Page 2 - INTRODUCTION; READ THIS MANUAL THOROUGHLY; This symbol points out potential explosion hazard.; CONTENTS; AUTHORIZED SERVICE
Generac ® Power Systems, Inc. INTRODUCTION Thank you for purchasing this model of thePRIMEPACT product line by Generac Power SystemsInc. This model is designed and manufactured tosupply electrical power for recreational vehicles. READ THIS MANUAL THOROUGHLY If you do not understand any portion of th...
Page 3 - Table of Contents; Part I – Owner’s Manual; Part II – Installation Instructions
Table of Contents PRIMEPACT 50 Recreational Vehicle Generator Generac ® Power Systems, Inc. 1 Part I – Owner’s Manual Introduction ......................................Inside Front Cover Read This Manual Thoroughly ....................................IFC Contents ......................................
Page 4 - GENERAL HAZARDS; DANGER; Safety Rules; The engine exhaust from this product
2 Generac ® Power Systems, Inc. Study these SAFETY RULES carefully beforeinstalling, 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. Many a...
Page 5 - ELECTRICAL HAZARDS
Generac ® Power Systems, Inc. 3 ELECTRICAL HAZARDS • The generator covered by this manual produces dangerous electrical voltages and can cause fatalelectrical shock. Avoid contact with bare wires, ter-minals, connections, etc., while the unit is running.Ensure all appropriate covers, guards and barr...
Page 6 - Section 1 – General Information; IDENTIFICATION; Generator AC Output Leads
4 Generac ® Power Systems, Inc. 1. Generator Air Intake2. Engine Start/Stop Switch3. Fuse4. Optional Remote Panel Receptacle (behind control panel) 5. Generator AC Output Leads (behind control panel) 6. Fuel Primer Switch7. Circuit Breaker8. Circuit Breaker9. Starter Contactor 10. Fuel Inlet11. Fuel...
Page 7 - APPLICABILITY; Figure 1.1 – Connections for 120 Volts Only
Generac ® Power Systems, Inc. 5 Section 1 – General Information PRIMEPACT 50 Recreational Vehicle Generator 1.2 GENERATOR APPLICABILITY These generators have been designed and manufac-tured for supplying electrical power for recreationalvehicles. You should not modify the generator or useit for any ...
Page 8 - Model
6 Generac ® Power Systems, Inc. Section 1 – General Information PRIMEPACT 50 Recreational Vehicle Generator NOTE: Using unleaded gasoline contributes to longerengine valve life by reducing lead and carbondeposits. Generac does not recommend using any gasoline containing alcohol (such as “gasohol”).I...
Page 9 - Section 2 – Operation; GENERATOR CONTROL PANEL; Figure 2.1 – Generator Control Panel; REMOTE
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 generatorcontrol panel (Figure 2.1): Figure 2.1 – Generator Control Panel 2.1.1 FUEL PRIMER Before starting a cold engine (if it has...
Page 10 - CHOKE
8 Generac ® Power Systems, Inc. Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator 2.3 AUTOMATIC CHOKE (GASOLINE ONLY) The engine is equipped with an automatic choke thatconsists of two main components: a choke solenoidand prechoke. 2.3.1 CHOKE SOLENOID During engine cranking (Start/S...
Page 11 - THE; Figure 2.2 – Heat Riser System
Generac ® Power Systems, Inc. 9 Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator To start the generator from either the generator con-trol panel or from the optional remote panel, proceedas follows:1. Turn OFF electrical loads using the means pro- vided in your vehicle (such as a ma...
Page 12 - • If a load does not show its rated wattage, multiply; SYSTEMS; Figure 2.3 – Low Oil Pressure and
10 Generac ® Power Systems, Inc. Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator 2.8.1 DO NOT OVERLOAD THE GENERATOR You can read the rated wattage/amperage capacity ofyour generator on the generator data decal (seeSection 1.1 on Page 4).Applying electrical loads in excess of the u...
Page 13 - Figure 2.5 – Solid State Voltage Regulator; ADDITIONAL INFORMATION; the engine piston rings properly.; AFTER SUBMERSION; MUST NOT; OR BRUSH
Generac ® Power Systems, Inc. 11 Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator 2.9.4 OVERVOLTAGE PROTECTION A solid-state voltage regulator (Figure 2.5) controlsthe generator’s AC output voltage. This regulator sup-plies an excitation current to the rotor. By regulatingthe rotor’...
Page 14 - Section 3 – Maintenance; Figure 3.1 – Oil Maintenance Features; CHECKING THE ENGINE OIL LEVEL; engine oil
12 Generac ® Power Systems, Inc. Section 3 – Maintenance PRIMEPACT 50 Recreational Vehicle Generator Figure 3.1 – Oil Maintenance Features 3.1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements, see “Engine OilRequirements,” Section 1.5.4 (Page 6). Check theengine crankcase oil level ...
Page 15 - Figure 3.2 – Engine Air Cleaner; THE PAPER FILTER; Figure 3.3 – Cleaning Air Intake
Section 3 – Maintenance PRIMEPACT 50 Recreational Vehicle Generator 3.3 MAINTAINING THE ENGINE AIR CLEANER 3.3.1 CLEANING THE FOAM PRECLEANER Clean and re-oil the foam precleaner every threemonths or every 25 hours of operation, whicheveroccurs first. Service the foam precleaner more fre-quently if ...
Page 16 - Figure 3.5 – Fuel Filter; • Inspect the battery posts and cables for tightness
14 Generac ® Power Systems, Inc. 3.6 FUEL FILTER (GASOLINE ONLY) 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 3.7 SPARK ARRESTOR MUFFLER If the generator is not equipped with a spark arrestorexhaust muf...
Page 17 - MAJOR SERVICE MANUAL
Generac ® Power Systems, Inc. 15 Do not dispose of the battery in a fire. The battery is capable of exploding. Storage batter-ies give off explosive hydrogen gas. This gascan form an explosive mixture around the bat-tery for several hours after charging. Theslightest spark can ignite the gas and cau...
Page 18 - OUT OF SERVICE PROCEDURE
16 Generac ® Power Systems, Inc. 3.13 OUT OF SERVICE PROCEDURE 3.13.1 REMOVAL 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. Start the engine and let it warm up.2. Close the fuel ...
Page 19 - ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!! DANGER
Page 20 - NOTICE TO INSTALLER; Installation Instructions
18 Generac ® Power Systems, Inc. NOTICE TO INSTALLER These Installation Instructions have been published by Generac to aid in the installation of the productsdescribed in this manual. Generac assumes thatinstallation personnel are familiar with the proce-dures for installing such products, or simila...
Page 22 - Figure 1.1 – 120-volt Single Voltage Connection
20 Generac ® Power Systems, Inc. 1.1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installersand owners of the applicable equipment with theproduct's installation requirements. Give seriousconsideration to all informati...
Page 23 - Figure 1.2 – Major Features and Dimensions
Generac ® Power Systems, Inc. 21 Figure 1.2 – Major Features and Dimensions Section 1 – General Information PRIMEPACT 50 Recreational Vehicle Generator
Page 24 - Figure 2.1 – Typical Horizontal Support Frame; Section 2 – Installation
22 Generac ® Power Systems, Inc. 2.1 LOCATION AND SUPPORT 2.1.1 GENERATOR LOCATION The most desirable location for the generator set isbetween the vehicle's main frame members. However,this is seldom possible. Most units must be installedon the side of the vehicle and are difficult to reinforce.Many...
Page 25 - Figure 2.3 – Typical Generator Restraint; COMPARTMENTS; Figure 2.4 – Clearances; • The generator compartment should be either con-; Figure 2.5 – Typical Compartment Construction; • If constructing a compartment, line the exterior
Generac ® Power Systems, Inc. 23 2.1.4 GENERATOR RESTRAINT Use four 3/8"-16 hardened steel bolts (Grade 5) to fas-ten the generator to the supporting frame or the sup-port tubing. These bolts must pass through (a) the gen-erator mounting base, (b) the compartment floor (if acompartment is used) ...
Page 26 - Figure 2.6 – Types of Lock Seams
24 Generac ® Power Systems, Inc. • If flexible metal conduit is used, it must be sealed internally at the end where it terminates inside thecompartment’s electrical junction box. NOTE: Flexible metal conduit, due to its unique con-struction, is NOT vapor tight along its entirelength. • Seams and joi...
Page 27 - Figure 2.7 – Typical Noise Abatement; Figure 2.8 – Compartment Floor Cutout
Generac ® Power Systems, Inc. 25 Figure 2.7 – Typical Noise Abatement 2.2.5 COMPARTMENT FLOOR CUTOUTS You 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• Four holes for passage of generato...
Page 28 - COOLING AND VENTILATING AIR; Figure 2.9 – Airflow Through Engine/Generator; at least 100 square inches; Figure 2.10 – Air Inlet in Compartment Door; • By providing an opening in the vehicle skirt and
26 Generac ® Power Systems, Inc. 2.3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of airfor cooling, ventilating and engine combustion besupplied to the generator set. Without sufficient air-flow, the engine/generator quickly overheats. Suchoverheating can cause serio...
Page 29 - Figure 2.12 – Air Inlet Using Ductwork; If you plan to use screening with an 80; FUEL; Figure 2.14 – Generator Fuel System
Generac ® Power Systems, Inc. 27 Figure 2.12 – Air Inlet Using Ductwork Figure 2.13 – Air Inlet in Vehicle Skirt 2.3.3 COMPENSATING FOR RESTRICTIONS Such materials as screening, louvers or expandedmetal can restrict the free flow of air. Compensate forthis restriction by making the actual air openin...
Page 30 - LP GAS FUEL SYSTEM
28 Generac ® Power Systems, Inc. 2.4.1 FUEL TANK Either the generator must share the vehicle engine'sfuel tank, or you must install a separate fuel tank forthe generator set. All fuel tanks installed on the vehi-cle must be constructed, installed and restrained sothey comply with applicable codes, s...
Page 31 - Figure 2.15 – Typical Propane Gas Fuel System; • Test the entire fuel system for leaks using approved; Figure 2.16 – LP Gas Carburetion Diagram
Generac ® Power Systems, Inc. 29 Figure 2.15 – Typical Propane Gas Fuel System 2.5.2 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system, consider seriouslythe following items:• All fittings, lines, hoses and clamps must be tight and free of leaks. Apply a pipe sealant to threadswhen asse...
Page 32 - SYSTEM
30 Generac ® Power Systems, Inc. The greater the airflow through the carburetor ven-turi, the lower the pressure at the venturi throat. Thelower the pressure at the venturi throat, the greaterthe diaphragm movement, and the greater the move-ment of the regulator valve. The more the regulatorvalve op...
Page 33 - CONNECTIONS
Generac ® Power Systems, Inc. 31 2.6.1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirementsof the U.S. Forest Service. Use only mufflers andparts approved by Generac. Any person(s) installingan unapproved muffler, or an unapproved exhaustsystem part, or modifying an exhaust...
Page 34 - Figure 2.17 – Generator AC Output Leads
32 Generac ® Power Systems, Inc. 2.7.2 WIRING • 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'srated maximum current. • If neutral conductors are used, the...
Page 35 - Figure 2.18 – Transfer Switch Isolation Method
Generac ® Power Systems, Inc. 33 2.7.6 POWER SUPPLY CORD The power supply cord must comply with all applic-able codes, standards and regulations. It must belarge enough to handle the full amperage to which itwill be subjected. 2.7.7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code (NFP...
Page 36 - INSTALLATION; • For prevailing ambient temperatures above 32° F; Figure 2.20 – Connecting Battery Cables; ACCESSORIES; Figure 2.21 – Remote Panel Plug-in Receptacle; CABLE LENGTH
34 Generac ® Power Systems, Inc. 2.8 BATTERY INSTALLATION 2.8.1 RECOMMENDED BATTERY Install a battery that meets the following requirements:• The battery must be a 12-volt, automotive type storage battery. • For prevailing ambient temperatures above 32° F (0° C), use a battery rated 70 amp-hours and...
Page 38 - Section 3 – Post-installation Start-up Adjustments
36 Generac ® Power Systems, Inc. 3.1 POST INSTALLATION TESTS The air-cooled generator set was factory tested andadjusted. You should not be required to adjust theunit any further except under special circumstances. Do not make any unnecessary adjustments.Factory settings are correct for most applica...
Page 39 - CHECKLIST
Generac ® Power Systems, Inc. 37 Section 3 – Post-installation Start-up Adjustments PRIMEPACT 50 Recreational Vehicle Generator 3.5 INSTALLATION CHECKLIST LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GENERATOR COMPARTMEN...
Page 40 - Appendix 1 – Notes
38 Generac ® Power Systems, Inc. Appendix 1 – Notes PRIMEPACT 50 Recreational Vehicle Generator
Page 41 - Appendix 2 – Troubleshooting; TROUBLESHOOTING GUIDE; PROBLEM
Generac ® Power Systems, Inc. 39 Appendix 2 – Troubleshooting PRIMEPACT 50 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 battery cables as necessary....
Page 42 - Appendix 3 — Electrical Data
40 Generac ® Power Systems, Inc. Appendix 3 — Electrical Data PRIMEPACT 50 Recreational Vehicle GeneratorElectrical Schematic and Wiring Diagram – Drawing No. 94210-A
Page 44 - Appendix 4 — Exploded Views and Parts Lists
42 Generac ® Power Systems, Inc. Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle GeneratorBase and Pulleys (Model 02010-0) – Drawing No. A8924-B
Page 45 - ITEM
Generac ® Power Systems, Inc. 43 ITEM PART NO. QTY. DESCRIPTION 1 C2368 1 BASE, MOUNTING 2 53407 1 GROUND CABLE 3 46911 4 MOUNT, (RUBBER) 4 25017 6 CAPSCREW, HEX HD.-3/8"-16X 1/2" 5 22237 6 LOCK WASHER-3/8" 6 22129 7 LOCK WASHER-M8 7 A6479 1 SKID, RUBBER MOUNT 8 77603 2 SAFETY BOLT 5/16&...
Page 55 - CARBURETOR; ASSEMBLY, CHOKE HEATER
Generac ® Power Systems, Inc. 53 Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 02010-0) – Drawing No. A8923-A ITEM PART NO. QTY. DESCRIPTION 1 A6532 1 MANIFOLD, INTAKE 2 91039 1 GASKET, MANIFOLD/HEAD 3 51753 1 HHCS-M6-1.0 X 40 LG. 4...
Page 57 - DETENT; M6 FLAT WASHER
Generac ® Power Systems, Inc. 55 ITEM PART NO. QTY. DESCRIPTION 1 A6532 1 MANIFOLD, INTAKE 2 91039 1 GASKET, MANIFOLD/HEAD 3 51753 1 HHCS-M6-1.0 X 40 LG. 4 72347 1 SPARK PLUG, CHAMP 5 89228 1 GASKET, CARB/MANIFOLD 6 A7336A 1 CARBURETOR, GN 410 L/P 7 90970 1 GASKET, CARB/AIR FILTER 8 A6564 1 BASE, AI...
Page 58 - CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT
56 Generac ® Power Systems, Inc. CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together withGenerac Power Systems, Inc. (Generac), are pleased to e...
Page 59 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:; Appendix 5 – Warranty
Generac ® Power Systems, Inc. 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 ECS Warranty Period shall begin on the date the new engine o...
Page 60 - GENERAC; GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY; WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS
Part No. C5080 GENERAC ® POWER SYSTEMS, INC. P.O. BOX 8 • WAUKESHA, WI 53187 Revision A (02/08/00) Printed in U.S.A. Appendix 5 – Warranty PRIMEPACT 50 Recreational Vehicle Generator GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS NOTE: ALL UNITS MUST BE INSTAL...
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