Generac 02010-1 User Manual

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Owner’s Manual and
Installation Instructions
Air-cooled Recreational
Vehicle Generators
• Model: 02010-1 PRIMEPACT 50
•Model: 04164-1 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:
DANGER
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.
--------
Ik CAUTION M.-------------
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
statements 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
A
safety and/or property of you and others.
This symbol points out potential explosion hazard.
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 generator model numbers 02010-0 and 04164-0. In addition, the lat ter portion of this manual contains information nec essary for the proper installation 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.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
A
Generac" Power Systems, Inc.
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 AT THIS NUMBER.

Table of Contents

PRIMEPACT 50 Recreational Vehicle Generator
Part I - Owner's Manual
Introduction
Read This Manual Thoroughly .........................................IFC
Contents Operation and Maintenance
How to Obtain Service........................................................IFC
Authorized Service Dealer Locator Number
Safety Rules......................................................................... 2
Section 1 - General Information
1.1 Generator Identification................................................ 4
1.2 Generator Applicability
1.3 Safety.... 5
1.4 Generator AC Connection System
1.5 Specifications ...................................................................5
Section 2 - Operation
2.1 Generator Control Panel ................................................7
2.2 Optional Remote StarhStop Panel
2.3 Automatic Choke (Gasoline Only)..................................8
2.4 Before Starting the Engine..............................................8
2.5 Starting the Generator
2.6 Stopping the Generator
2.7 Applying Loads to Generator
2.8 Summer.Winter Heat Riser System
2.9 Protection Systems.........................................................10
2.10 Additional Information
Section 3 - Maintenance
3.1 Checking the Engine Oil Level
3.2 Changing the Engine Oil and/or Oil Filter
3.3 Maintaining the Engine Air Cleaner............................13
3.4 Clean Air Intake
3.5 Checking the Engine Spark Plug..................................13
3.6 Fuel Filter (Gasoline Only)
3.7 Spark/Vrrestor Muffler ................................................14
3.8 Cleaning the Generator
3.9 Battery Maintenance
3.10 Major Service Manual ..................................................15
3.11 Drive Belt........................................................................15
3.12 Exercising the Generator
3.13 Out of Service Procedure
........................................
...............................................................................
....Inside Front Cover
.............................................
...................
...........................................
IFC IFC
IFC
4
..................................................
.................................
1.5.1 Fuel Requirements
1.5.2 Optional Propane Fuel System
...........................................
.......................
1.5.3 Fuel Consumption............................................6
1.5.4 Engine Oil Requirements
................................
1.5.5 Engine................................................................6
1.5.6 Generator .........................................................6
.............................................................
2.1.1 Fuel Primer ......................................................7
2.1.2 StarhStop Switch..............................................7
2.1.3 Fuse
..................................................................
2.1.4 Main Breaker....................................................7
.................................
2.3.1 Choke Solenoid.................................................8
2.3.2 Prechoke............................................................8
2.4.1 InstalIatlon8
2.4.2 Engine Lubrication
..........................................
2.4.3 Fuel Supply ......................................................8
2.4.4 Cooling and Ventilating Air
2.4.5 Engine Exhaust Gas
.........................................
...........................
....................................................
...................................................
.........................................
2.7.1 Letting the Engine Stabilize
............................
..............................
2.8.1 Do Not Overload the Generator
2.9.1 Low Oil Pressure Switch
2.9.2 High Temperature Switch
2.9.3 Field Boost
.....................................................
...................
...............................
............................
10
10 10 10
2.9.4 Overvoltage Pr otection.................................11
................................................
11
2.10.1 25-Hour Break-in Period................................11
2.10.2 25-Hour Checkup
2.10.3 Attention Required After Submersion
2.10.4 Operation in High Grass or Brush
2.10.5 Effects of Moisture and Dirt
.............
.........................................
................
.........................
....................................
......................................
.................
........
12
11 11 11 11
12 12
3.3.1 Cleaning the Foam Precleaner .....................13
3.3.2 Cleaning or Replacing the Paper Filter
............................................................
...........................................
................................................
....................................................
........
13 14 14
14
3.9.1 Weekly.............................................................14
3.9.2 Every Six Months...........................................14
..............................................
...............................................
3.13.1 Removal From Service
3.13.2 Return to Service
...........................................
..................................
15 16 16 16
.7
7
13
Part II - Installation Instructions
Safety Rules
Section 1 - General Information....................................20
1.1 Purpose and Scope of the Manual................................20
1.2 Safety............................................................................... 20
1.3 Standards Booklets
1.4 Equipment Description .................................................20
1.5 Generator Engine Operating Speed
1.6 Generator AC Connection System
Section 2 - Installation
5
2.1 Location and Support
5 5
6
2.2 Generator Compartments
6
2.3 Cooling and Ventllatmg Air
7
2.4 Gasoline Fuel System.....................................................27
2.5 LP Gas Fuel System28
8 8
8 8 9 9 9 9
2.6 Exhaust System
2.7 Electrical Connections
2.8 Battery Installation
2.9 Optional Accessories
Section 3 - Post-installation Start-up
3.1 Post Installation Tests ...................................................36
3.2 Before Initial Start-up ...................................................36
3.3 Initial Start .....................................................................36
3.4 Testing Under Load
3.5 Installation Checklist
Appendix 1 - Notes ........
Appendix 2 - Troubleshooting......
Appendix 3 - Electrical Data
Appendix 4 - Exploded Views and Parts Lists.....................44
Appendix 5 - Warranty...............................................
......................................................................
........................................................
.............................
................................
..................................................
....................................................
18
20 20
20
22
22
2.1.1 Generator Location .......................................22
2.1.2 Generator Support ........................................22
2.1.3 Suspended Mounting
.....................................
22
2.1.4 Generator Restraint.......................................23
2.2.1 Compartment Size
.........................................
2.2.2 Compartment Construction
2.2.3 Sound Insulating Materials
......................................
..........................
..........................
23 23 23 24
2.2.4 Acoustics..........................................................24
2.2.5 Compartment Floor Cutouts
.........................................
.......................
25 26
2.3.1 Generator Airflow .........................................26
2.3.2 Cooling Air Inlet Openings
2.3.3 Compensating for Restrictions
2.3.4 Testing the Installation
...........................
.....................
..................................
26 27 27
2.4.1 Fuel Tank........................................................28
2.4.2 Generator Fuel Supply Line
2.4.2.1 Rigid Fuel Lines
.........................
...........................
28 28
2.4.2.2 Flexible Fuel Line.........................28
2.5.1 Parts Not Included in Fuel System
2.5.2 Some Important Considerations
2.5.3 Vapor Withdrawal
2.5.4 Primary Regulator
2.5.5 Gaseous Carburetlon
........................................
.........................................
.....................................
...............
..................
28 29 29 29 29
2.5.6 Fuel Supply Lines ..........................................30
2.5.7 Excess Flow Valve
2.5.8 Leakage Tests
........
30
2.6.1 Mufflers and Spark Arrestors
2.6.2 Type of Exhaust System
2.6.3 Exhaust System Safety
2.7.1 Electrical Junction Box
2.7.2 Wiring
.............................................................
2.7.3 Generator AC Connections
.........................................
................................................
.....................
................................
..................................
....................................................
.................................
..........................
30 30
31 31 31 31 31 32 32
2.7.4 Conduit............................................................32
2.7.5 Isolating Different Power Sources
...............
32
2.7.6 Power Supply Cord .......................................33
2.7.7 Ground Fault Circuit Interrupters
........................................................
2.8.1 Recommended Battery
2.8.2 Battery Cables
................................................
..................................
2.8.3 Battery Cable Connections
..............
............................
33 34 34 34 34
2.8.4 Battery Compartment ...................................34
2.9.1 Remote Panel Models
......................................................
2.9.1.1 Model 9042
2.9.1.2 Model 9043
2.9.2 Remote Panel Cables
Adjustments
.............. ..............................
.......................................................
.....................................................
...........................
.................. .
..........
....................................
..................................
..................................
.....................................
........................
...................41
.............................
34 35 35 35 35
36
36 37
38
.......42
60
Generac® Power Systems, Inc. 1

SAFETY RULES

operation be copied and posted in potential hazard areas of the recreational vehicle. Jk
Safety should be stressed to all operators and potential operators of this equipment.
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Safety Rules PRIMEPACT 50 Recreational Vehicle Generator
SAVE THESE INSTRUCTIONS - The manufacturer suggests that these rules for safe
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.
DANGER
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.
Potentially lethal voltages are generated by
A
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.

m 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 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 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.
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.
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.
Generac® Power Systems, Inc.

Safety Rules

PRIMEPACT 50 Recreational Vehicle Generator
SAFETY RULES
A

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, 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.
A
A

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 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
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.
HAZARDS
A
Generac® Power Systems, Inc.
GENERAL
INFORMATION
Section 1 - General Information
PRIMEPACT 50 Recreational Vehicle Generator
1J GENERATOR IDENTIFICATION
Please record the following information from the generator DATA DECAL or information decal.
1. Model Number
3. kW Rating
_________________________
_____________________________
2. Serial Number
4. Rated Voltage______________________________
____________________________
Model: 02010-0 - PRIMEPACT 50
Generator Air Intake
1.
2.
Engine StartyStop Switch
3.
Fuse Optional Remote Panel
4. Receptacle (behind control panel) Generator AC Output Leads
5. (behind control panel) Fuel Primer Switch
6.
7.
Circuit Breaker Circuit Breaker
8.
Starter Contactor
9. Fuel Inlet
10.
Fuel Pump
11.
Fuel Filter
12.
Oil Filter
13. Oil Drain Cap
14. Oil Dipstick
15.
Data Decal
16.
Oil Fill
17. Spark Plug
18.
Generac* Power Systems, Inc.
Model: 04164-0 - PRIMEPACT 50LP
1.
Generator Air Intake
2.
Engine StartyStop Switch
3.
Fuse
4.
Optional Remote Panel Receptacle (behind control panel)
5.
Generator AC Output Leads (behind control panel) Fuel Primer Switch
6.
7.
Circuit Breaker
8.
Circuit Breaker Starter Contactor
9. Fuel Solenoid
10.
Demand Regulator
11.
Oil Filter
12.
Oil Drain Cap
13.
14.
Oil Dipstick Data Decal
15. Oil Fill
16.
17.
Spark Plug
Section 1 - General Information
PRIMEPACT 50 Recreational Vehicle Generator
GENERAL
INFORMATION

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.
DANGER
For fire safety, the generator must have been
A
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 (model 02010-0). For the PRIMEPACT 50LP (model 04164-0), 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.
--------
Jk CAUTION
Do not overload the generator. Some installa
tions may require that electrical loads be alter
A
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.
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1.4 GENERATOR AC CONNECTION SYSTEM
This generator set is equipped with dual 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
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.
GENERAL
INFORMATION
Section 1 - General Information
PRIMEPACT 50 Recreational Vehicle Generator
-A CAUTION A~
Generac does not recommend using any
A
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
PRIMEPACT 50 (02010-0) PRIMEPACT 50 LP (04164-0)
Gasoline is in gal/h. LP is in gal/h and cf/h.
0.32 0.46
0.47/17.05 0.72/3.06
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 lOW-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.
1/2 Load Full Load
0.76
1.25/45.35
♦ 1.5.5 ENGINE
Type of Engine.........................................GN-410, Single-cylinder
Cooling Method Rated Horsepower Displacement Cylinder Block
Type of Governor ..................................Mechanical, Fixed Speed
Air Cleaner
Starter Ignition System Recommended Spark Plug
Champion .......................................................................RC12YC
AC...........................................................................................R45S
FFam Autolite ............................................................................65
Spark Plug Gap...............................................0.030 inch (76 mm)
Recommended Minimum Battery
............................
...............................................................
________________________________
..............................................................
...............................................
...........................................................................
.............................
...........................
Aluminum w/Cast Iron Sleeve
Paper Element w/Foam Precleaner
12-volt DC Electric
Solid-state w/Flywheel Magneto
..................
400 Cold-cranking
Amperes
Air-cooled
15 @ 4,200 rpm
407cc
♦ 1.5.6 GENERATOR
Rated Maximum Continuous
AC Output (Gasoline)
AC Output (LP Fuel).................................4,500 Watts (4.5 kW)
Rated Voltage ..........................................................120 Volts AC*
Rated Maximum Continuous
AC Current (Gasoline)..........................................40 Amperes**
AC Current (LP FUel) .......................................37.5 Amperes**
Phase........................................................................................Single
Rotor RPM...............................................................................3,600
Number of Rotor Poles...................................................................2
Engine RPM Rated AC Frequency Battery Charge Voltage Battery Charge Current Weight
Gasoline
LP Fuel........................................................................200 Pounds
Length
Width...........................................................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 (02010-0), and 18.8
_
AC amperes for model PRIMEPACT 50 LP (04164-0).
...........................................................................
......................................................................
...........................................................
...............................
.............................................................
...............................................
.....................................
4,800 Watts (4.8 kW)
14 Volts DC
2 Amperes (max)
198 Pounds
25.5 Inches (648 mm)
2,571 60 Hz
♦ 1.5.7 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 C = 125 hours, B=250 hours, and A=500 hours.
For engines of 225 cc or more. Category C=250
hours, B = 500 hours, and A=1000 hours.
Section 2 - Operation
PRIMEPACT 50 Recreational Vehicle Generator
OPERATiON

2.1 GENERATOR CONTROL PANEL

The following features are mounted on the generator control panel (Figure 2.1):
Figure 2.1 - Generator Control Panel
START 1BA BREAKER
♦ 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.
FUSE iVIAirU
FUEL.
PRIMER
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 is available that
allows you to start and stop the generator engine con veniently from Inside the vehicle. The model 9042 remote panel includes a Start/Stop switch and a gen
erator run lamp. You also can order model 9043, a remote panel that
includes a Start/Stop switch, a generator run lamp and an hourmeter. The hourmeter provides a contin uous indication of engine/generator operating time. Use the hourmeter for checking off periodic mainte nance requirements on the unit.
♦ 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 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.
Generac® Power Systems, Inc.
OPERATION

(jO:

Section 2 - Operation
PRIMEPACT 50 Recreational Vehicle Generator
2.3 AUTOMATIC CHOICE
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.
♦ 2.5.2 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.
(gasoline only)
_____________________
___
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 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.
--------
Jk CAUTION
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.
_________________
_________________
A-
________
♦ 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.
_
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.
NOTE:
DANGER
The generator engine gives off DEADLY carbon
A
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 SYS TEM IS LEAKING OR HAS BEEN DAMAGED. SYMP TOMS OF CARBON MONOXIDE POISONING ARE (a) inability to think coherently; (b) vomiting; (c) twitching muscles; (d) throbbing temples; (e) dizzi
_
ness; (f) headaches; (g) weakness; and (h) sleepi ness. IF YOU FEEL ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMP TOMS PERSIST, GET MEDICAL HELP.
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 lighting and other DC loads.
Section 2 - Operation
PRIMEPACT 50 Recreational Vehicle Generator
OPERATION

(jti

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.
-------
-Jk CAUTION Jk
If the engine does not start after it has been
A
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).
-------------
♦ 2.7.1 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 the load being applied during these weather conditions. Generators running with no-load or light loads applied usually have the most problems.
The Summer/Wlnter Lever (Figure 2.2) 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 2.2 - Heat Riser System
WINTER POSITION

2.6 STOPPING THE GENERATOR

1. Turn OFF all electrical loads using the 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.
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. 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.
OPERATION
(ji>
Section 2 - Operation
PRIMEPACT 50 Recreational Vehicle Generator
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 than 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

Figure 2.3 - Low Oil Pressure and
High Temperature Switches
HIGH
♦ 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 2.4). 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.
2.9. LOW OIL PRESSURE SWITCH
This switch (Figure 2.3) 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 2.3), which has normally open
(N.O.) contacts, is mounted near the oil filter. The contacts close if the temperature should exceed approximately 293° F (145° C), initiating an engine shutdown.
1 O Generac* Power Systems, Inc.
Figure 2.4- Field Boost Circuit
CLOSEST TO BEARING
Section 2 - Operation
PRIMEPACT 50 Recreational Vehicle Generator
OPERATION
♦ 2.9.4 OVERVOLTAGE PROTECTION_______________
A solid-state voltage regulator (Figure 2.5) controls
the generator’s AC output voltage. This regulator sup plies an excitation current to the rotor. By regulating the rotor’s excitation current, the strength of its mag netic field is regulated and, in turn, the voltage deliv ered to connected electrical loads is controlled. When the AC frequency is 60 Hertz, voltage is regulated at
120 volts (voltage-to-frequency ratio is 2-to-l).
Figure 2.5 - Solid State Voltage Regulator
I—TO ROTOR CZD—K-t—F (DIRECT CURRENT)
^tiZZFFROH STATOR
-SESSIK8
EXCITATION WINDING (AUERNATING CURRENT)
The voltage regulator also incorporates a “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 25­hour 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 these 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 EFFEQS OF MOISTURE AND DIRT
Keep the generator set 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.
Generac® Power Gvstems. Inc. 1 ”1
MAINTENANCE
Section 3 - Maintenance
PRIMEPACT 50 Recreational Vehicle Generator
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):
Be sure the generator is as level as possible.
1.
Remove the dipstick and wipe it dry with a clean,
2.
lint-free cloth. install and tighten the dipstick cap; then, remove
3. it again. The oil level should be at the dipstick “Full” mark.
If necessary, remove the oil fill cap on the rocker
4. cover and slowly add oil until it reaches the dip stick “Full” mark. DO NOT FILL ABOVE THE “FULL’ MARK.
-------
M. CAUTION Mk
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.
----------
Figure 3.1 - Oil Maintenance Features
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 by turning it counterclockwise.
5. Apply a 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. Install and tighten the oil fill cap and the dipstick
9. before operating the engine.
10. Start the engine and check for leaks.
NOTE:
Check the oil level and fill to the “FULE’ mark after checking for leaks. The filter will retain some oil.
1 a Generac* Power Systems, Inc.
Section 3 - Maintenance
PRIMEPACT 50 Recreational Vehicle Generator
MAINTENANCE
3.3 iVIAINTAINING THE ENGINE
AIR CLEANER
♦ 3.3.1 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):
1.
Turn the two screws counterclockwise to loosen.
2.
Remove the cover, foam precleaner and paper filter.
3.
Remove the foam precleaner from the cover.
4.
Wash the foam precleaner in liquid detergent and water.
5.
Wrap the foam precleaner in a clean cloth and
gently squeeze it dry. 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).
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.
Figure 3.2 - Engine Air Cleaner
4. Clean the air cleaner cover then reassemble following steps 7-9 in Section 3.3.1.

3.4 CLEAN AIR INTAKE

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 vwre 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).
4 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.
Figure 3.4 - Setting the Spark Plug Gap
SET PLUG GAP AT 0.030 inch
--------
Jk CAUTION Jk
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. 1 3
------------------
MAINTENANCE
Section 3 - Maintenance
PRIMEPACT 50 Recreational Vehicle Generator
3.6 FUEL FILTER (gasoline only)
Remove and replace the fuel filter (Figure 3.5) once each year or every 100 hours of operation, whichever comes first.
Figure 3.5 - Fuel Filter

3 J SPARK ARRESTOR IVlUFFLER

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.
-A WARNING Ar
Be sure to reinstall the muffler plug tightly.
A
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.

3.8 CLEANING THE GENERATOR

Keep the generator set 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.
--------
Jk CAUTION ià-------------------
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
A
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:
♦ 5.9.1 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.
♦ 5.9.2 EVERY SIX MONTHS
_____________________
_
• Have the state of charge and condition checked. This should be done with an automotive-type bat 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.
i >4 Generac* Power Systems, Inc.
Section 3 - Maintenance
PRIMEPACr 50 Recreational Vehicle Generator
MAINTENANCE
DANGER
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 battery presents a risk of electrical shock
A
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 booster battery to
crank and start the generator engine. If any battery has discharged, remove it for recharging.
-A WARNING A~
• 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 IVIANUAL
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 warranted 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.
Do not open or mutilate the battery. Released
A
electrolyte has been known to be harmful to the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
A
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;
Generac® Power Systems, Inc. i 5
MAINTENANCE
Section 3 - Maintenance
PRIMEPACT 50 Recreational Vehicle Generator

3.13 OUT OF SERVICE PROCEDURE

♦ 5.13.1 REMOVAL FROM SERVICE
If you cannot exercise the generator every seven days, and it is to be out of service longer than 30 days, pre pare the generator for storage as follows:
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down.
3. While the engine is still warm from running, drain the oil completely. Refill the crankcase with SAE lOW-30 oil having API classification “For Service SF.”
4. Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase.
5. 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.
6. 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.
7. Clean and wipe the entire generator.
________________
♦ 3.13.2 RETURN TO SERVICE
To return the unit to service after storage, proceed
as follows:
Check the tag on the engine for oil viscosity and
1.
classification. Verily 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
2.
unsealed batteries to the proper level with distiUed 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.
3. Reconnect the battery. Observe battery polarity.
4. 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.
6.
Apply electrical loads to at least 50 percent of the
7. unit’s rated wattage capacity.
When the engine is thoroughly warmed up, shut
8.
it down.
9. Your generator is now ready for service.
1 6 Generac* Power Systems, Inc.
PART II -
INSTALLATION
INSTRUCTIONS
DANGER
-A
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

SAFETY RULES

strictly with article 551, NFPA 70; ANSI Cl- 1975; AND, ANSI All9.2-1975/NFPA 501C “Standard Ik
for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation **
A
must comply with the manufacturer’s instructions and recommendations.
Safety Rules
PRIMEPACT 50 Recreational Vehicle Generator
DANGER: For fire safety, installation of a generator into a recreational vehicle must comply

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 available 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.
DANGER
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.
Potentially lethal voltages are generated by
A
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.

A GENERAL HAZARDS A

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 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 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.
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. Diseonnect 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 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.
1 S Generac* Power Systems, Inc.
Safety Rules
PRIMEPACT 50 Recreational Vehicle Generator
SAFETY RULES
A

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 “dock­side” power receptacle), there must be no possibil ity of connecting the different power 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.
A
A

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 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.
A

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) 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.
Oenerac® Power Systems, Inc. 1 S
GENERAL
INFORMATION
Section 1 - General Information
PRIMEPACT 50 Recreational Vehicle Generator
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.

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.
6. CSA Electrical Bulletin 946, available from the Canadian Standards Association, Housing 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, 60­Hertz, 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
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 Cl-1975 and ANSI 119.2-1975, available from the American National Standards Institute,
1430 Broadway, New York, NY 10018.
4. ANSI A119.2/NFPA 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, RO. Box 1015, North Highlands, CA 95660.
so Generac* Power Systems, Inc.
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 T1 (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 two 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
Figure 1.2 - Major Features and Dimensions
GENERAL
INFORMATION
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INSTALLATION
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator

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 recreabonal 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 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 t}q)ical 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.
_______________
_______
______
_
' 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
♦ 2.1.3 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. Baffles 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)
The installer must make certain that the selected
location will permit adequate cooling and ventilat ing airflow to be supplied.
SS
Oenerac* Power Systems, Inc.
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator
INSTALLATION
♦ 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) tire 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 threads 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
1/2 INCH THICK

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:
• 2.2.2 COMPARTMENT CONSTRUaiON
• The generator compartment should be either con structed of, or lined with, 26-gauge galvanized steel.
NOTE:
Aluminum is NOT an acceptable alternative 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 „ETAL LINING
♦ 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
• 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 aeeeptable. 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.
Generac® Power Systems, Inc. S3
INSTALLATION
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator
» If flexible metal conduit is used, it must be sealed
internally at the end where it terminates inside the compartment’s electrical junction box.
NOTE:
Flexible metal conduit, due to its unique 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
1_ r ff
LOCKED STANDINC
I I
* ■ OFF SET
DOUBLE LOCK DOUBLE SEAM
STAWIARD LAP JOINT
r
ACME LOCA
After the compartmeirt 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.
DANGER
Do not install any flammable material directly above or around the compartment. Heat, transferred through the compartment structure, may be sufficient to ignite, char or discolor seat cushions, fiberboard and other flammable materials. You may need to use approved nonflammable insulating materials in high temperature areas.
DANGER
Do not install sound insulation or any
absorbent material on the compartment floor
A
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 reduce 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.
DANGER
♦ 2.2.5 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 t}qDe. One excellent insulating material is a 1­inch (25 mm) thick fiberglass having a 2-pound den sity. When fiberglass is used, its coated side should face toward the compartment interior.
Generac* Power Systems, Inc.
A To prevent fire or explosion, do not install any
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 2­pound density).
Section 2 - installation
PRIMEPACr 50 Recreational Vehicle Generator
INSTALLATION
Figure 2.7 - Typical Noise Abatement
Figure 2.8 - Compartment Floor Cutout
♦ 2.2.5 COMPARTMENT FLOOR CUTOUTS
You must provide openings in the generator compart
ment for the following items (Figure 2.8):
• Engine exhaust and cooling air outlets » Generator cooling air inlet
» Four holes for passage of generator mounting
bolts. See Section 2.1.4 (Page 23).
DANGER
Fuel lines and exhaust piping must not pene
A
trate into the vehicle living area.
Sv/«5 ft ear««. 8r»i^
INSTALLATION
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator

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, V/ithout 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 provide for a path for exhausting the cooling air to the exterior of a com partment, if so equipped.
DANGER
A Never use discharged cooling air for heating or permit
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 ttie ground.
Figure 2.9 - Airflow Through Engine/Generator
_________________
___
NOTE:
Screening, louvers or expanded metal that cover air openings restrict airflow. You must 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
100 SQUARE INCHES UNRESTRICTED [ MINIMUM OPENINGS
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
♦ 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.
SB Generao® Power Systems, Inc.
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.
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).
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator
INSTALLATION
Figure 2.12 - Air Inlet Using Ductwork
ANTI-SPLASH
Figure 2.13 - Air Inlet in Vehicle Skirt
♦ 2.5.4 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 alasolutely 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
♦ 2.5.5 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 0.8, which results in 125 square inches. Minimum actual size of air inlet opening in this case is 125 square inches.
FUEL LINE
FUEL PUMP
FUEL FILTER
DANGER
Gasoline is highly flammable, and its vapors are
explosive. Comply with all codes, standards and
A
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. 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.
S7
INSTALLATION
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator
♦ 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.
--------
ik CAUTION A
Do NOT tee the generator fuel supply line into
the vehicle engine fuel supply line. If this is
A
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 codes, 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.
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

—EKES A—
lp gas is highly EXPLOSIVE. The gas is heavier
than air and tends to settle in low areas. Even
A
the slightest 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
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).
Use only approved components in the fuel sup
A
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.
PARTS NOT INCLUDED IN FUEL
DANGER
HS Generac® Power Systems, Inc.
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator
INSTALLATION
Figure 2.15 - Typical Propane Gas Fuel System
• 2.5.2 SOME IMPORTANT CONSIDERATIONS
When installing an LP gas system, consider seriously the following items:
• All fittings, lines, hoses and clamps must be tight and free of leaks. Apply a pipe sealant to threads
when assembling threaded connections. This reduces the possibility of leakage.
• 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.
• 2.5.3 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.
♦ 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 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 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
FLOW
LOW PRESSURE
AREA
GAS AT
ZERO PRESSURE
GASAI
POSITIVE
PRESSURE
Oenerac® Power 5yst;ems, Inc. 29
INSTALLATION
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator
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 do 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.
2.5.7 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.
The leak test must comply fully with NFPA, Paragraph 318. All 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.
DANGER
Gaseous fuel lines between the tank and the
secondary regulator are under a positive pres
A
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.
DANGER
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 SYMPTOMS, 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.
---------
M. CAUTION
Never tee the generator engine exhaust pipe
into the vehicle engine exhaust piping. This causes excessive back pressure on the genera tor engine. Also, water from one engine can damage the other engine.
----------------------
30 Generac® Power Systems, Inc.
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator
INSTALLATION
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 1­1/4” O.D., 18 gauge, model 4172.
NOTE:
No matter what type of exhaust kit best fits your 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.
• 2.6.5 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.
• 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 such unauthorized pants.
• 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.

2J 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.
• 2.7.1 ELECTRICAL JUNaiON 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
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator
♦ 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), T3 (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 vehicle electrical circuits from iDCing connected to two different power suppUes 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.
• 2.7.5 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 T3 (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
Line T1 (red) to T2 (white) is protected against over
load by a 30-amp circuit breaker (CBl). Use this line­to-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.
--------
Jk CAUTION
Do NOT connect electrical loads in excess of any
A
circuit breaker rating or you will develop prob lems with circuit breaker tripping, which causes a loss of AC output. 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
________________
A-
___
__________
_
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 vapor­proof along its entire length.
♦ 2.7.5
SOURCES
ISOLATING DIFFERENT POWER
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.
3S Qenerac® Power Systems, Inc.
Section 2 - Installation
PRIMEPACT so Recreational Vehicle Generator
INSTALLATION
2.7.6 POWER SUPPLY CORD_______________
____
The power supply cord must comply with all applic able codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected.
Figure 2.18 - Transfer Switch Isolation Method
FROM 20 AMP
HACR BREAKER
♦ 2.7.7 GROUND FAULT CIRCUIT INTERRUPTERS
The National Electrical Code (NFPA 70, 551-7) requires that you install ground fault circuit inter
rupters (GFCIs) on all external and some internal electrical receptacles. Contact your manufacturer or
dealer for recommendations.
2ND AIR CONDITIONER
VEHICLE AC DISTRIBUTION PANEL
30 AMP MAIN BREAKER
HACR BREAKERS FOR AIR
CONDITIONERS
POWER SUPPLY CORD
Figure 2.19 - Installation With Isolation Receptacle
GFCI BREAKERS
DOCKSIDE POWER RECEPTACLE
POWER SUPPLY
CORD
Qenerac® Power Systems, Inc. 33
INSTALLATION
Section 1 - Installation
PRIMEPACT so Recreational Vehicle Generator

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-cranking 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)
0 to 10 (0 to 3)
11 to 15 (3.4 to 4.5)
16 to 20 (4.5 to 6)
CABLE SIZE
2*
0
000
Figure 2.20 - Connecting Battery Cables
SIDE VIEW OF GENERATOR
♦ 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 starVstop 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
*For warm weather, use No. 2 cable up to 20 feet.
♦ 2.8.5 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.
34 Oenerac® Power Systems, Inc.
WIRE #0
(GROUND)
Section 2 - Installation
PRIMEPACT 50 Recreational Vehicle Generator
INSTALLATION
♦ 2.9.1 REMOTE PANEL MODELS
2.9.1.1 Model 9042
This remote panel mounts a rocker type startystop switch and a “Generator Run” advisory lamp. The lamp will turn on to indicate the engine is running.
2.9.1.2 Model 9043
This remote panel mounts a rocker type switch, a “Generator Run” lamp and an hourmeter. The hourmeter should be used in conjunction with the maintenance operations found in Part I of this manu al.
• 2.9.2 REMOTE PANEL CABLES
________________
Interconnection cables are available from Generac for connecting the optional remote panels to the genera tor receptacle.
• To order a 10-foot long, four-wire cable, specify model 9045.
• To order a 30-foot long, four-wire cable, specify model 9046.
Generac* Power Systems, Inc. 35
POST-1 INSTALLATION START-UP ADJUSTMENTS
Section 3 - Post-installation Start-up Adjustments
PRIMEPACT 50 Recreational Vehicle Generator

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 A-
Do not make any unnecessary adjustments.
Factory settings are correct for most applica
A
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 (cross­hatched 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.
DANGER
-A
If a liquid propane (LP) gas fuel system has
been installed, it must be properly tested for
A
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.

3.3 INITIAL START

When you are absolutely certain that the 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 I, 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 engineZ-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

Apply 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.
36 Generao® Power Systems, Inc.
Section 5 - Post-installation Start-up Adjustments
PRIMEPACT 50 Recreational Vehicle Generator
POST-1 INSTALLATION START-UP ADJUSTMENTS

3.5 INSTALLATION CHECKLIST

♦ LOCATION AND SUPPORT
□ Generator is properly located. □ Generator is properly supported. □ Generator is properly restrained.
♦ GENERATOR COMPARTMENT__________________
□ Compartment construction is proper. □ Holes/Openings are vapor-sealed. □ Compartment size is correct. □ Compartment is vapor-sealed.
□ Sound insulation is correct.
□ Floor cutouts are properly completed.
♦ COOLING AND VENTILATING AIR
□ Airflow is adequate. □ Air inlet opening is correct. □ Compensate for restrictions. □ Check that installation has been tested.
♦ GASOLINE FUEL SYSTEM
_________
□ Fuel tank complies with all applicable codes. □ Fuel system is properly installed and checked
for leaks.
♦ OPTIONAL LP GAS FUEL SYSTEM______________
□ Fuel system is properly installed and checked
for leaks. □ Pressure at regulator inlet is correct. □ Rated flow of primary regulator is correct. □ All parts are properly installed.
□ Fuel system is properly tested/adjusted.
_______________
♦ EXHAUST SYSTEM
□ Exhaust system complies with all applicable
codes.
□ Exhaust system is properly and safely installed.
♦ ELECTRICAL CONNECTIONS
□ Connections comply with local code requirements
and all National Electrical Codes. □ Junction box is properly Installed. □ Wiring meets all standards. □ All connections are correct. □ Conduit is properly installed and sealed.
□ Generator is properly bonded to the vehicle.
♦ BATTERY INSTALLATION
□ Recommended battery is installed. □ Recommended cables are installed. □ Cables are clean and tight. □ Cables are connected properly. □ Proper ventilation is provided. □ 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 properly.
DATE OF INSTALLATION
NAME OF INSTALLER
SIGNATURE OF INSTALLER
Generac* Power Systems, Inc. 37
NOTES
Appendix 1 - Notes
PRIMEPACT 50 Recreational Vehicle Generator
3S Generac* Power Systems, Inc.
Appendix 1 - Notes
PRIMEPACT 50 Recreational Vehicle Generator
NOTES
Generac® Power Systems, Inc. 3S
NOTES
Appendix 1 - Notes
PRIMEPACT 50 Recreational Vehicle Generator
40 Oenerac® Power Systeme, Inc.
TROUBLESHOOTING GUIDE
Appendix 2 - Troubleshooting
PRIMEPACT 50 Recreational Vehicle Generator
TROUBLESHOOTING
PROBLEM
The engine will not crank.
The engine cranks but
will not start.
The engine starts hard and runs rough.
The engine starts, but shuts down when the Start/Stop switch is released.
CAUSE
1. Fuse blown
2. Loose, corroded or defective battery cables
3. Defective engine Start/Stop
switch
4. Defective starter contactor
5. Defective starter motor
6. Low or defective battery
1. Out of fuel
2. Defective fuel pump
3. Open #14 wire from engine control board
4. Flooded engine
5. Defective spark plug(s)
6. Fuel line shut-off closed
7. Plugged fuel filter
1. Air cleaner plugged or damaged
2. Defective spark plug(s)
1. Engine oil level low
2. Defective low oil pressure switch
3. Defective high temperature switch
4. Defective engine control board
5. Overheated engine
CORRECTION
1. Replace fuse.
2. Tighten, clean or replace as necessary.
3. Replace Start/Stop switch.
4. Replace contactor.
5. Replace starter motor.
6. Charge or replace battery.
1. Replenish fuel.
2. Replace fuel pump.
3. Check connections and. insulation of #14 wires.
4. Wait 5-10 minutes before trying.
5. Clean, re-gap or replace plug{s).
6. Open fuel line shut-off.
7. Clean or replace fuel filter.
1. Check, clean or replace air cleaner.
2. Clean, re-gap or replace plug(s).
1. Check oil and add oil as needed.
2. Replace pressure switch.
3. Replace temperature switch.
4. Replace control board.
5. Check that the airflow openings are adequate.
The Start/Stop switch is
set to Stop, but the engine continues to run.
There is no AC output from the generator.
1. Defective Start/Stop switch
2. Open/Disconnected #18 wire between Start/Stop switch and engine control board
3. Open/Disconnected #0 wire between Start/Stop switch and engine control board
4. Defective engine control board
1. Main line circuit breaker open
2. Fault with vehicle circuit
breaker and/or fuses
3. Transfer switch set to NORMAL
4. Start switch not held long enough to flash the field
5. Generator internal failure
1. Replace switch.
2. Reconnect or close wire.
3. Reconnect or close wire.
4. Replace control board.
1. Reset circuit breaker to ON (or closed).
2. Reset and replace if necessary.
3. Set switch to GENERATOR.
4. Stop, then restart the engine (Hold Start switch for at least 2 seconds).
5. Contact a Generac Authorized Service Dealer.
Oenerac® Power Systems, Inc. 41
ELECTRICAL
DATA
Appendix 3 — Electrical Data
PRIMEPACT 50 Recreational Vehicle Generator Electrical Schematic and Wiring Diagram - Drawing No. D1754
BATTERY
-RED
-NEUTRAL CDNNECTIDN BY CUSTOMER
4S Generac® Power Systems, Inc.
BATTERY CHARGE RECTIFIER
I FGEND
CIRCUIT BREAKER, BOA
CIRCUIT BREAKER, EOA CIRCUIT BREAKER, e.5A CHOKE HEATER (GASOLINE MODELS ONLY) CHOKE SOLENOID (GASOLINE MODELS ONLY)
FUSE, ISA
FUEL PUMP“DR-LPG SHUT OFF VALVE TERMINAL, GROUND 4-TAB METER, HOUR (OPTIDNAL)
• SWITCH, HIGH TEMP. OIL (CLOSES ON HIGH TEMP.) IGNITION MAGNETO LIGHT, RUN (OPTIONAL)
SWITCH, LOW OIL PRESSURE (CLOSES ON LOW PRESSURE) ENGINE CONTROLLER
RESISTOR, 1 OHM 25W
• STARTER CONTACTOR
• STARTER MOTOR
SWITCH, START/STDP
• SWITCH FUEL PRIMER
SPARK PLUG »1 CYL.
- TERMINAL, CONN. 4-TAB
• CONNECTOR
Appendix 3 — Electrical Data
PRIMEPACT 50 Recreational Vehicle Generator
Electrical Schematic and Wiring Diagram - Drawing No. D1754
pswiiin
^ ELECTRICAL
DATA
CL(/0
CLD
DO
s °
in OD
CO
U3 CO
IT
in
1
DO
n nj
S t
OOoOoOOoCDOCOOO *|-f'J<nrrin\Df^C0a^O-^0JC0'9-in
ffi
U
a.
r^
i-
Oenerac* Power Systems, Inc. 43
PARTS
LISTS
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 02010-0) - Drawing No. D1759-A
44 Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
Base and Pulleys (Model 02010-0) - Drawing No. D1759-A
.^PARTS
LISTS
ITEM PART NO.
1
C2368 1 2 53407 3 46911 4 4 25017 5 22237 6
22129 9 7
A6479 1 8
77603 9
22259 2 10 11 12 13 75215 2 14 15 16 A8341 1 17
18 40976 2 SOCKET HD. CAPSCR.,-
19 A6858 1 20 A8614 1 21 22 73106-B
23 75216 1 24 25
26 27 28 56893 7 29 A8615 1 30 Cl 320 1 31 32 33 34
52858 6 51730 2 29459 2
73146 4 75209 2
90239 1
75224-B
49451 1 42633 1
39253 A8250 1
63036 3 CRIMTITE-#8-18X1/4" A8694 1 A8726 1 75242
QTY. DESCRIPTION
BASE, MOUNTING
1 GROUND CABLE
MOUNT, (RUBBER) 37 6 CAPSCREW, HEX HD.-3/8"-16 X 1/2" 6
LOCK WASH ER-3/8" 39
LOCK WASHER-M8
SKID, RUBBER MOUNT 41
2
SAFETY BOLT 5/16"-18X 31/2"
NUT, HEX-5/16“-18
NUT, FLANGED LOCK-M8-1.25 44 A8010A
CAPSCR. HEX HD.-M8-1.25 X 60MM SPRING, BELT TENSION 46 75237 4 WASHER, SPRING CNTR. 47 SLIDE (NYLON) SUPPORT, NYLON SLIDE MANIFOLD, EXHAUST GASKET, EXHAUST MANIFOLD
M8-1,25X20 LG. GASKET, COLLECTOR PAN 54
SKID, RUBBER MOUNT 1 PULLEY. ENGINE 1 PULLEY, ALT.
BELT (POLY V 4L)-40"
WASHER, PULLEY RETAINER
CAPSCR., SOCKET HD. 3/8"-24 X 1"
(GRADE 5) 3 CAPSCR., HEX HD.-M8-1.25X20 62
CAPSCR., HEX HD.-3/8"-24 X 2"
CRIMPTITE-#10-24X 1/2"
BRACKET-FUEL PUMP
HOUSING, BLOWER
SCREEN, SLIDE PAN
GASKET, BLOWER / PAN 4
SPRING, GENERATOR SET MT
ITEM PART NO.
35 C4006 1 36 A4456 2
90475
38 87769 1 FUEL FILTER
A7695
40
42 22145 43
45 77643 1 EXHAUST PIPE GASKET
48 90859 1 EXHAUST COVER PLATE 49 30340 6 IN. HOSE, FUEL 50 A8594 1 51 A1658 52 23152 53 A8475
55 22131 1 56 48031-C 57
58 59 D1227 1 60 A8010 61 C2824 7
63 64 D1741 2 BOOT, STARTER CONTACTOR 65 66 22158 67 68 A8407 1 GASKET, BLOWER SIDE 69 22473 1 FLAT WASHER ^A"
A6922 79246 2
38150
D1741A 1
45756 2
81105 2 66849
131-74260 24114
22152 2 LOCKWASHER-M4
A8531 1 PLATE, BLOWER SIDE
QTY. DESCRIPTION
CABLE, BATTERY 3/8" SPECIAL LOCK WASHER
1
FUEL PUMP
1
FITTING-1/8" PIPE TO 1/4" TUBE
1 FUEL TUBE, METAL
CAPSCR,, HEX HD.-M6-1.0X 16
5
FLATWASHER-M8-5/16"
3
FLATWASHER-#8
1 GASKET, BLOWER HSNG
WASHER, SPRING RETAINER BOOT, STARTER CONTACTOR
PAN, SLIDE
2
SPECIAL LOCK WASHER, 'A"
2 CAPSCR., HEX HD.-3/8"-16 X 3/4"
SPECIAL LOCK WASHER, M5
3
SCREW, TAPTITE-M6-1.0 X 10 LG. FLAT WASHER-MI 0
2
CLAMP, HOSE NUT, FLANGE-5/16"-18 (SPECIAL)
5 SCREW, TAPTITE M5-0.8 X 16 LG.
STARTER CONTACTOR
1
GASKET, BLOWER HSNG
HHS #10-32X9/16" LG, TAP-R 1 STARTER CABLE 2 HEX NUT-5/16"-24
2
HEX NUT-#10-32
Oenerac® Power Systems, Inc. 45
PARTS
LISTS
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 04164-0) - Drawing No. D1758-B
58
4B Generac® Power Systems, Inc.
31
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
Base and Pulleys (Model 04164-0) - Drawing No. D1758-B
..PARTS
USTS
ITEM
10 52858 6 NUT, FLANGED LOCK-M8-1.25 46 11 12 13 75215 14 15 75209 2 16 A8341 1 17 18 40976 2 SOCKET HD. CAPSCR.,- 54 C3766
19 A6858 1 GASKET, COLLECTOR PAN 56 20 21 22 73106-B 1 PULLEY, ALT. 23 75216 24 25 42633
26 39253 3 CAPSCR., HEX HD.-M8-1.25X20 27 28 29 30 31 63036 3 32 A8694 1 SCREEN, SLIDE PAN 33 A8726 34 75242 35 36 A4456 2 3/8“ SPECIAL LOCK WASHER
PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.
1
C2368 1 BASE, MOUNTING 2 53407 1 3 46911 4
25017
22237
5 6 22129 7
A6479 1 SKID, RUBBER MOUNT 8 77603 2 SAFETY BOLT 5/16"-18X 31/2" 9 22259
51730 2 CAPSCR. HEX HD.-M8-1.25 X 60MM
29459
73146
90239
A8614 1 SKID, RUBBER MOUNT 57
75224-B
49451
A8250
56893
A7837
Cl 320
62684
GROUND CABLE
4 MOUNT, (RUBBER)
CAPSCREW, HEX HD.-3/8"-16 X 1/2"
6
6
LOCK WASHER-3/8"
12
LOCKWASHER-M8
2
NUT, HEX-5/16"-18 45 77643
2 SPRING, BELT TENSION
2 WASHER, SPRING CNTR.
4
SLIDE (NYLON) 50 SUPPORT, NYLON SLIDE MANIFOLD, EXHAUST
1 GASKET, EXHAUST MANIFOLD
M8-1.25X20 LG.
1 PULLEY, ENGINE
1
BELT (POLY V4L)-40" 60 A8010 1 WASHER, PULLEY RETAINER 1
CAPSCR., SOCKET HD. 3/8"-24 X 1" 62 131-74260
(GRADE 5)
1
CAPSCR., HEX HD.-3/8"-24 X 2" 65
14 CRIMPTITE-#10-24X1/2"
1 BRACKET, LP REGULATOR 1
HOUSING, BLOWER 68
CRIMTITE-#8-18X1/4"
1 GASKET, BLOWER/PAN 71
4 SPRING, GENERATOR SET MT 72 26915
1
GROUNDING LUG 73
37 38 39 40 61696 41 79246 42 43 38150 44 A8010A
47 75763-A 1 48 49
51 52 23152 53 A8475
55 22131
58 66849 59
61
63 64 22097 2
66 22158 67
69 22473 70 38750
D2530 A6894 A2666
22145
75237
90859 74994 A8594 D1741
57822 2 #8 HOSE CLAMP 81105
D1227
45771 3
24114 2
22152 , 2
A8531 A8407
49813
26307 1
DESCRIPTION
1
REGULATOR, GAS FUEL
1
MANIFOLD, LP
1
SOLENOID, GAS FUEL
1
BARB, 90 DEG. ’/2" X 3/8" NPT
2
CAPSCR., HEXHD.-M6-1.0X 16
8
FLATWASHER-M8-5/16"
3 FLATWASHER-#8
1
GASKET, BLOWER HSNG
1
EXHAUST PIPE GASKET
4
WASHER, SPRING RETAINER BOOT, BATTERY CABLE
1 EXHAUST COVER PLATE
10.5"
HOSE, '/2 ID PETROLEOM
1
PAN, SLIDE 2 BOOT, STARTER CONTACTOR 2 CAPSCR., HEX HD.-3/8"-16 X 3/4" 2 SPECIAL LOCK WASHER, M5
1 3/4" NPT PLUG
1
FLAT WASHER-MI 0
NUT, FLANGE-5/16"-18 (SPECIAL)
2 2 SCREW, TAPTITE M5-0.8 X 16 LG. 1 STARTER CONTACTOR 1 GASKET, BLOWER HSNG
M8-1.25HEX NUT
STARTER CABLE
1
HEX NUT- 5/16-24
LOCKWASHER-1/4"
LOCKWASHER-M4
HEX NUT-#10-32
2 1 PLATE, BLOWER SIDE
GASKET, BLOWER SIDE
1 1 FLAT WASHER’/4"
M6-1.0X30HHCS
2 2 M6-1.0 HEX NUT
CLOSE NIPPLE 3/4" NPT
2
90 DEG. %" STREET ELBOW
Generac* Power Systems, Inc. 47
PARTS
LISTS
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
Alternator and Panel (Model 02010-0) - Drawing No. A8922-F
4S Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACr 50 Recreational Vehicle Generator
Alternator and Panel (Model 02010-0) - Drawing No. A8922-F
..PARTS
LISTS
ITEM
10 11 12 13 75234 14 15 16 17 90141 2 18 A1658 19 20 92234 1 21 22 24 25 26 27 30 31 22264 4 #8/M4-LOCK WASHER 32 33 90987 2 M3-0.5X12LG. PPHMS 34 35 36 82737 4
PART NO.
1
75995
2
A5649H 1 ROTOR ASSEM. 3 A5646H 4
73159
31971 1 BALL BEARING
5 6 72379-B 7
A6529 8
52858
9
66386 66849 3 D2724
C3818
22473
22097
A2053
74906
C2337
22129
86316
53650
C4258
75244
75476
65795
86317A
75235 3
QTY.
DESCRIPTION ITEM PART NO. QTY.
LOWER BEARING CARRIER 37 49813 4 M6-1.0 HEX NUT
1
1 STATOR ASSEM,
BALL BEARING 40
1
1 UPPER BEARING CARRIER 4 STUD-STATOR 4 M8-1.25 FLANGE LOCKNUT 45 1 BRUSH HOLDER 46
M5-0.8X 16LG.TAPTITE BOOT, ROCKER SWITCH
2 1 GENERATOR TOP HOUSING 1
RESISTOR1R5%25 WLVG
2 y47M6-FLAT WASHER
%7M6-LOCK WASHER
5 1 M6-1.0X65 LG. CAPSCREW
GROUND CABLE 53 2 SPECIAL LOCK WASHER, M6 4 M6-1.0X20 LG.TAPTITE 55
CONTROLLER P.C.B. 56
DECAL, UNIT GAS 57
1 4 5/16" -M8 LOCK WASHER 58 1 PANEL SHEET METAL 59 1 4-PIN CONNECTOR 60
CONDUIT ASSEMBLY
1 1 ASSEMBLY, REMOTE CABLE 63
M4-0.7X 16 LG. CAPSCREW
3
1 BATTERY CHARGE RECTIFIER
1 PANEL SUPPORT BRACKET 69
M5-0.8 X 30 LG. CAPSCREW
VIBRATION MOUNT
DESCRIPTION
38 55440
39
41
43 83049 1 REGULATOR VOLTAGE 44
47 48
49 86315
50
51 22985 52 32300 1
54 87798
62
64 74908 2 65 23484-S 67 94070 68
70 A8475 3
43182 45771 53623
22152 51716
90144 1 90145
25105 4
90734
22676 1
92113 75210-A A8475A 1 51715 1 90157 90156 31791 23897 2
94071 27756 4
2
M5-08 X 25 LG. HEX HD. CAPSCR. M3-LOCK WASHER
2 4 HEX NUT, M8 1 C/BREAKER 2.5A.-ON
LOCKWASHER, #10
5
M5-0.8 HEX NUT
3
C/BREAKER 20A.
1 C/BREAKER 30A. ALL UNITS
#6-32 SCREW W/LOCK WASHER
1 PANEL COVER
4 M4-0.7 X 12 LG. CAPSCR.W/LOCK-
WASHER & FLAT WASHER #6-FLAT WASHER
1
FUSE HOLDER FUSEAGC-15A.
1 SWITCH S.P.D.T, 6A,-(START-STOP)
SWITCH S.P,D.T,-(FUEL PUMP)
1
TERMINAL BLOCK
1
SPECIAL LOCKWASHER, M4 M4-0.7 HEX NUT DECAL, CB RATING 30A.
1
DECAL, CB RATING 20A.
1
CLAMP, HOSE
1
#10/M5-FLAT WASHER
M5-0.8X10LONGTAPTITE 1 BUSHING 1 SPACER-PLASTIC
M5-.08X 110 LG. PPHMS
1
NYLON WASHER
SPECIAL LOCKWASHER, M5
Generac* Power Systems, Inc. 4S
^PARTS
LISTS
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
Alternator and Panel (Model 04164-0) - Drawing No. D1776-A
50 Generac’ Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
Alternator and Panel (Model 04164-0) - Drawing No. D1776-A
^PARTS
LISTS
ITEM
10 11 A8475 3 12 C3818 13 14 22473 15 16 17 90141 18
19 20 21 C2337A 1 22 22129 23 24 86316 25 26 27 75244 28 29 30 31 32 33
PART NO.
1 C9675
2 A5649H
A5646H
3 4
73159 31971 1 BALL BEARING
5
C9674 1 UPPER BEARING CARRIER 39
6
A6529
7
52858
8
66386
9
66849
75234 1 RESISTOR1R5%25 WLVG 46
22097 A2053
A1658 74906 94039 1 CONTROLLER ROB.
27756
53650 C4258
94071 1 94070 75476 3 22264 4 #8/M4-LOCK WASHER 63 65795 90987 2
QTY. DESCRIPTION ITEM PART NO.
1 LOWER BEARING CARRIER 1
ROTOR ASSEM.
1
STATOR ASSEM,
1 BALL BEARING
4
STUD-STATOR
4 M8-1.25 FLANGE LOCK NUT 41 53623
1
BRUSH HOLDER M5-0.8X16LG.TAPTITE
3
SPECIAL LOCK WASHER, M5
1 GENERATOR TOP HOUSING 45
2 ’/47 M6-FLAT WASHER 47 90145
’/47 M6-LOCK WASHER 48
5
1 M6-1.0X65 LG, CAPSCREW 49
2 GROUND CABLE 50 2 SPECIAL LOCK WASHER, M6
M6-T0X20 LG.TAPTITE
4
DECAL, UNIT (LP MODEL) 4 5/16" -M8 LOCK WASHER 4
NYLON WASHER 55
1 PANEL SHEET METAL 56
1
4-PIN CONNECTOR
1 CONDUIT ASSEMBLY 1 ASSEMBLY, REMOTE CABLE
M5-.08X110LG, PPHMS
1
SPACER-PLASTIC
M4-0.7X 16 LG, CAPSCREW 62 31791
1 BATTERY CHARGE RECTIFIER
M3-0.5X12LG.PPHMS
34 86317A 35 75235 36
37 49813
38 55440
40
42 43 44 22152 5
51 22985
52 53 54
57
58 59 60
61 74908
64 D2724
82737
43182 45771
23484-S 83049
51716 90144
25105 86315 90734
32300 22676 87798 92113 75210-A A8475A 51715 90157 90156
23897
QTY.
DESCRIPTION
PANEL SUPPORT BRACKET
1
3 M5-0.8 X 30 LG, CAPSCREW 4 VIBRATION MOUNT 4
M6-1.0 HEX NUT
2
M5-08 X 25 LG, HEX HD, CAPSCR, 2 M3-LOCK WASHER 4 HEX NUT, M8
1 C/BREAKER 2.5A.-ON 1 BUSHING 1
REGULATOR VOLTAGE
LOCKWASHER, #10 3 M5-0.8 HEX NUT
1 C/BREAKER 20A, 1 C/BREAKER 30A. ALL UNITS
#6-32 SCREW W/LOCK WASHER
4
1 PANEL COVER
4 M4-0,7 X12LG, CAPSCR.W/LOCK-
WASHER & FLAT WASHER
1 #6-FLAT WASHER 1 FUSE HOLDER
1 FUSEAGC-15A,
1 SWITCH S,P.D.T, 6A,-(START-STOP) 1 SWITCH S,P.D.T.-(FUEL PUMP)
1
TERMINAL BLOCK
SPECIAL LOCK WASHER, M4
1 1 M4-0.7 HEX NUT 1 DECAL, CB RATING 30A.
1 DECAL, CB RATING 20A.
2 M5-0.8X 10LONGTAPTITE
1 CLAMP, HOSE 2 #10/ M5-FLAT WASHER 2 BOOT, ROCKER SWITCH
Generac* Power Systems, Inc. 51
PARTS
LISTS
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator Engine Sheet Metal (Model 02010-0 and 04164-0) - Drawing No. D1760-A
CM
Oenerac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
Engine Sheet Metal (Model 02010-0 and 04164-0) - Drawing No. D1760-A
^PARTS
LISTS
TEM
1 A4323 2 45756 8 3 4 5 6
7 A4456
8
9 10 91646 11 92572 12 92079 13 14 15 16 17 22129 6 18 19 20 21 22 23 24 A8875 25 26 27 A7838 1 28 29 22473 30 31 32 A6489 33 A6359 34 131-74260 35 36 91159 37 91160 38 91161 39 40 86999 41 A8584 1 42 75281 43 44 45 46 47 48 C2308 49 A1658 50 90388 51 75474A 52 D1624 1 BOOT, OIL PRESSURE SWITCH
PART NO. QTY.
1 SCROLL, FLYWHEEL
29289 SRV 91222D 67198N 1 67890
56893 A6358
22717A
73132 61669 89685
22127 57821 2 59637 21544 40976 25034 1 PLUG, BUnON 1-1/16"
A7299 A9539
38593
A6357 1 90954 1 WRAPPER, STARTER SIDE
90892
49821 2 BOLT SOCKET HD. CAPSCR.-M8-1.25 X 30MM
Cl 085 43182 2 LOCK WASHER-M3 70185 A7629 1 82774 1
2.5 FT. 1
1 NUT, M20X 1.5, FLYWHEEL 1
21
1 COVER,TOP FLYWHEEL 1 1 ASSEMBLY, IGNITION COIL 2 1 GROMMET, RUBBER 1 BOOT, SPARK PLUG 1 2
1
2 1 2 SOCKET HD. CAPSCR., M8-1.25 X 20MM
1 1 1
1 1 FLAT WASHER, 1/4"-M6
1 1 1 1 SUPPORT, OIL FILTER 1 BUSHING, RUBBER 1 1
1 GASKET OIL FILTER SUPPORT
1 2
1 FILTER, OIL
1 1 1 1 BOOT, TEMPERATURE SWITCH
DESCRIPTION
SCREW, TAPTITE M6-1.0 X 10MM FOAM TAPE FLYWHEEL WASHER, BELLVILLE M20 X 2.2
3/8" SPECIAL LOCK WASHER SCREW, CRIMPTITE #10-24 X 0.5“
DEFLECTOR, EXHAUST PORT
SCREW, TAPTITE M6-1.0 X 25MM
PLUG, BUTTON 3/4" GROMMET, RUBBER LOCK WASHER-M8 HEX NUT-1/4"-20 CAPSCR., HEX HD.-M8-1.25 X 40MM SCREW, TAPTITE 3/8“-16 X 0.75" MOTOR, STARTER-12VOLT
ASSEMBLY, DIPSTICK & CAP OIL DRAIN/DIPSTICK TUBE OIL DRAIN HOSE ASSEMBLY
PIPE NIPPLE, 3/8" X 8" LG. BRASS STREET ELBOW, 3/8"
WRAPPER, ENGINE SPARK PLUG
WRAPPER, REAR GEAR CASE WRAPPER, CARB. SIDE ASSEMBLY, WIRE-STARTER (#16)
WASHER, RUBBER
BOLT SHOULDER-M6-1.0 X 15MM
SWITCH, OIL PRESSURE-10 PSI SWITCH, OIL TEMPERATURE SCREW, PHILIPS PAN HD. MACH.-M3-0.5 X 8MM
ENGINE, LONG BLOCK-GN410VSRV KEY, WOODRUFF 4 X 19 DIA. COVER, CARB. SPECIAL LOCK WASHER, M6
TAPTITE, M6-1.00X12MM
Generao® Power Systems, Inc. S3
^PARTS
LISTS
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator CN-410 Engine (Model 02010-0 and 04164-0) - Drawing No. A7894-E
-11
-14
-54
42
5<4 Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
GN-410 Engine (Model 02010-0 and 04164-0) - Drawing No. A7894-E
..PARTS
LISTS
ITEM PART NO.
1
21533 1 PISTON RING SET
3
71978 1
4
71980 1 5 71983 2 6 21713B 7
A1442
8 21742 9 96699 1
10 76701 1 CRANKCASE GASKET 11
12 13 14 15 26925 1 16 17 72694 18 72696 2 19 20 78694 1 21 83907 22 21714
23 86514
24 25 26 27 28
45756 2
80308 2 BREATHER GASKET 80309 1 BREATHER COVER 80338 1
83897
78672
86515 4 86516 1 EXHAUST VALVE 86517 89673 2
C4391 2
QTY. DESCRIPTION
CONNECTING ROD WITH CAP & BOLT PISTON PIN PISTON PIN RETAINER
1
CYLINDER HEAD GASKET 34
8 FLANGED HEX HD, CAPSCREW
M8-1.25 X 42
4 MIO 1.5X 105MM HHFL
PISTON
M6-1.0X 10TAPTITE (THD. FORMING)
OIL BREATHER SEPARATOR
PIPE PLUG-3/8” 2 TAPPET, SOLID 2
PIVOT BALL STUD
JAM NUT (ROCKER ARM)
1 SEAL, VALVE STEM
PUSH ROD GUIDE PLATE 2 ROCKER ARM 1
CYLINDER HEAD WA/ALVE SEATS AND GUIDES
2
VALVE SPRING RETAINER VALVE SPRING KEEPER
1
INTAKE VALVE WASHER, VALVE SPRING 64 86254
VALVE SPRING
ITEM
29 30 72655 2 31 32 33 A7308 1
35 78691 1 COVER, OIL PRESSURE RELIEF 36 37 38
39 B2104 1 40 89280D 1 42 43 78659 2 THRUST WASHER 46 A7628 1 48 C3396C 1 CRANKCASE SUB ASSEMBLY 49 84430 1 BALANCER 50 51 86026 1 52 88396B 2 PUSH ROD 53
54 90747 1 55 C3150 57 92362 1 ROCKER COVER W/FILL 58 79246
59 83921 1 BEARING TUBE SHAFT 60 77158 63
65
PART NO. QTY.
A9877
76361 1 A5776
78645 1
74908 A8930 1 A5771 1
78658
86002 1
90416A 1
1
4
1
76329
93064 1
1 OIL FILL PLUG 1 "0” RING 17.8 I.D. X 2.4 THICK
DESCRIPTION
1 CAMSHAFT ASSEMBLY
CRANKSHAFT 35 I.D. SEAL
THRUST WASHER
1
PRESSURE RELIEF BALL GOVERNOR SPOOL GOVERNOR RETAINER (C-RING)
1
M5-0.8X 10MMTAPTITE GOVERNOR GEAR ASSEMBLY OIL PRESSURE SPRING SPRING WASHER OIL SUMP ASSEMBLY
1
GOVERNOR ARM "R" PIN
GOVERNOR ARM RC45
OUTER GEROTOR
INNER GEROTOR
CRANKSHAFT ASSEMBLY BREATHER VALVE ASSEMBLY ROCKER COVER GASKET
M6-1.0X 16MM HEX HEAD.
SCREW. AND LOCKWASHER
OIL SCREEN PICKUP ASSEMBLY
OIL FILL CAP ASSEMBLY
Generac* Power Systems, Inc. BB
PARTS
LISTS
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
Engine Accessories (Model 02010-0) - Drawing No. A8923-B
SB Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
Engine Accessories (Model 02010-0) - Drawing No. A8923-B
.PARTS
LISTS
TEM
1 2 3 51753 4 72347 1 SPARK PLUG, CHAMP 5 89228 6 A6562 7 8 A6564 1 BASE, AIR FILTER
9 10 A6566 11 12 13 73111 14 15 16 C3633 17 18 C2332 1 DECAL, AIRBOX QP55 19 20 83503 21 24 26 83512 2 27 28 29 30 89473 31 A7094 2 32 33 22473 34 35 A6582 36 A6503 37 38 39 40 41 42 83532 1 43 86681 44 45 46 47 48 49 50 A6778 51
PART NO. QTY. DESCRIPTION
A6532 91039
90970
56893
A6780 96290
81646 A6563
A7095
92164
A7029 49813
A6239 A6584 1 LINKAGE, CHOKE 36544 1
20753
22097
A6569 A6565 A6568 A6567 1 SPRING, DETENT 90968
A8222 A6753 92586 91161 A6913 A6785
A6581
1 MANIFOLD, INTAKE
1
1 HHCS-M6-1.0X40MM
1 1 1 GASKET. CARB/AIR FILTER
3 1 DETENT 1 SPRING, A/L BELLCRANK-CARB, 2 STUD, CARB, MOUNT 90 LG. 1 1 1 COVER, AIR FILTER 2 KNOB, AIR CLEANER 2 RHMS-#4-40X5/16"
1 1 NUT, LOCKING M5-0.8 1 2
1
1 ASSEMBLY, CHOKE HEATER
1 2 M6 FLAT WASHER 4 M6 LOCK WASHER 1 TUBE, WINTER INLET 1 1 GROMMET, AIR IN/OUT 1 VALVE, WINTER/SUMMER 1 GROMMET, WINTER/SUMMER VALVE
1 LEVER, GOVERNOR ARM
1 1 1 2 WASHER, FELT 1 BOLT, SHOULDER, M6-1.0 X 15MM 1 1 1 SPRING, A/L GOV. LEVER-BELLCRANK 1 BREATHER, TUBE
GASKET, MANIFOLD/HEAD
GASKET, CARB/MANIFOLD CARBURETOR
CRIMPTITE #10-24X1/2"
FILTER, AIR PRE-CLEANER, AIR FILTER
ASSEMBLY, GOV, SPRING ADI BRACKET
NYLON WASHER, .31" X .26" X .13" NUT, M6-1.0 TAPTITE-M8-1.25X 16MM ASSEMBLY, CHOKE SOLENOID
PIN, COHER, 3/32" X V2"
SCREW, PHILLIPS PAN HD. MACH. #4-40 X .25" HHCS-M6-1.0X60MM
GROMMET 1/16"-1-1/2"
BOLT, HEX HD. WASHER/LOCK WASHER-M6-1.0 X 30MM
NUT, GOVERNOR LEVER
SPRING, GOVERNOR
BELLCRANK, GOV. RODS
ROD, LINKAGE GOV. LEVER-BELLCRANK
ROD, LINKAGE BELLCRANK-CARB.
Generac* Power Systems, Inc.
S"7
PARTS
LISTS
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 04164-0) - Drawing No. C3880-A
CO m
CM CM
5S Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists
PRIMEPACT 50 Recreational Vehicle Generator
Engine Accessories (Model 04164-0) - Drawing No. C3880-A
^PARTS
LISTS
TEM PART NO.
1 2
3
4
5
6 A7336A 1
7
8 A6564 1
9
10 A6566
11 12
13 14 15 16 17 18 C2332 19
20 21 22
23 91161 24 25 26 83512 27 28 29 30 A8222 31 32 33 34 35 A6582 36 37 38 39 40 41 42
A6532 1
91039 51753 72347 89228
90970
56893 3
A6780 96290 73111 81646 A6563 C3633
A6581 1
92164 83503 A7029 A6913
49813 92586
A6778 A6785 A6753
86681 1
20753 22473 22097
A6503 A6569 A6565 A6568 A6567 90968 83532
QTY. DESCRIPTION
MANIFOLD, INTAKE
1
GASKET MANIFOLD/HEAD
1 HHCS-M6-1.0X40MM 1
1
SPARK PLUG, CHAMP
GASKET CARB/MANIFOLD
CARBURETOR, GN 410 L/P
1 GASKET, CARB/AIR FILTER
BASE, AIR FILTER
CRIMPTITE #10-24 X 1/2"
1 DETENT 1
2 1 1
SPRING, A/L BELLCRANK-CARB, STUD, CARB. MOUNT 90 LG. FILTER, AIR PRE-CLEANER, AIR FILTER
1 COVER, AIR FILTER
2 KNOB. AIR CLEANER
BREATHER, TUBE
1 DECAL, AIRBOX QP55 1 1 1 1 1
ASSEMBLY, GOV. SPRING ADI BRACKET NUT, LOCKING M5-0.8 NYLON WASHER, .31" X ,26" X .13“ ROD, LINKAGE GOV. LEVER-BELLCRANK BOLT, SHOULDER, M6-1.0X 15MM
2 NUT, M6-1.0
2 WASHER, FELT
2 TAPTITE-M8-1.25X 16MM 1 1 1
SPRING, A/L GOV. LEVER-BELLCRANK ROD, LINKAGE BELLCRANK-CARB. BELLCRANK, GOV. RODS
1 SPRING, GOVERNOR
NUT, GOVERNOR LEVER
1
2
4
1 1 1 1
1
1 1
1
HHCS-M6-1.0X60MM 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
Oenerac® Power Systems, Inc. SS
Appendix 5 - 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 warrcUit 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.
MANUFAaURER'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 Service 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 pursuant 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/shlpped 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, Wl 53190
Part 1
60 Generac® Power Systems, Inc.
Appendix 5 - Warranty
PRIMEPACT 50 Recreational Vehicle Generator
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 ERA 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 falls during the ECS Warranty Period, It shall be repaired or replaced by Generac according 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) /Vny 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 falls 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 for 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:
1.1) Gasoline carburetor assembly and its Internal components (if so equipped).
a) Fuel filter (if so equipped) b) Carburetor gaskets c) Fuel pump (if so equipped)
1.2) LPG carburetion assembly and its
internal components (if so equipped). a) Fuel controller (if so equipped) b) Mixer and its gaskets (if so equipped) c) Carburetor and its gaskets (if so equipped) d) Primary gas regulator (if so equipped)
2) Air Induction System including: a) Intake pipe/manifold b) Air cleaner
3) Ignition System including: a) Spark plug b) Ignition module
4) Catalytic Muffler Assembly (if so equipped) including: a) Muffler gasket b) Exhaust manifold
5) Crankcase Breather Assembly including: a) Breather connection tube
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. 61
Appendix 5 - 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, inspection 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 tlie purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility. All transportation 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) appli
cations, 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 - /Vll components
• Alternator - All components
• Transfer System - All components YEAR Three - 100% (one hundred percent) only on selected part(s) and labor listed (/Vny labor and part(s) not listed, and removal and réin
stallation 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
FOR THE LIFE OF THE RECREATIONAL VEHICLE GENERATOR (IF SO EQUIPPED)
The drive train belt and pulleys (if so equipped) on generators used in recreational vehicles shall be warranted against failure due to defec tive materials or normal usage for the life of the generator. For the original purchaser/owner, this drive train warranty shall include part(s) and labor (removal and reinstallation are not Included) plus $50 (fifty dollars - U.S.) payment upon return of the failed belt or pulley by the original purchaser/owner. For subsequent purchaser/owner, this drive train warranty shall cover belt and pulley part(s) ONLY (labor not included). Labor, removal and reinstallation is the responsibility of the subsequent purchaser/owner.
Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators manu factured after January 1, 1998, have a transferable warranty to the second owner ONLY for the remainder of the three-year limited war ranty. Proof-of-purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any warranty service.
/\11 warranty expense allowances are subject to the conditions defined in Generac’s super seWice 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, hail, 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 replace ment of the defective part(s).
• Failure due to misapplication.
• Telephone, telegraph, teletype or other communication expenses.
Living or travel expenses of pei'son(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. SPE‘ 'hi'
WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE > "u
A'J Y A Nf M .1 it '• 1 Mu’]
' ! EU
I) 1 .,i. .1,
' (I OR
(, Tow
long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC’S ONLY LIABILITY SIR LL BE Ti F HE ’Ml O' 1 f pj.A'EMLTO'OF PART( 31 A . 'I'ATEl ERAC BE LIABLE FOR ANY INCIDEN TAi Oi C'CI 1 qi Í N' A - HiCwS EVEN IF 3U' HO Mi ERAC’S NEGLIGENCE. Some si des do noi tfli i in la > ,n n In in dion of m identai > 11 >
) f . M TT 3 í'^ [ J' , ! ' W ] 1 j > Ci a.
u ' IAÍ
n 1 EN-
1 icr ' '■ N
1 ' .boi 'll It 1-
tion may not apply to you. Purch.'ser/owner >n es t n ü no < laims against Gen rac ¡las ' • an -e ■
This warranty gives you specific'e 1 ri hts You il ‘ini, - w, 'th-rrwd thr i^om
I E
I ' ■ 1. 1 dJ 1 • y/wl J) ' -H Y'/i j j I O
Part No. 01756
. ijw.sicj.i '3 [i-J 1 /1 LJ/OI ]
Printed in LJ.S.r
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