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