Generac Power Systems 009600-5, 009734-5 Owner'S Manual Download

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POWER SYSTEMS, INC.

Owner’s Manual

Air-cooled Recreational

Vehicle Generators

• Model: 009600-5 and 009734-5

PRIMEPACT 66G and 66LP

Summary of Contents for 009600-5, 009734-5

Page 1: ...POWER SYSTEMS INC Owner s Manual Air cooled Recreational Vehicle Generators Model 009600 5 and 009734 5 PRIMEPACT 66G and 66LP ...

Page 2: ... this manual and thor oughly understand all instructions before using this equipment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of r...

Page 3: ...val From Service 15 3 13 2 Return to Service 15 3 14 Wattage Reference Guide 15 Section 4 Notes 16 Part II Installation Instructions 17 Safety Rules 18 19 Section 5 General Information 20 5 1 Purpose and Scope of the Manual 20 5 2 Safety 20 5 3 Standard Booklets 20 5 4 Equipment Description 20 5 5 Generator Engine Operating Speed 20 5 6 Generator AC Connection System 20 Major Dimensions and Featur...

Page 4: ...e 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 uno...

Page 5: ... 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 i...

Page 6: ...___ 4 Rated Voltage __________________ 5 Phase ______________________________ 6 Hertz __________________________ 1 1 GENERATOR IDENTIFICATION REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake Screen 2 Data Plate 3 Engine Start Stop Switch 4 15 amp Fuse 5 30 amp Circuit Breaker 6 Optional Remote Panel Receptacle 7 Generator AC Output Leads 8 Starter Contactor 9 Fuel Inlet 10 Fuel Primer Switch...

Page 7: ...iply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of current for starting than for continuous operation 1 3 INSTALLATION This Owner s Manual has been prepared under the assumption that a competent qualified technician installed the generator into an industrial vehicle We also assume the installer complied with all applicable codes sta...

Page 8: ...enerator 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 ...

Page 9: ...00 hours For engines of 225 cc or more Category C 250 hours B 500 hours and A 1000 hours 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 2 1 1 FUEL PRIMER Before starting a cold engine if it has not been start ed in more than two weeks you must press this switch for approximately ten seconds to bring fuel from the tank to the fuel pump This ...

Page 10: ... 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 choke valve This may take about three minutes in cooler weather 2 4 BEFORE STARTING THE ENGINE NOTE Instructions and information in this manual assume the generator has been properly in...

Page 11: ...erator 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 10 sec...

Page 12: ...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 on page 10 has normally open N O contacts that are held open by engine oil pressure during cranking and operating Should oil pressure drop below a preset level switch...

Page 13: ... ton rings resulting in blowby and high oil con sumption After operating the unit for 25 hours complete the tasks recommended under Section 2 8 6 2 8 6 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 Check all fluid levels Ins...

Page 14: ... an additional 3 4 to one turn 7 Remove the dipstick and fill crankcase with the proper type and amount of recommended oil see Section 1 6 2 Page 6 The engine crankcase can hold about 1 4 liters DO NOT FILL ABOVE THE FULL MARK 8 Install and tighten the dipstick before operating the engine 9 Start the engine and check for leaks NOTE Check the oil level and fill to the FULL mark after checking for l...

Page 15: ...ting the Spark Plug Gap Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end If necessary re form the wire terminal to obtain a tight fit 3 6 FUEL FILTER GASOLINE ONLY Remove and replace the fuel filter Figure 3 6 once each year or every 100 hours of operation whichever comes first Figure 3 6 Fuel Filter 3 7 SPARK ARRESTOR MUFFLER If the generator is not equip...

Page 16: ...ay from batteries Damage will result if the battery connections are made in reverse Do not dispose of the battery in a 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 charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the b...

Page 17: ...nd wipe the entire generator 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 p...

Page 18: ...16 Generac Power Systems Inc Section 4 Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators ...

Page 19: ...PART II INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION ...

Page 20: ...stallation 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 Followi...

Page 21: ...orking 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 reg...

Page 22: ... 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI A119 2 NFPA 501C available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 available from the State of California Documents Section P O Box 1015 North Highlands CA 95660 6 CSA Electrical Bulletin 946 available from the ...

Page 23: ...ions Section 5 General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators Control Panel Fuel Filter Fuel Pump Oil Filter Oil Drain Plug Starter Contactor Oil Fill Oil Level Spark Plugs both sides not shown Air Filter Ground Lug PrimePact 66G and 66LP ...

Page 24: ... and ven tilating airflow for the generator without a great deal of work and expense 6 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 will restrain the generator set should consist of at least two horizon tal beams These bea...

Page 25: ...rator or inside a compartment that the installer constructs the compartment MUST meet certain specifications as out lined in the following sections 6 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 compart ment has been lined with met...

Page 26: ...erials You may need to use approved nonflammable insulating materials in high temperature areas 6 2 3 SOUND INSULATING MATERIALS Once installers have determined that a compartment is properly constructed and metal lined they can add acoustical material This may include additional sealant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of ...

Page 27: ... 3 To prevent fire or explosion do not install any 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 inch 25 mm thick fiberglass with a 2 pound density Figure 6 7 ...

Page 28: ...s the engine generator and electronic components The second part of the cooling system a suction fan draws air that is heated from a hot engine into a collector pan at the base of the unit This heated air although cooler than exhaust muffler is then deflected out the bottom toward the ground Figure 6 9 Airflow Through Engine Generator 6 3 2 COOLING AIR INLET OPENINGS The minimum size of the air in...

Page 29: ...vice If the unit shows signs of overheating you will need to enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate NOTE You must test the installation especially if you bring in air from below the generator set 6 4 GASOLINE FUEL SYSTEM The installation of a gasoline fuel system Figure 6 14 for a recreational vehicle generator set...

Page 30: ...m parts Use nonferrous metal straps without sharp edges to secure fuel lines 6 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 shift ing settling or movement The following rules apply The flexible hose must comply with SAE J30B Standard for Fuel and Oil Hose...

Page 31: ...outlet or in the supply line from the gas tank The following rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column Do NOT exceed 14 inches water col umn The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommended MINIMUM...

Page 32: ... 318 All connections hoses valve regulators fittings and other fuel system parts must be tested under gas or air pressure of not less than 90 psi 620 kPa while using soap and water or an equivalent solution to check for leaks Other approved methods of testing for leaks may be used if appropriate DO NOT USE ANY FLAME TO TEST FOR LEAKS Gaseous fuel lines between the tank and the sec ondary regulator...

Page 33: ...t that can be opened or is not per manently 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 installati...

Page 34: ...he 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 generator movement If you use metallic conduit vapor seal the end of the cond...

Page 35: ...drop between battery terminals and the gen erator connection point 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 larger the cable size must be as shown in the c...

Page 36: ...ucture where leaks and spills of battery fluid will not cause damage 6 9 OPTIONAL ACCESSORIES A plug in receptacle Figure 6 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 generator engine from any convenient location inside ...

Page 37: ...imed use of the primer switch will shorten this time 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 com pleted apply electrical loads and check for proper operat...

Page 38: ...stem is properly and safely installed ELECTRICAL CONNECTIONS Connections comply with local code requirements and all National Electrical Codes Junction box is properly installed Wiring meets all standards All 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 insta...

Page 39: ...s 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 Bad ignition magneto on engine 8 Replace if defective 9 Bad carburetor 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 Au...

Page 40: ...38 Generac Power Systems Inc Section 9 Electrical Data PRIMEPACT 66G and 66LP Recreational Vehicle Generators Electrical Schematic and Wiring Diagram Drawing No D3148 A ...

Page 41: ...Generac Power Systems Inc 39 Section 9 Electrical Data PRIMEPACT 66G and 66LP Recreational Vehicle Generators Electrical Schematic and Wiring Diagram Drawing No 0D3148 A ...

Page 42: ...40 Generac Power Systems Inc Section 10 Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Sheet Metal Drawing No 0D3150 A ...

Page 43: ...L 2 12 074908 9 SCREW TAPTITE M5 x 10MM 13 073190 1 WRAPPER CYL 2 14 078858 1 COVER VALLEY 15 078859 1 WRAPPER CYL 1 16 074902 2 WRAPPER BARREL 17 066476 4 HHCS LW M6 x 1 0 x 12MM 19 073191 1 COVER BASE CYL 1 20 042907 2 CAPSCREW HEX HD M8 x 1 25 x 16MM 21 022129 2 LOCK WASHER M8 22 075246 4 SCREW TAPTITE 3 8 16 x 1 1 4 23 0742600133 1 WIRE ASSEMBLY NO 16 24 074900 1 STARTER COVER 25 073186 1 WRAP...

Page 44: ...2 50 79 28 57 74 5 6 69 65 62 59 64 3 60 61 36 43 46 3 35 47 83 49 44 45 80 77 76 28 87 20 52 66 52 2 28 29 28 38 90 91 96 5 94 83 82 81 95 41 79 89 54 83 6 84 86 88 68 TO ENGINE Section 10 Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Base and Pulleys Drawing No 0D3151 A ...

Page 45: ...1 1 PIPE OIL DRAIN ADAPTOR 49 022413 1 SCREW HHC 1 4 20 X 1 G5 ITEM PART NO QTY DESCRIPTION 50 0A5802 1 TINNERMAN CLIP 51 022237 8 WASHER LOCK 3 8 52 022145 2 WASHER FLAT 5 16 ZINC 54 092120 2 NUT LOCK TRIC M6 X 1 0 Y ZNC 55 0742600133 1 CABLE STARTER 56 073179 1 OIL FILTER SUPPORT 57 070185 1 FILTER OIL FRAM PH3614 58 0A8584 1 10 PSI SWITCH OIL PRESSURE 59 074948 3 FITTING COMP 5 16 X1 8 SLF ALGN...

Page 46: ...1 10 13 12 37 79 28 57 74 58 56 69 71 70 61 60 59 64 32 60 61 36 43 46 32 35 47 83 38 44 45 16 17 80 78 77 76 28 87 20 3 66 39 2 5 8 2 81 84 41 79 49 50 54 53 48 TO ENGINE Section 10 Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Base and Pulleys Drawing No 0D3154 A ...

Page 47: ...46 A5508 1 OIL FILL TUBE GASKET ITEM PART NO QTY DESCRIPTION 47 75711 1 PIPE OIL DRAIN ADAPTOR 48 92120 2 NUT LOCK TRIC M6 X 1 0 Y ZNC 49 D1227 1 STARTER CONTACTOR 50 D1741 2 BOOT STARTER CONTACTOR 51 24114 2 NUT HEX 5 16 24 STEEL 52 D1741A 1 BOOT BATTERY CABLE 53 22152 2 WASHER LOCK 10 54 22158 2 NUT HEX 10 32 STEEL 55 133 74260 1 CABLE STARTER 56 73179 1 OIL FILTER SUPPORT 57 70185 1 FILTER OIL ...

Page 48: ...0 36 45 4 43 15 37 35 48 44 57 2 53 31 49 40 63 45 44 58 31 30 56 26 27 26 25 59 46 55 62 45 44 20 21 61 TO ENGINE GROUND 63 13 15 16 14 47 22 60 18 14 40 42 64 Section 10 Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Alternator and Control Panel Drawing No 0D3149 C ...

Page 49: ...7 2 M3 0 5 x 12 LG PPHMS ITEM PART NO QTY DESCRIPTION 34 086317A 1 PANEL SUPPORT BRACKET 35 075235 2 M5 0 8 x 30 LG CAPSCREW 36 082737 4 VIBRATION MOUNT 37 049813 4 M6 1 0 HEX NUT 38 049815 1 M5 08 x 16 LG HEX HD CAPSCR 39 043182 2 M3 LOCK WASHER 40 0A8475 3 10 SPECIAL LOCK WASHER 41 053623 1 C BREAKER 2 5A PP55 054502 1 C BREAKER 3 0A PP66 42 0D2724 2 BOOT ROCKER SWITCH 43 083049 1 REGULATOR VOLT...

Page 50: ...48 Generac Power Systems Inc Section 10 Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Exploded View Engine Common Parts Drawing No 079216 G ...

Page 51: ...70554 1 CARBURETOR SPACER 42 070568 4 ROCKER ARM STUD ITEM PART NO QTY DESCRIPTION 43 075253 4 WASHER VALVE COVER SEAL 44 067885 4 M6 NYLON NUT 45 075254 4 VALVE ADJUST SCREW 46 070535 1 OIL SCREEN 47 0C2881 1 STARTER MOTOR NOT SHOWN 50 067891 1 IGNITION COIL 51 075236 4 IGNITION ARMATURE SCREW 52 072347 2 SPARK PLUG 53 075258 1 ENGINE GASKET KIT 57 066480 1 AIR CLEANER GASKET 59 072361 1 GOVERNOR...

Page 52: ...50 Generac Power Systems Inc Section 10 Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Carburetor Drawing No 093753 H ...

Page 53: ...15 089473 1 BI METAL ASSEMBLY CHOKE 16 091306 1 SOLENOID CHOKE 17 077091 1 HAIR PIN COTTER 18 031879 4 WASHER FLAT 4 19 022159 4 WASHER LOCK 4 21 072536 4 SCREW PPMS 4 40 X 22 087770 1 TUBE FUEL GASOLINE 5 16 I D 23 074946 1 LINK CHOKE 25 030340 1 HOSE I D 4 5 LONG 26 0C2338B 1 DECAL AIR CLEANER PRIMEPACT 66G 0C2338 1 DECAL AIR CLEANER PRIMEPACT 55G 0C2338D 1 DECAL AIR CLEANER PRIMEPACT 70G 27 075...

Page 54: ... X 30MM HEX HD CAPSCR 13 037398 1 HEX LOCK NUT NYLON 14 074961 1 GOVERNOR ADJUSTER BRACKET 15 056893 5 10 24 X 1 2 SCREW 16 047227 1 GOVERNOR ADJUSTER SCREW 17 074962C 1 GOVERNOR SPRING PP55G LP PP66G LP 074962G 1 GOVERNOR SPRING PP70G LP Q70G ITEM PART NO QTY DESCRIPTION 18 066476 2 M6 1 0 X 12MM HEX SCREW W LOCK WASHER 19 0C2338E 1 AIR CLEANER DECAL PRIMEPACT 70LP 0C2338C 1 AIR CLEANER DECAL PRI...

Page 55: ...Generac Power Systems Inc 53 Section 11 Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators ...

Page 56: ...54 Generac Power Systems Inc Section 11 Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators ...

Page 57: ...Generac Power Systems Inc 55 Section 11 Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators ...

Page 58: ...f your engine or a part component thereof has failed 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 a...

Page 59: ...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 F...

Page 60: ...ars 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 warranty Generac R...

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