Generac Power Systems 004709-0 User manual

Owner’s Manual and
Installation Instructions
This manual should remain with the unit.
Air-cooled Recreational
Vehicle Generators
Model: 004709-0
QUIETPACT 40G

INTRODUCTION
Thank you for purchasing this model by Generac
Power Systems Inc. This model is designed and man-
ufactured to supply electrical power for recreational
vehicles.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, con-
tact the nearest Authorized Service Dealer for starting,
operating and servicing procedures.
Throughout this publication, and on tags and decals
affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert person-
nel to special instructions about a particular opera-
tion that may be hazardous if performed incorrectly
or carelessly. Observe them carefully. Their defini-
tions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious per-
sonal injury up to and including death, or property
damage.
After this heading, ead instructions that, if not
strictly complied with, may result in personal injury
or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compli-
ance with the special instructions while performing
the service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates follows:
This symbol points out important safety informa-
tion that, if not followed, could endanger person-
al safety and/or property of others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
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The operator (driver) is responsible for proper and
safe use of the vehicle and its equipment, and the
safety of all vehicle occupants. We strongly recom-
mend that the operator read this manual and thor-
oughly understand all instructions before using this
equipment. We also strongly recommend instructing
other occupants in the vehicle to properly start and
operate the generator. This prepares them if they need
to operate the equipment in an emergency.
CONTENTS
This manual contains pertinent owner’s information,
including warranty, electrical diagrams, exploded
views and lists of repair parts. In addition, the latter
portion of this manual contains information neces-
sary for the proper installation of these generators.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by an Authorized
Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the
owner/operator and, as such, are not considered
defects in materials or workmanship within the
terms of the warranty. Individual operating habits
and usage contribute to the need for maintenance
service.
Proper maintenance and care of the generator ensures
a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
simply contact an Authorized Service Dealer for
assistance. Service technicians are factory-trained
and are capable of handling all service needs.
When contacting an Authorized Service Dealer or the
factory about parts and service, always supply the
complete model number and serial number of the
unit as given on its data label, which is located on the
generator.
Model No. ____________ Serial No.______________
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AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED SERVICE
DEALER, please call this number:
1-800-333-1322
or locate us on the web at:
www.guardiangenerators.com

Table of Contents
Recreational Vehicle Generator
1
Part – Owner’s Manual
Introduction ........................................Inside Front Cover
Read This Manual Thoroughly.................................IFC
Contents .................................................................. IFC
Operation and Maintenance ..................................... IFC
How to Obtain Service ............................................. IFC
Authorized Service Dealer Locator Number ............... IFC
Safety Rules ........................................................................2
Section 1 – General Information...................................4
1.1 Generator Identification ....................................... 4
1.2 Generator Applicability ........................................ 5
1.3 Safety.................................................................... 5
1.4 Generator AC Connection System ........................ 5
1.5 Specifications ....................................................... 5
Section 2 – Operation ......................................................7
2.1 Generator Control Panel....................................... 7
2.2 Optional Remote Start/Stop Panel ........................ 7
2.3 Automatic Choke.................................................. 7
2.4 Before Starting the Engine ................................... 7
2.5 Starting the Generator ......................................... 8
2.6 Stopping the Generator........................................ 9
2.7 Applying Loads to Generator................................ 9
2.8 Do Not Overload the Generator............................ 9
2.9 Protection Systems............................................... 9
2.10 Additional Information ....................................... 10
Section 3 – Maintenance.............................................. 11
3.1 Checking the Engine Oil Level............................ 11
3.2 Changing the Engine Oil and/or Oil Filter .......... 11
3.3 Maintaining the Engine Air Cleaner.................... 12
3.4 Clean Air Intake ................................................. 12
3.5 Checking the Engine Spark Plug ........................ 12
3.6 Fuel Filter........................................................... 13
3.7 Clean Spark Arrestor ......................................... 13
3.8 Cleaning the Generator ...................................... 13
3.9 Battery Maintenance........................................... 14
3.10 Major Service Manual......................................... 14
3.11 Exercising the Generator.................................... 14
3.12 Out of Service Procedure.................................... 14
3.13 Adjusting Valve Clearance................................... 15
3.14 RV Generator Service Interval ............................ 15
Section 4 – Notes ........................................................... 16
Part II – Installation Instructions
Safety Rules ..................................................................... 18
Section 1 – General Information................................ 20
1.1 Purpose and Scope of the Manual...................... 20
1.2 Safety.................................................................. 20
1.3 Standards Booklets............................................ 20
1.4 Equipment Description ...................................... 20
1.5 Generator Engine Operating Speed .................... 20
1.6 Generator AC Connection System ...................... 20
Section 2 – Installation................................................. 22
2.1 Location and Support ........................................ 22
2.2 Generator Compartments .................................. 23
2.3 Cooling and Ventilating Air................................. 25
2.4 Gasoline Fuel System ......................................... 27
2.5 Exhaust System.................................................. 28
2.6 Electrical Connections........................................ 29
2.7 Battery Installation............................................. 31
2.8 Optional Accessories .......................................... 32
Section 3 – Post-installation Start-up
Adjustments............................................... 33
3.1 Post Installation Tests ........................................ 33
3.2 Before Initial Start-up......................................... 33
3.3 Initial Start......................................................... 33
3.4 Testing Under Load............................................ 33
3.5 Installation Checklist.......................................... 34
Section 4 – Troubleshooting........................................ 35
Section 5 – Electrical Data ........................................... 36
Section 6 – Exploded Views and Parts Lists............ 38
Section 7 – Warranty ..................................................... 48

2
Study these SAFETY RULES carefully before install-
ing, operating or servicing this equipment. Become
familiar with this manual and with the unit. The gen-
erator can operate safely, efficiently and reliably 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 warn-
ings in this manual, and on tags and decals affixed
to the unit, are, therefore, not all-inclusive. If using
a procedure, work method or operating technique
the manufacturer does not specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique uti-
lized does not render the generator unsafe.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
GENERAL HAZARDS 
For safety reasons, the manufacturer recommends
that the installation, initial start-up and main-
tenance 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 concentra-
tions, can cause unconsciousness or even death.
Never operate the generator set with the vehicle
inside any garage or other enclosed area. DO NOT
OPERATE THE GENERATOR IF THE EXHAUST
SYSTEM IS LEAKING OR HAS BEEN DAMAGED.
SYMPTOMS OF CARBON MONOXIDE POISONING
ARE (a) inability to think coherently, (b) nausea,
(c) vomiting, (d) twitching muscles, (e) throbbing
temples, (f) dizziness, (g) headaches, (h) weak-
ness, and (i) sleepiness. IF EXPERIENCING ANY
OF THESE SYMPTOMS, MOVE INTO FRESH AIR
IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP. Shut down the generator and
do not operate it until it has been inspected and
repaired.
Never sleep in the vehicle while the genset is run-
ning unless the vehicle has a working carbon
monoxide detector. The exhaust system must be
installed in accordance with the genset installation
manual. Make sure there is ample fresh air when
operating the genset in a confined area.
The engine exhaust fumes contain carbon monox-
ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust
system must be installed properly, in strict com-
pliance with applicable codes and standards.
Following installation, do nothing that might ren-
der the system unsafe or in noncompliance with
such codes and standards. The generator com-
partment must be completely vapor sealed from
the vehicle interior. There must be no possibility of
exhaust fumes entering the vehicle interior. Never
operate this equipment with a leaking or defective
exhaust system.
Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
Adequate, unobstructed flow of cooling and ven-
tilating air is critical to correct generator opera-
tion 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 ventilation provi-
sions, as this can seriously affect safe operation of
the generator.
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Safety Rules
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 product contains
chemicals known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:•

This product contains or emits chemicals known
to the state of California to cause cancer,
birth defects or other reproductive harm.
WARNING:•
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3
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 replacement.
Before performing any maintenance on the gen-
erator, disconnect 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 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 fatal
electrical shock. Avoid contact with bare wires, ter-
minals, connections, etc., while the unit is running.
Ensure all appropriate covers, guards and barriers
are in place before operating the generator. If work
must be done around an operating unit, stand on
an insulated, dry surface to reduce shock hazard.
Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
During installation onto the vehicle, have the
generator properly grounded (bonded) either by
solid mounting to the vehicle frame or chassis,
or by means of an approved bonding conductor.
DO NOT disconnect the bonding conductor, if so
equipped. DO NOT reconnect the bonding conduc-
tor to any generator part that might be removed or
disassembled during routine maintenance. If the
grounding conductor must be replaced, use only a
flexible conductor that is of No. 8 American Wire
Gauge (AWG) copper wire minimum.
In case of accident caused by electric shock, imme-
diately shut down the source of electrical power.
If this is not possible, attempt to free the victim
from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting imple-
ment, such as a rope or board, to free the victim
from the live conductor. If the victim is uncon-
scious, apply first aid and get immediate medical
help.
Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.
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FIRE HAZARDS 
For fire safety, the generator must be installed
and maintained properly. Installation always must
comply with applicable codes, standards, laws
and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installa-
tion, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regu-
lations.
Keep a fire extinguisher in the vehicle at all times.
Extinguishers rated “ABC” by the National Fire
Protection Association are appropriate for use on
the recreational vehicle generator electrical sys-
tem. Keep the extinguisher properly charged and
be familiar with its use. If there are any questions
pertaining to fire extinguishers, consult the local fire
department.
EXPLOSION HAZARDS 
Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no com-
bustible materials are left in the generator com-
partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing the generator clean and free from debris.
Gasoline is extremely FLAMMABLE and its vapors
are EXPLOSIVE. Do not permit smoking, open
flame, sparks or any source of heat in the vicinity
while handling gasoline. Comply with all laws gov-
erning the storage and handling of gasoline.
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Safety Rules
Recreational Vehicle Generator

4
1. Generator Air Intake
2. Engine Start/Stop Switch
3. Fuse
4. Optional Remote Panel Receptacle (Side View)
5. Generator AC Output Leads (Side View)
6. Fuel Primer Switch
7. Circuit Breaker
8. Starter Contactor
9. Fuel Inlet
10. Fuel Pump (Behind Access Panel)
11. Fuel Filter (Side View)
12. Oil Filter
13. Oil Drain Cap
14. Oil Dipstick
15. Air Filter (Behind Access Panel)
16. Oil Fill
17. Spark Plug
18 External Vacuum Port (model 004709-0 only)
Section 1 – General Information
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 __________________
I
t
r
e
,
e
w
a
D
W
AC
*
SERVICE ACCESS PANEL
OIL LEVEL: CHECK DAILY
AIR FILTER: CLEAN PREFILTER
EVERY 100 HOURS.
REPLACEELEMENT
EVERY 250 HOURS.
OIL & OIL FILTER: CHANGE EVERY 100
(IF NECESSARY)
EVERY 500 HOURS.
HOURS.REPLACE PLUGS
PLUGSEVERY 100
INSPECT & CLEANSPARKPLUGS:
REPLACEMENT INFORMATION
*
PERFORMMORE OFTEN IN DUSTY CONDITIONS
AIR FILTERLOCATED BEHIND PANEL.
MAINTENANCE SCHEDULE
AIR FILTERP/N: 0D3262
070185OILFILTER P/N:
SPARKPLUG P/N: 072347
OIL CAPACITYWITH FILTER: 0.8L/0.84QT
TEMPERATURE SAE VISCOSITY
32°F AND HIGHER
10°FTO 100°F
0°FTO 80°F
-20°FTO 50°F 5W-30
10W-30
15W-40
30
WHEN SERVICE OR PARTSARE NEEDED IN
THE USA OR CANADA,CONTACT THE GENERAC
SERVICE LOCATORAT 1-800-333-1322.
HOURS.(OR ANNUALLY)
PREFILTERP/N: 0D4511
FUEL FILTERP/N: 0D7515
FUEL FILTER: CHANGE EVERY 400
HOURS.(OR ANNUALLY)
*
*
PRIME
FUEL
STOP
START 30A
C.B .
15 A
FUSE
CONTROL CENTER
1
2
3
7
6
10/15
17
8
14,16
13 12
4
18
5
9/11
1.1 GENERATOR IDENTIFICATION

5
Section 1 – General Information
Recreational Vehicle Generator
1.2 GENERATOR APPLICABILITY
These generators have been designed and manufac-
tured for supplying electrical power for recreational
vehicles. Do not modify the generator or use it for
any application other than for what it was designed. If
there are any questions pertaining to its application,
contact an Authorized Service Dealer. Do not use the
unit until advised by a competent authority.
DANGER
For fire safety, the generator must have been
properly installed in compliance with ANSI
119.2-1975/NFPA 501C-1974, “Standard for
Recreational Vehicles, Part III – Installation of
Electrical Systems.” The generator also must
have been installed in strict compliance with the
manufacturer’s detailed installation instructions.
After installation, do nothing that might render
the unit in noncompliance with such codes, stan-
dards and instructions.
Use this generator to supply electrical power for
operating 120-volt, single-phase, 60 Hertz, AC electri-
cal loads. These loads can require up to 3,600 watts
(3.6 kW) of power, but cannot exceed 30 AC amperes
of current at 120 volts.
Do not overload the generator. Some installa-
tions may require that electrical loads be alter-
nated to avoid overloading. Applying excessively
high electrical loads may damage the generator
and may shorten its life. Add up the rated watts
of all electrical lighting, appliance, tool and
motor loads the generator will power at one
time. This total should not be greater than the
wattage capacity of the generator. If an electri-
cal device nameplate gives only volts and amps,
multiply volts times amps to obtain watts (volts
x amps = watts). Some electric motors require
more watts of power (or amps of current) for
starting than for continuous operation.
1.3 SAFETY
Before attempting to use the generator set, care-
fully read the “Safety Rules” section of this manual.
Comply strictly with these rules to prevent accidents
and damage to equipment and/or property. We sug-
gest copying and posting the “Safety Rules” in poten-
tial hazard areas of the vehicle. Stress safety to all
operators and potential operators of this equipment.
1.4 GENERATOR AC
CONNECTION SYSTEM
This generator set is equipped with dual stator AC
power windings. These two-stator windings sup-
ply electrical power to customer electrical loads by
means of a two-wire connection system. Note, how-
ever, that the neutral is bonded to the frame of the
engine-generator.
The generator may have been installed so that it pow-
ers 120-volt AC loads (Figure 1.1). It can be wired to
connect 120-volt AC electrical loads. This procedure
should be done by an Authorized Service Dealer or
other qualified installer.
Figure 1.1 – Connections for 120 Volts Only
1.5 SPECIFICATIONS
1.5.1 FUEL REQUIREMENTS
This generator is equipped with a gasoline fuel sys-
tem. Depending on the installation, the generator may
have either a separate fuel tank, or it may “share” the
vehicle engine’s fuel tank.
NOTE:
Some installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter
than the vehicle engine’s pickup tube. Such an
arrangement causes the generator engine to “run
out of gas” while adequate fuel for the vehicle
remains in the tank.
To reduce lead and carbon deposits use high qual-
ity UNLEADED gasoline with the generator. Leaded
REGULAR grade gasoline is an acceptable substitute.
NOTE:
Using unleaded gasoline contributes to longer
engine valve life by reducing lead and carbon
deposits.
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6
Section 1 – General Information
Recreational Vehicle Generator
The manufacturer does not recommend using
any gasoline containing alcohol (such as “gaso-
hol”). If using any gasoline containing alcohol, it
must not contain more than 10 percent ethanol,
and it must be removed from the generator dur-
ing storage. Do NOT use any gasoline
containing methanol. If using gasoline with alco-
hol, inspect more frequently for fuel leaks and
other abnormalities.
1.5.2 FUEL CONSUMPTION
Model No Load 1/2 Load Full Load
004709-0 0.24 0.35 0.55
Fuel consumption is in gal/hr.
1.5.3 ENGINE OIL REQUIREMENTS
Use only high quality detergent oil rated with American
Petroleum Institute (API) Service Classification SF,
SG or SH. The recommended oil weights include the
following:
During summer months: SAE 30. An acceptable
substitute is SAE 10W-30.
During winter months: SAE 5W-30. DO NOT USE
SAE 10-W40.
Crankcase and oil filter capacity is approximately
800 mL or .84 U.S. quarts. Do NOT use special addi-
tives. See sections "Checking the Engine Oil Level"
and "Changing the Engine Oil and/or Oil Filter" for oil
level check and fill procedures.
1.5.4 ENGINE
Type of Engine................................... GN-220, Single-cylinder
Cooling Method ........................................................Air-cooled
Rated Horsepower .......................................7.8 @ 4,200 rpm
Displacement.................................................................. 220cc
Cylinder Block .........................Aluminum w/Cast Iron Sleeve
Type of Governor .............................Mechanical, Fixed Speed
Air Cleaner ........................Paper Element w/Foam Precleaner
Starter ....................................................... 12-volt DC Electric
Ignition System ..................... Solid-state w/Flywheel Magneto
Recommended Spark Plug
Champion ................................................................ RC14YC
AC.................................................................................. R45S
Fram Autolite .....................................................................65
Spark Plug Gap....................................... 0.030 inch (76 mm)
Recommended Minimum Battery..............400 Cold-cranking
Amperes
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1.5.5 GENERATOR
Rated Maximum Continuous
AC Output (Gasoline)...........................3,600 Watts (3.6 kW)
Rated Voltage....................................................... 120 Volts AC
Rated Maximum Continuous
AC Current (Gasoline) ....................................... 30 Amperes
Phase .............................................................................. Single
Rotor RPM.......................................................................3,600
Number of Rotor Poles...........................................................2
Engine RPM.....................................................................3,600
Rated AC Frequency....................................................... 60 Hz
Battery Charge Voltage ..........................................14 Volts DC
Battery Charge Current................................ 2 Amperes (max)
Gasoline weight .....................................................170 Pounds
Length....................................................749.8 mm (29.52 in.)
Width .....................................................483.1 mm (19.02 in.)
Height .................................................... 342.2 mm (13.47 in.)
* 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 above sea level; and will also decrease
about 1% for each 6° C (10° F) above 16° C (60° F) ambient temperature.
1.5.6 EMISSIONS COMPLIANCE PERIOD
For non-handheld engines the Emissions Compliance
Period referred to on the Emissions Compliance
Label indicates the number of operating hours for
which the engine has been shown to meet Federal
emission requirements.
For engines less than 225 cc displacement, Category
C=125 hours, B=250 hours, and A=500 hours.
For engines of 225 cc or more, Category C=250
hours, B=500 hours, and A=1000 hours.
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7
Section 2 – Operation
Recreational Vehicle Generator
2.1 GENERATOR CONTROL PANEL
The following features are mounted on the generator
control panel (Figure 2.1):
Figure 2.1 – Generator Control Panel
PRIME
FUEL
STOP
START 30A
C.B.
FUS E
CONTROL CENTER
7. 5 A
2.1.1 FUEL PRIMER
Before starting a cold engine (if it has not been
started in more than two weeks), press this switch
for approximately 10 to 15 seconds to bring fuel
from the tank to the carburetor. This rocker type
switch springs back into its original position when
released.
2.1.2 START/STOP SWITCH
To crank and start the engine, hold this switch in the
START position. Release the switch when the engine
starts. To stop an operating engine, press and hold
the switch in the STOP position until the engine shuts
off. The switch center position is the RUN position.
2.1.3 FUSE
The fuse protects the engine’s DC control circuit
against electrical overload. If the fuse element has
melted open due to overloading, the engine cannot
be cranked. If the fuse must be replaced, use only an
identical replacement.
2.1.4 MAIN BREAKER
The main breaker protects the generator’s AC output
circuit against overload and provides a method of
turning OFF the generator’s 120-volt AC output to the
vehicle circuits. This generator has 30-amp breaker.
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2.2 OPTIONAL REMOTE
START/STOP PANEL
A remote mounted Start/Stop Panel is available that
allows starting 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 generator
run lamp, a fuel prime switch, and an hourmeter.
The hourmeter provides a continuous indication of
engine/generator operating time. Use the hourmeter
for checking off periodic maintenance requirements
on the unit.
2.3 AUTOMATIC CHOKE
The engine is equipped with an automatic choke that
consists of two main components: a choke solenoid
and prechoke.
2.3.1 CHOKE SOLENOID
During engine cranking (Start/Stop switch at START),
a solid-state choke module signals the choke sole-
noid to activate and cycle (choke on/choke off) until
the engine starts. The choke solenoid thus opens
and closes the carburetor choke valve only when the
engine is cranking. When the engine starts, the choke
stops cycling.
2.3.2 PRECHOKE
The choke system also has a temperature-sensitive
metal strip that adjusts choke valve angle according
to ambient temperatures (i.e., in cold ambient tem-
peratures, choke valve closes more). Once the engine
starts, an element heats the temperature-sensitive
strip to a normal operating condition, opening the
choke valve. This may take about three minutes in
cooler weather.
2.4 BEFORE STARTING THE ENGINE
NOTE:
Instructions and information in this manual
assume the generator has been properly installed,
connected, serviced, tested and adjusted by a
qualified installation technician or installation
contractor.
2.4.1 INSTALLATION
Generator installation must have been properly com-
pleted so it complies with all applicable codes, stan-
dards and regulations and with the manufacturer's
recommendations.
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8
Section 2 – Operation
Recreational Vehicle Generator
2.4.2 ENGINE LUBRICATION
Have the engine crankcase properly serviced with the
recommended oil before starting. Refer to sections
"Engine Oil Requiremtents", "Checking the Engine Oil
Level" and "Changing the Engine Oil and/or Oil Filter"
for oil servicing procedures and recommendations.
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
2.4.3 FUEL SUPPLY
The engine must have an adequate supply of proper
fuel to operate. Before starting it, check that suffi-
cient fuel is available.
NOTE:
Depending on the installation, the generator may
have either a separate fuel tank, or it may “share”
the vehicle engine’s fuel tank.
2.4.4 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator com-
partment must be open and unobstructed for con-
tinued proper operation. Without sufficient cooling
and ventilating airflow, the engine/generator quickly
overheats, which causes it to shut down and may
damage the generator.
2.4.5 ENGINE EXHAUST GAS
Before starting the generator engine, be sure there is
no way for exhaust gases to enter the vehicle interior
and endanger people or animals. Close windows,
doors and other openings in the vehicle that, if open,
might permit exhaust gases to enter the vehicle.
DANGER
The generator engine releases DEADLY carbon
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient con-
centrations, 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 coher-
ently, (b) nausea, (c) vomiting, (d) twitching
muscles, (e) throbbing temples, (f) dizziness,
(g) headaches, (h) weakness, and (i) sleepiness.
IF EXPERIENCING ANY OF THESE SYMPTOMS,
MOVE INTO FRESH AIR IMMEDIATELY. IF
SYMPTOMS PERSIST, GET MEDICAL HELP. Shut
down the generator and do not operate it until
it has been inspected and repaired.




DANGER
Never sleep in the vehicle while the genset is
running unless the vehicle has a working carbon
monoxide detector. The exhaust system must be
installed in accordance with the genset installa-
tion manual. Make sure there is ample fresh air
when operating the genset in a confined area.
2.5 STARTING THE GENERATOR
NOTE:
Read the vehicle manufacturer’s instructions.
The owner/operator should become familiar with
the vehicle in which this generator is installed.
Differences exist between vehicles. For example,
some vehicles may use a transfer switch to isolate
dockside power from the generator, while other
vehicles may use an isolating receptacle. Some
vehicles may be equipped with a DC converter,
which allows the generator to power certain DC
lighting and other DC loads.
To start the generator from either the generator con-
trol panel or from the optional remote panel, proceed
as follows:
1. Turn OFF electrical loads using the means pro-
vided in the vehicle (such as a main line circuit
breaker or transfer switch).
NOTE:
If starting from the generator control panel, turn
OFF loads by setting the generator’s main circuit
breaker to the OFF (or open) position. If starting
from a remote panel, turn OFF loads using the
means provided in the vehicle (such as a main
circuit breaker). Electrical load circuits will be
turned ON after the generator has started, stabi-
lized and warmed up.
2. If the engine has not been started in more than
two weeks, press the Fuel Pump Primer switch
and hold it for about 10 to 15 seconds to prime
the fuel system. However, if the engine is warm,
skip Step 2.
3. Hold the engine Start/Stop switch in the START
position to crank the engine. Release the switch
when the engine starts.
If the engine does not start after it has been
cranking for 15 seconds, release the Start/Stop
switch, wait one minute and try again. Holding
the switch for longer than 15 seconds can dam-
age the starter motor.
4. Let the engine run at no-load for a few minutes to
stabilize and warm up.
5. Turn ON electrical loads using the means pro-
vided (such as a main circuit breaker or transfer
switch).

9
Section 2 – Operation
Recreational Vehicle Generator
2.6 STOPPING THE GENERATOR
1. Turn OFF all electrical loads using the means
provided (such as a main circuit breaker or
transfer switch).
2. Let generator run at no-load for a few minutes, to
stabilize internal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position.
2.7 APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator,
observe these guidelines:
Before applying electrical loads, let the generator
stabilize and warm up for a minute or two.
DO NOT overload the generator.
2.7.1 LETTING THE ENGINE STABILIZE
The generator supplies correct rated voltage only at
the proper governed speed. Some electrical appli-
ances may be extremely sensitive to voltage. Incorrect
voltages can damage such appliances.
If electrical loads are applied at reduced operating
speeds, such loads imposed on the engine when suf-
ficient power is not available may shorten engine life.
Never turn ON electrical loads until after the generator
engine has started and stabilized at no-load.
2.8 DO NOT OVERLOAD THE
GENERATOR
Read the rated wattage/amperage capacity of the
generator on the generator data label (see "Generator
Identification").
Applying electrical loads in excess of the unit’s rated
capacity will cause the engine/generator to automati-
cally shut down.
To avoid overloading, add up the wattage of all con-
nected electrical lighting, appliance, tool and motor
loads. This total should not be greater than the
generator’s rated wattage capacity.
Most lighting, appliance, tool and motor loads
indicate their required watts on their nameplate or
data plate. For light bulbs, simply note the wattage
rating of the bulb.
If a load does not show its rated wattage, multiply
that load’s rated VOLTS times AMPS to obtain
WATTS.
•
•

•
•
Induction type motors (such as those that run the
vehicle’s furnace fan, refrigerator, air conditioner,
etc.) need about 2-1/2 time more watts of power for
starting than for running (for a few seconds dur-
ing motor starting). Be sure to allow for this when
connecting electrical loads to the generator. First,
figure the watts needed to start electric motors in
the system. To that figure, add the running watt-
ages of other items that will be operated by the
generator.
Do not apply heavy electrical loads for the first two
or three hours of operation.
2.9 PROTECTION SYSTEMS
2.9.1 LOW OIL PRESSURE SWITCH
This switch (Figure 2.2) has normally closed (N.C.)
contacts that are held open by engine oil pressure dur-
ing cranking and operating. Should oil pressure drop
below a preset level, switch contacts close, and the
engine automatically shuts down. The unit should not
be restarted until oil is added.
2.9.2 HIGH TEMPERATURE SWITCH
This switch (Figure 2.2), which has normally open
(N.O.) contacts, is mounted near the oil filter. The
contacts close if the temperature should exceed
approximately 305º F (152º C), initiating an engine
shutdown.
Figure 2.2 – Low Oil Pressure and
High Temperature Switches
High Temperature Switch
Low Oil Pressure
Switch
•
•
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

10
Section 2 – Operation
Recreational Vehicle Generator
2.9.3 FIELD BOOST
The Controller Circuit Board houses a field boost
diode and resistor that are not part of the automatic
choke circuit. These two components are part of
a “field boost” circuit (Figure 2.3). During engine
cranking only, a positive DC (battery) voltage is
delivered through the diode, resistor, brushes and
slip rings, to the generator rotor. Application of this
voltage to the rotor “flashes the field” whenever it is
started. Flashing of the field each time the generator
starts makes sure that a sufficiently strong magnetic
field is available to produce “pickup” voltage in the
stator windings.
Figure 2.3 – Field Boost Circuit
2.9.4 OVERVOLTAGE PROTECTION
A solid-state voltage regulator (Figure 2.4) controls
the generator’s AC output voltage. This regulator sup-
plies an excitation current to the rotor. By regulating
the rotor’s excitation current, the strength of its mag-
netic field is regulated and, in turn, the voltage deliv-
ered to connected electrical loads is controlled. When
the AC frequency is 60 Hertz, voltage is regulated at
120 volts (voltage-to-frequency ratio is 2-to-1).
Figure 2.4 – Solid State Voltage Regulator


The voltage regulator also incorporates a “voltage
surge protection circuit.” This circuit prevents trou-
blesome surges in the generator AC output voltage.
Voltage surge is a common cause of damage to elec-
tronic equipment.
2.10 ADDITIONAL INFORMATION
2.10.1 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 an
Authorized Service Dealer thoroughly clean and dry
the generator.
2.10.2 OPERATION IN HIGH GRASS
OR BRUSH
Never operate the generator while the vehicle is
parked over high grass, weeds, brush, leaves or any
other combustible substance. Such materials can
ignite and burn from the heat of the exhaust system.
The generator exhaust system becomes extremely
hot during operation and remains hot for a long time
after it has shut down.
2.10.3 EFFECTS OF MOISTURE AND DIRT
Keep the generator set as clean and dry as possible.
Protect the unit against excessive dust, dirt, corrosive
vapors, road splash, etc. Permitting dirt and mois-
ture to accumulate on generator windings will have
an adverse effect on the insulation resistance of those
windings.
When moisture is allowed to remain in contact with
windings, some of the moisture will be retained in
voids and cracks in the insulation. This causes a
reduced insulation resistance and will eventually
cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with
windings. Salt (as from sea air) also will worsen the
problem since it tends to absorb moisture from the
air. Salt and moisture, when combined, form a good
electrical conductor.
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11
Section 3 – Maintenance
Recreational Vehicle Generator
3.1 CHECKING THE ENGINE OIL
LEVEL
For oil capacities and requirements, see “Engine Oil
Requirements”. Check the engine crankcase oil level
at least every eight hours of operation, or before each
use. To check the engine oil level, proceed as follows
(see Figure 3.1):
1. Be sure the generator is as level as possible.
2. Remove the dipstick and wipe it dry with a clean,
lint-free cloth.
3. Install and tighten the dipstick cap; then, remove
it again. The oil level should be at the dipstick
“Full” mark.
4. If necessary, remove the oil fill cap on the rocker
cover and slowly add oil until it reaches the dip-
stick “Full” mark. DO NOT FILL ABOVE THE
“FULL” MARK.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
5. Install and tighten the oil fill cap and the dipstick
before operating the engine.
3.2 CHANGING THE ENGINE OIL
AND/OR OIL FILTER
Change the engine oil after the first 25 hours of
operation. Thereafter, change the oil every 100
operating hours. Change the oil more frequently if
operating consistently under heavy load or at high
ambient temperatures.
•
Change the engine oil filter after the first 25 hours
of operation, and every 100 operating hours there-
after.
To change the oil and/or oil filter, proceed as fol-
lows (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 the
oil drain cover free of the base. Remove the plug
from the tube with a 5/16” allen wrench and drain
the oil into a suitable container. Loosening the oil
fill cap will allow the crankcase to drain faster.
3. After the oil has drained, replace the plug onto the
end of the oil drain tube. Retain the cover in the
base.
4. With the oil drained, remove the old oil filter by
turning it counterclockwise. Place a towel under-
neath to catch excess oil.
5. Apply a light coating of clean engine oil to the gas-
ket of the new filter. Fill the filter until saturated
with clean oil.
6. Screw the new filter on by hand until its gasket
lightly contacts the oil filter adapter. Then, tighten
the filter an additional 3/4 to one turn.
7. Remove the dipstick and wipe it dry with a clean,
lint-free cloth. This will be used later to check the
oil level.
8. Remove the oil fill cap on the oil fill tube and
slowly add the proper type and amount of rec-
ommended oil (see “Engine Oil Requirements”).
Periodically use the dipstick to check the oil level
and continue to fill the crankcase until the oil
reaches the dipstick “Full” mark. DO NOT FILL
ABOVE THE “FULL” MARK.
9. Install and tighten the oil fill cap and the dipstick
before operating the engine.
10. Start the engine and check for leaks.
•
•
GENERAC OHVI INDUSTRIAL ENGINE
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GENERAC
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RV SERVICE LOCATOR:
1.800.333.1322
QUIETPACT 40G
*
SERVICE ACCESS PANEL
OIL LEVEL: CHECK DAILY
AIR FILTER: CLEANPREFILTER
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 & CLEANSPARK PLUGS:
REPLACEMENT INFORMATION
*
PERFORMMORE 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: CHANGEEVERY 400
HOURS. (OR ANNUALLY)
*
*
PRIME
FUEL
STOP
START 30A
C.B .
A
FUSE
CONTROL CENTER
7.5
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Oil Dipstick/Oil Fill Oil Drain Oil Filter
Figure 3.1 – Oil Maintenance Features

12
Section 3 – Maintenance
Recreational Vehicle Generator
NOTE:
Check the oil level and fill to the “FULL” mark
after checking for leaks. The filter will retain some
oil.
3.3 MAINTAINING THE ENGINE
AIR CLEANER
3.3.1 CLEANING THE FOAM PRECLEANER
Clean and re-oil the foam precleaner every three
months or every 25 hours of operation, whichever
occurs first. Service the foam precleaner more fre-
quently if operating the generator in extremely dusty
or dirty conditions. Use the following procedure
(Figure 3.2):
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover, foam precleaner and paper filter.
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 remove
excess oil and to distribute oil (DO NOT TWIST).
7. Install the foam precleaner into the cover, fol-
lowed by the paper filter.
8. Install the cover, foam precleaner and paper filter.
9. Tighten the two screws to retain the filter in place.
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 paper
filter. The new replacement filter must be flame
retardant. Service the paper filter more frequently 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 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 a
new one. Dispose of the old filter properly.
4. Clean the air cleaner cover then reassemble fol-
lowing steps 7-9 in section "Cleaning the Foam
Precleaner".
3.4 CLEAN AIR INTAKE
Clean all foreign material from the air intake (Figure
3.3) at least once every 100 hours of operation. Clean
more 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
USTC
USTC
3.5 CHECKING THE ENGINE
SPARK PLUG
Clean the spark plug and reset the spark plug gap
every 100 hours of operation.
1. Clean the area around the base of the spark plug
to keep dirt and debris out of the engine. Remove
the spark plug and check the condition. Replace
the spark plug if worn or if reuse is question-
able.
2. Clean spark plug by scraping or washing using a
wire brush and commercial solvent. Do not blast
the spark plug to clean.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.030 inch (0.76 mm)
by carefully bending the ground electrode (Figure
3.4).

Section 3 – Maintenance
Recreational Vehicle Generator
Figure 3.4 – Setting the Spark Plug Gap
Sparking can occur if the wire terminal does not
fit firmly on the spark plug terminal end. If nec-
essary, re-form the wire terminal to obtain a
tight fit.
3.6 FUEL FILTER
Remove and replace the fuel filter (Figure 3.5) once
each year or every 400 hours of operation, whichever
comes first. Fuel filter is removed with a 15/16” deep
well socket.
Figure 3.5 – Fuel Filter
NEG
FUEL
POS
3.7 CLEAN SPARK ARRESTOR
The engine exhaust muffler has a spark arrestor
screen. Inspect and clean the screen every 50 hours
of operation or once each year, whichever comes
first.
NOTE:
If using the generator on any forest-covered,
brush-covered or grass-covered unimproved land,
it must equipped with a spark arrestor. The spark
arrestor must be maintained in good condition by
the owner/operator.
Clean and inspect the spark arrestor as follows:
Remove the screen retaining bracket by removing
the screw.
Slide the spark arrestor screen out from the tail
pipe.
Inspect screen and replace if torn, perforated or
otherwise damaged. DO NOT USE a defective
screen. If screen is not damaged, clean it with com-
mercial solvent.
Replace the screen and the retaining bracket.
Figure 3.6 - Spark Arrestor
RETAINING
SCREW P/N 056892
SPARK ARRRESTOR
SCREEN P/N 089680
TAILPIPE
P/N 0E0683
3.8 CLEANING THE GENERATOR
Keep the generator set as clean and dry as possible.
Protect the unit against excessive dust, dirt, corrosive
vapors, road splash, etc. Permitting dirt and mois-
ture to accumulate on generator windings will have
an adverse effect on the insulation resistance of those
windings.
When moisture is allowed to remain in contact with
windings, some of the moisture will be retained in
voids and cracks in the insulation. This causes a
reduced insulation resistance and will eventually
cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with
windings. Salt (as from sea air) also will worsen the
problem since it tends to absorb moisture from the
air. Salt and moisture, when combined, form a good
electrical conductor which can be damaging to the
generator windings.
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
interior and cause problems, and may also con-
taminate the generator fuel system.
•
•
•
•
13

14
3.9 BATTERY MAINTENANCE
All lead-acid batteries will discharge when not in
use. The generator battery should be inspected as
follows:
3.9.1 WEEKLY
Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
Check the battery fluid level of unsealed batteries
and, if necessary, fill with Distilled Water Only. Do
not use tap water in batteries.
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 or
supervised by personnel knowledgeable of batter-
ies and the required precautions. Keep unauthor-
ized personnel away from batteries.
Damage will result if the battery connections are
made in reverse.
DANGER
Do not dispose of the battery in a fire. The
battery is capable of exploding. Storage batter-
ies give off explosive hydrogen gas. This gas can
form an explosive mixture around the battery
for several hours after charging. The slightest
spark can ignite the gas and cause an explo-
sion. Such an explosion can shatter the battery
and cause blindness or other injury. Any area
that houses a storage battery must be properly
ventilated. Do not allow smoking, open flame,
sparks, or any spark producing tools or equip-
ment near the battery. Discharge static electric-
ity from body before touching the battery by
first touching a grounded metal surface.
A battery presents a risk of electrical shock
and high short circuit current. The following pre-
cautions are to be observed when working on
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 battery
has discharged, remove it for recharging.

•
•

•
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following
procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or water. The bicar-
bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
3.10 MAJOR SERVICE MANUAL
To obtain a service manual for the generator, contact
the nearest Authorized Service Dealer. Make sure to
identify the MODEL NUMBER and SERIES.
3.11 EXERCISING THE GENERATOR
The manufacturer recommends that the generator be
started and operated 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 SERVICE
If the generator cannot be exercised 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 deposits
from forming in the engine’s fuel system.
3. While the engine is still warm from running, drain
the oil completely. Refill the crankcase with SAE
10W-30 oil having API classification “For Service
SF.”

Section 3 – Maintenance
Recreational Vehicle Generator

15
4. Attach a tag to the engine indicating the viscosity
and classification of the oil in the crankcase.
5. Remove the spark plug and pour two or three
tablespoons of clean, fresh engine oil into the
spark plug threaded openings. Reinstall and
tighten the spark plug.
6. Remove the battery and store it in a cool, dry
room on a wooden board. Never store the battery
on any concrete or earthen floor.
7. Clean and wipe the entire generator.
3.12.2 RETURN TO SERVICE
To return the unit to service after storage, proceed
as follows:
1. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recom-
mended oil is used in the engine (see "Engine Oil
Requirements"). If necessary, drain and refill with
the proper oil.
2. Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with dis-
tilled water. DO NOT USE TAP WATER IN THE
BATTERY. Recharge the battery to 100 percent
state of charge, or, if defective, replace the battery.
3. Clean and wipe the entire generator.
4. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected
incorrectly.
5. Turn OFF all electrical loads. Add fuel if neces-
sary and then start the engine.
6. Allow the unit to run for several minutes to warm
up.
7. Apply electrical loads to at least 50 percent of the
unit’s rated wattage capacity.
8. When the engine is thoroughly warmed up, shut
it down.
9. The generator is now ready for service.
3.13 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, adjust the valve
clearance in the engine.
When adjusting valve clearance, the engine should be
at room temperature and the piston should be at Top
Dead Center (TDC) of its compression stroke (both
valves closed). Correct clearance is 0.001-0.003 inch
(0.03-0.07mm). Adjust valve clearance as follows:
1. Loosen the rocker arm jam nut. Use an allen
wrench to turn the pivot ball stud while checking
clearance between the rocker arm and the valve
stem with a feeler gauge (Figure 3.7).

Figure 3.7 — Adjusting Valve Clearance
FEELER GAUGE
ALLEN WRENCH
2. When valve clearance is correct, hold the pivot
ball stud with the allen wrench and tighten the
rocker arm jam nut with a crows foot. Tighten
the jam nut to 65-85 inch-pounds torque. After
tightening the jam nut, recheck valve 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
100 Hours.................................. Clean Air Pre-filter
100 Hours................................ Inspect Spark Plugs
250 Hours............ Replace Paper Air Filter Element
400 Hours...................................Replace Fuel Filter
500 Hours................................Replace Spark Plugs
1st 50 Hours-then
every 500 Hrs. .......................... Adjust Valve Lash
Section 3 – Maintenance
Recreational Vehicle Generator

16
Section 4 – Notes
Recreational Vehicle Generator

PART II –
INSTALLATION
INSTRUCTIONS
DANGER
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!

18
NOTICE TO INSTALLER
These Installation Instructions have been published
by the manufacturer to aid in the installation of the
products described in this manual. The manufac-
turer assumes that installation personnel are familiar
with the procedures for installing such products, or
similar products manufactured. The manufacturer
also assumes that personnel have been trained in
the recommended installation procedures for these
products and that such training includes (a) use of
common hand tools, (b) use of special tools, and (c)
use of any tools and/or equipment from other sup-
pliers.
The manufacturer cannot possibly know of and
advise the recreational vehicle trade of all conceiv-
able methods, procedures or techniques by which to
perform an installation. Nor can we anticipate every
possible hazard that might result from each installa-
tion method, procedure or technique. The manufac-
turer has not undertaken any such wide evaluation.
Therefore, people who use a method, procedure or
technique that the manufacturer does not specifically
recommend must first completely satisfy themselves
that their safety, the safety of the vehicle's occupants
and the product's safety is not endangered by the
method, procedure or technique selected.
Information, illustrations, specifications, etc., con-
tained in these Installation Instructions are based on
the latest information available at the time of publica-
tion. Every effort has been expended to be sure that
such data is both accurate and current. However, the
manufacturer reserves the right to change, alter or
otherwise improve this product at any time without
prior notice.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
GENERAL HAZARDS 
For safety reasons, the manufacturer recommends
that the installation, initial start-up and main-
tenance of this equipment is carried out by an
Authorized Service Dealer.
The engine exhaust fumes contain carbon monox-
ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust
system must be installed properly, in strict com-
pliance with applicable codes and standards.
Following installation, do nothing that might ren-
der the system unsafe or in noncompliance with
such codes and standards. The generator com-
partment must be completely vapor sealed from
the vehicle interior. There must be no possibility of
exhaust fumes entering the vehicle interior. Never
operate this equipment with a leaking or defective
exhaust system.
Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
Adequate, unobstructed flow of cooling and ven-
tilating air is critical to correct generator opera-
tion 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 ventilation provi-
sions, as this can seriously affect safe operation of
the generator.
When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
Before performing any maintenance on the gen-
erator, disconnect 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 dangerous operating con-
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
Never insert any tool or other object through open-
ings in the generator interior, even if the unit is not
running. Serious injury or damage to the equip-
ment may occur.
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Safety Rules
Recreational Vehicle Generator
DANGER: For fire safety, installation of a generator into a recreational vehicle must comply
strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard
for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation
must comply with the manufacturer’s instructions and recommendations.
