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
A
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
A
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
4
.................................
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
15
15
Part II - installation Instructions
Safety Rules
Section 1 - General Information
............................................................................18
............................................
20
1.1 Purpose and Scope of the Manual..................................20
1.2 Safety................................................................................20
1.3 Standards Booklets......................................................... 20
1.4 Equipment Description
.2
1.5 Generator Engine Operating Speed..............................20
1.6 Generator AC Connection System
Section 2 - Installation...........................................................
..................................................
................................
20
20
22
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
........
29
.......................................
........................................
.......................................
..........................
..........................
.........................
........................................
.........................................
............................
......................
..........................
..........................
.......................
.....................
22
22
23
23
24
24
25
26
26
26
27
27
28
28
28
28
29
2.5.2 Exhaust System Safely....................................29
8
9
9
9
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
............................................................
...........
32
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
...................................
33
31
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
...................................................
35
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
.......................................................
..............................................
..................................................
.....................
..............................................................
...........................................................
36
37
38
40
61
64
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. ““
A
• 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
A
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
A
A
ELECTRICAL HAZARDS
• The generator covered by this manual produces
dangerous electrical voltages and can cause fatal
electrical shock. Avoid contact with bare wires, ter
minals, connections, etc., while the unit is running.
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
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
22
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
A
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
A
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
BLUKl
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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.
9
p
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
A
the engine is hot or serious burns from boiling
liquid or steam could result.
Ethylene glycol base antifreeze is poisonous. Do
A
not use your mouth to siphon coolant from the
radiator, recovery bottle or any container. Wash
your hands thoroughly after handling. Never store
used antifreeze in an open container because 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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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
A
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
2.
if the engine Is cold, press the Preheat switch for
15 to 30 seconds maximum.
3.
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.
4.
Let the engine rim at no-load for a few minutes to
stabilize and warm up.
5.
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.
3.
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):
1.
Be sure the generator is as level as possible.
2.
Remove the dipstick and wipe it dry with a clean,
lint-free cloth.
3.
Install 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.
5.
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
A
ly hot and remains hot after shutdown. High
grass, weeds, brush, leaves, etc. must remain
clear of the exhaust. Such materials may ignite
and burn from the heat of the exhaust system.
-------
-ik WARNING ik
Be sure to reinstall the the hex pipe cap tightly to
A
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
A
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
A
the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
A
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following
procedures are to be observed:
• Wear full eye protection and protective clothing;
• 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
A
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
1.
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.
2.
Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with distilled
water. DO NOT USE TAP WATER IN THE BAT
TERY Recharge the battery to 100 percent state of
charge, or, if defective, replace the battery.
Clean and wipe the entire generator.
3.
Reconnect the battery. Observe battery polarity.
4.
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.
6.
7.
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.
9.
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
X
X
X
X
X
X
X R X
X EVERY 750 H
X R EVERY 750 H
X
X X AFTER 25-H BREAK-IN, W
Change
X
X
X
X
R EVERY 750 H
Clean
X 1
X
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
W
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
A
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
A
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
A GENERAL HAZARDS ^
• For safety reasons, Generac recommends
that the installation, initial 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
A
ELECTRICAL HAZARDS
• The generator covered by this manual produces
dangerous electrical voltages and can cause fatal
electrical shock. Avoid contact with bare wires, ter
minals, connections, etc., while the unit is running.
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.
A
A
FIRE HAZARDS
For fire safety, the generator must be installed
and maintained properly. Installation always
must comply with applicable codes, standards,
laws and regulations. Adhere strictly to local,
state and national electrical and building codes.
Comply with regulations the Occupational Safety
and Health Administration (OSHA) has estab
lished. Also, ensure that the generator is
installed in accordance with the manufacturer’s
instructions and recommendations. Following
proper installation, do nothing that might alter a
safe installation and render the unit in noncom
pliance with the aforementioned codes, stan
dards, laws and regulations.
Keep a fire extinguisher in the vehicle at all times.
Extinguishers rated “ABC” by the National Fire
Protection Association are appropriate for use on
the recreational vehicle generator electrical system.
Keep the extinguisher properly charged and be
familiar with its use. If you have any question per
taining to fire extinguishers, consult your local fire
department.
A
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
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