Guardian Technologies Portable Generator 004270 2 User Manual

Owner’s Manual and  
Installation Instructions  
Liquid-cooled Recreational Vehicle Generator  
• Model: 004270-2  
QUIETPACT™ 75D  
This manual should remain with the unit.  
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Table of Contents  
QUIETPACT™ 75D 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 ....................................................32  
Power Supply Cord ..................................32  
Ground Fault Circuit Interrupters ............32  
Isolating Different Power Sources ............32  
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 ................................................33  
2.8  
Additional Information ..........................................10  
2.7.1  
2.7.2  
2.7.3  
2.7.4  
Recommended Battery..............................33  
Battery Cables ..........................................33  
Battery Cable Connections........................33  
Battery Compartment ..............................34  
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 ..............................................34  
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.........................................................35  
3.1  
3.2  
3.3  
3.4  
3.5  
Post Installation Tests ............................................35  
Before Initial Startup..............................................35  
Initial Start ............................................................35  
Testing Under Load ................................................35  
Installation Checklist..............................................36  
Appendix 1 – Troubleshooting....................................37  
Appendix 2 - Notes........................................................38  
Appendix 3 – Electrical Data ......................................40  
Appendix 4 – Exploded Views and Parts Lists ......44  
Appendix 5 – Notes ......................................................63  
Appendix 6 – Warranty ................................................64  
3.10 Drive Belt ..............................................................14  
3.11 Exercising the Generator........................................14  
3.12 Out-of-Service Procedure........................................15  
3.12.1 Removal From Service..............................15  
3.12.2 Return to Service......................................15  
3.13 Service Schedule ....................................................16  
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Safety Rules  
QUIETPACT™ 75D 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 generator engine releases DEADLY carbon  
monoxide gas through its exhaust system. This  
dangerous gas, if breathed in sufficient concentra-  
tions, 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 MONOXIDE POISON-  
ING ARE (a) inability to think coherently, (b) nau-  
sea, (c) vomiting, (d) twitching muscles, (e) throb-  
bing temples, (f) dizziness, (g) headaches, (h)  
weakness, and (i) sleepiness. IF EXPERIENCING  
ANY OF THESE SYMPTOMS, MOVE INTO FRESH  
AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET  
MEDICAL HELP. Shut down the generator and do  
not operate it until it has been inspected and  
repaired.  
• Never sleep in the vehicle while the genset is run-  
ning unless the vehicle has a working carbon  
monoxide detector. The exhaust system must be  
installed in accordance with the genset installation  
manual. Make sure there is ample fresh air when  
operating the genset in a confined area.  
• 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. Thus, the exhaust  
system must be installed properly, in strict com-  
pliance with applicable codes and standards.  
Following installation, do nothing that might ren-  
der the system unsafe or in noncompliance with  
such codes and standards. The generator com-  
partment must be completely vapor-sealed from  
the vehicle interior. There must be no possibility of  
exhaust fumes entering the vehicle interior. Never  
operate this equipment with a leaking or defective  
exhaust system.  
!
!
!
WARNING:  
The engine exhaust from this product  
contains chemicals known to the state  
of California to cause cancer, birth  
defects, or other reproductive harm.  
!
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth 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.  
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  
using a procedure, work method, or operating tech-  
nique that Generac does not specifically recommend,  
ensure that it is safe for others. Also make sure the  
procedure, work method, or operating technique  
chosen does not render the generator unsafe.  
DANGER  
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.  
• 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.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
!
generators.  
• 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.  
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.  
®
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Safety Rules  
QUIETPACT™ 75D Recreational Vehicle Generator  
• When working on this equipment, remain alert at  
• 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.  
all times. Never work on the equipment when  
physically or mentally fatigued.  
• Inspect the generator regularly, and contact the  
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.  
FIRE HAZARDS  
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 there are any questions  
pertaining to fire extinguishers, consult the local  
fire department.  
• Never insert any tool or other object through open-  
ings in the generator interior, even if the unit is not  
running. Serious injury or damage to the equip-  
ment could be done.  
ELECTRICAL 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  
work must be done 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.  
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.  
• 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.  
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Section 1 – General Information  
QUIETPACT™ 75D 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: 04270-2  
QUIETPACT™ 75D  
1. 2-Pole, 35-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™ 75D 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. DO NOT modify the generator nor use it for  
any application other than for what it was designed.  
If there are any questions pertaining to its applica-  
tion, write or call the factory. Do not use the unit until  
advised by a competent authority.  
CONNECTION SYSTEM  
This generator 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.  
The generator may have been installed so that it pow-  
ers 120- and/or 240-volt AC electrical loads (Figure  
1.1). It can be rewired to connect 120-volt AC electri-  
cal loads only. This procedure should be done by a  
Generac Authorized Service Dealer or other qualified  
installer. Refer to the installation portion of this man-  
ual for more information.  
DANGER  
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.  
Figure 1.1 – Connections for 120/240 Dual  
Voltage  
Use this generator to supply electrical power for  
operating 120/240-volt, single-phase, 60-Hertz, AC  
electrical loads. These loads can require up to 7,500  
watts (7.5 kW) of power, but cannot exceed 62.5 AC  
amps of current at 120 volts, or 31.2 AC amps at 240  
volts.  
Do not overload the generator. Some installa-  
tions may require that electrical loads be alter-  
1.5 SPECIFICATIONS  
!
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.  
1.5.1 FUEL REQUIREMENTS  
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.  
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.  
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.  
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  
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Section 1 – General Information  
QUIETPACT™ 75D Recreational Vehicle Generator  
1.5.2 FUEL CONSUMPTION (GAL/HR)  
1.5.5 ENGINE  
Type of Engine ..........................................................ISM Diesel  
Cylinder Arrangement ................................................3, in-line  
Displacement ................................................58.2 in . (954 cc)  
Model  
No Load Half Load Full Load  
QUIETPACT™ 75D  
(004270-0)  
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  
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 viscosity rating, based on the ambient tempera-  
ture 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 for oil level checking and  
changing procedures.  
Recommended Battery....................70 Ah, 360 Cold-cranking  
Amps (Minimum ratings)  
1.5.4 COOLANT  
Maximum Cranking Current ....................................220 Amps  
Ground Polarity ............................................................Negative  
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,  
a high-quality rust inhibitor to the recommended  
coolant mixture may be added. When adding coolant,  
always add the recommended 50-50 mixture.  
1.5.6 GENERATOR  
Rated Maximum Continuous AC Output at ...  
85º F (29º C) Ambient..........................7,500 Watts (7.5 kW)  
100º F (38º C) Ambient ......................7,000 Watts (7.0 kW)  
120º F (49º C) Ambient ......................6,000 Watts (6.0 kW)  
Rated Voltage................................................120/240 Volts AC*  
DANGER  
Do not remove the radiator pressure cap while  
the engine is hot; otherwise, serious burns  
from boiling liquid or steam could result.  
Rated Maximum Continuous AC Current at ...  
7,500 Watts  
!
120 Volts........................................................62.5 Amps  
240 Volts........................................................31.2 Amps  
7,000 Watts  
Ethylene glycol base antifreeze is poisonous.  
Do not use mouth to siphon coolant from the  
!
120 Volts........................................................58.3 Amps  
240 Volts........................................................29.2 Amps  
radiator, recovery bottle, or any container.  
Wash hands thoroughly after handling. Never  
store used antifreeze in an open container  
because animals are attracted to the smell and  
taste of antifreeze, even though it is poisonous  
to them.  
6,000 Watts  
120 Volts........................................................50.0 Amps  
240 Volts........................................................25.0 Amps  
Phase ................................................................................Single  
Rotor Speed at No Load ..........................................3,780 rpm  
Number of Rotor Poles ............................................................2  
Engine RPM ......................................................................1,950  
Rated AC Frequency ........................................................60 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)  
*All units are reconnectable to 120-volt-only AC output.  
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. DO NOT use any soluble oil  
inhibitor for this equipment.  
®
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Section 2 – Operation  
QUIETPACT™ 75D Recreational Vehicle Generator  
2.1.4 LINE BREAKER  
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 120/240-volt  
AC output to the vehicle circuits. The QUIETPACT™  
75D has two 35-amp breakers.  
Figure 2.1 – Generator Control Panel  
NOTE:  
Refer to Section 1.4, “Generator AC Connection  
System,”. Individual installations will differ. If an  
overload occurs, the dual breakers will open the  
ungrounded (i.e., hot) stator leads (11 and 44 in  
Figure 1.1). When the generator has been con-  
nected for 120 volts only (Figure 2.16, Page 31),  
the line breakers will operate independently on  
the ungrounded (i.e., hot) stator leads (11 and 33  
in Figure 2.16, Page 31).  
2.1.5 PREHEAT SWITCH  
The diesel engine is equipped with glow plugs, one  
for each cylinder. When the preheat switch is pressed,  
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.  
2.1.1 HOURMETER  
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 the generator are completed on a  
timely basis.  
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 for  
starting and stopping the generator conveniently  
from within the vehicle. Refer to Part II - Installation  
Instructions, Section 2.8, for details on the remote  
start/stop option.  
2.1.2 START/STOP SWITCH  
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.  
2.3 BEFORE STARTING THE ENGINE  
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  
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 the fuse must be replaced, use only  
an identical replacement (i.e., SFE-14).  
2.3.1 INSTALLATION  
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, find the cause of the  
overload before replacing the fuse.  
®
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Section 2 – Operation  
QUIETPACT™ 75D Recreational Vehicle Generator  
2.3.2 ENGINE LUBRICATION  
DANGER  
Before starting the engine, have the engine crankcase  
properly serviced with the recommended oil. Refer to  
Section 1.5.3 and Sections 3.1 and 3.2 for oil servic-  
ing procedures and recommendations.  
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) nausea, (c) vomiting, (d) twitching  
muscles, (e) throbbing temples, (f) dizziness, (g)  
headaches, (h) weakness, and (i) sleepiness. IF  
EXPERIENCING ANY OF THESE SYMPTOMS,  
MOVE INTO FRESH AIR IMMEDIATELY. IF SYMP-  
TOMS PERSIST, GET MEDICAL HELP. Shut down  
the generator and do not operate it until it has  
been inspected and repaired.  
!
Any attempt to crank or start the engine before  
it has been properly serviced it with the recom-  
mended oil may result in an engine failure.  
!
2.3.3 FUEL SUPPLY  
The engine must have an adequate supply of proper  
fuel to operate. Before starting it, check that sufficient  
fuel is available.  
NOTE:  
Depending on the installation, the generator may  
have either a separate fuel tank or “share” the  
vehicle’s engine fuel tank.  
DANGER  
Never sleep in the vehicle while the genset is  
running unless the vehicle has a working carbon  
monoxide detector. The exhaust system must be  
installed in accordance with the genset installa-  
tion manual. Make sure there is ample fresh air  
when operating the genset in a confined area.  
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.  
!
2.4 STARTING THE GENERATOR  
2.3.4 COOLANT LEVEL  
NOTE:  
Check the engine coolant level prior to initial use and  
at recommended intervals. Refer to Section 1.5.4,  
“Coolant”, and Section 3.8, “Engine Coolant”, for pro-  
cedures and recommendations.  
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.  
2.3.5 COOLING AND VENTILATING AIR  
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.  
To start the generator from either the generator con-  
trol panel or from the optional remote panel, proceed  
as follows:  
2.3.6 ENGINE EXHAUST GAS  
1. Turn OFF electrical loads using the means pro-  
vided in the vehicle (such as, a main-line circuit  
breaker or transfer switch).  
Before starting the generator engine, 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.  
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.  
®
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Section 2 – Operation  
QUIETPACT™ 75D Recreational Vehicle Generator  
2. If the engine is cold, press the Preheat switch for  
2.6.2 DO NOT OVERLOAD THE GENERATOR  
Read the rated wattage/amperage capacity of the gen-  
erator on the generator data decal located below the  
user control panel.  
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.  
Applying electrical loads in excess of the unit’s rated  
capacity may trip the line breaker or cause the  
engine/generator to shut down.  
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.  
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.  
• 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.  
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 the vehicle (such as, a main-line cir-  
cuit breaker or transfer switch).  
2.5 STOPPING THE GENERATOR  
1. Turn OFF all electrical loads, using the means  
provided in the vehicle (such as, a main-line cir-  
cuit breaker or transfer switch).  
• 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.  
2. Let the generator run at no-load for a few minutes,  
to stabilize internal engine generator temperatures.  
Do not stop the engine/generator immediately  
after running under load. This can overheat  
!
For the first two or three hours of operation, do not  
apply electrical loads over 75 percent of the unit’s  
rating.  
and damage the engine and/or generator.  
3. Press and hold the Start/Stop switch in the STOP  
position, until the engine shuts off.  
2.7 PROTECTION SYSTEMS  
2.6 APPLYING LOADS TO GENERATOR  
When applying electrical loads to the generator,  
observe these guidelines:  
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 for the  
location of these devices. If automatic shutdown does  
occur, refer to “Troubleshooting Guide”.  
• Before applying electrical loads, let the generator  
stabilize and warm up for a minute or two.  
• DO NOT overload the generator.  
2.7.1 LOW OIL PRESSURE SWITCH  
2.6.1 LETTING THE ENGINE STABILIZE  
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.  
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.  
2.7.2 HIGH COOLANT TEMPERATURE SWITCH  
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™ 75D 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  
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.  
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  
A DC control circuit board senses engine speed from  
the frequency of the alternator AC output. Should the  
alternator output frequency exceed approximately 72  
Hertz (4,320 alternator rpm), circuit board action  
initiates an automatic engine shutdown.  
2.7.4 OVERVOLTAGE PROTECTION  
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 60 Hertz, voltage is regulated at  
120 volts (voltage-to-frequency ratio is 2-to-1).  
2.8.2 25-HOUR CHECK-UP  
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  
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™ 75D Recreational Vehicle Generator  
Figure 3.1 – Oil Maintenance Features  
2.8.4 OPERATION IN HIGH GRASS  
OR BRUSH  
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  
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). See the “Service Schedule,”  
Section 3.13, for subsequent oil and filter changes.  
Change the oil more frequently, if operating consis-  
tently under heavy load or at high ambient tempera-  
tures.  
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. 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 “FULLmark.  
DO NOT FILL ABOVE THE “FULLMARK.  
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™ 75D Recreational Vehicle Generator  
9. Remove the dipstick, and wipe it dry with a clean,  
3.4 SPARK ARRESTOR MUFFLER  
The exhaust muffler supplied with the QUIETPACT™  
75D is a spark arrestor type. Generac exhaust muf-  
flers for recreational vehicle generators do not have a  
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). Periodically use the dipstick to  
check the oil level and continue to fill the  
crankcase until the oil reaches the dipstick  
“FULLmark. 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 gas-  
ket.  
11. Install the oil-fill plug and the dipstick.  
12. Reinstall the air filter.  
13. Reattach the front service door; make sure the  
latches are fully engaged.  
14. Start the engine, and check for leaks.  
NOTE:  
4. Remove the hex pipe cap from the end of the  
Check the oil level and fill to the “FULLmark,  
after checking for leaks. The filter will retain some  
oil.  
spark arrestor cleanout pipe.  
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.  
3.3 SERVICING THE ENGINE  
AIR FILTER  
To access the engine air filter (Figure 3.2), 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 posi-  
tioned properly before reattaching the service door.  
Make sure the service door latches are fully engaged.  
6. Start and run the engine for approximately 15  
minutes.  
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.  
10. Reinstall the hex pipe cap, spark arrestor access  
Figure 3.2 – Engine Air Filter  
plate, gasket, and two screws.  
The exhaust system of this product gets  
extremely 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.  
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.  
See the “Service Schedule,” Section 3.13, for recom-  
mended air cleaner maintenance.  
®
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Section 3 – Maintenance  
QUIETPACT™ 75D Recreational Vehicle Generator  
3.6 BATTERY MAINTENANCE  
All lead-acid batteries will discharge when not in use.  
Be sure to reinstall the hex pipe cap tightly to  
The generator battery should be inspected per the  
“Service Schedule,” Section 3.13. The following pro-  
cedure should be used for inspection:  
the spark arrestor cleanout pipe. Vibration  
could cause a loose cap to fall out, resulting in  
hot engine exhaust being drawn through the  
centrifugal cooling fan and out beneath the  
unit. This could result in damage to the genera-  
tor or in discharge of hot exhaust sparks  
beneath the unit.  
• Inspect the battery posts and cables for tightness  
and corrosion. Tighten and clean as necessary.  
• Check the battery fluid level of unsealed batteries  
and, if necessary, fill with Distilled Water Only. Do  
not use tap water in batteries.  
• Have the state of charge and condition checked by  
Figure 3.3 – Spark Arrestor  
Muffler Maintenance  
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.  
DANGER  
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 body before touching the battery by  
first touching a grounded metal surface.  
GASKET  
ACCESS PLATE  
3.5 CLEANING THE GENERATOR  
Keep the 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.  
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;  
• Disconnect any charging source prior to connect-  
ing, or disconnecting, battery terminals; and  
Finally, have the insulation resistance of stator and  
rotor windings checked. If insulation resistances are  
excessively low, the generator may require drying.  
• 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.  
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Section 3 – Maintenance  
QUIETPACT™ 75D Recreational Vehicle Generator  
DANGER  
Do not open or mutilate the battery. Released  
electrolyte has been known to be harmful to  
the skin and eyes, and to be toxic.  
Do not remove the radiator pressure cap while  
the engine is hot; otherwise, serious burns  
from boiling liquid or steam could result.  
!
!
!
!
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:  
Ethylene glycol base antifreeze is poisonous.  
Do not use mouth to siphon coolant from the  
radiator, recovery bottle, or any container.  
Wash hands thoroughly after handling. Never  
store used antifreeze in an open container  
because animals are attracted to the smell and  
taste of antifreeze, even though it is poisonous  
to them.  
• Wear full eye protection and protective clothing;  
• Immediately wash with water all skin areas that  
come into contact with the electrolyte.  
• If the electrolyte contacts the eyes, immediately  
flush eyes thoroughly with water, and seek med-  
ical attention.  
• Spilled electrolyte is to be washed down with an  
acid-neutralizing agent. 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.  
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. DO NOT use  
any soluble oil inhibitor for this equipment.  
!
3.7 COOLING SYSTEM  
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.  
3.9 MAJOR SERVICE MANUAL  
To obtain a service manual for the generator, the  
nearest Generac Authorized Service Dealer. Make  
sure to identify the MODEL NUMBER and SERIES.  
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 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), as nec-  
essary; the tank should be kept within the levels indi-  
cated on the adjacent decal. If desired, a high-quality  
rust inhibitor to the recommended 50-50 coolant  
mixture may be added. If added consistently, the rec-  
ommended mixture will protect the unit against  
freezing temperatures.  
3.11 EXERCISING THE GENERATOR  
At least once every seven days, start and operate the  
generator. Let the unit run for at least 30 minutes to  
“exercise” the engine. If the generator cannot be exer-  
cised 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.  
®
14 Generac Power Systems, Inc.  
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Section 3 – Maintenance  
QUIETPACT™ 75D Recreational Vehicle Generator  
3.12.2 RETURN TO SERVICE  
To return the unit to service after storage, proceed  
as follows:  
3.12 OUT-OF-SERVICE PROCEDURE  
3.12.1 REMOVAL FROM SERVICE  
Prepare the generator for storage as follows:  
1. Check the tag on the engine for oil viscosity and  
classification. Verify that the correct recommended  
1. Start the engine and let it run until it is thoroughly  
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). Refill the  
crankcase with the recommended oil (see Section  
1.5.3).  
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.  
oil is used in the engine (see Section 1.5.3). If nec-  
essary, 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 distilled  
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 incor-  
rectly.  
5. Turn OFF all electrical loads. Add fuel, if necessary,  
5. Clean and wipe the entire generator.  
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. The generator is now ready for service.  
®
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Section 3 – Maintenance  
QUIETPACT™ 75D Recreational Vehicle Generator  
3.13 SERVICE SCHEDULE  
ATTENTION: It is recommended that all service work  
be performed by the 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  
DANGER  
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS  
SHOULD ATTEMPT INSTALLATION!!  
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Safety Rules  
QUIETPACT™ 75D 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  
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.  
For safety reasons, Generac recommends that the  
installation, initial startup, and maintenance of  
this equipment is carried out by a Generac  
Authorized Service Dealer.  
• The engine exhaust fumes contain carbon monox-  
ide, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. This exhaust sys-  
tem must be installed properly, in strict compli-  
ance with applicable codes and standards.  
Following installation, do nothing that might ren-  
der the system unsafe or in noncompliance with  
such codes and standards. The generator com-  
partment must be completely vapor-sealed from  
the vehicle interior. There must be no possibility of  
exhaust fumes entering the vehicle interior. 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.  
• When working on this equipment, remain alert at  
all times. Never work on the equipment when  
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. Serious injury or damage to the equip-  
ment could be done.  
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.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting  
!
its maintenance, or being careless can cause  
possible injury or death. Permit only responsible  
and capable persons to operate or maintain this  
equipment.  
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™ 75D 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  
work must be done 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 there are any questions per-  
taining to fire extinguishers, consult the 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.  
• It is required that an approved, flexible, noncon-  
ductive fuel line between the generator fuel con-  
nection point and the rigid fuel lines be installed.  
• 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™ 75D 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 QUIETPACT  
75D operates 120/240-volt, single-phase, 60-Hertz, AC  
electrical loads that require up to 62.5 amps at 120  
volts or 31.2 amps at 240 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 120/240 volts AC at 60 Hertz,  
when the rotor is operating at 3,600 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  
The generator is equipped with dual stator power  
windings, as shown in Figure 1.1.  
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 120/240 Dual  
Voltage  
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.  
4. California Administrative Code, Title 25, avail-  
able from the State of California, Documents  
Section, P.O. Box 1015, North Highlands,  
CA 95660.  
• The AC connection system uses a GROUNDED  
neutral. A separate green ground wire is connected  
to the recreational vehicle’s junction box.  
For this QUIETPACT™ unit, each stator winding can  
support 120-volt, 60-Hertz, AC electrical output  
(3,600 rpm). When the two stator windings are con-  
nected in series, the unit can generate an output of  
240 volts AC.  
NOTE:  
Do NOT connect loads in excess of circuit  
breaker ratings.  
®
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Section 1 – General Information  
QUIETPACT™ 75D Recreational Vehicle Generator  
Major Features and Dimensions — Drawing No. 0D2650-A  
Figure 1.2 – Major Features and Dimensions  
®
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Section 2 – Installation  
QUIETPACT™ 75D 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  
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  
Plan the generator location based on the following:  
If the generator will be suspended below the horizon-  
tal support tubing, the suspension method used with  
the vehicle frame members must (a) be able to sup-  
port the weight of the generator AND (b) provide suf-  
ficient restraint for the generator. One typical sus-  
pended mounting system is shown in Figure 2.1. The  
location of a suspended mounting system must be  
carefully planned, keeping the following general 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  
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™ 75D Recreational Vehicle Generator  
Figure 2.3 – Typical Compartment Construction  
2.1.4 GENERATOR RESTRAINT  
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  
generator or inside a compartment that the installer  
constructs, the compartment must meet certain spec-  
ifications, as outlined in the following sections:  
Caulking must be done so that the caulking mate-  
rial will stay in place permanently. Pressing mate-  
rials 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  
• 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 con-  
structed of, or lined with, 26-gauge galvanized  
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™ 75D Recreational Vehicle Generator  
• Seams and joints of the galvanized steel (whether  
DANGER  
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.  
Using a combination of sound-insulating materials  
can often reduce noise more effectively than a single  
material. For example, a sheet of lead or visco-elastic  
material, along with a layer of other acoustical mate-  
rial, is more effective than when a single material is  
used.  
Figure 2.4 – Types of Lock Seams  
2.2.3 ACOUSTICS  
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):  
DANGER  
Do not install any flammable material directly  
above or around the compartment. Heat, trans-  
ferred through the compartment structure, may  
be sufficient to ignite, char, or discolor seat  
cushions, fiberboard, and other flammable  
materials. Use approved, nonflammable insulat-  
ing 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.  
2.2.2 SOUND INSULATING MATERIALS  
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.  
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.  
DANGER  
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).  
®
24 Generac Power Systems, Inc.  
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Section 2 – Installation  
QUIETPACT™ 75D Recreational Vehicle Generator  
Figure 2.5 – Typical Noise Abatement  
2.2.4 COMPARTMENT FLOOR CUTOUTS  
Provide openings in the generator compartment 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.  
• Rear service door.  
DANGER  
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™ 75D Recreational Vehicle Generator  
2.3.2 COOLING AIR INLET OPENINGS  
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. Compensate for this  
by making the actual air opening proportionately  
larger. See Section 2.3.3.  
DANGER  
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  
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). The installer must be  
sure air is available to the sides of the generator for  
proper air intake.  
• Provide an opening in the vehicle skirt and space  
around the generator for cooling airflow (Figure  
2.11). Recommended clearance around all sides of  
the generator is at least two inches (50 mm).  
®
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Section 2 – Installation  
QUIETPACT™ 75D Recreational Vehicle Generator  
Figure 2.10 – Air Inlet Using Ductwork  
2.3.4 TESTING THE INSTALLATION  
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, enlarge the air openings. Never  
place a unit into service until absolutely certain that  
cooling and ventilation is adequate.  
NOTE:  
The installation must be tested, especially if bring-  
ing in air from below the generator set.  
2.4 DIESEL FUEL SYSTEM  
Figure 2.11 – Air Inlet in Vehicle Skirt  
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  
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 being used.  
DANGER  
For example: If planning to use screening with an 80  
percent free air inlet area, divide 150 (975) by 0.8,  
which results in 187.5 square inches (1,218.75 cm2).  
Minimum actual size of air inlet opening in this case  
is 187.5 square inches (1,218.75 cm2).  
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.  
®
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Section 2 – Installation  
QUIETPACT™ 75D Recreational Vehicle Generator  
Because diesel fuels are less volatile than gasoline or  
2.4.2 GENERATOR FUEL SUPPLY LINES  
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:  
gaseous fuels, they are considered safer from the  
standpoint of storage and handling. As a result,  
installers may tend to be careless in their installation  
practices, which can result in poor engine perfor-  
mance. 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 starting and rough engine operation.  
• 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  
Either the generator must share the vehicle’s engine  
fuel tank, or a separate fuel tank for the generator set  
must be installed. All fuel tanks installed on the vehi-  
cle 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 the fuel  
pickup tube be two to three 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 peri-  
ods.  
2.4.3 GENERATOR FUEL RETURN LINES  
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 inch-  
es from the tank fuel pickup tubes to prevent air  
bubbles 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.  
®
28 Generac Power Systems, Inc.  
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Section 2 – Installation  
QUIETPACT™ 75D Recreational Vehicle Generator  
2.5.2 EXHAUST SYSTEM SAFETY  
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 the 3-inch  
(76 mm) clearance cannot be maintained, 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.  
DANGER  
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 FEELING  
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 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.  
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  
The exhaust muffler supplied with the QUIETPACT ™  
75D 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.  
MUFFLER PERMANENTLY  
MOUNTED INSIDE  
ENCLOSURE  
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.  
• Use enough exhaust system hangers to prevent any  
part of the system from being dislocated.  
®
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Section 2 – Installation  
QUIETPACT™ 75D Recreational Vehicle Generator  
• Use exhaust system parts recommended by  
• Route power supply conductors from generator AC  
output leads T1 (red), T2 (white), T3 (black), and  
the green ground wire through approved flexible  
conduit to the electrical junction box on the com-  
partment wall.  
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.  
• Never tee the generator engine exhaust pipe into  
the vehicle engine exhaust piping. This causes  
excessive back pressure on the generator engine.  
Also, water from one engine can damage the other  
engine.  
If a flexible metal conduit is used between the gen-  
erator and the compartment junction box, the con-  
duit end that terminates at the compartment junc-  
tion box must be vapor-sealed. Flexible metal con-  
duit is NOT vapor-tight along its entire length.  
• From the junction box, route power supply wires  
through approved conduit to either (a) double-  
pole, double-throw transfer switch, or (b)  
approved isolation receptacle. Connecting to a  
transfer switch or isolation receptacle must pre-  
vent vehicle electrical circuits from being connect-  
ed to two different power supplies at the same time  
(such as, generator and dockside power).  
• Plan exhaust system installation carefully. Comply  
with all applicable codes, standards, and regula-  
tions.  
2.6 ELECTRICAL CONNECTIONS  
• Conductors must be rated 221° F (105° C) or must  
Be sure to read Section 1.6.  
be of a larger conductor size.  
The following general rules apply to electrical con-  
nections in a recreational vehicle:  
2.6.3 GENERATOR AC CONNECTIONS  
Generator AC output leads T1 (red), T2 (white), and  
T3 (black) come out of the generator, as shown in  
Figure 2.14. Leads T1 (red) and T3 (black) are “hot,”  
while T2 (white) is the grounded neutral lead. 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)  
T2 Neutral (White)  
• 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.  
T3 (Black)  
T2 Neutral  
(White)  
Ground  
(Green)  
2.6.1 ELECTRICAL JUNCTION BOX  
Install an approved, square electrical junction box  
with a blank cover on the interior or exterior wall of  
the area planed for installation of the generator (NOT  
on the generator). Route the generator's AC output  
leads into this junction box through approved flexible  
conduit. This is the point of first termination for gen-  
erator AC output leads.  
QUIETPACT ™ generators use a four-position termi-  
nal block to connect between stator power leads and  
vehicle 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  
dual-voltage (120/240 volts AC) output (See Figure  
2.15). The stator power windings are connected in  
series. Lead 11/11A connects to T1 (Red), lead  
44/44A connects to T3 (Black), while leads 22 and 33  
are grounded and connect to T2 NEUTRAL (White). A  
"tie bar" connects the two switch handles on line  
breaker CB1.  
2.6.2 WIRING  
• Wiring should be of stranded copper to reduce the  
chance that vibration may cause breakage.  
• Wire gauge size should be large enough to handle  
at least 115 percent of the installed generator's  
rated maximum current.  
• If neutral conductors are used, they must be the  
same size as other leg wires.  
®
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Section 2 – Installation  
QUIETPACT™ 75D Recreational Vehicle Generator  
When connecting vehicle load leads, the following  
2.6.3.1 Generator Coversion to  
120 Volts Only — Dual Circuits  
NOTE:  
rules apply:  
• Connect 120-volt, single-phase, 60-Hertz, AC elec-  
trical loads, requiring up to the trip rating of cir-  
cuit breaker CB1, across AC output leads T1 (red)  
and T2 (white).  
• Connect 120-volt, single-phase, 60-Hertz, AC elec-  
trical loads, requiring up to the trip rating of cir-  
cuit breaker CB1A, across AC output leads T3  
(black) and T2 (white).  
• Try to keep the load balanced between the two cir-  
cuit breakers and the stator windings.  
• The neutral line (T2, white) on all units is a  
grounded neutral.  
Conversion of a QUIETPACT™ generator from  
"120/240 volt dual voltage" to "120 volts only -  
dual circuits" (or vice-versa) requires rerouting  
wires within the unit enclosure. It is recommend-  
ed that this conversion be performed by a Generac  
Authorized Service Dealer.  
Figure 2.16 shows the stator power winding connec-  
tions for 120 volts only - dual circuits. Two stator  
power windings are used, with each winding capable  
of supplying half of the unit's rated wattage/amperage  
capacity. The circuit from each winding is protected  
against overload by a line breaker (CB1 and CB1A).  
Line breakers CB1 and CB1A have a trip rating of 35  
amps.  
Do NOT connect electrical loads in excess of any  
circuit breaker rating, or problems will develop  
with circuit breaker tripping, which causes a loss  
of AC output. Also, do NOT exceed the genera-  
tor'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.  
To convert from "120/240 volt dual voltage" to "120  
volts only - dual circuits", disconnect battery power  
from the generator and reverse stator lead wires 33  
and 44 as follows:  
NOTE:  
It is necessary to feed stator lead wires 33 and 44  
through grommets on the electrical enclosure and  
engine control box in order to perform the rerout-  
ing outlined below. The front and top unit enclo-  
sure panels, as well as the user control panel,  
must be removed to perform this. After re-routing,  
wires should be properly tied down to prevent  
chafing or contact with moving internal compo-  
nents  
Figure 2.15 – Connections for 120/240 Dual  
Voltage  
1. Remove stator lead wire 33, as shown in Figure  
2.15, from the ground stud adjacent to the four-  
position terminal block. Reroute stator lead 44  
from the line side terminal of CB1 (renamed as  
CB1A in Figure 2.16) to the ground stud location  
previously occcupied by stator lead wire 33.  
2. Move smaller gauge (#18 AWG) wire labeled #44  
(not shown), from the top of CB1A to the top of  
CB1. Renumber this wire #11.  
Figure 2.16 – Connections for 120 Volts Only —  
Dual Circuits  
3. Reroute stator lead wire 33, removed in step 1,  
to the line side terminal on CB1A.  
4. Renumber ground wire "33", located between the  
four-position terminal block and ground in  
Figure 2.15, as ground wire "44", as shown in  
Figure 2.16.  
5. Renumber wire "44A" from Figure 2.15 as wire  
"33A" in Figure 2.16.  
6. Connect a 12 AWG jumper wire between line  
breakers CB1 and CB1A, as shown in Figure  
2.16.  
7. Remove the "tie bar" between the two-line break-  
er switch handles.  
®
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Section 2 – Installation  
QUIETPACT™ 75D Recreational Vehicle Generator  
2.6.4 CONDUIT  
2.6.6 GROUND FAULT CIRCUIT INTERRUPTERS  
Route the connections between the generator and the  
junction box through approved, flexible conduit. The  
following general rules apply:  
The National Electrical Code (NFPA 70, 551-7)  
requires that ground-fault circuit interrupters  
(GFCIs) be installed on all external and some internal  
electrical receptacles. Contact the manufacturer or  
dealer for recommendations.  
• All wiring, conduit, and interconnections must be  
installed in compliance with applicable codes,  
standards, and regulations.  
2.6.7 ISOLATING DIFFERENT POWER SOURCES  
• Cut wiring to the required length, and allow extra  
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). Whichever method is used, be certain  
that both power sources are NOT connected at the  
same time.  
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.  
• If using metallic conduit, vapor-seal the end of the  
conduit where it enters the junction box. Do this  
because flexible metallic conduit is not vaporproof  
along its entire length.  
DANGER  
If the vehicle’s 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 vehicle’s circuits at the same  
time. The dockside (utility) power source must  
be positively isolated from the vehicle’s circuits  
whenever the generator 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 electrical  
energy. Installation and connection of the gen-  
erator must comply with NFPA 70, Article 551,  
and NFPA 1192 (latest editions).  
• All openings in the generator compartment for the  
passage of wiring and conduit must be sealed and  
made vapor-tight.  
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  
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.  
Figure 2.17 – Transfer Switch Isolation Method  
®
32 Generac Power Systems, Inc.  
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Section 2 – Installation  
QUIETPACT™ 75D Recreational Vehicle Generator  
Figure 2.18 – Installation With Isolation Receptacle  
2.7.3 BATTERY CABLE CONNECTIONS  
2.7 BATTERY INSTALLATION  
1. Connect the battery cable from the battery post or  
2.7.1 RECOMMENDED BATTERY  
terminal, indicated by a POSITIVE, POS, or (+),  
Install a battery that meets the following require-  
ments:  
to the insulated lug on the unit frame (Figure  
2.19).  
NOTE:  
• The battery must be a 12-volt, automotive-type  
storage battery.  
• Use a battery with minimum ratings of 70 amp-  
hours and 360 cold-cranking amps.  
NOTE:  
Check to be sure the cable boot for the positive  
cable has been installed.  
2. Connect the battery cable from the battery post,  
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.  
If the battery is to be used to power other vehicle  
accessories, as well as to start the generator, a bat-  
tery with a larger capacity may be necessary.  
2.7.2 BATTERY CABLES  
Using battery cables that are too long or too small in  
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.  
Figure 2.19 – Connecting Battery Cables  
The QUIETPACT™ 75D 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)  
CABLE SIZE  
2*  
11 to 15 (3.4 to 4.5)  
16 to 20 (4.5 to 6)  
0
000  
*For warm weather, use No. 2 cable up to 20 feet.  
®
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Section 2 – Installation  
QUIETPACT™ 75D Recreational Vehicle Generator  
• 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.  
• 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.  
DANGER  
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-  
mits starting and stopping 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 body before touching the bat-  
tery by first touching a grounded metal surface.  
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  
• Remove watches, rings, or 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;  
2.8.1 REMOTE START/STOP CONNECTIONS  
• 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.  
The following steps are necessary to connect the  
remote start/stop option:  
1. If the six-wire remote connector is visible below  
the control panel, as shown in Figure 2.20, skip  
to step 5. 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.  
Do not open or mutilate the battery. Released  
electrolyte is known to be harmful to the skin  
!
and eyes, and to be toxic.  
3. Remove the “REMOTE” knock-out, taking care  
not to damage the wiring behind it.  
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically  
!
4. Feed the remote connector through the hole, and  
fit the supplied grommet into position.  
5. Wire the remote harness (Part # 0D2021C, sup-  
plied as an accessory with the generator) to the  
vehicle’s remote start panel. Refer to Figure 2.20  
for a wiring legend.  
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.  
6. Plug the remote harness into the mating remote  
connector on the generator.  
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Section 3 – Post-installation Start-up Checks  
QUIETPACT™ 75D Recreational Vehicle Generator  
CHECKS  
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.  
3.1 POST INSTALLATION TESTS  
The generator set was factory-tested and adjusted. It  
is not necessary to adjust the unit any further, except  
under special circumstances.  
6. Turn off all electrical loads by setting the genera-  
tor’s line breakers to their “OFF” (or open) posi-  
tion.  
7. Let the unit run at no-load for a few minutes to  
stabilize internal engine/generator temperatures.  
Then, shut down the engine.  
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.  
!
3.2 BEFORE INITIAL STARTUP  
Before starting, complete the following:  
The generator set was thoroughly tested and  
adjusted at the factory before shipping. No  
additional adjustment should be necessary.  
Only trained, qualified service technicians  
should perform adjustments outlined in this  
manual.  
!
1. Check the engine crankcase oil level and, if nec-  
essary, fill to the dipstick “FULLmark (cross-  
hatched area) with the recommended oil. Do not  
fill above the FULL mark.  
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.  
3.4 TESTING UNDER LOAD  
Apply electrical loads equal to about 50 to 75 percent  
of the unit's rated wattage/amperage capacity.  
3.3 INITIAL START  
Let the unit run at least 30 minutes with load  
applied. During this part of the test, check that the  
unit is not running excessively hot and that adequate  
cooling airflow is available. Do not allow the unit to  
overheat during prolonged operation.  
When absolutely certain that the unit has been prop-  
erly 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.  
2. Refer to Part I, Section 2.4, “Starting the  
Generator”, for cranking and starting instruc-  
tions. 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).  
NOTE:  
The generator engine is equipped with a high  
coolant temperature switch. The switch has nor-  
mally open (N.O.) contacts. When the engine  
coolant temperature is too high, switch contacts  
close, and the engine shuts down automatically.  
GENERAC RECOMMENDS THAT THE GENERA-  
TOR BE TESTED FOR ADEQUATE COOLING.  
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.  
®
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Section 3 – Post-installation Start-up Checks  
QUIETPACT™ 75D Recreational Vehicle Generator  
CHECKS  
EXHAUST SYSTEM  
3.5 INSTALLATION CHECKLIST  
Exhaust system complies with all applicable  
LOCATION AND SUPPORT  
codes.  
Generator is properly located.  
Generator is properly supported.  
Generator is properly restrained.  
Exhaust system is properly and safely installed.  
ELECTRICAL CONNECTIONS  
Connections comply with local code requirements  
and all National Electrical Codes.  
GENERATOR COMPARTMENT  
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  
Recommended battery is installed.  
Recommended cables are installed.  
Cables are clean and tight.  
COOLING AND VENTILATING AIR  
Airflow is adequate.  
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  
and terminal covers are positioned.  
Fuel tank complies with all applicable codes.  
OPTIO``NAL ACCESSORIES  
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  
Check that all tests are completed properly.  
DATE OF INSTALLATION ____________________________________________________  
NAME OF INSTALLER ______________________________________________________  
SIGNATURE OF INSTALLER ________________________________________________  
®
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Appendix 1 – Troubleshooting  
QUIETPACT™ 75D 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.  
®
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Appendix 2 – Notes  
QUIETPACT™ 75D Recreational Vehicle Generator  
®
38 Generac Power Systems, Inc.  
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Appendix 2 – Notes  
QUIETPACT™ 75D Recreational Vehicle Generator  
®
Generac Power Systems, Inc. 39  
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Appendix 3 — Electrical Data  
QUIETPACT™ 75D Recreational Vehicle Generator  
Electrical Schematic – 120/240 VAC Output– Drawing No. 0D2792-A  
®
40 Generac Power Systems, Inc.  
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Appendix 3 — Electrical Data  
QUIETPACT™ 75D Recreational Vehicle Generator  
Electrical Schematic – 120/240 VAC Output – Drawing No. 0D2792-A  
®
Generac Power Systems, Inc. 41  
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Appendix 3 — Electrical Data  
QUIETPACT™ 75D Recreational Vehicle Generator  
Wiring Diagram 120/240 Dual Voltage– Drawing No. - 0D2793-B Part 1  
®
42 Generac Power Systems, Inc.  
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Appendix 3 — Electrical Data  
QUIETPACT™ 75D Recreational Vehicle Generator  
Wiring Diagram 120 VAC– Drawing No. - 0D2793-B Part 2  
®
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
Engine, Alternator Drive and Starter Assembly – Drawing No. 0D2355-C  
26  
25  
27  
11  
39  
21  
49  
22  
22  
41  
43  
28  
29  
26  
21  
25  
24  
32  
7
49  
46  
6
28  
13  
45  
4
44  
39  
26  
35  
18  
23  
9
3
50  
33  
6
34  
5
37  
21  
17  
12  
1
14  
36  
30  
31  
40  
38  
10  
21  
9
20  
22  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
0C5598  
0C9674  
0C6055H  
0C6054H  
031971  
073159  
066386  
066849  
0C6862  
0C3168  
0C5014  
0C7646  
0C8646  
0C5298  
020692  
0C4841  
073106G  
0C6363  
051730  
071956  
022129  
045771  
040250  
0C7933  
068485  
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
Bearing Carrier, Front  
Bearing Carrier, Upper  
Rotor Assembly  
Stator Assembly  
Ball Bearing  
Ball Bearing  
Brush Holder  
Taptite M5-0.8 x 16mm  
Bolt , Stator  
5/16 Special Lock Washer  
Lug, Lift  
Rail, Engine RH  
Pulley, 4.5" Flat  
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  
051769  
0C4537  
022304  
023316  
049451  
042633  
046526  
052212  
069673J  
051756  
049813  
043107  
0C2417A  
039253  
0A1658  
067989  
0C1069  
0C6609  
049808  
055934D  
0A7043  
0C8644  
024426  
048705  
022145  
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
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, 1-1/16"  
HHCS M12-1.25 x 25mm  
Tensioner, SE-F18-4.5"  
½"-13 x1-3/4" HHCS  
½"-13 Flange Nut  
Belt, V-Rib  
Starter Motor  
Spacer, Starter  
Pulley, Alternator  
Flywheel Assembly  
HHCS M8-1.25 x 60mm  
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  
Flat Washer, 5/16"  
®
44 Generac Power Systems, Inc.  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
Base Frame – Drawing No. 0D2357-A  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
0D2126  
0D2131  
0C5088  
0C5644  
056326  
029451  
0C7857  
070936E  
0C6721  
0C6722  
042907  
022129  
022097  
1
1
1
4
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  
Gasket, Cleanout  
Plate, Cleanout  
HHCS M8-1.25 x 16  
Washer, Split Lk- M8  
Washer, Split Lk -1/4-M6  
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  
Carriage Bolt 3/8 -16 x 55mm  
3/8 Special Lock Washer  
Hex Nut 3/8-16 Brass  
HHCS M6-1.00 x 16  
Nut, Hex M6.0 -1.0  
Block, Terminal Battery Post  
Stud 3/8-16 x 55mm  
Washer 3/8 Flat  
2
677mm  
4
4
1
1
8
8
3
Washer Split Lk -3/8  
mm = Millimetres  
®
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
Enclosure – Drawing No. 0D2358-D  
25  
12  
17  
11  
17  
24  
17  
2
13  
20  
34  
VIEW "A"  
27  
10  
32  
17  
38  
22  
1
17  
9
30  
31  
26  
35  
8
14  
15  
5
23  
17  
19  
28  
21  
33  
29  
16  
A
7
17  
6
17  
36  
37  
4
17  
3
17  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
0D2315  
0C4534  
0C4532  
0C4535  
0C4536  
0C5525  
0C5527  
0C5528  
0C5529  
0C5530  
0C5531  
0C4986  
0C4987  
0C5091  
0C6362  
0D7176  
0A7215  
0C5096  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
33  
57  
1
Enclosure Panel RH  
Enclosure Panel Top  
Enclosure Panel LH  
Enclosure Panel Front  
Enclosure Rear Panel  
Insulation, Front Panel  
Insulation, LH Side Panel  
Insulation, RH Side Panel  
Insulation, Top Front Panel  
Insulation, Top Rear Panel  
Insulation, Lifting Lug Cover  
Cover, Access Lift  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
0C7024  
0C7025  
0C7026  
0C7027  
0C7028  
0C7029  
0C7030  
0C2340  
0C6425  
049813  
0C7047A  
0C7047B  
0D7804  
022097  
098761  
042755  
0A2115  
0E4443  
055934V  
1
1
1
1
1
1
1
1
1
3
1
1
1
3
1
1
2
2
1
Decal, Radiator Cap  
Decal, Remote  
Decal, Coolant  
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  
Foam, Air Duct Face  
Foam, Air Duct Side  
Decal, Unit  
Washer, Split Lock ¼" - M6  
Decal, Engine Data  
Decal, CSA Approval  
Washer Nylon 0.250"  
Screw SW ¼"-20 X 3/8" Long  
Clamp Vinyl 1.5" X 0.281"  
Cover, Radiator Fill  
Cover, Access Electrical  
Gasket, Electrical Access  
Washer, Self Locking  
¼ -20 x 5/8 W/Washer  
Frame Control Panel - Refer to Drawing  
C8005  
19  
0C7023  
1
Decal, Battery +/-  
®
46 Generac Power Systems, Inc.  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
Cooling System – Drawing No. 0D2360-B  
18  
19  
45  
41  
44  
21  
20  
43  
39  
13  
14  
14  
3
14  
21  
39  
14  
21  
42  
25  
48  
41  
47  
40  
42  
34  
6
49  
16  
32  
4
17  
35  
25  
12  
46  
30  
27  
2
1
5
8
7
9
15  
18  
11  
10  
3
3
34  
29  
26  
34  
34  
33  
50  
28  
53  
25  
37  
55  
38  
23  
54  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
0C4551  
0C4550  
0C4552  
0C4554  
0C4555  
0C4557  
0C4556  
0C4553  
049869  
081810  
070265  
058443  
043146  
022097  
049815  
22152  
051716  
052857  
0C4312  
043116  
022473  
0C8645  
0C8507  
039253  
022129  
0C6549A  
0C5108  
0C6236  
1
1
1
1
1
1
1
1
1
1
1
7
2
7
4
4
4
12  
1
3
5
1
1
2
6
1
1
1
Cover Plate, Scroll Weldment  
Housing, Fan Scroll Weldment  
Fan, Squirrel Cage  
Shaft, Fan  
Carrier, Bearing  
Key, Square 3/16" x 3/16" x ½"  
Pulley, Fan 4-7/8"  
Bearing 2 Row Ball  
Fender Washer M16  
Nut, Hex M16.0 -1.5mm  
LockWasher M16.0  
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  
Nut Top Lock Flange M6-1.0  
Radiator 1.0L RV  
HHCS M6-1.00 x 12mm  
Washer ¼"-M6  
Pulley, 3" Flat Flanged  
Bracket, Rotary Tensioner  
HHCS M8-1.25 x 20mm  
Washer, Split Lk -M8  
61" Green Belt  
Filler Neck Assembly, Radiator Remote  
Hose Tee  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
49  
51  
52  
53  
54  
55  
0C7384  
0C5543  
0C4460  
0C4845  
0C5544  
086133A  
035473  
050968  
042911  
046526  
047411  
0C7997  
0C7649  
042907  
0C5605  
0C6976  
0C7997  
55934K  
0C4976  
0C7040  
045771  
0C5105  
024426  
0C8643  
048705  
1
1
1
1
1
8
2
Coupling, Hose  
Hose, Radiator Lower  
Hose, Water Pump Lower  
Hose, Top  
Hose, Lower Intermediate  
Hose Clamp Hi Trq 1-3/4" Max  
Hose Clamp #12  
Hose, ¾" SAE-20R3  
M10-1.5 x 30mm HHCS  
M10 Lockwasher  
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  
Tank, Coolant Overflow  
Hose 5/16" SAE-20R4  
Clamp, Vinyl Coated 1-5/8"  
Cap, Radiator Pressure  
Gasket, Radiator Base  
Nut, Hex M8-1.25  
720mm  
1
1
2
270mm  
4
4
1
1
510mm  
2
1
1
1
1
1
1
1
Bracket, Support  
½"-13 x 1-¾" HHCS  
Tensioner, SE-18-3"  
½"-13 Flange Nut  
mm = Millimeters  
®
Generac Power Systems, Inc. 47  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
Electrical Enclosure Assembly – Drawing No. 0D2361-E  
1
28  
27  
18  
29  
2
31  
11  
31  
9
3
25  
26  
27  
20  
16  
33  
28  
12  
19  
17  
8
25  
6
26  
7
27  
13  
28  
4
15  
11  
14  
32  
5
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
0D2412  
071914  
083048  
0C7610  
093642  
065795  
048512  
027565  
066849C  
066849  
022264  
051715  
040213  
0C8620  
043180  
0D2021B  
0C3992  
0C7022  
1
1
1
1
1
1
1
A/R  
2
1
3
2
4
1
1
1
4
1
Weldment, Electrical Enclosure  
Terminal Block 4 Position  
Assembly, Potted Regulator  
Resistor 20R 5% 12W  
Assembly Marine Control Board  
Rectifier, Battery Charging  
Circuit Breaker 5 Amp  
Tape, Glass Insulated  
Taptite, M5-0.8 x 30  
Taptite, M5-0.8 x 16  
Lockwasher M5  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
31  
32  
33  
038150  
4
1
1
1
1
1
2
2
7
7
3
4
1
1
Washer, Flat #8  
0C6359  
0D2021G*  
0D2021F*  
0D2021D*  
0D2021E*  
0A1658  
022473  
022097  
049813  
023484D  
051787  
0C7390  
0C7487  
Gasket, Electrical Enclosure  
Wire Assembly # 32  
Wire Assembly # 22  
Diode Assembly  
Wire Assembly # 162  
¼ Special Lockwasher  
Washer, Flat ¼-M6  
Washer, Split Lk ¼-M6  
Nut, Hex M6-1  
Bushing, Snap  
HHCS, M4-0.7 x 16mm  
Gasket, Electrical Enclosure Divider  
Harness, Ac Output  
Nut, Hex M4-0.7  
Pcb Support Snap -In  
HHMS, #8-32 x 2.25"  
Washer, Flat M5  
Harness  
M4-0.7 x 16 HHCS Taptite  
Decal, Customer Connection  
A/R = As Required  
* Not shown refer to Wiring Diagram C4946  
®
48 Generac Power Systems, Inc.  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
Intake and Exhaust System – Drawing No. 0D2362-C  
16  
15  
6
22  
8
24  
29  
15  
22  
19  
21  
15  
10  
1
27  
18  
15  
16  
5
2
20  
26  
28  
9
3
O ENGINE AIR INTAKE  
3
4
9
7
11  
17  
12  
15  
14  
16  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
075674  
0C4879  
0C4880  
0C5493  
0C4727  
025145  
0C7645  
0C5022  
035685  
0C4878  
0C6243  
0C6244  
051730  
071956  
022129  
1
1
1
1
1
2
1
1
3
1
1
1
2
2
10  
EXHAUST GASKET  
CHAMBER AIR INTAKE  
AIR FILTER  
HOSE, AIR INLET  
MUFFLER WELDMENT  
U BOLT & SADDLE 1.25  
RAIL, ENGINE LH, WELDMENT  
INSULATION, EXHAUST  
HOSE CLAMP #28  
OUTLET, EXHAUST FLEX  
GASKET, EXHAUST OUTLET  
PLATE, EXHAUST OUTLET  
HHCS M8-1.25 X 60  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
045771  
058443  
0C5105  
022145  
039253  
043107  
035586  
042909  
042907  
022145  
0709390357  
075673  
0E3692  
0E4491  
5
3
1
4
2
4
2
1
1
2
1
1
1
1
NUT, HEX M8-1.25  
CRIMPTITE, ¼"-20 X 5/8"  
BRACKET, SUPPORT  
WASHER, FLAT - M8  
HHCS M8-1.25 X 20  
HHCS M8-1.25 X 25  
HOSE CLAMP #20  
HHCS M8-1.25 X 30  
HHCS M8-1.25 X 16  
FLATWASHER, 5/16"  
MANIFOLD GASKET  
HORIZONTAL EXHAUST MANIFOLD  
GROMMET 1-3/4" X 1/8" X 2"  
WASHER FLAT 0.336"ID X 0.876"OD  
WASHER, VIBRATION ISOLATOR  
WASHER, SPLIT LK -M8  
®
Generac Power Systems, Inc. 49  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
Fuel and Electrical Systems – Drawing No. 0D2363-D  
18  
20  
TO STATOR  
TO GROUND  
7
16  
23  
22  
4
9
24  
17  
29  
17  
TO STARTER  
MOTOR BOLT  
15  
14  
16  
TO STARTER MOTOR  
16  
9
3
2
TO GLOW PLUGS  
4
7
12  
27  
21  
6
11  
10  
25  
4
19  
4
26  
5
27  
12  
13  
2
1
25  
30  
4
17  
2
12  
10  
28  
8
26  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
0C6946A  
052219  
069598B  
022097  
038750  
056739  
049813  
055934D  
022473  
040173  
028414A  
0C7649  
047411  
0C7968  
022237  
075763  
075763A  
1
3
2
7
1
2
5
1
5
2
1
3
1
1
1
3
3
Fuel Pump Assembly  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
023484F  
022127  
053621-201  
053621-197  
0A2053  
0742600-158  
075234  
030340  
0C8008  
0C8008  
0C8009  
0D2021H  
0D8914  
2
1
1
1
1
1
1
Snap Bushing 1"  
Hex Nut ¼ - 20  
Cable, Battery  
Cable, Starter  
HHCS M6-1 x 65  
Wire Assembly, Black #4 Ground  
Resistor  
Hose, 1/4 ID SAE-30R7  
Hose, 5/16 ID SAE-30R7  
Hose, 5/16 ID SAE-30R7  
Clamp, Fuel Pump  
Wire Assy, #0 (PHC-SC)  
Fuel Filter  
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  
Nut, Hex M6-1  
Clamp, Vinyl Coat 1-1/16"  
Washer, Flat -M6  
1.04M  
635mm  
375mm  
10  
11  
12  
13  
14  
15  
16  
17  
Hose Clamp  
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  
Boot, Battery Cable  
Boot, Battery Cable  
1
1
1
M = Meters  
mm = Millimetres  
®
50 Generac Power Systems, Inc.  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
Customer Controls Assembly – Drawing No. 0D2364-D  
13  
15  
24  
23  
28  
31  
26  
2
17  
18  
21  
5
14  
2
7
25  
20  
9
16  
22  
34  
26  
1
27  
22  
12  
8
30  
11  
4
10  
32  
29  
33  
3
6
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
080825  
0C4540  
0C1457  
081904  
055920  
043181  
022159  
055927  
0C5127  
0C7341  
049226  
0C7340  
0D2021A  
051714  
0C4476  
0C5096  
0D4372  
1
1
1
1
1
2
2
1
1
1
4
1
1
2
1
1
1
Start / Stop Switch  
Cover, Engine Control Box  
Hour Meter  
Fuse Holder, SFE-14  
Switch, Pushbutton SPST  
PPHMS M3-0.5 x 10  
Lockwasher M3  
Fuse, SFE-14  
Decal  
Boot / Nut / Preheat Switch  
Lockwasher, M5  
Boot, Circuit Breaker  
Harness  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
0C3971B  
0C4883  
0C4884  
0C7649  
057824  
0C3992  
022985  
084135  
0C6440  
074969  
049813  
052749  
038150  
022097  
036900  
0D9283  
0D9391  
1
1
1
2
2
4
4
1
2
1
2
4
4
2
4
1
1
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  
Grommet  
Gasket, Engine Control Box  
Circuit Breaker, 35A, 2 Pole  
Nut, Hex M6-1.0  
PHMS M5-0.8 x 12  
Flatwasher, #8  
Washer, Split Lock ¼" - M6  
Screw, PPHM #6-32 x 1/4"  
Gasket, Hourmeter  
Hex Nut, M3  
Box, Engine Control  
Frame, Control Panel  
Plug, Oil Fill  
Gasket, Switch  
®
Generac Power Systems, Inc. 51  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
1.0 Liter Diesel Camshaft – Drawing No. 075677  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
0709390232  
0709390233  
1
1
CAMSHAFT ASSEMBLY  
CAMSHAFT GEAR  
8
9
0709390238  
0709390239  
1
1
PLATE  
TACHOMETER SHAFT  
3
4
5
6
7
0709390195  
0709390234  
0709390235  
0709390236  
0709390237  
1
1
3
1
1
KEY  
GEAR  
SPACER  
BALL BEARING  
SLIDER  
10  
11  
12  
13  
0709390240  
0709390241  
0709390242  
0709390243  
1
1
1
1
BOLT  
BOLT  
GASKET  
NUT  
®
52 Generac Power Systems, Inc.  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
1.0 Liter Diesel Cylinder Block– Drawing No. 075676  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
0709390100  
0709390447  
1
1
COMPLETE CYLINDER BLOCK  
EXPANSION PLUG  
17  
18  
0709390117  
0709390118  
2
2
DOWEL PIN  
SPRING PIN  
3
4
5
6
7
8
9
10  
11  
0709390101  
0709390102  
0709390103  
0709390104  
0709390105  
0709390106  
0709390107  
0709390108  
0709390109  
0709390110  
0709390111  
0709390112  
0709390113  
0709390114  
0709390115  
0709390116  
1
2
2
1
4
4
1
1
1
1
1
1
1
1
1
1
EXPANSION PLUG  
EXPANSION PLUG  
EXPANSION PLUG  
EXPANSION PLUG  
PLUG  
PLUG  
IDLE GEAR SHAFT  
BUSHING  
BUSHING-STANDARD  
0.25MM U.S. BUSHING  
0.50MM U.S. BUSHING  
BALL BEARING  
EXPANSION PLUG  
BALL BEARING  
DOWEL PIN  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
0709390119  
0709390120  
0709390121  
0709390131  
0709390123  
0709390124  
0709390125  
0709390126  
0709390127  
0709390128  
0709390129  
0709390130  
2
1
1
1
1
1
1
1
6
6
1
1
STUD  
STUD  
STUD  
SNAP RING  
OIL SEAL  
DRAIN COCK  
CONNECTOR  
OIL FILTER  
TAPPET  
PUSH ROD  
RELIEF VALVE  
O-RING  
12  
13  
14  
15  
16  
MM = MILLIMETER  
U.S. = UNDERSIZE  
DOWEL PIN  
®
Generac Power Systems, Inc. 53  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
1.0 Liter Diesel Cylinder Head – Drawing No. 0D2794  
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
3
2
3
3
3
3
6
CYLINDER HEAD ASSEMBLY  
EXPANSION PLUG  
EXPANSION PLUG  
EXPANSION PLUG  
INTAKE VALVE  
EXHAUST VALVE  
VALVE GUIDE SEAL (EXHAUST)  
VALVE GUIDE SEAL (INTAKE)  
SPRING  
RETAINER  
KEY  
CAP  
CYLINDER HEAD GASKET, 1.2MM  
THICK  
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  
LIFTING EYE  
BOLT  
TUBING  
BOLT  
OIL SWITCH  
THERMO-SWITCH  
GASKET  
WASHER  
ADAPTOR  
0D2791  
8
9
10  
11  
12  
0709390168  
0709390169  
042574  
6
12  
6
1
MM=MILLIMETER  
0709390159  
1
CYLINDER HEAD GASKET, 1.3MM  
THICK  
®
54 Generac Power Systems, Inc.  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D 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
3
4
5
6
7
8
9
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  
1
1
1
1
1
1
1
1
6
CRANKSHAFT ASSEMBLY  
CRANKSHAFT GEAR  
KEY  
DOWEL PIN  
SPRING PIN  
BEARING HOLDER ASSEMBLY  
BEARING HOLDER ASSEMBLY  
BEARING HOLDER ASSEMBLY  
BOLT  
070939-216  
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  
AR  
3
AR  
AR  
3
6
3
3
6
6
6
PISTON ASSEMBLY-1.0MM O.S.  
STANDARD PISTON RING SET  
PISTON RING SET-0.5MM O.S.  
PISTON RING SET-1.0MM O.S.  
PISTON PIN  
SNAP RING  
CONNECTING ROD ASSEMBLY  
BUSHING  
CONNECTING ROD BOLT  
NUT, CONNECTING ROD BOLT  
STANDARD BEARING  
BEARING-0.25MM U.S.  
BEARING-0.50MM U.S.  
PULLEY  
17  
18  
19  
20  
21  
22  
23  
24  
10  
11  
6
3
DOWEL PIN  
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  
3
AR  
AR  
2
2
1
3
AR  
AR  
AR  
1
12  
28  
30  
1
NUT  
13  
14  
15  
16  
U.S. - UNDERSIZE  
O.S. - OVERSIZE  
AR - AS REQUIRED  
MM - MILLIMETER  
BOLT  
STANDARD PISTON ASSEMBLY  
PISTON ASSEMBLY-0.5MM O.S.  
®
Generac Power Systems, Inc. 55  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
1.0 Liter Diesel Oil Pump – Drawing No. 075682  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
0709390250  
0709390252  
1
1
IDLER GEAR ASSEMBLY  
SPRING  
7
8
0709390259  
0709390260  
1
1
SPRING  
COLLAR  
3
4
5
6
0709390251  
0709390253  
0709390254  
0709390255  
0709390532  
0709390533  
0709390258  
1
1
1
AR  
AR  
AR  
AR  
THRUST WASHER  
ROTOR  
9
10  
11  
12  
0709390261  
0709390262  
0709390263  
0709390264  
1
1
1
3
SNAP RING  
FRONT PLATE  
GASKET  
OIL PUMP COVER  
0.10MM SHIM  
0.15MM SHIM  
0.20MM SHIM  
0.50MM SHIM  
BOLT  
AR - AS REQUIRED  
®
56 Generac Power Systems, Inc.  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
1.0 Liter Diesel Rocker Arm Assembly – Drawing No. 075683-A  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
070939-170  
070939-171  
070939-172  
070939-174  
070939-173  
070939-175  
070939-176  
070939-177  
070939-178  
070939-179  
070939-180  
070939-181  
1
3
3
6
6
3
1
2
2
3
3
3
ROCKER ARM ASSEMBLY(INCLUDES ALL COMPONENTS SHOWN BELOW)  
INTAKE ROCKER ARM  
EXHAUST ROCKER ARM  
NUT  
STUD  
ROCKER ARM BRACKET  
ROCKER ARM SHAFT  
SPRING  
SCREW  
SPRING,PIN  
NUT  
10  
11  
12  
STUD  
®
Generac Power Systems, Inc. 57  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D 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
2
3
3
3
3
1
1
1
1
1
INJECTOR PUMP ASSEMBLY  
SHIM-0.2MM  
SHIM-0.3MM  
SHIM-0.5MM  
SHIM-1.0MM  
NUT  
BOLT  
GASKET  
INSERT  
CAP  
INJECTOR  
TUBING  
TUBING  
TUBING  
TUBING  
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)  
TUBE, ENGINE OIL FILL (MODEL  
04270 & 04614)  
BOLT  
SOLENOID  
WASHER  
WASHER  
SCREW  
3
4
5
6
7
8
9
10  
11  
12  
13  
0C4736  
1
20  
26  
27  
28  
29  
0709390264  
0709390341  
0709390342  
0709390343  
0709390344  
2
1
1
1
1
AR - AS REQUIRED  
CLAMP  
®
58 Generac Power Systems, Inc.  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D 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
3
4
5
6
7
8
9
0709390661  
069858  
0C8008  
0C8008  
040173  
0709390378  
0709390379  
074808  
052233  
039450  
1
1
FUEL FILTER SUPPORT  
FUEL FILTER  
HOSE, 5/16" SAE 30R7  
HOSE, 5/16" SAE 30R7  
HOSE CLAMP  
GASKET  
BANJO FITTING  
FUEL BLEED FITTING  
1/8" NPT TEE (BRASS)  
1/8" NPT x 3/16" 90 DEG. BARBED  
FITTING  
1/8" NPT x 3/16" BARBED STRAIGHT  
FITTING  
12  
13  
14  
15  
16  
17  
18  
19  
068736  
068736  
074823  
074819  
0709390651  
0709290662  
0709390663  
028414A  
275MM  
240MM  
HOSE, 3/16" SAE 30R2  
HOSE, 3/16" SAE 30R2  
HOSE CLAMP  
FUEL BLEED FITTING  
FUEL BLEED GASKET  
HOLLOW BOLT  
BANJO FITTING  
1/8" NPT x 1/4" BARBED STRAIGHT  
FITTING (MODEL 04270 & 04614)  
AR  
250MM  
4
1
5
2
2
1
3
2
1
1
2
2
10  
* -QTY 1 (MODEL 04270 & 04614)  
AR - AS REQUIRED  
11  
030096  
2 *  
®
Generac Power Systems, Inc. 59  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
1.0 Liter Diesel Timing and Governor – Drawing No. 082067-B  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
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  
®
1
1
1
1
1
2
1
2
1
1
1
1
1
1
3 *  
5
1
4
5
1
1
1
1
1
1
1
1
1
HOUSING, TIMING GEAR  
SPRING PIN  
GASKET  
SPRING  
WASHER  
NUT  
STOP LEVER  
COVER  
GOVERNOR LEVER  
BOLT  
NUT  
SHAFT  
O-RING  
SNAP RING  
BOLT  
BOLT  
OIL SEAL  
BOLT  
BOLT  
ARM  
SNAP RING  
O-RING  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
0709390293  
0709390294  
0709390295  
0709390291  
0709390302  
0709390271  
0709390303  
071944  
0709390660  
0709390534  
0709390535  
0709390536  
0709390537  
0709390539  
0709390188  
0709390541  
0709390538  
0C4888  
1
1
1
1
1
3
2
1
SPRING  
ARM  
O-RING  
SNAP RING  
BRACKET  
BOLT  
BOLT  
SCREW HHC M6-1.0 X 25  
O-RING  
O-RING  
SPACER  
GASKET  
HOLDER (OIL FILL)  
O-RING  
CAP  
BOLT  
NUT  
1
1 *  
1 *  
1
1 *  
1 *  
1 *  
1 *  
3 *  
1
BRACKET, FUEL FILTER (MODEL  
04270 & 04614)  
49  
50  
51  
52  
051730  
052265  
045771  
022129  
3
1
4
4
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)  
GOVERNOR LEVER ASSEMBLY  
TENSION LEVER  
SNAP RING  
WASHER  
COTTER PIN  
SPRING  
WASHER LOCK M8-5/16 (MODEL  
04270 & 04614)  
* NOT USED ON MODEL 04270 & 04614  
60 Generac Power Systems, Inc.  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
1.0 Liter Diesel Engine Block – Drawing No. 082961-C  
24  
23  
22  
25  
18  
28  
17  
15  
20  
19  
13  
12  
14  
14  
33  
3
30  
29  
1
14  
31  
2
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
3
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  
070939-244  
070939-245  
070939-246  
070939-122  
1
1
1
1
3
1
1
1
1
1
1
1
ROCKER COVER  
OIL STOPPER  
SCREEN  
GASKET  
NUT  
CAP  
O-RING  
1/4" PIPE PLUG SQ. HD.  
O-RING  
TUBING  
O-RING (MODELS 04270 & 04614 ONLY)  
DIPSTICK TUBE (ALL MODELS  
EXCEPT 04270 & 04614)  
DIPSTICK TUBE (MODELS 04270 &  
04614 ONLY)  
O-RING (ALL MODELS EXCEPT 04270  
& 04614)  
12  
070939-143  
1
0C4641  
097843  
1
2
13  
14  
15  
070939-145  
070939-146  
5
1
BOLT  
DIPSTICK (ALL MODELS EXCEPT  
04270 & 04614)  
SUCTION FILTER  
GASKET  
17  
070939-183  
1
ROCKER COVER GASKET  
®
Generac Power Systems, Inc. 61  
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Appendix 4 — Exploded Views and Parts Lists  
QUIETPACT™ 75D Recreational Vehicle Generator  
1.0 Liter Diesel Water Pump – Drawing No. 082962  
ITEM PART NO. QTY.  
DESCRIPTION  
ITEM PART NO. QTY.  
DESCRIPTION  
1
2
0709390265  
0709390266  
1
1
WATER PUMP ASSEMBLY  
PLUG  
8
9
0709390272  
0709390273  
1
1
GASKET  
BOLT  
3
4
5
6
7
0709390267  
0709390268  
0709390269  
0709390270  
0709390271  
1
1
3
1
1
THERMOSTAT  
SPRING  
GASKET  
SET PLATE  
BOLT  
10  
11  
12  
15  
0709390274  
0709390275  
0709390247  
0709390284  
1
1
1
1
BOLT  
NUT  
PULLEY  
BOLT  
®
62 Generac Power Systems, Inc.  
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Appendix 5 — Notes  
QUIETPACT™ 75D Recreational Vehicle Generator  
®
Generac Power Systems, Inc. 63  
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Appendix 6 – Warranty  
QUIETPACT™ 75D 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 6 – Warranty  
QUIETPACT™ 75D 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 6 – Warranty  
QUIETPACT™ 75D Recreational Vehicle Generator  
GENERAC POWER SYSTEMSTHREE-YEAR LIMITED WARRANTY  
FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS  
NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period  
of 3 (three) years of operation from the date of original sale, 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 pur-  
chaser/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) applications, as Generac has defined  
Recreational Vehicle generator applications. The factory recommends exercising the unit one half-hour every month.  
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  
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  
YEAR THREE – 100% (one hundred percent) only on selected part(s) and labor listed [Any labor and part(s) not listed, and removal  
and reinstallation are the owner’s responsibility]:  
Rotor, Stator, Computer Control Board (part numbers 0A6060 and 0A3369) and inverter, (if applicable with regard to the generator)  
Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Valve, Valve Lifter(s), Intake and Exhaust Manifolds  
Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators  
manufactured after January 1, 1998, have a transferable warranty to the second owner ONLY for the remainder of the three-year lim-  
ited warranty. 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 Guardian’s Warranty Policies and Procedures Guide.  
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:  
• Generac Guardian generators that utilize non-Generac replacement parts.  
• Costs of normal maintenance, adjustments, installation and start-up.  
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by  
Generac Power Systems.  
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.  
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all  
mechanical devices, the Generac 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.  
• Damage related to rodent and/or insect infestation.  
• 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  
replacement of the defective part(s).  
• Failure due to misapplication.  
Telephone, cellular phone, facsimile, internet access 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.  
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.  
• 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 lim-  
itations 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  
GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT  
RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages,  
so the above limitation may not apply to you.  
This warranty gives you specific legal rights. You also have other rights from state to state.  
GENERAC® POWER SYSTEMS, INC.  
P.O. BOX 297  
WHITEWATER, WI 53190  
Revision 02.05  
Part No. 0D7427  
Revision K (02/15/05)  
Printed in U.S.A.  
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