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
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..................................IFCContents ........................................
Page 4 - GENERAL HAZARDS; • For safety reasons, Generac recommends; DANGER
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; Safety Rules
Generac ® Power Systems, Inc. 3 • Adequate, unobstructed flow of cooling and venti- lating air is critical to correct generator operationand is required to expel toxic fumes and fuelvapors from the generator compartment. Withoutsufficient cooling airflow, the engine/generatorquickly overheats, which...
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 - GENERATOR 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 - • During summer months: SAE 30. An acceptable; • For engines less than 225 cc displacement,
6 Generac ® Power Systems, Inc. Section 1 – General Information PRIMEPACT 50 Recreational Vehicle Generator Generac does not recommend using any gasoline containing alcohol (such as “gasohol”).If you use any gasoline containing alcohol, itmust not contain more than 10 percent ethanol,and it must be ...
Page 9 - Section 2 – Operation; GENERATOR CONTROL PANEL; Figure 2.1 – Generator Control Panel; REMOTE; Figure 2.2 — Optional Remote Panel
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 - Figure 2.3 – Heat Riser System
Generac ® Power Systems, Inc. 9 Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator 2.5 STARTING THE GENERATOR NOTE: Read the vehicle manufacturer’s instructions. Theowner/operator should become familiar with thevehicle in which this generator is installed.Differences exist between veh...
Page 12 - • If a load does not show its rated wattage, multiply; SYSTEMS; LOW OIL PRESSURE SWITCH; Figure 2.4 – Low Oil Pressure and
10 Generac ® Power Systems, Inc. Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator When the heat riser is in the WINTER (up) position,air is drawn from the lower intake tube, which ispositioned to draw the heated air near the exhaustmanifold. To prevent carburetor icing, the owner/op...
Page 13 - Figure 2.6 – Solid State Voltage Regulator; ADDITIONAL INFORMATION; • Run the unit at varying electrical loads to help seat; 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 2.6) 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; Fuel Filter
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. Man...
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 generat...
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; • Provide a door in the vehicle skirt having an air; Figure 2.11 – Suspended Mount: Inlet 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; 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
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 ass...
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; SOURCES
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 - GROUND FAULT CIRCUIT INTERRUPTERS; 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; 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 an...
Page 37 - Section 3 – Post-installation Start-up Adjustments
Generac ® Power Systems, Inc. 35 2.9.1 REMOTE PANEL MODELS The remote panels mount a rocker type start/stopswitch, a “Generator Run” advisory lamp and anhourmeter. The hourmeter should be used in con-junction with the maintenance operations found inPart I of this manual. • Model 004057 includes the ...
Page 38 - CHECKLIST
3.5 INSTALLATION CHECKLIST LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GENERATOR COMPARTMENT ❑ Compartment construction is proper. ❑ Holes/Openings are vapor-sealed. ❑ Compartment size is correct. ❑ Compartment is vapor...
Page 39 - Section 4 – Troubleshooting; TROUBLESHOOTING GUIDE; PROBLEM
Generac ® Power Systems, Inc. 37 Section 4 – 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 40 - Section 5 — Electrical Data
38 Generac ® Power Systems, Inc. Section 5 — Electrical Data PRIMEPACT 50 Recreational Vehicle GeneratorElectrical Schematic and Wiring Diagram – Drawing No. D1754-A
Page 42 - Section 6 — Exploded Views and Parts Lists
40 Generac ® Power Systems, Inc. Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle GeneratorBase and Pulleys (Model 02010-2) – Drawing No. D1759-A
Page 43 - ITEM
Generac ® Power Systems, Inc. 41 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"-16 X 1/2" 5 22237 6 LOCK WASHER-3/8" 6 22129 9 LOCK WASHER-M8 7 A6479 1 SKID, RUBBER MOUNT 8 77603 2 SAFETY BOLT 5/16...
Page 57 - DETENT
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 40MM 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, AIR ...
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:; Section 7 – 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 POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY; GENERAC
Part No. 0D7431 Revision A (08/06/02) Printed in U.S.A. Section 7 – Warranty PRIMEPACT 50 Recreational Vehicle Generator GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. Fo...
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