Generac 005852-0 User Manual
Models: 004709-0,
005852-0
Owner's Manual and
Installation Instructions
This manual should remain with the unit.
Air-cooled Recreational
Vehicle Generators
Quietpact 40G
Table of Contents
Part – Owner’s Manual
Introduction .............................................................................1
Read This Manual Thoroughly .........................................................1
Contents .........................................................................................1
Operation and Maintenance .............................................................1
How to Obtain Service ....................................................................1
Authorized Service Dealer Locator Number ...........................................1
Safety Rules ...........................................................................2
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
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 ...........................................................8
2.7 Applying Loads to Generator ...................................................8
2.8 Do Not Overload the Generator ................................................9
2.9 Protection Systems .................................................................9
2.10 Additional Information ...........................................................10
Maintenance ......................................................................... 10
3.1 Checking the Engine Oil Level................................................10
3.2 Changing the Engine Oil and/or Oil Filter ................................ 10
3.3 Maintaining the Engine Air Cleaner ........................................11
3.4 Clean Air Intake .....................................................................12
3.5 Checking the Engine Spark Plug ............................................ 12
3.6 Fuel Filter ..............................................................................12
3.7 Clean 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 ..................................................... 14
3.14 RV Generator Service Interval ................................................ 15
Notes ....................................................................................16
Part II – Installation Instructions
Safety Rules .........................................................................18
Notice to Installer .............................................................................. 18
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
Installation ............................................................................ 22
2.1 Location and Support............................................................ 22
2.2 Generator Compartments ...................................................... 23
2.3 Cooling and Ventilating Air ..................................................... 26
2.4 Gasoline Fuel System ............................................................26
2.5 Exhaust System........ ............................................................27
2.6 Electrical Connections ...........................................................28
2.7 Battery Installation... .............................................................29
2.8 Optional Accessories ............................................................31
Post-installation Start-up Adjustments .................................32
3.1 Post Installation Tests ............................................................32
3.2 Before Initial Start-up ............................................................32
3.3 Initial Start ............................................................................32
3.4 Testing Under Load ...............................................................32
3.5 Installation Checklist .............................................................33
Troubleshooting .................................................................... 34
Troubleshooting Guide .......................................................................34
Notes ....................................................................................35
Electrical Data ...................................................................... 36
Exploded Views and Parts Lists ............................................38
Warranty ............................................................................... 48
Introduction
INTRODUCTION
Thank you for purchasing this model by Generac Power Systems
Inc. This model is designed and manufactured to supply electrical
power for recreational vehicles.
READ T HIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact 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 personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:
Indicates a hazardous situation or action which, if
not avoided, will result in death or serious injury.
Indicates a hazardous situation or action which,
if not avoided, could result in death or serious
injury.
Indicates a hazardous situation or action which,
if not avoided, could result in minor or moderate
injury.
NOTE:
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the action or service are essential to
preventing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
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 recommend that the operator read this manual and
thoroughly 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.
C ONTENTS
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 necessary 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. ______________
This symbol points out important safety
n
information that, if not followed, could
endanger personal 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.
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
1
Safety Rules
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
n
all operators and potential operators of this equipment.
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 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 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.
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
n
ing 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 run-
n
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) 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 running 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 monoxide, 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 compliance
with applicable codes and standards. Following installation, do
nothing that might render the system unsafe or in noncompliance with such codes and standards. The generator compartment 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 ventilation 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 replacement.
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 dangerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage, etc.
2
Safety Rules
ELECTRICAL HAZARDS
The generator covered by this manual produces dangerous •
electrical voltages and can cause fatal electrical shock. Avoid
contact with bare wires, terminals, 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 stand-•
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
During installation onto the vehicle, have the generator prop-•
erly 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 conductor to any generator part
that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a
flexible conductor that is of No. 8 American Wire Gauge (AWG)
copper wire minimum.
In case of accident caused by electric shock, immediately •
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
implement, such as a rope or board, to free the victim 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 electric shock, or may get
caught in moving components causing injury.
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 installation, do nothing that might alter a safe installation and render the unit in
noncompliance with the aforementioned codes, standards,
laws and regulations.
Keep a fire extinguisher in the vehicle at all times. Extinguishers •
rated “ABC” by the National Fire Protection Association are
appropriate for use on the recreational vehicle generator electrical
system. Keep the extinguisher properly charged and be familiar
with its use. If 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 combustible materials are left in the
generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding 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
governing the storage and handling of gasoline.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
3
I
t
r
e
,
e
w
a
W
*
SERVICE ACCESS PANEL
OIL LEVEL: 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 & CLEANSPARK PLUGS:
REPLACEMENT INFORMATION
*
PERFORM MORE OFTEN IN DUSTY CONDITIONS
AIR FILTER LOCATED BEHIND PANEL.
MAINTENANCE SCHEDULE
AIR FILTER P/N: 0D3262
070185OIL FILTER P/N:
SPARK PLUG P/N: 072347
OIL CAPACITY WITH FILTER:
0.8L/0.84QT
TEMPERATURE SAE VISCOSITY
32°F AND HIGHER
10°F TO 100°F
0°F TO 80°F
-20°F TO 50°F 5W-30
10W-30
15W-40
30
WHEN SERVICE OR PARTS ARE NEEDED IN
THE USA OR CANADA, CONTACT THE GENERAC
SERVICE LOCATOR AT 1-800-333-1322.
HOURS. (OR ANNUALLY)
PREFILTER P/N: 0D4511
FUEL FILTER P/N: 0D7515
FUEL FILTER: CHANGE EVERY 400
HOURS. (OR ANNUALLY)
*
*
PRIME
FUEL
STOP
START
30A
C.B.
15A
FUSE
CONTROL CENTER
1
2
3
7
6
10/15
17
8
14,16
13
12
4
18
5
9/11
General Information
1.1 GENERATOR IDENTIFICATION
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 _________________
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 Evaporative Port (model 004709-0 only)
4
General Information
1.2 GENERATOR APPLICABILITY
These generators have been designed and manufactured 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.
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, standards and instructions.
Use this generator to supply electrical power for operating 120-volt,
single-phase, 60 Hertz, AC electrical loads. These loads can require
up to 3,600 watts (3.6 kW) of power, but cannot exceed 30 AC
amperes of current at 120 volts.
Do not overload the generator. Some installations may require that electrical loads be
n
alternated 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 electrical
device nameplate gives only volts and amps,
multiply volts times amps to obtain watts
(volts x amps = watts). Some electric motors
require more watts of power (or amps of current) for starting than for continuous operation.
1.3 SAFETY
Before attempting to use the generator set, carefully read the
“Safety Rules” section of this manual. Comply strictly with these
rules to prevent accidents and damage to equipment and/or
property. We suggest copying and posting the “Safety Rules” in
potential 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 supply electrical power to customer
electrical loads by means of a two-wire connection system. Note,
however, that the neutral is bonded to the frame of the enginegenerator.
The generator may have been installed so that it powers 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 system. Depending
on the installation, the generator may have either a separate fuel
tank, or it may “share” the vehicle engine’s fuel tank.
NOTE:
Some installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine’s
pickup tube. Such an arrangement causes the generator engine
to “run out of gas” while adequate fuel for the vehicle remains
in the tank.
To reduce lead and carbon deposits use high quality 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.
5
General Information
The manufacturer does not recommend
n
using any gasoline containing alcohol (such
as “gasohol”). If using any gasoline containing alcohol, it must not contain more than
10 percent ethanol, and it must be removed
from the generator during storage. Do NOT
use any gasoline containing methanol. If
using gasoline with alcohol, 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 additives. See sections "Checking
the Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter"
for oil level check and fill procedures.
1.5.5 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.
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
6
1.5.7 EVAPORATIVE EMISSIONS INFORMATION
This generator is subject to evaporative emission standards which
have been implemented by the California Air Resource Board
(CARB) and the Environmental Protection Agency (EPA). If this
generator is offered for sale in the state of California, it must be
covered by a CARB evaporative Executive Order. If this generator
is offered for sale to the final consumer in any other state, certified
low-permeation fuel line must be used to supply fuel to the generator as required by EPA.
Anyone who installs or configures a fuel system to supply this
generator with gasoline is required to comply with all applicable
evaporative emission regulations. If this generator is configured
such that it shares the primary fuel system of a vehicle in which it
is installed, reduced certification requirements may apply. See the
CARB guidance document MAC 05-05, located at http://www.arb.
ca.gov/msprog/macs/mac0505/mac0505.pdf for further details. If
this generator is installed such that it uses a dedicated fuel system,
detailed evaporative emission requirements apply; contact a reputable fuel system manufacturer to purchase a complete fuel system certified for use with this generator, or consult the California
Code of Regulations if you wish to obtain certification on your
own. See the installation instructions in this manual for connecting
fuel system vapor lines to the engine.
PRIME
FUEL
STOP
START
30A
C.B.
FUSE
CONTROL CENTER
7. 5 A
Operation
This generator is not legal for sale in the state of California unless
all CARB evaporative emission requirements are adhered to, and
is not legal for sale in any other state unless certified low-permeation fuel line is used to supply the generator with gasoline.
Contact the California Air Resource Board or the Environmental
protection agency for further information. CARB regulations can
be found in 13 CCR §§2750 – 2773; EPA regulations can be
found in 40 CFR Part 90.
2.1 GENERATOR CONTROL PANEL
The following features are mounted on the generator control panel
(Figure 2.1):
Figure 2.1 – Generator Control Panel
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 solenoid to activate and cycle
(choke on/choke off) until the engine starts. The choke solenoid
thus opens and closes the carburetor choke valve only when the
engine is cranking. When the engine starts, the choke stops
cycling.
2.1.1 FUEL PRIMER
Before starting a cold engine (if it has not been 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.
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 temperatures, 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 completed so it
complies with all applicable codes, standards and regulations and
with the manufacturer's recommendations.
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.
7
Operation
Any attempt to crank or start the engine
before it has been properly serviced with the
n
recommended 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 sufficient fuel is available.
NOTE:
Depending on the installation, the generator may have either a
separate fuel tank, or it may “share” the vehicle engine’s fuel
tank.
2.4.4 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compartment must
be open and unobstructed for continued 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.
The generator engine releases DEADLY
carbon monoxide gas through its exhaust
n
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) 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.
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 control panel or
from the optional remote panel, proceed as follows:
1. Turn OFF electrical loads using the means provided 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, stabilized and warmed up.
2. If the engine has not been star ted 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 Star t/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/
n
Stop switch, wait one minute and try again.
Holding the switch for longer than 15 seconds can damage the starter motor.
4. Let the engine run at no-load for a few minutes to stabilize and
warm up.
5. Turn ON electrical loads using the means provided (such as a
main circuit breaker or transfer switch).
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 inter-
nal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position.
Never sleep in the vehicle while the genset
is running unless the vehicle has a working
n
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.
8
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.•
Operation
2.7.1 LETTING THE ENGINE STABILIZE
The generator supplies correct rated voltage only at the proper
governed speed. Some electrical appliances 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 sufficient 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 automatically shut down.
To avoid overloading, add up the wattage of all connected 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 during 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 wattages of other items that will be operated by the generator.
Do not apply heavy electrical loads for the first two or three •
hours of operation.
Figure 2.2 – Low Oil Pressure and
High Temperature Switches
High Temperature Switch
Low Oil Pressure
Switch
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 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 during 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.
2.9.4 OVERVOLTAGE PROTECTION
A solid-state voltage regulator (Figure 2.4) controls the generator’s
AC output voltage. This regulator supplies an excitation current to
the rotor. By regulating the rotor’s excitation current, the strength
of its magnetic field is regulated and, in turn, the voltage delivered
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).
9
Maintenance
Figure 2.4 – Solid State Voltage Regulator
The voltage regulator also incorporates a “voltage surge protection
circuit.” This circuit prevents troublesome surges in the generator
AC output voltage. Voltage surge is a common cause of damage
to electronic equipment.
2.10 ADDITIONAL INFORMATION
2.10.1 ATTENTION REQUIRED AFTER SUBMERSION
If the recreational vehicle generator has been submerged in water,
it be started and operated. 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 moisture 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.
10
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 dipstick “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
n
this could damage the engine.
5. Install and tighten the oil fill cap and the dipstick before oper-
ating the engine.
3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER
Change the 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 after the first 25 hours of operation, and •
every 100 operating hours thereafter.
To change the oil and/or oil filter, proceed as follows (see Figure •
3.1):
1. Run the engine until it is thoroughly warmed up (at least five
minutes) then shut OFF the engine.
2. Immediately after the engine shuts OFF, pull 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 coun-
terclockwise. Place a towel underneath to catch excess oil.
5. Apply a light coating of clean engine oil to the gasket 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 recommended 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.
Figure 3.1 – Oil Maintenance Features
Maintenance
GENERAC
POWERED
OHVI
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S
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m
QUIETPACT 40G
I
W
,
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e
t
a
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t
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W
.
-
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I
,
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GENERAC OHVI INDUSTRIAL ENGINE
TM
RV SERVICE LOCATOR:
1.800.333.1322
Oil Dipstick/Oil Fill
9. Install and tighten the oil fill cap and the dipstick before operating the engine.
10. Start the engine and check for leaks.
NOTE:
Check the oil level and fill to the “FULL” mark after checking for
leaks. The filter will retain some oil.
o
T
R
e
m
o
v
e
Oil Drain Oil Filter
Figure 3.2 – Engine Air Cleaner
CONTROL CENTER
FUEL
START
STOP
PRIME
FUSE
7.5
A
SERV IC E ACCESS P ANEL
AIR FILTER LOCATED BEHIND PANEL.
MAINTENANCE SCHEDULE
OIL LEVEL: CHECK DAILY
AIR FILTER: CLEAN PREFILTER
EVERY 100 HOURS.
REPLACE ELEMENT
EVERY 250 HOURS.
OIL & OIL FILTER:
CHANGE EVERY 100
HOURS. (OR ANNUALLY)
PERFORM MORE OFTEN IN DUSTY CONDITIONS
*
INSPECT & CLEANSPARK PLUGS:
PLUGS EVERY 100
HOURS. REPLACE PLUGS
EVERY 500 HOURS.
(IF NECESSARY)
FUEL FILTER: CHANGE EVERY 400
HOURS. (OR ANNUALLY)
REPLACEMENT INFORMATION
PREFILTER P/N: 0D4511
AIR FILTER P/N: 0D3262
SPARK PLUG P/N: 072347
FUEL FILTER P/N: 0D7515
OIL CAPACITY WITH FILTER:
TEMPERATURE SAE VISCOSITY
32˚F AND HIGHER
10˚F TO 100˚F
0˚F TO 80˚F
-20˚F TO 50˚F 5W-30
WHEN SERVICE OR PARTS ARE NEEDED IN
THE USA OR CANADA, CONTACT THE GENERAC
SERVICE LOCATOR AT 1-800-333-1322.
C.B.
30A
*
*
*
070185OIL FILTER P/N:
0.8L/0.84QT
30
15W-40
10W-30
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 frequently 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, followed by the
paper filter.
8. Install the cover, foam precleaner and paper filter.
9. Tighten the two screws to retain the filter in place.
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 following steps
7-9 in section "Cleaning the Foam Precleaner".
11
USTC
NEG
FUEL
POS
Maintenance
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 muffler periodically
and remove all grass, leaves, dirt, etc., from this area.
Sparking can occur if the wire terminal does
not fit firmly on the spark plug terminal end.
n
If necessary, re-form the wire terminal to
obtain a tight fit.
Figure 3.3 – Cleaning Air Intake
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 questionable.
2. Clean spark plug by scraping or washing using a wire brush
and commercial solvent. Do not blast the spark plug to
clean.
3. Check the spark plug gap using a wire feeler gauge. Adjust the
gap to 0.030 inch (0.76 mm) by carefully bending the ground
electrode (Figure 3.4).
Figure 3.4 – Setting the Spark Plug Gap
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
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.
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 commercial solvent.
Replace the screen and the retaining bracket.•
12
Maintenance
Figure 3.6 - Spark Arrestor
TAILPIPE
P/N 0E0683
SPARK ARRRESTOR
SCREEN P/N 089680
RETAINING
SCREW P/N 056892
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 moisture 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 gen-
n
erator interior and cause problems, and may
also contaminate the generator fuel system.
3.9.2 EVERY SIX MONTHS
Have the state of charge and condition checked. This should be •
done with an automotive-type battery hydrometer.
Note:
Servicing of the battery is to be performed or supervised by
personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.
Damage will result if the battery connections are made in
reverse.
Do not dispose of the battery in a fire. The
battery is capable of exploding. Storage batteries 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 explosion. Such an explosion can
shatter the battery and cause blindness or
other injury. Any area that houses a storage
battery must be properly ventilated. Do not
allow smoking, open flame, sparks, or any
spark producing tools or equipment near the
battery. Discharge static electricity from 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
precautions 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.
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 corro-•
sion. Tighten and clean as necessary.
Check the battery fluid level of unsealed batteries and, if nec-•
essary, fill with Distilled Water Only. Do not use tap water in
batteries.
Do not open or mutilate the battery.
Released electrolyte has been known to
n
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 electri-
n
cally 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;
13
Maintenance
• 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 bicarbonate 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, prepare 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 stabilizer, 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 com-
pletely. Refill the crankcase with SAE 10W-30 oil having API
classification “For Service SF.”
4. Attach a tag to the engine indicating the viscosity and clas-
sification 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 recommended 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 distilled 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 necessary 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
14
ALLEN WRENCH
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