Generac 02010-1 User Manual

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POWER SYSTEMS, INC

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.

A

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.

A-

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.