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Guardian 004702-0, 004703-0, 004704-0, 004705-0, 004706-0, 004707-0 Owner's Manual

Guardian air-cooled automatic standby generator installation and owner's manual.

 
Owner's Manual
Air-cooled Recreational
Vehicle Generators
®
QUIETPACT
55, 65 and 75
• Models: 004702-0, 004703-0
004704-0, 004705-0
004706-0, & 004707-0
This manual should remain with the unit.

Summary of Contents

  • Page 1

    Owner’s Manual Air-cooled Recreational Vehicle Generators ® QUIETPACT 55, 65 and 75 • Models: 004702-0, 004703-0 004704-0, 004705-0 004706-0, & 004707-0 This manual should remain with the unit.

  • Page 2: Numbers 004702-0, 004703-0, 004704-0

    INTRODUCTION READ THIS MANUAL THOROUGHLY 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, WARNING, CAUTION and NOTE blocks are used to alert person- nel to special instructions about a particular opera- tion that may be hazardous if performed incorrectly...

  • Page 3: Table Of Contents

    Part I — Operating Instructions Introduction ... Inside Front Cover Read This Manual Thoroughly ...IFC Contents ...IFC Operation and Maintenance ...IFC How to Obtain Service ...IFC Authorized Service Dealer Locator Number ... IFC Safety Rules ... 2 Section 1 – General Information ... 4 Generator Identification ...

  • Page 4: Safety Rules

    Safety Rules Recreational Vehicle Generators  SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment. ...

  • Page 5

    • 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 NEGATIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step.

  • Page 6: Section 1 – General Information, Generator Identification

    Section 1 – General Information Recreational Vehicle Generators GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal. 1. Model Number _____________________ 3. kW Rating _________________________ 5. Phase ______________________________ 1. Generator Air Intake Screen 2. Data Plate 3.

  • Page 7: Generator Applicability, Installation, Safety, Generator Ac Connection System

    GENERATOR APPLICABILITY 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 its applica- tion, write or call the factory.

  • Page 8: Specifications

    Section 1 – General Information Recreational Vehicle Generators Figure 1.1 – Connection for 120 Volts Only Figure 1.2 - Connection for 120/240 Volts GROUNDED NEUTRAL STATOR WINDINGS SPECIFICATIONS 1.6.1 FUEL REQUIREMENTS (GASOLINE) This generator is equipped with a gasoline fuel system as standard equipment.

  • Page 9: Section 2 – Operation, Generator Control Panel

    1.6.3 GENERATOR SPECIFICATIONS SERIES Rotor RPM Rotor Poles Engine RPM Rated Max. Continuous AC Output Watts* Voltage* Rated Max. Continuous Current Amps (240V) Phase Frequency Battery Charging Current (Max.) Weight Length Width Height * All units are reconnectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output 1.6.5 EMISSIONS COMPLIANCE PERIOD For nonhandled engines the Emissions Compliance Period referred to on the Emissions Compliance...

  • Page 10: Optional Remote Start/stop Panel, Automatic Choke, Before Starting The Engine

    Section 2 – Operation Recreational Vehicle Generators OPTIONAL REMOTE START/STOP PANEL A remote mounted Start/Stop Panel (Figure 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 prime switch, and a wire harness.

  • Page 11: Starting The Generator, Stopping The Generator, Applying Loads To Generator

    DANGER  The generator engine releases DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient con- centrations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area.

  • Page 12: Protection Systems

    Section 2 – Operation Recreational Vehicle Generators 2.7.2 DO NOT OVERLOAD THE GENERATOR 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.

  • Page 13: Section 3 – Maintenance, Checking The Engine Oil Level

    2.8.4 OVERVOLTAGE PROTECTION 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, in turn, the voltage delivered to connected electrical loads is controlled.

  • Page 14: Changing The Engine Oil And/or Oil Filter, Maintaining The Engine Air Cleaner

    Section 3 – Maintenance Recreational Vehicle Generators CHANGING THE ENGINE OIL AND/OR OIL FILTER • 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.

  • Page 15: Checking The Engine Spark Plug, Clean Spark Arrestor

    Figure 3.3 – Engine Air Cleaner Offset S Wing CHECKING THE ENGINE SPARK PLUG 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.

  • Page 16: Cleaning The Generator, Battery Maintenance

    Section 3 – Maintenance Recreational Vehicle Generators CLEANING THE GENERATOR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and mois- ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings.

  • Page 17: Major Service Manual, Drive Belt, Exercising The Generator, Out Of Service Procedure

    MAJOR SERVICE MANUAL To 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. 3.10 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement.

  • Page 18: Section 4 – Notes

    Section 4 – Notes Recreational Vehicle Generators...

  • Page 19: Part Ii — Installation Instructions

    PART II – INSTALLATION INSTRUCTIONS DANGER ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

  • Page 20

    Safety Rules Recreational Vehicle Generators  DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the manufacturer’s instructions and recommendations.

  • Page 21

    • 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 interior, even if the unit is not running.

  • Page 22: Section 5 — General Information, Purpose And Scope Of The Installation Instructions, Safety, Standards Booklets

    Section 5 – General Information Recreational Vehicle Generators PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS 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 continued reliable operation of the equipment.

  • Page 23: Major Features And Dimensions

    Section 5 – General Information Recreational Vehicle Generators Figure 5.2 - Major Features and Dimensions (Drawing No. 0E1058-E)

  • Page 24: Section 6 — Installation, Location And Support

    Section 6 – Installation Recreational Vehicle Generators Figure 5.3 - Connection for 120/240 Volts GROUNDED NEUTRAL STATOR WINDINGS • The AC connection system on all air-cooled PRIMEPACT series generators uses a GROUNDED neutral. • A separate green ground wire is connected to the recreational vehicle’s junction box.

  • Page 25: Generator Compartments

    • 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 SUSPENDED MOUNTING If planning to suspend the generator below the hori- zontal support tubing, the suspension method to use with the vehicle frame members must (a) be able to support the weight of the generator AND (b) provide...

  • Page 26

    Section 6 – Installation Recreational Vehicle Generators • 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).

  • Page 27: Cooling And Ventilating Air

    Using a combination of sound insulating materials can often reduce noise more effectively than a single material. For 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.

  • Page 28: Gasoline Fuel System

    Section 6 – Installation Recreational Vehicle Generators HOT AIR EXHAUST TAILPIPE LOCATION 25.4 [ 1"] 526.2 [ 20 11/16"] [ 19 1/2"] TYP. TYP. 516.2 469.8 [ 20 5/16"] [ 18 1/2"] TYP. [ 1/4"] Figure 6.9 – Airflow Through Engine/Generator 6.3.2 TESTING THE INSTALLATION The manufacturer recommends testing the installa- tion to be sure adequate cooling airflow is available to...

  • Page 29: Lp Gas Fuel System

    Figure 6.10 – Generator Fuel System Fuel Line Factory 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.

  • Page 30

    Section 6 – Installation Recreational Vehicle Generators 6.5.2 PARTS NOT INCLUDED IN FUEL SYSTEM 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).

  • Page 31: Exhaust System

    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.

  • Page 32: Electrical Connections

    Section 6 – Installation Recreational Vehicle Generators  Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping. This causes excessive back pressure on the generator engine. Also, water from one engine can dam- age the other engine. 6.6.1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U.S.

  • Page 33

    6.7.1 ELECTRICAL JUNCTION 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.

  • Page 34: Battery Installation

    Section 6 – Installation Recreational Vehicle Generators 6.7.6 POWER SUPPLY CORD 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 GROUND FAULT CIRCUIT INTERRUPTERS...

  • Page 35

    Section 6 – Installation Recreational Vehicle Generators Figure 6.15 — Transfer Switch Isolation Method QUIETPACT POWERED BY GUARDIAN 760cc OHVI V-TWIN INDUSTRIAL Figure 6.16 — Installation With Isolation Receptacle QUIETPACT POWERED BY GUARDIAN 760cc OHVI V-TWIN INDUSTRIAL...

  • Page 36: Optional Accessories, Section 7 — Post Installation, Post Installation Tests, Before Initial Start-up, Initial Start

    Section 7 – Post Installation Recreational Vehicle Generators OPTIONAL ACCESSORIES A plug-in receptacle (Figure 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 the vehicle.

  • Page 37: Testing Under Load, Installation Checklist

    TESTING UNDER LOAD 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.

  • Page 38: Section 8 – Troubleshooting, Troubleshooting Guide

    Section 8 – Troubleshooting Recreational Vehicle Generators TROUBLESHOOTING GUIDE Problem Engine won’t crank. Engine cranks, won't start. Engine starts hard, runs rough. Engine starts, then shuts down. No AC output voltage. Cause 7.5 amp fuse blown. Loose, or corroded or defective battery cable(s).

  • Page 39: Section 9 – Notes

    Section 9 – Notes Recreational Vehicle Generators...

  • Page 40: Section 10 – Electrical Data

    Section 10 — Electrical Data Recreational Vehicle Generators Electrical Schematic - V-Twin – Drawing No. 0E1057-E WHITE GREEN 120V 30A - QP55 & QP65 120V 35A - QP75 NEUTRAL CONNECTION BY CUSTOMER BATTERY J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 (START) J1-7 (STOP) J1-8...

  • Page 41

    TO 12V BATTERY J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 PCB J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 CONN. 1 PIN# CONN. 2 PIN# Electrical Schematic - V-Twin – Drawing No. 0E1057-E 6 2A Section 10 — Electrical Data Recreational Vehicle Generators ELECTRONIC VOLTAGE...

  • Page 42: Section 11 – Exploded Views And Parts Lists

    Section 11 — Exploded Views and Parts Lists Recreational Vehicle Generators Base & Pulley – Drawing No. 0E1323-C "B" "A "B" TO CARB. 26 52 50 51...

  • Page 43

    ITEM PART NO. QTY. DESCRIPTION 0E0196 FRAME, 760 ENGINE 022129 WASHER LOCK M8-5/16 022145 WASHER FLAT 5/16-M8 ZINC 022259 NUT HEX 5/16-18 STEEL 0C7758 VIB MNT 1.5 X 1.38 X 5/16-18 0C3168 WASHER LOCK SPECIAL 5/16 0C2417 EARTH STRAP 077603 SCREW HHC 5/16-18 X 3.5 SPC 0E0588 SPACER, SAFETY BOLT .375 I.D.

  • Page 44

    Section 11 — Exploded Views and Parts Lists Recreational Vehicle Generators Enclosure – Drawing No. 0E1011-C...

  • Page 45

    ITEM PART NO. QTY. 0D8827 0A7215 029451 11.5 FT. 0D8825 0D3700 0D3700 090388 0D8979 0D8960 023484D 0E0594 064113 0E0575 0D8980 0E1376 0E1377 0D8628 0D8910 0D8826 0D9162 0C5644 0D8828 0E0585 0E1486 0E1774 0D9099 074908 022473 022097 022507 0742600149 0C7968 022237 0C7423 0742600151 0A4456 0D8502...

  • Page 46

    Section 11 — Exploded Views and Parts Lists Recreational Vehicle Generators Sheet Metal – Drawing No. 0F1996-C "A" "B" "C" "A" "C" "B" TO LP REGULATOR "C"...

  • Page 47

    ITEM PART NO. QTY. DESCRIPTION 045756 SCREW HHTT M6-1.0 X 10 YC 0D1131 GUARD,FAN 12KW HSB 0F1169G HOUSING, BLOWER V-TWIN RV 0C9763 NUT,GROMMET 1/4 PLUG 0D9782A HOSE, BREATHER 0C3034 NUT HEX M24-2.0 G8 YEL CHR 0C3033 WASHER,BELLEVILLE 25MM BOLT 051754 SCREW HHC M8-1.25 X 12 G8.8 0A5992 WASHER SHAKEPROOF INT M8 SS...

  • Page 48

    Section 11 — Exploded Views and Parts Lists Recreational Vehicle Generators Control Panel – Drawing No. 0E1013-A 12 2 14 4 27 7 28,2 45 5 44 4 34 35...

  • Page 49

    ITEM PART NO. QTY. DESCRIPTION 0C2375 SCREW HHC M8-1.25 X 90 G8.8 022145 WASHER FLAT 5/16-M8 ZINC 029459 TENSION SPRING 075215 WASHER, SPRING CENTER 052858 NUT LOCK FL M8-1.25 047411 SCREW HHC M6-1.0 X 16 G8.8 022097 WASHER LOCK M6-1/4 022473 WASHER FLAT 1/4-M6 ZINC 080925...

  • Page 50

    Section 11 — Exploded Views and Parts Lists Recreational Vehicle Generators 760 V-Twin Engine – Drawing No. 0F1997...

  • Page 51

    ITEM PART NO. QTY. DESCRIPTION 0C5730A ASSEMBLY, CRANKCASE RV 0E9843 SEAL, 38 I.D. CRANKCASE 090388 SCREW, HHTT M6-1.0 X 12mm 0C5372 ASSEMBLY, BREATHER 0C3005 GASKET, BREATHER COVER 0E3372A SEPARATOR, OIL BREATHER 0D8067A ASSEMBLY, HEAD #1 0C2981C COVER, ROCKER 071983 RETAINER, PISTON PIN 20 0E2985 PISTON, HC 021533...

  • Page 52

    Section 11 — Exploded Views and Parts Lists Recreational Vehicle Generators LP Regulator – Drawing No. 0E1530-C...

  • Page 53

    ITEM PART NO. QTY. 0D5694 0F4795 0F5022 0C6070 0C4680 0C4647 0C4643 0D3973 0C6606 026073 0D3308 070728 0C5764 0C4643A 0C6066 0C5968 0C5759 0C5761 0C6069 0C6731 0C6067 0C4706 0C6068 0C5762 045764 Section 11 — Exploded Views and Parts Lists Recreational Vehicle Generators LP Regulator –...

  • Page 54: Section 12 – Warranty

    Section 12 – Warranty Recreational Vehicle Generators CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.* New utility, and lawn and garden equipment engines must be designed, built and equipped to meet stringent anti-smog standards for the state of California and the federal government.

  • Page 55

    Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.

  • Page 56

    Section 12 – Warranty Recreational Vehicle Generators GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (three) years of operation from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

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