Owner’s Manual Air-cooled Recreational Vehicle Generators QUIETPACT 55, 65 and 75 • Models: 004702-0, 004703-0 004704-0, 004705-0 004706-0, & 004707-0 QUIETPACT 55G POWERED BY GUARDIAN 760cc OHVI V-TWIN INDUSTRIAL This manual should remain with the unit.
INTRODUCTION ◆ 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, WARNING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
Table of Contents QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Part I — Operating Instructions Introduction ..................................................Inside Front Cover Read This Manual Thoroughly ..........................................IFC Contents ............................................................................IFC Operation and Maintenance ..............................................IFC How to Obtain Service ......................................................
Safety Rules QUIETPACT 55, 65, and 75 Recreational Vehicle Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment. ! ! WARNING: ! The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
Safety Rules QUIETPACT 55, 65, and 75 Recreational Vehicle Generators • Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step.
Section 1 – General Information QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 1.1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal. 1. Model Number ____________________ 2. Serial Number __________________ 3. kW Rating__________________________ 4. Rated Voltage __________________ 5. Phase ______________________________ 6.
Section 1 – General Information QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 1.2 GENERATOR APPLICABILITY These generators have been designed and manufactured for supplying electrical power for recreational vehicles. You should not modify the generator or use it for any application other than for what it was designed. If there are any questions pertaining to its application, write or call the factory. Do not use the unit until you have been advised by competent authority.
Section 1 – General Information QUIETPACT 55, 65, and 75 Recreational Vehicle Generators ✧ Figure 1.1 – Connection for 120 Volts Only 1.6.1.1 Fuel Consumption (gph/lbs.ph) Model QuietPact 55G QuietPact 65G QuietPact 75G 10% Load 0.51 0.51 0.51 50% Load 0.73 0.76 0.80 100% Load 0.97 1.07 1.28 NOTE Some installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine’s pickup tube.
Section 2 – Operation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Type of Engine QUIETPACT 55/65/75 ................................................GT-760 Cooling Method ........................................................Air-cooled Rated Horsepower QUIETPACT 55..............................................27 at 3600 rpm QUIETPACT 65..............................................27 at 3600 rpm QUIETPACT 75..............................................
Section 2 – Operation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 2.2 OPTIONAL REMOTE START/STOP PANEL A remote mounted Start/Stop Panel (Figure 2.2) is available that allows you to start and stop the generator engine conveniently from inside the vehicle. The remote panel includes a Start/Stop switch, hourmeter, generator run lamp and a wire harness. Figure 2.2 — Optional Remote Panel (Models 004057 and 004184) ◆ 2.4.
Section 2 – Operation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators DANGER ! The generator engine releases DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED.
Section 2 – Operation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators ◆ 2.7.2 DO NOT OVERLOAD THE GENERATOR You can read the rated wattage/amperage capacity of your generator on the generator data decal (see Section 1.1 on Page 4). Applying electrical loads in excess of the unit’s rated capacity will cause the engine/generator to automatically shut down. To avoid overloading, add up the wattage of all connected electrical lighting, appliance, tool and motor loads.
Section 3 – Maintenance QUIETPACT 55, 65, and 75 Recreational Vehicle Generators ◆ 2.8.4 OVERVOLTAGE PROTECTION A solid-state voltage regulator (Figure 2.5) controls the generator’s AC output voltage. This regulator supplies an excitation current to the rotor. By regulating the rotor’s excitation current, the strength of its magnetic field is regulated and, in turn, the voltage delivered to connected electrical loads is controlled. When the AC frequency is 60 Hertz, voltage is regulated at 115 volts.
Section 3 – Maintenance QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER 9. Start the engine and check for leaks. Figure 3.2 — Engine Oil Filter • Change the engine oil after the first 25 hours of operation (after the 25-hour break-in period, see Section 2.8.5, Page 10). Thereafter, change the oil every 100 operating hours. Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures.
Section 3 – Maintenance QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Figure 3.3 – Engine Air Cleaner P l Flat Washer Figure 3.5 – Fuel Filter Wing Nut FUEL FILTER TO FUEL PUMP A Offset S x Compartment Wing Nut 3.4 CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation. 1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.
Section 3 – Maintenance QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 3.7 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings.
Section 3 – Maintenance QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 3.9 MAJOR SERVICE MANUAL To obtain a service manual for your generator, contact your nearest Generac Authorized Service Dealer. Make sure to identify your MODEL NUMBER and SERIES. Manuals can be obtained from the internet website (www.generac.com) or a service dealer. 3.10 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement.
Section 4 – Notes QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 16 Generac® Power Systems, Inc.
PART II – INSTALLATION INSTRUCTIONS DANGER ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
Safety Rules QUIETPACT 55, 65, and 75 Recreational Vehicle Generators ! DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the manufacturer’s instructions and recommendations.
Safety Rules QUIETPACT 55, 65, and 75 Recreational Vehicle Generators • Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc. • Never insert any tool or other object through openings in the generator interior, even if the unit is not running. You might seriously injure yourself or damage the equipment.
Section 5 – General Information QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 5.1 PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS 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.
526.2 516.2 TYP. 495 A 497.4 469.8 TYP. 25.4 TAILPIPE LOCATION HOT AIR EXHAUST 226.5 183.5 95.5 TYP. 45˚ 344.6 POWERED BY GUARDIAN 760cc OHVI V-TWIN QUIETPACT 855.8 834.9 FRONT DOOR ACCESS FOR ALL REQUIRED MAINTENANCE 574.7 545 3/8"-16 WELDNUTS (8 PLACES) 70.8 305.9 195.8 821.2 INDUSTRIAL 55G 469 FRONT 233.2 57 126.2 FUEL INLET 90 FUEL INLET AIR INTAKE 54 TYP. 536.2 212 84 AC OUTPUT HARNESS 39.8 REMOTE PANEL CONNECTOR 564.1 VIEW FROM TOP 89.4 120.5 190.4 513.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Figure 5.3 - Connection for 120/240 Volts CB1 T1 RED T2 WHITE • The location must provide sufficient room to allow minimum clearances as outlined in Section 6.2. If sound insulation is to be used on the compartment walls and ceiling, the minimum recommended applies to the space between the generator and such insulation.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators ◆ 6.1.3 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 typical suspended mounting system is shown in Figure 6.2.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Figure 6.5 – Typical Compartment Construction Figure 6.6 – Types of Lock Seams • 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 6.2.3. • If constructing a compartment, line the exterior (underside) of the compartment floor with 26gauge galvanized steel.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators ◆ 6.2.4 ACOUSTICS ◆ 6.2.5 COMPARTMENT FLOOR CUTOUTS For additional noise abatement, the installer may wish to consider the following: You must provide openings in the generator compartment for the following items (Figure 6.8, Page 26): • Using special sound insulating materials. • Construction of a special noise abatement compartment.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Figure 6.8 — Compartment Floor Cutout HOT AIR EXHAUST 821.2 TAILPIPE 469 195.8 25.4 VIEW FROM TOP 233.2 4 YP. 45˚ 526.2 AIR INTAKE 516.2 TYP. 536.2 564.1 344.6 305.9 FUEL INLET 90 70.8 126.2 57 5 3/8"-16 WELDNUTS (8 PLACES) 226.5 545 FRONT 574.7 834.9 NOTE: ALL AIR INTAKES AND EXHAUST OUTLETS MUST BE KEPT CLEAR OF ANY OBSTRUCTIONS. ALL OPEN AREA IS REQUIRED FOR COOLING. ◆ 6.3.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Factory installed generator fuel system components include (a) fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and (d) interconnecting lines and fittings. Connect a fuel supply line to the fuel filter inlet. Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines. ◆ 6.4.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Figure 6.15 – Typical Propane Gas Fuel System ◆ 6.5.5 PRIMARY REGULATOR Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regulator. Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank. The following rules apply: • For best results, the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators The greater the airflow through the carburetor venturi, the lower the pressure at the venturi throat. The lower the pressure at the venturi throat, the greater the diaphragm movement, and the greater the movement of the regulator valve. The more the regulator valve opens, the greater the gas flow that is proportional to airflow through the generator.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators ◆ 6.6.1 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.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators ◆ 6.7.2 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. • If neutral conductors are used, they must be the same size as other leg wires.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators ◆ 6.7.7 GROUND FAULT CIRCUIT ◆ 6.8.3 BATTERY CABLE CONNECTIONS INTERRUPTERS The National Electrical Code (NFPA 70, article 551) requires that you install ground fault circuit interrupters (GFCIs) on all external and some internal electrical receptacles. Contact your manufacturer or dealer for recommendations. 6.8 BATTERY INSTALLATION ◆ 6.8.
Section 6 – Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Figure 6.18 — Transfer Switch Isolation Method QUIETPACT 55G POWERED BY GUARDIAN 760cc OHVI V-TWIN INDUSTRIAL Figure 6.19 — Installation With Isolation Receptacle QUIETPACT 55G POWERED BY GUARDIAN 760cc OHVI V-TWIN INDUSTRIAL Generac® Power Systems, Inc.
Section 7 – Post Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 6.9 OPTIONAL ACCESSORIES A plug-in receptacle (Figure 6.22) is provided on the generator set, above the muffler enclosure. Use this receptacle to connect an optional remote-mounted start/stop panel to the generator. Installation of such a panel will permit you to start and stop the generator engine from any convenient location inside the vehicle. Figure 6.22 – Remote Panel Plug-in Receptacle 7.
Section 7 – Post Installation QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 7.4 TESTING UNDER LOAD ◆ OPTIONAL LP GAS FUEL SYSTEM Apply electrical loads equal to about 75 to 100 percent of the unit's rated wattage/amperage capacity. ❑ Fuel system is properly installed and checked for leaks. 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 airflow is available.
Section 8 – Troubleshooting QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 8.1 TROUBLESHOOTING GUIDE PROBLEM Engine won’t crank. CAUSE 1. 2. CORRECTION 3. 4. 5. 6. 7. 7.5 amp fuse blown. Loose, or corroded or defective battery cable(s). Battery is discharged or defective. Defective Start/Stop switch. Defective starter contactor. Defective starter motor. Defective Engine Control Board 3. 4. 5. 6. 7. Replace blown fuse. Tighten, clean or replace, as necessary. Recharge or replace battery.
Section 9 – Notes QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Generac® Power Systems, Inc.
Section 10 — Electrical Data QUIETPACT 55, 65, and 75 Recreational Vehicle Generators V-Twin – Drawing No. 0E1057-B BATTERY RED BLK SC RED 13 16 13 0 SM 16 0 SC SCR 14 F1 0 FS 15 14A 0 FP 0 14 CH SW2 16 PCB 15 56 J2 90 14 15 15 0 SCR J3 J1-4 18A J1-5 18A J1-6 17 J1-7 17 CS 0 SP2 0B J1-8 J1-9 4 14A 85 85 HTO 0 85 LOP 0 REMOTE PANEL 66 18 J1-15 4 18 17 0I 1 14 15 1 55 R1 CB3 - CIRCUIT BREAKER, 2.5A (QP55 MODEL) CIRCUIT BREAKER, 3.
Section 10 — Electrical Data QUIETPACT 55, 65, and 75 Recreational Vehicle Generators V-Twin – Drawing No.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Base & Pulley – Drawing No. 0E1323-A 4 4 2 3 3 6 8 3 9 7 1 "B 10 11 5 8 12 3 2 13 3 2 4 1 3 15 2 23 22 21 19 18 20 25 26 27 45 A " 14 16 17 28 59 30 60 49 48 44 3 37 36 6 61 33 32 26 52 50 51 47 53 43 42 41 54 55 56 40 10 50 52 TO CARB. 39 "B 31 46 57 34 53 58 "A " 35 40 Generac® Power Systems, Inc.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Base & Pulley – Drawing No. 0E1323-A ITEM PART NO. QTY. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 0E0196 022129 022145 022259 0C7758 0C3168 0C2417 077603 0E0588 029451 0D8912 0E0571 0D8911 043107 0D9021 096289 0D8940 070006 070008 040976 056893 023897 0E1078 0C4138 043116 1 12 15 6 4 1 1 2 1 1.5 FT.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Enclosure – Drawing No. 0E1011-B 30 31 32 GROUND TO CONT. PANEL GROUND TO ENGINE 29 28 27 26 33 3 34 1 TARTER 25 35 36 30 31 30 48 37 24 2 42 9 43 44 23 4 38 46 VIEW "A" 3 6 48 38 47 7 5 5 5 40 VIEW "A" 16 17 14 13 15 5 8 5 40 6 10 6 12 2 11 41 22 5 21 18 2 5 19 9 42 Generac® Power Systems, Inc.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Enclosure – Drawing No. 0E1011-B ITEM PART NO. QTY.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Sheet Metal – Drawing No.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Sheet Metal – Drawing No. 0E1012-B ITEM PART NO. QTY.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Control Panel – Drawing No. 0E1013-A 3 6 7 8 9 2 4 1 5 9 10 13 11 46 12 2 39 40 37 36 35 47 45 5 25 14 4 26 27 7 7 44 4 49 8 43 50 8 51 52 7 42 15 41 28,2 55 16 39 17 40 56 53 5 30 31 18 19 20 60 32 33 37 36 34 35 54 59 39 61 62 63 65 7 8 64 67 21 22 23 24 5 46 Generac® Power Systems, Inc.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators Control Panel – Drawing No. 0E1013-A ITEM PART NO. QTY.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 760 V-Twin Engine – Drawing No. 0E1014-B 3 4 2 5 62 63 1 6 64 7 8 22 9 59 61 60 58 11 19 7 18 12 56 17 54 53 44 2 51 50 49 48 16 14 15A 15B 15A 13 25 26 24 20 23 47 46 27 21 28 45 43 33 3 42 29 34 30 36 33 32 31 37 41 40 39 48 Generac® Power Systems, Inc.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 760 V-Twin Engine – Drawing No. 0E1014-B ITEM PART NO. QTY.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators LP Regulator – Drawing No. 0E1530 2 3 5 4 6 7 8 1 11 10 9 12 16 13 17 14 18 19 15 21 22 20 23 24 25 26 27 50 Generac® Power Systems, Inc.
Section 11 — Exploded Views and Parts Lists QUIETPACT 55, 65, and 75 Recreational Vehicle Generators LP Regulator – Drawing No. 0E1530 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 PART NO. 0D5694 075475 022264 043180 0C5765 0C6070 0C4680 0C4647 0C4643 0D3973 0C6606 026073 0D3308 070728 0C5764 0C4643A 0C6066 0C5968 0C5759 0C5761 0C6069 0C6731 0C6067 0C4706 0C6068 0C5762 045764 QTY.
Section 12 – Warranty QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 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 System Warranty on your new engine.
Section 12 – Warranty QUIETPACT 55, 65, and 75 Recreational Vehicle Generators 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/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Section 12 – Warranty QUIETPACT 55, 65, and 75 Recreational Vehicle Generators GENERAC 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 (three) years or 2,000 (two thousand) hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc.
