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Generac 02010-2, 04164-2 manual

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Table of contents for the manual

  • Page 1

    PO WER SY STEMS, INC. ® Owner’ s Man ual and Installation Instructions Air -cooled Recreational V ehic le Generators • Model: 02010-2 PRIMEP A CT 50 • Model: 04164-2 PRIMEP A CT 50LP[...]

  • Page 2

    Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the PRIMEP ACT product line by Generac P ower Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. R EAD THIS MAN UAL THOROUGHL Y If you do not understand any portion of this manual, contact Generac or your near[...]

  • Page 3

    T able of Contents PRIMEP A C T 5 0 Recreational V ehicle Generator Generac ® Pow er Systems, Inc. 1 P ar t I – Owner’s Manual Introduction ........................................Inside F ront Cover Read This Manual Thoroughly ..................................IFC Contents ..................................................................IFC [...]

  • Page 4

    2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this manual and with the unit. The generator can operate safely , efficiently and reli- ably only if it is properly installed, operated and main- tained. Many accidents are caused by failing to follow s[...]

  • Page 5

    Generac ® Pow er Systems, Inc. 3 • Adequate, unobstructed flow of cooling and venti- lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment. W ithout sufficient cooling airflow , the engine/generator quickly overheats, which causes serious damage to the generator [...]

  • Page 6

    4 Generac ® Pow er Systems, Inc. 1. Generator Air Intake 2. Engine Start/Stop Switch 3. F use 4. Optional Remote P anel Receptacle (behind control panel) 5. Generator AC Output Leads (behind control panel) 6. F uel P rimer Switch 7. Circuit Breaker 8. Circuit Breaker 9. Starter Contactor 10. F uel Inlet 11. F uel Pump 12. F uel F ilter 13. Oil Fil[...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 Section 1 – General Information PRIMEP A C T 5 0 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. Y ou should not modify the generator or use it for any application other than for w[...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. Section 1 – General Information PRIMEP A C T 5 0 Recreational V ehicle Generator Generac does not recommend using any gasoline containing alcohol (such as “gasohol”). If you use any gasoline containing alcohol, it must not contain more than 10 per cent ethanol, and it must be removed fr om the generator durin[...]

  • Page 9

    Generac ® Pow er Systems, Inc. 7 Section 2 – Operation PRIMEP A C T 5 0 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 2.1.1 F U EL PRIMER Before starting a cold engine (if it has not been start- ed in more th[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. Section 2 – Operation PRIMEP A C T 5 0 Recreational V ehicle Generator 2.3 AUT OMA TIC CHOKE (GA SOLIN E ONL Y) The engine is equipped with an automatic choke that consists of two main components: a choke solenoid and prechoke. 2.3.1 CHOKE SOLENOID During engine cranking (Start/Stop switch at ST ART), a solid- st[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 Section 2 – Operation PRIMEP A C T 5 0 Recreational V ehicle Generator 2.5 S T ARTI NG THE GEN ER A T OR NOTE: Read the vehicle manufacturer’s instructions. The owner/operator should become familiar with the vehicle in which this generator is installed. Differences exist between vehicles. F or example, some veh[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. Section 2 – Operation PRIMEP A C T 5 0 Recreational V ehicle Generator When the heat riser is in the WINTER (up) position, air is drawn from the lower intake tube, which is positioned to draw the heated air near the exhaust manifold. T o prevent carburetor icing , the owner/operator should physically position th[...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 Section 2 – Operation PRIMEP A C T 5 0 Recreational V ehicle Generator 2.9.4 OVERV OL T AGE PROTE CTION 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 st[...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. Section 3 – Maintenance PRIMEP A C T 5 0 Recreational V ehicle Generator Figure 3.1 – Oil Maintenance Features 3.1 CH ECKING TH E ENGI N E OI L LEVEL F or oil capacities and requirements, see “Engine Oil Requirements,” Section 1.5.4 (P age 6). Check the engine crankcase oil level at least every eight hours[...]

  • Page 15

    Section 3 – Maintenance PRIMEP A C T 5 0 Recreational V ehicle Generator 3.3 MAI NT AI N I NG TH E ENGI N E AI R CLEAN ER 3.3.1 CLEAN I NG TH E FO AM PR ECLEANER Clean and re - oil the foam precleaner every three months or every 25 hours of operation, whichever occurs first. Service the foam precleaner more fre- quently if operating the generator[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. 3.6 F U EL FI L TER (GAS OLIN E ON L Y) 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 3.7 SP ARK AR R ES T OR MUFFL E R If the generator is not equipped with a spark arrestor exhaust muffler and is to be used on any[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 Do not dispose of the battery in a fire. The battery is capable of exploding. Storage batter- ies give off explosive hydr ogen gas. This gas can form an explosive mixture ar ound the bat- tery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can sha[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. 3.1 3 OUT OF SERVICE P ROCEDU R E 3.1 3.1 REMOV AL FROM SERVICE If you cannot exercise the generator every seven days, and it is to be out of service longer than 30 days, pre- pare the generator for storage as follows: 1. Start the engine and let it warm up. 2. Close the fuel shutoff valve in the fuel supply line [...]

  • Page 19

    P ART I I – I NS T ALL A TION I NS TR UCTIONS ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!! D ANGER[...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. NO TICE T O I NST ALLER These Installation Instructions have been published by Generac to aid in the installation of the products described in this manual. Generac assumes that installation personnel are familiar with the proce- dures for installing such products, or similar prod- ucts that Generac manufactures. G[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 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 [...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. 1.1 P U R POSE AND SC OPE 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[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Figure 1.2 – Major Features and Dimensions Section 1 – General Information PRIMEP A C T 5 0 Recreational V ehicle Generator[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. 2.1 L OCA TION AN D SU P PORT 2.1.1 GEN ER A 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 reinforce. Many recreational vehicles have[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 2.1.4 GEN ER A T OR RES TRAI NT Use four 3/8"-16 hardened steel bolts (Grade 5) to fas- ten the generator to the supporting frame or the sup- port tubing . These bolts must pass through (a) the gen- erator mounting base, (b) the compartment floor (if a compartment is used) and (c) the supporting frame- work ([...]

  • Page 26

    24 Generac ® Pow er Systems, Inc. • 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 con- struction, is NOT vapor tight along its entire length. • Seams and joints of the galvanized steel (whether u[...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 Figure 2.7 – T ypical Noise Abatement 2.2.5 COMP ARTM ENT F L OOR CUT OUTS Y ou must provide openings in the generator compart- ment for the following items (Figure 2.8): • Engine exhaust and cooling air outlets • Generator cooling air inlet • F our holes for passage of generator mounting bolts. See Sectio[...]

  • Page 28

    26 Generac ® Pow er Systems, Inc. 2.3 C OOLI NG AN D VENTI L A TI NG AI R It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. W ithout sufficient air- flow , the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also[...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 Figure 2.12 – Air Inlet Using Ductwork Figure 2.13 – Air Inlet in V ehicle Skirt 2.3.3 COMP ENSA TI NG FOR R E STRICTIONS Such materials as screening, louvers or expanded metal can restrict the free flow of air . Compensate for this restriction by making the actual air opening pro- portionately larger . Some m[...]

  • Page 30

    28 Generac ® Pow er Systems, Inc. 2.4.1 F U EL T AN K Either the generator must share the vehicle engine's fuel tank, or you must install a separate fuel tank for the generator set. All fuel tanks installed on the vehi- cle must be constructed, installed and restrained so they comply with applicable codes, standards and regulations. If the ge[...]

  • Page 31

    Generac ® Pow er Systems, Inc. 29 Figure 2.15 – T ypical Propane Gas Fuel System 2.5.2 SOME I M PORT ANT C ONSIDER A TIONS 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. This [...]

  • Page 32

    30 Generac ® Pow er Systems, Inc. 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 flow that is propo[...]

  • Page 33

    Generac ® Pow er Systems, Inc. 31 2.6.1 MUFF LERS AN D SP ARK AR R ES T ORS This muffler meets code and standard requirements of the U .S. F orest Service. Use only mufflers and parts approved by Generac. Any person(s) installing an unapproved muffler , or an unapproved exhaust system part, or modifying an exhaust system in any way that might caus[...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. 2 .7 .2 W IRING • 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 [...]

  • Page 35

    Generac ® Pow er Systems, Inc. 33 2.7 .6 POWER SUP PL Y CORD The power supply cord must comply with all applic- able codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected. 2.7 .7 GROUN D F AU L T CI RCU IT INTE R R U PTERS The National Electrical Code (NFP A 70, 551-7) requires that you[...]

  • Page 36

    34 Generac ® Pow er Systems, Inc. 2.8 B A T TER Y I NST ALL A TION 2.8.1 R EC OMM EN DED BA T TER Y Install a battery that meets the following requirements: • The battery must be a 12-volt, automotive type storage battery . • F or prevailing ambient temperatures above 32° F (0° C), use a battery rated 70 amp -hours and capa- ble of deliverin[...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 2.9.1 R EMO TE P AN EL MODEL S 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 P art I of this manual. • Model 004057 includes the remote panel and a 10 foot lon[...]

  • Page 38

    3.5 I NS T ALL A TION CH ECKLIS T L OCA TION AN D SU PPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GEN ERA T OR COMP ARTM ENT ❑ Compartment construction is proper . ❑ Holes/Openings are vapor - sealed. ❑ Compartment size is correct. ❑ Compartment is vapor - sealed. ❑ So[...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 Section 4 – T roubleshooting PRIMEP A C T 5 0 Recreational V ehicle Generator TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION 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[...]

  • Page 40

    38 Generac ® Pow er Systems, Inc. Section 5 — Electrical Data PRIMEP A C T 5 0 Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. D1 7 54-A[...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 Section 5 — Electrical Data PRIMEP A C T 5 0 Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. D1 7 54-A[...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Base and Pulleys (Model 020 10-2) – Drawing No. D1 75 9-A[...]

  • Page 43

    Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 C2368 1 BASE, MOUNTING 2 53407 1 GROUND CABLE 3 46911 4 MOUNT , (RUBBER) 4 25017 6 CAPSCREW , HEX HD .-3/8"-16 X 1/2" 5 22237 6 LOCK W ASHER-3/8" 6 22129 9 LOCK W ASHER-M8 7 A6479 1 SKID , R UBBER MOUNT 8 77603 2 SAFETY BOL T 5/16"-18 X 3 1/2" 9 22259 2 [...]

  • Page 44

    42 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Base and Pulleys (Model 04 1 64-2) – Drawing No. D1 75 8-D[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 0C2368 1 BASE, MOUNTING 2 053407 1 GROUND CABLE 3 046911 4 MOUNT , (R UBBER) 4 025017 6 CAPSCREW , HEX HD .-3/8"-16 X 1/2" 5 022237 6 LOCK W ASHER-3/8" 6 022129 12 LOCK W ASHER-M8 7 0A6479 1 SKID , R UBBER MOUNT 8 077603 2 SAFETY BOL T 5/16"-18 X 3 1/2" [...]

  • Page 46

    44 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Alternator and P anel (Model 020 10-2) – Drawing No. A892 2-H[...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Alternator and P anel (Model 020 10-2) – Drawing No. A892 2-H ITEM P ART NO . QTY . DESCRIPTION 1 0C9675 1 LO WER BEARING CARRIER 2 0A5649H 1 R O T OR ASSEM. 3 0A5646H 1 ST A T OR ASSEM. 4 073159 1 BALL BEARING 5 03197[...]

  • Page 48

    46 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Alternator and P anel (Model 04 1 64-2) – Drawing No. D1 77 6-C[...]

  • Page 49

    Generac ® Pow er Systems, Inc. 47 ITEM P ART NO . QTY . DESCRIPTION 1 0C9675 1 LO WER BEARING CARRIER 2 0A5649H 1 R O T OR ASSEM. 3 0A5646H 1 ST A T OR ASSEM. 4 073159 1 BALL BEARING 5 031971 1 BALL BEARING 6 0C9674 1 UPPER BEARING CARRIER 7 0A6529 4 STUD-ST A T OR 8 052858 4 M8-1.25 FLANGE LOCK NUT 9 066386 1 BR USH HOLDER 10 066849 3 M5-0.8 X 16[...]

  • Page 50

    48 Generac ® Pow er Systems, Inc. Starter 18 23 8 3 1 3 4 8 3 2 3 To 5 4 6 9 29 21 28 20 7 19 17 24 25 39 41 2 44 43 42 26 17 45 30 11 12 2 1 3 4 17 22 16 13 15 14 8 8 46 47 40 48 3 7 36 38 10 2 2 8 33 8 50 49 5 2 5 1 Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Sheet Metal (Model 020 1 0-2 [...]

  • Page 51

    Generac ® Pow er Systems, Inc. 49 Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Sheet Metal (Model 020 1 0-2 and 04 1 64-2) – Drawing No. D1 760-B ITEM P ART NO . QTY . DESCRIPTION 1 0A4323 1 SCROLL, FL YWHEEL 2 045756 8 SCREW , T APTITE M6-1.0 X 10MM 3 029289 2.5 FT . FOAM T APE 4 SR V 091[...]

  • Page 52

    50 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator GN-4 1 0 Engine (Model 020 1 0-2 and 04 1 64-2) – Drawing No. A7 894-E[...]

  • Page 53

    Generac ® Pow er Systems, Inc. 51 Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator GN-4 1 0 Engine (Model 020 1 0-2 and 04 1 64-2) – Drawing No. A7 894-E ITEM P ART NO . QTY . DESCRIPTION 1 21533 1 PIST ON RING SET 3 71978 1 CONNECTING ROD WITH CAP & BOL T 4 71980 1 PIST ON PIN 5 71983 2 PIST ON [...]

  • Page 54

    52 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Accessories (Model 020 1 0-2) – Drawing No. A8923-B[...]

  • Page 55

    Generac ® Pow er Systems, Inc. 53 Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Accessories (Model 020 1 0-2) – Drawing No. A8923-B ITEM P ART NO . QTY . DESCRIPTION 1 A6532 1 MANIFOLD , INT AKE 2 91039 1 GASKET , MANIFOLD/HEAD 3 51753 1 HHCS-M6-1.0 X 40MM 4 72347 1 SP ARK PLUG, CHAMP 5 892[...]

  • Page 56

    54 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Accessories (Model 041 64-2) – Drawing No. C3 880-A[...]

  • Page 57

    Generac ® Pow er Systems, Inc. 55 ITEM P ART NO . QTY . DESCRIPTION 1 A6532 1 MANIFOLD , INT AKE 2 91039 1 GASKET , MANIFOLD/HEAD 3 51753 1 HHCS-M6-1.0 X 40MM 4 72347 1 SP ARK PLUG, CHAMP 5 89228 1 GASKET , CARB/MANIFOLD 6 A7336A 1 CARBURET OR, GN 410 L/P 7 90970 1 GASKET , CARB/AIR FIL TER 8 A6564 1 BASE, AIR FIL TER 9 56893 3 CRIMPTITE #10-24 X [...]

  • Page 58

    56 Generac ® Pow er Systems, Inc. CALI FOR NIA AN D F EDER AL EM ISSION C ONTROL W AR R ANT Y ST A TEM ENT Y OU R W ARR ANT Y RIGHTS AND OB LIGA 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 Cont[...]

  • Page 59

    Generac ® Pow er Systems, Inc. 57 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 P eriod shall begin on the date the new engine or equipment is purchased by/delivered[...]

  • Page 60

    Part No. 0D7431 R evision A (08/06/02) Printed in U.S.A. Section 7 – W arranty PRIMEP A C T 5 0 Recreational V ehicle Generator GEN ERAC PO WER SY S TEMS’ TH REE- YEAR LIM ITED W ARR ANT Y FOR R E CR EA TIONAL VEH ICLE GEN ER A T ORS NOTE: ALL UNITS MUST BE INST ALLED BY GENERAC POWER SYSTEMS AUTHORIZED SER VICE F ACILITIES. F or a period of 3 [...]