Guardian 004702-0, 004703-0, 004704-0, 004705-0, 004706-0, 004707-0 manual

Owner’ s Man ual Air -cooled Recreational V ehic le Generators QUIETP A CT ® 55, 65 and 75 • Models: 004702-0, 004703-0 004704-0, 004705-0 004706-0, & 004707-0 This manual should remain with the unit.[...]

I NTRODUCTION R EAD THIS MAN UAL THOROUGHL Y If any portion of this manual is not understood, con- tact the nearest Authorized Service Dealer for start - ing, operating and servicing procedures. Throughout this publication, and on tags and decals affixed to the generator , DANGER, W ARNING, CA UTION and NOTE blocks are used to alert person- nel to [...]

T able of Contents Recreational V ehicle Generators 1 Part I — Operating Instructions Introduction ...................................... Inside Front Cover Read This Manual Thoroughly ................................ IFC Contents ................................................................. IFC Operation and Maintenance .....................[...]

2 Study these SAFETY RULES carefully before install- ing, operating or servicing this equipment. Become familiar with this manual and with the unit. The gen- erator 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 p[...]

3 • Before performing any maintenance on the gen- erator , disconnect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGA TIVE, 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[...]

4 Section 1 – General Information Recreational V ehicle Generators Please recor d the following information from the generator DA T A DECAL or information decal. 1. Model Number _____________________ 2. Serial Number __________________ 3. kW Rating _________________________ 4. Rated V oltage __________________ 5. Phase ___________________________[...]

5 Section 1 – General Information Recreational V ehicle Generators 1.2 GEN ER A T OR AP P LICAB 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 pertainin[...]

6 Section 1 – General Information Recreational V ehicle Generators Figure 1.1 – Connection for 120 V olts Only Figure 1.2 - Connection for 120/240 V olts T1 RED T2 WHITE T3 BLACK GROUNDED NEUTRAL ST A TOR WINDINGS CB1 CB2 1.6 SP E CI F ICA TIONS 1.6.1 F UEL REQ UIRE MEN T S ( GA S O LINE ) This generator is equipped with a gasoline fuel system [...]

7 Section 2 – Operation Recreational V ehicle Generators 1.6.5 EM IS SIONS COMP LIANCE P ERIOD F or nonhandled engines the Emissions Compliance P eriod referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet F ederal emission requirements. • F or engines less than 225 cc [...]

8 Section 2 – Operation Recreational V ehicle Generators 2.2 OPTIONAL R EMO TE S T ART/ST OP P AN EL A remote mounted Start/Stop P anel (F igure 2.2) is available that allows starting and stopping the gen- erator engine conveniently from inside the vehicle. The remote panel includes a Start/Stop switch, hour - meter , generator run lamp, a fuel p[...]

9 Section 2 – Operation Recreational V ehicle Generators D ANGER  The generator engine releases DEADL Y carbon monoxide gas through its exhaust system. This dangerous gas, if br eathed in sufficient con- centrations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed ar[...]

10 Section 2 – Operation Recreational V ehicle Generators 2.7 .2 DO NO T O VERLO AD TH E GENER A T OR Read the rated wattage/amperage capacity of the gen- erator on the generator data decal (see Section 1.1). Applying electrical loads in excess of the unit ’s rated capacity will cause the engine/generator to automati- cally shut down. T o avoid[...]

11 Section 3 – Maintenance Recreational V ehicle Generators 2.8.4 OVERV OL T AGE PRO TE CTION A solid- state voltage regulator (Figure 2.5) controls the generator’s AC output voltage. This regulator supplies an excitation current to the rotor . By regulat- ing the rotor’s excitation current, the strength of its magnetic field is regulated and[...]

12 Section 3 – Maintenance Recreational V ehicle Generators 3.2 CHANGI NG TH E ENGI N E OI L AN D/OR OI L F I L TER • Change the engine oil after the first 25 hours of operation (after the 25-hour break -in period, see Section 2.8.5). Thereafter , change the oil every 100 operating hours. Change the oil more frequently if operating consistently[...]

Section 3 – Maintenance Recreational V ehicle Generators Figure 3.3 – Engine Air Cleaner Win g N ut O ffset S A Pl Fl at Washer Win g N ut x Com p artmen t 3.4 CH E CKI NG TH E ENGI N E 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 [...]

14 3.7 CLEAN I NG TH E GEN ER A T OR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dirt, corrosive vapors, road splash, etc. P ermitting dirt and mois- ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings. When moisture is allowed to remai[...]

15 3.9 MA JOR SERVICE MAN UAL T o obtain a service manual for the generator , contact the nearest Authorized Service Dealer . Make sure to identify the MODEL NUMBER and SERIES. Manuals can be obtained from the internet website or a service dealer . 3.1 0 DR IVE BEL T The engine drives the generator rotor by means of a pulley and drive belt arrangem[...]

16 Section 4 – Notes Recreational V ehicle Generators[...]

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

18 Safety Rules Recreational V ehicle Generators 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 product[...]

19 Safety Rules Recreational V ehicle Generators • 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 con- ditions from leaking exhaust gases, fuel leakage, oil leakage, etc. • Never insert any tool or other object through open- ings in the generator inte[...]

20 5.1 P U R POSE AN D S C OP E OF TH E I NS T ALL A TION I NSTR UCTIONS 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, bot[...]

21 Figure 5.2 - Major Features and Dimensions (Drawing No. 0E1058-E) Section 5 – General Information Recreational V ehicle Generators A B C C 5 4 5 [ 21 7/16" ] TYP. 9 5 . 6 [ 3 3 /4" ] 1 83 . 6 [ 7 1/4" ] 8 21.2 [ 3 2 5/16" ] 2 33 .2 [ 9 3 /16" ] 46 9 [ 1 8 7/16" ] 1 9 5 . 8 [ 7 11/16" ] 5 7 [ 2 1/4" ] TYP[...]

22 Figure 5.3 - Connection for 120/240 V olts T1 RED T2 WHITE T3 BLACK GROUNDED NEUTRAL ST A TOR WINDINGS CB1 CB2 • The AC connection system on all air - cooled PRIMEP ACT series generators uses a GROUNDED neutral. • A separate green ground wire is connected to the recreational vehicle’s junction box. • Loads connected across T1 (Red) to T2[...]

23 • If the generator cannot be bolted directly to the supporting frame or support tubing, consider using additional tubing, angle brackets or other supports to give the supporting frame sufficient strength. 6.1.3 SUSP ENDED MOU NTI NG If planning to suspend the generator below the hori- zontal support tubing, the suspension method to use with th[...]

24 • If the compartment is lined with galvanized steel, it may be constructed of any material. The manu- facturer recommends that the compartment be constructed of 1/2-inch thick plywood (not strand- board), with the floor made of a double thickness of 1/2-inch plywood with the grain of the wood at cross section for added strength (Figure 6.5). F[...]

25 Section 6 – Installation Recreational V ehicle Generators Using a combination of sound insulating materials can often reduce noise more effectively than a single material. F or example, a sheet of lead or visco - elastic material, along with a layer of other acoustical mate - rial, is more effective than when a single material is used. 6.2.4 A[...]

26 Figure 6.9 – Airflow Through Engine/Generator 6.3.2 TES TING TH E I NST ALL A 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[...]

27 Figure 6.10 – Generator Fuel System Fuel Pump (Behind Access Cover) Fuel Filter (Side of Unit) Fuel Line F actory installed generator fuel system components include (a) fuel filter , (b) 12-volt DC electric pump, (c) engine carburetor , and (d) interconnecting lines and fittings. Connect a fuel supply line to the fuel filter inlet. Use a flexi[...]

28 6.5.2 P ART S NO T INCL UDED I N F U EL SYSTE M The propane fuel system does NOT include such items as (a) gas tank, (b) gas piping, (c) fittings, (d) valves, and (e) primary regulator , used to store the gaseous fuel and deliver it to the gaseous fuel sole - noid (Figure 6.11). D ANGER  Use only approved components in the fuel sup- ply syste[...]

29 Figure 6.12 – LP Gas Carburetion Diagram The greater the airflow through the carburetor ven- turi, the lower the pressure at the venturi throat. The lower the pressure at the venturi throat, the greater the diaphragm movement, and the greater the move - ment of the regulator valve. The more the regulator valve opens, the greater the gas flow t[...]

30  Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping. This causes excessive back pressur e on the generator engine. Also, water from one engine can dam- age the other engine. 6.6.1 MUFF LERS AN D SP AR K AR R ES T ORS This muffler meets code and standard requirements of the U .S. F orest Service. Use only muffle[...]

31 6.7 .1 ELECTRICAL J UNCTION BOX Install an approved, square electrical junction box with a blank cover on the interior or exterior wall of the area planned for installation of the generator (NOT on the generator). Route the generator's AC output leads into this junction box through approved flexible conduit. This is the point of first termi[...]

32 Section 6 – Installation Recreational V ehicle Generators 6.7 .6 POWER S UPPL Y C ORD The power supply cord must comply with all appli- cable codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected. 6.7 .7 GROU N D F AU L T CI RCUIT I NTERR U PTERS The National Electrical Code (NFP A [...]

33 Section 6 – Installation Recreational V ehicle Generators Figure 6.15 — T ransfer Switch Isolation Method P O WERED BY GU ARDIAN 7 60 cc O HVI V-TWI N QU IETPA CT INDU S TRIAL 55 G Figure 6.16 — Installation With Isolation Receptacle P O WERED BY GU ARDIAN 7 60cc O HVI V-TWI N QU IETPA CT INDU S TRIAL 55 G[...]

34 6.9 OPTIONAL A C C ESSO R I ES A plug-in receptacle (F igure 6.18) is provided on the generator set, above the muffler enclosure. Use this receptacle to connect an optional remote -mounted start/stop panel to the generator . Installation of such a panel will permit starting and stopping the gen- erator engine from any convenient location inside [...]

35 7 .4 TE STING U N DER L O AD Apply electrical loads equal to about 75 to 100 per - cent of the unit's rated wattage/amperage capacity . Let the unit run at least 30 minutes with load applied. During this part of the test, check that the unit is not running excessively hot and that adequate cooling airflow is available. Do not allow the unit[...]

36 Section 8 – T roubleshooting Recreational V ehicle Generators 8.1 TROU B LE SHOO TI NG GU I DE Problem Cause Correction Engine won’t crank. 1. 7.5 amp fuse b lown. 1. Replace blown fuse . 2. Loose, or corroded or def ective 2. Tighten, clean or replace, batter y cable(s). as necessary . 3. Battery is discharged or defective . 3. Recharge or [...]

37 Section 9 – Notes Recreational V ehicle Generators[...]

38 Section 1 0 — Electrical Data Recreational V ehicle Generators Electrical Schematic - V - Twin – Drawing No. 0E1 05 7 -E S W 1 S CR BLK T2 NE U TRAL CO NNE C TI ON BY CU S T O ME R G REE N WHITE 0F 0N 22P 44 0K 0N 120V 3 5A - Q P7 5 120V 3 0A - Q P55 & Q P6 5 RE GU LAT OR V O LTA GE ELE C TR O NI C FIELD 120V 20A - Q P5 5 120V 3 5A - Q P[...]

39 Section 1 0 — Electrical Data Recreational V ehicle Generators Electrical Schematic - V - Twin – Drawing No. 0E1 05 7 -E 0 CO NN. 2 PIN# 0 9 0 14 14 CH 1 8 A 9 0 8 5 L OP C S 0 1 8 R ED 1 8 8 5 17 1 8 A 8 5 P CB J 1- 7 J 1- 9 J 1-1 2 J 1-1 1 J 1-1 0 J 1- 8 J 1-1 5 J 1-1 4 J 1-1 3 J 1- 2 J 1- 5 J 1- 4 J 1- 3 J 1- 1 J2 J 1- 6 J 3 1 8 1 F S 14 [...]

40 1 3 2 4 6 3 4 7 9 8 5 1 0 1 1 1 2 1 3 3 2 1 1 5 14 3 2 1 6 17 2 0 1 8 1 9 2 3 4 2 3 2 2 21 2 5 2 6 27 2 8 4 5 3 0 1 0 3 1 3 2 33 3 4 3 5 3 6 3 7 38 39 4 0 41 42 4 3 44 4 6 52 47 4 8 4 9 50 51 2 6 52 57 56 55 5 3 54 50 5 3 5 8 5 9 60 61 62 A " A T O C ARB . " B" " B" Section 1 1 — Exploded V iews and Parts Lists Recreat[...]

41 Section 1 1 — Exploded V iews and Parts Lists Recreational V ehicle Generators Base & Pulley – Drawing No. 0E1 32 3-C ITEM P ART NO . QTY . DESCRIPTION 1 0E0196 1 FRAME, 760 ENGINE 2 022129 12 W ASHER LOCK M8-5/16 3 022145 15 W ASHER FLA T 5/16-M8 ZINC 4 022259 6 NUT HEX 5/16-18 STEEL 5 0C7758 4 VIB MNT 1.5 X 1.38 X 5/16-18 6 0C3168 1 WA[...]

42 11 2 CO NT. PANE L G R OU ND T O VIEW " A " 4 8 38 3 7 3 0 3 1 3 0 33 3 5 3 6 3 3 2 3 1 2 3 2 9 2 8 2 7 26 TO EN G INE G R OU ND O S TARTER 9 24 1 8 6 12 1 9 5 5 40 4 8 38 47 17 16 6 1 5 5 2 1 1 4 1 3 4 7 6 5 5 42 10 20 41 2 2 21 VIEW " A " 3 4 3 44 8 Section 1 1 — Exploded V iews and Parts Lists Recreational V ehicle Gener[...]

43 ITEM P ART NO . QTY . DESCRIPTION 1 0D8827 1 P ANEL, ENCLOSURE ROOF 2 0A7215 22 SCREW SW 1/4-20X5/8 N W A JS500 3 029451 11.5 FT . T APE ELEC UL FOAM 1/8 X 1/2" 4 0D8825 1 P ANEL, SIDE AND BACK ENCLOSURE 5 0D3700 14 NUT FLANGE M6-1.0 NYLOK (GASOLINE ONL Y) 0D3700 17 NUT FLANGE M6-1.0 NYLOK (LP ONL Y) 6 090388 8 SCREW HHTT M6-1.0 X 12 YC 7 0[...]

44 110 111 116 REGULA TOR TO L P 49 43 22 6 18 117 1 18 21 20 17 18 105 19 2 15 14 16 1 13 12 11 10 7 3 1 72 68 67 66 31 25 24 23 29 28 26 36 27 32 30 35 65 34 60 59 47 46 45 33 37 40 39 38 103 39 61 62 63 57 56 66 104 51 42 44 58 55 50 112 101 100 103 87 74 71 69 64 70 8 9 4 76 73 75 86 85 84 88 90 89 102 5 66 92 91 94 113 107 79 78 77 83 80 106 8[...]

45 ITEM P ART NO . QTY . DESCRIPTION 1 045756 15 SCREW HHTT M6-1.0 X 10 YC 2 0D1131 1 GU ARD ,F AN 12KW HSB 3 0F1169G 1 HOUSING, BLOWER V -TWIN RV 4 0C9763 4 NUT ,GROMMET 1/4 PLUG 5 0D9782A 1 HOSE, BREA THER 6 0C3034 1 NUT HEX M24-2.0 G8 YEL CHR 7 0C3033 1 W ASHER,BELLEVILLE 25MM BOL T 8 051754 2 SCREW HHC M8-1.25 X 12 G8.8 9 0A5992 2 W ASHER SHAKE[...]

46 1 2 3 4 5 6 7 8 9 9 1 0 11 12 2 1 3 14 4 1 5 1 6 17 1 8 1 9 2 0 21 22 2 3 24 5 2 5 2 6 27 7 28,2 30 31 32 33 34 35 36 37 39 4 0 41 42 4 3 44 4 45 5 4 6 39 40 37 36 35 47 4 9 50 8 51 52 7 53 54 55 56 5 59 60 39 61 62 63 8 7 64 65 66 8 7 67 Section 1 1 — Exploded V iews and Parts Lists Recreational V ehicle Generators Control Panel – Drawing N[...]

47 ITEM P ART NO . QTY . DESCRIPTION 1 0C2375 2 SCREW HHC M8-1.25 X 90 G8.8 2 022145 2 WASHER FLA T 5/16-M8 ZINC 3 029459 2 TENSION SPRING 4 075215 2 WASHER, SPRING CENTER 5 052858 6 NUT LOCK FL M8-1.25 6 047411 7 SCREW HHC M6-1.0 X 16 G8.8 7 022097 13 W ASHER LOCK M6-1/4 8 022473 10 W ASHER FLA T 1/4-M6 ZINC 9 080925 8 WASHER NYLON .404 10 0D9921 [...]

48 Section 1 1 — Exploded V iews and Parts Lists Recreational V ehicle Generators 7 60 V - Twin Engine – Drawing No. 0F1 99 7 1 6 3 64 33 3 2 9 3 1 3 0 40 42 39 38 3 2 3 7 3 4 3 5 3 6 33 1 8 17 4 47 4 6 4 5 4 3 50 4 9 51 54 5 3 5 44 5 9 5 8 61 57 60 22 2 0 1 5A 1 6 1 5B 1 5A 14 2 21 8 7 2 6 1 3 2 2 5 1 9 12 9 62 6 2 5 52 4 11 8[...]

49 ITEM P ART NO . QTY . DESCRIPTION 1 0C5730A 1 ASSEMBL Y , CRANKCASE R V 2 0E9843 1 SEAL, 38 I.D . CRANKCASE 3 090388 6 SCREW , HHTT M6-1.0 X 12mm 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER CO VER 6 0E3372A 1 SEP ARA TOR, OIL BREA THER 7 0D8067A 1 ASSEMBL Y , HEAD #1 8 0C2981C 1 COVER, ROCKER 9 071983 4 RET AINER, PISTON PIN 2[...]

50 11 1 6 14 1 3 2 0 1 8 1 5 17 1 9 21 2 5 2 3 22 24 2 7 2 6 1 0 12 6 8 7 5 1 9 2 Section 1 1 — Exploded V iews and Parts Lists Recreational V ehicle Generators LP Regulator – Drawing No. 0E1 53 0-C[...]

51 ITEM P ART NO . QTY . DESCRIPTION 1 0D5694 1 CASTING, TWIN REGULA TOR HOUSING 2 0F4795 4 SCREW PPHM SEMS M4-0.7 X 10 5 0F5022 1 SOLENOID COIL, 12VDC 6 0C6070 1 SPRING-SOLENOID PLUNGER 7 0C4680 1 PLUNGER LP REG. ASSY 8 0C4647 1 GASKET , SOLENOID 9 0C4643 1 INLET , TWIN REGULA T OR NO HOLE 10 0D3973 1 PLUG, EXP ANSION 16MM TWINREG 11 0C6606 1 BARB[...]

52 Section 1 2 – W arranty Recreational V ehicle Generators CALI FOR N IA AND F EDER AL EM ISSION C ONTROL W AR R ANT Y ST A TEM ENT Y OU R W ARR ANT Y RIGHTS AN D OBLIGA 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 t[...]

53 Section 1 2 – W arranty Recreational V ehicle Generators EM IS SION CONTROL S Y STEM W AR R ANT Y 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 Period shall begin on the date the new engine or equipmen[...]

Part No. 0E1015 Revision L (09/15/05) Printed in U.S.A. Section 1 2 – W arranty Recreational V ehicle Generators GENERA C PO WER SYSTEMS’ THREE-YEAR LIMITED W ARRANTY FOR GU ARDIAN RECREA TIONAL VEHICLE GENERA T ORS NO TE: ALL UNITS MUST BE INST ALLED BY GENERAC PO WER SYSTEMS AUTHORIZED SER VICE F ACILITIES. For a period of 3 (three) years of [...]