GermGuardian 004700-0 - Manuals

Page 2 - INTRODUCTION; DANGER; After this heading, read explanatory statements; AUTHORIZED SERVICE

INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc. This model is designed and man-ufactured to supply electrical power for recreational vehicles. READ T HIS MANUAL THOROUGHLY If any portion of this manual is not understood, con-tact the nearest Authorized Service Dealer...

Page 3 - Table of Contents; Recreational Vehicle Generator; Part – Owner’s Manual

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

Page 4 - Despite the safe design of this generator,; GENERAL HAZARDS; For safety reasons, the manufacturer recommends; Safety Rules; The engine exhaust from this product contains

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 fail...

Page 6 - Sectio n 1 – General Information; Number; GENERATOR IDENTIFICATION

4 1. Generator Air Intake 2. Engine Start/Stop Switch 3. Fuse 4. Optional Remote Panel Receptacle (Side View) 5. Generator AC Output Leads (Side View) 6. Fuel Primer Switch 7. Circuit Breaker 8. Starter Contactor 9. Fuel Inlet 10. Fuel Pump (Behind Access Panel) 11. Fuel Filter (Side View) 12. Oil F...

Page 7 - Section 1 – General Information; APPLICABILITY; For fire safety, the generator must have been; GENERATOR AC; Figure 1.1 – Connections for 120 Volts Only; SPECIFICATIONS; REQUIREMENTS

5 Section 1 – General Information Recreational Vehicle Generator 1.2 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. ...

Page 8 - The manufacturer does not recommend using; CONSUMPTION; Model; For engines less than 225 cc displacement, Category

6 Section 1 – General Information Recreational Vehicle Generator  The manufacturer does not recommend using any gasoline containing alcohol (such as “gaso-hol”). If using any gasoline containing alcohol, it must not contain more than 10 percent ethanol, and it must be removed from the generator dur...

Page 9 - Section 2 – Operation; GENERATOR CONTROL PANEL; Figure 2.1 – Generator Control Panel; PRIMER; OPTIONAL REMOTE; SOLENOID; BEFORE STARTING THE ENGINE

7 Section 2 – Operation Recreational Vehicle Generator 2.1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control Panel P R I M E F U E L S T O P S T A R T 3 0 A C . B . F U S E CONTROL CENTER 7. 5 A 2.1.1 FUEL PRIMER ...

Page 10 - LUBRICATION; Any attempt to crank or start the engine before; SUPPLY; The generator engine releases DEADLY carbon; Never sleep in the vehicle while the genset is; STARTING THE GENERATOR; Read the vehicle manufacturer’s instructions.; If the engine does not start after it has been

8 Section 2 – Operation Recreational Vehicle Generator 2.4.2 ENGINE LUBRICATION 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/o...

Page 11 - STOPPING THE GENERATOR; Figure 2.2 – Low Oil Pressure and

9 Section 2 – Operation Recreational Vehicle Generator 2.6 STOPPING THE GENERATOR 1. Turn 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. ...

Page 12 - BOOST; Figure 2.3 – Field Boost Circuit; PROTECTION; Figure 2.4 – Solid State Voltage Regulator; ADDITIONAL INFORMATION; AFTER SUBMERSION; MUST NOT; OR BRUSH

10 Section 2 – Operation Recreational Vehicle Generator 2.9.3 FIELD 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 pos...

Page 13 - Section 3 – Maintenance; Never operate the engine with the oil level; CHANGING THE ENGINE OIL; engine oil; Oil Dipstick/Oil Fill; Figure 3.1 – Oil Maintenance Features

11 Section 3 – Maintenance Recreational Vehicle Generator 3.1 CHECKING THE ENGINE OIL LEVEL For 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. To check the engine oil level, proceed as ...

Page 14 - MAINTAINING THE ENGINE; Figure 3.2 – Engine Air Cleaner; CLEANING OR REPLACING; CLEAN AIR INTAKE; Figure 3.3 – Cleaning Air Intake; CHECKING THE ENGINE

12 Section 3 – Maintenance Recreational Vehicle Generator NOTE: Check the oil level and fill to the “FULL” mark after checking for leaks. The filter will retain some oil. 3.3 MAINTAINING THE ENGINE AIR CLEANER 3.3.1 CLEANING THE FOAM PRECLEANER Clean and re-oil the foam precleaner every three mont...

Page 15 - Figure 3.4 – Setting the Spark Plug Gap; Sparking can occur if the wire terminal does not; Figure 3.5 – Fuel Filter; CLEAN SPARK ARRESTOR; Clean and inspect the spark arrestor as follows:; SPARK ARRRESTOR; CLEANING THE GENERATOR; Do NOT use a forceful spray of water to clean

Section 3 – Maintenance Recreational Vehicle 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 FUEL FILTER Remove and replace the fuel fil...

Page 16 - BATTERY MAINTENANCE; MAJOR SERVICE MANUAL

14 3.9 BATTERY MAINTENANCE All lead-acid batteries will discharge when not in use. The generator battery should be inspected as follows: 3.9.1 WEEKLY Inspect the battery posts and cables for tightness • and corrosion. Tighten and clean as necessary. Check the battery fluid level of unsealed batter...

Page 17 - ADJUSTING VALVE CLEARANCE; Figure 3.7 — Adjusting Valve Clearance; Figure 3.8 — Tightening Jam Nut

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...

Page 18 - Section 4 – Notes

16 Section 4 – Notes Recreational Vehicle Generator

Page 19 - ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

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

Page 20 - NOTICE TO INSTALLER; Installation Instructions

18 NOTICE TO INSTALLER 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...

Page 22 - Figure 1.1 – 120-volt Single Voltage Connection

20 1.1 PURPOSE AND SCOPE OF THE 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 ...

Page 24 - LOCATION AND SUPPORT; LOCATION; Figure 2.1 – Typical Horizontal Support Frame; MOUNTING; Section 2 – Installation

22 2.1 LOCATION AND SUPPORT 2.1.1 GENERATOR LOCATION 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 ...

Page 25 - RESTRAINT; Figure 2.3 – Typical Generator Restraint; GENERATOR COMPARTMENTS; SIZE; Figure 2.4 – Clearances; CONSTRUCTION; The generator compartment should be either con-; Figure 2.5 – Typical Compartment Construction

23 Figure 2.2 – Typical Suspended Mounting System GENERATOR SUPPORT FRAME(MODEL 004718-0) GENERATOR MOUNTINGHOLES FOR 5/16" - 18BOLTS (6 PLACES) 2.1.4 GENERATOR RESTRAINT Use four 5/16"-18 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing....

Page 26 - Figure 2.6 – Types of Lock Seams; Do not install any flammable material directly; Do not install sound insulation or any absorbent

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 ...

Page 27 - Figure 2.7 – Typical Noise Abatement; To prevent fire or explosion, do not install any; Fuel lines and exhaust piping must not pen-; COOLING AND VENTILATING AIR; Never use discharged cooling air for heating or; AIRFLOW; Figure 2.9 – Airflow Through Engine/Generator

25 Figure 2.7 – Typical Noise Abatement Line the compartment interior walls and floor, as • well as the underside of the floor, with 26-gauge galvanized steel. Vapor seal all compartment seams and joints. • Over the galvanized steel lining, install a combi- • nation of acoustical materials as mentio...

Page 29 - GASOLINE FUEL SYSTEM; Figure 2.10 – Generator Fuel System; Gasoline is highly flammable, and its vapors are; TANK; Do NOT tee the generator fuel supply line

27 2.3.2 TESTING THE INSTALLATION 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 absolut...

Page 30 - EXHAUST SYSTEM; The generator engine gives off DEADLY carbon; ARRESTOR; Figure 2.12 — Spark Arrestor Installation

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 J30R...

Page 31 - SYSTEM SAFETY; ELECTRICAL CONNECTIONS

29 2.5.2 EXHAUST SYSTEM SAFETY 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 e...

Page 32 - Figure 2.13 – Generator AC Output Leads; Do NOT connect electrical loads in excess of any; ISOLATING DIFFERENT POWER; Figure 2.14 – Transfer Switch Isolation Method

30 Figure 2.13 – Generator AC Output Leads 483.1 AC OUTPUTHARNESS REMOTE PANELCONNECTOR BATTERY CONNECTIONS FUEL FILTER I t r e , e h it 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 breaker rating or problems will develop wit...

Page 33 - BATTERY INSTALLATION; The battery must be a 12-volt, automotive type; CABLES; Figure 2.15 – Installation With Isolation Receptacle; CABLE

31 2.6.7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code (NFPA 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 BATTERY INSTALLATION 2.7.1 RECOMMEND...

Page 34 - Figure 2.16 – Connecting Battery Cables; COMPARTMENT; OPTIONAL ACCESSORIES; Figure 2.17 – Remote Panel Plug-in Receptacle; Figure 2.18 – Optional Remote Panel

32 2.7.3 BATTERY CABLE CONNECTIONS 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 ca...

Page 35 - Section 3 – Post-Installation Start-up Adjustments; POST INSTALLATION TESTS; Do not make any unnecessary adjustments.; If a liquid propane (LP) gas fuel system has been; TESTING UNDER LOAD

33 Section 3 – Post-Installation Start-up Adjustments Recreational Vehicle Generator 3.1 POST INSTALLATION TESTS 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 ad...

Page 36 - INSTALLATION CHECKLIST

34 Section 3 – Post-Installation Start-up Adjustments Recreational Vehicle Generator 3.5 INSTALLATION CHECKLIST LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GENERATOR COMPARTMENT ❑ Compartment construction is proper....

Page 37 - Section 4 – Troubleshooting; TROUBLESHOOTING GUIDE; Problem Cause

35 Section 4 – Troubleshooting Recreational Vehicle Generator TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse 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 S...

Page 38 - Section 5 — Electrical Data

RED BLUE ORANGE BR O W N 7 7 YELLO W WHITE 15 BATTERY 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 REGULATOR VOLTAGE 2A 0N 0N R1 POWER WINDING 22 S 11 S 77 55 BLACK FUEL PRIME 11P 4 4 T1 4 CB1 REMOTE PANEL(OPTIONAL) 33 4...

Page 40 - Section 6 — Exploded Views and Parts Lists

38 Section 6 — Exploded Views and Parts Lists Recreational Vehicle GeneratorEnclosure – Drawing No. 0D8352-M

Page 43 - ITEM PART

41 Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Generator – Drawing No. 0D8353-M ITEM PART NO. QTY. DESCRIPTION 1 029092 1 S CREW IHHC 5/16”-24 X 11-1/4” G5 2 022129 22 WA S HER LOCK M8-5/16” 3 049451 1 WA S HER FLAT .406” I.D. X 1.62” O.D. 4 0C8096A 1 FAN, 8" CURVE ...

Page 50 - CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT

48 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 S...

Page 51 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:; Section 7 – Warranty

49 EMISSION CONTROL SYSTEM WARRANTY 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/de...

Page 52 - GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY

Part No. 0D8351A Revision A (08/15/08) Printed in U.S.A. Section 7 – Warranty Recreational Vehicle Generator 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...