Guardian 02010-2, 04164-3 manual

Owner’ s Man ual and Installation Instructions Air -cooled Recreational V ehic le Generators • Model: 02010-2 PRIMEP A CT 50 • Model: 04164-3 PRIMEP A CT 50LP[...]

I NTRODUCTION Thank you for purchasing this model manufac- tured by Generac P ower Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. 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 s[...]

T able of Contents Recreational V ehicle Generator 1 Part I – Owner’s Manual 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 Adequate, unobstructed flow of cooling and ven- tilating air is critical to correct generator opera- tion and is required to expel toxic fumes and fuel vapors from the generator compartment. W ithout sufficient cooling airflow , the engine/generator quickly overheats, which causes serious damage to the generator . Do not alter the installation or[...]

4 1. Generator Air Intake 2. Engine Start/Stop Switch 3. F use 4. Optional Remote P anel Receptacle (behind control panel) 5. Generator AC Output Leads (behind control panel) 6. F uel Primer Switch 7. Circuit Breaker 8. Circuit Breaker 9. Starter Contactor 10. F uel Inlet 11. F uel Pump 12. F uel Filter 13. Oil Filter 14. Oil Drain Cap 15. Oil Dips[...]

5 Section 1 – General Information Recreational V ehicle Generator 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 pertaining[...]

6 Section 1 – General Information Recreational V ehicle Generator  The manufacturer does not r ecommend using any gasoline containing alcohol (such as “gaso- hol”). If using any gasoline containing alcohol, it must not contain more than 10 per cent ethanol, and it must be removed fr om the generator dur - ing storage. Do NOT use any gasoli[...]

7 Section 2 – Operation Recreational V ehicle Generator 2.1 GEN ER A T OR CONTROL P AN EL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control Panel 2.1.1 F UEL PRIME R Before starting a cold engine (if it has not been started in more than two weeks), this switch must be pressed for appr[...]

8 Section 2 – Operation Recreational V ehicle Generator 2.4 B EFOR E S T ARTI NG TH E ENGI N E NOTE: Instructions and information in this manual assume the generator has been properly installed, connected, serviced, tested and adjusted by a qualified installation technician or installation contractor . 2.4.1 I NS T ALLA TION Generator installatio[...]

9 Section 2 – Operation Recreational V ehicle 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 circui[...]

10 Section 2 – Operation Recreational V ehicle Generator 2.8.1 DO NO T O VERL O AD THE GEN ER A T OR Read the rated wattage/amperage capacity of the gen- erator on the generator data decal (see "Generator Identification"). Applying electrical loads in excess of the unit ’s rated capacity will cause the engine/generator to automati- ca[...]

11 2.9.4 OVERV OL T A GE P RO TE CTION A solid- state voltage regulator (Figure 2.6) controls the generator’s AC output voltage. This regulator sup- plies an excitation current to the rotor . By regulating the rotor’s excitation current, the strength of its mag- netic field is regulated and, in turn, the voltage deliv- ered to connected electri[...]

12 Section 3 – Maintenance Recreational V ehicle Generator Figure 3.1 – Oil Maintenance Features 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. Thereafter , change the oil every 100 operating hours. Change the oil more frequently if operating consistently under heavy load or [...]

Section 3 – Maintenance Recreational V ehicle Generator 5. W rap the foam precleaner in a clean cloth and gently squeeze it dry . 6. Saturate the foam precleaner in clean engine oil. Gently squeeze it in a clean cloth to remove excess oil and to distribute oil (DO NOT TWIST). 7. Install the foam precleaner into the cover , fol- lowed by the paper[...]

14 3.6 F U EL F I L TER (GA S OLI N E ON L Y) Remove and replace the fuel filter (Figure 3.5) once each year or every 100 hours of operation, whichever comes first. Figure 3.5 – Fuel Filter Fuel Filter 3.7 SP ARK AR R ES T OR MUFFLE R If the generator is not equipped with a spark arres- tor exhaust muffler and is to be used on any forest covered,[...]

15 D ANGER  Do not dispose of the battery in a fire. The bat- tery is capable of exploding. Storage batteries give off explosive hydr ogen gas. This gas can form an explosive mixture ar ound the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and c[...]

16 3.1 3.2 RETUR N T O SERVICE T o return the unit to service after storage, proceed as follows: 1. Check the tag on the engine for oil viscosity and classification. V erify that the correct recommend- ed oil is used in the engine (see the "Engine Oil Requirements" section). If necessary , drain and refill with the proper oil. 2. Check th[...]

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 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 famil- iar with the procedures for installing such products, or similar products that are manufactured. The manufacturer al[...]

19  ELE CTR ICAL HA Z AR DS  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 mus[...]

20 1.1 P U R POSE AN D S COPE OF TH E MAN U AL 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 conti[...]

21 Figure 1.2 – Major Features and Dimensions (Drawing 0F1127) Section 1 – General Information Recreational V ehicle Generator O IL FILTER O IL DRAIN H O S E S IDE EXHA U S T OU TLET O IL FILL A IR C LEANER " + " BATTERY CO NNE C TI O N C IR CU IT BREAKER S 4 26.7 [ 16. 8 " ] 4 8 0.0 [ 1 8 .9" ] 6 42.0 [ 25. 3 " ] FU S [...]

22 2.1 L OCA TION AN D SU P PORT 2.1.1 GEN ERA 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 [...]

23 2.1.4 GEN ERA T OR R ES TRAI NT Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing . These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compartment is used) and (c) the supporting framework (Figure 2.3). All bolts must be long enou[...]

24 If flexible metal conduit is used, it must be sealed internally at the end where it terminates inside the compartment ’s electrical junction box. NOTE: Flexible metal conduit, due to its unique construc- tion, is NOT vapor tight along its entire length. Seams and joints of the galvanized steel (whether used as a liner or for the compartment it[...]

25 Figure 2.7 – T ypical Noise Abatement 2.2.5 COMP ARTM ENT F L OOR CUT OUTS Provide openings in the generator compartment for the following items (Figure 2.8): Engine exhaust and cooling air outlets Generator cooling air inlet F our holes for passage of generator mounting bolts. See the "Generator Restraint" section. D ANGER  Fuel [...]

26 2.3 C OOLI NG AN D VENTI L A TI NG AI R It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. W ithout sufficient airflow , the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also may cause fire and personal injur[...]

27 Figure 2.12 – Air Inlet Using Ductwork Figure 2.13 – Air Inlet in V ehicle Skirt MINIMUM CLEARANCE 1-1/2" VEHICLE FLOOR VEHICLE SKIRT AIR INLET 2.3.3 COMP ENS A TING FOR R ES TRICTIONS Such materials as screening, louvers or expanded metal can restrict the free flow of air . Compensate for this restriction by making the actual air openi[...]

28 2.4.1 F UEL T AN K Either the generator must share the vehicle engine's fuel tank, or a separate fuel tank must be installed for the generator set. All fuel tanks installed on the vehicle must be constructed, installed and restrained so they comply with applicable codes, standards and regulations. If the generator is to share the vehicle en[...]

29 Figure 2.15 – T ypical Propane Gas Fuel System 2.5.2 SOME I MPORT ANT CONSIDER A TIONS When installing an LP gas system, consider seriously the following items: All fittings, lines, hoses and clamps must be tight and free of leaks. Apply a pipe sealant to threads when assembling threaded connections. This reduces the possibility of leakage. T [...]

30 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 that is propor - tional to airflow through t[...]

31 2.6.1 MUFF LERS AN D SP ARK AR R ES T ORS This muffler meets code and standard requirements of the U .S. F orest Service. Use only mufflers and parts approved by the manufacturer . Any person(s) installing an unapproved muffler , or an unapproved exhaust system part, or modifying an exhaust system in any way that might cause a hazard, is liable [...]

32 2 .7 . 2 W IRIN G W iring should be of stranded copper to reduce the chance that vibration may cause breakage. W ire gauge size should be large enough to handle at least 115 percent of the installed generator's rated maximum current. If neutral conductors are used, they must be the same size as other leg wires. Route power supply conductors[...]

33 2.7 .6 POWER S UPPL Y C O RD 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.  2.7 .7 GROU ND F AU L T CI RCU IT I NTERR U PTERS The National Electrical Code (NFP A 70, 551-7) requires that ground fault circuit interrupt[...]

34 2.8 B A T TER Y I NST ALL A TION 2.8.1 R E COMM EN DED BA TTER Y Install a battery that meets the following require - ments: The battery must be a 12-volt, automotive type storage battery . F or prevailing ambient temperatures above 32° F (0° C), use a battery rated 70 amp -hours and capable of delivering 400 cold- cranking amperes. F or preva[...]

35 2.9.1 R EMO TE P AN EL MODEL S The remote panels mount a rocker type start/stop switch, a “Generator Run ” advisory lamp and an hourmeter . The hourmeter should be used in con- junction with the maintenance operations found in P art I of this manual. Model 004057 includes the remote panel and a 10 foot long, 4 wire harness. Model 004184 incl[...]

3.5 I NS T ALL A TION CH E CKLIST L OCA TION AN D 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. ❑ So[...]

37 Section 4 – T roubleshooting Recreational V ehicle Generator TROU B LE SHOO TI NG GU I 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[...]

38 Section 5 — Electrical Data Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D1 7 54-A[...]

39 Section 5 — Electrical Data Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D1 7 54-A[...]

40 12 9 1 2 0 2 3 24 2 5 2 9 2 7 6 8 5 3 0 1 6 1 5 1 0 17 1 8 11 22 14 1 3 1 9 21 27 2 6 2 8 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Regulator (Model 020 1 0-2) – Drawing No. 0F11 2 5-C[...]

41 ITEM P ART NO . QTY . DESCRIPTION 1 0D56 9 4 1 CASTING, TWIN REGULA T OR HOUSING 2 0F47 9 5 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 TOR NO HOLE 10 0D3 9 73 1 PLUG, EXP ANSION 16MM TWINREG 11 0E6183 [...]

42 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Base and Pulleys (Model 04 1 64-3) – Drawing No. 0F1 1 24-C[...]

43 ITEM P ART NO . QTY . DESCRIPTION 1 1 ASSEMBL Y REGULA TOR (SEE E.V . 0F1125) 2 048031M 2 #8 HOSE CLAMP 3 0F7065 16” HOSE, 1/2” I.D . PETR OLEOM 4 022145 8 W ASHER FLA T 5/16”- M8 5 02212 9 12 W ASHER LOCK M8 - 5/16” 6 045771 3 NUT HEX M8-1.25 7 06684 9 2 SCREW , T APTITE M5-0.8 X 16MM LONG 8 022473 1 W ASHER FLA T 1/4” - M6 9 062684 1[...]

44 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Alternator and P anel (Model 04 1 64-3) – Drawing No. 0D1 77 6-F[...]

45 ITEM P ART NO . QTY . DESCRIPTION 1 0C 9 675 1 LOWER BEARING CARRIER 2 0A564 9 H 1 RO TOR ASSEM. 3 0A5646H 1 ST A T OR ASSEM. 4 07315 9 1 BALL BEARING 5 031 9 71 1 BALL BEARING 6 0C 9 674 1 UPPER BEARING CARRIER 7 0A652 9 4 STUD-ST A T OR 8 052858 4 M8-1.25 FLANGE LOCK NUT 9 066386 1 BR USH HOLDER 10 06684 9 3 M5-0.8 X 16 LG. T APTITE 11 0A8475 [...]

46 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Engine Sheet Metal (Model 020 1 0-2 and 04 1 64-3) – Drawing No. 0D1 760-H[...]

47 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Engine Sheet Metal (Model 020 1 0-2 and 04 1 64-3) – Drawing No. 0D1 760-H ITEM P ART NO . QTY . DESCRIPTION 1 0A4323 1 SCROLL, FL YWHEEL 2 045756 8 SCREW , T APTITE M6-1.0 X 10MM 3 02 9 28 9 2.5 FT . FO AM T APE 4 SR V 0 9 1222D 1 FL YWHEEL 5 0671 9 8N 1 WASHER, BEL[...]

48 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-4 1 0 Engine (Model 020 1 0-2 and 04 1 64-3) – Drawing No. 0E96 1 5-A[...]

49 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-4 1 0 Engine (Model 020 1 0-2 and 04 1 64-3) – Drawing No. 0E96 1 5-A ITEM P ART NO . QTY . DESCRIPTION 1 0G2565 1 RING SET , PIST ON DIA 9 0 2 0E3221 1 CONNECTING ROD 3 0E1466 1 PIST ON PIN 4 071 9 83 2 PIST ON PIN RET AINER 5 021713B 1 CYLINDER HEAD GASKET 6 0A1[...]

50 15 3 2 41 3 4 3 3 4 1 3 9 6 5 7 3 5 2 3 6 33 9 3 4 38 24 1 3 14 12 8 17 27 10 9 40 41 3 1 2 3 22 25 41 42 3 7 21 1 8 16 20 19 2 3 0 29 25 2 8 11 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Engine Accessories (Model 041 64-3) – Drawing No. 0F1 13 5[...]

51 ITEM P ART NO . QTY . DESCRIPTION 1 0A6532 1 MANIFOLD , INT AKE 2 0 9 103 9 1 GASKET , MANIFOLD/HEAD 3 051753 1 HHCS-M6-1.0 X 40MM 4 0E7585 1 SP ARK PLUG, CHAMP 5 08 9 228 1 GASKET , CARB/MANIFOLD 6 0A7336B 1 CARBURET OR, GN 410 L/P 7 0 9 0 9 70 1 GASKET , CARB/AIR FIL TER 8 0A6564 1 BASE, AIR FIL TER 9 0568 9 3 3 CRIMPTITE #10-24 X 1/2" 10[...]

52 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 to explain the Emission Control System W arranty on your new[...]

53 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 P eriod shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purch[...]

Part No. 0F1118 Revision F (10/23/07) Printed in U.S.A. Section 7 – W arranty Recreational V ehicle Generator 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 GENERA C PO WER SYSTEMS A UTHORIZED SER VICE F ACILITIES. F or a period of 3 (three) years of [...]