GermGuardian 004702-0, 004703-0, 004704-0, 004705-0, 004706-0, 004707-0 - Manuals

Page 2 - INTRODUCTION; READ THIS MANUAL THOROUGHLY; After this heading, read explanatory statements; CONTENTS; AUTHORIZED SERVICE

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 ...

Page 3 - Table of Contents; Recreational Vehicle Generators; Part I — Operating Instructions

Table of Contents Recreational Vehicle Generators 1 Part I — Operating Instructions Introduction ...................................... Inside Front Cover Read This Manual Thoroughly ................................ IFC Contents ................................................................. IFC O...

Page 4 - DANGER; Despite the safe design of this generator,; GENERAL HAZARDS

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 5 - Safety Rules

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

Page 6 - Section 1 – General Information; Number; GENERATOR IDENTIFICATION; REFERENCE NUMBER IDENTIFICATION

4 Section 1 – General Information Recreational Vehicle Generators Please record the following information from the generator DATA DECAL or information decal. 1. Model Number _____________________ 2. Serial Number __________________ 3. kW Rating _________________________ 4. Rated Voltage ____________...

Page 7 - APPLICABILITY; For fire safety, the generator must have been; 20 VAC loads only — one load with a maximum

5 Section 1 – General Information Recreational Vehicle Generators 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 - Figure 1.1 – Connection for 120 Volts Only; NOTE; The manufacturer does not recommend using; SPECIFICATIONS

6 Section 1 – General Information Recreational Vehicle Generators Figure 1.1 – Connection for 120 Volts Only Figure 1.2 - Connection for 120/240 Volts T1 RED T2 WHITE T3 BLACK GROUNDED NEUTRAL STATOR WINDINGS CB1 CB2 1.6 SPECIFICATIONS 1.6.1 FUEL REQUIREMENTS (GASOLINE) This generator is equipped wi...

Page 9 - Section 2 – Operation; • For engines less than 225 cc displacement, Category; GENERATOR CONTROL PANEL; PRIMER; Figure 2.1 – Typical Control Panel; GENERATOR SPECIFICATIONS; SERIES

7 Section 2 – Operation Recreational Vehicle Generators 1.6.5 EMISSIONS COMPLIANCE PERIOD For nonhandled engines the Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal emission requirem...

Page 10 - Figure 2.2 — Optional Remote Panel; CHOKE; SOLENOID; BEFORE STARTING THE ENGINE; LUBRICATION; Any attempt to crank or start the engine before; SUPPLY

8 Section 2 – Operation Recreational Vehicle Generators 2.2 OPTIONAL REMOTESTART/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-me...

Page 11 - The generator engine releases DEADLY carbon; Never sleep in the vehicle while the genset is; THE; If the engine does not start after it has been; STOPPING THE GENERATOR

9 Section 2 – Operation Recreational Vehicle Generators 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 vehic...

Page 12 - • Most lighting, appliance, tool and motor loads; SYSTEMS; Figure 2.3 – Low Oil Pressure and; BOOST; Figure 2.4 – Field Boost Circuit

10 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 a...

Page 13 - Section 3 – Maintenance; PROTECTION; Figure 2.5 – Solid State Voltage Regulator; (The vehicle owner is responsible for any; Never operate the generator while the vehicle

11 Section 3 – Maintenance Recreational Vehicle Generators 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 ...

Page 14 - engine oil; Location of Oil Drain Plug

12 Section 3 – Maintenance Recreational Vehicle Generators 3.2 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. Change the oil more fre...

Page 15 - Figure 3.3 – Engine Air Cleaner; Figure 3.4 – Setting the Spark Plug Gap; Sparking can occur if the wire terminal does not; FILTER; Figure 3.5 – Fuel Filter; SPARK; Clean and inspect the spark arrestor as follows:; TO FUEL PUMP

Section 3 – Maintenance Recreational Vehicle Generators Figure 3.3 – Engine Air Cleaner WingNut Offset S A P l FlatWasher WingNut x Compartment 3.4 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 ...

Page 16 - • Inspect the battery posts and cables for tightness

14 3.7 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 wi...

Page 18 - Section 4 – Notes

16 Section 4 – Notes Recreational Vehicle Generators

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 Safety Rules Recreational Vehicle Generators 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 ...

Page 21 - ELECTRICAL HAZARDS

19 Safety Rules Recreational Vehicle 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 obj...

Page 22 - Figure 5.1 – Connection for 120 Volts Only; Section 5 – General Information

20 5.1 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 i...

Page 24 - LOCATION AND SUPPORT; LOCATION; Figure 6.1 – Typical Horizontal Support Frame; Section 6 – Installation

22 Figure 5.3 - Connection for 120/240 Volts T1 RED T2 WHITE T3 BLACK GROUNDED NEUTRAL STATOR WINDINGS CB1 CB2 • 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. • L...

Page 25 - • If the generator cannot be bolted directly to; MOUNTING; • Protect the generator against road splash and; Figure 6.2 – Typical Suspended Mounting; • The installer must make certain that the selected; RESTRAINT; Figure 6.3 – Typical Generator Restraint; GENERATOR COMPARTMENTS; SIZE; Figure 6.4 – Clearances; CONSTRUCTION; • The generator compartment should be either con-

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 SUSPENDED MOUNTING If planning to suspend the generator below the hori-zontal support ...

Page 26 - Do not install any flammable material directly; Do not install sound insulation or any absorbent

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 cr...

Page 27 - • Construct the compartment floor of a double thick-; Figure 6.7 – Typical Noise Abatement; To prevent fire or explosion, do not install any; • Seal all compartment door edges to prevent noise; FLOOR; Fuel lines and exhaust piping must not pen-; COOLING AND VENTILATING AIR; Never use discharged cooling air for heating or; AIRFLOW

25 Section 6 – Installation Recreational Vehicle Generators 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 th...

Page 28 - Figure 6.9 – Airflow Through Engine/Generator; GASOLINE FUEL SYSTEM; Gasoline is highly flammable, and its vapors are; Figure 6.8 — Compartment Floor Cutout

26 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 the unit before placing the unit into service. If the unit shows signs of overheating, enlarge the air openings. N...

Page 29 - Figure 6.10 – Generator Fuel System; TANK; Do NOT tee the generator fuel supply line; LP GAS FUEL SYSTEM; LP gas is highly EXPLOSIVE. The gas is heavier

27 Figure 6.10 – Generator Fuel System Fuel Pump(Behind AccessCover) Fuel Filter(Side of Unit) 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 ...

Page 30 - Use only approved components in the fuel sup-; Figure 6.11 – Typical Propane Gas Fuel System; WITHDRAWAL

28 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). DANGER  Use only approved c...

Page 31 - Figure 6.12 – LP Gas Carburetion Diagram; SUPPLY LINES; Gaseous fuel lines between the tank and the; TESTS; The generator engine gives off DEADLY carbon

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 regu...

Page 32 - Never tee the generator engine exhaust pipe; Figure 6.13 — Spark Arrestor Installation; SYSTEM SAFETY; ELECTRICAL CONNECTIONS

30  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 ...

Page 33 - Figure 6.14 – Generator AC Output Leads; Do NOT connect electrical loads in excess of any

31 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 flexibl...

Page 34 - SUPPLY CORD; INSTALLATION; BATTERY; Figure 6.17 – Connecting Battery Cables; COMPARTMENT; CABLE

32 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 The ...

Page 35 - Figure 6.15 — Transfer Switch Isolation Method; Figure 6.16 — Installation With Isolation Receptacle

33 Section 6 – Installation Recreational Vehicle Generators Figure 6.15 — Transfer Switch Isolation Method POWERED BY GUARDIAN 760cc OHVI V-TWIN QUIETPACT INDU S TRIAL 55G Figure 6.16 — Installation With Isolation Receptacle POWERED BY GUARDIAN 760cc OHVI V-TWIN QUIETPACT INDU S TRIAL 55G

Page 36 - OPTIONAL ACCESSORIES; Figure 6.18 – Remote Panel Plug-in Receptacle; PANEL; POST INSTALLATION TESTS; Do not make any unnecessary adjustments.; If a liquid propane (LP) gas fuel system has been

34 6.9 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 eng...

Page 37 - Section 7 – Post Installation

35 7.4 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...

Page 38 - Section 8 – Troubleshooting; GUIDE; Problem Cause

36 Section 8 – Troubleshooting Recreational Vehicle Generators 8.1 TROUBLESHOOTING GUIDE Problem Cause Correction Engine won’t crank. 1. 7.5 amp fuse blown. 1. Replace blown fuse. 2. Loose, or corroded or defective 2. Tighten, clean or replace, battery cable(s). as necessary. 3. Battery is discharge...

Page 39 - Section 9 – Notes

37 Section 9 – Notes Recreational Vehicle Generators

Page 40 - Section 10 — Electrical Data

38 Section 10 — Electrical Data Recreational Vehicle GeneratorsElectrical Schematic - V-Twin – Drawing No. 0E1057-E S W1 S CR BLK T2 NEUTRAL CONNECTIONBY CU S TOMER GREEN WHITE 0F 0N 22P 44 0K 0N 120V 3 5A - QP75 120V 3 0A - QP55 & QP65 REGULATOR VOLTAGE ELECTRONIC FIELD 120V 20A - QP55 120V 3 5...

Page 42 - Section 11 — Exploded Views and Parts Lists

40 1 3 2 4 6 3 4 7 9 8 5 10 11 12 1 3 3 2 1 15 14 3 2 16 17 20 1 8 1 9 2 3 4 2 3 22 21 25 26 27 2 8 45 3 0 10 3 1 3 2 33 3 4 3 5 3 6 3 7 38 39 40 41 42 4 3 44 46 52 47 4 8 4 9 50 51 26 52 57 56 55 5 3 54 50 5 3 5 8 5 9 60 61 62 A "A TO CARB. "B" "B" Section 11 — Exploded Views an...

Page 54 - Section 12 – Warranty; CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT

52 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. (G...

Page 55 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

53 Section 12 – Warranty Recreational Vehicle Generators 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 t...

Page 56 - GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY; GENERAC

Part No. 0E1015 Revision L (09/15/05) Printed in U.S.A. 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 ...