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Generac Power Systems PRIMEPACT 50 04164-3 Owner's Manual

Air-cooled recreational vehicle generators.
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Owner's Manual and
Installation Instructions
Air-cooled Recreational Vehicle Generators
• Model: 05754-0
PRIMEPACT 50
• Model: 04164-3
PRIMEPACT 50LP

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   Summary of Contents for Generac Power Systems PRIMEPACT 50 04164-3

  • Page 1: Installation Instructions

    Owner's Manual and Installation Instructions Air-cooled Recreational Vehicle Generators • Model: 05754-0 PRIMEPACT 50 • Model: 04164-3 PRIMEPACT 50LP...

  • Page 2: Introduction

    INTRODUCTION Thank you for purchasing this model manufactured 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, contact the near- est Authorized Service Dealer for starting, operating and servicing procedures.

  • Page 3: Table Of Contents

    Part I – Owner’s Manual Introduction ... Inside Front Cover Read This Manual Thoroughly ...IFC Contents ...IFC Operation and Maintenance ...IFC How to Obtain Service ...IFC Authorized Service Dealer Locator Number ...IFC Safety Rules ...2 Section 1 – General Information ...4 Generator Identification ...4 Generator Applicability ...5 Safety ...5...

  • Page 4: Safety Rules

    Safety Rules Recreational Vehicle Generator  SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment.

  • Page 5: Fire Hazards

    • Adequate, unobstructed flow of cooling and ventilating air is critical for expelling toxic carbon monoxide gas and fuel vapors from the generator compartment and for proper genera- tor operation. Without sufficient cooling airflow, deadly carbon monoxide gas can accumulate and the engine/generator may quickly overheat, causing serious damage to the generator.

  • Page 6: Section 1 - General Information

    Section 1 – General Information Recreational Vehicle Generator GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal. 1. Model Number _____________________ 3. kW Rating _________________________ 2. Serial Number __________________ 4. Rated Voltage __________________ Model: 05754-0 1.

  • Page 7: Generator Applicability

    GENERATOR APPLICABILITY These generators have been designed and manufactured for sup- plying electrical power for recreational vehicles. Do not modify the generator or use it for any application other than for what it was designed. If there are any questions pertaining to its application, write or call the factory.

  • Page 8

    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- ing storage.

  • Page 9: Evaporative Emissions Information

    EVAPORATIVE EMISSIONS INFORMATION This generator is subject to evaporative emission standards which have been implemented by the California Air Resource Board (CARB) and the Environmental Protection Agency (EPA). If this generator is offered for sale in the state of California, it must be covered by a CARB evaporative Executive Order.

  • Page 10: Section 2 - Operation

    Section 2 – Operation Recreational Vehicle Generator 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), this switch must be pressed for approximately 10 to 15 seconds to bring fuel from the tank to the carburetor.

  • Page 11: Before Starting The Engine

    BEFORE STARTING THE ENGINE NOTE: Instructions and information in this manual assume the genera- tor has been properly installed, connected, serviced, tested and adjusted by a qualified installation technician or installation contractor. 2.4.1 INSTALLATION Generator installation must have been properly completed so it complies with all applicable codes, standards and regulations and with the manufacturer's recommendations.

  • Page 12: Stopping The Generator

    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 main circuit breaker).

  • Page 13: Protection Systems

    2.8.1 DO NOT OVERLOAD THE GENERATOR Read the rated wattage/amperage capacity of the generator on the generator data decal (see "Generator Identification"). Applying electrical loads in excess of the unit’s rated capacity will cause the engine/generator to automatically shut down. To avoid overloading, add up the wattage of all connected electrical lighting, appliance, tool and motor loads.

  • Page 14: 2.10 Additional Information

    Section 3 – Maintenance Recreational Vehicle Generator 2.10 ADDITIONAL INFORMATION 2.10.1 ATTENTION REQUIRED AFTER SUBMERSION If the recreational vehicle generator has been submerged in water, it MUST NOT be started and operated. Following any submersion in water, have an Authorized Service Dealer thoroughly clean and dry the generator.

  • Page 15: Maintaining The Engine Air Cleaner

    • Change the engine oil filter after the first 25 hours of operation, and every 100 operating hours thereafter. • To change the oil and/or oil filter, proceed as follows (see Figure 3.1): Run the engine until it is thoroughly warmed up (at least five minutes) then shut OFF the engine.

  • Page 16: Checking The Engine Spark Plug

    Section 3 – Maintenance Recreational Vehicle Generator CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.

  • Page 17: Battery Maintenance

    3.10 MAJOR SERVICE MANUAL To obtain a service manual for the generator, contact the nearest Authorized Service Dealer or, go to www.generac.com. Make sure to identify the 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

    Section 3 – Maintenance Recreational Vehicle Generator 3.13 OUT OF SERVICE PROCEDURE 3.13.1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days, and it is to be out of service longer than 30 days, prepare the generator for storage as follows: Start the engine and let it warm up.

  • Page 19: Part Ii - Installation Instructions

    PART II – INSTALLATION INSTRUCTIONS DANGER ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

  • Page 20: Safety Rules

    Safety Rules Recreational Vehicle Generator  DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strict- ly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must com- ply with the manufacturer’s instructions and recommendations.

  • Page 21

    • Do not operate the generator if the exhaust system is leaking or has been damaged or if you have experienced carbon monoxide poisoning symptoms during use. Shut down the generator and do not operate it until it has been inspected and/or repaired. •...

  • Page 22: Section 1 - General Information

    Section 1 – General Information Recreational Vehicle Generator 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 seri- ous consideration to all information and instructions in the manual, both for safety and for continued reliable operation of the equip- ment.

  • Page 23

    Section 1 – General Information Recreational Vehicle Generator Figure 1.2 – Major Features and Dimensions (Drawing 0F1127-A)

  • Page 24: Section 2 - Installation

    Section 2 – Installation Recreational Vehicle Generator 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 reinforce.

  • Page 25: Generator Compartments

    Figure 2.3 – Typical Generator Restraint GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compart- ment that the installer constructs, the compartment MUST meet certain specifications as outlined in the following sections: 2.2.1 COMPARTMENT SIZE Plan the compartment size carefully.

  • Page 26

    Section 2 – Installation Recreational Vehicle Generator Figure 2.6 – Types of Lock Seams • After the compartment has been metal lined and vapor sealed, line the compartment interior walls and ceiling with an approved, nonflammable sound insulating material. See the "Sound Insulating Materials"...

  • Page 27: Cooling And Ventilating Air

    2.2.5 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items (Figure 2.8): • Engine exhaust and cooling air outlets • Generator cooling air inlet • Four holes for passage of generator mounting bolts. See the "Generator Restraint" section. DANGER ...

  • Page 28

    Section 2 – Installation Recreational Vehicle Generator DANGER  Never use discharged cooling air for heating or permit such air to enter the vehicle interior. This air contains deadly carbon monoxide gas and other poisonous, flammable or explosive gases. 2.3.1 GENERATOR AIRFLOW Engine operation drives cooling fans for the two-stage cooling air system.

  • Page 29: Gasoline Fuel System

    Figure 2.13 – Air Inlet in Vehicle Skirt VEHICLE FLOOR MINIMUM CLEARANCE 1-1/2" 2.3.3 COMPENSATING FOR RESTRICTIONS Such materials as screening, louvers or expanded metal can restrict the free flow of air. Compensate for this restriction by mak- ing the actual air opening proportionately larger. Some materials may offer only a 60 percent “free air inlet area.”...

  • Page 30: Lp Gas Fuel System

    Section 2 – Installation Recreational Vehicle Generator 2.4.2 GENERATOR FUEL SUPPLY LINE 2.4.2.1 Rigid Fuel Lines Those lines used to supply fuel from a tank to the generator must comply with applicable codes, standards and regulations. The fol- lowing general rules apply to rigid fuel lines: •...

  • Page 31

    2.5.3 VAPOR WITHDRAWAL LP gas is stored in pressure tanks as a liquid. The gas systems used with these generators were designed only for vapor with- drawal type systems. Vapor withdrawal systems use the gas vapors that form above the liquid fuel in the tank. Do NOT attempt to use the generator with any liquid withdrawal type system.

  • Page 32: Exhaust System

    Section 2 – Installation Recreational Vehicle Generator DANGER Gaseous fuel lines between the tank and the  secondary regulator are under a positive pres- sure (about 11 inches water column). Gas pres- sure at the outlet side of the secondary regula- tor, however, is a negative pressure and can draw flame inside a line or fitting and cause an explosion.

  • Page 33: Electrical Connections

    • 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 damage the other engine. • Plan exhaust system installation carefully. Comply with all appli- cable codes, standards and regulations.

  • Page 34: Battery Installation

    Section 2 – Installation Recreational Vehicle Generator • Route conduit so it does not interfere with generator move- ment. • If using metallic conduit, vapor seal the end of the conduit where it enters the junction box. Do this because flexible metal- lic conduit is not vaporproof along its entire length.

  • Page 35

    These generators are rated at about 100 DC amperes of cranking current. Select battery cables based on (a) cable length and (b) prevail- ing ambient temperatures. Generally, the longer the cable and the colder the weather, the larger the cable size must be, as shown in the chart.

  • Page 36: Optional Accessories

    Section 3 – Post-installation Start-up Adjustments Recreational Vehicle Generator 2.8.4 BATTERY COMPARTMENT Install the generator battery in its own, vented compartment. Place the battery compartment away from any source of heat, sparks or flame. Provide ventilation openings in the battery compartment. The minimum size of openings should be 2 square inches at the top of the compartment.

  • Page 37: Testing Under Load

    NOTE: The generator set was thoroughly tested and adjusted at the factory before shipping. No additional adjustment should be necessary. Only qualified service technicians who have been trained should perform adjustments outlined in this manual. TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 percent of the unit's rated wattage/amperage capacity.

  • Page 38: Installation Checklist

    Section 3 – Post-installation Start-up Adjustments Recreational Vehicle Generator 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. ❑...

  • Page 39: Section 4 - Troubleshooting

    TROUBLESHOOTING GUIDE Problem The engine will not crank. The engine cranks but will not start. The engine starts hard and runs rough. The engine starts, but shuts down when the Start/Stop switch is released. The Start/Stop switch is set to Stop, but the engine continues to run.

  • Page 40: Section 5 - Electrical Data

    Section 5 — Electrical Data Recreational Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D1754-B...

  • Page 41

    Section 5 — Electrical Data Recreational Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D1754-B...

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

    Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Base and Pulleys (Model 05754-0) – Drawing No. 0D1759-E...

  • Page 43

    ITEM PART NO. QTY. DESCRIPTION 0C2368 BASE, MOUNTING 053407 GROUND CABLE 046911 MOUNT, (RUBBER) 025017 CAPSCREW, HEX HD.-3/8"-16 X 1/2" 022237 LOCK WASHER-3/8" 022129 LOCK WASHER-M8 0A6479 SKID, RUBBER MOUNT 077603 SAFETY BOLT 5/16"-18 X 3 1/2" 022259 NUT, HEX-5/16"-18 052858 NUT, FLANGED LOCK-M8-1.25 051730...

  • Page 44

    Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Base and Pulleys (Model 04164-3) – Drawing No. 0F1124-D...

  • Page 45

    ITEM PART NO. QTY. DESCRIPTION 0F1126 ASSEMBLY REGULATOR 048031M #8 HOSE CLAMP 0F7065 16” HOSE, 1/2” I.D. PETROLEOM 022145 WASHER FLAT 5/16”- M8 022129 WASHER LOCK M8 - 5/16” 045771 NUT HEX M8-1.25 066849 SCREW, TAPTITE M5-0.8 X 16MM LONG 022473 WASHER FLAT 1/4”...

  • Page 46

    Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Alternator and Panel (Model 04164-3) – Drawing No. 0D1776-J...

  • Page 47

    ITEM PART NO. QTY. DESCRIPTION 0C9675 LOWER BEARING CARRIER 0A5649H ROTOR ASSEM. 0A5646H STATOR ASSEM. 073159 BALL BEARING 031971 BALL BEARING 0C9674 UPPER BEARING CARRIER 0A6529 STUD-STATOR 052858 M8-1.25 FLANGE LOCK NUT 066386 BRUSH HOLDER 066849 M5-0.8 X 16 LG. TAPTITE 0A8475 SPECIAL LOCK WASHER, M5 0C3818...

  • Page 48

    Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Engine Sheet Metal – Drawing No. 0D1760-J...

  • Page 49

    ITEM PART NO. 0A4323 045756 029289 091222DSRV 067198N 067890 0A4456 056893 0A6358 091646 0G3279 0G3111 022717A 073132 061669 089685 022129 049813 057821 059637 0D9004A 059985 025034 0A8875 0A7299 0A9539 0A7838 038593 022473 0A6357 0A6360 0A6489 0A6359 0742600131 090892 091159 091160 091161 049821 086999...

  • Page 50

    Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator GN-410 Engine – Drawing No. 0E9615-B...

  • Page 51

    ITEM PART NO. QTY. DESCRIPTION 0G2565 RING SET, PISTON DIA 90 0E3221 CONNECTING ROD 0E1466 PISTON PIN 071983 PISTON PIN RETAINER 021713B CYLINDER HEAD GASKET 0A1442 FLANGED HEX HD. CAPSCREW M8-1.25 X 42 021742 M10 1.5 X 105MM HHFL 0G2751 PISTON, FLAT TOP DIA 90 COATED 076701 CRANKCASE GASKET...

  • Page 52: Primepact

    Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Engine Accessories – Drawing No. 0F1135-E...

  • Page 53

    ITEM PART NO. 0A6532 091039 051753 0E7585 089228 0A7336B 0A6562 090970 0A7660 0A7660A 056893 0A6566 0A6780 096290 073111 0A6563 0C3633 0A6581A 0C2332 092164 082025 0A7029 0A6913 091161 049813 092586 083512 0A6778 0A6785 0A6753 0A8222 086681 020753 022473 022097 0A6582 0A6503 0A6569 0A7660 0A6568...

  • Page 54

    Section 6 — Exploded Views and Parts Lists Recreational Vehicle Generator Alternator & Panel – Drawing No. 0H3636-A...

  • Page 55

    ITEM PART NO. QTY. DESCRIPTION 0C9675 LOWER BEARING CARRIER 0A5649H ROTOR ASSEM. 0A5646H STATOR ASSEM. 073159 BALL BEARING 031971 BALL BEARING 0C9674 UPPER BEARING CARRIER 0A6529 STUD-STATOR 052858 M8-1.25 FLANGE LOCK NUT 066386 BRUSH HOLDER 066849 M5-0.8 X 16 LG. TAPTITE 0A8475 SPECIAL LOCK WASHER, M5 0C3818...

  • Page 56: Section 7 - Notes

    Section 7 – Notes...

  • Page 57

    Section 7 – Notes...

  • Page 58: Section 8 - Warranty

    Generac pursuant to California and federal law. See also the “Generac 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.

  • Page 59: Emission Control System Warranty

    (1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below.

  • Page 60

    NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (three) years of operation from the date of original sale, 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.

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