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PO WER SY STEMS, INC. ® Owner’ s Man ual and Installation Instructions Air -cooled Recreational V ehic le Generators • Model: 02010-0 PRIMEP A CT 50 • Model: 04164-0 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 Front 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 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 .
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 Primer 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 NOTE: Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits. 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 (GASOLINE ON L 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 T o start the generator from either the generator con- trol panel or from the optional remote panel, proceed as follows: 1.
10 Generac ® Pow er Systems, Inc. Section 2 – Operation PRIMEP A C T 5 0 Recreational V ehicle Generator 2.8.1 DO NO T O VERLO AD TH E GEN ERA T OR Y ou can read the rated wattage/amperage capacity of your generator on the generator data decal (see Section 1.
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 A GE P RO TE CTION A solid- state voltage regulator (Figure 2.5) 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 E CKI NG 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 ING TH E FO AM P RECLEANER 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 F I L TER (GA SOLINE 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 AN D S C OP E 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 AND SU P PORT 2.1.1 GEN ERA 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 ERA T OR R ES 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 OUT S 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 COOLI 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 ENS A TING FOR R ES TRICTIONS 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 UEL 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 MPORT ANT CONSIDER 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 AR K ARR 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 IRIN G • 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 COR D 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 NS T ALL A TION 2.8.1 R E COMM EN DED B A TTER 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 ANEL MODEL S 2.9.1.1 Model 9042 This remote panel mounts a rocker type start/stop switch and a “Generator Run ” advisory lamp.
36 Generac ® Pow er Systems, Inc. 3.1 POS T I NST ALL A TION TE S T S The air - cooled generator set was factory tested and adjusted. Y ou should not be required to adjust the unit any further except under special circumstances. Do not make any unnecessary adjustments.
Generac ® Pow er Systems, Inc. 37 Section 3 – Post-installation Start-up Adjustments PRIMEP A C T 5 0 Recreational V ehicle Generator 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.
38 Generac ® Pow er Systems, Inc. Appendix 1 – Notes PRIMEP A C T 5 0 Recreational V ehicle Generator.
Generac ® Pow er Systems, Inc. 39 Appendix 2 – 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 ECTION The engine will not crank. 1. F use blown 1. Replace fuse. 2. Loose, corroded or defective 2.
40 Generac ® Pow er Systems, Inc. Appendix 3 — Electrical Data PRIMEP A C T 5 0 Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No.
Generac ® Pow er Systems, Inc. 41 Appendix 3 — Electrical Data PRIMEP A C T 5 0 Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No.
42 Generac ® Pow er Systems, Inc. Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Base and Pulleys (Model 020 1 0-0) – Drawing No.
Generac ® Pow er Systems, Inc. 43 ITEM P AR T NO . QTY . DESCRIPTION 1 C2368 1 BASE, MOUNTING 2 53407 1 GROUND CABLE 3 46911 4 MOUNT , (R UBBER) 4 25017 6 CAPSCREW , HEX HD .
44 Generac ® Pow er Systems, Inc. Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Base and Pulleys (Model 04 1 64-0) – Drawing No.
Generac ® Pow er Systems, Inc. 45 ITEM P AR T NO . QTY . DESCRIPTION 1 C2368 1 BASE, MOUNTING 2 53407 1 GROUND CABLE 3 46911 4 MOUNT , (R UBBER) 4 25017 6 CAPSCREW , HEX HD .
46 Generac ® Pow er Systems, Inc. Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Alternator and P anel (Model 020 1 0-0 and 04 1 64-0) – Drawing No.
Generac ® Pow er Systems, Inc. 47 Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Alternator and P anel (Model 020 1 0-0 and 04 1 64-0) – Drawing No. A8922-B ITEM P AR T NO . QTY . DESCRIPTION 1 75995 1 LO WER BEARING CARRIER 2 A5649H 1 RO T OR ASSEM.
48 Generac ® Pow er Systems, Inc. Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Sheet Metal (Model 020 1 0-0 and 04 1 64-0) – Drawing No.
Generac ® Pow er Systems, Inc. 49 Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Sheet Metal (Model 020 1 0-0 and 04 1 64-0) – Drawing No. A8921 -A IT EM P ART NO . QTY . DESCRIPTION 1 A4323 1 SCROLL, FL YWHEEL 2 45756 9 SCREW , T APTITE M6-1.
50 Generac ® Pow er Systems, Inc. Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator GN-4 1 0 Engine (Model 020 1 0-0 and 04 1 64-0) – Drawing No.
Generac ® Pow er Systems, Inc. 51 Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator GN-4 1 0 Engine (Model 020 1 0-0 and 04 1 64-0) – Drawing No.
52 Generac ® Pow er Systems, Inc. Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Accessories (Model 020 1 0-0) – Drawing No.
Generac ® Pow er Systems, Inc. 53 Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Accessories (Model 020 1 0-0) – Drawing No. A8923-A ITEM P AR T 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. Appendix 4 — Exploded Views and P arts Lists PRIMEP A C T 5 0 Recreational V ehicle Generator Engine Accessories (Model 041 64-0) – Drawing No.
Generac ® Pow er Systems, Inc. 55 ITEM P AR T 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 TEMENT Y OU R W ARR ANT Y RIGHTS AN D OBLIGA 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 ANT Y 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. C5080 GENERAC ® POWER SY STEMS, INC. P .O. BOX 8 • W AUKESHA, WI 53187 Revision A (02/08/00) Printed in U.S.A. Appendix 5 – W arranty PRIMEP A C T 5 0 Recreational V ehicle Generator GEN.
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