Generac Power Systems 00784-2, 09290-4 Owners And Installation Manual
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Generac Power Systems 00784-2, 09290-4 Owners And Installation Manual

Generac Power Systems 00784-2, 09290-4 Owners And Installation Manual

Air-cooled recreational vehicle generators
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®
POWER SYSTEMS, INC.
Owner's Manual and

Installation Instructions

Air-cooled Recreational
Vehicle Generators
• Model Nos: 00784-2 and 09290-4

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Summary of Contents for Generac Power Systems 00784-2, 09290-4

  • Page 1: Installation Instructions

    ® POWER SYSTEMS, INC. Owner’s Manual and Installation Instructions Air-cooled Recreational Vehicle Generators • Model Nos: 00784-2 and 09290-4...

  • Page 2: Introduction

    Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum. See your Generac Authorized Service Dealer for service aids and acces- sories. HOW TO OBTAIN SERVICE...

  • Page 3: Table Of Contents

    Gasoline Fuel System ...27 Exhaust System ...28 Electrical connections...29 Battery Installation ...32 Optional Accessories...32 Adjustments ...33 Post Installation Tests...33 Before Initial Start-up ...33 Initial Start-up ...33 Testing Under Load ...33 Installation Checklist ...34 Troubleshooting Guide ...35 ® Generac Power Systems, Inc.

  • Page 4: Safety Rules

    If you use a procedure, work method or operating tech- nique Generac does not specifically recommend, you must satisfy yourself that it is safe for you and others. You also must make sure the procedure, work method or operating technique that you choose does not render the generator unsafe.

  • Page 5: Electrical Hazards

    EXPLOSIVE. Do not permit smoking, open flame, sparks or any source of heat in the vicinity while handling gasoline. Comply with all laws gov- erning the storage and handling of gasoline. Safety Rules FIRE HAZARDS EXPLOSION HAZARDS Generac ® Power Systems, Inc.

  • Page 6: Section 1 - General Information

    4. 15 amp Fuse 5. 25 or 30 Amp (2 Pole) Circuit Breaker 6. Optional Remote Panel Receptacle 7. Generator AC Output Leads ® Generac Power Systems, Inc. 2. Serial Number __________________ 4. Rated Voltage __________________ 6. Hertz __________________________ REFERENCE NUMBER IDENTIFICATION 8.

  • Page 7: Generator Applicability

    This generator set is equipped with dual stator AC power windings. These two-stator windings supply electrical power to customer electrical loads. One side of the winding is grounded. Figure 1.1 – Connections for 230 Volts Only INSTALLATION SAFETY GENERATOR AC CONNECTION SYSTEM NOTE: Generac ® Power Systems, Inc.

  • Page 8: Specifications

    Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits. Generac does not recommend using any gasoline containing alcohol (such as “gasohol”). If you use any gasoline containing alcohol, it must not contain more than 10 percent ethanol, and it must be removed from the generator during storage.

  • Page 9: Section 2 - Operation

    This may take about three minutes in cooler weather. Section 2 – Operation OPTIONAL REMOTE START/STOP PANEL Figure 2.2 — Optional Remote Panel (Models 004057 and 004184) AUTOMATIC CHOKE ® Generac Power Systems, Inc.

  • Page 10: Before Starting The Engine

    Close windows, doors and other openings in the vehi- cle that, if open, might permit exhaust gases to enter the vehicle. ® Generac Power Systems, Inc. The generator engine gives off DEADLY carbon monoxide gas through its exhaust system. This...

  • Page 11: Stopping The Generator

    “pickup” voltage in the stator windings. Section 2 – Operation PROTECTION SYSTEMS Figure 2.3 – Low Oil Pressure and High Temperature Switches Generac ® Power Systems, Inc.

  • Page 12: Additional Information

    • After operating the unit for 25 hours, complete the tasks recommended under Section 2.10.2. After the 25-hour break-in period, contact a Generac Authorized Service Dealer for the following mainte- nance. The vehicle owner is responsible for any charges: •...

  • Page 13: Section 3 - Maintenance

    The filter will retain some oil. OIL DRAIN PLUG then shut Section 3 – Maintenance NOTE: Figure 3.1 — Oil Dipstick/Fill Tube and Location of Oil Drain Plug OIL DIPSTICK Figure 3.2 — Engine Oil Filter Generac ® Power Systems, Inc. 11...

  • Page 14: Maintaining The Engine Air Cleaner

    PAPER FOAM FILTER PRE-CLEANER COVER ® 12 Generac Power Systems, Inc. CLEAN AIR INTAKE SCREEN Clean all foreign material from the air intake screen (Figure 3.4) at least once every 100 hours of opera- tion. Clean more often if necessary.

  • Page 15: Fuel Filter (Gasoline Only)

    For assistance in ordering, installing and maintaining spark arrestor exhaust mufflers, contact your nearest Generac Authorized Service Dealer. Exhaust mufflers supplied by Generac are spark arrestor types. Generac exhaust mufflers for recre- ational vehicle generators do not have a spark arrestor screen, but are of the more efficient “toroid”...

  • Page 16: 3.10 Major Service Manual

    Generac Authorized Service Dealer. 3.12 EXERCISING THE GENERATOR Generac recommends that you start and operate the generator at least once every seven days. Let the unit run for at least 30 minutes to “exercise” the engine.

  • Page 17: 3.14 Wattage Reference Guide

    *Submersible Pump (1-1/2 HP) ...2800 *Submersible Pump (1 HP) ...2000 *Paint Sprayer, Airless (1/3 HP) ...600 *Table Saw (10”) ...1750 to 2000 * Allow 2-1/2 times the listed watts for starting these devices. Running Generac ® Power Systems, Inc. 15 Watts...

  • Page 18: Notes

    Notes PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 16 Generac ® Power Systems, Inc.

  • Page 19: Part Ii - Installation Instructions

    PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!! ® Generac Power Systems, Inc. 17...

  • Page 20: Safety Rules

    NOTICE TO INSTALLER These Installation Instructions have been published by Generac to aid in the installation of the products described in this manual. Generac assumes that installation personnel are familiar with the proce- dures for installing such products, or similar prod- ucts that Generac manufactures.
  • Page 21 • You are required to install an approved, flexible, nonconductive fuel line between the generator fuel connection point and rigid fuel lines. Safety Rules FIRE HAZARDS EXPLOSION HAZARDS Generac ® Power Systems, Inc. 19...

  • Page 22: Section 1 - General Information

    Boulevard, Rexdale, Ontario, Canada, M9W 1R3. EQUIPMENT DESCRIPTION Instructions and information in this section pertain to Generac air-cooled generators. These generators are designed specifically for installing in recreational vehicles. They operate 230-volt, single-phase, 50- Hertz, AC electrical loads that require 20.8 amps (PP50) or 30.4 amps (PP70).
  • Page 23 Figure 1.2 – Major Features and Dimensions PrimePact 50 and 70 Control Panel Spark Plugs (both sides, not shown) Oil Fill/Oil Level Fuel Filter Oil Drain Plug Fuel Pump Starter Contactor Oil Filter Air Filter Ground Lug Generac ® Power Systems, Inc. 21...

  • Page 24: Section 2 - Installation

    The fol- lowing general rules apply: • Vehicle construction MUST be capable of support- ing the weight of the generator. 22 Generac ® Power Systems, Inc. • Whether the generator is mounted above the hori-...

  • Page 25: Generator Compartments

    • If the compartment is lined with galvanized steel, it may be constructed of any material. Generac rec- ommends that the compartment be constructed of 1/2-inch thick plywood (not strandboard), with the...
  • Page 26 One excellent insulating material is a 1- inch (25 mm) thick fiberglass having a 2-pound den- sity. When fiberglass is used, its coated side should face toward the compartment interior. 24 Generac ® Power Systems, Inc. Do not install sound insulation or any absorbent material on the compartment floor interior.
  • Page 27 • Engine exhaust and cooling air outlets • Generator cooling air inlet • Four holes for passage of generator mounting bolts. See Section 2.1.4 (Page 23). Fuel lines and exhaust piping must not pene- trate into the vehicle living area. Generac ® Power Systems, Inc. 25...

  • Page 28: Cooling And Ventilating Air

    ® 26 Generac Power Systems, Inc. NOTE: Screening, louvers or expanded metal that cover air openings restrict airflow. You must compensate for this by making the actual air opening propor- tionately larger.

  • Page 29: Gasoline Fuel System

    125 square inches. PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators 2.3.4 TESTING THE INSTALLATION Generac recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, you will need to enlarge the air openings.

  • Page 30: Exhaust System

    If the generator is to share the vehicle engine's tank, separate fuel pickup tubes are required for the engine and the generator. Generac recommends that you make the fuel pickup tube 2 to 3 inches (51 to 76 mm) shorter than the vehicle engine's pickup tube.

  • Page 31: Electrical Connections

    2.5.1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U.S. Forest Service. Use only mufflers and parts approved by Generac. Any person(s) installing an unapproved muffler, or an unapproved exhaust system part, or modifying an exhaust system in any...
  • Page 32 Lead T1 (red) is “hot”. There is also a green lead that connects to ground in the junction box of the recre- ational vehicle. Figure 2.17 – Generator AC Output Leads 30 Generac ® Power Systems, Inc. Do NOT connect electrical loads in excess of...
  • Page 33 Section 2 – Installation PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Figure 2.18 — Transfer Switch Isolation Method Figure 2.19 — Installation With Isolation Receptacle Generac ® Power Systems, Inc. 31...

  • Page 34: Battery Installation

    (Figure 2.20). 3. Connect cables so the connectors are clean and tight. ® 32 Generac Power Systems, Inc. 2.7.4 BATTERY COMPARTMENT Install the generator battery in its own, vented com- partment. Place the battery compartment away from any source of heat, sparks or flame.

  • Page 35: Section 3 - Post Installation Start-Up And Adjustments

    The switch has normally closed (N.C.) contacts. When the engine temperature is too high, switch contacts close, and the engine shuts down automatically. GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLING. NOTE: TESTING UNDER LOAD NOTE: Generac ®...

  • Page 36: Installation Checklist

    ❑ Exhaust system complies with all applicable codes. ❑ Exhaust system is properly and safely installed. DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER 34 Generac ® Power Systems, Inc. ELECTRICAL CONNECTIONS ❑ Connections comply with local code requirements and all National Electrical Codes.

  • Page 37: Section 4 - Troubleshooting

    Replace it if defective. Add oil as needed. Replace, if bad. Replace Switch, if bad. Drain fuel tank and refill. Close main breaker(s). Reset transfer switch. See vehicle manual. Contact an authorized service facility. Generac ® Power Systems, Inc. 35...

  • Page 38: Section 5 - Electrical Data

    Section 5 – Electrical Data PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Wiring Diagram & Electrical Schematic — Drawing No. 0D6579 36 Generac ® Power Systems, Inc.
  • Page 39 Section 5 – Electrical Data PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Wiring Diagram & Electrical Schematic — Drawing No. 0D6579 Generac ® Power Systems, Inc. 37...

  • Page 40: Section 6 - Exploded Views And Parts Lists

    Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Base and Pulleys – Drawing No. 0D6577-A 38 Generac ® Power Systems, Inc.
  • Page 41 WASHER, LOCK #10 COVER, EXHAUST OUTLET NUT, LOCK TRIC M6-1.0 GASKET, EXHAUST OUTLET LOCKWASHER, SPECIAL ¼" CLAMP, VINYL COATED FLANGE NUT, (SPECIAL) 5/16"-18 FLAT WASHER, #10 -M5 DECAL-GROUND TAPTITE, M6-1.00 x 10mm FLATWASHER, M10 Generac ® Power Systems, Inc. 39...
  • Page 42 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Alternator and Control Panel – Drawing No. 0D6578-A 40 Generac ® Power Systems, Inc.
  • Page 43 SWITCH S.P.D.T.-(FUEL PUMP) TERMINAL BLOCK #8 SPECIAL LOCK WASHER M4-0.7 HEX NUT DECAL, CB RATING 30A. (PP70) DECAL, CB RATING 25A. (PP50) M5-0.8 x 25, CAPSCREW DECAL, CUSTOMER CONNECTION CLAMP, HOSE #10/ M5-FLAT WASHER Generac ® Power Systems, Inc. 41...
  • Page 44 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Engine Sheet Metal – Drawing No. 0D3150-A 42 Generac ® Power Systems, Inc.
  • Page 45 WIRE ASSEMBLY-NO, 16 STARTER COVER WRAPPER, CRANKCASE BUSHING, SNAP GROMMET -RUBBER GROMMET -RUBBER O-RING PLUG, OIL FILL BOOT, SPARK PLUG GROUND WIRE ASEMBLY-CYL. #1 2FT. FOAM TAPE GROUND WIRE ASSEMBLY-CYL. #2 OIL DRAIN DECAL Generac ® Power Systems, Inc. 43...
  • Page 46 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Engine – Drawing No. 79216-G 44 Generac ® Power Systems, Inc.
  • Page 47 VALVE COVER GASKET VALVE COVER OIL PUMP ASSEMBLY GOVERNOR SLIDER PUSH ROD ROCKER ARM ASSEMBLY ROCKER ARM SUPPORT VALVE OVERHAUL KIT EXHAUST GASKET (NOT SHOWN) GASKET AND CAP ASSEMBLY ROCKER ARM COVER GOVERNOR CRANK Generac ® Power Systems, Inc. 45...
  • Page 48 Section 6 — Exploded Views and Parts Lists PRIMEPACT 50 and 70 (50Hz) Recreational Vehicle Generators Carburetor – Drawing No. 0D6576-A 46 Generac ® Power Systems, Inc.
  • Page 49 HOSE ¼" I.D., 4.5" LONG DECAL, AIR CLEANER PRIMEPACT 70G (50Hz) DECAL, AIR CLEANER PRIMEPACT 50G (50Hz) KIT, CARBURETOR OVERHAUL-NOT SHOWN FLYWHEEL ASSEMBLY CLAMP, HOSE (SCREW TYPE) RIVET-1/8" DIAMETER x 1/8" LONG BRACKET, GOVERNOR SPRING Generac ® Power Systems, Inc. 47...

  • Page 50: Section 7 - Warranty

    Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period.

  • Page 51: Emission Control System Warranty

    Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or ‘grey market’...
  • Page 52 NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (three) years or 2,000 (two thousand) hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

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