Generac 004700-0 owner manual Notice To Installer, General Hazards, Danger

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NOTICE TO INSTALLER

Safety Rules

QUIETPACT 40G Recreational Vehicle Generator

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.

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 proce- dures for installing such products, or similar prod- ucts that Generac manufactures. Generac also assumes that personnel have been trained in the rec- ommended installation procedures for these prod- ucts and that such training includes (a) use of com- mon hand tools, (b) use of special Generac tools, and

(c)use of any tools and/or equipment from other sup- pliers.

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.

Manual backgroundManual background 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.

Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot

!during operation. Exercise care near running generators.

! 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 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 venti- lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment. Without sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to the generator. Do not alter the installation or per- mit 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.

18 Generac® Power Systems, Inc.

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Contents Air-cooled Recreational Vehicle Generators This manual should remain with the unitModel QUIETPACT 40G GENERA OHVIAUTHORIZED SERVICE DEALER LOCATION CONTENTSOPERATION AND MAINTENANCE HOW TO OBTAIN SERVICEPart II - Installation Instructions Safety RulesAdjustments Exploded Views and Parts ListsGENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot during operation. Exercise care near running generatorsEXPLOSION HAZARDS ELECTRICAL HAZARDSFIRE HAZARDS 1.1 GENERATOR IDENTIFICATION Model 004700-0 - QUIETPACT 40GModel Number kW Rating1.3 SAFETY 1.5 SPECIFICATIONSDo not overload the generator. Some installa 1.2 GENERATOR APPLICABILITYGenerac does not recommend using any 1.5.5 GENERATOR1.5.2 FUEL CONSUMPTION 1.5.3 ENGINE OIL REQUIREMENTS2.1.2 START/STOP SWITCH 2.4.1 INSTALLATION2.1 GENERATOR CONTROL PANEL 2.2 OPTIONAL REMOTE START/STOP PANEL2.5 STARTING THE GENERATOR 2.4.2 ENGINE LUBRICATION2.4.3 FUEL SUPPLY 2.4.4 COOLING AND VENTILATING AIR2.9.1 LOW OIL PRESSURE SWITCH 2.9.2 HIGH TEMPERATURE SWITCHFigure 2.2 - Low Oil Pressure and High Temperature Switches 2.6 STOPPING THE GENERATOR2.10 ADDITIONAL INFORMATION 2.9.3 FIELD BOOST2.10.1 25-HOUR BREAK-IN PERIOD 2.9.4 OVERVOLTAGE PROTECTIONFigure 3.1 - Oil Maintenance Features 3.1 CHECKING THE ENGINE OIL LEVEL3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER 2.10.4 OPERATION IN HIGH GRASS OR BRUSH3.3 MAINTAINING THE ENGINE AIR CLEANER 3.3.1 CLEANING THE FOAM PRECLEANERFigure 3.2 - Engine Air Cleaner 3.3.2 CLEANING OR REPLACING THE PAPER FILTER3.4 CLEAN AIR INTAKE 3.7 CLEAN SPARK ARRESTORFigure 3.3 - Cleaning Air Intake Figure 3.4 - Setting the Spark Plug Gap3.8 CLEANING THE GENERATOR 3.9 BATTERY MAINTENANCEDo NOT use a forceful spray of water to clean Use tools with insulated handles Wear rubber gloves and boots3.12 OUT OF SERVICE PROCEDURE 3.13 ADJUSTING VALVE CLEARANCE3.12.1 REMOVAL FROM SERVICE 3.12.2 RETURN TO SERVICE3.14 RV GENERATOR SERVICE INTERVAL Figure 3.8 - Tightening Jam NutINSTALLATION INSTRUCTIONS SHOULD ATTEMPT INSTALLATIONPART ONLY QUALIFIED ELECTRICIANS OR CONTRACTORSNOTICE TO INSTALLER FIRE HAZARDS 1.2 SAFETY 1.1 PURPOSE AND SCOPE OF THE MANUAL1.4 EQUIPMENT DESCRIPTION 1.5 GENERATOR ENGINE OPERATING SPEEDMajor Features VIEW FROM TOP2.1 LOCATION AND SUPPORT 2.1.1 GENERATOR LOCATION2.1.2 GENERATOR SUPPORT 2.1.3 SUSPENDED MOUNTING2.2 GENERATOR COMPARTMENTS 2.1.4 GENERATOR RESTRAINT2.2.2 COMPARTMENT CONSTRUCTION 2.2.1 COMPARTMENT SIZEFigure 2.6 - Types of Lock Seams 2.2.4 ACOUSTICS2.2.3 SOUND INSULATING MATERIALS Figure 2.7 - Typical Noise Abatement 2.2.5 COMPARTMENT FLOOR CUTOUTS Figure 2.8 - Compartment Floor Cutout Drawing 0D8716-CVIEW FROM TOP All measurements are in millimeters, 25.4 mm = 1”2.3.2 TESTING THE INSTALLATION 2.3 COOLING AND VENTILATING AIR2.4 GASOLINE FUEL SYSTEM 2.3.1 GENERATOR AIRFLOW2.5 EXHAUST SYSTEM 2.4.1 FUEL TANK2.4.2.2 Flexible Fuel Line 2.4.2 GENERATOR FUEL SUPPLY LINE 2.4.2.1 Rigid Fuel Lines2.5.2 EXHAUST SYSTEM SAFETY Figure 2.12 - Spark Arrestor Installation2.6 ELECTRICAL CONNECTIONS 2.5.1 SPARK ARRESTOR2.6.2 WIRING 2.6.1 ELECTRICAL JUNCTION BOX2.6.3 GENERATOR AC CONNECTIONS 2.6.4 CONDUITFigure 2.14 - Transfer Switch Isolation Method 2.6.5 ISOLATING DIFFERENT POWER SOURCES2.6.6 POWER SUPPLY CORD 2.7 BATTERY INSTALLATION 2.8 OPTIONAL ACCESSORIES2.7.1 RECOMMENDED BATTERY 2.7.2 BATTERY CABLES3.1 POST INSTALLATION TESTS 3.4 TESTING UNDER LOADDo not make any unnecessary adjustments 3.2 BEFORE INITIAL START-UP3.5 INSTALLATION CHECKLIST Appendix 1 - Notes 34 Generac Power Systems, IncTROUBLESHOOTING GUIDE PROBLEMCAUSE CORRECTIONBROWN Appendix 3 - Electrical Data36 Generac Power Systems, Inc Data PowerQUIETPACT Appendix 3 - Electrical38 Generac Power Systems, Inc Appendix 4 - Exploded Views and Parts ListsEnclosure - Drawing No. 0D8352-E TO CARBDESCRIPTION Appendix 4 - Exploded Views and Parts ListsPART NO. QTY 40 Generac Power Systems, Inc Appendix 4 - Exploded Views and Parts Lists 42 Generac Power Systems, Inc 25 24Appendix 4 - Exploded Views and Parts Lists 44 Generac Power Systems, Inc ASSEMBLY BRACKET GOVERNOR BOOT CHOKE SOLENOID PLASTICASSEMBLY, GOVERNOR LEVER GASKET CARBURETOR/MANIFOLD46 Generac Power Systems, Inc TAPERED CRANKSHAFT ASSEMBLY SCREW, HHFC M8-1.25 X 35MMVALVE SPRING WEAR WASHER OIL PRESSURE RELIEF COVERCALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONSMANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIESEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWING1 Utility 2 Lawn and Garden Equipment 3 Recreational Vehicle RV Generator 4 Industrial Mobile IM GeneratorGENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY WARRANTY SCHEDULE - COMMERCIAL APPLICATIONSWARRANTY SCHEDULE - CONSUMER/PERSONAL APPLICATIONS GENERAC POWER SYSTEMS, INC