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Owner’s Manual andInstallation InstructionsAir-cooled RecreationalVehicle GeneratorsModel: 004709-0QUIETPACT 40GThis manual should remain with the unit.
INTRODUCTIONThank you for purchasing this model by GeneracPower Systems Inc. This model is designed and manufactured to supply electrical power for recreationalvehicles. READ THIS MANUAL THOROUGHLYIf 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 decalsaffixed 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 incorrectlyor carelessly. Observe them carefully. Their definitions are as follows:DANGERAfter this heading, read instructions that, if notstrictly complied with, will result in serious personal injury up to and including death, or propertydamage.After this heading, ead instructions that, if notstrictly complied with, may result in personal injuryor property damage.After this heading, read instructions that, if notstrictly complied with, could result in damage toequipment and/or property.NOTE:After this heading, read explanatory statementsthat require special emphasis.These safety warnings cannot eliminate the hazardsthat they indicate. Common sense and strict compliance with the special instructions while performingthe service are essential to preventing accidents.Four commonly used safety symbols accompany theDANGER, WARNING and CAUTION blocks. The typeof information each indicates follows:symbol points out important safety informa Thistion that, if not followed, could endanger person-The operator (driver) is responsible for proper andsafe use of the vehicle and its equipment, and thesafety of all vehicle occupants. We strongly recommend that the operator read this manual and thoroughly understand all instructions before using thisequipment. We also strongly recommend instructingother occupants in the vehicle to properly start andoperate the generator. This prepares them if they needto operate the equipment in an emergency. CONTENTSThis manual contains pertinent owner’s information,including warranty, electrical diagrams, explodedviews and lists of repair parts. In addition, the latterportion of this manual contains information necessary for the proper installation of these generators. OPERATION AND MAINTENANCEIt is the operator's responsibility to perform all safetychecks, to make sure that all maintenance for safeoperation is performed promptly, and to have theequipment checked periodically by an AuthorizedService Dealer. Normal maintenance service andreplacement of parts are the responsibility of theowner/operator and, as such, are not considereddefects in materials or workmanship within theterms of the warranty. Individual operating habitsand usage contribute to the need for maintenanceservice.Proper maintenance and care of the generator ensuresa minimum number of problems and keep operatingexpenses at a minimum. See an Authorized ServiceDealer for service aids and accessories. HOW TO OBTAIN SERVICEWhen the generator requires servicing or repairs,simply contact an Authorized Service Dealer forassistance. Service technicians are factory-trainedand are capable of handling all service needs.When contacting an Authorized Service Dealer orfactory about parts and service, always supplycomplete model number and serial number ofunit as given on its data label, which is located ongenerator.Model No.Serial No.al safety and/or property of others. This symbol points out potential explosion hazard. This symbol points out potential fire hazard.symbol points out potential electrical shock Thishazard.thethethetheAUTHORIZED SERVICEDEALER LOCATIONTo locate the nearest AUTHORIZED SERVICEDEALER, please call this number:1-800-333-1322or locate us on the web at:www.guardiangenerators.com
Table of ContentsRecreational Vehicle GeneratorPart – Owner’s ManualPart II – Installation InstructionsIntroduction .Inside Front CoverSafety Rules . 18Read This Manual Thoroughly . IFCSection 1 – General Information . 20Contents . IFC1.1Purpose and Scope of the Manual . 20Operation and Maintenance . IFC1.2Safety. 20How to Obtain Service . IFC1.3Standards Booklets . 20Authorized Service Dealer Locator Number . IFC1.4Equipment Description . 20Safety Rules .21.5Generator Engine Operating Speed . 20Section 1 – General Information .41.6Generator AC Connection System . 201.1Generator Identification . 4Section 2 – Installation . 221.2Generator Applicability . 52.11.3Safety. 52.2Generator Compartments . 231.4Generator AC Connection System . 52.3Cooling and Ventilating Air . 251.5Specifications . 52.4Gasoline Fuel System . 27Section 2 – Operation .72.5Exhaust System. 282.1Generator Control Panel. 72.6Electrical Connections. 292.2Optional Remote Start/Stop Panel . 72.7Battery Installation. . 312.3Automatic Choke . 72.8Optional Accessories . 322.4Before Starting the Engine . 72.5Starting the Generator . 8Section 3 – Post-installation Start-upAdjustments. 332.6Stopping the Generator . 93.1Post Installation Tests . 332.7Applying Loads to Generator. 93.2Before Initial Start-up. 332.8Do Not Overload the Generator . 93.3Initial Start . 332.9Location and Support . 22Protection Systems . 93.4Testing Under Load . 332.10 Additional Information . 103.5Installation Checklist. 34Section 3 – Maintenance . 11Section 4 – Troubleshooting . 353.1Checking the Engine Oil Level . 11Section 5 – Electrical Data . 363.2Changing the Engine Oil and/or Oil Filter . 11Section 6 – Exploded Views and Parts Lists . 383.3Maintaining the Engine Air Cleaner . 12Section 7 – Warranty . 483.4Clean Air Intake . 123.5Checking the Engine Spark Plug . 123.6Fuel Filter . 133.7Clean Spark Arrestor . 133.8Cleaning the Generator . 133.9Battery Maintenance . 143.10 Major Service Manual. 143.11 Exercising the Generator . 143.12 Out of Service Procedure. 143.13 Adjusting Valve Clearance. 153.14 RV Generator Service Interval . 15Section 4 – Notes . 161
Safety RulesRecreational Vehicle Generator SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safeoperation 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. WARNING: The engine exhaust from this product containschemicals known to the state of California to causecancer, birth defects or other reproductive harm. WARNING: This product contains or emits chemicals knownto the state of California to cause cancer,birth defects or other reproductive harm.Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Becomefamiliar with this manual and with the unit. The generator can operate safely, efficiently and reliably onlyif it is properly installed, operated and maintained.Many accidents are caused by failing to follow simpleand fundamental rules or precautions.The manufacturer cannot anticipate every possiblecircumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixedto the unit, are, therefore, not all-inclusive. If usinga procedure, work method or operating techniquethe manufacturer does not specifically recommend,ensure that it is safe for others. Also make sure theprocedure, work method or operating technique utilized does not render the generator unsafe.DANGERthe safe design of this generator, Despiteoperating this equipment imprudently, neglectingits maintenance or being careless can causepossible injury or death. Permit only responsibleand capable persons to operate or maintain thisequipment.lethal voltages are generated by Potentiallythese machines. Ensure all steps are taken torender the machine safe before attempting towork on the generator.of the generator are rotating and/or hot Partsduring operation. Exercise care near runninggenerators. GENERAL HAZARDS For safety reasons, the manufacturer recommendsthat the installation, initial start-up and maintenance of this equipment is carried out by anAuthorized Service Dealer.2 The generator engine releases DEADLY carbonmonoxide gas through its exhaust system. Thisdangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death.Never operate the generator set with the vehicleinside any garage or other enclosed area. DO NOTOPERATE THE GENERATOR IF THE EXHAUSTSYSTEM IS LEAKING OR HAS BEEN DAMAGED.SYMPTOMS OF CARBON MONOXIDE POISONINGARE (a) inability to think coherently, (b) nausea,(c) vomiting, (d) twitching muscles, (e) throbbingtemples, (f) dizziness, (g) headaches, (h) weakness, and (i) sleepiness. IF EXPERIENCING ANYOF THESE SYMPTOMS, MOVE INTO FRESH AIRIMMEDIATELY. IF SYMPTOMS PERSIST, GETMEDICAL HELP. Shut down the generator anddo not operate it until it has been inspected andrepaired. Never sleep in the vehicle while the genset is running unless the vehicle has a working carbonmonoxide detector. The exhaust system must beinstalled in accordance with the genset installationmanual. Make sure there is ample fresh air whenoperating the genset in a confined area. The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, ifbreathed in sufficient concentrations, can causeunconsciousness or even death. This exhaustsystem 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 withsuch codes and standards. The generator compartment must be completely vapor sealed fromthe vehicle interior. There must be no possibility ofexhaust fumes entering the vehicle interior. Neveroperate this equipment with a leaking or defectiveexhaust system. Keep hands, feet, clothing, etc., away from drivebelts, fans, and other moving or hot parts. Neverremove any drive belt or fan guard while the unitis operating. Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation and is required to expel toxic fumes and fuelvapors from the generator compartment. Withoutsufficient cooling airflow, the engine/generatorquickly overheats, which causes serious damageto the generator. Do not alter the installation orpermit even partial blockage of ventilation provisions, as this can seriously affect safe operation ofthe generator.
Safety RulesRecreational Vehicle Generator When working on this equipment, remain alertat all times. Never work on the equipment whenphysically or mentally fatigued. Inspect the generator regularly, and contact thenearest Authorized Service Dealer immediately forparts needing repair or replacement. Before performing any maintenance on the generator, disconnect its battery cables to preventaccidental start up. Disconnect the cable from thebattery post indicated by a NEGATIVE, NEG or (–)first. Reconnect that cable last. Never use the generator or any of its parts as astep. Stepping on the unit can stress and breakparts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage,oil leakage, etc. ELECTRICAL HAZARDS The generator covered by this manual producesdangerous electrical voltages and can cause fatalelectrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running.Ensure all appropriate covers, guards and barriersare in place before operating the generator. If workmust be done around an operating unit, stand onan insulated, dry surface to reduce shock hazard. Do not handle any kind of electrical device whilestanding in water, while barefoot, or while hands orfeet are wet. DANGEROUS ELECTRICAL SHOCKMAY RESULT. During installation onto the vehicle, have thegenerator properly grounded (bonded) either bysolid mounting to the vehicle frame or chassis,or by means of an approved bonding conductor.DO NOT disconnect the bonding conductor, if soequipped. DO NOT reconnect the bonding conductor to any generator part that might be removed ordisassembled during routine maintenance. If thegrounding conductor must be replaced, use only aflexible conductor that is of No. 8 American WireGauge (AWG) copper wire minimum. In case of accident caused by electric shock, immediately shut down the source of electrical power.If this is not possible, attempt to free the victimfrom the live conductor. AVOID DIRECT CONTACTWITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victimfrom the live conductor. If the victim is unconscious, apply first aid and get immediate medicalhelp. Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting inelectric shock, or may get caught in moving components causing injury. FIRE HAZARDS For fire safety, the generator must be installedand maintained properly. Installation always mustcomply with applicable codes, standards, lawsand regulations. Adhere strictly to local, state andnational electrical and building codes. Complywith regulations the Occupational Safety andHealth Administration (OSHA) has established.Also, ensure that the generator is installed inaccordance with the manufacturer’s instructionsand recommendations. Following proper installation, do nothing that might alter a safe installationand render the unit in noncompliance with theaforementioned codes, standards, laws and regulations. Keep a fire extinguisher in the vehicle at all times.Extinguishers rated “ABC” by the National FireProtection Association are appropriate for use onthe recreational vehicle generator electrical system. Keep the extinguisher properly charged andbe familiar with its use. If there are any questionspertaining to fire extinguishers, consult the local firedepartment. EXPLOSION HAZARDS Do not smoke around the generator. Wipe up anyfuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE orEXPLOSION may result. Keep the area surrounding the generator clean and free from debris. Gasoline is extremely FLAMMABLE and its vaporsare EXPLOSIVE. Do not permit smoking, openflame, sparks or any source of heat in the vicinitywhile handling gasoline. Comply with all laws governing the storage and handling of gasoline.3
Section 1 – General InformationRecreational Vehicle Generator1.1GENERATOR IDENTIFICATIONPlease record the following information from the generator DATA DECAL or information decal.1.2.3.4.5.6.7.8.9.10.1. Model Number2. Serial Number3. kW Rating4. Rated VoltageGenerator Air IntakeEngine Start/Stop SwitchFuseOptional Remote Panel Receptacle (Side View)Generator AC Output Leads (Side View)Fuel Primer SwitchCircuit BreakerStarter ContactorFuel InletFuel Pump (Behind Access Panel)14,1681711.12.13.14.15.16.17.182 673CONTROL CENTERC .B .3 0 AF U E LS T A R TS T O PP R IM EF U S E15 AS E R V IC EA C C E S SP A N E L10/15AIR FILTER LOCATED BEHIND PANEL.MAINTENANCE SCHEDULEOIL LEVEL:CHECK DAILYAIR FILTER:CLEAN PREFILTEREVERY 100 HOURS. *REPLACE ELEMENTEVERY 250 HOURS. *OIL & OIL FILTER:CHANGE EVERY 100HOURS. (OR ANNUALLY) *SPARK PLUGS:INSPECT & CLEANPLUGS EVERY 100HOURS. REPLACE PLUGSEVERY 500 HOURS.(IF NECESSARY)FUEL FILTER:CHANGE EVERY 400HOURS. (OR ANNUALLY)*ACD, Wterew aFuel Filter (Side View)Oil FilterOil Drain CapOil DipstickAir Filter (Behind Access Panel)Oil FillSpark PlugExternal Vacuum Port (model 004709-0 only)PERFORM MORE OFTEN IN DUSTY CONDITIONS5418REPLACEMENT INFORMATIONIPREFILTER P/N:AIR FILTER P/N:OIL FILTER P/N:SPARK PLUG P/N:FUEL FILTER P/N:OIL CAPACITY WITH FILTER:TEMPERATURE32 F AND HIGHER10 F TO 100 F0 F TO 80 F-20 F TO 50 F0D45110D32620701850723470D75150.8L/0.84QTSAE VISCOSITY3015W-4010W-305W-30WHEN SERVICE OR PARTS ARE NEEDED INTHE USA OR CANADA, CONTACT THE GENERACSERVICE LOCATOR AT 1-800-333-1322.9/1113 1241
Section 1 – General InformationRecreational Vehicle Generator1.2GENERATOR APPLICABILITYThese generators have been designed and manufactured for supplying electrical power for recreationalvehicles. Do not modify the generator or use it forany application other than for what it was designed. Ifthere are any questions pertaining to its application,contact an Authorized Service Dealer. Do not use theunit until advised by a competent authority.DANGERfire safety, the generator must have been Forproperly installed in compliance with ANSI119.2-1975/NFPA 501C-1974, “Standard forRecreational Vehicles, Part III – Installation ofElectrical Systems.” The generator also musthave been installed in strict compliance with themanufacturer’s detailed installation instructions.After installation, do nothing that might renderthe unit in noncompliance with such codes, standards and instructions.Use this generator to supply electrical power foroperating 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 amperesof current at 120 volts.not overload the generator. Some installa Dotions may require that electrical loads be alternated to avoid overloading. Applying excessivelyhigh electrical loads may damage the generatorand may shorten its life. Add up the rated wattsof all electrical lighting, appliance, tool andmotor loads th
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
