Guardian Technologies 004701-0 manual

Owner’s Manual and Installation Instructions Air-cooled Recreational Vehicle Generators • Model: 004701-0 QUIETPACT 40LP This manual should remain with the unit.[...]

I NTRODUCTION Thank you for purchasing this model of the QUIETP ACT product line. This model is designed and manufactured to supply electrical power for rec- reational vehicles. R EAD TH IS MANUAL THOROUGH L Y If any po rt io n of th is m an ua l is n ot unde rs to od , co nt ac t an A uth or iz ed S er vi ce De al er for st ar ti ng , ope ra ti ng[...]

Table of Contents Recreational Vehicle Generator 1 Part I – Owner’s Manual Introduction ........................................Inside Front Cover Read This Manual Thoroughly ....................................... IFC Contents ........................................................................ IFC Operation and Maintenance ...............[...]

2 WARNING! This product contains or emits chemical s known to the state of Calif ornia to cause cancer , birth defects or other reproductive harm.   WARNING! The engine exhaust fr om this pr oduct contains chemicals known to the state of California to cause cancer , birth defects or other reproductive harm.   Study these SAFETY RULES ca[...]

3 • When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued. • Insp ect the gene rat or reg ula rly , and cont act the nea res t Auth ori zed Ser vic e Dea ler imme dia tel y for par ts nee din g repa ir or rep lac eme nt. • Before performing any maintenance on the gen- erato[...]

4 1. Generator Air Intake 2. Engine Start/Stop Switch 3. F use 4. Optional Remote Panel Receptacle (Side View) 5. Generator A C Output Leads (Side V iew) 6. F uel Primer Switch 7. Circuit Breaker 8. Starter Contactor 9. F uel Inlet 10. Battery Hookup 11. LP Regulator/Solenoid 12. Oil Filter 13. Oil Drain Cap 14. Oil Dipstick 15. Air Filter (Behind [...]

5 Section 1 – General Information Recreational Vehicle Generator 1.2 GEN ERA T OR AP PLICAB I LIT Y These generators have been designed and manufac- tured 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[...]

6 Section 1 – General Information Recreational Vehicle Generator 1.5.3 ENGIN E OIL R E QUI REM ENT S Use only high quality detergent oil rated with American P etroleum 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. [...]

7 Section 2 – Operation Recreational Vehicle Generator 2.2 OPTIONAL R EMO TE S T ART/ST OP P AN EL A remote mounted Start/Stop P anel is available that permits starting and stopping the generator engine conveniently from inside the vehicle. Contact an Authorized Service Dealer to order , a remote panel that includes a Start/Stop switch, a generat[...]

8 Section 2 – Operation Recreational Vehicle Generator 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 circuit[...]

9 Section 2 – Operation Recreational Vehicle Generator Figure 2.2 – Low Oil Pressure and High T emperature Switches High T emperature Switch Low Oil Pressure Switch 2.8.3 FI ELD BOOS T 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 “fiel[...]

10 Section 3 – Maintenance Recreational Vehicle Generator 10 2.9.3 A TTENTION R E QUI RED AF TER SU BM ERSION If the recreational vehicle generator has been sub - merged in water , it MUST NOT be started and oper- ated. F ollowing any submersion in water , have an Authorized Service Dealer thoroughly clean and dry the generator . 2.9.4 OPER A TIO[...]

11 Section 3 – Maintenance Recreational Vehicle Generator • Change the engine oil filter after the first 25 hours of operation, and every 100 operating hours there - after . T o 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 eng[...]

12 Section 3 – Maintenance Recreational Vehicle Generator Figure 3.3 – Cleaning Air Intake USTC 3.5 CH E CKING TH E ENGI NE SP AR K P L UG 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 [...]

Section 3 – Maintenance Recreational Vehicle Generator  Do NOT use a forceful spray of water to clean the generator . Water will enter the generator interior and cause problems, and may also con- taminate the generator fuel system. 3.8 B A T TER Y MAI NTENANCE All lead-acid batteries will discharge when not in use. The generator battery should[...]

14 3. While the engine is still warm from running , drain the oil completely . Refill the crankcase with SAE 10W -30 oil having API classification “F or Service SF .” 4. Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase. 5. Remove the spark plug and pour two or three tablespoons of clean, fresh e[...]

P ART I I – I NS T ALL A TION I NS TR UCTIONS D ANGER ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS[...]

16 NO TICE T O I NST ALLER These Installation Instructions have been published by the manufacturer to aid in the installation of the products described in this manual. The manufac- turer assumes that installation personnel are familiar with the procedures for installing such products, or similar products. The manufacturer also assumes that personne[...]

17  ELE CTR ICAL HA Z ARDS  • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. A void contact with bare wires, ter- minals, connections, etc., while the unit is running . Ensure all appropriate covers, guards and barriers are in place before operating the generator . If work m[...]

18 1.1 P UR POSE AN D S C OPE OF TH E MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to all information and instructions in the manual, both for safety and for continu[...]

19 Figure 1.2 – Major Features and Dimensions (Drawing No. 0F4610) Section 1 – General Information Recreational Vehicle Generator 3 42. 2 [13 1/2"] 77 8 . 9 [ 30 11/16" ] REF. FR O NT D OO R A CC E SS F OR ALL RE Q UIRED MAINTENANC E REM O TE PANE L CO NNE C T OR 500 . 2 [ 19 11/16" ] REF. A C OU TP UT HARNE SS H O T AI R EXHA US[...]

20 2.1 L OCA TION AND SU P PORT 2.1.1 GENER A T OR L OCA TION The most desirable location for the generator set is between the vehicle's main frame members. However , this is seldom possible. Most units must be installed on the side of the vehicle and are difficult to rein- force. Many recreational vehicles have been factory equipped with an a[...]

21 2.2 GEN ERA T OR COMP ARTM ENT S Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compartment that the installer constructs, the compartment must meet certain spec- ifications as outlined in the following sections: 2.2.1 C OMP ARTM ENT SIZE Plan the compartment size care[...]

22 Figure 2.5 – T ypes of Lock Seams D ANGER  Do not install any flammable material dir ectly above or around the compartment. Heat, transferred through the compartment structur e, may be sufficient to ignite, char or discolor seat cushions, fiberboard and other flammable materials. Use approved nonflammable insulat- ing materials in high temp[...]

23 2.2.5 C OMP ARTM ENT FL OOR CUT OUTS Provide openings in the generator compartment for the following items (Figure 2.7): • Engine exhaust and cooling air outlets • Generator cooling air inlet • F our holes for passage of generator mounting bolts. See Section 2.1.4. D ANGER  Fuel lines and exhaust piping must not pen- etrate into the veh[...]

24 Figure 2.8 – Airflow Through Engine/Generator 2.3.2 TE S TI NG TH E INST ALLA TION The manufacturer recommends testing the installa- tion to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, enlarge the air openings. Never place a unit into service until abso[...]

25 • Use a length of approved flexible fuel hose between the gaseous fuel solenoid valve and rigid gas pip - ing . The flexible line should be at least 6 inches longer than necessary . 2.4.3 V APOR WITH DRAW AL LP gas is stored in pressure tanks as a liquid. The gas systems used with these generators were designed only for vapor withdrawal type s[...]

26 2.4.8 LEAKAGE TE S T S Do not place the generator into service until the gas system has been properly tested for leaks. T o test the system, a separate source of 12 volts DC is needed to open the gaseous fuel solenoid valve. The leak test must comply fully with NFP A, P aragraph 318. All connections, hoses, valve regulators, fittings, and other [...]

27 Figure 2.12 — Spark Arrestor Installation 40 [ 1.58" ] 5.5 [ 7/32" ] DRIL L B O TT O M S IDE O NL Y 27.4 [ 1.08" ] I.D . 2.5.2 EXHAUS T S Y S TEM S AFET Y • Maintain a clearance of at least 3 inches (76 mm) between exhaust system parts and any combus - tible material (such as wood, felt, cotton, organic fibers or other like ma[...]

28 • Conductors must be rated 221° F (105° C) or must be of a larger conductor size. 2.6.3 GENER A T OR A C C ONN E CTIONS Generator AC output leads (BLACK) “ hot ” and (WHITE) grounded neutral come out of the generator as shown in Figure 2.13. There is also a green lead that connects to ground in the junction box of the recreational vehicl[...]

29 These generators are rated at about 100 DC amperes of cranking current. Select battery cables based on (a) cable length and (b) prevailing ambient temperatures. Generally , the longer the cable and the colder the weather , the larger the cable size must be, as shown in the following chart. * F or warm weather , use No. 2 cable up to 20 feet. Sec[...]

30 2.7 .3 BA T TER Y CAB LE C ONN ECTIONS 1. Connect the battery cable from the battery post or terminal indicated by a POSITIVE, POS or (+) to the lug on the starter contactor (Figure 2.16). NOTE: Check to be sure the battery cable boot for the starter cable has been installed. 2. Connect the battery cable from the battery post indicated by a NEGA[...]

31 Section 3 – Post-installation Start-up Adjustments Recreational Vehicle Generator 3.1 POS T I NS T ALL A TION TES T S The air - cooled generator set was factory tested and adjusted. It should not be necessary to adjust the unit any further except under special circumstances.  Do not make any unnecessary adjustments. Factory settings are cor[...]

32 3.5 I NS T ALL A TION CH E CKLIS T L OCA TION AND SU PPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GEN ERA T OR COMP ARTM ENT ❑ Compartment construction is proper . ❑ Holes/Openings are vapor-sealed. ❑ Compartment size is correct. ❑ Compartment is vapor-sealed. ❑ Sou[...]

33 Appendix 1 – Troubleshooting Recreational Vehicle Generator TROU BLESHOO TI NG GUI DE Problem Cause Correction The engine will not crank. 1. F use blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary . 3. Defective engine Start/Stop 3. Replace Start/Stop switch. switch 4. Defective sta[...]

RED BLUE ORANGE BROWN 7 7 YELLOW WHITE 15 BA TTERY CHARGE WINDING NEUTRAL CONNECTION GREEN BY CUSTOMER WHITE T2 FIELD 120V 30A 44 0F 0N 0K 22P DPE WINDING 2 CB3 6 ELECTRONIC REGULA TOR VOL T AGE 2A 0N 0N R1 POWER WINDING 22S 11S 77 55 BLACK FUEL PRIME 11P 4 4 T1 4 CB1 REMOTE P ANEL (OPTIONAL) 33 4 66 ST ART HM L1 1 STOP 8 A 4 1 8 5 14 18 0 17 BLK 1[...]

35 Appendix 2 — Electrical Data Recreationl Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D 0 CONN. 2 PIN# 0 90 14 14 CH 18A 90 85 LOP CS 0 18 RED 18 85 17 18A 85 PCB J1-7 J1-9 J1-12 J1-11 J1-10 J1-8 J1-15 J1-14 J1-13 J1-2 J1-5 J1-4 J1-3 J1-1 J2 J1-6 J3 18 1 FS 14 2 3 18 18A 18 CONN. 1 PIN# 0 0 FP 90 14 2 1 2A 2[...]

36 23 46 3 7 41 16 2 21 38 15 45 5 4 5 4 3 2 30 3 1 17 19 5 2 42 33 34 5 2 50 5 2 40 5 1 21 41 3 9 21 2 1 52 28 43 36 2 1 4 2 21 18 1 53 21 39 2 3 22 6 10 47 8 24 22 20 44 25 49 7 21 24 26 13 14 12 11 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator Enclosure – Drawing No. 0F4589[...]

37 ITEM PART NO. QTY. DESCRIPTION 1 0F3916 1 TRAY, ENCLOSURE 2 0D6942 1 PANEL, ENCLOSURE SIDE 3 0D6939 1 PANEL, REAR DIVIDER 4 0F3920 1 PANEL, ENCLOSURE ROOF 5 0F3917 1 PANEL, ENCLOSURE BACK 6 0F3918 1 PANEL, FRONT DIVIDER 7 0F3919 1 COMPARTMENT, AIR INTAKE 8 0D6944 1 PANEL, ENCLOSURE DOOR 9 0D8254 1 SHIELD, MUFFLER 10 0C5644 2 SLIDE LATCH, FLUSH 1[...]

38 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator Generator – Drawing No. 0F4590 22 2 2 5 3 24 25 18 4 1 7 8 9 24 2 21 2 3 7 18 23 2 21 15 18 21 2 18 2 8 38 10 35 28 27 26 11 2 18 23 36 13 2 39 12 2 18 17 43 18 16 14 29 0 1 34 30 3 2 42 3 1 29 33[...]

39 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator Generator – Drawing No. 0F4590 ITEM PART NO. QTY. DESCRIPTION 1 050322 1 SCREW IHHC 5/16"-24 X 9-3/4" 2 022129 22 WASHER LOCK M8-5/16" 3 049451 1 WASHER FLAT .406" I.D. X 1.62" O.D. 4 0C8096A 1 FAN, 8" CURVE BLADE, 16.5MM I.D. 5 0D8120 4 [...]

40 31 1 3 1 1 37 36 30 12 1 0 25 1 9 2 8 22 35 14 23 2 3 8 2 9 9 1 6 1 2 6 1 7 1 5 17 3 21 27 6 5 4 17 1 8 24 25 2 0 2 24 2 3 7 2 5 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator Control Panel – Drawing No. 0F4591[...]

41 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator Control Panel – Drawing No. 0F4591 ITEM PART NO. QTY. DESCRIPTION 1 0830490 1 REGULATOR VOLTAGE 2 075210A 1 TERMINAL BLOCK 3 092234 1 CONTROLLER P.C.B. 4 065795 1 BATTERY CHARGER RECTIFIER 5 023484F 2 BUSHING SNAP 1" 6 023484R 1 BUSHING SNAP 1-1/4" 7 075234 [...]

42 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator GN-220 H/SH Engine – Drawing No. 0F5791 Part 1 44 3 4 38 43 42 41 9 9 33 37 53 49 50 5 2 48 5 1 9 10 9 40 20 20 18 47 46 9 45 21 23 22 14 19 29 3 2 25 24 26 27 3 1 8 13 15 15 35 30 6 28 36 1 1 12 7 3 9 1 16 16 2[...]

43 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator GN-220 H/SH Engine – Drawing No. 0F5791 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 NUT, HEX M16-1.5 5 083312 1 WASHER, M16 CONICAL 6 0D8400 1 ASSEMBLY, CHOKE SOLENOID BRACKET 7[...]

44 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator GN-220 H/SH Engine – Drawing No. 0F5791 Part 2 20 36 50 43 42 45 44 46 25 26 48 24 22 23 31 30 3 2 17 28 13 4 29 38 37 40 39 21 5 1 15 35 16 5 41 49 34 19 18 1 8 1 5 2 7 2 6 47 11 13 7 3 10 12 9 10[...]

45 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator GN-220 H/SH Engine – Drawing No. 0F5791 Part 2 ITEM PART NO. QTY. DESCRIPTION N/A 0F5800 1 LONG BLOCK ASSEMBLY 220 RV LP 1 078621 1 CONNECTING ROD ASSEMBLY 2 076389 1 PISTON PIN 3 088411 1 PISTON RING SET 4 0A8897B 1 GEAR COVER ASSEMBLY 5 077168 5 M8 X 56MM HEAD BOLT [...]

46 9 14 12 11 1 8 1 6 1 3 1 5 17 1 9 2 3 21 2 0 22 2 5 24 2 6 8 1 0 4 6 5 3 2 1 7 Appendix 3 — Exploded Views and Parts Lists Recreational Vehicle Generator Regulator – Drawing No. 0F5819[...]

47 ITEM PART NO. QTY. DESCRIPTION 1 0D5694 1 CASTING, TWIN REGULATOR HOUSING 2 0F4795 4 SCREW PPHM SEMS M4-0.7 X 10 3 0F5022 1 SOLENOID COIL, 12VDC 4 0C6070 1 SPRING-SOLENOID PLUNGER 5 0C4680 1 PLUNGER LP REG. ASSY 6 0C4647 1 GASKET, SOLENOID 7 0C4643 1 INLET, TWIN REGULATOR NO HOLE 8 0D3973 1 PLUG, EXPANSION 16MM TWINREG 9 0D7020A 1 BARBED STR 1/2[...]

48 CALI FORN IA AND F EDER AL EMISSION C ONTROL W AR RANT Y S T A TEM ENT Y OUR W ARR ANT Y R IGHT S AND OB LIGA TIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EP A), together with Generac P ower Systems, Inc. (Generac), are pleased to explain the Emission Control System W arranty on your new [...]

49 EM IS SION CONTROL S Y STEM W ARR ANTY Emission Control System W arranty (ECS W arranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS W arranty P eriod shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchas[...]

Part No. 0F4594 Revision 0 (06/29/05) Printed in U.S.A. Appendix 4 – Warranty Recreational Vehicle Generator GENERA C PO WER SYSTEMS’ THREE-YEAR LIMITED W ARRANTY FOR GU ARDIAN RECREA TIONAL VEHICLE GENERA T ORS NO TE: ALL UNIT S MUST BE INST ALLED BY GENERA C PO WER SYSTEMS A UT HORIZED SER VICE F AC ILITIES . F or a period of 3 (three) years [...]