Generac Power Systems 4270-0 User Manual

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POWER SYSTEMS, INC

Owner’s Manual and

Installation Instructions

Liquid-cooled Recreational Vehicle Generator

Model: 04270-0 QUIETPACT™ 75D

INTRODUaiON

Thank you for purchasing this model of the QUIETPACT™ product line by Generac Power Systems Inc. This model is designed and manufactured to sup ply electrical power for recreational vehicles.

♦ 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 instruction about a particular opera

tion 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.

---

A WARNING A

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

--------

ik CAUTION Mr

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 eUminate the hazards that they indicate. Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents.

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates follows:

This symbol points out important safety informa

tion that, if not followed, could endanger personal safety and/or property of you and others.

This symbol points out potential explosion hazard.

______________

-----

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

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

ate the equipment in an emergency.

♦ CONTENTS

This manual contains pertinent owner’s Information, including warranty, electrical diagrams, exploded views and lists of repair parts for generator model number 04270-0. In addition, the latter portion of this manual contains information necessary for the proper installation of these generators.

♦ OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by a Generac Authorized Service Dealer. Normal main tenance service and replacement of parts are the responsibility 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 ensure a minimum number of problems and keep operating expenses at a minimum. See your

Generac Authorized Service Dealer for service aids

and accessories.

♦ HOW TO OBTAIN SERVICE

When your generator requires servicing or repairs,

simply contact a Generac Authorized Service Dealer

for assistance. Service technicians are factory-trained

and are capable of handling all of your service needs.

When contacting a Generac Authorized Service

Dealer or the factory about parts and service, always supply the complete model number and serial num ber of your unit as given on its data decal, which is located on your generator.

Model No.

__________________________________

_______________

Serial No.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock

hazard.

Generac* Power Systems, Inc.

AUTHORIZED SERVICE

DEALER LOCATION

To locate the GENERAC AUTHORIZED SERVICE

DEALER nearest you, please call this number:

1-800-33S-1322

ONLY DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

Table of Contents

QUIETPACT™ 75D Recreational Vehicle Generator

Part I ~ Owner's Manual

Introduction

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

Contents

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

How to Obtain Service........................................................IFC

Authorized Service Dealer Locator Number

Safety Rules

Section 1 - General Information

1.1 Generator Identification..................................................4

1.2 Generator Applicability...................................................5

1.3 Safely.... 5

1.4 Generator AC Connection System

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

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

2.1 Generator Control Panel ................................................7

2.2 Optional Remote Start/Stop ...........................................7

2.3 Before Starting the Engine

2.4 Starting the Generator.....................................................8

2.5 Stopping the Generator

2.6 Applying Loads to Generator..........................................9

2.7 Protection Systems

2.8 Additional Information .................................................10

Section 3 - Maintenance

3.1 Checking the Engine OH Level

3.2 Changing the Engine OH and/or OH FUter

3.3 Servicing the Engine Air FHter

3.4 Spark Arrestor Muffler ................................................13

3.5 Cleaning the Generator

3.6 Battery Maintenance

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

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

3.9 Major Service Manual ..................................................15

3.10 Drive Belt

3.11 Exercising tlie Generator...............................................15

3.12 Out of Service Procedure

3.13 Service SchediHe............................................................16

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

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

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

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

.................Inside Front Cover

IFC

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

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

IFC

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

1.5.1 Fuel Requirements

1.5.2 Fuel Consumption

1.5.3 Engine OH Requirements

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

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

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

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

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

1.5.6 Generator .........................................................6

2.1.1 Hourmeter

2.1.2 Start/Stop Switch

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

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

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

2.1.4 Line Breaker.....................................................7

2.1.5 Preheat Switch..................................................7

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

2.3.1 Installation 7

2.3.2 Engine Lubrication

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

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

2.3.4 Coolant Level....................................................8

2.3.5 Cooling and Ventilating Air

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

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

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

2.6.1 Letting the Engine Stabilize

2.6.2 Do Not Overload the Generator

2.7.1 Low OH Pressure Switch..................................9

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

2.7.2 High Temperature Switch

2.7.3 Over speed Shutdown

2.7.4 Overvoltage Protection

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

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

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

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

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

2.8.1 25-Hour Break-in Period...............................10

2.8.2 25-Hour Check-up

2.8.3 Attention Required After Submersion

2.8.4 Operation In High Grass or Brush

2.8.5 Effects of Moisture and Dirt

..................................................... 12

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

........

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

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

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

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

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

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

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

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

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

3.12.1 Removal From Service

3.12.2 Return to Service

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

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

10 10

11 11 11 11

12 12 12

13 14

15 15

Part II - installation Instructions

Safety Rules Section 1 - General Information

............................................................................18

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

1.1 Purpose and Scope of the Manual..................................20

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

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

1.4 Equipment Description

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

1.6 Generator AC Connection System

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

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

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

20 20

2.1 Location and Support.....................................................22

2.1.1 Generator Location

5 5

6 6

2.1.2 Generator Support

2.1.3 Suspended Moimtlng......................................22

2.1.4 Generator Restraint

2.2 Generator Compartments .............................................23

2.2.1 Compartment Construction

2.2.2 Sound Insulating Materials

2.2.3 Acoustics

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

2.2.4 Compartment Floor Cutouts

2.3 Cooling and VentHattng Air

2.3.1 Generator Airflow

7 7

2.3.2 Cooling Air Inlet Openings

2.3.3 Compensating for Restrictions

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

2.4 Diesel Fuel System

2.4.1 Fuel Tank

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

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

2.4.2 Generator Fuel Supply Line

7 8

2.5 Exhaust System

2.5.1 Mufflers and Speirk Arrestors

2.4.2.1 Rigid Fuel Lines

2.4.2.2 Flexible Fuel Line

........

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

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

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

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

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

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

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

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

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

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

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

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22 22

23 23

24 24 25 26 26 26 27

27 28

28 28 28

2.5.2 Exhaust System Safely....................................29

9 9

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

2.6.1 Electrical Junction Box

2.6.2 Wiring

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

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

30 30

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

2.6.3.1 Generator Coversion to 120

2.6.4 Conduit

Volts Only - Dual Circuits

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

...........

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

2.6.6 Ground Fault Circuit Interrupters

2.6.7 Isolating Different Power Sources

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

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

32 32

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

2.7.1 Recommended Battery

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

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

2.7.3 Battery Cable Connections

2.7.4 Battery Compartment

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

2.8.1 Remote Start/Stop Connections......................34

Section 3 - Post-installation Start-up

Checks 35

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

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

33 34

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

3.2 Before Initial Start-up

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

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

3.4 Testing Under Load........................................................35

3.5 Installation Checklist

Appendix 1 - Troubleshooting

Appendix 2 - Electrical Data Appendix 3 - Exploded Views and Parts Lists Appendix 4 - Notes Appendix 5 - Warranty

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

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

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

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

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

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

37 38

Generac* Power Systems, Inc.

SAFETY RULES

Safety Rules

QUIETPACT™ 75D Recreational Vehicle Generator

SAVE THESE INSTRUCTIONS - The manufacturer suggests that these rules for scfe .

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. ““

• 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

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 main tained. 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 tech nique Generac does not specifically recommend, you must satisfy yourself that it is safe for you and others.

You also must make sure the procedure, work

method or operating technique that you choose does not render the generator unsafe.

DANGER

Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to operate or maintain this equipment.

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

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.

A GENERAL HAZARDS A

For safety reasons, Generac recommends that the installation, initial start-up and mainte nance of this equipment is carried out 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. 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 opera tion and is required to expel toxic fumes and fuel vapors from the generator compartment. Without

sufficient cooling airflow, the engine/gener ator quickly overheats, which causes serious damage to the generator. Do not alter the installation or permit even partial blockage of ventilation provi sions, as this can seriously affect safe operation of the generator.

• When working on this equipment, remain alert at

all times. Never work on the equipment when you are physically or mentally fatigued.

• Inspect the generator regularly, and contact your

nearest Generac Authorized Service Dealer immedi ately for parts needing repair or replacement.

• Before performing any maintenance on the genera

tor, disconnect its battery cables to prevent acci dental start up. Disconnect the cable from the bat tery 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 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.

Generac* Power Systems, Inc.

Safety Rules

QUIETPACT™ 75D Recreational Vehicle Generator

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, ter minals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands

or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• During installation onto the vehicle, have the genera tor properly groimded (bonded) either by soUd

mounting to the vehicle frame or chassis, or by means of an approved bonding conductor. DO NOT dlscormect the bonding conductor, if so equipped. DO NOT reconnect the bonding conductor to any generator part that might be removed or disassem bled dming routine maintenance. If the groimding conductor must be replaced, use only a flexible con ductor 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 noncon ducting 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 FIRE HAZARDS A

For fire safety, the generator must be installed and

maintained properly. Installation must always comply with ANSI 119.2-1975/NFPA 501C-1974, “Standard for Recreational Vehicles, Part III Installation of Electrical Systems," along with all applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electri cal and building codes. Comply with regulations the Occupational Safety and Health Administration

(OSHA) has established. Also, ensure that the gen erator is Installed in accordance with the manufac turer’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 sys tem. Keep the extinguisher properly charged and be familiar with its use. If you have any question pertaining to Are extinguishers, consult your local fire department.

A EXPLOSION HAZARDS A

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 regulaüng the storage and han dling of fuels. Inspect the unit’s fuel system frequent ly and correct any leaks immediately. Fuel supply lines must be properly installed, purged and leak tested according to apphcable fuel-gas codes before placing this equipment into service.

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 ___________________________ 2. Serial Number

3. kW Rating

_______________________________

15 1 2 3

FRONT VIEW

_______________________________

4. Rated Voltage _______________________________

Model: 04270-0 QUIETPACT™ 75D

1. 2-Pole, 35-amp Circuit Breaker

2. Hour meter

3. Oil Fill Opening and Plug

4. Oil Dipstick

5. Engine StartyStop 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. Cooling Fan Drive Belt

25. Cooling Fan Drive Belt Tensioner

26. Engine

REARVIEW

Generac* Power Syateme, Inc.

Section 1 - General Information

QUIETPACT™ 75D Recreational Vehicle Generator

GENERAL

INFORMATION

1.2 GENERATOIIAPPLIGIBILITY

These generators have been designed and manu factured for supplying electrical power for recre

ational vehicles. You should not modify the gener

ator 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 fac tory. Do not use the unit until you have been

advised by a competent authority.

DANGER

For fire safety, the generator must have been

properly installed in compliance with ANSI

119.2-1975/NFPA 501C-1974, "Standard for Recreational Vehicles, Part III - Installation of Electrical Systems." The generator also must have been installed in strict compliance with

the manufacturer's detailed installation instruc tions. After installation, do nothing that might

render the unit in noncompliance with such codes, standards and instructions.

You can use this generator to supply electrical power

for operating 120/240-volt, single-phase, 60 Hertz, AC electrical 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.

----------

Mk CAUTION Jk

Do not overload the generator. Some installa

tions may require that electrical loads be alter

nated to avoid overloading. Applying excessive ly high electrical loads may damage the genera

tor 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 cur rent) for starting than ifor continuous operation.

13 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 damage to equipment and/or property. We sug gest copying and posting the “Safety Rules” in poten tial hazard areas of the vehicle. Stress safety to all operators and potential operators of this equipment.

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

1.4 GENERATOR AC CONNEQION SYSTEM

This generator is equipped with dual stator AC power windings. These two-stator windings supply electri

cal 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 pow ers 120- and/or 240-volt AC electrical loads (Figure

1.1). It can be rewired to connect 120-volt AC electri

cal loads only. This procedure should be done by a Generac Authorized Service Dealer or other qualified installer. Refer to the installation portion of this man ual for more information.

Figure 1.1 - Connections for 120/240 Dual

Voltage

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1.S 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 min imum Cetane number of 40. It also must 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 separate fuel tank, or it may “share” the vehi cle engine’s fuel tank.

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

remain 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 - Generai Information

QUIETPACT™ 75D Recreational Vehicle Generator

♦ 1.5.2 FUEL CONSUMPTION (GAl/HR)

Modd No Load Half Load

QUTETPACT™ 75D

0.28 0.45 0.78

ЕШ Load

(04270-0)

♦ 1.5.3 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 oil having the following SAE vis cosity rating, based on the amMent temperature range anticipated before the next oil change:

Temperature Oil Grade (Recommended)

Above 100° F (38° C)

40° to 100° F (4.4° to 38° C) SAE 10W-30 or SAE 30

Below 40° F (4.4° C) SAE 5W-20 or 5W-30

SAE 15W-40 or SAE 40

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 check

ing and changing procedures.

♦ 1.5.4 COOLANT

____________________

_________

Use a mixture of 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 recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.

DANGER

Do not remove the radiator pressure cap while

the engine is hot or 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 container because ani mals are attracted to the smell and taste of antifreeze even though it is poisonous to them.

---------

Ik CAUTION

Do not use any chromate base rust inhibitor with ethylene glycol base antifreeze, or 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 also will cause overheating. We also recommend that you DO NOT use any soluble oil inhibitor for this equipment.

Generac*

Power Systems, Inc.

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

♦ 1.5.5 ENGINE_________________________________

туре of Engtae

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

Displacement........................................................58.2 in. (954 cc)

Bore

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

Stroke.....................................................................2.83 in. (72 mm)

Compression Ratio................................................................23-to-l

Combustion Chamber Type

Rated Horsepower...............................................13 @ 1,950 rpm

Cylinder Block...................................................................Cast Iron

Number of Main Bearings..............................................................4

Number of Tteeth on Flywheel Type of Governor

Fhel Filter...............................FbU Flow Spln-On (Part # 69858)

Oil Filter

Oil Pressure.......................................................................29-71 psl

туре of Cooling System Cooling Method туре of Cooling Fhn Cooling System Capaclly

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

Starter

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

Maximum Cranking Current Ground Polarity

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

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

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

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

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

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

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

Mechanical, Fixed Speed

Pull Flow with Bypass Valve

Pressurized, Closed Recovery

Amps

ISM Diesel

2.95 in. (75 mm)

Pre-Combustion

104

(Part # 126-70939)

Liquid-cooled

Centrifu^ Puller

1.4 U.S. gals (5.3 L)

12-volt DC Electric

220 Amps

Negative

♦ 1.5.6 GENERATOR

Rated Maximum Continuous AC Output at...

85° F (29° C) Ambient

100° F (38° C) Ambient ..........................7,000 Watts (7.0 kW)

120° F (49° C) Ambient Rated Voltage Rated Maximum Continuous AC Current at...

7,500 Watts

7.000 Watts

6.000 Watts

Phase

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

Rotor Speed at No Load

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

Engine RPM........................................................................

Rated AC Frequency ............................................................

Batteiy Charge Voltage Battery Charge Current

Weight...........................................................................

Length.........................................................

Width...

Height..........................................................

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

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

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

240 Volts

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

240 Volts

120 Volts

240 Volts

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

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

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

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

.............................................................50.0 Amps

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

...

............................................3,780 rpm

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

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

7,500 Watts (7.5 kW)

6,000 Watts (6.0 kW)

120/240 Volts AC*

31.2 Amps

29.2 Amps

25.0 Amps Single

1,950

60 Hz

14 Volts DC

2 Amps (max)

486 Pounds

36.6 inches (929 mm|

23.8 Inches (604 mm)

22.3 Inches (567 mm)

Section 2 - Operation

QUIETPACT™ 75D Recreational Vehicle Generator

OPERATION

(Jti

2.1 GENERATOR CONTROL PANEL

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

Figure 2.1 - Generator Control Panel

UNE BREAKER

♦ 2.1.1 HOURMETER

This indicates the 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 emd hold

the switch in the STOP position until the engine shuts

off. The switch 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 (SFE-14).

--------

ik CAUTION ik

If a fuse element melts, you should find the

cause of the overload before replacing the fuse.

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

FUSE

PREHEAT

♦ 2.1.4 LINE BREAKER

The line (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 differ. If an overload occurs, the dual breakers will open the ungrounded(hot) stator leads (11 and 44). When the generator has been connected for 120 volts only, the line breakers will operate independently on the ungrounded (hot) stator leads (11 and 33).

♦ 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 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 which can be interfaced with an optional remote panel provided inside the vehicle. This option allows you to start and stop the generator conveniently from within the vehicle. Refer to Part II - Installation Instructions, Section 2.8 for details on the remote

start/stop option.

23 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 completed so it complies with all applicable codes, standards and regulations and with the manufac turer's recommendations.

___________________________

Generac* Power Systems, Inc.

OPERATION

QCe

Section 2 - Operation

QUIETPACT™ 75D Recreational Vehicle Generator

♦ 2.3.2 ENGINE LUBRICATION

Have the engine crankcase properly serviced with the recommended oil before starting. Refer to Section 1.5.3 (Page 6) and Sections 3.1 and 3.2 (Page 12) for oil ser vicing procedures and recommendations.

----------

-Jà CAUTION Jk-----------------------

Any attempt to crank or start the engine before

▲

you have properly serviced it with the recom

mended oil may result in an engine failure.

♦ 2.3.3 FUEL SUPPLY

The engine must have an adequate supply of proper fuel to operate. Before starting it, check tiiat 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.

Some installations using a “shared” iiiel 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 fuel” while adequate fuel for the vehicle remains in the tank.

♦ 2.3.4 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 the “Maintenance" portion of

this manual for procedures and recommendations.

♦ 2.3.5 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, which causes it to shut down and may damage 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 gives off DEADLY carbon

monoxide gas through its exhaust system. This

dangerous gas, if breathed in sufficient concentra tions. 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 SYS TEM IS LEAKING OR HAS BEEN DAMAGED. SYMP TOMS OF CARBON MONOXIDE POISONING ARE

(a) inability to think coherently; (b) vomiting; (c)

twitching muscles; (d) throbbing temples; (e) dizzi

ness; (f) headaches; (g) weakness; and (h) sleepi

ness. IF YOU FEEL ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMP

TOMS 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 cir cuit breaker). Electrical load circuits will be turned ON after the generator has started, stabi lized and warmed up.

Generac* Power Systems, Inc.

QUIETPACT™ 75D Recreational Vehicle Generator

if the engine Is cold, press the Preheat switch for

15 to 30 seconds maximum.

Hold the engine Start/Stop switch in the START

position while pressing the Preheat switch to

crank the engine. Release the switches when the engine starts.

CAUTION

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.

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

Turn ON electrical loads using the means 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 generator run at no-load for a few minutes, to stabilize Internal engine generator temperatures.

CAUTION

Do not stop the engine/generator immediately

^ after running under load. This can overheat

and damage the engine and/or generator.

Press and hold the Start/Stop switch in the STOP position imtll the engine shuts off.

2.6 APPLYING LOADS TO GENERATOR

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

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

• DO NOT overload the generator.

• 2.6.1 LEHING THE ENGINE STABILIZE

The generator supplies correct rated voltage only at the proper governed speed. Some electrical appli ances 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 suffi cient 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.

Section 2 - Operation

OPERATION

0tt

• 2.6.2 DO 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.

Appl}dng 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 indi cate 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, multi

ply 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, fig ure 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 electrical loads over 75 percent of the unit’s rating for the first two or three hours of operation.

2.7 PROTEOION SYSTEMS

The engine has several safety switches that cause it to automatically shut down under the following con ditions: low oil pressure, high coolant temperature, and engine overspeed. See Figure 2.2 (Page 10) for the loca tion of these devices. If automatic shut down does occur, refer to ‘Troubleshooting Guide” on page 39.

• 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 approximately 110° C (230° F), the switch contacts close, which causes the engine to shut down automatically.

______________

1C* Power Systems, Inc.

OPERATION

(jet

Section 2 - Operation

QUIETPACT™ 75D Recreational Vehicle Generator

Figure 2.2 - Engine Protective Devices

♦ 2.7.3 OVERSPEED SHUTDOWN

The DC control circuit board (inside control panel) senses engine speed from the frequency of the alter nator AC output. Should the alternator output fre quency exceed approximately 72 Hertz (4,320 alter nator rpm), circuit board action initiates an automat ic engine shutdown.

♦ 2.7.4 OVERVOLTAGE PROTEQION

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 - Soiid-state Voitage Regulator

_ (nuaanwGiinni

Cr3=-«(+)-l_™i

BKnmiiitMMK (NlBUnKClBmi)

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 piston rings, resulting in blowby and high oil consumption.

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

_______________

i O Generac* Power Systems, Inc.

Section 2 - Operation

QUIETPACT" 75D Recreational Vehicle Generator

OPERATION

♦ 2.8.2 25-HOUR CHECK-UP

After the 25-hour break-ln period, contact a Generac Authorized Service Dealer for the following mainte

nance. 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.

♦ 2.8.3 ATTENTION REQUIRED

AFTER SUBMERSION

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.

♦ 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 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.

♦ 2.8.5 EFFECTS OF MOISTURE AND DIRT

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

Generac* Power Systems, Inc. 1 1

MAINTENANCE

Section 3 - Maintenance

QUIETPACT™ 75D Recreational Vehicle Generator

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 level as possible.

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

Install the dipstick and fully seat the T-handle; 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 “Full” mark. DO NOT FILL ABOVE THE “FULL’ MARK.

----------ik CAUTION Jk--------------------------

Never operate the engine with the oil level

i. below the "Add" mark on the dipstick. Doing

this could damage the engine.

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

Figure 3.1 - Oil Maintenance Features

OiL FILL

OIL DIPSTICK

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

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

the engine.

2. Immediately after the engine shuts OFF, remove the front service door located beneath the unit by retracting the two latches and pivoting the door downward.

3. Remove the air filter (see Section 3.3).

4. Remove the oil drain plug and drain the oil into a suitable container. Removing the oil fill plug will allow the crankcase to drain faster.

5. After the oil has drained, replace the oil drain plug. GO TO STEP 8 IF CHANGING OIL ONLY.

6. With the oil drained, remove the old oil filter by turning it counterclockwise.

7. Apply a light coating of clean engine oil to the gas ket of the new filter.

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

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 proper type and amount of recommended oil (see Section

1.5.3, Page 6). Periodically use the dipstick to check the oil level and continue to fill the crankcase until the oil reaches the dipstick “Full” mark. DO NOT FILL ABOVE THE “FULL MARK.

11. Install the oil fill plug and the dipstick before operating the engine.

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.

3.2 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.

1 a Generac* Power Systems, Inc.

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 ser vice door. Make sure the service door latches are fully engaged.

Section 3 - Maintenance

QUIETPACT" 75D Recreational Vehicle Generator

MAINTENANCE

Figure 3.2 - Engine Air Filter

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 spark arrestor screen, but are of the more efficient

“toroid” or “swirl” type. To remove carbon and com bustion deposits from the muffler, proceed as follows

(see Figure 3.3):

1. Locate the unit above a non-combustable sur face and ensure that the generator exhaust pip ing 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.

-A WARNING A~

The exhaust system of this product gets extreme

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.

-------

-ik WARNING ik

Be sure to reinstall the the hex pipe cap tightly to

the spark arrestor cleanout pipe. Vibration could

cause a loose cap to fall out, resulting in hot engine exhaust being drawn through the centrifu gal cooling fan and out beneath the unit. This could result in damage to the generator or dis charge of hot exhaust sparks beneath the unit.

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

Figure 3.3 - Spark Arrestor

Muffler Maintenance

3.5 CLEANING THE GENERATOR

Keep your generator as clean and as dry as possi ble. Dirt and moisture that accumulate on internal

generator windings have an adverse effect on insu

lation resistance.

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 gener

ator is housed inside an all-weather enclosure;

clean the enclosure with a soft, damp cloth or

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

console 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.

----------

-ik CAUTION ik--------------------------

Do NOT use a forceful spray of water to clean

the generator. Water will enter the generator

interior and cause problems, and may also

contaminate the generator fuel system.

Generac® Power Systems, Inc. 1 3

iX)=

MAINTENANCE

Section 3 - Maintenance

QUIETPACT™ 75D Recreational Vehicle Generator

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.

• 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 personnel knowledgeable of batter ies and 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 give off explosive hydrogen gas. This gas can form an explosive mixture around the bat tery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks, or any spark producing tools or equipment near the battery. Discharge static electricity from your body before touch ing 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.

-A WARNING A-

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to

the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following

procedures are to be observed:

• Wear full eye protection and protective clothing;

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

• Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention.

• 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. This includes such obstructions

as high grass, weeds, brush, leaves and snow.

Without sufficient cooUng 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 recommended coolant mixture (see Section 1.5.4, Page 6) as neces

sary; the bottle should be kept half full. 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 to

make sure the coolant recovery system is functioning properly. Coolant should be at the bottom of the radi

ator 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 Deader. Inspect the

cooling system and coolant recovery system for leaks.

II Generac* Power Systems, Inc.

Section 3 - Maintenance

QUIETPAOT” 75 D Recreational Vehicle Generator

MAINTENANCE

DANGER

Do not remove the radiator pressure cap while the engine is hot or 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.

----------Ék CAUTION ià

Do not use any chromate base rust inhibitor with

ethylene glycol base antifreeze, or 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 also will cause overheating. We also recommend 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 ten sion 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

♦ 5.12.1 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. 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.

♦ 3.12.2 RETURN TO SERVICE____________________

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

Check the tag on the engine for oil viscosity and

classification. Verify that the correct recommend ed oil is used in the engine (see Section 1.5.3,

Page 6). If necessary, drain and refill with the proper oil.

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 BAT TERY Recharge the battery to 100 percent state of charge, or, if defective, replace the battery.

Clean and wipe the entire generator.

Reconnect the battery. Observe battery polarity.

Damage may occur if the battery is connected incorrectly. Turn OFF all electrical loads. Add fuel if neces sary and then start the engine.

Allow the unit to warm up thoroughly.

Apply electrical loads to at least 50 percent of the unit’s rated wattage capacity.

When the engine is thoroughly warmed up, shut it down.

Your generator is now ready for service.

Generac* Power Systems, Inc. 1 5

Section 3 - Maintenance

MAINTENANCE

QUIETPACT™ 75D Recreational Vehicle Generator

3.13 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by your nearest Generac Authorized Service Dealer.

SYSTEM/COMPONENT PROCEDURE

X = Action

R = Replace/Adjnst as Needed * = To Be Completed by a

Generac Authorized Service Dealer.

FUEL

Fuel level

Fuel lines and connections* X

Füel Filter*

LUBRICATION

Oil level Oil

Oil filter

Oil line leakage* COOLING Engine cooling system*

Coolant level

Coolant* Enclosure louvers EXHAUST Exhaust system X Retorque Exhaust Manifold* Clean out MuiUer/Spark Arrestor BATTERY Electrolyte fluid level

Charge and condition FAN/ALTERNATOR BELTS Tension and condition* I X R

ENGINE

Retorque cylinder head* X

Retorque intake manifold*

Starter motor* X EVERY 750 H Air filter X R EVERY 500 H

Compression* X EVERY 750 H Valve clearance*

Governor* X R EVERY 750 H

Safety devices* X R EVERY 750 H

Injection system*

GENERAL

Overall condition

Exercise system

COMPLETE TUNE-UP* X X X Y

Inspect

X X R X

X EVERY 750 H

X R EVERY 750 H

X X AFTER 25-H BREAK-IN, W

Change

R EVERY 750 H

Clean

X 1

FREQUENCY

D = Dally W = Weekly 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 100 H

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 5œH

AFTER 25-H BREAK-IN, W

W, EVERY 250 H / 6 M

EVERY 750H

EVERY 750 H

1 B Generac* Power Systems, Inc.

PART II -

INSTALLATION

INSTRUaiONS

DANGER

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

SAFETY RULES

strictly with article 551, NFPA 70; ANSI Cl-1975; AND, ANSIAl 19.2-1975/NFPA 501C “Standcwd iV

for Recreational Vehicles" (Part 3, “Installation of Electrical Systems"). In addition, installation

must comply with the manufacturer’s instructions and recommendations.

Safety Rules

QUIETPACT™ 75D Recreational Vehicle Generator

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

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 and 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 product's safety is not endangered by the method, procedure 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 is both accurate and current. However, the manufacturer reserves the right to change, alter or otherwise improve this product at any time without 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

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 start-up 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 DE/UDLY. 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 start up. Disconnect the cable from the bat

tery 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 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

QU1ETPACT“ 75 D Recreational Vehicle Generator

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, ter minals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

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

• 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 vehicle circuits at the same time. The dockside (utility) power source must be positively isolated from the vehicle circuits whenever the generator is operating. Failure to isolate the vehicle circuits from the dockside power supply when the generator is running may result in damage to the generator or serious injury or death to dockside (utility) power workers due to backfeed of electrical energy.

• 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 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 imme diate 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.

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.

A EXPLOSION HAZARDS A

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

EXPLOSIVE and should be handled with care.

Comply with all laws regulating the storage and handhng of fuels.

Ftiel supply fines 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 fine between the generator fuel connection point and rigid fuel fines.

Generac* Power Systems, Inc. 1 S

GENERAL

INFORMATION

Section 1 - General Information

QUIETPACT™ 75D Recreational Vehicle Generator

1.1 PURPOSE AND SCOPE

OF THE IVIANUAL

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, personal injury or damage to equipment and/or property. Stress safety to all installers, operators and service technicians who work on this equipment.

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 fol'owing standards booklets (latest revision) are available from the sources indicated:

1. NFPA Standard 501C, “Standard for Recreational Vehicles,” available from the National Fire Protection Association, Batterymarch Park, Qui icy, MA 02269,

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

3. ANSI Cl-1975 and ANSI 119.2-1975, available from the American National Standards Institute,

1430 Broadway, N(Av York, NY 10018.

4 ANSI A119.2/NFPA 501C, available from the

Recreational Vehicle Association, 1896 Preston White Drive, Reston, VA 22090.

5, California Administrative Code, Title 25, avail

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

20 Generac* Power Systems, Inc.

6. CSA Electrical Bulletin 946, available from the 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

T1 T2 T3

(RED) ^whItD ^ BLACK)

1 1

--------

44A

----

-----

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

CB ij

llA

-----

33 0.

\ 22

CB l J

..........

■d

H 1’'

• 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.

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INSTALLATION

Section 2 - Installation

QUIETPACT™ 75 D Recreational Vehicle Generator

2.1 LOCATION ÄND SUPPORT

• 2.1.1 GENERATOR LOGVTION

__________________

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

Many recreational vehicles have been factory

equipped with an area for the generator set. Some vehicles 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 applies to the space between the gener ator 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.

• 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 typ ical 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

• 2.1.2 GENERATOR SUPPORT

___________________

The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding. The metal frame work on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams. These beams should consist of (a) 1-

1/2-inch 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 th& generator.

Generac* Power Systems, Inc.

SUPPORT

BRACES

The installer must make certain that the selected

location will permit adequate cooling and ventilat ing airflow to be supplied.

Section 2 - Installation

QUIETPACT“ 75D Recreational Vehicle Generator

INSTALLATION

♦ 2.T.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, are engaged at least 3/8” of an inch [9.5 mil

limeters]. Refer to Section 2.2 for the location of the generator mounting holes.

Figure 2.2 - Typical Generator Restraint

METAL LINED

t/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.T COMPARTMENT CONSTRUCTION

* •

• 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 with the grain of the wood at cross section for added strength (Figure 2.3).

Figure 2.3 - Typical Compartment Construction

• If constructing a compartment, line the exterior (underside) of the compartment floor with 26gauge 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 such materials 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 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. S3

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

IL W p

FOUI

LOCKED STANDING

GORDON SEAM LOCK SEAM

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.

I I

* ■ OFF SI

DOUBLE LOCK

STANDARD UP JOINT

OFFSET

DOUBU SEAM

ACME LOCK

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 MATERIALS

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 compartnyent interior.

DANGER

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.

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 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.

______________________________

NOTE:

DANGER

gk 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).

Generac* Power Systems, Inc.

Section 2 - Installation

QUIETPACF” 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

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

DANGER

Fuel lines and exhaust piping must not pene

trate into the vehicle living area.

NDTE^ FÜR A FULL SIZE TEMPLATE, CONTACT GENERAL SERVICE DEPARTMENT AT: 1-262-544-4811

Generac* Power Systems, Inc. SS

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, ventilating 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 com bustion. The installer also must provide for 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.

♦ 2.3.1 GENERATOR AIRFLOW

____________________

This unit uses a centrifugal blower to cool the gener ator’s internal components. Blower fan air is then expelled from a blower air outlet duct. The engine cooling fan draws air in through air inlet openings, moves that air around the engine/generator and across the radiator, then discharges that air out the bottom (see Figure 2.7).

♦ 2.3.2 COOLING 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 L MINIMUM OPENING

Figure 2.7 - Airflow Through Engine/Generator

305mm ( 12’ ) UNRESTRICTED UNDERFRAUe CLEARANCE TO THE GROUND

S6 Generac* Power Systems, Inc.

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

Using ductwork (Figure 2.10, Page 27). The installer must be sure air is available to the top of the generator since air Inlets are located at the top.

By providing an opening in the vehicle skirt and

space behind the generator for cooling airflow

(Figure 2.11 Page 27). Recommended clearance

behind the back of the generator is at least

2 inches (50 mm).

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

INSTALLATION

Figure 2.10 - Air Iniet Using Ductwork

ANTI-SPLASH

Figure 2.11 - Air Inlet in Vehicle Skirt

♦ 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

♦ 2.3.3 COMPENSATING FOR RESTRidlO NS

Such materials 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 suppher 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 cm^). Minimum 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 Syetems, Inc. S7

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 le^tage; 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) fuel filter, (b) 12-volt DC electric pump, (c) injection pump, and (d) interconnecting lines and fit tings. Connect a fuel supply line to the fuel inlet and the return line back to die tank. Use a flexible length of approved fuel hose between the fuel filter inlet con nection and rigid fuel lines.

♦ 2.4.1 FUEL TANK

_______________________

Either the generator must share the vehicle engine's 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 engine's 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 engine's pickup tube. This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods.

----------

CAUTION --------------------------------

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 J512F, “Standard Automotive Fittings,” or with ANSI B 126.26 (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 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 an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines. This prevents breaking of the line caused by vibration, shifting, settling or movement. The follow ing 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.

• 2.4.5 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 Syeteme, Inc.

Section 2 - Installation

QUIETPACr™ 75D Recreational Vehicle Generator

INSTALLATION

2.5 EXHAUST SYSTEil

The generator exhaust system must be safely and properly Installed. Only approved mufflers and other

exhaust system parts must be used. A properly installed exhaust system 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

properly repaired.

• 2.5.2 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 cannot 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 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.

• The hole in the generator compartment floor through which the exhaust pipe passes must be

larger than the exhaust pipe. Hole size should per mit Installation of a ventilated metal thimble that is at least 2 inches larger in diameter than the exhaust pipe (Figure 2.13)

—A CAUTION M-----------------------------

Never tee the generator engine exhaust pipe

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 MUFFLERS AND SPARK ARRESTORS

This muffler meets code and standard requirements of the U.S. Forest Service. Use only mufflers and parts approved by Generac. Any person(s) installing

an unapproved muffler, or an unapproved exhaust system part, or modifying an exhaust system in any

way that might cause a hazard, is liable for any dam

age, injury or warranty expense that might be caused

by such unapproved installation or modification.

Failure to provide and malntam 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, you must provide a spark arrestor.

The vehicle owner or operator must maintain this device in good condition. In the state of California, the preceding is required by law (Section 4442 of the California PubUc Resources Code). Other states may have similar laws. Federal laws apply on federal lands.

Figure 2.13 - Typical Exhaust System

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.

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 ELEaRICAL CONNEQIONS

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 flexible metal conduit is used between the genera

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

• From the jimctlon 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 CO NNECTIONS

_______________

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 JUNQION 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 NEUTRiAL (White). A "tie bar" connects the two switch handles on line breaker CBl.

Section 2 - Installation

QUIETPACT™ 75D Recreational Vehicle Generator

INSTALLATION

p. 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 re-routing 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 controls box in order to perform the re-rout

ing outlined below. The front and top unit enclo

sure panels as well as the user controls 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. Re-route stator lead wire 44 from the line side terminal of CBIA to the ground stud location pre viously occupied by stator lead wire 33.

2. Move smaller gauge (#18 AWG) wire labeled #44, from the top of CBIA to the top of CBl. Renumber this wire #11.

3. Re-route stator lead wire 33 from the ground stud adjacent to the four-position terminal block to the line side terminal on CBl (renamed as CBIA in Figure 2.16).

4. Re-number ground wire "33" located between the four-position terminal block and ground as wire "44".

5. Re-number wire "44A" as "33A".

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 circuit 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 circuit breaker CBIA across AC output leads T3 (black) and T2 (white).

Try to keep the load balanced between the two cir

cuit breakers and stator windings.

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

ed neutral.

--------

A CAUTION ik

Do NOT connect electrical loads in excess of any

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 T3

|wlMiM||M|

^-vixujLT-' SFiyNDp LtjujujiJ

Figure 2.16 - Connections for 120 Volts Only ■

Dual Circuits

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

Voltage

Generac* Power Systems, Inc. 31

INSTALLATION

Section 2 - Installation

QUIETPAG^“ 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 methods (such as explosion proof flttings) to seal such openings.

♦ 2.6.5 POWER SUPPLY CORD

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 is by 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 electrical circuits can be powered by

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 circuits at the same time. The dockside (utility) power source must be positively isolated from the vehicle circuits whenever the generator is operating. Failure to isolate the vehicle circuits from the dockside power supply when the gener ator is running may result in damage to the gener ator or serious injury or death to dockside (utility) power workers due to backfeed of electrical ener gy. Installation and connection of the generator

must comply with ANSI A119.2/NFPA 501C and ANSI/RVIA EGS-1 (latest editions).

32 Generac* Power Systems, Inc.

Figure 2.17 - Transfer Switch Isolation Method

2ND AIR

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 that meets the following requirements:

• The battery must be a 12-volt, automotive type storage battery.

• Use a battery rated 70 amp-hours and capable of delivering 360 cold-cranking amps.

NOTE:

If the battery is to be used to power other vehicle accessories, as well as 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 diameter may cause a drop in voltage, which causes starting problems. For the best cold weather starting, the voltage drop between battery terminals and the gen erator connection point should not exceed 0.12 volts per 100 amps of cranking current.

QUIETPACT™ generators are rated at about 100 DC amps of cranking current.

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

CABLE LENGTH

in Feet (meters]

0 to 10 (0 to 3) 2*

11 to 15 (3.4 to 4.5) 0

16 to 20 (4.5 to 6) 000

_____________________

CABLE SIZE

♦ 2.7.3 BATTERY CABLE CONNEQIONS

_____________

1. Connect the battery cable from the battery post or terminal indicated by a POSITIVE, POS or (-t) 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

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

the negative post on the generator frame. Connect cables so the connectors are clean

4. and tight.

Figure 2.19 - Connecting Battery Cables

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

Generac* Power Systems, Inc. 33

INSTALLATION

Section 2 - Installation

QUIETPACF“ 75D Recreational Vehicle Generator

♦ 2.7.4 BATTERY COMPARTMENT

__________________

Install the generator battery in Its own, vented com

partment. Place the battery compartment away from any source of heat, sparks or flame.

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 batter

ies give off explosive hydrogen gas. This gas can form an explosive mixture around the bat tery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks, or any spark producing tools or equipment near the battery. Discharge static electricity from your body before touch ing 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.

------

ik WARNING ik

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to

the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

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

• Wear full eye protection and protective clothing;

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

----------

• Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention.

• 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.

2.8 OPTIONAL ACCESSORIES

A plug-in connector (Figure 2.20) is provided on the generator set, below the control panel. Use this to connect an optional remote-mounted start/stop panel to the generator. Installation of such a panel will per mit you to start and stop the generator engine from any convenient location inside the vehicle.

Figure 2.20 - Remote Panel Plug-in Receptacle

♦ 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 on Figure 2.20, skip to step 5. Otherwise, proceed with step 2.

2. Remove the electrical access panel located just below the knock-out labaled “REMOTE.” The remote connector will be located inside the elec trical 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, sup plied as an accessory with the generator) to the coach’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

POSTINSTALLATION 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.

Factory settings are correct for most applica

tions. When making adjustments, however, be

careful to avoid overspeeding the engine.

-----

3.2 BEFORE INITIAL START-UP

Before starting, complete the following:

1. Check the engine crankcase oil level and, if nec essary, fill to the dipstick “FULL’ 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 1, 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

qualified service technicians who have been trained should perform adjustments outlined in this manual.

3.4 TESTING

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. 'Vbu must not allow the unit to over heat during prolonged operation.

UNDER

LOAD

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

POSTINSTALLATION 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 COMPARTMENT

□ 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 AIR

□ 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 CONNEQIONS

□ 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 any other options and accessories (if

used) are installed properly.

DATE OF INSTALLATION

NAME OF INSTALLER

SIGNATURE OF INSTALLER

3G 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.

1. System control fuse blown

2. Loose corroded or defective battery cables

3. Defective engine Start/Stop switch

4. Defective starter contactor

5. Defective starter motor

6. Low or defective battery

7. Defective engine control board

1. Vehicle fuel shutoff valve closed

2. Out of fuel

3. Defective fuel solenoid (FS)

4. Defective fuel pump (FP)

5. Open #14 wire from engine control board

6. Plugged fuel filter or fuel line

7. Engine mechanical parts failure

8. Defective engine control board

1. Air filter plugged or damaged

2. Defective fuel pump (FP)

3. Plugged fuel filter or fuel line

4. Water in fuel

5. Improper preheat

CORRECTION

1. Replace fuse.

2. Tighten, clean or replace as necessary.

3. Replace Star VS top switch.

4. Replace contactor.

5. Replace starter motor.

6. Charge or replace battery.

7. Replace control board.

1. Open valve, if so equipped.

2. Replenish fuel.

3. Replace solenoid.

4. Repair or replace fuel pump.

5. Check connections and. insulation of #14 wires.

6. Clean or replace fuel filter or line.

7. Repair or replace parts.

8. Replace control board.

1. Check, clean or replace as needed.

2. Repair or replace fuel pump.

3. Clean or replace fuel filter or line.

4. Drain fuel system and refill.

5. Preheat unit.

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.

1. Engine oil level low

2. Overheated engine

3. Defective low oil pressure switch

4. Defective high coolant temperature switch

5. Defective engine control board

1. Defective Start/Stop switch

2. Open/Disconnected #18 wire between Start/Stop switch and engine control board

3. Open/Disconnected #0 wire between Start/Stop switch and engine control board

4. Defective engine control board

1. Main line circuit breaker open

2. Fault with vehicle circuit breaker and/or fuses

3. Generator internal failure

1. Check oil and add oil as needed.

2. Check cooling system for leaks.

3. Replace pressure switch.

4. Replace temperature switch.

5. 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.

Generao* Power Systems, Inc. 37

ELECTRICAL

DATA

_.EGEND

AVR BCR BH1 BH1ABH2 BH2ACB1 CB2 C0NN1 D1 D2 -

n -

FP FS GND1GND2GND3GND4GND5GND6HV^ HM LOS PHC R1 R2 SC SM SW1 -SW2 IS -

Appendix 2 — Electrical Data

QUIETPACT“ 75D Recreational Vehicle Generator Wiring Diagram - Drawing No. C4946-

BRUSH WITH RED(4) LEAD

CLOSEST TO BEARING

AUTOMATIC VOLTAGE REGULATOR

BATTERY CHARGER RECTIFIER BULK HEAD CONNECTOR. RECEPTACLE (BLACK) BULK HEAD CONNECTOR. PLUG (BLACK) BULK HEAD CONNECTOR, RECEPTACLE (GRAY)

BULK HEAD CONNECTOR. PLUG (GRAY) CIRCUIT BREAKER 35A CIRCUIT BREAKER 4A

- CUSTOMER REMOTE CONNECTION DIODE 600V, 6AMP

DIODE 600V, 6AMP

FUSE I4AMP SFE

FUEL PUMP FUEL SOLENOID ENGINE GROUND

frame STUD

GROUND (BEARING CARRIER) THRU BOLT (CONTROL PANEL) GROUND STUD (NON-SEALED COMP) GROUND STUD (SEALED COMP) HIGH WATER TEMP SWITCH HOURMETER

LOW OIL PRESSURE SWITCH

PREHEAT CONTACTOR

RESISTOR, 1 ohm 25W

RESISTOR 10 ohm, 5W START CONTACTOR STARTER MOTOR SWITCH START/STOP

- PREHEAT SWITCH TERMINAL STRIP CUSTOMER CONNECTION

38 Generac* Power Systems, Inc.

12V BATTERY CONNECTION CUSTOMER PROVIDED

O O 0

GLOW PLUGS

Appendix 2 — Electrical Data

QUIETPACT™ 75D Recreational Vehicle Generator

Wiring Diagram - Drawing No. C4946-

ELECTRICAL

DATA

Generac* Power Systems, Inc. 3S

ELECTRICAL

DATA

Appendix 2 — Electrical Data

QUIETPACF“ 75D Recreational Vehicle Generator Electrical Schematic - Drawing No. - C4945

LEGEND

AVR -AUTOMATIC VOLTAGE REGULATOR BCR -BATTERY CHARGE RECTIFIER BCW -BATTERY CHARGER CB1 -CIRCUIT BREAKER 35A CB2 -CIRCUIT BREAKER (4A) D1 -DIODE 600V, 6AMP D2 -DIODE 600V, 6AMP DPE -EXCITATION WINDING F1 -FUSE 14AMP SFE FS -FUEL SOLENOID FP -FUEL PUMP GP -GLOW PLUGS HM —HOURMETER

40 Generac® Power Syst:ems, Inc.

HWT -HIGH WATER TEMP SWITCH LOS -LOW OIL PRESSURE SWITCH PHC -PREHEAT CONTACTOR R1 -RESISTOR, 1 OHM, 25W R2 -RESISTOR 10 OHM, 5W S -STARTER SC -START CONTACTOR SW -PREHEAT SWITCH SW1 -SWITCH, START/STOP

Appendix 2 — Electrical Data

QUIETPACT™ 75D Recreational Vehicle Generator

Electrical Schematic - Drawing No. - C4945

ELECTRICAL

DATA

Qenerac* Power Systems, Inc. 4T

^PARTS

LISTS

Appendix 5 — Exploded Views and Parts Lists

QUIETPACT" 75D Recreational Vehicle Generator Engine, Alternator Drive and Starter Assembly - Drawing No. C7651

ITEM PART NO. QTY. DESCRIPTION ITEM

1 2 72379B 1 BEARING CARRIER, UPPER 25 68485 3 4 C6054H 1 STATOR ASSEMBLY 5 31971 1 BALL BEARING 28 6 73159 1 BALL BEARING 29 22511 7 8 66849 2 TAPTITE M5-0.8X 16 31 42633 9 C6862 4 BOLT , STATOR 32 46526 10 11 C5014 1 12 13 14 C5298 1 BELT, V-RIB 15 16 C4841 1 SPACER, STARTER 39 39253 4 17 18 C6363 1 FLYWHEEL ASSEMBLY 19 20 71956 2 WASHER, VIBRATION ISOLATOR 43 C6609 21 22129 22 45771 23 40250 2 SHCS 5/16-18 X 11/2 46 A7043 2 HHCSM12-1.25X25

C5598 1

C6055H

66386 1 BRUSH HOLDER 30

C3168 6

C4538 1 C4544 1

20692

73106G 1 PULLEY, ALTERNATOR 40 A1658

39288

43 Generac* Power Systems, Inc.

BEARING CARRIER, FRONT 24 C7933

ROTOR ASSEMBLY 26 51769 6

5/16 SPECIAL LOCK WASHER 33 LUG, LIFT RAIL, ENGINE RH 35 51756 5 ROTARY TENSIONER 4.5“ 36 49813 1 M6 HEX NUT

1 STARTER MOTOR

HHCS M8-1.25X 55

8 WASHER, SPLIT LK -M8

NUT, HEX M8-1.25 45 55934M

PART NO. QTY.

27 C4537 2 ENGINE BRACKET

22237 1

49451 1

52212

37 38 21991 1 EARTH STRAP

42 Cl 069 3 TAPTITE, M6-1.0X8

69673J

43107

67989

49808

DESCRIPTION

1 GUARD, FLYWHEEL 4 HHCS M12-1.25X20

WASHER, SPLIT LK-M12

WASHER, SPLIT LK -3/8 HHCS 3/8-16 X 11/2

FENDER WASHER 7GA HHCS 3/8-24 X 1 "

1 11 LOCKWASHER MIO

HHCS M10-1.25X25

6 2 5/16 FLANGE NUT

HHCSM10-1.25X20

2 HHCS M8-1.25 X 25

HHCS M8-1.25 X 20 1 % SPECIAL LOCK WASHER 4 M8 FLANGE NUT

1 ENGINE, 1.0L DIESEL 2 WASHER. FLAT Ml2 1

CLAMP, VINYL COATED, Y4

Appendix 5 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

Base Frame - Drawing No. C7652

^PARTS

LISTS

PART NO.

ITEM

1 2 C5087 1 DOOR, SERVICE REAR 3 4 5 C5712 6 29451 7 C7857 2 GROMMET 1/8 X 13/32 8 70936 4 VIBRATION MOUNT 9 C6721 1 GASKET, CLEANOUT

10 11 12 13 22097 1 WASHER, SPLIT LK -1/4-M6 14

C6950

C5088 C5644 2

C6722 1 42907 8 22129 8

43146 2 HHCS M6-1.00 X 10 C7561

QTY. DESCRIPTION

BASE FRAME WELDMENT 16

1 DOOR, SERVICE FRONT

SLIDE LATCH FLUSH 19

1 GASKET , SERVICE DOOR REAR 20

220MM RUBBER TAPE 1/8 X Vz”

PLATE, CLEANOUT 25 HHCS M8-1.25X 16 26 WASHER, SPLIT LK- M8

1 CARRIAGE BOLT 3/8 -16 X 55MM

ITEM PART NO.

A4456 1 17 18

22 23 24

76821 2

47411 2

52857

C5443 1

C7423

22131 1

22237 1

22264

51718 8

56326 2

DESCRIPTION

QTY.

3/8 SPECIAL LOCK WASHER HEX NUT 3/8-16 BRASS HHCS M6-1.00 X 16 NUT, LOCKING M6.0 -1

BLOCK, TERMINAL BATTERY POST STUD 3/8-16 X 55MM

WASHER 3/8 FLAT WASHER SPLIT LK -3/8

LOCKWASHER #8 -M4

HHCS M4-0.7X 10

VINYL TRIM -BLACK 180MM

MM = MILLIMETRES

Generac* Power Systems, Inc. 43

^PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator Enclosure - Drawing No. C7653

ITEM

PART NO. QTY.

1 2 3 4 5 6 7 8 9

10 11

13 C4987 1

14 15 16

C5607 C4534 1 C4532 1 C4535 1 C4536 1 C5525 1 C5527 1 C5528 C5529 1 C5530 1 C5531 1 C4986 1

C5091 1 C6362 1 78115 33 WASHER, SELF LOCK DOME A7215

Generac* Power Systems, Inc.

DESCRIPTION ITEM PART NO. QTY.

ENCLOSURE PANEL RH 18 ENCLOSURE PANEL TOP ENCLOSURE PANEL LH 19 ENCLOSURE PANEL FRONT 20 ENCLOSURE REAR PANEL 21 INSULATION, FRONT PANEL INSULATION, LH SIDE PANEL

INSULATION, RH SIDE PANEL 24 INSULATION, TOP FRONT PANEL INSULATION, TOP REAR PANEL INSULATION, LIFTING LUG COVER COVER, ACCES LIFT COVER, RADIATOR FILL COVER, ACCESS ELECTRICAL GASKET, ELECTRICAL ACCESS

58 'A -20 X 5/8 W/WASHER

22 C7026 1 DECAL, COOLANT

23 C7027 1 DECAL, FUEL RETURN/SUPPLY

25 C7029 1 DECAL, LIFTING LUG 26 C7030 1 DECAL, MAX HOT / MIN COOLANT

27 28 C6425 1 SUPPORT, COOLANT TANK 29 52857 30 31 C7047B 1 FOAM, AIR DUCT SIDE 32

C5096

C7023 C7024 C7025 1 DECAL, REMOTE

C7028

C2340

C7047A

C4816 1 DECAL, UNIT

DESCRIPTION

FRAME CONTROL PANEL -

REFER TO DRAWING C8005 1 DECAL, BATTERY +/- 1

DECAL, RADIATOR CAP

DECAL, OIL FILL/LEVEL

1 DECAL, WARNING RV

3 NUT, LOCKING M6-1

1 FOAM, AIR DUCT FACE

Appendix 5 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

Base Frame - Drawing No. C7652'B

'=Pl .1"-Î1 ' ""1

■'r-y

..PARTS

LISTS

ITEM

PART NO. QTY.

C6950 1 2 C5087 3

C5088

C5644 2 SLIDE LATCH FLUSH 5 C5712 1 6

29451

C7857 2 GROMMET 1/8X13/32

70936D 4 VIBRATION MOUNT 23

C6721 1

C6722 1 PLATE, CLEANOUT

42907

22129 8

22097 3

43146 2 HHCS M6-1.00X10

C7561 1 CARRIAGE BOLT 3/8 -16 X 55MM

1 1 DOOR, SERVICE FRONT 18

220MM RUBBERTAPE 1/8X72" 21 C7423 1 STUD 3/8-16 X55MM

8 HHCS M8-1.25X16

DESCRIPTION

BASE FRAME WELDMENT 16 DOOR, SERVICE REAR 17 76821 2 HEX NUT 3/8-16 BRASS

GASKET , SERVICE DOOR REAR

GASKET, CLEANOUT

WASHER, SPLIT LK- M8 WASHER, SPLIT LK -1/4-M6

PART NO. QTY. DESCRIPTION

ITEM

A4456

47411

19 49813 2 NUT, HEX M6.0 -1.0

20 C5443

22 22131

22237 24 22264 25 51718

56326

MM = MILLIMETERS

1 BLOCK, TERMINAL BATTERY POST

1 WASHER 3/8 FLAT 1 WASHER SPLIT LK -3/8 8 LOCKWASHER #8 -M4 8 HHCS M4-0.7X10 2 VINYL TRIM-BLACK 180MM

3/8 SPECIAL LOCK WASHER

HHCS M6-1.00X16

Generac* Power Systems, Inc. 4S

^PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACF“ 75D Recreational Vehicle Generator Enclosure - Drawing No. C7653-A

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION

1 C5607 2 C4534 3

C4532 1 ENCLOSURE PANEL LH 21 C7025 1 DECAL, REMOTE

C4535 1 ENCLOSURE PANEL FRONT 22 C7026 1 DECAL, COOLANT

C4536 1 ENCLOSURE REAR PANEL 23 C7027 1

C5525 1 INSULATION, FRONT PANEL 24 C7028

C5527 1 INSULATION, LH SIDE PANEL 25 C7029 8 C5528 1 INSULATION, RH SIDE PANEL 9

C5529 1 INSULATION, TOP FRONT PANEL 27

10 C5530 1 11 12

C5531 1 INSULATION, LIFTING LUG COVER

C4986 1 COVER, ACCESS LIFT

13 C4987 14

C5091 1

15 C6362 1 GASKET, ELECTRICAL ACCESS 33 22097 16 78115 17 A7215 58 18 C5096 1 FRAME CONTROL PANEL -

Generac® Power Systems, Inc.

1 ENCLOSURE PANEL RH 19 C7023 1 DECAL, BATTERY 1 ENCLOSURE PANEL TOP 20 C7024 1

DECAL, RADIATOR CAP

DECAL, FUEL RETURN/SUPPLY 1 DECAL, OIL FILL/LEVEL 1

DECAL, LIFTING LUG

26 C7030

C2340

INSULATION, TOP REAR PANEL 28 C6425

29 49813 30

C7047A 1 FOAM, AIR DUCT FACE

1 COVER. RADIATOR FILL 31 C7047B

COVER, ACCESS ELECTRICAL 32 C4816

33 WASHER, SELF LOCK DOME

98761 1 DECAL, ENGINE DATA

’A -20 X 5/8 W/WASHER 35 42755

1 DECAL, MAX HOT / MIN COOLANT 1 DECAL, WARNING RV 1 SUPPORT, COOLANT TANK 3 NUT, HEX M6-1.0

FOAM, AIR DUCT SIDE 1

DECAL, UNIT

WASHER, SPLIT LOCK 'A" - M6

DECAL, CSA APPROVAL

REFER TO DRAWING C8005

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

Cooling System - Drawing No. C7654-B

i II

ti--' II

..PARTS

LISTS

ITEM PART NO. QTY. DESCRIPTION

1 C4551 1 2

C4550 1

3 C4552 1 FAN, SQUIRREL CAGE 4 C4554 1 SHAFT, FAN

C4555

C4557

6 7 C4556 1 8 C4553 1

49869

10 81810

11 70265 1

58443

13 43146 2 HHCS M6-1.00X10MM

22097

14 15

49815 16 22152 4 WASHER, SPLIT LK #10 17 51716 4 HEX NUT M5

18 49813 12

19 C4312 1

20 43116 3 21 22473 22 C8643 23 C8507 1 BRACKET, ROTARY TENSIONER 24

39253 2

25 22129 6

C6549A

26 27 C5108 1

1 1

7 CRIMPTITE, 1/4’’-20 X 5/8” 19

4 HHCS M5-0.8X16MM

1 61" GREEN BELT

COVER PLATE, SCROLL WELDMENT 28 HOUSING, FAN SCROLL WELDMENT

CARRIER, BEARING 33 KEY, SQUARE 3/16X3/16X1/2 PULLEY, FAN 4 7/8 BEARING 2 ROW BALL FENDER WASHER M16 NUT, HEXM16.0-1.5MM 38 LOCKWASHER M16.0

WASHER, SPLIT LK 1/4- M6

NUT, HEX M6.0-1.0MM 46 RADIATOR 1.0LRV 47 HHCS M6-1.00X12MM WASHER y4-M6 PULLEY, 3” FLAT FLANGED

HHCS M8-1.25X20 WASHER, SPLIT LK -M8

FILLER NECK ASSEMBLY,

RADIATOR REMOTE

ITEM PART NO. QTY.

C6236

29 C7384

30 C5543 31 C4460 32 C4845

C5544 34 86133A 35 57822 36 50968

42911 1

46526

47411 2

C7997 270MM

40 41 C7649

42 42907 43 C5605

44 C6976

C7997 510MM

55934K C4976 55934D

C7040

55934V

45771

51 52 C5105 53 24426 54 C8643

48705 1

MM = MILLIMETERS

1 HOSE TEE 1 1 1 HOSE, WATER PUMP LOWER 1 HOSE, TOP

1 HOSE, LOWER INTERMEDIATE 8 2 HOSE CLAMP #8 720MM

1 M10 LOCKWASHER

4 HOSE CLAMP 7/8 3/8 4

1 TANK, COOLANT OVERFLOW

1 CLAMP, VINYL COATED 1 5/8

1 CAP, RADIATOR PRESSURE

1 CLAMP, VINYL COATED 1 1/16

1 GASKET, RADIATOR BASE

1 CLAMP, VINYL COATED 1 '/2

1 1/2”-13X 1-3/4” HHCS

1 TENSIONER, SE-18-3”

DESCRIPTION

COUPLING, HOSE HOSE, RADIATOR LOWER

HOSE CLAMP HI TRQ 1-3/4 MAX HOSE, 3/4 SAE-20R3

M10-1.5X30MM HHCS HHCS M6-1.00X16MM

HOSE, 5/16 SAE-20R4 HHCS M8-1.25X 16MM

CAP, COOLANT FILL HOSE 5/16 SAE-20R4

NUT HEX M8-1.25 BRACKET, SUPPORT

1/2"-13 FLANGE NUT

Generac* Power Systems, Inc. 47

^PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator Electrical Enclosure Assembly - Drawing No. C7655-B

ITEM

PART NO. QTY.

C6878

71914

83048

C7610 1

93642 1

65795 1

48512 1

27565 A/R TAPE, GLASS INSULATED

66849C 10 11 12 13 14 15

16 C6712A

17 18

66849 3 TAPTITE, M5-0.8 X 16

49226 1 LOCKWASHER M5

33134 2 HHMS, #6-32 X 1/2“

40213 4 PCB SUPPORT SNAP -IN

C8620 1 HHMS, #8-32 X 2.25"

51713 1 WASHER, FLAT M5

22985

C7022 1

4S Generac* Power Systems, Inc.

1 WELDMENT, ELECTRICAL ENCLOSURE 1 1

2 TAPTITE, M5-0.8 X 30

1 4 WAHSER, FLAT #6

DESCRIPTION ITEM PART NO.

19 C3992

C6359

C6712D*

22473

49813 82121A

C7390 1 GASKET, ELECTRICAL ENCLOSURE

DIVIDER

C7487

A/R = AS REQUIRED * NOT SHOWN REFER TO WIRING DIAGRAM C4946

TERMINAL BLOCK 4 POSITION ASSEMBLY, POTTED REGULATOR RESISTOR 20R 5% 12W ASSEMBLY MARINE CONTROL BOARD RECTIFIER, BATTERY CHARGING CIRCUIT BREAKER 5 AMP

HARNESS

DECAL, CUSTOMER CONNECTION

21 C6712G*

22 C6712F* 1 23 24 C6712E* 25 A1658 2 26 27 22097 7

29 30 22717B 32

QTY. DESCRIPTION

4 TAPTITE, SCREW 1 GASKET, ELECTRICAL ENCLOSURE 1 WIRE ASSEMBLY # 32

WIRE ASSEMBLY #22 1 DIODE ASSEMBLY 1 WIRE ASSEMBLY #162

'/4 SPECIAL LOCKWASHER

2 WASHER, FLAT 'A-MQ

WASHER, SPLIT LK '/4-M6 7 NUT, HEX M6-1 1 CLAMP, OPEN TYPE 2 GROMMET

1 HARNESS, AC OUTPUT

Appendix 5 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

Intake and Exhaust System - Drawing No. C7656-A

^PARTS

LISTS

J 3 s

1 ^ i ! '

j d

^ ll

ITEM

PART NO. QTY.

75674 1 EXHAUST GASKET

C4879 1 CHAMBER AIR INTAKE

C4880

C5493 1 HOSE, AIR INLET

DESCRIPTION

AIR FILTER

5 C4727 1 MUFFLER WELDMENT

25145 2 U BOLT & SADDLE 1.25

10 11

13 14 15 16 17

C4539

C5022 1

35685 4 C4878 C6243 1 GASKET, EXHAUST OUTLET C6244 1 PLATE, EXHAUST OUTLET 39288 2 71956 2 WASHER, VIBRATION ISOLATOR 22129 10 WASHER, SPLIT LK -M8 45771 58443

RAIL, ENGINE LH, WELDMENT INSULATION, EXHAUST HOSE CLAMP #28

OUTLET, EXHAUST FLEX

HHCS M8-1.25X55

NUT, HEX M8-1.25

CRIMPTITE, y4"-20 X 5/8”

PART NO. QTY. DESCRIPTION

ITEM

C5105 1 BRACKET, SUPPORT 19 22145 4 WASHER, FLAT - M8 20

39253 2 HHCS M8-1.25 X 20

43107 4

HHCS M8-1.25 X 25 22 35586 2 HOSE CLAMP #20 23

42909 1 HHCS M8-1.25 X 30 24 42907 1 HHCS M8-1.25 X 16 25

77642

ADAPTOR, EXHAUST FLANGE

BOTTOM OUT

357-70939 1 MANIFOLD GASKET 27 75673 1 HORIZONTAL EXHAUST MANIFOLD 28 29 30 31 32

A8543 1 ADAPTOR, UNIVERSAL EXHAUST

68527 2 HHCS M6-1 X 20 W/LOCKWASHER

22097 2

WASHER, SPLIT LK M6 49813 2 NUT, HEX M6-1 77643 1 GASKET, EXHAUST FLANGE

Generac* Power Systems, Inc. 4S

^PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator Fuel and Electrical Systems - Drawing No. C7657-A

ITEM PART NO.

1 C6946A

2 52219 3

69598B 2

22097 7

4 5 38750

56739 2

6 7 49813 5

55934M 1

22473 5

40173 2

28414A 1

12 C7649 13 47411 14 76821

22237 1

50 Generac*

Power Sys-tems, Inc.

QTY. DESCRIPTION

3 1 1

FUEL PUMP ASSEMBLY 16 1/8 NPTX 5/16 BARBED 17 STRAIGHT FITTING BULKHEAD ADAPTOR FITTING WASHER, SPLIT LK- ’A -M6 HHCS M6-1.00X30 RELAY SOLENOID NUT, HEX M6-1 CLAMP, VINYL COAT 3/4 WASHER, FLAT -M6 HOSE CLAMP 1/8 NPT X 1/4 BARBED STRAIGHT FITTING HOSE CLAMP 7/8/3/8 HHCS M6-1.00X16 HEX NUT 3/8-16 BRASS WASHER SPLIT LK 3/8

ITEM

18 19 20

22 A2053 24 75234 25 30340 26 27 28 C8009

PART NO.

75763 75763A 3 C7413 1 22127 1 20153621 1

19753621 1

C8008 635MM C8008 375MM

C6712H 1

M = METERS MM = MILLIMETERS

QTY. DESCRIPTION

1 1 RESISTOR

1.04M

BOOT, BAHERY CABLE BOOT, BATTERY CABLE GROMMET 3/8 l/D X 1 GD HEX NUT 'A - 20 CABLE, BATTERY CABLE, STARTER HHCS M6-1 X 65

HOSE, 1/4 ID SAE-30R2 HOSE, 5/16 ID SAE-30R7 HOSE, 5/16 ID SAE-30R7 CLAMP, FUEL PUMP WIRE ASSY, #0 (PHC-SC)

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Camshaft - Drawing No. 75677

.PARTS

LISTS

ITEM PART NO.

1 2 233-70939 1 CAMSHAFT GEAR 3 195-70939 1 KEY 10 4 5 235-70939 6

232-70939

234-70939 1 GEAR

236-70939 1 237-70939 1 SLIDER

QTY. DESCRIPTION

1 CAMSHAFT ASSEMBLY 8

SPACER 12

BALL BEARING 13

ITEM

PART NO.

238-70939 1

239-70939 1

240-70939 241-70939 242-70939 1 243-70939 1 NUT

QTY.

1 1

Generac* Power Systems, Inc. 51

DESCRIPTION

PLATE TACHOMETER SHAFT BOLT

BOLT GASKET

.PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT” 75D Recreational Vehicle Generator

1.0 Liter Diesel Cylinder Head - Drawing No. 75678-A

ITEM

PART NO. QTY. DESCRIPTION

3 4 5 150-70939 3 INTAKE VALVE 6 151-70939 3 EXHAUST VALVE 7

8 154-70939 6 9 10 11

147-70939 1 CYLINDER HEAD ASSEMBLY

148-70939 6 EXPANSION PLUG 14 161-70939

447-70939 3 EXPANSION PLUG

149-70939

152-70939 3 VALVE GUIDE SEAL (EXHAUST) 153-70939 3

155-70939 6 RETAINER 156-70939 12 KEY 157-70939 6 CAP 158-70939 1

159-70939 1

EXPANSION PLUG 16

VALVE GUIDE SEAL (INTAKE) 20 SPRING

CYLINDER HEAD GASKET,

1.2MM THICK

CYLINDER HEAD GASKET,

1.3MM THICK

ITEM PART NO. QTY. DESCRIPTION

13 160-70939

15 162-70939 2 LIFTING EYE

163-70939 17 164-70939 1 18 165-70939 2 BOLT 19 A8584 1 OIL SWITCH

167-70939

C8010

21 168-70939 4

22 169-70939 1 WASHER 23 42574 1

BOLT BOLT

BOLT TUBING

THERMO-SWITCH (ALL MODELS EXCEPT 04270)

THERMO-SWITCH (MODEL 04270 ONLY ) GASKET

ADAPTOR

52 Qenerac’ Power Systems, Inc.

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Crankshaft, Piston and Flywheel - Drawing No. 75679-A

..PARTS

LISTS

ITEM

PART NO.

1 143-70939 1

QTY. DESCRIPTION

CRANKSHAFT ASSEMBLY

2 194-70939 1 CRANKSHAFT GEAR

5 226-70939 1 SPRING PIN 6 197-70939 1 BEARING HOLDER ASSEMBLY

7 8

9 198-70939 6 BOLT

10 199-70939 6 DOWEL PIN 11

13 14 15

195-70939 196-70939 1 DOWEL PIN

200-70939 1 664-70939

202-70939 3 STANDARD BEARING 203-70939 204-70939 AR 0.50MM U.S. BEARING 205-70939 3 STANDARD BEARING 206-70939 AR 0.25MM U.S. BEARING

207-70939 AR

208-70939

204-70939 2 BOLT 210-70939

1 KEY

BEARING HOLDER ASSEMBLY

1 BEARING HOLDER ASSEMBLY

0.25MM U.S. BEARING

0.50MM U.S. BEARING

2 THRUST WASHER

BOLT

ITEM

18 19 20

22 23

28 30

PART NO. QTY. DESCRIPTION

214-70939 3 215-70939 AR 216-70939 AR 211-70939 212-70939 AR 213-70939 217-70939 218-70939 219-70939 220-70939 221-70939 222-70939 6 223-70939 224-70939 AR BEARING-0.25MM U.S. 225-70939 230-70939 1 231-70939

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

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

PISTON PIN

SNAP RING

CONNECTING ROD ASSEMBLY

BUSHING

CONNECTING ROD BOLT

NUT, CONNECTING ROD BOLT STANDARD BEARING

BEARING-0.50MM U.S.

PULLEY NUT

- UNDERSIZE

U.S.

- OVERSIZE

O.S.

AR - ■ AS REQUIRED

MM - MILLIMETER

Generac* Power Systems, Inc. S3

^PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Oil Pump - Drawing No. 75682

PART NO.

ITEM

1 2 3 251-70939 1 THRUST WASHER 4 5 6

250-70939 1 IDLER GEAR ASSEMBLY 252-70939 1 SPRING

253-70939 254-70939 1 OIL PUMP COVER 255-70939 532-70939 AR 0.15MM SHIM 533-70939 AR 0.20MM SHIM 258-70939

5<4 Generac* Power Systems, Inc.

QTY. DESCRIPTION

ROTOR

AR 0.10MM SHIM

0.50MM SHIM

PART NO.

ITEM

7 8 260-70939 1 9 261-70939 1 SNAP RING

10 262-70939 11 263-70939 1 GASKET 12

259-70939

264-70939 3

DESCRIPTION

QTY.

1 SPRING

COLLAR

1 FRONT PLATE

BOLT

AR - AS REQUIRED

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Rocker Arm Assembly - Drawing No. 75683

^PARTS

LISTS

ITEM

PART NO.

QTY. DESCRIPTION

1 170-70939 1 ROCKER ARM ASSEMBLY

3 172-70939 3 4 5 173-70939 6 6 175-70939 3 ROCKER ARM BRACKET

171-70939 3 174-70939 6 NUT

INTAKE ROCKER ARM 8 EXHAUST ROCKER ARM 9

STUD

PART NO. QTY.

ITEM

10 11

176-70939 1 177-70939

178-70939

179-70939

180-70939 3 181-70939

DESCRIPTION

ROCKER ARM SHAFT SPRING

SCREW

SPRING,PIN

NUT STUD

Generac* Power Systems, Inc. 5S

^PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Injector Pump - Drawing No. 75686-B

PART NO.

ITEM

1 2

3 298-70939 4 5 6 323-70939 3 7 8 325-70939 9 10 11 12 329-70939 1

316-70939 1 INJECTOR PUMP ASSEMBLY 317-70939 AR SHIM-0.2MM 14 331-70939 1 318-70939 AR 319-70939 AR 320-70939 AR

321-70939 2 BOLT (ALL MODELS EXCEPT 04270) 322-70939 3 GASKET

324-70939

326-70939 1 327-70939 328-70939 1

56 Generac* Power Systems, Inc.

QTY.

3 CAP 3

DESCRIPTION ITEM

SHIM-0.3MM 16 332-70939 3 GLOW PLUG SHIM-0.5MM 17 333-70939 1 SHIM-1.OMM 18 334-70939 1 NUT

INSERT

INJECTOR 26 341-70939 1 SOLENOID TUBING 27 342-70939 1 TUBING TUBING TUBING

PART NO. QTY. DESCRIPTION

19 335-70939 1 COVER

20 264-70939 2 BOLT

28 343-70939 1 WASHER 29 344-70939 1 SCREW

330-70939 1 CLAMP

BOLT

CONNECTOR

GASKET

C4736 1 TUBE, ENGINE OIL FILL

(MODEL 04270 ONLY)

WASHER

AR ■

■ AS REQUIRED

Appendix 3 — Exploded Views and Parts Lists

QUlETPACr™ 75 D Recreational Vehicle Generator

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

^PARTS

LISTS

ITEM

PART NO.

1 2 3

5 6 378-70939 2 GASKET 7 8 74808 1 FUEL BLEED FITTING 9

661-70939 1 FUEL FILTER SUPPORT 69858 C8008 C8008 250MM 40173

379-70939 1 BANJO FITTING

52233 2 1/8" NPTTEE (BRASS)

39450

QTY. DESCRIPTION

AR HOSE, 5/16" SAE 30R7

FUEL FILTER

HOSE, 5/16" SAE 30R7 HOSE CLAMP

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

BARBED FITTING

ITEM PART NO.

11 30096

12 68736 275MM 13 68736 14 74823 15 74819 16 17 662-70929 18 663-70939 19

651 -70939 5

28414A 1

QTY.

240MM 4 HOSE CLAMP

2 BANJO FITTING

Qenerac* Power Systems, Inc. 57

DESCRIPTION

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

FUEL BLEED FITTING FUEL BLEED GASKET HOLLOW BOLT

1/8" NPT X '/*" BARBED STRAIGHT FITTING (MODEL 04270 ONLY)

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

^PARTS

USTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT" 75D Recreational Vehicle Generator

1.0 Liter Diesel Timing and Governor - Drawing No. 82067

ITEM

PART NO. QTY.

285-70939 1 TIMING GEAR HOUSING 30

286-70939 1 SPRING PIN 31 293-70939 1 SPRING

287-70939 1

307-70939 1

308-70939 1 WASHER 34

309-70939

310-70939 1

314-70939 2

296-70939

297-70939 1 BOLT

298-70939 1 NUT

299-70939 1 SHAFT

300-70939 1 0-RING

301-70939

540-70939 3 * BOLT

282-70939 5 BOLT

288-70939 1 OIL SEAL

274-70939 4

311-70939 5 BOLT

304-70939 1 ARM

305-70939 1

306-70939 1

289-70939 1 GOVERNOR LEVER ASSEMBLY

290-70939

291-70939 1

136-70939 1 WASHER

292-70939 1

Generac*

Power

DESCRIPTION ITEM PART NO.

313-70939

GASKET 32 294-70939 SPRING 33 295-70939 1 0-RING

291-70939 NUT 35 302-70939 1 BRACKET STOP LEVER 36 271-70939 3 BOLT COVER 37 303-70939 GOVERNOR LEVER 38 71944 1 HHCS M6-1.0 X 25MM

39 660-70939 1 0-RING 40 534-70939 41 535-70939 1 *

SNAP RING

BOLT 47

SNAP RING 49 0-RING 50

TENSION LEVER SNAP RING

COTTER PIN

Systems,

Inc.

42 536-70939 1 43 537-70939 44 539-70939 1 * 0-RING 45 188-70939 1 * CAP 46 541-70939

538-70939 3 * NUT

48 C4888 1 BRACKET, FUEL FILTER (MODEL

51730 52265

51 45771 4 NUT (MODEL 04270 ONLY)

52 22129 4 SPLIT LOCK WASHER M8

* NOT USED ON MODEL 04270

QTY. DESCRIPTION

2 BOLT

1 * HOLDER (OIL FILL)

1 *

3 1 BOLT (MODEL 04270 ONLY)

1 SPRING

1 SNAP RING

1 *

ARM

0-RING

SPACER GASKET

BOLT

04270 ONLY)

BOLT (MODEL 04270 ONLY)

(MODEL 04270 ONLY)

Appendix 5 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Engine Block - Drawing No. 82961-A

^PARTS

LISTS

ITEM PART NO.

2 140-70939 20

12 143-70939 1 DIPSTICK TUBE

13 144-70939 2

14 15 146-70939 1 DIPSTICK

17 183-70939 18

139-70939 1 OIL PAN

C4641

145-70939 5

184-70939 1

QTY. DESCRIPTION

BOLT

(ALL MODELS EXCEPT 04270)

1 DIPSTICK TUBE

(MODEL 04270 ONLY) O-RING BOLT

(ALL MODELS EXCEPT 04270) 31

1 ROCKER COVER GASKET

ROCKER COVER

ITEM PART NO.

19 185-70939 20 186-70939 22 23 187-70939 24

25 189-70939

29 244-70939 30 245-70939

33 122-70939

168-70939

188-70939

26073-A 1

246-70939

DESCRIPTION

QTY.

OIL STOPPER

1 1 SCREEN 1 GASKET

NUT

1 CAP 1

O-RING

1/4" PIPE PLUG SO. HD,

O-RING 1 TUBING 1 SUCTION FILTER

1 GASKET

Generac* Power Systems, Inc. 59

.PARTS

LISTS

Appendix 3 — Exploded Views and Parts Lists

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Water Pump - Drawing No. 82962

ITEM PART NO.

3 4 5 6 7

265-70939 1 WATER PUMP ASSEMBLY 8 272-70939 266-70939 1 267-70939 268-70939 269-70939 3 GASKET 12 247-70939 270-70939 1 SET PLATE 15 284-70939 271-70939 1 BOLT

QTY. DESCRIPTION ITEM PART NO.

PLUG 1 THERMOSTAT 1

SPRING

9 273-70939 1

10 11 275-70939 1 NUT

274-70939 1

QTY.

DESCRIPTI

1 GASKET

BOLT BOLT

1 PULLEY 1 BOLT

BO Generac* Power Systems, Inc.

Appendix 4 — Notes

QUIETPACT™ 75D Recreational Vehicle Generator

NOTES

Generac* Power Systems, Inc. 61

NOTES

Appendix 4 — Notes

QUIETPACT“ 75D Recreational Vehicle Generator

62 Generac® Power Systems, Inc.

Appendix 4 — Notes

QUIETPACT™ 75D Recreational Vehicle Generator

NOTES

Generac* Power Systems, Inc. 63

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, Ishikawajlma 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 stringent 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 arid 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,

MANUFACTURER'S WARRANTY COVERAGE

For 2000 and later small non-road diesel engines first sold in California, and 2000 and later non-road diesel engines rated under 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 your 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

• Intake Manifold

• Air Cleaner Element

As the engine owner, you are responsible for the performance of the required maintenance listed in your Owner's Manual. 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:

• Fuel Injectors

• Exhaust Manifold

• Miscellaneous Hoses, Bolts and Connectors

OWNER'S WARRANTY RESPONSIBILITIES

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, W! 53119

Page 1

64 Generac* Power Systems, Inc.

Appendix 5 - Warranty

QUIETPACT™ 75D Recreational Vehicle Generator

OBLIGATIONS AND RIGHTS OF THE MANUFACTURER AND OWNER

The new model year, class of diesel engine, and emission application determination for your engine are Identifled 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 falls prior

to replacement will be repaired or replaced under warranty, and the repaired or replaced part will be covered under warran ty for the remainder of the period prior to the first scheduled replacement. The warranty repairs and service will be performed 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 Owner's Manual. 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 warranty repairs. Such use will be grounds for disallowing a warranty claim, and GENERAC will not be liable to warrant failures 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. (b) 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. (1) 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. 65

Appendix 5 - Warranty

QUIETPACT™ 75D Recreational Vehicle Generator

GENEiAC POWER SYSTEMS' 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 (Üiree) years or 2,000 (two thousand) hours of operation from the date of originaJ 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 Wai'ranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty

schedule set fortli below. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest

Generac Autliorized 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

die original purchaser/owrrer, of a completed Warranty Registration Card. This cai'd is tire 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 part(s), 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 partis) and labor listed (Any labor and part(s) 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), Valve,

Valve Lifter(s), Intake and Exhaust IVIanifolds

stallatio, are the owner’s responsibility):

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

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 part(s) 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 part(s) 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 se®Wice 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.

• /Vny 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 while warranty repairs are being performed.

• Overnight freight costs for replacement part(s),

• Overtime labor.

• Starting batteries, fuses, light bulbs, and engine fluids. THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC IVLAKES 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. EVEN 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.

GENERAC« POWER SYSTEMS, INC.

P.O. BOX

Part No. C4547

S • WAUKESHA,

Revision a CIQ/a'7/OO]

W! 531

Printed in U.S.A.

Generac Power Systems 4270-0 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Part I ~ Owner's Manual

WARNING;

QUIETPACT™ 75D Recreational Vehicle Generator

1.2 GENERATOIIAPPLIGIBILITY

13 SAFETY

1.4 GENERATOR AC CONNEQION SYSTEM

1.S SPECIFICATIONS

QUIETPACT™ 75D Recreational Vehicle Generator

(Jti

2.1 GENERATOR CONTROL PANEL

NOTE:

2.2 OPTIONAL REMOTE START/STOP

23 BEFORE STARTING THE ENGINE

NOTE:

STARTING THE GENERATOR

2.5 STOPPING THE GENERATOR

2.6 APPLYING LOADS TO GENERATOR

2.7 PROTEOION SYSTEMS

2.8 ADDITIONAL INFORMATION

♦ 2.8.2 25-HOUR CHECK-UP

♦ 2.8.4 OPERATION IN HIGH GRASS

OR BRUSH

♦ 2.8.5 EFFECTS OF MOISTURE AND DIRT

3.1 CHECKING THE ENGINE OIL LEVEL

3.4 SPARK ARRESTOR MUFFLER

3.6 BATTERY MAINTENANCE

3.7 COOLING SYSTEM

3.8 ENGINE COOLANT

MAINTENANCE

3.9 MAJOR SERVICE MANUAL

3.10 DRIVE BELT

3.11 EXERCISING THE GENERATOR

3.12 OUT OF SERVICE PROCEDURE

QUIETPACT™ 75D Recreational Vehicle Generator

NOTICE TO INSTALLER

A GENERAL HAZARDS ^

ELECTRICAL HAZARDS

FIRE HAZARDS

QUIETPACT™ 75D Recreational Vehicle Generator

1.2 SAFETY

1.3 STANDARDS BOOKLETS

1.4 EQUIPMENT DESCRIPTION

2.1 LOCATION ÄND SUPPORT

2.2 GENERATOR COMPARTMENTS

QUIETPACT™ 75D Recreational Vehicle Generator

2.4 DIESEL FUEL SYSTEM

♦ 2.4.1 FUEL TANK

^ 2.4.2.2 Flexible Fuel Line

• 2.4.5 GENERATOR FUEL RETURN LINES

2.5 EXHAUST SYSTEil

QUIETPACT™ 75D Recreational Vehicle Generator

2.6 ELEaRICAL CONNEQIONS

NOTE:

NOTE:

2.7 BATTERY INSTALLATION

2.8 OPTIONAL ACCESSORIES

3.1 POST INSTALLATION TESTS

3.5 INSTALLATION CHECKLIST

QUIETPACT™ 75D Recreational Vehicle Generator Electrical Enclosure Assembly - Drawing No. C7655-B

QUIETPACT™ 75D Recreational Vehicle Generator Fuel and Electrical Systems - Drawing No. C7657-A

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Crankshaft, Piston and Flywheel - Drawing No. 75679-A

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Oil Pump - Drawing No. 75682

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Rocker Arm Assembly - Drawing No. 75683

QUlETPACr™ 75 D Recreational Vehicle Generator

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

QUIETPACT™ 75D Recreational Vehicle Generator

1.0 Liter Diesel Engine Block - Drawing No. 82961-A

QUIETPACT™ 75D Recreational Vehicle Generator

QUIETPACT™ 75D Recreational Vehicle Generator

WARRANTY SCHEDULE - COMMERCIAL APPLICATIONS

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