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