® POWER SYSTEMS, INC.
INTRODUCTION ◆ READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual, contact Generac or your nearest Generac Authorized Service Dealer for starting, operating and servicing procedures. Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
Table of Contents PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generatorss Part I — Owner’s Manual Part II — Installation Instructions Introduction ........................................Inside Front Cover Safety Rules ......................................................................18 Read This Manual Thoroughly..................................IFC Section 1 – General Information ................................20 Contents ..................................................................
Safety Rules PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment. WARNING: The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
Safety Rules PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators ELECTRICAL HAZARDS FIRE HAZARDS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.
Section 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. 1. Model Number ____________________ 2. Serial Number __________________ 3. kW Rating__________________________ 4. Rated Voltage __________________ 5. Phase ______________________________ 6.
Section 1 – General Information PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 1.2 GENERATOR APPLICABILITY These generators have been designed and manufactured for supplying electrical power for recreational vehicles. You should not modify the generator or use it for any application other than for what it was designed. If there are any questions pertaining to its application, write or call the factory. Do not use the unit until you have been advised by a competent authority.
Section 1 – General Information PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 1.6 SPECIFICATIONS ◆ 1.6.1 FUEL REQUIREMENTS These generators are equipped with a gasoline fuel system. Depending on the installation, the generator may have either a separate fuel tank, or it may “share” the vehicle engine’s fuel tank. NOTE: Some installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine’s pickup tube.
Section 2 – Operation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 2.1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control Panel 2.2 OPTIONAL REMOTE START/STOP PANEL A remote mounted Start/Stop Panel (Figure 2.2) is available that allows you to start and stop the generator engine conveniently from inside the vehicle.
Section 2 – Operation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 2.4 BEFORE STARTING THE ENGINE NOTE: The generator engine gives off DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED.
Section 2 – Operation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 2.6 STOPPING THE GENERATOR 1. Turn OFF all electrical loads using the means provided (such as a main circuit breaker or transfer switch). 2. Let generator run at no-load for a few minutes, to stabilize internal engine generator temperatures. 3. Place the Start/Stop switch in its STOP position. 2.
Section 2 – Operation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Figure 2.4 – Field Boost Circuit 2.9 ADDITIONAL INFORMATION ◆ 2.9.1 25-HOUR BREAK-IN PERIOD The first 25 hours of operation is the break-in period for the generator. Properly breaking in the generator is essential to minimize fuel consumption and provide maximum engine performance. During this 25hour break-in period, follow this procedure: ◆ 2.8.4 OVERVOLTAGE PROTECTION A solid-state voltage regulator (Figure 2.
Section 3 – Maintenance PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 3.1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements, see “Engine Oil Requirements,” Section 1.6.2 (Page 6). Check the engine crankcase oil level at least every eight hours of operation, or before you use it. To check the engine oil level, proceed as follows (see Figure 3.1): 1. Be sure the generator is as level as possible. 2. Remove the dipstick and wipe it dry with a clean, lint-free cloth. 3.
Section 3 – Maintenance PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 3.3 MAINTAINING THE ENGINE AIR CLEANER 3.4 ◆ 3.3.1 CLEANING THE FOAM PRECLEANER Clean and re-oil the foam precleaner every three months or every 25 hours of operation, whichever occurs first. Service the foam precleaner more frequently if operating the generator in extremely dusty or dirty conditions. Use the following procedure (Figure 3.3): 1. 2. 3. 4. 5. 6. 7. 8. 9. Turn the knob counterclockwise to loosen.
Section 3 – Maintenance PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 3.6 FUEL FILTER (GASOLINE ONLY) Remove and replace the fuel filter (Figure 3.6) once each year or every 100 hours of operation, whichever comes first. Figure 3.6 – Fuel Filter FUEL FILTER TO FUEL PUMP CUSTOMER FUEL CONNECTION 3.7 3.8 When moisture is allowed to remain in contact with windings, some of the moisture will be retained in voids and cracks in the insulation.
Section 3 – Maintenance PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 3.10 MAJOR SERVICE MANUAL Do not dispose of the battery in a fire. The battery is capable of exploding. Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury.
Section 3 – Maintenance PRIMEPACT 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 recommended oil is used in the engine (see Section 1.5.4, Page 6). If necessary, drain and refill with the proper oil. 2. Check the state of the battery. Fill all cells of unsealed batteries to the proper level with distilled water.
Notes PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 16 Generac® Power Systems, Inc.
PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!! Generac® Power Systems, Inc.
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 C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the manufacturer’s instructions and recommendations.
Safety Rules PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators ELECTRICAL HAZARDS FIRE HAZARDS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.
Section 1 – General Information PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 1.1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to all information and instructions in the manual, both for safety and for continued reliable operation of the equipment.
Section 1 – General Information PRIMEPACT 50 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) Oil Fill/Oil Level Fuel Filter Oil Drain Plug Fuel Pump Starter Contactor Oil Filter Air Filter Ground Lug Generac® Power Systems, Inc.
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 2.1 LOCATION AND SUPPORT ◆ 2.1.1 GENERATOR LOCATION The most desirable location for the generator set is between the vehicle's main frame members. However, this is seldom possible. Most units must be installed on the side of the vehicle and are difficult to reinforce. Many recreational vehicles have been factory equipped with an area for the generator set.
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators ◆ 2.1.4 GENERATOR RESTRAINT ◆ 2.2.2 COMPARTMENT CONSTRUCTION Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing. These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compartment is used) and (c) the supporting framework (Figure 2.3).
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators • If flexible metal conduit is used, it must be sealed internally at the end where it terminates inside the compartment’s electrical junction box. NOTE: Flexible metal conduit, due to its unique construction, is NOT vapor tight along its entire length. • Seams and joints of the galvanized steel (whether used as a liner or for the compartment itself) must be lapped and mechanically secured.
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Figure 2.7 – Typical Noise Abatement ◆ 2.2.5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compartment for the following items (Figure 2.8): • Engine exhaust and cooling air outlets • Generator cooling air inlet • Four holes for passage of generator mounting bolts. See Section 2.1.4 (Page 23). Fuel lines and exhaust piping must not penetrate into the vehicle living area. Figure 2.
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 2.3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. Without sufficient airflow, the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also may cause fire and personal injury.
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Figure 2.12 – Air Inlet Using Ductwork ◆ 2.3.4 TESTING THE INSTALLATION Generac recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, you will need to enlarge the air openings. Never place a unit into service until absolutely certain that cooling and ventilation is adequate.
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators ◆ 2.4.1 FUEL TANK Either the generator must share the vehicle engine's fuel tank, or you must install a separate fuel tank for the generator set. All fuel tanks installed on the vehicle must be constructed, installed and restrained so they comply with applicable codes, standards and regulations. If the generator is to share the vehicle engine's tank, separate fuel pickup tubes are required for the engine and the generator.
Section 2 – Installation PRIMEPACT 50 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.
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators ◆ 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.
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Figure 2.18 — Transfer Switch Isolation Method Figure 2.19 — Installation With Isolation Receptacle Generac® Power Systems, Inc.
Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 2.7 BATTERY INSTALLATION ◆ 2.7.1 Figure 2.20 – Connecting Battery Cables RECOMMENDED BATTERY Install a battery that meets the following requirements: • The battery must be a 12-volt, automotive type storage battery. • For prevailing ambient temperatures above 32° F (0° C), use a battery rated 70 amp-hours and capable of delivering at least 400 cold-cranking amperes.
Section 3 – Post Installation Start-up and Adjustments 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 conjunction with the maintenance operations found in Part I of this manual. • Model 004057 includes the remote panel and a 10 foot long, 4 wire harness. • Model 004184 includes the remote panel and a 30 foot long, 4 wire harness.
Section 3 – Post Installation Start-up and Adjustments PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 3.5 INSTALLATION CHECKLIST ◆ LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. ◆ GENERATOR COMPARTMENT ❑ Compartment construction is proper. ❑ Holes/Openings are vapor-sealed. ❑ Compartment size is correct. ❑ Compartment is vapor-sealed. ❑ Sound insulation is correct. ❑ Floor cutouts are properly completed.
Section 4 – Troubleshooting PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 4.1 TROUBLESHOOTING GUIDE PROBLEM Engine won’t crank. CAUSE 1. 2. CORRECTION 1. 2. 3. 4. 5. 6. 7. 15 amp fuse blown. Loose, or corroded or defective battery cable(s). Battery is discharged or defective. Defective starter contactor. Defective starter motor. Defective Start/Stop switch Defective Engine Control Board 3. 4. 5. 6. 7. Replace blown fuse. Tighten, clean or replace, as necessary.
Section 5 – Electrical Data PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Wiring Diagram & Electrical Schematic — Drawing No. 0D6579 36 Generac® Power Systems, Inc.
Section 5 – Electrical Data PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Wiring Diagram & Electrical Schematic — Drawing No. 0D6579 Generac® Power Systems, Inc.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Base and Pulleys – Drawing No. 0D6577-A 38 Generac® Power Systems, Inc.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Base and Pulleys – Drawing No. 0D6577-A ITEM PART NO. QTY.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Alternator and Control Panel – Drawing No. 0D6578-A 40 Generac® Power Systems, Inc.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Alternator and Control Panel – Drawing No. 0D6578-A ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 PART NO. QTY.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Engine Sheet Metal – Drawing No. 0D3150-A 42 Generac® Power Systems, Inc.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Engine Sheet Metal – Drawing No. 0D3150-A ITEM 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 33 34 35 36 PART NO. --------99258 67198N 67890 87865 A4456 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 QTY.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Engine – Drawing No. 79216-G 44 Generac® Power Systems, Inc.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Engine – Drawing No. 79216-G ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Carburetor – Drawing No. 0D6576-A 46 Generac® Power Systems, Inc.
Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Carburetor – Drawing No. 0D6576-A ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 PART NO. 073112B 074962C 074962E 074962G 070155 070108 056893 074961 047227 037398 073131 066476 070575 070125 073374 074947 089473 091306 077091 031879 022159 077075 072536 087770 074946 070594 030340 0C2338D 0C2338F 075252 0A7782A 040173 066829 075944 QTY.
Section 7 – 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.
Section 7 – Warranty PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Section 7 – 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.
