Instruction/ maintenance manual of the product 02010-2, 04164-2 Generac
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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.
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.
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 ..................
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.
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.
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.
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.
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”).
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
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.
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 .
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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 ® 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.
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.
An important point after buying a device Generac 02010-2, 04164-2 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Generac 02010-2, 04164-2 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Generac 02010-2, 04164-2 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Generac 02010-2, 04164-2 you will learn all the available features of the product, as well as information on its operation. The information that you get Generac 02010-2, 04164-2 will certainly help you make a decision on the purchase.
If you already are a holder of Generac 02010-2, 04164-2, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac 02010-2, 04164-2.
However, one of the most important roles played by the user manual is to help in solving problems with Generac 02010-2, 04164-2. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac 02010-2, 04164-2 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
