POWER SYSTEMS, INC
• Model: 009600-5and PRIMEPACT 66G and 66LP
Owner’s Manual
Air-cooledRecreational Vehicle Generators
CONTENTS
AUTHORIZED SERVICE DEALER LOCATION
OPERATION AND MAINTENANCE
HOW TO OBTAIN SERVICE
Table of Contents
GENERAL HAZARDS
EXPLOSION HAZARDS
ELECTRICAL HAZARDS
FIRE HAZARDS
1 2 3
1.1GENERATOR IDENTIFICATION
REFERENCE NUMBER IDENTIFICATION
1.4SAFETY
1.3INSTALLATION
1.2GENERATOR APPLICABILITY
1.5GENERATOR AC CONNECTION SYSTEM
Fuel Consumption gph/lbs.ph
1.6SPECIFICATIONS
1.6.1 FUEL REQUIREMENTS
1.6.2 ENGINE OIL REQUIREMENTS
2.1.2 START/STOP SWITCH
1.6.4 ENGINE SPECIFICATIONS
2.1GENERATOR CONTROL PANEL
1.6.5 EMISSIONS COMPLIANCE PERIOD
2.2OPTIONAL REMOTE START/STOP PANEL
2.4.1 INSTALLATION
2.3AUTOMATIC CHOKE
2.4BEFORE STARTING THE ENGINE
2.5STARTING THE GENERATOR
2.6STOPPING THE GENERATOR
2.7APPLYING LOADS TO GENERATOR
2.4.5 ENGINE EXHAUST GAS
2.8.1 LOW OIL PRESSURE SWITCH
2.8.2 HIGH TEMPERATURE SWITCH
High Temperature Switches
2.8PROTECTION SYSTEMS
2.8.4 OVERVOLTAGE PROTECTION
3.1CHECKING THE ENGINE OIL LEVEL
2.8.6 25-HOUR CHECK-UP
2.8.5 25-HOUR BREAK-INPERIOD
3.3.1 CLEANING THE FOAM PRECLEANER
3.3MAINTAINING THE ENGINE AIR CLEANER
3.2CHANGING THE ENGINE OIL AND/OR OIL FILTER
Figure 3.1 — Oil Dipstick/Fill Tube and
Figure 3.3 – Engine Air Cleaner
3.4CLEAN AIR INTAKE SCREEN
Figure 3.4 – Cleaning Air Intake
Figure 3.5 – Setting the Spark Plug Gap
3.9BATTERY MAINTENANCE
3.8CLEANING THE GENERATOR
3.9.1 WEEKLY
3.9.2 EVERY SIX MONTHS
3.13 OUT OF SERVICE PROCEDURE
3.10 MAJOR SERVICE MANUAL
3.13.1 REMOVAL FROM SERVICE
3.13.2 RETURN TO SERVICE
Section 4 – Notes
16 Generac Power Systems, Inc
SHOULD ATTEMPT INSTALLATION
INSTALLATION INSTRUCTIONS
PART II –
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
GENERAL HAZARDS
NOTICE TO INSTALLER
ELECTRICAL HAZARDS
•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
EXPLOSION HAZARDS
FIRE HAZARDS
5.2SAFETY
INSTALLATION INSTRUCTIONS
5.1PURPOSE AND SCOPE OF THE
5.3STANDARDS BOOKLETS
PrimePact 66G and 66LP
Figure 5.2 - Major Features and Dimensions
Control Panel Spark Plugs
Oil Fill/Oil Level Fuel Filter Oil Drain Plug
6.1.2 GENERATOR SUPPORT
6.1LOCATION AND SUPPORT
6.1.1 GENERATOR LOCATION
6.1.3 SUSPENDED MOUNTING
6.1.4 GENERATOR RESTRAINT
6.2 GENERATOR COMPARTMENTS
6.2.2 COMPARTMENT CONSTRUCTION
6.2.1 COMPARTMENT SIZE
6.2.4 ACOUSTICS
6.2.3 SOUND INSULATING MATERIALS
Figure 6.6 – Types of Lock Seams
Figure 6.7 – Typical Noise Abatement
Figure 6.8 — Compartment Floor Cutout
6.2.5 COMPARTMENT FLOOR CUTOUTS
6.3COOLING AND VENTILATING AIR
6.3.2 COOLING AIR INLET OPENINGS
6.3.1 GENERATOR AIRFLOW
Figure 6.12 – Air Inlet Using Ductwork
6.3.4 TESTING THE INSTALLATION
6.4GASOLINE FUEL SYSTEM
6.3.3 COMPENSATING FOR RESTRICTIONS
6.4.1 FUEL TANK
6.5LP GAS FUEL SYSTEM
6.4.2 GENERATOR FUEL SUPPLY LINE
6.4.2.1 Rigid Fuel Lines
6.5.4 PRIMARY REGULATOR
Figure 6.16 – LP Gas Carburetion Diagram
6.5.2 SOME IMPORTANT CONSIDERATIONS
6.5.3 VAPOR WITHDRAWAL
6.5.6 FUEL SUPPLY LINES
6.6EXHAUST SYSTEM
6.5.7 EXCESS FLOW VALVE
6.5.8 LEAKAGE TESTS
6.7.2 WIRING
6.6.3 EXHAUST SYSTEM SAFETY
6.7ELECTRICAL CONNECTIONS
6.6.2 TYPE OF EXHAUST SYSTEM
6.7.5 ISOLATING DIFFERENT POWER SOURCES
6.8BATTERY INSTALLATION
6.7.6 POWER SUPPLY CORD
6.7.7 GROUND FAULT CIRCUIT INTERRUPTERS
Figure 6.18 — Transfer Switch Isolation Method
6.8.2 BATTERY CABLES
6.8.3 BATTERY CABLE CONNECTIONS
6.9OPTIONAL ACCESSORIES
6.8.4 BATTERY COMPARTMENT
Figure 6.20 – Connecting Battery Cables
7.4TESTING UNDER LOAD
7.1POST INSTALLATION TESTS
7.2BEFORE INITIAL START-UP
7.3INITIAL START
7.5INSTALLATION CHECKLIST
PROBLEM
8.1TROUBLESHOOTING GUIDE
CAUSE
CORRECTION
Section 9 - Electrical Data
Section 9 — Electrical Data
Generac Power Systems, Inc.
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Section 10 — Exploded Views and Parts Lists
PART NO
ITEM
DESCRIPTION
TO ENGINE
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PART NO
ITEM
DESCRIPTION
PART NO
TO ENGINE
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PART NO
ITEM
DESCRIPTION
ITEM
Section 10 — Exploded Views and Parts Lists
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
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PART NO
ITEM
DESCRIPTION
ITEM
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PART NO
ITEM
DESCRIPTION
Carburetor – Drawing No. 093753-H
PART NO
ITEM
DESCRIPTION
ITEM
Section 11 — Notes
Generac Power Systems, Inc
Section 11 — Notes
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Section 11 — Notes
Generac Power Systems, Inc.
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES
YOUR WARRANTY RIGHTS AND OBLIGATIONS
1-800-333-1322
EMISSION RELATED PARTS INCLUDE THE FOLLOWING
EMISSION CONTROL SYSTEM WARRANTY
FOR RECREATIONAL VEHICLE GENERATORS
GENERAC POWER SYSTEMS’ THREE-YEARLIMITED WARRANTY
P.O. BOX 8 • WAUKESHA, WI
Part No. 0D7803