PRIMEPACT 55G
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.
Table of Contents PRIMEPACT 55G and 55LP Recreational Vehicle Generators Part I — Operating Instructions Introduction ..................................................Inside Front Cover Read This Manual Thoroughly ..........................................IFC Contents ............................................................................IFC Operation and Maintenance ..............................................IFC How to Obtain Service ......................................................
Safety Rules PRIMEPACT 55G and 55LP 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. WARNING: The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
ELECTRICAL HAZARDS FIRE 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.
Section 1 – General Information PRIMEPACT 55G and 55LP Recreational Vehicle Generators Please record the following information from the generator DATA DECAL or information decal. 4 1. Model Number ____________________ 2. Serial Number __________________ 3. kW Rating__________________________ 4. Rated Voltage __________________ 5. Phase ______________________________ 6. Hertz __________________________ Generac® Power Systems, Inc.
Section 1 – General Information PRIMEPACT 55G and 55LP 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 competent authority.
Section 1 – General Information PRIMEPACT 55G and 55LP Recreational Vehicle Generators 1.6 SPECIFICATIONS ◆ 1.6.1 FUEL REQUIREMENTS This generator is equipped with a gasoline fuel system as standard equipment. Specific installations may provide either a separate fuel tank for the generator, or the generator may “share” the vehicle engine’s fuel tank. Model PrimePact 55G PrimePact 55LP No Load 0.29 0.47/2.01 1/2 Load 0.54 0.85/3.62 Full Load 0.96 1.66/7.
Section 2 – Operation PRIMEPACT 55G and 55LP Recreational Vehicle Generators • For engines of 225 cc or more, Category C=250 hours, B=500 hours, and A=1000 hours. 2.1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel (Figure 2.1): ◆ 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 10 seconds to bring fuel from the tank to the fuel pump.
Section 2 – Operation PRIMEPACT 55G and 55LP Recreational Vehicle Generators ◆ 2.3.2 PRECHOKE ◆ 2.4.5 ENGINE EXHAUST GAS 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. 2.
Section 2 – Operation PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 seconds. However, if the engine is warm, skip Step 2. 3. To crank and start the engine, hold the start/stop switch at START. 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 wait 1 minute before trying again.
Section 2 – Operation PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 ◆ 2.8.4 OVERVOLTAGE PROTECTION A solid-state voltage regulator (Figure 2.5) controls the generator’s AC output voltage.
Section 3 – Maintenance PRIMEPACT 55G and 55LP Recreational Vehicle Generators ◆ 2.8.6 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. Check all fluid levels. Inspect the cooling and ventilation openings. Check the engine ignition system. Inspect the entire electrical system. Inspect the engine exhaust system. ◆ 2.8.
Section 3 – Maintenance PRIMEPACT 55G and 55LP Recreational Vehicle Generators 3.4 Figure 3.2 — Engine Oil Filter 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 3.3 MAINTAINING THE ENGINE AIR CLEANER ◆ 3.3.
Section 3 – Maintenance PRIMEPACT 55G and 55LP 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 FUEL FILTER TO FUEL PUMP CUSTOMER FUEL CONNECTION 3.7 3.8 When moisture is allowed to remain in contact with windings, some of the moisture will be retained in voids and cracks in the insulation.
Section 3 – Maintenance PRIMEPACT 55G and 55LP Recreational Vehicle Generators 3.10 MAJOR SERVICE MANUAL 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.
Section 3 – Maintenance PRIMEPACT 55G and 55LP Recreational Vehicle Generators ◆ 3.13.2 RETURN TO SERVICE To return the unit to service after storage, proceed as follows: 1. Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see Section 1.5.4, Page 6). If necessary, drain and refill with the proper oil. 2. Check the state of the battery. Fill all cells of unsealed batteries to the proper level with distilled water.
Section 4 – Notes PRIMEPACT 55G and 55LP Recreational Vehicle Generators 16 Generac® Power Systems, Inc.
PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
Safety Rules PRIMEPACT 55G and 55LP Recreational Vehicle Generators DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the manufacturer’s instructions and recommendations.
Safety Rules PRIMEPACT 55G and 55LP Recreational Vehicle Generators ELECTRICAL HAZARDS FIRE 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.
Section 5 – General Information PRIMEPACT 55G and 55LP Recreational Vehicle Generators 5.1 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.
Section 5 – General Information PRIMEPACT 55G and 55LP Recreational Vehicle Generators Figure 5.2 – Major Features and Dimensions PrimePact 55G and 55LP Control Panel Spark Plugs (both sides, not shown) Oil Fill/Oil Level Fuel Filter Oil Drain Plug Fuel Pump Starter Contactor Oil Filter Air Filter Ground Lug Generac® Power Systems, Inc.
Section 6 – Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators 6.1 LOCATION AND SUPPORT ◆ 6.1.1 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.
6.1.4 GENERATOR RESTRAINT 6.2.2 COMPARTMENT CONSTRUCTION Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing. These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compartment is used) and (c) the supporting framework (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.
Section 6 – Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators • 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 construction, 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.
Section 6 – Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators Figure 6.7 – Typical Noise Abatement ◆ 6.2.5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compartment 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). Fuel lines and exhaust piping must not penetrate into the vehicle living area. Generac® Power Systems, Inc.
6.3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. Without sufficient airflow, 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 available to the generator for cooling, ventilating and combustion.
Figure 6.12 – Air Inlet Using Ductwork ◆ 6.3.4 TESTING THE INSTALLATION Generac recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, you will need to enlarge the air openings. Never place a unit into service until absolutely certain that cooling and ventilation is adequate. NOTE: You must test the installation, especially if you bring in air from below the generator set. Figure 6.
Section 6 – Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators ◆ 6.4.1 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 vehicle 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.
Figure 6.15 – Typical Propane Gas Fuel System ◆ 6.5.4 PRIMARY REGULATOR Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regulator. Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank. The following rules apply: • For best results, the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column. Do NOT exceed 14 inches water column.
Section 6 – Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators The greater the airflow through the carburetor venturi, 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 movement of the regulator valve. The more the regulator valve opens, the greater the gas flow that is proportional to airflow through the generator.
Section 6 – Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators ◆ 6.6.1 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.
Section 6 – Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators ◆ 6.7.2 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.
Section 6 – Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators ◆ 6.7.6 POWER SUPPLY CORD The power supply cord must comply with all applicable codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected. ◆ 6.7.7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code (NFPA 70, 551-7) requires that you install ground fault circuit interrupters (GFCIs) on all external and some internal electrical receptacles.
Section 6 – Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators 6.8 BATTERY INSTALLATION Figure 6.20 – Connecting Battery Cables ◆ 2.8.1 RECOMMENDED BATTERY Install a battery requirements: that meets the following • 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 capable of delivering 400 cold-cranking amperes.
Section 7 – Post Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators ◆ 6.9.1 REMOTE PANEL MODELS The remote panels mount a rocker type start/stop switch, a “Generator Run” advisory lamp and an hourmeter. The hourmeter should be used in conjunction with the maintenance operations found in Part I of this manual. • Model 004057 includes the remote panel and a 10 foot long, 4 wire harness. • Model 004184 includes the remote panel and a 30 foot long, 4 wire harness. 7.
Section 7 – Post Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators 7.5 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.
Section 8 – Troubleshooting PRIMEPACT 55G and 55LP Recreational Vehicle Generators 8.1 TROUBLESHOOTING GUIDE PROBLEM Engine won’t crank. CAUSE 1. 2. CORRECTION 3. 4. 5. 6. 7. 15 amp fuse blown. Loose, or corroded or defective battery cable(s). Battery is discharged or defective. Defective starter contactor. Defective starter motor. Defective Start/Stop switch Defective Engine Control Board 3. 4. 5. 6. 7. Replace blown fuse. Tighten, clean or replace, as necessary. Recharge or replace battery.
Section 9 — Electrical Data PRIMEPACT 55G and 55LP Recreational Vehicle Generators Electrical Schematic – Drawing No.
Generac® Power Systems, Inc. 39 SES ON LOW PRESSURE) TEMP.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators Sheet Metal – Drawing No. D3150-A 40 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators Sheet Metal – Drawing No. D3150-A ITEM PART NO. QTY.
42 Generac® Power Systems, Inc.
ITEM PART NO. QTY. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 086318 090141 046911 025017 046526 022129 072391 077603 022259 052858 1 1 4 8 2 8 2 2 2 6 BASE, MOUNTING GROUND CABLE MOUNT VIBR 1.50X1.38 X 3/8-16) SCREW HHC 3/8-16 X 1/2 G5 WASHER LOCK M10 WASHER LOCK M8-5/16 SKID, RUBBER MOUNT SAFETY BOLT 5/16-18 x 3 1/2" NUT HEX 5/16-18 STEEL NUT LOCK M8 Generac® Power Systems, Inc.
12 13 11 10 28 4 1 40 14 3 7 6 9 88 14 15 7 34 73 10 24 23 27 67 67 72 32 33 85 79 44 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators Base and Pulleys – Drawing No. D3154-A ITEM PART NO. QTY.
44 45 51 57 8 29 22 TO ENGINE GROUND 38 23 6 45 21 40 17 36 15 61 34 9 18 14 60 40 10 58 20 12 11 31 37 18 43 24 3 14 16 63 35 19 55 2 13 15 62 17 4 44 40 63 44 48 49 4 45 47 5 1 46 50 7 2,53 25 28 27 26 26 56 39 30 31 31 46 Generac® Power Systems, Inc.
ITEL4686.6(P)996.8AR TY DESCRIPTION7 NO Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators Exploded View - Engine Common Parts – Drawing No. 079216-G 48 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators Exploded View - Engine Common Parts – Drawing No. 079216-G ITEM PART NO. QTY.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators Carburetor – Drawing No. 093753-H 50 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators Carburetor – Drawing No. 093753-H ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 25 26 27 28 29 30 31 32 33 PART NO. 073112B 074962C 074962G 070155 070108 056893 074961 047227 037398 073131 066476 070575 070125 073374 074947 089473 091306 077091 031879 022159 072536 087770 074946 030340 0C2338B 0C2338 0C2338D 075252 0A7782A 040173 066829 075944 070594 077075 QTY.
13 25 15 17 1 11 2 18 23 27 29 4 21 3 2 5 2 3 7 6 28 4 4 12 9 8 10 9 52 Generac® Power Systems, Inc.
Section 11 — Notes PRIMEPACT 55G and 55LP Recreational Vehicle Generators Generac® Power Systems, Inc.
Section 11 — Notes PRIMEPACT 55G and 55LP Recreational Vehicle Generators 54 Generac® Power Systems, Inc.
Section 11 — Notes PRIMEPACT 55G and 55LP Recreational Vehicle Generators Generac® Power Systems, Inc.
Section 12 – Warranty PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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.
Section 12 – Warranty PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 continue for 24 consecutive months thereafter.
Section 12 – Warranty PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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.
