Generac Power Systems 009592-5, 009735-5 - page 47

Generac®Power Systems, Inc. 45

ITEM PART NO. QTY. DESCRIPTION

1 86318 1 BASE, MOUNTING

2 90141 1 GROUND CABLE

3 46911 4 MOUNT, (RUBBER)

4 25017 8 SCREW HHC 3/8-16 X 1/2 G5

5 46526 2 WASHER LOCK M10

6 22129 8 WASHER LOCK M8-5/16

7 72391 2 SKID, RUBBER MOUNT

8 77603 2 SAFETY BOLT 5/16"-18 x 3-1/2"

9 22259 2 NUT HEX 5/16-18 STEEL

10 52858 6 NUT LOCK M8

11 51730 2 SCREW HHC M8-1.25 X 60 G8.8

12 29459 2 SPRING, BELT TENSION

13 75215 2 WASHER, SPRING CNTR

14 73146 4 SLIDE (NYLON)

15 75209 2 SUPPORT, NYLON SLIDE

16 73174 1 MANIFOLD, EXHAUST

17 79678 2 RING, SEALING

18 40976 4 SCREW SHC M8-1.25 X 20 G12.9

19 72383 2 GASKET, COLLECTOR PAN

20 90859 1 COVER PLATE -EXTERNAL

21 75224-B 1 PULLEY, ENGINE

22 73106-B 1 PULLEY, ALT.

23 75216 1 BELT (POLY V 4L)-40"

24 49451 1 WASHER FLAT SPECIAL .406 I.D.

25 42633 1 SCREW HHC 3/8-24 X 1 G5

26 77017 1 GUIDE, BLOWER HOUSING

27 73118 1 SCREW HHC 3/8-24X2-1/4 G8

28 74906 5 SCREW TAPTITE M6X20 BP

30 72375 1 HOUSING, BLOWER

31 73185 1 SPACER ROLL 2.36X.230X.042 BRZ

32 22097 7 WASHER LOCK M6-1/4

33 77682 1 SCREW HHC M5-0.8 X 80 G8.8

34 75242 4 SPRING, GENERATOR SET MT

35 49813 2 NUT HEX M6 -1.0 G8 YEL CHR

36 45757 2 SCREW HHC M6-1.0 X 25 G8.8

37 A5802 1 TINNERMAN CLIP

38 22413 1 SCREW HHC 1/4-20 X 1 G5

39 22145 2 WASHER FLAT 5/16 ZINC

40 22237 8 WASHER LOCK 3/8

41 A8475 1 WASHER SPECIAL LOCK M5

42 26925 1 PLUG STD PIPE 3/8 STEEL SQ HD

43 75710-A 1 TUBE, OIL FILL AND DRAIN

44 74958 1 CAP & DIPSTICK ASSEMBLY

45 67871 1 O-RING, CAP

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 (FRAM#PH3614)

58 A8584 1 10 PSI-SWITCH, OIL PRESSURE

59 74948 3 FITTING COMP 5/16X1/8 SLF-ALGN

60 74950 1 TUBE, OUTER OIL

61 74951 1 TUBE, INNER OIL

62 73134 1 ADAPTOR, OIL FILTER ADAPTER

63 38750 3 SCREW HHC M6-1.0 X 30 G8.8

64 74949 1 ELBOW 90D TUBE CMP 5/16X1/8NPT

65 68548 1 GASKET, OIL FILTER ADAPTER

66 C4006 1 CABLE,BATTERY

67 29289 -- TAPE ELEC NON-UL FOAM 1/16X1/2

68 22131 1 WASHER FLAT 3/8 ZINC

69 75281 1 SWITCH, HIGH TEMPERATURE

70 C1085 2 SCREW PPHM M3-0.5 X 8

71 43182 2 WASHER LOCK M3

72 45756 9 SCREW TAPTITE M6X10 YEL CHR

73 75237 4 WASHER, SPRING RETAINER

74 D1624 1 BOOT, OIL PRESSURE SWITCH

75 75474 1 BOOT, TEMPERATURE SWITCH

76 90800 1 ELBOW, EXHAUST

77 94670 1 EXHAUST CLAMP

78 75226 1 COVER, AIR

79 56893 23 SCREW CRIMPTITE #10-24 X 1/2

80 75229 1 SLIDE PAN, GASKET

81 D3158 1 SLIDE PAN

82 79246 6 CAPSCREW, HEX HEAD- M6-1.00 x 16mm

WITH LOCK WASHER

83 22473 7 WASHER FLAT 1/4 ZINC

84 67210 1 DECAL-GROUND

85 72384-C 1 COVER, EXHAUST OUTLET

86 23897 6 WASHER FLAT #10 ZINC

87 77643 1 GASKET, EXHAUST OUTLET

88 81105 2 FLANGE NUT, (SPECIAL) 5/16"-18

89 90088 1 CLAMP VINYL .25 X .28 Z

90 A1658 2 LOCKWASHER, SPECIAL ¼"

Section 10 — Exploded Views and Parts Lists

PRIMEPACT 55G and 55LP Recreational Vehicle Generators

Base and Pulleys – Drawing No. D3154-A

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: