®
POWER SYSTEMS, INC.
Owner’s Manual and
Installation Instructions
Liquid-cooled Recreational Vehicle Generator
• Model: 004614-1
QUIETPACT™ 65D
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Table of Contents
QUIETPACT™ 65D Recreational Vehicle Generator
Part I – Owner’s Manual
Part II – Installation Instructions
Introduction ......................................Inside Front Cover
Read This Manual Thoroughly ....................................IFC
Contents ......................................................................IFC
Operation and Maintenance ........................................IFC
How to Obtain Service..................................................IFC
Authorized Service Dealer Locator Number ....................IFC
Safety Rules ....................................................................18
Section 1 – General Information................................20
1.1
1.2
1.3
1.4
1.5
1.6
Purpose and Scope of the Manual ..........................20
Safety......................................................................20
Standards Booklets ................................................20
Equipment Description ..........................................20
Generator Engine Operating Speed ........................20
Generator AC Connection System ..........................20
Safety Rules ......................................................................2
Section 1 – General Information..................................4
1.1
1.2
1.3
1.4
1.5
Generator Identification............................................4
Generator Applicability ............................................5
Safety........................................................................5
Generator AC Connection System ............................5
Specifications ..........................................................5
Section 2 – Installation ................................................22
2.1
2.2
2.3
2.4
Location and Support ............................................22
2.1.1
2.1.2
2.1.3
2.1.4
Generator Location ..................................22
Generator Support ..................................22
Suspended Mounting................................22
Generator Restraint..................................23
1.5.1
1.5.2
1.5.3
1.5.4
1.5.5
1.5.6
Fuel Requirements......................................5
Fuel Consumption ......................................6
Engine Oil Requirements............................6
Coolant ......................................................6
Engine ........................................................6
Generator ..................................................6
Generator Compartments ......................................23
2.2.1
2.2.2
2.2.3
2.2.4
Compartment Construction ......................23
Sound Insulating Materials ......................24
Acoustics ..................................................24
Compartment Floor Cutouts ....................25
Section 2 – Operation ....................................................7
2.1
Generator Control Panel ..........................................7
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
Hourmeter ..................................................7
Start/Stop Switch........................................7
Fuse............................................................7
Line Breaker ..............................................7
Preheat Switch............................................7
Cooling and Ventilating Air ....................................26
2.3.1
2.3.2
2.3.3
2.3.4
Generator Airflow ....................................26
Cooling Air Inlet Openings........................26
Compensating for Restrictions..................27
Testing the Installation..............................27
2.2
2.3
Optional Remote Start/Stop ....................................7
Before Starting the Engine........................................7
Diesel Fuel System..................................................27
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
Installation ....................................................7
Engine Lubrication........................................8
Fuel Supply ..................................................8
Coolant Level ................................................8
Cooling and Ventilating Air ..........................8
Engine Exhaust Gas......................................8
2.4.1
2.4.2
2.4.3
Fuel Tank .................................................28
Generator Fuel Supply Lines ....................28
Generator Fuel Return Lines ....................28
2.5
2.6
Exhaust System......................................................29
2.5.1
2.5.2
Muffler and Spark Arrestor ......................29
Exhaust System Safety..............................29
2.4
2.5
2.6
Starting the Generator..............................................8
Stopping the Generator ............................................9
Applying Loads to Generator....................................9
Electrical Connections............................................30
2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
2.6.6
2.6.7
Electrical Junction Box ............................30
Wiring ......................................................30
Generator AC Connections ......................30
Conduit ....................................................31
Power Supply Cord ..................................31
Ground Fault Circuit Interrupters ............31
Isolating Different Power Sources ............31
2.6.1
2.6.2
Letting the Engine Stabilize ........................9
Do Not Overload the Generator ..................9
2.7
Protection Systems ..................................................9
2.7.1
2.7.2
2.7.3
2.7.4
Low Oil Pressure Switch ............................9
High Coolant Temperature Switch ..............9
Overspeed Shutdown................................10
Overvoltage Protection ..............................10
2.7
2.8
Battery Installation ................................................32
2.8
Additional Information ..........................................10
2.7.1
2.7.2
2.7.3
2.7.4
Recommended Battery..............................32
Battery Cables ..........................................32
Battery Cable Connections........................32
Battery Compartment ..............................33
2.8.1
2.8.2
2.8.3
2.8.4
2.8.5
25-Hour Break-in Period ..........................10
25-Hour Check-up ....................................10
Attention Required After Submersion ......10
Operation in High Grass or Brush............11
Effects of Moisture and Dirt ....................11
Optional Accessories ..............................................33
2.8.1 Remote Start/Stop Connections................34
Section 3 – Maintenance..............................................11
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Checking the Engine Oil Level ................................11
Changing the Engine Oil and/or Oil Filter ..............11
Servicing the Engine Air Filter................................12
Spark Arrestor Muffler ..........................................12
Cleaning the Generator ..........................................13
Battery Maintenance ..............................................13
Cooling System ......................................................14
Engine Coolant ......................................................14
Major Service Manual ............................................14
Section 3 – Post-installation Startup
Checks.........................................................34
3.1
3.2
3.3
3.4
3.5
Post Installation Tests ............................................34
Before Initial Startup..............................................34
Initial Start ............................................................34
Testing Under Load ................................................34
Installation Checklist..............................................35
Appendix 1 – Troubleshooting....................................36
Appendix 2 – Electrical Data ......................................37
Appendix 3 – Exploded Views and Parts Lists ......40
Appendix 4 - Notes........................................................62
Appendix 5 – Warranty ................................................64
3.10 Drive Belt ..............................................................14
3.11 Exercising the Generator........................................14
3.12 Out-of-Service Procedure........................................14
3.12.1 Removal From Service..............................14
3.12.2 Return to Service......................................15
3.13 Service Schedule ....................................................16
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Safety Rules
QUIETPACT™ 65D Recreational Vehicle Generator
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.
• The engine exhaust fumes contain carbon monox-
ide, which can be DEADLY. This dangerous gas, if
WARNING:
breathed in sufficient concentrations, can cause
The engine exhaust from this product
unconsciousness or even death. Thus, the exhaust
system must be installed properly, in strict com-
contains chemicals known to the state
of California to cause cancer, birth
pliance 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.
defects, or other reproductive harm.
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. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.
• 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 seriously damages the
generator. Do not alter the installation or permit
even partial blockage of ventilation provisions, as
this can also seriously affect the safe operation of
the generator.
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
technique that Generac does not specifically recom-
mend, 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.
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance, or being careless can cause
possible injury or death. Permit only responsi-
ble and capable persons to operate and main-
tain this equipment.
• 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 imme-
diately for parts needing repair or replacement.
• Before performing any maintenance on the genera-
tor, disconnect its battery cables to prevent acci-
dental startup. First, disconnect the cable from the
battery post, indicated by a NEGATIVE, NEG, or
(–). Reconnect this cable last.
• Never use the generator, or any of its parts, as a
step. Stepping on the unit can stress and break
parts, resulting in dangerous operating conditions
due to leaking exhaust gases, fuel leakage, oil leak-
age, etc.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
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.
GENERAL HAZARDS
• For safety reasons, Generac recommends
that the installation, initial startup, and mainte-
nance of this equipment be performed by a
Generac Authorized Service Dealer.
• 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.
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Safety Rules
QUIETPACT™ 65D Recreational Vehicle Generator
ELECTRICAL HAZARDS
FIRE 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.
Before operating the generator, ensure all appro-
priate covers, guards, and barriers are in place . 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 gen-
erator properly grounded (bonded), either by solid
mounting to the vehicle frame or chassis, or by
means of an approved bonding conductor. DO
NOT disconnect the bonding conductor, if so
equipped. DO NOT reconnect the bonding conduc-
tor 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.
• In case of an 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 nonconduct-
ing 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.
• For fire safety, the generator must be installed and
maintained properly. Installation must always
comply with NFPA 70 (latest edition), “National
Electrical Code”, Article 551, and NFPA 1192 (lat-
est edition), “Standard for Recreational Vehicles”,
along with all applicable codes, standards, laws,
and regulations. Adhere strictly to local, state, and
federal electrical and building codes. Comply with
regulations the Occupational Safety and Health
Administration (OSHA) has established. Also,
ensure that the generator is installed in accor-
dance with the manufacturer’s instructions and
recommendations. After proper installation, do
nothing that might alter the installation and render
the unit in noncompliance with the aforemen-
tioned 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 fire extinguishers, consult your local
fire department.
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe off any
fuel or oil spills immediately. Ensure that no com-
bustible material is left in the generator compart-
ment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing the generator clean and free of debris.
• All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care.
Comply with all laws regulating the storage and
handling of fuels. Inspect the unit’s fuel system fre-
quently and correct any leaks immediately. Before
placing this equipment into service, the fuel supply
lines must be properly installed, purged, and leak-
tested according to applicable fuel-gas codes.
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Section 1 – General Information
QUIETPACT™ 65D 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 ____________________
3. kW Rating__________________________
2. Serial Number __________________
4. Rated Voltage __________________
Model: 004614-1
QUIETPACT™ 65D
1. 2-Pole, 30-amp Circuit
Breaker
2. Hourmeter
3. Oil Fill Opening and Plug
4. Oil Dipstick
5. Engine Start/Stop 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
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Section 1 – General Information
QUIETPACT™ 65D Recreational Vehicle Generator
1.2 GENERATOR APPLICABILITY
1.4 GENERATOR AC
These generators have been designed and manufac-
tured for supplying electrical power to recreational
vehicles. You should neither modify the generator nor
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 a competent
authority.
CONNECTION SYSTEM
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. Note,
however, that the neutral is grounded.
Figure 1.1 – Connections for 230 Volts Only
For fire safety, the generator must have been
properly installed in compliance with NFPA 70
(latest edition), “National Electrical Code”,
Article 551, and NFPA 1192 (latest edition),
“Standard for Recreational Vehicles”. The gen-
erator also must have been installed in strict
compliance with the manufacturer’s detailed
installation instructions. After installation, do
nothing that might render the unit in noncom-
pliance with such codes, standards, and instruc-
tions.
You can use this generator to supply electrical power
for operating 230-volt, single-phase, 50-Hertz, AC
electrical loads. These loads can require up to 6,500
watts (6.5 kW) of power, but cannot exceed 28.2 AC
amps at 230 volts.
1.5 SPECIFICATIONS
1.5.1 FUEL REQUIREMENTS
N
The generator is equipped with a diesel fuel system.
Use clean, fresh No. 1D or No. 2D diesel fuel with
minimum Cetane number of 40. The diesel fuel must
also 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
“share” the vehicle’s engine fuel tank.
Do not overload the generator. Some installa-
tions may require that electrical loads be alter-
nated to avoid overloading. Applying exces-
sively high electrical loads may damage the
generator and 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 current) for starting than for continuous
operation.
NOTE:
Some installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter
than the vehicle’s engine pickup tube. Such an
arrangement causes the generator engine to “run
out of fuel”, while adequate fuel for the vehicle
engine remains 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.
1.3 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.
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Section 1 – General Information
QUIETPACT™ 65D Recreational Vehicle Generator
1.5.2 FUEL CONSUMPTION (GAL/HR)
1.5.5 ENGINE
N
N
Type of Engine ..........................................................ISM Diesel
Cylinder Arrangement ................................................3, in-line
Displacement ................................................58.2 in . (954 cc)
Model
QUIETPACT™ 65D
(004614-1)
No Load Half Load Full Load
0.28 0.45 0.78
3
Bore ................................................................2.95 in. (75 mm)
Stroke ............................................................2.83 in. (72 mm)
Compression Ratio ........................................................23-to-1
Combustion Chamber Type ............................Pre-Combustion
Rated Horsepower..........................................13 @ 1,950 rpm
Cylinder Block ............................................................Cast Iron
Number of Main Bearings........................................................4
Number of Teeth on Flywheel..............................................104
Type of Governor ..............................Mechanical, Fixed Speed
Fuel Filter ............................Full Flow Spin-On (Part # 69858)
1.5.3 ENGINE OIL REQUIREMENTS
N
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 ambient temperature range
anticipated before the next oil change:
Temperature
Above 100º F (38º C)
40º to 100º F (4.4º to 38º C)
Below 40º F (4.4º C)
Oil Grade (Recommended)
SAE 15W-40* or SAE 40
SAE 10W-30 or SAE 30
SAE 5W-20 or 5W-30
Oil Filter ........................................Full Flow with Bypass Valve
(Part # 126-70939)
Oil Pressure ................................................................29-71 psi
Type of Cooling System..............Pressurized, Closed Recovery
Cooling Method....................................................Liquid-cooled
Type of Cooling Fan ......................................Centrifugal Puller
Cooling System Capacity ..........................1.4 U.S. gals (5.3 L)
Air Cleaner............................Disposable Filter (Part # C4880)
Starter..........................................................12-volt DC Electric
* - in units from the factory
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.
Recommended Battery....................70 Ah, 360 Cold-cranking
Amps (Minimum ratings)
Maximum Cranking Current ....................................220 Amps
Ground Polarity ............................................................Negative
1.5.4 COOLANT
N
Use a 50:50 mixture that is 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 rec-
ommended coolant mixture. When adding coolant,
always add the recommended 50-50 mixture.
1.5.6 GENERATOR
N
Rated Maximum Continuous AC Output at ...
85º F (29º C) Ambient..........................6,500 Watts (6.5 kW)
Rated Voltage ......................................................230 Volts AC*
Rated Maximum Continuous AC Current at ...
6,500 Watts
Do not remove the radiator pressure cap while
the engine is hot; otherwise, serious burns
from boiling liquid or steam could result.
230 Volts........................................................28.2 Amps
Phase ................................................................................Single
Rotor Speed at No Load ..........................................3,150 rpm
Number of Rotor Poles ............................................................2
Engine RPM ......................................................................1,950
Rated AC Frequency ........................................................50 Hz
Battery Charge Voltage............................................14 Volts DC
Battery Charge Current ......................................2 Amps (max)
Weight......................................................................486 Pounds
Length ....................................................36.6 inches (929 mm)
Width......................................................23.8 inches (604 mm)
Height ....................................................22.3 inches (567 mm)
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.
Do not use any chromate base rust inhibitor
with ethylene glycol base antifreeze; or else,
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 eth-
ylene glycol base antifreeze. Using any high-sil-
icate antifreeze boosters or additives will also
cause overheating. We also recommend that
you DO NOT use any soluble oil inhibitor for
this equipment.
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Section 2 – Operation
QUIETPACT™ 65D Recreational Vehicle Generator
2.1.4 LINE BREAKER
N
2.1 GENERATOR CONTROL PANEL
The following features are mounted on the generator
control panel (Figure 2.1):
The line (i.e., main) breaker protects the generator’s
AC output circuit against overload and provides a
method of turning OFF the generator’s 230-volt AC
output to the vehicle circuits. The QUIETPACT™ 65D
has two 30-amp breakers.
Figure 2.1 – Generator Control Panel
NOTE:
Refer to Section 1.4, “Generator AC Connection
System,” (Page 5). Individual installations will dif-
fer. If an overload occurs, the dual breakers will
open the ungrounded (i.e., hot) stator leads (11
and 44 in Figure 1.1, Page 5).
2.1.5 PREHEAT SWITCH
N
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,
allowing 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
that can be interfaced with an optional remote panel
provided inside the vehicle. This option allows you to
start and stop the generator conveniently from with-
in the vehicle. Refer to Part II - Installation
Instructions, Section 2.8, for details on the remote
start/stop option.
2.1.1 HOURMETER
N
This indicates the length of 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
N
2.3 BEFORE STARTING THE ENGINE
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 and hold
the switch in the STOP position until the engine shuts
off. The switch’s center position is the RUN position.
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.
2.1.3 FUSE
N
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 (i.e., SFE-14).
2.3.1 INSTALLATION
N
Generator installation must have been properly com-
pleted so that it complies with all applicable codes,
standards, and regulations and with the manufactur-
er's recommendations.
If a fuse element melts, you should find the
cause of the overload before replacing the fuse.
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Section 2 – Operation
QUIETPACT™ 65D Recreational Vehicle Generator
2.3.2 ENGINE LUBRICATION
N
Before starting the engine, have the engine crankcase
properly serviced with the recommended oil. Refer to
Section 1.5.3 (Page 6) and Sections 3.1 and 3.2 (Page
12) for oil servicing procedures and recommenda-
tions.
The generator engine releases DEADLY carbon
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concen-
trations, 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. SYMPTOMS OF CARBON MONOX-
IDE POISONING ARE (a) inability to think coher-
ently, (b) vomiting, (c) twitching muscles, (d)
throbbing temples, (e) dizziness, (f) headaches,
(g) weakness, and (h) sleepiness. IF YOU FEEL
ANY OF THESE SYMPTOMS, MOVE INTO FRESH
AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP.
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
N
The engine must have an adequate supply of proper
fuel to operate. Before starting it, check that sufficient
fuel is available.
NOTE:
2.4 STARTING THE GENERATOR
Depending on the installation, the generator may
have either a separate fuel tank or “share” the
vehicle’s engine fuel tank.
NOTE:
Some installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter
than the vehicle’s engine pickup tube. Such an
arrangement causes the generator engine to “run
out of fuel”, while adequate fuel for the vehicle
engine remains in the tank.
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.
2.3.4 COOLANT LEVEL
N
Check the engine coolant level prior to initial use and
at recommended intervals. Refer to Section 1.5.4,
“Coolant” (Page 6), and Section 3.8, “Engine Coolant”
(Page 14), for procedures and recommendations.
To start the generator from either the generator con-
trol panel or from the optional remote panel, proceed
as follows:
2.3.5 COOLING AND VENTILATING AIR
N
1. Turn OFF electrical loads using the means pro-
vided in your vehicle (such as, a main-line circuit
breaker or transfer switch).
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, causing engine shutdown and damage to
the generator.
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
circuit breaker). Electrical load circuits will be
turned ON, after the generator has started, stabi-
lized, and warmed up.
2.3.6 ENGINE EXHAUST GAS
N
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.
2. If the engine is cold, press the Preheat switch for
a maximum of 15 to 30 seconds.
3. While pressing the Preheat switch to crank the
engine, hold the engine Start/Stop switch in the
START position. When the engine starts, release
the switches.
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Section 2 – Operation
QUIETPACT™ 65D Recreational Vehicle Generator
2.6.2 DO NOT OVERLOAD THE GENERATOR
N
You can read the rated wattage/amperage capacity of
your generator on the generator data decal located
below the user control panel.
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.
Applying electrical loads in excess of the unit’s rated
capacity may trip the line breaker or cause the
engine/generator to shut down.
4. Let the engine run 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).
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
indicate 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, multiply
that load’s rated VOLTS times AMPS to obtain
WATTS.
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 the generator run at no-load for a few minutes,
to stabilize internal engine generator temperatures.
• 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, cal-
culate 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 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, until the engine shuts off.
2.6 APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator,
observe these guidelines:
• For the first two or three hours of operation, do not
apply electrical loads over 75 percent of the unit’s
rating.
• Before applying electrical loads, let the generator
stabilize and warm up for a minute or two.
• DO NOT overload the generator.
2.7 PROTECTION SYSTEMS
The engine has several safety switches that cause
it to automatically shut down, under the following
conditions: low oil pressure, high coolant tempera-
ture, and engine overspeed. See Figure 2.2 (Page 10)
for the location of these devices. If automatic shut-
down does occur, refer to “Troubleshooting Guide”,
on page 37.
2.6.1 LETTING THE ENGINE STABILIZE
N
The generator supplies correctly rated voltage only at
the proper governed speed. Some electrical appli-
ances may be extremely sensitive to voltage. Incorrect
voltages can damage such appliances.
Electrical loads applied on the engine at reduced
operating speeds, such loads imposed on the engine,
when sufficient 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.
2.7.1 LOW OIL PRESSURE SWITCH
N
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
N
This normally-open (N.O.) thermostatic switch has a
sensing tip that is immersed in captive coolant.
Should the coolant temperature exceed approximate-
ly 115° C (240° F), the switch contacts close, and the
engine shuts down automatically.
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Section 2 – Operation
QUIETPACT™ 65D Recreational Vehicle Generator
The voltage regulator also incorporates a “voltage
Figure 2.2 – Engine Protective Devices
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
N
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 pis-
ton rings, resulting in blowby and high oil con-
sumption.
• Check the engine oil level frequently. Add oil if
needed. It is normal for the generator engine to
consume more oil than normally, until the piston
rings have properly seated.
2.7.3 OVERSPEED SHUTDOWN
N
A DC control circuit board senses engine speed from
the frequency of the alternator AC output. Should the
alternator output frequency exceed approximately 60
Hertz (3,600 alternator rpm), circuit board action
initiates an automatic engine shutdown.
2.7.4 OVERVOLTAGE PROTECTION
N
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 50 Hertz, voltage is regulated at
230 volts.
2.8.2 25-HOUR CHECK-UP
N
After the 25-hour break-in period, contact a Generac
Authorized Service Dealer for the following mainte-
nance, for which 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).
Figure 2.3 – Solid-state Voltage Regulator
• Visually inspect the unit for any leaks or loose
hardware.
• Inspect the exhaust tailpipe for any leaks or
damage.
2.8.3 ATTENTION REQUIRED
N
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.
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Section 3 – Maintenance
QUIETPACT™ 65D Recreational Vehicle Generator
Figure 3.1 – Oil Maintenance Features
2.8.4 OPERATION IN HIGH GRASS
OR BRUSH
N
Never operate the generator while the vehicle is
parked over high grass, weeds, brush, leaves, or
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.
OIL FILL
OPENING AND PLUG
OIL DIPSTICK
(PANEL TRANSPARENT
FOR VIEWING PURPOSES.
SERVICE THROUGH FRONT
SERVICE DOOR.)
OIL
FILTER
2.8.5 EFFECTS OF MOISTURE AND DIRT
N
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
windings.
OIL DRAIN
PLUG
LATCHES
FRONT SERVICE
DOOR
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 reduces insu-
lation resistance and will eventually cause problems.
Dirt will make the problem worse, since it tends to
hold moisture in contact with windings. Salt (as from
sea air) will also worsen the problem, since it tends
to absorb moisture from the air. Salt and moisture,
when combined, form a good electrical conductor.
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.
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):
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
(for 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.
1. Be sure the generator is as leveled 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.
4. If necessary, remove the oil fill plug and slowly
add oil until it reaches the dipstick “FULL” mark.
DO NOT FILL ABOVE THE “FULL” MARK.
5. After the oil has drained, replace the oil-drain
plug.
Go to step 9 if changing oil only.
Never operate the engine with the oil level
below the “ADD” mark on the dipstick. Doing
this could damage the engine.
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.
5. Install the oil-fill plug and the dipstick before
operating the engine.
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Section 3 – Maintenance
QUIETPACT™ 65D Recreational Vehicle Generator
9. Remove the dipstick, and wipe it dry with a clean,
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):
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 1.5.3, Page 6). Periodically use the dip-
stick 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.
1. Place the unit above a noncombustable surface,
and ensure that the generator exhaust piping 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.
11. Install the oil-fill plug and the dipstick.
12. Reinstall the air filter.
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.
13. Reattach the front service door; make sure the
latches are fully engaged.
14. Start the engine, and check for leaks.
NOTE:
6. Start and run the engine for approximately 15
minutes.
Check the oil level and fill to the “FULL” mark,
after checking for leaks. The filter will retain some
oil.
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.
3.3 SERVICING THE ENGINE
AIR FILTER
10. Reinstall the hex pipe cap, spark arrestor access
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 service
door. Make sure the service door latches are fully
engaged.
plate, gasket, and two screws.
The exhaust system of this product gets extreme-
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.
Figure 3.2 – Engine Air Filter
Failure to provide and maintain a spark arrestor
may be in violation of the law. If this generator
is used on any forest-covered, brush-covered,
or grass-covered unimproved land, the vehicle
owner or operator must maintain the spark
arrestor in good condition. In the state of
California, the preceding is required by law
(Section 4442 of the California Public Resources
Code). Other states may have similar laws.
Federal laws apply on federal lands.
Be sure to reinstall the hex pipe cap tightly to the
spark arrestor cleanout pipe. Vibration could cause
a loose cap to fall out, resulting in hot engine
exhaust being drawn through the centrifugal cool-
ing fan and out beneath the unit. This could result
in damage to the generator or in discharge of hot
exhaust sparks beneath the unit.
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™
65D is a spark arrestor type. Generac exhaust muf-
flers for recreational vehicle generators do not have a
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Section 3 – Maintenance
QUIETPACT™ 65D Recreational Vehicle Generator
• Check the battery fluid level of unsealed batteries
Figure 3.3 – Spark Arrestor
Muffler Maintenance
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 knowledgeable personnel, accord-
ing to the required precautions. Keep unautho-
rized personnel away from batteries.
3/8" NPT HEX
PIPE CAP
Damage will result if the battery connections are
made in reverse.
GASKET
ACCESS PLATE
Do not dispose of the battery in a fire. The
battery is capable of exploding. Storage batter-
ies release explosive hydrogen gas. This gas can
form an explosive mixture around the battery
for several hours after charging. The slightest
spark can ignite the gas and cause an explo-
sion. 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 tool or equip-
ment near the battery. Discharge static electrici-
ty from your body before touching the battery
by first touching a grounded metal surface.
3.5 CLEANING THE GENERATOR
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.
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 generator is
housed inside an all-weather enclosure; clean the
enclosure with a soft, damp cloth or with sponge and
water.
A battery presents a risk of electrical shock and
high short-circuit current. The following precau-
tions are to be observed when working on bat-
teries:
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 con-
sole should be cleaned and inspected at this time, as
well.
• Remove watches, rings, and 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;
Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.
• Disconnect any charging source prior to connect-
ing, or disconnecting, battery terminals; and
• Do not use any jumper cables or booster battery
to crank and start the generator engine. If any bat-
tery has discharged, remove it for recharging.
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.
3.6 BATTERY MAINTENANCE
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
the skin and eyes, and to be toxic.
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:
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following
procedures are to be observed:
• Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
• Wear full eye protection and protective clothing;
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Section 3 – Maintenance
QUIETPACT™ 65D Recreational Vehicle Generator
• 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.
Do not use any chromate base rust inhibitor
with ethylene glycol base antifreeze; other-
wise, 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 addi-
tives will also cause overheating. We also rec-
ommend that you DO NOT use any soluble oil
inhibitor for this equipment.
• 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
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.
Air intake and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. Avoid obstructions, such as,
high grass, weeds, brush, leaves, and snow.
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down.
3.10 DRIVE BELT
The engine drives the generator rotor by means of a
pulley and drive belt arrangement. Drive belt tension
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.
3.8 ENGINE COOLANT
Check the coolant level in the coolant recovery tank
at least once daily or prior to use. Add the recom-
mended coolant mixture (see Section 1.5.4, Page 6),
as necessary; the tank should be kept within the lev-
els indicated on the adjacent decal. 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.
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.
Periodically remove the radiator pressure cap, locat-
ed behind the access cover above the user control
panel, to make sure the coolant recovery system is
functioning properly. Coolant should be at the bottom
of the radiator 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
Dealer. Inspect both the cooling system and coolant
recovery system for leaks.
3.12 OUT-OF-SERVICE PROCEDURE
3.12.1 REMOVAL FROM SERVICE
N
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 (see Section 3.2, Page
12). Refill the crankcase with the recommended
oil (see Section 1.5.3, Page 6).
Do not remove the radiator pressure cap while
the engine is hot; otherwise, serious burns
from boiling liquid or steam could result.
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.
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.
5. Clean and wipe the entire generator.
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Section 3 – Maintenance
QUIETPACT™ 65D Recreational Vehicle Generator
3.12.2 RETURN TO SERVICE
N
To return the unit to service after storage, proceed
as follows:
1. Check the tag on the engine for oil viscosity and
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 dis-
tilled water. DO NOT USE TAP WATER IN THE
BATTERY. Recharge the battery to 100 percent
state of charge, or, if defective, replace the battery.
3. Clean and wipe the entire generator.
4. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected
incorrectly.
5. Turn OFF all electrical loads. Add fuel, if neces-
sary, and then start the engine.
6. Allow the unit to warm up thoroughly.
7. Apply electrical loads to at least 50 percent of the
unit’s rated wattage capacity.
8. When the engine is thoroughly warmed up, shut
it down.
9. Your generator is now ready for service.
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Section 3 – Maintenance
QUIETPACT™ 65D 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
FREQUENCY
X = Action
Inspect
Change
Clean
D = Daily
M = Monthly
H = Hours
W = Weekly
Y = Yearly
R = Replace/Adjust as Needed
* = To Be Completed by a
Generac Authorized
Service Dealer.
FUEL
Fuel level
X
X
AFTER 25-H BREAK-IN,
D / BEFORE USE
AFTER 25-H BREAK-IN,
EVERY 250 H / 6 M
Fuel lines and connections*
Fuel Filter*
LUBRICATION
Oil level
X
EVERY 250 H / 6 M
X
EVERY 8 H / D
Oil
X
X
AFTER 25-H BREAK-IN,
EVERY 250 H / 6 M
AFTER 25-H BREAK-IN,
EVERY 250 H / 6 M
Oil Filter
Oil line leakage*
COOLING
X
EVERY 100 H
Engine cooling system*
X
X
AFTER 25-H BREAK-IN,
EVERY 100 H / M
AFTER 25-H BREAK-IN,
D / BEFORE USE
Coolant level
Coolant*
X
EVERY 500 H / Y
Enclosure louvers
EXHAUST
X
X
EVERY 250 H / 6 M
Exhaust system
X
X
EVERY 100 H / M
EVERY 750 H
EVERY 150 H/Y
Retorque Exhaust Manifold*
Clean out Muffler/Spark Arrestor
BATTERY
Electrolyte fluid level
Charge and condition
FAN/ALTERNATOR BELTS
Tension and condition*
ENGINE
X
X
X
X
AFTER 25-H BREAK-IN, W
W, EVERY 250 H / 6 M
R
R
X
EVERY 750 H
Retorque cylinder head*
Retorque intake manifold*
Starter motor*
Air filter
Compression*
Valve clearance*
Governor*
Safety devices*
Injection system*
GENERAL
X
X
X
X
X
X
X
X
X
EVERY 750 H
EVERY 750 H
EVERY 750 H
EVERY 500 H
EVERY 750 H
EVERY 750 H
EVERY 750 H
EVERY 750 H
EVERY 750 H
R
R
R
R
R
Overall condition
Exercise system
COMPLETE TUNE-UP*
X
X
X
X
AFTER 25-H BREAK-IN, W
W
Y
X
®
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PART II –
INSTALLATION
INSTRUCTIONS
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
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Safety Rules
QUIETPACT™ 65D Recreational Vehicle Generator
DANGER: For fire safety, installation of a generator into a recreational vehicle must comply
strictly with NFPA 70 (latest edition), “National Electrical Code”, Article 551, and NFPA 1192
(latest edition), “Standard for Recreational Vehicles”. In addition, installation must comply with
the manufacturer’s instructions and recommendations.
NOTICE TO INSTALLER
GENERAL HAZARDS
These Installation Instructions have been published
by Generac to aid in the installation of the products
• For safety reasons, Generac recommends
that the installation, initial startup, and mainte-
nance of this equipment is carried out by a
Generac Authorized Service Dealer.
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.
• 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.
Generac cannot possibly know of, nor 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 prod-
uct's safety are not endangered by the method, pro-
cedure, or technique selected.
• 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.
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 are both accurate and current. However,
the manufacturer reserves the right to change, alter,
or otherwise improve this product at any time, with-
out prior notice.
• 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 startup. First, disconnect the cable from the
battery post, indicated by a NEGATIVE, NEG, or
(–). 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.
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
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
®
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Safety Rules
QUIETPACT™ 65D Recreational Vehicle Generator
ELECTRICAL HAZARDS
FIRE HAZARDS
• The generator covered by this manual produces
dangerous electrical voltages that 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 barri-
ers 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.
• 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.
• 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 vehi-
cle’s circuits at the same time. The dockside (utility)
power source must be positively isolated from the
vehicle’s circuits whenever the generator is operat-
ing. Failure to isolate the vehicle’s circuits from the
dockside power supply when the generator is run-
ning may result in damage to the generator or in
serious injury or death to dockside (utility) power
workers due to backfeed of electrical energy.
• In case of an 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
immediate medical help.
EXPLOSION HAZARDS
• 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 han-
dling of fuels.
• Fuel supply lines 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 line between the generator fuel
connection point and the rigid fuel lines.
• 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.
®
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Section 1 – General Information
QUIETPACT™ 65D Recreational Vehicle Generator
5. CSA Electrical Bulletin 946, available from the
1.1 PURPOSE AND SCOPE
Canadian Standards Association, Housing and
Constructions Materials Section, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada, M9W 1R3.
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 manual, both for safety and for continued reliable
operation of the equipment.
1.4 EQUIPMENT DESCRIPTION
Instructions and information in this section pertain to
Generac liquid-cooled generators, designed specifically
for installing in recreational vehicles. The QUIET-
PACT™ 65D operates 230-volt, single-phase, 50-Hertz,
AC electrical loads that require up to 28.2 amps at 230
volts.
Because of the different recreational vehicle models
and the variations between the models, it would be
extremely difficult, if not impractical, to provide
detailed instructions for every possible installation.
For that reason, instructions and illustrations in this
manual are general in nature. Illustrations are not
intended to serve as detailed installation blueprints.
1.5 GENERATOR ENGINE
OPERATING SPEED
The generator’s two-pole revolving field (rotor) is dri-
ven by a three-cylinder, 1.0-liter diesel engine. The
generator supplies 230 volts AC at 50 Hertz, when
the rotor is operating at 3,000 rpm. Engine speed is
held nearly constant by a mechanical, fixed speed
governor at 1,950 rpm.
The installation should comply strictly with all
applicable codes, standards, and regulations pertain-
ing to the installation and use of this product. If any
portion of this manual appears to be in conflict with
such codes, standards, or regulations, the applicable
codes, standards, or regulations must take prece-
dence over the manual.
1.6 GENERATOR AC
CONNECTION SYSTEM
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. Note,
however, that the neutral is grounded.
1.2 SAFETY
Before handling, installing, operating, or servicing
this equipment, carefully read the “Notice to
Installer” and “Safety Rules” on Pages 18 and 19.
Comply with all safety rules to prevent death, per-
sonal injury, or damage to equipment and/or proper-
ty. Stress safety to all installers, operators, and ser-
vice technicians who work on this equipment.
Figure 1.1 – Connections for 230 Volts Only
1.3 STANDARDS BOOKLETS
Installation, use, and servicing of this equipment
should comply strictly with published standards, as
well as the manufacturer's recommendations. The
following standards booklets (latest revision) are
available from the sources indicated:
1. NFPA 1192, “Standard for Recreational Vehicles”
(replaces ANSI A119.2/NFPA 501C), available
from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
2. NFPA 70, “NFPA Handbook of the National
Electric Code,” available same as Item 1.
3. ANSI/RVIA EGS-1, “Engine Generator Sets for
Recreational Vehicle Safety Requirements”, ava-
ialable from the Recreational Vehicle Industry
Association, 1896 Preston White Drive, Reston,
VA 22090.
NOTE:
Do NOT connect loads in excess of circuit
breaker ratings.
4. California Administrative Code, Title 25, avail-
able from the State of California, Documents
Section, P.O. Box 1015, North Highlands,
CA 95660.
®
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Section 1 – General Information
QUIETPACT™ 65D Recreational Vehicle Generator
Major Features and Dimensions — Drawing No. D2650-A
Figure 1.2 – Major Features and Dimensions
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
• Whether the generator is mounted above the hori-
2.1 LOCATION AND SUPPORT
zontal support tubing or suspended below the tub-
ing, the supporting frame used must be structural-
ly sound.
2.1.1 GENERATOR LOCATION
N
The most desirable location for the generator set is
between the vehicle's main frame members.
• If the generator cannot be bolted directly to
the supporting frame or support tubing, consider
using
additional
tubing,
angle
brackets
Many recreational vehicles have been factory-
equipped with an area for the generator set. Some
may even have a generator compartment provided by
the vehicle manufacturer.
or other supports to give the supporting frame suf-
ficient strength.
2.1.3 SUSPENDED MOUNTING
N
Plan the generator location based on the following:
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 typ-
ical suspended mounting system is shown in Figure
2.1. The location of a suspended mounting system
must be carefully planned, keeping the following gen-
eral rules in mind:
• The generator set must be installed on a frame-
work that is part of the recreational vehicle, as out-
lined in Section 2.1.2.
• The location must provide an access opening that
is large enough to permit generator removal
(unless the generator is to be removed from under-
neath the supporting framework).
• The location must provide easy access to frequent-
ly serviced components, such as, filters, oil drains,
and other common maintenance parts.
• The location must provide sufficient room to
allow minimum clearances for air circulation. If
sound insulation is to be used on the compart-
ment walls and ceiling, the minimum recom-
mended clearance applies to the space between
the generator and such insulation.
• Protect the generator against road splash and debris.
Baffles or splash guards may be required to protect
certain areas of the generator. To make sure the gen-
erator is adequately protected, road-test the installa-
tion through mud, water, and slush.
Figure 2.1 – Typical Suspended Mounting System
• The location must provide adequate cooling and
ventilating airflow for the generator, without a great
deal of work and expense.
2.1.2 GENERATOR SUPPORT
N
The generator must be securely attached to a metal
framework that has been affixed to the vehicle frame
structure by bolting or welding. The metal framework
on which the generator will rest, and which will restrain
the generator set, should consist of at least two hori-
zontal beams. These beams should consist of (a) 1-1/2-
inch square, 11-gauge steel tubing OR (b) 1-1/2-inch,
11-gauge angle iron.
The generator can be installed so that it sits on top of
the horizontal support tubing, if the vehicle design
permits. Another method is to suspend the generator
below the horizontal support tubing by means of suit-
able, structurally-sound metal framework. The fol-
lowing general rules apply:
• The installer must make certain that the selected
location will permit adequate cooling and ventilat-
ing airflow.
• Vehicle construction MUST be capable of support-
ing the weight of the generator.
®
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
Figure 2.3 – Typical Compartment Construction
2.1.4 GENERATOR RESTRAINT
N
Use four 3/8"-16 hardened steel bolts (Grade 5) to fas-
ten the generator to the supporting frame or the sup-
port tubing. These bolts must pass through (a) the gen-
erator mounting base, (b) the compartment floor (if a
compartment is used), and (c) the supporting frame-
work (Figure 2.2). All bolts must be long enough so
that, when tight, they engage at least 3/8” of an inch [9.5
millimeters]. Refer to Section 2.2 for the location of the
generator mounting holes.
Figure 2.2 – Typical Generator Restraint
• If constructing a compartment, line the exterior
(underside) of the compartment floor with 26-
gauge galvanized steel.
• All seams, splices, and joints of the compartment
walls (unless vapor-tight by design) should
be caulked to prevent poisonous, flammable, or
explosive vapors from entering the vehicle interior.
NOTE:
2.2 GENERATOR COMPARTMENTS
Whether the generator set is being installed inside a
compartment specifically manufactured to house a gen-
erator or inside a compartment that the installer con-
structs, the compartment MUST meet certain specifi-
cations, as outlined in the following sections:
Caulking must be done so that the caulking materi-
al will stay in place permanently. Pressing materials
such as, putty tape, onto joints and seams is NOT
acceptable. A high-quality silicone rubber base
sealant is recommended.
2.2.1 COMPARTMENT CONSTRUCTION
N
• 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 a flexible metal conduit is used, it must be sealed
internally at the end, where it terminates inside
the compartment’s electrical junction box.
NOTE:
• The generator compartment should be either
constructed of, or lined with, 26-gauge galva-
nized steel.
NOTE:
Aluminum is NOT an acceptable alternative
to galvanized steel due to aluminum’s low
melting point.
• If the compartment is lined with galvanized steel, it
may be constructed of any material. Generac rec-
ommends that the compartment be constructed of
1/2-inch thick plywood (not strandboard), with the
floor made of a double thickness of 1/2-inch ply-
wood, having the grain of the wood at cross section
for added strength (Figure 2.3).
Flexible metal conduit, due to its unique con-
struction, is NOT vapor-tight along its entire
length.
®
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
• 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 2.4. Installer-constructed compartments
typically utilize a standard lap joint.
Do not install sound insulation or any
absorbent material on the compartment floor
interior. Such materials will become soaked
with combustible or explosive vapors and
liquids and will become a fire hazard.
Figure 2.4 – Types of Lock Seams
Using a combination of sound-insulating materials
can often reduce noise more effectively than a sin-
gle material. For example, a sheet of lead or visco-
elastic material, along with a layer of other acousti-
cal material, is more effective than when a single
material is used.
2.2.3 ACOUSTICS
N
For additional noise abatement, the installer may
wish to consider the following:
• Using special sound-insulating materials.
• Construction of a special noise abatement
compartment.
NOTE:
• 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 2.2.2.
Any method used to reduce noise must not
adversely affect the flow of cooling and ventilating
air into, or out of, the compartment.
In addition to the effective use of sound insulating
materials, construction of a special noise abatement
compartment might be considered to reduce noise
levels. Such a compartment might be constructed as
follows (Figure 2.5, Page 25):
Do not install any flammable material directly
above or around the compartment. Heat,
transferred through the compartment structure,
may be sufficient to ignite, char, or discolor
seat cushions, fiberboard, and other flammable
materials. You may need to use approved,
nonflammable insulating materials in high
temperature areas.
• Use 5/8-inch thick or 3/4-inch thick plywood in the
compartment.
• Construct the compartment floor of a double thick-
ness of 5/8-inch or 3/4-inch plywood.
• Line the compartment’s interior walls and floor, as
well as the underside of the floor, with 26-gauge
galvanized steel.
• Vapor-seal all compartment seams and joints.
• Over the galvanized steel lining, install a combina-
tion of acoustical materials, as mentioned in
Section 2.2.2.
2.2.2 SOUND INSULATING MATERIALS
N
Once installers have determined that a compartment
is properly constructed and metal-lined, they can add
acoustical material. This may include additional
sealant or insulating material, to reflect noise away
from the vehicle interior.
Sound insulating materials should be of a nonflam-
mable type. One excellent insulating material is a 1-
inch (25 mm) thick fiberglass having a 2-pound den-
sity. When fiberglass is used, its coated side should
face toward the compartment interior.
To prevent fire or explosion, do not install any
insulation, or other absorbent materials, on the
interior or underside of the compartment floor.
• Seal all compartment door edges to prevent noise
leakage around the door perimeter.
• 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).
®
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
Figure 2.5 – Typical Noise Abatement
2.2.4 COMPARTMENT FLOOR CUTOUTS
N
You must provide openings in the generator compart-
ment for the following items (Figure 2.6):
• Engine exhaust and cooling air outlets
• Generator cooling air inlet and front service door
• Four holes for passage of generator mounting
bolts. See Section 2.1.4 (Page 23)
• Rear service door.
Fuel lines and exhaust piping must not pene-
trate into the vehicle living area.
Figure 2.6 – Compartment Floor Cutout
®
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
2.3.2 COOLING AIR INLET OPENINGS
N
2.3 COOLING AND VENTILATING AIR
It is absolutely essential that an adequate flow of air
for cooling, ventilation, and engine combustion be
supplied to the generator set. Without sufficient air-
flow, the engine/generator quickly overheats. Such
overheating can cause serious operating difficulties
and also may cause fire and personal injury. The
installer must make sure that sufficient air is avail-
able to the generator for cooling, ventilating, and
combustion. The installer also must provide a path
for exhausting the cooling air to the exterior of a com-
partment, if so equipped.
The minimum size of the air inlet opening, whether
the generator is housed in a conventional compart-
ment or not, is at least 150 square inches
2
(975 cm ) (see Figure 2.8). This rule applies whether
inlet air is brought in through an opening in the com-
partment door, an opening in the vehicle skirt,
through ductwork, or by any other means.
NOTE:
Screening, louvers, or expanded metal that cover air
openings restrict airflow. You must compensate for
this by making the actual air opening proportion-
ately larger. See Section 2.3.3 (Page 27).
Never use discharged cooling air for heating or
permit such air to enter the vehicle interior. This
air contains deadly carbon monoxide gas and
other poisonous, flammable, or explosive gases.
Figure 2.8 – Air Inlet in Compartment Door
2.3.1 GENERATOR AIRFLOW
N
This unit uses an impellar fan located on the alterna-
tor drive pulley to cool the alternator’s internal com-
ponents. Air is drawn through the alternator and
expelled radially behind the drive pulley. An engine-
driven centrifugal blower draws in cooling air
through air inlet openings, moves that air around the
engine/generator and across the radiator, then dis-
charges that air out the bottom (see Figure 2.7).
Figure 2.7 – Airflow Through Engine/Generator
When the unit is installed on a suspended mounting
system, one of several different methods of supplying
airflow may be used as follows:
• Provide a door in the vehicle skirt having an air
inlet opening (Figure 2.9).
Figure 2.9 – Suspended Mount: Inlet Door
• Use ductwork (Figure 2.10, Page 27). The installer
must be sure air is available to the sides of the gen-
erator for proper air intake.
• Provide an opening in the vehicle skirt and space
around the generator for cooling airflow (Figure
2.11, Page 27). Recommended clearance around
all sides of the generator is at least 2 inches (50
mm).
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
Figure 2.10 – Air Inlet Using Ductwork
2.3.4 TESTING THE INSTALLATION
N
Generac recommends testing the installation to be
sure adequate cooling airflow is available to the
unit, before placing the unit into service. If the unit
shows signs of overheating, you will need to
enlarge the air openings. Never place a unit into
service until absolutely certain that cooling and
ventilation is adequate.
NOTE:
You must test the installation, especially if you
bring in air from below the generator set.
Figure 2.11 – Air Inlet in Vehicle Skirt
2.4 DIESEL FUEL SYSTEM
The installation of a diesel fuel system (Figure 2.12)
for a recreational vehicle generator set must comply
with applicable codes, standards, and regulations.
The entire fuel system must be completely free of
leaks. There must be no possibility of fuel vapors
entering the vehicle interior.
Figure 2.12 – Generator Fuel System
2.3.3 COMPENSATING FOR RESTRICTIONS
N
Materials, such as, screening, louvers, or expanded
metal, can restrict the free flow of air. Compensate for
this restriction by making the actual air opening pro-
portionately larger.
Some materials may offer only a 60 percent “free air
inlet area.” Other more efficient materials may pro-
vide up to a 90 percent free air inlet area. The per-
centage of free air inlet opening is usually available
from the material’s supplier or manufacturer.
To determine the actual air inlet opening size
2
required, divide 150 square inches (975 cm )by
the percentage of free air inlet area for the mater-
ial you will use.
For example: If you plan to use screening with an 80
percent free air inlet area, divide 150 (975) by 0.8,
2
which results in 187.5 square inches (1,218.75 cm ).
All fuel types are potentially FLAMMABLE
and/or EXPLOSIVE and should be handled
with care. Comply with all laws regulating the
storage and handling of fuels. Properly install
and maintain the fuel system, and keep it
entirely free of leaks. Fuel vapors must
not enter the vehicle interior.
Minimum actual size of air inlet opening in this case is
2
187.5 square inches (1,218.75 cm ).
®
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
Because diesel fuels are less volatile than gasoline or
2.4.2 GENERATOR FUEL SUPPLY LINES
N
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. For
example, a poorly tightened fuel line may not show any
signs of leakage; however, air can be drawn into the
loose connection and cause problems. Air that is
trapped in the diesel fuel system results in hard start-
ing and rough engine operation.
2.4.2.1 Rigid Fuel Lines
Those lines used to supply fuel from a tank to the
generator must comply with applicable codes, stan-
dards, and regulations. The following general rules
apply to rigid fuel lines:
• Rigid lines should be of annealed, seamless, drawn
aluminum, or steel.
• Lines and fittings must comply with SAE J512F,
“Standard Automotive Fittings,” or with ANSI
B126.26 (latest edition).
• Route the fuel line so that at least 2 inches (51 mm)
of clearance is maintained between the line and
any exhaust system parts.
• Do not attach electrical wiring to fuel lines. Route
the wiring so it cannot come into contact with any
fuel line.
• Route fuel lines so that, if they leak, fuel does not
drip onto any electrical or exhaust system parts.
• Use nonferrous metal straps without sharp edges
to secure fuel lines.
Dirt that enters the fuel system also may cause prob-
lems. Lines and piping must be properly installed
and tightened to prevent dirt from entering. Diesel
fuel must be kept clean.
Factory-installed generator fuel system components
include (a) a fuel filter, (b) a 12-volt DC electric pump,
(c) an injection pump, and (d) interconnecting lines
and fittings. Connect a fuel supply line to the supply
fitting and a return line from the fuel return fitting
back to the tank.
NOTE:
Fuel supply and return fittings located on the gen-
erator are 1/8” NPT.
• Fuel system components must be accessible, but
protected from abrasion, chafing, road damage,
and kinking.
Use a length of approved flexible fuel hose between
the fuel connection fittings and rigid fuel lines (see
Sections 2.4.2 and 2.4.3).
2.4.2.2 Flexible Fuel Line
Use a length of approved flexible fuel hose between
the generator fuel supply fitting and rigid fuel lines.
This prevents breaking of the line caused by vibra-
tion, shifting, settling, or movement. The following
rules apply:
2.4.1 FUEL TANK
N
Either the generator must share the vehicle’s
engine fuel tank, or you must 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 regulations.
• The flexible hose must comply with SAE J30B,
“Standard for Fuel and Oil Hose.” It must be
approved for use with diesel fuel.
• The hose should be at least 6 inches (152 mm)
longer than is needed, to prevent the hose from
rupturing if the generator shifts or settles.
If the generator is to share the vehicle’s engine
tank, separate fuel pickup tubes are required for
the engine and the generator. Generac recommends
that you make the fuel pickup tube 2 to 3 inches
(51 to 76 mm) shorter than the vehicle’s engine
pickup tube. This prevents the generator from
depleting the entire fuel supply during prolonged
generator operating periods.
2.4.3 GENERATOR FUEL RETURN LINES
N
The same general rules that apply to fuel supply lines
also apply to fuel return lines.
NOTE:
Locate the diesel fuel return line at least 12 inches
from the tank fuel pickup tubes to prevent air bub-
bles from entering the fuel supply lines.
Do NOT tee the generator fuel supply line into
the vehicle engine fuel supply line. If this is
done, the generator will be starved of fuel
when both engines are operating at the same
time. Also, while the vehicle engine is not run-
ning, generator operation may drain the vehi-
cle engine supply line, making it difficult to
start the vehicle engine.
®
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
2.5.2 EXHAUST SYSTEM SAFETY
N
2.5 EXHAUST SYSTEM
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.
• Maintain a clearance of at least 3 inches (76 mm)
between exhaust system parts and any com-
bustible material (such as, wood, felt, cotton,
organic fibers, or other like material). If you can-
not maintain the 3-inch (76 mm) clearance, locate,
insulate, or shield the exhaust part(s) so that the
temperature of any combustible material is not
raised to more than 117° F (65° C) above the
ambient air temperature.
• Terminate the exhaust tailpipe at least 3 feet (91
cm) from the vehicle’s fuel filler cap and at least
2 inches (51 mm) past the outer edge of the vehi-
cle. Do not terminate the exhaust system under
the vehicle.
The generator engine gives off DEADLY carbon
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concen-
trations, 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. SYMPTOMS OF CARBON MONOX-
IDE POISONING ARE (a) inability to think coher-
ently, (b) vomiting, (c) twitching muscles, (d)
throbbing temples, (e) dizziness, (f) headaches,
(g) weakness, and (h) sleepiness. IF YOU FEEL
ANY OF THESE SYMPTOMS, MOVE INTO FRESH
AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP. Do not operate the generator
until its exhaust system has been inspected and
properly repaired.
• Terminate the exhaust tailpipe such that exhaust
gases will not be drawn back into the generator
compartment and recirculated.
• Fuel and oil must NOT be able to drip onto any
exhaust system part.
Figure 2.13 – Typical Exhaust System
Never tee the generator engine exhaust pipe
into the vehicle engine exhaust piping. This
causes excessive back pressure on the genera-
tor engine. Also, water from one engine can
damage the other engine.
2.5.1 MUFFLER AND SPARK ARRESTOR
N
MUFFLER PERMANENTLY
MOUNTED INSIDE
ENCLOSURE
The exhaust muffler supplied with the QUIETPACT ™
65D is a spark arrestor type that meets code and
standard requirements of the U.S. Forest Service.
Any person(s) installing an unapproved muffler, or an
unapproved exhaust system part, or modifying an
exhaust system in any way that might cause a hazard,
is liable for any damage, injury, or warranty expense
that might be caused by such unapproved installation
or modification.
TAILPIPE MUST EXTEND 2 INCHES
BEYOND THE COACH BODYWORK
• If there is any possibility of the tailpipe or muffler
being damaged, protect these damage-prone
areas by means of a protective device (such as, a
skid bar).
• Install the generator exhaust system according to
safe automotive practices.
The inside diameter of the muffler outlet tube is 33.5
mm/1.32 inches. Nominal pipe diameter of 1-5/16”
(1.31”) will fit snuggly inside and 1-3/8” muffler clamp
will hold in place.
• Use enough exhaust system hangers to prevent any
part of the system from being dislocated.
• Use exhaust system parts recommended by
Generac. Using unapproved exhaust mufflers and
exhaust system parts is the responsibility of the
person(s) installing such unauthorized parts.
• Do not terminate the exhaust system under any
opening, window, or vent that can be opened or is
not permanently sealed from the vehicle interior.
• Exhaust piping must be large enough to prevent
excessive back pressure on the generator engine.
®
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
• Never tee the generator engine exhaust pipe into
• From the junction box, route power supply wires
through approved conduit to either (a) double-pole,
double-throw transfer switch, or (b) approved isola-
tion receptacle. Connecting to a transfer switch or
isolation receptacle must prevent vehicle electrical
circuits from being connected to two different power
supplies at the same time (such as, generator and
dockside power).
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.
Comply with all applicable codes, standards, and
regulations.
• Conductors must be rated 221° F (105° C) or must
2.6 ELECTRICAL CONNECTIONS
be of a larger conductor size.
Be sure to read Section 1.6 on Page 20.
2.6.3 GENERATOR AC CONNECTIONS
N
The following general rules apply to electrical con-
nections in a recreational vehicle:
Generator AC output leads T1 (red), and T3 (black)
come out of the generator, as shown in Figure 2.14.
Leads T1 (red) and T3 (black) are “hot.” There is also
a green lead that connects to ground in the junction
box of the recreational vehicle.
• Qualified electricians who are familiar with applic-
able codes, standards, and regulations should
install electrical wiring.
• The wiring should comply with codes, standards,
and regulations. The National Electrical Code
(NFPA 70), and state and local codes apply.
• Switches and circuit breakers should be of a type
approved for use in recreational vehicles and must
be mounted and installed to prevent damage from
road shock.
Figure 2.14 – Generator AC Output Leads
T1 (Red)
T3 (Black)
• 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.
Ground
(Green)
2.6.1 ELECTRICAL JUNCTION BOX
N
Install an approved, square electrical junction box
with a blank cover on the interior or exterior wall of
the area you plan to install the generator (NOT on the
generator). Route the generator's AC output leads
into this junction box through approved flexible con-
duit. This is the point of first termination for genera-
tor AC output leads.
QUIETPACT ™ generators use a four-position terminal
block to connect between stator power leads and vehi-
cle load leads. This terminal block is accessible by
removing the access panel, shown in Figure 2.14. Units
are shipped from the factory connected for (230 volts
AC) output (See Figure 2.15). The stator power wind-
ings are connected in series. Lead 11/11A connects to
T3 (Black), lead 44/44A connects to T1 (Red), while
leads 22 and 33 are isolated. A "tie bar" connects the
two switch handles on line breaker CB1.
2.6.2 WIRING
N
• 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
Do NOT connect electrical loads in excess of
any circuit breaker rating, or you will develop
problems with circuit breaker tripping, which
causes a loss of AC output. Also, do NOT exceed
the generator’s rated wattage capacity. Add the
watts or amps of all lighting, appliance, tool,
and motor loads the generator will operate at
one time. This total should be less than the
unit’s rated wattage/amperage capacity.
same size as other leg wires.
• Route power supply conductors from generator AC
output leads T1 (red), T3 (black), and the green
ground wire through approved flexible conduit to
the electrical junction box on the compartment wall.
If a flexible metal conduit is used between the gener-
ator and the compartment junction box, the conduit
end that terminates at the compartment junction box
must be vapor-sealed. Flexible metal conduit is NOT
vapor-tight along its entire length.
®
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
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.
• If you use metallic conduit, vapor-seal the end of
the conduit where it enters the junction box. Do
this because flexible metallic conduit is not vapor-
proof along its entire length.
• All openings in the generator compartment for the
passage of wiring and conduit must be sealed and
made vapor-tight.
Figure 1.1 – Connections for 230 Volts Only
NOTE:
Use a high-quality silicone rubber base sealant or
other approved method (such as, explosion-proof
fittings) to seal such openings.
2.6.5 POWER SUPPLY CORD
N
The power supply cord must comply with all applic-
able codes, standards, and regulations. It must be
large enough to handle the full amperage to which it
will be subjected.
2.6.6 GROUND FAULT CIRCUIT INTERRUPTERS
N
The National Electrical Code (NFPA 70, 551-7)
requires that you install ground-fault circuit inter-
rupters (GFCIs) on all external and some internal
electrical receptacles. Contact your manufacturer or
dealer for recommendations.
2.6.4 CONDUIT
Route the connections between the generator and the
junction box through approved, flexible conduit. The
following general rules apply:
N
2.6.7 ISOLATING DIFFERENT POWER SOURCES
N
• All wiring, conduit, and interconnections must be
installed in compliance with applicable codes,
standards, and regulations.
Connections from the junction box must terminate in
a double-pole, double-throw transfer switch (Figure
2.17). An alternate method for isolating different
power sources includes using an isolating receptacle
(Figure 2.18 on page 32). Whichever method you use,
you must be certain that both power sources are NOT
connected at the same time.
• Cut wiring to the required length, and allow extra
wire for junction box connections.
• Carefully prepare conduit ends to prevent sharp
edges from cutting through wiring insulation.
• Route conduit so it does not interfere with genera-
tor movement.
Figure 2.17 – Transfer Switch Isolation Method
®
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
Figure 2.18 – Installation With Isolation Receptacle
2.7.2 BATTERY CABLES
N
Using battery cables that are too long or too small in
If the vehicle’s electrical circuits can be powered by
any other source of electricity (such as, a “dock-
side” power receptacle), there must be no possibil-
ity of connecting the different power sources to
the vehicle’s circuits at the same time. The dock-
side (utility) power source must be positively iso-
lated from the vehicle’s circuits whenever the gen-
erator is operating. Failure to isolate the vehicle’s
circuits from the dockside power supply when the
generator is running may result in damage to the
generator or in serious injury or death to dockside
(utility) power workers due to backfeed of electri-
cal energy. Installation and connection of the gen-
erator must comply with NFPA 70, Article 551, and
NFPA 1192 (latest editions).
diameter may cause a drop in voltage, which causes
starting problems. For the best cold weather starting,
the voltage drop between battery terminals and the
generator connection point should not exceed 0.12
volts per 100 amps of cranking current.
The QUIETPACT™ 65D generator is rated at about
160 DC amps of cranking current to operate the
starter and glow plugs.
Select battery cables based on (a) cable length and (b)
prevailing ambient temperatures. Generally, the
longer the cable and the colder the weather, the larg-
er the cable size must be, as shown in the chart.
CABLE LENGTH
in Feet (meters)
0 to 10 (0 to 3)
11 to 15 (3.4 to 4.5)
16 to 20 (4.5 to 6)
CABLE SIZE
2.7 BATTERY INSTALLATION
2*
0
000
2.7.1 RECOMMENDED BATTERY
N
Install
a
battery that meets the following
requirements:
*For warm weather, use No. 2 cable up to 20 feet.
• The battery must be a 12-volt, automotive-type
storage battery.
2.7.3 BATTERY CABLE CONNECTIONS
N
• Use a battery with minimum ratings of 70 amp-
hours and 360 cold-cranking amps.
NOTE:
1. Connect the battery cable from the battery post or
terminal, indicated by a POSITIVE, POS, or (+),
to the insulated lug on the unit frame (Figure 2.19
on page 33).
If the battery is to be used to power other vehicle
accessories, as well as to start the generator, you
may need a battery with a larger capacity.
NOTE:
Check to be sure the cable boot for the positive
cable has been installed.
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Section 2 – Installation
QUIETPACT™ 65D Recreational Vehicle Generator
2. Connect the battery cable from the battery post,
• Remove watches, rings, or other metal objects;
• Use tools with insulated handles;
indicated by a NEGATIVE, 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.
4. Connect cables so the connectors are clean
and tight.
• 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.
Figure 2.19 – Connecting Battery Cables
Do not open or mutilate the battery. Released
electrolyte is known to be harmful to the skin
and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
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.
• If the electrolyte contacts the eyes, immediately
flush eyes thoroughly with water, and seek med-
ical attention.
2.7.4 BATTERY COMPARTMENT
Install the generator battery in its own, vented com-
partment. Place the battery compartment away from
any source of heat, sparks, or flame.
N
• 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.
Provide ventilation openings in the battery compart-
ment. The minimum size of openings should be 2
square inches at the top of the compartment. Mount
the battery on a strong, rigid supporting structure,
where leaks and spills of battery fluid will not cause
damage.
2.8 OPTIONAL ACCESSORIES
A plug-in connector (Figure 2.20) is provided on the
generator set, below the control panel. Use this to
connect an optional remote-mounted start/stop panel
to the generator. Installation of such a panel will per-
mit you to start and stop the generator engine from
any convenient location inside the vehicle.
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 tool
or equipment near the battery. Discharge static
electricity from your body before touching the
battery by first touching a grounded metal sur-
face.
Figure 2.20 – Remote Panel Plug-in Receptacle
WIRE #18
(STOP)
WIRE #150
(PREHEAT)
WIRE #15
(12 VDC)
WIRE #0
(GROUND)
WIRE #14
(ENGINE RUN SIGNAL)
WIRE #17
(START)
A battery presents a risk of electrical shock
and high short-circuit current. The following
precautions are to be observed when working
on batteries:
ELECTRICAL ACCESS PANEL
®
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Section 3 – Post-installation Start-up Checks
QUIETPACT™ 65D Recreational Vehicle Generator
CHECKS
2. Refer to Part I, Section 2.4, “Starting the
2.8.1 REMOTE START/STOP CONNECTIONS
The following steps are necessary to connect the
remote start/stop option:
N
Generator” (Page 8), for cranking and starting
instructions. The engine may require more
cranking for initial starting, since the fuel lines
have to be primed (use of the preheat switch will
operate the generator’s electrical fuel pump and
shorten this time).
1. If the six-wire remote connector is visible below
the control panel, as shown in Figure 2.20, skip
to step 5. Otherwise, proceed with step 2.
2. Remove the electrical access panel located just
below the knock-out labeled “REMOTE.” The
remote connector will be located inside the elec-
trical enclosure, along the right side.
3. Let the engine warm up for about five minutes to
allow internal temperatures to stabilize.
4. Carefully inspect the engine/generator for fuel, oil,
and exhaust system leaks. Before proceeding to the
next step, correct any leakage immediately.
5. When all tests and adjustments at no-load are
completed, apply electrical loads and check
for proper operation under load. See Section
3.4. Run the unit at least 30 minutes, with
loads applied.
6. Turn off all electrical loads by setting the gen-
erator’s line breakers to their “OFF” (or open)
position.
7. Let the unit run at no-load for a few minutes to
stabilize internal engine/generator temperatures.
Then, shut down the engine.
3. Remove the “REMOTE” knock-out, taking care
not to damage the wiring behind it.
4. Feed the remote connector through the hole, and
fit the supplied grommet into position.
5. Wire the remote harness (Part # C6712C, sup-
plied as an accessory with the generator) to the
vehicle’s remote start panel. Refer to Figure 2.20
for a wiring legend.
6. Plug the remote harness into the mating remote
connector on the generator.
3.1 POST INSTALLATION TESTS
NOTE:
The generator set was factory-tested and adjusted.
You should not be required to adjust the unit any fur-
ther, except under special circumstances.
The generator set was thoroughly tested and
adjusted at the factory before shipping. No addi-
tional adjustment should be necessary. Only
trained, qualified service technicians should
perform adjustments outlined in this manual.
Do not make any unnecessary adjustments.
Factory settings are correct for most applica-
tions. When making adjustments, however, be
careful to avoid overspeeding the engine.
3.4 TESTING UNDER LOAD
Apply electrical loads equal to about 50 to 75 percent
of the unit's rated wattage/amperage capacity.
3.2 BEFORE INITIAL STARTUP
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 air-
flow is available. You must not allow the unit to over-
heat during prolonged operation.
Before starting, complete the following:
1. Check the engine crankcase oil level and, if nec-
essary, fill to the dipstick “FULL” mark (cross-
hatched area) with the recommended oil. Do not
fill above the FULL mark.
NOTE:
2. Check the fuel supply. Fuel lines must have been
properly purged and leak-tested in accordance
with applicable fuel codes. All fuel shutoff valves
in the fuel supply lines must be open.
The generator engine is equipped with a high
coolant temperature switch. The switch has normal-
ly open (N.O.) contacts. When the engine coolant
temperature is too high, switch contacts close, and
the engine shuts down automatically.
3.3 INITIAL START
GENERAC RECOMMENDS THAT YOU TEST THE
GENERATOR FOR ADEQUATE COOLING.
When you are absolutely certain that the unit has
been properly installed and prepared for use, start
the engine as follows:
1. Turn off all electrical loads. Do this by setting the
generator’s line breakers to their “OFF” (or open)
position.
®
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Section 3 – Post-installation Start-up Checks
QUIETPACT™ 65D Recreational Vehicle Generator
CHECKS
EXHAUST SYSTEM
N
3.5 INSTALLATION CHECKLIST
❑ Exhaust system complies with all applicable
LOCATION AND SUPPORT
N
codes.
❑ Generator is properly located.
❑ Generator is properly supported.
❑ Generator is properly restrained.
❑ Exhaust system is properly and safely installed.
ELECTRICAL CONNECTIONS
N
❑ Connections comply with local code requirements
and all National Electrical Codes.
GENERATOR COMPARTMENT
N
❑ Junction box is properly installed.
❑ Wiring meets all standards.
❑ Compartment construction is proper.
❑ Holes/Openings are vapor-sealed.
❑ Compartment size is correct.
❑ All connections are correct.
❑ Conduit is properly installed and sealed.
❑ Generator is properly bonded to the vehicle.
❑ Compartment is vapor-sealed.
❑ Sound insulation is correct.
❑ Floor cutouts are properly completed.
BATTERY INSTALLATION
N
❑ Recommended battery is installed.
❑ Recommended cables are installed.
❑ Cables are clean and tight.
COOLING AND VENTILATING AIR
❑ Airflow is adequate.
N
❑ Air inlet opening is correct.
❑ Compensate for restrictions.
❑ Check that installation has been tested.
❑ Cables are connected properly.
❑ Proper ventilation is provided.
❑ Terminals are coated with anti-corrosion grease,
DIESEL FUEL SYSTEM
N
and terminal covers are positioned.
❑ Fuel tank complies with all applicable codes.
OPTIONAL ACCESSORIES
N
❑ Fuel system is properly installed and checked
❑ Check that remote start/stop panels (if used) are
for leaks.
installed properly.
❑ Check that all other options and accessories (if
used) are installed properly.
POST INSTALLATION TESTS
N
❑ Check that all tests are completed properly.
DATE OF INSTALLATION ____________________________________________________
NAME OF INSTALLER ______________________________________________________
SIGNATURE OF INSTALLER ________________________________________________
®
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Appendix 1 – Troubleshooting
QUIETPACT™ 65D Recreational Vehicle Generator
TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
CORRECTION
The engine will not crank.
1. System control fuse blown
2. Loose corroded or defective
battery cables
1. Replace fuse.
2. Tighten, clean, or replace,
as necessary.
3. Defective engine Start/Stop
switch
3. Replace Start/Stop switch.
4. Defective starter contactor
5. Defective starter motor
6. Low or defective battery
7. Defective engine control board
4. Replace contactor.
5. Replace starter motor.
6. Charge or replace battery.
7. Replace control board.
The engine cranks but
will not start.
1. Vehicle fuel shutoff valve closed
2. Out of fuel
1. Open valve, if so equipped.
2. Replenish fuel.
3. Defective fuel solenoid (FS)
4. Defective fuel pump (FP)
5. Open #14 wire from
3. Replace solenoid.
4. Repair or replace fuel pump.
5. Check connections and
insulation of #14 wires.
engine control board
6. Plugged fuel filter or fuel line
7. Engine mechanical parts failure
8. Defective engine control board
6. Clean or replace fuel filter or line.
7. Repair or replace parts.
8. Replace control board.
The engine starts hard
and runs rough.
1. Plugged or damaged
air filter
1. Check, clean, or replace, as needed.
2. Defective fuel pump (FP)
3. Plugged fuel filter or fuel line
4. Water in fuel
2. Repair or replace fuel pump.
3. Clean or replace fuel filter or line.
4. Drain fuel system and refill.
5. Preheat unit.
5. Improper preheat
The engine starts, but shuts
down when the Start/Stop
switch is released.
1. Low engine oil level
2. Overheated engine
3. Defective Start/Stop Switch
on panel or remote Start/Stop
4. Defective low-oil
1. Check oil and add oil, as needed.
2. Check cooling system for leaks.
3. Disconnect Remote Harness
Check/Replace Start/Stop Switch
4. Replace pressure switch.
pressure switch
5. Defective high-coolant
temperature switch
5. Replace temperature switch.
6. No AC output
6. Contact a Generac Authorized
Service Dealer
7. Defective engine control board
7. Replace control board.
The Start/Stop switch is
set to Stop, but the engine
continues to run.
1. Defective Start/Stop switch
2. Open/Disconnected #18 wire
between Start/Stop switch
1. Replace switch.
2. Reconnect or close wire.
and engine control board
3. Open/Disconnected #0 wire
3. Reconnect or close wire.
between Start/Stop switch
and engine control board
4. Defective engine control board
1. Main-line circuit breaker open
4. Replace control board.
1. Reset line breaker
There is no AC output from
the generator.
to ON (or closed).
2. Fault with vehicle circuit
breaker and/or fuses
2. Reset and replace, if necessary.
3. Generator internal failure
3. Contact a Generac Authorized
Service Dealer.
®
36 Generac Power Systems, Inc.
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Appendix 2 — Electrical Data
QUIETPACT™ 65D Recreational Vehicle Generator
Electrical Schematic – Drawing No. - 0D5037-A
®
Generac Power Systems, Inc. 37
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Appendix 2 — Electrical Data
QUIETPACT™ 65D Recreational Vehicle Generator
Wiring Diagram – Drawing No. 0D5036-A
®
38 Generac Power Systems, Inc.
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Appendix 2 — Electrical Data
QUIETPACT™ 65D Recreational Vehicle Generator
Wiring Diagram – Drawing No. 0D5036-A
®
Generac Power Systems, Inc. 39
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Engine, Alternator Drive and Starter Assembly – Drawing No. 0D5057-A
®
40 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Engine, Alternator Drive and Starter Assembly – Drawing No. 0D5057-A
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0C5598
0C9674
0C6055H
0D5030H
031971
073159
066386
066849
0C6862
0C3168
0C5014
0C7646
0C8646
0C5298
020692
0C4841
073106D
0D5046
039288
071956
022129
045771
040250
0C7933
068485
051769
0C4537
022304
023316
049451
042633
046526
052212
069673J
051756
049813
043107
021991
039253
0A1658
067989
0C1069
0C6609
049808
055934M
0A7043
0C8644
024426
048705
022145
1
1
1
1
1
1
1
2
4
6
1
1
1
1
1
1
1
1
2
2
8
8
2
1
4
6
2
2
1
1
1
11
6
2
5
1
2
1
4
1
4
3
1
2
1
2
1
1
2
2
BEARING CARRIER, FRONT
BEARING CARRIER, UPPER
ROTOR ASSEMBLY
STATOR ASSEMBLY
BALL BEARING
3
4
5
6
BALL BEARING
BRUSH HOLDER
7
8
TAPTITE M5-0.8 X 16MM
BOLT , STATOR
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
5/16 SPECIAL LOCK WASHER
LUG, LIFT
RAIL, ENGINE RH
PULLEY, 4.5" FLAT
BELT, V-RIB
STARTER MOTOR
SPACER, STARTER
PULLEY, ALTERNATOR
FLYWHEEL ASSEMBLY
HHCS M8-1.25 X 55MM
WASHER, VIBRATION ISOLATOR
WASHER, SPLIT LK -M8
NUT, HEX M8-1.25
SHCS 5/16"-18 X 1-1/2"
GUARD, FLYWHEEL
HHCS M12-1.25 X 20MM
WASHER, SPLIT LK -M12
ENGINE BRACKET
½" FLAT WASHER
½"-13 X 4" HHCS
FENDER WASHER 7GA
HHCS 3/8-24 X 1"
LOCKWASHER M10
HHCS M10-1.25 X 25MM
5/16 FLANGE NUT
HHCS M10-1.25 X 20MM
M6 HEX NUT
HHCS M8-1.25 X 25MM
EARTH STRAP
HHCS M8-1.25 X 20MM
¼" SPECIAL LOCK WASHER
M8 FLANGE NUT
TAPTITE, M6-1.0 X 8MM
ENGINE, 1.0L DIESEL
WASHER, FLAT M12
CLAMP, VINYL COATED, ¾"
HHCS M12-1.25 X 25MM
TENSIONER, SE-F18-4.5"
½"-13 X1-3/4" HHCS
½"-13 FLANGE NUT
FLAT WASHER, 5/16"
®
Generac Power Systems, Inc. 41
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Base Frame – Drawing No. D2357-A
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
0D2126
0D2131
0C5088
0C5644
056326
029451
0C7857
070936E
0C6721
0C6722
042907
022129
022097
1
BASE FRAME WELDMENT
DOOR, SERVICE REAR
DOOR, SERVICE FRONT
SLIDE LATCH FLUSH
VINYL TRIM -BLACK 180MM
RUBBER TAPE 1/8 X ½"
GROMMET 1/8 X 13/32
VIBRATION MOUNT
14
15
16
17
18
19
20
21
22
23
043146
0C7561
0A4456
0C7968
047411
049813
0C5443
0C7423
022131
022237
2
1
1
3
2
2
1
1
1
1
HHCS M6-1.00 X 10
1
CARRIAGE BOLT 3/8 -16 X 55MM
3/8 SPECIAL LOCK WASHER
HEX NUT 3/8-16 BRASS
HHCS M6-1.00 X 16
3
1
4
4
5
2
677MM
6
NUT, HEX M6.0 -1.0
7
4
4
1
1
8
8
3
BLOCK, TERMINAL BATTERY POST
STUD 3/8-16 X 55MM
WASHER 3/8 FLAT
8
9
GASKET, CLEANOUT
PLATE, CLEANOUT
HHCS M8-1.25 X 16
10
11
12
13
WASHER SPLIT LK -3/8
WASHER, SPLIT LK- M8
WASHER, SPLIT LK -1/4-M6
MM = MILLIMETRES
®
42 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Enclosure – Drawing No. 0D5059-B
25
12
17
11
17
13
17
2
20
34
10
32
9
30
1
31
26
35
8
14
15
5
23
17
21
19
28
33
29
1
A
7
17
6
17
4
17
3
17
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
1
2
0D2315
0C4534
0C4532
0C4535
0C4536
0C5525
0C5527
0C5528
0C5529
0C5530
0C5531
0C4986
0C4987
0C5091
0C6362
0D7176
0A7215
0C5096
1
1
ENCLOSURE PANEL RH
ENCLOSURE PANEL TOP
ENCLOSURE PANEL LH
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
0C7023
0C7024
0C7025
0C7026
0C7027
0C7028
0C7029
0C7030
0C2340
0C6425
049813
0C7047A
0C7047B
0D7805
022097
098761
042755
1
1
1
1
1
1
1
1
1
1
3
1
1
1
3
1
1
DECAL, BATTERY +/-
DECAL, RADIATOR CAP
DECAL, REMOTE
DECAL, COOLANT
3
1
4
1
ENCLOSURE PANEL FRONT
ENCLOSURE REAR PANEL
INSULATION, FRONT PANEL
5
1
DECAL, FUEL RETURN/SUPPLY
DECAL, OIL FILL / LEVEL
DECAL, LIFTING LUG
DECAL, MAX HOT / MIN COOLANT
DECAL, WARNING RV
SUPPORT, COOLANT TANK
NUT, HEX M6-1.0
6
1
7
1
INSULATION, LH SIDE PANEL
INSULATION, RH SIDE PANEL
8
1
9
1
INSULATION, TOP FRONT PANEL
INSULATION, TOP REAR PANEL
10
11
12
13
14
15
16
17
18
1
1
INSULATION, LIFTING LUG COVER
COVER, ACCESS LIFT
COVER, RADIATOR FILL
1
FOAM, AIR DUCT FACE
FOAM, AIR DUCT SIDE
DECAL, UNIT
1
1
COVER, ACCESS ELECTRICAL
GASKET, ELECTRICAL ACCESS
WASHER, SELF LOCK
1
WASHER, SPLIT LOCK ¼" - M6
DECAL, ENGINE DATA
DECAL, CSA APPROVAL
33
58
1
¼ -20 X 5/8 W/WASHER
FRAME CONTROL PANEL - REFER TO
DRAWING C8005
®
Generac Power Systems, Inc. 43
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Cooling System – Drawing No. D2360
®
44 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Cooling System – Drawing No. D2360
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0C4551
0C4550
0C4552
0C4554
0C4555
0C4557
0C4556
0C4553
049869
081810
070265
058443
043146
022097
049815
022152
051716
049813
0C4312
043116
022473
0C8645
0C8507
039253
022129
0C6549A
0C5108
0C6236
0C7384
0C5543
0C4460
0C4845
0C5544
086133A
035473
050968
042911
046526
047411
0C7997
0C7649
042907
0C5605
0C6976
0C7997
055934K
0C4976
055934D
0C7040
055934V
045771
0C5105
024426
00C8643
048705
1
Cover Plate, Scroll Weldment
Housing, Fan Scroll Weldment
Fan, Squirrel Cage
1
3
1
4
1
Shaft, Fan
Carrier, Bearing
5
1
6
1
Key, Square 3/16" x 3/16" x ½"
Pulley, Fan 4-7/8"
Bearing 2 Row Ball
7
1
8
1
9
1
Fender Washer M16
Nut, Hex M16.0 -1.5mm
LockWasher M16.0
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
1
1
7
Crimptite, ¼"-20 x 5/8"
HHCS M6-1.00 x 10mm
Washer, Split Lk ¼"- M6
HHCS M5-0.8 x 16mm
Washer, Split Lk #10
Hex Nut M5
2
19
4
4
4
12
Nut, Hex M6.0 -1.0mm
Radiator 1.0L RV
1
3
HHCS M6-1.00 x 12mm
Washer ¼"-M6
5
1
Pulley, 3" Flat Flanged
Bracket, Rotary Tensioner
HHCS M8-1.25 x 20mm
Washer, Split Lk -M8
61" Green Belt
1
2
6
1
1
Filler Neck Assembly, Radiator Remote
Hose Tee
Coupling, Hose
1
1
1
Hose, Radiator Lower
Hose, Water Pump Lower
Hose, Top
1
1
1
Hose, Lower Intermediate
Hose Clamp Hi Trq 1-3/4" Max
Hose Clamp #12
8
2
720mm
Hose, ¾" SAE-20R3
M10-1.5 x 30mm HHCS
M10 Lockwasher
1
1
2
270mm
HHCS M6-1.00 x 16mm
Hose, 5/16" SAE-20R4
Hose Clamp 7/8" 3/8"
HHCS M8-1.25 x 16mm
Cap, Coolant Fill
4
4
1
1
510mm
Tank, Coolant Overflow
Hose 5/16" SAE-20R4
Clamp, Vinyl Coated 1-5/8"
Cap, Radiator Pressure
Clamp, Vinyl Coated 1-1/16"
Gasket, Radiator Base
Clamp, Vinyl Coated 1-½"
Nut, Hex M8-1.25
1
1
1
1
1
1
1
1
1
1
Bracket, Support
½"-13 x 1-¾" HHCS
Tensioner
½"-13 Flange Nut
mm = Millimeters
®
Generac Power Systems, Inc. 45
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Electrical Enclosure Assembly – Drawing No. 0D5056-A
1
28
18
30
2
11
1
3
9
25
26
20
16
28
12
17
19
8
6
7
27
13
28
32
5
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
0D2412
1
WELDMENT, ELECTRICAL
ENCLOSURE
19
20
21
22
23
24
25
26
27
28
29
30
31
32
022985
4
1
1
1
1
1
2
2
7
7
1
2
4
1
WASHER, FLAT #6
0C6359
0D2021G*
0D2021F*
0D2021D*
0D2021E*
0A1658
GASKET, ELECTRICAL ENCLOSURE
WIRE ASSEMBLY # 32
WIRE ASSEMBLY # 22
DIODE ASSEMBLY
2
3
071914
083048
0C7610
093642
065795
048512
027565
066849C
066849
022264
051715
040213
0C8620
043180
0D2021B
0C3992
0C7022
1
1
TERMINAL BLOCK 4 POSITION
ASSEMBLY, POTTED REGULATOR
RESISTOR 20R 5% 12W
4
1
5
1
ASSEMBLY MARINE CONTROL BOARD
RECTIFIER, BATTERY CHARGING
CIRCUIT BREAKER 5 AMP
TAPE, GLASS INSULATED
TAPTITE, M5-0.8 X 30
WIRE ASSEMBLY # 162
¼ SPECIAL LOCKWASHER
WASHER, FLAT ¼-M6
WASHER, SPLIT LK ¼-M6
NUT, HEX M6-1
6
1
7
1
022473
022097
049813
8
A/R
2
9
10
11
12
13
14
15
16
17
18
1
TAPTITE, M5-0.8 X 16
LOCKWASHER M5
NUT, HEX M4-0.7
023484D
022717B
051787
BUSHING, SNAP
GROMMET
3
2
HHCS, M4-0.7 X 16MM
GASKET, ELECTRICAL ENCLOSURE
DIVIDER
4
PCB SUPPORT SNAP -IN
HHMS, #8-32 X 2.25"
WASHER, FLAT M5
0C7390
1
1
33
0D5035
1
HARNESS, AC OUTPUT
1
HARNESS
M4-0.7 X 16 HHCS TAPTITE
DECAL, CUSTOMER CONNECTION
4
A/R = AS REQUIRED
* NOT SHOWN REFER TO WIRING DIAGRAM C4946
1
®
46 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Intake and Exhaust System – Drawing No. D2362
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
075674
0C4879
0C4880
0C5493
0C4727
025145
0C7645
0C5022
035685
0C4878
0C6243
0C6244
039288
071956
1
1
1
1
1
2
1
1
4
1
1
1
2
2
EXHAUST GASKET
15
16
17
18
19
20
21
22
23
24
25
26
27
022129
045771
058443
0C5105
022145
039253
043107
035586
042909
042907
022145
0709390357
075673
10
5
3
1
4
2
4
2
1
1
2
1
1
WASHER, SPLIT LK -M8
NUT, HEX M8-1.25
CHAMBER AIR INTAKE
AIR FILTER
HOSE, AIR INLET
3
CRIMPTITE, ¼"-20 X 5/8"
BRACKET, SUPPORT
WASHER, FLAT - M8
HHCS M8-1.25 X 20
4
5
MUFFLER WELDMENT
U BOLT & SADDLE 1.25
RAIL, ENGINE LH, WELDMENT
INSULATION, EXHAUST
HOSE CLAMP #28
6
7
HHCS M8-1.25 X 25
HOSE CLAMP #20
8
9
HHCS M8-1.25 X 30
HHCS M8-1.25 X 16
10
11
12
13
14
OUTLET, EXHAUST FLEX
GASKET, EXHAUST OUTLET
PLATE, EXHAUST OUTLET
HHCS M8-1.25 X 55
FLAT WASHER, 5/16"
MANIFOLD GASKET
HORIZONTAL EXHAUST MANIFOLD
WASHER, VIBRATION ISOLATOR
®
Generac Power Systems, Inc. 47
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Fuel and Electrical Systems – Drawing No. 0D2363-A
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
0C6946A
052219
069598B
022097
038750
056739
049813
055934M
022473
040173
028414A
0C7649
047411
0C7968
022237
075763
1
3
2
7
1
2
5
1
5
2
1
3
1
1
1
3
Fuel Pump Assembly
1/8 NPT x 5/16 Barbed Straight Fitting
Bulkhead Adaptor Fitting
Washer, Split Lk- ¼ -M6
HHCS M6-1.00 x 30
Relay Solenoid
17
18
19
20
21
22
24
25
26
27
28
29
075763A
0C7413
022127
3
Boot, Battery Cable
Grommet 3/8 I/D x 1 GD
Hex Nut ¼ - 20
1
3
1
4
053621-201
053621-197
0A2053
1
Cable, Battery
Cable, Starter
5
1
6
1
1
HHCS, M6-1 x 65
Resistor
7
Nut, Hex M6-1
075234
030340
8
Clamp, Vinyl Coat 3/4
Washer, Flat -M6
Hose Clamp
1.04M
635mm
375mm
1
Hose, 1/4 ID SAE-30R2
Hose, 5/16 ID SAE-30R7
Hose, 5/16 ID SAE-30/R7
Clamp, Fuel Pump
Wire Assy, #0 (PHC-SC)
9
0C8008
0C8008
10
11
12
13
14
15
16
1/8 NPT x 1/4 Barbed Straight Fitting
Hose Clamp 7/8 / 3/8
HHCS M6-1.00 x 16
Hex Nut 3/8-16 Brass
Washer Split Lk 3/8
0C8009
0D2021H
1
M = Meters
mm = Millimeters
Boot, Battery Cable
®
48 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
Customer Controls Assembly – Drawing No. 0D5055-A
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
0D2398
0C4540
0C1457
081904
055920
043181
022159
055927
0C5127
0C7341
049226
0C7340
1
1
1
1
1
2
2
1
1
1
4
1
START / STOP SWITCH
COVER, ENGINE CONTROL BOX
HOUR METER
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
0C5096
0D4372
0C3971B
0C4883
0C4884
0C7649
057824
0C3992
022985
084135
0C6440
082081
049813
052749
038150
022097
1
1
1
1
1
2
2
4
4
1
2
1
2
4
4
2
FRAME, CONTROL PANEL
PLUG, OIL FILL
3
DIPSTICK ASSEMBLY
HOSE, DIPSTICK TUBE
HOSE, FILLER TUBE
HOSE CLAMP 7/8-3/8
HOSE CLAMP SIZE #16
M4-0.7 X 16 HHCS TAPTITE
WASHER, FLAT #6
4
FUSE HOLDER, SFE-14
SWITCH, PUSHBUTTON SPST
PPHMS M3-0.5 X 10
LOCKWASHER M3
5
6
7
8
FUSE, SFE-14
DECAL
9
10
11
12
BOOT / NUT / PREHEAT SWITCH
LOCKWASHER, M5
GROMMET
GASKET, ENGINE CONTROL BOX
CIRCUIT BREAKER, 30A, 2 POLE
NUT, HEX M6-1.0
BOOT, CIRCUIT BREAKER (WITH 4
SEALING SCREWS)
HARNESS
13
14
15
0D2021A
051714
0C4476
1
2
1
PHMS M5-0.8 X 12
FLATWASHER, #8
WASHER, SPLIT LOCK 1/4”-M6
HEX NUT, M3
BOX, ENGINE CONTROL
®
Generac Power Systems, Inc. 49
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Camshaft – Drawing No. 75677
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
3
4
5
6
7
0709390232
0709390233
0709390195
0709390234
0709390235
0709390236
0709390237
1
1
1
1
3
1
1
CAMSHAFT ASSEMBLY
CAMSHAFT GEAR
KEY
8
9
0709390238
0709390239
0709390240
0709390241
0709390242
0709390243
1
1
1
1
1
1
PLATE
TACHOMETER SHAFT
10
11
12
13
BOLT
BOLT
GEAR
SPACER
GASKET
NUT
BALL BEARING
SLIDER
®
50 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Cylinder Block– Drawing No. 75676
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
0709390100
0709390447
0709390101
0709390102
0709390103
0709390104
0709390105
0709390106
0709390107
0709390108
0709390109
0709390110
0709390111
0709390112
0709390113
0709390114
0709390115
0709390116
1
1
1
2
2
1
4
4
1
1
1
1
1
1
1
1
1
1
COMPLETE CYLINDER BLOCK
EXPANSION PLUG
EXPANSION PLUG
EXPANSION PLUG
EXPANSION PLUG
EXPANSION PLUG
PLUG
17
18
19
20
21
22
23
24
25
26
27
28
29
30
0709390117
0709390118
0709390119
0709390120
0709390121
0709390131
0709390123
0709390124
0709390125
0709390126
0709390127
0709390128
0709390129
0709390130
2
2
2
1
1
1
1
1
1
1
6
6
1
1
DOWEL PIN
SPRING PIN
STUD
3
4
STUD
STUD
5
6
SNAP RING
OIL SEAL
DRAIN COCK
CONNECTOR
OIL FILTER
TAPPET
7
8
PLUG
IDLE GEAR SHAFT
BUSHING
9
10
11
BUSHING-STANDARD
0.25MM U.S. BUSHING
0.50MM U.S. BUSHING
BALL BEARING
EXPANSION PLUG
BALL BEARING
DOWEL PIN
PUSH ROD
RELIEF VALVE
O-RING
12
13
14
15
16
MM = MILLIMETER
U.S. = UNDERSIZE
DOWEL PIN
®
Generac Power Systems, Inc. 51
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Cylinder Head – Drawing No. D2794
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
3
4
5
6
7
0709390147
0709390148
0709390447
0709390149
0709390150
0709390151
0709390152
0709390153
0709390154
0709390155
0709390156
0709390157
0709390158
1
6
CYLINDER HEAD ASSEMBLY
EXPANSION PLUG
EXPANSION PLUG
EXPANSION PLUG
INTAKE VALVE
13
14
15
16
17
18
19
20
21
22
23
0709390160
0709390161
0709390162
0709390163
0709390164
0709390165
0A8584
11
3
2
2
1
2
1
1
4
1
1
BOLT
BOLT
3
LIFTING EYE
BOLT
TUBING
2
3
3
EXHAUST VALVE
VALVE GUIDE SEAL (EXHAUST)
VALVE GUIDE SEAL (INTAKE)
SPRING
BOLT
3
OIL SWITCH
THERMO-SWITCH
GASKET
WASHER
ADAPTOR
3
0D2791
8
9
6
0709390168
0709390169
042574
6
RETAINER
KEY
10
11
12
12
6
CAP
CYLINDER HEAD GASKET, 1.2MM
THICK
1
MM=MILLIMETER
0709390159
1
CYLINDER HEAD GASKET, 1.3MM
THICK
®
52 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Crankshaft, Piston and Flywheel – Drawing No. 075679-B
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
070939-193
070939-194
070939-195
070939-196
070939-226
070939-197
070939-200
070939-664
070939-198
070939-199
070939-202
070939-203
070939-204
070939-205
070939-206
070939-207
070939-208
070939-204
070939-210
070939-214
070939-215
070939-216
1
1
CRANKSHAFT ASSEMBLY
CRANKSHAFT GEAR
KEY
17
070939-211
070939-212
070939-213
070939-217
070939-218
070939-219
070939-220
070939-221
070939-222
070939-223
070939-224
070939-225
070939-230
070939-231
3
AR
AR
3
STANDARD PISTON RING SET
PISTON RING SET-0.5MM O.S.
PISTON RING SET-1.0MM O.S.
PISTON PIN
3
1
4
1
DOWEL PIN
SPRING PIN
18
19
20
21
22
23
24
5
1
6
SNAP RING
CONNECTING ROD ASSEMBLY
BUSHING
6
1
BEARING HOLDER ASSEMBLY
BEARING HOLDER ASSEMBLY
BEARING HOLDER ASSEMBLY
BOLT
3
7
1
3
8
1
6
CONNECTING ROD BOLT
NUT, CONNECTING ROD BOLT
STANDARD BEARING
BEARING-0.25MM U.S.
BEARING-0.50MM U.S.
PULLEY
9
6
6
10
11
6
DOWEL PIN
6
3
STANDARD BEARING
0.25MM U.S. BEARING
0.50MM U.S. BEARING
STANDARD BEARING
0.25MM U.S. BEARING
0.50MM U.S. BEARING
THRUST WASHER
BOLT
AR
AR
1
AR
AR
3
28
30
12
1
NUT
AR
AR
2
U.S. - UNDERSIZE
O.S. - OVERSIZE
AR - AS REQUIRED
MM - MILLIMETER
13
14
15
16
2
1
BOLT
3
STANDARD PISTON ASSEMBLY
PISTON ASSEMBLY-0.5MM O.S.
PISTON ASSEMBLY-1.0MM O.S.
AR
AR
®
Generac Power Systems, Inc. 53
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Oil Pump – Drawing No. 75682
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
3
4
5
6
0709390250
0709390252
0709390251
0709390253
0709390254
0709390255
0709390532
0709390533
0709390258
1
1
IDLER GEAR ASSEMBLY
SPRING
7
8
0709390259
0709390260
0709390261
0709390262
0709390263
0709390264
1
1
1
1
1
3
SPRING
COLLAR
1
THRUST WASHER
ROTOR
9
SNAP RING
FRONT PLATE
GASKET
BOLT
1
10
11
12
1
OIL PUMP COVER
0.10MM SHIM
0.15MM SHIM
0.20MM SHIM
0.50MM SHIM
AR
AR
AR
AR
AR - AS REQUIRED
®
54 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Rocker Arm Assembly – Drawing No. 075683-A
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
070939-170
1
ROCKER ARM ASSEMBLY (INCLUDES
ALL COMPONENTS SHOWN BELOW)
INTAKE ROCKER ARM
EXHAUST ROCKER ARM
NUT
7
8
070939-176
070939-177
070939-178
070939-179
070939-180
070939-181
1
2
2
3
3
3
ROCKER ARM SHAFT
SPRING
SCREW
2
3
4
5
6
070939-171
070939-172
070939-174
070939-173
070939-175
3
3
6
6
3
9
10
11
12
SPRING,PIN
NUT
STUD
STUD
ROCKER ARM BRACKET
®
Generac Power Systems, Inc. 55
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Injector Pump – Drawing No. 075686-C
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
0709390316
0709390317
0709390318
0709390319
0709390320
0709390298
0709390321
0709390322
0709390323
0709390324
0709390325
0709390326
0709390327
0709390328
0709390329
0709390330
1
AR
AR
AR
AR
3
INJECTOR PUMP ASSEMBLY
SHIM-0.2MM
SHIM-0.3MM
SHIM-0.5MM
SHIM-1.0MM
NUT
14
16
17
18
19
0709390331
0709390332
0709390333
0709390334
0709390335
1
3
1
1
1
BOLT
GLOW PLUG
CONNECTOR
GASKET
COVER (ALL MODELS EXCEPT 04270
& 04614)
3
4
2
BOLT
GASKET
0C4736
1
TUBE, ENGINE OIL FILL (MODEL
04270 & 04614)
BOLT
5
3
6
3
INSERT
CAP
20
26
27
28
29
0709390264
0709390341
0709390342
0709390343
0709390344
2
1
1
1
1
7
3
SOLENOID
WASHER
WASHER
SCREW
8
3
INJECTOR
TUBING
TUBING
9
1
10
11
12
13
1
1
TUBING
TUBING
CLAMP
1
AR - AS REQUIRED
1
®
56 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Fuel Supply – Drawing No. 075693-C
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
0709390661
069858
0C8008
1
FUEL FILTER SUPPORT
FUEL FILTER
12
13
14
15
16
17
18
19
068736
068736
275MM
240MM
HOSE, 3/16" SAE 30R2
HOSE, 3/16" SAE 30R2
HOSE CLAMP
1
AR
3
HOSE, 5/16" SAE 30R7
HOSE, 5/16" SAE 30R7
HOSE CLAMP
074823
074819
4
1
5
2
2
1
4
0C8008
040173
250MM
FUEL BLEED FITTING
FUEL BLEED GASKET
HOLLOW BOLT
5
3
2
1
1
2
2
0709390651
0709290662
0709390663
028414A
6
0709390378
0709390379
074808
GASKET
BANJO FITTING
7
BANJO FITTING
1/8" NPT X 1/4" BARBED STRAIGHT
FITTING (MODEL 04270 & 04614)
8
FUEL BLEED FITTING
1/8" NPT TEE (BRASS)
1/8" NPT X 3/16" 90 DEG. BARBED
FITTING
9
10
052233
039450
* -QTY 1 (MODEL 04270 & 04614)
AR - AS REQUIRED
11
030096
2 *
1/8" NPT X 3/16" BARBED STRAIGHT
FITTING
®
Generac Power Systems, Inc. 57
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Timing and Governor – Drawing No. 082067-B
®
58 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Timing and Governor – Drawing No. 082067-B
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0709390285
0709390286
0709390287
0709390307
0709390308
0709390309
0709390310
0709390314
0709390296
0709390297
0709390298
0709390299
0709390300
0709390301
0709390540
0709390282
0709390288
0709390274
0709390311
0709390304
0709390305
0709390306
0709390289
0709390290
0709390291
0709390136
0709390292
0709390313
0709390293
0709390294
0709390295
0709390291
0709390302
0709390271
0709390303
071944
1
HOUSING, TIMING GEAR
SPRING PIN
1
3
1
GASKET
SPRING
4
1
5
1
WASHER
NUT
6
2
7
1
STOP LEVER
COVER
8
2
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
1
GOVERNOR LEVER
BOLT
1
1
NUT
SHAFT
1
1
O-RING
SNAP RING
1
3 *
5
BOLT
BOLT
1
OIL SEAL
BOLT
4
5
BOLT
ARM
1
1
SNAP RING
O-RING
1
1
GOVERNOR LEVER ASSEMBLY
TENSION LEVER
1
1
SNAP RING
WASHER
1
1
COTTER PIN
SPRING
1
1
SPRING
ARM
1
1
O-RING
SNAP RING
1
1
BRACKET
BOLT
3
2
BOLT
SCREW HHC M6-1.0 X 25
1
0709390660
0709390534
0709390535
0709390536
0709390537
0709390539
0709390188
0709390541
0709390538
0C4888
1
O-RING
O-RING
1 *
1 *
1
SPACER
GASKET
1 *
1 *
1 *
1 *
3 *
1
HOLDER (OIL FILL)
O-RING
CAP
BOLT
NUT
BRACKET, FUEL FILTER (MODEL 04270 & 04614)
SCREW HHC M8-1.25 X 60 G8.8 (MODEL 04270 & 04614)
SCREW HHC M8-1.25 X 65 G8.8 (MODEL 04270 & 04614)
NUT HEX M8-1.25 G8 (MODEL 04270 & 04614)
WASHER LOCK M8-5/16 (MODEL 04270 & 04614)
051730
052265
3
1
045771
022129
4
4
* NOT USED ON MODEL 04270 & 04614
®
Generac Power Systems, Inc. 59
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Engine Block – Drawing No. 082961-C
23
22
25
18
28
15
20
19
14
30
29
14
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
070939-139
070939-140
0D7124
1
20
1
OIL PAN
BOLT
18
19
20
22
23
24
25
28
29
30
31
33
070939-184
070939-185
070939-186
070939-168
070939-187
070939-188
070939-189
026073-A
1
1
1
1
3
1
1
1
1
1
1
1
ROCKER COVER
OIL STOPPER
SCREEN
3
12
O-RING (MODELS 04270 & 04614 ONLY)
DIPSTICK TUBE (ALL MODELS
EXCEPT 04270 & 04614)
DIPSTICK TUBE (MODELS 04270 &
04614 ONLY)
070939-143
1
GASKET
NUT
0C4641
097843
1
2
CAP
O-RING
13
O-RING (ALL MODELS EXCEPT 04270
& 04614)
BOLT
1/4" PIPE PLUG SQ. HD.
O-RING
TUBING
070939-244
070939-245
070939-246
070939-122
14
15
070939-145
070939-146
5
1
DIPSTICK (ALL MODELS EXCEPT
04270 & 04614)
ROCKER COVER GASKET
SUCTION FILTER
GASKET
17
070939-183
1
®
60 Generac Power Systems, Inc.
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Appendix 3 — Exploded Views and Parts Lists
QUIETPACT™ 65D Recreational Vehicle Generator
1.0 Liter Diesel Water Pump – Drawing No. 82962
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
2
3
4
5
6
7
0709390265
0709390266
0709390267
0709390268
0709390269
0709390270
0709390271
1
1
1
1
3
1
1
WATER PUMP ASSEMBLY
PLUG
8
9
0709390272
0709390273
0709390274
0709390275
0709390247
0709390284
1
1
1
1
1
1
GASKET
BOLT
BOLT
THERMOSTAT
SPRING
GASKET
10
11
12
15
NUT
PULLEY
BOLT
SET PLATE
BOLT
®
Generac Power Systems, Inc. 61
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Appendix 4 – Notes
QUIETPACT™ 65D Recreational Vehicle Generator
®
62 Generac Power Systems, Inc.
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Appendix 4 – Notes
QUIETPACT™ 65D Recreational Vehicle Generator
®
Generac Power Systems, Inc. 63
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Appendix 5 – Warranty
QUIETPACT™ 65D Recreational Vehicle Generator
FEDERAL AND CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT
(for non-road Diesel engines rated under 19 kW)
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), Generac Power Systems, Inc.
(GENERAC), and the engine manufacturer for this equipment, Ishikawajima Shibaura Machinery Co., Ltd. (ISM), are
pleased to explain the federal and California emission control system warranty on your engine.
In California, new 2000 and later small non-road engines must be designed, built, and equipped to meet the state's strin-
gent anti-smog standards. In other states, new 2000 and later non-road diesel engines rated under 19 kW must be designed,
built, and equipped to conform to applicable EPA regulations.
ISM must warrant the emission control system on your engine for that period of time listed below, provided there has been
no abuse, neglect, or improper maintenance of your small non-road diesel engine.
Your California and EPA emission control system may include parts, such as, the fuel injection system and other emission-
related assemblies.
Where a warrantable condition exists, GENERAC will repair your engine at no cost to you, including diagnosis, parts, and labor,
on behalf of ISM. Although ISM is ultimately responsible for this warranty, GENERAC has agreed to carry out ISM's warranty
repair responsibilities, and GENERAC should be your primary contact for emission-related warranty service.
MANUFACTURER'S WARRANTY COVERAGE
For 2000 and later small non-road diesel engines, first sold in California, and for 2000 and later non-road diesel engines
rated under 19 kW, first sold in all other states, the applicable warranty period is two (2) years or 1,500 hours, whichever comes
first.
If any emission-related part on your engine is defective, the part will be repaired or replaced by a Generac Authorized
Warranty Service Facility on behalf of ISM.
PARTS COVERED
This emission control system warranty applies to the following engine emission control parts.
• Fuel Injection Pump
• Intake Manifold
• Air Cleaner Element
• Fuel Injectors
• Exhaust Manifold
• Miscellaneous Hoses, Bolts and Connectors
OWNER'S WARRANTY RESPONSIBILITIES
As the engine owner, you are responsible for the performance of the required maintenance listed in your Owner's Manual.
GENERAC and ISM recommend that you retain the original purchase documentation and all receipts covering maintenance
on your engine, but GENERAC and ISM cannot deny warranty solely for the lack of receipts or for your failure to ensure the
performance of all scheduled maintenance.
As the engine owner, you should be aware, however, that GENERAC and ISM may deny you warranty coverage if your engine
or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.
You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty Service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.
To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:
1-800-333-1322
If you have any questions regarding your warranty rights and responsibilities, you should contact GENERAC at the
following address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
211 MURPHY DRIVE
EAGLE, WI 53119
Page 1
®
64 Generac Power Systems, Inc.
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Appendix 5 – Warranty
QUIETPACT™ 65D Recreational Vehicle Generator
OBLIGATIONS AND RIGHTS OF THE MANUFACTURER AND OWNER
The new model year, class of diesel engine, and emission application determination for your engine are identified on the
emission control information label affixed to the right-hand side of your engine's timing gear case. The warranty period
begins on the date the new equipment is sold to the first retail purchaser.
Any emission control system parts scheduled for regular inspection that are proven defective during normal use will be
repaired or replaced during the warranty period. Any warranted part that is scheduled for replacement, and that fails prior
to replacement, will be repaired or replaced under warranty, and the repaired or replaced part will be covered under war-
ranty for the remainder of the period prior to the first scheduled replacement. The warranty repairs and service will be per-
formed by any Generac Authorized Warranty Service Facility, with no charge for parts or labor (including diagnosis).
As the engine owner, you are responsible to perform all the required maintenance listed in your Owner's Manual. GEN-
ERAC will not deny an emission warranty claim solely because you have no record of maintenance; however, a claim
may be denied if your failure to perform maintenance resulted in the failure of a warranted part. Receipts covering reg-
ular maintenance should be retained in the event of questions, and these receipts should be passed on to each subse-
quent owner of the engine.
It is recommended that replacement parts used for maintenance or repairs be GENERAC authorized and approved parts,
to maintain the quality originally designed into your emission-certified engine. However, any replacement part may be used
in the performance of any warranty maintenance or repairs and must be provided without charge to the owner. Such use
will not reduce the warranty obligations of GENERAC. Add-on or modified parts may not be used for maintenance or war-
ranty repairs. Such use will be grounds for disallowing a warranty claim, and GENERAC will not be liable to warrant fail-
ures of warranted parts caused by the use of an add-on or modified part.
LIMITATIONS
This warranty shall not cover any of the following:
(a) Systems and parts that were not first installed on the new equipment or engine as original equipment by GENERAC.
(b) Conditions resulting from tampering, misuse, abuse, improper adjustment, engine alteration, use of add-on or modified
parts, use of replacement parts that are not the same in performance and durability as GENERAC-approved replacement
parts, accident, failure to use the recommended fuel or oil, use of unapproved fuel or oil additives, or failure to perform
required maintenance.
(c) Replacement parts used for required or scheduled maintenance.
(d) Consequential damages, such as, loss of time, inconvenience, or loss of use of this engine or equipment.
(e) Damages or repair costs caused by the owner's unreasonable delay in making the engine available for inspection
and repair.
(f) Diagnosis or inspection fees that do not result in eligible warranty service being performed.
(g) Equipment with an altered or disconnected hourmeter, where the hours cannot be determined.
(h) Equipment normally operated outside the United States.
(i) Accident-caused damage, acts of nature, or other events beyond GENERAC’S control.
(j) Warranty repairs undertaken or attempted by the owner or any other person who is not affiliated with a Generac
Authorized Warranty Service Facility.
OBTAINING WARRANTY SERVICE
To obtain service under this warranty, promptly contact your nearest Generac Authorized Service Dealer or a Generac
Authorized Warranty Service Facility. If available, provide the GENERAC representative with the original purchase receipt
(showing the initial date of purchase) and all available maintenance records.
Page 2
®
Generac Power Systems, Inc. 65
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Appendix 5 – Warranty
QUIETPACT™ 65D Recreational Vehicle Generator
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. (Generac) will, at its option, repair or replace any part which, upon examination, inspection, and testing by Generac
or a Generac Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty
schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest
Generac Authorized Warranty Service Facility. All transportation costs under the warranty, including return to the factory, are to be borne
and prepaid by the purchaser/owner. This warranty applies only to Generac generators sold and rated for “Recreational Vehicle” (RV) appli-
cations, as Generac has defined Recreational Vehicle generator applications. This warranty is effective only upon Generac’s receipt, from
the original purchaser/owner, of a completed Warranty Registration Card. This card is the only valid registration identification and must be
presented at time of request for warranty service. Claims will not be accepted without presentation of the Warranty Registration Card. The
factory recommends exercising the unit one half-hour every season.
WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS
YEAR ONE – 100% (one hundred percent) coverage on part(s), labor, removal, and reinstallation listed:
• Engine – All components
• Alternator – All components
• Transfer System – All components
WARRANTY SCHEDULE – CONSUMER/PERSONAL APPLICATIONS
YEARS ONE AND TWO – 100% (one hundred percent) coverage on part(s), labor, removal, and reinstallation listed:
• Engine – All components
• Alternator – All components
• Transfer System – All components
YEAR Three – 100% (one hundred percent) only on selected part(s) and labor listed (Any labor and part(s) not listed, and removal and rein-
stallatio, are the owner’s responsibility):
• Rotor, Stator, Computer Control Board, (if applicable with regard to the generator) Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Valve,
Valve Lifter(s), Intake and Exhaust Manifolds
FOR THE LIFE OF THE RECREATIONAL VEHICLE GENERATOR (IF SO EQUIPPED)
The drive train belt and pulleys (excluding tensioners) on generators used in recreational vehicles shall be warranted against failure due to
defective materials or normal usage for the life of the generator. For the original purchaser/owner, this drive train warranty shall include
part(s) and labor (removal and reinstallation are not included), plus $50 (fifty dollars – U.S.) payment upon return of the failed belt or pul-
ley by the original purchaser/owner. For subsequent purchaser/owner, this drive train warranty shall cover belt and pulley part(s) ONLY
(labor not included). Labor, removal, and reinstallation are the responsibility of the subsequent purchaser/owner.
Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators manu-
factured after January 1, 1998, have a transferable warranty to the second owner, ONLY for the remainder of the three-year limited war-
ranty. Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of
any warranty service.
All warranty expense allowances are subject to the conditions defined in Generac’s SUPER SERVICE INFORMATION MANUAL.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
•
•
•
Costs of normal maintenance, adjustments, installation, and startup.
Failures caused by any contaminated fuels or oils.
Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all
mechanical devices, engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when
normal use has exhausted the life of a part(s) or engine.
Failures caused by any external cause or act of God, such as, collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing,
lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
Products that are modified or altered in a manner not authorized by Generac in writing.
Any incidental, consequential, or indirect damages caused by defects in materials or workmanship, or any delay in repair or replace-
ment of the defective part(s).
•
•
•
•
•
•
•
•
•
•
Failure due to misapplication.
Telephone, telegraph, teletype or other communication expenses.
Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.
Rental equipment used while warranty repairs are being performed.
Overnight freight costs for replacement part(s).
Overtime labor.
Starting batteries, fuses, light bulbs, and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER
WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how
long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S), AS STATED ABOVE. IN NO EVENT SHALL GEN-
ERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GEN-
ERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limita-
tion may not apply to you. Purchaser/owner agrees to make no claims against Generac based on negligence.
This warranty gives you specific legal rights. You also may have other rights that vary from state to state.
®
GENERAC POWER SYSTEMS, INC.
P.O. BOX 8 • WAUKESHA, WI 53187
Part No. 0D7428
Revision 0 (11/29/01)
Printed in U.S.A.
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