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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.
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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Generac® Power Systems, Inc. HI
3
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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
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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 >
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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
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Part No. 01756
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Printed in LJ.S.r
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