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Guardian Technologies 04164-3 - page 1
Owner’ s Man ual and Installation Instructions Air -cooled Recreational V ehic le Generators • Model: 02010-2 PRIMEP A CT 50 • Model: 04164-3 PRIMEP A CT 50LP ...
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Guardian Technologies 04164-3 - page 2
I NTRODUCTION Thank you for purchasing this model manufac- tured by Generac P ower Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. R EAD THIS MAN UAL THOROUGHL Y If any portion of this manual is not understood, con- tact the nearest Authorized Service Dealer for start - ing, operating and s ...
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Guardian Technologies 04164-3 - page 3
T able of Contents Recreational V ehicle Generator 1 Part I – Owner’s Manual Introduction ........................................ Inside Front Cover Read This Manual Thoroughly ................................. IFC Contents .................................................................. IFC Operation and Maintenance ........................ ...
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Guardian Technologies 04164-3 - page 4
2 Study these SAFETY RULES carefully before install- ing, operating or servicing this equipment. Become familiar with this manual and with the unit. The gen- erator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or p ...
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Guardian Technologies 04164-3 - page 5
3 Adequate, unobstructed flow of cooling and ven- tilating air is critical to correct generator opera- tion and is required to expel toxic fumes and fuel vapors from the generator compartment. W ithout sufficient cooling airflow , the engine/generator quickly overheats, which causes serious damage to the generator . Do not alter the installation or ...
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Guardian Technologies 04164-3 - page 6
4 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. Circuit Breaker 9. Starter Contactor 10. F uel Inlet 11. F uel Pump 12. F uel Filter 13. Oil Filter 14. Oil Drain Cap 15. Oil Dips ...
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Guardian Technologies 04164-3 - page 7
5 Section 1 – General Information 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. Do not modify the generator or use it for any application other than for what it was designed. If there are any questions pertaining ...
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Guardian Technologies 04164-3 - page 8
6 Section 1 – General Information Recreational V ehicle Generator The manufacturer does not r ecommend using any gasoline containing alcohol (such as “gaso- hol”). If using any gasoline containing alcohol, it must not contain more than 10 per cent ethanol, and it must be removed fr om the generator dur - ing storage. Do NOT use any gasoli ...
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Guardian Technologies 04164-3 - page 9
7 Section 2 – Operation 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 2.1.1 F UEL PRIME R Before starting a cold engine (if it has not been started in more than two weeks), this switch must be pressed for appr ...
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Guardian Technologies 04164-3 - page 10
8 Section 2 – Operation Recreational V ehicle Generator 2.4 B EFOR E S T ARTI NG TH E ENGI N E NOTE: Instructions and information in this manual assume the generator has been properly installed, connected, serviced, tested and adjusted by a qualified installation technician or installation contractor . 2.4.1 I NS T ALLA TION Generator installatio ...
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Guardian Technologies 04164-3 - page 11
9 Section 2 – Operation Recreational V ehicle 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 ...
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Guardian Technologies 04164-3 - page 12
10 Section 2 – Operation Recreational V ehicle Generator 2.8.1 DO NO T O VERL O AD THE GEN ER A T OR Read the rated wattage/amperage capacity of the gen- erator 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 automati- ca ...
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Guardian Technologies 04164-3 - page 13
11 2.9.4 OVERV OL T A GE P RO TE 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 . By regulating the rotor’s excitation current, the strength of its mag- netic field is regulated and, in turn, the voltage deliv- ered to connected electri ...
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Guardian Technologies 04164-3 - page 14
12 Section 3 – Maintenance Recreational V ehicle Generator Figure 3.1 – Oil Maintenance Features 3.2 CHANGI NG TH E ENGI N E OI L AN D/OR OI L F I L TER Change the engine oil after the first 25 hours of operation. Thereafter , change the oil every 100 operating hours. Change the oil more frequently if operating consistently under heavy load or ...
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Guardian Technologies 04164-3 - page 15
Section 3 – Maintenance Recreational V ehicle Generator 5. W rap the foam precleaner in a clean cloth and gently squeeze it dry . 6. Saturate the foam precleaner in clean engine oil. Gently squeeze it in a clean cloth to remove excess oil and to distribute oil (DO NOT TWIST). 7. Install the foam precleaner into the cover , fol- lowed by the paper ...
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Guardian Technologies 04164-3 - page 16
14 3.6 F U EL F I L TER (GA S OLI N 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. Figure 3.5 – Fuel Filter Fuel Filter 3.7 SP ARK AR R ES T OR MUFFLE R If the generator is not equipped with a spark arres- tor exhaust muffler and is to be used on any forest covered, ...
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Guardian Technologies 04164-3 - page 17
15 D ANGER Do not dispose of the battery in a fire. The bat- tery is capable of exploding. Storage batteries give off explosive hydr ogen gas. This gas can form an explosive mixture ar ound the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and c ...
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Guardian Technologies 04164-3 - page 18
16 3.1 3.2 RETUR N T O SERVICE T o return the unit to service after storage, proceed as follows: 1. Check the tag on the engine for oil viscosity and classification. V erify that the correct recommend- ed oil is used in the engine (see the "Engine Oil Requirements" section). If necessary , drain and refill with the proper oil. 2. Check th ...
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Guardian Technologies 04164-3 - page 19
P ART I I – I NS T ALL A TION I NS TR UCTIONS D ANGER ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION! ...
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Guardian Technologies 04164-3 - page 20
18 NO TICE T O I NST ALLER These Installation Instructions have been published by the manufacturer to aid in the installation of the products described in this manual. The manufac- turer assumes that installation personnel are famil- iar with the procedures for installing such products, or similar products that are manufactured. The manufacturer al ...
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Guardian Technologies 04164-3 - page 21
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 . Ensure all appropriate covers, guards and barriers are in place before operating the generator . If work mus ...
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Guardian Technologies 04164-3 - page 22
20 1.1 P U R POSE AN D S COPE 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. Give serious consideration to all information and instructions in the manual, both for safety and for conti ...
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Guardian Technologies 04164-3 - page 23
21 Figure 1.2 – Major Features and Dimensions (Drawing 0F1127) Section 1 – General Information Recreational V ehicle Generator O IL FILTER O IL DRAIN H OS E S IDE EXHA US T OU TLET O IL FILL A IR C LEANER " + " BATTERY CO NNE C TI O N C IR CU IT BREAKER S 4 26.7 [ 16.8" ] 4 80.0 [ 18.9" ] 6 42.0 [ 25.3" ] FUS E O IL DIP ...
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Guardian Technologies 04164-3 - page 24
22 2.1 L OCA TION AN D 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 rein- force. Many recreational vehicles have been factory equipped with an ...
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Guardian Technologies 04164-3 - page 25
23 2.1.4 GEN ERA T OR R ES TRAI NT Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing . These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compartment is used) and (c) the supporting framework (Figure 2.3). All bolts must be long enou ...
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Guardian Technologies 04164-3 - page 26
24 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 construc- tion, is NOT vapor tight along its entire length. Seams and joints of the galvanized steel (whether used as a liner or for the compartment it ...
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Guardian Technologies 04164-3 - page 27
25 Figure 2.7 – T ypical Noise Abatement 2.2.5 COMP ARTM ENT F L OOR CUT OUTS Provide openings in the generator compartment 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. See the "Generator Restraint" section. D ANGER Fuel ...
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Guardian Technologies 04164-3 - page 28
26 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 airflow , the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also may cause fire and personal injur ...
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Guardian Technologies 04164-3 - page 29
27 Figure 2.12 – Air Inlet Using Ductwork Figure 2.13 – Air Inlet in V ehicle Skirt MINIMUM CLEARANCE 1-1/2" VEHICLE FLOOR VEHICLE SKIRT AIR INLET 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 . Compensate for this restriction by making the actual air openi ...
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Guardian Technologies 04164-3 - page 30
28 2.4.1 F UEL T AN K Either the generator must share the vehicle engine's fuel tank, or a separate fuel tank must be installed for the generator set. All fuel tanks installed on the vehicle must be constructed, installed and restrained so they comply with applicable codes, standards and regulations. If the generator is to share the vehicle en ...
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Guardian Technologies 04164-3 - page 31
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. Apply a pipe sealant to threads when assembling threaded connections. This reduces the possibility of leakage. T ...
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Guardian Technologies 04164-3 - page 32
30 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. The more the regulator valve opens, the greater the gas flow that is propor - tional to airflow through t ...
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Guardian Technologies 04164-3 - page 33
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. Use only mufflers and parts approved by the manufacturer . Any person(s) installing an unapproved muffler , or an unapproved exhaust system part, or modifying an exhaust system in any way that might cause a hazard, is liable ...
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Guardian Technologies 04164-3 - page 34
32 2 .7 . 2 W IRIN G W iring should be of stranded copper to reduce the chance that vibration may cause breakage. W ire gauge size should be large enough to handle at least 115 percent of the installed generator's rated maximum current. If neutral conductors are used, they must be the same size as other leg wires. Route power supply conductors ...
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Guardian Technologies 04164-3 - page 35
33 2.7 .6 POWER S UPPL Y C O RD The power supply cord must comply with all appli- cable codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected. 2.7 .7 GROU ND F AU L T CI RCU IT I NTERR U PTERS The National Electrical Code (NFP A 70, 551-7) requires that ground fault circuit interrupt ...
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Guardian Technologies 04164-3 - page 36
34 2.8 B A T TER Y I NST ALL A TION 2.8.1 R E COMM EN DED BA TTER Y Install a battery that meets the following require - ments: The battery must be a 12-volt, automotive type storage battery . F or prevailing ambient temperatures above 32° F (0° C), use a battery rated 70 amp -hours and capable of delivering 400 cold- cranking amperes. F or preva ...
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Guardian Technologies 04164-3 - page 37
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. Model 004057 includes the remote panel and a 10 foot long, 4 wire harness. Model 004184 incl ...
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Guardian Technologies 04164-3 - page 38
3.5 I NS T ALL A TION CH E CKLIST 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. ❑ Compartment size is correct. ❑ Compartment is vapor - sealed. ❑ So ...
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Guardian Technologies 04164-3 - page 39
37 Section 4 – T roubleshooting Recreational V ehicle Generator TROU B LE SHOO TI NG GU I DE Problem Cause Correction The engine will not crank. 1. F use blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary . 3. Defective engine Start/Stop 3. Replace Start/Stop switch. switch 4. Defective ...
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Guardian Technologies 04164-3 - page 40
38 Section 5 — Electrical Data Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D1 7 54-A ...
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Guardian Technologies 04164-3 - page 41
39 Section 5 — Electrical Data Recreational V ehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 0D1 7 54-A ...
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Guardian Technologies 04164-3 - page 42
40 12 9 1 2 0 2 3 24 2 5 2 9 2 7 6 8 5 30 1 6 1 5 1 0 17 1 8 11 22 14 1 3 1 9 21 27 2 6 2 8 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Regulator (Model 020 1 0-2) – Drawing No. 0F11 2 5-C ...
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Guardian Technologies 04164-3 - page 43
41 ITEM P ART NO . QTY . DESCRIPTION 1 0D56 9 4 1 CA S TING, TWIN REGULA T OR HOU S ING 2 0F47 9 5 4 S CREW PPHM S EM S M4-0.7 X 10 5 0F5022 1 S OLENOID COIL, 12VDC 6 0C6070 1 S PRING- S OLENOID PLUNGER 7 0C46 8 0 1 PLUNGER LP REG. A SS Y 8 0C4647 1 GA S KET , S OLENOID 9 0C464 3 1 INLET , TWIN REGULA T OR NO HOLE 10 0D 39 7 3 1 PLUG, EXP AN S ION ...
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Guardian Technologies 04164-3 - page 44
42 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Base and Pulleys (Model 04 1 64-3) – Drawing No. 0F1 1 24-B ...
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Guardian Technologies 04164-3 - page 45
43 ITEM P ART NO . QTY . DESCRIPTION 1 1 A SS EMBL Y REGULA T OR ( S EE E.V . 0F1125) 2 057 8 22 2 # 8 HO S E CLAMP 3 074 99 4 16" HO S E, 1/2" I.D . PETROLEOM 4 022145 8 WA S HER FLA T 5/16"- M 8 5 02212 9 12 W A S HER LOCK M 8 - 5/16" 6 045771 3 NUT HEX M 8 -1.25 7 066 8 4 9 2 S CREW , T APTITE M5-0. 8 X 16MM LONG 8 02247 3 1 ...
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Guardian Technologies 04164-3 - page 46
44 44 4 5 2 8 53 27 2 6 5 7 1 1 0 9 3 22 2 3 61 8 4 1 8 2 34 6 4 0 35 17 12 42 33 39 31 3 56 47 31 30 65 2 5 50 2 6 60 59 36 17 1 9 4 6 24 11 54 4 5 64 55 4 8 1 5 4 3 37 2 0 38 4 9 57 1 4 44 14 62 63 35 44 1 3 21 1 5 1 6 2 9 1 8 31 51 63 11 58 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Alternator and P anel (Model ...
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Guardian Technologies 04164-3 - page 47
45 ITEM P ART NO . QTY . DESCRIPTION 1 0C 9 675 1 LOWER BEARING CARRIER 2 0A564 9 H 1 ROT OR A SS EM. 3 0A5646H 1 S T A T OR A SS EM. 4 07 3 15 9 1 BALL BEARING 5 0 3 1 9 71 1 BALL BEARING 6 0C 9 674 1 UPPER BEARING CARRIER 7 0A652 9 4 S TUD- S TAT O R 8 052 8 5 8 4 M 8 -1.25 FLANGE LOCK NUT 9 066 38 6 1 BR U S H HOLDER 10 066 8 4 9 3 M5-0. 8 X 16 ...
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Guardian Technologies 04164-3 - page 48
46 10 2 8 3 4 23 8 3 1 3 8 3 2 18 To 4 5 6 9 41 28 19 7 20 17 30 25 26 5 2 24 1 3 4 16 13 53 15 14 2 11 12 8 40 43 47 5 1 44 48 36 45 29 3 7 38 8 8 2 50 49 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Engine Sheet Metal (Model 020 1 0-2 and 04 1 64-3) – Drawing No. 0D1 760-E ...
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Guardian Technologies 04164-3 - page 49
47 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Engine Sheet Metal (Model 020 1 0-2 and 04 1 64-3) – Drawing No. 0D1 760-E ITEM P ART NO . QTY . DESCRIPTION 1 0A4 3 2 3 1 S CROLL, FL YWHEEL 2 045756 8 S CREW , T APTITE M6-1.0 X 10MM 3 02 9 2 89 2.5 FT . FO AM T APE 4 S RV 0 9 1222D 1 FL YWHEEL 5 0671 98 N 1 W A S ...
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Guardian Technologies 04164-3 - page 50
48 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-4 1 0 Engine (Model 020 1 0-2 and 04 1 64-3) – Drawing No. 0E96 1 5 55 33 5 4 3 2 14 30 36 42 2 3 1 8 40 4 9 47 43 41 29 20 39 6 29 3 1 53 5 44 26 27 3 7 3 4 22 16 23 5 1 50 56 49 2 28 45 5 2 18 7 45 24 25 11 12 38 21 46 15 17 19 5 11 48 13 10 ...
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Guardian Technologies 04164-3 - page 51
49 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator GN-4 1 0 Engine (Model 020 1 0-2 and 04 1 64-3) – Drawing No. 0E96 1 5 ITEM P ART NO . QTY . DESCRIPTION 1 0215 33 1 PI S T ON RING S ET 2 0E 3 221 1 CONNECTING ROD 3 0E1466 1 PI S T ON PIN 4 071 983 2 PI S T ON PIN RET AINER 5 02171 3 B 1 CYLINDER HEAD GA S KET 6 0A ...
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Guardian Technologies 04164-3 - page 52
50 15 3 2 41 3 4 3 3 4 1 39 6 5 7 35 2 36 33 9 34 38 24 13 14 12 8 17 27 10 9 40 41 3 1 23 22 25 41 42 3 7 21 18 16 20 19 2 30 29 25 28 11 Section 6 — Exploded Views and P arts Lists Recreational V ehicle Generator Engine Accessories (Model 041 64-3) – Drawing No. 0F1 13 5 ...
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Guardian Technologies 04164-3 - page 53
51 ITEM P ART NO . QTY . DESCRIPTION 1 0A65 3 2 1 MANIFOLD , INT AKE 2 0 9 10 39 1 GA S KET , MANIFOLD/HEAD 3 05175 3 1 HHC S -M6-1.0 X 40MM 4 0E75 8 5 1 S P ARK PLUG, CHAMP 5 0 89 22 8 1 GA S KET , CARB/MANIFOLD 6 0A7 33 6B 1 CARBURET OR, GN 410 L/P 7 0 9 0 9 70 1 GA S KET , CARB/AIR FIL TER 8 0A6564 1 BA S E, AIR FIL TER 9 056 893 3 CRIMPTITE #10 ...
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Guardian Technologies 04164-3 - page 54
52 CALI FOR N IA AND F EDER AL EM ISSION C ONTROL W AR R ANT Y ST A TEM ENT 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), are pleased to explain the Emission Control System W arranty on your new ...
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Guardian Technologies 04164-3 - page 55
53 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. The ECS W arranty P eriod shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purch ...
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Guardian Technologies 04164-3 - page 56
Part No. 0F1118 Revision D (06/15/06) Printed in U.S.A. Section 7 – W arranty Recreational V ehicle Generator GENERA C PO WER SYSTEMS’ THREE-YEAR LIMITED W ARRANTY FOR GU ARDIAN RECREA TIONAL VEHICLE GENERA T ORS NO TE: ALL UNITS MUST BE INST ALLED BY GENERA C PO WER SYSTEMS A UTHORIZED SER VICE F A CILITIES. F or a period of 3 (three) years of ...
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