Generac 00784-2, 09290-4 User Manual
POWER SYSTEMS, INC.
®
Owner’s Manual and
Installation Instructions
Air-cooled Recreational
Vehicle Generators
• Model Nos: 00784-2 and 09290-4
Generac®Power Systems, Inc.
INTRODUCTION
READ THIS MANUAL THOROUGHLY
If you do not understand any portion of this manual,
contact Generac or your nearest Generac Authorized
Service Dealer for starting, operating and servicing procedures.
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 carelessly. Observe them carefully. Their definitions are
as follows:
After this heading, you can read instructions that,
if not strictly complied with, will result in personal
injury or property damage.
After this heading, you can read instructions that,
if not strictly complied with, may result in personal
injury or property damage.
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 compliance 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 information that, if not followed, could endanger personal
safety and/or property of you and others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator (driver) is responsible for proper and
safe use of the vehicle and its equipment, and the safety of all vehicle occupants. We strongly recommend
that the operator read this manual and thoroughly
understand all instructions before using this equipment. We also strongly recommend instructing other
occupants in the vehicle to properly start and operate
the generator. This prepares them if they need to operate 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 009290-4 and 00784-2. In addition, the latter portion of this manual contains information necessary for the proper installation of these generators.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety 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 service 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 accessories.
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. ______________
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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 and 70 (50Hz) Recreational Vehicle Generatorss
Generac®Power Systems, Inc. 1
Part I — Owner’s Manual
Introduction ........................................Inside Front Cover
Read This Manual Thoroughly..................................IFC
Contents ..................................................................IFC
Operation and Maintenance ......................................IFC
How to Obtain Service ..............................................IFC
Authorized Service Dealer Locator Number ................IFC
Safety Rules ........................................................................2
Section 1 – General Information....................................4
1.1 Generator Identification ........................................4
1.2 Generator Applicability ..........................................5
1.3 Installation ............................................................5
1.4 Safety ....................................................................5
1.5 Generator AC Connection System..........................5
1.6 Specifications ........................................................6
Section 2 – Operation ......................................................7
2.1 Generator Control Panel ........................................7
2.2 Optional Remote Start/Stop Panel ........................7
2.3 Automatic Choke ..................................................7
2.4 Before Starting the Engine ....................................8
2.5 Starting the Generator ..........................................8
2.6 Stopping the Generator ........................................9
2.7 Applying Loads to Generator ................................9
2.8 Protection Systems ................................................9
2.9 Additional Information ........................................10
Section 3 – Maintenance ..............................................11
3.1 Checking the Engine Oil Level ............................11
3.2 Changing the Engine Oil and/or Oil Filter ............11
3.3 Maintaining the Engine Air Cleaner ....................12
3.4 Clean Air Intake Screen ......................................12
3.5 Checking the Engine Spark Plug..........................12
3.6 Fuel Filter (Gasoline Only) ..................................13
3.7 Spark Arrestor Muffler ........................................13
3.8 Cleaning the Generator ........................................13
3.9 Battery Maintenance ............................................13
3.10 Major Service Manual ..........................................14
3.11 Drive Belt ............................................................14
3.12 Exercising the Generator ....................................14
3.13 Out of Service Procedure ....................................14
3.14 Wattage Reference Guide......................................15
Notes ..................................................................................16
P
artII — Installation Instructions
Safety Rules ......................................................................18
Section 1 – General Information ................................20
1.1 Purpose and Scope of the Manual ......................20
1.2 Safety ..................................................................20
1.3 Standards Booklets ............................................20
1.4 Equipment Description........................................20
1.5 Generator Engine Operating Speed ....................20
1.6 Generator AC Connection System........................20
Section 2 – Installation ..................................................22
2.1 Location and Support ..........................................22
2.2 Generator Compartments ....................................23
2.3 Cooling and Ventilating Air ..................................26
2.4 Gasoline Fuel System ..........................................27
2.5 Exhaust System ..................................................28
2.6 Electrical connections..........................................29
2.7 Battery Installation ..............................................32
2.8 Optional Accessories............................................32
Section 3 – Post Installation Start-up and
Adjustments ................................................33
3.1 Post Installation Tests ..........................................33
3.2 Before Initial Start-up ..........................................33
3.3 Initial Start-up ....................................................33
3.4 Testing Under Load ............................................33
3.5 Installation Checklist ..........................................34
Section4–Troubleshooting ........................................35
4.1 Troubleshooting Guide ........................................35
Section 5 – Electrical Data ............................................36
Section 6 – Exploded Views and Parts Lists ............38
Section7–Warranty......................................................48
2 Generac®Power Systems, Inc.
Study these SAFETY RULES carefully before
installing, operating or servicing this equipment.
Become familiar with this manual and with the unit.
The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow
simple and fundamental rules or precautions.
Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warnings 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 technique 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.
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
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.
GENERAL HAZAR
DS
• For safety reasons, Generac recommends
that the installation, initial start-up and maintenance of this equipment is carried out by a
Generac Authorized Service Dealer.
• The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust system must be installed properly, in strict compliance with applicable codes and standards.
Following installation, you must do nothing that
might render the system unsafe or in noncompliance with such codes and standards. The generator compartment must be completely vapor sealed
from the vehicle interior. There must be no possibility of exhaust fumes entering the vehicle interior. 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 ventilating 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 permit 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 immediately for parts needing repair or replacement.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start up. Disconnect the cable from the battery 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 conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
Safety Rules
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas of the recreational vehicle.
Safety should be stressed to all operators and potential operators of this equipment.
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.
WARNING:
Generac®Power Systems, Inc. 3
ELECTRICAL HAZARDS
• The generator covered by this manual produces
dangerous electrical voltages and can cause fatal
electrical shock. Avoid contact with bare wires, terminals, 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 generator 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 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.
• In case of accident caused by electric shock, immediately 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 implement, such as a rope or board, to free the victim
from the live conductor. If the victim is unconscious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.
FIREHAZARDS
• 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 installation, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regulations.
• 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 pertaining to fire extinguishers, consult your local fire
department.
EXP
LOSION HAZARDS
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding 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 governing the storage and handling of gasoline.
Safety Rules
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
4 Generac®Power Systems, Inc.
Section 1 – General Information
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
Please record the following information from the generator DATA DECAL or information decal.
1. Model Number ____________________ 2. Serial Number __________________
3. kW Rating __________________________ 4. Rated Voltage __________________
5. Phase ______________________________ 6. Hertz __________________________
1.1 GENERATOR IDENTIFICATION
REFERENCE NUMBER IDENTIFICATION
1. Generator Air Intake Screen
2. Data Plate
3. Engine Start/Stop Switch
4. 15 amp Fuse
5. 25 or 30 Amp (2 Pole) Circuit Breaker
6. Optional Remote Panel Receptacle
7. Generator AC Output Leads
8. Fuel Inlet
9. Fuel Primer Switch
10. Fuel Pump
11. Oil Filter
12. Starter Contactor
13. Oil Drain Plug
14. Oil Dipstick and Filler Tube
1
3
2
4
11
10
9
8
12
7
6
5
14
13
Generac®Power Systems, Inc. 5
Section 1 – General Information
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
1.2 GENERATOR APPLICABILITY
These generators have been designed and manufactured 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.
For fire safety, the generator must have been
properly installed in compliance with ANSI
119.2-1975/NFPA 501C-1974, “Standard for
Recreational Vehicles, Part III – Installation of
Electrical Systems.” The generator also must
have been installed in strict compliance with
the manufacturer’s detailed installation instructions. After installation, do nothing that might
render the unit in noncompliance with such
codes, standards and instructions.
1.2.1 PRIMEPACT 70
Use this generator to supply electrical power for
operating 230-volt, single-phase, 50 Hertz, AC electrical loads. These loads can require up to 7,000
watts (7.0 kW) of power, but cannot exceed 30.4 AC
amperes of current at 230 volts.
1.2.2 PRIMEPACT 50
Use this generator to supply electrical power for
operating 230 volt, single phase, 50 Hertz AC electrical loads. These loads can require up to 5,000 watts
(5.0 kW) of power, but cannot exceed 20.8 amperes of
current at 230 volts.
Do not overload the generator. Some installations may require that electrical loads be alternated to avoid overloading. Applying excessively high electrical loads may damage the
generator 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 current) for starting than for continuous
operation.
1.3 INSTALLATION
This manual has been prepared under the assumption that a competent, qualified technician installed
the generator into a recreational vehicle. We also
assume the installer complied with all applicable
codes, standards and regulations pertaining to installation.
Owners/Operators should make sure nothing is done
during installation that might render the unit unsafe
or in noncompliance with applicable codes standards
and instructions. They should be sure the unit has
been installed to allow adequate ventilation for cooling and exhaust air.
1.4 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 suggest copying and posting the “Safety Rules” in potential hazard areas of the vehicle. Stress safety to all
operators and potential operators of this equipment.
1.5 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.
NOTE:
One side of the winding is grounded.
Figure 1.1 – Connections for 230 Volts Only
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6 Generac®Power Systems, Inc.
Section 1 – General Information
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
1.6 SPECIFICATIONS
1.6.1 FUEL REQUIREMENTS
These generators are equipped with a gasoline fuel 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 REGULAR grade gasoline is an acceptable substitute.
NOTE:
Using unleaded gasoline contributes to longer
engine valve life by reducing lead and carbon
deposits.
Generac does not recommend using any
gasoline containing alcohol (such as “gasohol”).
If you use any gasoline containing alcohol, it
must not contain more than 10 percent ethanol,
and it must be removed from the generator
during storage. Do NOT use any gasoline
containing methanol. If you use gasoline with
alcohol, inspect more frequently for fuel leaks
and other abnormalities.
1.6.2 ENGINE OIL REQUIREMENTS
Use only high quality detergent oil classified “For
Service SF” and with an oil viscosity rating of SAE
10W-30 oil. Do not pour in any additives to the recommended oil. Engine crankcase capacity is 1.4
liters. See Section 3.2 on page 11 for oil level check
and filing procedures.
1.6.3 ENGINE
Type of Engine ......................................GN-480, Twin-cylinder
Cooling Method..........................................................Air-cooled
Rated Horsepower ..........................................16 @ 3,600 rpm
Displacement ....................................................................480cc
Compression Ratio ........................................................8.6 to 1
Cylinder Block ..........................Aluminum w/Cast Iron Sleeve
Type of Governor ..............................Mechanical, Fixed Speed
Engine Governor Speed ............................................3000 rpm
Air Cleaner..........................Paper Element w/Foam Precleaner
Starter..........................................................12-volt DC Electric
Ignition System........................Solid-state w/Flywheel Magneto
Recommended Spark Plug
Champion ..................................................................RC12YC
AC....................................................................................R45S
Fram Autolite ......................................................................65
Spark Plug Gap ........................................0.030 inch (0.8 mm)
1.6.4 GENERATOR PP50G/PP70G
Rated Maximum Continuous
AC Output ....................5,000 (5.0 kW)/7,000 Watts (7.0 kW)
Rated Voltage ..............................................................230 Volts
Rated Maximum Continuous
AC Current ................................21.8 Amperes/30.4 Amperes
Phase ................................................................................Single
Rotor RPM ........................................................................3,000
Number of Rotor Poles ............................................................2
Engine RPM ............................................................2,900/3,000
Rated AC Frequency ........................................................50 Hz
Weight......................................................................222 Pounds
Length........................................................25 inches (635 mm)
Width ..................................................18.5 inches (469.9 mm)
Height..............................................16.75 inches (425.45 mm)
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Generac®Power Systems, Inc. 7
Section 2 – Operation
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
2.1 GENERATOR CONTROL PANEL
The following features are mounted on the generator
control panel (Figure 2.1):
Figure 2.1 – Generator Control Panel
2.1.1 FUEL PRIMER
Before starting a cold engine (if it has not been started in more than two weeks), you must press this
switch for approximately five seconds to bring fuel
from the tank to the fuel pump. This rocker type
switch springs back into its original position when
you release it.
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 230-volt AC output to the
vehicle circuits. These generators have either a 25
Amp, 2-Pole circuit breaker (PP50) or a 30 Amp
2-Pole circuit breaker (PP70).
2.2 OPTIONAL REMOTE
START/STOP PANEL
A remote mounted Start/Stop Panel (Figure 2.2) is
available that allows you to start and stop the generator engine conveniently from inside the vehicle. The
remote panel includes a Start/Stop switch, hour
meter, generator run lamp and a wire harness.
Figure 2.2 — Optional Remote Panel
(Models 004057 and 004184)
2.3 AUTOMATIC CHOKE
This engine is equipped with an automatic choke that
consists of two main components: a choke solenoid
and prechoke.
2.3.1 CHOKE SOLENOID
During engine cranking (Start/Stop switch at
START), a solid-state choke module signals the
choke solenoid to activate and cycle (choke on/choke
off) until the engine starts. The choke solenoid thus
opens and closes the carburetor choke valve only
when the engine is cranking. When the engine starts,
the choke stops cycling.
2.3.2 PRECHOKE
The choke system also has a temperature-sensitive
metal strip that adjusts choke valve angle according
to ambient temperatures (i.e., in cold ambient temperatures, 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.
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8 Generac®Power Systems, Inc.
Section 2 – Operation
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
2.4 BEFORE STARTING THE ENGINE
NOTE:
Instructions and information in this 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 completed so it complies with all applicable codes, standards 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 1.6.3
(Page 6) and Sections 3.1 and 3.2 (Page 11) for oil servicing procedures and recommendations.
Any attempt to crank or start the engine before
you have properly serviced it with the recommended oil may result in an engine failure.
2.4.3 FUEL SUPPLY
The engine must have an adequate supply of proper
fuel to operate. Before starting it, check that sufficient
fuel is available.
NOTE:
Depending on the installation, the generator may
have either a separate fuel tank, or it may “share”
the vehicle engine’s fuel tank.
2.4.4 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. Without sufficient cooling and
ventilating airflow, the engine/generator quickly overheats, 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 vehicle that, if open, might permit exhaust gases to enter
the vehicle.
The generator engine gives off DEADLY carbon
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even
death. Never operate the generator set with
the vehicle inside any garage or other enclosed
area. DO NOT OPERATE THE GENERATOR IF THE
EXHAUST SYSTEM IS LEAKING OR HAS BEEN
DAMAGED. SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a) inability to think coherently; (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.
2.5 STARTING THE GENERATOR
To start the generator from either the generator control 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 circuit breaker). Electrical load circuits will be
turned ON after the generator has started, stabilized 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 five 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.
If the engine does not start after it has been
cranking for 15 seconds, release the Start/Stop
switch and try again. Holding the switch for
longer than 15 seconds can damage the
starter motor.
4. Let the engine run at no-load for a few minutes to
stabilize and warm up.
5. Turn ON electrical loads using the means
provided (such as a main circuit breaker or
transfer switch).
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Generac®Power Systems, Inc. 9
Section 2 – Operation
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
2.6 STOPPING THE GENERATOR
1. Turn OFF all electrical loads using the means
provided (such as a main circuit breaker or
transfer switch).
2. Let generator run at no-load for a few minutes, to
stabilize internal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position.
2.7 APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator,
observe these guidelines:
• Before applying electrical loads, let the generator
stabilize and warm up for a minute or two.
• DO NOT overload the generator.
2.7.1 LETTING THE ENGINE STABILIZE
The generator supplies correct rated voltage only at
the proper governed speed. Some electrical appliances 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 sufficient 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.
2.7.2 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 automatically shut down.
To avoid overloading, add up the wattage of all connected electrical lighting, appliance, tool and motor
loads. This total should not be greater than the generator’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 times more watts of power
for starting than for running (for a few seconds
during motor starting). Be sure to allow for this
when connecting electrical loads to the generator.
First, figure 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.
2.8 PROTECTION SYSTEMS
2.8.1 LOW OIL PRESSURE SWITCH
This switch (Figure 2.3) has normally open (N.O.) contacts that are held open by engine oil pressure during
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.
2.8.2 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 284º F (140º C), initiating an engine
shutdown.
Figure 2.3 – Low Oil Pressure and
High Temperature Switches
2.8.3 FIELD BOOST
The Controller Circuit Board houses a field boost
diode and resistor. These two components are part of
a “field boost” circuit (Figure 2.4). During engine
cranking only, a positive DC (battery) voltage is delivered 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.
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10 Generac®Power Systems, Inc.
Section 2 – Operation
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
Figure 2.4 – Field Boost Circuit
2.8.4 OVERVOLTAGE PROTECTION
A solid-state voltage regulator (Figure 2.5) controls
the generator’s AC output voltage. This regulator supplies an excitation current to the rotor. By regulating
the rotor’s excitation current, the strength of its magnetic field is regulated and, in turn, the voltage delivered to connected electrical loads is controlled. When
the AC frequency is 50 Hertz, voltage is regulated at
115 volts.
NOTE:
The solid state voltage regulator is only connected across 1/2 of the output winding.
Figure 2.5 – Solid State Voltage Regulator
The voltage regulator also incorporates a “voltage
surge protection circuit.” This circuit prevents troublesome surges in the generator AC output voltage.
Voltage surge is a common cause of damage to electronic equipment.
2.9 ADDITIONAL INFORMATION
2.9.1 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 provide 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 piston rings, resulting in blowby and high oil consumption.
• After operating the unit for 25 hours, complete the
tasks recommended under Section 2.10.2.
2.9.2 25-HOUR CHECK-UP
After the 25-hour break-in period, contact a Generac
Authorized Service Dealer for the following maintenance. The vehicle owner is responsible for any
charges:
• Change the engine crankcase oil and oil filter.
• Inspect the cooling and ventilation openings.
• Check the engine ignition system.
• Inspect the entire electrical system.
• Inspect the engine exhaust system.
2.9.3 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.
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Generac®Power Systems, Inc. 11
Section 3 – Maintenance
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
3.1 CHECKING THE ENGINE OIL
LEVEL
For oil capacities and requirements, see “Engine Oil
Requirements,” Section 1.6.2 (Page 6). Check the
engine crankcase oil level at least every eight hours of
operation, or before you use it. To check the engine
oil level, proceed as follows (see Figure 3.1):
1. Be sure the generator is as level as possible.
2. Remove the dipstick and wipe it dry with a clean,
lint-free cloth.
3. Install and tighten the dipstick cap; then, remove
it again. The oil level should be at the dipstick
“Full” mark.
4. If necessary, remove the oil fill cap on the rocker
cover and slowly add oil until it reaches the dipstick “Full” mark. DO NOT FILL ABOVE THE
“FULL” MARK.
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 2.9.1, Page 10). 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 thereafter.
To change the oil and/or oil filter, proceed as
follows:
1. Run the engine until it is thoroughly warmed up
(at least five minutes) then shut OFF
the engine.
2. With the engine still warm from running, remove
the oil drain plug (Figure 3.1). Drain the oil into
a suitable container.
3. After the oil has drained, replace the oil drain plug.
(If only changing the oil, go to step 7.)
4. With the oil drained, remove the old oil filter by
turning it counterclockwise (Figure 3.2).
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, tighten the filter an additional 3/4 to one turn.
7. Remove the dipstick and fill crankcase with the
proper type and amount of recommended oil (see
Section 1.6.2, Page 6). The engine crankcase can
hold about 1.4 liters. DO NOT FILL ABOVE THE
“FULL” MARK.
8. Install and tighten the dipstick before operating
the engine.
9. Start the engine and check for leaks.
NOTE:
Check the oil level and fill to the “FULL” mark
after checking for leaks. The filter will retain some
oil.
Figure 3.1 — Oil Dipstick/Fill Tube and
Location of Oil Drain Plug
Figure 3.2 — Engine Oil Filter
OIL DIPSTICK
OIL DRAIN PLUG
12 Generac®Power Systems, Inc.
Section 3 – Maintenance
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
3.3 MAINTAINING 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 frequently if operating the generator in extremely dusty
or dirty conditions. Use the following procedure
(Figure 3.3):
1. Turn the knob 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.
6. Saturate the foam precleaner in clean engine oil.
Gently squeeze it in a clean cloth to remove
excess oil and to distribute oil (DO NOT TWIST).
7. Install the foam precleaner into the cover, fol-
lowed by the paper filter. Tabs at edges of paper
filter must lock into slots on cover.
8. Install the cover, foam precleaner and paper filter.
9. Replace knob to retain the filter in place.
Figure 3.3 – Engine Air Cleaner
3.4 CLEAN AIR INTAKE SCREEN
Clean all foreign material from the air intake screen
(Figure 3.4) at least once every 100 hours of operation. Clean more often if necessary.
Inspect the area around the generator exhaust muffler periodically and remove all grass, leaves, dirt,
etc., from this area.
Figure 3.4 – Cleaning Air Intake
3.5 CHECKING THE ENGINE
SPARK PLUG
Clean the spark plug and reset the spark plug gap
every 100 hours of operation.
1. Clean the area around the base of the spark plug
to keep dirt and debris out of the engine. Clean by
scraping or washing using a wire brush and commercial 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 questionable.
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 3.5).
Figure 3.5 – Setting the Spark Plug Gap
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.
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PAPER
FILTER
FOAM
PRE-CLEANER
COVER
KNOB
Section 3 – Maintenance
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
3.6 FUEL FILTER (GASOLINE ONLY)
Remove and replace the fuel filter (Figure 3.6)
once each year or every 100 hours of operation,
whichever comes first.
Figure 3.6 – Fuel Filter
3.7 SPARK ARRESTOR MUFFLER
If the generator is not equipped with a spark arrestor
exhaust muffler and is to be used on any forest covered, brush covered or grass covered unimproved
land, you may have to install a spark arrestor. The
spark arrestor must be maintained in effective working 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 recreational 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.
Be sure to reinstall the muffler plug tightly.
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 moisture 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.
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
interior and cause problems, and may also contaminate the generator fuel system.
3.9 BATTERY MAINTENANCE
All lead-acid batteries will discharge when not in use.
The generator battery should be inspected as follows:
3.9.1 WEEKLY
• Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
• Check the battery fluid level of unsealed batteries
and, if necessary, fill with Distilled Water Only. Do
not use tap water in batteries.
3.9.2 EVERY SIX MONTHS
• Have the state of charge and condition checked.
This should be done with an automotive-type battery hydrometer.
NOTE:
Servicing of the battery is to be performed or
supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.
Damage will result if the battery connections are
made in reverse.
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Generac®Power Systems, Inc. 13
TO FUEL PUMP
CUSTOMER FUEL CONNECTION
FUEL FILTER
14 Generac®Power Systems, Inc.
Do not dispose of the battery in a fire. The
battery is capable of exploding. Storage batteries give off explosive hydrogen gas. This gas
can form an explosive mixture around the battery 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 touching the battery by first touching a grounded
metal surface.
A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when working
on batteries:
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery;
• Disconnect any charging source prior to connecting
or disconnecting battery terminals; and
• Do not use any jumper cables or booster battery to
crank and start the generator engine. If any battery
has discharged, remove it for recharging.
Do not open or mutilate the battery. Released
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
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;
• 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 bicarbonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
3.10 MAJOR SERVICE MANUAL
To obtain a service manual for your generator, contact Generac or your nearest Generac Authorized
Service Dealer. 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.
3.13 OUT OF SERVICE PROCEDURE
3.13.1 REMOVAL FROM SERVICE
If you cannot exercise the generator every seven days,
and it is to be out of service longer than 30 days, prepare 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 10W-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.
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Section 3 – Maintenance
PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators
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