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Generac Power Systems 02010-2, 04164-2 Owners And Installation Manual

Generac air-cooled recreational vehicle generator owner's manual
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POWER SYSTEMS, INC.

Installation Instructions

Owner's Manual and
Air-cooled Recreational
Vehicle Generators
• Model: 02010-2
PRIMEPACT 50
• Model: 04164-2
PRIMEPACT 50LP
®

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Summary of Contents for Generac Power Systems 02010-2, 04164-2

  • Page 1: Installation Instructions

    POWER SYSTEMS, INC. Installation Instructions Owner’s Manual and Air-cooled Recreational Vehicle Generators • Model: 02010-2 PRIMEPACT 50 • Model: 04164-2 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

    Initial Start ...35 Testing Under Load ...35 Installation Checklist ...36 Section 4 – Troubleshooting ...37 Section 5 – Electrical Data ...38 Section 6 – Exploded Views and Parts Lists ...40 Section 7 – Warranty ...56 Generac ® 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

    Never work on the equipment when you are physically or mentally fatigued. • Inspect the generator regularly, and contact your nearest Generac Authorized Service Dealer immedi- ately for parts needing repair or replacement. • Before performing any maintenance on the genera- tor, disconnect its battery cables to prevent acci- dental start up.

  • 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 __________________ Model: 02010-2 —...

  • 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. Figure 1.1 – Connections for 120 Volts Only SPECIFICATIONS 1.5.1 FUEL REQUIREMENTS...
  • Page 8 Section 1 – General Information PRIMEPACT 50 Recreational Vehicle 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 percent ethanol, and it must be removed from the generator during storage.

  • Page 9: Section 2 - Operation

    The remote panel includes a Start/Stop switch, hourme- ter, generator run lamp and a wire harness. Figure 2.2 — Optional Remote Panel (Models 004057 and 004184) 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: Starting The Generator

    40° F (4.4° C). Figure 2.3 – Heat Riser System When the heat riser is in the SUMMER (down) posi- tion (Figure 2.2), air is drawn into the air cleaner from the upper intake tube. Generac ® Power Systems, Inc.

  • Page 12: Protection Systems

    (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 2.4 – Low Oil Pressure and High Temperature Switches 2.9.3 FIELD BOOST...

  • Page 13: 2.10 Additional Information

    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: 3.10 Major Service Manual

    3.10 MAJOR SERVICE MANUAL To obtain a service manual for your generator, con- tact Generac or your nearest Generac Authorized Service Dealer or, go to www.generac.com. Make sure to identify your MODEL NUMBER and SERIES. 3.11 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement.

  • Page 18: 3.13 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...

  • 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...

  • 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 Compartments

    • 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 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 • 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: Lp Gas Fuel System

    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 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: Exhaust System

    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: Electrical Connections

    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 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 (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: 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. NOTE: NOTE: Generac ®...

  • Page 38: Installation Checklist

    Rated flow of primary regulator is correct. All parts are properly installed. Fuel system is properly tested/adjusted. DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER 36 Generac ® Power Systems, Inc. EXHAUST SYSTEM Exhaust system complies with all applicable codes.

  • Page 39: Section 4 - 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. 37...

  • Page 40: Section 5 - Electrical Data

    Section 5 — Electrical Data PRIMEPACT 50 Recreational Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. D1754-A 38 Generac ® Power Systems, Inc.
  • Page 41 Section 5 — Electrical Data PRIMEPACT 50 Recreational Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. D1754-A Generac ® Power Systems, Inc. 39...

  • Page 42: Section 6 - Exploded Views And Parts Lists

    Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 02010-2) – Drawing No. D1759-A 40 Generac ® Power Systems, Inc.
  • Page 43 SCREW, TAPTITE M5-0.8 X 16 LG. STARTER CONTACTOR GASKET, BLOWER HSNG HHS #10-32 X 9/16" LG, TAP-R STARTER CABLE HEX NUT-5/16"-24 BOOT, STARTER CONTACTOR LOCK WASHER-M4 HEX NUT-#10-32 PLATE, BLOWER SIDE GASKET, BLOWER SIDE FLAT WASHER ¼" Generac ® Power Systems, Inc. 41...
  • Page 44 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 04164-2) – Drawing No. D1758-D 42 Generac ® Power Systems, Inc.
  • Page 45 LOCK WASHER-M4 HEX NUT-#10-32 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 ELBOW, 90 DEG. 3/8" X 3/4" Generac ® Power Systems, Inc. 43...
  • Page 46 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Alternator and Panel (Model 02010-2) – Drawing No. A8922-H 44 Generac ® Power Systems, Inc.
  • Page 47 M4-0.7 HEX NUT DECAL, CB RATING 30A. DECAL, CB RATING 20A. CLAMP, HOSE #10/ M5-FLAT WASHER M5-0.8 X 10 LONG TAPTITE BUSHING SPACER-PLASTIC M5-.08 X 110 LG. PPHMS NYLON WASHER SPECIAL LOCK WASHER, M5 Generac ® Power Systems, Inc. 45...
  • Page 48 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Alternator and Panel (Model 04164-2) – Drawing No. D1776-C 46 Generac ® Power Systems, Inc.
  • Page 49 SWITCH S.P.D.T.-(FUEL PUMP) TERMINAL BLOCK SPECIAL LOCK WASHER, M4 M4-0.7 HEX NUT DECAL, CB RATING 30A. DECAL, CB RATING 20A. M5-0.8 X 10 LONG TAPTITE CLAMP, HOSE #10/ M5-FLAT WASHER BOOT, ROCKER SWITCH WASHER FLAT #4 Generac ® Power Systems, Inc. 47...
  • Page 50 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Sheet Metal (Model 02010-2 and 04164-2) – Drawing No. D1760-B 48 Generac ® Power Systems, Inc.
  • Page 51 SCREW, PHILIPS PAN HD. MACH.-M3-0.5 X 8MM LOCK WASHER-M3 FILTER, OIL ENGINE, LONG BLOCK-GN410VSRV KEY, WOODRUFF 4 X 19 DIA. COVER, CARB. SPECIAL LOCK WASHER, M6 TAPTITE, M6-1.00 X 12MM BOOT, TEMPERATURE SWITCH BOOT, OIL PRESSURE SWITCH Generac ® Power Systems, Inc. 49...
  • Page 52 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator GN-410 Engine (Model 02010-2 and 04164-2) – Drawing No. A7894-E 50 Generac ® Power Systems, Inc.
  • Page 53 88396B 90416A 90747 C3150 92362 79246 83921 77158 76329 86254 93064 Generac DESCRIPTION CAMSHAFT ASSEMBLY CRANKSHAFT 35 I.D. SEAL THRUST WASHER PRESSURE RELIEF BALL GOVERNOR SPOOL GOVERNOR RETAINER (C-RING) COVER, OIL PRESSURE RELIEF M5-0.8 X 10MM TAPTITE GOVERNOR GEAR ASSEMBLY...
  • Page 54 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 02010-2) – Drawing No. A8923-B 52 Generac ® Power Systems, Inc.
  • Page 55 BOLT, HEX HD. WASHER/LOCK WASHER-M6-1.0 X 30MM NUT, GOVERNOR LEVER SPRING, GOVERNOR BELLCRANK, GOV. RODS WASHER, FELT BOLT, SHOULDER, M6-1.0 X 15MM ROD, LINKAGE GOV. LEVER-BELLCRANK ROD, LINKAGE BELLCRANK-CARB. SPRING, A/L GOV. LEVER-BELLCRANK BREATHER, TUBE Generac ® Power Systems, Inc. 53...
  • Page 56 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 04164-2) – Drawing No. C3880-A 54 Generac ® Power Systems, Inc.
  • Page 57 HHCS-M6-1.0 X 60MM 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 30MM Generac ® Power Systems, Inc. 55...

  • Page 58: Section 7 - 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 Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspec- tion 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. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility.

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