Page 2 - INTRODUCTION; READ THIS MANUAL THOROUGHLY; This symbol points out potential explosion hazard.; CONTENTS; AUTHORIZED SERVICE
Generac ® Power Systems, Inc. INTRODUCTION READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual,contact Generac or your nearest Generac AuthorizedService Dealer for starting, operating and servicing pro-cedures. Throughout this publication, and on tags anddecals affixed to...
Page 3 - Table of Contents; Part I — Owner’s Manual
Table of Contents PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generatorss Generac ® Power Systems, Inc. 1 Part I — Owner’s Manual Introduction ........................................Inside Front Cover Read This Manual Thoroughly..................................IFC Contents .......................
Page 4 - GENERAL HAZARDS
2 Generac ® Power 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. Many ...
Page 5 - ELECTRICAL HAZARDS; Safety Rules
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; GENERATOR IDENTIFICATION; REFERENCE NUMBER IDENTIFICATION
4 Generac ® Power Systems, Inc. Section 1 – General Information PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Please record the following information from the generator DATA DECAL or information decal. 1. Model Number ____________________ 2. Serial Number __________________ 3. kW Rating...
Page 7 - GENERATOR APPLICABILITY; One side of the winding is grounded.; Figure 1.1 – Connections for 230 Volts Only
Generac ® Power Systems, Inc. 5 Section 1 – General Information PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 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...
Page 8 - SPECIFICATIONS
6 Generac ® Power Systems, Inc. Section 1 – General Information PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 1.6 SPECIFICATIONS 1.6.1 FUEL REQUIREMENTS These generators are equipped with a gasoline fuel sys-tem. Depending on the installation, the generator mayhave either a separate fue...
Page 9 - Section 2 – Operation; GENERATOR CONTROL PANEL; Figure 2.1 – Generator Control Panel; AUTOMATIC CHOKE
Generac ® Power Systems, Inc. 7 Section 2 – Operation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 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 en...
Page 10 - BEFORE STARTING THE ENGINE
8 Generac ® Power Systems, Inc. Section 2 – Operation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 2.4 BEFORE STARTING THE ENGINE NOTE: Instructions and information in this manualassume the generator has been properly installed,connected, serviced, tested and adjusted by aqualified ins...
Page 11 - STOPPING THE GENERATOR; Figure 2.3 – Low Oil Pressure and
Generac ® Power Systems, Inc. 9 Section 2 – Operation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 2.6 STOPPING THE GENERATOR 1. Turn OFF all electrical loads using the meansprovided (such as a main circuit breaker ortransfer switch). 2. Let generator run at no-load for a few minutes, ...
Page 12 - Figure 2.4 – Field Boost Circuit; The solid state voltage regulator is only con-; Figure 2.5 – Solid State Voltage Regulator; ADDITIONAL INFORMATION; OR BRUSH
10 Generac ® Power Systems, Inc. Section 2 – Operation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Figure 2.4 – Field Boost Circuit 2.8.4 OVERVOLTAGE PROTECTION A solid-state voltage regulator (Figure 2.5) controlsthe generator’s AC output voltage. This regulator sup-plies an excitati...
Page 13 - Section 3 – Maintenance; Location of Oil Drain Plug
Generac ® Power Systems, Inc. 11 Section 3 – Maintenance PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 3.1 CHECKING THE ENGINE OILLEVEL For oil capacities and requirements, see “Engine OilRequirements,” Section 1.6.2 (Page 6). Check theengine crankcase oil level at least every eight hou...
Page 14 - Figure 3.3 – Engine Air Cleaner; CLEAN AIR INTAKE SCREEN; Figure 3.4 – Cleaning Air Intake
12 Generac ® Power Systems, Inc. Section 3 – Maintenance PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 3.3 MAINTAINING THE ENGINEAIR 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. S...
Page 15 - FUEL FILTER; Figure 3.6 – Fuel Filter; SPARK ARRESTOR MUFFLER
Section 3 – Maintenance PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 3.6 FUEL FILTER (GASOLINE ONLY) Remove and replace the fuel filter (Figure 3.6)once each year or every 100 hours of operation,whichever comes first. Figure 3.6 – Fuel Filter 3.7 SPARK ARRESTOR MUFFLER If the generator...
Page 16 - MAJOR SERVICE MANUAL
14 Generac ® Power Systems, Inc. Do not dispose of the battery in a fire. Thebattery 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 caus...
Page 17 - WATTAGE REFERENCE GUIDE
Generac ® Power Systems, Inc. 15 3.13.2 RETURN TO SERVICE To return the unit to service after storage, proceedas follows: 1. Check the tag on the engine for oil viscosity andclassification. Verify that the correct recommend-ed oil is used in the engine (see Section 1.5.4,Page 6). If necessary, drain...
Page 18 - Notes
16 Generac ® Power Systems, Inc. Notes PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
Page 19 - PART II –; ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
Generac ® Power Systems, Inc. 17 PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
Page 20 - NOTICE TO INSTALLER
18 Generac ® Power Systems, Inc. Safety Rules PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 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 a...
Page 22 - SAFETY; EQUIPMENT DESCRIPTION
20 Generac ® Power Systems, Inc. 1.1 PURPOSE AND SCOPEOF 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 informatio...
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 and 70 (50Hz) Recreational Vehicle Generators PrimePact 50 and 70 Control Panel Fuel Filter Fuel Pump Oil Filter Oil Drain Plug Starter Contactor Oil Fill/Oil Level Spark Plugs (b...
Page 24 - LOCATION AND SUPPORT; 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; GENERATOR COMPARTMENTS; Figure 2.4 – Clearances; Figure 2.5 – Typical Compartment Construction
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
Generac ® Power Systems, Inc. 25 Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 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...
Page 28 - COOLING AND VENTILATING AIR; Figure 2.9 – Airflow Through Engine/Generator; Figure 2.10 – Air Inlet in Compartment Door; Figure 2.11 – Suspended Mount: Inlet Door
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; GASOLINE FUEL SYSTEM; 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 - EXHAUST 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 - ELECTRICAL CONNECTIONS
Generac ® Power Systems, Inc. 29 2.5.1 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 32 - Figure 2.17 – Generator AC Output Leads; SOURCES
30 Generac ® Power Systems, Inc. 2.6.2 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 33 - Figure 2.18 — Transfer Switch Isolation Method
Generac ® Power Systems, Inc. 31 Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Figure 2.18 — Transfer Switch Isolation Method Figure 2.19 — Installation With Isolation Receptacle
Page 34 - BATTERY INSTALLATION; Figure 2.20 – Connecting Battery Cables; OPTIONAL ACCESSORIES; Figure 2.21 – Remote Panel Plug-in Receptacle; CABLE LENGTH
32 Generac ® Power Systems, Inc. 2.7 BATTERY INSTALLATION 2.7.1 RECOMMENDED BATTERY Install a battery that meets the following require-ments: • 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 a...
Page 35 - POST INSTALLATION TESTS; Section 3 – Post Installation Start-up and Adjustments
Generac ® Power Systems, Inc. 33 2.8.1 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 36 - INSTALLATION CHECKLIST
34 Generac ® Power Systems, Inc. 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 i...
Page 37 - Section 4 – Troubleshooting; TROUBLESHOOTING GUIDE; PROBLEM
Generac ® Power Systems, Inc. 35 Section 4 – Troubleshooting PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 4.1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace blown fuse. 2. Loose, or corroded or defective 2. Tighten, clean or replace,...
Page 38 - Section 5 – Electrical Data
36 Generac ® Power Systems, Inc. Section 5 – Electrical Data PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle GeneratorsWiring Diagram & Electrical Schematic — Drawing No. 0D6579
Page 40 - Section 6 — Exploded Views and Parts Lists
38 Generac ® Power Systems, Inc. Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle GeneratorsBase and Pulleys – Drawing No. 0D6577-A
Page 41 - ITEM
Generac ® Power Systems, Inc. 39 ITEM PART NO. QTY. DESCRIPTION 1 086318 1 BASE, MOUNTING 2 090141 1 GROUND CABLE 3 046911 4 MOUNT, (RUBBER) 4 025017 8 CAPSCREW, HEX HD.3/8"-16 X 1/2" 5 046526 2 LOCKWASHER-M10 6 022129 8 LOCKWASHER, 5/16" -M8 7 072391 2 SKID, RUBBER MOUNT 8 077603 2 SAFE...
Page 50 - Section 7 – Warranty; CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT
48 Generac ® Power Systems, Inc. Section 7 – Warranty PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and the United States Environmental Protection Ag...
Page 51 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
Generac ® Power Systems, Inc. 49 Section 7 – Warranty PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 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 mode...
Page 52 - GENERAC POWER SYSTEMS THREE-YEAR LIMITED WARRANTY; WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS
Part No. 0D6583 Revision 0 (10/26/01) Printed in U.S.A. Section 7 – Warranty PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators GENERAC POWER SYSTEMS THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE ...