GermGuardian 02010-2, 04164-3 - Manuals

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

INTRODUCTION Thank you for purchasing this model manufac-tured by Generac Power Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood, con-tact the nearest Authorized Serv...

Page 3 - Table of Contents; Part I – Owner’s Manual

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

Page 4 - DANGER; Despite the safe design of this generator, operat-; GENERAL HAZARDS; For safety reasons, the manufacturer recommends

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 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. Without sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to t...

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

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

Page 7 - APPLICABILITY; For fire safety, the generator must have been; CONNECTION SYSTEM; Figure 1.1 – Connections for 120 Volts Only; 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; During summer months: SAE 30. An acceptable; 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; Figure 2.2 — Optional Remote Panel; AUTOMATIC CHOKE; SOLENOID

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 2.1.1 FUEL PRIMER Before starting a cold engine (if it has not been started in more than two weeks),...

Page 10 - BEFORE STARTING THE ENGINE; NOTE; 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.

8 Section 2 – Operation Recreational Vehicle Generator 2.4 BEFORE STARTING THE ENGINE 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 ...

Page 11 - If the engine does not start after it has been; STOPPING THE GENERATOR; Figure 2.3 – Heat Riser System

9 Section 2 – Operation Recreational Vehicle 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 ...

Page 12 - Most lighting, appliance, tool and motor loads; PROTECTION SYSTEMS; LOW OIL PRESSURE SWITCH; Figure 2.4 – Low Oil Pressure and; BOOST; Figure 2.5 – Field Boost Circuit

10 Section 2 – Operation Recreational Vehicle Generator 2.8.1 DO NOT OVERLOAD THE GENERATOR 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...

Page 13 - PROTECTION; Figure 2.6 – Solid State Voltage Regulator; ADDITIONAL INFORMATION; AFTER SUBMERSION; MUST NOT; OR BRUSH; CHECKING THE ENGINE OIL LEVEL; If necessary, remove the oil fill cap on the rocker; Never operate the engine with the oil level; Install and tighten the oil fill cap and the dipstick; Section 3 – Maintenance

11 2.9.4 OVERVOLTAGE PROTECTION 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 volta...

Page 14 - Figure 3.1 – Oil Maintenance Features; CHANGING THE ENGINE OIL

12 Section 3 – Maintenance Recreational Vehicle Generator Figure 3.1 – Oil Maintenance Features 3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER 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...

Page 15 - Figure 3.2 – Engine Air Cleaner; CLEAN AIR INTAKE; Figure 3.3 – Cleaning Air Intake; CHECKING THE ENGINE; Sparking can occur if the wire terminal does not; Figure 3.4 – Setting the Spark Plug Gap

Section 3 – Maintenance Recreational Vehicle Generator 5. Wrap 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 precle...

Page 16 - Figure 3.5 – Fuel Filter; Fuel Filter; SPARK ARRESTOR MUFFLER; Be sure to reinstall the muffler plug tightly.; CLEANING THE GENERATOR; Do NOT use a forceful spray of water to clean; BATTERY MAINTENANCE; Inspect the battery posts and cables for tightness

14 3.6 FUEL FILTER (GASOLINE ONLY) 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 SPARK ARRESTOR MUFFLER If the generator is not equipped with a spark arres-tor exhaust muffler and is to ...

Page 17 - MAJOR SERVICE MANUAL

15 DANGER  Do not dispose of the battery in a fire. The bat- tery is capable of exploding. Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Su...

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 famil-iar with the procedures for installing such products, or similar product...

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 23 - LL DIMEN

21 Figure 1.2 – Major Features and Dimensions (Drawing 0F1127) Section 1 – General Information Recreational Vehicle 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 426.7 [16. 8 "] 4 8 0.0 [1 8 .9...

Page 24 - LOCATION AND SUPPORT; LOCATION; Figure 2.1 – Typical Horizontal Support Frame; MOUNTING; Figure 2.2 – Typical Suspended Mounting System; 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 ha...

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; If constructing a compartment, line the exterior

23 2.1.4 GENERATOR RESTRAINT 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...

Page 26 - Figure 2.6 – Types of Lock Seams; Do not install any flammable material directly; Do not install sound insulation or any absorbent; To prevent fire or explosion, do not install any

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 (whe...

Page 27 - Figure 2.7 – Typical Noise Abatement; FLOOR; Fuel lines and exhaust piping must not penetrate; Figure 2.8 – Compartment Floor Cutout

25 Figure 2.7 – Typical Noise Abatement 2.2.5 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items (Figure 2.8): Engine exhaust and cooling air outletsGenerator cooling air inletFour holes for passage of generator mounting bolts. See the "Generator Rest...

Page 28 - COOLING AND VENTILATING AIR; Never use discharged cooling air for heating or; AIRFLOW; Figure 2.9 – Airflow Through Engine/Generator; at least 100 square inches; Figure 2.10 – Air Inlet in Compartment Door; Provide a door in the vehicle skirt having an air; Figure 2.11 – Suspended Mount: Inlet Door; By providing an opening in the vehicle skirt and

26 2.3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. Without sufficient airflow, the engine/generator quickly overheats. Such overheating can cause serious operating difficulties an...

Page 29 - If planning to use screening with an 80; GASOLINE FUEL SYSTEM; Figure 2.14 – Generator Fuel System; Gasoline is highly flammable, and its vapors are

27 Figure 2.12 – Air Inlet Using Ductwork Figure 2.13 – Air Inlet in Vehicle Skirt MINIMUM CLEARANCE 1-1/2" VEHICLE FLOOR VEHICLE SKIRT AIR INLET 2.3.3 COMPENSATING FOR RESTRICTIONS Such materials as screening, louvers or expanded metal can restrict the free flow of air. Compensate for this rest...

Page 30 - TANK; Do NOT tee the generator fuel supply line; LP GAS FUEL SYSTEM; LP gas is highly EXPLOSIVE. The gas is heavier; Use only approved components in the fuel sup-

28 2.4.1 FUEL TANK 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. I...

Page 31 - Figure 2.15 – Typical Propane Gas Fuel System; WITHDRAWAL; Figure 2.16 – LP Gas Carburetion Diagram

29 Figure 2.15 – Typical Propane Gas Fuel System 2.5.2 SOME IMPORTANT CONSIDERATIONS 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. ...

Page 32 - Gaseous fuel lines between the tank and the sec-; The generator engine gives off DEADLY carbon

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 fl...

Page 33 - ELECTRICAL CONNECTIONS

31 2.6.1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U.S. Forest 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 wa...

Page 34 - Figure 2.17 – Generator AC Output Leads; Do NOT connect electrical loads in excess of any

32 2.7.2 WIRING Wiring should be of stranded copper to reduce the chance that vibration may cause breakage. Wire 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 le...

Page 35 - SUPPLY CORD; Figure 2.18 – Transfer Switch Isolation Method; Figure 2.19 – Installation With Isolation Receptacle

33 2.7.6 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. 2.7.7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code (NFPA 70, 551-7) requires that...

Page 36 - BATTERY INSTALLATION; BATTERY; Figure 2.20 – Connecting Battery Cables; COMPARTMENT; OPTIONAL ACCESSORIES; Figure 2.21 – Remote Panel Plug-in Receptacle; CABLE LENGTH

34 2.8 BATTERY INSTALLATION 2.8.1 RECOMMENDED BATTERY Install a battery that meets the following require-ments: The battery must be a 12-volt, automotive type storage battery. For prevailing ambient temperatures above 32° F (0° C), use a battery rated 70 amp-hours and capable of delivering 400 cold-...

Page 37 - POST INSTALLATION TESTS; Do not make any unnecessary adjustments.; If a liquid propane (LP) gas fuel system has been; TESTING UNDER LOAD; Section 3 – Post-installation Start-up Adjustments

35 2.9.1 REMOTE PANEL MODELS 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 Part I of this manual. Model 004057 includes the remote panel and a 10 foot lo...

Page 38 - INSTALLATION CHECKLIST

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. ❑ Holes/Openings are vapor-sealed. ❑ Compartment size is correct. ❑ Compartment is vapor...

Page 39 - Section 4 – Troubleshooting; TROUBLESHOOTING GUIDE; Problem Cause

37 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 40 - Section 5 — Electrical Data

38 Section 5 — Electrical Data Recreational Vehicle GeneratorElectrical Schematic and Wiring Diagram – Drawing No. 0D1754-A

Page 42 - Section 6 — Exploded Views and Parts Lists

40 12 9 1 20 2 3 24 25 29 2 7 6 8 5 3 0 16 15 10 17 1 8 11 22 14 1 3 19 21 27 26 2 8 Section 6 — Exploded Views and Parts Lists Recreational Vehicle GeneratorRegulator (Model 02010-2) – Drawing No. 0F1125-C

Page 49 - ITEM PART

47 Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Engine Sheet Metal (Model 02010-2 and 04164-3) – Drawing No. 0D1760-H ITEM PART NO. QTY. DESCRIPTION 1 0A4323 1 SCROLL, FLYWHEEL 2 045756 8 SCREW, TAPTITE M6-1.0 X 10MM 3 02 9 28 9 2.5 FT. FOAM TAPE 4 SRV 0 9 1222D 1 FLYWHE...

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

52 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 55 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:; Section 7 – Warranty

53 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 56 - GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY; GENERAC

Part No. 0F1118 Revision F (10/23/07) 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 ...