® POWER SYSTEMS, INC.
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 procedures.
Table of Contents PRIMEPACT 50 Recreational Vehicle Generator 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 .................
Safety Rules PRIMEPACT 50 Recreational Vehicle Generator 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.
Safety Rules PRIMEPACT 50 Recreational Vehicle Generator 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 50 Recreational Vehicle Generator 1.1 GENERATOR IDENTIFICATION 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 __________________ Model: 02010-0 PRIMEPACT 50 1. 2. 3. 4. 5. 18 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Section 1 – General Information PRIMEPACT 50 Recreational Vehicle Generator 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.
Section 1 – General Information PRIMEPACT 50 Recreational Vehicle Generator NOTE: Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits. 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. ◆ 1.5.5 ENGINE ! Generac does not recommend using any gasoline containing alcohol (such as “gasohol”).
Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator 2.1 NOTE: GENERATOR CONTROL PANEL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control Panel 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).
Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator 2.3 AUTOMATIC CHOKE (GASOLINE ONLY) The engine is equipped with an automatic choke that consists of two main components: a choke solenoid and prechoke. ◆ 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: ◆ 2.3.
Section 2 – Operation PRIMEPACT 50 Recreational Vehicle 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 provided 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.
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). Figure 2.3 – Low Oil Pressure and High Temperature Switches Applying electrical loads in excess of the unit’s rated capacity will cause the engine/generator to automatically shut down.
Section 2 – Operation PRIMEPACT 50 Recreational Vehicle Generator ◆ 2.9.4 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.
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): 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.
Section 3 – Maintenance PRIMEPACT 50 Recreational Vehicle Generator 3.3 4. Clean the air cleaner cover then reassemble following steps 7-9 in Section 3.3.1. 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 3.2): 1. 2. 3. 4. 5.
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 3.8 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.
Section 3 – Maintenance PRIMEPACT 50 Recreational Vehicle Generator DANGER 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.
Section 3 – Maintenance PRIMEPACT 50 Recreational Vehicle Generator 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.
PART II – INSTALLATION INSTRUCTIONS DANGER ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
Safety Rules PRIMEPACT 50 Recreational Vehicle Generator ! 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 50 Recreational Vehicle Generator 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 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.
Section 1 – General Information PRIMEPACT 50 Recreational Vehicle Generator Figure 1.2 – Major Features and Dimensions Generac® Power Systems, Inc.
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.
Section 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator ◆ 2.1.4 GENERATOR RESTRAINT ◆ 2.2.2 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).
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 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 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator Figure 2.7 – Typical Noise Abatement ◆ 2.2.5 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). DANGER ! Fuel lines and exhaust piping must not penetrate into the vehicle living area. Figure 2.
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. Without sufficient airflow, the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also may cause fire and personal injury.
Section 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator Figure 2.12 – Air Inlet Using Ductwork ◆ 2.3.4 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.
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 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.
Section 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator Figure 2.15 – Typical Propane Gas Fuel System ◆ 2.5.4 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.
Section 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator 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 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator ◆ 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 damage, injury or warranty expense that might be caused by such unapproved installation or modification.
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.
Section 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator ◆ 2.7.6 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. ◆ 2.7.7 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 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator 2.8 BATTERY INSTALLATION Figure 2.20 – 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 2 – Installation PRIMEPACT 50 Recreational Vehicle Generator ◆ 2.9.1 REMOTE PANEL MODELS 2.9.1.1 Model 9042 This remote panel mounts a rocker type start/stop 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 manual. ◆ 2.9.
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. ! 3.2 Do not make any unnecessary adjustments. Factory settings are correct for most applications. When making adjustments, however, be careful to avoid overspeeding the engine.
Section 3 – Post-installation Start-up Adjustments PRIMEPACT 50 Recreational Vehicle Generator 3.5 INSTALLATION CHECKLIST ◆ LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. ◆ GENERATOR COMPARTMENT ◆ 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.
Appendix 1 – Notes PRIMEPACT 50 Recreational Vehicle Generator 38 Generac® Power Systems, Inc.
Appendix 2 – Troubleshooting PRIMEPACT 50 Recreational Vehicle Generator TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION The engine will not crank. 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. 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.
Appendix 3 — Electrical Data PRIMEPACT 50 Recreational Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 94210-A 40 Generac® Power Systems, Inc.
Appendix 3 — Electrical Data PRIMEPACT 50 Recreational Vehicle Generator Electrical Schematic and Wiring Diagram – Drawing No. 94210-A Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 02010-0) – Drawing No. A8924-B 42 Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 02010-0) – Drawing No. A8924-B ITEM PART NO. QTY.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 04164-0) – Drawing No. C3878-A 44 Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Base and Pulleys (Model 04164-0) – Drawing No. C3878-A ITEM PART NO. QTY.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Alternator and Panel (Model 02010-0 and 04164-0) – Drawing No. A8922-B 46 Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Alternator and Panel (Model 02010-0 and 04164-0) – Drawing No. A8922-B ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 30 31 32 33 34 35 36 37 38 PART NO. QTY.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Sheet Metal (Model 02010-0 and 04164-0) – Drawing No. A8921-A 48 Generac® 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. A8921-A ITEM PART NO. 1 A4323 2 45756 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 QTY. DESCRIPTION 1 9 SCROLL, FLYWHEEL SCREW, TAPTITE M6-1.0 X 10 LG 29289 2.5 FT.FOAM TAPE SRV 91222-D 1 FLYWHEEL 67198-N 1 WASHER, BELLVILLE M20 X 2.2 67890 1 NUT, M20 X 1.5, FLYWHEEL A4456 1 3/8" SPECIAL LOCK WASHER 56893 21 SCREW, CRIMPTITE #10-24 X .
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator GN-410 Engine (Model 02010-0 and 04164-0) – Drawing No. A7894-D 50 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-D ITEM PART NO. QTY.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 02010-0) – Drawing No. A8923-A 52 Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 02010-0) – Drawing No. A8923-A ITEM PART NO. QTY.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 04164-0) – Drawing No. C3880- 54 Generac® Power Systems, Inc.
Appendix 4 — Exploded Views and Parts Lists PRIMEPACT 50 Recreational Vehicle Generator Engine Accessories (Model 04164-0) – Drawing No. C3880- ITEM PART NO. QTY. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 A6532 91039 51753 72347 89228 A7336A 90970 A6564 56893 A6566 A6780 1 1 1 1 1 1 1 1 3 1 1 12 13 14 15 16 17 18 19 96290 73111 81646 A6563 C3633 A6581 C2332 92164 2 1 1 1 2 1 1 1 20 21 83503 A7029 1 1 22 A6913 1 MANIFOLD, INTAKE GASKET, MANIFOLD/HEAD HHCS-M6-1.0 X 40 LG.
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.
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 continue for 24 consecutive months thereafter.
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.
