Generac QuietPact 40G Generator Set

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