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Generac 02010-2, 04164-2 2.1 GENERATOR CONTROL PANEL, 2.2 OPTIONAL REMOTE START/STOP PANEL

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Generac®Power Systems, Inc. 7

Section 2 – Operation

PRIMEPACT 50 Recreational Vehicle Generator

2.1 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 start-

ed in more than two weeks), you must press this

switch for approximately 10 to 15 seconds to bring

fuel from the tank to the carburetor. This rocker type

switch springs back into its original position when

you release it. It is not necessary to press the primer

switch for LP units.

2.1.2 START/STOP SWITCH

To crank and start the engine, hold this switch in the

START position. Release the switch when the engine

starts. To stop an operating engine, press and hold

the switch in the STOP position until the engine shuts

off. The switch center position is the RUN position.

2.1.3 FUSE

The fuse protects the engine’s DC control circuit

against electrical overload. If the fuse element has

melted open due to overloading, the engine cannot be

cranked. If you must replace the fuse, use only an

identical replacement.

2.1.4 MAIN BREAKER

The main breaker protects the generator’s AC output

circuit against overload and provides a method of

turning OFF the generator’s 120/240-volt AC output

to the vehicle circuits. The PRIMEPACT 50 has one

20-amp breaker and one 30-amp breaker.

NOTE:

If the PRIMEPACT 50 has been reconnected for

dual voltage AC output (120/240 volts), you can

install line breakers having an amperage rating

that is different than that stated in Section 1.4

(Page 5). The replacement line breakers consist of

two separate breakers (one 20 amp, and one 30

amp) with a connecting piece between the breaker

handles (so that both breakers will operate at the

same time). If the unit is reconnected for dual

voltage, it is no longer RVIA listed.

2.2 OPTIONAL REMOTESTART/STOP PANEL

A remote mounted Start/Stop Panel (Figure 2.2) is

available that allows you to start and stop the gener-

ator engine conveniently from inside the vehicle. 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)

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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.