Owner’s Manual and
Installation Instructions
Air-cooled Recreational
Vehicle Generators
• Model: 004700-0
QUIETPACT 40G
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This manual should remain with the unit.
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Table of Contents
QUIETPACT 40G Recreational Vehicle Generator
Part I – Owner’s Manual
Part II – Installation Instructions
Safety Rules ....................................................................18
Section 1 – General Information................................20
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
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
Section 2 – Installation ................................................22
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
2.1
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
Engine ........................................................6
Generator ..................................................6
Emissions Compliance Period ....................6
2.2
Generator Compartments ......................................23
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
Compartment Size....................................23
Compartment Construction ......................23
Sound Insulating Materials ......................24
Acoustics.... ..............................................24
Compartment Floor Cutouts ....................25
2.3
2.4
Cooling and Ventilating Air ....................................26
Section 2 – Operation ....................................................7
2.3.1
2.3.2
Generator Airflow ....................................26
Testing the Installation..............................26
2.1
Generator Control Panel ............................................7
2.1.1
2.1.2
2.1.3
2.1.4
Fuel Primer..................................................7
Start/Stop Switch ........................................7
Fuse .............................................................7
Main Breaker ..............................................7
Gasoline Fuel System..............................................26
2.4.1
2.4.2
Fuel Tank..................................................27
Generator Fuel Supply Line......................27
2.4.2.1
2.4.2.2
Rigid Fuel Lines ......................27
Flexible Fuel Line ....................27
2.2
2.3
Optional Remote Start/Stop Panel..............................7
Automatic Choke ......................................................7
2.5
2.6
Exhaust System......................................................27
2.5.1
2.5.2
Mufflers and Spark Arrestors ..................28
Exhaust System Safety..............................28
2.3.1
2.3.2
Choke Solenoid............................................7
Prechoke......................................................7
Electrical Connections............................................28
2.4
Before Starting the Engine ........................................7
2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
2.6.6
2.6.7
Electrical Junction Box ............................29
Wiring......... ..............................................29
Generator AC Connections ......................29
Conduit.....................................................29
Isolating Different Power Sources ............30
Power Supply Cord ..................................30
Ground Fault Circuit Interrupters ............31
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
Installation ....................................................7
Engine Lubrication ........................................8
Fuel Supply ....................................................8
Cooling and Ventilating Air ............................8
Engine Exhaust Gas ......................................8
2.5
2.6
2.7
Starting the Generator ..............................................8
Stopping the Generator..............................................9
Applying Loads to Generator ....................................9
2.7
2.8
Battery Installation... ..............................................31
2.7.1
2.7.2
2.7.3
2.7.4
Recommended Battery..............................31
Battery Cables ..........................................31
Battery Cable Connections........................31
Battery Compartment ..............................31
2.7.1
Letting the Engine Stabilize ........................9
2.8
2.9
Do Not Overload the Generator ................................9
Protection Systems ....................................................9
2.9.1
2.9.2
2.9.3
2.9.4
Low Oil Pressure Switch..............................9
High Temperature Switch ............................9
Field Boost ................................................10
Overvoltage Protection ..............................10
Optional Accessories ..............................................31
2.8.1
Remote Start/Stop Panels ........................32
Section 3 – Post-installation Start-up
Adjustments ..............................................32
2.10 Additional Information ............................................10
2.10.1 25-Hour Break-in Period............................10
2.10.2 25-Hour Checkup ......................................10
2.10.3 Attention Required After Submersion........10
2.10.4 Operation in High Grass or Brush ............11
2.10.5 Effects of Moisture and Dirt ......................11
3.1
3.2
3.3
3.4
3.5
Post Installation Tests ............................................32
Before Initial Start-up ............................................32
Initial Start ............................................................32
Testing Under Load ................................................32
Installation Checklist..............................................33
Section 3 – Maintenance ..............................................11
Appendix 1 – Notes ......................................................34
Appendix 2 – Troubleshooting....................................35
Appendix 3 – Electrical Data ......................................36
Appendix 4 – Exploded Views and Parts Lists ......38
Appendix 5 – Warranty ................................................48
3.1
3.2
3.3
Checking the Engine Oil Level ................................11
Changing the Engine Oil and/or Oil Filter................11
Maintaining the Engine Air Cleaner ........................12
3.3.1
3.3.2
Cleaning the Foam Precleaner....................12
Cleaning or Replacing the Paper Filter ......12
3.4
3.5
3.6
3.7
3.8
3.9
Clean Air Intake ......................................................13
Checking the Engine Spark Plug..............................13
Fuel Filter ................................................................13
Spark Arrestor Service ............................................13
Cleaning the Generator............................................14
Battery Maintenance ................................................14
3.9.1
3.9.2
Weekly........................................................14
Every Six Months ......................................14
3.10 Major Service Manual ..............................................15
3.11 Exercising the Generator ........................................15
3.12 Out of Service Procedure ........................................15
3.12.1 Removal From Service ..............................15
3.12.2 Return to Service ......................................15
3.13 Adjusting Valve Clearance........................................15
3.14 RV Generator Service Interval..................................16
®
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Safety Rules
QUIETPACT 40G 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 YOU EXPERI-
ENCE ANY OF THESE SYMPTOMS, MOVE INTO
FRESH AIR IMMEDIATELY. IF SYMPTOMS PER-
SIST, GET MEDICAL HELP. Shut down the gener-
ator and do not operate it until it has been inspect-
ed 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. This exhaust sys-
tem must be installed properly, in strict compli-
ance with applicable codes and standards.
Following installation, you must do nothing that
might render the system unsafe or in noncompli-
ance with such codes and standards. The genera-
tor compartment must be completely vapor sealed
from the vehicle interior. There must be no possi-
bility of exhaust fumes entering the vehicle interi-
or. Never operate this equipment with a leaking or
defective exhaust system.
!
!
!
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 main-
tained. 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
you use a procedure, work method or operating tech-
nique Generac does not specifically recommend, you
must satisfy yourself that it is safe for you and others.
You also must make sure the procedure, work
method or operating technique that you choose does
not render the generator unsafe.
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.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit is
operating.
• Adequate, unobstructed flow of cooling and venti-
lating air is critical to correct generator operation
and is required to expel toxic fumes and fuel
vapors from the generator compartment. Without
sufficient cooling airflow, the engine/generator
quickly overheats, which causes serious damage to
the generator. Do not alter the installation or per-
mit even partial blockage of ventilation provisions,
as this can seriously affect safe operation of the
generator.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
!
generators.
!
!
GENERAL HAZARDS
• For safety reasons, Generac recommends
that the installation, initial start-up and mainte-
nance of this equipment is carried out by a
Generac Authorized Service Dealer.
®
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Safety Rules
QUIETPACT 40G Recreational Vehicle Generator
• When working on this equipment, remain alert at
all times. Never work on the equipment when you
are physically or mentally fatigued.
FIRE HAZARDS
• Inspect the generator regularly, and contact your
nearest Generac Authorized Service Dealer immedi-
ately for parts needing repair or replacement.
• Before performing any maintenance on the genera-
tor, disconnect its battery cables to prevent acci-
dental start up. Disconnect the cable from the bat-
tery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating con-
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
• 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 established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installa-
tion, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regu-
lations.
• Keep a fire extinguisher in the vehicle at all times.
Extinguishers rated “ABC” by the National Fire
Protection Association are appropriate for use on
the recreational vehicle generator electrical system.
Keep the extinguisher properly charged and be
familiar with its use. If you have any question per-
taining to fire extinguishers, consult your local fire
department.
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.
Ensure all appropriate covers, guards and barriers
are in place before operating the generator. If you
must work around an operating unit, stand on an
insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands
or feet are wet. DANGEROUS ELECTRICAL
SHOCK MAY RESULT.
• During installation onto the vehicle, 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.
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.
• Gasoline is extremely FLAMMABLE and its vapors
are EXPLOSIVE. Do not permit smoking, open
flame, sparks or any source of heat in the vicinity
while handling gasoline. Comply with all laws gov-
erning the storage and handling of gasoline.
• In case of accident caused by electric shock, imme-
diately 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 nonconducting imple-
ment, such as a rope or board, to free the victim
from the live conductor. If the victim is uncon-
scious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.
®
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Section 1 – General Information
QUIETPACT 40G Recreational Vehicle Generator
1.1 GENERATOR IDENTIFICATION
Please record the following information from the generator DATA DECAL or information decal.
1. Model Number ____________________
3. kW Rating__________________________
2. Serial Number __________________
4. Rated Voltage __________________
Model: 004700-0 — QUIETPACT 40G
1. Generator Air Intake
2. Engine Start/Stop Switch
3. Fuse
4. Optional Remote Panel Receptacle
(Side View)
9. Fuel Inlet
10. Fuel Pump (Behind Access Panel)
11. Fuel Filter (Side View)
12. Oil Filter
13. Oil Drain Cap
5. Generator AC Output Leads (Side
View)
6. Fuel Primer Switch
7. Circuit Breaker
14. Oil Dipstick
15. Air Filter (Behind Access Panel)
16. Oil Fill
17. Spark Plug
8. Starter Contactor
17
8
2 6
14,16
CONTROL CENTER
7
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B
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A
4
5
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AIR FILTER LOCATED BEHIND PANEL.
MAINTENANCE SCHEDULE
OIL LEVEL:
AIR FILTER:
CHECK DAILY
CLEAN PREFILTER
EVERY 100 HOURS.
REPLACE ELEMENT
EVERY 250 HOURS.
*
*
10/15
OIL
&
OIL FILTER:
CHANGE EVERY 100
HOURS. (OR ANNUALLY)
*
PERFORM MORE OFTEN IN DUSTY CONDITIONS
*
SPARK PLUGS:
FUEL FILTER:
INSPECT
&
CLEAN
PLUGS EVERY 100
HOURS. REPLACE PLUGS
EVERY 500 HOURS.
(IF NECESSARY)
AC
CHANGE EVERY 400
HOURS. (OR ANNUALLY)
D
REPLACEMENT INFORMATION
PREFILTER P/N:
AIR FILTER P/N:
OIL FILTER P/N:
SPARK PLUG P/N:
FUEL FILTER P/N:
0D4511
0D3262
070185
072347
0D7515
OIL CAPACITY WITH FILTER:
0.8L/0.84QT
TEMPERATURE
SAE VISCOSITY
32˚F AND HIGHER
10˚F TO 100˚F
0˚F TO 80˚F
30
15W-40
10W-30
5W-30
RAC OHVI INDUSTRIAL ENGINE
TM
-20˚F TO 50˚F
WHEN SERVICE OR PARTS ARE NEEDED IN
THE USA OR CANADA, CONTACT THE GENERAC
SERVICE LOCATOR AT 1-800-333-1322.
PACT 40G
RV SERVICE LOCATOR:
1.800.333.1322
9/11
13
1
12
®
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Section 1 – General Information
QUIETPACT 40G Recreational Vehicle Generator
1.2 GENERATOR APPLICABILITY
1.4 GENERATOR AC
These generators have been designed and manufac-
tured for supplying electrical power for recreational
vehicles. You should not modify the generator or use
it for any application other than for what it was
designed. If there are any questions pertaining to its
application, write or call the factory. Do not use the
unit until you have been advised by a competent
authority.
CONNECTION SYSTEM
This generator set is equipped with dual stator AC
power windings. These two-stator windings supply
electrical power to customer electrical loads by
means of a two-wire connection system. Note, howev-
er, that the neutral is bonded to the frame of the
engine-generator.
The generator may have been installed so that it pow-
ers 120-volt AC loads (Figure 1.1). It can be wired to
connect 120-volt AC electrical loads. This procedure
should be done by a Generac Authorized Service
Dealer or other qualified installer.
DANGER
For fire safety, the generator must have been
properly installed in compliance with ANSI
119.2-1975/NFPA 501C-1974, “Standard for
Recreational Vehicles, Part III – Installation of
Electrical Systems.” The generator also must
have been installed in strict compliance with
the manufacturer’s detailed installation instruc-
tions. After installation, do nothing that might
render the unit in noncompliance with such
codes, standards and instructions.
Figure 1.1 – Connections for 120 Volts Only
You can use this generator to supply electrical power for
operating 120-volt, single-phase, 60 Hertz, AC electrical
loads. These loads can require up to 3,600 watts
(3.6 kW) of power, but cannot exceed 30 AC amperes of
current at 120 volts.
Do not overload the generator. Some installa-
tions may require that electrical loads be alter-
1.5 SPECIFICATIONS
!
nated to avoid overloading. Applying excessive-
ly high electrical loads may damage the genera-
tor and may 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 cur-
rent) for starting than for continuous operation.
1.5.1 FUEL REQUIREMENTS
◆
The QUIETPACT series generator is equipped with a
gasoline fuel system. Depending on the installation, the
generator may have either a separate fuel tank, or it
may “share” the vehicle engine’s fuel tank.
NOTE:
Some installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter
than the vehicle engine’s pickup tube. Such an
arrangement causes the generator engine to “run
out of gas” while adequate fuel for the vehicle
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.
To reduce lead and carbon deposits use high quality
UNLEADED gasoline with the generator. Leaded REG-
ULAR grade gasoline is an acceptable substitute.
NOTE:
Using unleaded gasoline contributes to longer
engine valve life by reducing lead and carbon
deposits.
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Section 1 – General Information
QUIETPACT 40G Recreational Vehicle Generator
1.5.5 GENERATOR
◆
Rated Maximum Continuous
Generac does not recommend using any
gasoline containing alcohol (such as “gasohol”).
If you use any gasoline containing alcohol, it
must not contain more than 10 percent ethanol,
and it must be removed from the generator
during storage. Do NOT use any gasoline
containing methanol. If you use gasoline with
alcohol, inspect more frequently for fuel leaks
and other abnormalities.
AC Output (Gasoline) ............................3,600 Watts (3.6 kW)
!
Rated Voltage ........................................................120 Volts AC
Rated Maximum Continuous
AC Current (Gasoline)..........................................30 Amperes
Phase ................................................................................Single
Rotor RPM ........................................................................3,600
Number of Rotor Poles ............................................................2
Engine RPM ......................................................................3,600
Rated AC Frequency ........................................................60 Hz
Battery Charge Voltage............................................14 Volts DC
Battery Charge Current..................................2 Amperes (max)
Gasoline weight ......................................................170 Pounds
Length ....................................................749.8 mm (29.52 in.)
Width ......................................................483.1 mm (19.02 in.)
Height......................................................342.2 mm (13.47 in.)
1.5.2 FUEL CONSUMPTION
◆
Model
QUIETPACT 40G
(004700-0)
No Load 1/2 Load Full Load
0.24
0.35
0.55
Fuel consumption is in gal/h.
1.5.6 EMISSIONS COMPLIANCE PERIOD
◆
1.5.3 ENGINE OIL REQUIREMENTS
◆
For non-handheld engines the Emissions Compliance
Period referred to on the Emissions Compliance
Label indicates the number of operating hours for
which the engine has been shown to meet Federal
emission requirements.
Use only high quality detergent oil rated with
American Petroleum Institute (API) Service
Classification SF, SG or SH. The recommended oil
weights include the following:
• During summer months: SAE 30. An acceptable
substitute is SAE 10W-30.
• For engines less than 225 cc displacement,
Category C=125 hours, B=250 hours, and A=500
hours.
• During winter months: SAE 5W-30. DO NOT USE
SAE 10-W40.
• For engines of 225 cc or more, Category C=250
Crankcase and oil filter capacity is approximately
800 mL or .84 U.S. quarts. Do NOT use special addi-
tives. See Sections 3.1 and 3.2 (Page 12) for oil level
check and fill procedures.
hours, B=500 hours, and A=1000 hours.
1.5.4 ENGINE
◆
Type of Engine ....................................GN-220, Single-cylinder
Cooling Method..........................................................Air-cooled
Rated Horsepower ........................................7.8 @ 4,200 rpm
Displacement....................................................................220cc
Cylinder Block ..........................Aluminum w/Cast Iron Sleeve
Type of Governor ..............................Mechanical, Fixed Speed
Air Cleaner..........................Paper Element w/Foam Precleaner
Starter..........................................................12-volt DC Electric
Ignition System........................Solid-state w/Flywheel Magneto
Recommended Spark Plug
Champion ..................................................................RC12YC
AC....................................................................................R45S
Fram Autolite ......................................................................65
Spark Plug Gap ........................................0.030 inch (76 mm)
Recommended Minimum Battery ..............400 Cold-cranking
Amperes
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Section 2 – Operation
QUIETPACT 40G Recreational Vehicle Generator
2.1 GENERATOR CONTROL PANEL
2.2 OPTIONAL REMOTE
The following features are mounted on the generator
control panel (Figure 2.1):
START/STOP PANEL
A remote mounted Start/Stop Panel is available that
allows you to start and stop the generator engine con-
veniently from inside the vehicle.
Figure 2.1 – Generator Control Panel
You can order model 4057 or 4184, a remote panel
that includes a Start/Stop switch, a generator run
lamp and an hourmeter. The hourmeter provides a
continuous indication of engine/generator operating
time. Use the hourmeter for checking off periodic
maintenance requirements on the unit.
CONTROL CENTER
C
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2.3 AUTOMATIC CHOKE
F U S E
7. 5
The engine is equipped with an automatic choke that
consists of two main components: a choke solenoid
and prechoke.
A
2.3.1 CHOKE SOLENOID
◆
During engine cranking (Start/Stop switch at
START), a solid-state choke module signals the
choke solenoid to activate and cycle (choke on/choke
off) until the engine starts. The choke solenoid thus
opens and closes the carburetor choke valve only
when the engine is cranking. When the engine starts,
the choke stops cycling.
2.1.1 FUEL PRIMER
◆
Before starting a cold engine (if it has not been start-
ed in more than two weeks), you must press this
switch for approximately 10 to 15 seconds to bring
fuel from the tank to the carburetor. This rocker type
switch springs back into its original position when
you release it.
2.3.2 PRECHOKE
◆
2.1.2 START/STOP SWITCH
◆
The choke system also has a temperature-sensitive
metal strip that adjusts choke valve angle according
to ambient temperatures (i.e., in cold ambient tem-
peratures, choke valve closes more). Once the engine
starts, an element heats the temperature-sensitive
strip to a normal operating condition, opening the
choke valve. This may take about three minutes in
cooler weather.
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 center position is the RUN position.
2.1.3 FUSE
◆
The fuse protects the engine’s DC control circuit
against electrical overload. If the fuse element has
melted open due to overloading, the engine cannot be
cranked. If you must replace the fuse, use only an
identical replacement.
2.4 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.
2.1.4 MAIN BREAKER
◆
The main breaker protects the generator’s AC output
circuit against overload and provides a method of
turning OFF the generator’s 120-volt AC output to the
vehicle circuits. The QUIETPACT 40G has 30-amp
breaker.
2.4.1 INSTALLATION
◆
Generator installation must have been properly com-
pleted so it complies with all applicable codes, stan-
dards and regulations and with the manufacturer's
recommendations.
®
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Section 2 – Operation
QUIETPACT 40G Recreational Vehicle Generator
2.4.2 ENGINE LUBRICATION
◆
DANGER
Have the engine crankcase properly serviced with the
recommended oil before starting. Refer to Section 1.5.4
(Page 6) and Sections 3.1 and 3.2 (Page 12) for oil ser-
vicing procedures and recommendations.
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.
!
Any attempt to crank or start the engine before
you have properly serviced it with the recom-
mended oil may result in an engine failure.
2.5 STARTING THE GENERATOR
!
NOTE:
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.
2.4.3 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 it may “share”
the vehicle engine’s fuel tank.
To start the generator from either the generator con-
trol panel or from the optional remote panel, proceed
as follows:
2.4.4 COOLING AND VENTILATING AIR
◆
Air inlet and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. Without sufficient cooling and
ventilating airflow, the engine/generator quickly over-
heats, which causes it to shut down and may damage
the generator.
1. Turn OFF electrical loads using the means pro-
vided in your vehicle (such as a main line circuit
breaker or transfer switch).
NOTE:
If starting from the generator control panel, turn
OFF loads by setting the generator’s main circuit
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 cir-
cuit breaker). Electrical load circuits will be
turned ON after the generator has started, stabi-
lized and warmed up.
2.4.5 ENGINE EXHAUST GAS
◆
Before starting the generator engine, you should be
sure there is no way for exhaust gases to enter the
vehicle interior and endanger people or animals.
Close windows, doors and other openings in the vehi-
cle that, if open, might permit exhaust gases to enter
the vehicle.
2. If you have not started the engine in more than
two weeks, press the Fuel Pump Primer switch
and hold it for about 10 to 15 seconds to prime
the fuel system. However, if the engine is warm,
skip Step 2.
3. Hold the engine Start/Stop switch in the START
position to crank the engine. Release the switch
when the engine starts.
DANGER
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
YOU EXPERIENCE 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.
If the engine does not start after it has been
!
cranking for 15 seconds, release the Start/Stop
switch, wait one minute and try again. Holding
the switch for longer than 15 seconds can dam-
age the starter motor.
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 (such as a main circuit breaker or
transfer switch).
®
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Section 2 – Operation
QUIETPACT 40G Recreational Vehicle Generator
• Induction type motors (such as those that run the
2.6 STOPPING THE GENERATOR
1. Turn OFF all electrical loads using the means
provided (such as a main circuit breaker or
transfer switch).
2. Let generator run at no-load for a few minutes, to
stabilize internal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position.
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, fig-
ure the watts needed to start electric motors in the
system. To that figure, add the running wattages of
other items that will be operated by the generator.
• Do not apply heavy electrical loads for the first two
or three hours of operation.
2.7 APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator,
observe these guidelines:
2.9 PROTECTION SYSTEMS
• Before applying electrical loads, let the generator
stabilize and warm up for a minute or two.
• DO NOT overload the generator.
2.9.1 LOW OIL PRESSURE SWITCH
◆
This switch (Figure 2.2) has normally closed (N.C.)
contacts that are held open by engine oil pressure dur-
ing cranking and operating. Should oil pressure drop
below a preset level, switch contacts close, and the
engine automatically shuts down. The unit should not
be restarted until oil is added.
2.7.1 LETTING THE ENGINE STABILIZE
◆
The generator supplies correct rated voltage only at
the proper governed speed. Some electrical appli-
ances may be extremely sensitive to voltage. Incorrect
voltages can damage such appliances.
If electrical loads are applied at reduced operating
speeds, such loads imposed on the engine when suffi-
cient 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.
2.9.2 HIGH TEMPERATURE SWITCH
◆
This switch (Figure 2.2), which has normally open
(N.O.) contacts, is mounted near the oil filter. The
contacts close if the temperature should exceed
approximately 293º F (145º C), initiating an engine
shutdown.
2.8 DO NOT OVERLOAD THE
GENERATOR
Figure 2.2 – Low Oil Pressure and
High Temperature Switches
You can read the rated wattage/amperage capacity of
your generator on the generator data decal (see
Section 1.1 on Page 4).
High Temperature Switch
Low Oil Pressure
Switch
Applying electrical loads in excess of the unit’s rated
capacity will cause the engine/generator to automati-
cally 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.
• Most lighting, appliance, tool and motor loads indi-
cate 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.
®
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Section 2 – Operation
QUIETPACT 40G Recreational Vehicle Generator
The voltage regulator also incorporates a “voltage
2.9.3 FIELD BOOST
◆
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.
The Controller Circuit Board houses a field boost
diode and resistor that are not part of the automatic
choke circuit. These two components are part of a
“field boost” circuit (Figure 2.3). During engine
cranking only, a positive DC (battery) voltage is deliv-
ered through the diode, resistor, brushes and slip
rings, to the generator rotor. Application of this volt-
age to the rotor “flashes the field” whenever it is start-
ed. Flashing of the field each time the generator starts
makes sure that a sufficiently strong magnetic field is
available to produce “pickup” voltage in the stator
windings.
2.10 ADDITIONAL INFORMATION
2.10.1 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 fuel consumption and pro-
vide maximum engine performance. During this 25-
hour break-in period, follow this procedure:
Figure 2.3 – Field Boost Circuit
• Run the unit at varying electrical loads to help seat
the engine piston rings properly.
• Check the engine oil level frequently. Add oil if
needed. It is normal for the generator engine to
consume more oil than is normal until the piston
rings have properly seated.
• For the 75-hour 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.
• After operating the unit for 25 hours, complete the
tasks recommended under Section 2.10.2.
2.9.4 OVERVOLTAGE PROTECTION
◆
2.10.2 25-HOUR CHECK-UP
◆
A solid-state voltage regulator (Figure 2.4) 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).
After the 25-hour break-in period, contact a Generac
Authorized Service Dealer for the following mainte-
nance. The vehicle owner is responsible for any
charges:
• Change the engine crankcase oil and oil filter.
• Check the oil level.
• Inspect the cooling and ventilation openings.
• Check the engine carburetor adjustments.
• Check the engine ignition system.
• Inspect the entire electrical system.
• Inspect the engine exhaust system.
Figure 2.4 – Solid State Voltage Regulator
2.10.3 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 40G Recreational Vehicle Generator
2.10.4 OPERATION IN HIGH GRASS
OR BRUSH
◆
3.1 CHECKING THE ENGINE OIL
LEVEL
Never operate the generator while the vehicle is
parked over high grass, weeds, brush, leaves or any
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.
For oil capacities and requirements, see “Engine Oil
Requirements,” Section 1.5.4 (Page 6). Check the
engine crankcase oil level at least every eight hours of
operation, or before you use it. To check the engine
oil level, proceed as follows (see Figure 3.1):
1. Be sure the generator is as level as possible.
2. Remove the dipstick and wipe it dry with a clean,
lint-free cloth.
3. Install and tighten the dipstick cap; then, remove
it again. The oil level should be at the dipstick
“Full” mark.
4. If necessary, remove the oil fill cap on the rocker
cover and slowly add oil until it reaches the dip-
stick “Full” mark. DO NOT FILL ABOVE THE
“FULL” MARK.
2.10.5 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.
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 causes a
reduced insulation resistance and will eventually
cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with
windings. Salt (as from sea air) also will worsen the
problem since it tends to absorb moisture from the
air. Salt and moisture, when combined, form a good
electrical conductor.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
!
5. Install and tighten the oil fill cap and the dipstick
before operating the engine.
3.2 CHANGING THE ENGINE OIL
AND/OR OIL FILTER
• Change the engine oil after the first 25 hours of
operation (after the 25-hour break-in period, see
Section 2.10.1, Page 10). Thereafter, change the
oil every 100 operating hours. Change the oil more
frequently if operating consistently under heavy
load or at high ambient temperatures.
Figure 3.1 – Oil Maintenance Features
CONTROL CENTER
C
3
.
0
B
A
.
S
T
A
R
T
F
U
E
L
S
T
O
P
P
R
I
M
E
F
U
S
E
7.5
A
S
E
R
V
IC
E
A
C
C
E
S
S
P
A
N
E
L
AIR FILTER LOCATED BEHIND PANEL.
MAINTENANCE SCHEDULE
OIL LEVEL:
AIR FILTER:
CHECK DAILY
CLEAN PREFILTER
EVERY 100 HOURS.
REPLACE ELEMENT
EVERY 250 HOURS.
*
*
OIL
&
OIL FILTER:
CHANGE EVERY 100
HOURS. (OR ANNUALLY)
*
PERFORM MORE OFTEN IN DUSTY CONDITIONS
*
SPARK PLUGS:
FUEL FILTER:
INSPECT
&
CLEAN
PLUGS EVERY 100
HOURS. REPLACE PLUGS
EVERY 500 HOURS.
(IF NECESSARY)
GENERAC
CHANGE EVERY 400
HOURS. (OR ANNUALLY)
POWERED
OHVI
REPLACEMENT INFORMATION
PREFILTER P/N:
AIR FILTER P/N:
OIL FILTER P/N:
SPARK PLUG P/N:
FUEL FILTER P/N:
0D4511
0D3262
070185
072347
0D7515
m
s
OIL CAPACITY WITH FILTER:
0.8L/0.84QT
TEMPERATURE
SAE VISCOSITY
32˚F AND HIGHER
10˚F TO 100˚F
0˚F TO 80˚F
30
15W-40
10W-30
5W-30
GENERAC OHVI INDUSTRIAL ENGINE
TM
-20˚F TO 50˚F
WHEN SERVICE OR PARTS ARE NEEDED IN
THE USA OR CANADA, CONTACT THE GENERAC
SERVICE LOCATOR AT 1-800-333-1322.
QUIETPACT 40G
RV SERVICE LOCATOR:
1.800.333.1322
Oil Drain
Oil Filter
Oil Dipstick/Oil Fill
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Section 3 – Maintenance
QUIETPACT 40G Recreational Vehicle Generator
• Change the engine oil filter after the first 25 hours
3. Remove the foam precleaner from the cover.
4. Wash the foam precleaner in liquid detergent and
water.
of operation, and every 100 operating hours there-
after.
To change the oil and/or oil filter, proceed as
5. Wrap the foam precleaner in a clean cloth and
follows (see Figure 3.1):
gently squeeze it dry.
1. Run the engine until it is thoroughly warmed up
(at least five minutes) then shut OFF
the engine.
6. Saturate the foam precleaner in clean engine oil.
Gently squeeze it in a clean cloth to remove
excess oil and to distribute oil (DO NOT TWIST).
7. Install the foam precleaner into the cover, fol-
lowed by the paper filter.
8. Install the cover, foam precleaner and paper filter.
9. Tighten the two screws to retain the filter in place.
2. Immediately after the engine shuts OFF, pull the
oil drain cover free of the base. Remove the plug
from the tube with a 5/16” allen wrench and drain
the oil into a suitable container. Loosening the oil
fill cap will allow the crankcase to drain faster.
3. After the oil has drained, replace the plug onto the
end of the oil drain tube. Retain the cover in the
base.
Figure 3.2 – Engine Air Cleaner
4. With the oil drained, remove the old oil filter by
turning it counterclockwise. Place a towel under-
neath to catch excess oil.
5. Apply a light coating of clean engine oil to the gas-
ket of the new filter. Fill the filter until saturated
with clean oil.
6. 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.
7. Remove the dipstick and wipe it dry with a clean,
lint-free cloth. This will be used later to check the
oil level.
8. Remove the oil fill cap on the oil fill tube and
slowly add the proper type and amount of rec-
ommended oil (see Section 1.5.4, Page 6).
Periodically use the dipstick to check the oil level
and continue to fill the crankcase until the oil
reaches the dipstick “Full” mark. DO NOT FILL
ABOVE THE “FULL” MARK.
3.3.2 CLEANING OR REPLACING
THE PAPER FILTER
Once each year or every 100 hours of operation
(whichever comes first), clean or replace the paper
filter. The new replacement filter must be flame retar-
dant. Service the paper filter more frequently if oper-
ating the generator in extremely dusty or dirty condi-
tions. Use the following procedure (Figure 3.2):
◆
9. Install and tighten the oil fill cap and the dipstick
before operating the engine.
10. Start the engine and check for leaks.
NOTE:
1. Follow steps 1-3 in Section 3.3.1; service the
foam precleaner if necessary.
2. Remove the paper filter.
Check the oil level and fill to the “FULL” mark
after checking for leaks. The filter will retain some
oil.
3. Clean the air filter by tapping it gently on a solid
surface. If the filter is too dirty, replace it with a
new one. Dispose of the old filter properly.
4. Clean the air cleaner cover then reassemble
following steps 7-9 in Section 3.3.1.
3.3 MAINTAINING THE ENGINE
AIR CLEANER
3.3.1 CLEANING THE FOAM PRECLEANER
◆
Clean and re-oil the foam precleaner every three
months or every 25 hours of operation, whichever
occurs first. Service the foam precleaner more fre-
quently if operating the generator in extremely dusty
or dirty conditions. Use the following procedure
(Figure 3.2):
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover, foam precleaner and paper filter.
®
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Section 3 – Maintenance
QUIETPACT 40G Recreational Vehicle Generator
3.4 CLEAN AIR INTAKE
3.6 FUEL FILTER
Clean all foreign material from the air intake (Figure
3.3) at least once every 100 hours of operation. Clean
more often if necessary.
Remove and replace the fuel filter (Figure 3.5)
once each year or every 400 hours of operation,
whichever comes first. Fuel filter is removed with a
15/16” deep well socket.
Inspect the area around the generator exhaust muf-
fler periodically and remove all grass, leaves, dirt,
etc., from this area.
Figure 3.5 – Fuel Filter
Figure 3.3 – Cleaning Air Intake
POS
FUEL
NEG
USTC
3.7 CLEAN SPARK ARRESTOR
The engine exhaust muffler has a spark arrestor
screen. Inspect and clean the screen every 50 hours
of operation or once each year, whichever comes first.
3.5 CHECKING THE ENGINE
SPARK PLUG
Clean the spark plug and reset the spark plug gap
every 100 hours of operation.
NOTE:
If you use your generator on any forest-covered,
brush-covered or grass-covered unimproved land,
it must equipped with a spark arrestor. The spark
arrestor must be maintained in good condition by
the owner/operator.
1. Clean the area around the base of the spark plug
to keep dirt and debris out of the engine. Remove
the spark plug and check the condition. Replace
the spark plug if worn or if reuse is questionable.
2. Clean spark plug by scraping or washing using a
wire brush and commercial solvent. Do not blast
the spark plug to clean.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.030 inch (0.76 mm)
by carefully bending the ground electrode
(Figure 3.4).
Clean and inspect the spark arrestor as follows:
• Remove the screen retaining bracket by removing
the screw.
• Slide the spark arrestor screen out from the tail
pipe.
• Inspect screen and replace if torn, perforated or
otherwise damaged. DO NOT USE a defective
screen. If screen is not damaged, clean it with com-
mercial solvent.
Figure 3.4 – Setting the Spark Plug Gap
• Replace the screen and the retaining bracket.
Figure 3.6 - Spark Arrestor
TAILPIPE
P/N 0E0683
Sparking can occur if the wire terminal does
not fit firmly on the spark plug terminal end. If
!
SPARK ARRRESTOR
SCREEN P/N 089680
necessary, re-form the wire terminal to obtain a
tight fit.
RETAINING
SCREW P/N 056892
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Section 3 – Maintenance
QUIETPACT 40G Recreational Vehicle Generator
3.8 CLEANING THE GENERATOR
DANGER
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.
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
tools or equipment near the battery. Discharge
static electricity from your body before touch-
ing the battery by first touching a grounded
metal surface.
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 causes a
reduced insulation resistance and will eventually
cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with
windings. Salt (as from sea air) also will worsen the
problem since it tends to absorb moisture from the
air. Salt and moisture, when combined, form a good
electrical conductor which can be damaging to the
generator windings.
A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when working
on batteries:
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
interior and cause problems, and may also cont-
aminate the generator fuel system.
• 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;
!
• 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.
3.9 BATTERY MAINTENANCE
All lead-acid batteries will discharge when not in use.
The generator battery should be inspected as follows:
3.9.1 WEEKLY
◆
• 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.
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
the skin and eyes, and to be toxic.
!
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
3.9.2 EVERY SIX MONTHS
◆
!
• Have the state of charge and condition checked.
This should be done with an automotive-type bat-
tery hydrometer.
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;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
NOTE:
Servicing of the battery is to be performed or
supervised by personnel knowledgeable of batter-
ies and the required precautions. Keep unautho-
rized personnel away from batteries.
• 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) or 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.
Damage will result if the battery connections are
made in reverse.
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Section 3 – Maintenance
QUIETPACT 40G Recreational Vehicle Generator
3. Clean and wipe the entire generator.
3.10 MAJOR SERVICE MANUAL
4. Reconnect the battery. Observe battery polarity.
To obtain a service manual for your generator, con-
tact Generac or your nearest Generac Authorized
Service Dealer or, go to www.generac.com. Make sure
to identify your MODEL NUMBER and SERIES.
Damage may occur if the battery is connected
incorrectly.
5. Turn OFF all electrical loads. Add fuel if neces-
sary and then start the engine.
6. Allow the unit to run for several minutes to warm
3.11 EXERCISING THE GENERATOR
Generac recommends that you start and operate the
generator at least once every seven days. Let
the unit run for at least 30 minutes to “exercise”
the engine.
up.
7. Apply electrical loads to at least 50 percent of the
unit’s rated wattage capacity.
8. When the engine is thoroughly warmed up, shut
it down.
9. Your generator is now ready for service.
3.12 OUT OF SERVICE PROCEDURE
3.13 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, you should
adjust the valve clearance in the engine.
3.12.1 REMOVAL FROM SERVICE
If you cannot exercise the generator every seven days,
and it is to be out of service longer than 30 days, pre-
pare the generator for storage as follows:
◆
When adjusting valve clearance, the engine should be
at room temperature and the piston should be at Top
Dead Center (TDC) of its compression stroke (both
valves closed). Correct clearance is 0.001-0.003 inch
(0.03-0.07mm). Adjust valve clearance as follows:
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
Note:
1. Loosen the rocker arm jam nut. Use an allen
wrench to turn the pivot ball stud while checking
clearance between the rocker arm and the valve
stem with a feeler gauge (Figure 3.7).
Using a fuel additive such as STA-BIL fuel stabi-
lizer, or an equivalent, will prevent gum deposits
from forming in the engine’s fuel system.
3. While the engine is still warm from running,
drain the oil completely. Refill the crankcase with
SAE 10W-30 oil having API classification “For
Service SF.”
Figure 3.7 — Adjusting Valve Clearance
4. Attach a tag to the engine indicating the viscosity
and classification of the oil in the crankcase.
5. Remove the spark plug and pour two or three
tablespoons of clean, fresh engine oil into the
spark plug threaded openings. Reinstall and
tighten the spark plug.
6. 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.
7. Clean and wipe the entire generator.
3.12.2 RETURN TO SERVICE
◆
To return the unit to service after storage, proceed
as follows:
1. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recommend-
ed oil is used in the engine (see Section 1.5.4,
Page 6). If necessary, drain and refill with the
proper oil.
2. Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with distilled
water. DO NOT USE TAP WATER IN THE BAT-
TERY. Recharge the battery to 100 percent state of
charge, or, if defective, replace the battery.
®
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Section 3 – Maintenance
QUIETPACT 40G Recreational Vehicle Generator
2. When valve clearance is correct, hold the pivot
3.14 RV GENERATOR SERVICE
ball stud with the allen wrench and tighten the
rocker arm jam nut with a crows foot. Tighten the
jam nut to 65-85 inch-pounds torque. After tight-
ening the jam nut, recheck valve clearance to
make sure it did not change (Figure 3.8).
INTERVAL
Quietpact 40
50 Hours ................................Clean Spark Arrestor
100 Hours ..........................Change Engine Oil/filter
100 Hours ..................................Clean Air Pre-filter
100 Hours ................................Inspect Spark Plugs
250 Hours ............Replace Paper Air Filter Element
400 Hours ..................................Replace Fuel Filter
500 Hours................................Replace Spark Plugs
1st 50 Hours-then
Figure 3.8 — Tightening Jam Nut
every 500 Hrs. ..........................Adjust Valve Lash
®
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PART II –
INSTALLATION
INSTRUCTIONS
DANGER
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
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Safety Rules
QUIETPACT 40G Recreational Vehicle Generator
DANGER: For fire safety, installation of a generator into a recreational vehicle must comply
strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard
for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation
must comply with the manufacturer’s instructions and recommendations.
!
!
NOTICE TO INSTALLER
!
!
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 proce-
dures for installing such products, or similar prod-
ucts that Generac manufactures. Generac also
assumes that personnel have been trained in the rec-
ommended installation procedures for these prod-
ucts and that such training includes (a) use of com-
mon hand tools, (b) use of special Generac tools, and
(c) use of any tools and/or equipment from other sup-
pliers.
• For safety reasons, Generac recommends
that the installation, initial start-up and mainte-
nance of this equipment is carried out by a
Generac Authorized Service Dealer.
• The engine exhaust fumes contain carbon monox-
ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust sys-
tem must be installed properly, in strict compli-
ance with applicable codes and standards.
Following installation, you must do nothing that
might render the system unsafe or in noncompli-
ance with such codes and standards. The genera-
tor compartment must be completely vapor sealed
from the vehicle interior. There must be no possi-
bility of exhaust fumes entering the vehicle interi-
or. Never operate this equipment with a leaking or
defective exhaust system.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit is
operating.
• Adequate, unobstructed flow of cooling and venti-
lating air is critical to correct generator operation
and is required to expel toxic fumes and fuel
vapors from the generator compartment. Without
sufficient cooling airflow, the engine/generator
quickly overheats, which causes serious damage to
the generator. Do not alter the installation or per-
mit even partial blockage of ventilation provisions,
as this can seriously affect safe operation of the
generator.
Generac cannot possibly know of and advise the
recreational vehicle trade of all conceivable methods,
procedures or techniques by which to perform an
installation. Nor can Generac anticipate every possi-
ble hazard that might result from each installation
method, procedure or technique. Generac has not
undertaken any such wide evaluation. Therefore,
people who use a method, procedure or technique
that Generac does not specifically recommend must
first completely satisfy themselves that their safety,
the safety of the vehicle's occupants and the product's
safety is not endangered by the method, procedure or
technique selected.
Information, illustrations, specifications, etc., con-
tained in these Installation Instructions are based on
the latest information available at the time of publi-
cation. Every effort has been expended to be sure that
such data is both accurate and current. However, the
manufacturer reserves the right to change, alter or
otherwise improve this product at any time without
prior notice.
• When working on this equipment, remain alert at
all times. Never work on the equipment when you
are physically or mentally fatigued.
• Before performing any maintenance on the genera-
tor, disconnect its battery cables to prevent acci-
dental start up. Disconnect the cable from the bat-
tery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating con-
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
!
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
• Never insert any tool or other object through open-
ings in the generator interior, even if the unit is not
running. You might seriously injure yourself or
damage the equipment.
!
®
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Safety Rules
QUIETPACT 40G Recreational Vehicle Generator
ELECTRICAL HAZARDS
FIRE HAZARDS
• The generator covered by this manual produces
dangerous electrical voltages and can cause fatal
electrical shock. Avoid contact with bare wires, ter-
minals, connections, etc., while the unit is running.
Ensure all appropriate covers, guards and barriers
are in place before operating the generator. If you
must work around an operating unit, stand on an
insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands
or feet are wet. DANGEROUS ELECTRICAL
SHOCK MAY RESULT.
• During installation onto the vehicle, properly
ground (bond) the generator either by solid mount-
ing to the vehicle frame or chassis, or by means of
an approved bonding conductor. DO NOT connect
the bonding conductor to any generator part that
might be removed or disassembled during routine
maintenance. If the grounding conductor must be
replaced, use only a flexible conductor that is of
No. 8 American Wire Gauge (AWG) copper wire
minimum.
• For fire safety, the generator must be installed and
maintained properly. Installation always must
comply with applicable codes, standards, laws and
regulations. Adhere strictly to local, state and
national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installa-
tion, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regu-
lations.
• Keep a fire extinguisher in the vehicle at all times.
Extinguishers rated “ABC” by the National Fire
Protection Association are appropriate for use on
the recreational vehicle generator electrical system.
Keep the extinguisher properly charged and be
familiar with its use. If you have any question per-
taining to fire extinguishers, consult your local fire
department.
• If the vehicle electrical circuits can be powered by
any other source of electricity (such as a “dock-
side” power receptacle), there must be no possibil-
ity of connecting the different power sources to the
vehicle circuits at the same time. The dockside
(utility) power source must be positively isolated
from the vehicle circuits whenever the generator is
operating. Failure to isolate the vehicle circuits
from the dockside power supply when the genera-
tor is running may result in damage to the genera-
tor or serious injury or death to dockside (utility)
power workers due to backfeed of electrical ener-
gy.
• In case of accident caused by electric shock, imme-
diately 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 nonconducting imple-
ment, such as a rope or board, to free the victim
from the live conductor. If the victim is uncon-
scious, 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.
• Gasoline is extremely FLAMMABLE and its vapors
are EXPLOSIVE. Do not permit smoking, open
flame, sparks or any source of heat in the vicinity
while handling gasoline. Comply with all laws gov-
erning the storage and handling of gasoline.
• Fuel lines must be properly installed and
fastened, and free of leaks. There must be
no possibility of gasoline vapors entering the vehi-
cle interior.
• You are required to install an approved, flexible,
nonconductive fuel line between the generator fuel
connection point and rigid fuel lines.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.
®
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Section 1 – General Information
QUIETPACT 40G Recreational Vehicle Generator
6. 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 air-cooled generators. This generator is
designed specifically for installing in recreational
vehicles. This generator operates 120-volts, single-
phase, 60-Hertz, AC electrical loads that require 30.0
amps.
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 revolving field (rotor) is driven by a
single-cylinder, four-cycle engine. The generator sup-
plies 120 volts AC at 60 Hertz when the rotor is oper-
ating at 3,600 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
Figure 1.1 – 120-volt Single Voltage Connection
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, personal injury or
damage to equipment and/or property. Stress safety
to all installers, operators and service technicians
who work on this equipment.
BLACK
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 Standard 501C, “Standard for Recreational
Vehicles,” 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 C1-1975 and ANSI 119.2-1975, available
from the American National Standards Institute,
1430 Broadway, New York, NY 10018.
• The AC connection system on all air-cooled
PRIMEPACT series generators uses a GROUNDED
neutral.
• A separate green ground wire is connected to the
recreational vehicle’s junction box.
NOTE:
Do NOT connect loads in excess of circuit
breaker ratings.
4. ANSI A119.2/NFPA 501C, available from the
Recreational Vehicle Association, 1896 Preston
White Drive, Reston, VA 22090.
5. California Administrative Code, Title 25, avail-
able from the State of California, Documents
Section, P.O. Box 1015, North Highlands,
CA 95660.
®
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Section 1 – General Information
QUIETPACT 40G Recreational Vehicle Generator
Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-C)
®
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Section 2 – Installation
QUIETPACT 40G 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. However,
this is seldom possible. Most units must be installed
on the side of the vehicle and are difficult to reinforce.
• If the generator cannot be bolted directly to
the supporting frame or support tubing, consider
using
additional
tubing,
angle
brackets
or other supports to give the supporting frame suf-
ficient strength.
Many recreational vehicles have been factory
equipped with an area for the generator set. Some
vehicles may even have a generator compartment
provided by the vehicle manufacturer.
Figure 2.1 – Typical Horizontal Support Frame
Plan the generator location based on the following:
• 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,
spark plugs and other common maintenance
parts.
• The location must provide sufficient room to allow
minimum clearances as outlined in Section 2.2. If
sound insulation is to be used on the compartment
walls and ceiling, the minimum recommended
applies to the space between the generator and
such insulation.
2.1.3 SUSPENDED MOUNTING
◆
If you are going to suspend the generator below the
horizontal support tubing, the suspension method
you use with the vehicle frame members must (a) be
able to support the weight of the generator AND (b)
provide sufficient restraint for the generator. One typ-
ical suspended mounting system is shown in Figure
2.2. The location of a suspended mounting system
must be carefully planned, keeping the following gen-
eral rules in mind:
• The location must provide adequate cooling and
ventilating airflow for the generator without a great
deal of work and expense.
• 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.
2.1.2 GENERATOR SUPPORT
◆
The generator must be securely attached to a metal
framework that has been made part of 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 horizontal 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. A typical sup-
porting frame with horizontal support tubing, is
shown in Figure 2.1.
Figure 2.2 – Typical Suspended Mounting System
GENERATOR
SUPPORT FRAME
(MODEL 004718-0)
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:
GENERATOR MOUNTING
HOLES FOR 5/16" - 18
BOLTS (6 PLACES)
• Vehicle construction MUST be capable of support-
ing the weight of the generator.
• The installer must make certain that the selected
location will permit adequate cooling and ventilat-
ing airflow to be supplied.
®
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Section 2 – Installation
QUIETPACT 40G Recreational Vehicle Generator
2.1.4 GENERATOR RESTRAINT
2.2.2 COMPARTMENT CONSTRUCTION
◆
◆
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 2.3). All bolts must be long enough so that
when tight, at least three threads are visible past the
retaining lock nuts. Refer to Section 2.2 for the location
of the generator mounting holes.
• 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 with the grain of the wood at cross section
for added strength (Figure 2.5).
Figure 2.3 – Typical Generator Restraint
Figure 2.5 – Typical Compartment Construction
2.2 GENERATOR COMPARTMENTS
Whether the generator set is being installed inside a
compartment specifically manufactured to house a gen-
erator or inside a compartment that the installer con-
structs, the compartment MUST meet certain specifi-
cations as outlined in the following sections:
2.2.1 COMPARTMENT SIZE
◆
Plan the compartment size carefully. Provide a mini-
mum clearance of 1/2 inch (13 mm) on the front and
top, 1/2 inch (25 mm) on the sides, and 1/2 inch (13
mm) from the back for air circulation AFTER the
compartment has been lined with metal and sound
insulation (Figure 2.4).
• 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:
NOTE:
Refer to “Figure 1.2 – Major Features and
Dimensions” on Page 21.
Figure 2.4 – Clearances
Plywood
Compartment
1/2" Clearance on Top
Caulking must be done so that the caulking materi-
al will stay in place permanently. Pressing such
materials as putty tape onto joints and seams is NOT
acceptable. A high quality silicone rubber base
sealant is recommended.
1/2" Clearance
in Back
• 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.
1/2" Each Side
1/2"
Insulation
in Front
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Section 2 – Installation
QUIETPACT 40G Recreational Vehicle Generator
• If flexible metal conduit is used, it must be sealed
DANGER
internally at the end where it terminates inside the
compartment’s electrical junction box.
NOTE:
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.
Flexible metal conduit, due to its unique con-
struction, is NOT vapor tight along its entire
length.
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.
• Seams and joints of the galvanized steel (whether
used as a liner or for the compartment itself) must
be lapped and mechanically secured. Such seams
may be manufactured, welded, bolted, riveted or
screwed. Manufactured lock seams are shown in
Figure 2.6. Installer constructed compartments
typically utilize a standard lap joint.
2.2.4 ACOUSTICS
For additional noise abatement, the installer may
wish to consider the following:
◆
Figure 2.6 – Types of Lock Seams
• Using special sound insulating materials.
• Construction of a special noise abatement
compartment.
NOTE:
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 2.7):
• 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 2.2.3.
• 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 interior walls and floor, as
well as the underside of the floor, with 26-gauge
galvanized steel.
• Vapor seal all compartment seams and joints.
• Over the galvanized steel lining, install a combina-
tion of acoustical materials as mentioned in
Section 2.2.3.
DANGER
Do not install any flammable material directly
above or around the compartment. Heat,
transferred through the compartment structure,
may be sufficient to ignite, char or discolor
seat cushions, fiberboard and other flammable
materials. You may need to use approved
nonflammable insulating materials in high
temperature areas.
DANGER
To prevent fire or explosion, do not install any
insulation or other absorbent materials on the
interior or underside of the compartment floor.
2.2.3 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.
• 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).
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.
®
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Section 2 – Installation
QUIETPACT 40G Recreational Vehicle Generator
Figure 2.7 – Typical Noise Abatement
2.2.5 COMPARTMENT FLOOR CUTOUTS
◆
You must provide openings in the generator compart-
ment for the following items (Figure 1.2, page 21):
• Engine exhaust and cooling air outlets
• Generator cooling air inlet
• Four holes for passage of generator mounting
bolts. See Section 2.1.4 (Page 23).
DANGER
Fuel lines and exhaust piping must not pene-
trate into the vehicle living area.
!
Figure 2.8 – Compartment Floor Cutout (Drawing 0D8716-C)
VIEW FROM TOP
724.4
429.9
350.1
24.7
32.2
59.2
50.8
60
259.7
277.2
11
210
170
HOT AIR
EXHAUST
427.7
AIR
INTAKE
376.5
TAIL PIPE
EXIT
79
10
176.6
83.5
63.5
36.5
29
5/16"-18 WELDNUTS
(6 PLACES)
54.8 TYP.
229.4
307.4
OIL DRAIN
376.4
695 TYP.
All measurements are in millimeters, 25.4 mm = 1”.
®
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Section 2 – Installation
QUIETPACT 40G Recreational Vehicle Generator
2.3.2 TESTING THE INSTALLATION
◆
2.3 COOLING AND VENTILATING AIR
It is absolutely essential that an adequate flow of air
for cooling, ventilating 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 com-
bustion. The installer also must provide for a path
for exhausting the cooling air to the exterior of a com-
partment, if so equipped.
Generac recommends testing the installation to be
sure adequate cooling airflow is available to the unit
before placing the unit into service. If the unit shows
signs of overheating, you will need to enlarge the air
openings. Never place a unit into service until
absolutely certain that cooling and ventilation is ade-
quate.
NOTE:
You must test the installation, especially if you
bring in air from below the generator set.
2.4 GASOLINE FUEL SYSTEM
DANGER
The installation of a gasoline fuel system (Figure
2.10) for a recreational vehicle generator set must
comply with applicable codes, standards and regula-
tions. The entire fuel system must be completely free
of leaks. There must be no possibility of gasoline
vapors entering the vehicle interior.
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, flam-
mable or explosive gases.
2.3.1 GENERATOR AIRFLOW
◆
Figure 2.10 – Generator Fuel System
Engine operation drives cooling fans for the two-stage
cooling air system. A pressure fan draws cooling air
into the bottom right side of the generator (Figure 2.9).
This airflow cools the engine/generator and electronic
components. The second part of the cooling system, a
suction fan, draws air that is heated from a hot engine
into a collector compartment at the left side of the unit.
This heated air (although cooler than exhaust muffler)
is then deflected out the bottom toward the ground.
CONTROL CENTER
C
.
B
.
S
T
A
R
T
F
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L
3
0
A
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7.5
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AIR FILTER LOCATED BEHIND PANEL.
MAINTENANCE SCHEDULE
OIL LEVEL:
AIR FILTER:
CHECK DAILY
CLEAN PREFILTER
EVERY 100 HOURS.
REPLACE ELEMENT
EVERY 250 HOURS.
*
*
OIL
&
OIL FILTER:
CHANGE EVERY 100
HOURS. (OR ANNUALLY)
*
PERFORM MORE OFTEN IN DUSTY CONDITIONS
*
SPARK PLUGS:
FUEL FILTER:
INSPECT
&
CLEAN
PLUGS EVERY 100
HOURS. REPLACE PLUGS
EVERY 500 HOURS.
(IF NECESSARY)
GENERAC
CHANGE EVERY 400
HOURS. (OR ANNUALLY)
POWERED
OHVI
REPLACEMENT INFORMATION
PREFILTER P/N:
AIR FILTER P/N:
OIL FILTER P/N:
SPARK PLUG P/N:
FUEL FILTER P/N:
0D4511
0D3262
070185
072347
0D7515
m
s
OIL CAPACITY WITH FILTER:
0.8L/0.84QT
TEMPERATURE
SAE VISCOSITY
32˚F AND HIGHER
10˚F TO 100˚F
0˚F TO 80˚F
30
15W-40
10W-30
5W-30
GENERAC OHVI INDUSTRIAL ENGINE
TM
-20˚F TO 50˚F
WHEN SERVICE OR PARTS ARE NEEDED IN
THE USA OR CANADA, CONTACT THE GENERAC
SERVICE LOCATOR AT 1-800-333-1322.
Figure 2.9 – Airflow Through Engine/Generator
QUIETPACT 40G
RV SERVICE LOCATOR:
1.800.333.1322
Fuel Pump & Fuel Filter
(Behind Access Panel & Air Filter)
GEN
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GENER
Gasoline is highly flammable, and its vapors are
explosive. Comply with all codes, standards and
regulations pertaining to gasoline fuel systems
used in recreational vehicle generators.
A
QUIET OHVI
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A DUST
RIAL ENGINE
C
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RV
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2
2
Properly install and maintain the fuel system
and keep it entirely free of leaks. Gasoline
vapors must not enter the vehicle interior.
Factory installed generator fuel system components
include (a) fuel filter, (b) 12-volt DC electric pump, (c)
engine carburetor, and (d) interconnecting lines and
fittings. Connect a fuel supply line to the fuel filter
inlet. Use a flexible length of approved fuel hose
between the fuel filter inlet connection and rigid fuel
lines.
®
26 Generac Power Systems, Inc.
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Section 2 – Installation
QUIETPACT 40G Recreational Vehicle Generator
2.4.1 FUEL TANK
2.4.2.2 Flexible Fuel Line
◆
Use an approved flexible length of fuel hose between
the generator fuel inlet connection and rigid fuel
lines. This prevents breaking of the line caused by
vibration, shifting, settling or movement. The follow-
ing rules apply:
Either the generator must share the vehicle engine's
fuel tank, or you must install a separate fuel tank for
the generator set. 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 gasoline.
• 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 engine's tank,
separate fuel pickup tubes are required for the engine
and the generator. Generac recommends that you
make the fuel pickup tube 2 to 3 inches (51 to 76
mm) shorter than the vehicle engine's pickup tube.
This prevents the generator from depleting the entire
fuel supply during prolonged generator operating
periods.
2.5 EXHAUST SYSTEM
The generator exhaust system must be safely and
properly installed. Only approved mufflers and other
exhaust system parts must be used. A properly
installed exhaust system must be vapor tight, quiet
and completely safe.
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.
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 YOU FEEL
ANY OF THESE SYMPTOMS, MOVE INTO FRESH
AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP. Do not operate the generator
until its exhaust system has been inspected and
properly repaired.
2.4.2 GENERATOR FUEL SUPPLY LINE
◆
2.4.2.1 Rigid Fuel Lines
Those lines used to supply fuel from a tank to the
generator must comply with applicable codes, stan-
dards and regulations. The following general rules
apply to rigid fuel lines:
• Rigid lines should be of annealed, seamless, drawn
aluminum or steel.
• Lines and fittings must comply with SAE J512F,
“Standard Automotive Fittings,” or with ANSI
B126.26 (latest edition).
• Route the fuel line so that at least 2 inches (51 mm)
of clearance is maintained between the line and
any exhaust system parts.
• Do not attach electrical wiring to fuel lines. Route
the wiring so it cannot come into contact with any
fuel line.
• Route fuel lines so 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.
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.
!
®
Generac Power Systems, Inc. 27
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Section 2 – Installation
QUIETPACT 40G Recreational Vehicle Generator
2.5.1 SPARK ARRESTOR
2.5.2 EXHAUST SYSTEM SAFETY
◆
◆
This spark arrestor assembly meets code and stan-
dard requirements of the U.S. Forest Service. Use
only mufflers and parts approved by Generac. 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.
• Maintain a clearance of at least 3 inches (76 mm)
between exhaust system parts and any com-
bustible material (such as wood, felt, cotton,
organic fibers or other like material). If you cannot
maintain the 3-inch (76 mm) clearance, locate,
insulate or shield the exhaust part(s) so that the
temperature of any combustible material is not
raised more than 117° F (65° C) above the ambient
air temperature.
• Extend the exhaust system at least 1 inch (25 mm)
past the outer edge of the vehicle. 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.
• 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.
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, you must provide a spark arrestor.
The vehicle owner or operator must maintain this
device 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.
When installing/replacing the tailpipe or spark
arrestor components, verify that the tailpipe has a
hole to securely fasten the spark arrestor compo-
nents (see Figures 2.11 and 2.12). Use only Generac
supplied hardware. Substitution of parts may cause
damage to the screen or a loose fit to the tailpipe.
• Use enough exhaust system hangers to prevent any
part of the system from being dislocated.
• Use exhaust system parts recommended by
Generac. Using unapproved exhaust mufflers and
exhaust system parts is the responsibility of the
person(s) installing such unauthorized parts.
• Do not terminate the exhaust system under any
opening, window or vent that can be opened or is
not permanently sealed from the vehicle interior.
• Exhaust piping must be large enough to prevent
excessive back pressure on the generator engine.
• 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.
Figure 2.11 - Spark Arrestor
TAILPIPE
P/N 0E0683
• Plan exhaust system installation carefully. Comply
with all applicable codes, standards and regula-
tions.
SPARK ARRRESTOR
SCREEN P/N 089680
RETAINING
SCREW P/N 056892
2.6 ELECTRICAL CONNECTIONS
Be sure to read Section 1.6 on Page 20.
Figure 2.12 — Spark Arrestor Installation
The following general rules apply to electrical con-
nections in a 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.
27.4 [1.08"] I.D.
5.5 [7/32"] DRILL
40 [1.58"]
BOTTOM SIDE ONLY
®
28 Generac Power Systems, Inc.
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Section 2 – Installation
QUIETPACT 40G Recreational Vehicle Generator
• Wiring must be of adequate size, have approved
Figure 2.13 – Generator AC Output Leads
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.
483.1
REMOTE PANEL
CONNECTOR
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 you plan to install the generator (NOT on the
generator). Route the generator's AC output leads
into this junction box through approved flexible con-
duit. This is the point of first termination for genera-
tor AC output leads.
AC OUTPUT
HARNESS
FUEL FILTER
BATTERY
CONNECTIONS
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.
Leads BLACK to WHITE are protected against over-
load by a 30-amp circuit breaker (CB1). Use this line-
to-neutral connection separately to operate 120-volt,
single-phase, 60 Hertz, AC loads requiring up to
3,600 watts (3.6 kW) of power.
• Neutral conductors must be the same size as other
leg wires.
• Route power supply conductors from generator AC
output leads (white), (black) and the green ground
wire through approved flexible conduit to the elec-
trical junction box on the compartment wall.
If flexible metal conduit is used between the gener-
ator and the compartment junction box, the con-
duit end that terminates the compartment junction
box must be vapor-sealed. Flexible metal conduit
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).
Do NOT connect electrical loads in excess of
any circuit breaker rating or you will develop
problems with circuit breaker tripping, which
causes a loss of AC output. Also, do NOT
exceed the generator's rated wattage capacity.
Add the watts or amperes of all lighting, appli-
ance, tool and motor loads the generator will
operate at one time. This total should be less
than the unit's rated wattage/amperage capaci-
ty.
2.6.4 CONDUIT
Route the connections between the generator and the
junction box through approved, flexible conduit. The
following general rules apply:
◆
• Cut wiring to the required length and allow extra
wire for junction box connections.
• Conductors must be rated 221° F (105° C) or must
be of a larger conductor size.
• 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 you use metallic conduit, vapor seal the end of
the conduit where it enters the junction box. Do
this because flexible metallic conduit is not vapor-
proof along its entire length.
2.6.3 GENERATOR AC CONNECTIONS
◆
Generator AC output leads (BLACK) “hot” and
(WHITE) grounded neutral come out of the generator
as shown in Figure 2.13. There is also a green lead
that connects to ground in the junction box of the
recreational vehicle.
®
Generac Power Systems, Inc. 29
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Section 2 – Installation
QUIETPACT 40G Recreational Vehicle Generator
2.6.5 ISOLATING DIFFERENT POWER
2.6.6 POWER SUPPLY CORD
◆
◆
SOURCES
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.
Connections from the junction box must terminate in
a double-pole, double-throw transfer switch (Figure
2.14). An alternate method for isolating different
power sources is by using an isolating receptacle
(Figure 2.15). Whichever method you use, you must
be certain that both power sources are NOT connect-
ed at the same time.
Figure 2.14 – Transfer Switch Isolation Method
GENERA
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:
1
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0
0
.3
3
3
.1
3
2
2
Figure 2.13 – Installation With Isolation Receptacle
G
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®
30 Generac Power Systems, Inc.
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Section 2 – Installation
QUIETPACT 40G Recreational Vehicle Generator
Figure 2.16 – Connecting Battery Cables
2.6.7 GROUND FAULT CIRCUIT
INTERRUPTERS
◆
POS
The National Electrical Code (NFPA 70, 551-7)
requires that you install ground fault circuit inter-
rupters (GFCIs) on all external and some internal
electrical receptacles. Contact your manufacturer or
dealer for recommendations.
FUEL
NEG
2.7 BATTERY INSTALLATION
2.7.4 BATTERY COMPARTMENT
2.7.1 RECOMMENDED BATTERY
◆
◆
Install the generator battery in its own, vented com-
partment. Place the battery compartment away from
any source of heat, sparks or flame.
Install
a
battery that meets the following
requirements:
• The battery must be a 12-volt, automotive type
storage battery.
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.
• For prevailing ambient temperatures above 32° F
(0° C), use a battery rated 70 amp-hours and capa-
ble of delivering 400 cold-cranking amperes.
• For prevailing ambient temperatures below 32° F
(0° C), use a battery rated 95 amp-hours and capa-
ble of delivering 400 cold-cranking amperes.
NOTE:
2.8 OPTIONAL ACCESSORIES
A plug-in receptacle (Figure 2.17) is provided on the
generator set. Use this receptacle to connect an
optional remote-mounted start/stop panel to the gen-
erator. Installation of such a panel will permit you to
start and stop the generator engine from any conve-
nient location inside the vehicle.
If the battery is to be used to power other vehicle
accessories, as well as start the generator, you may
need a battery with a larger capacity.
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 amperes of cranking current.
Figure 2.17 – Remote Panel Plug-in Receptacle
PRIMEPACT generators are rated at about 100 DC
amperes of cranking current.
6
5
4
3
2
1
14A
18
14A
18
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.
15
14
0
15
14
0
17
17
2.7.3 BATTERY CABLE CONNECTIONS
◆
1. Connect the battery cable from the battery post or
terminal indicated by a POSITIVE, POS or (+) to
the lug on the starter contactor (Figure 2.16).
NOTE:
12.00"
WIRE
No.
WIRE
COLOR
LENGTH (mm)
FUNCTION
GROUND
Check to be sure the battery cable boot for the
starter cable has been installed.
0
14
15
17
18
WHITE
RED
ORANGE
YELLOW
BROWN
BLUE
12.0 (305)
12.0 (305)
12.0 (305)
12.0 (305)
12.0 (305)
12.0 (305)
ENGINE RUN SIGNAL
2. Connect the battery cable from the battery post
indicated by a NEGATIVE, NEG or (-) to the
frame ground connection (Figure 2.16).
3. Connect cables so the connectors are clean
and tight.
12 VDC
START
STOP
PRIME
14A
P/N: 0D9099-B
®
Generac Power Systems, Inc. 31
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Section 3 – Post-Installation Start-up Adjustments
QUIETPACT 40G Recreational Vehicle Generator
2.8.1 REMOTE START/STOP PANEL
◆
3.3 INITIAL START
When you are absolutely certain that the unit has
been properly installed and prepared for use, start
the engine as follows:
A remote mounted Start/Stop panel (Figure 2.18) is
available that allows the user to start and stop the
generator engine conveniently from inside the vehicle.
The remote panel includes a Start/Stop switch,
hourmeter, generator run lamp and a wire harness.
The hourmeter should be used in conjunction with
the maintenance operations found in Part I of this
manual.
1. Turn off all electrical loads. Do this by setting the
generator’s main circuit breakers to their “OFF”
(or open) position.
2. Refer to Part I, Section 2.5, “Starting the
Generator” (Page 8), for cranking and starting
instructions. The engine may require more
cranking for initial starting since the fuel lines
have to be primed (use of the primer switch will
shorten this time).
Figure 2.18 – Optional Remote Panel
3. Let the engine warm up for about five minutes to
allow internal temperatures to stabilize.
4. Carefully inspect the engine/generator for fuel, oil
and exhaust system leaks. Before proceeding to the
next step, correct any leakage immediately.
5. When all tests and adjustments at no-load are
completed, apply electrical loads and check for
proper operation under load. See Section 3.4.
Run the unit at least 30 minutes with loads
applied.
6. Turn off all electrical loads by setting the genera-
tor’s main circuit breakers to their “OFF” (or
open) position.
7. Let the unit run at no-load for a few minutes to
stabilize internal engine/-generator temperatures.
Then, shut down the engine.
3.1 POST INSTALLATION TESTS
The air-cooled generator set was factory tested and
adjusted. You should not be required to adjust the
unit any further except under special circumstances.
NOTE:
The generator set was thoroughly tested and
adjusted at the factory before shipping. No addi-
tional adjustment should be necessary. Only qual-
ified service technicians who have been trained
should perform adjustments outlined in this man-
ual.
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 START-UP
Before starting, complete the following:
3.4 TESTING UNDER LOAD
1. Check the engine crankcase oil level and, if nec-
essary, fill to the dipstick “FULL” mark (cross-
hatched area) with the recommended oil. Do not
fill above the FULL mark.
2. Check the fuel supply. Gas fuel lines must have
been properly purged and leak tested in accor-
dance with applicable fuel codes. All fuel shutoff
valves in the fuel supply lines must be open.
Apply electrical loads equal to about 75 to 100 per-
cent of the unit's rated wattage/amperage capacity.
Let the unit run at least 30 minutes with load applied.
During this part of the test, check that the unit is not
running excessively hot and that adequate cooling air-
flow is available. You must not allow the unit to over-
heat during prolonged operation.
NOTE:
DANGER
The generator engine is equipped with a high tem-
perature switch. The switch has normally closed
(N.C.) contacts. When the engine temperature is
too high, switch contacts close, and the engine
shuts down automatically.
If a liquid propane (LP) gas fuel system has
been installed, it must be properly tested for
leaks before operating the system in compli-
ance with ANSI A119.2/NFPA 501C. No leakage
is permitted. You must be sure no gasoline fuel
vapors enter the vehicle interior.
!
GENERAC RECOMMENDS THAT YOU TEST THE
GENERATOR FOR ADEQUATE COOLING.
®
32 Generac Power Systems, Inc.
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Section 3 – Post-installation Start-up Adjustments
QUIETPACT 40G Recreational Vehicle Generator
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,
GASOLINE FUEL SYSTEM
◆
and terminal covers are positioned.
◆ Fuel tank complies with all applicable codes.
OPTIONAL ACCESSORIES
◆
◆ Fuel system is properly installed and checked
◆ Check that remote start/stop panels (if used) are
for leaks.
installed properly.
OPTIONAL LP GAS FUEL SYSTEM
◆
◆ Check that hourmeter kit (if used) is installed
properly.
◆ Fuel system is properly installed and checked
for leaks.
◆ Check that any other options and accessories (if
used) are installed properly.
◆ Pressure at regulator inlet is correct.
◆ Rated flow of primary regulator is correct.
◆ All parts are properly installed.
POST INSTALLATION TESTS
◆
◆ Check that all tests are completed properly.
◆ Fuel system is properly tested/adjusted.
DATE OF INSTALLATION ____________________________________________________
NAME OF INSTALLER ______________________________________________________
SIGNATURE OF INSTALLER ________________________________________________
®
Generac Power Systems, Inc. 33
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Appendix 1 – Notes
QUIETPACT 40G Recreational Vehicle Generator
®
34 Generac Power Systems, Inc.
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Appendix 2 – Troubleshooting
QUIETPACT 40G Recreational Vehicle Generator
TROUBLESHOOTING GUIDE
PROBLEM
The engine will not crank.
CAUSE
1. Fuse blown
CORRECTION
1. Replace fuse.
2. Loose, corroded or defective
2. Tighten, clean or replace
battery cables
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
4. Replace contactor.
5. Replace starter motor.
6. Charge or replace battery.
The engine cranks but
will not start.
1. Out of fuel
1. Replenish fuel.
2. Replace fuel pump.
2. Defective fuel pump
3. Open #14 wire from
engine control board
4. Flooded engine
5. Defective spark plug(s)
6. Fuel line shut-off closed
7. Plugged fuel filter
3. Check connections and.
insulation of #14 wires.
4. Wait 5-10 minutes before trying.
5. Clean, re-gap or replace plug(s).
6. Open fuel line shut-off.
7. Clean or replace fuel filter.
The engine starts hard
and runs rough.
1. Air cleaner
plugged or damaged
2. Defective spark plug(s)
1. Check, clean or replace air cleaner.
2. Clean, re-gap or replace plug(s).
The engine starts, but shuts
down when the Start/Stop
switch is released.
1. Engine oil level low
2. Defective low oil
pressure switch
1. Check oil and add oil as needed.
2. Replace pressure switch.
3. Defective high temperature
switch
3. Replace temperature switch.
4. Defective engine control board
5. Overheated engine
4. Replace control board.
5. Check that the airflow
openings are adequate.
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.
4. Replace control board.
between Start/Stop switch
and engine control board
4. Defective engine control board
There is no AC output from
the generator.
1. Main line circuit breaker open
1. Reset circuit breaker
to ON (or closed).
2. Fault with vehicle circuit
breaker and/or fuses
2. Reset and replace if necessary.
3. Transfer switch set to NORMAL 3. Set switch to GENERATOR.
4. Start switch not held long
4. Stop, then restart the engine
(Hold Start switch for at least
2 seconds).
enough to flash the field
5. Generator internal failure
5. Contact a Generac Authorized
Service Dealer.
®
Generac Power Systems, Inc. 35
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Appendix 3 — Electrical Data
QUIETPACT 40G Recreational Vehicle Generator
Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-A
BATTERY
RED
RED
BLK
SC
16
SM
13
F1
15
14A
14
FP
CH
SW2
14
SC
0
0
16
FS
PCB
15
J3
J2
J1-1
56
90
CS
J1-2
0
J1-3
14
SP
IM
15
J1-4
18A
J1-5
J1-6
17
17
(START)
(STOP)
0B
SW1
J1-7
J1-8
HTO
0
J1-9
4
85
85
J1-10
J1-11
J1-12
J1-13
J1-14
J1-15
66
85
0
LOP
0
REMOTE
PANEL
CONNECTOR
66
18
18
4
17
0I
1
1
17
14
18
15
14 A
2
2
14
15
3
4
5
6
3
4
5
6
BCR
66
7
8
7
8
15
14
18
0
14A
17
66
77
BATTERY CHARGE WINDING
STOP
55
R1
START
0N
4
L1
HM
POWER WINDING
33
0N
22S
11S
FUEL
PRIME
44
11P
22P
REMOTE PANEL
(OPTIONAL)
ELECTRONIC
VOLTAGE
CB1
REGULATOR
0K
LEGEND
2A
CB3
BCR - BATTERY CHARGE RECTIFIER
CB1 - CIRCUIT BREAKER, 30A
CB3 - CIRCUIT BREAKER, 2.5A
CH - CHOKE HEATER
4
0N
T1
4
2
6
CS - CHOKE SOLENOID
F1 - FUSE, 7.5A
FP - FUEL PUMP-OR-LPG SHUT OFF VALVE
FS - FUEL SOLENOID
GT - TERMINAL, GROUND 4-TAB
HM - METER, HOUR (OPTIONAL)
DPE WINDING
FIELD
0F
4
BLACK
WHITE
T2
HTO - SWITCH, HIGH TEMP. OIL (CLOSES ON HIGH TEMP.)
IM - IGNITION MAGNETO
GREEN
L1 - LIGHT, RUN (OPTIONAL)
LOP - SWITCH, LOW OIL PRESSURE (CLOSES ON LOW PRESSURE)
PCB - ENGINE CONTROLLER
120V 30A
R1 - RESISTOR, 1 OHM 25W
SC - STARTER CONTACTOR
SM - STARTER MOTOR
NEUTRAL CONNECTION
BY CUSTOMER
SW1 - SWITCH, START/STOP
SW2 - SWITCH FUEL PRIMER
SP - SPARK PLUG
TC - TERMINAL, CONN. 4-TAB
®
36 Generac Power Systems, Inc.
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Appendix 3 — Electrical Data
QUIETPACT 40G Recreational Vehicle Generator
Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-A
R E D
®
Generac Power Systems, Inc. 37
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
Enclosure – Drawing No. 0D8352-E
37
20
42
22
23
24
4
36
44
39
58
21
22
23
21
49
7
24
26
45
5
6
21
21
28
21
27
25
18
46
47
29
51
8
9
21
38
3
59
1
21
53
54
10
41
50
21
12
16
57
2
21
21
11
43
13
14
42
17
40
52
29
19
15
30
34
55
TO CARB
33
29
31
®
38 Generac Power Systems, Inc.
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
Enclosure – Drawing No. 0D8352-E
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
29
30
31
0D6822
0D6942
0D6939
0D6943
0D6941
0D6940
0D6945
0D6944
0D8254
0C5644
0D7513
087769
0D7613
0D7614
048031C
047411
022473
023484S
022097
086729
0D3700
022129
022259
075763A
0D7293
064113
0C7561
0A4456
076821
049813
022237
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
2
2
1
2
1
24
2
2
2
1
1
1
1
2
2
1
TRAY, ENCLOSURE
32
33
34
35
36
37
38
39
40
41
022131
0C5443
0C7423
029451
074908
0D8717
0D9020
0742600144
0E0724
0A7215
2
1
1
2.1'
4
1
1
1
1
18
WASHER FLAT 3/8-M10"
BLOCK, TERMINAL BATTERY POST
STUD 3/8"-16 X 2"-1/4" BRASS
TAPE FOAM 1/8" X ½"
SCREW HHTT M5-0.8 X 10
CUSTOMER CONNECTION HARNESS
FOAM, AIR OUT COMPARTMENT SIDE
CABLE, STARTER
ASSEMBLY OIL DRAIN
SCREW SW ¼"-20 X 5/8" WITH NYLON
WASHER
CABLE, BATTERY CONNECTION
MOUNT, FUEL FILTER SUPPORT
FOAM, AIR INTAKE COMPARTMENT
FOAM, ROOF AIR OUT COMPARTMENT
FOAM, BACK COMPARTMENT
FOAM, DOOR PANEL
WASHER SELF LOCKING 1"
WASHER NYLON .250"
HARDWARE CLOTH COMPARTMENT
AIR OUT
BUSHING, 0.50" SNAP
HOSE, 1/4" ID
BOX, MUFFLER TAIL PIPE
GASKET, MUFFLER TAIL PIPE BOX
NUT HEX JAM 3/8"-16 BRASS
DIPSTICK
FILTER GASKET
FOAM TAPE 1/16" X ½"
PANEL, ENCLOSURE SIDE
PANEL, REAR DIVIDER
PANEL, ENCLOSURE ROOF
PANEL, ENCLOSURE BACK
PANEL, FRONT DIVIDER
COMPARTMENT, AIR INTAKE
PANEL, ENCLOSURE DOOR
SHIELD, MUFFLER
SLIDE LATCH, FLUSH
PUMP, FUEL
FILTER, FUEL
42
43
44
45
46
47
48
49
50
0742600143
0D8595
0D8627
0D8628
0D8628A
0D8691
0D7176
0A2115
1
1
2
1
1
1
4
1
1
FUEL LINE, FILTER TO PUMP
FUEL LINE, PUMP TO CARB
CLAMP HOSE BAND ¼"
SCREW HHC M6-1.0 X 16
WASHER FLAT ¼"
BUSHING, 1.09" SNAP
WASHER LOCK M6-1/4"
CONTACTOR, STARTER
NUT FLANGE M6-1.0 NYLOK
WASHER LOCK M8-5/16"
NUT HEX 5/16"-18
BOOT BATTERY CABLE
PANEL AIR BOX COVER
SCREW, M6-1.00 X 20MM WING
BOLT CARR 3/8"-16 X 1"
3/8" SPECIAL L/WASHER
NUT HEX 3/8"-16 BRASS
NUT HEX M6 X 1.0
0D9282
51
52
53
54
55
56
57
58
59
023484E
030340
0E0014
0E0017
0C7968
0E0361
0D8981
029451A
0D8628B
1
8.5"
1
1
1
1
1
8.75'
1
FOAM, FRONT AIR OUT
COMPARTMENT
WASHER LOCK 3/8"
®
Generac Power Systems, Inc. 39
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
Generator – Drawing No. 0D8353-F
®
40 Generac Power Systems, Inc.
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
Generator – Drawing No. 0D8353-F
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
050322
022129
049451
0C8096A
0D8120
0C2824
066386
0D4217
073159
0D4484H
0D4430H
0D4216
048614
0D2588A
022131
027028
0D6832
022145
030231
0C3168
022259
0C8565
0D8048
083512
0D6831
029451
0D6918
0D2558
087680
0D7530
0D9723
0D4511
0D8451
022097
0D7440
090388
0D7441
081105
089476
045771
022531
0D8981
1
22
1
1
4
2
1
1
1
1
1
1
4
1
4
4
1
18
3
1
10
1
4
6
1
2.14'
1
1
2
1
1
1
1
1
1
2
SCREW IHHC 5/16"-24 X 9-3/4"
WASHER LOCK M8-5/16"
WASHER FLAT .406" I.D. X 1.62" O.D.
FAN, 8" CURVE BLADE, 16.5MM I.D.
SCREW IHHC M8-1.25 X 260MM
SCREW TAP-R #10-32 X 9/16"
ASSEMBLY, BRUSH HOLDER
CARRIER, REAR BEARING
BEARING
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
ROTOR
STATOR
ADAPTOR, ENGINE
SCREW HHC 5/16"-24 X 3/4"
GASKET, FRONT DIVIDER
WASHER FLAT 3/8"-M10
NUT LOCK HEX 5/16"-18 NYLON INSERT
BRACKET, ENGINE MOUNTING
WASHER FLAT 5/16"
SCREW HHC 5/16"-18 X 1-1/2"
5/16" SPECIAL LOCK WASHER
NUT HEX 5/16"-18
SCREW SHC M8-1.25 X 18MM
VIBRATION MOUNT
SCREW HHTT M8-1.2 X 16MM
BRACKET, ALTERNATOR MOUNTING
TAPE ELEC. UL FOAM 1/8" X 1/2"
DUCT, ALTERNATOR AIR
GASKET, ALTERNATOR DUCT
NUT WING M6-1.0
STUD, M6-1.0 OFFSET
ELEMENT, AIR FILTER
PRECLEANER, AIR
WASHER FLAT .281" I.D. X 1.50" O.D.
WASHER LOCK M6-1/4"
MUFFLER
SCREW HHTT M6-1.0 X 12MM
BOLT CARR 5/16"-18 X 2"
NUT FLANG 5/16"-18 LOCK
GASKET, EXHAUST
NUT, HEX M8-1.25
SCREW HHC 5/16"-18 X 1-3/4"
FILTER GASKET RV
2
2
1
1
1
1
®
Generac Power Systems, Inc. 41
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
Control Panel – Drawing No. 0D8354-C
3
26
24
9
17
20
23
2
13
16
15
17
1
12
1
31
39
38
30
27
8
4
18
5
6
37
25
36
25
23
29
19
22
®
42 Generac Power Systems, Inc.
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
Control Panel – Drawing No. 0D8354-C
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0830490
075210A
0922340
065795
023484F
023484R
075234
053623
087798
092113
032300
0A9611
090145
0A1658
075235
047411
049226
051716
075476
022264
051715
0A2053
022473
022097
049813
055440
049815
038750
051714
0D8794
025105
028739
0D8308
0D8418
023484G
043182
031879
0D6575D
0A9973
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
5
1
2
2
2
1
5
5
5
2
1
2
2
1
2
2
1
1
1
2
2
1
1
REGULATOR VOLTAGE
TERMINAL BLOCK
CONTROLLER P.C.B.
BATTERY CHARGER RECTIFIER
BUSHING SNAP 1"
BUSHING SNAP 1-1/4"
RESISTOR, 1 OHM 25W
CIRCUIT BREAKER
SWITCH S.P.D.T.
SWITCH S.P.D.T. ON-MOM-ON
HOLDER FUSE
FUSE 7.5A
CIRCUIT BREAKER
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
LOCK WASHER SPECIAL
SCREW HHC M5-0.8 X 30MM
SCREW HHC M6-1.0 X 16MM
WASHER LOCK M5
NUT HEX M5-0.8
SCREW PPHM M4-0.7 X 16MM
WASHER LOCK #8-M4
NUT HEX M4-0.7
SCREW HHC M6-1.0 X 65MM
WASHER FLAT 1/4"
WASHER LOCK M6-1/4"
NUT HEX M6-1.0
SCREW HHC M5-0.8 X 25MM
SCREW HHC M5-0.8 X 16MM
SCREW HHC M6-1.0 X 30MM
NUT, HEX M3-0.5
PANEL CONTROL
SCREW RHM #6-32 X 1/4" SIMS
TIE WRAP UL 4" (NOT SHOWN)
DECAL (NOT SHOWN)
HARNESS (NOT SHOWN)
BUSHING, SNAP 1.09"
WASHER LOCK M3
WASHER FLAT M3
DEUTSCH, MOUNTING CLIP
RIVET POP 0.125" LARGE FLANGE
®
Generac Power Systems, Inc. 43
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
GN-220 H/SH Engine – Drawing No. 0D8355-C Part 1
®
44 Generac Power Systems, Inc.
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
GN-220 H/SH Engine – Drawing No. 0D8355-C Part 1
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
0D8433
0C1069
090695F
081810
083312
0D8400
1
10
1
1
1
GUARD, FAN
SCREW, HHTT M6-1.0 X 8MM
BLOWER HOUSING
30
31
32
33
0D7458
0C3979
085953
0D8739
1
1
1
1
ROD, GOVERNOR
SPRING, ANTI LASH
WASHER, CARB WEAR
ASSEMBLY BRACKET GOVERNOR
ADJUST
ROD, CHOKE LINKAGE
SPRING, GOVERNOR
SCREW HHTT M8-1.2 X 16MM
NUT, M5-0.8 LOCK
TOP WRAPPER
PLUG, EXPANSION
LOWER WRAPPER
GASKET, OIL PSI PAD
ADAPTER, OIL FILTER
SCREW SHC M6-1.0 X 22MM
SWITCH, OIL- 10 PSI
FILTER, OIL
SWITCH, THERMAL 293F
WASHER LOCK M3
SCREW PPHM M3-0.5 X 8MM
ELBOW 45D STREET 1/8NPT
RHMS #4-40 X 5/16" SEMS
COTTER PIN
ROD, CHOKE CONTROL
BOOT CHOKE SOLENOID PLASTIC
SCREW TAP-R #10-32 X 9/16"
RHMS #4-40 X 1/4" SEMS
ASSEMBLY, BI-METAL/HEATER
SOLENOID, CHOKE
NUT, HEX M16-1.5
WASHER, M16 CONICAL
ASSEMBLY CHOKE SOLENOID
BRACKET
FLYWHEEL, WITH RING GEAR
BACKPLATE, ELECTRIC START
SCREW HHTT M6-1.0 X 10MM
KEY, WOODRUFF 4 X 19D
5/16"-M8 LOCK WASHER
SCREW SHC M8-1.25 X 40MM
STARTER ASSEMBLY
1
34
35
36
37
38
39
40
41
42
43
44
45
52
53
54
55
56
57
58
59
60
61
62
63
0D8398
091638
083512
083503
092984
094820
089739
091848
0D8778
0D8803
0A8584
070185
094090
043182
0C1085
0D9689
0A7095
077091
0D8397
077075
0C2824
0A7094
0D8590
0D8591
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
2
1
1
1
2
2
1
1
7
8
9
0C8917A
0C8798A
045756
082774
022129
081990
0C9706
072347
022097
082981
081675
0C2018
0D7666
090051
080316
090948
078631
0D8332
091846
0D7558
078643
0D8372
0C2756
1
1
9
1
2
2
1
1
2
2
1
2
1
1
2
1
1
1
1
1
2
1
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
SPARKPLUG
LOCKWASHER, ¼"- M6
TAPTITE, M6-1.0 X 30MM
ASSEMBLY, IGNITION COIL
WASHER
BREATHER TUBE
GASKET, MANIFOLD/ HEAD
SCREW HHFC M6-1.0 X 30MM
INTAKE MANIFOLD
GASKET CARBURETOR/MANIFOLD
CARBURETOR
GASKET, CARB/ ADAPTOR
ADAPTOR, CARB
BOLT, CARB MOUNT M6-1.0 X 75MM
GASKET, CARB TO AIRBOX
ASSEMBLY, GOVERNOR LEVER
®
Generac Power Systems, Inc. 45
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
GN-220 H/SH Engine – Drawing No. 0D8355-C Part 2
®
46 Generac Power Systems, Inc.
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Appendix 4 — Exploded Views and Parts Lists
QUIETPACT 40G Recreational Vehicle Generator
GN-220 H/SH Engine – Drawing No. 0D8355-C Part 2
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
N/A
1
2
3
4
5
6
7
8
0C8925
078621
076389
088411
0A8897B
077168
088057
076390
083337A
078658
078659
089213E
0A7637
081695
0D1303
078645
0A7811
072683A
0A9878
089096
088156
0A8822
078691
0A5772
0A5776
074908
078606
1
1
1
1
1
5
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
4
LONG BLOCK ASSEMBLY
CONNECTING ROD ASSEMBLY
PISTON PIN
27
076361
1
GOVERNOR GEAR THRUST
WASHER
SCREW, HHFC M8-1.25 X 35MM
SPRING WASHER
VALVE RETAINER
VALVE SPRING
VALVE SPRING WEAR WASHER
GEROTER SET
"O" RING
SLEEVE, SEAM DWL
CYLINDER HEAD ASSEMBLY
EXHAUST VALVE
INTAKE VALVE
PUSH ROD
TAPPET
OIL PICK-UP ASSEMBLY
ROCKER COVER GASKET
PIVOT BALL STUD
GN- 191/220 ROCKER ARM
ROCKER ARM JAM NUT
PUSH ROD GUIDE PLATE
1/4" NPT PIPE PLUG
ROCKER COVER ASSEMBLY
PLASTIC OIL FILL PLUG
VALVE SPRING KEEPER
BARBED ELBOW 90 1/4" NPT X 3/8"
STUD M8-1.25 / 10MM X 30MM
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
0D2414
099922
0C3733
088401
084186
083192
086254
078699B
021705B
0C3590
0C3591
088396A
083235
080336
0C8754
077161
077160
076307
088403
026073A
0D1411A
076329
0C3592
049340A
045761A
6
1
2
2
2
1
1
4
1
1
1
2
2
1
1
2
2
2
1
1
1
1
4
1
1
PISTON RING SET
GEAR COVER ASSEMBLY
M8 X 56MM HEAD BOLT
PISTON
PIN RETAINER RING
TAPERED CRANKSHAFT ASSEMBLY
GOVERNOR "R" PIN
GOVERNOR ARM THRUST WASHER
CRANKCASE ASSEMBLY
GOVERNOR ARM
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
OIL SEAL
GOVERNOR GEAR ASSEMBLY
GOVERNOR GEAR C-RING
GOVERNOR SPOOL
1/8" NPT PIPE PLUG
CAMSHAFT ASSEMBLY
CRANKCASE GASKET
VALVE STEM SEAL
CYLINDER HEAD GASKET
OIL PRESSURE RELIEF COVER
OIL PRESSURE SPRING
11/32" BALL
M5 FORM SCREW
M6-1.0 X 12MM SCREW
®
Generac Power Systems, Inc. 47
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Appendix 5 – Warranty
QUIETPACT 40G Recreational Vehicle Generator
CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with
Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.*
New utility, and lawn and garden equipment engines must be designed, built and equipped to meet stringent anti-smog stan-
dards for the state of California and the federal government. Generac will warrant the emission control system on your
engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improp-
er maintenance of your engine.
Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair
your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted. If, dur-
ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or
workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory
supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance
on your engine. However, Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure
the completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or
responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unap-
proved modifications, or the use of counterfeit and/or ‘grey market’ parts not made, supplied or approved by Generac.
You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a prob-
lem 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
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the “Generac
Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you
by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in
terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where
the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe
important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty ser-
vice, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner shall
be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the
inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or losses incurred
while the engine is being transported/shipped for inspection or warranty repairs.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the fol-
lowing address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part 1
®
48 Generac Power Systems, Inc.
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Appendix 5 – Warranty
QUIETPACT 40G Recreational Vehicle Generator
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:
(a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on
the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall contin-
ue for 24 consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or
equipment, and to each subsequent purchaser/owner, that each of its engines is ...
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant
to their respective authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a war-
ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine manu-
facturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace
as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty
shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsi-
ble for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce
Generac’s ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or ‘grey market’ parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterfeit and/or ‘grey market’ part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
3) Ignition System including:
a) Spark plug
b) Ignition module
1.1) Gasoline carburetor assembly and its
internal components (if so equipped).
a) Fuel filter (if so equipped)
b) Carburetor gaskets
c) Fuel pump (if so equipped)
1.2) LPG carburetion assembly and its
internal components (if so equipped).
a) Fuel controller (if so equipped)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)
5) Crankcase Breather Assembly including:
a) Breather connection tube
*Generac engine types covered by this warranty statement include the following:
1) Utility
2) Lawn and Garden Equipment
3) Recreational Vehicle (RV) Generator
4) Industrial Mobile (IM) Generator
Part 2
®
Generac Power Systems, Inc. 49
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Appendix 5 – Warranty
QUIETPACT 40G Recreational Vehicle Generator
GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY
FOR RECREATIONAL VEHICLE GENERATORS
NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES.
For a period of 3 (three) years or 2,000 (two thousand) hours of operation from the date of original sale, whichever occurs
first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspec-
tion and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective under normal use
and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to
be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility. All trans-
portation 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. This warranty is effective only upon Generac’s receipt, from the
original purchaser/owner, of a completed Warranty Registration Card. This card is the only valid registration identification
and must be presented at time of request for warranty service. Claims will not be accepted without presentation of the
Warranty Registration Card. The factory recommends exercising the unit one half-hour every season.
WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS
YEAR ONE – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:
• Engine – All components
• Alternator – All components
• Transfer System – All components
WARRANTY SCHEDULE – CONSUMER/PERSONAL APPLICATIONS
YEARS ONE AND TWO – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:
• Engine – All components
• Alternator – All components
• Transfer System – All components
YEAR Three – 100% (one hundred percent) only on selected part(s) and labor listed (Any labor and part(s) not listed, and
removal and reinstallation are the owner’s responsibility):
• Rotor, Stator, Computer Control Board, (if applicable with regard to the generator) Cylinder Block, Cylinder Head, Crankshaft,
Piston(s), Valve, Valve Lifter(s), Intake and Exhaust Manifolds
Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV gen-
erators manufactured after January 1, 1998, have a transferable warranty to the second owner ONLY for the remainder of
the three-year limited 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 Generac’s SUPER SERVICE INFORMATION MANUAL.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
•
•
•
Costs of normal maintenance, adjustments, installation and start-up.
Failures caused by any contaminated fuels or oils.
Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As
with all mechanical devices, the GN-Series engines need periodic part(s) service and replacement to perform well. This
warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.
Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust,
fire, freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
Products that are modified or altered in a manner not authorized by Generac in writing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair
or replacement of the defective part(s).
•
•
•
•
•
•
Failure due to misapplication.
Telephone, telegraph, teletype or other communication expenses.
Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit
warranty period.
Rental equipment used while warranty repairs are being performed.
Overnight freight costs for replacement part(s).
Overtime labor.
Starting batteries, fuses, light bulbs and engine fluids.
•
•
•
•
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some
states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL 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. Purchaser/owner agrees to make no claims against
Generac based on negligence.
This warranty gives you specific legal rights. You also may have other rights that vary from state to state.
®
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Part No. 0D8351
Revision C (08/07/02)
Printed in U.S.A.
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