Generac Power Systems 004709-0 Owner'S Manual Download Page 4

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Study these SAFETY RULES carefully before installing, operating 

or servicing this equipment. Become familiar with this manual and 

with the unit. The generator can operate safely, efficiently and reli-

ably only if it is properly installed, operated and maintained. Many 

accidents are caused by failing to follow simple and fundamental 

rules or precautions.
The manufacturer cannot anticipate every possible circumstance 

that might involve a hazard. The warnings in this manual, and on 

tags and decals affixed to the unit, are, therefore, not all-inclusive. 

If using a procedure, work method or operating technique the 

manufacturer does not specifically recommend, ensure that it is 

safe for others. Also make sure the procedure, work method or 

operating technique utilized does not render the generator unsafe.

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 Despite the safe design of this generator, 

operating this equipment imprudently, neglect-

ing its maintenance or being careless can 

cause 

possible injury or death. Permit only respon-

sible and capable persons to operate or main-

tain 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.

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 Parts of the generator are rotating and/or 

hot during operation. Exercise care near run-

ning generators. 

GENERAL HAZARDS

For safety reasons, the manufacturer recommends that the 

• 

installation, initial start-up and maintenance of this equipment 

is carried out by an Authorized Service Dealer.

The generator engine releases DEADLY carbon monoxide gas 

• 

through its exhaust system. This dangerous gas, if breathed 

in sufficient concentrations, 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 

POISONING ARE (a) inability to think coherently, (b) nausea, 

(c) vomiting, (d) twitching muscles, (e) throbbing temples, 

(f) dizziness, (g) headaches, (h) weakness, and (i) sleepi-

ness. IF EXPERIENCING ANY OF THESE SYMPTOMS, MOVE 

INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET 

MEDICAL HELP. Shut down the generator and do not operate it 

until it has been inspected and repaired.

Never sleep in the vehicle while the genset is running unless the 

• 

vehicle has a working carbon monoxide detector. The exhaust 

system must be installed in accordance with the genset instal-

lation manual. Make sure there is ample fresh air when operat-

ing the genset in a confined area.

The engine exhaust fumes contain carbon monoxide, which can 

• 

be DEADLY. This dangerous gas, if breathed in sufficient con-

centrations, can cause unconsciousness or even death. This 

exhaust system must be installed properly, in strict compliance 

with applicable codes and standards. Following installation, do 

nothing that might render the system unsafe or in noncompli-

ance with such codes and standards. The generator compart-

ment must be completely vapor sealed from the vehicle interior. 

There must be no possibility of exhaust fumes entering the 

vehicle interior. Never operate this equipment with a leaking or 

defective exhaust system.

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 ventilating 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 permit even partial blockage of ven-

tilation provisions, as this can seriously affect safe operation of 

the generator.

When working on this equipment, remain alert at all times. 

• 

Never work on the equipment when physically or mentally 

fatigued.

Inspect the generator regularly, and contact the nearest Authorized 

• 

Service Dealer immediately for parts needing repair or replace-

ment.

Before performing any maintenance on the generator, discon-

• 

nect its battery cables to prevent accidental start up. Disconnect 

the cable from the battery 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 dan-

gerous operating conditions from leaking exhaust gases, fuel 

leakage, oil leakage, etc.

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 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.

Safety Rules

Summary of Contents for 004709-0

Page 1: ...This manual should remain with the unit Air cooled Recreational Vehicle Generators Quietpact 40G Models 004709 0 005852 0 Owner s Manual and Installation Instructions...

Page 2: ...Spark Arrestor 12 3 8 Cleaning the Generator 13 3 9 Battery Maintenance 13 3 10 Major Service Manual 14 3 11 Exercising the Generator 14 3 12 Out of Service Procedure 14 3 13 Adjusting Valve Clearance...

Page 3: ...t and the safety of all vehicle occupants We strongly recommend that the operator read this manual and thoroughly understand all instructions before using this equipment We also strongly recommend ins...

Page 4: ...icle 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 instal lation manual Make sure there is am...

Page 5: ...ety 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...

Page 6: ...CHECK DAILY AIR FILTER CLEAN PREFILTER EVERY 100 HOURS REPLACE ELEMENT EVERY 250 HOURS OIL OIL FILTER CHANGE EVERY 100 IF NECESSARY EVERY 500 HOURS HOURS REPLACE PLUGS PLUGS EVERY 100 INSPECT CLEAN S...

Page 7: ...rs require more watts of power or amps of cur rent for starting than for continuous opera tion 1 3 SAFETY Before attempting to use the generator set carefully read the Safety Rules section of this man...

Page 8: ...47 in Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine condition etc Maximum power decreases about 3 5 for each 1 000 feet...

Page 9: ...l is available that allows start ing and stopping the generator engine conveniently from inside the vehicle Order part number 0F0429 or 0F0430 a remote panel that includes a Start Stop switch a genera...

Page 10: ...le 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 tr...

Page 11: ...e generator Do not apply heavy electrical loads for the first two or three hours of operation 2 9 PROTECTION SYSTEMS 2 9 1 LOW OIL PRESSURE SWITCH This switch Figure 2 2 has normally closed N C contac...

Page 12: ...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 ro...

Page 13: ...ently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 2 1 Follow steps 1 3 in Cleaning the Foam Precleaner service the foam precleaner if necessa...

Page 14: ...the Spark Plug Gap nSparking can occur if the wire terminal does not fit firmly on the spark plug terminal end If necessary re form the wire terminal to obtain a tight fit 3 6 FUEL FILTER Remove and...

Page 15: ...ttery is to be performed or supervised by personnel knowledgeable of batteries and the required precau tions Keep unauthorized personnel away from batteries Damage will result if the battery connectio...

Page 16: ...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 fl...

Page 17: ...lve clearance to make sure it did not change Figure 3 8 Figure 3 8 Tightening Jam Nut CROW S FOOT 3 14 RV GENERATOR SERVICE INTERVAL 50 Hours Clean Spark Arrestor 100 Hours Change Engine Oil filter 10...

Page 18: ...16 Notes...

Page 19: ...PART II INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION...

Page 20: ...al start up and maintenance of this equipment is carried out by an Authorized Service Dealer The engine exhaust fumes contain carbon monoxide which can be DEADLY This dangerous gas if breathed in suff...

Page 21: ...m from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in ele...

Page 22: ...llowing standards booklets latest revi sion are available from the sources indicated 1 NFPA Standard 501C Standard for Recreational Vehicles available from the National Fire Protection Association Bat...

Page 23: ...21 Figure 1 2 Major Features and Dimensions Drawing No 0D8716 K General Information...

Page 24: ...ngle iron A typical supporting frame with horizontal support tubing is shown in Figure 2 1 The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design...

Page 25: ...f a double thickness of 1 2 inch plywood with the grain of the wood at cross section for added strength Figure 2 5 Figure 2 5 Typical Compartment Construction If constructing a compartment line the ex...

Page 26: ...aterial is used 2 2 4 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement compa...

Page 27: ...25 Figure 2 8 Compartment Floor Cutout Drawing 0G3723 A Installation...

Page 28: ...lation of a gasoline fuel system Figure 2 10 for a recreational vehicle generator set must comply with applicable codes standards and regulations The entire fuel system must be completely free of leak...

Page 29: ...d to prevent the hose from rupturing if the generator shifts or settles 2 5 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust s...

Page 30: ...damage the other engine Plan exhaust system installation carefully Comply with all appli cable codes standards and regulations 2 6 ELECTRICAL CONNECTIONS The following general rules apply to electric...

Page 31: ...the required length and allow extra wire for junc tion box connections Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation Route conduit so it does not interfe...

Page 32: ...30 Figure 2 14 Transfer Switch Isolation Method Figure 2 15 Installation With Isolation Receptacle Installation...

Page 33: ...ERY COMPARTMENT Install the generator battery in its own vented compartment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compa...

Page 34: ...of the primer switch will shorten this time 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 exhau...

Page 35: ...system is properly and safely installed ELECTRICAL CONNECTIONS Connections comply with local code requirements and all National Electrical Codes Junction box is properly installed Wiring meets all st...

Page 36: ...shuts 1 Engine oil level low 1 Check oil and add oil as needed down when the Start Stop 2 Defective low oil pressure switch 2 Replace pressure switch switch is released 3 Defective high temperature sw...

Page 37: ...Generac Power Systems Inc 35 35 Notes...

Page 38: ...5 18 1 0I 17 66 85 85 3 3 6 5 4 6 5 4 1 2 1 2 PANEL REMOTE LOP 0 0 SP 0B START STOP SW1 IM SC 14 CH CS 0 0 0 FS FP SM HTO SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP L1 LIGHT RUN OPTIONAL LOP SWITCH LOW...

Page 39: ...17 0 15 SW1 SW2 TC 0K 0 0 0 0B 17 18 GT 0 0I 4 2 0 11S 13 0K 4 22S 4 2A 6 2A REGULATOR VOLTAGE ELECTRONIC 14A 15 14A 14A 0F 44 14 0F 17 11P 22P 77 22S 11S 33 66 RED 22P 11P 44 55 6 2 R1 CONNECTOR 17...

Page 40: ...38 Exploded Views Parts Lists Enclosure Drawing No 0D8352 N...

Page 41: ...16 X 1 28 0A4456 1 3 8 SPECIAL L WASHER 30 049813 2 NUT HEX M6 X 1 0 ITEM PART NO QTY DESCRIPTION 31 022237 1 WASHER LOCK 3 8 32 022131 2 WASHER FLAT 3 8 M10 33 0C5443 1 BLOCK TERMINAL BATTERY POST 34...

Page 42: ...40 Exploded Views Parts Lists Generator Drawing No 0D8353 M...

Page 43: ...T 5 16 19 030231 3 SCREW HHC 5 16 18 X 1 1 2 20 0C3168 1 5 16 SPECIAL LOCK WASHER 21 022259 10 NUT HEX 5 16 18 22 0C8565 2 SCREW SHC M8 1 25 X 18MM 23 0D8048 4 VIBRATION MOUNT 24 083512 6 SCREW HHTT M...

Page 44: ...42 Exploded Views Parts Lists Control Panel Drawing No 0D8354 H...

Page 45: ...047411 2 SCREW HHC M6 1 0 X 16mm 17 049226 5 WASHER LOCK M5 18 051716 1 NUT HEX M5 0 8 19 075476 2 SCREW PPHM M4 0 7 x 16mm 20 022264 2 WASHER LOCK 8 M4 21 051715 4 NUT HEX M4 0 7 22 0A2053 1 SCREW HH...

Page 46: ...44 Exploded Views Parts Lists GN 220 H SH Engine Drawing No 0D8355 AG Part 1...

Page 47: ...E LINKAGE ITEM PART NO QTY DESCRIPTION 35 091638A 1 SPRING GOVERNOR 36 0G7967 1 SCREW HHTT 5 16 X SEMI GIMLET 37 082025 1 NUT M5 0 8 LOCK 38 092984 1 TOP WRAPPER 39 094820 1 PLUG EXPANSION 40 089739 1...

Page 48: ...46 Exploded Views Parts Lists GN 220 H SH Engine Drawing No 0D8355 AG Part 2...

Page 49: ...IL PRESSURE SPRING 24 0A5776 1 11 32 BALL 25 074908 1 M5 FORM SCREW 26 078606 4 M6 1 0 X 12MM SCREW 27 076361 1 GOVERNOR GEAR THRUST WASHER 28 0D2414 6 SCREW HHFC M8 1 25 X 35MM 29 099922 1 SPRING WAS...

Page 50: ...e to abuse neglect improper maintenance or unapproved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your...

Page 51: ...ed 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...

Page 52: ...PLY TO THE FOLLOWING Generac generators that utilize non Generac replacement parts Costs of normal maintenance adjustments installation and start up Repairs or diagnostics performed by individuals oth...

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