Models: 004703-1, 004705-1, 004706-1,
004707-1, 005750-0. 005854-0,
005858-0, 005859-0, 005860-0
Owner's Manual
This manual should remain with the unit.
Air-cooled Recreational
Vehicle Generators
Quietpact
®
55, 65 and 75
Table of Contents
Part I — Operating Instructions
Introduction ............................................................................1
Read This Manual Thoroughly ........................................................1
Contents ........................................................................................1
Operation and Maintenance ............................................................1
How to Obtain Service ...................................................................1
Authorized Service Dealer Locator Number ......................................... 1
Safety Rules ..........................................................................2
Section 1 – General Information ............................................4
1.1 Generator Identification ..........................................................4
1.2 Generator Applicability ...........................................................5
1.3 Installation .............................................................................5
1.4 Safety ....................................................................................5
1.5 Generator AC Connection System ..........................................5
1.6 Specifications ........................................................................6
1.7 Evaporative Emissions Information .........................................7
1.8 Exhaust Emissions Information (Gasoline) ..............................7
1.9 Exhaust Emissions Information (Propane) ..............................8
Section 2 – Operation ............................................................8
2.1 Generator Control Panel .........................................................8
2.2 Optional Remote Start/Stop Panel...........................................9
2.3 Automatic Choke....................................................................9
2.4 Before Starting the Engine ......................................................9
2.5 Starting the Generator ..........................................................10
2.6 Stopping the Generator ........................................................10
2.7 Applying Loads to Generator ................................................10
2.8 Protection Systems ..............................................................11
Section 3 – Maintenance .....................................................12
3.1 Checking the Engine Oil Level...............................................12
3.2 Changing the Engine Oil and/or Oil Filter ...............................12
3.3 Maintaining the Engine Air Cleaner .......................................13
3.4 Checking the Engine Spark Plug ...........................................13
3.5 Fuel Filter (Gasoline Only) .....................................................14
3.6 Clean Spark Arrestor ............................................................14
3.7 Cleaning the Generator .........................................................14
3.8 Battery Maintenance ............................................................14
3.9 Adjusting Valve Clearance ....................................................15
3.10 Major Service Manual ..........................................................16
3.11 Drive Belt .............................................................................16
3.12 Exercising the Generator ......................................................16
3.13 Out of Service Procedure .....................................................16
3.14 RV Generator Service Interval ...............................................16
Part II — Installation Instructions
Safety Rules ........................................................................20
Notice to Installer .........................................................................20
Section 1 — General Information ........................................22
1.1 Purpose and Scope of the Installation Instructions................22
1.2 Safety ..................................................................................22
1.3 Standards Booklets ..............................................................22
1.4 Equipment Description .........................................................22
1.5 Generator Engine Operating Speed .......................................22
1.6 Generator AC Connection System ........................................22
Major Features and Dimensions ...........................................23
Section 2 — Installation ......................................................24
2.1 Location and Support...........................................................24
2.2 Generator Compartments .....................................................25
2.3 Cooling and Ventilating Air ....................................................27
2.4 Gasoline Fuel System ...........................................................29
2.5 LP Gas Fuel System .............................................................30
2.6 Exhaust System ...................................................................31
2.7 Electrical Connections ..........................................................33
2.8 Battery Installation ...............................................................34
2.9 Optional Accessories ...........................................................36
Section 3 — Post Installation ..............................................36
3.1 Post Installation Tests ...........................................................36
3.2 Before Initial Start-up ...........................................................36
3.3 Initial Start ...........................................................................36
3.4 Testing Under Load ..............................................................37
3.5 Installation Checklist ............................................................38
Section 4 – Troubleshooting ................................................39
4.1 Troubleshooting Guide ..........................................................39
Section 5 – Electrical Data ..................................................40
Section 6 – Exploded Views and Parts Lists ........................42
Section 7 – Warranty ...........................................................52
Section 4 – Notes ................................................................17
Introduction
INTRODUCTION
Thank you for purchasing this model by Generac Power Systems
Inc. This model is designed and manufactured to supply electrical
power for recreational vehicles.
READ T HIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing
procedures.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:
Indicates a hazardous situation or action which, if
not avoided, will result in death or serious injury.
Indicates a hazardous situation or action which, if
not avoided, could result in death or serious injury.
Indicates a hazardous situation or action which,
if not avoided, could result in minor or moderate
injury.
The operator (driver) is responsible for proper and safe use of the
vehicle and its equipment, and the safety of all vehicle occupants.
We strongly recommend that the operator read this manual and
thoroughly understand all instructions before using this equipment.
We also strongly recommend instructing other occupants in the
vehicle to properly start and operate the generator. This prepares
them if they need to operate the equipment in an emergency.
C ONTENTS
This manual contains pertinent owner’s information, including
warranty, electrical diagrams, exploded views and lists of repair
parts. 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
an Authorized Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the owner/operator
and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits
and usage contribute to the need for maintenance service.
Proper maintenance and care of the generator ensures a minimum
number of problems and keep operating expenses at a minimum.
See an Authorized Service Dealer for service aids and accessories.
NOTE:
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the action or service are essential to
preventing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
This symbol points out important safety information that, if not followed, could endanger
n
personal safety and/or property of others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical
shock hazard.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, simply contact
an Authorized Service Dealer for assistance. Service technicians
are factory-trained and are capable of handling all service needs.
When contacting an Authorized Service Dealer or the factory about
parts and service, always supply the complete model number and
serial number of the unit as given on its data label, which is located
on the generator.
Model No. _________________ Serial No. ______________
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED SERVICE
DEALER, please call this number:
1-800-333-1322
or locate us on the web at:
www.guardiangenerators.com
1
Safety Rules
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be
copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all
n
operators and potential operators of this equipment.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this manual and
with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and fundamental
rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit, are, therefore, not all-inclusive.
If using a procedure, work method or operating technique the
manufacturer does not specifically recommend, ensure that it is
safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
Despite the safe design of this generator,
operating this equipment imprudently, neglecting
n
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
n
generators.
GENERAL HAZARDS
For safety reasons, the manufacturer recommends that the •
installation, initial start-up and maintenance of this equipment
is carried out by an Authorized Service Dealer.
The generator engine releases DEADLY carbon monoxide gas •
through its exhaust system. This dangerous gas, if breathed
in sufficient concentrations, can cause unconsciousness or
even death. Never operate the generator set with the vehicle
inside any garage or other enclosed area. DO NOT OPERATE
THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR
HAS BEEN DAMAGED. SYMPTOMS OF CARBON MONOXIDE
POISONING ARE (a) inability to think coherently, (b) nausea,
(c) vomiting, (d) twitching muscles, (e) throbbing temples,
(f) dizziness, (g) headaches, (h) weakness, and (i) sleepiness. IF EXPERIENCING ANY OF THESE SYMPTOMS, MOVE
INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP. Shut down the generator and do not operate it
until it has been inspected and repaired.
Never sleep in the vehicle while the genset is running unless the •
vehicle has a working carbon monoxide detector. The exhaust
system must be installed in accordance with the genset installation manual. Make sure there is ample fresh air when operating the genset in a confined area.
The engine exhaust fumes contain carbon monoxide, which can •
be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This
exhaust system must be installed properly, in strict compliance
with applicable codes and standards. Following installation, do
nothing that might render the system unsafe or in noncompliance with such codes and standards. The generator compartment must be completely vapor sealed from the vehicle interior.
There must be no possibility of exhaust fumes entering the
vehicle interior. 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 ventilating air is •
critical to correct generator operation and is required to expel
toxic fumes and fuel vapors from the generator compartment.
Without sufficient cooling airflow, the engine/generator quickly
overheats, which causes serious damage to the generator. Do
not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of
the generator.
When working on this equipment, remain alert at all times. •
Never work on the equipment when physically or mentally
fatigued.
Inspect the generator regularly, and contact the nearest Authorized •
Service Dealer immediately for parts needing repair or replacement.
Before performing any maintenance on the generator, discon-•
nect its battery cables to prevent accidental start up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
or (–) first. Reconnect that cable last.
Never use the generator or any of its parts as a step. Stepping •
on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
2
Safety Rules
ELECTRICAL HAZARDS
The generator covered by this manual produces dangerous •
electrical voltages and can cause fatal electrical shock. Avoid
contact with bare wires, terminals, connections, etc., while the
unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must
be done around an operating unit, stand on an insulated, dry
surface to reduce shock hazard.
Do not handle any kind of electrical device while stand-•
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
During installation onto the vehicle, have the generator prop-•
erly grounded (bonded) either by solid mounting to the vehicle
frame or chassis, or by means of an approved bonding conductor. DO NOT disconnect the bonding conductor, if so equipped.
DO NOT reconnect the bonding conductor to any generator part
that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a
flexible conductor that is of No. 8 American Wire Gauge (AWG)
copper wire minimum.
In case of accident caused by electric shock, immediately •
shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting
implement, such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply first aid and
get immediate medical help.
Never wear jewelry when working on this equipment. Jewelry •
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
FIRE HAZARDS
For fire safety, the generator must be installed and maintained •
properly. Installation always must comply with applicable
codes, standards, laws and regulations. Adhere strictly to local,
state and national electrical and building codes. Comply with
regulations the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is
installed in accordance with the manufacturer’s instructions
and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in
noncompliance with the aforementioned codes, standards,
laws and regulations.
Keep a fire extinguisher in the vehicle at all times. Extinguishers •
rated “ABC” by the National Fire Protection Association are
appropriate for use on the recreational vehicle generator electrical
system. Keep the extinguisher properly charged and be familiar
with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department.
EXPLOSION HAZARDS
Do not smoke around the generator. Wipe up any fuel or oil spills •
immediately. Ensure that no combustible materials are left in the
generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator
clean and free from debris.
Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE. •
Do not permit smoking, open flame, sparks or any source of
heat in the vicinity while handling gasoline. Comply with all laws
governing the storage and handling of gasoline.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
3
General Information
1.1 GENERATOR IDENTIFICATION
Please record the following information from the generator DATA DECAL or information decal.
1. Model Number _____________________ 2. Serial Number __________________
3. kW Rating _________________________ 4. Rated Voltage __________________
5. Phase _____________________________ 6. Hertz __________________________
14
16
8
17
13
12
4
CONTROL CENTER
FUSE
7.5A
IF GENERATOR DOES NOT START, REMOVE
AND INSPECT FUSE.
(SEE OWNER'S MANUAL TROUBLE SHOOTING
GUIDE.)
PRESS PRIME SWITCH FOR 10 SECONDS BEFORE STARTING. WHEN STARTING, DO
NOT PRESS START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT.
SERVICEACCESSPA NEL
AIR FILTER LOCATED BEHIND PANEL.
MAINTENANCE SCHEDULE
AIR FILTER:
CLEAN PREFILTER
EVERY 100 HOURS.
*
REPLACE ELEMENT
EVERY 250 HOURS.
*
CHANGE EVERY 100
OIL & OIL FILTER:
HOURS. (OR ANNUALLY)
*
PERFORM MORE OFTEN IN DUSTY CONDITIONS
*
OIL CAPACITY
1.8L/1.9QT
WITH FILTER:
(SAE VISCOSITY)
TEMPERATURE:
SAE 30 OR 10W-30
40°F AND HIGHER
-20°F TO 40°F
5W-30 OR 5W-20
WHEN SERVICE OR PARTS ARE NEEDED IN THE USA OR CANADA,
CONTACT THE GUARDIAN SERVICE LOCATOR AT 1-800-333-1322.
1
2
CIRCUIT
BREAKER
CIRCUIT
BREAKER
FUEL
START
STOP
PRIME
INSPECT & CLEAN
SPARK PLUGS:
PLUGS EVERY 100 HOURS.
REPLACE PLUGS EVERY
500 HOURS. (IF NECESSARY)
FUEL FILTER:
CHANGE EVERY 400 HOURS.
(OR ANNUALLY)
CHECK DAILY
OIL LEVEL:
PREFILTER P/N:
0D4511
REPLACEMENT
INFORMATION:
0D9723
AIR FILTER P/N:
070185
OIL FILTER P/N:
072347
SPARK PLUG P/N:
FUEL FILTER P/N:
087769
5
10
3
11, 15 (Behind Access Panel)
19
7
6
1. Generator Air Intake Screen
2. Data Plate
3. Engine Start/Stop Switch
4. 7.5 amp Fuse
5. Circuit Breaker
6. Optional Remote Panel Receptacle
7. Generator AC Output Leads
8. Starter Contactor
9. Fuel Inlet
10. Fuel Primer Switch
4
9, 18
20
REFERENCE NUMBER IDENTIFICATION
11. Fuel Pump (Behind access panel.)
12. Oil Filter
13. Oil Drain Plug
14. Oil Dipstick and Filler Tube
15. Air Filter (Behind access panel.)
16. Spark Plugs
17. Exhaust Outlet
18. Fuel Filter
19. LP Fuel Inlet
20. Evaporative Port
General Information
1.2 GENERATOR APPLICABILITY
These generators have been designed and manufactured for supplying electrical power for recreational vehicles. DO NOT modify
the generator or use it for any application other than for what it
was designed. If there are any questions pertaining to its application, write or call the factory. Do not use the unit until advised by
competent authority.
For fire safety, the generator must have been
properly installed in compliance with ANSI
119.2-1975/NFPA 501C-1974, “Standard for
Recreational Vehicles, Part III – Installation of
Electrical Systems.” The generator also must
have been installed in strict compliance with the
manufacturer’s detailed installation instructions.
After installation, do nothing that might render
the unit in noncompliance with such codes,
standards and instructions.
Use the generator set to supply electrical power for operating one
of the following electrical loads:
QUIETPACT 55G & LP: 120 and/or 240 volts, single phase, 60 •
Hz electrical loads. These loads can require up to 5500 watts
(5.5 kW) of total power, but cannot exceed 45.8 AC amperes of
current at 120 volts or exceed 22.9 AC amperes at 240 volts.
QUIETPACT 65G & LP: 120 and/or 240 volts, single phase, 60 •
Hz electrical loads. These loads can require up to 6500 watts
(6.5 kW) of total power, but cannot exceed 54.1 AC amperes of
current at 120 volts or exceed 27 AC amperes at 240 volts.
QUIETPACT 75G & LP: 120 and/or 240 volts, single phase, 60 •
Hz electrical loads. These loads can require up to 7500 watts
(7.5 kW) of total power, but cannot exceed 62.5 AC amperes of
current at 120 volts or exceed 31.2 AC amperes at 240 volts.
Do not overload the generator. Some installations may require that electrical loads be alter-
n
nated to avoid overloading. Applying excessively high electrical loads may damage the
generator and may shorten its life. Add up the
rated watts of all electrical lighting, appliance,
tool and motor loads the generator will power
at one time. This total should not be greater
than the wattage capacity of the generator. If
an electrical device nameplate gives only volts
and amps, multiply volts times amps to obtain
watts (volts x amps = watts). Some electric
motors require more watts of power (or amps
of current) for starting than for continuous
operation.
1.3 INSTALLATION
This Owner’s Manual has been prepared under the assumption
that a competent, qualified technician installed the generator into
a recreational vehicle. We also assume the installer complied
with all applicable codes, standards and regulations pertaining to
installation.
An INSTALLATION MANUAL was shipped with the generator. That
Manual contains manufacturer’s instructions and recommendations for installing the unit into an industrial vehicle. After installation, installers should forward the Installation Manual to Owners/
Operators for their information.
Owners/Operators have the responsibility to make sure that nothing is done that might render the installation unsafe or in noncompliance with applicable codes, standards and instructions.
1.4 SAFETY
Before using the generator set, carefully read GENERAL SAFETY
RULES inside the cover. Comply with these RULES to prevent
accidents and damage to equipment and/or property. The manufacturer suggests copying and posting the GENERAL SAFETY
RULES to potential operators of this equipment.
1.5 GENERATOR AC CONNECTION SYSTEM
These air-cooled generator sets are equipped with dual stator
AC power windings. These two stator windings supply electrical
power to customer electrical loads by means of a dual 2-wire
connection system.
Generators may be installed to provide the following outputs:
1. 120 VAC loads only — one load with a maximum total watt-
age requirement equal to the generator’s rated power output
(in watts), and 120V across the generator output terminals.
Figure 1.1 shows the generator lead wire connections for
120VAC ONLY.
Figure 1.1 – Connection for 120 Volts Only
5
General Information
2. 120/240 VAC loads — one load with a maximum total wattage requirement equal to the generator’s rated power output,
and 240V across the generator output terminals; or two seperate loads, each with a maximum total wattage requirement
equal to half of the generator’s rated power output (in watts),
and 120V across the generator output terminals. Figure 1.2,
shows the generator lead wire connections for 120/240 VAC
loads. Also refer to the "Line Breakers" section for circuit
breaker ratings.
This procedure should be done by an Authorized Service Dealer or
other qualified installer.
Figure 1.2 - Connection for 120/240 Volts
T1
CB1
RED
T2
WHITE
The manufacturer does not recommend using
any gasoline containing alcohol (such as
n
“gasohol”). If using any gasoline containing
alcohol, it must not contain more than 10 percent ethanol, and it must be removed from the
generator during storage. Do NOT use any
gasoline containing methanol. If using gasoline
with alcohol, inspect more frequently for fuel
leaks and other abnormalities.
LP Fuel Consumption (lb./hour)
The LP powered range of generators are fitted with a nonadjustable, factory set system. These systems are tamper-proof to meet
1997 California Air Resources Board requirements for engine
emission.
Model Idle 50% Load 100% Load
QuietPact 55LP 2.34 3.96 5.07
QuietPact 65LP 2.34 4.20 6.50
QuietPact 75LP 2.34 4.44 8.75
STATOR POWER
WINDINGS
CB2
GROUNDED NEUTRAL
T3
BLACK
1.6 SPECIFICATIONS
1.6.1 FUEL REQUIREMENTS
This generator is equipped with a gasoline or LP fuel system.
Specific installations may provide either a separate fuel tank for
the generator, or the generator may “share” the vehicle engine’s
fuel tank.
Gasoline Fuel Consumption (gph)
Model 10% Load 50% Load 100% Load
QuietPact 75G 0.51 0.80 1.28
NOTE
Some installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine’s
pickup tube. Such an arrangement causes the generator engine
to “run out of gas” while adequate fuel for the vehicle remains
in the tank.
To reduce lead and carbon deposits use high quality UNLEADED
gasoline with the generator. Leaded REGULAR grade gasoline is an
acceptable substitute.
NOTE:
Using unleaded gasoline contributes to longer engine valve life
by reducing lead and carbon deposits.
1.6.2 ENGINE OIL REQUIREMENTS
Use only high quality detergent oil rated with American Petroleum
Institued (API) Classification SF, SG, SH or SJ. The recommended
oil viscosity weights include the following:
During summer months (40 deg. F and higher), SAE 30 or SAE •
10W-30
During winter months (40 deg. F to -20 deg. F), SAE 5W-30 or •
SAE5W20
DO NOT USE SAE 10W-40•
Crankcase and oil filter capacity is approximately 1.8 L or 1.9 U.S.
quarts. DO NOT use special additives. See sections "Checking the
Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter" for
oil level check and filling procedures.
1.6.3 ENGINE SPECIFICATIONS
Type of Engine ..................................................................................... GT-760
Cooling Method ...............................................................................Air-cooled
Rated Horsepower ..................................................................27 at 3600 rpm
Displacement ......................................................................................... 760cc
Compression Ratio ..............................................................................8.6 to 1
Cylinder Block ................................................... Aluminum w/Cast Iron Sleeve
Type of Governor ......................................................Mechanical, Fixed Speed
Engine Governor Speed
QUIETPACT 55 .............................................................................. 2200 rpm
QUIETPACT 65/75 ......................................................................... 2571 rpm
Air Cleaner ................................................. Paper Element w/Foam Precleaner
Starter .................................................................................12-volt DC Electric
Ignition System .............................................. Solid-state w/Flywheel Magneto
Recommended Spark Plug
Champion .........................................................................................RC14YC
AC ......................................................................................................... R45S
Fram Autolite ..............................................................................................65
6
General Information
1.6.4 GENERATOR SPECIFICATIONS
SERIES QP55LP QP65LP QP75G QP75LP
Rotor RPM 3600 3600 3600 3600
Rotor Poles 2 2 2 2
Engine RPM 2200 2571 2571 2571
Rated Max. Continuous AC Output Watts*/**
Voltage* 120 120 120 120
Rated Max. Continuous Current Amps (240V)** 45.8 (22.9) 54.1 (27.0) 62.5 (31.2) 62.5 (31.2)
Phase 1 1 1 1
Frequency 60 Hertz 60 Hertz 60 Hertz 60 Hertz
Battery Charging Current (Max.) 2 amps 2 amps 2 amps 2 amps
Weight 329 lbs. 331 lbs. 330 lbs. 333 lbs.
Length 33.7 in. 33.7 in. 33.7 in. 33.7 in.
Width 22.2 in. 22.2 in. 22.2 in. 22.2 in.
Height 19.6 in. 19.6 in. 19.6 in. 19.6 in.
* All units are reconnectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output
** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambient temperature, altitude, engine condition, etc.. Maximum power
decreases about 3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16° C (60° F) ambient temperature.
5500 6500 7500 7500
Spark Plug Gap .............................................................0.040 inch (1.02 mm)
Recommended Min. Battery ....................................400 Cold Cranking Amps
Class II Emission Certified
1.7 EVAPORATIVE EMISSIONS
INFORMATION
This generator is subject to evaporative emission standards which
have been implemented by the California Air Resource Board
(CARB) and the Environmental Protection Agency (EPA). If this
generator is offered for sale in the state of California, it must be
covered by a CARB evaporative Executive Order. If this generator
is offered for sale to the final consumer in any other state, certified
low-permeation fuel line must be used to supply fuel to the generator as required by EPA.
Anyone who installs or configures a fuel system to supply this
generator with gasoline is required to comply with all applicable
evaporative emission regulations. If this generator is configured
such that it shares the primary fuel system of a vehicle in which it
is installed, reduced certification requirements may apply. See the
CARB guidance document MAC 05-05, located at http://www.arb.
ca.gov/msprog/macs/mac0505/mac0505.pdf for further details. If
this generator is installed such that it uses a dedicated fuel system,
detailed evaporative emission requirements apply; contact a reputable fuel system manufacturer to purchase a complete fuel system certified for use with this generator, or consult the California
Code of Regulations if you wish to obtain certification on your
own. See the installation instructions in this manual for connecting
fuel system vapor lines to the engine.
This generator is not legal for sale in the state of California unless
all CARB evaporative emission requirements are adhered to, and
is not legal for sale in any other state unless certified low-permeation fuel line is used to supply the generator with gasoline.
Contact the California Air Resource Board or the Environmental
protection agency for further information. CARB regulations can
be found in 13 CCR §§2750 – 2773; EPA regulations can be
found in 40 CFR Part 90.
1.8 EXHAUST EMISSIONS INFORMATION (GASOLINE)
The Environmental Protection Agency (EPA) and the California Air
Resource Board (CARB) require that this generator comply with
exhaust emission standards. The generator is certified to meet all
applicable exhaust emission levels. This generator is certified for
use as a mobile engine. It is important that you follow the maintenance specifications listed in this manual to ensure that the engine
complies with emission standards for the duration of its life. This
engine is certified to operate on gasoline. The emission control
system on the generator consists of the following:
Fuel Metering System•
~ Carburetor assembly
~ Fuel pump and lines
Air Induction System•
~ Intake pipe / manifold
~ Air cleaner
Ignition System•
~ Spark plug
~ Ignition module
Catalytic Converter (if equipped)•
7
Operation
The Emissions Compliance Period referred to on the Emissions
Compliance Label indicates the number of operating hours for
which the engine has been shown to meet Federal and California
emission requirements. See the table below to determine the compliance period for this generator. The displacement of the engine is
listed on the Emissions Compliance Label.
Displacement Category Compliance Period
A 500 Hours
> 66 cc - < 225 cc
B 250 Hours
C 125 HOurs
A 1000 Hours
≥ 225 cc
B 500 Hours
C 250 Hours
1.9 EXHAUST EMISSIONS INFORMATION (PROPANE)
The Environmental Protection Agency (EPA) and the California Air
Resource Board (CARB) require that this generator comply with
exhaust emission standards. The generator is certified to meet all
applicable exhaust emission levels. This generator is certified for
use as a mobile engine. It is important that you follow the maintenance specifications listed in this manual to ensure that the engine
complies with emission standards for the duration of its life. This
engine is certified to operate on propane fuel (LP). The emission
control system on the generator consists of the following:
Fuel Metering System•
~ Mixer assembly
~ Fuel regulator and lines
Air Induction System•
~ Intake pipe / manifold
~ Air cleaner
Ignition System•
~ Spark plug
~ Ignition module
Catalytic Converter (if equipped)•
The Emissions Compliance Period referred to on the Emissions
Compliance Label indicates the number of operating hours for
which the engine has been shown to meet Federal and California
emission requirements. See the table below to determine the compliance period for this generator. The displacement of the engine is
listed on the Emissions Compliance Label.
2.1 GENERATOR CONTROL PANEL
The following features are mounted on the generator control panel
(Figure 2.1):
2.1.1 FUEL PRIMER
Before starting a cold engine (if it has not been started in more
than two weeks), press this switch for approximately ten seconds
to bring fuel from the tank to the fuel pump. This rocker type switch
springs back into its original position when it is released.
2.1.2 START/STOP SWITCH
To crank and start the engine, hold this switch in the START position. Release the switch when the engine starts. To stop an operating engine, press and hold the switch in the STOP position until the
engine shuts off. The switch center position is the RUN position.
2.1.3 7.5 AMP FUSE
The fuse protects the engine’s DC control circuit against electrical
overload. If the fuse element has melted open due to overloading,
the engine cannot be cranked. If the fuse must be replaced, use
only an identical 7.5 amp replacement fuse.
Figure 2.1 – Typical Control Panel
CONTROL CENTER
CIRCUIT
BREA KER
CIRCUIT
BREA KER
FUS E
7.5A
IF GENERATOR DOES NOT START.
REMOVE AND INSPECT FUSE.
(SEE OWNER'S MANUAL TROUBLE SHOOTING GUIDE.)
PRESS PRIME SWITCH FOR 10 SECONDS
BEFORE STARTING. WHEN STARTING, DO NOT PRESS
START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT.
STA RT
STOP
FUEL
0E0580 REV. B
PRIM E
Displacement Category Compliance Period
A 500 Hours
> 66 cc - < 225 cc
B 250 Hours
C 125 HOurs
A 1000 Hours
≥ 225 cc
B 500 Hours
C 250 Hours
8
2.1.4 LINE BREAKERS
Protects generator’s AC output circiut against overload, i.e., prevents unit from exceeding wattage/amperage capacity. The circuit
breaker ratings are as follows:
Model Circuit Breaker 1 Circuit Breaker 2 240 Volt
QuietPact 55 30A 20A 25A 2P
QuietPact 65 30A 30A 30A 2P
QuietPact 75 35A 35A 35A 2P
Operation
NOTE:
If this generator has been reconnected for dual voltage AC output (120/240 volts), install line breakers having an amperage
rating that is different than that stated above. The replacement
line breakers consist of two separate breakers with a connecting piece between the breaker handles (so that both breakers
will operate at the same time). If the unit is reconnected for dual
voltage, it is no longer RVIA or CSA listed.
2.2 OPTIONAL REMOTE START/STOP PANEL
A remote mounted Start/Stop Panel is available that allows starting and stopping the generator engine conveniently from inside the
vehicle. The remote panel includes a Start/Stop switch, hourmeter,
generator run lamp, a fuel prime switch, and a wire harness.
2.3 AUTOMATIC CHOKE
This engine is equipped with an automatic choke that consists of
two main components: a choke solenoid and prechoke.
2.3.1 CHOKE SOLENOID
During engine cranking (Start/Stop switch at START), a solid-state
choke module signals the choke solenoid to activate and cycle
(choke on/choke off) until the engine starts. The choke solenoid
thus opens and closes the carburetor choke valve only when the
engine is cranking. When the engine starts, the choke stops
cycling.
2.3.2 PRECHOKE
The choke system also has a temperature-sensitive metal strip that
adjusts choke valve angle according to ambient temperatures (i.e.,
in cold ambient temperatures, choke valve closes more). Once the
engine starts, an element heats the temperature-sensitive strip to
a normal operating condition, opening the choke valve. This may
take about three minutes in cooler weather.
2.4 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.
2.4.1 INSTALLATION
Generator installation must have been properly completed so it
complies with all applicable codes, standards and regulations and
with the manufacturer's recommendations.
2.4.2 ENGINE LUBRICATION
Have the engine crankcase properly serviced with the recommended oil before starting. Refer to sections "Engine Specifications",
"Checking the Engine Oil Level" and "Changing the Engine Oil and/
or Oil Filter" for oil servicing procedures and recommendations.
Any attempt to crank or start the engine before
it has been properly serviced it with the recom-
n
mended oil may result in an engine failure.
2.4.3 FUEL SUPPLY
The engine must have an adequate supply of proper fuel to operate. Before starting it, check that sufficient fuel is available.
NOTE:
Depending on the installation, the generator may have either a
separate fuel tank, or it may “share” the vehicle engine’s fuel
tank.
2.4.4 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. Without
sufficient cooling and ventilating airflow, the engine/generator
quickly overheats, which causes it to shut down and may damage
the generator.
2.4.5 ENGINE EXHAUST GAS
Before starting the generator engine, inspect for exhaust leaks and
ensure 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.
Generator engine exhaust contains DEADLY
carbon Monoxide, an odorless, colorless poi-
n
sonous gas. Breathing carbon monoxide can
cause: dizziness, throbbing temples, nausea,
muscular twitching, headache, vomiting, weakness and sleepiness, inability to think clearly,
fainting, unconsciousness or even death. If you
experience any carbon monoxide poisoning
symptoms, move into fresh air and immediately
seek medical attention.
Never operate the generator set with the vehicle inside any garage or other enclosed area.
n
9
Operation
Adequate, unobstructed flow of cooling and
ventilating air is critical for expelling toxic car-
n
bon monoxide gas and fuel vapors from the
generator compartment and for proper generator operation. Without sufficient cooling airflow,
deadly carbon monoxide gas can accumulate
and the engine/generator may quickly overheat, causing serious damage to the generator. Do not operate the genset in any confined
space.
The exhaust system must be installed in accordance with the genset installation manual. Do
n
not alter the installation or permit even partial
blockage of ventilation systems, as this can
seriously affect the safe and proper operation
of the generator.
Do not operate the generator if the exhaust
system is leaking or has been damaged or if
n
you have experienced carbon monoxide poisoning symptoms during use. Shut down the
generator and do not operate it until it has
been inspected and/or repaired.
Never sleep in the vehicle while the genset is
running unless the vehicle has a working car-
n
bon monoxide detector.
2.5 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 crank and start the generator engine, proceed as follows:
1. Turn OFF electrical loads using the means provided in the
vehicle (such as a main line circuit breaker or transfer
switch).
NOTE:
If starting from the generator control panel, turn OFF loads
by setting the generator’s main circuit breaker to the OFF (or
open) position. If starting from a remote panel, turn OFF loads
using the means provided in the vehicle (such as a main circuit
breaker). Electrical load circuits will be turned ON after the
generator has started, stabilized and warmed up.
2. If the engine has not been star ted in more than two weeks,
press the Fuel Pump Primer switch and hold it for about 10
seconds. However, if the engine is warm, skip Step 2.
3. To crank and start the engine, hold the start/stop switch at
START. Release the switch when the engine starts.
If the engine does not start after it has been
cranking for 15 seconds, release the Start/Stop
n
switch and wait 1 minute before trying again.
Holding the switch for longer than 15 seconds
can damage the starter motor.
4. Let the engine run at no-load for a few minutes to stabilize and
warm up.
5. Turn ON electrical loads using the means provided (such as a
main circuit breaker or transfer switch).
2.6 STOPPING THE GENERATOR
1. Turn OFF all electrical loads using the means provided (such
as a main circuit breaker or transfer switch).
2. Let generator run at no-load for a few minutes, to stabilize
internal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position. The engine
will come to a complete stop.
2.7 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.•
2.7.1 LETTING THE ENGINE STABILIZE
The generator supplies correct rated voltage only at the proper
governed speed. Some electrical appliances may be extremely
sensitive to voltage. Incorrect voltages can damage such appliances.
If electrical loads are applied at reduced operating speeds, such
loads imposed on the engine when sufficient power is not available
may shorten engine life. Never turn ON electrical loads until after
the generator engine has started and stabilized at no-load.
2.7.2 DO NOT OVERLOAD THE GENERATOR
Read the rated wattage/amperage capacity of the generator on the
generator data label (see "Generator Identification").
Applying electrical loads in excess of the unit’s rated capacity will
cause the engine/generator to automatically shut down.
To avoid overloading, add up the wattage of all connected electrical
lighting, appliance, tool and motor loads. This total should not be
greater than the generator’s rated wattage capacity.
Most lighting, appliance, tool and motor loads indicate their •
required watts on their nameplate or data plate. For light bulbs,
simply note the wattage rating of the bulb.
If a load does not show its rated wattage, multiply that load’s •
rated VOLTS times AMPS to obtain WATTS.
10
Operation
Induction type motors (such as those that run the vehicle’s •
furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2
times more watts of power for starting than for running (for a
few seconds during motor starting). Be sure to allow for this
when connecting electrical loads to the generator. First, figure
the watts needed to start electric motors in the system. To that
figure, add the running wattages of other items that will be operated by the generator.
Do not apply heavy electrical loads for the first two or three •
hours of operation.
2.8 PROTECTION SYSTEMS
2.8.1 LOW OIL PRESSURE SWITCH
This switch (Figure 2.3) has normally closed (N.C.) contacts that
are held open by engine oil pressure during cranking and operating. Should oil pressure drop below a preset level, switch contacts
close, and the engine automatically shuts down. The unit should
not be restarted until oil is added.
2.8.2 HIGH TEMPERATURE SWITCH
This switch (Figure 2.3), which has normally open (N.O.) contacts,
is mounted near the oil filter. The contacts close if the temperature should exceed approximately 270º F (132º C) for gasoline
models, and 284° F (140° C) for LP models, initiating an engine
shutdown.
Figure 2.4 – Field Boost Circuit
2.8.4 OVERVOLTAGE PROTECTION
A solid-state voltage regulator (Figure 2.5) controls the generator’s
AC output voltage. This regulator supplies an excitation current to
the rotor. By regulating the rotor’s excitation current, the strength
of its magnetic field is regulated and, in turn, the voltage delivered
to connected electrical loads is controlled. When the AC frequency
is 60 Hertz, voltage is regulated at 115 volts.
Figure 2.5 – Solid State Voltage Regulator
Figure 2.3 – Low Oil Pressure and
High Temperature Switches
2.8.3 FIELD BOOST
The Controller Circuit Board houses a field boost diode and resistor
that are not part of the automatic choke circuit. These two components are part of a “field boost” circuit (Figure 2.4). During engine
cranking only, a positive DC (battery) voltage is delivered through
a diode, resistor, brushes, slip rings, and the generator rotor.
Application of this voltage to the rotor “flashes the field” whenever
it is started. Flashing of the field each time the generator starts
makes sure that a sufficiently strong magnetic field is available to
produce “pickup” voltage in the stator windings.
The voltage regulator also incorporates a “voltage surge protection
circuit.” This circuit prevents troublesome surges in the generator
AC output voltage. Voltage surge is a common cause of damage
to electronic equipment.
2.8.5 OPERATION IN HIGH GRASS OR BRUSH
Never operate the generator while the vehicle
is parked over high grass, weeds, brush, leaves
or any other combustible substance. Such
materials can ignite and burn from the heat of
the exhaust system. The generator exhaust system becomes extremely hot during operation
and remains hot for a long time after it has shut
down.
11
Maintenance
3.1 CHECKING THE ENGINE OIL LEVEL
For oil capacities and requirements, see the “Engine Oil
Requirements” section. Check the engine crankcase oil level at
least every eight hours of operation, or before it is used. To check
the engine oil level, proceed as follows (see Figure 3.1):
1. Be sure the generator is as level as possible.
2. Remove the dipstick and wipe it dry with a clean, lint-free
cloth.
3. Install and tighten the dipstick cap; then, remove it again. The
oil level should be at the dipstick “Full” mark.
4. If necessary, remove the oil fill cap on the rocker cover and
slowly add oil until it reaches the dipstick “Full” mark. DO NOT
FILL ABOVE THE “FULL” MARK.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
n
this could damage the engine.
5. Install and tighten the oil fill cap and the dipstick before oper-
ating the engine.
3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER
Hot oil may cause burns. Allow engine to cool
before draining oil. Avoid prolonged or repeat-
n
ed skin exposure with used oil. Thoroughly
wash exposed areas with soap.
Change the • engine oil after the first 25 hours of operation.
Thereafter, change the oil every 100 operating hours. Change
the oil more frequently if operating consistently under heavy
load or at high ambient temperatures.
Change the engine • oil filter after the first 25 hours of operation,
and every 100 operating hours thereafter.
To change the oil and/or oil filter, proceed as follows:
1. Run the engine until it is thoroughly warmed up (at least five
minutes) then shut OFF the engine.
2. With the engine still warm from running, remove the oil drain
plug (Figure 3.1). Drain the oil into a suitable container.
3. After the oil has drained, replace the oil drain plug. (If only
changing the oil, go to step 7.)
4. With the oil drained, remove the old oil filter by turning it coun-
terclockwise (Figure 3.2).
5. Apply a light coating of clean engine oil to the gasket of the
new filter.
6. Screw the new filter on by hand until its gasket lightly contacts
the oil filter adapter. Then, tighten the filter an additional 3/4 to
one turn.
3. After the oil has drained, replace the oil drain plug. (If only
changing the oil, go to step 7.)
4. With the oil drained, remove the old oil filter by turning it coun-
terclockwise (Figure 3.2).
Figure 3.1 — Oil Dipstick/Fill Tube and
Location of Oil Drain Plug
Oil Dipstick
Oil Drain Hose
5. Apply a light coating of clean engine oil to the gasket of the
new filter.
6. Screw the new filter on by hand until its gasket lightly contacts
the oil filter adapter. Then, tighten the filter an additional 3/4 to
one turn.
7. Remove the dipstick and fill crankcase with the proper
type and amount of recommended oil (see "Engine Oil
Requirements"). The engine crankcase can hold about 1.8
liters or 1.9 quarts with oil filter change. DO NOT FILL ABOVE
THE “FULL” MARK.
8. Install and tighten the dipstick before operating the engine.
9. Start the engine and check for leaks.
10. Dispose of used oil at a proper collection center.
NOTE:
Check the oil level and fill to the “FULL” mark after checking for
leaks. The filter will retain some oil.
Figure 3.2 — Engine Oil Filter
12
Maintenance
3.3 MAINTAINING THE ENGINE AIR CLEANER
3.3.1 CLEANING THE FOAM PRECLEANER
Clean and re-oil the foam pre-cleaner every three months or every
100 hours of operation, whichever occurs first. Service the foam
pre-cleaner more frequently if operating the generator in extremely
dusty or dirty conditions. Use the following procedure (Figure
3.3).
1. At the Air Box Cover, turn the plastic wing screw counter-
clockwise to loosen.
2. Remove the Air Box Cover by pulling up and left to clear the
three locating tabs.
3. Turn the exterior steel wing nut on the left side of the Air Box
Compartment counterclockwise and remove.
4. Pull the Air Filter Assembly to the right and out of the front of
the compartment.
5. Remove the foam pre-cleaner from the air filter.
6. Wash the foam pre-cleaner in liquid detergent and water.
7. Wrap the foam pre-cleaner in a clean cloth and gently squeeze
it dry.
8. Saturate the foam pre-cleaner in clean engine oil. Gently
squeeze it in a clean cloth to remove excess oil and to distribute the oil evenly (DO NOT TWIST).
9. Slide the foam pre-cleaner onto the air filter.
10. With your right hand on the air filter end, angle the assembly
into the compartment and insert the Offset Stud into the hole
on the left side of the Air Box Compartment. Before the air
filter gasket contacts the sheet metal wall, ensure the rubber
snout of the carburetor intake adapter is "captured" within the
footprint of the Air Filter.
11. Replace the steel wing nut onto the Offset Stud and tighten
clockwise.
12. Replace the Air Box Compartment Cover back into all three
locating tabs and replace the plastic wing screw (Tighten
clockwise carefully).
Figure 3.3 – Engine Air Cleaner
GASKET
LOCK
WASHER
FLAT
WASHER
STEEL
WING
NUT
STEEL
WING
NUT
PLASTIC
WING SCREW
AIR BOX COVER
OFFSET
STUD
PRE-CLEANER
AIR FILTER
2. Remove the Air Box Cover by pulling up and left to clear the
three locating tabs.
3. Turn the exterior steel wing nut on the left side of the Air Box
Compartment counterclockwise and remove.
4. Pull the Air Filter Assembly to the right and out of the front of
the compartment.
5. Twist the steel wing nut counterclockwise while holding the
offset stud. Set aside and save all this hardware for use with
the new air filter and pre-cleaner.
6. Discard old air filter and pre-cleaner safely.
7. Insert the flanged end of the Offset Stud into the new air filter
and through the hole in the end plate.
8. Install the gasket, flat washer, lock washer and wing nut in that
order. Tighten the wing nut clockwise while aligning the Offset
Stud as in Figure 3.3.
9. Saturate the foam pre-cleaner in clean engine oil. Gently
squeeze it in a clean cloth to remove excess oil and to distribute the oil evenly (DO NOT TWIST).
10. Slide the foam pre-cleaner onto the air filter.
11. With your right hand on the air filter end, angle the assembly
into the compartment and insert the Offset Stud into the hole
on the left side of the Air Box Compartment. Before the air
filter gasket contacts the sheet metal wall, ensure the rubber
snout of the carburetor intake adapter is "captured" within the
footprint of the Air Filter.
12. Replace the steel wing nut onto the Offset Stud and tighten
clockwise.
13. Replace the Air Box Compartment Cover back onto all three
locating tabs and replace the plastic screw (Tighten clockwise
carefully).
3.4 CHECKING THE ENGINE
SPARK PLUG
Clean the spark plug and reset the spark plug gap every 100 hours
of operation.
1. Clean the area around the base of the spark plug to keep dirt
and debris out of the engine. Clean by scraping or washing
using a wire brush and commercial solvent. Do not blast the
spark plug to clean.
2. Remove the spark plug and check the condition. Replace the
spark plug if worn or if reuse is questionable.
3. Check the spark plug gap using a wire feeler gauge. Adjust the
gap to 0.040 inch (1.02 mm) by carefully bending the ground
electrode (Figure 3.4).
Figure 3.4 – Setting the Spark Plug Gap
3.3.2 REPLACING THE PAPER AIR FILTER
Replace the Paper Air Filter Element after every 250 hours of
operation. Use the following procedure (Figure 3.3).
1. At the Air Box Cover, turn the plastic wing screw counterclockwise to loosen.
13
Maintenance
Sparking can occur if the wire terminal does
not fit firmly on the spark plug terminal end. If
n
necessary, re-form the wire terminal to obtain a
tight fit.
3.5 FUEL FILTER
Remove and replace the fuel filter (Figure 3.5) once each year or
every 400 hours of operation, whichever comes first.
Figure 3.5 – Fuel Filter
FUEL FILTER
(GASOLINE ONLY)
TO FUEL PUMP
3.7 CLEANING THE GENERATOR
Keep the generator set as clean and dry as possible. Protect the
unit against excessive dust, dirt, corrosive vapors, road splash,
etc. Permitting dirt and moisture to accumulate on generator
windings will have an adverse effect on the insulation resistance
of those windings.
When moisture is allowed to remain in contact with windings,
some of the moisture will be retained in voids and cracks in the
insulation. This causes a reduced insulation resistance and will
eventually cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with windings. Salt (as
from sea air) also will worsen the problem since it tends to absorb
moisture from the air. Salt and moisture, when combined, form a
good electrical conductor which is detrimental to the generator.
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
n
interior and cause problems, and may also
contaminate the generator fuel system.
CUSTOMER FUEL CONNECTION
3.6 CLEAN SPARK ARRESTOR
The engine exhaust muffler has a spark arrestor screen. Inspect
and clean the screen every 50 hours of operation or once each
year, whichever comes first.
NOTE:
If using the generator on any forest-covered, brush-covered or
grass-covered unimproved land, it must equipped with a spark
arrestor. The spark arrestor must be maintained in good condition by the owner/operator.
Clean and inspect the spark arrestor as follows (Figure 3.6):
Remove the screen retaining bracket by removing the screw.•
Slide the spark arrestor screen out from the tail pipe.•
Inspect screen and replace if torn, perforated or otherwise •
damaged. DO NOT USE a defective screen. If screen is not
damaged, clean it with commercial solvent.
Replace the screen and the retaining bracket.•
Figure 3.6 - Spark Arrestor
3.8 BATTERY MAINTENANCE
All lead-acid batteries will discharge when not in use. The generator battery should be inspected as follows:
3.8.1 WEEKLY
Inspect the battery posts and cables for tightness and corro-•
sion. Tighten and clean as necessary.
Check the battery fluid level of unsealed batteries and, if nec-•
essary, fill with Distilled Water Only. Do not use tap water in
batteries.
3.8.2 EVERY SIX MONTHS
Have the state of charge and condition checked. This should be •
done with an automotive-type battery hydrometer.
NOTE:
Servicing of the battery is to be performed or supervised by
personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.
Damage will result if the battery connections are made in
reverse.
14
TAILPIPE
P/N 0E0907
RETAINER
P/N 0D5133A
SPARK ARRRESTOR
SCREEN
RETAINING
SCREW
P/N 0D5133
P/N 045764
Do not dispose of the battery in a fire. The
battery is capable of exploding. Stored batteries
give off explosive hydrogen gas. This gas can
form an explosive mixture around the battery
for several hours after charging. The slightest
spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery
and cause blindness or other injury. Any area
that houses a storage battery must be properly
ventilated. Do not allow smoking, open flame,
sparks, or any spark producing tools or equipment near the battery. Discharge static electricity from body before touching the battery by
first touching a grounded metal surface.
A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when working
on batteries:
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery;
• Disconnect any charging source prior to connecting
or disconnecting battery terminals; and
• Do not use any jumper cables or booster battery to
crank and start the generator engine. If any battery
has discharged, remove it for recharging.
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
n
the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
n
conductive and corrosive. The following
procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or water. The bicarbonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
Maintenance
3.9 ADJUSTING VALVE CLEARANCE
After the first six (6) months of operation, check the valve clearance in the engine, adjust if necessary.
Important: If feeling uncomfortable about doing this procedure or
the proper tools are not available, please contact the Authorized
Dealer for service assistance. This is a very important step to
insure longest life for the engine.
To check valve clearance:
The engine should be cool before checking. If valve clearance is •
0.002" - 0.004" (0.05 - 0.1mm), adjustment is not needed.
Remove spark plug wires and position wires away from plugs.•
Remove spark plugs.•
Make sure the piston is at Top Dead Center (TDC) of its com-•
pression stroke (both valves closed). To get the piston at TDC,
remove the intake screen at the front of the engine to gain
access to the flywheel nut. Use a large socket and socket
wrench to rotate the nut and hence the engine in a clockwise
direction. While watching the piston through the spark plug
hole. The piston should move up and down. The piston is at
TDC when it is at its highest point of travel.
To adjust valve clearance (if necessary):
Make sure the engine is at 60° to 80° F.•
Make sure that the spark plug wire is removed from the spark •
plug and out of the way.
Remove the four screws attaching the valve cover with a #2 or •
#3 Phillips screwdriver.
Loosen the rocker jam nut. Use an 10mm allen wrench to turn •
the pivot ball stud while checking clearance between the rocker
arm and the valve stem with a feeler gauge. Correct clearance
is 0.002-0.004 inch (0.05-0.1 mm). (Figure 3.7).
Figure 3.7 - Valve Clearance Adjustment
Rocker
Pivot Ball
Stud
Jam Nut
NOTE:
Hold the rocker arm jam nut in place as the pivot ball stud is
turned.
Arm
Valve
Stem
15
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