Related Manuals for Generac Power Systems 02010-0, 04164-0
Summary of Contents for Generac Power Systems 02010-0, 04164-0
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Page 1: Installation Instructions
POWER SYSTEMS, INC. Installation Instructions Owner’s Manual and Air-cooled Recreational Vehicle Generators • Model: 02010-0 PRIMEPACT 50 • Model: 04164-0 PRIMEPACT 50LP ®... -
Page 2: Introduction
Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum. See your Generac Authorized Service Dealer for service aids and acces- sories. HOW TO OBTAIN SERVICE... -
Page 3: Table Of Contents
Appendix 1 – Notes ...38 Appendix 2 – Troubleshooting...39 Appendix 3 – Electrical Data ...40 Appendix 4 – Exploded Views and Parts Lists ...42 Appendix 5 – Warranty ...56 Generac Rigid Fuel Lines ...28 Flexible Fuel Line ...28 Model 9042 ...35 Model 9043 ...35 Power Systems, Inc. -
Page 4: Safety Rules
Many accidents are caused by failing to follow simple and fundamental rules or precautions. Generac cannot possibly anticipate every possible cir cumstance that might involve a hazard. The warn- ings in this manual, and on tags and decals affixed to the unit, are, therefore, not all-inclusive. -
Page 5: Fire Hazards
• This generator may use liquid propane (LP) gas as a fuel. LP gas is highly EXPLOSIVE. The gas is heavier than air and tends to settle in low areas where even the slightest spark can ignite the gas and cause an explosion. Generac Power Systems, Inc. ®... -
Page 6: Section 1 - General Information
PRIMEPACT 50 Recreational Vehicle Generator GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal. 1. Model Number ____________________ 3. kW Rating__________________________ Generac Power Systems, Inc. ® 2. Serial Number __________________ 4. Rated Voltage __________________... -
Page 7: Generator Applicability
120-volt AC loads (Figure 1.1). It can be wired to connect both 120- and/or 240-volt AC electrical loads. This procedure should be done by a Generac Authorized Service Dealer or other qualified installer. A jumper wire must be installed between the circuit breakers when reconnecting for 120/240 volts. -
Page 8: Optional Propane Fuel System
Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits. 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 percent ethanol, and it must be removed from the generator during storage. -
Page 9: Section 2 - Operation
Start/Stop switch, a generator run lamp and an hourmeter. The hourmeter provides a contin- uous indication of engine/generator operating time. Use the hourmeter for checking off periodic mainte- nance requirements on the unit. Generac NOTE: Power Systems, Inc. ®... -
Page 10: Automatic Choke (Gasoline Only)
(Page 6) and Sections 3.1 and 3.2 (Page 12) for oil ser- vicing procedures and recommendations. Any attempt to crank or start the engine before you have properly serviced it with the recom- mended oil may result in an engine failure. Generac Power Systems, Inc. ® 2.4.3 FUEL SUPPLY (GASOLINE ONLY) The engine must have an adequate supply of proper fuel to operate. -
Page 11: Stopping The Generator
To prevent carburetor icing, the owner/operator should physically position the heat riser to the prop- er position dependent on the temperature. Generac Power Systems, Inc. ®... -
Page 12: Do Not Overload The Generator
(N.O.) contacts, is mounted near the oil filter. The contacts close if the temperature should exceed approximately 293º F (145º C), initiating an engine shutdown. 10 Generac Power Systems, Inc. ® Figure 2.3 – Low Oil Pressure and High Temperature Switches 2.9.3 FIELD BOOST... -
Page 13: Overvoltage Protection
Section 2.10.2. Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator 2.10.2 25-HOUR CHECK-UP After the 25-hour break-in period, contact a Generac Authorized Service Dealer for the following mainte- nance. The vehicle owner is responsible for any charges: •... -
Page 14: Section 3 - Maintenance
• Change the engine oil filter after the first 25 hours of operation, and every 100 operating hours there- after. 12 Generac ® Power Systems, Inc. To change the oil and/or oil filter, proceed as follows (see Figure 3.1):... -
Page 15: Maintaining The Engine Air Cleaner
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 necessary, re-form the wire terminal to obtain a tight fit. Generac Power Systems, Inc. 13 ®... -
Page 16: Fuel Filter (Gasoline Only)
For assistance in ordering, installing and maintaining spark arrestor exhaust mufflers, contact your nearest Generac Authorized Service Dealer. Exhaust mufflers supplied by Generac are spark arrestor types. Generac exhaust mufflers for recre- ational vehicle generators do not have a spark arrestor screen, but are of the more efficient “toroid”... -
Page 17: Major Service Manual
Generac Authorized Service Dealer. 3.12 EXERCISING THE GENERATOR Generac recommends that you start and operate the generator at least once every seven days. Let the unit run for at least 30 minutes to “exercise” the engine. -
Page 18: Out Of Service Procedure
6. Remove the battery and store it in a cool, dry room on a wooden board. Never store the battery on any concrete or earthen floor. 7. Clean and wipe the entire generator. 16 Generac Power Systems, Inc. ® 3.13.2 RETURN TO SERVICE... -
Page 19: Part Ii - Installation Instructions
PART II – INSTALLATION INSTRUCTIONS DANGER ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!! -
Page 20: Safety Rules
NOTICE TO INSTALLER 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. - Page 21 LP gas is highly explosive. The gas tends to settle in low areas where even the slightest spark can ignite it and cause an explo- sion. Do not allow gas vapors to enter the vehicle. Generac Power Systems, Inc. 19 ®...
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Page 22: Section 1 - General Information
Boulevard, Rexdale, Ontario, Canada, M9W 1R3. EQUIPMENT DESCRIPTION Instructions and information in this section pertain to Generac air-cooled generators. These generators are designed specifically for installing in recreational vehicles. They operate 120-volt, single-phase, 60- Hertz, AC electrical loads that require 40.0 amps (gasoline) or 37.5 amps (LP fuel) at 120 volts. - Page 23 Section 1 – General Information PRIMEPACT 50 Recreational Vehicle Generator Figure 1.2 – Major Features and Dimensions Generac Power Systems, Inc. 21 ®...
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Page 24: Section 2 - Installation
The fol- lowing general rules apply: • Vehicle construction MUST be capable of support- ing the weight of the generator. 22 Generac Power Systems, Inc. ® • Whether the generator is mounted above the hori-... -
Page 25: Generator Restraint
• If the compartment is lined with galvanized steel, it may be constructed of any material. Generac rec- ommends that the compartment be constructed of 1/2-inch thick plywood (not strandboard), with the... -
Page 26: Sound Insulating Materials
One excellent insulating material is a 1- inch (25 mm) thick fiberglass having a 2-pound den- sity. When fiberglass is used, its coated side should face toward the compartment interior. 24 Generac Power Systems, Inc. ® DANGER Do not install sound insulation or any absorbent material on the compartment floor interior. -
Page 27: Compartment Floor Cutouts
• Generator cooling air inlet • Four holes for passage of generator mounting bolts. See Section 2.1.4 (Page 23). Fuel lines and exhaust piping must not pene- trate into the vehicle living area. Generac DANGER Power Systems, Inc. 25 ®... -
Page 28: Cooling And Ventilating Air
Figure 2.10). This rule applies whether inlet air is brought in through an opening in the compartment door, an opening in the vehicle skirt, through duct- work, or by any other means. 26 Generac Power Systems, Inc. ® NOTE: Screening, louvers or expanded metal that cover air openings restrict airflow. -
Page 29: Gasoline Fuel System
Section 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator 2.3.4 TESTING THE INSTALLATION Generac recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, you will need to enlarge the air openings. -
Page 30: Fuel Tank
If the generator is to share the vehicle engine's tank, separate fuel pickup tubes are required for the engine and the generator. Generac recommends that you make the fuel pickup tube 2 to 3 inches (51 to 76 mm) shorter than the vehicle engine's pickup tube. -
Page 31: Some Important Considerations
A lever attached to the diaphragm opens a valve to permit gas glow through the carburetor. Figure 2.16 – LP Gas Carburetion Diagram Generac NOTE: Power Systems, Inc. 29 ®... -
Page 32: Fuel Supply Lines
To test the system, you need a separate source of 12 volts DC to open the gaseous fuel solenoid valve. 30 Generac Power Systems, Inc. ® The leak test must comply fully with NFPA, Paragraph 318. -
Page 33: Mufflers And Spark Arrestors
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 Generac. Any person(s) installing an unapproved muffler, or an unapproved exhaust system part, or modifying an exhaust system in any... -
Page 34: Wiring
Figure 2.17 – Generator AC Output Leads 32 Generac Power Systems, Inc. ® Line T1 (red) to T2 (white) is protected against over- load by a 30-amp circuit breaker (CB1). -
Page 35: Power Supply Cord
(GFCIs) on all external and some internal electrical receptacles. Contact your manufacturer or dealer for recommendations. Figure 2.18 – Transfer Switch Isolation Method Section 2 – Installation 2.7.7 GROUND FAULT CIRCUIT INTERRUPTERS Generac Power Systems, Inc. 33 ®... -
Page 36: Battery Installation
NEGATIVE, NEG or (-) to the frame ground connection (Figure 2.20). 3. Connect cables so the connectors are clean and tight. 34 Generac Power Systems, Inc. ® following Install the generator battery in its own, vented com- partment. -
Page 37: Remote Panel Models
Part I of this manu- Section 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator 2.9.2 REMOTE PANEL CABLES Interconnection cables are available from Generac for connecting the optional remote panels to the genera- tor receptacle. • To order a 10-foot long, four-wire cable, specify model 9045. -
Page 38: Section 3 - Post-Installation Start-Up Adjustments
The generator engine is equipped with a high tem- perature switch. The switch has normally closed (N.C.) contacts. When the engine temperature is too high, switch contacts close, and the engine shuts down automatically. GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLING. -
Page 39: Installation Checklist
Check that hourmeter kit (if used) is installed properly. Check that any other options and accessories (if used) are installed properly. POST INSTALLATION TESTS Check that all tests are completed properly. ____________________________________________________ ______________________________________________________ ________________________________________________ Generac Power Systems, Inc. 37 ®... -
Page 40: Appendix 1 - Notes
Appendix 1 – Notes PRIMEPACT 50 Recreational Vehicle Generator 38 Generac Power Systems, Inc. ®... -
Page 41: Appendix 2 - Troubleshooting
ON (or closed). 2. Reset and replace if necessary. 3. Set switch to GENERATOR. 4. Stop, then restart the engine (Hold Start switch for at least 2 seconds). 5. Contact a Generac Authorized Service Dealer. Generac Power Systems, Inc. 39 ®... -
Page 42: Appendix 3 - Electrical Data
Appendix 3 — Electrical Data PRIMEPACT 50 Recreational Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 94210-A 40 Generac Power Systems, Inc. ®... - Page 43 Appendix 3 — Electrical Data PRIMEPACT 50 Recreational Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 94210-A Generac Power Systems, Inc. 41 ®...
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Page 44: Appendix 4 - Exploded Views And Parts Lists
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 02010-0) – Drawing No. A8924-B 42 Generac Power Systems, Inc. ®... - Page 45 SCREW, TAPTITE M5-0.8 X 16 STARTER CONTACTOR GASKET, BLOWER HSNG HHS #10-32 X 9/16" LG, TAP-R STARTER CABLE HEX NUT-1/4"-20 LOCK WASHER-1/4" LOCK WASHER-M4 HEX NUT-#8-32 PLATE, BLOWER SIDE GASKET, BLOWER SIDE FLAT WASHER ¼" Generac Power Systems, Inc. 43 ®...
- Page 46 Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 04164-0) – Drawing No. C3878-A 44 Generac Power Systems, Inc. ®...
- Page 47 LOCK WASHER-1/4" LOCK WASHER-M4 HEX NUT-#8-32 PLATE, BLOWER SIDE GASKET, BLOWER SIDE FLAT WASHER ¼" M6-1.0 X 30 HHCS M6-1.0 HEX NUT CLOSE NIPPLE ¾" NPT 90 DEG. ¾" STREET ELBOW M8-1.25 HEX NUT Generac Power Systems, Inc. 45 ®...
- Page 48 Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Alternator and Panel (Model 02010-0 and 04164-0) – Drawing No. A8922-B 46 Generac Power Systems, Inc. ®...
- Page 49 23365 51715 90157 90156 31791 23897 74908 23484-S 94070 94071 27756 A8475 Generac M3-LOCK WASHER HEX NUT, M8 C/BREAKER 2.5A.-ON #10-SHAKEPROOF WASHER REGULATOR VOLTAGE #10-LOCK WASHER M5-0.8 HEX NUT C/BREAKER 20A. C/BREAKER 30A. ALL UNITS #6-32 SCREW W/LOCK WASHER PANEL COVER M4-0.7 X 12 LG.
- Page 50 Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Sheet Metal (Model 02010-0 and 04164-0) – Drawing No. A8921-A 48 Generac Power Systems, Inc. ®...
- Page 51 41 60108 42 75281 43 70728 44 43182 45 70185 46 A7629 47 82774 48 C2308 Generac QTY. DESCRIPTION OIL DRAIN HOSE ASSEMBLY PIPE NIPPLE, 3/8" X 8" LG. BRASS STREET ELBOW, 3/8" FLAT WASHER, 1/4"-M6 WRAPPER, ENGINE SPARK PLUG...
- Page 52 Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator GN-410 Engine (Model 02010-0 and 04164-0) – Drawing No. A7894-D 50 Generac Power Systems, Inc. ®...
- Page 53 86026 88396B 90416A 90747 C3150 92362 79246 83921 77158 76329 86254 93064 Generac PRESSURE RELIEF BALL GOVERNOR SPOOL GOVERNOR RETAINER (C-RING) COVER, OIL PRESSURE RELIEF M5-0.8 X 10MM TAPTITE GOVERNOR GEAR ASSEMBLY OIL PRESSURE SPRING SPRING WASHER OIL SUMP ASSEMBLY GOVERNOR ARM "R"...
- Page 54 Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 02010-0) – Drawing No. A8923-A 52 Generac Power Systems, Inc. ®...
- Page 55 WASHER-M6-1.0 X 30 LG. NUT, GOVERNOR LEVER SPRING, GOVERNOR BELLCRANK, GOV. RODS WASHER, FELT BOLT, SHOULDER, M6 X 15 ROD, LINKAGE GOV. LEVER- BELLCRANK ROD, LINKAGE BELLCRANK- CARB. SPRING, A/L GOV. LEVER- BELLCRANK BREATHER, TUBE Generac Power Systems, Inc. 53 ®...
- Page 56 Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 04164-0) – Drawing No. C3880- 54 Generac Power Systems, Inc. ®...
- Page 57 HHCS-M6-1.0 X 60 LG. M6 FLAT WASHER M6 LOCK WASHER TUBE, WINTER INLET GROMMET 1/16"-1-1/2" GROMMET, AIR IN/OUT VALVE, WINTER/SUMMER GROMMET, WINTER/SUMMER VALVE SPRING, DETENT LEVER, GOVERNOR ARM BOLT, HEX HD. WASHER/LOCK WASHER-M6-1.0 X 30 LG. Generac Power Systems, Inc. 55 ®...
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Page 58: Appendix 5 - Warranty
Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period. -
Page 59: Emission Control System Warranty
Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or ‘grey market’... - Page 60 NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (three) years or 2,000 (two thousand) hours of operation from the date of original sale, whichever occurs first, 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.