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Generac 04164-3 manual

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Table of contents for the manual

  • Page 1

    Owner's Manual and Installation Instructions Air -cooled Recreational V ehicle Generators • Model: 05754-0 PRIMEP ACT 50 • Model: 04164-3 PRIMEP ACT 50LP[...]

  • Page 2

    INTRODUCTION Thank you for purchasing this model manufactured by Generac P ower Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. READ THIS MANUAL THOROUGHL Y  If any por tion of this manual is not understood, contact the near - est Authorized Ser vice Dealer for star ting, operating and s[...]

  • Page 3

    T able of Contents Recreational Vehicle Generator 1 P art I – Owner’s Manual Introduction .................................. Inside Front Cover Read This Manual Thoroughly .......................................................IFC Contents ....................................................................................... IFC Operation and [...]

  • Page 4

    2 Study these SAFETY RULES carefully before installing, operating or ser vicing 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 maintained. Many accidents are caused by failing to follow simple and fundamental r ules or p[...]

  • Page 5

    3 Adequate, unobstr ucted flow of cooling and ventilating air • is critical for expelling toxic carbon monoxide gas and fuel vapors from the generator compar tment and for proper genera- tor operation. Without sufficient cooling air flow , deadly carbon monoxide gas can accumulate and the engine/generator may quickly overheat, causing serious dam[...]

  • Page 6

    4 1. Generator Air Intake 2. Engine Star t/Stop Switch 3. Fuse 4. Optional R emote P anel Receptacle (behind control panel) 5. Generator AC Output Leads (behind control panel) 6. Fuel P rimer Switch 7. Circuit Breaker 8. Circuit Breaker 9. Star ter Contactor 10. Fuel Inlet 11. Fuel Pump 12. Fuel Filter 13. Oil Filter 14. Oil Drain Cap 15. Oil Dipst[...]

  • Page 7

    5 Section 1 – General Information Recreational Vehicle Generator 1.2 GENERA TOR 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 per taining to its [...]

  • Page 8

    6 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. Do NOT use any gasoline co[...]

  • Page 9

    7 1.6 EV APORA TIVE EMIS SIONS INFORMA TION This generator is subject to evaporative emission standards which have been implemented by the California Air Resource Board (CARB) and the Environmental Protection Agency (EP A). If this generator is offered for sale in the state of California, it must be covered by a CARB evaporative Executive Order . I[...]

  • Page 10

    8 Section 2 – Operation Recreational Vehicle Generator 2.1 GENERA TOR CONTROL P ANEL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control P anel 2.1.1 FUEL PRIMER  Before star ting a cold engine (if it has not been star ted in more than two weeks), this switch must be pressed for appr[...]

  • Page 11

    9 Section 2 – Operation Recreational Vehicle Generator 2.4 BEFORE ST ARTING 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 INST ALLA TION  Generator installation mu[...]

  • Page 12

    10 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). Electrical load circui[...]

  • Page 13

    11 2.8.1 DO NOT OVERL OAD THE GENERA TOR  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. T o avoid overloading, add up the wattage of all[...]

  • Page 14

    12 Section 3 – Maintenance Recreational Vehicle Generator Figure 3.1 – Oil Maintenance F eatures 2.10 ADDITIONAL INFORMA TION 2.10.1 A T TENTION REQUIRED AFTER SUBMERSION  If the recreational vehicle generator has been submerged in water , it MUST NOT be star ted and operated. Following any submersion in water , have an Authorized Ser vice D[...]

  • Page 15

    Section 3 – Maintenance Recreational Vehicle Generator Change the engine oil filter af ter the first 25 hours of operation, • and ever y 100 operating hours thereaf ter . T o change the oil and/or oil filter , proceed as follows (see Figure • 3.1): 1. Run the engine until it is thoroughly warmed up (at least five minutes) then shut OFF the en[...]

  • Page 16

    14 3.5 CHECKING THE ENGINE SP ARK PLUG Clean the spark plug and reset the spark plug gap ever y 100 hours of operation. 1. Clean the area around the base of the spark plug to keep dir t and debris out of the engine. Clean by scraping or washing using a wire br ush and commercial solvent. Do not blast the spark plug to clean. 2. Remove the spark plu[...]

  • Page 17

    15 3.9 BA T TERY MAINTENANCE All lead-acid batteries will discharge when not in use. The genera- tor batter y should be inspected as follows: 3.9.1 WEEKL Y  Inspect the batter y posts and cables for tightness and corro- • sion. Tighten and clean as necessar y . Check the batter y fluid level of unsealed batteries and, if nec- • essar y , fil[...]

  • Page 18

    16 3.13 OUT OF SERVICE PROCEDURE 3.13.1 REMOVAL FROM SERVICE  If the generator cannot be exercised ever y seven days, and it is to be out of ser vice longer than 30 days, prepare the generator for storage as follows: 1. Star t the engine and let it warm up. 2. Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down. [...]

  • Page 19

    P ART II – INST ALLA TION INSTRUCTIONS D ANGER ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A T TEMPT INST ALLA TION![...]

  • Page 20

    18 NOTICE TO INST ALLER These Installation Instructions have been published by the manu- facturer to aid in the installation of the products described in this manual. The manufacturer assumes that installation personnel are familiar with the procedures for installing such products, or similar products manufactured. The manufacturer also assumes tha[...]

  • Page 21

    19 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. Never sleep in the vehicle while the genset is r unning unless the • vehicle has a working car[...]

  • Page 22

    20 1.1 PURPOSE AND SCOPE OF THE MANU 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. Give seri- ous consideration to all information and instr uctions in the manual, both for safety and for continued[...]

  • Page 23

    21 Figure 1.2 – Major F eatures and Dimensions (Drawing 0F1127-A) Section 1 – General Information Recreational Vehicle Generator[...]

  • Page 24

    22 2.1 L OCA TION AND SUPPORT 2.1.1 GENERA TOR 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. Many recreational vehicles have been factor y equipped with an ar[...]

  • Page 25

    23 Figure 2.3 – T ypical Generator Restraint 2.2 GENERA TOR COMP ARTMENTS Whether the generator set is being installed inside a compar tment specifically manufactured to house a generator or inside a compar t- ment that the installer constr ucts, the compar tment MUST meet cer tain specifications as outlined in the following sections: 2.2.1 COMP [...]

  • Page 26

    24 Figure 2.6 – T ypes of Lock Seams Af ter the compar tment has been metal lined and vapor • sealed, line the compar tment interior walls and ceiling with an approved, nonflammable sound insulating material. See the "Sound Insulating Materials" section. D ANGER  Do not install any flammable material directly above or around the co[...]

  • Page 27

    25 2.2.5 COMP ARTMENT FLOOR CUTOUTS  Provide openings in the generator compar tment 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. D ANGER  Fuel lines and exhaust piping mus[...]

  • Page 28

    26 D ANGER  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 GENERA TOR AIRFL OW  Engine operation drives cooling fans for the two-stage cooling air system. A pressure fan draws cooling air into [...]

  • Page 29

    27 Figure 2.13 – Air Inlet in Vehicle Skirt MINIMUM CLEARANCE 1-1/2" VEHICLE FLOOR VEHICLE SKIRT AIR INLET 2.3.3 COMPENSA TING 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 propor tionately larger . Some materi[...]

  • Page 30

    28 2.4.2 GENERA TOR FUEL SUPPL Y LINE  2.4.2.1 Rigid F uel 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 r ules apply to rigid fuel lines: Rigid lines should be of annealed, seamless, drawn aluminum • or steel. Lines and fittings must com[...]

  • Page 31

    29 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. V apor 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. 2.5.4 P[...]

  • Page 32

    30 D ANGER  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. 2.6 EXHA UST SYSTEM The generator exhaust[...]

  • Page 33

    31 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. 2.7 ELECTRICAL CONNECTIONS Be[...]

  • Page 34

    32 Route conduit so it does not inter fere 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. 2.7.5 ISOLA TING DIFFERENT POWER SOURCES  Connections from the junction box must termin[...]

  • Page 35

    33 These generators are rated at about 100 DC amperes of cranking current. Select batter y 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 char t. CABLE LENGTH in Feet (meters) CABLE SIZE 0 to 10 (0 to 3) 2* 1[...]

  • Page 36

    34 2.8.4 BA T TERY COMP ARTMENT  Install the generator batter y in its own, vented compar tment. Place the batter y compar tment away from any source of heat, sparks or flame. Provide ventilation openings in the battery compar tment. The minimum size of openings should be 2 square inches at the top of the compar tment. Mount the batter y on a st[...]

  • Page 37

    35 NOTE: The generator set was thoroughly tested and adjusted at the factory before shipping. No additional adjustment should be necessary . Only qualified ser vice technicians who have been trained should perform adjustments outlined in this manual. 3.4 TESTING UNDER L OAD Apply electrical loads equal to about 75 to 100 percent of the unit's [...]

  • Page 38

    3.5 INST ALLA TION CHECKLIST L OCA TION AND SUPPORT  ❑ Generator is properly located. ❑ Generator is properly suppor ted. ❑ Generator is properly restrained. GENERA TOR COMP ARTMENT  ❑ Compar tment constr uction is proper . ❑ Holes/Openings are vapor -sealed. ❑ Compar tment size is correct. ❑ Compar tment is vapor -sealed. ❑ S[...]

  • Page 39

    37 Section 4 – T roubleshooting Recreational Vehicle Generator TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace batter y cables as necessary . 3. Defective engine Star t/Stop 3. Replace Star t/Stop switch. switch 4. Defective star [...]

  • Page 40

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

  • Page 41

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

  • Page 42

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

  • Page 43

    41 ITEM P ART NO . QTY . DESCRIPTION 1 0C2368 1 BASE, MOUNTING 2 053407 1 GROUND CABLE 3 046911 4 MOUNT , (RUBBER) 4 025017 6 CAPSCREW , HEX HD.-3/8"-16 X 1/2" 5 022237 6 L OCK W ASHER-3/8" 6 022129 9 L OCK W ASHER-M8 7 0A6479 1 SKID, RUBBER MOUNT 8 077603 2 SAFETY BOL T 5/16"-18 X 3 1/2" 9 022259 2 NUT , HEX -5/16"-18[...]

  • Page 44

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

  • Page 45

    43 ITEM P ART NO . QTY . DESCRIPTION 1 0F1126 1 ASSEMBL Y REGUL A TOR 2 048031M 2 #8 HOSE CLAMP 3 0F7065 16” HOSE, 1/2” I.D. PETROLEOM 4 022145 8 WASHER FLA T 5/16”- M8 5 022129 12 WASHER L OCK M8 - 5/16” 6 045771 3 NUT HEX M8-1.25 7 066849 2 SCREW , T APTITE M5-0.8 X 16MM L ONG 8 022473 1 WASHER FLA T 1/4” - M6 9 062684 1 GROUNDING LUG 1[...]

  • Page 46

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

  • Page 47

    45 ITEM P ART NO . QTY . DESCRIPTION 1 0C9675 1 L OWER BEARING CARRIER 2 0A5649H 1 ROTOR ASSEM. 3 0A5646H 1 ST A TOR AS SEM. 4 073159 1 BALL BEARING 5 031971 1 BALL BEARING 6 0C9674 1 UPPER BEARING CARRIER 7 0A6529 4 STUD-ST A TOR 8 052858 4 M8-1.25 FLANGE L OCK NUT 9 066386 1 BRUSH HOLDER 10 066849 3 M5-0.8 X 16 LG. T APTITE 11 0A8475 3 SPECIAL L [...]

  • Page 48

    46 Section 6 — Exploded Views and P arts Lists Recreational Vehicle Generator Engine Sheet Metal – Drawing No. 0D1760- J[...]

  • Page 49

    47 Section 6 — Exploded Views and P arts Lists Recreational Vehicle Generator Engine Sheet Metal – Drawing No. 0D1760- J ITEM P ART NO . QTY . DESCRIPTION 1 0A4323 1 SCROLL, FL YWHEEL 2 045756 8 SCREW , T APTITE M6-1.0 X 10MM 3 029289 2.5 FT . FOAM T APE 4 091222DSRV 1 FL YWHEEL 5 067198N 1 WASHER , BELL VILLE M20 X 2.2 6 067890 1 NUT , M20 X 1[...]

  • Page 50

    48 Section 6 — Exploded Views and P arts Lists Recreational Vehicle Generator GN-410 Engine – Drawing No. 0E9615-B[...]

  • Page 51

    49 Section 6 — Exploded Views and P arts Lists Recreational Vehicle Generator GN-410 Engine – Drawing No. 0E9615-B ITEM P ART NO . QTY . DESCRIPTION 1 0G2565 1 RING SET , PISTON DIA 90 2 0E3221 1 CONNECTING ROD 3 0E1466 1 PISTON PIN 4 071983 2 PISTON PIN RET AINER 5 021713B 1 CYLINDER HEAD GASKET 6 0A1442 8 FL ANGED HEX HD. CAPSCREW M8-1.25 X 4[...]

  • Page 52

    50 Section 6 — Exploded Views and P arts Lists Recreational Vehicle Generator Engine Accessories – Drawing No. 0F1135-E[...]

  • Page 53

    51 ITEM P ART NO . QTY . DESCRIPTION 1 0A6532 1 MANIFOLD, INT AKE 2 091039 1 GASKET , MANIFOLD/HEAD 3 051753 1 HHCS-M6-1.0 X 40MM 4 0E7585 1 SP ARK PLUG, CHAMP 5 089228 1 GASKET , CARB/MANIFOLD 6 0A7336B 1 CARBURETOR , GN 410 L/P 0A6562 1 CARBURETOR, GN410 GAS 7 090970 1 GASKET , CARB/AIR FIL TER 8 0A7660 1 ASSY , AIR CLEANER/VAL VE 0A7660A 1 ASSY [...]

  • Page 54

    52 Section 6 — Exploded Views and P arts Lists Recreational Vehicle Generator Alternator & Panel – Drawing No. 0H3636-A[...]

  • Page 55

    53 ITEM P ART NO . QTY . DESCRIPTION 1 0C9675 1 L OWER BEARING CARRIER 2 0A5649H 1 ROTOR ASSEM. 3 0A5646H 1 ST A TOR AS SEM. 4 073159 1 BALL BEARING 5 031971 1 BALL BEARING 6 0C9674 1 UPPER BEARING CARRIER 7 0A6529 4 STUD-ST A TOR 8 052858 4 M8-1.25 FLANGE L OCK NUT 9 066386 1 BRUSH HOLDER 10 066849 3 M5-0.8 X 16 LG. T APTITE 11 0A8475 3 SPECIAL L [...]

  • Page 56

    54 Section 7 – Notes[...]

  • Page 57

    55 Section 7 – Notes[...]

  • Page 58

    56 CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY ST A TEMENT Y OUR WARRANTY RIGHTS AND OBLIGA TIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EP A), together with Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.* New utili[...]

  • Page 59

    57 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The EC S Warranty P eriod shall begin on the date the new engine or equip- ment is purchased by/delivered to its original, end-use purchaser/own[...]

  • Page 60

    Part No. 0H3468 Revision A (06/26/09) Printed in U.S.A. Section 8 – W arranty Recreational Vehicle Generator GENERAC POWER SYSTEMS’ THREE- YEAR LIMITED WARRANTY FOR GUARDIAN RECREA TIONAL VEHICLE GENERA TORS NOTE: ALL UNITS MUST BE INST ALLED B Y GENERAC POWER SYSTEMS AUTHORIZED SERVICE F ACILITIES. For a period of 3 (three) years of operation [...]