Generac Power Systems 009600-5, 009734-5 manual

PO WER SY STEMS, INC. ® Owner’ s Man ual Air -cooled Recreational V ehic le Generators • Model: 009600-5 and 009734-5 PRIMEP A CT 66G and 66LP[...]

Generac ® Pow er Systems, Inc. I NTRODUCTION R EAD THIS MAN UAL THOROUGHL Y 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, W ARNING, CA UTIO[...]

T able of Contents PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Generac ® Pow er Systems, Inc. 1 Part I — Operating Instructions Introduction ..................................................Inside Front Cover Read This Manual Thoroughly ..........................................IFC Contents .......................................[...]

2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this manual and with the unit. The generator can operate safely , efficiently and reli- ably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow sim[...]

Generac ® Pow er Systems, Inc. 3 ELE CTR ICAL HA Z AR DS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. A void 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 t[...]

4 Generac ® Pow er Systems, Inc. Section 1 – General Information PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Please recor d the following information from the generator DA T A DECAL or information decal. 1. Model Number ____________________ 2. Serial Number __________________ 3. kW Rating __________________________ 4. Rated V olta[...]

Generac ® Pow er Systems, Inc. 5 Section 1 – General Information PRIMEP A C T 66G and 66LP Recreational V ehicle Generators 1.2 GEN ER A T OR AP P LICAB I LIT Y These generators have been designed and manufac- tured for supplying electrical power for recreational vehicles. Y ou should not modify the generator or use it for any application other [...]

6 Generac ® Pow er Systems, Inc. Section 1 – General Information PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Figure 1.1 – Connection for 120 V olts Only Figure 1.2 - Connection for 120/240 V olts 1.6 SP E CI F ICA TIONS 1.6.1 F UEL R EQ UIRE ME NT S This generator is equipped with a gasoline fuel system as standard equipment. Sp[...]

Generac ® Pow er Systems, Inc. 7 Section 2 – Operation PRIMEP A C T 66G and 66LP Recreational V ehicle Generators 1.6.4 ENGI NE SP ECIF ICA TIONS T ype of Engine PRIMEP ACT 66G/66LP ..............................................GN-480 Cooling Method ........................................................Air - cooled Rated Horsepower PRIMEP ACT [...]

8 Generac ® Pow er Systems, Inc. Section 2 – Operation PRIMEP A C T 66G and 66LP Recreational V ehicle 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 s[...]

Generac ® Pow er Systems, Inc. 9 Section 2 – Operation PRIMEP A C T 66G and 66LP Recreational V ehicle Generators 2.4.5 ENGI NE EXHAUST GA S 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- [...]

10 Generac ® Pow er Systems, Inc. Section 2 – Operation PRIMEP A C T 66G and 66LP Recreational V ehicle Generators 2.7 .2 DO NO T O VERL O AD THE GEN ER A T OR Y ou can read the rated wattage/amperage capacity of your generator on the generator data decal (see Section 1.1 on P age 4). Applying electrical loads in excess of the unit ’s rated ca[...]

Generac ® Pow er Systems, Inc. 11 Section 3 – Maintenance PRIMEP A C T 66G and 66LP Recreational V ehicle Generators 2.8.4 OVERV OL T A GE P RO TE CTION 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 [...]

12 Generac ® Pow er Systems, Inc. Section 3 – Maintenance PRIMEP A C T 66G and 66LP Recreational V ehicle Generators 3.2 CHANGI NG TH E ENGI N E OI L AN D/OR OI L F I L TER • Change the engine oil after the first 25 hours of operation (after the 25-hour break -in period, see Section 2.8.5, P age 10). Thereafter , change the oil every 100 opera[...]

Section 3 – Maintenance PRIMEP A C T 66G and 66LP Recreational V ehicle Generators 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 3.4 CLEAN AI R I NT AKE SCR EEN Clean all foreign material from the air intake screen ([...]

14 Generac ® Pow er Systems, Inc. Be sure to r einstall 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 ar eas not able to withstand the extreme heat such as wooden floor[...]

Generac ® Pow er Systems, Inc. 15 3.1 0 MA JOR SERVICE MAN U AL T o 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. 3.1 1 DR IVE B EL T The engine drives the generator rotor by means of a pulley and drive belt arrangement. The dri[...]

16 Generac ® Pow er Systems, Inc. Section 4 – Notes PRIMEP A C T 66G and 66LP Recreational V ehicle Generators[...]

P ART I I – I NS T ALL A TION I NS TR UCTIONS ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!![...]

18 Generac ® Pow er Systems, Inc. Safety Rules PRIMEP A C T 66G and 66LP Recreational V ehicle Generators NO TICE T O I NST ALLER 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 inst[...]

Generac ® Pow er Systems, Inc. 19 Safety Rules PRIMEP A C T 66G and 66LP Recreational V ehicle Generators ELE CTR ICAL HA Z AR DS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. A void contact with bare wires, ter- minals, connections, etc., while the unit is running . Ensure al[...]

20 Generac ® Pow er Systems, Inc. 5.1 P U R POSE AN D S COPE OF TH E I NS T ALL A TION I NSTR UCTIONS 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. Give serious consideration to all information and i[...]

Generac ® Pow er Systems, Inc. 21 Figure 5.2 - Major Features and Dimensions Section 5 – General Information PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Control Panel Fuel Filter Fuel Pump Oil Filter Oil Drain Plug Starter Contactor Oil Fill/Oil Level Spark Plugs (both sides, not shown) Air Filter Ground Lug PrimePact 66G and 66LP[...]

22 Generac ® Pow er Systems, Inc. Figure 5.3 - Connection for 120/240 V olts • The AC connection system on all air - cooled PRIMEP ACT series generators uses a GROUNDED neutral. • A separate green ground wire is connected to the recreational vehicle’s junction box. • Loads connected across T1 (Red) to T2 (White), and T3 (Black) to T2 (Whit[...]

Generac ® Pow er Systems, Inc. 23 • Protect the generator against road splash and debris. Baffles or splash guards may be required to protect cer- tain areas of the generator . T o make sure the generator is adequately protected, road test the installation through mud, water and slush. Figure 6.2 – T ypical Suspended Mounting System • The in[...]

24 Generac ® Pow er Systems, Inc. • 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 inter[...]

Generac ® Pow er Systems, Inc. 25 Section 6 – Installation PRIMEP A C T 66G and 66LP Recreational V ehicle Generators • V apor seal all compartment seams and joints. • Over the galvanized steel lining, install a combination of acoustical materials as mentioned in Section 6.2.3. T o prevent fir e or explosion, do not install any insulation or[...]

26 Generac ® Pow er Systems, Inc. 6.2.5 COMP ARTM ENT F L OOR CUT OUT S Y ou must provide openings in the generator compart- ment for the following items (Figure 6.8, P age 25): • Engine exhaust and cooling air outlets • Generator cooling air inlet • F our holes for passage of generator mounting bolts. See Section 6.1.4 (P age 23). Fuel line[...]

Generac ® Pow er Systems, Inc. 27 behind the generator for cooling airflow (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 V ehicle Skirt 6.3.3 COMP ENS A TING FOR R ES TRICTIONS Such materials as screening, louvers or expande[...]

28 Generac ® Pow er Systems, Inc. 6.4.1 F UEL T AN K 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. If the gen[...]

Generac ® Pow er Systems, Inc. 29 Figure 6.15 – T ypical Propane Gas Fuel System 6.5.2 SOME I MPORT ANT CONSIDER A TIONS 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. This re[...]

30 Generac ® Pow er Systems, Inc. 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. The more the regulator valve opens, the greater the gas flow that is proportio[...]

Generac ® Pow er Systems, Inc. 31 F ailure 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. In the state of Califo[...]

32 Generac ® Pow er Systems, Inc. • F rom 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 pow[...]

Generac ® Pow er Systems, Inc. 33 Section 6 – Installation PRIMEP A C T 66G and 66LP Recreational V ehicle Generators 6.8.2 BA T TER Y CAB LES Using battery cables that are too long or too small in diameter may cause a drop in voltage, which causes starting problems. F or the best cold weather starting , the voltage drop between battery terminal[...]

34 Generac ® Pow er Systems, Inc. 6.8.3 BA T TER Y CAB LE C ON N E CTIONS 1. Connect the battery cable from the battery post or terminal indicated by a POSITIVE, POS or (+) to the lug on the starter contactor (Figure 6.20). NOTE: Check to be sure the battery cable boot for the starter cable has been installed. 2. Connect the battery cable from the[...]

Generac ® Pow er Systems, Inc. 35 7 .1 POS T I NS T ALL A TION TES T S The air - cooled generator set was factory tested and adjusted. Y ou should not be required to adjust the unit any further except under special circumstances. Do not make any unnecessary adjustments. Factory settings are corr ect for most applications. When making adjustments, [...]

36 Generac ® Pow er Systems, Inc. 7 .5 I NS T ALL A TION CH E CKLIST L OCA TION AN D SU PPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GEN ERA T OR COMP ARTM ENT ❑ Compartment construction is proper . ❑ Holes/Openings are vapor - sealed. ❑ Compartment size is correct. ❑ C[...]

Generac ® Pow er Systems, Inc. 37 Section 8 – T roubleshooting PRIMEP A C T 66G and 66LP Recreational V ehicle Generators 8.1 TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION Engine won’t crank. 1. 15 amp fuse b lown. 1. Replace blown fuse . 2. Loose, or corroded or def ectiv e 2. Tighten, clean or replace, battery cable(s). as nece[...]

38 Generac ® Pow er Systems, Inc. Section 9 — Electrical Data PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Electrical Schematic and Wiring Diagram – Drawing No. D3 1 48-A[...]

Generac ® Pow er Systems, Inc. 39 Section 9 — Electrical Data PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Electrical Schematic and Wiring Diagram – Drawing No. 0D3 1 48-A[...]

40 Generac ® Pow er Systems, Inc. Section 1 0 — Exploded V iews and Parts Lists PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Sheet Metal – Drawing No. 0D31 5 0-A[...]

Generac ® Pow er Systems, Inc. 41 Section 1 0 — Exploded V iews and Parts Lists PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Sheet Metal – Drawing No. 0D31 5 0-A ITEM P ART NO . QTY . DESCRIPTION 1 --------- 1 SEE ENGINE EXPLODED VIEW of ENGINE 2 099258 1 KEY -WOODR UFF 6 x 22MM 3 067198N 1 BEVELLED W ASHER 4 067890 1 HEX NUT 5 0[...]

42 Generac ® Pow er Systems, Inc. 30 1 7 9 85 33 32 67 2 5 5 2 3 92 18 1 9 7 93 9 10 7 3 34 1 5 1 4 7 14 6 2 8 51 4 1 0 1 3 12 50 7 9 2 8 57 74 5 6 69 65 62 59 64 3 60 61 36 4 3 4 6 3 35 47 83 4 9 44 4 5 80 77 7 6 2 8 87 2 0 5 2 66 52 2 28 2 9 2 8 38 90 91 96 5 94 83 8 2 81 95 41 7 9 89 54 83 6 84 86 88 68 TO ENGINE Section 1 0 — Exploded V iews[...]

Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 086318 1 BASE, MOUNTING 2 090141 1 GR OUND CABLE 3 046911 4 MOUNT VIBR 1.50X1.38 X 3/8-16) 4 025017 8 SCREW HHC 3/8-16 X 1/2 G5 5 046526 2 W ASHER LOCK M10 6 022129 8 W ASHER LOCK M8-5/16 7 072391 2 SKID , RUBBER MOUNT 8 077603 2 SAFETY BOL T 5/16-18 x 3 1/2" 9 022259 2 NUT[...]

44 Generac ® Pow er Systems, Inc. 30 1 7 9 85 33 32 72 67 67 27 2 3 24 7 88 9 10 7 3 34 1 5 14 7 3 14 6 2 8 4 0 4 11 1 0 1 3 12 37 7 9 2 8 5 7 74 58 56 69 71 7 0 61 60 59 64 32 60 61 36 4 3 4 6 32 35 47 83 38 44 4 5 1 6 17 80 7 8 77 7 6 2 8 87 2 0 3 66 39 2 5 8 2 81 84 41 7 9 4 9 50 54 53 4 8 TO ENGINE Section 1 0 — Exploded V iews and Parts Lis[...]

Generac ® Pow er Systems, Inc. 45 ITEM P ART NO . QTY . DESCRIPTION 1 86318 1 BASE, MOUNTING 2 90141 1 GROUND CABLE 3 46911 4 MOUNT , (R UBBER) 4 25017 8 SCREW HHC 3/8-16 X 1/2 G5 5 46526 2 W ASHER LOCK M10 6 22129 8 W ASHER LOCK M8-5/16 7 72391 2 SKID , R UBBER MOUNT 8 77603 2 SAFETY BOL T 5/16"-18 x 3-1/2" 9 22259 2 NUT HEX 5/16-18 STE[...]

46 Generac ® Pow er Systems, Inc. 51 18 7 9 3 2 9 8 10 11 2 3 1 31 30 39 33 2 8 50 19 34 4 5 2 17 6 17 38 12 24 4 0 36 45 4 4 3 15 37 35 4 8 44 57 2, 5 3 31 4 9 40 63 4 5 44 58 31 30 56 2 6 27 2 6 2 5 59 4 6 55 62 4 5 44 2 0 21 61 T O EN G IN E G R OU N D 63 13 15 16 14 47 22 60 18 14 40 42 6 4 Section 1 0 — Exploded V iews and Parts Lists PRIME[...]

Generac ® Pow er Systems, Inc. 47 ITEM P ART NO . QTY . DESCRIPTION 1 0C9675 1 LOWER BEARING CARRIER 2 077005H 1 RO TOR ASSEM. PP55 077004H 1 R O T OR ASSEM. PP66 3 087844H 1 ST A T OR ASSEM. 55 087845H 1 ST A T OR ASSEM. 66 4 073159 1 BALL BEARING 5 031971 1 BALL BEARING 6 0C9674 1 UPPER BEARING CARRIER 7 077006 4 STUD-ST A T OR 8 052858 4 M8-1.2[...]

48 Generac ® Pow er Systems, Inc. Section 1 0 — Exploded V iews and Parts Lists PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Exploded View - Engine Common Parts – Drawing No. 0 7 921 6-G[...]

Generac ® Pow er Systems, Inc. 49 ITEM P ART NO. QTY . DESCRIPTION 1 069331 1 CYLINDER ASSEMBL Y 2 069333 1 SLEEVE BEARING 3 067805 1 OIL SEAL 4 0851100101 1 NO. 1 CYLINDER HEAD ASSEMBL Y 5 0851100102 1 NO. 2 CYLINDER HEAD ASSEMBL Y 6 070169 4 SEALING W ASHER 7 069332 2 CYLINDER HEAD GASKET 8 0851100104 1 BREA THER ASSEMBL Y 9 072315 1 BREA THER G[...]

50 Generac ® Pow er Systems, Inc. Section 1 0 — Exploded V iews and Parts Lists PRIMEP A C T 66G and 66LP Recreational V ehicle Generators Carburetor – Drawing No. 093 7 53-H[...]

Generac ® Pow er Systems, Inc. 51 ITEM P ART NO . QTY . DESCRIPTION 1 073112B 1 CARBURET OR ASSEMBY 2 074962C 1 SPRING, GOVERNOR - GREEN (PP55G/LP , PP66G/LP) 074962G 1 SPRING, GOVERNOR - BR OWN (PP70G/LP , Q70G) 3 070155 1 LEVER, GOVERNOR 4 070108 1 ROD , GO VERNOR T O CARBURET OR 5 056893 5 SCREW CRMPTIT 10-24 X ½ 6 074961 1 BRACKET , GOVERNOR [...]

52 Generac ® Pow er Systems, Inc. 21 27 11 9 1 0 9 4 3 2 2 8 1 8 22 1 0 3 2 5 4 1 1 9 12 4 7 2 9 11 1 3 2 5 8 Section 1 0 — Exploded V iews and Parts Lists PRIMEP A C T 66G and 66LP Recreational V ehicle Generators LP Carburetor & Air Cleaner – Drawing No. 0A4029-G ITEM P ART NO . QTY . DESCRIPTION 1 0A1662A 1 CARB. V -TWIN L/P 2 057822 2 [...]

Generac ® Pow er Systems, Inc. 53 Section 1 1 — Not es PRIMEP A C T 66G and 66LP Recreational V ehicle Generators[...]

54 Generac ® Pow er Systems, Inc. Section 1 1 — Not es PRIMEP A C T 66G and 66LP Recreational V ehicle Generators[...]

Generac ® Pow er Systems, Inc. 55 Section 1 1 — Not es PRIMEP A C T 66G and 66LP Recreational V ehicle Generators[...]

56 Generac ® Pow er Systems, Inc. Section 1 2 – W arranty PRIMEP A C T 66G and 66LP Recreational V ehicle Generators CALI FOR N IA AND F EDER AL EM ISSION C ONTROL W AR R ANT Y ST A TEM ENT Y OU R W ARR ANT Y RIGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EP A), together [...]

Generac ® Pow er Systems, Inc. 57 Section 1 2 – W arranty PRIMEP A C T 66G and 66LP Recreational V ehicle Generators EM IS SION CONTROL S Y STEM W AR R ANTY Emission Control System W arranty (ECS W arranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS W arranty [...]

Part No. 0D7803 GENERAC ® POWER SY STEMS, INC. P.O. BO X 8 • W AUKESHA, WI 53187 Revision 0 (11/14/01) Printed in U.S.A. Section 1 2 – W arranty PRIMEP A C T 66G and 66LP Recreational V ehicle Generators GEN ERAC PO WER SY S TEMS’ TH REE- YEAR LIM ITED W ARR ANT Y FOR R E CR EA TIONAL VEH ICLE GEN ER A T ORS NOTE: ALL UNITS MUST BE INST ALLE[...]