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Generac 02010-2, 04164-2 Portable Generator User Manual

1. caution Ak Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 5 Install and tighten the oil fill cap and the dipstick before operating the engine 3 2 CHANGING THE ENGINE OIL AND OR OIL FILTER Change the engine oil after the first 25 hours of operation after the 25 hour break in period see Section 2 10 1 Page 11 Thereafter change the oil every 100 operating hours Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures Change the engine oil filter after the first 25 hours of operation and every 100 operating hours there after 12 Generac Power Systems Inc lt N ON i A OIL FILTER OIL DRAIN CAP PRIMEPACT 50 Recreational Vehicle Generator To 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 engine 2 Immediately after the engine shuts OFF pull the oil drain hose free of its retaining clip Remove the cap from the hose and drain the oil into a suitable container Loosening the oil fill cap will allow the crankcase to drain faster 3 After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip 4 With the oil drained remove the old oil filter
2. 2 3 4 TESTING THE INSTALLATION Generac recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of overheating you will need to enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is ade quate NOTE You must test the installation especially if you bring in air from below the generator set 2 4 GASOLINE FUEL SYSTEM The installation of a gasoline fuel system Figure 2 14 for a recreational vehicle generator set must comply with applicable codes standards and regula tions The entire fuel system must be completely free of leaks There must be no possibility of gasoline vapors entering the vehicle interior Figure 2 14 Generator Fuel System FUEL LINE BAS FUEL FILTER FUEL PUMP A DIG A Gasoline is highly flammable and its vapors are 3 explosive Comply with all codes standards and regulations pertaining to gasoline fuel systems used in recreational vehicle generators Properly install and maintain the fuel system and keep it entirely free of leaks Gasoline vapors must not enter the vehicle interior Factory installed generator fuel system components include a fuel filter b 12 volt DC electric pump c engine carburetor and d interconnecting lines and fittings
3. Jl 4 X 18 uen xs SSD J Jl 6 2 17 O y START J1 7 3 17 ISWI zO 08 J 82 J1 9 gt 4 J1 102 66 J1 112 85 J1 182 0 21 13 REMOTE J1 142 18 PANEL JI 15 18 CONNECTOR 01 41 1 2 14 3 3 4 4 LEGEND BCR BATTERY CHARGE RECTIFIER CBI CIRCUIT BREAKER 30 CB2 CIRCUIT BREAKER 20 CIRCUIT BREAKER 2 54 CH CHOKE HEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY Fl FUSE 15 FP FUEL PUMP OR LPG SHUT OFF VALVE GT TERMINAL GROUND 4 TAB HM METER HOUR OPTIONAL HTO SWITCH HIGH TEMP DIL CLOSES ON HIGH TEMP IM IGNITION MAGNETO LI LIGHT RUN OPTIONAL SWITCH LOW DIL PRESSURE CLOSES ON LOW PRESSURE PCB ENGINE CONTROLLER RI RESISTOR 1 OHM 25W SC STARTER CONTACTOR SM STARTER MOTOR POWER WINDING SWI SWITCH START STOP SW2 SWITCH FUEL PRIMER SPl SPARK PLUG 1 CYL 44 TC TERMINAL CONN 4 TAB CONNECTOR ELECTRONIC VOLTAGE REGULATOR DPE WINDING OF OW OF 4 FIELD BLACK RED GREEN 120v 208 oo 1 0 30a e NEUTRAL CONNECTION BY CUSTOMER 38 Generac Power Systems Inc Data PRIMEPACT 50 Recreational Vehicle Generator Ica Electrical Schematic and Wiring Diagram Drawing No D1754 A 5 Electr lon Sect ELECTRICAL DATA a 3 015 39 Ad NDIL23NNDO
4. A 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 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used A properly installed exhaust system must be vapor tight quiet and completely safe A The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concen trations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOX IDE POISONING ARE a inability to think coher ently b vomiting c twitching muscles d throbbing temples e dizziness f headaches g weakness and h sleepiness IF YOU FEEL ANY OF THESE SYMPTOMIS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Do not operate the generator until its exhaust system has been inspected and properly repaired caution amp A Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This ca
5. By providing an opening in the vehicle skirt and space behind the generator for cooling airflow Figure 2 13 Page 27 Recommended clearance behind the back of the generator is at least 1 2 inch 13 mm PRIMEPACT 50 Recreational Vehicle Generator Figure 2 12 Air Inlet Using Ductwork ANTI SPLASH BAFFLE 1 V GENERATOR yt 1 ku AIR OUT AIR IN Figure 2 13 Air Inlet in Vehicle Skirt Y VEHICLE FLOOR VEHICLE SKIRT AIR INLET MINIMUM CLEARANCE 1 1 2 2 3 3 COMPENSATING FOR RESTRICTIONS Such materials as screening louvers or expanded metal can restrict the free flow of air Compensate for this restriction by making the actual air opening pro portionately larger Some materials may offer only a 60 percent free air inlet area Other more efficient materials may pro vide up to a 90 percent free air inlet area The per centage of free air inlet opening is usually available from the material supplier or manufacturer To determine the actual air inlet opening size required divide 100 square inches by the per centage of free air inlet area for the material you will use For example If you plan to use screening with an 80 percent free air inlet area divide 100 by O 8 which results in 125 square inches Minimum actual size of air inlet opening in this case is 125 square inches INSTALLATION Section 2 Installation
6. 1 2 SAFETY Before handling installing operating or servicing this equipment carefully read the Notice to Installer and Safety Rules on Pages 18 and 19 Comply with all safety rules to prevent death personal injury or damage to equipment and or property Stress safety to all installers operators and service technicians who work on this equipment 1 3 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The following standards booklets latest revision are available from the sources indicated 1 NFPA Standard 501C Standard for Recreational Vehicles available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 NFPA 70 NFPA Handbook of the National Electric Code available same as Item 1 3 ANSI C1 1975 and ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI 119 2 501C available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 avail able from the State of California Documents Section PO Box 1015 North Highlands CA 95660 Generac Power Systems Inc PRIMEPACT 50 Recreational Vehicle Generator 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing
7. Clean all foreign material from the air intake Figure 3 3 at least once every 100 hours of operation Clean more often if necessary Inspect the area around the generator exhaust muf fler periodically and remove all grass leaves dirt etc from this area Figure 3 3 Cleaning Air Intake CLEAN THESE AREAS 3 5 CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and com mercial solvent Do not blast the spark plug to clean 2 Remove the spark plug and check the condition Replace the spark plug if worn or if reuse is ques tionable 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 030 inch 0 76 mm by carefully bending the ground electrode Figure 3 4 Figure 3 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 030 inch 0 76 mm caution A A Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end If necessary re form the wire terminal to obtain a tight fit Generac Power Systems Inc 13 MAINTENANCE 20 Section 3 Maintenance 3 6 FUEL FILTER casoLine 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 Fuel
8. 2 3 AUTOMATIC CHOKE casoLiNE ONLY The engine is equipped with an automatic choke that consists of two main components a choke solenoid and prechoke 2 3 1 CHOKE SOLENOID During engine cranking Start Stop switch at START a solid state choke module signals the choke solenoid to activate and cycle choke on choke off until the engine starts The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking When the engine starts the choke stops cycling 2 3 2 PRECHOKE The choke system also has a temperature sensitive metal strip that adjusts choke valve angle according to ambient temperatures i e in cold ambient tem peratures choke valve closes more Once the engine starts an element heats the temperature sensitive strip to a normal operating condition opening the choke valve This may take about three minutes in cooler weather 2 4 BEFORE STARTING THE ENGINE 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 INSTALLATION Generator installation must have been properly com pleted so it complies with all applicable codes stan dards and regulations and with the manufacturer s recommendations 2 4 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommended oil before
9. In addition installation must comply with the manufacturer s instructions and recommendations NOTICE TO INSTALLER These Installation Instructions have been published by Generac to aid in the installation of the products described in this manual Generac assumes that installation personnel are familiar with the proce dures for installing such products or similar prod ucts that Generac manufactures Generac also assumes that personnel have been trained in the rec ommended installation procedures for these prod ucts and that such training includes a use of com mon hand tools b use of special Generac tools and c use of any tools and or equipment from other sup pliers Generac cannot possibly know of and advise the recreational vehicle trade of all conceivable methods procedures or techniques by which to perform an installation Nor can Generac anticipate every possi ble hazard that might result from each installation method procedure or technique Generac has not undertaken any such wide evaluation Therefore people who use a method procedure or technique that Generac does not specifically recommend must first completely satisfy themselves that their safety the safety of the vehicle s occupants and the product s safety is not endangered by the method procedure or technique selected Information illustrations specifications etc con tained in these Installation Instructions are based on the latest information ava
10. PRIMARY REGULATOR VAPOR WIDTHDRAWAL TANK 2 5 2 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system consider seriously the following items 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 Test the entire fuel system for leaks using approved test methods Optimum gas pressure at the inlet to the gaseous fuel solenoid valve and secondary regulator is 11 inches water column The installer s fuel supply connection point is at the gaseous fuel solenoid valve This is a 3 4 inch female connection Provide a suitable 3 4 inch NPT male connector to attach to the fuel supply line Use a length of approved flexible fuel hose between the gaseous fuel solenoid valve and rigid gas pip ing The flexible line should be at least 6 inches longer than necessary 2 5 5 VAPOR WITHDRAWAL LP gas is stored in pressure tanks as a liquid The gas systems used with these generators were designed only for vapor withdrawal type systems Vapor 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 with drawal type system n 2 5 4 PRIMARY REGULATOR Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regula tor Mount the primary regulator at
11. accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system Keep the extinguisher properly charged and be familiar with its use If you have any question per taining to fire extinguishers consult your local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline This generator may use liquid propane LP gas as a fuel LP gas is highly EXPLOSIVE The gas is heavier than air and tends to settle in low areas where even the slightest spark can ignite the gas and cause an explosion Generac Power Systems Inc 3 1 1 Sec
12. tery hydrometer NOTE Servicing of the battery is to be performed or supervised by personnel knowledgeable of batter ies and the required precautions Keep unautho rized personnel away from batteries Damage will result if the battery connections are made in reverse PRIMEPACT 50 Recreational Vehicle Generator A N A Do not dispose of the battery in a fire The battery is capable of exploding Storage batter ies give off explosive hydrogen gas This gas can form an explosive mixture around the bat tery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery Discharge static electricity from your body before touch ing the battery by first touching a grounded metal surface A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery Disconnect any charging source prior to connecting or disconnecting battery terminals and Do not use any jumper cables or
13. to galvanized steel due to aluminum s low melting point If the compartment is lined with galvanized steel it may be constructed of any material Generac rec ommends that the compartment be constructed of 1 2 inch thick plywood not strandboard with the floor made of a double thickness of 1 2 inch ply wood with the grain of the wood at cross section for added strength Figure 2 5 Figure 2 5 Typical Compartment Construction CROSS SECTION VIEW METAL LINING FIREPROOF SOUND INSULATION METAL LINING VAPOR SEALED PLYWOOD ATALLTIMES E METAL LINING If constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel All seams splices and joints of the compartment walls unless vapor tight by design should be caulked to prevent poisonous flammable or explosive vapors from entering the vehicle interior NOTE Caulking must be done so that the caulking materi al will stay in place permanently Pressing such materials as putty tape onto joints and seams is NOT acceptable A high quality silicone rubber base sealant is recommended Holes and openings made in the compartment walls to allow for the passage of electrical conduit conductors hoses cables etc into the vehicle liv ing area must be sealed vapor tight with silicone rubber base sealant G
14. 1 BELT POLY V 4L 40 60 0A8010 1 GASKET BLOWER HSNG 24 049451 1 WASHER PULLEY RETAINER 61 045771 3 M8 1 25 HEX NUT 25 042633 1 CAPSCR SOCKET HD 3 8 24X 1 62 074260 131 1 STARTER CABLE GRADE 5 63 024114 2 HEX NUT 5 16 24 26 039253 3 CAPSCR HEX HD M8 1 25 X 20 64 022097 2 LOCK WASHER 1 4 27 0A8250 1 CAPSCR HEX HD 3 8 24 X 2 65 022152 2 LOCK WASHER M4 28 056893 14 10 24 X 1 2 66 022158 2 HEX NUT 4H 0 32 29 0A7837 1 BRACKET LP REGULATOR 67 048531 1 PLATE BLOWER SIDE 30 0C1320 1 HOUSING BLOWER 68 0A8407 1 GASKET BLOWER SIDE 31 063036 3 CRIMTITE 8 18 X 1 4 69 022473 1 FLAT WASHER 4 32 0A8694 1 SCREEN SLIDE PAN 70 038750 2 M6 1 0 X 30 HHCS 33 0A8726 1 GASKET BLOWER PAN 71 049813 2 M6 1 0 HEX NUT 34 075242 4 SPRING GENERATOR SET MT 72 026915 2 CLOSE NIPPLE 34 NPT 35 062684 1 GROUNDING 73 026307 1 90 DEG 94 STREET ELBOW 36 0A4456 2 3 8 SPECIAL LOCK WASHER 74 0A5606 1 ELBOW 90 DEG 3 8 X 3 4 Generac Power Systems Inc 43 i urs Section 6 Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator 0 Alternator and Panel Model 02010 2 Drawing No A8922 H 44 Generac Power Systems Inc 2 e d 2 Sos EL Section 6 Exploded Views and Parts Lists CG urs PRIMEPACT 50 Recreational Vehicle Generator Alternator and Panel Model 02010 2 Drawing No A8922 H ITEM PART NO QTY D
15. 1 PLUG BUTTON 1 1 16 0A8875 1 ASSEMBLY DIPSTICK amp CAP 0A7299 1 OIL DRAIN DIPSTICK TUBE 0A9539 1 OIL DRAIN HOSE ASSEMBLY 0A7838 1 PIPE NIPPLE 3 8 X 8 LG 038593 1 BRASS STREET ELBOW 3 8 022473 1 FLAT WASHER 1 4 M6 0A6357 1 WRAPPER ENGINE SPARK PLUG 0A6360 1 WRAPPER STARTER SIDE 0A6489 1 WRAPPER REAR GEAR CASE 0A6359 1 WRAPPER CARB SIDE 131 074260 1 ASSEMBLY WIRE STARTER 16 090892 1 SUPPORT OIL FILTER 091159 1 BUSHING RUBBER 091160 1 WASHER RUBBER 091161 1 BOLT SHOULDER M6 1 0 X 15MM 049821 2 BOLT SOCKET HD CAPSCR M8 1 25 X 30MM 086999 1 GASKET OIL FILTER SUPPORT 0A8584 1 SWITCH OIL PRESSURE 10 PSI 075281 1 SWITCH OIL TEMPERATURE 0C1085 2 SCREW PHILIPS PAN HD MACH M3 0 5 X 8MM 043182 2 LOCK WASHER M3 070185 1 FILTER OIL 0A7629 1 ENGINE LONG BLOCK GN410VSRV 082774 1 KEY WOODRUFF 4 X 19 DIA 002308 1 0A1658 1 SPECIAL LOCK WASHER M6 090388 1 TAPTITE M6 1 00 X 12MM 075474A 1 BOOT TEMPERATURE SWITCH 0D1624 1 BOOT OIL PRESSURE SWITCH Generac Power Systems Inc 49 ums Section 6 Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator GN 410 Engine Model 02010 2 and 04164 2 Drawing No A7894 E Generac Power Systems Inc Section 6 Exploded Views and Parts Lists CG urs PRIMEPACT 50 Recreational Vehicle Generator GN 410 Engine Model 02010 2 and 04164 2
16. 145 C initiating an engine shutdown 10 Generac Power Systems Inc Figure 2 4 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE SWITCH L ENGINE OIL OIL PRESSURE FILTER SWITCH 2 9 3 FIELD BOOST The Controller Circuit Board houses a field boost diode and resistor that are not part of the automatic choke circuit These two components are part of a field boost circuit Figure 2 5 During engine cranking only a positive DC battery voltage is deliv ered through the diode resistor brushes and slip rings and the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Figure 2 5 Field Boost Circuit Sl SE 16 CONTROLLER CIRCUIT CLOSEST TO BOARD E BEARING 4 9 N GRND Section 2 Operation OPERATION PRIMEPACT 50 Recreational Vehicle Generator ip 2 9 4 OVERVOLTAGE PROTECTION 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
17. Also do NOT exceed the gen erator s rated wattage capacity Add the watts or amperes of all lighting appliance tool and motor loads the generator will operate at one time This total should be less than the unit s rated wattage amperage capacity 2 7 4 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The following general rules apply Cut wiring to the required length and allow extra wire for junction box connections Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation Route conduit so it does not interfere with genera tor movement If you use metallic conduit vapor seal the end of the conduit where it enters the junction box Do this because flexible metallic conduit is not vapor proof along its entire length 2 75 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 2 18 Page 33 An alternate method for isolating dif ferent power sources is by using an isolating recepta cle Figure 2 19 Page 33 Whichever method you use you must be certain that both power sources are NOT connected at the same time Section 2 Installation INSTALLATION PRIMEPACT 50 Recreational Vehicle Generator 2 7 6 POWER SUPPLY CORD 2 7 7 GROUND FAULT CIRCUIT INTERRUPTERS The power supply cord must comply with all applic
18. EMISSIONS COMPLIANCE PERIOD For non handheld engines the Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal emission requirements For engines less than 225 cc displacement Category 125 hours B 250 hours and A 500 hours For engines of 225 cc or more Category 250 hours B 500 hours and A 1000 hours Section 2 Operation PRIMEPACT 50 Recreational Vehicle Generator ix 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 Figure 2 1 Generator Control Panel FUSE MAIN START 15 BREAKER STOP FUEL PRIMER 2 1 1 FUEL PRIMER Before starting a cold engine if it has not been start ed in more than two weeks you must press this switch for approximately 10 to 15 seconds to bring fuel from the tank to the carburetor This rocker type switch springs back into its original position when you release it It is not necessary to press the primer switch for LP units 2 1 2 START STOP SWITCH To crank and start the engine hold this switch in the START position Release the switch when the engine starts To stop an operating engine press and hold the switch in the STOP position until the engine shuts off The switch center position is the RUN position 2 1 3 FUSE The fuse protects the
19. Fuel system is properly installed and checked for leaks OPTIONAL LP GAS FUEL SYSTEM for leaks Pressure at regulator inlet is correct Rated flow of primary regulator is correct A All parts are properly installed Fuel system is properly tested adjusted DATE OF INSTALLATION A Fuel system is properly installed and checked PRIMEPACT 50 Recreational Vehicle Generator EXHAUST SYSTEM Q Exhaust system complies with all applicable codes A Exhaust system is properly and safely installed ELECTRICAL CONNECTIONS Connections comply with local code requirements and all National Electrical Codes A Junction box is properly installed Wiring meets all standards A connections are correct A Conduit is properly installed and sealed Generator is properly bonded to the vehicle BATTERY INSTALLATION Q Recommended battery is installed Q Recommended cables are installed Q Cables are clean and tight A Cables are connected properly A Proper ventilation is provided Q Terminals are coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES Check that remote start stop panels if used are installed properly Check that hourmeter kit if used is installed properly Check that any other options and accessories if used are installed properly POST INSTALLATION TESTS Check that all tests are completed p
20. IVILANIN NOILI3NND9 Iv 33HW0DLSNI v 30123NND2 TI3NVd 310N38 1 ems MIYIS 91W 3317113 st st 81 ONISV38 01 1535013 19 10 30 0 M3YIS 91 0 p SeeSIt 8 3WDOISQ2 A8 5 El 31 194 XIJWDLSNI A8 lt 39 Generac Power Systems Inc ums Section 6 Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator 0 Base and Pulleys Model 02010 2 Drawing No D1759 A z e z o mud CN e 33 4O Generac Power Systems Inc PART NO QTY C2368 53407 46911 25017 22237 22129 A6479 71603 22259 52858 51730 29459 75215 73146 75209 A8341 90239 40976 A6858 A8614 75224 B 73106 B 75216 49451 42633 39253 A8250 56893 A8615 C1320 63036 A8694 A8726 75242 NA ODD A i h o dd de de bh a Jo Sectio
21. Panel Receptacle behind control panel Generator AC Output Leads behind control panel Fuel Primer Switch Circuit Breaker Circuit Breaker Starter Contactor Fuel Solenoid Demand Regulator Oil Filter Oil Drain Cap Oil Dipstick Data Decal Oil Fill Spark Plug 1 2 GENERATOR APPLICABILITY These generators have been designed and manufac tured for supplying electrical power for recreational vehicles You should not modify the generator or use it for any application other than for what it was designed If there are any questions pertaining to its application write or call the factory Do not use the unit until you have been advised by a competent authority DIG A For fire safety the generator must have been properly installed in compliance with ANSI 119 2 1975 NFPA 501C 1974 Standard for Recreational Vehicles Part III Installation of Electrical Systems The generator also must have been installed in strict compliance with the manufacturer s detailed installation instruc tions After installation do nothing that might render the unit in noncompliance with such codes standards and instructions You can use this generator to supply electrical power for operating 120 240 volt single phase 60 Hertz AC elec trical loads These loads can require up to 4 800 watts 4 8 kW of power but cannot exceed 40 AC amperes of current at 120 volts or 20 AC amperes at 240 volts for the PRIMEPACT 50 m
22. Systems Inc PRIMEPACT 50 Recreational Vehicle Generator 3 13 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Check the tag the engine for oil viscosity classification Verify that the correct recommend ed oil is used in the engine see Section 1 5 4 Page 6 If necessary drain and refill with the proper oil Check the state of the battery Fill all cells of unsealed batteries to the proper level with distilled water DO NOT USE TAP WATER IN THE BAT TERY Recharge the battery to 100 percent state of charge or if defective replace the battery Clean and wipe the entire generator Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly Turn OFF all electrical loads Add fuel if neces sary and then start the engine Allow the unit to warm up thoroughly Apply electrical loads to at least 50 percent of the unit s rated wattage capacity When the engine is thoroughly warmed up shut it down Your generator is now ready for service PART Il INSTALLATION INSTRUCTIONS SAFETY RULES Safety Rules PRIMEPACT 50 Recreational Vehicle Generator DANGER For fire safety installation of a generator into a recreational vehicle must comply strictly with article 551 NFPA 70 ANSI C1 1975 AND ANSI A119 2 1975 NFPA 501 Standard for Recreational Vehicles Part 3 Installation of Electrical Systems
23. TUBING 2 1 5 SUSPENDED MOUNTING If you are going to suspend the generator below the horizontal support tubing the suspension method you use with the vehicle frame members must a be able to support the weight of the generator AND b provide sufficient restraint for the generator One typ ical suspended mounting system is shown in Figure 2 2 The location of a suspended mounting system must be carefully planned keeping the following gen eral rules in mind Protect the generator against road splash and debris 5 or splash guards may be required to protect certain areas of the generator To make sure the gen erator is adequately protected road test the installa tion through mud water and slush Figure 2 2 Typical Suspended Mounting System GENERATOR MOUNTING HOLES FOR 3 8 16 BOLTS BOTH SIDES SUPPORT GENERATOR FRAME SUPPORT FRAME The installer must make certain that the selected location will permit adequate cooling and ventilat ing airflow to be supplied PRIMEPACT 50 Recreational Vehicle Generator 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 a compartment is used and c the supporting frame work Figure 2 3 All bolts must be long enough so that when tight at least three thread
24. and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 1 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to Generac air cooled generators These generators are designed specifically for installing in recreational vehicles They operate 120 volt single phase 60 Hertz AC electrical loads that require 40 0 amps gasoline or 37 5 amps LP fuel at 120 volts 1 5 GENERATOR ENGINE OPERATING SPEED The generator s revolving field rotor is driven by a single cylinder four cycle engine through a pulley and drive belt arrangement The generator supplies 120 volts AC at 60 Hertz when the rotor is operating at 3 600 rpm The drive belt arrangement allows the engine to operate at a lower speed than the rotor 1 6 GENERATOR AC CONNECTION SYSTEM The generator is equipped with dual stator power windings as shown in Figure 1 1 Figure 1 1 120 volt Single Voltage Connection STATOR POWER WINDINGS GROUNDED NEUTRAL The AC connection system on all air cooled PRIMEPACT series generators uses a GROUNDED neutral A separate green ground wire is connected to the recreational vehicle s junction box For these PRIMEPACT units loads connected across 1 red to T2 white MUST NOT exceed 30 amperes or 3 600 watts and loads connected across T3 black and T2 white MUST NOT exceed 20 amperes or 2 400 watts each at 120 volts The combined loading of the tw
25. by turning it counterclockwise 5 Applya light coating of clean engine oil to the gas ket of the new filter 6 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tight en the filter an additional 3 4 to one turn 7 Remove the dipstick and wipe it dry with a clean lint free cloth This will be used later to check the oil level 8 Remove the oil fill cap on the rocker cover and slowly add the proper type and amount of rec ommended oil see Section 1 5 4 Page 6 Periodically use the dipstick to check the oil level and continue to fill the crankcase until the oil reaches the dipstick Full mark DO NOT FILL ABOVE THE FULL MARK 9 Install and tighten the oil fill cap and the dipstick before operating the engine 10 Start the engine and check for leaks NOTE Check the oil level and fill to the FULL mark after checking for leaks The filter will retain some oil E RETAINING CLIP PRIMEPACT 50 Recreational Vehicle Generator 3 3 MAINTAINING THE ENGINE AIR CLEANER 3 5 1 CLEANING THE FOAM PRECLEANER Clean and re oil the foam precleaner every three months or every 25 hours of operation whichever occurs first Service the foam precleaner more fre quently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 2 Turn the two screws counterclockwise to loosen Remove the
26. gas fuel system install the unit so it complies with all codes standards and regulations pertain ing to such systems LP gas is highly explosive The gas tends to settle in low areas where even the slightest spark can ignite it and cause an explo sion Do not allow gas vapors to enter the vehicle Generac Power Systems Inc 19 Section 1 General Information 1 1 PURPOSE AND SCOPE OF THE MANUAL 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 continued reliable operation of the equipment Because of the different recreational vehicle models and the variations between the models it would be extremely difficult if not impractical to provide detailed instructions for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all applicable codes standards and regulations pertain ing to the installation and use of this product If any portion of this manual appears to be in conflict with such codes standards or regulations the applicable codes standards or regulations must take prece dence over the manual
27. have the genera tor properly grounded bonded either by solid mounting to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT disconnect the bonding conductor if so equipped DO NOT reconnect the bonding conductor to any generator part that might be removed or disassem bled during routine maintenance If the grounding conductor must be replaced use only a flexible con ductor that is of No 8 American Wire Gauge AWG copper wire minimum In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in
28. low pressure A lever attached to the diaphragm opens a valve to permit gas glow through the carburetor Figure 2 16 LP Gas Carburetion Diagram AIR GAS AT FLOW POSITIVE 4 PRESSURE QU GAS AT LOW PRESSURE ARES AREA Generac Power Systems Inc 29 INSTALLATION Section 2 Installation PRIMEPACT 50 Recreational Vehicle Generator Fs 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 the generator The following facts about the secondary regulator must be emphasized The regulator must be sensitive to venturi throat pressure changes throughout the operating range The regulator must be properly adjusted so it will stop the flow of gas when the engine is not running no air flow through the carburetor The slightest airflow and vacuum in the venturi throat should move the regulator valve off its seat and permit gas to flow 2 5 6 FUEL SUPPLY LINES LP gas lines must be accessible but protected against possible damage Do NOT connect electrical wiring to any LP gas fuel line or run wiring alongside the lines Route gas lines away from hot engine exhausts Retain gas lines with metal clamps that d
29. such unauthorized parts Do not terminate the exhaust system under any opening window or vent that can be opened or is not permanently sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine 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 applicable codes standards and regula tions 2 7 ELECTRICAL CONNECTIONS Be sure to read Section 1 6 on Page 20 The following general rules apply to electrical con nections in a recreational vehicle Qualified electricians who are familiar with applic able codes standards and regulations should install electrical wiring The wiring should comply with codes standards and regulations The National Electrical Code NFPA 70 and state and local codes apply Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent damage from road shock Wiring must be of adequate size have approved insulative qualities and be properly supported Conduit and wire openings into the generator com partment if used must be vapor sealed to prevent entry of flammable explosive or poisonous gases into the vehicle 2 71 ELECTRICAL JUNCT
30. 0 Section 2 Installation 22 2 1 Location and Support eene 22 2 2 Generator 23 2 3 Cooling and Ventilating 26 2 4 Gasoline Fuel System eese 27 2 5 LP Gas Fuel System 28 2 0 Exhaust Systeri eoe eroe e sehe teas 30 2 7 Electrical Connections ooccccoccnnnnccnnnncnnnnccnnnacinnnos 31 2 8 Battery Installation 34 2 9 Optional 8 ensi 34 Section 3 Post installation Start up Adjustments es 35 3 1 Post Installation Tests eeeeeeeeee 35 3 2 Before Initial Start up eee 35 3 9 Initial Start iiec ken ran nono ens 35 3 4 Testing Under Load 35 3 5 Installation Checklist 36 Section 4 Troubleshooting Section 5 Electrical Data Section 6 Exploded Views and Parts Lists Section 7 Generac Power Systems Inc 1 SAFETY RULES Safety Rules PRIMEPACT 50 Recreational Vehicle Generator SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recrea
31. 0 72 3 06 1 25 45 35 04164 2 Gasoline is in gal h LP is in gal h and cf h 1 5 4 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum Institute API Service Classification SF SG or SH The recommended oil weights include the following During summer months SAE 30 An acceptable substitute is SAE 10W 30 During winter months SAE 5W 30 DO NOT USE SAE 10 W40 Crankcase and oil filter capacity is approximately 1 400 mL or 1 5 U S quarts Do NOT use special additives See Sections 3 1 and 3 2 Page 12 for oil level check and fill procedures 6 Generac Power Systems Inc Section 1 General Information PRIMEPACT 50 Recreational Vehicle Generator 1 5 5 ENGINE of Engine GN 410 Single cylinder Cooling Air cooled Rated Horsepower 15 4 200 rpm Displacement err reae tm rnt eh aet enero rena 407cc Cylinder Block Aluminum w Cast Iron Sleeve Type of Governor Mechanical Fixed Speed Air Cleaner Paper Element w Foam Precleaner cidad ia 12 volt DC Electric Ignition System Solid state w Flywheel Magneto Recommended Spark Plug ANS RC12YC Ali A Ad R45S Frami eee eate 65 Spark Plug Gap 0 030 inch 76 mm Recommended Minimu
32. 646 A6563 C3633 A6581 C2332 92164 83503 A7029 A6913 91161 49813 92586 83512 A6778 A6785 A6753 A8222 86681 20753 22473 22097 A6582 A6503 A6569 A6565 A6568 A6567 90968 83532 Section 6 Exploded Views and Parts Lists et PRIMEPACT 50 Recreational Vehicle Generator LISTS Engine Accessories Model 04164 2 Drawing No C3880 A QTY E SS pw is DESCRIPTION MANIFOLD INTAKE GASKET MANIFOLD HEAD HHCS M6 1 0 X 40MM SPARK PLUG CHAMP GASKET CARB MANIFOLD CARBURETOR GN 410 L P GASKET CARB AIR FILTER BASE AIR FILTER CRIMPTITE 10 24 X 1 2 DETENT SPRING A L BELLCRANK CARB STUD CARB MOUNT 90 LG FILTER AIR PRE CLEANER AIR FILTER COVER AIR FILTER KNOB AIR CLEANER BREATHER TUBE DECAL AIRBOX QP55 ASSEMBLY GOV SPRING ADI BRACKET NUT LOCKING M5 0 8 NYLON WASHER 31 X 26 X 13 ROD LINKAGE GOV LEVER BELLCRANK BOLT SHOULDER M6 1 0 X 15MM NUT M6 1 0 WASHER FELT TAPTITE M8 1 25 X 16MM SPRING A L GOV LEVER BELLCRANK ROD LINKAGE BELLCRANK CARB BELLCRANK GOV RODS SPRING GOVERNOR NUT GOVERNOR LEVER HHCS M6 1 0 X 60MM M6 FLAT WASHER M6 LOCK WASHER TUBE WINTER INLET GROMMET 1 16 1 1 2 GROMMET AIR IN OUT VALVE WINTER SUMMER GROMMET WINTER SUMMER VALVE SPRING DETENT LEVER GOVERNOR ARM BOLT HEX HD WASHER LOCK WASHER M6 1 0 X 30
33. 75476 3 M4 0 7 X 16 LG CAPSCREW 62 031791 1 CLAMP HOSE 31 022264 4 8 M4 LOCK WASHER 63 023897 2 10 M5 FLAT WASHER 32 065795 1 BATTERY CHARGE RECTIFIER 64 0D2724 2 BOOT ROCKER SWITCH 33 090987 2 M3 0 5 X 12 LG PPHMS 65 031879 2 WASHER FLAT 4 Generac Power Systems Inc 47 ums Section 6 Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Sheet Metal Model 02010 2 and 04164 2 Drawing No D1760 B 43 Generac Power Systems Inc gt Section 6 Exploded Views and Parts Lists CG urs PRIMEPACT 50 Recreational Vehicle Generator Engine Sheet Metal Model 02010 2 and 04164 2 Drawing No D1760 B PART NO QTY DESCRIPTION 0A4323 1 SCROLL FLYWHEEL 045756 8 SCREW TAPTITE M6 1 0 X 10MM 029289 2 5 FT FOAM TAPE SRV 091222D 1 FLYWHEEL 067198N 1 WASHER BELLVILLE M20 X 2 2 067890 1 NUT M20 X 1 5 FLYWHEEL 0A4456 1 3 8 SPECIAL LOCK WASHER 056893 21 SCREW CRIMPTITE 10 24 X 0 5 0A6358 1 COVER TOP FLYWHEEL 091646 1 DEFLECTOR EXHAUST PORT 092572 1 ASSEMBLY IGNITION COIL 092079 2 SCREW TAPTITE M6 1 0 X 25MM 022717A 1 GROMMET RUBBER 073132 1 BOOT SPARK PLUG 061669 1 PLUG BUTTON 089685 2 GROMMET RUBBER 022129 6 LOCK WASHER M8 022127 1 HEX NUT 1 4 20 057821 2 CAPSCR HEX HD M8 1 25 X 40MM 059637 2 SCREW TAPTITE 3 8 16 X 0 75 021544 1 MOTOR STARTER 12VOLT 040976 2 SOCKET HD CAPSCR M8 1 25 X 20MM 025034
34. 9 043182 2 M3 LOCK WASHER 7 0A6529 4 STUD STATOR 40 045771 4 HEX NUT M8 8 052858 4 M8 1 25 FLANGE LOCK NUT 41 053623 1 C BREAKER 2 5A ON 9 066386 1 BRUSH HOLDER 42 0234845 1 BUSHING 10 066849 3 M5 0 8 X 16 LG TAPTITE 43 083049 1 REGULATOR VOLTAGE 11 0A8475 3 SPECIAL LOCK WASHER M5 44 022152 5 LOCKWASHER 10 12 0C3818 1 GENERATOR TOP HOUSING 45 051716 3 M5 0 8 HEX NUT 13 075234 1 RESISTOR1R 5 25 WLVG 46 090144 1 C BREAKER 20A 14 022473 2 14 M6 FLAT WASHER 47 090145 1 C BREAKER 30A ALL UNITS 15 022097 5 14 Me LOCK WASHER 48 025105 4 6 32 SCREW W LOCK WASHER 16 055816 1 M6 1 0 X 70 LG CAPSCREW 49 086315 1 PANEL COVER 17 090141 2 GROUND CABLE 50 090734 4 M4 0 7 X 12 LG CAPSCR W LOCK 18 0A1658 2 SPECIAL LOCK WASHER M6 WASHER amp FLAT WASHER 19 074906 4 M6 1 0 X 20 LG TAPTITE 51 022985 1 6 FLAT WASHER 20 094039 1 CONTROLLER 52 032300 1 FUSE HOLDER 21 0C2337A 1 DECAL UNIT LP MODEL 53 022676 1 FUSE AGC 15A 22 022129 4 5 16 M8 LOCK WASHER 54 087798 1 SWITCH S P D T 6A START STOP 23 027756 4 NYLON WASHER 55 092113 1 SWITCH S P D T FUEL PUMP 24 086316 1 PANEL SHEET METAL 56 075210A 1 TERMINAL BLOCK 25 053650 1 4 PIN CONNECTOR 57 0A8475A 1 SPECIAL LOCK WASHER 4 26 004258 1 CONDUIT ASSEMBLY 58 051715 1 M4 0 7 HEX NUT 27 075244 1 ASSEMBLY REMOTE CABLE 59 090157 1 DECAL CB RATING 30A 28 094071 1 M5 08 X 110 LG PPHMS 60 090156 1 DECAL CB RATING 20 29 094070 1 SPACER PLASTIC 61 074908 2 M5 0 8 X 10 LONG TAPTITE 30 0
35. AT THIS NUMBER PRIMEPACT 50 Recreational Vehicle Generator Part Owner s Manual Introduction Inside Front Cover Read This Manual Thoroughly IFC aurigae EX IFC Operation and IFC How to Obtain Service IFC Authorized Service Dealer Locator Number IFC Safety em a ii o 2 Section 1 General Information 4 1 1 Generator Identification 1 2 Generator L9 Safely bs 1 4 Generator AC Connection 5 1 5 Specifications it 5 Section 2 Operation 7 2 1 Generator Control 7 2 2 Optional Remote Start Stop Panel 7 2 3 Automatic Choke Gasoline 8 2 4 Before Starting the Engine 8 2 5 Starting the Generator 9 2 6 Stopping the Generator eee 9 2 7 Applying Loads to Generator 9 2 8 Summer Winter Heat Riser System 9 2 9 Protection Systems oooccconccnonccnnonccnnnccnnnnccnonacinnnos 10 2 10 Additional Informatio
36. CT 50 Recreational Vehicle Generator WARRANTY 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 or equipment is purchased by delivered to its original end use purchaser owner and shall contin ue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine manu facturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac accordin
37. Connect a fuel supply line to the fuel filter inlet Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines Generac Power Systems Inc 27 INSTALLATION Ps Section 2 Installation 2 4 1 FUEL TANK Either the generator must share the vehicle engine s fuel tank or you must install a separate fuel tank for the generator set All fuel tanks installed on the vehi cle must be constructed installed and restrained so they comply with applicable codes standards and regulations If the generator is to share the vehicle engine s tank separate fuel pickup tubes are required for the engine and the generator Generac recommends that you make the fuel pickup tube 2 to 3 inches 51 to 76 mm shorter than the vehicle engine s pickup tube This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods A caution A A Do NOT tee the generator fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not run ning generator operation may drain the vehi cle engine supply line making it difficult to start the vehicle engine 2 4 2 GENERATOR FUEL SUPPLY LINE 2 4 2 1 Rigid Fuel Lines Those lines used to supply fuel from a tank to the generator must comply with applicable c
38. Drawing No A7894 E ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 21533 1 PISTON RING SET 29 A9877 1 CAMSHAFT ASSEMBLY 3 71978 1 CONNECTING ROD WITH CAP amp 30 72655 2 CRANKSHAFT 35 I D SEAL BOLT 31 76361 1 THRUST WASHER 4 71980 1 PISTON PIN 32 A5776 1 PRESSURE RELIEF BALL 5 71983 2 PISTON PIN RETAINER 33 A7308 1 GOVERNOR SPOOL 6 21713B 1 CYLINDER HEAD GASKET 34 78645 1 GOVERNOR RETAINER C RING 7 1442 8 FLANGED HEX HD CAPSCREW 35 78691 1 COVER OIL PRESSURE RELIEF M8 1 25 X 42 36 74908 1 M5 0 8 X 10MM TAPTITE 8 21742 4 M10 1 5 X 105MM HHFL 37 A8930 1 GOVERNOR GEAR ASSEMBLY 9 96699 1 PISTON 38 5771 1 OIL PRESSURE SPRING 10 76701 1 CRANKCASE GASKET 39 B2104 1 SPRING WASHER 11 45756 2 M6 1 0 X 10 TAPTITE THD 40 89280D 1 OIL SUMP ASSEMBLY FORMING 42 78658 1 GOVERNOR ARM R PIN 12 80308 2 BREATHER GASKET 43 78659 2 THRUST WASHER 13 80309 1 BREATHER COVER 46 A7628 1 GOVERNOR ARM RC45 14 80338 1 OIL BREATHER SEPARATOR 48 C3396C 1 CRANKCASE SUB ASSEMBLY 15 26925 1 PIPE PLUG 3 8 49 84430 1 BALANCER 16 83897 2 TAPPET SOLID 50 86002 1 OUTER GEROTOR 17 72694 2 PIVOT BALL STUD 51 86026 1 INNER GEROTOR 18 72696 2 JAM NUT ROCKER ARM 52 88396B 2 PUSH ROD 19 78672 1 SEAL VALVE STEM 53 90416A 1 CRANKSHAFT ASSEMBLY 20 78694 1 PUSH ROD GUIDE PLATE 54 90747 1 BREATHER VALVE ASSEMBLY 21 83907 2 ROCKER ARM 55 C3150 1 ROCKER COVER GASKET 22 21714 1 CYLINDER HEAD W VALVE SEATS 57 92362 1 ROCKER COVER W FILL AND GUIDES 58 79246 4 M6 1 0
39. ESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0 9675 1 LOWER BEARING CARRIER 36 082737 4 VIBRATION MOUNT 2 0A5649H 1 ROTOR ASSEM 37 049813 4 M6 1 0 HEX NUT 3 0A5646H 1 STATOR ASSEM 38 055440 2 M5 08 X 25 LG HEX HD CAPSCR 4 073159 1 BALL BEARING 39 043182 2 M3 LOCK WASHER 5 031971 1 BALL BEARING 40 045771 4 HEX NUT M8 6 0C9674 1 UPPER BEARING CARRIER 41 053623 1 C BREAKER 2 5A ON 7 0A6529 4 STUD STATOR 43 083049 1 REGULATOR VOLTAGE 8 052858 4 M8 1 25 FLANGE LOCK NUT 44 022152 5 LOCKWASHER 10 9 066386 1 BRUSH HOLDER 45 051716 3 M5 0 8 HEX NUT 10 066849 3 M5 0 8 X 16 LG TAPTITE 46 090144 1 C BREAKER 20 11 002724 2 BOOT ROCKER SWITCH 47 090145 1 C BREAKER 304 ALL UNITS 12 003818 1 GENERATOR TOP HOUSING 48 025105 4 46 32 SCREW W LOCK WASHER 13 075234 1 RESISTOR1R 5 25 WLVG 49 086315 1 PANEL COVER 14 022473 2 14 M6 FLAT WASHER 50 090734 4 M4 0 7 X 12 LG CAPSCR W LOCK 15 022097 5 14 Me LOCK WASHER WASHER amp FLAT WASHER 16 055816 1 M6 1 0 X 70 LG CAPSCREW 51 022985 1 6 FLAT WASHER 17 090141 2 GROUND CABLE 52 032300 1 FUSE HOLDER 18 0A1658 2 SPECIAL LOCK WASHER M6 53 022676 1 FUSE AGC 15A 19 074906 4 M6 1 0 X 20 LG TAPTITE 54 087798 1 SWITCH S P D T 6A START STOP 20 092234 1 CONTROLLER P C B 55 092113 1 SWITCH S P D T FUEL PUMP 21 002337 1 DECAL UNIT GAS 56 0752104 1 TERMINAL BLOCK 22 022129 4 5 16 M8 LOCK WASHER 57 0A8475A 1 SPECIAL LOCK WASHER 4 23 031879 2 WASHER FLAT 4 58 051715 1 M4 0 7 HEX NUT 24 086316 1 PANEL
40. FUEL TUBE METAL CAPSCR HEX HD M6 1 0 X 16 FLAT WASHER M8 5 16 FLAT WASHER 8 GASKET BLOWER HSNG EXHAUST PIPE GASKET WASHER SPRING RETAINER BOOT STARTER CONTACTOR EXHAUST COVER PLATE HOSE FUEL PAN SLIDE SPECIAL LOCK WASHER 14 CAPSCR HEX HD 3 8 16 X 3 4 SPECIAL LOCK WASHER M5 SCREW TAPTITE M6 1 0 X 10 LG FLAT WASHER M10 CLAMP HOSE NUT FLANGE 5 16 18 SPECIAL SCREW TAPTITE M5 0 8 X 16 LG STARTER CONTACTOR GASKET BLOWER HSNG HHS 10 32 X 9 16 LG TAP R STARTER CABLE HEX NUT 5 16 24 BOOT STARTER CONTACTOR LOCK WASHER M4 HEX NUT 10 32 PLATE BLOWER SIDE GASKET BLOWER SIDE FLAT WASHER 4 Generac Power Systems Inc 41 ums Section 6 Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys Model 04164 2 Drawing No D1758 D TO ENGINE 56 40 49 56 p 29 33 32 31 42 Generac Power Systems Inc Section 6 Exploded Views and Parts Lists CG urs PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys Model 04164 2 Drawing No D1758 D ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0 2368 1 BASE MOUN
41. Filter e 3 7 SPARK ARRESTOR MUFFLER If the generator is not equipped with a spark arrestor exhaust muffler and is to be used on any forest cov ered brush covered or grass covered unimproved land you may have to install a spark arrestor The spark arrestor must be maintained in effective work ing order by the vehicle owner operator For assistance in ordering installing and maintaining spark arrestor exhaust mufflers contact your nearest Generac Authorized Service Dealer Exhaust mufflers supplied by Generac are spark arrestor types Generac exhaust mufflers for recre ational vehicle generators do not have a spark arrestor screen but are of the more efficient toroid or swirl type To remove carbon and combustion deposits from such mufflers remove the plug from the muffler and run the engine for approximately 15 minutes Shut down the engine let the muffler cool and install the plug WARNING amp Be sure to reinstall the muffler plug tightly po Engine vibration could cause a loose plug to fall out Without the plug in place hot engine exhaust is directed out the opening This hot exhaust depending on the installation could be directed to areas not able to withstand the extreme heat such as wooden floor boards or other flammable material This could result in a fire 14 Generac Power Systems Inc PRIMEPACT 50 Recreational Vehicle Generator 3 8 CLEANING THE GENERATOR Keep the generator set
42. GENERAG POW ER SYSTEMS INC Owner s Manual and Installation Instructions Air cooled Recreational Vehicle Generators Model 02010 2 PRIMEPACT 50 Model 04164 2 PRIMEPACT 50LP INTRODUCTION Thank you for purchasing this model of the PRIMEPACT product line by Generac Power Systems Inc This model is designed and manufactured to supply electrical power for recreational vehicles READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual contact Generac or your nearest Generac Authorized Service Dealer for starting operating and servicing pro cedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or care lessly Observe them carefully Their definitions are as follows A A After this heading you can read instructions that if not strictly complied with will result in personal injury or property damage WARNING After this heading you can read instructions that if not strictly complied with may result in personal injury or property damage caution A After this heading you can read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading you can read explanatory stat
43. ION BOX Install an approved square electrical junction box with a blank cover on the interior or exterior wall of the area you plan to install the generator NOT on the generator Route the generator s AC output leads into this junction box through approved flexible con duit This is the point of first termination for genera tor AC output leads Generac Power Systems Inc 31 INSTALLATION Ps Section 2 Installation 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 s rated maximum current If neutral conductors are used they must be the same size as other leg wires Route power supply conductors from generator AC output leads T1 red T2 white black and the green ground wire through approved flexible conduit to the electrical junction box on the com partment wall If flexible metal conduit is used between the genera tor and the compartment junction box the conduit end that terminates the compartment junction box must be vapor sealed Flexible metal conduit is NOT vapor tight along its entire length From the junction box route power supply wires through approved conduit to either a double pole double throw transfer switch or b approved isola tion receptacle Connecting to a transfer switch or isolation receptacle must prevent ve
44. MM Generac Power Systems Inc 55 Section 7 Warranty WARRANTY PRIMEPACT 50 Recreational Vehicle Generator 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 with Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine New utility and lawn and garden equipment engines must be designed built and equipped to meet stringent anti smog stan dards for the state of California and the federal government Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modification or improp er maintenance of your engine Your emission control system may include parts such as the carburetor ignition and exhaust systems Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Serv
45. Power Systems Inc PRIMEPACT 50 Recreational Vehicle Generator Figure 2 20 Connecting Battery Cables SIDE VIEW OF GENERATOR STARTER CONTACTOR GROUND LUG NEGATIVECABLE BATTERY 2 8 4 BATTERY COMPARTMENT Install the generator battery in its own vented com partment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage 2 9 OPTIONAL ACCESSORIES A plug in receptacle Figure 2 21 is provided on the generator set above the muffler enclosure Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit you to start and stop the genera tor engine from any convenient location inside the vehicle Figure 2 21 Remote Panel Plug in Receptacle NS eetct NC CURAE CY YN E WIRE 187 STOP p N whey WIRE 17 ENGINE RUN CRANK SIGNAL bs WIRE 0 GROUND Section 3 Post installation Start up Adjustments PRIMEPACT 50 Recreational Vehicle Generator 2 9 1 REMOTE PANEL MODELS 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 junc
46. SHEET METAL 59 090157 1 DECAL CB RATING 30 25 053650 1 4 PIN CONNECTOR 60 090156 1 DECAL CB RATING 20 26 004258 1 CONDUIT ASSEMBLY 62 031791 1 CLAMP HOSE 27 075244 1 ASSEMBLY REMOTE CABLE 63 023897 2 10 M5 FLAT WASHER 30 075476 3 M4 0 7 X 16 LG CAPSCREW 64 074908 2 M5 0 8 X 10 LONG TAPTITE 31 022264 4 8 M4 LOCK WASHER 65 0234848 1 BUSHING 32 065795 1 BATTERY CHARGE RECTIFIER 67 094070 1 SPACER PLASTIC 33 090987 2 M3 0 5 X 12 LG PPHMS 68 094071 1 M5 08 X 110 LG PPHMS 34 086317A 1 PANEL SUPPORT BRACKET 69 027756 4 NYLON WASHER 35 075235 3 M5 0 8 X 30 LG CAPSCREW 70 0A8475 3 SPECIAL LOCK WASHER M5 Generac Power Systems Inc 45 ums Section 6 Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator 0 Alternator and Panel Model 04164 2 Drawing No D1776 C A 46 Generac Power Systems Inc Section 6 Exploded Views and Parts Lists CG urs PRIMEPACT 50 Recreational Vehicle Generator Alternator and Panel Model 04164 2 Drawing No D1776 C ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0 9675 1 LOWER BEARING CARRIER 34 086317A 1 PANEL SUPPORT BRACKET 2 0A5649H 1 ROTOR ASSEM 35 075235 3 M5 0 8 X 30 LG CAPSCREW 3 0A5646H 1 STATOR ASSEM 36 082737 4 VIBRATION MOUNT 4 073159 1 BALL BEARING 37 049813 4 M6 1 0 HEX NUT 5 031971 1 BALL BEARING 38 055440 2 M5 08 X 25 LG HEX HD CAPSCR 6 0C9674 1 UPPER BEARING CARRIER 3
47. SKET CARB MANIFOLD CARBURETOR GASKET CARB AIR FILTER BASE AIR FILTER CRIMPTITE 10 24 X 1 2 DETENT SPRING BELLCRANK CARB STUD CARB MOUNT 90 LG FILTER AIR PRE CLEANER AIR FILTER COVER AIR FILTER KNOB AIR CLEANER RHMS 4 40 X 5 16 DECAL AIRBOX QP55 ASSEMBLY GOV SPRING ADI BRACKET NUT LOCKING M5 0 8 NYLON WASHER 31 X 26 X 13 NUT M6 1 0 TAPTITE M8 1 25 X 16MM ASSEMBLY CHOKE SOLENOID LINKAGE CHOKE PIN COTTER 3 32 X 1 2 ASSEMBLY CHOKE HEATER SCREW PHILLIPS PAN HD MACH 4 40 X 25 HHCS M6 1 0 X 60MM M6 FLAT WASHER M6 LOCK WASHER TUBE WINTER INLET GROMMET 1 16 1 1 2 GROMMET AIR IN OUT VALVE WINTER SUMMER GROMMET WINTER SUMMER VALVE SPRING DETENT LEVER GOVERNOR ARM BOLT HEX HD WASHER LOCK WASHER M6 1 0 X 30MM NUT GOVERNOR LEVER SPRING GOVERNOR BELLCRANK GOV RODS WASHER FELT BOLT SHOULDER M6 1 0 X 15MM ROD LINKAGE GOV LEVER BELLCRANK ROD LINKAGE BELLCRANK CARB SPRING GOV LEVER BELLCRANK BREATHER TUBE Generac Power Systems Inc 53 ums Section 6 Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator 0 Engine Accessories Model 04164 2 Drawing No C3880 A 54 Generac Power Systems Inc gt PART 6532 91039 51753 72347 89228 A7336A 90970 6564 56893 6566 6780 96290 73111 81
48. TING 37 0D2530 1 REGULATOR GAS FUEL 2 053407 1 GROUND CABLE 38 0A6894 1 MANIFOLD LP 3 046911 4 MOUNT RUBBER 39 0A2666 1 SOLENOID GAS FUEL 4 025017 6 CAPSCREW HEX HD 3 8 16 X 1 2 40 061696 1 BARB 90 DEG 1 2 X 3 8 NPT 5 022237 6 LOCK WASHER 3 8 41 079246 2 CAPSCR HEX HD M6 1 0 X 16 6 022129 12 LOCK WASHER M8 42 022145 8 FLAT WASHER M8 5 16 7 0A6479 1 SKID RUBBER MOUNT 43 038150 3 FLAT WASHER 8 8 077603 2 SAFETY BOLT 5 16 18 X 3 1 2 44 0A8010A 1 GASKET BLOWER HSNG 9 022259 2 NUT HEX 5 16 18 45 077643 1 EXHAUST PIPE GASKET 10 052858 6 NUT FLANGED LOCK M8 1 25 46 075237 4 WASHER SPRING RETAINER 11 051730 2 CAPSCR HEX HD M8 1 25 X 60MM 47 075763A 1 BOOT BATTERY CABLE 12 029459 2 SPRING BELT TENSION 48 090859 1 EXHAUST COVER PLATE 13 075215 2 WASHER SPRING CNTR 49 074994 10 5 HOSE ID PETROLEOM 14 073146 4 SLIDE NYLON 50 0A8594 1 PAN SLIDE 15 075209 2 SUPPORT NYLON SLIDE 51 0D1741 2 BOOT STARTER CONTACTOR 16 0A8341 1 MANIFOLD EXHAUST 52 023152 2 CAPSCR HEX HD 3 8 16 X 3 4 17 090239 1 GASKET EXHAUST MANIFOLD 53 0A8475 2 SPECIAL LOCK WASHER M5 18 040976 2 SOCKET HD CAPSCR 54 025655A 1 34 NPT PLUG M8 1 25 X 20 LG 55 022131 1 FLAT WASHER M10 19 0A6858 1 GASKET COLLECTOR PAN 56 057822 2 8 HOSE CLAMP 20 0A8614 1 SKID RUBBER MOUNT 57 081105 2 NUT FLANGE 5 16 18 SPECIAL 21 075224B 1 PULLEY ENGINE 58 066849 2 SCREW TAPTITE M5 0 8 X 16 LG 22 073106B 1 PULLEY ALT 59 0D1227 1 STARTER CONTACTOR 23 075216
49. The National Electrical Code NFPA 70 551 7 able codes standards and regulations It must be requires that you install ground fault circuit inter large enough to handle the full amperage to which it rupters GFCIs on all external and some internal electrical receptacles Contact your manufacturer or will be subjected dealer for recommendations Figure 2 18 Transfer Switch Isolation Method 2ND AIR FROM 20 AMP CONDITIONER HACR BREAKER JUNCTION VEHICLE FLEXIBLE WIRING CONDUIT DOUBLE I VEHICLE AC DOUBLE DISTRIBUTION PANEL THROW SWITCHING DEVICE 30 AMP MAIN BREAKER HACR BREAKERS FOR AIR CONDITIONERS GFCI BREAKERS POWER SUPPLY CORD Figure 2 19 Installation With Isolation Receptacle DOCKSIDE POWER RECEPTACLE JUNCTION e POWER SUPPLY CORD FLEXIBLE CONDUIT VEHICLE AC DISTRIBUTION PANEL Generac Power Systems Inc 33 INSTALLATION Fs Section 2 Installation 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 capa ble of delivering 400 cold cranking amperes For prevailing ambient temperatures below 32 F 0 C use a battery rated 95 amp hours and capa ble of delivering 400 cold cra
50. X 16MM HEX HEAD 23 86514 2 VALVE SPRING RETAINER SCREW AND LOCKWASHER 24 86515 4 VALVE SPRING KEEPER 59 83921 1 BEARING TUBE SHAFT 25 86516 1 EXHAUST VALVE 60 77158 1 OIL SCREEN PICKUP ASSEMBLY 26 86517 1 INTAKE VALVE 63 76329 1 OIL FILL PLUG 27 89673 2 WASHER VALVE SPRING 64 86254 1 O RING 17 81 0 X 2 4 THICK 28 C4391 2 VALVE SPRING 65 93064 1 OIL FILL CAP ASSEMBLY Generac Power Systems Inc 51 ums Section 6 Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator 0 Engine Accessories Model 02010 2 Drawing A8923 B 52 Generac Power Systems Inc gt PART 6532 91039 51753 72347 89228 6562 90970 6564 56893 6566 6780 96290 73111 81646 6563 C3633 A7095 C2332 92164 83503 A7029 49813 83512 A6239 A6584 36544 89473 A7094 20753 22473 22097 A6582 A6503 A6569 A6565 A6568 A6567 90968 83532 86681 A8222 A6753 92586 91161 A6913 A6785 A6778 A6581 Section 6 Exploded Views and Parts Lists et PRIMEPACT 50 Recreational Vehicle Generator LISTS Engine Accessories Model 02010 2 Drawing No A8923 B QTY oom pS Sep ep DESCRIPTION MANIFOLD INTAKE GASKET MANIFOLD HEAD HHCS M6 1 0 X 40MM SPARK PLUG CHAMP GA
51. ail volcanic eruption water or flood tornado or hurricane Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone telegraph teletype or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you Purchaser owner agrees to make no c
52. ammable materials You may need to use approved nonflammable insulating materials in high temperature areas 2 2 3 SOUND INSULATING MATERIALS Once installers have determined that a compartment is properly constructed and metal lined they can add acoustical material This may include additional sealant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a nonflam mable type One excellent insulating material is a 1 inch 25 mm thick fiberglass having a 2 pound den sity When fiberglass is used its coated side should face toward the compartment interior 24 Generac Power Systems Inc PRIMEPACT 50 Recreational Vehicle Generator A A Do not install sound insulation or any 3 absorbent material on the compartment floor interior Such materials will become soaked with combustible or explosive vapors and liquids and will become a fire hazard Using a combination of sound insulating materials can often reduce noise more effectively than a single material For example a sheet of lead or visco elastic material along with a layer of other acoustical mate rial is more effective than when a single material is used 2 2 4 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement compartment NOTE Any method used to reduc
53. and in turn the voltage deliv ered to connected electrical loads is controlled When the AC frequency is 60 Hertz voltage is regulated at 120 volts voltage to frequency ratio is 2 to 1 Figure 2 6 Solid State Voltage Regulator O S S 1 sense c a TO ROTOR e Ecc DIRECT CURRENT FROM STATOR EXCITATION WINDING z ALTERNATING CURRENT S S The voltage regulator also incorporates voltage surge protection circuit This circuit prevents trou blesome surges in the generator AC output voltage Voltage surge is a common cause of damage to elec tronic equipment 2 10 ADDITIONAL INFORMATION 2 10 1 25 HOUR BREAK IN PERIOD The first 25 hours of operation is the break in period for the generator Properly breaking in the generator is essential to minimize fuel consumption and pro vide maximum engine performance During this 25 hour break in period follow this procedure Run the unit at varying electrical loads to help seat the engine piston rings properly Check the engine oil level frequently Add oil if needed It is normal for the generator engine to consume more oil than is normal until the piston rings have properly seated For the 75 hour operation following the break in period avoid light electrical loads Load the generator at 50 percent or more of its rated wattage capacity Repeated light loads during the
54. anted for the life of the generator Drive belt tension was properly adjusted before the unit was shipped from the factory If you suspect that drive belt tension is incorrect contact a Generac Authorized Service Dealer 3 12 EXERCISING THE GENERATOR Generac recommends that you start and operate the generator at least once every seven days Let the unit run for at least 30 minutes to exercise the engine Generac Power Systems Inc 15 MAINTENANCE Section 3 Maintenance 20 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 2 3 Start the engine and let it warm up Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 10W 30 oil having API classification For Service SF Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase Remove the spark plug and pour two or three tablespoons of clean fresh engine oil into the spark plug threaded openings Reinstall and tighten the spark plug Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor Clean and wipe the entire generator 16 Generac Power
55. as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor caution 4 A Do NOT use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also cont aminate the generator fuel system 3 9 BATTERY MAINTENANCE All lead acid batteries will discharge when not in use The generator battery should be inspected as follows 3 9 1 WEEKLY Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary Check the battery fluid level of unsealed batteries and if necessary fill with Distilled Water Only Do not use tap water in batteries 3 9 2 EVERY SIX MONTHS Have the state of charge and condition checked This should be done with an automotive type bat
56. booster battery to crank and start the generator engine If any battery has discharged remove it for recharging WARNING amp 0 Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic A The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water MAINTENANCE 20 Section 3 Maintenance Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried 3 10 MAJOR SERVICE MANUAL To obtain a service manual for your generator con tact Generac or your nearest Generac Authorized Service Dealer or go to www generac com Make sure to identify your MODEL NUMBER and SERIES 3 11 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement The drive belt and pulleys are warr
57. c Fuel pump if so equipped b Ignition module 1 2 LPG carburetion assembly and its 4 Catalytic Muffler Assembly if so equipped including internal components if so equipped a Muffler gasket a Fuel controller if so equipped b Exhaust manifold b Mixer and its gaskets if so equipped 5 Crankcase Breather Assembly including c Carburetor and its gaskets if so equipped a Breather connection tube d Primary gas regulator if so equipped e LP liquid vaporizer if so equipped Generac engine types covered by this warranty statement include the following 1 Utility 2 Lawn and Garden Equipment 3 Recreational Vehicle RV Generator 4 Industrial Mobile IM Generator Part 2 Generac Power Systems Inc 57 Section 7 Warranty 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 For a period of 3 three years or 2 000 two thousand hours of operation from the date of original sale whichever occurs first Generac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspec tion and testing by Generac or a Generac Authorized Warranty Service Facility is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that
58. cover foam precleaner and paper filter Remove the foam precleaner from the cover Wash the foam precleaner in liquid detergent and water Wrap 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 filter 8 Install the cover foam precleaner and paper filter 9 Tighten the two screws to retain the filter in place gt ot Figure 3 2 Engine Air Cleaner PAPER AIR FILTER FOAM PRECLEANER AIR CLEANER 3 3 2 CLEANING OR REPLACING THE PAPER FILTER Once each year or every 100 hours of operation whichever comes first clean or replace the paper filter The new replacement filter must be flame retar dant Service the paper filter more frequently if oper ating the generator in extremely dusty or dirty condi tions Use the following procedure Figure 3 2 1 Follow steps 1 3 in Section 3 3 1 service the foam precleaner if necessary 2 Remove the paper filter 3 Clean the air filter by tapping it gently on a solid surface If the filter is too dirty replace it with a new one Dispose of the old filter properly MAINTENANCE 20 Section 3 Maintenance 4 Clean the air cleaner cover then reassemble following steps 7 9 in Section 3 3 1 3 4 CLEAN AIR INTAKE
59. de for a path for exhausting the cooling air to the exterior of a com partment if so equipped A DIG A Never use discharged cooling air for heating or permit 2 such air to enter the vehicle interior This air contains deadly carbon monoxide gas and other poisonous flam mable or explosive gases 2 3 1 GENERATOR AIRFLOW Engine operation drives cooling fans for the two stage cooling air system A pressure fan draws cooling air into the top of the generator Figure 2 9 This airflow cools the engine generator and electronic components The second part of the cooling system a suction fan draws air that is heated from a hot engine into a collec tor pan at the base of the unit This heated air although cooler than exhaust muffler is then deflected out the bottom toward the ground Figure 2 9 Airflow Through Engine Generator 2 3 2 COOLING AIR INLET OPENINGS The minimum size of the air inlet opening whether the generator is housed in a conventional compart ment or not is at least 100 square inches see Figure 2 10 This rule applies whether inlet air is brought in through an opening in the compartment door an opening in the vehicle skirt through duct work or by any other means 26 Generac Power Systems Inc PRIMEPACT 50 Recreational Vehicle Generator NOTE Screening louvers or expanded metal that cover air openings restrict airflow You m
60. dust dirt corrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor Generac Power Systems Inc 11 MAINTENANCE 20 Section 3 Maintenance 3 1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements see Engine Oil Requirements Section 1 5 4 Page 6 Check the engine crankcase oil level at least every eight hours of operation or before you use it To check the engine oil level proceed as follows see Figure 3 1 1 Be sure the generator is as level as possible 2 Remove the dipstick and wipe it dry with a clean lint free cloth 3 Install and tighten the dipstick cap then remove it again The oil level should be at the dipstick Full mark 4 If necessary remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dip stick Full mark DO NOT FILL ABOVE THE FULL MARK
61. e noise must not adversely affect the flow of cooling and ventilating air into or out of the compartment In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise levels Such a compartment might be constructed as follows Figure 2 7 Use 5 8 inch thick or 3 4 inch thick plywood in the compartment Construct the compartment floor of a double thick ness of 5 8 inch or 3 4 inch plywood Line the compartment interior walls and floor as well as the underside of the floor with 26 gauge galvanized steel Vapor seal all compartment seams and joints Over the galvanized steel lining install a combina tion of acoustical materials as mentioned in Section 2 2 3 A A To prevent fire or explosion do not install any 3 insulation or other absorbent materials on the interior or underside of the compartment floor Seal all compartment door edges to prevent noise leakage around the door perimeter Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 inch 25 mm thick fiberglass with a 2 pound density Section 2 Installation INSTALLATION PRIMEPACT 50 Recreational Vehicle Generator E Figure 2 7 Typical Noise Abatement 2 2 5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compart ro OS THICK ment for the following items Fi
62. ements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of you and others This symbol points out potential explosion hazard This symbol points out potential fire hazard A This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator driver is responsible for proper and safe use of the vehicle and its equipment and the safe ty of all vehicle occupants We strongly recommend that the operator read this manual and thoroughly understand all instructions before using this equip ment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to oper ate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for this generator model In addition the latter portion of this manual contains information necessary for the proper instal lation
63. enerac Power Systems Inc 23 INSTALLATION Fs Section 2 Installation If flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartments electrical junction box NOTE Flexible metal conduit due to its unique con struction is NOT vapor tight along its entire length Seams and joints of the galvanized steel whether used as a liner or for the compartment itself must be lapped and mechanically secured Such seams may be manufactured welded bolted riveted or screwed Manufactured lock seams are shown in Figure 2 6 Installer constructed compartments typically utilize a standard lap joint Figure 2 6 Types of Lock Seams MT ACME LOCK FOLD LOCKED STANDING OFF SET DOUBLE LOCK DOUBLE SEAM E Aa m _ GORDON SEAM LOCK SEAM STANDARD LAP JOINT After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material See Section 2 2 3 A DX A Do not install any flammable material directly A above or around the compartment Heat transferred through the compartment structure may be sufficient to ignite char or discolor seat cushions fiberboard and other fl
64. engine s DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine cannot be cranked If you must replace the fuse use only an identical replacement 2 1 4 MAIN BREAKER The main breaker protects the generator s AC output circuit against overload and provides a method of turning OFF the generator s 120 240 volt AC output to the vehicle circuits The PRIMEPACT 50 has one 20 amp breaker and one 30 amp breaker NOTE If the PRIMEPACT 50 has been reconnected for dual voltage AC output 120 240 volts you can install line breakers having an amperage rating that is different than that stated in Section 1 4 Page 5 The replacement line breakers consist of two separate breakers one 20 amp and one 30 amp with a connecting piece between the breaker handles so that both breakers will operate at the same time If the unit is reconnected for dual voltage it is no longer RVIA listed 2 2 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel Figure 2 2 is available that allows you to start and stop the gener ator engine conveniently from inside the vehicle The remote panel includes a Start Stop switch hourme ter generator run lamp and a wire harness Figure 2 2 Optional Remote Panel Models 004057 and 004184 Generac Power Systems Inc 7 Section 2 Operation PRIMEPACT 50 Recreational Vehicle Generator
65. even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued Inspect the generator regularly and contact your nearest Generac Authorized Service Dealer immedi ately for parts needing repair or replacement Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental start up Disconnect the cable from the bat tery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc ZA ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid 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 you must work around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle
66. g to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsi ble f
67. ghtest spark can ignite it and cause and explosion Only competent qualified people should be allowed to install test adjust or ser vice an LP gas fuel system Install the optional fuel system in compliance with applicable codes standards and regulations After the installation do not do anything that might ren der the system in noncompliance with applica ble codes and standards The LP powered range of generators are fitted with a nonadjustable factory set system These systems are tamper proof to meet 1997 California Air Resources Board requirements for engine emission 2 5 1 PARTS NOT INCLUDED IN FUEL SYSTEM The propane fuel system does NOT include such items as a gas tank b gas piping c fittings d valves and e primary regulator used to store the gaseous fuel and deliver it to the gaseous fuel sole noid Figure 2 15 Page 29 A Dd A Use only approved components in the fuel sup 3 ply system All components must be properly installed in accordance with applicable codes Improper installation or use of unauthorized components may result in fire or an explosion Follow approved methods to test the system for leaks No leakage is permitted Do not allow fuel vapors to enter the vehicle interior Section 2 Installation INSTALLATION PRIMEPACT 50 Recreational Vehicle Generator Figure 2 15 Typical Propane Gas Fuel System CARBURETOR REGULATOR LOCKOFF SOLENOID
68. gt C LII 2 mo No va 5 a Qu Generac Power Systems Inc 21 INSTALLATION Section 2 Installation PRIMEPACT 50 Recreational Vehicle Generator 5 2 1 LOCATION AND SUPPORT 2 1 1 GENERATOR LOCATION 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 factory equipped with an area for the generator set Some vehicles may even have a generator compartment provided by the vehicle manufacturer Plan the generator location based on the following The generator set must be installed on a frame work that is part of the recreational vehicle as out lined in Section 2 1 2 The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from under neath the supporting framework The location must provide easy access to frequent ly serviced components such as filters oil drains spark plugs and other common maintenance parts The location must provide sufficient room to allow minimum clearances as outlined in Section 2 2 If sound insulation is to be used on the compartment walls and ceiling the minimum recommended applies to the space between the generator and such insulation The location
69. gure 2 8 INSOLATION MATERIAL Engine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts See Section 2 1 4 Page 23 DAA A Fuel lines and exhaust piping must not pene trate into the vehicle living area PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION Figure 2 8 Compartment Floor Cutout 586 23 1 1 r 32 564 22 27 Y 913 MOUNTING HOLES 5 85 3 4 863 ROS Ima 85 B3 117 4 67 i 7 da 13 87 ee 178 7 1 TYP m S0 Ue 480 18 973 N ell 18 34 j Y THIS HOLE IS OPTIONAL FOR MOUNTING GENERATOR 348 13 77 O 642 25 3 THIS IS THE MINIMUM OPENING NEEDED IN THE CUMPARTMENT FLOOR FOR OUTLET AIR Generac Power Systems Inc 25 INSTALLATION Fs Section 2 Installation 2 3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling ventilating and engine combustion be supplied to the generator set Without sufficient air flow the engine generator quickly overheats Such overheating can cause serious operating difficulties and also may cause fire and personal injury The installer must make sure that sufficient air is avail able to the generator for cooling ventilating and com bustion The installer also must provi
70. h Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOX IDE POISONING ARE a inability to think coher ently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weakness and i sleepiness IF YOU EXPERIENCE ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMP TOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired A A A Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installa tion manual Make sure there is ample fresh air when operating the genset in a confined area Section 2 Operation PRIMEPACT 50 Recreational Vehicle Generator d 2 5 STARTING THE GENERATOR NOTE Read the vehicle manufacturer s instructions The owner operator should become familiar with the vehicle in which this generator is installed Differences exist between vehicles For example some vehicles may use a transfer switch to isolate dockside power from the generator while other vehicles may use an isolating receptacle Some vehicles may be equipped with a DC converter which allows the generator to power certain DC
71. han the gen erator s rated wattage capacity Most lighting appliance tool and motor loads indi cate their required watts on their nameplate or data plate For light bulbs simply note the wattage rating of the bulb If a load does not show its rated wattage multiply that load s rated VOLTS times AMPS to obtain WATTS Induction type motors such as those that run the vehicle s furnace fan refrigerator air conditioner etc need about 2 1 2 time more watts of power for starting than for running for a few seconds during motor starting Be sure to allow for this when con necting electrical loads to the generator First fig ure the watts needed to start electric motors in the system To that figure add the running wattages of other items that will be operated by the generator Do not apply heavy electrical loads for the first two or three hours of operation 2 9 PROTECTION SYSTEMS 2 9 LOW OIL PRESSURE SWITCH This switch Figure 2 4 has normally closed N C contacts that are held open by engine oil pressure dur ing cranking and operating Should oil pressure drop below a preset level switch contacts close and the engine automatically shuts down The unit should not be restarted until oil is added 2 9 2 HIGH TEMPERATURE SWITCH This switch Figure 2 4 which has normally open N O contacts is mounted near the oil filter The contacts close if the temperature should exceed approximately 293 F
72. he means provided such as a main circuit breaker or transfer switch 2 Let generator run at no load for a few minutes to stabilize internal engine generator temperatures 3 Place the Start Stop switch in its STOP position 2 7 APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Before applying electrical loads let the generator stabilize and warm up for a minute or two DO NOT overload the generator 2 71 LETTING THE ENGINE STABILIZE The generator supplies correct rated voltage only at the proper governed speed Some electrical appli ances may be extremely sensitive to voltage Incorrect voltages can damage such appliances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when suffi cient power is not available may shorten engine life Never turn ON electrical loads until after the generator engine has started and stabilized at no load 2 8 SUMMER WINTER HEAT RISER SYSTEM Under certain weather conditions it is possible for ice to form in the venturi area of the carburetor This condition can be very dangerous because it can pre vent the governor system from functioning properly which results in a runaway engine The most common weather conditions leading to this problem are temperatures in the range of 25 F to 35 F 4 C to 1 7 C along with high humidity This ice formation also can be attributed to
73. he unit has been properly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s main circuit breakers to their OFF or open position 2 Refer to Part 1 Section 2 5 Starting the Generator Page 8 for cranking and starting instructions The engine may require more cranking for initial starting since the fuel lines have to be primed use of the primer switch will shorten this time 3 Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load See Section 3 4 Run the unit at least 30 minutes with loads applied 6 Turn off all electrical loads by setting the genera tor s main circuit breakers to their OFF or open position 7 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine NOTE The generator set was thoroughly tested and adjusted at the factory before shipping No addi tional adjustment should be necessary Only qual ified service technicians who have been trained should perform adjustments outlined in this man ual 3 4 TESTING UNDER LOAD Ap
74. hicle electrical circuits from being connected to two different power supplies at the same time such as generator and dockside power Conductors must be rated 221 F 105 C or must be of a larger conductor size 2 75 GENERATOR AC CONNECTIONS Generator AC output leads T1 red T2 white and T3 black come out of the generator as shown in Figure 2 17 Leads T1 red and black are hot while T2 white is the grounded neutral lead There is also a green lead that connects to ground in the junction box of the recreational vehicle Figure 2 17 Generator AC Output Leads 32 Generac Power Systems Inc PRIMEPACT 50 Recreational Vehicle Generator Line T1 red to T2 white is protected against over load by a 30 amp circuit breaker CB1 Use this line to neutral connection separately to operate 120 volt single phase 60 Hertz AC loads requiring up to 3 600 watts 3 6 kW of power Line T3 black to T2 white also is protected against overload by a 20 amp circuit breaker CB2 Use this line to neutral connection sep arately to operate similar loads However be sure the total unit load does not exceed the maximum rating of the generator The neutral line T2 white on all units is a grounded neutral caution Ak A Do NOT connect electrical loads in excess of any circuit breaker rating or you will develop prob lems with circuit breaker tripping which causes a loss of AC output
75. ice Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a prob lem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursua
76. ilable at the time of publi cation Every effort has been expended to be sure that such data is both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time without prior notice DX A A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators 18 Generac Power Systems Inc GENERAL HAZARDS For safety reasons Generac recommends that the installation initial startup and mainte nance of this equipment is carried out by a Generac Authorized Service Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust sys tem must be installed properly in strict compli ance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in noncompli ance with such codes and standards The genera tor c
77. l stator AC power windings These two stator windings supply electrical power to customer electrical loads by means of a dual two wire connection system Note however that the neutral is grounded The generator may have been installed so that it pow ers 120 volt AC loads Figure 1 1 It can be wired to connect both 120 and or 240 volt AC electrical loads This procedure should be done by a Generac Authorized Service Dealer or other qualified installer Figure 1 1 Connections for 120 Volts Only STATOR POWER WINDINGS GROUNDED NEUTRAL 1 5 SPECIFICATIONS 1 5 1 FUEL REQUIREMENTS The PRIMEPACT series generator is equipped with a gasoline fuel system Depending on the installation the generator may have either a separate fuel tank or it may share the vehicle engine s fuel tank NOTE Some installations using a shared fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine s pickup tube Such an arrangement causes the generator engine to run out of gas while adequate fuel for the vehicle remains in the tank To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator Leaded REG ULAR grade gasoline is an acceptable substitute NOTE Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits Generac Power Systems Inc 5 GENERAL INFORMATION caution A A Generac does not
78. laims against Generac based on negligence This warranty gives you specific legal rights You also may have other rights that vary from state to state GENERAC POWER SYSTEMIS INC P O BOX 297 WHITEWATER WI 53190 Part No OD7431 Revision A 08 06 02 Printed in U S A
79. lighting and other DC loads To start the generator from either the generator con trol panel or from the optional remote panel proceed as follows 1 Turn OFF electrical loads using the means pro vided in your vehicle such as a main line circuit breaker or transfer switch 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 cir cuit breaker Electrical load circuits will be turned ON after the generator has started stabi lized and warmed up 2 If you have not started the engine in more than two weeks press the Fuel Pump Primer switch and hold it for about 10 to 15 seconds to prime the fuel system However if the engine is warm skip Step 2 3 Hold the engine Start Stop switch in the START position to crank the engine Release the switch when the engine starts caution Ak If the engine does not start after it has been cranking for 15 seconds release the Start Stop switch and try again Holding the switch for longer than 15 seconds can damage the starter motor 4 Let the engine run at no load for a few minutes to stabilize and warm up 5 Turn ON electrical loads using the means provided such as a main circuit breaker or transfer switch 2 6 STOPPING THE GENERATOR Turn OFF all electrical loads using t
80. m Battery 400 Cold cranking Amperes 1 5 6 GENERATOR Rated Maximum Continuous AC Output Gasoline 4 800 Watts 4 8 kW AC Output LP Fuel 4 500 Watts 4 5 kW Rated Voltage sss 120 Volts AC Rated Maximum Continuous AC Current Gasoline ees 40 Amperes AC Current LP Fuel sees 37 5 Amperes Phase nte He D RA teens Single Rotor RPM ee 3 600 Number of Rotor Poles oooonnnccnnnnonooonnccnnnnnnononononnnnncnanonons 2 Engine RPM teinninn eiaeiiai 2 571 Rated AC Frequency eae retenta te tene treten 60 Hz Battery Charge Voltage esses 14 Volts DC Battery Charge Current sess 2 Amperes max Weight Gasol br rp bee De ve ERE 198 Pounds 200 Pounds Length iman cd rtt 25 5 inches 648 mm incienso EEE 18 88 inches 479 mm Height 16 75 inches 425 mm All units are reconnectable to 120 and or 240 volt dual voltage output Units are no longer listed per RVIA ANSI when recon nected for dual voltage output If reconnected for dual voltage the ampere rating for 240 volts is 20 AC amperes for model PRIMEPACT 50 02010 2 and 18 8 AC amperes for model PRIMEPACT 50 LP 04164 2 1 5 7
81. moval and reinstallation are the owner s responsibility Rotor Stator Computer Control Board if applicable with regard to the generator Cylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Manifolds Generac RV generators manufactured prior to December 31 1997 DO NOT have a transferable warranty Generac RV gen erators manufactured after January 1 1998 have a transferable warranty to the second owner ONLY for the remainder of the three year limited warranty Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any warranty service All warranty expense allowances are subject to the conditions defined in Generac s SUPER SERVICE INFORMATION MANUAL THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels or oils Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the GN Series engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm h
82. must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense 2 1 2 GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding The metal framework on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams These beams should consist of a 1 1 2 inch square 11 gauge steel tubing OR b 1 1 2 inch 11 gauge angle iron A typical sup porting frame with horizontal support tubing is shown in Figure 2 1 The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the generator below the horizontal support tubing by means of suit able structurally sound metal framework The fol lowing general rules apply Vehicle construction MUST be capable of support ing the weight of the generator ee Generac Power Systems Inc Whether the generator is mounted above the hori zontal support tubing or suspended below the tub ing the supporting frame used must be structural ly sound If the generator cannot be bolted directly to the supporting frame or support tubing consider using additional tubing angle brackets or other supports to give the supporting frame suf ficient strength Figure 2 1 Typical Horizontal Support Frame p
83. n eese 11 Section 3 Maintenance 12 3 1 Checking the Engine Oil Level 12 3 2 Changing the Engine Oil and or Oil Filter 12 3 3 Maintaining the Engine Air Cleaner 13 3 4 Clean Air Intake reet Reeve aes 13 3 5 Checking the Engine Spark 13 3 6 Fuel Filter Gasoline Only 14 3 7 Spark Arrestor Muffler 14 3 8 Cleaning the Generator oooooooooconccncccnnnnnninnnnnononinos 14 3 9 Battery 14 3 10 Major Service Manual eene 15 3 11 Drive ORE 15 3 12 Exercising the Generator 15 3 13 Out of Service Procedure 16 Table of Contents Ex F CONTENTS Part Installation Instructions Safety Rules emm 18 Section 1 General Information 20 1 1 Purpose and Scope of the Manual 20 1 2 Safety exe tn EE 20 1 3 Standards Booklets 2 0 0 0 20 1 4 Equipment Description eee eee ee eee 20 15 Generator Engine Operating Speed 20 16 Generator AC Connection System 2
84. n 6 Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys Model 02010 2 Drawing No D1759 A DESCRIPTION BASE MOUNTING GROUND CABLE MOUNT RUBBER CAPSCREW HEX HD 3 8 16 X 1 2 LOCK WASHER 3 8 LOCK WASHER M8 SKID RUBBER MOUNT SAFETY BOLT 5 16 18 X 3 1 2 NUT HEX 5 16 18 NUT FLANGED LOCK M8 1 25 CAPSCR HEX HD M8 1 25 X 60MM SPRING BELT TENSION WASHER SPRING CNTR SLIDE NYLON SUPPORT NYLON SLIDE MANIFOLD EXHAUST GASKET EXHAUST MANIFOLD SOCKET HD CAPSCR M8 1 25 X 20 LG GASKET COLLECTOR PAN SKID RUBBER MOUNT PULLEY ENGINE PULLEY ALT BELT POLY V 4L 40 WASHER PULLEY RETAINER CAPSCR SOCKET HD 3 8 24 X 1 GRADE 5 CAPSCR HEX HD M8 1 25 X 20 CAPSCR HEX HD 3 8 24 X 2 CRIMPTITE 10 24 X 1 2 BRACKET FUEL PUMP HOUSING BLOWER CRIMTITE 8 18 X 1 4 SCREEN SLIDE PAN GASKET BLOWER PAN SPRING GENERATOR SET MT PART NO QTY C4006 4456 90475 87769 7695 6922 79246 22145 38150 A8010A 71643 75237 D1741A 90859 30340 A8594 A1658 23152 A8475 45756 22131 48031 C 81105 66849 D1227 A8010 C2824 131 74260 24114 D1741 22152 22158 A8531 A8407 22473 A A Pp 2 1 ro Ce viia DESCRIPTION CABLE BATTERY 3 8 SPECIAL LOCK WASHER FUEL PUMP FUEL FILTER FITTING 1 8 PIPE TO 1 4 TUBE
85. nking amperes NOTE If the battery is to be used to power other vehicle accessories as well as start the generator you may need a battery with a larger capacity 2 8 2 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes starting problems For the best cold weather starting the voltage drop between battery terminals and the gen erator connection point should not exceed 0 12 volts per 100 amperes of cranking current PRIMEPACT generators are rated at about 100 DC amperes of cranking current Select battery cables based on a cable length and b prevailing ambient temperatures Generally the longer the cable and the colder the weather the larger the cable size must be as shown in the chart CABLE LENGTH in Feet meters CABLE SIZE O to 10 0 to 3 2 11 to 15 3 4 to 4 5 0 16 to 20 4 5 to 6 For warm weather use No 2 cable up to 20 feet 2 8 3 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or to the lug on the starter contactor Figure 2 20 NOTE Check to be sure the battery cable boot for the starter cable has been installed 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connection Figure 2 20 3 Connect cables so the connectors are clean and tight Generac
86. ns Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system Keep the extinguisher properly charged and be familiar with its use If you have any question per taining to fire extinguishers consult your local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline Fuel lines must be properly installed and fastened and free of leaks There must be no possibility of gasoline vapors entering the vehi cle interior You are required to install an approved flexible nonconductive fuel line between the generator fuel connection point and rigid fuel lines If the generator is equipped with a liquid propane LP
87. nt to California and federal law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty ser vice evidence must be presented showing the date of the sale to the original purchaser owner The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and or transportation of the product to from the inspection or repair facilities The purchaser owner also shall be responsible for any and or all damages or losses incurred while the engine is being transported shipped for inspection or warranty repairs If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 56 Generac Power Systems Inc Section 7 Warranty PRIMEPA
88. o breakers should not exceed 5 500 watts NOTE Do NOT connect loads in excess of circuit breaker ratings Section 1 General Information PRIMEPACT 50 Recreational Vehicle Generator INFORMATION GENERAL Figure 1 2 Major Features and Dimensions z 2 z 5 E o 2 z 3 a gt E 5 z 5 a EP a z 00 a HOO 4 6 a i LI AN a 5 1 D Q e S B o HAN Qu 4 ul ul E UJ a o oro o bi c n Z 4 3 a E z gt a x o d o gt e 5 c a p lt a st gt LJ wh A o Ze Y Fu N gt 5 ot az U 4 eu uz mm Sa Fi P LJ LJ Y T Io i 2 Aas 2 2 1 ca F Z fll 8 lt HY N 2 Z Co CY O HB NA oO uw Bl LJ c E JE S U
89. o not have sharp edges Install an approved length of flexible hose between the gaseous fuel solenoid valve and rigid fuel sup ply lines The flexible line must be nonmetallic nonorganic and nonconductive It must be approved for use with LP gas 2 5 EXCESS FLOW VALVE LP gas tanks should have an excess flow valve according to NFPA 501C Paragraph 3 4 4 This valve and the gas lines must be carefully sized so the valve will close when a fuel line is severed or broken Consult the Natural LP Gas Association for informa tion and limitations of excess flow valves Manual shutoff valves on the supply tank and else where in the system must be fully open when operat ing the generator The excess flow valve functions properly only if all valves are fully open 2 5 8 LEAKAGE TESTS Do not place the generator into service until you have properly tested the gas system for leaks To test the system you need a separate source of 12 volts DC to open the gaseous fuel solenoid valve 30 Generac Power Systems Inc The leak test must comply fully with NFPA Paragraph 318 connections hoses valve regula tors fittings and other fuel system parts must be tested under gas or air pressure of not less than 90 psi 620 kPa while using soap and water or an equivalent solution to check for leaks Other approved methods of testing for leaks may be used if appropriate DO NOT USE ANY FLAME TO TEST FOR LEAKS A
90. odel 02010 2 For the PRIMEPACT 50LP model 04164 2 the loads can require up to 4 500 watts 4 5 kW of power but can not exceed 37 5 amperes of current at 120 volts or 18 8 amperes at 240 volts cauroN Ak Do not overload the generator Some installa tions may require that electrical loads be alter nated to avoid overloading Applying excessive ly high electrical loads may damage the genera tor and may shorten its life Add up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one time This total should not be greater than the wattage capacity of the generator If an electrical device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of cur rent for starting than for continuous operation 1 3 SAFETY Before attempting to use the generator set carefully read the Safety Rules section of this manual Comply strictly with these rules to prevent accidents and damage to equipment and or property We sug gest copying and posting the Safety Rules in poten tial hazard areas of the vehicle Stress safety to all operators and potential operators of this equipment Section 1 General Information PRIMEPACT 50 Recreational Vehicle Generator GENERAL INFORMATION 1 4 GENERATOR AC CONNECTION SYSTEM This generator set is equipped with dua
91. odes stan dards and regulations The following general rules apply to rigid fuel lines Rigid lines should be of annealed seamless drawn aluminum or steel Lines and fittings must comply with SAE J512E Standard Automotive Fittings or with ANSI B126 26 latest edition Route the fuel line so that at least 2 inches 51 mm of clearance is maintained between the line and any exhaust system parts Do not attach electrical wiring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so if they leak fuel does not drip onto any electrical or exhaust system parts Use nonferrous metal straps without sharp edges to secure fuel lines 28 Generac Power Systems Inc PRIMEPACT 50 Recreational Vehicle Generator 2 4 2 2 Flexible Fuel Line Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines This prevents breaking of the line caused by vibration shifting settling or movement The follow ing rules apply The flexible hose must comply with SAE J30B Standard for Fuel and Oil Hose It must be approved for use with gasoline The hose should be at least 6 inches 152 mm longer than is needed to prevent the hose from rupturing if the generator shifts or settles 2 5 LP GAS FUEL SYSTEM A EXE A A LP gas is highly EXPLOSIVE The gas is heavier 3 than air and tends to settle in low areas Even the sli
92. of these generators OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safe ty checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Authorized Service Dealer Normal maintenance ser vice and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum See your Generac Authorized Service Dealer for service aids and acces sories HOW TO OBTAIN SERVICE When your generator requires servicing or repairs simply contact a Generac Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all of your service needs When contacting a Generac Authorized Service Dealer or the factory about parts and service always supply the complete model number and serial number of your unit as given on its data decal which is located on your generator Model No Serial No AUTHORIZED SERVICE DEALER LOCATION To locate the GENERAC AUTHORIZED SERVICE DEALER nearest you please call this number 1 800 333 1322 ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED
93. ompartment must be completely vapor sealed from the vehicle interior There must be no possi bility of exhaust fumes entering the vehicle interi or Never operate this equipment with a leaking or defective exhaust system Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or per mit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental start up Disconnect the cable from the bat tery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc Never insert any
94. or diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the purchaser owner Such use shall not reduce Generac s ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 2 Air Induction System including 1 1 Gasoline carburetor assembly and its a Intake pipe manifold internal components if so equipped b Air cleaner a Fuel filter if so equipped 3 Ignition System including b Carburetor gaskets a Spark plug
95. ply electrical loads equal to about 75 to 100 per cent of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling air flow is available You must not allow the unit to over heat during prolonged operation NOTE The generator engine is equipped with a high tem perature switch The switch has normally closed N C contacts When the engine temperature is too high switch contacts close and the engine shuts down automatically GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLING Generac Power Systems Inc 35 2 POST CED Section 3 Post installation Start up Adjustments INSTALLATION START UP ADJUSTMENTS 3 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT Q Generator is properly located Q Generator is properly supported Q Generator is properly restrained GENERATOR COMPARTMENT Q Compartment construction is proper Q Holes Openings are vapor sealed Q Compartment size is correct Q Compartment is vapor sealed Sound insulation is correct Floor cutouts are properly completed COOLING AND VENTILATING AIR A Airflow is adequate Air inlet opening is correct Q Compensate for restrictions A Check that installation has been tested GASOLINE FUEL SYSTEM Fuel tank complies with all applicable codes A
96. r sources to the vehicle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operating Failure to isolate the vehicle circuits from the dockside power supply when the genera tor is running may result in damage to the genera tor or serious injury or death to dockside utility power workers due to backfeed of electrical ener gy In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendatio
97. recommend using any gasoline containing alcohol such as gasohol If you use any gasoline containing alcohol it must not contain more than 10 percent ethanol and it must be removed from the generator during storage Do NOT use any gasoline containing methanol If you use gasoline with alcohol inspect more frequently for fuel leaks and other abnormalities 1 5 2 OPTIONAL PROPANE FUEL SYSTEM The PRIMEPACT 50LP series generator is equipped with a liquid propane LP gas fuel system LP gas is usually supplied as a liquid in pressure tanks PRIMEPACT series generators require a vapor with drawal type fuel system This type of gaseous fuel sys tem uses the vapors forming above the liquid fuel in the storage tank Air temperature around the storage tank must be high enough to sustain adequate fuel vaporization In colder climates you may need to use an independent heat source to be sure the fuel suffi ciently vaporizes in the storage tank LP gas may consist of propane butane or a mixture of the two gases Propane vaporizes at temperatures as low as 20 F 29 C but butane returns to its liq uid state when the temperature drops below about 32 F 0 C For that reason a higher ratio of propane is desired in the gas mixture when tempera tures drop below freezing 1 5 3 FUEL CONSUMPTION Model No Load 1 2 Load Full Load PRIMEPACT 50 0 32 0 46 0 76 02010 2 PRIMEPACT 50 LP 0 47 17 05
98. recreational vehicle the mounting base has open ings for either bottom out or side out exhaust systems Use the cover plate provided with the generator to cover the opening you do NOT use 2 6 3 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any com bustible material such as wood felt cotton organic fibers or other like material If you cannot maintain the 3 inch 76 mm clearance locate insulate or shield the exhaust part s so that the temperature of any combustible material is not raised more than 117 F 65 C above the ambient air temperature Extend the exhaust system at least 1 inch 25 mm past the outer edge of the vehicle Do not terminate the exhaust system under the vehicle Terminate the exhaust tailpipe such that exhaust gases will not be drawn back into the generator compartment and recirculated INSTALLATION Section 2 Installation If there is any possibility of the tailpipe or muffler being damaged protect these damage prone areas by means of a protective device such as a skid bar Install the generator exhaust system according to safe automotive practices Use enough exhaust system hangers to prevent any part of the system from being dislocated Use exhaust system parts recommended by Generac Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person s installing
99. rking carbon monoxide detector The exhaust system must be installed in accordance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Thus the exhaust system must be installed properly in strict com pliance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in noncompli ance with such codes and standards The genera tor compartment must be completely vapor sealed from the vehicle interior There must be no possi bility of exhaust fumes entering the vehicle interi or Never operate this equipment with a leaking or defective exhaust system Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating AFETY RULE Safety Rules PRIMEPACT 50 Recreational Vehicle Generator Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or per mit
100. rmit only responsible and capable persons to operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot A during operation Exercise care near running generators 2 Generac Power Systems Inc GENERAL HAZARDS For safety reasons Generac recommends that the installation initial start up and mainte nance of this equipment is carried out by a Generac Authorized Service Dealer The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentra tions can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISON ING ARE a inability to think coherently b nau sea c vomiting d twitching muscles e throb bing temples f dizziness g headaches h weakness and i sleepiness IF YOU EXPERI ENCE ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PER SIST GET MEDICAL HELP Shut down the gener ator and do not operate it until it has been inspect ed and repaired Never sleep in the vehicle while the genset is run ning unless the vehicle has a wo
101. roperly NAME OF INSTALLER SIGNATURE OF INSTALLER 36 Generac Power Systems Inc Section 4 Troubleshooting TROUBLESHOOTING PRIMEPACT 50 Recreational Vehicle Generator TROUBLESHOOTING GUIDE PROBLEM The engine will not crank CAUSE 1 Fuse blown CORRECTION 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 starter contactor 4 Replace contactor 5 Defective starter motor 5 Replace starter motor 6 Low or defective battery 6 Charge or replace battery The engine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel pump 2 Replace fuel pump 3 Open 14 wire from 3 Check connections and engine control board insulation of 14 wires 4 Flooded engine 4 Wait 5 10 minutes before trying 5 Defective spark plug s 5 Clean re gap or replace plug s 6 Fuelline shut off closed 6 Open fuel line shut off 7 Plugged fuel filter 7 Clean or replace fuel filter The engine starts hard l Air cleaner 1 Check clean or replace air cleaner and runs rough plugged or damaged 2 Defective spark plug s 2 Clean re gap or replace plug s The engine starts but shuts 1 Engine oil level low 1 Check oil and add oil as needed down when the Start Stop 2 Defective low oil 2 Replace pressure switch switch is released pressure s
102. s are visible past the retaining lock nuts Refer to Section 2 2 for the location of the generator mounting holes Figure 2 3 Typical Generator Restraint METAL LINED Y INCHTHICK BASE PLYWOOD TUBULAR METAL SUPPORT FRAME GRADE 5 BOLTS METAL LINED VEHICLE BOTTOM CHASSIS 2 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a gen erator or inside a compartment that the installer con structs the compartment MUST meet certain specifi cations as outlined in the following sections 2 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a mini mum clearance of 1 2 inch 13 mm on the front and top 1 inch 25 mm on the sides and 1 2 inch 13 mm from the back for air circulation AFTER the compartment has been lined with metal and sound insulation Figure 2 4 NOTE Refer to Figure 1 2 Major Features and Dimensions on Page 21 Figure 2 4 Clearances Plywood Compartment 11 2 Clearance on Top 1 Clearance in Back AS 1 Each Side Insulation INSTALLATION he Section 2 Installation 2 2 2 COMPARTMENT CONSTRUCTION The generator compartment should be either con structed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative
103. se 75 hours can cause improper seating of engine pis ton rings resulting in blowby and high oil con sumption After operating the unit for 25 hours complete the tasks recommended under Section 2 10 2 2 10 2 25 HOUR CHECK UP After the 25 hour break in period contact a Generac Authorized Service Dealer for the following mainte nance The vehicle owner is responsible for any charges Change the engine crankcase oil and oil filter Check the oil level Inspect the cooling and ventilation openings Check the engine carburetor adjustments Check the engine ignition system Inspect the entire electrical system Inspect the engine exhaust system 2 10 3 ATTENTION REQUIRED AFTER SUBMERSION If the recreational vehicle generator has been sub merged in water it MUST NOT be started and oper ated Following any submersion in water have a Generac Authorized Service Dealer thoroughly clean and dry the generator 2 10 4 OPERATION IN HIGH GRASS OR BRUSH Never operate the generator while the vehicle is parked over high grass weeds brush leaves or any other combustible substance Such materials can ignite and burn from the heat of the exhaust system The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down 2 10 5 EFFECTS OF MOISTURE AND DIRT Keep the generator set as clean and dry as possible Protect the unit against excessive
104. starting Refer to Section 1 5 4 Page 6 and Sections 3 1 and 3 2 Page 12 for oil ser vicing procedures and recommendations cauroN Ak Any attempt to crank or start the engine before you have properly serviced it with the recom mended oil may result in an engine failure Generac Power Systems Inc 2 4 3 FUEL SUPPLY The engine must have an adequate supply of proper fuel to operate Before starting it check that sufficient fuel is available NOTE Depending on the installation the generator may have either a separate fuel tank or it may share the vehicle engine s fuel tank 2 4 4 COOLING AND VENTILATING AIR Air inlet and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation Without sufficient cooling and ventilating airflow the engine generator quickly over heats which causes it to shut down and may damage the generator 2 4 5 ENGINE EXHAUST GAS Before starting the generator engine you should be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals Close windows doors and other openings in the vehi cle that if open might permit exhaust gases to enter the vehicle Dia A A The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concen trations can cause unconsciousness or even deat
105. the gas tank out let or in the supply line from the gas tank The fol lowing rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inch es water column Do NOT exceed 14 inches water column The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommended MINIMUM gas flow rate for all air cooled PRIMEPACT series generators is 67 cubic feet per hour If an existing primary gas regulator does not have a sufficient flow capacity for the generator and other gas appliances in the circuit a install a pri mary regulator with adequate flow rate or b install a separate regulator only and rated at least 67 cubic feet per hour The inlet side of any pri mary regulator that supplies the generator must connect directly to a gas pressure tank Do NOT tee the generator line into a gas circuit feeding other areas 2 5 5 GASEOUS CARBURETION LP gas vapors should be supplied to the secondary regulator inlet at about 11 inches water column pos itive pressure The engine pistons draw air in during the intake stroke Figure 2 16 This air passes through a carburetor venturi which creates a low pressure that is proportional to the quantity of air being pumped The low pressure from the carburetor venturi acts on the regulator diaphragm to pull the diaphragm toward the source of
106. the load being applied during these weather conditions Generators running with no load or light loads applied usually have the most problems The Summer Winter Lever Figure 2 3 should be in the WINTER position for ambient temperatures below 40 F 4 4 C and in the SUMMER position for ambient temperatures above 40 F 4 4 C Figure 2 3 Heat Riser System WINTER POSITION SUMMER POSITION 2 When the heat riser is in the SUMMER down posi tion Figure 2 2 air is drawn into the air cleaner from the upper intake tube Generac Power Systems Inc 9 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 is positioned to draw the heated air near the exhaust manifold To prevent carburetor icing the owner operator should physically position the heat riser to the prop er position dependent on the temperature 2 8 1 DO NOT OVERLOAD THE GENERATOR You can read the rated wattage amperage capacity of your generator on the generator data decal see Section 1 1 on Page 4 Applying electrical loads in excess of the unit s rated capacity will cause the engine generator to automati cally shut down To avoid overloading add up the wattage of all con nected electrical lighting appliance tool and motor loads This total should not be greater t
107. the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility All trans portation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac generators sold and rated for Recreational Vehicle RV applications as Generac has defined Recreational Vehicle generator applications This warranty is effective only upon Generac s receipt from the original purchaser owner of a completed Warranty Registration Card This card is the only valid registration identification and must be presented at time of request for warranty service Claims will not be accepted without presentation of the Warranty Registration Card The factory recommends exercising the unit one half hour every season WARRANTY SCHEDULE COMMERCIAL APPLICATIONS YEAR ONE 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components Transfer System All components WARRANTY SCHEDULE CONSUMER PERSONAL APPLICATIONS YEARS ONE AND TWO 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components Transfer System All components YEAR Three 100 one hundred percent only on selected part s and labor listed Any labor and part s not listed and re
108. tion 1 General Information PRIMEPACT 50 Recreational Vehicle Generator GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal Model Number 1 3 kW Rating 2 Serial Number 4 Rated Voltage L X No y gt que ___2 FSD S m ANN J 2 y el SS E ENE 3 1 SZ 1 3 16 1 aa GEM A 13 12 14 11 4 Generac Power Systems Inc Model 02010 2 PRIMEPACT 50 l 2 3 4 A p IMS e 10 11 12 13 14 15 16 17 18 Generator Air Intake Engine Start Stop Switch Fuse Optional Remote Panel Receptacle behind control panel Generator AC Output Leads behind control panel Fuel Primer Switch Circuit Breaker Circuit Breaker Starter Contactor Fuel Inlet Fuel Pump Fuel Filter Oil Filter Oil Drain Cap Oil Dipstick Data Decal Oil Fill Spark Plug Model 04164 2 PRIMEPACT 50LP 2 4 Generator Air Intake Engine Start Stop Switch Fuse Optional Remote
109. tion with the maintenance operations found in Part I of this manual Model 004057 includes the remote panel and a 10 foot long 4 wire harness Model 004184 includes the remote panel and a 30 foot long 4 wire harness 3 1 POST INSTALLATION TESTS The air cooled generator set was factory tested and adjusted You should not be required to adjust the unit any further except under special circumstances A WARNING amp A Do not make any unnecessary adjustments Factory settings are correct for most applica tions When making adjustments however be careful to avoid overspeeding the engine 3 2 BEFORE INITIAL START UP Before starting complete the following 1 Check the engine crankcase oil level and if nec essary fill to the dipstick FULL mark cross hatched area with the recommended oil Do not fill above the FULL mark 2 Check the fuel supply Gas fuel lines must have been properly purged and leak tested in accor dance with applicable fuel codes All fuel shutoff valves in the fuel supply lines must be open A Dia A A If a liquid propane LP gas fuel system has been installed it must be properly tested for leaks before operating the system in compli ance with ANSI A119 2 NFPA 501C No leakage is permitted You must be sure no gasoline fuel vapors enter the vehicle interior 2 POST c INSTALLATION START UP ADJUSTMENTS 3 3 INITIAL START When you are absolutely certain that t
110. tional vehicle A Safety should be stressed to all operators and potential operators of this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm 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 accidents are caused by failing to follow simple and fundamental rules or precautions Generac cannot possibly anticipate every possible cir cumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If you use a procedure work method or operating tech nique Generac does not specifically recommend you must satisfy yourself that it is safe for you and others You also must make sure the procedure work method or operating technique that you choose does not render the generator unsafe A DX A A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Pe
111. tool or other object through open ings in the generator interior even if the unit is not running You might seriously injure yourself or damage the equipment SAFETY RULES Safety Rules PRIMEPACT 50 Recreational Vehicle Generator ZA ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid 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 you must work around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mount ing to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum If the vehicle electrical circuits can be powered by any other source of electricity such as a dock side power receptacle there must be no possibil ity of connecting the different powe
112. uses excessive back pressure on the genera tor engine Also water from one engine can damage the other engine PRIMEPACT 50 Recreational Vehicle Generator 2 6 1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U S Forest Service Use only mufflers and parts approved by Generac 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 for any dam age injury or warranty expense that might be caused by such unapproved installation or modification Failure to provide and maintain a spark arrestor may be in violation of the law If this generator is used on any forest covered brush covered or grass covered unimproved land you must provide a spark arrestor The vehicle owner or operator must maintain this device in good condition In the state of California the preceding is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands 2 6 2 TYPE OF EXHAUST SYSTEM Two types of exhaust systems for PRIMEPACT series generators are available from Generac They include the following Out the bottom exhaust system dimensions are 15 16 O D model 9742 Out the side exhaust system dimensions are 1 1 4 O D 18 gauge model 4172 NOTE No matter what type of exhaust kit best fits your
113. ust compensate for this by making the actual air opening proportion ately larger See Section 2 3 3 Page 27 Figure 2 10 Air Inlet in Compartment Door X XX de XK XS 0000 d 0 e S xx Xx AA OOK SERS rns SREB RR KKK Y e M OO ARAS 900000090 AS 00 t 100 SQUARE INCHES UNRESTRICTED MINIMUM OPENINGS COON eam XX Xo SS XX e A XK KK 00 xx xx e 5000 i MM AR M aes 595 lt 95 eo cee SS ES lt gt 55 SS M SOI A Xx S o 0 n OSI xXx i NN XX NOTE Be sure to meet the minimum clearances illustrat ed in Figure 2 4 Page 23 When the unit is installed on a suspended mounting system one of several different methods of supplying airflow may be used as follows Provide a door in the vehicle skirt having an air inlet opening Figure 2 11 Figure 2 11 Suspended Mount Inlet Door Using ductwork Figure 2 12 Page 27 The installer must be sure air is available to the top of the generator since air inlets are located at the top
114. witch 3 Defective high temperature 3 Replace temperature switch switch 4 Defective engine control board 4 Replace control board 5 Overheated engine 5 Check that the airflow openings are adequate The Start Stop switch is 1 Defective Start Stop switch 1 Replace switch set to Stop but the engine 2 Open Disconnected 18 wire 2 Reconnect or close wire continues to run between Start Stop switch and engine control board 3 Open Disconnected 0 wire 3 Reconnect or close wire between Start Stop switch and engine control board 4 Defective engine control board 4 Replace control board There is no AC output from 1 Main line circuit breaker open 1 Reset circuit breaker the generator to ON or closed 2 Fault with vehicle circuit 2 Reset and replace if necessary breaker and or fuses Transfer switch set to NORMAL 3 Set switch to GENERATOR 4 Start switch not held long 4 Stop then restart the engine enough to flash the field Hold Start switch for at least 2 seconds 5 Generator internal failure 5 Contact a Generac Authorized Service Dealer Generac Power Systems Inc 37 Section 5 Electrical Data PRIMEPACT 50 Recreational Vehicle Generator ELECTRICAL E DAA gt Electrical Schematic and Wiring Diagram Drawing No D1754 A BATTERY I II 5 13 RED 16 CH 16 Ji 1 gt 56 gt 90 cs 0 J1 3 gt

Generac 02010-2, 04164-2 Portable Generator User Manual

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