Page 2 - INTRODUCTION; READ THIS MANUAL THOROUGHLY; This symbol points out potential explosion hazard.; CONTENTS; AUTHORIZED SERVICE; To locate the GENERAC AUTHORIZED SERVICE
Generac ® Power Systems, Inc. INTRODUCTION Thank 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 THOROUGHLY If you do not understand any portion of th...
Page 3 - Table of Contents; QUIETPACT 40G Recreational Vehicle Generator; Part I – Owner’s Manual
Table of Contents QUIETPACT 40G Recreational Vehicle Generator Generac ® Power Systems, Inc. 1 Part I – Owner’s Manual Introduction ......................................Inside Front Cover Read This Manual Thoroughly ....................................IFCContents ......................................
Page 4 - GENERAL HAZARDS; • For safety reasons, Generac recommends; DANGER
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 a...
Page 5 - ELECTRICAL HAZARDS; Safety Rules
Generac ® Power Systems, Inc. 3 • When working on this equipment, remain alert at all times. Never work on the equipment when youare physically or mentally fatigued. • Inspect the generator regularly, and contact your nearest Generac Authorized Service Dealer immedi-ately for parts needing repair or...
Page 6 - Section 1 – General Information; IDENTIFICATION
4 Generac ® Power Systems, Inc. 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 Inlet 10. Fuel Pump (Behind Access Panel)11. Fuel Filt...
Page 7 - GENERATOR APPLICABILITY; Figure 1.1 – Connections for 120 Volts Only
Generac ® Power Systems, Inc. 5 Section 1 – General Information QUIETPACT 40G Recreational Vehicle Generator 1.2 GENERATOR APPLICABILITY These generators have been designed and manufac-tured for supplying electrical power for recreationalvehicles. You should not modify the generator or useit for any...
Page 8 - • During summer months: SAE 30. An acceptable; Amperes; • For engines less than 225 cc displacement,
6 Generac ® Power Systems, Inc. Section 1 – General Information QUIETPACT 40G Recreational Vehicle Generator 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...
Page 9 - Section 2 – Operation; GENERATOR CONTROL PANEL; Figure 2.1 – Generator Control Panel; REMOTE
Generac ® Power Systems, Inc. 7 Section 2 – Operation QUIETPACT 40G Recreational Vehicle Generator 2.1 GENERATOR CONTROL PANEL The following features are mounted on the generatorcontrol panel (Figure 2.1): Figure 2.1 – Generator Control Panel 2.1.1 FUEL PRIMER Before starting a cold engine (if it ha...
Page 10 - THE
8 Generac ® Power Systems, Inc. Section 2 – Operation QUIETPACT 40G Recreational Vehicle Generator 2.4.2 ENGINE LUBRICATION Have 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 proced...
Page 11 - Figure 2.2 – Low Oil Pressure and
Generac ® Power Systems, Inc. 9 Section 2 – Operation QUIETPACT 40G Recreational Vehicle Generator 2.6 STOPPING THE GENERATOR 1. 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, to stabilize ...
Page 12 - Figure 2.3 – Field Boost Circuit; ADDITIONAL INFORMATION; • Run the unit at varying electrical loads to help seat; AFTER SUBMERSION; MUST NOT
10 Generac ® Power Systems, Inc. Section 2 – Operation QUIETPACT 40G Recreational Vehicle Generator 2.9.3 FIELD BOOST The 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...
Page 13 - Section 3 – Maintenance; OR BRUSH; If necessary, remove the oil fill cap on the rocker; CHANGING THE ENGINE OIL; • Change the; Oil Dipstick/Oil Fill; Figure 3.1 – Oil Maintenance Features
Generac ® Power Systems, Inc. 11 Section 3 – Maintenance QUIETPACT 40G Recreational Vehicle Generator 2.10.4 OPERATION IN HIGH GRASS OR BRUSH Never operate the generator while the vehicle isparked over high grass, weeds, brush, leaves or anyother combustible substance. Such materials canignite and b...
Page 14 - oil filter; MAINTAINING THE ENGINE; Figure 3.2 – Engine Air Cleaner; THE PAPER FILTER
12 Generac ® Power Systems, Inc. Section 3 – Maintenance QUIETPACT 40G Recreational Vehicle Generator • 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 follows (see Figure 3.1): 1. Run the ...
Page 15 - Figure 3.3 – Cleaning Air Intake; Clean and inspect the spark arrestor as follows:
Section 3 – Maintenance QUIETPACT 40G Recreational Vehicle Generator 3.4 CLEAN AIR INTAKE Clean 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 remov...
Page 16 - • Inspect the battery posts and cables for tightness
14 Generac ® Power Systems, Inc. 3.8 CLEANING THE GENERATOR Keep 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 insula...
Page 17 - MAJOR SERVICE MANUAL; Figure 3.7 — Adjusting Valve Clearance
Generac ® Power Systems, Inc. 15 3.10 MAJOR SERVICE MANUAL To 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 GENERATOR Generac recommends t...
Page 18 - When valve clearance is correct, hold the pivot; Figure 3.8 — Tightening Jam Nut; RV GENERATOR SERVICE
16 Generac ® Power Systems, Inc. 2. When valve clearance is correct, hold the pivot ball 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 chang...
Page 19 - ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!! DANGER
Page 20 - NOTICE TO INSTALLER; Installation Instructions
18 Generac ® Power Systems, Inc. NOTICE TO INSTALLER These Installation Instructions have been published by 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 simila...
Page 22 - Figure 1.1 – 120-volt Single Voltage Connection
20 Generac ® Power Systems, Inc. 1.1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installersand owners of the applicable equipment with theproduct's installation requirements. Give seriousconsideration to all informati...
Page 23 - IEW FR
Generac ® Power Systems, Inc. 21 Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-C) Section 1 – General Information QUIETPACT 40G Recreational Vehicle Generator b y Generac Power S y stems Inc. GU ARDIAN 7 4 9 .8 3 42.2 483 .1 H O T AI R E XHA US T TAIL P IPE EXIT O IL DRAIN AIR INTAK...
Page 24 - Figure 2.1 – Typical Horizontal Support Frame; Section 2 – Installation
22 Generac ® Power Systems, Inc. 2.1 LOCATION AND SUPPORT 2.1.1 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. Man...
Page 25 - Figure 2.3 – Typical Generator Restraint; COMPARTMENTS; Figure 2.4 – Clearances; • The generator compartment should be either con-; Figure 2.5 – Typical Compartment Construction; • If constructing a compartment, line the exterior
Generac ® Power Systems, Inc. 23 2.1.4 GENERATOR RESTRAINT Use four 3/8"-16 hardened steel bolts (Grade 5) to fas-ten the generator to the supporting frame or the sup-port tubing. These bolts must pass through (a) the gen-erator mounting base, (b) the compartment floor (if acompartment is used) ...
Page 26 - Figure 2.6 – Types of Lock Seams
24 Generac ® Power Systems, Inc. • If flexible metal conduit is used, it must be sealed internally 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 joi...
Page 27 - Figure 2.7 – Typical Noise Abatement; VIEW FROM TOP
Generac ® Power Systems, Inc. 25 Figure 2.7 – Typical Noise Abatement 2.2.5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compart-ment for the following items (Figure 1.2, page 21): • Engine exhaust and cooling air outlets• Generator cooling air inlet• Four holes for passage o...
Page 28 - COOLING AND VENTILATING AIR; Figure 2.9 – Airflow Through Engine/Generator; FUEL; Figure 2.10 – Generator Fuel System
26 Generac ® Power Systems, Inc. 2.3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of airfor cooling, ventilating and engine combustion besupplied to the generator set. Without sufficient air-flow, the engine/generator quickly overheats. Suchoverheating can cause serio...
Page 29 - SYSTEM
Generac ® Power Systems, Inc. 27 2.4.1 FUEL TANK Either the generator must share the vehicle engine'sfuel tank, or you must install a separate fuel tank forthe generator set. All fuel tanks installed on the vehi-cle must be constructed, installed and restrained sothey comply with applicable codes, s...
Page 30 - Figure 2.12 — Spark Arrestor Installation; CONNECTIONS
28 Generac ® Power Systems, Inc. 2.5.1 SPARK ARRESTOR This spark arrestor assembly meets code and stan-dard requirements of the U.S. Forest Service. Useonly mufflers and parts approved by Generac. Anyperson(s) installing an unapproved muffler, or anunapproved exhaust system part, or modifying anexha...
Page 31 - Figure 2.13 – Generator AC Output Leads
Generac ® Power Systems, Inc. 29 • Wiring must be of adequate size, have approved insulative qualities and be properly supported. • Conduit and wire openings into the generator com- partment (if used) must be vapor-sealed to prevententry of flammable, explosive or poisonous gasesinto the vehicle. 2....
Page 32 - SOURCES; Figure 2.14 – Transfer Switch Isolation Method
30 Generac ® Power Systems, Inc. 2.6.5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate ina double-pole, double-throw transfer switch (Figure2.14). An alternate method for isolating differentpower sources is by using an isolating receptacle(Figure 2.15). Whichever m...
Page 33 - INTERRUPTERS; INSTALLATION; Figure 2.16 – Connecting Battery Cables; ACCESSORIES; Figure 2.17 – Remote Panel Plug-in Receptacle; FUNCTION
Generac ® Power Systems, Inc. 31 2.6.7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code (NFPA 70, 551-7)requires that you install ground fault circuit inter-rupters (GFCIs) on all external and some internalelectrical receptacles. Contact your manufacturer ordealer for recommendations. ...
Page 34 - Figure 2.18 – Optional Remote Panel; Section 3 – Post-Installation Start-up Adjustments
32 Generac ® Power Systems, Inc. 2.8.1 REMOTE START/STOP PANEL A remote mounted Start/Stop panel (Figure 2.18) isavailable that allows the user to start and stop thegenerator engine conveniently from inside the vehicle.The remote panel includes a Start/Stop switch,hourmeter, generator run lamp and a...
Page 35 - Section 3 – Post-installation Start-up Adjustments; CHECKLIST
Generac ® Power Systems, Inc. 33 Section 3 – Post-installation Start-up Adjustments QUIETPACT 40G Recreational Vehicle Generator 3.5 INSTALLATION CHECKLIST LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GENERATOR COMPARTME...
Page 36 - Appendix 1 – Notes
34 Generac ® Power Systems, Inc. Appendix 1 – Notes QUIETPACT 40G Recreational Vehicle Generator
Page 37 - Appendix 2 – Troubleshooting; TROUBLESHOOTING GUIDE; PROBLEM
Generac ® Power Systems, Inc. 35 Appendix 2 – Troubleshooting QUIETPACT 40G Recreational Vehicle Generator TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION The engine will not crank. 1. Fuse blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary...
Page 38 - Appendix 3 — Electrical Data
4 6 6 4 5 5 1 5 5 8 8 7 7 1 1 A 1 A BATTERY CHARGE WINDING 120V 30A DPE WINDING VOLTAGE REGULATOR POWER WINDING ELECTRONIC BY CUSTOMER NEUTRAL CONNECTION WHITE T2 GREEN 0F FIELD CB3 0N 0K 2 2A 22P 44 22S 0N 0N R1 55 4 BLACK 6 4 T1 4 11S CB1 11P 33 HM START STOP 4 L1 16 BATTERY 14 15 77 BCR 66 J1-14 ...
Page 40 - TO CARB; Appendix 4 — Exploded Views and Parts Lists
38 Generac ® Power Systems, Inc. 22 39 23 20 21 24 11 12 43 41 2 21 3 29 28 27 21 1 9 8 10 21 6 7 21 26 25 36 37 4 5 16 55 34 33 31 29 19 30 22 23 24 42 42 47 45 46 59 44 13 38 49 50 17 21 21 21 15 TO CARB 51 18 14 52 21 53 54 29 21 40 56 57 58 Appendix 4 — Exploded Views and Parts Lists QUIETPACT 4...
Page 41 - ITEM
Generac ® Power Systems, Inc. 39 ITEM PART NO. QTY. DESCRIPTION 1 0D6822 1 TRAY, ENCLOSURE 2 0D6942 1 PANEL, ENCLOSURE SIDE 3 0D6939 1 PANEL, REAR DIVIDER 4 0D6943 1 PANEL, ENCLOSURE ROOF 5 0D6941 1 PANEL, ENCLOSURE BACK 6 0D6940 1 PANEL, FRONT DIVIDER 7 0D6945 1 COMPARTMENT, AIR INTAKE 8 0D6944 1 P...
Page 47 - DESCRIPTION
Generac ® Power Systems, Inc. 45 Appendix 4 — Exploded Views and Parts Lists QUIETPACT 40G Recreational Vehicle Generator GN-220 H/SH Engine – Drawing No. 0D8355-C Part 1 ITEM PART NO. QTY. DESCRIPTION 1 0D8433 1 GUARD, FAN 2 0C1069 10 SCREW, HHTT M6-1.0 X 8MM 3 090695F 1 BLOWER HOUSING 4 081810 1 N...
Page 50 - CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT
48 Generac ® Power Systems, Inc. CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together withGenerac Power Systems, Inc. (Generac), are pleased to e...
Page 51 - EMISSION CONTROL SYSTEM WARRANTY; to their respective authority, and; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:; Appendix 5 – Warranty
Generac ® Power Systems, Inc. 49 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine o...
Page 52 - GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY; RV
Part No. 0D8351 Revision C (08/07/02) Printed in U.S.A. Appendix 5 – Warranty QUIETPACT 40G Recreational Vehicle Generator GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. ...
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