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Generac 09290-4 Owner's Manual

1. ENGINE OL OIL PRESSURE FILTER SWITCH RES 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 deliv ered through the diode resistor brushes and slip rings and the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Generac Power Systems Inc 9 Section 2 Operation ix PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Figure 2 4 Field Boost Circuit 16 CONTROLLER CIRCUIT CLOSEST TO BOARD BEARING 4 Sp rm GRND 2 8 4 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 5 controls the generator s AC output voltage This regulator sup plies an excitation current to the rotor By regulating the rotor s excitation current the strength of its mag netic field is regulated and in turn the voltage deliv ered to connected electrical loads is controlled When the AC frequency is 50 Hertz voltage is regulated at 115 volts NOTE The solid state voltage reg
2. 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage 5 Phase 6 Hertz 9 14 PRIMEPACT 506 I DU isi D S ELO comm 07 REFERENCE NUMBER IDENTIFICATION l Generator Air Intake Screen 8 FuelInlet 2 Data Plate 9 Fuel Primer Switch 3 Engine Start Stop Switch 10 Fuel Pump 4 15 amp Fuse 11 Oil Filter 5 25 or 30 Amp 2 Pole Circuit Breaker 12 Starter Contactor 6 Optional Remote Panel Receptacle 13 Oil Drain Plug 7 Generator AC Output Leads 14 Oil Dipstick and Filler Tube Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 1 2 GENERATOR APPLICABILITY These generators have been designed and manufac tured for supplying electrical power for recreational vehicles You should not modify the generator or use it for any application other than for what it was designed If there are any questions pertaining to its application write or call the factory Do not use the unit until you have been advised by a competent authority DIG A 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 Installation of Electrical Systems The generator also must have been installed in strict compliance with the manufacturer s
3. TUBULAR METAL gt El SUPPORT FRAME VEHICLE METAL LINED CHASSIS BOTTOM 2 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a gen erator or inside a compartment that the installer con structs the compartment MUST meet certain specifi cations as outlined in the following sections 2 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a mini mum clearance of 1 2 inch 13 mm on the front and top 1 inch 25 mm on the sides and 1 2 inch 13 mm from the back for air circulation AFTER the compartment has been lined with metal and sound insulation Figure 2 4 NOTE Refer to Figure 1 2 Major Features and Dimensions on Page 21 Figure 2 4 Clearances Plywood Compartment 11 2 Clearance on Top 1 Clearance in Back INSTALLATION Section 2 Installation 2 2 2 COMPARTMENT CONSTRUCTION The generator compartment should be either con structed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative to gal vanized steel due to aluminum s low melting point If the compartment is lined with galvanized steel it may be constructed of any material Generac rec ommends that the compartment be constructed of 1 2 inch thick plywood not strandboard with the floor made of a double thickness of
4. M 25 inches 635 mm MAII sesta yen tei tee RR 18 5 inches 469 9 mm Height toners 16 75 inches 425 45 mm Section 2 Operation PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators aE 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 Figure 2 1 Generator Control Panel FUSE MAIN START 15 BREAKER STOP FUEL PRIMER 2 1 1 FUEL PRIMER Before starting a cold engine if it has not been start ed in more than two weeks you must press this switch for approximately 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 5 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 g
5. RON oOo oy 22 dE AS Section 6 Exploded Views and Parts Lists PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Base and Pulleys Drawing 0D6577 A DESCRIPTION BASE MOUNTING GROUND CABLE MOUNT RUBBER CAPSCREW HEX HD 3 8 16 X 1 2 LOCKWASHER M10 LOCKWASHER 5 16 M8 SKID RUBBER MOUNT SAFETY BOLT 5 16 18 x 3 1 2 NUT HEX 5 16 18 NUT FLANGED LOCK M8 1 25 CAPSCR HEX HD M8 1 25 x 60mm SPRING BELT TENSION WASHER SPRING CNTR SLIDE NYLON SUPPORT NYLON SLIDE MANIFOLD EXHAUST RING SEALING SHCS M8 1 25 x 20mm GASKET COLLECTOR PAN COVER PLATE EXTERNAL PULLEY ENGINE PP70 PULLEY ENGINE 50 PULLEY ALT PP70 PULLEY ALT PP50 BELT POLY V 4L 40 WASHER PULLEY RETAINER 7GA 0 41 x 1 62 HHCS 3 8 24 X 1 GRADE 5 GUIDE BLOWER HOUSING CAPSCR HEX HD 3 8 24 x 2 1 4 TAPTITE M6 1 00 x 20mm BRACKET FUEL PUMP HOUSING BLOWER SPACER BLOWER HOUSING 2 3 8 LOCKWASHER M6 CAPSCR HEX HD M5 0 80 x 80mm SPRING GENERATOR SET MT NUT HEX M6 x 1 0mm CAPSCREW HEX HEAD M6 1 0 x 25mm FUEL PUMP FUEL FILTER FITTING 1 8 PIPE TO TUBE FUEL LINE CAPSCREW HEX HD 1 4 20 x 1 PIPE PLUG 3 8 SQ HD FILL TUBE amp PLUG CAP amp DIPSTICK ASSEMBLY O RING CAP OIL FILL TUBE GASKET ITEM 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 7
6. 200 Furnace Fan 1 3 HP eee 500 Refrigerdlor riina 600 Air Conditioner 12 000 1700 LHP 2000 Breeze 500 Milk Goolet e e eerte a reve dert 1100 Submersible Pump 1 1 2 2800 Submersible Pump 1 2000 Paint Sprayer Airless 1 3 HP 600 Table Saw 10 1750 to 2000 Allow 2 1 2 times the listed watts for starting these devices Generac Power Systems Inc 15 5 Notes PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 16 Generac Power Systems Inc PART Il INSTALLATION INSTRUCTIONS A EX A ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS enerac Power Systems 1 SAFETY RULES Safety Rules PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators DANGER For fire safety installation of a generator into a recreational vehicle must comply strictly with article 551 NFPA 70 ANSI 1 1975 AND ANSI 119 2 1975 501C Standard for Recreational Vehicles Part 3 Installation of Electrical Systems In addition installation must comply with the manufacturer s instructions and recommendations NOTICE TO INSTALLER These Installation Instructions have been published by Generac to aid in the installation of the products de
7. 3 0 8 052858 4 8 1 25 FLANGE LOCK NUT 42 094192 1 HARNESS CUSTOMER CONNECTION 9 066386 1 BRUSH HOLDER 43 083049 1 REGULATOR VOLTAGE 10 066849 2 M5 0 8 x 16 LG TAPTITE 44 022152 6 M5 LOCK WASHER 11 027756 4 NYLON WASHER 45 051716 4 M5 0 8 HEX NUT 12 086314 1 GENERATOR TOP HOUSING 46 082081 1 CIRCUIT BREAKER 30A PP70 13 075234 1 RESISTOR 074968 1 CIRCUIT BREAKER 25 50 14 022473 2 14 M6 FLAT WASHER 47 045771 4 M8 1 25 HEX NUT 15 022097 5 14 M6 LOCK WASHER 48 025105 4 6 32 x SCREW W LOCK WASHER 16 055816 1 M6 1 0 x 70 LG CAPSCREW 49 086315 1 PANEL COVER 17 090141 2 GROUND CABLE 50 090734 4 M4 0 7 x 12 LG CAPSCR W LOCK 18 0A1658 2 SPECIAL LOCK WASHER WASHER amp FLAT WASHER 19 074906 4 M6 1 0 x 20 LG TAPTITE 51 022985 1 6 FLAT WASHER 20 092234 1 CONTROLLER 52 032300 1 FUSE HOLDER 21 0D2724 2 BOOT ROCKER SWITCH 53 022676 1 FUSE AGC 15A 22 022129 4 5 16 M8 LOCKWASHER 54 087798 1 SWITCH S P D T 6A START STOP 23 031879 2 WASHER FLAT 4 55 092113 1 SWITCH S P D T FUEL PUMP 24 086316 1 PANEL SHEET METAL 56 075210A 1 TERMINAL BLOCK 25 053650 1 4 PIN CONNECTOR 57 0A8475A 1 8 SPECIAL LOCK WASHER 26 004258 1 CONDUIT ASSEMBLY 58 051715 1 M4 0 7 HEX NUT 27 075244 1 ASSEMBLY REMOTE CABLE 59 090157 1 DECAL CB RATING 30A PP70 28 0234845 1 BUSHING 092854 1 DECAL CB RATING 25A PP50 29 074908 1 M5 0 8 x 10 LONG TAPTITE 60 055440 2 M5 0 8 x 25 CAPSCREW 30 075476 4 M4 0 7 x 16 LG CAPSCREW 61 094191 1 DECAL
8. ational vehicle generators do not have a spark arrestor screen but are of the more efficient toroid or swirl type To remove carbon and combustion deposits from such mufflers remove the plug from the muffler and run the engine for approximately 15 minutes Shut down the engine let the muffler cool and install the plug WARNING amp 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 MAINTENANCE 2 0 Section 5 Maintenance 5 8 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the
9. Exhaust System ees teen nonna eR neue on uh ns 28 2 0 Electrical conn ctions oerte nonet ve 29 2 7 Battery Installation eret rere neon 2 8 Optional Accessories Section 3 Post Installation Start up and Adjustmients assassin itin nianniannin 33 3 1 Post Installation 33 3 2 Before Initial 33 3 9 Aminal s odo repu orent 33 34 Testing Under Load 33 3 5 Installation Checklist nna 34 Section 4 Troubleshooting 35 4 1 Troubleshooting 35 Section 5 Electrical Data 36 Section 6 Exploded Views and Parts Lists 38 Section 7 Warranty 48 Generac Power Systems Inc 1 SAFETY RULES 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 A 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 WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects
10. GENERAL HAZARDS For safety reasons Generac recommends that the installation initial start up and mainte nance of this equipment is carried out by a Generac Authorized Service Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust sys tem must be installed properly in strict compli ance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in noncompli ance with such codes and standards The genera tor compartment must be completely vapor sealed from the vehicle interior There must be no possi bility of exhaust fumes entering the vehicle interi or Never operate this equipment with a leaking or defective exhaust system Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or per mit even partial blockage of ventilation provisions as this can seriously affect safe operat
11. choke valve This may take about three minutes in cooler weather Generac Power Systems Inc 7 Section 2 Operation ix 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 com pleted so it complies with all applicable codes stan dards and regulations and with the manufacturer s recommendations 2 4 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommended oil before starting Refer to Section 1 6 3 Page 6 and Sections 3 1 and 3 2 Page 11 for oil ser vicing procedures and recommendations caution Ak Any attempt to crank or start the engine before you have properly serviced it with the recom mended oil may result in an engine failure 2 4 5 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 com partment must be
12. 1 2 inch ply wood with the grain of the wood at cross section for added strength Figure 2 5 Figure 2 5 Typical Compartment Construction CROSS SECTION VIEW METAL LINING FIREPROOF SOUND INSULATION is 9 9l METAL LINING pee VAPOR SEALED PLYWOOD ATALLTIMES METAL LINING f If constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel All seams splices and joints of the compartment walls unless vapor tight by design should be caulked to prevent poisonous flammable or explo sive vapors from entering the vehicle interior NOTE Caulking must be done so that the caulking mate rial will stay in place permanently Pressing such materials as putty tape onto joints and seams is not acceptable A high quality silicone rubber base sealant is recommended e Holes and openings made in the compartment walls to allow for the passage of electrical conduit conductors hoses cables etc into the vehicle liv ing area must be sealed vapor tight with silicone rubber base sealant Generac Power Systems Inc 23 INSTALLATION Section 2 Installation If flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartments electrical junction box NOTE Flexible metal conduit due to i
13. 5 Engine is flooded 5 Wait 5 10 minutes try again 6 Fuel filter is clogged 6 Replace filter if clogged 7 Engine spark plugs defective 7 Clean regap or replace as needed 8 Badignition magneto on engine 8 Replace if defective 9 Badcarburetor 9 Adjust repair or replace 10 Dirty air cleaner 10 Clean or replace as needed Engine starts hard runs rough 1 Dirty engine air cleaner 1 Clean or replace as needed 2 Automatic Choke sticking 2 Freechoke linkage as needed 3 Defective spark plugs 3 Clean regap or replace 4 Defective ignition magneto 4 Replace it if defective Engine starts then shuts down 1 Engine oil level is low 1 Add oil as needed 2 Bad low oil pressure switch 2 Replace if bad 3 Defective High Temp Switch 3 Replace Switch if bad 4 _ Water in fuel 4 Drain fuel tank and refill No AC output voltage 1 Main breaker s open Close main breaker s 2 Transfer switch if so equipped is Reset transfer switch set to wrong position 3 Failure in vehicle electrical system 3 See vehicle manual 4 Generator component failure 4 Contact an authorized service facility Generac Power Systems 35 ELECTRICAL i DATA Wiring Diagram amp Electrical Schematic Drawing No 0D6579 LEGEND BCR BATTERY CHARGE RECTIFIER CIRCUIT BREAKER 25 50 CIRCUIT BREAKER 30 PP70 CIRCUIT BREAKER 3 0 CH HEATER
14. 59 072361 1 GOVERNOR SHAFT BUSHING 12 069336 1 OIL SUMP GASKET 60 072362 1 GOVERNOR SHAFT BUSHING 13 069325 8 CYLINDER HEAD BOLT 61 070199 1 BREATHER BAFFLE 14 067888 2 3 8 NPT OIL DRAIN PLUG 62 072366 1 COTTER PIN 15 072334 1 CRANKSHAFT ASSEMBLY 64 072365 1 GOVERNOR SHAFT WASHER 16 075247 1 OIL SUMP ASSEMBLY 65 068555 2 CRANKCASE DOWEL 17 067924 1 OIL SEAL 66 067806 4 CYLINDER HEAD DOWEL 18 067878 9 OIL SUMP BOLT 73 068572 2 OIL PUMP SCREW 19 075248 2 STANDARD PISTON ASSEMBLY 74 075272 2 SPARK PLUG TERMINAL 20 075249 2 STANDARD PISTON RING SET 75 070122 4 VALVE STEM SEAL 21 069327 4 PISTON PIN RING 76 067910 2 INTAKE VALVE SEAT 22 075250 2 PISTON PIN ASSEMBLY 78 067813 4 VALVE GUIDE 23 089972 2 CONNECTING ROD ASSEMBLY 81 070592 1 AIR CLEANER BASE 24 072346 4 CONNECTING ROD BOLT 82 073123 1 AIR FILTER NOT SHOWN 25 069316 2 EXHAUST VALVE 83 070593 1 AIR CLEANER COVER 26 069317 2 INTAKE VALVE 84 003633 1 AIR CLEANER COVER SCREW 27 067816 4 VALVE SPRING 85 067156 2 AIR CLEANER BASE SCREW 28 069320 4 VALVE SPRING RETAINER 86 069341 1 PRE CLEANER ELEMENT 29 070513 4 VALVE KEEPER 88 070597 1 AIR INLET TUBE 30 070584 4 VALVE TAPPET 89 072305 1 BREATHER DEFLECTOR 31 070530 1 CAMSHAFT ASSEMBLY 90 067920 2 VALVE COVER GASKET 32 072358 1 INTAKE MANIFOLD 91 069328 1 VALVE COVER 33 069379 2 CARBURETOR MOUNTING GASKET 92 070547 1 OIL PUMP ASSEMBLY 34 067895 2 INTAKE MANIFOLD GASKET 93 070536 1 GOVERNOR SLIDER 35 070594 2 CARBURETOR MOUNTING BOLT 94 070577 4 PU
15. CS CHOKE SOLENOID Fl FUSE 15 FP FUEL PUMP DR LPG SHUT VALVE GT TERMINAL GROUND 4 HM METER HOUR OPTIONAL HTO SWITCH HIGH TEMP DIL CLOSES ON IM IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO CYL Ll LIGHT RUN OPTIONAL SWITCH LOW DIL PRESSURE CLOSES PCB ENGINE CONTROLLER Rl RESISTOR 1 OHM 25W SC STARTER CONTACTOR SM STARTER MOTOR SWI SWITCH START STOP SW2 SWITCH FUEL PRIMER 1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TC TERMINAL CONN 4 TAB CONNECTOR 36 Generac Power Systems Inc Section 5 Electrical Data PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators BATTERY BLK SC 13 RED _ 16 Ji 1 gt 4 X J1 5 6 17 J1 7 2 17 J1 8 5 J1 9 gt 4 J1 102 66 J1 112 85 J1 12 0 J1 137 J1 142 18 PANEL J1 152 18 CONNECTOR 0I 1 e 3 4 66 77 66 HIGH TEMP BATTERY CHARGE WINDING 55 ON LOW PRESSURE RI ON POWER WINDING 60V 60V 33 ELECTRONIC VOLTAGE REGULATOR CB2 BLACK ON 9 T1 e 6 T3 DPE WINDING h OF O A A AA 4 FIELD BLACK RED GREEN 230V Section 5 Electrical Data PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators EUEPTBIGAE Wiring Diagram amp Electrical Schematic Drawing
16. Filter 11 3 3 Maintaining the Engine Air Cleaner 12 3 4 Clean Air Intake 12 3 5 Checking the Engine Spark 12 3 6 Fuel Filter Gasoline Only 13 3 7 park Arrestor erre en 13 3 8 Cleaning the 13 3 9 Battery Maintenance eee er ee reete depart 13 3 10 Major Service Manual eese 14 S L1 Drive ss coin 14 3 12 Exercising the Generator 14 3 13 Out of Service Procedure 14 3 14 Wattage Reference 9 15 E 16 Table of Contents TABLE 5 Part 1 Installation Instructions Safety RSS 2 18 Section 1 General Information 20 1 1 Purpose and Scope of the Manual 20 IM quA 20 1 3 Standards Booklets eese 20 1 4 Equipment 20 15 Generator Engine Operating Speed 20 1 6 Generator AC Connection System 20 Section 2 Installation 2 1 Location and Support esineen neos 2 2 Generator 2 3 Cooling and Ventilating Air 2 4 Gasoline Fuel System 2 5
17. JUNCTION BOX Install an approved square electrical junction box with a blank cover on the interior or exterior wall of the area you plan to install the generator NOT on the generator Route the generator s AC output leads into this junction box through approved flexible con duit This is the point of first termination for genera tor AC output leads Generac Power Systems Inc 29 INSTALLATION Section 2 Installation 2 6 2 WIRING Wiring should be of stranded copper to reduce the chance that vibration may cause breakage Wire gauge size should be large enough to handle at least 115 percent of the installed generator s rated maximum current If neutral conductors are used they must be the same size as other leg wires Route power supply conductors from generator AC output leads T1 red T3 black and the green ground wire through approved flexible conduit to the electrical junction box on the compartment wall If flexible metal conduit is used between the gener ator and the compartment junction box the con duit end that terminates the compartment junction box must be vapor sealed Flexible metal conduit is NOT vapor tight along its entire length From the junction box route power supply wires through approved conduit to either a double pole double throw transfer switch or b approved isolation receptacle Connecting to a transfer switch or isolation receptacle must pre vent vehicle electrical circui
18. and it is to be out of service longer than 30 days pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 10W 30 oil having API classification For Service SE 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 PRIMEPACT 50 and 70 50Hz 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 recommend ed 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 DO NOT USE TAP WATER IN THE BAT TERY Recharge the battery to 100 percent state of charge or if defective replace the battery 3 Clean and
19. causes excessive back pressure on the genera tor engine Also water from one engine can damage the other engine PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 2 5 1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U S Forest Service Use only mufflers and parts approved by Generac Any person s installing an unapproved muffler or an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable for any dam age injury or warranty expense that might be caused by such unapproved installation or modification Failure to provide and maintain a spark arrestor may be in violation of the law If this generator is used on any forest covered brush covered or grass covered unimproved land you must provide a spark arrestor The vehicle owner or operator must maintain this device in good condition In the state of California the preceding is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands 2 5 2 TYPE OF EXHAUST SYSTEM Two types of exhaust systems for PRIMEPACT series generators are available from Generac They include the following Out the bottom exhaust system dimensions are 1 5 16 O D model 9742 Outthe side exhaust system dimensions are 1 O D 18 gauge modelS 9743 and 9326 NOTE No matter what type of exhaust kit
20. detailed installation instruc tions 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 elec trical 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 electri cal 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 caution Ak Do not overload the generator Some installa tions may require that electrical loads be alter nated to avoid overloading Applying exces sively 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 Section 1 General Information GENERAL INFORMATION 1 5 INSTALLATION This manual
21. each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine manu facturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is sc
22. light coating of clean engine oil to the gas ket of the new filter 6 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tight en the filter an additional 3 4 to one turn MAINTENANCE 2 0 Section 5 Maintenance 7 Remove dipstick and fill crankcase with 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 OIL DRAIN PLUG Figure 3 2 Engine Oil Filter ENGINE OIL FILTER TWIST COUNTER CLOCKWISE TO LOOSEN Generac Power Systems Inc 11 MAINTENANCE 2 09 Section 5 Maintenance 5 5 AIR CLEANER 3 3 1 CLEANING THE FOAM PRECLEANER Clean and re oil the foam precleaner every three months or every 25 hours of operation whichever occurs first Service the foam precleaner more fre quently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 3 Turn the knob counterclockwise to loosen Remove the cover foam precleaner and paper filter Re
23. of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage 2 8 OPTIONAL ACCESSORIES A plugin receptacle Figure 2 21 is provided on the generator set above the muffler enclosure Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit you to start and stop the genera tor engine from any convenient location inside the vehicle Figure 2 21 Remote Panel Plug in Receptacle NS ecce NS BG VION is WIRE 0 i GROUND ENGINE RUN CRANK SIGNAL WIRE 18 STOP 3 Section 3 Post Installation Start up and Adjustments POST PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 2 8 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 con junction 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 5 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 WARNING amp Do not make any unnecessary adjustments Factory
24. on a suspended mounting system one of several different methods of supplying airflow may be used as follows Provide a door in the vehicle skirt having an air inlet opening Figure 2 11 Figure 2 11 Suspended Mount Inlet Door Using ductwork Figure 2 12 Page 27 The installer must be sure air is available to the top of the generator since air inlets are located at the top By providing an opening in the vehicle skirt and space behind the generator for cooling airflow Figure 2 13 Page 27 Recommended clearance behind the back of the generator is at least 1 2 inch 13 mm PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Figure 2 12 Air Inlet Using Ductwork ANTI SPLASH BAFFLE 1 IN AIR OUT AIR IN Figure 2 13 Air Inlet in Vehicle Skirt VEHICLE FLOOR VEHICLE SKIRT AIR INLET MINIMUM CLEARANCE 1 1 2 2 5 5 COMPENSATING FOR RESTRICTIONS Such materials as screening louvers or expanded metal can restrict the free flow of air Compensate for this restriction by making the actual air opening pro portionately larger Some materials may offer only a 60 percent free air inlet area Other more efficient materials may pro vide up to a 90 percent free air inlet area The per centage of free air inlet opening is usually available from the material supplier or manufacturer To determine the actual air inlet o
25. open and unobstructed for contin ued proper operation Without sufficient cooling and ventilating airflow the engine generator quickly over heats which causes it to shut down and may damage the generator 2 4 5 ENGINE EXHAUST GAS Before starting the generator engine you should be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals Close windows doors and other openings in the vehi cle that if open might permit exhaust gases to enter the vehicle 8 Generac Power Systems Inc DIE A A The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concen trations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOX IDE POISONING ARE a inability to think coher ently b vomiting c twitching muscles d throbbing temples e dizziness f headaches g weakness and h sleepiness IF YOU FEEL ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP 2 STARTING THE GENERATOR To start the generator from either the generator con trol panel or from the optional remote panel proceed as follows 1 Turn OFF electrical loads using the means vided in y
26. or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and main tained Many accidents are caused by failing to follow simple and fundamental rules or precautions Generac cannot possibly anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If you use a procedure work method or operating tech nique Generac does not specifically recommend you must satisfy yourself that it is safe for you and others You also must make sure the procedure work method or operating technique that you choose does not render the generator unsafe A Despite 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 A 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 e Generac Power Systems Inc
27. problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor caution A A Do NOT use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also cont aminate the generator fuel system 3 9 BATTERY MAINTENANCE All lead acid batteries will discharge when not in use The generator battery should be inspected as follows 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 bat tery hydrometer NOTE Servicing of the battery is to be performed or supervised by personnel knowledgeable of batter ies and the required precautions Keep unautho rized personnel away from batteries Damage will result if the battery connections are made in reverse Generac Power Systems Inc 13 MAINTENANCE 2 09 Section 5 Maintenance A Do not dispose of the battery fire The battery is capable of exploding Storage batter ies give off explosive hydrogen gas This gas can form an explosive mixture around the bat tery for several hours after ch
28. settings are correct for most applica tions When making adjustments however be careful to avoid overspeeding the engine 3 2 BEFORE INITIAL START UP Before starting complete the following 1 Check the engine crankcase oil level and if nec essary fill to the dipstick FULL mark cross hatched area with the recommended oil Do not fill above the FULL mark 2 Check the fuel supply Gas fuel lines must have been properly purged and leak tested in accor dance with applicable fuel codes All fuel shutoff valves in the fuel supply lines must be open 3 3 INITIAL START When you are absolutely certain that the unit has been properly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s main circuit breakers to their OFF or open position 2 Refer to Part I Section 2 5 Starting the Generator Page 8 for cranking and starting instructions The engine may require more cranking for initial starting since the fuel lines have to be primed use of the primer switch will shorten this time 2 INSTALLATION START UP ADJUSTMENTS 3 Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed a
29. should not exceed 0 12 volts per 100 amperes of cranking current PRIMEPACT generators are rated at about 100 DC amperes of cranking current Select battery cables based on a cable length and b prevailing ambient temperatures Generally the longer the cable and the colder the weather the larg er the cable size must be as shown in the chart CABLE LENGTH CABLE SIZE 16 to 20 4 5 to 6 For warm weather use No 2 cable up to 20 feet 2 1 5 BATTERY CABLE CONNECTIONS 1 Connect battery cable from the battery post or terminal indicated by a POSITIVE POS to the lug on the starter contactor Figure 2 20 NOTE Check to be sure the battery cable boot for the starter cable has been installed 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connection Figure 2 20 3 Connect cables so the connectors are clean and tight Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Figure 2 20 Connecting Battery Cables SIDE VIEW OF GENERATOR STARTER CONTACTOR GROUND LUG NEGATIVE CABLE BATTERY 2 74 BATTERY COMPARTMENT Install the generator battery in its own vented com partment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top
30. state POWER SYSTEMIS INC P O BOX 297 WHITEWATER WI 53190 Revised 10 05 01 Part No 2006583 Revision O 10 26 01 Printed in U S A
31. use metallic conduit vapor seal the end of the conduit where it enters the junction box Do this because flexible metallic conduit is not vapor proof along its entire length 2 6 5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 2 18 Page 31 An alternate method for isolating dif ferent power sources is by using an isolating recepta cle Figure 2 19 Page 31 Whichever method you use you must be certain that both power sources are NOT connected at the same time 2 6 6 POWER SUPPLY CORD The power supply cord must comply with all applic able codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected 2 6 7 GROUND FAULT CIRCUIT INTER RUPTERS The National Electrical Code NFPA 70 551 7 requires that you install ground fault circuit inter rupters GFCIs on all external and some internal electrical receptacles Contact your manufacturer or dealer for recommendations Section 2 Installation PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Figure 2 18 Transfer Switch Isolation Method INSTALLATION 2ND AIR FROM 20 AMP CONDITIONER HACR BREAKER JUNCTION BOX VEHICLE FLEXIBLE WIRING CONDUIT SS VEHICLE S DOUBLE DISTRIBUTION 4 6 PANEL TH
32. warranty Generac RV generators manu factured after January 1 1998 have a transferable warranty to the second owner ONLY for the remainder of the three year limited war ranty Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Dealer prior to the performance of any warranty service All warranty expense allowances are subject to the conditions defined in Generac s WARRANTY PLOICY AND PROCEDURES MANUAL THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac RVgenerators that utilize non Generac replacement parts Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or in
33. will restrain the generator set should consist of at least two horizontal beams These beams should consist of 1 1 2 inch square 11 gauge steel tubing OR b 1 1 2 inch 11 gauge angle iron A typical sup porting frame with horizontal support tubing is shown in Figure 2 1 The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the generator below the horizontal support tubing by means of suit able structurally sound metal framework The fol lowing general rules apply Vehicle construction MUST be capable of support ing the weight of the generator ee Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Whether the generator is mounted above the hori zontal support tubing or suspended below the tub ing the supporting frame used must be structural ly sound If the generator cannot be bolted directly to the supporting frame or support tubing consider using additional tubing angle brackets or other supports to give the supporting frame sufficient strength Figure 2 1 Typical Horizontal Support Frame PX L SUPPORT TUBING 2 1 3 SUSPENDED MOUNTING If you are going to suspend the generator below the horizontal support tubing the suspension method you use with the vehicle frame members must a be able to support the weight of the generator AND b provide sufficient r
34. wipe the entire generator 4 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 5 Turn OFF all electrical loads Add fuel if neces sary and then start the engine 6 Allow the unit to warm up thoroughly 7 Apply electrical loads to at least 50 percent of the units rated wattage capacity 8 When the engine is thoroughly warmed up shut it down 9 Your generator is now ready for service MAINTENANCE 2 0 Section 5 Maintenance 5 14 WATTAGE REFERENCE GUIDE Running Watts Battery Charger osten ene p PU 500 Belt Sander 1000 Chain Saw oeste eei o Eve 1200 Circular Saw 6 12 800 to 1000 Disc Sander 9 rere SEE 1200 DEIUL LT iieri Ed 1100 Hedge Trimmer rint ter rere rere 450 Impact Wrench eter irae 500 Lawn MOWED rey 1200 Electric Range one element 1500 TELEVISION ose aE 750 to 1000 Coffee ec cec rex E Re 1000 Electric Skillet eie 1250 DI YEP ue M 1200 Light BuUID nu eios 100 Microwave OV esee rero e Pr EVO 700 Oil Burner on Furnace eere 300 Oil Fired Space Heater 140 000 Btu 400 MET 50 to 200 SIOW COOKGE iocos steve
35. without prior notice A 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 A 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 Generac Power Systems Inc GENERAL HAZARDS For safety reasons Generac recommends that the installation initial start up and mainte nance of this equipment is carried out by a Generac Authorized Service Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust sys tem must be installed properly in strict compli ance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in noncompli ance with such codes and standards The genera tor compartment must be completely vapor sealed from the vehicle interior There must be no possi bility of exhaust fumes entering the vehicle interi or Never operate this equipment with a leaking or defective exhaust system
36. 16mm WITH LOCK WASHER FLATWASHER M6 WASHER LOCK 10 COVER EXHAUST OUTLET NUT LOCK TRIC M6 1 0 GASKET EXHAUST OUTLET LOCKWASHER SPECIAL CLAMP VINYL COATED FLANGE NUT SPECIAL 5 16 18 FLAT WASHER 10 M5 DECAL GROUND TAPTITE M6 1 00 x 10mm FLATWASHER M10 Generac Power Systems Inc 39 Section 6 Exploded Views and Parts Lists PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 0 Alternator and Control Panel Drawing 006578 Rm 12 5 BERN 11 Sal gt 49 40 gt R TE 52 53 59 4O Generac Power Systems Inc Section 6 Exploded Views and Parts Lists CG urs PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Alternator and Control Panel Drawing 0D6578 A 0 PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0C9675 1 LOWER BEARING CARRIER 33 090987 2 M3 0 5 x 12 LG PPHMS 2 073163H 1 ROTOR ASSEMBLY PP70 34 086317A 1 PANEL SUPPORT BRACKET 093940H 1 ROTOR ASSEMBLY PP50 35 075235 2 M5 0 8 x 30 LG CAPSCREW 3 021441H 1 STATOR ASSEMBLY PP70 36 082737 4 VIBRATION MOUNT 080095H 1 STATOR ASSEMBLY PP50 37 049813 4 M6 1 0 HEX NUT 4 073159 1 BALL BEARING 38 049815 1 M5 08 x 16 LG HEX HD CAPSCR 5 031971 1 BALL BEARING 39 043182 2 M3 LOCK WASHER 6 0C9674 1 UPPER BEARING CARRIER 40 0A8475 3 M5 SPECIAL LOCK WASHER 7 077006 4 STUD STATOR 41 054502 1
37. 7 78 79 80 81 82 83 84 85 86 87 90 91 93 94 95 96 97 PART NO QTY 075711 048475 045802 022237 022145 0742600133 001227 001741 001741 073179 070185 048584 074948 074950 074951 073134 038750 074949 068548 0 4006 029289 024114 075281 0 1085 043182 022158 075237 001624 075474 090800 094670 075226 056893 075229 003158 079246 022473 022152 072384 092120 077643 0 1658 090088 081105 023897 067210 045756 022131 1 1 1 8 2 1 1 1 2 1 1 1 3 1 1 1 3 0 ON PARTS Qa ae 00 DESCRIPTION PIPE OIL DRAIN ADAPTOR SPECIAL LOCK WASHER M5 TINNERMAN CLIP LOCKWASHER 3 8 FLATWASHER 5 16 M8 CABLE STARTER CONTACTOR STARTER BOOT BATTERY CABLE BOOT BATTERY CABLE OIL FILTER SUPPORT FILTER OIL FRAM PH3614 SWITCH OIL PRESSURE FITTING 5 16 TUBE OUTER OIL TUBE INNER OIL ADAPTOR OIL FILTER ADAPTER CAPSCREW HEX HEAD M6 1 00 x 30mm FITTING BARBED 90 DEGREE 5 16 GASKET OIL FILTER ADAPTER CABLE BATTERY TAPE FOAM 1 16 THICK x 8 NUT HEX 5 16 24 STEEL SWITCH HIGH TEMPERATURE SCREW PAN HEAD M3 0 50 x 8mm LOCKWASHER M3 NUT HEX 10 32 STEEL WASHER SPRING RETAINER BOOT OIL PRESSURE SWITCH BOOT TEMPERATURE SWITCH ELBOW EXHAUST CLAMP EXHAUST COVER AIR CRIMPTITE NO 10 24 x 1 2 SLIDE PAN GASKET WELDMENT SLIDE PAN RV CAPSCREW HEX HEAD M6 1 00 x
38. AIR CLEANER SUPPORT 066476 2 SCREW HHSW 6 1 0 X 12 070575 2 SCREW HHSW 6 1 0 X 25 070125 1 SPRING ANTI LASH 073374 1 BRACKET CHOKE SUPPORT 074947 1 ROD CHOKE CONTROL 089473 1 BI METAL ASSEMBLY CHOKE 091306 1 SOLENOID CHOKE 077091 1 HAIR PIN COTTER 031879 4 WASHER FLAT 4 022159 4 WASHER LOCK 4 077075 1 COVER CHOKE COIL 072536 4 SCREW PPMS 4 40 X 4 087770 1 TUBE FUEL GASOLINE 5 16 I D 074946 1 LINK CHOKE 070594 2 SCREW HHC M6 1 0 X 93 WITH LOCK WASHER 030340 1 HOSE 1 0 4 5 LONG 0C2338D 1 DECAL AIR CLEANER PRIMEPACT 70G 50Hz 0C2338F 1 DECAL AIR CLEANER PRIMEPACT 50G 50Hz 075252 1 KIT CARBURETOR OVERHAUL NOT SHOWN 0A7782A 1 FLYWHEEL ASSEMBLY 040173 2 CLAMP HOSE SCREW TYPE 066829 2 RIVET 1 8 DIAMETER x 1 8 LONG 075944 1 BRACKET GOVERNOR SPRING Generac Power Systems 47 Section 7 Warranty WARRANTY PRIMEPACT 50 and 70 50Hz 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 New utility and lawn and garden equipment engines must be designed built and equipped to meet stringent anti smog stan dards for the state of California and the federal government Generac will warrant t
39. CUSTOMER CONNECTION 31 022264 4 8 M4 LOCK WASHER 62 031791 1 CLAMP HOSE 32 065795 1 BATTERY CHARGER RECTIFIER 63 023897 3 10 M5 FLAT WASHER Generac Power Systems Inc 41 Section 6 Exploded Views and Parts Lists LISTS PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 0 Engine Sheet Metal Drawing 0D3150 A See Carburetor Exploded View et NOOB WD 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 33 34 35 36 99258 67198 67890 87865 4456 86313 56893 87750 74916 74908 73190 78858 78859 74902 66476 73191 42907 22129 75246 133 74260 74900 73186 81108 22717B 22717A 67866A 77001A 73132 87858A 29289 87858B 50277 Section 6 Exploded Views and Parts Lists PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators QTY nia Engine Sheet Metal Drawing 0D3150 A DESCRIPTION SEE ENGINE EXPLODED VIEW of ENGINE KEY WOODRUFF 6 x 22MM BEVELLED WASHER HEX NUT PLUG FLYWHEEL ACCESS 3 8 SPECIAL LOCK WASHER HOUSING ENGINE TOP SCREW CRIMPTITE NO 10 24 x 1 2 SCROLL FLYWHEEL COVER BASE CYL 2 SCREW TAPTITE M5 x 10MM WRAPPER CYL 2 COVER VALLEY WRAPPER CYL 1 WRAPPER BARREL HHCS LW M6 x 1 0 x 12MM C
40. GENERAG POWER SYSTEMS INC Owner s Manual and Installation Instruct IONS Vehicle Generators Air cooled Recreational Model Nos 00784 2 and 09290 4 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 pro cedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or care lessly Observe them carefully Their definitions are as follows A EX A After this heading you can read instructions that if not strictly complied with will result in personal injury or property damage WARNING amp After this heading you can read instructions that if not strictly complied with may result in personal injury or property damage caution amp After this heading you can read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading you can read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing
41. 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 dip stick Full mark DO NOT FILL ABOVE THE FULL MARK caution amp 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 there after 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
42. Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or per mit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental start up Disconnect the cable from the bat tery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc Never insert any tool or other object through open ings in the generator interior even if the unit is not running You might seriously injure yourself or damage the equipment AFETY RULE Safety Rules 8 PRIMEPACT 50 70 50Hz
43. No 0D6579 E DATA SUPPLIED BY CUSTOMER SUPPLIED BY BATTERY CUSTOMER 0 40K 6 2 ELECTRONIC REGULATOR sss M gt z J gt 1 E 1 J1 701 17 CLOSEST BEARING o 15 7 11 MTG SCREW op PANEL 14 3 CONNECTOR 18 18 L FILTER MTG Se ee 3 SCREV BLACK RED 1 L Generac Power Systems Inc 37 Section 6 Exploded Views and Parts Lists PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 0 Base and Pulleys Drawing 0D6577 A TO ENGINE 38 Generac Power Systems Inc 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 PART QTY 086318 090141 046911 025017 046526 022129 072391 077603 022259 052858 051730 029459 075215 073146 075209 073174 079678 040976 072383 090859 075224D 075224G 073106D 073106G 075216 049451 042633 077017 073118 074906 091123 072375 073185 022097 077682 075242 049813 045757 090475 087769 087768 087770 022413 0D4788 075710A 074958 067871 0A5508 mA eee SH O HF
44. OVER BASE CYL 1 CAPSCREW HEX HD M8 x 1 25 x 16MM LOCK WASHER M8 SCREW TAPTITE 3 8 16 x 1 1 4 WIRE ASSEMBLY NO 16 STARTER COVER WRAPPER CRANKCASE BUSHING SNAP GROMMET RUBBER GROMMET RUBBER O RING PLUG OIL FILL BOOT SPARK PLUG GROUND WIRE ASEMBLY CYL 1 FOAM TAPE GROUND WIRE ASSEMBLY CYL 2 OIL DRAIN DECAL PARTS 9 20 Generac Power Systems Inc 43 Section 6 Exploded Views and Parts Lists LISTS 0 PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 0 Engine Drawing 79216 G 44 Generac Power Systems Inc ea 1 7 GRAPHOILG Section 6 Exploded Views and Parts Lists CG urs PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Engine Drawing No 79216 G 0 PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 069331 1 CYLINDER ASSEMBLY 43 075253 4 WASHER VALVE COVER SEAL 2 069333 1 SLEEVE BEARING 44 067885 4 6 NYLON NUT 3 067805 1 OIL SEAL 45 075254 4 VALVE ADJUST SCREW 4 0851100101 1 NO 1 CYLINDER HEAD ASSEMBLY 46 070535 1 OIL SCREEN 5 0851100102 1 NO 2 CYLINDER HEAD ASSEMBLY 47 002881 1 STARTER MOTOR NOT SHOWN 6 070169 4 SEALING WASHER 50 067891 1 IGNITION COIL 7 069332 2 CYLINDER HEAD GASKET 51 075236 4 IGNITION ARMATURE SCREW 8 0851100104 1 BREATHER ASSEMBLY 52 072347 2 SPARK PLUG 9 072315 1 BREATHER GASKET 53 075258 1 ENGINE GASKET KIT 10 089967 1 BREATHER SCREW 57 066480 1 AIR CLEANER GASKET 11 070596 1 BREATHER TUBE
45. ROW SWITCHING 30 AMP DEVICE MAIN BREAKER Oog Gain 85 0 TT HACR 5 I CONDITI NERS a 5 LL BREAKERS POWER SUPPLY CORD Figure 2 19 Installation With Isolation Receptacle DOCKSIDE POWER RECEPTACLE U 200 JUNCTION BOX FLEXIBLE CONDUIT SSS VEHICLE DISTRIBUTION PANEL d Generac Power Systems Inc 31 INSTALLATION Section 2 Installation 2 7 BATTERY INSTALLATION 2 71 RECOMMENDED BATTERY Install a battery that meets the following require ments 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 at least 400 cold cranking amperes For prevailing ambient temperatures below 32 0 C use a battery rated 95 amp hours and capa ble of delivering at least 600 cold cranking amperes NOTE If the battery is to be used to power other vehicle accessories as well as start the generator you may need a battery with a larger capacity 2 72 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes starting problems For the best cold weather starting the voltage drop between battery terminals and the generator connection point
46. Recreational Vehicle Generators A ELECTRICAL HAZARDS A The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If you must work around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mount ing to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum If the vehicle electrical circuits can be powered by any other source of electricity such as a dock side power receptacle there must be no possibil ity of connecting the different power sources to the vehicle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operating Failure to isolate the veh
47. SH ROD 36 067158 4 INTAKE MANIFOLD MOUNTING BOLT 95 070599 4 ROCKER ARM ASSEMBLY 37 068574 1 1 8 NPT PLUG PIPE 97 070566 4 ROCKER ARM SUPPORT 38 068554A 1 GOVERNOR SHAFT SEAL 98 075271 1 VALVE OVERHAUL KIT 39 068573 1 OIL PUMP O RING 99 067897 2 EXHAUST GASKET NOT SHOWN 40 070506 1 OIL GALLEY O RING 100 091481 1 GASKET AND CAP ASSEMBLY 41 070554 1 CARBURETOR SPACER 101 091480 1 ROCKER ARM COVER 42 070568 4 ROCKER ARM STUD 102 0D1198 1 GOVERNOR CRANK Generac Power Systems 45 urs Section 6 Exploded Views and Parts Lists PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators OG Carburetor Drawing 0D6576 A C 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Section 6 Exploded Views and Parts Lists CG urs PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Carburetor Drawing No 0D6576 A 0 DESCRIPTION 073112B 1 CARBURETOR ASSEMBY 074962C 1 SPRING GOVERNOR GREEN PP55G LP PP66G LP 074962E 1 SPRING GOVERNOR PURPLE PP50G 50Hz 074962G 1 SPRING GOVERNOR BROWN PP70G LP PP70G 50Hz 070155 1 LEVER GOVERNOR 070108 1 ROD GOVERNOR TO CARBURETOR 056893 5 SCREW 10 24 X 074961 1 BRACKET GOVERNOR ADJUSTER 047227 1 SCREW GOVERNOR ADJUSTER 037398 1 NUT HEX LOCK NYLON 073131 1 BRACKET
48. This may include additional sealant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a nonflam mable type One excellent insulating material is a 1 inch 25 mm thick fiberglass having a 2 pound den sity When fiberglass is used its coated side should face toward the compartment interior 24 Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators DIE A Do not install sound insulation or any absorbent material on the compartment floor interior Such materials will become soaked with combustible or explosive vapors and liq uids and will become a fire hazard Using a combination of sound insulating materials can often reduce noise more effectively than a single material For example a sheet of lead or visco elastic material along with a layer of other acoustical mate rial is more effective than when a single material is used 2 2 4 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement compartment NOTE Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compartment In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise l
49. UP ADJUSTMENTS 5 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT Generator is properly located Generator is properly supported Generator is properly restrained GENERATOR COMPARTMENT Compartment construction is proper Q Holes Openings are vapor sealed Compartment size is correct Compartment is vapor sealed Sound insulation is correct Floor cutouts are properly completed COOLING AND VENTILATING AIR Airflow is adequate Air inlet opening is correct Compensate for restrictions Check that installation has been tested GASOLINE FUEL SYSTEM Fuel tank complies with all applicable codes Fuel system is properly installed and checked for leaks EXHAUST SYSTEM codes Exhaust system is properly and safely installed DATE OF INSTALLATION Exhaust system complies with all applicable PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators ELECTRICAL CONNECTIONS Connections comply with local code requirements and all National Electrical Codes Junction box is properly installed Wiring meets all standards Q connections are correct Conduit is properly installed and sealed Generator is properly bonded to the vehicle BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Cables are clean and tight Cables are connected properly Proper ven
50. a 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 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 run ning 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 con tacts 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 20 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 284 F 140 C initiating an engine shutdown Figure 2 3 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE
51. arging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery Discharge static electricity from your body before touch ing the battery by first touching a grounded metal surface A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries Remove watches rings or other metal objects e 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 WARNING amp A Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic A 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 immediat
52. best fits your recreational vehicle the mounting base has open ings for either bottom out or side out exhaust systems Use the cover plate provided with the generator to cover the opening you do NOT use 2 5 5 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any com bustible material such as wood felt cotton organic fibers or other like material If you cannot maintain the 3 inch 76 mm clearance locate insulate or shield the exhaust part s so that the temperature of any combustible material is not raised more than 117 F 65 C above the ambient air temperature Extend the exhaust system at least 1 inch 25 mm past the outer edge of the vehicle Do not terminate the exhaust system under the vehicle Terminate the exhaust tailpipe such that exhaust gases will not be drawn back into the generator compartment and recirculated INSTALLATION Section 2 Installation If there is any possibility of tailpipe or muffler being damaged protect these damage prone areas by means of a protective device such as a skid bar Install the generator exhaust system according to safe automotive practices Use enough exhaust system hangers to prevent any part of the system from being dislocated Use exhaust system parts recommended by Generac Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person s instal
53. direct damages caused by defects in materials or workmanship or any delay in repair or replace ment of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GEN ERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GEN ERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limita tion may not apply to you This warranty gives you specific legal rights You also may have other rights that vary from state to
54. e extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system Keep the extinguisher properly charged and be familiar with its use If you have any question per taining to fire extinguishers consult your local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline Fuel lines must be properly installed and fastened and free of leaks There must be no possibility of gasoline vapors entering the vehi cle interior You are required to install an approved flexible nonconductive fuel line between the generator fuel connection point and rigid fuel lines Generac Power Systems Inc 19 Section 1 General Information 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 equipm
55. e to the purchaser owner Such use shall not reduce Generac s ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 2 Air Induction System including 1 1 Gasoline carburetor assembly and its a Intake pipe manifold internal components if so equipped b Air cleaner a Fuel filter if so equipped 3 Ignition System including b Carburetor gaskets a Spark plug c Fuel pump if so equipped b Ignition module 1 2 LPG carburetion assembly and its 4 Catalytic Muffler Assembly if so equipped including internal components if so equipped a Muffler gasket a Fuel controller if so equipped b Exhaust manifold b Mixer and its gaskets if so equipped 5 Crankcase Breather Assembly including c Carburetor and its gaskets if so equipped a Breather connection tube d Primary gas regulator if so equipped e LP liquid vaporizer if so equipped Generac engine types covered by this warranty statement include the following 1 Utility 2 Lawn and Garden E
56. el supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not run ning generator operation may drain the vehi cle engine supply line making it difficult to start the vehicle engine 2 4 2 GENERATOR FUEL SUPPLY LINE 2 4 2 1 Rigid Fuel Lines Those lines used to supply fuel from a tank to the generator must comply with applicable codes stan dards and regulations The following general rules apply to rigid fuel lines Rigid lines should be of annealed seamless drawn aluminum or steel Lines and fittings must comply with SAE 4512 Standard Automotive Fittings or with ANSI 126 26 latest edition Route the fuel line so that at least 2 inches 51 mm of clearance is maintained between the line and any exhaust system parts Do not attach electrical wiring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so if they leak fuel does not drip onto any electrical or exhaust system parts Use nonferrous metal straps without sharp edges to secure fuel lines 28 Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 2 4 2 2 Flexible Fuel Line Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines This prevents breaking of the line caused by vibration shifting settling or
57. ely 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 bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried 14 Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 3 10 MAJOR SERVICE MANUAL To obtain a service manual for your generator con tact Generac or your nearest Generac Authorized Service Dealer Make sure to identify yur 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 5 13 OUT OF SERVICE PROCEDURE 3 13 1 REMOVAL FROM SERVICE If you cannot exercise the generator every seven days
58. enerator 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 22 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel Figure 2 2 is available that allows you to start and stop the gener ator 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 MOBILE GE 2 5 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 tem peratures choke valve closes more Once the engine starts an element heats the temperature sensitive strip to a normal operating condition opening the
59. ent with the product s installation requirements Give serious consideration to all information and instructions in the manual both for safety and for continued reliable operation of the equipment Because of the different recreational vehicle models and the variations between the models it would be extremely difficult if not impractical to provide detailed instructions for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all applicable codes standards and regulations pertain ing to the installation and use of this product If any portion of this manual appears to be in conflict with such codes standards or regulations the applicable codes standards or regulations must take prece dence over the manual 1 2 SAFETY Before handling installing operating or servicing this equipment carefully read the Notice to Installer and Safety Rules on Pages 18 and 19 Comply with all safety rules to prevent death personal injury or damage to equipment and or property Stress safety to all installers operators and service technicians who work on this equipment 1 3 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The following standa
60. estraint for the generator One typ ical suspended mounting system is shown in Figure 2 2 The location of a suspended mounting system must be carefully planned keeping the following gen eral rules in mind Protect the generator against road splash and debris 5 or splash guards may be required to protect certain areas of the generator To make sure the gen erator is adequately protected road test the installa tion through mud water and slush Figure 2 2 Typical Suspended Mounting System GENERATOR MOUNTING HOLES FOR 3 8 16 BOLTS BOTH SIDES SUPPORT GENERATOR FRAME SUPPORT FRAME The installer must make certain that the selected location will permit adequate cooling and ventilat ing airflow to be supplied PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 2 1 4 GENERATOR RESTRAINT Use four 3 8 16 hardened steel bolts Grade 5 to fas ten the generator to the supporting frame or the sup port tubing These bolts must pass through a the gen erator mounting base b the compartment floor if a compartment is used and c the supporting frame work Figure 2 3 All bolts must be long enough so that when tight at least three threads are visible past the retaining lock nuts Refer to Section 2 2 for the location of the generator mounting holes Figure 2 3 Typical Generator Restraint METAL LINED 1 2 INCH THICK BASE PLYWOOD
61. evels Such a compartment might be constructed as follows Figure 2 7 Use 5 8 inch thick or 3 4 inch thick plywood in the compartment Construct the compartment floor of a double thick ness of 5 8 inch or 3 4 inch plywood Line the compartment interior walls and floor as well as the underside of the floor with 26 gauge galvanized steel Vapor seal all compartment seams and joints Over the galvanized steel lining install a combina tion of acoustical materials as mentioned in Section 2 2 3 DIG To prevent fire or explosion do not install 3 insulation or other absorbent materials on the interior or underside of the compartment floor Seal all compartment door edges to prevent noise leakage around the door perimeter Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 25 mm thick fiberglass with a 2 pound density Section 2 Installation INSTALLATION PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Jm Figure 2 7 Typical Noise Abatement 2 2 5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compart ment for the following items Figure 2 8 5 8 OR 3j THICK RENAL 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 DIE A A Fuel lines and exhaust piping mu
62. generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system Keep the extinguisher properly charged and be familiar with its use If you have any question per taining to fire extinguishers consult your local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline Generac Power Systems Inc 3 Section 1 General Information PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 1 1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal
63. has been prepared under the assump tion 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 instal lation 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 cool ing 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 sug gest copying and posting the Safety Rules in poten tial hazard areas of the vehicle Stress safety to all operators and potential operators of this equipment 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 NC 7 o 1 E RED Generac Power Systems Inc 5 GENERAL INFORMATION 1 6 SPECIFICATIONS 1 6 1 FUEL REQUIREMENTS These generators are equipped with a gasoline fuel sys tem Depending on the installation the ge
64. he emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modification or improp er maintenance of your engine Your emission control system may include parts such as the carburetor ignition and exhaust systems Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has fai
65. heduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsi ble for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charg
66. icle circuits from the dockside power supply when the genera tor is running may result in damage to the genera tor or serious injury or death to dockside utility power workers due to backfeed of electrical ener gy In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fir
67. ion is performed promptly and to have the equipment checked periodically by a Generac Authorized Service Dealer Normal maintenance ser vice and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum See your Generac Authorized Service Dealer for service aids and acces sories HOW TO OBTAIN SERVICE When your generator requires servicing or repairs simply contact a Generac Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all of your service needs When contacting a Generac Authorized Service Dealer or the factory about parts and service always supply the complete model number and serial number of your unit as given on its data decal which is located on your generator Model No Serial No 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 PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generatorss Part Owner s Manual Introduction Inside Fr
68. ion of the generator When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued Inspect the generator regularly and contact your nearest Generac Authorized Service Dealer immedi ately for parts needing repair or replacement Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental start up Disconnect the cable from the bat tery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc Safety Rules SAFETY RULES PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators A ELECTRICAL HAZARDS A The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If you must work around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During ins
69. led due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a prob lem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California and federal law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Auth
70. ling such unauthorized parts Do not terminate the exhaust system under any opening window or vent that can be opened or is not permanently sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all applicable codes standards and regula tions 2 6 ELECTRICAL CONNECTIONS Be sure to read Section 1 6 on Page 20 The following general rules apply to electrical con nections in a recreational vehicle Qualified electricians who are familiar with applic able codes standards and regulations should install electrical wiring The wiring should comply with codes standards and regulations The National Electrical Code NFPA 70 and state and local codes apply Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent damage from road shock Wiring must be of adequate size have approved insulative qualities and be properly supported Conduit and wire openings into the generator com partment if used must be vapor sealed to prevent entry of flammable explosive or poisonous gases into the vehicle 2 6 1 ELECTRICAL
71. main frame members However this is seldom possible Most units must be installed on the side of the vehicle and are difficult to reinforce Many recreational vehicles have been factory equipped with an area for the generator set Some vehicles may even have a generator compartment provided by the vehicle manufacturer Plan the generator location based on the following The generator set must be installed on a frame work that is part of the recreational vehicle as out lined in Section 2 1 2 The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from under neath the supporting framework The location must provide easy access to frequent ly serviced components such as filters oil drains spark plugs and other common maintenance parts The location must provide sufficient room to allow minimum clearances as outlined in Section 2 2 If sound insulation is to be used on the compartment walls and ceiling the minimum recommended applies to the space between the generator and such insulation The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense 2 1 2 GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding The metal framework on which the generator will rest and which
72. move the foam precleaner from the cover Wash the foam precleaner in liquid detergent and water 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 px Figure 3 3 Engine Air Cleaner PAPER FOAM FILTER PRE CLEANER COVER Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 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 opera tion Clean more often if necessary Inspect the area around the generator exhaust muf fler periodically and remove all grass leaves dirt etc from this area Figure 3 4 Cleaning Air Intake CLEAN THESE AREAS 3 5 CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation 1 Clean the area around base of the spark plug to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and com mercial solvent Do not blast the spark plug t
73. movement The follow ing rules apply The flexible hose must comply with SAE Standard for Fuel and Oil Hose It must be approved for use with gasoline The hose should be at least 6 inches 152 mm longer than is needed to prevent the hose from rupturing if the generator shifts or settles 2 5 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used A properly installed exhaust system must be vapor tight quiet and completely safe DIE A A The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concen trations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOX IDE POISONING ARE a inability to think coher ently b vomiting c twitching muscles d throbbing temples e dizziness f headaches g weakness and h sleepiness IF YOU FEEL ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Do not operate the generator until its exhaust system has been inspected and properly repaired caution Never tee generator engine exhaust pipe into the vehicle engine exhaust piping This
74. nd 70 50Hz Recreational Vehicle Generators 1 6 5 ENGINE of ERI GN 480 Twin cylinder Cooling Air cooled Rated HorsepoWer eerte dieiis 16 3 600 rpm Displacernent ni cerner retenti 480cc Compression ceci teet 8 6 to 1 Cylinder Block Aluminum w Cast Iron Sleeve of Mechanical Fixed Speed Engine Governor Speed 3000 rpm Cleaner onere Paper Element w Foam Precleaner LATED M UE 12 volt DC Electric Ignition System Solid state w Flywheel Magneto Recommended Spark Plug Champion ne ento e ra eet a scenes RC12YC Lo R45S Frami ro ene Ren erem en 65 Spark Plug 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 eene 230 Volts Rated Maximum Continuous AC GULE IIU tec erre eta 21 8 Amperes 30 4 Amperes Phase Single Rotor 3 000 Number Rotor Poles 5r Lettre ert eer caseo vn 2 Engine RPM eee Rr ente aene 2 900 3 000 Rated AC Frequency nere sun RR ei 50 Hz WIRING iiie EEUU 222 Pounds
75. ne pis ton rings resulting in blowby and high oil con sumption After operating the unit for 25 hours complete 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 mainte nance 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 nspect the entire electrical system Inspect the engine exhaust system 2 9 5 OPERATION IN HIGH GRASS OR BRUSH warninc amp 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 dur ing operation and remains hot for a long time after it has shut down 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
76. nerator may have either a separate fuel tank or it may share the vehicle engine s fuel tank NOTE Some installations using a shared fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine s pickup tube Such an arrangement causes the generator engine to run out of gas while adequate fuel for the vehicle remains in the tank To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator Leaded REG ULAR grade gasoline is an acceptable substitute NOTE Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits caution A A 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 rec ommended oil Engine crankcase capacity is 1 4 liters See Section 3 2 on page 11 for oil level check and filing procedures 6 Generac Power Systems Inc Section 1 General Information PRIMEPACT 50 a
77. o clean 2 Remove the spark plug and check the condition Replace the spark plug if worn or if reuse is ques tionable 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 030 inch 0 76 mm by carefully bending the ground electrode Figure 3 5 Figure 3 5 Setting the Spark Plug Gap SET PLUG GAP AT 0 030 inch 0 76 mm caution 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 PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 3 6 FUEL FILTER casouiNE 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 TO FUEL PUMP gt CUSTOMER FUEL CONNECTION 5 7 SPARK ARRESTOR MUFFLER If the generator is not equipped with a spark arrestor exhaust muffler and is to be used on any forest cov ered brush covered or grass covered unimproved land you may have to install a spark arrestor The spark arrestor must be maintained in effective work ing order by the vehicle owner operator For assistance in ordering installing and maintaining spark arrestor exhaust mufflers contact your nearest Generac Authorized Service Dealer Exhaust mufflers supplied by Generac are spark arrestor types Generac exhaust mufflers for recre
78. omponents Alternator All components WARRANTY SCHEDULE CONSUMER PERSONAL APPLICATIONS YEARS ONE AND TWO 100 one hundred percent coverage part s labor removal and reinstallation listed Engine All components Alternator All components YEAR Three 10090 one hundred percent only on selected part s and labor listed Any labor and part s not listed and removal and reinstallation are the owner s responsibility Rotor Stator IMPACT Series Variable Speed Computer Control Board Part Numbers A3369 A6060 Cylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Manifolds FOR THE LIFE OF THE RECREATIONAL VEHICLE GENERATOR IF SO EQUIPPED The drive train belt and pulleys if so equipped on generators used in recreational vehicles shall be warranted against failure due to defec tive materials or normal usage for the life of the generator For the original purchaser owner this drive train warranty shall include part s and labor removal and reinstallation are not included plus 50 fifty dollars U S payment upon return of the failed belt or pulley by the original purchaser owner For subsequent purchaser owner this drive train warranty shall cover belt and pulley part s ONLY labor not included Labor removal and reinstallation is the responsibility of the subsequent purchaser owner Generac RV generators manufactured prior to December 31 1997 DO NOT have a transferable
79. ont Cover Read This Manual Thoroughly IFC Contents MR IFC Operation and IFC How to Obtain eene eun ca IFC Authorized Service Dealer Locator Number IFC Safety Rules pid pia pica iam pri sain 2 Section 1 General Information 4 1 1 Gener tor Identification 4 1 2 Generator 5 ES InstallQblOn sce rotor 5 1 4 ciens ior tee disp oon qu See eut bens 5 1 5 Generator AC Connection System 5 1 0 Specifications sesser yt Precor eene rol to 6 Section 2 Operation ren 7 2 1 Generator Control 4 2 2 Optional Remote Start Stop Panel T 2 9 Automati CHOKE iier or a EREET 7 24 Before Starting the Engine sisisi 8 25 Starting Generator 2 6 Stopping Generator 2 7 Applying Loads to Generator 9 28 Protection Systems eessen trei enie 9 2 9 Additional Information eese 10 Section 3 Maintenance 11 3 1 Checking the Engine Oil Level 11 3 2 Changing the Engine Oil and or
80. orized Warranty Service Facility When requesting warranty ser vice evidence must be presented showing the date of the sale to the original purchaser owner The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and or transportation of the product to from the inspection or repair facilities The purchaser owner also shall be responsible for any and or all damages or losses incurred while the engine is being transported shipped for inspection or warranty repairs If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 Generac Power Systems Inc Section 7 Warranty PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1997 and later model year engines a Applicability This warranty shall apply to 1997 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall contin ue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that
81. ough a pulley and drive belt arrangement The generator supplies 230 volts AC at 50 Hertz when the rotor is operating at 3 000 rpm The drive belt arrangement allows the engine to operate at a lower speed than the rotor 1 6 GENERATOR AC CONNECTION SYSTEM This generator set is equipped with dual stator AC power windings as shown in Figure 1 1 These two stator windings supply electrical power to customer electrical loads by means of a dual two wire connec tion system Note however that the neutral is grounded Figure 1 1 Connections for 230 Volts Only 11 BLACK A 240 VOLTS CIRCUIT BREAKER 1 240 VOLTS T1 GROUND NOTE Do NOT connect loads in excess of circuit breaker ratings Section 1 General Information PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators Figure 1 2 Major Features and Dimensions PrimePact 50 and 70 Control Panel Spark Plugs both sides not shown LJ Fill Oil Level Fuel Filter Cil Drain Plug Fuel Pump Starter Contactor Filter Air Filter 16 13 Generac Power Systems 21 INSTALLATION Section 2 Installation 2 1 LOCATION AND SUPPORT 2 1 1 GENERATOR LOCATION The most desirable location for the generator set is between the vehicle s
82. our vehicle such as a main line circuit breaker or transfer switch NOTE If starting from the generator control panel turn OFF loads by setting the generator s main circuit breaker to the OFF or open position If starting from a remote panel turn OFF loads using the means provided in the vehicle such as a main cir cuit breaker Electrical load circuits will be turned ON after the generator has started stabi lized and warmed up 2 If you have not started the engine in more than two weeks press the Fuel Pump Primer switch and hold it for about 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 caution Ak 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 Section 2 Operation PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators aE 2 6 STOPPING THE GENERATOR 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 fe
83. out sufficient air flow the engine generator quickly overheats Such overheating can cause serious operating difficulties and also may cause fire and personal injury The installer must make sure that sufficient air is avail able to the generator for cooling ventilating and com bustion The installer also must provide for a path for exhausting the cooling air to the exterior of a com partment if so equipped A Never use discharged cooling air for heating 23 permit such air to enter the vehicle interior This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases 2 5 1 GENERATOR AIRFLOW Engine operation drives cooling fans for the two stage cooling air system A pressure fan draws cooling air into the top of the generator Figure 2 9 This airflow cools the engine generator and electronic compo nents The second part of the cooling system a suc tion fan draws air that is heated from a hot engine into a collector pan at the base of the unit This heat ed air although cooler than exhaust muffler is then deflected out the bottom toward the ground Figure 2 9 Airflow Through Engine Generator ERA 2 3 2 COOLING AIR INLET OPENINGS The minimum size of the air inlet opening whether the generator is housed in a conventional compart ment or not is at least 100 square inches sce Figure 2 10 This rule a
84. pening size required divide 100 square inches by the per centage of free air inlet area for the material you will use For example If you plan to use screening with an 80 percent free air inlet area divide 100 by 0 8 which results in 125 square inches Minimum actual size of air inlet opening in this case is 125 square inches INSTALLATION Section 2 Installation 2 5 4 TESTING THE INSTALLATION Generac recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of overheating you will need to enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is ade quate NOTE You must test the installation especially if you bring in air from below the generator set 2 4 GASOLINE FUEL SYSTEM The installation of a gasoline fuel system Figure 2 14 for a recreational vehicle generator set must comply with applicable codes standards and regula tions The entire fuel system must be completely free of leaks There must be no possibility of gasoline vapors entering the vehicle interior Figure 2 14 Generator Fuel System SS CENERE Ora PRIMEPACT 556 Sapo Fuel Pump Fuel Filter Fuel Line DIG A Gasoline is highly flammable and its vapors are 3 ex
85. plosive Comply with all codes standards and regulations pertaining to gasoline fuel systems used in recreational vehicle generators Properly install and maintain the fuel system and keep it entirely free of leaks Gasoline vapors must not enter the vehicle interior Factory installed generator fuel system components include a fuel filter b 12 volt DC electric pump c engine carburetor and d interconnecting lines and fittings Connect a fuel supply line to the fuel filter inlet Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines Generac Power Systems Inc 27 INSTALLATION Section 2 Installation 2 4 1 FUEL TANK Either the generator must share the vehicle engine s fuel tank or you must install a separate fuel tank for the generator set All fuel tanks installed on the vehi cle must be constructed installed and restrained so they comply with applicable codes standards and regulations If the generator is to share the vehicle engine s tank separate fuel pickup tubes are required for the engine and the generator Generac recommends that you make the fuel pickup tube 2 to 3 inches 51 to 76 mm shorter than the vehicle engine s pickup tube This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods caution Do tee generator fuel supply line into the vehicle engine fu
86. pplies whether inlet air is brought in through an opening in the compartment door an opening in the vehicle skirt through duct work or by any other means 26 Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators NOTE Screening louvers or expanded metal that cover air openings restrict airflow You must compensate for this by making the actual air opening propor tionately larger See Section 2 3 3 Page 27 Figure 2 10 Air Inlet in Compartment Door gt lt lt o see QA xx 5 SS ANY 2R L S 0 4244 XXX 100 SQUARE INCHES UNRESTRICTED MINIMUM OPENINGS xx 0 Xx Xx X MT RIG n 9999 99 5555 KY XX A A 5 Xx NN XX Xo i ANNA XX 5 X X 000 PN sure to meet the minimum clearances illustrat ed in Figure 2 4 Page 23 When the unit is installed
87. pply electrical loads and check for proper operation under load See Section 3 4 Run the unit at least 30 minutes with loads applied 6 Turn off all electrical loads by setting the genera tor s main circuit breakers to their OFF or open position 7 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine NOTE The generator set was thoroughly tested and adjusted at the factory before shipping No addi tional adjustment should be necessary Only qual ified service technicians who have been trained should perform adjustments outlined in this man ual 5 4 TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 per cent of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling airflow is available You must not allow the unit to overheat during prolonged operation NOTE The generator engine is equipped with a high tem perature switch The switch has normally closed N C contacts When the engine temperature is too high switch contacts close and the engine shuts down automatically GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLING Generac Power Systems Inc 33 2 POST Section 3 Post Installation Start up and Adjustments INSTALLATION START
88. quipment 3 Recreational Vehicle RV Generator 4 Industrial Mobile IM Generator Part 2 Generac Power Systems Inc 49 Section 7 Warranty WARRANTY PRIMEPACT 50 and 70 50Hz 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 Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Dealer is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac generators sold and rated for Recreational Vehicle RV appli cations as Generac has defined Recreational Vehicle generator applications WARRANTY SCHEDULE COMMERCIAL APPLICATIONS YEAR ONE 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All c
89. rds booklets latest revision are available from the sources indicated 1 NFPA Standard 501C Standard for Recreational Vehicles available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 NFPA 70 NFPA Handbook of the National Electric Code available same as Item 1 3 ANSI C1 1975 and ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI 119 2 501C available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 avail able from the State of California Documents Section PO Box 1015 North Highlands CA 95660 20 Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 1 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to Generac air cooled generators These generators are designed specifically for installing in recreational vehicles They operate 230 volt single phase 50 Hertz AC electrical loads that require 20 8 amps PP50 or 30 4 amps PP70 1 5 GENERATOR ENGINE OPERATING SPEED The generator s revolving field rotor is driven by a single cylinder four cycle engine thr
90. scribed in this manual Generac assumes that installation personnel are familiar with the proce dures for installing such products or similar prod ucts that Generac manufactures Generac also assumes that personnel have been trained in the rec ommended installation procedures for these prod ucts and that such training includes a use of com mon hand tools b use of special Generac tools and c use of any tools and or equipment from other sup pliers Generac cannot possibly know of and advise the recreational vehicle trade of all conceivable methods procedures or techniques by which to perform an installation Nor can Generac anticipate every possi ble hazard that might result from each installation method procedure or technique Generac has not undertaken any such wide evaluation Therefore people who use a method procedure or technique that Generac does not specifically recommend must first completely satisfy themselves that their safety the safety of the vehicle s occupants and the product s safety is not endangered by the method procedure or technique selected Information illustrations specifications etc con tained in these Installation Instructions are based on the latest information available at the time of publi cation Every effort has been expended to be sure that such data is both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time
91. st not pene trate into the vehicle living area PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION Figure 2 8 Compartment Floor Cutout e 38915 31 a 180 7 09 57L8 24 e58 1016 9013 547 1 i E 8 9713 82 A 2 7 i po n 45 ENGINE COOLING AIR DUTLETS UST BE FREE DF 194U7 64 602 36 BSTRUCTIONS 59 2 32 1 416 16 38 1 BOTTOM EXHAUST REM IUP CONNECTION lt OPTIONAL D 50 81 9711 366 14 41 183 7 20 1 13 80 5171 HOLES FOR SECURING UNIT TO COACH 55 2 17 4 REQUIRED Y d NT AIR FILTER Mem AIR FILTER SID 220 877 581 22 87 Generac Power Systems 25 INSTALLATION Section 2 Installation 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 With
92. tallation onto the vehicle have the genera tor properly grounded bonded either by solid mounting to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT disconnect the bonding conductor if so equipped DO NOT reconnect the bonding conductor to any generator part that might be removed or disassem bled during routine maintenance If the grounding conductor must be replaced use only a flexible con ductor that is of No 8 American Wire Gauge AWG copper wire minimum case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the
93. 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 A This symbol points out important safety informa tion 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 A This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator driver is responsible for proper and safe use of the vehicle and its equipment and the safe ty of all vehicle occupants We strongly recommend that the operator read this manual and thoroughly understand all instructions before using this equip ment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to oper ate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for generator model numbers 009290 4 and 00784 2 In addition the lat ter portion of this manual contains information nec essary for the proper installation of these generators OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safe ty checks to make sure that all maintenance for safe operat
94. tilation is provided Oovovov Terminals are coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES Check that remote start stop panels if used are installed properly Check that hourmeter kit if used is installed properly Check that any other options and accessories if used are installed properly POST INSTALLATION TESTS Check that all tests are completed properly NAME OF INSTALLER SIGNATURE OF INSTALLER Generac Power Systems Inc Section 4 Troubleshooting TROUBLESHOOTING PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators 41 TROUBLESHOOTING GUIDE PROBLEM Engine won t crank CAUSE 1 15 fuse blown CORRECTION Replace blown fuse 2 Loose or corroded or defective Tighten clean or replace battery cable s as necessary 3 Battery is discharged or defective 3 Recharge or replace battery 4 Defective starter contactor 4 Replace starter contactor 5 Defective starter motor 5 Replace starter motor 6 Defective Start Stop switch 6 Replace switch 7 Defective Engine Control Board 7 Contact an authorized service dealer Engine cranks won t start 1 Outoffuel 1 Refill fuel tank 2 Fuel shutoff valve is closed 2 Open fuel shutoff valve s 3 Fuel pump not operating 3 Repair or replace pump 4 Automatic choke not operating properly 4 Repair replace or adjust
95. ts from being connect ed to two different power supplies at the same time such as generator and dockside power Conductors must be rated 221 F 105 C or must be of a larger conductor size 2 6 5 GENERATOR AC CONNECTIONS Generator AC output leads T1 red and T3 black come out of the generator as shown in Figure 2 17 Lead T1 red is hot There is also a green lead that connects to ground in the junction box of the recre ational vehicle Figure 2 17 Generator AC Output Leads Generac Power Systems Inc PRIMEPACT 50 and 70 50Hz Recreational Vehicle Generators caution A Do NOT connect electrical loads in excess of any circuit breaker rating or you will develop problems with circuit breaker tripping which causes a loss of AC output Also do NOT exceed the generator s rated wattage capacity Add the watts or amperes of all lighting appli ance tool and motor loads the generator will operate at one time This total should be less than the unit s rated wattage amperage capaci ty 2 6 4 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The following general rules apply Cut wiring to the required length and allow extra wire for junction box connections Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation Route conduit so it does not interfere with genera tor movement If you
96. ts unique con struction is NOT vapor tight along its entire length Seams and joints of the galvanized steel whether used as a liner or for the compartment itself must be lapped and mechanically secured Such seams may be manufactured welded bolted riveted or screwed Manufactured lock seams are shown in Figure 2 6 Installer constructed compartments typically utilize a standard lap joint Figure 2 6 Types of Lock Seams n ACME LOCK FOLD LOCKED STANDING OFF SET DOUBLE LOCK DOUBLE SEAM GORDON SEAM LOCK SEAM STANDARD LAP JOINT After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material See Section 2 2 3 DIG A Do not install any flammable material directly f above or around the compartment Heat transferred through the compartment structure may be sufficient to ignite char or discolor seat cushions fiberboard and other flammable materials You may need to use approved nonflammable insulating materials in high temperature areas 2 2 5 SOUND INSULATING MATERIALS Once installers have determined that a compartment is properly constructed and metal lined they can add acoustical material
97. ulator is only con nected across 1 2 of the output winding Figure 2 5 Solid State Voltage Regulator Or 2 SENSING gt 4 TO ROTOR c o DIRECT CURRENT 8 STATOR EXCITATION WINDING ALTERNATING CURRENT 6 S The voltage regulator also incorporates a voltage surge protection circuit This circuit prevents trou blesome surges in the generator AC output voltage Voltage surge is a common cause of damage to elec tronic equipment Generac Power Systems Inc 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 pro vide maximum engine performance During this 25 hour 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 engi
98. w 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 appli ances may be extremely sensitive to voltage Incorrect voltages can damage such appliances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when suffi cient power is not available may shorten engine life Never turn ON electrical loads until after the generator engine has started and stabilized at no load 2 72 DO NOT OVERLOAD THE GENERATOR You can read the rated wattage amperage capacity of your generator on the generator data decal see Section 1 1 on Page 4 Applying electrical loads in excess of the unit s rated capacity will cause the engine generator to automati cally shut down To avoid overloading add up the wattage of all con nected electrical lighting appliance tool and motor loads This total should not be greater than the gen erator s rated wattage capacity Most lighting appliance tool and motor loads indi cate their required watts on their nameplate or dat

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