Owner’s Manual and Installation...

Owner’s Manual andInstallation Instructions

Air-cooled RecreationalVehicle Generators

• Model: 004700-0QUIETPACT 40G

This manual should remain with the unit.

Generac® Power Systems, Inc.

INTRODUCTIONThank you for purchasing this model of thePRIMEPACT product line by Generac Power SystemsInc. This model is designed and manufactured tosupply electrical power for recreational vehicles.

READ THIS MANUAL THOROUGHLYIf you do not understand any portion of this manual,contact Generac or your nearest Generac AuthorizedService Dealer for starting, operating and servicing pro-cedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING,CAUTION and NOTE blocks are used to alert you tospecial instruction about a particular operation thatmay be hazardous if performed incorrectly or care-lessly. Observe them carefully. Their definitions areas follows:

After this heading, you can read instructions that,if not strictly complied with, will result in personalinjury or property damage.

After this heading, you can read instructions that, if not strictly complied with, may result in personalinjury or property damage.

After this heading, you can read instructions that, ifnot strictly complied with, could result in damage toequipment and/or property.

NOTE:After this heading, you can read explanatorystatements that require special emphasis.

These safety warnings cannot eliminate the hazardsthat they indicate. Common sense and strict compli-ance with the special instructions while performing theservice are essential to preventing accidents.

Four commonly used safety symbols accompany theDANGER, WARNING and CAUTION blocks. The typeof information each indicates follows:

This symbol points out important safety informa-tion that, if not followed, could endanger personalsafety and/or property of you and others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shockhazard.

The operator (driver) is responsible for proper andsafe use of the vehicle and its equipment, and the safe-ty of all vehicle occupants. We strongly recommendthat the operator read this manual and thoroughlyunderstand all instructions before using this equip-ment. We also strongly recommend instructing otheroccupants in the vehicle to properly start and operatethe generator. This prepares them if they need to oper-ate the equipment in an emergency.

CONTENTSThis manual contains pertinent owner’s information,including warranty, electrical diagrams, explodedviews and lists of repair parts for generator modelnumbers 004700-0. In addition, the latter portion ofthis manual contains information necessary for theproper installation of these generators.

OPERATION AND MAINTENANCEIt is the operator's responsibility to perform all safe-ty checks, to make sure that all maintenance for safeoperation is performed promptly, and to have theequipment checked periodically by a GeneracAuthorized Service Dealer. Normal maintenance ser-vice and replacement of parts are the responsibility ofthe owner/operator and, as such, are not considereddefects in materials or workmanship within theterms of the warranty. Individual operating habitsand usage contribute to the need for maintenanceservice.

Proper maintenance and care of your generatorensure a minimum number of problems and keepoperating expenses at a minimum. See your GeneracAuthorized Service Dealer for service aids and acces-sories.

HOW TO OBTAIN SERVICEWhen your generator requires servicing or repairs,simply contact a Generac Authorized Service Dealerfor assistance. Service technicians are factory-trainedand are capable of handling all of your service needs.

When contacting a Generac Authorized Service Dealeror the factory about parts and service, always supplythe complete model number and serial number of yourunit as given on its data decal, which is located on yourgenerator.

Model No. ____________ Serial No. ______________

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DANGER

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AUTHORIZED SERVICEDEALER LOCATION

To locate the GENERAC AUTHORIZED SERVICE

DEALER nearest you, please call this number:

1-800-333-1322ONLY DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

Table of ContentsQUIETPACT 40G Recreational Vehicle Generator

Generac® Power Systems, Inc. 1

Part I – Owner’s ManualIntroduction ......................................Inside Front Cover

Read This Manual Thoroughly ....................................IFCContents ......................................................................IFCOperation and Maintenance ........................................IFCHow to Obtain Service..................................................IFCAuthorized Service Dealer Locator Number ....................IFC

Safety Rules ......................................................................2Section 1 – General Information..................................41.1 Generator Identification............................................41.2 Generator Applicability ............................................51.3 Safety..... ..................................................................51.4 Generator AC Connection System ............................51.5 Specifications ..........................................................5

1.5.1 Fuel Requirements......................................51.5.2 Fuel Consumption ......................................61.5.3 Engine Oil Requirements ............................61.5.4 Engine ........................................................61.5.5 Generator ..................................................61.5.6 Emissions Compliance Period ....................6

Section 2 – Operation ....................................................72.1 Generator Control Panel ............................................7

2.1.1 Fuel Primer ..................................................72.1.2 Start/Stop Switch ........................................72.1.3 Fuse .............................................................72.1.4 Main Breaker ..............................................7

2.2 Optional Remote Start/Stop Panel..............................72.3 Automatic Choke ......................................................7

2.3.1 Choke Solenoid............................................72.3.2 Prechoke ......................................................7

2.4 Before Starting the Engine ........................................72.4.1 Installation ....................................................72.4.2 Engine Lubrication ........................................82.4.3 Fuel Supply ....................................................82.4.4 Cooling and Ventilating Air ............................82.4.5 Engine Exhaust Gas ......................................8

2.5 Starting the Generator ..............................................82.6 Stopping the Generator..............................................92.7 Applying Loads to Generator ....................................9

2.7.1 Letting the Engine Stabilize ........................92.8 Do Not Overload the Generator ................................92.9 Protection Systems ....................................................9

2.9.1 Low Oil Pressure Switch ..............................92.9.2 High Temperature Switch ............................92.9.3 Field Boost ................................................102.9.4 Overvoltage Protection ..............................10

2.10 Additional Information ............................................102.10.1 25-Hour Break-in Period............................102.10.2 25-Hour Checkup ......................................102.10.3 Attention Required After Submersion ........102.10.4 Operation in High Grass or Brush ............112.10.5 Effects of Moisture and Dirt ......................11

Section 3 – Maintenance ..............................................113.1 Checking the Engine Oil Level ................................113.2 Changing the Engine Oil and/or Oil Filter ................113.3 Maintaining the Engine Air Cleaner ........................12

3.3.1 Cleaning the Foam Precleaner....................123.3.2 Cleaning or Replacing the Paper Filter ......12

3.4 Clean Air Intake ......................................................133.5 Checking the Engine Spark Plug..............................133.6 Fuel Filter ................................................................133.7 Spark Arrestor Service ............................................133.8 Cleaning the Generator ............................................143.9 Battery Maintenance ................................................14

3.9.1 Weekly........................................................143.9.2 Every Six Months ......................................14

3.10 Major Service Manual ..............................................153.11 Exercising the Generator ........................................15

3.12 Out of Service Procedure ........................................153.12.1 Removal From Service ..............................153.12.2 Return to Service ......................................15

3.13 Adjusting Valve Clearance ........................................153.14 RV Generator Service Interval..................................16

Part II – Installation InstructionsSafety Rules ....................................................................18Section 1 – General Information................................201.1 Purpose and Scope of the Manual ..........................201.2 Safety...... ................................................................201.3 Standards Booklets ................................................201.4 Equipment Description ..........................................201.5 Generator Engine Operating Speed ........................201.6 Generator AC Connection System ..........................20

Section 2 – Installation ................................................222.1 Location and Support ............................................22

2.1.1 Generator Location ..................................222.1.2 Generator Support ..................................222.1.3 Suspended Mounting ................................222.1.4 Generator Restraint ..................................23

2.2 Generator Compartments ......................................232.2.1 Compartment Size ....................................232.2.2 Compartment Construction ......................232.2.3 Sound Insulating Materials ......................242.2.4 Acoustics.... ..............................................242.2.5 Compartment Floor Cutouts ....................25

2.3 Cooling and Ventilating Air ....................................262.3.1 Generator Airflow ....................................262.3.2 Testing the Installation..............................26

2.4 Gasoline Fuel System..............................................262.4.1 Fuel Tank..................................................272.4.2 Generator Fuel Supply Line ......................27

2.5 Exhaust System........ ..............................................272.5.1 Mufflers and Spark Arrestors ..................282.5.2 Exhaust System Safety..............................28

2.6 Electrical Connections ............................................282.6.1 Electrical Junction Box ............................292.6.2 Wiring......... ..............................................292.6.3 Generator AC Connections ......................292.6.4 Conduit.....................................................292.6.5 Isolating Different Power Sources ............302.6.6 Power Supply Cord ..................................302.6.7 Ground Fault Circuit Interrupters ............31

2.7 Battery Installation... ..............................................312.7.1 Recommended Battery..............................312.7.2 Battery Cables ..........................................312.7.3 Battery Cable Connections........................312.7.4 Battery Compartment ..............................31

2.8 Optional Accessories ..............................................312.8.1 Remote Start/Stop Panels ........................32

Section 3 – Post-installation Start-up Adjustments ..............................................32

3.1 Post Installation Tests ............................................323.2 Before Initial Start-up ............................................323.3 Initial Start ............................................................323.4 Testing Under Load ................................................323.5 Installation Checklist ..............................................33

Appendix 1 – Notes ......................................................34Appendix 2 – Troubleshooting....................................35Appendix 3 – Electrical Data ......................................36Appendix 4 – Exploded Views and Parts Lists ......38Appendix 5 – Warranty ................................................48

2 Generac® Power Systems, Inc.

Study these SAFETY RULES carefully beforeinstalling, 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 followsimple and fundamental rules or precautions.

Generac cannot possibly anticipate every possible circumstance 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. Ifyou use a procedure, work method or operating tech-nique Generac does not specifically recommend, youmust satisfy yourself that it is safe for you and others.You also must make sure the procedure, workmethod or operating technique that you choose doesnot render the generator unsafe.

Despite the safe design of this generator, operating this equipment imprudently, neglectingits maintenance or being careless can cause possible injury or death. Permit only responsibleand capable persons to operate or maintain thisequipment.

Potentially lethal voltages are generated bythese machines. Ensure all steps are taken torender the machine safe before attempting towork on the generator.

Parts of the generator are rotating and/or hotduring operation. Exercise care near runninggenerators.

GENERAL HAZARDS• For safety reasons, Generac recommends

that the installation, initial start-up and mainte-nance of this equipment is carried out by aGenerac Authorized Service Dealer.

• The generator engine releases DEADLY carbonmonoxide gas through its exhaust system. Thisdangerous gas, if breathed in sufficient concentra-tions, can cause unconsciousness or even death.Never operate the generator set with the vehicleinside any garage or other enclosed area. DO NOTOPERATE THE GENERATOR IF THE EXHAUSTSYSTEM IS LEAKING OR HAS BEEN DAMAGED.SYMPTOMS OF CARBON MONOXIDE 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 INTOFRESH 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 carbonmonoxide detector. The exhaust system must beinstalled in accordance with the genset installationmanual. Make sure there is ample fresh air whenoperating the genset in a confined area.

• The engine exhaust fumes contain carbon monox-ide, which can be DEADLY. This dangerous gas, ifbreathed in sufficient concentrations, can causeunconsciousness 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 thatmight render the system unsafe or in noncompli-ance with such codes and standards. The genera-tor compartment must be completely vapor sealedfrom the vehicle interior. There must be no possi-bility of exhaust fumes entering the vehicle interi-or. Never operate this equipment with a leaking ordefective exhaust system.

• Keep hands, feet, clothing, etc., away from drivebelts, fans, and other moving or hot parts. Neverremove any drive belt or fan guard while the unit isoperating.

• Adequate, unobstructed flow of cooling and venti-lating air is critical to correct generator operationand is required to expel toxic fumes and fuelvapors from the generator compartment. Withoutsufficient cooling airflow, the engine/generatorquickly overheats, which causes serious damage tothe generator. Do not alter the installation or per-mit even partial blockage of ventilation provisions,as this can seriously affect safe operation of thegenerator.

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Safety RulesQUIETPACT 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 engine exhaust from this productcontains chemicals known to the state

of California to cause cancer, birthdefects or other reproductive harm.

WARNING:! !

This product contains or emits chemicalsknown to the state of California to cause

cancer, birth defects or other reproductive harm.

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• When working on this equipment, remain alert atall times. Never work on the equipment when youare physically or mentally fatigued.

• Inspect the generator regularly, and contact yournearest 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 astep. Stepping on the unit can stress and breakparts, and may result in dangerous operating con-ditions from leaking exhaust gases, fuel leakage,oil leakage, etc.

ELECTRICAL HAZARDS• The generator covered by this manual produces

dangerous electrical voltages and can cause fatalelectrical shock. Avoid contact with bare wires, ter-minals, connections, etc., while the unit is running.Ensure all appropriate covers, guards and barriersare in place before operating the generator. If youmust work around an operating unit, stand on aninsulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device whilestanding in water, while barefoot, or while handsor feet are wet. DANGEROUS ELECTRICALSHOCK MAY RESULT.

• During installation onto the vehicle, have the gen-erator properly grounded (bonded) either by solidmounting to the vehicle frame or chassis, or bymeans of an approved bonding conductor. DONOT disconnect the bonding conductor, if soequipped. DO NOT reconnect the bonding conduc-tor to any generator part that might be removed ordisassembled during routine maintenance. If thegrounding conductor must be replaced, use only aflexible conductor that is of No. 8 American WireGauge (AWG) copper wire minimum.

• In case of accident caused by electric shock, imme-diately shut down the source of electrical power. Ifthis is not possible, attempt to free the victim fromthe live conductor. AVOID DIRECT CONTACTWITH THE VICTIM. Use a nonconducting imple-ment, such as a rope or board, to free the victimfrom the live conductor. If the victim is uncon-scious, apply first aid and get immediate medicalhelp.

• Never wear jewelry when working on this equip-ment. Jewelry can conduct electricity resulting inelectric shock, or may get caught in moving com-ponents causing injury.

FIRE HAZARDS

• For fire safety, the generator must be installed andmaintained properly. Installation always mustcomply with applicable codes, standards, laws andregulations. Adhere strictly to local, state andnational electrical and building codes. Complywith regulations the Occupational Safety andHealth Administration (OSHA) has established.Also, ensure that the generator is installed inaccordance with the manufacturer’s instructionsand recommendations. Following proper installa-tion, do nothing that might alter a safe installationand render the unit in noncompliance with theaforementioned codes, standards, laws and regu-lations.

• Keep a fire extinguisher in the vehicle at all times.Extinguishers rated “ABC” by the National FireProtection Association are appropriate for use onthe recreational vehicle generator electrical system.Keep the extinguisher properly charged and befamiliar with its use. If you have any question per-taining to fire extinguishers, consult your local firedepartment.

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 orEXPLOSION may result. Keep the area surround-ing the generator clean and free from debris.

• Gasoline is extremely FLAMMABLE and its vaporsare EXPLOSIVE. Do not permit smoking, openflame, sparks or any source of heat in the vicinitywhile handling gasoline. Comply with all laws gov-erning the storage and handling of gasoline.



1. Generator Air Intake2. Engine Start/Stop Switch3. Fuse4. Optional Remote Panel Receptacle

(Side View)5. Generator AC Output Leads (Side

View)6. Fuel Primer Switch7. Circuit Breaker8. Starter Contactor

9. Fuel Inlet10. Fuel Pump (Behind Access Panel)11. Fuel Filter (Side View)12. Oil Filter13. Oil Drain Cap14. Oil Dipstick15. Air Filter (Behind Access Panel)16. Oil Fill17. Spark Plug

Section 1 – General InformationQUIETPACT 40G Recreational Vehicle Generator

Please record the following information from the generator DATA DECAL or information decal.

1. Model Number ____________________ 2. Serial Number __________________

3. kW Rating__________________________ 4. Rated Voltage __________________

RAC OHVI INDUSTRIAL ENGINE

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AC

TM

RV SERVICE LOCATOR: 1.800.333.1322

PACT 40G

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S E R V IC E A C C E S S P A N E L

OIL LEVEL: CHECK DAILY

AIR FILTER: CLEAN PREFILTEREVERY 100 HOURS.REPLACE ELEMENTEVERY 250 HOURS.

OIL & OIL FILTER: CHANGE EVERY 100

(IF NECESSARY)EVERY 500 HOURS.HOURS. REPLACE PLUGSPLUGS EVERY 100INSPECT & CLEANSPARK PLUGS:

REPLACEMENT INFORMATION

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PERFORM MORE OFTEN IN DUSTY CONDITIONS

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE

AIR FILTER P/N: 0D3262

070185OIL FILTER P/N:

SPARK PLUG P/N: 072347

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

-20˚F TO 50˚F 5W-30

10W-30

15W-40

30

WHEN SERVICE OR PARTS ARE NEEDED IN

THE USA OR CANADA, CONTACT THE GENERAC

SERVICE LOCATOR AT 1-800-333-1322.

HOURS. (OR ANNUALLY)

PREFILTER P/N: 0D4511

FUEL FILTER P/N: 0D7515

FUEL FILTER: CHANGE EVERY 400HOURS. (OR ANNUALLY)

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1.1 GENERATOR IDENTIFICATION

Model: 004700-0 — QUIETPACT 40G



1.2 GENERATOR APPLICABILITYThese generators have been designed and manufac-tured for supplying electrical power for recreationalvehicles. You should not modify the generator or useit for any application other than for what it wasdesigned. If there are any questions pertaining to itsapplication, write or call the factory. Do not use theunit until you have been advised by a competentauthority.

For fire safety, the generator must have beenproperly installed in compliance with ANSI119.2-1975/NFPA 501C-1974, “Standard forRecreational Vehicles, Part III – Installation ofElectrical Systems.” The generator also musthave been installed in strict compliance withthe manufacturer’s detailed installation instruc-tions. After installation, do nothing that mightrender the unit in noncompliance with suchcodes, standards and instructions.

You can use this generator to supply electrical power foroperating 120-volt, single-phase, 60 Hertz, AC electricalloads. These loads can require up to 3,600 watts (3.6 kW) of power, but cannot exceed 30 AC amperes ofcurrent at 120 volts.

Do not overload the generator. Some installa-tions may require that electrical loads be alter-nated to avoid overloading. Applying excessive-ly high electrical loads may damage the genera-tor and may shorten its life. Add up the ratedwatts of all electrical lighting, appliance, tooland motor loads the generator will power atone time. This total should not be greater thanthe wattage capacity of the generator. If anelectrical device nameplate gives only volts andamps, multiply volts times amps to obtain watts(volts x amps = watts). Some electric motorsrequire more watts of power (or amps of cur-rent) for starting than for continuous operation.

1.3 SAFETYBefore attempting to use the generator set, carefullyread the “Safety Rules” section of this manual.Comply strictly with these rules to prevent accidentsand 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 alloperators and potential operators of this equipment.

1.4 GENERATOR AC CONNECTION SYSTEM

This generator set is equipped with dual stator ACpower windings. These two-stator windings supplyelectrical power to customer electrical loads bymeans of a two-wire connection system. Note, howev-er, that the neutral is bonded to the frame of theengine-generator.

The generator may have been installed so that it pow-ers 120-volt AC loads (Figure 1.1). It can be wired toconnect 120-volt AC electrical loads. This procedureshould be done by a Generac Authorized ServiceDealer or other qualified installer.

Figure 1.1 – Connections for 120 Volts Only

1.5 SPECIFICATIONS

1.5.1 FUEL REQUIREMENTSThe QUIETPACT series generator is equipped with agasoline fuel system. Depending on the installation, thegenerator may have either a separate fuel tank, or itmay “share” the vehicle engine’s fuel tank.

NOTE:

Some installations using a “shared” fuel tank mayhave a generator fuel pickup tube that is shorterthan the vehicle engine’s pickup tube. Such anarrangement causes the generator engine to “runout of gas” while adequate fuel for the vehicleremains in the tank.

To reduce lead and carbon deposits use high qualityUNLEADED gasoline with the generator. Leaded REG-ULAR grade gasoline is an acceptable substitute.

NOTE:

Using unleaded gasoline contributes to longerengine valve life by reducing lead and carbondeposits.

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Generac does not recommend using any gasoline containing alcohol (such as “gasohol”).If you use any gasoline containing alcohol, itmust not contain more than 10 percent ethanol,and it must be removed from the generatorduring storage. Do NOT use any gasoline containing methanol. If you use gasoline withalcohol, inspect more frequently for fuel leaksand other abnormalities.

1.5.2 FUEL CONSUMPTION

Fuel consumption is in gal/hr.

1.5.3 ENGINE OIL REQUIREMENTSUse only high quality detergent oil rated withAmerican Petroleum Institute (API) ServiceClassification SF, SG or SH. The recommended oilweights include the following:

• During summer months: SAE 30. An acceptablesubstitute is SAE 10W-30.

• During winter months: SAE 5W-30. DO NOT USESAE 10-W40.

Crankcase and oil filter capacity is approximately800 mL or .84 U.S. quarts. Do NOT use special addi-tives. See Sections 3.1 and 3.2 (Page 12) for oil levelcheck and fill procedures.

1.5.4 ENGINEType of Engine ....................................GN-220, Single-cylinderCooling Method..........................................................Air-cooledRated Horsepower ........................................7.8 @ 4,200 rpmDisplacement....................................................................220ccCylinder Block ..........................Aluminum w/Cast Iron SleeveType of Governor ..............................Mechanical, Fixed SpeedAir Cleaner..........................Paper Element w/Foam PrecleanerStarter..........................................................12-volt DC ElectricIgnition System........................Solid-state w/Flywheel MagnetoRecommended Spark PlugChampion ..................................................................RC14YCAC....................................................................................R45SFram Autolite ......................................................................65

Spark Plug Gap ........................................0.030 inch (76 mm)Recommended Minimum Battery ..............400 Cold-cranking

Amperes

1.5.5 GENERATORRated Maximum Continuous AC Output (Gasoline) ............................3,600 Watts (3.6 kW)

Rated Voltage ........................................................120 Volts ACRated Maximum Continuous AC Current (Gasoline)..........................................30 Amperes

Phase ................................................................................SingleRotor RPM ........................................................................3,600Number of Rotor Poles ............................................................2Engine RPM ......................................................................3,600Rated AC Frequency ........................................................60 HzBattery Charge Voltage............................................14 Volts DCBattery Charge Current..................................2 Amperes (max)Gasoline weight ......................................................170 PoundsLength ....................................................749.8 mm (29.52 in.)Width ......................................................483.1 mm (19.02 in.)Height ......................................................342.2 mm (13.47 in.)

1.5.6 EMISSIONS COMPLIANCE PERIODFor non-handheld engines the Emissions CompliancePeriod referred to on the Emissions ComplianceLabel indicates the number of operating hours forwhich the engine has been shown to meet Federalemission requirements.

• For engines less than 225 cc displacement,Category C=125 hours, B=250 hours, and A=500hours.

• For engines of 225 cc or more, Category C=250hours, B=500 hours, and A=1000 hours.

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Model No Load 1/2 Load Full LoadQUIETPACT 40G 0.24 0.35 0.55(004700-0)


Section 2 – OperationQUIETPACT 40G Recreational Vehicle Generator

2.1 GENERATOR CONTROL PANELThe following features are mounted on the generatorcontrol panel (Figure 2.1):

Figure 2.1 – Generator Control Panel

2.1.1 FUEL PRIMERBefore starting a cold engine (if it has not been start-ed in more than two weeks), you must press thisswitch for approximately 10 to 15 seconds to bringfuel from the tank to the carburetor. This rocker typeswitch springs back into its original position whenyou release it.

2.1.2 START/STOP SWITCHTo crank and start the engine, hold this switch in theSTART position. Release the switch when the enginestarts. To stop an operating engine, press and holdthe switch in the STOP position until the engine shutsoff. The switch center position is the RUN position.

2.1.3 FUSEThe fuse protects the engine’s DC control circuitagainst electrical overload. If the fuse element hasmelted open due to overloading, the engine cannot becranked. If you must replace the fuse, use only anidentical replacement.

2.1.4 MAIN BREAKERThe main breaker protects the generator’s AC outputcircuit against overload and provides a method ofturning OFF the generator’s 120-volt AC output to thevehicle circuits. The QUIETPACT 40G has 30-ampbreaker.

2.2 OPTIONAL REMOTESTART/STOP PANEL

A remote mounted Start/Stop Panel is available thatallows you to start and stop the generator engine con-veniently from inside the vehicle.

You can order part number 0F0429 or 0F0430, aremote panel that includes a Start/Stop switch, a gen-erator run lamp, a fuel prime switch, and an hourme-ter. The hourmeter provides a continuous indicationof engine/generator operating time. Use the hourme-ter for checking off periodic maintenance require-ments on the unit.

2.3 AUTOMATIC CHOKEThe engine is equipped with an automatic choke thatconsists of two main components: a choke solenoidand prechoke.

2.3.1 CHOKE SOLENOIDDuring engine cranking (Start/Stop switch atSTART), a solid-state choke module signals thechoke solenoid to activate and cycle (choke on/chokeoff) until the engine starts. The choke solenoid thusopens and closes the carburetor choke valve onlywhen the engine is cranking. When the engine starts,the choke stops cycling.

2.3.2 PRECHOKEThe choke system also has a temperature-sensitivemetal strip that adjusts choke valve angle accordingto ambient temperatures (i.e., in cold ambient tem-peratures, choke valve closes more). Once the enginestarts, an element heats the temperature-sensitivestrip to a normal operating condition, opening thechoke valve. This may take about three minutes incooler weather.

2.4 BEFORE STARTING THE ENGINENOTE:

Instructions and information in this manualassume the generator has been properly installed,connected, serviced, tested and adjusted by aqualified installation technician or installationcontractor.

2.4.1 INSTALLATIONGenerator installation must have been properly com-pleted so it complies with all applicable codes, stan-dards and regulations and with the manufacturer'srecommendations.

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2.4.2 ENGINE LUBRICATIONHave the engine crankcase properly serviced with therecommended 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.

Any attempt to crank or start the engine beforeyou have properly serviced it with the recom-mended oil may result in an engine failure.

2.4.3 FUEL SUPPLYThe engine must have an adequate supply of properfuel to operate. Before starting it, check that sufficientfuel is available.

NOTE:

Depending on the installation, the generator mayhave either a separate fuel tank, or it may “share”the vehicle engine’s fuel tank.

2.4.4 COOLING AND VENTILATING AIRAir inlet and outlet openings in the generator com-partment must be open and unobstructed for contin-ued proper operation. Without sufficient cooling andventilating airflow, the engine/generator quickly over-heats, which causes it to shut down and may damagethe generator.

2.4.5 ENGINE EXHAUST GASBefore starting the generator engine, you should besure there is no way for exhaust gases to enter thevehicle interior and endanger people or animals.Close windows, doors and other openings in the vehi-cle that, if open, might permit exhaust gases to enterthe vehicle.

The generator engine releases DEADLY carbonmonoxide gas through its exhaust system. Thisdangerous gas, if breathed in sufficient concen-trations, can cause unconsciousness or evendeath. Never operate the generator set withthe vehicle inside any garage or other enclosedarea. DO NOT OPERATE THE GENERATOR IF THEEXHAUST SYSTEM IS LEAKING OR HAS BEENDAMAGED. SYMPTOMS OF CARBON MONOX-IDE POISONING ARE (a) inability to think coher-ently, (b) nausea, (c) vomiting, (d) twitchingmuscles, (e) throbbing temples, (f) dizziness, (g)headaches, (h) weakness, and (i) sleepiness. IFYOU EXPERIENCE ANY OF THESE SYMPTOMS,MOVE INTO FRESH AIR IMMEDIATELY. IF SYMP-TOMS PERSIST, GET MEDICAL HELP. Shut downthe generator and do not operate it until it hasbeen inspected and repaired.

Never sleep in the vehicle while the genset isrunning unless the vehicle has a working carbonmonoxide detector. The exhaust system must beinstalled in accordance with the genset installa-tion manual. Make sure there is ample fresh airwhen operating the genset in a confined area.

2.5 STARTING THE GENERATORNOTE:

Read the vehicle manufacturer’s instructions. Theowner/operator should become familiar with thevehicle in which this generator is installed.Differences exist between vehicles. For example,some vehicles may use a transfer switch to isolatedockside power from the generator, while othervehicles may use an isolating receptacle. Somevehicles may be equipped with a DC converter,which allows the generator to power certain DClighting and other DC loads.

To start the generator from either the generator con-trol panel or from the optional remote panel, proceedas follows:

1. Turn OFF electrical loads using the means pro-vided in your vehicle (such as a main line circuitbreaker or transfer switch).

NOTE:If starting from the generator control panel, turnOFF loads by setting the generator’s main circuitbreaker to the OFF (or open) position. If startingfrom a remote panel, turn OFF loads using themeans provided in the vehicle (such as a main cir-cuit breaker). Electrical load circuits will beturned ON after the generator has started, stabi-lized and warmed up.

2. If you have not started the engine in more thantwo weeks, press the Fuel Pump Primer switchand hold it for about 10 to 15 seconds to primethe fuel system. However, if the engine is warm,skip Step 2.

3. Hold the engine Start/Stop switch in the STARTposition to crank the engine. Release the switchwhen the engine starts.

If the engine does not start after it has beencranking for 15 seconds, release the Start/Stopswitch, wait one minute and try again. Holdingthe switch for longer than 15 seconds can dam-age the starter motor.

4. Let the engine run at no-load for a few minutes tostabilize and warm up.

5. Turn ON electrical loads using the means provided (such as a main circuit breaker ortransfer switch).

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2.6 STOPPING THE GENERATOR1. Turn OFF all electrical loads using the means

provided (such as a main circuit breaker ortransfer switch).

2. Let generator run at no-load for a few minutes, tostabilize internal engine generator temperatures.

3. Place the Start/Stop switch in its STOP position.

2.7 APPLYING LOADS TO GENERATORWhen applying electrical loads to the generator,observe these guidelines:

• Before applying electrical loads, let the generatorstabilize and warm up for a minute or two.

• DO NOT overload the generator.

2.7.1 LETTING THE ENGINE STABILIZEThe generator supplies correct rated voltage only atthe proper governed speed. Some electrical appli-ances may be extremely sensitive to voltage. Incorrectvoltages can damage such appliances.

If electrical loads are applied at reduced operatingspeeds, 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 generatorengine has started and stabilized at no-load.

2.8 DO NOT OVERLOAD THE GENERATOR

You can read the rated wattage/amperage capacity ofyour generator on the generator data decal (seeSection 1.1).

Applying electrical loads in excess of the unit’s ratedcapacity 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 motorloads. 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 ordata plate. For light bulbs, simply note the wattagerating of the bulb.

• If a load does not show its rated wattage, multiplythat load’s rated VOLTS times AMPS to obtainWATTS.

• Induction type motors (such as those that run thevehicle’s furnace fan, refrigerator, air conditioner,etc.) need about 2-1/2 time more watts of power forstarting than for running (for a few seconds duringmotor 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 thesystem. To that figure, add the running wattages ofother items that will be operated by the generator.

• Do not apply heavy electrical loads for the first twoor three hours of operation.

2.9 PROTECTION SYSTEMS2.9.1 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 dropbelow a preset level, switch contacts close, and theengine automatically shuts down. The unit should notbe restarted until oil is added.

2.9.2 HIGH TEMPERATURE SWITCHThis switch (Figure 2.2), which has normally open(N.O.) contacts, is mounted near the oil filter. Thecontacts close if the temperature should exceedapproximately 284º F (140º C), initiating an engineshutdown.

Figure 2.2 – Low Oil Pressure and High Temperature Switches

High Temperature Switch

Low Oil PressureSwitch

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2.9.3 FIELD BOOSTThe Controller Circuit Board houses a field boostdiode and resistor that are not part of the automaticchoke circuit. These two components are part of a“field boost” circuit (Figure 2.3). During enginecranking only, a positive DC (battery) voltage is deliv-ered through the diode, resistor, brushes and sliprings, 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 startsmakes sure that a sufficiently strong magnetic field isavailable to produce “pickup” voltage in the statorwindings.

Figure 2.3 – Field Boost Circuit

2.9.4 OVERVOLTAGE PROTECTIONA solid-state voltage regulator (Figure 2.4) controlsthe generator’s AC output voltage. This regulator sup-plies an excitation current to the rotor. By regulatingthe 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. Whenthe AC frequency is 60 Hertz, voltage is regulated at120 volts (voltage-to-frequency ratio is 2-to-1).

Figure 2.4 – Solid State Voltage Regulator

The voltage regulator also incorporates a “voltagesurge protection circuit.” This circuit prevents trou-blesome surges in the generator AC output voltage.Voltage surge is a common cause of damage to elec-tronic equipment.

2.10 ADDITIONAL INFORMATION2.10.1 25-HOUR BREAK-IN PERIOD

The first 25 hours of operation is the break-in periodfor the generator. Properly breaking in the generatoris essential to minimize fuel consumption and pro-vide maximum engine performance. During this 25-hour break-in period, follow this procedure:

• Run the unit at varying electrical loads to help seatthe engine piston rings properly.

• Check the engine oil level frequently. Add oil ifneeded. It is normal for the generator engine toconsume more oil than is normal until the pistonrings have properly seated.

• For the 75-hour operation following the break-inperiod, avoid light electrical loads. Load the generator at 50 percent (or more) of its ratedwattage capacity. Repeated light loads during these75 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 thetasks recommended under Section 2.10.2.

2.10.2 25-HOUR CHECK-UPAfter the 25-hour break-in period, contact a GeneracAuthorized Service Dealer for the following mainte-nance. The vehicle owner is responsible for anycharges:

• 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.

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 aGenerac Authorized Service Dealer thoroughly cleanand dry the generator.

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Section 3 – MaintenanceQUIETPACT 40G Recreational Vehicle Generator

2.10.4 OPERATION IN HIGH GRASSOR BRUSH

Never operate the generator while the vehicle isparked over high grass, weeds, brush, leaves or anyother combustible substance. Such materials canignite and burn from the heat of the exhaust system.The generator exhaust system becomes extremely hotduring operation and remains hot for a long timeafter it has shut down.

2.10.5 EFFECTS OF MOISTURE AND DIRTKeep the generator set as clean and dry as possible.Protect the unit against excessive dust, dirt, corrosivevapors, road splash, etc. Permitting dirt and mois-ture to accumulate on generator windings will havean adverse effect on the insulation resistance of thosewindings.

When moisture is allowed to remain in contact withwindings, some of the moisture will be retained invoids and cracks in the insulation. This causes areduced insulation resistance and will eventuallycause problems. Dirt will make the problem worse,since dirt tends to hold moisture in contact withwindings. Salt (as from sea air) also will worsen theproblem since it tends to absorb moisture from theair. Salt and moisture, when combined, form a goodelectrical conductor.

3.1 CHECKING THE ENGINE OILLEVEL

For oil capacities and requirements, see “Engine OilRequirements,” Section 1.5.4 (Page 6). Check theengine crankcase oil level at least every eight hours ofoperation, or before you use it. To check the engineoil 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 rockercover and slowly add oil until it reaches the dip-stick “Full” mark. DO NOT FILL ABOVE THE“FULL” MARK.

Never operate the engine with the oil levelbelow the “Add” mark on the dipstick. Doingthis could damage the engine.

5. Install and tighten the oil fill cap and the dipstickbefore operating the engine.

3.2 CHANGING THE ENGINE OILAND/OR OIL FILTER

• Change the engine oil after the first 25 hours ofoperation (after the 25-hour break-in period, seeSection 2.10.1, Page 10). Thereafter, change the oil every 100 operating hours. Change the oil morefrequently if operating consistently under heavyload or at high ambient temperatures.

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RV SERVICE LOCATOR: 1.800.333.1322

QUIETPACT 40G

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S E R V IC E A C C E S S P A N E L

OIL LEVEL: CHECK DAILY

AIR FILTER: CLEAN PREFILTEREVERY 100 HOURS.REPLACE ELEMENTEVERY 250 HOURS.

OIL & OIL FILTER: CHANGE EVERY 100

(IF NECESSARY)EVERY 500 HOURS.HOURS. REPLACE PLUGSPLUGS EVERY 100INSPECT & CLEANSPARK PLUGS:

REPLACEMENT INFORMATION

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PERFORM MORE OFTEN IN DUSTY CONDITIONS

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE

AIR FILTER P/N: 0D3262

070185OIL FILTER P/N:

SPARK PLUG P/N: 072347

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

-20˚F TO 50˚F 5W-30

10W-30

15W-40

30

WHEN SERVICE OR PARTS ARE NEEDED IN

THE USA OR CANADA, CONTACT THE GENERAC

SERVICE LOCATOR AT 1-800-333-1322.

HOURS. (OR ANNUALLY)

PREFILTER P/N: 0D4511

FUEL FILTER P/N: 0D7515

FUEL FILTER: CHANGE EVERY 400HOURS. (OR ANNUALLY)

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CONTROL CENTER

7.5

To Remove

Oil Dipstick/Oil Fill Oil Drain Oil Filter

Figure 3.1 – Oil Maintenance Features



• Change the engine oil filter after the first 25 hoursof operation, and every 100 operating hours there-after.

To change the oil and/or oil filter, proceed as follows (see Figure 3.1):

1. Run the engine until it is thoroughly warmed up(at least five minutes) then shut OFF the engine.

2. Immediately after the engine shuts OFF, pull theoil drain cover free of the base. Remove the plugfrom the tube with a 5/16” allen wrench and drainthe oil into a suitable container. Loosening the oilfill cap will allow the crankcase to drain faster.

3. After the oil has drained, replace the plug onto theend of the oil drain tube. Retain the cover in thebase.

4. With the oil drained, remove the old oil filter byturning 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 saturatedwith clean oil.

6. Screw the new filter on by hand until its gasketlightly 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 theoil level.

8. Remove the oil fill cap on the oil fill tube andslowly 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 leveland continue to fill the crankcase until the oilreaches the dipstick “Full” mark. DO NOT FILLABOVE THE “FULL” MARK.

9. Install and tighten the oil fill cap and the dipstickbefore operating the engine.

10. Start the engine and check for leaks.NOTE:

Check the oil level and fill to the “FULL” markafter checking for leaks. The filter will retain someoil.

3.3 MAINTAINING THE ENGINE AIR CLEANER

3.3.1 CLEANING THE FOAM PRECLEANERClean and re-oil the foam precleaner every threemonths or every 25 hours of operation, whicheveroccurs first. Service the foam precleaner more fre-quently if operating the generator in extremely dustyor 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.

3. Remove the foam precleaner from the cover.4. Wash the foam precleaner in liquid detergent and

water.5. Wrap the foam precleaner in a clean cloth and

gently squeeze it dry.6. Saturate the foam precleaner in clean engine oil.

Gently squeeze it in a clean cloth to removeexcess 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.

Figure 3.2 – Engine Air Cleaner

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 paperfilter. 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):

1. Follow steps 1-3 in Section 3.3.1; service thefoam precleaner if necessary.

2. Remove the paper filter.3. Clean the air filter by tapping it gently on a solid

surface. If the filter is too dirty, replace it with anew one. Dispose of the old filter properly.

4. Clean the air cleaner cover then reassemble following steps 7-9 in Section 3.3.1.

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3.4 CLEAN AIR INTAKEClean all foreign material from the air intake (Figure3.3) at least once every 100 hours of operation. Cleanmore often if necessary.

Inspect the area around the generator exhaust muf-fler periodically and remove all grass, leaves, dirt,etc., from this area.

Figure 3.3 – Cleaning Air Intake

3.5 CHECKING THE ENGINE SPARK PLUG

Clean the spark plug and reset the spark plug gapevery 100 hours of operation.

1. Clean the area around the base of the spark plugto keep dirt and debris out of the engine. Removethe spark plug and check the condition. Replacethe spark plug if worn or if reuse is questionable.

2. Clean spark plug by scraping or washing using awire brush and commercial solvent. Do not blastthe spark plug to clean.

3. Check the spark plug gap using a wire feelergauge. Adjust the gap to 0.030 inch (0.76 mm) by carefully bending the ground electrode (Figure 3.4).

Figure 3.4 – Setting the Spark Plug Gap

Sparking can occur if the wire terminal doesnot fit firmly on the spark plug terminal end. Ifnecessary, re-form the wire terminal to obtain atight fit.

3.6 FUEL FILTERRemove 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 a15/16” deep well socket.

Figure 3.5 – Fuel Filter

3.7 CLEAN SPARK ARRESTORThe engine exhaust muffler has a spark arrestorscreen. Inspect and clean the screen every 50 hoursof operation or once each year, whichever comes first.

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 sparkarrestor must be maintained in good condition bythe owner/operator.

Clean and inspect the spark arrestor as follows:

• Remove the screen retaining bracket by removingthe screw.

• Slide the spark arrestor screen out from the tailpipe.

• Inspect screen and replace if torn, perforated orotherwise damaged. DO NOT USE a defectivescreen. If screen is not damaged, clean it with com-mercial solvent.

• Replace the screen and the retaining bracket.

Figure 3.6 - Spark Arrestor

RETAINING SCREW P/N 056892

SPARK ARRRESTORSCREEN P/N 089680

TAILPIPEP/N 0E0683

NEG

FUEL

POS

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3.8 CLEANING THE GENERATORKeep the generator set as clean and dry as possible.Protect the unit against excessive dust, dirt, corrosivevapors, road splash, etc. Permitting dirt and mois-ture to accumulate on generator windings will havean adverse effect on the insulation resistance of thosewindings.

When moisture is allowed to remain in contact withwindings, some of the moisture will be retained invoids and cracks in the insulation. This causes areduced insulation resistance and will eventuallycause problems. Dirt will make the problem worse,since dirt tends to hold moisture in contact withwindings. Salt (as from sea air) also will worsen theproblem since it tends to absorb moisture from theair. Salt and moisture, when combined, form a goodelectrical conductor which can be damaging to thegenerator windings.

Do NOT use a forceful spray of water to cleanthe generator. Water will enter the generatorinterior and cause problems, and may also cont-aminate the generator fuel system.

3.9 BATTERY MAINTENANCEAll 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. Donot use tap water in batteries.

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.

NOTE:

Servicing of the battery is to be performed orsupervised by personnel knowledgeable of batter-ies and the required precautions. Keep unautho-rized personnel away from batteries.

Damage will result if the battery connections aremade in reverse.

Do not dispose of the battery in a fire. The battery is capable of exploding. Storage batter-ies give off explosive hydrogen gas. This gascan form an explosive mixture around the bat-tery for several hours after charging. Theslightest spark can ignite the gas and cause anexplosion. Such an explosion can shatter thebattery and cause blindness or other injury.Any area that houses a storage battery must beproperly ventilated. Do not allow smoking,open flame, sparks, or any spark producingtools or equipment near the battery. Dischargestatic electricity from your body before touch-ing the battery by first touching a groundedmetal surface.

A battery presents a risk of electrical shock and high short circuit current. The followingprecautions are to be observed when workingon batteries:

• 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 batteryhas discharged, remove it for recharging.

Do not open or mutilate the battery. Releasedelectrolyte has been known to be harmful tothe skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that isharmful to the skin and eyes. It is electricallyconductive 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 seekmedical attention; and

• Spilled electrolyte is to be washed down with anacid neutralizing agent. A common practice is touse a solution of 1 pound (500 grams) bicarbonateof soda to 1 gallon (4 liters) or water. The bicar-bonate of soda solution is to be added until theevidence of reaction (foaming) has ceased. Theresulting liquid is to be flushed with water and thearea dried.

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3.10 MAJOR SERVICE MANUALTo obtain a service manual for your generator, con-tact Generac or your nearest Generac AuthorizedService Dealer or, go to www.generac.com. Make sureto identify your MODEL NUMBER and SERIES.

3.11 EXERCISING THE GENERATORGenerac recommends that you start and operate thegenerator at least once every seven days. Let the unit run for at least 30 minutes to “exercise” the engine.

3.12 OUT OF SERVICE PROCEDURE

3.12.1 REMOVAL FROM SERVICEIf 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:

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:

Using a fuel additive such as STA-BIL fuel stabi-lizer, or an equivalent, will prevent gum depositsfrom forming in the engine’s fuel system.

3. While the engine is still warm from running,drain the oil completely. Refill the crankcase withSAE 10W-30 oil having API classification “ForService SF.”

4. Attach a tag to the engine indicating the viscosityand classification of the oil in the crankcase.

5. Remove the spark plug and pour two or threetablespoons of clean, fresh engine oil into thespark plug threaded openings. Reinstall andtighten the spark plug.

6. Remove the battery and store it in a cool, dryroom on a wooden board. Never store the batteryon any concrete or earthen floor.

7. Clean and wipe the entire generator.

3.12.2 RETURN TO SERVICETo return the unit to service after storage, proceed as follows:

1. Check the tag on the engine for oil viscosity andclassification. 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 theproper oil.

2. Check the state of the battery. Fill all cells ofunsealed batteries to the proper level with distilledwater. DO NOT USE TAP WATER IN THE BAT-TERY. Recharge the battery to 100 percent state ofcharge, or, if defective, replace the battery.

3. Clean and wipe the entire generator.4. Reconnect the battery. Observe battery polarity.

Damage may occur if the battery is connectedincorrectly.

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 warmup.

7. Apply electrical loads to at least 50 percent of theunit’s rated wattage capacity.

8. When the engine is thoroughly warmed up, shutit down.

9. Your generator is now ready for service.

3.13 ADJUSTING VALVE CLEARANCEAfter the first 50 hours of operation, you shouldadjust the valve clearance in the engine.

When adjusting valve clearance, the engine should beat room temperature and the piston should be at TopDead Center (TDC) of its compression stroke (bothvalves closed). Correct clearance is 0.001-0.003 inch(0.03-0.07mm). Adjust valve clearance as follows:

1. Loosen the rocker arm jam nut. Use an allenwrench to turn the pivot ball stud while checkingclearance between the rocker arm and the valvestem with a feeler gauge (Figure 3.7).

Figure 3.7 — Adjusting Valve Clearance

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2. When valve clearance is correct, hold the pivotball stud with the allen wrench and tighten therocker arm jam nut with a crows foot. Tighten thejam nut to 65-85 inch-pounds torque. After tight-ening the jam nut, recheck valve clearance tomake sure it did not change (Figure 3.8).

Figure 3.8 — Tightening Jam Nut

3.14 RV GENERATOR SERVICE INTERVAL

Quietpact 4050 Hours ................................Clean Spark Arrestor100 Hours ..........................Change Engine Oil/filter100 Hours ..................................Clean Air Pre-filter100 Hours ................................Inspect Spark Plugs250 Hours ............Replace Paper Air Filter Element400 Hours ..................................Replace Fuel Filter500 Hours................................Replace Spark Plugs1st 50 Hours-then

every 500 Hrs. ..........................Adjust Valve Lash


PART II –INSTALLATIONINSTRUCTIONS

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

DANGER


NOTICE TO INSTALLERThese Installation Instructions have been publishedby Generac to aid in the installation of the productsdescribed in this manual. Generac assumes thatinstallation personnel are familiar with the proce-dures for installing such products, or similar prod-ucts that Generac manufactures. Generac alsoassumes 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.

Generac cannot possibly know of and advise therecreational vehicle trade of all conceivable methods,procedures or techniques by which to perform aninstallation. Nor can Generac anticipate every possi-ble hazard that might result from each installationmethod, procedure or technique. Generac has notundertaken any such wide evaluation. Therefore,people who use a method, procedure or techniquethat Generac does not specifically recommend mustfirst completely satisfy themselves that their safety,the safety of the vehicle's occupants and the product'ssafety is not endangered by the method, procedure ortechnique selected.

Information, illustrations, specifications, etc., con-tained in these Installation Instructions are based onthe latest information available at the time of publi-cation. Every effort has been expended to be sure thatsuch data is both accurate and current. However, themanufacturer reserves the right to change, alter orotherwise improve this product at any time withoutprior notice.

Despite the safe design of this generator, operating this equipment imprudently, neglectingits maintenance or being careless can cause possible injury or death. Permit only responsibleand capable persons to operate or maintain thisequipment.

Potentially lethal voltages are generated bythese machines. Ensure all steps are taken torender the machine safe before attempting towork on the generator.

Parts of the generator are rotating and/or hotduring operation. Exercise care near runninggenerators.

GENERAL HAZARDS

• For safety reasons, Generac recommends that the installation, initial start-up and mainte-nance of this equipment is carried out by aGenerac Authorized Service Dealer.

• The engine exhaust fumes contain carbon monox-ide, which can be DEADLY. This dangerous gas, ifbreathed in sufficient concentrations, can causeunconsciousness 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 thatmight render the system unsafe or in noncompli-ance with such codes and standards. The genera-tor compartment must be completely vapor sealedfrom the vehicle interior. There must be no possi-bility of exhaust fumes entering the vehicle interi-or. Never operate this equipment with a leaking ordefective exhaust system.

• Keep hands, feet, clothing, etc., away from drivebelts, fans, and other moving or hot parts. Neverremove any drive belt or fan guard while the unit isoperating.

• Adequate, unobstructed flow of cooling and venti-lating air is critical to correct generator operationand is required to expel toxic fumes and fuelvapors from the generator compartment. Withoutsufficient cooling airflow, the engine/generatorquickly overheats, which causes serious damage tothe generator. Do not alter the installation or per-mit even partial blockage of ventilation provisions,as this can seriously affect safe operation of thegenerator.

• When working on this equipment, remain alert atall times. Never work on the equipment when youare 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 astep. Stepping on the unit can stress and breakparts, and may result in dangerous operating con-ditions from leaking exhaust gases, fuel leakage,oil leakage, etc.

• Never insert any tool or other object through open-ings in the generator interior, even if the unit is notrunning. You might seriously injure yourself ordamage the equipment.

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DANGER


DANGER: For fire safety, installation of a generator into a recreational vehicle must complystrictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standardfor Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installationmust comply with the manufacturer’s instructions and recommendations.

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ELECTRICAL HAZARDS• The generator covered by this manual produces

dangerous electrical voltages and can cause fatalelectrical shock. Avoid contact with bare wires, ter-minals, connections, etc., while the unit is running.Ensure all appropriate covers, guards and barriersare in place before operating the generator. If youmust work around an operating unit, stand on aninsulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device whilestanding in water, while barefoot, or while handsor feet are wet. DANGEROUS ELECTRICALSHOCK MAY RESULT.

• During installation onto the vehicle, properlyground (bond) the generator either by solid mount-ing to the vehicle frame or chassis, or by means ofan approved bonding conductor. DO NOT connectthe bonding conductor to any generator part thatmight be removed or disassembled during routinemaintenance. If the grounding conductor must bereplaced, use only a flexible conductor that is ofNo. 8 American Wire Gauge (AWG) copper wireminimum.

• If the vehicle electrical circuits can be powered byany other source of electricity (such as a “dock-side” power receptacle), there must be no possibil-ity of connecting the different power sources to thevehicle circuits at the same time. The dockside(utility) power source must be positively isolatedfrom the vehicle circuits whenever the generator isoperating. Failure to isolate the vehicle circuitsfrom 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. Ifthis is not possible, attempt to free the victim fromthe live conductor. AVOID DIRECT CONTACTWITH THE VICTIM. Use a nonconducting imple-ment, such as a rope or board, to free the victimfrom the live conductor. If the victim is uncon-scious, apply first aid and get immediate medicalhelp.

• Never wear jewelry when working on this equip-ment. Jewelry can conduct electricity resulting inelectric shock, or may get caught in moving com-ponents causing injury.

FIRE HAZARDS

• For fire safety, the generator must be installed andmaintained properly. Installation always mustcomply with applicable codes, standards, laws andregulations. Adhere strictly to local, state andnational electrical and building codes. Complywith regulations the Occupational Safety andHealth Administration (OSHA) has established.Also, ensure that the generator is installed inaccordance with the manufacturer’s instructionsand recommendations. Following proper installa-tion, do nothing that might alter a safe installationand render the unit in noncompliance with theaforementioned codes, standards, laws and regu-lations.

• Keep a fire extinguisher in the vehicle at all times.Extinguishers rated “ABC” by the National FireProtection Association are appropriate for use onthe recreational vehicle generator electrical system.Keep the extinguisher properly charged and befamiliar with its use. If you have any question per-taining to fire extinguishers, consult your local firedepartment.

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 orEXPLOSION may result. Keep the area surround-ing the generator clean and free from debris.

• Gasoline is extremely FLAMMABLE and its vaporsare EXPLOSIVE. Do not permit smoking, openflame, sparks or any source of heat in the vicinitywhile handling gasoline. Comply with all laws 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 fuelconnection point and rigid fuel lines.



1.1 PURPOSE AND SCOPE OF THE MANUAL

These Installation Instructions have been preparedespecially for the purpose of familiarizing installersand owners of the applicable equipment with theproduct's installation requirements. Give seriousconsideration to all information and instructions inthe manual, both for safety and for continued reliableoperation of the equipment.

Because of the different recreational vehicle modelsand the variations between the models, it would beextremely difficult, if not impractical, to providedetailed instructions for every possible installation.For that reason, instructions and illustrations in thismanual are general in nature. Illustrations are notintended to serve as detailed installation blueprints.

The installation should comply strictly with allapplicable codes, standards and regulations pertain-ing to the installation and use of this product. If anyportion of this manual appears to be in conflict withsuch codes, standards or regulations, the applicablecodes, standards or regulations must take prece-dence over the manual.

1.2 SAFETYBefore handling, installing, operating or servicing thisequipment, carefully read the “Notice to Installer”and “Safety Rules” on Pages 18 and 19. Comply withall safety rules to prevent death, personal injury ordamage to equipment and/or property. Stress safetyto all installers, operators and service technicianswho work on this equipment.

1.3 STANDARDS BOOKLETSInstallation, use and servicing of this equipmentshould comply strictly with published standards, aswell as the manufacturer's recommendations. Thefollowing standards booklets (latest revision) areavailable from the sources indicated:

1. NFPA Standard 501C, “Standard for RecreationalVehicles,” available from the National FireProtection Association, Batterymarch Park,Quincy, MA 02269.

2. NFPA 70, “NFPA Handbook of the NationalElectric Code,” available same as Item 1.

3. ANSI C1-1975 and ANSI 119.2-1975, availablefrom the American National Standards Institute,1430 Broadway, New York, NY 10018.

4. ANSI A119.2/NFPA 501C, available from theRecreational Vehicle Association, 1896 PrestonWhite Drive, Reston, VA 22090.

5. California Administrative Code, Title 25, avail-able from the State of California, DocumentsSection, P.O. Box 1015, North Highlands, CA 95660.

6. CSA Electrical Bulletin 946, available from theCanadian Standards Association, Housing andConstructions Materials Section, 178 RexdaleBoulevard, Rexdale, Ontario, Canada, M9W 1R3.

1.4 EQUIPMENT DESCRIPTIONInstructions and information in this section pertainto Generac air-cooled generators. This generator isdesigned specifically for installing in recreationalvehicles. This generator operates 120-volts, single-phase, 60-Hertz, AC electrical loads that require 30.0amps.

1.5 GENERATOR ENGINEOPERATING SPEED

The generator’s revolving field (rotor) is driven by asingle-cylinder, four-cycle engine. The generator sup-plies 120 volts AC at 60 Hertz when the rotor is oper-ating at 3,600 rpm.

1.6 GENERATOR AC CONNECTION SYSTEM

The generator is equipped with dual stator powerwindings as shown in Figure 1.1.

Figure 1.1 – 120-volt Single Voltage Connection

• The AC connection system on all air-cooledPRIMEPACT series generators uses a GROUNDEDneutral.

• A separate green ground wire is connected to therecreational vehicle’s junction box.

NOTE:

Do NOT connect loads in excess of circuit breaker ratings.

BLACK



Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-F)


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2.1 LOCATION AND SUPPORT2.1.1 GENERATOR LOCATION

The most desirable location for the generator set isbetween the vehicle's main frame members. However,this is seldom possible. Most units must be installedon the side of the vehicle and are difficult to reinforce.

Many recreational vehicles have been factoryequipped with an area for the generator set. Somevehicles may even have a generator compartmentprovided by the vehicle manufacturer.

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 thatis 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 maintenanceparts.

• The location must provide sufficient room to allowminimum clearances as outlined in Section 2.2. Ifsound insulation is to be used on the compartmentwalls and ceiling, the minimum recommendedapplies to the space between the generator andsuch insulation.

• The location must provide adequate cooling andventilating airflow for the generator without a greatdeal of work and expense.

• If mounting the generator in an enclosed compart-ment, the base of the generator must rest flat onthe floor without any gaps.

• When using a suspended mounting system, ensurethe base of the generator is flush with the sur-rounding bodywork. If the unit is mounted higherin the structure, heated air may recirculate into thegenerator causing it to overheat.

2.1.2 GENERATOR SUPPORTThe generator must be securely attached to a metalframework that has been made part of the vehicleframe structure by bolting or welding. The metalframework on which the generator will rest andwhich will restrain the generator set should consist ofat least two horizontal beams. These beams shouldconsist of (a) 1-1/2-inch square, 11-gauge steel tubingOR (b) 1-1/2-inch, 11-gauge angle iron. A typical sup-porting frame with horizontal support tubing, isshown in Figure 2.1.

The generator can be installed so that it sits on top ofthe horizontal support tubing if the vehicle designpermits. 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:

• Vehicle construction MUST be capable of support-ing the weight of the generator.

• Whether the generator is mounted above the hori-zontal support tubing or suspended below the tub-ing, the supporting frame used must be structural-ly sound.

• If the generator cannot be bolted directly to the supporting frame or support tubing, considerusing additional tubing, angle brackets or other supports to give the supporting frame suf-ficient strength.

Figure 2.1 – Typical Horizontal Support Frame

2.1.3 SUSPENDED MOUNTINGIf you are going to suspend the generator below thehorizontal support tubing, the suspension methodyou use with the vehicle frame members must (a) beable to support the weight of the generator AND (b)provide sufficient restraint for the generator. One typ-ical suspended mounting system is shown in Figure2.2. The location of a suspended mounting systemmust be carefully planned, keeping the following gen-eral rules in mind:

• Protect the generator against road splash and debris.Baffles or splash guards may be required to protectcertain areas of the generator. To make sure the gen-erator is adequately protected, road test the installa-tion through mud, water and slush.

Figure 2.2 – Typical Suspended Mounting System

GENERATOR SUPPORT FRAME(MODEL 004718-0)

GENERATOR MOUNTINGHOLES FOR 5/16" - 18BOLTS (6 PLACES)

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◆

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Section 2 – InstallationQUIETPACT 40G Recreational Vehicle Generator


• The installer must make certain that the selectedlocation will permit adequate cooling and ventilat-ing airflow to be supplied.

2.1.4 GENERATOR RESTRAINTUse four 5/16"-18 hardened steel bolts (Grade 5) tofasten the generator to the supporting frame or thesupport tubing. These bolts must pass through (a)the generator mounting base, (b) the compartmentfloor (if a compartment is used) and (c) the support-ing framework (Figure 2.3). All bolts must be longenough so that when tight, at least three threads arevisible past the retaining lock nuts. Refer to Section2.2 for the location of the generator mounting holes.

Figure 2.3 – Typical Generator Restraint

2.2 GENERATOR COMPARTMENTSWhether the generator set is being installed inside acompartment specifically manufactured to house agenerator or inside a compartment that the installerconstructs, the compartment must meet certain spec-ifications as outlined in the following sections:

2.2.1 COMPARTMENT SIZEPlan the compartment size carefully. Provide a mini-mum clearance of 1/2 inch (13 mm) on the front andtop, 1/2 inch (25 mm) on the sides, and 1/2 inch (13mm) from the back for air circulation AFTER thecompartment has been lined with metal and soundinsulation (Figure 2.4).

Figure 2.4 – Clearances

NOTE:

Refer to “Figure 1.2 – Major Features andDimensions”.

2.2.2 COMPARTMENT CONSTRUCTION• The generator compartment should be either con-

structed of, or lined with, 26-gauge galvanizedsteel.

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, itmay be constructed of any material. Generac rec-ommends that the compartment be constructed of1/2-inch thick plywood (not strandboard), with thefloor made of a double thickness of 1/2-inch ply-wood with the grain of the wood at cross sectionfor added strength (Figure 2.5).

Figure 2.5 – Typical Compartment Construction

• If constructing a compartment, line the exterior(underside) of the compartment floor with 26-gauge galvanized steel.

• All seams, splices and joints of the compartmentwalls (unless vapor tight by design) should be caulked to prevent poisonous, flammable orexplosive vapors from entering the vehicle interior.

NOTE:

Caulking must be done so that the caulking materi-al will stay in place permanently. Pressing suchmaterials as putty tape onto joints and seams is NOTacceptable. A high quality silicone rubber basesealant is recommended.

◆

1" Clearancein Back

1/2" Clearance on Top

1" Each Side

1/2"in Front

Insulation

PlywoodCompartment

18" Cle

arance

Recom

mende

d

Below

(Minim

um 12"

)

◆

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Section 2 – InstallationQUIETPACT 40G Recreational Vehicle Generator


• Holes and openings made in the compartmentwalls to allow for the passage of electrical conduit,conductors, hoses, cables, etc., into the vehicle liv-ing area must be sealed vapor tight with siliconerubber base sealant.

• If flexible metal conduit is used, it must be sealedinternally at the end where it terminates inside thecompartment’s electrical junction box.

NOTE:

Flexible metal conduit, due to its unique con-struction, is NOT vapor tight along its entirelength.

• Seams and joints of the galvanized steel (whetherused as a liner or for the compartment itself) mustbe lapped and mechanically secured. Such seamsmay be manufactured, welded, bolted, riveted orscrewed. Manufactured lock seams are shown inFigure 2.6. Installer constructed compartmentstypically utilize a standard lap joint.

Figure 2.6 – Types of Lock Seams

• After the compartment has been metal lined andvapor sealed, line the compartment interior wallsand ceiling with an approved, nonflammablesound insulating material. See Section 2.2.3.

Do not install any flammable material directlyabove or around the compartment. Heat, transferred through the compartment structure

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