Page 2 - INTRODUCTION; READ THIS MANUAL THOROUGHLY; After this heading, read explanatory statements; CONTENTS; AUTHORIZED SERVICE; To locate the nearest AUTHORIZED SERVICE
INTRODUCTION Thank you for purchasing this model of the QUIETPACT product line by Generac Power Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood, con-tact the nearest...
Page 3 - Table of Contents; Recreational Vehicle Generator; Part I – Owner’s Manual
Table of Contents Recreational Vehicle Generator 1 Part I – Owner’s Manual Introduction ...................................... Inside Front Cover Read This Manual Thoroughly ................................ IFC Contents ................................................................. IFC Operation ...
Page 4 - DANGER; Despite the safe design of this generator,; GENERAL HAZARDS; • For safety reasons, the manufacturer recommends
2 Study these SAFETY RULES carefully before install-ing, operating or servicing this equipment. Become familiar with this manual and with the unit. The gen-erator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by fail...
Page 5 - Safety Rules
3 • When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued. • Inspect the generator regularly, and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement. • Before performing any maintenan...
Page 6 - Section 1 – General Information; Number; GENERATOR IDENTIFICATION
4 1. Generator Air Intake 2. Engine Start/Stop Switch 3. Fuse 4. Optional Remote Panel Receptacle (Side View) 5. Generator AC Output Leads (Side View) 6. Fuel Primer Switch 7. Circuit Breaker 8. Starter Contactor 9. Fuel Inlet 10. Fuel Pump (Behind Access Panel) 11. Fuel Filter (Side View) 12. Oil F...
Page 7 - APPLICABILITY; For fire safety, the generator must have been; CONNECTION SYSTEM; Figure 1.1 – Connections for 120 Volts Only; REQUIREMENTS
5 Section 1 – General Information Recreational Vehicle Generator 1.2 GENERATOR APPLICABILITY These generators have been designed and manufac-tured for supplying electrical power for recreational vehicles. Do not modify the generator or use it for any application other than for what it was designed. ...
Page 8 - The manufacturer does not recommend using; CONSUMPTION; • During summer months: SAE 30. An acceptable; Amperes; • For engines less than 225 cc displacement, Category
6 Section 1 – General Information Recreational Vehicle Generator The manufacturer does not recommend using any gasoline containing alcohol (such as “gaso-hol”). If using any gasoline containing alcohol, it must not contain more than 10 percent ethanol, and it must be removed from the generator dur...
Page 9 - Section 2 – Operation; GENERATOR CONTROL PANEL; Figure 2.1 – Generator Control Panel; PRIMER; OPTIONAL REMOTE; SOLENOID; BEFORE STARTING THE ENGINE
7 Section 2 – Operation Recreational Vehicle Generator 2.1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control Panel P R I M E F U E L S T O P S T A R T 3 0 A C . B . F U S E CONTROL CENTER 7. 5 A 2.1.1 FUEL PRIMER Be...
Page 10 - LUBRICATION; Any attempt to crank or start the engine before; SUPPLY; The generator engine releases DEADLY carbon; Never sleep in the vehicle while the genset is; STARTING THE GENERATOR; Read the vehicle manufacturer’s instructions.; If the engine does not start after it has been
8 Section 2 – Operation Recreational Vehicle Generator 2.4.2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommended oil before starting. Refer to Section 1.5.4, and Sections 3.1 and 3.2 for oil servicing proce-dures and recommendations. Any attempt to crank or start th...
Page 11 - STOPPING THE GENERATOR; Figure 2.2 – Low Oil Pressure and
9 Section 2 – Operation Recreational Vehicle Generator 2.6 STOPPING THE GENERATOR 1. Turn OFF all electrical loads using the means provided (such as a main circuit breaker or transfer switch). 2. Let generator run at no-load for a few minutes, to stabilize internal engine generator temperatures. 3. ...
Page 12 - BOOST; Figure 2.3 – Field Boost Circuit; PROTECTION; Figure 2.4 – Solid State Voltage Regulator; ADDITIONAL INFORMATION; AFTER SUBMERSION; MUST NOT
10 Section 2 – Operation Recreational Vehicle Generator 2.9.3 FIELD BOOST The Controller Circuit Board houses a field boost diode and resistor that are not part of the automatic choke circuit. These two components are part of a “field boost” circuit (Figure 2.3). During engine cranking only, a posit...
Page 13 - Section 3 – Maintenance; OR BRUSH; If necessary, remove the oil fill cap on the rocker; Never operate the engine with the oil level; Install and tighten the oil fill cap and the dipstick; CHANGING THE ENGINE OIL; • Change the; Oil Dipstick/Oil Fill; Figure 3.1 – Oil Maintenance Features
11 Section 3 – Maintenance Recreational Vehicle Generator 2.10.4 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. ...
Page 14 - oil filter; MAINTAINING THE ENGINE; Figure 3.2 – Engine Air Cleaner
12 Section 3 – Maintenance Recreational Vehicle Generator • Change the engine oil filter after the first 25 hours of operation, and every 100 operating hours there-after. 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 ...
Page 15 - CLEAN AIR INTAKE; Figure 3.3 – Cleaning Air Intake; CHECKING THE ENGINE; Figure 3.4 – Setting the Spark Plug Gap; Sparking can occur if the wire terminal does not; Figure 3.5 – Fuel Filter; CLEAN SPARK ARRESTOR; Clean and inspect the spark arrestor as follows:
Section 3 – Maintenance Recreational Vehicle Generator 3.4 CLEAN AIR INTAKE Clean all foreign material from the air intake (Figure 3.3) at least once every 100 hours of operation. Clean more often if necessary. Inspect the area around the generator exhaust muf-fler periodically and remove all grass,...
Page 16 - • Inspect the battery posts and cables for tightness
14 3.8 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and mois-ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those wi...
Page 17 - Figure 3.7 — Adjusting Valve Clearance
15 3.10 MAJOR SERVICE MANUAL To obtain a service manual for the generator, contact the nearest Authorized Service Dealer. Make sure to identify the MODEL NUMBER and SERIES. 3.11 EXERCISING THE GENERATOR The manufacturer recommends that the generator be started and operated at least once every seven ...
Page 18 - When valve clearance is correct, hold the pivot; Figure 3.8 — Tightening Jam Nut
16 2. When valve clearance is correct, hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut with a crows foot. Tighten the jam nut to 65-85 inch-pounds torque. After tightening the jam nut, recheck valve clearance to make sure it did not change (Figure 3.8). Figure 3.8 —...
Page 19 - ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
PART II – INSTALLATION INSTRUCTIONS DANGER ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
Page 20 - NOTICE TO INSTALLER; Installation Instructions
18 NOTICE TO INSTALLER These Installation Instructions have been published by the manufacturer to aid in the installation of the products described in this manual. The manufac-turer assumes that installation personnel are familiar with the procedures for installing such products, or similar products...
Page 22 - Figure 1.1 – 120-volt Single Voltage Connection
20 1.1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to all information and instructions in the ...
Page 23 - VIEW FR
21 Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-G) Section 1 – General Information Recreational Vehicle Generator REF . 749.8 [ 29 1/2"] 342.2 [ 13 1/2"] REF . 483.1 [ 19"] HO T AIR EXHA UST TA IL PIPE EXIT OIL DRAIN AIR INT AKE A C OUTPUT HARNESS REMO TE P ANEL CONNECT...
Page 24 - LOCATION AND SUPPORT; LOCATION; Figure 2.1 – Typical Horizontal Support Frame; MOUNTING; Figure 2.2 – Typical Suspended Mounting System; Section 2 – Installation
22 2.1 LOCATION AND SUPPORT 2.1.1 GENERATOR LOCATION The most desirable location for the generator set is between the vehicle's main frame members. However, this is seldom possible. Most units must be installed on the side of the vehicle and are difficult to rein-force. Many recreational vehicles ha...
Page 25 - • The installer must make certain that the selected; RESTRAINT; Figure 2.3 – Typical Generator Restraint; GENERATOR COMPARTMENTS; SIZE; Figure 2.4 – Clearances; CONSTRUCTION; • The generator compartment should be either con-; Figure 2.5 – Typical Compartment Construction; • If constructing a compartment, line the exterior
23 • The installer must make certain that the selected location will permit adequate cooling and ventilat-ing airflow to be supplied. 2.1.4 GENERATOR RESTRAINT Use four 5/16"-18 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing. These bolts must...
Page 26 - Figure 2.6 – Types of Lock Seams; Do not install any flammable material directly; Do not install sound insulation or any absorbent; To prevent fire or explosion, do not install any
24 • 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 ...
Page 27 - • Line the compartment door interior (except for air; Figure 2.7 – Typical Noise Abatement; FLOOR; Fuel lines and exhaust piping must not pen-; VIEW FROM TOP
25 • Line the compartment door interior (except for air openings) with suitable, fireproof sound insulation (such as 1-inch (25 mm) thick fiberglass with a 2-pound density). Figure 2.7 – Typical Noise Abatement 2.2.5 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the fol...
Page 28 - COOLING AND VENTILATING AIR; Never use discharged cooling air for heating or; AIRFLOW; Figure 2.9 – Airflow Through Engine/Generator; GASOLINE FUEL SYSTEM; Figure 2.10 – Generator Fuel System; Gasoline is highly flammable, and its vapors are
26 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 airflow, the engine/generator quickly overheats. Such overheating can cause serious operating difficulties an...
Page 29 - TANK; Do NOT tee the generator fuel supply line; The generator engine gives off DEADLY carbon
27 2.4.1 FUEL TANK Either the generator must share the vehicle engine's fuel tank, or 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 regula-tions. If the gen...
Page 30 - ARRESTOR; Figure 2.12 — Spark Arrestor Installation; SYSTEM SAFETY; ELECTRICAL CONNECTIONS
28 2.5.1 SPARK ARRESTOR This spark arrestor assembly meets code and stan-dard requirements of the U.S. Forest Service. Use only mufflers and parts approved by the manufactur-er. Any person(s) installing an unapproved muffler, or an unapproved exhaust system part, or modifying an exhaust system in an...
Page 31 - Figure 2.13 – Generator AC Output Leads; Do NOT connect electrical loads in excess of any
29 • 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. 2.6.1 ELECTRICAL JUNCTION BOX ...
Page 32 - SUPPLY CORD
30 2.6.5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double-pole, double-throw transfer switch (Figure 2.14). An alternate method for isolating different power sources is by using an isolating receptacle (Figure 2.15). Whichever method is used, be certain ...
Page 33 - BATTERY INSTALLATION; Figure 2.16 – Connecting Battery Cables; COMPARTMENT; OPTIONAL ACCESSORIES; Figure 2.17 – Remote Panel Plug-in Receptacle; CABLE
31 2.6.7 GROUND FAULT CIRCUITINTERRUPTERS The National Electrical Code (NFPA 70, 551-7) requires that ground fault circuit interrupters (GFCIs) be installed on all external and some internal electri-cal receptacles. Contact the dealer for recommenda-tions. 2.7 BATTERY INSTALLATION 2.7.1 RECOMMENDED ...
Page 34 - Figure 2.18 – Optional Remote Panel; POST INSTALLATION TESTS; Do not make any unnecessary adjustments.; If a liquid propane (LP) gas fuel system has been; TESTING UNDER LOAD; Section 3 – Post-Installation Start-up Adjustments
32 2.8.1 REMOTE START/STOP PANEL A remote mounted Start/Stop panel (Figure 2.18) is available that allows the user to start and stop the generator engine conveniently from inside the vehicle. The remote panel includes a Start/Stop switch, hour-meter, generator run lamp, a fuel prime switch, and a wi...
Page 35 - Section 3 – Post-installation Start-up Adjustments; INSTALLATION CHECKLIST
33 Section 3 – Post-installation Start-up Adjustments 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. ❑ H...
Page 36 - Appendix 1 – Notes
34 Appendix 1 – Notes Recreational Vehicle Generator
Page 37 - Appendix 2 – Troubleshooting; TROUBLESHOOTING GUIDE; Problem Cause
35 Appendix 2 – Troubleshooting Recreational Vehicle Generator TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary. 3. Defective engine Start/Stop 3. Replace ...
Page 38 - Appendix 3 — Electrical Data
RED BLUE ORANGE BR O W N 7 7 YELLO W WHITE 15 BATTERY CHARGE WINDING NEUTRAL CONNECTION GREEN BY CUSTOMER WHITE T2 FIELD 120V 30A 44 0F 0N 0K 22P DPE WINDING 2 CB3 6 ELECTRONIC REGULATOR VOLTAGE 2A 0N 0N R1 POWER WINDING 22S 11S 77 55 BLACK FUEL PRIME 11P 4 4 T1 4 CB1 REMOTE PANEL(OPTIONAL) 33 4 66 ...
Page 40 - CARB; Appendix 4 — Exploded Views and Parts Lists
38 23 46 42 55 37 17 2 54 34 32 31 33 55 50 55 16 40 56 T O CARB 12 57 21 13 43 15 21 52 41 3 48 9 21 21 27 28 55 58 36 21 35 42 41 21 18 1 53 21 51 39 23 22 6 10 47 8 24 22 20 15 21 11 14 44 25 49 7 21 24 26 41 21 38 59 45 5 4 30 19 Appendix 4 — Exploded Views and Parts Lists Recreational Vehicle G...
Page 43 - ITEM PART
41 Appendix 4 — Exploded Views and Parts Lists Recreational Vehicle Generator Generator – Drawing No. 0D8353-H ITEM PART NO. QTY. DESCRIPTION 1 050322 1 SCREW IHHC 5/16"-24 X 9-3/4" 2 022129 22 WASHER LOCK M8-5/16" 3 049451 1 WASHER FLAT .406" I.D. X 1.62" O.D. 4 0C8096A 1 FAN, 8...
Page 50 - CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT
48 CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control S...
Page 51 - EMISSION CONTROL SYSTEM WARRANTY; to their respective authority, and; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:; Appendix 5 – Warranty
49 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/de...
Page 52 - GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY
Part No. 0D8351 Revision R (02/22/06) Printed in U.S.A. Appendix 5 – Warranty Recreational Vehicle Generator GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a...