Instruction/ maintenance manual of the product 004614-1 Generac
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PO WER SY STEMS, INC. ® Owner’ s Man ual and Installation Instructions Liquid-cooled Recreational V ehic le Generator • Model: 004614-1 QUIETP A CT™ 65D.
Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the QUIETP ACT™ product line by Generac P ower Systems, Inc. This model is designed and manufac- tured to supply electrical power for recreational vehi- cles.
T able of Contents QUI ETP ACT™ 65D Recreational V ehicle Generator Generac ® Pow er Systems, Inc. 1 P ar t I – Owner’s Manual Introduction ......................................Inside Front Cover Read This Manual Thoroughly ...................
2 Generac ® Pow er Systems, Inc. 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 maintained.
Generac ® Pow er Systems, Inc. 3 ELE CTR ICAL HA Z AR DS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. A void contact with bare wires, ter- minals, connections, etc., while the unit is running .
4 Generac ® Pow er Systems, Inc. Section 1 – General Information QUI ETP ACT™ 65D Recreational V ehicle Generator Please recor d the following information from the generator DA T A DECAL or information decal, located below the user control panel.
Generac ® Pow er Systems, Inc. 5 Section 1 – General Information QUI ETP ACT™ 65D Recreational V ehicle Generator 1.2 GEN ER A T OR AP P LICAB I LIT Y These generators have been designed and manufac- tured for supplying electrical power to recreational vehicles.
6 Generac ® Pow er Systems, Inc. Section 1 – General Information QUI ETP ACT™ 65D Recreational V ehicle Generator 1.5.2 F UEL CONSUM PTION (GAL/H R) 1.5.3 ENGI NE OI L R EQ UIRE MEN T S Use a high- quality detergent oil with American P etroleum Institute (API) classification “F or Service CC.
Generac ® Pow er Systems, Inc. 7 Section 2 – Operation QUI ETP ACT™ 65D Recreational V ehicle Generator 2.1 GENER A T OR CONTROL P AN EL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control Panel 2.
8 Generac ® Pow er Systems, Inc. Section 2 – Operation QUI ETP ACT™ 65D Recreational V ehicle Generator 2.3.2 ENGI NE L U BR ICA TION Before starting the engine, have the engine crankcase properly serviced with the recommended oil. Refer to Section 1.
Generac ® Pow er Systems, Inc. 9 Section 2 – Operation QUI ETP ACT™ 65D Recreational V ehicle Generator 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 .
10 Generac ® Pow er Systems, Inc. Section 2 – Operation QUI ETP ACT™ 65D Recreational V ehicle Generator Figure 2.2 – Engine Protective Devices 2.7 .3 O VERSP EED SH UTDO WN A DC control circuit board senses engine speed from the frequency of the alternator AC output.
Generac ® Pow er Systems, Inc. 11 Section 3 – Maintenance QUI ETP ACT™ 65D Recreational V ehicle Generator 2.8.4 OP ERA TION I N H IGH GRASS OR B RUSH Never operate the generator while the vehicle is parked over high grass, weeds, brush, leaves, or other combustible substance.
12 Generac ® Pow er Systems, Inc. Section 3 – Maintenance QUI ETP ACT™ 65D Recreational V ehicle Generator 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 prop- er type and amount of recommended oil (see Section 1.
Section 3 – Maintenance QUI ETP ACT™ 65D Recreational V ehicle Generator Figure 3.3 – Spark Arrestor Muffler Maintenance 3.5 CLEAN I NG THE GEN ER A T OR Keep your generator as clean and as dry as possible. Dirt and moisture that accumulate on internal gener- ator windings have adversely affect insulation resis- tance.
14 Generac ® Pow er Systems, Inc. • Immediately wash with water all skin areas that come into contact with the electrolyte. • If the electrolyte contacts the eyes, immediately flush eyes thoroughly with water , and seek med- ical attention. • Spilled electrolyte is to be washed down with an acid-neutralizing agent.
Generac ® Pow er Systems, Inc. 15 3.1 2.2 R ETUR N T O SERVICE T o return the unit to service after storage, proceed as follows: 1. Check the tag on the engine for oil viscosity and classification. V erify that the correct recommend- ed oil is used in the engine (see Section 1.
3.1 3 SERVICE S CH EDU LE A TTENTION: It is recommended that all service work be performed by your nearest Generac Authorized Service Dealer . SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect C.
P ART I I – I NS T ALL A TION I NS TR UCTIONS ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!!.
18 Generac ® Pow er Systems, Inc. NO TICE T O I NST ALLER 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 ® Pow er Systems, Inc. 19 ELE CTR ICAL HA Z AR DS • The generator covered by this manual produces dangerous electrical voltages that can cause fatal electrical shock. A void contact with bare wires, ter- minals, connections, etc., while the unit is running .
20 Generac ® Pow er Systems, Inc. 1.1 P U R POSE AND S C OP E OF TH E MAN U AL 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.
Generac ® Pow er Systems, Inc. 21 Section 1 – General Information QUI ETP ACT™ 65D Recreational V ehicle Generator Major Features and Dimensions — Drawing No. D2 650-A [ .94" ] 595.0 [ 23.43" ] 604 [ 23.78" ] O VER SC REW S 929 [ 36.
22 Generac ® Pow er Systems, Inc. 2.1 L OCA TION AN D SU P PORT 2.1.1 GEN ERA T OR L OCA TION The most desirable location for the generator set is between the vehicle's main frame members. Many recreational vehicles have been factory- equipped with an area for the generator set.
Generac ® Pow er Systems, Inc. 23 2.1.4 GEN ERA T OR R E STRAI NT Use four 3/8"-16 hardened steel bolts (Grade 5) to fas- ten the generator to the supporting frame or the sup- port tubing .
24 Generac ® Pow er Systems, Inc. • Seams and joints of the galvanized steel (whether used as a liner or for the compartment itself) must be lapped and mechanically secured. Such seams may be manufactured, welded, bolted, riveted, or screwed. Manufactured lock seams are shown in Figure 2.
Generac ® Pow er Systems, Inc. 25 Figure 2.5 – T ypical Noise Abatement 2.2.4 COMP ARTM ENT F L OOR CUT OUTS Y ou must provide openings in the generator compart- ment for the following items (Figure 2.
26 Generac ® Pow er Systems, Inc. 2.3 C OOLI NG AN D VENTI L A TI NG AI R It is absolutely essential that an adequate flow of air for cooling, ventilation, and engine combustion be supplied to the generator set. W ithout sufficient air- flow , the engine/generator quickly overheats.
Generac ® Pow er Systems, Inc. 27 Figure 2.10 – Air Inlet Using Ductwork Figure 2.11 – Air Inlet in V ehicle Skirt 2.3.3 COMP ENS A TI NG FOR R ES TRICTIONS Materials, such as, screening, louvers, or expanded metal, can restrict the free flow of air .
28 Generac ® Pow er Systems, Inc. Because diesel fuels are less volatile than gasoline or gaseous fuels, they are considered safer from the stand- point of storage and handling . As a result, installers may tend to be careless in their installation practices, which can result in poor engine performance.
Generac ® Pow er Systems, Inc. 29 2.5 EXHAUS T S YS TEM The generator exhaust system must be safely and properly installed. Only approved exhaust system parts must be used. A properly installed exhaust sys- tem must be vapor -tight, quiet, and completely safe.
30 Generac ® Pow er Systems, Inc. • Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping . This causes excessive back pressure on the generator engine. Also, water from one engine can damage the other engine. • Plan exhaust system installation carefully .
Generac ® Pow er Systems, Inc. 31 This generator set is equipped with dual- stator AC power windings. These two - stator windings supply electrical power to customer electrical loads by means of a dual, two -wire connection system. Figure 1.1 – Connections for 230 V olts Only 2.
32 Generac ® Pow er Systems, Inc. If the vehicle’ s electrical circuits can be powered by any other source of electricity (such as, a “dock- side” power receptacle), ther e must be no possibil- ity of connecting the differ ent power sources to the vehicle’ s circuits at the same time.
Generac ® Pow er Systems, Inc. 33 2. Connect the battery cable from the battery post, indicated by a NEGA TIVE, NEG, or (-), to the vehicle frame ground connection (Figure 2.19). 3. Connect a cable from the vehicle frame ground to the negative post on the generator frame.
34 Generac ® Pow er Systems, Inc. 2.8.1 R EMO TE ST ART/ST OP CONN ECTIONS The following steps are necessary to connect the remote start/stop option: 1. If the six-wire remote connector is visible below the control panel, as shown in Figure 2.20, skip to step 5.
Generac ® Pow er Systems, Inc. 35 Section 3 – Post-installation Start-up Checks QUI ETP ACT™ 65D Recreational V ehicle Generator CHECKS 3.5 I NS T ALL A TION CH E CKLIS T L OCA TION AN D SU PPORT ❑ Generator is properly located. ❑ Generator is properly supported.
36 Generac ® Pow er Systems, Inc. Appendix 1 – T roubleshooting QUI ETP ACT™ 65D Recreational V ehicle Generator TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION The engine will not crank. 1. System control fuse blown 1. Replace fuse. 2.
Appendix 2 — Electrical Data QUI ETP ACT™ 65D Recreational V ehicle Generator Electrical Schematic – Drawing No. - 0D503 7 -A Generac ® Pow er Systems, Inc.
38 Generac ® Pow er Systems, Inc. Appendix 2 — Electrical Data QUI ETP ACT™ 65D Recreational V ehicle Generator Wiring Diagram – Drawing No. 0D5 036-A.
Generac ® Pow er Systems, Inc. 39 Appendix 2 — Electrical Data QUI ETP ACT™ 65D Recreational V ehicle Generator Wiring Diagram – Drawing No. 0D5 036-A.
40 Generac ® Pow er Systems, Inc. Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator Engine, Alternator Drive and Starter Assembly – Drawing No.
Generac ® Pow er Systems, Inc. 41 IT EM P ART NO . QTY . DESCRIPTION 1 0C5598 1 BEARING CARRIER, FRONT 2 0C9674 1 BEARING CARRIER, UPPER 3 0C6055H 1 RO TOR ASSEMBL Y 4 0D5030H 1 ST A TOR ASSEMBL Y 5 031971 1 BALL BEARING 6 073159 1 BALL BEARING 7 066386 1 BR USH HOLDER 8 066849 2 T APTITE M5-0.
42 Generac ® Pow er Systems, Inc. Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator Base Frame – Drawing No.
Generac ® Pow er Systems, Inc. 43 Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator Enclosure – Drawing No. 0D505 9-B 2 1 0 5 7 3 4 6 17 17 1 5 14 1 9 8 1 3 12 17 1 11 17 17 17 17 17 17 2 0 32 2 5 23 1 9 21 2 6 27 24 VIEW " A" A 2 9 31 30 28 33 35 34 IT EM P ART NO .
44 Generac ® Pow er Systems, Inc. Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator Cooling System – Drawing No.
Generac ® Pow er Systems, Inc. 45 IT EM P ART NO . QTY . DESCRIPTION 1 0C4551 1 Cov er Plate, Scroll Weldment 2 0C4550 1 Housing, F an Scroll W eldment 3 0C4552 1 F an, Squirrel Cage 4 0C4554 1 Shaft.
IT EM P ART NO . QTY . DESCRIPTION 1 0D2412 1 WELDMENT , ELECTRICAL ENCLOSURE 2 071914 1 TERMINAL BLOCK 4 POSITION 3 083048 1 ASSEMBL Y , POTTED REGULA TOR 4 0C7610 1 RESIST OR 20R 5% 12W 5 093642 1 A.
Generac ® Pow er Systems, Inc. 47 Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator Intake and Exhaust System – Drawing No.
48 Generac ® Pow er Systems, Inc. Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator Fuel and Electrical Syst ems – Drawing No.
Generac ® Pow er Systems, Inc. 49 IT EM P ART NO . QTY . DESCRIPTION 1 0D2398 1 ST ART / ST OP SWITCH 2 0C4540 1 CO VER, ENGINE CONTROL BO X 3 0C1457 1 HOUR METER 4 081904 1 FUSE HOLDER, SFE-14 5 055920 1 SWITCH, PUSHBUTT ON SPST 6 043181 2 PPHMS M3-0.
50 Generac ® Pow er Systems, Inc. Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator 1.0 Liter Diesel Camshaft – Drawing No.
Generac ® Pow er Systems, Inc. 51 Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator 1.0 Liter Diesel Cylinder Block– Drawing No.
52 Generac ® Pow er Systems, Inc. Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator 1.0 Liter Diesel Cylinder Head – Drawing No.
Generac ® Pow er Systems, Inc. 53 Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator 1.0 Liter Diesel Crankshaft, Piston and Flywheel – Drawing No.
54 Generac ® Pow er Systems, Inc. Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator 1.0 Liter Diesel Oil Pump – Drawing No.
Generac ® Pow er Systems, Inc. 55 Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator 1.0 Liter Diesel Rocker Arm Assembly – Drawing No.
IT EM P ART NO . QTY . DESCRIPTION 1 0709390316 1 INJECT OR PUMP ASSEMBL Y 2 0709390317 AR SHIM-0.2MM 0709390318 AR SHIM-0.3MM 0709390319 AR SHIM-0.5MM 0709390320 AR SHIM-1.
Generac ® Pow er Systems, Inc. 57 IT EM P ART NO . QTY . DESCRIPTION 1 0709390661 1 FUEL FIL TER SUPPORT 2 069858 1 FUEL FIL TER 3 0C8008 AR HOSE, 5/16" SAE 30R7 4 0C8008 250MM HOSE, 5/16" .
58 Generac ® Pow er Systems, Inc. Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator 1.0 Liter Diesel T iming and Governor – Drawing No.
Generac ® Pow er Systems, Inc. 59 IT EM P ART NO . QTY . DESCRIPTION 1 0709390285 1 HOUSING, TIMING GEAR 2 0709390286 1 SPRING PIN 3 0709390287 1 GASKET 4 0709390307 1 SPRING 5 0709390308 1 W ASHER 6.
IT EM P ART NO . QTY . DESCRIPTION 1 070939-139 1 OIL P AN 2 070939-140 20 BOL T 3 0D7124 1 O-RING (MODELS 04270 & 04614 ONL Y) 12 070939-143 1 DIPSTICK TUBE (ALL MODELS EXCEPT 04270 & 04614) .
Generac ® Pow er Systems, Inc. 61 Appendix 3 — Exploded Views and P ar ts Lists QUI ETP ACT™ 65D Recreational V ehicle Generator 1.0 Liter Diesel W ater Pump – Drawing No.
62 Generac ® Pow er Systems, Inc. Appendix 4 – Notes QUI ETP ACT™ 65D Recreational V ehicle Generator.
Generac ® Pow er Systems, Inc. 63 Appendix 4 – Notes QUI ETP ACT™ 65D Recreational V ehicle Generator.
64 Generac ® Pow er Systems, Inc. Appendix 5 – W arranty QUI ETP ACT™ 65D Recreational V ehicle Generator F EDER AL AN D CALI FOR N IA EM IS SIONS CONTROL W AR R ANT Y S T A TEM ENT (for non-road Diesel engines rated under 19 kW) Y OU R W AR R ANT Y R IGHTS AND OB LIGA TIONS The U .
Generac ® Pow er Systems, Inc. 65 Appendix 5 – W arranty QUI ETP ACT™ 65D Recreational V ehicle Generator OB LIGA TIONS AN D R IGHT S OF TH E MAN UF ACTUR ER AN D OWNER The new model year , class.
Part No. 0D7428 GENERAC ® POWER SY STEMS, INC. P.O. BO X 8 • W AUKESHA, WI 53187 Revision 0 (11/29/01) Printed in U.S.A. Appendix 5 – W arranty QUI ETP ACT™ 65D Recreational V ehicle Generator .
An important point after buying a device Generac 004614-1 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Generac 004614-1 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Generac 004614-1 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Generac 004614-1 you will learn all the available features of the product, as well as information on its operation. The information that you get Generac 004614-1 will certainly help you make a decision on the purchase.
If you already are a holder of Generac 004614-1, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac 004614-1.
However, one of the most important roles played by the user manual is to help in solving problems with Generac 004614-1. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac 004614-1 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
