Generac Power Systems 009592-5, 009735-5

PART II –

INSTALLATION

INSTRUCTIONS

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

Contents

Main INTRODUCTION READ THIS MANUAL THOROUGHLY CONTENTS OPERATION AND MAINTENANCE HOW TO OBTAIN SERVICE Table of Contents PRIMEPACT 55G and 55LP Recreational Vehicle Generators Section 4 Notes......................................................................16 Section 2 Operation................................................................7 Section 3 Maintenance........................................................11 WARNING: ELECTRICAL HAZARDS FIRE HAZARDS EXPLOSION HAZARDS Page 1.2 GENERATOR APPLICABILITY 1.3 INSTALLATION Figure 1.1 Connection for 120 Volts Only 1.4 SAFETY 1.5 GENERATOR AC CONNECTION SYSTEM 1.6 SPECIFICATIONS 1.6.1 FUEL R EQUIREMENTS 1.6.2 ENGINE OI L REQUIREMENTS 1.6.3 ENGINE SP ECIFICATIONS 2.1 GENERATOR CONTROL PANEL 2.1.1 FUEL PRIMER Figure 2.1 Typical Control Panel 2.1.2 START/STOP SWITCH 2.1.3 15 AMP FUSE 2.4 BEFORE STARTING THE ENGINE 2.4.1 INSTALLATION 2.4.2 ENGINE LUBR ICATION 2.4.3 FUEL SU PPLY 2.4.4 COOLING AND VENTIL ATING AIR 2.6 STOPPING THE GENERATOR 2.7 APPLYING LOADS TO GENERATOR 2.7.1 LETTING THE ENGI NE STABILIZE 2.7.2 DO NOT OVERLOAD THE GENERATOR 2.8 PROTECTION SYSTEMS 2.8.2 HIGH TEMP ERATURE SWITCH Figure 2.3 Low Oil Pressure and High Temperature Switches Figure 2.4 Field Boost Circuit 2.8.3 FIELD BOOST 2.8.4 OVERVOLTAGE PROTECTION 3.1 CHECKING THE ENGINE OIL LEVEL 3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER Figure 3.1 Oil Dipstick/Fill Tube and Location of Oil Drain Plug Figure 3.2 Engine Oil Filter 3.3 MAINTAINING THE ENGINE AIR CLEANER Figure 3.3 Engine Air Cleaner 3.3.1 CLEANING TH E FOAM PRECLEANER 3.4 CLEAN AIR INTAKE SCREEN Figure 3.4 Cleaning Air Intake 3.6 FUEL FILTER Figure 3.6 Fuel Filter 3.7 SPARK ARRESTOR MUFFLER 3.8 CLEANING THE GENERATOR 3.9 BATTERY MAINTENANCE 3.10 MAJOR SERVICE MANUAL 3.11 DRIVE BELT 3.12 EXERCISING THE GENERATOR 3.13 OUT OF SERVICE PROCEDURE 3.13.1 REMOVAL FROM SERVICE 3.14 WATTAGE REFERENCE GUIDE Page Page NOTICE TO INSTALLER GENERAL HAZARDS ELECTRICAL HAZARDS FIRE HAZARDS EXPLOSION HAZARDS 5.1 PURPOSE AND SCOPE OF THE MANUAL 5.2 SAFETY 5.3 STANDARDS BOOKLETS 5.4 EQUIPMENT DESCRIPTION 5.5 GENERATOR ENGINE OPERATING SPEED PrimePact 55G and 55LP 6.1 LOCATION AND SUP PORT 6.1.1 GEN ERATOR LOCATION 6.1.2 GEN ERATOR SUPPORT Figure 6.1 Typical Horizontal Support Frame 6.1.3 SUSP ENDED MOUNTING 6.2 GENERATOR COMPARTMENTS 6.2.1 COMPARTMENT SIZE 6.2.2 COMPARTMENT CONSTRUCTION Figure 6.5 Typical Compartment Construction Figure 6.6 Types of Lock Seams 6.2.3 SOUND INSU LATING MATERIALS 6.2.4 ACOUSTICS Figure 6.7 Typical Noise Abatement 6.2.5 COMPARTMENT FLOOR CUTOUTS 6.3 COOLING AND VENTILATING AIR 6.3.1 GENERATOR AIRFLOW Figure 6.9 Airflow Through Engine/Generator 6.3.2 COOLING AIR IN LET OPENINGS Figure 6.10 Air Inlet in Compartment Door 6.4 GASOLINE FUEL SYSTEM Figure 6.14 Generator Fuel System 6.4.1 FUEL TANK 6.4.2 GENERATOR FUEL SUPPLY LINE 6.4.2.1 Rigid Fuel Lines 6.4.2.2 Flexible Fuel Line 6.5 LP GAS FUEL SYSTEM 6.5.1 PARTS NOT INCLUDED IN FUEL SYSTEM Figure 6.15 Typical Propane Gas Fuel System 6.5.2 SOME IMPORTANT CONSIDERATIONS Figure 6.16 LP Gas Carburetion Diagram 6.5.3 VAPOR WITHDRAWAL 6.5.4 PRI MARY REGULATOR 6.5.5 GASEOUS CARBURETION 6.6 EXHAUST SYSTEM 6.6.1 MUFFLERS AND SPARK ARRESTORS 6.6.2 TYPE OF EXHAUST SYSTEM 6.6.3 EXHAUST SYSTEM SAFETY 6.7 ELECTRICAL CONNECTIONS 6.7.1 ELECTRICAL JUNCTION BOX 6.7.2 WIRING 6.7.3 GENERATOR AC CONNECTIONS Figure 6.17 Generator AC Output Leads 6.7.4 CONDUIT 6.7.5 ISOLATING DIFFERENT POWER SOURCES 6.7.6 POWER SUPPLY CORD 6.7.7 GROUND FAULT CIRCUIT INTERRUPTERS 6.8 BATTERY INSTALLATION 2.8.1 R ECOMMENDED BATTERY Figure 6.21 Remote Panel Plug-in Receptacle 6.8.2 BATTERY CABLES 6.8.3 BATTERY CABLE CONNECTIONS 7.1 POST INSTALL ATION TESTS 7.2 BEFORE INITIAL START-UP 7.3 INITIAL START 7.4 TESTING UNDER LOAD 7.5 INSTALLATION CHECKLIST LOCATION AND SUPPORT GENERATOR COMPARTMENT COOLING AND VENTILATING AIR GASOLINE FUEL SYSTEM 8.1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION 38 GeneracPower Systems, Inc. Section 9 Electrical Data PRIMEPACT 55G and 55LP Recreational Vehicle Generators Electrical Schematic Drawing No. D3148-A GeneracPower Systems, Inc. 39 Page Page Page Page 44 GeneracPower Systems, Inc. Page Page Page Page Page Page Page Page Page Page Page Section 12 Warranty CALIFORNIA AND FEDERAL EM ISSION CONTROL WARRANTY STATEM ENT YOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURERS EMISSION CONTROL SYSTEM WARRANTY COVERAGE: PURCHASERS/OWNERS WARRANTY RESPONSIBILITIES: 1-800-333-1322 EMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWING: