Generac Power Systems 009600-5, 009734-5 Owner's Manual
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Generac Power Systems 009600-5, 009734-5 Owner's Manual

Generac Power Systems 009600-5, 009734-5 Owner's Manual

Air-cooled recreational vehicle generators
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POWER SYSTEMS, INC.
Owner's Manual
Air-cooled Recreational
Vehicle Generators
• Model: 009600-5 and 009734-5
PRIMEPACT 66G and 66LP

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Summary of Contents for Generac Power Systems 009600-5, 009734-5

  • Page 1 ® POWER SYSTEMS, INC. Owner’s Manual Air-cooled Recreational Vehicle Generators • Model: 009600-5 and 009734-5 PRIMEPACT 66G and 66LP...

  • Page 2: Introduction

    INTRODUCTION READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual, contact Generac or your nearest Generac Authorized Service Dealer for starting, operating and servicing procedures. Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or care-...

  • Page 3: Table Of Contents

    Part I — Operating Instructions Introduction ...Inside Front Cover Read This Manual Thoroughly ...IFC Contents ...IFC Operation and Maintenance ...IFC How to Obtain Service ...IFC Authorized Service Dealer Locator Number ...IFC Safety Rules ...2 Section 1 – General Information ...4 Generator Identification ...4 Generator Applicability ...5 Installation ...5...

  • Page 4: Safety Rules

    Safety Rules PRIMEPACT 66G and 66LP Recreational Vehicle Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment. WARNING: The engine exhaust from this product contains chemicals known to the state...

  • Page 5: Fire Hazards

    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.

  • Page 6: Section 1 - General Information

    Section 1 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal. 1. Model Number ____________________ 3. kW Rating__________________________ 5. Phase ______________________________ 1. Generator Air Intake Screen 2.

  • Page 7: Generator Applicability

    GENERATOR APPLICABILITY These generators have been designed and manufac- tured for supplying electrical power for recreational vehicles. You should not modify the generator or use it for any application other than for what it was designed. If there are any questions pertaining to its application, write or call the factory.

  • Page 8: Specifications

    Section 1 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators Figure 1.1 – Connection for 120 Volts Only Figure 1.2 - Connection for 120/240 Volts GROUNDED NEUTRAL STATOR WINDINGS SPECIFICATIONS 1.6.1 FUEL REQUIREMENTS This generator is equipped with a gasoline fuel system as standard equipment.

  • Page 9: Engine Specifications

    1.6.4 ENGINE SPECIFICATIONS Type of Engine PRIMEPACT 66G/66LP ...GN-480 Cooling Method ...Air-cooled Rated Horsepower PRIMEPACT 66G/66LP ...16 at 3600 Displacement PRIMEPACT 66G/66LP...480cc Compression Ratio...8.6 to 1 Cylinder Block ...Aluminum w/Cast Iron Sleeve Type of Governor ...Mechanical, Fixed Speed Engine Governor Speed ...2700 rpm Air Cleaner ...Paper Element w/Foam Precleaner Starter ...12-volt DC Electric Ignition System ...Solid-state w/Flywheel Magneto...

  • Page 10: Optional Remote Start/Stop Panel

    Section 2 – Operation PRIMEPACT 66G and 66LP Recreational Vehicle Generators NOTE: If this generator has been reconnected for dual voltage AC output (120/240 volts), you can install line breakers having an amperage rating that is different than that stated above. The replacement line breakers consist of two separate breakers with a connecting piece between the breaker handles (so that both breakers will operate at the same...

  • Page 11: Engine Exhaust Gas

    2.4.5 ENGINE EXHAUST GAS Before starting the generator engine, you should be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals. Close windows, doors and other openings in the vehi- cle that, if open, might permit exhaust gases to enter the vehicle.

  • Page 12: Do Not Overload The Generator

    Section 2 – Operation PRIMEPACT 66G and 66LP Recreational Vehicle Generators 2.7.2 DO NOT OVERLOAD THE GENERATOR You can read the rated wattage/amperage capacity of your generator on the generator data decal (see Section 1.1 on Page 4). Applying electrical loads in excess of the unit’s rated capacity will cause the engine/generator to automati- cally shut down.

  • Page 13: Overvoltage Protection

    2.8.4 OVERVOLTAGE PROTECTION A solid-state voltage regulator (Figure 2.5) controls the generator’s AC output voltage. This regulator sup- plies an excitation current to the rotor. By regulating the rotor’s excitation current, the strength of its mag- netic field is regulated and, in turn, the voltage deliv- ered to connected electrical loads is controlled.

  • Page 14: Changing The Engine Oil And/Or Oil Filter

    Section 3 – Maintenance PRIMEPACT 66G and 66LP Recreational Vehicle Generators CHANGING THE ENGINE OIL AND/OR OIL FILTER • Change the engine oil after the first 25 hours of operation (after the 25-hour break-in period, see Section 2.8.5, Page 10). Thereafter, change the oil every 100 operating hours.

  • Page 15: Clean Air Intake Screen

    filter must lock into slots on cover. 8. Install the cover, foam precleaner and paper filter. 9. Replace knob to retain the filter in place. Figure 3.3 – Engine Air Cleaner PAPER FOAM FILTER PRE-CLEANER COVER 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.

  • Page 16: Cleaning The Generator

    Section 3 – Maintenance PRIMEPACT 66G and 66LP Recreational Vehicle Generators Be sure to reinstall the muffler plug tightly. Engine vibration could cause a loose plug to fall out. Without the plug in place, hot engine exhaust is directed out the opening. This hot exhaust, depending on the installation, could be directed to areas not able to withstand the extreme heat such as wooden floor boards or...

  • Page 17: Major Service Manual

    3.10 MAJOR SERVICE MANUAL To obtain a service manual for your generator, con- tact Generac or your nearest Generac Authorized Service Dealer. Make sure to identify your MODEL NUMBER and SERIES. 3.11 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement.

  • Page 18: Section 4 - Notes

    Section 4 – Notes PRIMEPACT 66G and 66LP 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!!

  • Page 20: Safety Rules

    Safety Rules PRIMEPACT 66G and 66LP Recreational Vehicle Generators DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the manufacturer’s instructions and recommendations.
  • Page 21 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.

  • Page 22: Section 5 - General Information

    Section 5 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements.

  • Page 23: Major Dimensions And Features

    Section 5 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators Figure 5.2 - Major Features and Dimensions PrimePact 66G and 66LP 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...

  • Page 24: Section 6 - Installation

    Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators Figure 5.3 - Connection for 120/240 Volts GROUNDED NEUTRAL STATOR WINDINGS • The AC connection system on all air-cooled PRIMEPACT series generators uses a GROUNDED neutral. • A separate green ground wire is connected to the recreational vehicle’s junction box.

  • Page 25: Generator Restraint

    • Protect the generator against road splash and debris. Baffles or splash guards may be required to protect cer- tain areas of the generator. To make sure the generator is adequately protected, road test the installation through mud, water and slush. Figure 6.2 –...

  • Page 26: Sound Insulating Materials

    Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators • If constructing a compartment, line the exterior (underside) of the compartment floor with 26-gauge galvanized steel. • All seams, splices and joints of the compartment walls (unless vapor tight by design) should be caulked to prevent poisonous, flammable or explo- sive vapors from entering the vehicle interior.

  • Page 27: Compartment Floor Cutouts

    • Vapor seal all compartment seams and joints. • Over the galvanized steel lining, install a combination of acoustical materials as mentioned in Section 6.2.3. To prevent fire or explosion, do not install any insulation or other absorbent materials on the interior or underside of the compartment floor.

  • Page 28: Cooling And Ventilation

    Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators 6.2.5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compart- ment for the following items (Figure 6.8, Page 25): • Engine exhaust and cooling air outlets • Generator cooling air inlet •...

  • Page 29: Compensating For Restrictions

    behind generator (Figure 6.13 ). Recommended clearance behind the back of the generator is at least 1/2 inch (13 mm). Figure 6.12 – Air Inlet Using Ductwork Figure 6.13 – Air Inlet in Vehicle Skirt VEHICLE FLOOR MINIMUM CLEARANCE 1-1/2" 6.3.3 COMPENSATING FOR RESTRICTIONS Such materials as screening, louvers or expanded metal can restrict the free flow of air.

  • Page 30: Fuel Tank

    Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators 6.4.1 FUEL TANK Either the generator must share the vehicle engine's fuel tank, or you must install a separate fuel tank for the generator set. All fuel tanks installed on the vehicle must be constructed, installed and restrained so they comply with applicable codes, standards and regula- tions.

  • Page 31: Some Important Considerations

    Figure 6.15 – Typical Propane Gas Fuel System 6.5.2 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system, consider seriously the following items: • All fittings, lines, hoses and clamps must be tight and free of leaks. Apply a pipe sealant to threads when assembling threaded connections.

  • Page 32: Fuel Supply Lines

    Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators The greater the airflow through the carburetor venturi, the lower the pressure at the venturi throat. The lower the pressure at the venturi throat, the greater the diaphragm movement, and the greater the movement of the regulator valve.

  • Page 33: Mufflers And Spark Arrestors

    Failure to provide and maintain a spark arrestor may be in violation of the law. If this generator is used on any forest covered, brush covered or grass covered unim- proved land, you must provide a spark arrestor. The vehicle owner or operator must maintain this device in good condition.

  • Page 34: Generator Ac Connections

    Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators • From the junction box, route power supply wires through approved conduit to either (a) double-pole, double-throw transfer switch, or (b) approved isola- tion receptacle. Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being connected to two different power supplies at the same time (such as generator and...

  • Page 35: Battery Cables

    6.8.2 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage, which causes starting problems. For the best cold weather starting, the voltage drop between battery terminals and the gen- erator connection point should not exceed 0.12 volts per 100 amperes of cranking current.

  • Page 36: Battery Cable Connections

    Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators CABLE LENGTH in Feet (meters) 0 to 10 (0 to 3) 11 to 15 (3.4 to 4.5) 16 to 20 (4.5 to 6) *For warm weather, use No. 2 cable up to 20 feet. 6.8.3 BATTERY CABLE CONNECTIONS 1.

  • Page 37: Section 7 - Post Installation

    POST INSTALLATION TESTS The air-cooled generator set was factory tested and adjusted. You should not be required to adjust the unit any further except under special circumstances. Do not make any unnecessary adjustments. Factory settings are correct for most applications. When making adjustments, however, be careful to avoid overspeeding the engine.

  • Page 38: Installation Checklist

    Section 7 – Post Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators INSTALLATION CHECKLIST LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GENERATOR COMPARTMENT ❑ Compartment construction is proper. ❑ Holes/Openings are vapor-sealed. ❑...

  • Page 39: Section 8 - Troubleshooting

    TROUBLESHOOTING GUIDE PROBLEM Engine won’t crank. Engine cranks, won't start. Engine starts hard, runs rough. Engine starts, then shuts down. No AC output voltage. Section 8 – Troubleshooting PRIMEPACT 66G and 66LP Recreational Vehicle Generators CAUSE 15 amp fuse blown. Loose, or corroded or defective battery cable(s).

  • Page 40: Section 9 - Electrical Data

    Section 9 — Electrical Data PRIMEPACT 66G and 66LP Recreational Vehicle Generators Electrical Schematic and Wiring Diagram – Drawing No. D3148-A 38 Generac Power Systems, Inc. ®...
  • Page 41 Section 9 — Electrical Data PRIMEPACT 66G and 66LP Recreational Vehicle Generators Electrical Schematic and Wiring Diagram – Drawing No. 0D3148-A Generac Power Systems, Inc. 39 ®...

  • Page 42: Section 10 - Exploded Views And Parts Lists

    Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Sheet Metal – Drawing No. 0D3150-A 40 Generac Power Systems, Inc. ®...
  • Page 43 ITEM PART NO. QTY. --------- 099258 067198N 067890 087865 0A4456 086313 056893 087750 074916 074908 073190 078858 078859 074902 066476 073191 042907 022129 075246 0742600133 074900 073186 081108 022717B 022717A 067866A 077001A 073132 087858A 029289 2FT. 087858B 050277 Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Sheet Metal –...
  • Page 44 Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Base and Pulleys – Drawing No. 0D3151-A TO ENGINE 42 Generac Power Systems, Inc. ®...
  • Page 45 ITEM PART NO. QTY. DESCRIPTION 086318 BASE, MOUNTING 090141 GROUND CABLE 046911 MOUNT VIBR 1.50X1.38 X 3/8-16) 025017 SCREW HHC 3/8-16 X 1/2 G5 046526 WASHER LOCK M10 022129 WASHER LOCK M8-5/16 072391 SKID, RUBBER MOUNT 077603 SAFETY BOLT 5/16-18 x 3 1/2" 022259 NUT HEX 5/16-18 STEEL 052858...
  • Page 46 Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Base and Pulleys – Drawing No. 0D3154-A TO ENGINE 44 Generac Power Systems, Inc. ®...
  • Page 47 ITEM PART NO. QTY. DESCRIPTION 86318 BASE, MOUNTING 90141 GROUND CABLE 46911 MOUNT, (RUBBER) 25017 SCREW HHC 3/8-16 X 1/2 G5 46526 WASHER LOCK M10 22129 WASHER LOCK M8-5/16 72391 SKID, RUBBER MOUNT 77603 SAFETY BOLT 5/16"-18 x 3-1/2" 22259 NUT HEX 5/16-18 STEEL 52858 NUT LOCK M8...
  • Page 48 Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Alternator and Control Panel – Drawing No. 0D3149-C 46 Generac Power Systems, Inc. ® TO ENGINE GROUND 40 63 2,53...
  • Page 49 ITEM PART NO. QTY. DESCRIPTION 0C9675 LOWER BEARING CARRIER 077005H ROTOR ASSEM. PP55 077004H ROTOR ASSEM. PP66 087844H STATOR ASSEM. 55 087845H STATOR ASSEM. 66 073159 BALL BEARING 031971 BALL BEARING 0C9674 UPPER BEARING CARRIER 077006 STUD-STATOR 052858 M8-1.25 FLANGE LOCK NUT 066386 BRUSH HOLDER 066849...
  • Page 50 Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Exploded View - Engine Common Parts – Drawing No. 079216-G 48 Generac Power Systems, Inc. ®...
  • Page 51 ITEM PART NO. QTY. DESCRIPTION 069331 CYLINDER ASSEMBLY 069333 SLEEVE BEARING 067805 OIL SEAL 0851100101 NO. 1 CYLINDER HEAD ASSEMBLY 0851100102 NO. 2 CYLINDER HEAD ASSEMBLY 070169 SEALING WASHER 069332 CYLINDER HEAD GASKET 0851100104 BREATHER ASSEMBLY 072315 BREATHER GASKET 089967 BREATHER SCREW 070596 BREATHER TUBE...
  • Page 52 Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Carburetor – Drawing No. 093753-H 50 Generac Power Systems, Inc. ®...
  • Page 53 ITEM PART NO. QTY. 073112B 074962C 074962G 070155 070108 056893 074961 047227 037398 073131 066476 070575 070125 073374 074947 089473 091306 077091 031879 022159 072536 087770 074946 030340 0C2338B 0C2338 0C2338D 075252 0A7782A 040173 066829 075944 070594 077075 Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Carburetor –...
  • Page 54 Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators LP Carburetor & Air Cleaner – Drawing No. 0A4029-G ITEM PART NO. QTY. DESCRIPTION 0A1662A CARB. V-TWIN L/P 057822 HOSE CLAMP 074994 1/2 I.D. X 10" LONG HOSE 026307 STREET ELBOWS 026915...

  • Page 55: Section 11 - Notes

    Section 11 — Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators Generac Power Systems, Inc. 53 ®...
  • Page 56 Section 11 — Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators 54 Generac Power Systems, Inc. ®...
  • Page 57 Section 11 — Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators Generac Power Systems, Inc. 55 ®...

  • Page 58: Section 12 - Warranty

    Warranty (ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the “Generac 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 59: Emission Control System Warranty

    Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall contin- ue for 24 consecutive months thereafter.
  • Page 60 GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY 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.

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Primepact 66gPrimepact 66lp

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