Generac QuietPact 40 LP Generator Set

Tools: Allen wrench, Feeler gauge, Crows foot

1. Loosen the rocker arm jam nut.
2. Use an allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and valve stem with a feeler gauge.
3. Hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut with a crows foot to 65-85 inch-pounds torque.
4. Recheck valve clearance after tightening the jam nut to make sure it did not change.

Tools: feeler gauge, 8mm allen wrench, crow's foot torque wrench

1. Adjust valve clearance with engine at room temperature, piston at TDC of compression stroke (both valves closed)
2. Alternatively, position intake valve fully open to adjust exhaust valve, and exhaust valve fully open to adjust intake valve
3. Loosen rocker arm jam nut; turn pivot ball stud with 8mm allen wrench while checking clearance with feeler gauge
4. Tighten rocker arm jam nut to specified torque with crow's foot while holding pivot ball stud
5. Recheck valve clearance after tightening to ensure it did not change
6. Install new rocker arm cover gasket and reinstall cover with four screws; install oil breather tube

Tools: voltmeter

1. Set frequency to 62.5 Hertz with no load on the generator
2. Slowly turn the voltage adjust pot on the voltage regulator until 124 VAC is measured

Tools: cylinder leak down tester, compression gauge

1. Remove spark plug and valve cover
2. Rotate crankshaft to TDC with both valves closed; lock flywheel
3. Attach cylinder leak down tester adapter to spark plug hole
4. Connect air source of at least 90 psi; adjust regulated pressure to 80 psi
5. Read cylinder pressure gauge; 20 percent leakage is normally acceptable
6. Listen for air escaping at carburetor (intake valve), exhaust (exhaust valve), or breather (piston rings)
7. For compression check, insert compression gauge in spark plug hole and crank engine until pressure stops increasing

Tools: VOM, oil pressure gauge

1. Check engine oil level, replenish to FULL mark if necessary
2. Set VOM to Rx1 scale and zero meter
3. Connect meter leads across switch terminals with engine shut down; should read continuity
4. Crank engine; meter should read infinity once oil pressure opens switch contacts
5. If contacts do not open, remove switch and connect oil pressure gauge in its place; start engine and measure pressure

Tools: VOM, thermometer

1. Remove Wire No. 85 from switch terminal and start generator to isolate the fault
2. Remove switch and place sensing tip into oil with a thermometer
3. Connect VOM test leads across switch terminals; should read infinity
4. Heat oil; at approximately 305°F (151°C) switch contacts should close and meter should read continuity

⚠ Check to be sure the battery cable boot for the starter cable has been installed.

⚠ Damage will result if the battery connections are made in reverse.

1. Connect the battery cable from the POSITIVE post or terminal to the lug on the starter contactor.
2. Connect the battery cable from the NEGATIVE post to the frame ground connection.
3. Connect cables so the connectors are clean and tight.

⚠ Do not fill above the FULL mark.

Tools: 5/16 inch allen wrench, Clean lint-free cloth

1. Run the engine until thoroughly warmed up (at least five minutes) then shut OFF.
2. Remove the plug from the oil drain tube with a 5/16 inch allen wrench and drain the oil into a suitable container.
3. After the oil has drained, replace the plug onto the end of the oil drain tube.
4. Remove the old oil filter by turning it counterclockwise. Place a towel underneath to catch excess oil.
5. Apply a light coating of clean engine oil to the gasket of the new filter and fill the filter with clean oil.
6. Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter, then tighten an additional 3/4 to one turn.
7. Add the proper type and amount of recommended oil until it reaches the dipstick FULL mark.
8. Install and tighten the oil fill cap and the dipstick.
9. Start the engine and check for leaks.

⚠ Do not fill above the FULL mark. Never operate the engine with the oil level below the Add mark.

Tools: Clean lint-free cloth

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. Oil level should be at the dipstick FULL mark.
4. If necessary, remove the oil fill cap and slowly add oil until it reaches the dipstick FULL mark.
5. Install and tighten the oil fill cap and the dipstick before operating the engine.

⚠ Do not blast the spark plug to clean.

Tools: Wire brush, Wire feeler gauge

1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine. Remove and check condition.
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 to 0.030 inch (0.76 mm) by bending the ground electrode.
4. Replace the spark plug if worn or if reuse is questionable.

⚠ DO NOT USE a defective screen.

Tools: Commercial solvent

1. Remove the screen retaining bracket by removing the screw.
2. Slide the spark arrestor screen out from the tail pipe.
3. Inspect screen and replace if torn, perforated or otherwise damaged.
4. If screen is not damaged, clean it with commercial solvent.
5. Replace the screen and the retaining bracket.

1. Remove the paper filter.
2. Clean the air filter by tapping it gently on a solid surface. If too dirty, replace it with a new one.
3. Clean the air cleaner cover then reassemble following steps 7-9 in Section 3.3.1.