (black), and
the green ground wire through approved flexible
conduit to the electrical junction box on the com
partment wall.

If a flexible metal conduit is used between the gener

ator and the compartment junction box, the conduit
end that terminates at the compantment junction box
must be vapor-sealed. Flexible metal conduit is NOT
vapor-tight along its entire length.

• From the junction box, route power supply wires
through approved conduit to either (a) double-pole,
double-throw transfer switch, or (b) approved isola
tion receptacle. Connecting to a transfer switch or
isolation receptacle must prevent vehicle electrical
circuits from being connected to two different power
supplies at the same time (such as, generator and
dockside power).

• Conductors must be rated 221° F (105° C) or must
be of a larger conductor size.

• 2.6.3 GENERATOR AC CONNECTIONS

Generator AC output leads T1 (red), T2 (white), and
T3 (black) come out of the generator, as shown in
Figure 2.14. Leads T1 (red) and T3 (black) are “hot,”
while T2 (white) is the grounded neutral lead. There
is also a green lead that connects to ground in the

junction box of the recreational vehicle.

Figure 2.14 - Generator AC Output Leads

2.6.1 ELEaRiCAL JUNCTION BOX

Install an approved, square electrical junction box

with a blank cover on the interior or exterior wall of

the area you plan to install the generator (NOT on the
generator). Route the generator's AC output leads
into this junction box through approved flexible con
duit. This is the point of first termination for genera
tor AC output leads.

• 2.6.2 WIRING

• Wiring should be of stranded copper to reduce the
chance that vibration may cause breakage.

• Wire gauge size should be large enough to handle
at least 115 percent of the installed generator's
rated maximum current.

30 Generac* Power Systems, Inc.

QUIETPACT ™ generators use a four-position terminal
block to connect between stator power leads and vehi
cle load leads. This terminal block is accessible by
removing the access panel, shown in Figure 2.14. Units
are shipped from the factory connected for dual-voltage

(120/240 volts AC) output (See Figure 2.15). The stator
power windings are connected in series. Lead 11/1 lA
connects to T1 (Red), lead 44/44A connects to T3

(Black), while leads 22 and 33 are grounded and con
nect to T2 NEUTRAL (White). A "tie bar" connects the
two switch handles on line breaker CB1.

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

INSTALLATION

^ 2.6.3.1 Generator Coversion to

120 Volts Only - Dual Circuits

NOTE:

Conversion of a QUIETPACT™ generator from
"120/240 volt dual voltage" to "120 volts only ­dual circuits" {or vice-versa) requires rerouting

wires within the unit enclosure. It is recommend

ed that this conversion be performed by a Generac

Authorized Service Dealer.

Figure 2.16 shows the stator power winding connec
tions for 120 volts only - dual circuits. Two stator
power windings are used, with each winding capable
of supplying half of the unit's rated wattage/amperage
capacity. The circuit from each winding is protected
against overload by a line breaker (CBl and CBIA).
Line breakers CBl and CBIA have a trip rating of 35
amps.

To convert from "120/240 volt dual voltage" to "120
volts only - dual circuits", disconnect battery power
from the generator and reverse stator lead wires 33
and 44 as follows:

NOTE:

It is necessary to feed stator lead wires 33 and 44
through grommets on the electrical enclosure and
engine control box in order to perform the rerout
ing outlined below. The front and top unit enclo
sure panels, as well as the user control panel, must
be removed to perform this. After re-routing, wires
should be properly tied down to prevent chafing or
contact with moving internal components

1. Remove stator lead wire 33, as shown in Figure

2.15, from the ground stud adjacent to the four­position terminal block. Reroute stator lead 44
from the line side terminal of CBl (renamed as
CBIA in Figure 2.16) to the ground stud location
previously occcupied by stator lead wire 33.

2. Move smaller gauge (#18 AWG) wire labeled #44
(not shown), from the top of CBIA to the top of

CB1. Renumber this wire #11.

3. Reroute stator lead wire 33, removed in step 1,

to the line side terminal on CBIA.

4. Renumber ground wire "33", located between

the four-position terminal block and ground in
Figure 2.15, as ground wire "44", as shown in
Figure 2.16.

5. Renumber wire "44A" from Figure 2.15 as wire

"33A" in Figure 2.16..

6. Connect a 12 AWG jumper wire between line

breakers CBl and CBIA, as shown in Figure

2.16.

7. Remove the "tie bar" between the two-line break
er switch handles.

When connecting vehicle load leads, the following
rules apply:

• Connect 120-volt, single-phase, 60-Hertz, AC elec

trical loads, requiring up to the trip rating of cir
cuit breaker CBl, across AC output leads T1 (red)
and T2 (white).

Connect 120-volt, single-phase, 60-Hertz, AC elec

trical loads, requiring up to the trip rating of cir
cuit breaker CBIA, across AC output leads T3
(black) and T2 (white).

Try to keep the load balanced between the two cir

cuit breakers and the stator windings.

The neutral line (T2, white) on all units is a ground

ed neutral.

-------

ik CAUTION Jk

Do NOT connect electrical loads in excess of any

A

circuit breaker rating, or you will develop prob

lems with circuit breaker tripping, which causes a
loss of AC output. Also, do NOT exceed the gen

erator's rated wattage capacity. Add the watts or
amps of all lighting, appliance, tool, and motor

loads the Generator will operate at one time. This

total should be less than the unit's rated
wattage/amperage capacity.

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

Figure 2.15 - Connections for 120/240 Dual

Ti Ta T3

(RED) neutral < BLACK)

mmmmi

,...prz::rJJ?.-rrrd

CB iJ

___________.1____

\

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

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

33 0^

!2

_________

.

....

..

~rrmr ,

______________

................................9.::.,

CB 1 J

3

I 1—k

kjUJUULr^ GROUT

Figure 2.16 - Connections for 120 Volts Only

Dual Circuits

Generac* Power Systems, Inc. 3i

“P KjlajuulH

NEUTR

NEUTRAL < BLACK.

A

INSTALLATION

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

♦ 2.6.4 CONDUIT

Route the connections between the generator and the

junction box through approved, flexible conduit. The

following general rules apply:

• All wiring, conduit, and interconnections must be
installed in compliance with applicable codes,
standards, and regulations.

• Cut wiring to the required length, and allow extra
wire for junction box connections.

• Carefully prepare conduit ends to prevent sharp
edges from cutting through wiring insulation.

• Route conduit so it does not interfere with genera
tor movement.

• If you use metallic conduit, vapor-seal the end of
the conduit where it enters the junction box. Do
this because flexible metallic conduit is not vapor­proof along its entire length.

• All openings in the generator compartment for the
passage of wiring and conduit must be sealed and
made vapor-tight.

NOTE:

Use a high-quality silicone rubber base sealant or
other approved method (such as, explosion-proof
fittings) to seal such openings.

• 2.6.5 POWER SUPPLY CORO

The power supply cord must comply with all applic
able codes, standards, and regulations. It must be
large enough to handle the full amperage to which it
will be subjected.

__________________

♦ 2.6.6 GROUND FAULT CIRCUIT INTERRUPTERS

The National Electrical Code (NFPA 70, 551-7)

requires that you install ground-fault circuit inter
rupters (GFCIs) on all external and some internal
electrical receptacles. Contact your manufacturer or
dealer for recommendations.

# 2.6.7 ISOLATING DIFFERENT POWER SOURCES

Connections from the junction box must terminate in
a double-pole, double-throw transfer switch (Figure

2.17). An alternate method for isolating different

power sources includes using an isolating receptacle

(Figure 2.18). Whichever method you use, you must

be certain that both power sources are NOT connect

ed at the same time.

DANGER

If the vehicle's electrical circuits can be powered by

A

any other source of electricity (such as, a "dock­side" power receptacle), there must be no possibil
ity of connecting the different power sources to

the vehicle's circuits at the same time. The dock-

side (utility) power source must be positively iso
lated from the vehicle's circuits whenever the gen

erator is operating. Failure to isolate the vehicle's

_

circuits from the dockside power supply when the
generator is running may result in damage to the
generator or in serious Injury or death to dockside
(utility) power workers due to backfeed of electri
cal energy. Installation and connection of the gen
erator must comply with NFPA 70, Article 551, and

NFPA 1192 (latest editions).

32 Generac* Power Systems, Inc.

Figure 2.17 - Transfer Switch Isolation Method

FROM 20 AMP
HACR BREAKER

POWER SUPPLY CORD

2ND AIR
CONDITIONER

VEHICLE AC
DISTRIBUTION
PANEL

30 AMP
MAIN BREAKER

HACR
BREAKERS
FOR AIR
CONDITIONERS

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

Figure 2.18 - Installation With Isolation Receptacle

DOCKSIDE
POWER

RECEPTACLE

INSTALLATION

2.7 BATTERY INSTALLATION

♦ 2.7.1 RECOMMENDED BATTERY

Install a battery
requirements:

• The battery must be
storage battery.

• Use a battery with minimum ratings of 70 amp-hours
and 360 cold-cranking amps.

NOTE:

If the battery is to be used to power other vehicle
accessories, as well as to start the generator, you may
need a battery with a larger capacity.

^ 2.7.2 BATTERY CABLES___________________________

Using battery cables that are too long or too small in diam
eter may cause a drop in voltage, which causes starting
problems. For the best cold weather starting, the voltage
drop between battery terminals and the generator con
nection point should not exceed 0.12 volts per 100 amps
of cranking current.

The QUIETPACT™ 75D generator is rated at about 160
DC amps of cranking current to operate the starter and
glow plugs.

Select battery cables based on (a) cable length and (b) pre
vailing ambient temperatures. Generally, the longer the
cable and the colder the weather, the larger the cable size
must be, as shown in the chart.

that meets the following

a 12-volt, automotive-type

» 2.7.5 BATTERY CABLE CQNNEaiONS

____________

1. Connect the battery cable from the battery post or
terminal, indicated by a POSITIVE, POS, or ( + ), to
the insulated lug on the unit frame (Figure 2.19).

NOTE:

Check to be sure the cable boot for the positive cable
has been installed.

Connect the battery cable from the battery post,

2.

indicated by a NEGATIVE, NEG, or (-), to the vehi
cle frame ground connection (Figure 2.19).

Connect a cable from the vehicle frame ground to

3.
the negative post on the generator frame.

Connect cables so the connectors are clean

4.
and tight.

Figure 2.19 - Connecting Battery Cables

CABLE LENGTH

in Feet (meters)

0 to 10 (0 to 3)

CABLE SIZE

2*

11 to 15 (3.4 to 4.5) 0

16 to 20 (4.5 to 6) 000

*For warm weather, use No. 2 cable up to 20 feet.

♦ 2.7.4 BAHERY COMPARTMENT

Install the generator battery in its own, vented compart
ment. Place the battery compartment away from any
source of heat, sparks, or flame.

Generac* Power Systems, Inc. 33

INSTALLATION

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

Provide ventilation openings in the battery compart
ment. The minimum size of openings should be 2
square inches at the top of the compartment. Mount the

battery on a strong, rigid supporting structure, where

leaks and spills of battery fluid will not cause damage.

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 tool or equipment near the bat
tery. 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

A

and high short-circuit current. The following pre
cautions 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.

-A WARNING A-

Do not open or mutilate the battery. Released

A

electrolyte is 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 con
ductive 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.

• If the electrolyte contacts the eyes, immediately flush

eyes thoroughly with water, and seek medical atten

tion.

• 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 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.

2.8 OPTIONAL ACCESSORIES

A plug-in connector (Figure 2.20) is provided on the
generator set, below the control panel. Use this to con

nect an optional remote-mounted start/stop panel to the

generator. Installation of such a panel will permit you to

start and stop the generator engine from any convenient
location inside the vehicle.

Figure 2.20 - Remote Panel Plug-in Receptacle

Ф 2.8.1 REMOTE START/STOP CONNECTIONS

The following steps are necessary to connect the remote
start/stop option:

1. If the six-wire remote connector is visible below the

control panel, as shown in Figure 2.20, skip to step

5. Otherwise, proceed with step 2.

2. Remove the electrical access panel located just
below the knock-out labeled “REMOTE.” The
remote connector will be located inside the electri
cal enclosure, along the right side.

3. Remove the “REMOTE” knock-out, taking care not
to damage the wiring behind it.

4. Feed the remote connector through the hole, and fit
the supplied grommet into position.

5. Wire the remote harness (Part # C6712C, supplied
as an accessory with the generator) to the vehicle’s
remote start panel. Refer to Figure 2.20 for a wiring
legend.

6. Plug the remote harness into the mating remote
connector on the generator.

34 Generac* Power Systems, Inc.

Section 3 - Post-installation Start-up Checks

QUIETPACT™ 75D Recreational Vehicle Generator

POST- (
INSTALLATION

START-UP

CHECKS

3.1 POST INSTALLATION TESTS

The generator set was factory-tested and adjusted.

You should not be required to adjust the unit any fur

ther, except under special circumstances.

-A WARNING A-

Do not make any unnecessary adjustments.

A

Factory settings are correct for most applica
tions, When making adjustments, however, be
careful to avoid overspeeding the engine.

3.2 BEFORE INITIAL STARTUP

Before starting, complete the following:

1. Check the engine crankcase oil level and, if nec
essary, fill to the dipstick “FULE’ mark (cross­hatched area) with the recommended oil. Do not
fill above the FULL mark.

2. Check the fuel supply. Fuel lines must have been
properly purged and leak-tested in accordance
with applicable fuel codes. All fuel shutoff valves
in the fuel supply lines must be open.

3.3 INITIAL START

When you are absolutely certain that the unit has

been properly installed and prepared for use, start
the engine as follows:

1. Turn off all electrical loads. Do this by setting the
generator’s line breakers to their “OFF” (or open)
position.

2. Refer to Part I, Section 2.4, “Starting the
Generator” (Page 8), for cranking and starting
instructions. The engine may require more
cranking for initial starting, since the fuel lines
have to be primed (use of the preheat switch will
operate the generator’s electrical fuel pump and
shorten this time).

3. Let the engine warm up for about five minutes to
allow internal temperatures to stabilize.

4. Carefully inspect the engine/generator for fuel, oil,
and exhaust system leaks. Before proceeding to the
next step, correct any leakage immediately.

5. When all tests and adjustments at no-load are
completed, apply electrical loads and check
for proper operation under load. See Section

3.4. Run the unit at least 30 minutes, with
loads applied.

6. Turn off all electrical loads by setting the gen
erator’s line breakers to their “OFF” (or open)
position.

7. Let the unit run at no-load for a few minutes to
stabilize internal engine/generator temperatures.
Then, shut down the engine.

NOTE:

The generator set was thoroughly tested and

adjusted at the factory before shipping. No addi
tional adjustment should be necessary. Only
trained, qualified service technicians should

perform adjustments outlined in this manual.

3.4 TESTING UNDER LOAD

Apply electrical loads equal to about 50 to 75 percent

of the unit's rated wattage/amperage capacity.
Let the unit run at least 30 minutes with load applied.

During this part of the test, check that the unit is not

running excessively hot and that adequate cooling air
flow is available. You must not allow the unit to over

heat during prolonged operation.

NOTE:

The generator engine is equipped with a high
coolant temperature switch. The switch has normal
ly open (N.O.) contacts. When the engine coolant
temperature is too high, switch contacts close, and
the engine shuts down automatically.

GENERAC RECOMMENDS THAT YOU TEST THE
GENERATOR FOR ADEQUATE COOLING.

Generac* Power Systems, Inc.

35

POST-1

INSTALLATION

START-UP
CHECKS

Section 3 - Post-installation Start-up Checks

QUIETPACF“ 75D Recreational Vehicle Generator

3.5 INSTALLATION CHECKLIST

♦ LOCATION AND SUPPORT

□ Generator is properly located.
□ Generator is properly supported.
□ Generator is properly restrained.

♦ GENERATOR COMPARTiVIENT

□ Compartment construction is proper.
□ Holes/Openings are vapor-sealed.
□ Compartment size is correct.
□ Compartment is vapor-sealed.

□ Sound insulation is correct.
□ Floor cutouts are properly completed.

♦ COOLING AND VENTILATING M R

□ Airflow is adequate.
□ Air inlet opening is correct.
□ Compensate for restrictions.
□ Check that installation has been tested.

♦ DIESEL FUEL SYSTEM

□ Fuel tank complies with all applicable codes.
□ Fuel system is properly installed and checked

for leaks.

__________________

♦ EXHAUST SYSTEM

□ Exhaust system complies with all applicable

codes.

□ Exhaust system is properly and safely installed.

♦ ELECTRICAL CONNEOIONS

□ Connections comply with local code requirements

and all National Electrical Codes.

□ Junction box is properly installed.

□ Wiring meets all standards.
□ All connections are correct.
□ Conduit is properly installed and sealed.
□ Generator is properly bonded to the vehicle.

♦ BATTERY INSTALLATION

□ Recommended battery is installed.
□ Recommended cables are installed.
□ Cables are clean and tight.
□ Cables are connected properly.
□ Proper ventilation is provided.
□ Terminals are coated with anti-corrosion grease,

and terminal covers are positioned.

♦ OPTIONAL ACCESSORIES

□ Check that remote start/stop panels (if used) are

installed properly.

□ Check that all other options and accessories (if

used) are installed properly.

DATE OF INSTALLATION

NAME OF INSTALLER

SIGNATURE OF INSTALLER

3S Generac® Power Systems, Inc.

♦ POST INSTALLATION TESTS

□ Check that all tests are completed properly.

TROUBLESHOOTING GUIDE

Appendix 1 - Troubleshooting

QUIETPACT™ 75D Recreational Vehicle Generator

TROUBLESHOOTING

PROBLEM CAUSE

The engine will not crank.

The engine cranks but
will not start.

The engine starts hard

and runs rough.

-

The engine starts, but shuts

down when the Start/Stop
switch is released.

The Start/Stop switch is

set to Stop, but the engine
continues to run.

There is no AC output from
the generator.

System control fuse blown

1.
Loose corroded or defective

2.
battery cables
Defective engine Start/Stop

3.
switch
Defective starter contactor

4.
Defective starter motor

5.
Low or defective battery

6.
Defective engine control board

7.
Vehicle fuel shutoff valve closed

1.

2.

Out of fuel
Defective fuel solenoid (FS)

3.
Defective fuel pump (FP)

4.
Open #14 wire from

5.
engine control board

Plumed fuel filter or fuel line

6.
Engine mechanical parts failure

7.
Defective engine control board

8.

1. Plugged or damaged
air filter
Defective fuel pump (FP)

2.
Plugged fuel filter or fuel line

3.
Water in fuel

4.
Improper preheat

5.
Low engine oil level

1.

2. Overheated engine
Defective Start/Stop Switch

3.
on panel or remote Start/Stop
Defective low-oil

4.
pressure switch
Defective high-coolant

5.
temperature switch
No AC output

6.

Defective engine control board

7.
Defective Start/Stop switch

1.
Open/Disconnected #18 wire

2.
between Start/Stop switch
and engine control board

Open/Disconnected #0 wire

3.
between Start/Stop switch
and engine control board
Defective engine control board

4.
Main-line circuit breaker open

1.

Fault with vehicle circuit

2.
breaker and/or fuses

Generator internal failure

3.

CORRECTION

1.

Replace fuse.

2.

Tighten, clean, or replace,
as necessary.

3. Replace Start/Stop switch.
Replace contactor.

4.

5. Replace starter motor.
Charge or replace battery.

6.

7. Replace control board.

1. Open valve, if so equipped.

2.

Replenish fuel.
Replace solenoid.

3.

4. Repair or replace fuel pump.
Check connections and

5.
insulation of #14 wires.

6. Clean or replace fuel filter or line.
Repair or replace parts.

7.
Replace control board.

8.

1. Check, clean, or replace, as needed.

Repair or replace fuel pump.

2.
Clean or replace fuel filter or line.

3,

4. Drain fuel system and refill.

5.

Preheat unit.

1. Check oil and add oil, as needed.
Check cooling system for leaks.

2.

3. Disconnect Remote Harness
Check/Replace Start/Stop Switch
Replace pressure switch.

4.

Replace temperature switch.

5.

6. Contact a Generac Authorized
Service Dealer

7. Replace control board.

1. Replace switch.

2. Reconnect or close wire.

3. Reconnect or close wire.

4.

Replace control board.

1. Reset line breaker
to ON (or closed).

2.

Reset and replace, if necessary.

3. Contact a Generac Authorized
Service Dealer.

Generac* Power Systems, Inc. 3"7

NOTES

Appendix 2 - Notes

QUIETPACT™ 75D Recreational Vehicle Generator

3S Generac® Power Systems, inc.

Appendix 2 - Notes

QUIETPACT“ 75D Recreational Vehicle Generator

NOTES

Generac* Power Systems, Inc. 39

nm^

ELECTRICAL

DATA

Appendix 2 — Electrical Data

9

QUIETPACT™ 75D Recreational Vehicle Generator
Electrical Schematic - 120/240 VAC Output- Drawing No. D2792-A

40 Generac* P*ower Systemsj Inc.

LEGEND

AVR -AUTOMATIC VOLTAGE REGULATOR
BCR -BATTERY CHARGE RECTIFIER
BOW -BATTERY CHARGER
CB1 -CIRCUIT BREAKER 35A
CB2 -CIRCUIT BREAKER (4A)
D1 -DIODE 600V, 6AMP
D2 -DIODE 600V, 6AMP
DPE -EXCITATION WINDING
FI -FUSE 14AMP SFE
FS -FUEL SOLENOID
FP -FUEL PUMP
CP -GLOW PLUGS
HM -HOURMETER

HWT -HIGH WATER TEMP SWITCH
LOS -LOW OIL PRESSURE SWITCH
PHC -PREHEAT CONTACTOR
R1 -RESISTOR, 1 OHM, 25W
R2 -RESISTOR, 20 OHM. 12W
S -STARTER

SC -START CONTACTOR
SW -PREHEAT SWITCH

SW1 -SWITCH, START/STOP

Appendix 2 — Electrical Data

QUIETPACT™ 75D Recreational Vehicle Generator

Electrical Schematic - 120/240 VAC Oytpyt - Drawing No. D2792-A

CMMT] r(5W

ELECTRICAL

DATA

^WIRE #11 FOR 120V ONI

OUTPUT CONNECTIONS

WIRE COLOR

LEGEND

WHITE

RED NDN-FUSED DC

ORANGE FUSED DC

BROWN

BLUE

BLACK

FUNCTION WIRE #'s

NEUTRAL

CONTROL

SIGNAL/SENSING

AC/MISC

.......

Y AC

0,1

4,13

14.15
17,18,157 (#18)
44,56,85,150
1IA,13,44A,I57 (#10)

Generac® Power Systems, Inc. 41

ELECTRICAL

DATA

Appendix 2 — Electrical Data

QUIETPACT™ 75D Recreational Vehicle Generator
Wiring Diagram - Drawing No. - D2793

WIRE CDLOR

LEGEND

WHITE NEUTRAL

RED

□RANGE FUSED DC 14,15

BROWN

BLUE

BLACK

function

NQN-FUSED DC 4,13

CONTROL

signal/sensing

AC/MISC 11A,13,44A,157 (ttlO>

WIRE #'s

0,1

17,18,157 <#18)
44,56,85,150

LEGEND

AVR ~

AUTOMATIC VOLTAGE REGULATOR

BCR -

BATTERY CHARGER RECTIFIER

BHl -

BULK HEAD CONNECTOR, RECEPTACLE (BLACK)

BH1A-

BULK HEAD CONNECTOR, PLUG (BLACK)

BH2 -

BULK HEAD CONNECTOR, RECEPTACLE (GRAY)

BH2A-

BULK HEAD CONNECTOR, PLUG (GRAY)

CB1 -

CIRCUIT BREAKER 35A

CB2 -

CIRCUIT BREAKER 4A

C0NN1

- CUST. REMOTE CONN

01 -

DIODE 600V, 6AMP

02

DIODE 600V, SAMP

FUSE 14AMP SFE

FP -

FUEL PUMP

FS -

FUEL SOLENOID
ENGINE GROUND

GNOl­GND2-

FRAME STUD

GN03-

GROUND (BEARING CARRIER)

GND4-

THRU BOLT (CONTROL PANEL)

GND5-

GROUND STUD (NON-SEALED COMP)

GND6-

GROUND STUD (SEALED COMP)

HWT -

HIGH WATER TEMP SWITCH

HM -

HOURMETER

LOS -

LOW OIL PRESSURE SWITCH

PHC -

PREHEAT CONTACTOR

RESISTOR, 1 ohm 25W

R2

RESISTOR 20 ohm, 12W

SC

START CONTACTOR

SM

STARTER MOTOR

SWl

SWITCH START/STOP

PREHEAT SWITCH

SW2
TS

TERMINAL STRIP
CUSTOMER CONNECTION

BRUSH WITH RED<4) LEAD

CLOSEST TO BEARING

42 Generac* Power Systems, Inc.

12V BATTERY CONNECTION

CUSTOMER PROVIDED

GLOW PLUGS

Appendix 2 — Electrical Data

QUIETPACT™ 75D Recreational Vehicle Generator

Wiring Diagram - Drawing No. - D2793

ELECTRICAL

DATA

Geoerac® Power Systems, loc. 43

.PARTS

LISTS

Appendix 5 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator
Engine, Alternator Drive and Starter Assembly - Drawing No. 0D2355

26

1 0C5598

0C9674 1

2

0C6055H 1 Rotor Assembly

3

0C6054H 1 Stator Assembly

4

031971 1

5

6 073159

066386 1

7

066849

8

0C6862 4 Bolt, Stator

9

10

11

0C3168 6

0C5O14 1 Lug, Lift

12 0C7646

13

14
15

16
17
18
19

20

21

22
23

24 0C7933
25

44

0C8646
0C5298 1 Belt, V-Rib

020692
0C4841
073106G 1
0C6363
039288
071956
022129 8
045771
040250

068485 4

Generac®

1 Bearing Carrier, Front

Bearing Carrier, Upper

Bail Bearing

1 Bali Bearing

Brush Holder

2 Taptite M5-0.8 x 16mm

5/16 Special Lock Washer

1 Rail, Engine RH
1 Pulley, 4.5" Flat

1 Starter Motor
1

1
2

Spacer, Starter
Pulley, Alternator
Flywheel Assembly
HHCS M8-1.25 x55mm

2 Washer, Vibration Isolator

Washer, split lk-M8

8

2

Nut, hex m8-1.25
SHCS 5/16”-18x 1-1/2” 48 024426 1

1 Guard, Flywheel

HHCS M12-1.25X 20mm 50

Power Systems, Inc.

26 051769 6
27 0C4537 2 Engine Bracket
28
29 023316 1
30 049451 1

31 042633 1

32 046526 11
33 052212 6
34 069673J 2 5/16 Flange Nut
35 051756 5
36 049813 1

37 043107 2 HHCS M8-1.25x25mm
38 021991 1

39
40 0A1658

41 067989 4

42
43 0C6609 1
44
45 055934M 1
46 0A7043 2

47

49 048705 2 y2"-13 Flange Nut

022304 2

039253

4

1 1/4" Special Lock Washer

0C1069 3
049808 2

0C8644 1 Tensioner, SE-F18-4.5"

022145 2 Flat Washer, 5/16"

Washer, Split Lk -M8

Vi Flat washer

72"-13

X

Fender Washer 7GA

HHCS 3/8-24x1"

Lockwasher MIO
HHCS M10-1.25X 25mm

HHCS M10-1.25 X 20mm
M6 Hex Nut

Earth Strap
HHCS M8-1.25x20mm

M8 Flange Nut

Taptite, M6-1.0 X 8mm

Engine, 1 .OL Diesel

Washer, Flat Ml 2
Clamp, Vinyl Coated,

HHCS M12-1.25X 25mm

y2"-13 X 1-3/4” HHCS

4" HHCS

Ya"

Appendix 5 — Exploded ¥îews and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

Base Frame - Drawing No. 0D2357

PART NO. QTY.

ITEM

1 0D2126 1

2 0D2131

0C5088 1

3

0C5644 4

4

056326 2

5

029451

6
7 0C7857 4

070936E 4

8

9 0C6721

10 0C6722 1
11 042907 8

022129 8

12

022097

13

14

043146
0C7561

15

DESCRIPTION

Base Frame Weldment

1

677mm Rubber Tape 1/8 x Vz

1

3
2

1

Door, Service Rear
Door, Service Front
Slide Latch Flush
Vinyl Trim -Black 180mm

Grommet 1/8 x 13/32
Vibration Mount
Gasket, Cleanout
Plate, Cleanout
HHCS M8-1.25x16
Washer, Split Lk- M8
Washer, Spilt Lk -1/4-M6
HHCS M6-1,00x10
Carriage Bolt 3/8 -16 x 55mm

PART NO.

ITEM

0A4456

16

17 076821

047411 2

18

049813

19

0C5443

20

0C7423

21
22 022131

022237

23

CTY. DESCRIPTION

1 3/8 Special Lock Washer
2

2

Hex Nut 3/8-16 Brass
HHCS M6-1.00X 16
Nut, HexM6.0-1.0

1 Block, Terminal Battery Post
1 Stud, 3/8-16

X

55mm

1 Washer, 3/8 Fiat
1 Washer, Split Lk - 3/8

mm = Millimeters

Geoerac* Power Systems, loc. 45

.PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator
Enclosure - Drawing No. 0D2358

iEM

PART NO. QTY. DESCRIPTION ITEM

1

0D2315 1 Enclosure Panel RH 19

2

0C4534 1 Enclosure Panel Top 20 0C7024
3 0C4532 1 Enclosure Panel LH 21
4

0C4535
5

0C4536 1 Enclosure Rear Pane! 23 0C7027 1

6

0C5525 1 Insulation, Front Panel
7

0C5527 1 Insulation, LFI Side Panel 25 0C7029

8 0C5528 1 Insulation, RH Side Panel 26 0C7030 1

9

0C5529

10 0C5530 1 Insulation, Top Rear Panel 28 0C6425 1
11

0C5531 1 Insulation, Lifting Lug Cover

12

0C4986

1 Enclosure Panel Front

1

Insulation, Top Front Panel

1

Cover, Access Lift 30 0C7047A 1

PART NC.

0C7023 1 Decal, Battery +/-

0C7025 1

22 0C7026 1

24

0C7028

27

0C2340 1

29

049813

13 0C4987 1 Cover, Radiator Fill 31 0C7047B
14

0C5091 1 Cover, Access Electrical 32

15 0C6362
16

078115 33

17

0A7215 58

18

0C5096

1

Gasket, Electrical Access 33
Washer, Self Lock Dome 34

1/4 -20

X

5/8 W/Washer 35

1 Frame Control Panel -

0C4816 1
022097
098761 1

042755 1

Refer to Drawing C8005

46

Generac* Power Systems, Inc.

CTY. DESCRIPTION

1

Decal, Radiator Cap
Decal, Remote
Decal, Coolant
Decal, Fuel Return/Supply

1

Decal, Oil Fill / Level

1

Decal, Lifting Lug
Decal, Max Hot / Min Cooiant
Decal, Warning Rv
Support, Cooiant Tank

3 Nut, Hex M6-1.0

Foam, Air Duct Face

1 Foam, Air Duct Side

Decal, Unit

3 Washer, Split Lock /4“ - M6

Decal, Engine Data
Decal, CSA Approval

Appendix 5 — Exploded ¥iews and Parts Lists

QUIETPACT” 75D Recreational Vehicle Generator

Cooling System - Drawing No. 0D2360

18 14

.PARTS

LISTS

ITEM PART NO.QTY. DESCRIPTION

1 0C4551 1
2 0C4550

0C4552

3

0C4554 1 Shaft, Fan

4

0C4555 1

5

0C4557 1

6

0C4556 1

7

0C4553

8

049869

9

081810 1

10

11 070265

12 058443

13 043146

022097 19

14

15 049815

022152 4

16

17 051716

049813

18

0C4312 1

19

20 043116 3

21 022473
22 0C8645

0C8507 1

23

24

039253
022129 6

25

0C6549A 1

26
27 0C5108 1

Cover Plate, Scroll Weldment
Housing, Fan Scroll Weldment

1

Fan, Squirrel Cage

1

Carrier, Bearing
Key, Square 3/16" x 3/16" x 72"
Pulley, Fan 4-7/8"
Bearing 2 Ro\w Ball

1

Fender Washer Ml 6

1

Nut, Hex M16.0 -1.5mm
LockWasher Ml6.0

1

Crimptite, 14"-20 x 5/8"

7

HHCS M6-1.00 X 10mm

2

Washer, Split Lk !4"- M6
HHCS M5-0.8 X 16mm

4

Washer, Split Lk #10

4 Hex Nut M5

Nut, Hex M6.0 -1.0mm

12

Radiator 1 .OL RV
HHCS M6-1.00 X 12mm
Washer Vi"-M6

5

1 Pulley, 3" Flat Flanged

Bracket, Rotary Tensioner
HHCS M8-1.25x20mm

2

Washer, Split Lk -M8
61" Green Belt

Filler Neck Assembly, Radiator
Remote

28 0C6236

1 Hose Tee

ITEM PART NO.QTY. DESCRIPTION

0C7384

29

0C5543

30

0C4460

31

0C4845

32

0C5544 1 Hose, Lower Intermediate

33

086133A 8

34

035473

35

050968 720mm

36
37

042911
046526

38

047411

39

0C7997 270mm

40

0C7649

41

042907 4 HHCS M8-1.25 X 16mm

42

0C5605

43

0C6976

44
45
46
47
48
49
50

51

52
53

54

55

0C7997
055934K
0C4976
055934D
0C7040
055934V
045771
0C5105
024426
00C8643
048705

510mm Hose 5/16" SAE-20R4

Coupling, Hose

1

1 Hose, Radiator Lower
1 Hose, Water Pump Lower
1 Hose, Top

Hose Clamp Hi Trq 1 -3/4" Max

2 Hose Clamp #12

Hose, %" SAE-20R3
1 M10-1.5 x30mm HHCS
1 MIO Lockwasher
2 HHCS M6-1.00 X 16mm

Hose, 5/16" SAE-20R4

4 Hose Clamp 7/8" 3/8"

1

Cap, Coolant Fill
Tank, Coolant Overflow

1
1 Clamp, Vinyl Coated 1-5/8"

1 Cap, Radiator Pressure

1

Clamp, Vinyl Coated 1-1/16“

1 Gasket, Radiator Base

Clamp, Vinyl Coated l-Ya"

1

1 Nut, Hex M8-1.25

Bracket, Support

1
1 72"-13 X 1-3/4" HHCS

1

Tensioner

1 72"-13 Flange Nut

mm = Millimeters

Generac® Power Systems^ Inc. 47

^PARTS

USTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator
Electflca! Enclosure Assembly - Drawing No. D2361-A

EM PART NO. QTY.

1 0D2412 1

2 071914 1

3 083048
4

0C7610

1 Assembly, Potted Regulator
1

5 093642 1
6

065795

7

048512
8 027565
9 066849C 2

10

066849

11 022264 1
12 036902 2
13 040213
14

0C8620

15 043180

0D2021B

16
17

0C3992
0C7022 1

18
19 022985

4S Generac* Power Systems, Inc.

1
1

A/R Tape, Glass Insulated

1

4 Pcb Support Snap -In
1

1

1 Harness

4

4

DESCRIPTION

Weldment, Electrical Enclosure
Terminal Block 4 Position

Resistor 20R 5% 12W

Assembly Marine Control Board

Rectifier, Battery Charging
Circuit Breaker 5 Amp

Taptite, M5-0.8 x 30
Taptite, M5-0.8 x 16

Lockwasher M5
Screw, PPHM #6-32 X Va

HHMS, #8-32 X 2.25"
Washer, Flat M5

M4-0.7X 16 HHCS Taptite
Decal, Customer Connection
Washer, Flat #6

ITEM PART NO. QTY.

20 0C6359

21 0D2021G*

0D2021F*

22

0D2021D*

23

0D2021E*

24

0A1658

25

022473

26

022097 7 Washer, Split Lk y4-M6

27

049813

28

082121A

29
30 022717B

051787

31

32 0C7390

0C7487 1

33

023484D

34

A/R = As Required
* Not shown refer to Wiring Diagram C4946

1 Gasket, Electrical Enclosure
1 Wire Assembly # 32
1 Wire Assembly # 22

1 Diode Assembly

1
2 Va Special Lockwasher

2 Washer, Flat V4-M6

7 Nut, Hex M6-1

1 Clamp, Open Type

2 Grommet

2 HHCS, M4-0.7X 16mm

1 Gasket, Electrical Enclosure Divider

1

DESCRIPTION

Wire Assembly # 162

Harness, Ac Output
Bushing, Snap

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

Intake and Exhaust System - Drawing No. 0D2362

.PARTS

LISTS

PART NO. QTY. DESCRIPTION

ITEM

075674 1 EXHAUST GASKET 15 022129

1

0C4879 1 CHAMBER AIR INTAKE 16

2

0C4880 1 AIR FILTER

3

0C5493 1

4

0C4727 1 MUFFLER WELDMENT 19

5

HOSE, AIR INLET

6 025145 2 U BOLT & SADDLE 1.25
7 0C7645 1 RAIL, ENGINE LH, WELDMENT

0C5022

8

1 INSULATION, EXHAUST 22 035586

9 035685 4 HOSE CLAMP #28

0C4878 1 OUTLET, EXHAUST FLEX

10

0C6243 1 GASKET, EXHAUST OUTLET 25 022145

11

0C6244 1

12

PLATE, EXHAUST OUTLET

13 039288 2 HHCS M8-1.25X55

071956

14

2 WASHER, VIBRATION ISOLATOR

ITEM PART NO.

QTY.

DESCRIPTION

10 WASHER, SPLIT LK -M8

045771 5 NUT. HEX M8-1.25
17 058443 3 CRIMPTITE, y4"-20 X 5/8"
18

0C5105

022145
20 039253

21 043107

1 BRACKET. SUPPORT

4

WASHER, FLAT - M8
2 HHCS M8-1.25X20
4

HHCS M8-1.25X25

2 HOSE CLAMP #20

23 042909
24 042907

26

0709390357 1 MANIFOLD GASKET

27 075673

1

HHCS M8-1.25X30

1

HHCS M8-1.25X 16

2

FLAT WASHER, 5/16“

1

HORIZONTAL EXHAUST MANIFOLD

Generac* Power Systems, Inc. <49

.PARTS

USTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT“ 75D Recreational Vehicle Generator
Fuel and Electrical Systems - Drawing No. 0D2363

18

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO.

1 0C6946A 1 Fuel Pump Assembly 17
2 052219 3 1/8 NPT X 5/16 Barbed Straight Fitting 18 0C7413 1
3 069598B 2 Bulkhead Adaptor Fitting 19 022127

022097

4

038750 1 HHCS M6-1.00x30

5
6 056739 2 Relay Solenoid 22
7 049813 5 Nut, Hex M6-1

8 055934M 1

022473

9

10 040173 2 Hose Clamp
11 028414A 1 1/8 NPT X1/4 Barbed Straight Fitting 28
12 0C7649 3 Hose Clamp 7/8 / 3/8

047411 1 HHCS M6-1.00X 16

13
14

076821
022237

15

075763 3 Boot, Battery Cable

16

50 Generac* Power Syst;ems, Inc.

7 Washer, Split Lk- % -M6 20

Clamp, Vinyl Coat 3/4 25

5

1 Hex Nut 3/8-16 Brass
1 Washer Split Lk 3/8

Washer, Flat -M6 26

075763A

0536210201
0536210197

21

0A2053

24

075234 1 Resistor
030340
OC8008

27

0C8008
0C8009 1 Clamp, Fuel Pump

29

0D2021H 1

QTY.

3 Boot, Battery Cable

1 Hex Nut 74 - 20
1
1
1

1.04M Hose, 1/4 ID SAE-30R2
635mm Hose, 5/16 ID SAE-30R7
375mm Hose, 5/16 ID SAE-30R7

DESCRIPTION

Grommet 3/8 l/D x 1 GD

Cable, Battery
Cable, Starter
HHCS M6-1 X 65

Wire Assy, #0 (PHC-SC)

M = Meters

mm = Millimeters

Appendix 5 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

Customer Controls Assembly - Drawing No. 0D2364

.PARTS

LISTS

EM PART NO.

1

0D2398 1

2

0C4540 1
0C1457

3
4

081904 1
5 055920
6

043181
7 022159
8 055927

9 0C5127
10 0C7341
11

049226

12

0C7340 1
13 0D2021A
14 051714
15 0C4476
16

0C5096 1

QTY. DESCRIPTION

Start / Stop Switch 17 0C5126 1
Cover, Engine Control Box

1

Hour Meter
Fuse Holder, SFE-14

1 Switch, Pushbutton SPST

2 PPHMS M3-0.5X10
2 Lockwasher M3

1

Fuse, SFE-14

1

Decal

1

Boot / Nut / Preheat Switch

4 Lockwasher, M5

Boot, Circuit Breaker (with 4 sealing screws)

1

Harness

2

Hex Nut, M3

1

Box, Engine Control
Frame, Control Panel

ITEM PART NO. QTY. DESCRIPTION

Plug, Oil Fill

0C3971B

18
19 0C4883 1

0C4884

20

21 0C7649

22 057824 2
23 0C3992
24 022985

084135 1

25
26 0C6440 2
27

074969
28 049813 2
29 052749 4

Dipstick Assembly

1

Hose, Dipstick Tube

1

Hose, Filler Tube

2

Hose Clamp 7/8-3/8
Hose Clamp Size #16

4

M4-0.7x16HHCSTaptite

4

Washer, Flat #6
Grommet
Gasket, Engine Control Box

1

Circuit Breaker, 35A, 2 Pole
Nut, HexM6-1.0
PHMS M5-0.8X12

30 038150 4 Flat washer, #8

022097

31

2 Washer, Split Lock 14" - M6

Generac* Power Systems, inc. 51

.PARTS

USTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Camshaft - Drawing No. 075677

ITEM

PART NO.

1

0709390232 1

2

0709390233 1

3

0709390195 1 KEY
4 0709390234
5

0709390235 3 SPACER
6 0709390236 1
7

0709390237 1

52 Generac* Power Systems, Inc.

QTY.

1 GEAR

DESCRIPTION

CAMSHAFT ASSEMBLY
CAMSHAFT GEAR

BALL BEARING
SLIDER

ITEM PART NO. QTY.

8

0709390238 1 PLATE

9

0709390239 1 TACHOMETER SHAFT

10

0709390240 1 BOLT

11 0709390241

12 0709390242
13

0709390243 1 NUT

DESCRIPTION

1 BOLT

1 GASKET

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT“ 75D Recreational Vehicle Generator

1.0 Liter Diesel Cylinder Block- Drawing No. 075676

.PARTS

LISTS

ITEM PARINO. QTY. DESCRIPTION

1

0709390100

1 COMPLETE CYLINDER BLOCK

2 0709390447 1 EXPANSION PLUG 18
3 0709390101

1 EXPANSION PLUG 19
4 0709390102 2 EXPANSION PLUG
5 0709390103 2 EXPANSION PLUG
6 0709390104 1

EXPANSION PLUG 22 0709390131

7 0709390105 4 PLUG
8 0709390106 4

PLUG

9 0709390107 1 IDLE GEAR SHAFT 25

10

0709390108 1 BUSHING

11

0709390109
0709390110
0709390111

12 0709390112 1 BALL BEARING 30
13 0709390113 1 EXPANSION PLUG
14

0709390114 1 BALL BEARING

1

BUSHING-STANDARD

1

0.25MM U.S. BUSHING 28

1 0.50MM U.S. BUSHING 29

15 0709390115 1 DOWEL PIN
16 0709390116 1 DOWEL PIN

ITEM PART NO. QTY. DESCRIPTION

0709390117 2 DOWEL PIN

17

0709390118
0709390119

20 0709390120

21 0709390121

2 SPRING PIN

2 STUD

1 STUD
1

STUD

1 SNAP RING

23 0709390123

0709390124 1 DRAIN COCK

24

0709390125

26 0709390126

0709390127 6 TAPPET

27

0709390128 6
0709390129
0709390130

MM = MILLIMETER
U.S. = UNDERSIZE

1 OIL SEAL
1

CONNECTOR

1 OIL FILTER

PUSH ROD

1

RELIEF VALVE

1

0-RING

Generac® Power Systems, Inc. 53

.PARTS

USTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 750 Recreational Vehicle Generator

1.0 Liter Diesel Cylinder Head - Drawing No. 002794

11

'EM PART N0. QTY.

0709390147

1
2

0709390148 6
3 0709390447 3
4

0709390149 2
5

0709390150 3 INTAKE VALVE 17
6

0709390151 3
7

0709390152 3 VALVE GUIDE SEAL (EXHAUST)

0709390153 3
8 0709390154
9 0709390155 6

10 0709390156 12 KEY

11 0709390157

12 0709390158 1

0709390159 1

DESCRIPTION ITEM PART NO. QTY.

1

CYLINDER HEAD ASSEMBLY 13
EXPANSION PLUG
EXPANSION PLUG 15 0709390162 2
EXPANSION PLUG 16

EXHAUST VALVE 18 0709390165 2

VALVE GUIDE SEAL (INTAKE) 20 0D2791 1

6 SPRING

RETAINER 22

CAP

6

CYLINDER HEAD GASKET,

1.2MM THICK

CYLINDER HEAD GASKET,

1.3MM THICK

0709390160

14

0709390161

0709390163 2 BOLT
0709390164

19 0A8584 1

21

0709390168
0709390169

23 042574 1

DESCRIPTION

11

BOLT

3

BOLT
LIFTING EYE

1

TUBING

BOLT
OIL SWITCH
THERMO-SWITCH

4

GASKET

1

WASHER
ADAPTOR

MM=MILLIMETER

18

54 Geoerac* Power Systems, Inc.

Appendix 5 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Crankshaft, Piston and Flywheel - Drawing No. 075679-A

22

.PARTS

LISTS

ITEM PARINO. QTY. DESCRIPTION

1 0709390143 1 CRANKSHAFT ASSEMBLY

0709390194 1 CRANKSHAFT GEAR

2
3 0709390195
4 0709390196

5 0709390226

0709390197 1 BEARING HOLDER ASSEMBLY

6

7 0709390200

0709390664 1 BEARING HOLDER ASSEMBLY

8

9 0709390198 6

0709390199 6 DOWEL PIN

10

1 KEY
1

DOWEL PIN

1

SPRING PIN

1 BEARING HOLDER ASSEMBLY

BOLT

11 0709390202 3 STANDARD BEARING

0709390203
0709390204

12 0709390205 3

0709390206 AR 0.25MM U.S. BEARING
0709390207 AR
0709390208 2 THRUST WASHER

13

14 0709390209 2 BOLT

15 0709390210

AR

0.25MM U.S. BEARING

AR 0.50MM U.S. BEARING

STANDARD BEARING

0.50MM U.S, BEARING

1 BOLT

ITEM PARINO. QTY. DESCRIPTION

0709390214

16

0709390215
0709390216

0709390211 3

17

0709390212
0709390213
0709390217 3 PISTON PIN

18

0709390218

19

0709390219 3

20

0709390220

21

0709390221

22

0709390222

23

0709390223

24

0709390224 AR BEARING-0.25MM U.S.
0709390225
0709390230

28

0709390231

30

U.S. - UNDERSIZE
O.S. - OVERSIZE
AR - AS REQUIRED
MM - MILLIMETER

Qenerac® Power Systems, Inc. 55

STANDARD PISTON ASSEMBLY

3

AR PISTON ASSEMBLY-0.5MM O.S.
AR PISTON ASSEMBLY-1.OMM O.S.

STANDARD PISTON RING SET
AR PISTON RING SET-0.5MM O.S.
AR PISTON RING SET-1 .OMM O.S.

6

SNAP RING
CONNECTING ROD ASSEMBLY

3

BUSHING

6

CONNECTING ROD BOLT
6 NUT, CONNECTING ROD BOLT
6

STANDARD BEARING

AR BEARING-0.50MM U.S.

1

PULLEY

1

NUT

.PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Oil Pump - Drawing No. 075682

ITEM PARINO. QTY. DESCRIPTION

1

0709390250

2

0709390252

3

0709390251 1 THRUST WASHER

4

0709390253 1

5

0709390254

6

0709390255 AR
0709390532

1

IDLER GEAR ASSEMBLY

1

SPRING 8
ROTOR 10

1 OIL PUMP COVER

0.10MM SHIM 12

AR 0.15MM SHIM
0709390533 AR 0.20MM SHIM
0709390258 AR

5B Generac* Power Systems, Inc.

0.50MM SHIM

ITEM PARINO. QTY. DESCRIPTION

7

0709390259 1

SPRING

0709390260 1 COLLAR

9

0709390261 1 SNAP RING
0709390262 1 FRONT PLATE

11

0709390263 1 GASKET
0709390264

3 BOLT

AR - AS REQUIRED

Appendix 3 — Exploded ¥iews and Parts Lists

QUIETPAO™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Rocker Arm Assembly - Drawing No. 075683

.PARTS

LISTS

PART NO. QTY. DESCRIPTION

ITEM

1 0709390170 1
2 0709390171

3

0709390172 3

4

0709390174 6 NUT
0709390173

5
6 0709390175

3

6

3

ITEM PART NO.

ROCKER ARM ASSEMBLY
INTAKE ROCKER ARM
EXHAUST ROCKER ARM

STUD

ROCKER ARM BRACKET 12 0709390181

7 0709390176 1 ROCKER ARM SHAFT

0709390177

8

9 0709390178 2

10

11 0709390180 3 NUT

0709390179 3 SPRING,PIN

QTY. DESCRIPTION

SPRING

2

SCREW

3 STUD

Generac® Power Systems, Inc.

.PARTS

USTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel injector Pump - Drawing No. 075686-B

PART NO.

ITEM

1

0709390316

2

0709390317
0709390318
0709390319
0709390320

3

0709390298

4

0709390321 2

5

0709390322

6

0709390323 3 INSERT

7

0709390324 3 CAP 20

8

0709390325

9

0709390326
10
11
12

0709390327 1

0709390328

0709390329

SS Generac* Power Sys1:ems, Inc.

QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION

1 INJECTOR PUMP ASSEMBLY
AR
AR
AR
AR
3

3

3 INJECTOR

1

1

1

13 0709390330 1
14

SHIM-0.2MM
SHIM-0.3MM
SHIM-0.5MM
SHIM-1.OMM
NUT 19 0709390335 1
BOLT
GASKET

26 0709390341 1
TUBING
TUBING
TUBING
TUBING

27 0709390342

28

29 0709390344 1

0709390331 1 BOLT
16 0709390332
17 0709390333 1

0709390334

18

0C4736

0709390264

0709390343 1

CLAMP

GLOW PLUG

3

CONNECTOR

1 GASKET

COVER
(ALL MODELS EXCEPT 04270)

1

TUBE, ENGINE OIL FILL
(MODEL 04270 ONLY)

2

BOLT
SOLENOID

1 WASHER

WASHER
SCREW

AR - AS REQUIRED

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Fuel Supply - Drawing No. 75693-B

.PARTS

LISTS

rEM PART NO.

0709390661

1

069858

2

0C8008 AR

3
4 0C8008

040173 3

5
6 0709390378
7

0709390379
074808

8
9 052233

039450 2

10

QTY. DESCRIPTION

1
1

250MM HOSE, 5/16" SAE 30R7

2

FUEL FILTER SUPPORT
FUEL FILTER
HOSE, 5/16" SAE 30R7

HOSE CLAMP
GASKET

1 BANJO FiniNG
1

2 1/8" NPTTEE (BRASS)

FUEL BLEED FITTING

1/8" NPT X 3/16" 90 DEG.
BARBED FiniNG

PART NO. QTY.

ITEM

030096 2*

11

068736 275MM

12

068736 240MM

13
14 074823

074819

15
16 0709390651
17 0709290662

0709390663

18

028414A

19

‘ QTY 1 (MODEL 04270 ONLY)
AR - AS REQUIRED

Generac® Power Systems, Inc. 53

DESCRIPTION

1/8" NPT X 3/16" BARBED
STRAIGHT FiniNG
HOSE, 3/16" SAE 30R2
HOSE, 3/16" SAE 30R2

4 HOSE CLAMP
1 FUEL BLEED FITTING
5
2

2 BANJO FITTING

FUEL BLEED GASKET
HOLLOW BOLT

1 1/8" NPT X V4" BARBED

STRAIGHT FiniNG
(MODEL 04270 ONLY)

.PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Timing and Governor - Drawing No. 082067

ITEM PART NO.

1

0709390285

2 0709390286 1 SPRING PIN
3 0709390287 1 GASKET
4

0709390307 1 SPRING 33

5 0709390308 1 WASHER 34
6 0709390309 2 NUT

7 0709390310 1

0709390314

8

11

0709390296 1 GOVERNOR LEVER 38 071944

12 0709390297 1 BOLT 39
13 0709390298
14

0709390299
15 0709390300 1 0-RING 42
16 0709390301
17

0709390540 3*
18

0709390282 5
19

0709390288 1 OIL SEAL 46 0709390541 1 * BOLT
20 0709390274 4 BOLT 47
21

0709390311 5 BOLT 48
22 0709390304 1 ARM
23 0709390305 1 SNAP RING
24

0709390306 1 0-RING 50
25 0709390289 1
26

0709390290
27

0709390291
28 0709390136 1 WASHER
29 0709390292 1 COTTER PIN

60

Generac® Power

QTY. DESCRIPTION ITEM

1

TIMING GEAR HOUSING 30

31 0709390293 1 SPRING
32 0709390294 1 ARM

35 0709390302 1 BRACKET

STOP LEVER 36 0709390271

2 COVER 37

1

1 SHAFT 41

1

1 TENSION LEVER

1

NUT 40 0709390534

SNAP RING 43
BOLT 44
BOLT

GOVERNOR LEVER ASSEMBLY 51 045771 4

SNAP RING

Systems, Inc.

45

49 051730 3

52 022129 4

PART NO. QTY. DESCRIPTION

0709390313 1 SPRING

0709390295 1 0-RING
0709390291 1 SNAP RING

0709390303 2

0709390660

0709390535
0709390536 1
0709390537 1 * HOLDER (OIL FILL)
0709390539 1 * 0-RING
0709390188

0709390538
0C4888

052265 1 BOLT (MODEL 04270 ONLY)

* NOT USED ON MODEL

3 BOLT

BOLT

1 HHCS M6-1.0X25MM

1 0-RING

1 * 0-RING
1 * SPACER

1 * CAP

3* NUT
1

GASKET

BRACKET, FUEL FILTER (MODEL

04270 ONLY)

BOLT (MODEL 04270 ONLY)

NUT (MODEL 04270 ONLY)
SPLIT LOCK WASHER M8
(MODEL 04270 ONLY)

04270

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Engine Block - Drawing No. 082961-A

.PARTS

LISTS

ITEM PART NO.

0709390139 1 OIL PAN

1

0709390140 20 BOLT

2

12 0709390143

0C4641

13
14 0709390145 5

0709390144

0709390146 1 DIPSTICK

15

0709390183 1 ROCKER COVER GASKET

17

0709390184

18

QTY. DESCRIPTION

1

DIPSTICK TUBE
(ALL MODELS EXCEPT 04270)

1

DIPSTICK TUBE
(MODEL 04270 ONLY)

0-RING

2

BOLT

(ALL MODELS EXCEPT 04270) 31

ROCKER COVER

1

ITEM

19 0709390185
20 0709390186
22 0709390168
23
24 0709390188
25
28
29
30

33

PART NO.

0709390187 3 NUT

0709390189
026073-A
0709390244
0709390245
0709390246

0709390122

29

QTY. DESCRIPTION

1

OIL STOPPER

1

SCREEN

1 GASKET

1 CAP
1

0-RING

1

1/4" PIPE PLUG SO. HD.

1

0-RING

1

TUBING

1

SUCTION FILTER

1 GASKET

Generac* Power Systems, Inc. Si

.PARTS

USTS

Appendix 3 - Exploded Views and Parts Lists

QUIETPACr* 75D Recreational Vehicle Generator

1.0 Liter Diesel Water Pump - Drawing No. 082962

10

ITEM PART NO.

1

0709390265 1

2

0709390266

3 0709390267 1
4

0709390268

5

0709390269 3

6

0709390270

7 0709390271 1 BOLT

DESCRIPTION

QTY.

WATER PUMP ASSEMBLY

1

PLUG
THERMOSTAT

1

SPRING 11
GASKET

1 SET PLATE

12

ITEM PART NO.

QTY. DESCRIP

8 0709390272 1 GASKET

9 0709390273 1 BOLT

10
12

15 0709390284 1 BOLT

0709390274
0709390275 1 NUT
0709390247 1 PULLEY

1 BOLT

15

S2

Generac* Power Systems, Inc.

Appendix 4 — Notes

QUIETPAGT™ 75D Recreational Vehicle Generator

NOTES

Generac® Power Systems, Inc. B3

Cr=^—I

Appendix 5 - Warranty

QUIETPACT™ 75D Recreational Vehicle Generator

FEDERAL AND CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT

(for non-road Diesel engines rated under 19 kW)

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), Generac Power Systems, Inc.
(GENERAC), and the engine manufacturer for this equipment, Ishikawajima Shibaura Machinery Co., Ltd. (ISM), are
pleased to explain the federal and California emission control system warranty on your engine.

In California, new 2000 and later small non-road engines must be designed, built, and equipped to meet the state's strin
gent anti-smog standards. In other states, new 2000 and later non-road diesel engines rated under 19 kW must be designed,
built, and equipped to conform to applicable EPA regulations.

ISM must warrant the emission control system on your engine for that period of time listed below, provided there has been
no abuse, neglect, or improper maintenance of your small non-road diesel engine.

Your California and EPA emission control system may include parts, such as, the fuel injection system and other emission­related assemblies.

Where a warrantable condition exists, GENERAC will repair your engine at no cost to you, including diagnosis, parts, and labor,

on behalf of ISM. Although ISM is ultimately responsible for this warranty, GENERAC has agreed to carry out ISM's warranty

repair responsibilities, and GENERAC should be your primary contact for emission-related warranty service.

iVIANUFAaURER'S WARRANTY COVERAGE

For 2000 and later small non-road diesel engines, first sold in California, and for 2000 and later non-road diesel engines
rated imder 19 kW, first sold in all other states, the applicable warranty period is two (2) years or 1,500 hours, whichever comes
first.

If any emission-related part on yom engine is defective, the part will be repaired or replaced by a Generac Authorized
Warranty Service Facility on behalf of ISM.

PARTS COVERED

This emission control system warranty applies to the following engine emission control parts.

• Fuel Injection Pump • Fuel Injectors
Intake Manifold

Air Cleaner Element

Exhaust Manifold
Miscellaneous Hoses, Bolts and Connectors

OWNER'S WARRANTY RESPONSIBILITIES

As the engine owner, you are responsible for the performance of the required maintenance listed in your Ow ne r's M an ua l.

GENERAC and ISM recommend that you retain the original purchase documentation and all receipts covering maintenance
on your engine, but GENERAC and ISM cannot deny warranty solely for the lack of receipts or for your failure to ensure the

performance of all scheduled maintenance.
As the engine owner, you should be aware, however, that GENERAC and ISM may deny you warranty coverage if your engine

or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The

warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty Service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.

To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

If you have any questions regarding your warranty rights and responsibilities, you should contact GENERAC at the
following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC

211 MURPHY DRIVE

EAGLE, Wl 53119

Page 1

64 Generac* Power Systems, Inc.

Appendix 5 - Warranty

QUIETPACr" 75D Recreational Vehicle Generator

OBLIGATIONS AND RIGHTS OF THE iVIANUFACTURER AND OWNER

The new model year, class of diesel engine, and emission application determination for your engine are identified on the
emission control information label affixed to the right-hand side of your engine's timing gear case. The warranty period

begins on the date the new equipment is sold to the first retail purchaser.
Any emission control system parts scheduled for regular inspection that are proven defective during normal use will be

repaired or replaced during the warranty period. Any warranted part that is scheduled for replacement, and that fails prior
to replacement, will be repaired or replaced under warranty, and the repaired or replaced part will be covered under war
ranty for the remainder of the period prior to the first scheduled replacement. The warranty repairs and service will be per
formed by any Generac Authorized Warranty Service Facility, with no charge for parts or labor (including diagnosis).

As the engine owner, you are responsible to perform all the required maintenance listed in your O w ne r' s Ma n ua l. GEN

ERAC will not deny an emission warranty claim solely because you have no record of maintenance; however, a claim
may be denied if your failure to perform maintenance resulted in the failure of a warranted part. Receipts covering reg
ular maintenance should be retained in the event of questions, and these receipts should be passed on to each subse
quent owner of the engine.

It is recommended that replacement parts used for maintenance or repairs be GENERAC authorized and approved parts,
to maintain the quality originally designed into your emission-certified engine. However, any replacement part may be used
in the performance of any warranty maintenance or repairs and must be provided without charge to the owner. Such use
will not reduce the warranty obligations of GENERAC. Add-on or modified parts may not be used for maintenance or war
ranty repairs. Such use will be grounds for disallowing a warranty claim, and GENERAC will not be liable to warrant fail
ures of warranted parts caused by the use of an add-on or modified part.

LIMITATIONS

This warranty shall not cover any of the following:

(a) Systems and parts that were not first installed on the new equipment or engine as original equipment by GENERAC.
(bj Conditions resulting from tampering, misuse, abuse, improper adjustment, engine alteration, use of add-on or modified

parts, use of replacement parts that are not the same in performance and durability as GENERAC-approved replacement
parts, accident,'failure to use the recommended fuel or oil, use of unapproved fuel or oil additives, or failure to perform
required maintenance.

(c) Replacement parts used for required or scheduled maintenance.
(d) Consequential damages, such as, loss of time, inconvenience, or loss of use of this engine or equipment.

(e) Damages or repair costs caused by the owner's unreasonable delay in making the engine available for inspection

and repair.
(f) Diagnosis or inspection fees that do not result in eligible warranty service being performed.
(g) Equipment with an altered or disconnected hourmeter, where the hours cannot be determined.
(h) Equipment normally operated outside the United States.
(i) Accident-caused damage, acts of nature, or other events beyond GENERAC’S control.
(j) Warranty repairs undertaken or attempted by the owner or any other person who is not affiliated with a Generac

Authorized Warranty Service Facility.

OBTAINING WARRANTY SERVICE

To obtain service under this warranty, promptly contact your nearest Generac Authorized Service Dealer or a Generac
Authorized Warranty Service Facility. If available, provide the GENERAC representative with the original purchase receipt

(showing the initial date of purchase) and all available maintenance records.

Page 2

Generac* Power Systems, Inc. S5

Appendix 5 - Warranty

QUIETPACT™ 75D Recreational Vehicle Generator

GENERAC POWER SYSTEIVIS^ THREE-YEAR LIMITED WARRANTY

FOR RECREATIONAL VEHICLE GENERATORS

NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES.
For a period of 3 (three) years or 2,000 (two thousand) hours of operation from the date of original sale, whichever occurs first, Generac
Power Systems, Inc, (Generac) will, at its option, repair or replace any part which, upon examination, inspection, and testing by Generac
or a Generac Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty
schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest
Generac Authorized Warranty Service Facility. All transportation costs under the warranty, including return to the factory, are to be borne
and prepaid by the purchaser/owner. This warranty applies only to Generac generators sold and rated for "Recreational Vehicle” (RV) appli
cations, as Generac has defined Recreational Vehicle generator applications. This warranty is effective only upon Generac’s receipt, from
the original purchaser/owner, of a completed Warranty Registration Card. This card is the only valid registration identification and must be
presented at time of request for warranty service. Claims will not be accepted without presentation of the Warranty Registration Card. The
factory recommends exercising the unit one half-hour every season.

WARRANTY SCHEDULE - COMMERCIAL APPLICATIONS

YEAR ONE - 100% (one hundred percent) coverage on partis), labor, removal, and réinstallation listed:

• Engine - All components

• Alternator - All components

• Transfer System - All components

WARRANTY SCHEDULE - CONSUMER/PERSONAL APPLICATIONS

YEARS ONE AND TWO - 100% (one hundred percent) coverage on part(s), labor, removal, and reinstallation listed:

• Engine - All components

• Alternator - All components

• Transfer System - All components
YEAR Three - 100% (one hundred percent) only on selected part(s) and labor listed (Any labor and partis) not listed, and removal and rein-

• Rotor, Stator, Computer Control Board, (if applicable with regard to the generator) Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Viilve,

Valve Lifter(s), IntaJkf and Exhaust Manifolds

The drive train belt and pulleys (excluding tensioners) on generators used in recreational vehicles shall be warranted against failure due to

defective materials or normal usage for the life of the generator. For the original purchaser/owner, this drive train warranty shall include
partis) and labor (removal and reinstallation are not included), plus $50 (fifty dollars - U.S.) payment upon return of the failed belt or pul
ley by the original purchaser/owner. For subsequent purchaser/owner, this drive train warranty shall cover belt and pulley partis) ONLY
(labor not included). Labor, removal, and reinstallation are the responsibility of the subsequent purchaser/owner.

Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators manu
factured after January 1, 1998, have a transferable warranty to the second owner, ONLY for the remainder of the three-year limited war
ranty. Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of
any warranty service.

All warranty expense allowances are subject to the conditions defined in Generac’s super seI^'^ice information manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Costs of normal maintenance, adjustments, installation, and startup,

• Failures caused by any contaminated fuels or oils.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all

mechanical devices, engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when
normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as, collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing,

lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any incidental, consequential, or indirect damages caused by defects in materials or workmanship, or any delay in repair or replace

ment of the defective part(s).

• Failure due to misapplication.

• Telephone, telegraph, teletype or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.

• Rental equipment used whfle warranty repairs are being performed.

• Overnight freight costs for replacement partis).

• Overtime labor.

• Starting batteries, fuses, light bulbs, and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER
WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how
long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S), AS STATED ABOVE, IN NO EVENT SHALL GEN
ERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEL^IF SUCH DAMAGES ARE A DIRECT RESULT OF GEN
ERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limita
tion may not apply to you. Purchaser/owner agrees to make no claims against Generac based on negligence.

This warranty gives you specific legal rights. You also may have other rights that vary from state to state.

Part Mo. D2354

stallatio, are the owner’s responsibility):

FOR THE LIFE OF THE RECREATIONAL VEHICLE GENERATOR (IF SO EQUIPPED)

GENERAC« POWER SYSTEMS, INC.

P.O.

BOX S • WAUKESHA, Wl

Revision O (03/01 /01 ]

531 S7

Printed in U.S.A.