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Guardian Technologies 004700-0 manual

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Table of contents for the manual

  • Page 1

    Owner’ s Man ual and Installation Instructions Air -cooled Recreational V ehic le Generators Models: 004700-0 004708-0 QUIETP A CT 40G This manual should remain with the unit.[...]

  • Page 2

    I NTRODUCTION Thank you for purchasing this model by Generac P ower Systems Inc. This model is designed and man- ufactured to supply electrical power for recreational vehicles. R EAD T  H IS MANUAL THOROUGHL Y If any portion of this manual is not understood, con- tact the nearest Authorized Service Dealer for starting , operating and servicing p[...]

  • Page 3

    T able of Contents Recreational V ehicle Generator 1 Part – Owner’s Manual Introduction ........................................ Inside Front Cover Read This Manual Thoroughly ................................. IFC Contents .................................................................. IFC Operation and Maintenance ..........................[...]

  • Page 4

    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[...]

  • Page 5

    3 When working on this equipment, remain alert • at all times. Never work on the equipment when physically or mentally fatigued. Inspect the generator regularly , and contact the • nearest Authorized Service Dealer immediately for parts needing repair or replacement. Before performing any maintenance on the gen- • erator , disconnect its batt[...]

  • Page 6

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

  • Page 7

    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[...]

  • Page 8

    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[...]

  • Page 9

    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 PRI ME FUEL STO P START 30A C. B . FUS E CONTROL CENTER 7. 5 A 2.1.1 F UEL PRIME R  Before starting a cold engine (if it has not been st[...]

  • Page 10

    8 Section 2 – Operation Recreational V ehicle Generator 2.4.2 ENGI NE L UB R ICA TION  Have the engine crankcase properly serviced with the recommended oil before starting . Refer to sections "Engine Oil Requiremtents", "Checking the Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter" for oil servici[...]

  • Page 11

    9 Section 2 – Operation Recreational V ehicle Generator 2.6 S T OP P I NG TH E GEN ER A T OR 1. T urn OFF all electrical loads using the means provided (such as a main circuit breaker or transfer switch). 2. Let generator run at no -load for a few minutes, to stabilize internal engine generator temperatures. 3. Place the Start/Stop switch in its [...]

  • Page 12

    10 Section 2 – Operation Recreational V ehicle Generator 2.9.3 F IELD BOOST  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 “field boost ” circuit (Figure 2.3). During engine cranking only , a positive DC (battery) voltage is delivere[...]

  • Page 13

    11 Section 3 – Maintenance Recreational V ehicle Generator 3.1 CH E CKI NG TH E ENGI N E OI L LEVEL F or oil capacities and requirements, see “Engine Oil Requirements”. Check the engine crankcase oil level at least every eight hours of operation, or before each use. T o check the engine oil level, proceed as follows (see Figure 3.1): 1. Be su[...]

  • Page 14

    12 Section 3 – Maintenance Recreational V ehicle Generator NOTE: Check the oil level and fill to the “FULL ” mark after checking for leaks. The filter will retain some oil. 3.3 MAI NT AI N I NG TH E ENGI N E AI R CLEAN ER 3.3.1 CLEAN ING TH E FO AM PR ECLEANER  Clean and re - oil the foam precleaner every three months or every 25 hours of [...]

  • Page 15

    Section 3 – Maintenance Recreational V ehicle Generator Figure 3.4 – Setting the Spark Plug Gap  Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end. If nec- essary , re-form the wire terminal to obtain a tight fit. 3.6 F U EL F I L TER Remove and replace the fuel filter (Figure 3.5) once each year or e[...]

  • Page 16

    14 3.9 B A T TER Y MAINTENANCE All lead-acid batteries will discharge when not in use. The generator battery should be inspected as follows: 3.9.1 WEEKL Y  Inspect the battery posts and cables for tightness • and corrosion. Tighten and clean as necessary . Check the battery fluid level of unsealed batteries • and, if necessary , fill with Di[...]

  • Page 17

    15 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 engine oil into the spark plug threaded openings. Reinstall and tighten the spark plug . 6. Remove the battery and store it in a cool, dry room on a wooden board. Never [...]

  • Page 18

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

  • Page 19

    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![...]

  • Page 20

    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 familiar with the procedures for installing such products, or similar products manufactured. The manufacturer also assumes [...]

  • Page 21

    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[...]

  • Page 22

    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[...]

  • Page 23

    21 Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-H) Section 1 – General Information Recreational V ehicle Generator[...]

  • Page 24

    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[...]

  • Page 25

    23 Figure 2.2 – T ypical Suspended Mounting System GENERA TOR SUPPORT FRAME (MODEL 004718-0) GENERA TOR MOUNTING HOLES FOR 5/16" - 18 BOL TS (6 PLACES) 2.1.4 GEN ERA T OR R ES TRAI NT  Use four 5/16"-18 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing . These bolts must pass through[...]

  • Page 26

    24 If constructing a compartment, line the exterior • (underside) of the compartment floor with 26- gauge galvanized steel. All seams, splices and joints of the compartment • walls (unless vapor tight by design) should be caulked to prevent poisonous, flammable or explo - sive vapors from entering the vehicle interior . NOTE: Caulking must be d[...]

  • Page 27

    25 Figure 2.7 – T ypical Noise Abatement Line the compartment interior walls and floor , as • well as the underside of the floor , with 26-gauge galvanized steel. V apor seal all compartment seams and joints. • Over the galvanized steel lining, install a combi- • nation of acoustical materials as mentioned in "Sound Insulating Material[...]

  • Page 28

    26 Section 2 – Installation Recreational V ehicle Generator Figure 2.8 – Compartment Floor Cutout (Drawing 0G3723-A)[...]

  • Page 29

    27 2.3.2 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 absolutely certain that cooling and ventilation [...]

  • Page 30

    28 2.4.2.2 Flexible Fuel Line Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines. This prevents breaking of the line caused by vibration, shifting, settling or movement. The follow- ing rules apply: The flexible hose must comply with SAE J30R7, • “Standard for F uel and Oil Hose.” It [...]

  • Page 31

    29 2.5.2 EXHAUST S Y STEM S AFETY  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 material). If the 3-inch (76 mm) clearance cannont be maintained, locate, insulate or shield the exhaust part(s) so that the tempera- ture o[...]

  • Page 32

    30 Figure 2.13 – Generator AC Output Leads 483.1 AC OUTPUT HARNESS REMOTE P ANEL CONNECTOR BA TTERY CONNECTIONS FUEL FIL TER I t r e , e h i t w a n c . - s m , I e W W y s S r o P w e A C N R E G E t TM  Do NOT connect electrical loads in excess of any circuit br eaker rating or problems will develop with circuit br eaker tripping, which caus[...]

  • Page 33

    31 2.6.7 GROU ND F AU L T CI RCUIT  I NTERR U PTERS The National Electrical Code (NFP A 70, 551-7) requires that ground fault circuit interrupters (GFCIs) be installed on all external and some internal electri- cal receptacles. Contact the dealer for recommenda- tions. 2.7 B A T TER Y INST ALL A TION 2.7 .1 REC OMM EN DED BA T TER Y  Install [...]

  • Page 34

    32 2.7 .3 B A T TER Y CABLE CONN 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 N[...]

  • Page 35

    33 Section 3 – Post-Installation Start-up Adjustments Recreational V ehicle Generator 3.1 POS T I NST ALLA TION T ESTS The air - cooled generator set was factory tested and adjusted. It should not be required to adjust the unit any further except under special circumstances.  Do not make any unnecessary adjustments. Factory settings are corr e[...]

  • Page 36

    34 Section 3 – Post-Installation Start-up Adjustments Recreational V ehicle Generator 3.5 I NS T ALL A TION CH ECKLIS T L OCA TION AN D SU P PORT  ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GEN ERA T OR COMP ARTM ENT  ❑ Compartment construction is proper . ❑ Holes/Openin[...]

  • Page 37

    35 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[...]

  • Page 38

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

  • Page 39

    37 Section 5 — Electrical Data Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D 0 CONN. 2 PIN# 0 90 14 14 CH 18A 90 85 LOP C S 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 F S 14 2 3 18 18A 18 CONN. 1 PIN# 0 0 FP 90 14 2 1 2[...]

  • Page 40

    38 Section 6 — Exploded Views and P ar ts Lists Recreational V ehicle Generator Enclosure – Drawing No. 0D835 2-M[...]

  • Page 41

    39 ITEM P ART NO . QTY . DESCRIPTION 1 0D6822 1 TRA Y , ENCLO S URE 2 0D6942 1 P ANEL, ENCLO S URE S IDE 3 0D6939 1 P ANEL, REAR DIVIDER 4 0D6943 1 P ANEL, ENCLO S URE ROOF 5 0D6941 1 P ANEL, ENCLO S URE BA CK 0D6941A 1 P ANEL, ENCLO S URE BACK, EXTERNAL PORT (04709 ONL Y) 6 0D6940 1 P ANEL, FRONT DIVIDER 0D6940A 1 P ANEL, FRONT DIVIDER, EXTERNAL P[...]

  • Page 42

    40 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Generator – Drawing No. 0D835 3-M[...]

  • Page 43

    41 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Generator – Drawing No. 0D835 3-M ITEM P ART NO . QTY . DESCRIPTION 1 029092 1 S CREW IHHC 5/16”-24 X 11-1/4” G5 2 022129 22 W A S HER LOCK M8-5/16” 3 049451 1 W A S HER FLA T .406” I.D . X 1.62” O .D . 4 0C8096A 1 F AN, 8" CURVE BLADE, 16.5MM I.D . 5 [...]

  • Page 44

    42 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Control Panel – Drawing No. 0D83 54-H[...]

  • Page 45

    43 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Control Panel – Drawing No. 0D83 54-H ITEM P ART NO . QTY . DESCRIPTION 1 0F9719 1 REGULA TOR V OL T AGE 2 075210A 1 TERMINAL BLOCK 3 092234 1 CONTROLLER P .C.B . 4 065795 1 BA TTER Y CHARGER RECTIFIER 5 023484F 1 BU S HING S NAP 1” 023484F 2 BU S HING S NAP 1” ([...]

  • Page 46

    44 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0D8355-AD P art 1[...]

  • Page 47

    45 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0D8355-AD P art 1 ITEM P ART NO . QTY . DESCRIPTION 1 0D8433 1 GUARD , F AN 2 0C1069 11 S CREW , HHTT M6-1.0 X 8MM 0C1069 10 (04709 ONL Y) 3 090965F 1 BLOWER HOU S ING 0G6468 1 BLOWER HOU S ING 220R V (04709 ONL Y) 4 081810 1 NUT , H[...]

  • Page 48

    46 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0D8355-AD P art 2[...]

  • Page 49

    47 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-22 0 H/SH Engine – Drawing No. 0D8355-AD P art 2 ITEM P ART NO . QTY . DESCRIPTION N/A 0E8804 1 LONG BLOCK A SS EMBL Y 1 078621 1 CONNECTING R OD A SS EMBL Y 2 076389 1 PI S T ON PIN 3 0G4379 1 PI S T ON RING S ET DIA 75 PLA TEA U HONED 4 0A8897B 1 GEAR CO VER A S[...]

  • Page 50

    48 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[...]

  • Page 51

    49 EM IS SION CONTROL S Y STEM W AR R 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 Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchas[...]

  • Page 52

    Part No. 0D8351A Revision A (08/15/08) 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 GENERAC PO WER SYSTEMS AUTHORIZED SER VICE F ACILITIES. F or a period of 3 (three) years of o[...]