Generac 02010-2, 04164-2

44 Generac®Power Systems, Inc.

Section 6 — Exploded Views and Parts Lists

PRIMEPACT 50 Recreational Vehicle Generator

Alternator and Panel (Model 02010-2) – Drawing No. A8922-H

Contents

Main INTRODUCTION READ THIS MANUAL THOROUGHLY CONTENTS OPERATION AND MAINTENANCE HOW TO OBTAIN SERVICE Part I Owners Manual Part II Installation Instructions GENERAL HAZARDS WARNING: !! WARNING: ELECTRICAL HAZARDS FIRE HAZARDS EXPLOSION HAZARDS 1.1 GENERATOR IDENTIFICATION Model: 02010-2 PRIMEPACT 50 Model: 04164-2 PRIMEPACT 50LP 1.2 GENERATOR APPLICABILITY 1.3 SAFETY 1.4 GENERATOR AC CONNECTION SYSTEM Figure 1.1 Connections for 120 Volts Only 1.5 SPECIFICATIONS 1.5.2 OPTIONAL PROPANE FUEL SYSTEM 1.5.3 FUEL CONSUMPTION 1.5.4 ENGINE OIL REQUIREMENTS 1.5.5 ENGINE 1.5.6 GENERATOR 2.1 GENERATOR CONTROL PANEL Figure 2.1 Generator Control Panel 2.1.1 FUEL PRIMER 2.1.2 START/STOP SWITCH 2.1.3 FUSE 2.3 AUTOMATIC CHOKE 2.3.1 CHOKE SOLENOID 2.3.2 PRECHOKE 2.4 BEFORE STARTING THE ENGINE 2.4.1 INSTALLATION 2.5 STARTING THE GENERATOR 2.6 STOPPING THE GEN ERATOR 2.7 APPLYING LOADS TO GENERATOR 2.7.1 LETTING THE ENGINE STABILIZE 2.8 SUMMER/WINTER HEAT RISER SYSTEM 2.9 PROTECTION SYSTEMS 2.9. LOW OIL PRESSURE SWITCH 2.9.2 HIGH TEMPERATURE SWITCH Figure 2.4 Low Oil Pressure and High Temperature Switches Figure 2.5 Field Boost Circuit 2.10 ADDITIONAL INFORMATION 2.10.1 25-HOUR BREAK-IN PER IOD 2.10.2 25-HOUR CHECK-UP 2.10.3 ATTENTION REQUIRED AFTER SUBMERSION 2.10.4 OPERATION IN HIGH GRASS OR BRUSH 3.1 CHECKING THE ENGINE OIL LEVEL 3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER 3.3 MAINTAINING THE ENGINE AIR CLEANER 3.3.1 CLEANING THE FOAM PRECLEANER Figure 3.2 Engine Air Cleaner 3.3.2 CLEANING OR REPLACING THE PAPER FILTER 3.4 CLEAN AIR INTAKE 3.6 FUEL FILTER Figure 3.5 Fuel Filter Fuel Filter 3.7 SPARK ARRESTOR MUFFLER 3.8 CLEANING THE GEN ERATOR 3.10 MAJOR SERVICE MANUAL 3.11 DRIVE BELT 3.12 EXERCISING THE GENERATOR 3.13 OUT OF SERVICE PROCEDURE 3.13.1 REMOVAL FROM SERVICE 3.13.2 RETURN TO SERVICE Page NOTICE TO INSTALLER GENERAL HAZARDS ELECTRICAL HAZARDS FIRE HAZARDS EXPLOSION HAZARDS 1.1 PURPOSE AND SCOPE OF THE MANUAL 1.2 SAFETY 1.3 STANDARDS BOOKLETS 1.4 EQUIPMENT DESCRIPTION 1.5 GENERATOR ENGINE OPERATING SPEED Page 2.1 LOCATION AND SUP PORT 2.1.1 GENERATOR LOCATION 2.1.2 GENERATOR SUPPORT Figure 2.1 Typical Horizontal Support Frame 2.1.3 SUSPENDED MOUNTING 2.2 GENERATOR COMPARTMENTS 2.2.1 COMPARTMENT SIZE 2.2.2 COMPARTMENT CONSTRUCTION Figure 2.5 Typical Compartment Construction Figure 2.6 Types of Lock Seams 2.2.3 SOUND INSULATING MATERIALS 2.2.4 ACOUSTICS 2.2.5 COMPARTMENT FLOOR CUTOUTS 2.3 COOLING AND VENTILATING AIR 2.3.1 GENERATOR AIRFLOW Figure 2.9 Airflow Through Engine/Generator 2.3.2 COOLING AIR INLET OPENINGS Figure 2.10 Air Inlet in Compartment Door 2.4 GASOLINE FUEL SYSTEM Figure 2.14 Generator Fuel System 2.4.1 FUEL TANK 2.4.2 GENERATOR FUEL SUPPLY LINE 2.4.2.1 Rigid Fuel Lines 2.4.2.2 Flexible Fuel Line 2.5 LP GAS FUEL SYSTEM 2.5.1 PARTS NOT INCLUDED IN FUEL SYSTEM Figure 2.15 Typical Propane Gas Fuel System 2.5.2 SOME IMPORTANT CONSIDERATIONS Figure 2.16 LP Gas Carburetion Diagram 2.5.3 VAPOR WITHDRAWAL 2.5.4 PRIMARY REGULATOR 2.5.5 GASEOUS CARBURETION 2.6 EXHAUST SYSTEM 2.6.1 MUFFLERS AND SPARK ARRESTORS 2.6.2 TYPE OF EXHAUST SYSTEM 2.6.3 EXHAUST SYSTEM SAFETY 2.7 ELECTRICAL CONNECTIONS 2.7.1 ELECTRICAL JUNCTION BOX 2.7.2 WIRING 2.7.3 GENERATOR AC CONNECTIONS Figure 2.17 Generator AC Output Leads 2.7.4 CONDUIT 2.7.5 ISOLATING DIFFERENT POWER SOURCES 2.7.6 POWER SUPPLY CORD 2.7.7 GROUND FAULT CIRCUIT INTERRUPTERS 2.8 BATTERY INSTALLATION 2.8.1 RECOMMENDED BATTERY Figure 2.21 Remote Panel Plug-in Receptacle 2.8.2 BATTERY CABLES 2.8.3 BATTERY CABLE CONNECTIONS 3.1 POST INSTALLATION TESTS 3.2 BEFORE I NITIAL START-UP 3.3 INITIAL START 3.4 TESTING UNDER LOAD 3.5 INSTALLATION CHECKLIST LOCATION AND SUPPORT GENERATOR COMPARTMENT COOLING AND VENTILATING AIR GASOLINE FUEL SYSTEM TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Page Page Page Page Page Page Page Page Page Page Page Section 6 Exploded Views and Parts Lists ITEM PART NO. QTY. DESCRIPTION Page Page Page Page Page Page CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURERS EMISSION CONTROL SYSTEM WARRANTY COVERAGE: PURCHASERS/OWNERS WARRANTY RESPONSIBILITIES: 1-800-333-1322 EMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWING: GENERAC POWER SYSTEMS THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS WARRANTY SCHEDULE COMMERCIAL APPLICATIONS WARRANTY SCHEDULE CONSUMER/PERSONAL APPLICATIONS GENERACPOWER SYSTEMS, INC.