Owner’s Manual - Norwall


Owner’s ManualAir-cooled RecreationalVehicle GeneratorsQUIETPACT 55, 65 and 75 Models: 004702-0, 004703-0004704-0, 004705-0004706-0, & 004707-0This manual should remain with the unit.

INTRODUCTION READ THIS MANUAL THOROUGHLYIf any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing procedures.Throughout this publication, and on tags and decalsaffixed to the generator, DANGER, WARNING,CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectlyor carelessly. Observe them carefully. Their definitions are as follows:DANGERAfter this heading, read instructions that, if notstrictly complied with, will result in personal injury, including death, and property damage.The operator (driver) is responsible for proper andsafe use of the vehicle and its equipment, and thesafety of all vehicle occupants. We strongly recommend that the operator read this manual and thoroughly understand all instructions before using thisequipment. We also strongly recommend instructingother occupants in the vehicle to properly start andoperate the generator. This prepares them if theyneed to operate the equipment in an emergency. CONTENTSThis manual contains pertinent owner’s information,including warranty, electrical diagrams, explodedviews and lists of repair parts for generator modelnumbers 004702-0, 004703-0, 004704-0, 004705-0,004706-0, and 004707-0. In addition, the latter portion of this manual contains information necessaryfor the proper installation of these generators. OPERATION AND MAINTENANCEAfter this heading, read instructions that, if notstrictly complied with, may result in personal injury or property damage.After this heading, read instructions that, if notstrictly complied with, could result in damage toequipment and/or property.NOTE:After this heading, read explanatory statementsthat require special emphasis.These safety warnings cannot eliminate the hazardsthat they indicate. Common sense and strict compliance with the special instructions while performingthe service are essential to preventing accidents.Four commonly used safety symbols accompany theDanger, Warning and Caution blocks. The type ofinformation each indicates follows:symbol points out important safety infor Thismation that, if not followed, could endangerpersonal safety and/or property of others.symbol points out potential explosion Thishazard. This symbol points out potential fire hazard.symbol points out potential electrical shock Thishazard.It is the operator's responsibility to perform all safetychecks, to make sure that all maintenance for safeoperation is performed promptly, and to have theequipment checked periodically by an AuthorizedService Dealer. Normal maintenance service andreplacement of parts are the responsibility of theowner/operator and, as such, are not considereddefects in materials or workmanship within theterms of the warranty. Individual operating habitsand usage contribute to the need for maintenanceservice.Proper maintenance and care of the generator ensuresa minimum number of problems and keep operatingexpenses at a minimum. See an Authorized ServiceDealer for service aids and accessories. HOW TO OBTAIN SERVICEWhen the generator requires servicing or repairs,simply contact an Authorized Service Dealer forassistance. Service technicians are factory-trainedand are capable of handling all service needs.When contacting an Authorized Service Dealer aboutparts and service, always supply the complete modelnumber and serial number of the unit as given on itsdata decal, which is located on the generator.Model No.Serial No.AUTHORIZED SERVICEDEALER LOCATIONTo locate the nearest AUTHORIZED SERVICEDEALER, please call this number:1-800-333-1322ONLY DEALER LOCATION INFORMATIONCAN BE OBTAINED AT THIS NUMBER;or locate us on the web atwww.guardiangenerators.com.

Table of ContentsRecreational Vehicle GeneratorsPart I — Operating InstructionsIntroduction . Inside Front CoverPart II — Installation InstructionsSafety Rules . 18Read This Manual Thoroughly .IFCContents .IFCSection 1 — General Information . 20Operation and Maintenance .IFC1.1Purpose and Scope of the InstallationInstructions . 201.2Safety . 201.3Standards Booklets . 201.4Equipment Description . 201.5Generator Engine Operating Speed . 201.6Generator AC Connection System . 20How to Obtain Service .IFCAuthorized Service Dealer Locator Number . IFCSafety Rules . 2Section 1 – General Information . 4Major Features and Dimensions . 211.1Generator Identification . 41.2Generator Applicability . 51.3Installation . 5Section 2 — Installation . 221.4Safety . 52.1Location and Support . 221.5Generator AC Connection System . 52.2Generator Compartments . 231.6Specifications . 62.3Cooling and Ventilating Air . 252.4Gasoline Fuel System . 27Section 2 – Operation . 72.5LP Gas Fuel System . 282.1Generator Control Panel. 72.6Exhaust System. 302.2Optional Remote Start/Stop Panel . 82.7Electrical Connections. 312.3Automatic Choke . 82.8Battery Installation . 322.4Before Starting the Engine . 82.9Optional Accessories . 342.5Starting the Generator . 92.6Stopping the Generator . 9Section 3 — Post Installation . 352.7Applying Loads to Generator. 93.1Post Installation Tests . 352.8Protection Systems . 103.2Before Initial Start-up. 353.3Initial Start . 353.4Testing Under Load . 353.5Installation Checklist. 36Section 3 – Maintenance . 113.1Checking the Engine Oil Level . 113.2Changing the Engine Oil and/or Oil Filter . 113.3Maintaining the Engine Air Cleaner . 123.4Checking the Engine Spark Plug . 133.5Fuel Filter (Gasoline Only). 133.6Clean Spark Arrestor . 143.7Cleaning the Generator . 14Section 6 – Exploded Views and Parts Lists . 403.8Battery Maintenance . 14Section 7 – Warranty . 523.9Adjusting Valve Clearance. 15Section 4 – Troubleshooting . 374.1Troubleshooting Guide . 37Section 5 – Electrical Data . 383.10 Major Service Manual. 163.11 Drive Belt . 163.12 Exercising the Generator . 163.13 Out of Service Procedure. 163.14 RV Generator Service Interval . 161

Safety RulesRecreational Vehicle Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safeoperation be copied and posted in potential hazard areas of the recreational vehicle.Safety should be stressed to all operators and potential operators of this equipment. WARNING: The engine exhaust from this productcontains chemicals known to the stateof California to cause cancer, birthdefects or other reproductive harm. WARNING: This product contains or emits chemicalsknown to the state of California to causecancer, birth defects or other reproductive harm.Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Becomefamiliar with this manual and with the unit. The generator can operate safely, efficiently and reliably onlyif it is properly installed, operated and maintained.Many accidents are caused by failing to follow simpleand fundamental rules or precautions.The manufacturer cannot anticipate every possiblecircumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixedto the unit, are, therefore, not all-inclusive. If usinga procedure, work method or operating techniquethe manufacturer does not specifically recommend,ensure that it is safe for others. Also make sure theprocedure, work method or operating technique thatchosen does not render the generator unsafe.DANGERthe safe design of this generator, Despiteoperating this equipment imprudently, neglecting its maintenance or being careless can causepossible injury or death. Permit only responsibleand capable persons to operate or maintain thisequipment.lethal voltages are generated by Potentiallythese machines. Ensure all steps are taken torender the machine safe before attempting towork on the generator.of the generator are rotating and/or hot Partsduring operation. Exercise care near runninggenerators.2 GENERAL HAZARDS For safety reasons, the manufacturer recommendsthat the installation, initial start-up and maintenance of this equipment is carried out by anAuthorized Service Dealer. The generator engine releases DEADLY carbonmonoxide gas through its exhaust system. Thisdangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death.Never operate the generator set with the vehicleinside any garage or other enclosed area. DO NOTOPERATE THE GENERATOR IF THE EXHAUSTSYSTEM IS LEAKING OR HAS BEEN DAMAGED.SYMPTOMS OF CARBON MONOXIDE POISONINGARE (a) inability to think coherently, (b) nausea,(c) vomiting, (d) twitching muscles, (e) throbbingtemples, (f) dizziness, (g) headaches, (h) weakness, and (i) sleepiness. IF EXPERIENCING ANYOF THESE SYMPTOMS, MOVE INTO FRESH AIRIMMEDIATELY. IF SYMPTOMS PERSIST, GETMEDICAL HELP. Shut down the generator anddo not operate it until it has been inspected andrepaired. Never sleep in the vehicle while the genset is running unless the vehicle has a working carbonmonoxide detector. The exhaust system must beinstalled in accordance with the genset installationmanual. Make sure there is ample fresh air whenoperating the genset in a confined area. Keep hands, feet, clothing, etc., away from drivebelts, fans, and other moving or hot parts. Neverremove any drive belt or fan guard while the unitis operating. Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation and is required to expel toxic fumes and fuelvapors from the generator compartment. Withoutsufficient cooling airflow, the engine/generatorquickly overheats, which causes serious damageto the generator. Do not alter the installation orpermit even partial blockage of ventilation provisions, as this can seriously affect safe operation ofthe generator. When working on this equipment, remain alertat all times. Never work on the equipment whenphysically or mentally fatigued. Inspect the generator regularly, and contact thenearest Authorized Service Dealer immediately forparts needing repair or replacement.

Safety RulesRecreational Vehicle Generators Before performing any maintenance on the generator, disconnect its battery cables to preventaccidental start up. Disconnect the cable from thebattery post indicated by a NEGATIVE, NEG or (–)first. Reconnect that cable last. Never use the generator or any of its parts as astep. Stepping on the unit can stress and breakparts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage,oil leakage, etc. ELECTRICAL HAZARDS The generator covered by this manual producesdangerous electrical voltages and can cause fatalelectrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running.Ensure all appropriate covers, guards and barriersare in place before operating the generator. If workmust be done around an operating unit, stand onan insulated, dry surface to reduce shock hazard. Do not handle any kind of electrical device whilestanding in water, while barefoot, or while hands orfeet are wet. DANGEROUS ELECTRICAL SHOCKMAY RESULT. During installation onto the vehicle, have thegenerator properly grounded (bonded) either bysolid mounting to the vehicle frame or chassis,or by means of an approved bonding conductor.DO NOT disconnect the bonding conductor, if soequipped. DO NOT reconnect the bonding conductor to any generator part that might be removed ordisassembled during routine maintenance. If thegrounding conductor must be replaced, use only aflexible conductor that is of No. 8 American WireGauge (AWG) copper wire minimum. In case of accident caused by electric shock, immediately shut down the source of electrical power.If this is not possible, attempt to free the victimfrom the live conductor. AVOID DIRECT CONTACTWITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victimfrom the live conductor. If the victim is unconscious, apply first aid and get immediate medicalhelp. Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting inelectric shock, or may get caught in moving components causing injury. FIRE HAZARDS For fire safety, the generator must be installedand maintained properly. Installation always mustcomply with applicable codes, standards, lawsand regulations. Adhere strictly to local, state andnational electrical and building codes. Complywith regulations the Occupational Safety andHealth Administration (OSHA) has established.Also, ensure that the generator is installed inaccordance with the manufacturer’s instructionsand recommendations. Following proper installation, do nothing that might alter a safe installationand render the unit in noncompliance with theaforementioned codes, standards, laws and regulations. Keep a fire extinguisher in the vehicle at all times.Extinguishers rated “ABC” by the National FireProtection Association are appropriate for use onthe recreational vehicle generator electrical system. Keep the extinguisher properly charged andbe familiar with its use. If there are any questionspertaining to fire extinguishers, consult the localfire department. EXPLOSION HAZARDS Do not smoke around the generator. Wipe up anyfuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE orEXPLOSION may result. Keep the area surrounding the generator clean and free from debris. Gasoline is extremely FLAMMABLE and its vaporsare EXPLOSIVE. Do not permit smoking, openflame, sparks or any source of heat in the vicinitywhile handling gasoline. Comply with all laws governing the storage and handling of gasoline. This generator may use liquid propane (LP) gasas a fuel. LP gas is highly EXPLOSIVE. The gas isheavier than air and tends to settle in low areaswhere even the slightest spark can ignite the gasand cause an explosion.3

Section 1 – General InformationRecreational Vehicle Generators1.1GENERATOR IDENTIFICATIONPlease record the following information from the generator DATA DECAL or information decal.1. Model Number2. Serial Number3. kW Rating4. Rated Voltage5. Phase6. Hertz1642CONTROL CENTER510C IR C U ITB REA K ERC IR C U ITB REA K ERFUS E7 .5 A8IF GENERATOR DOES NOT START, REMOVEAND INSPECT FUSE.(SEE OWNER'S MANUAL TROUBLE SHOOTINGGUIDE.)S T A RTFUELS T OPP R IM EPRESS PRIME SWITCH FOR 10 SECONDS BEFORE STARTING. WHEN STARTING, DONOT PRESS START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT.143S E R V IC E A C C E S S P A N E LAIR FILTER LOCATED BEHIND PANEL.MAINTENANCE SCHEDULEAIR FILTER:OIL & OIL FILTER:CLEAN PREFILTEREVERY 100 HOURS.*REPLACE ELEMENTEVERY 250 HOURS.**OIL CAPACITYWITH FILTER:SPARK PLUGS:CHANGE EVERY 100HOURS. (OR ANNUALLY)INSPECT & CLEANPLUGS EVERY 100 HOURS.REPLACE PLUGS EVERY500 HOURS. (IF NECESSARY)FUEL FILTER:CHANGE EVERY 400 HOURS.(OR ANNUALLY)OIL LEVEL:CHECK DAILYREPLACEMENTINFORMATION:PREFILTER P/N:AIR FILTER P/N:OIL FILTER P/N:SPARK PLUG P/N:0D45110D9723070185072347FUEL FILTER P/N:087769*PERFORM MORE OFTEN IN DUSTY CONDITIONS1.8L/1.9QTTEMPERATURE:(SAE VISCOSITY)40 F AND HIGHER-20 F TO 40 FSAE 30 OR 10W-305W-30 OR 5W-2011, 15 (Behind Access Panel)WHEN SERVICE OR PARTS ARE NEEDED IN THE USA OR CANADA,CONTACT THE GUARDIAN SERVICE LOCATOR AT 1-800-333-1322.131712119769, 18 REFERENCE NUMBER IDENTIFICATION1. Generator Air Intake Screen2. Data Plate3. Engine Start/Stop Switch4. 7.5 amp Fuse5. Circuit Breaker6. Optional Remote Panel Receptacle7. Generator AC Output Leads8. Starter Contactor9. Fuel Inlet10. Fuel Primer Switch411. Fuel Pump (Behind access panel.)12. Oil Filter13. Oil Drain Plug14. Oil Dipstick and Filler Tube15. Air Filter (Behind access panel.)16. Spark Plugs17. Exhaust Outlet18. Fuel Filter19. LP Fuel Inlet

Section 1 – General InformationRecreational Vehicle Generators1.2GENERATOR APPLICABILITYThese generators have been designed and manufactured for supplying electrical power for recreationalvehicles. DO NOT modify the generator or use it forany application other than for what it was designed.If there are any questions pertaining to its application, write or call the factory. Do not use the unit untiladvised by competent authority.DANGERfire safety, the generator must have been Forproperly installed in compliance with ANSI119.2-1975/NFPA 501C-1974, “Standard forRecreational Vehicles, Part III – Installation ofElectrical Systems.” The generator also musthave been installed in strict compliance with themanufacturer’s detailed installation instructions.After installation, do nothing that might renderthe unit in noncompliance with such codes, standards and instructions.Use the generator set to supply electrical power foroperating one of the following electrical loads: QUIETPACT 55G & LP: 120 and/or 240 volts,single phase, 60 Hz electrical loads. These loadscan require up to 5500 watts (5.5 kW) of totalpower, but cannot exceed 45.8 AC amperes of current at 120 volts or exceed 22.9 AC amperes at240 volts. QUIETPACT 65G & LP: 120 and/or 240 volts, single phase, 60 Hz electrical loads. These loads canrequire up to 6500 watts (6.5 kW) of total power,but cannot exceed 54.1 AC amperes of current at120 volts or exceed 27 AC amperes at 240 volts. QUIETPACT 75G & LP: 120 and/or 240 v

Owner’s Manual Air-cooled Recreational Vehicle Generators QUIETPACT 55, 65 and 75 † Models: 004702-0, 004703-0 004704-0, 004705-0 004706-0