Generac Power Systems 000595-1 User Manual

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POWER SYSTEMS, INC

Owner’s Manual

• Model: 000595-1 and 009843-3 PRIMEPACT 70G and 70LP

Air-cooled Recreational

Vehicle Generators

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 starling, operating and servicing procedures.

'rhroughoLit this publication, and on tags and decals affixed to the generator, DANGER, WARNING. CAUTION and NOTE blocks arc used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or care lessly. Observe them carefully. Their definitions are as follows:

DANGER

After this heading, you can read instructions that, if not strictly complied with, will result in personal injury or property damage.

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M. WARNING

After this heading, you can read instructions that, if not strictly complied with, may result in person al injury or property damage.

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M. CAUTION

After this heading, you can read instructions that, if not strictly complied with, could result in dam age to equipment and/or property.

NOTE:

After this heading, you can read explanatory statements that require special emphasis.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli

ance with the sirecial instructions while performing

the service are essential to preventing accidents. lanir commonly used safety symbols accompany the

Danger, Warning aiid Caution blocks. The type of

information eacli indicates follows:

This symbol points out important safety infor

mation that, if not followed, could endanger personal safety and/or property of you and others.

This symbol points out potential explosion

hazard.

This symbol points out potential fire hazard.

A-

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^ This symbol points out potential electrical

shock hazard.

The operator (driver) is responsible for proper and safe use of the vehicle and its equipment, and the safety of all vehicle occupants. We strongly recom mend that the operator read this manual and thor oughly understand all instructions before using this equipment. We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator. This prepares them if they need to operate the equipment in an emergency.

♦ CONTENTS

This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views and lists of repair parts for generator model numbers 000595-1 and 009843-3. In addition, the latter portion of this manual contains information necessary for the proper installation of these generators.

♦ OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safe ty checks, to make sure that all maintenance for safe operation is performed promptly and to have the

equipment checked periodically by a Generac Authorized Service Dealer. Normal maintenance ser vice and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service.

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

When your generator requires servicing or repairs, simply contact a Generac Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all of your service needs.

When contacting a Generac Authorized Service Dealer or the factory about parts and service, always supply the complete model number and serial num ber of your unit as given on its data decal, which is located on your generator.

Model No. Serial No.

_________________________________

_________________

_____________________

AUTHORIZED SERVICE

DEALER LOCATION

To locale the GENERAC AUTHORIZED SERVICE

DEALER nearest you, please call tills number:

Generac* Power Systems, Inc.

1-800-333-1322

ONLY DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

Locate us on the web at:

www.generac.com

Table of Contents

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

Part I — Operating Instructions

Introduction..................................Inside Front Cover

Read This Manual Thoroughly ..........................................................IFC

Contents..............................................................................................IFC

Operation and Maintenance ...............................................................IFC

How to Obtain Service Autliorized Service Dealer Locator Number

Safety Rules

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IFC

It'C

Section 1 - General Information..............................4

1.1 Generator Identification ................................................................4

1.2 Generator Applicability

1.3 Installation .................................................................................... 5

1.4 Safety ............................................................................................5

1.5 Generator AC Connection System.................................................5

1.6 Specifications ................................................................................6

1.6.1 Fuel Requirements & Consumption

1.6.2 Engine Oil Requirements

1.6.3 Generator Specifications

1.6.4 Engine Specifications

1.6.5 Emissions Compliance Period ..........................................7

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Section 2 - Operation...........................................7

2.1 Generator Control Panel..................................................................7

2.1.1 Fuel Primer........................................................................ 7

2.1.2 Star:. Slop Switcli .............................................................7

2.1.3 15 Amp Fuse.....................................................................7

2.1.4 Line Breakers.....................................................................7

2.2 Optional Remote Start/Stop Panel

2.3 Automatic Choke

2.3.1 Choke Solenoid .................................................................8

2.3.2 Prechoke............................................................................8

2.4 Before Starting the Engine ............................................................8

2.4.1 Installation

2.4.2 Engine Lubrication

2.4.3 Fuel Supply .......................................................................8

2.4.4 Cooling and Ventilating Air

2.4.5 Engine Exhaust Gas ..........................................................9

2.5 Starting the Generator ...................................................................9

2.6 Stopping the Generator.................................................................. 9

2.7 Applying Loads to Generator ........................................................9

2.7.1 Letting the Engine Stabilize

2.7.2 Do Not Overload the Generator ......................................10

2.8 Protection Systems.......................................................................10

2.8.1 Low Oil Pressure Switch.................................................10

2.8.2 High Temperature Switch................................................10

2.8.3 Field Boost.......................................................................10

2.8.4 Overvoltage Protection ....................................................II

2.8.5 25-Hour Break-in Period

2.8.6 25-Hour Checkup............................................................11

2.8.7 Operation in High Grass or Brush ..................................11

Section 3 - Maintenance

3.1 Checking the Engine Oil Level.....................................................11

3.2 Changing the Engine Oil and/or Oil Filter...................................12

3.3 Maintaining the Engine Air Cleaner ...........................................12

3.3.1 Cleaning the Foam Precleaner.........................................12

3.4 Clean Air Intake Screen ..............................................................13

3.5 Checking the Engine Spark Plug

3.6 Fuel Filter (Gasoline Only] .........................................................13

3.7 Spark Arrestor Muffler

3.8 Cleaning the Generator................................................................ 14

3.9 Battery Maintenance....................................................................14

3.9.1 Weekly ............................................................................14

3.9.2 Every Six Months ...........................................................14

3.10 Major Service Manual

3.11 Drive Belt ....................................................................................15

3.12 Exercising the Generator

3.13 Out of Service Procedure ............................................................15

3.13.1 Removal From Service

3.13.2 Return to Service

3.14 Wattage Reference Guide

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—11

15 15 15

Section 4 - Notes...............................................16

Part II - Installation Instructions Safety Rules

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Section 5 — General Information

5.1 Purpose and Scope of the Manual..........................................20

5.2 Safely ...........................................................................................70

5.3 Standard Booklets ........................................................................20

5.4 Eciuipment Description

5.5 Generator Engine Operating Speed..............................................20

5.6 Generator AC Connection System Major Dimensions and F'eatures

6 6 6 7

8 8

Section 6 — Installation......................................22

6.1 Location and Sup]«)ii

6.1.1 Generator Locati(3ii

6.1.2 Generator Supports .........................................................22

6.1.3 Suspended Mounting

6.1.4 Generator Restraint .........................................................23

6.2 Generator Compartments

6.2.1 Comi)artmenl Size .........................................................23

6.2.2 Conqiartmenl Construction .............................................23

6.2.3 Sound Insulating Materials

6.2.4 Acoustics .........................................................................24

6.2.5 Compaiiinent Floor Cutouts

6.3 Cooling and Ventihition............................................................... 26

6.3.1 Generator Airflow............................................................26

6.3.2 Cooling Air Inlet Openings .............................................26

6.3.3 Compensating for Restrictions ........................................27

6.3.4 Testing the Installation ....................................................27

6.4 Gasoline luiel System ..................................................................27

6.4.1 Fuel'Rutk .........................................................................28

6.4.2 Generator Fuel Supply Line ............................................28

6.4.2.1 Rigid Fuel Lines

6.4.2.2 Flexible Fuel Lines

6.5 LP Gas Fuel System ....................................................................28

6.5.1 Parts not included in Fuel System ..................................28

6.5.2 Some Important Considerations.......................................29

6.5.3 Vapor Withdrawal

6.5.4 Primary Regulator............................................................29

6.5.5 Gaseous Carburetion .......................................................29

6.5.6 Fuel Supply Lines............................................................30

6.5.7 Excess Flow Valve

6.5.8 Leakage 'lests...................................................................30

6.6 Exhaust Systems...........................................................................30

6.6.1 Mufflers and Spark Arrestors..........................................31

6.6.2 lYpe of Exhaust System

6.6.3 Exhaust System Safety

6.7 Electrical Connections ................................................................31

6.7.1 Electrical Junction Box

6.7.2 Wiring.............................................................................. 32

6.7.3 Generator AC Connections .............................................32

6.7.4 Conduit.............................................................................32

6.7.5 Isolating Different Power Sources...................................32

6.7.6 Power Supply Cord..........................................................33

6.7.7 Ground Fault Circuit Interrupters

6.8 Battery Installation ......................................................................34

6.8.1 Ftecomrnended Battery ...................................................34

6.8.2 Battery Cables .................................................................34

6.8.3 Battery Cable Connections

6.8.4 Battery Compartment

6.9 Optional Accessories.................................................................... 34

6.9.1 Remote Panel Models

...............................................................

..................................................................

Section 7 — Post Installation

7.1 Post Installation Tests

7.2 Before Initial Start-up

7.3 Initial Start....................................................................................35

7.4 Testing Under Load......................................................................35

7.5 Installation Checklist ...................................................................36

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Section 8 - Troubleshooting

8.1 Troubleshooting Guide

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18-19

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22 22

2.5

28 28

31 31

1.14 34

35 35

Section 9 - Electrical Data....................................39

Section 10 - Exploded Views and Parts Lists

.............

Section 11 - Notes.............................................51

Section 12 - Warranty ........................................52

Generac® Power Syetems, Inc.

SAFETY RULES

operation be copied and posted in potential hazard areas of the recreational vehicle. Vk

Safety should be stressed to all operators and potential operators of this equipment.

Safety Rules

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

SAVE THESE INSTRUCTIONS - The manufacturer suggests that these rules for safe

Ma\

The engine exhaust from this product

contains chemicals known to the state

defects or other reproductive harm.

■ 1

This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

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 simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warn ings in this manual, and on tags and decals affixed to the unit, are, therefore, not all-inclusive. If

yon 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 operaiing technique that you choose does not render the generator unsafe.

Despite the safe design of this generator,

operating this equipment imprudently, neglect ing its maintenance or being careless can cause possible injury or death. Permit only responsi ble and capable persons to operate or maintain

this equipment.

Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.

WARNING:

of California to cause cancer, birth

WARNING: □

DANGER

^ GENERAL HAZARDS ^

For safety reasons, Generac recommends

that the installation, initial start-up and mainte nance of this equipment is carried out by a Generac Authorized Service Dealer.

The engine exhaust fumes contain carbon monox

ide. which can be DEADLY. This dangerous gas, if

breathed in sufficient concentrations, can cause

unconsciousness or even death. This exhaust sys tem must be installed properly, in strict compli

ance with applicable codes and standards. Following installation, you must do nothing that might render the system unsafe or in noncompli

ance with such codes and standards. The genera tor compartment must be completely vapor sealed from the vehicle interior. There must be no possi bility of exhaust fumes entering the vehicle interi or. Never operate this equipment with a leaking or defective exhaust system.

Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and venti

lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment. Without sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to the generator. Do not alter the installation or per mit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator.

When working on this equipment, remain alert at

all times. Never work on the equipment when you are physically or mentally fatigued.

Inspect the generator regularly, and contact your

nearest Generac Authorized Service Dealer imme diately for parts needing repair or replacement.

Before performing any maintenance on the genera

tor, disconnect its battery cables to prevent acci dental start up. Disconnect the cable from the bat tery post indicated by a NEGATIVE, NEG or (-) first. Reconnect that cable last.

Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break parts, and may result in dangerous operating con ditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

Generac' Power Systems, Pnc.

Safety Rules

PRiMEPACT 70G and 70LP Recreational Vehicle Generators

SAFETY RULES

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 operafing the generator. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of elecfrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• During installation onto the vehicle, have the gen erator properly grounded (bonded) either by solid mounting to the vehicle frame or chassis, or by means of an approved bonding conductor. DO NOT disconnect the bonding conductor, if so equipped. DO NOT reconnect the bonding conduc tor to any generator part that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 American Wire Gauge (AWG) copper wire minimum.

• In case of accident caused by electric shock, imme diately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting imple ment, such as a rope or board, to free the victim from the live conductor. If the victim is uncon scious, apply first aid and get immediate medical help.

• Never wear Jewelry when working on this equip ment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving com ponents causing injury.

FIRE HAZARDS

For fire safety, the generator must be installed and

maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, slate and national electrical and building codes. Comjdy

with regulations the Occupational Safety and

Health Administration (OSHA) has establislu'd.

Also, ensure that the generator is installed in

accordance with the manufacturer’s instructions and recommendations. Following proper installa tion, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regu lations.

Keep a fire extinguislicr in the vehi('le at all times.

Extinguishers rated “ABC’’ by the National Fire Protection Association are appropriate for use on the recreational vehicle generator elei’lrical sys tem. Keep the extinguisher properly charged and be familiar with its use. If you have any question pertaining to fire extinguishers, consult your local fire department.

EXPLOSION HAZARDS

Do not snroke around the generator. Wi]re rqr any

fuel or oil spills immediately. Ensure that no com bustible materials arc left in the generator com partment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surround ing the generator clean and free from debris.

Gasoline is extremely FLAMMABLE and its vapors

are 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.

This generator may use liquid propane (LP) gas as

a fuel. LP gas is highly EXPLOSIVE. The gas is heavier than air and tends to settle in low areas

where even the slightest spark can ignite the gas

and cause an explosion.

Generac* Power Systems, Inc.

GENERAL

INFORMATION

Section 1 - General Information

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

1.1 GENERATOR IDENTIFICATION

Please record the following information from the generator DATA DECAL or information decal.

1. Model Number____________________ 2. Serial Number

3. kW Rating

5. Phase___________________________6. Hertz ______________________________

_______________________

4. Rated Voltage

______________________

_______________________

REFERENCE NUMBER IDENTIFICATION

1. Generator Air Intake Screen

8. Starter Contactor

2. Data Plate 9. Fuel Inlet

3. Enirine Start/Stop Switch 10. Fuel Primer Switch

4. 15 amp Fuse 11. Fuel Pump

5. 30 amp Circuit Breaker

6. Optional Remote Panel Receptacle

12. Oil Filter

13. Oil Drain Plug

7. Generator AC Output Leads 14. Oil Dipstick and Filler Tube

Generac* Power Systems, Inc.

Section 1 - General Information

PRiMEPACT 70G and 70LP Recreational Vehicle Generators

GENERAL

INFORMATION

1.2 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. Do not use the unit until you have been advised by competent authority.

DANGER

For fire safety, the generator must have been

properly installed in compliance with ANSI

119.2-1975/NFPA 501C-1974, "Standard for Recreational Vehicles, Part III - Installation of Electrical Systems." The generator also must have been installed in strict compliance with

the manufacturer's detailed installation instruc tions. After installation, do nothing that might render the unit in noncompliance with such codes, standards and instructions.

You can use your generator set to supply electrical power for operating one of the following electrical

loads:

• PRIMEPACT 70G: 120 and/or 240 volts, single phase, 60 Hz electrical loads. These loads can require up to 7000 watts (7.0 kW) of power, but cannot exceed 58.3 AC amperes of current at 120 volts or exceed 29.2 AC amperes at 240 volts.

• PRIMEPACT 70LP: 120 and/or 240 volts, single phase, 60 Hz electrical loads. These loads can require up to 6600 watts (6.6 kW) of power, but cannot exceed 55 AC amperes of current at 120

volts or exceed 27.5 AC amperes at 240 volts.

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M. CAUTION M

Do not overload the generator. Some installa tions may require that electrical loads be alter nated to avoid overloading. Applying exces sively high electrical loads may damage the generator and may shorten its life. Add up the rated watts of all electrical lighting, appliance, tool and motor loads the generator will power at one time. This total should not be greater than the wattage capacity of the generator. If an electrical device nameplate gives only volts and amps, multiply volts times amps to obtain watts (volts X amps = watts). Some electric motors require more watts of power (or amps of current) for starting than for continuous operation.

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1.3 INSTALLATION

This Owner's Manual has been prepared under (he assumption that a competent, qualified technician installed the generator into an induslrial vehicle. We also assume the installer complied with all apirlicable codes, standards and regulations pertaining to instal lation.

An INSTALLATION MANUAL was sliipped witli llie generator. That Manual contains inanufactnrer's

instructions and recommendations for installing the unit into an industrial vehicle. After installation, installers should forward the Installation Manual to Owners/Operators for their information.

Owners/Operators have the responsibility to make sure that nothing is done that might render the instal lation unsafe or in non-complianc(' with apirlicable codes, standards and instructions.

1.4 SAFETY

Before using the generator set, carefully read GEN ERAL SAFETY RULES inside the cover. Comply with these RULES to prevent accidents and damage to equipment and/or property. Generac suggests copy ing and posting the GENERAL SAFE'l'Y RULES to

potential operators of this equipment.

1.5 GENERATOR AC CONNECTION

SYSTEM

These air-cooled generator sets are equipped with dual stator AC power windings. These two stator windings supply electrical power to customer electri cal loads by means of a dual 2-wire connection sys tem.

Generators may be installed to provide the following outputs;

1) 120 VAC loads only — one load with a mirxiinum total wattage requirement equal to the generator’s rated power output (in watts), and 120V across the

generator output terminals.

2) 120/240 VAC loads — one load with a niiiximum

total wattage requirement equal to the generator’s rated power output, and 240 V across the generator output terminals; or two seperate loads, each willi a maximum total wattage requirement equal to half of the generator’s rated power output (in watts), and

120 V across the generator output terminals.

Generac* Power Systems, inc.

GENERAL

INFORMATION

Section 1 - General Information

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

Figure 1.1 - Connection for 120 Volts Only

Figure 1.2 - Connection for 120/240 Volts

1.6 SPECIFICATIONS

♦ 1.6.1 FUEL REQUIREMENTS

'I'llis <>('ncralor is equijiped with a gasoline fuel system as standard e(|uipinent. Specific installations may pro vide either a separate fuel tank for the generator, or the

generator may ''share’' the veliicle engine's fuel tank.

Fuel Consumption (gph/ibs.ph)

Model PrimePact 70G

PrimePact 70LP

No Load 1/2 Load

0.34 0.65

0.47/2.01

0.85/3.62 1.66/7.05

Full Load

1.12

NOTE

Some installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine’s pickup tube. Such an

arrangement causes the generator engine to “run

out of gas” while adequate fuel for the vehicle

remains in the tank.

To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator. Leaded REGULAR grade gasoline is an acceptable substitute.

NOTE:

Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits.

-A CAUTION A-

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. Do NOT use any gasoline containing methanol. If you use gasoline with alcohol, inspect more frequently for fuel leaks and other abnormalities.

♦ 1.6.2 ENGINE OIL REQUIREMENTS

________________

Use only high quality detergent oil classified “For

Service SF” and with an oil viscosity rating of SAE

lOW-30 oil. Do not pour in any additives to the rec

ommended oil. Engine crankcase capacity is 1.4

liters. See Section 3.2 on page 11 for oil level check and filing procedures.

♦ 1.6.3 GENERATOR SPECIFICATIONS

SERIES

Rotor RPM Rotor Poles Engine RPM Rated Max. Continuous AC Output* Voltage* Rated Max. Continuous Current* 58.3 AC ampsf Phase Frequency Battery Charging Current (Max.) Weight Length Width Height 15.75 inches 15.75 inches

■ All units are reconnectable to 120 and’or 240 volts, dual voltage output. Units are not listed per RVIA'ANSI when reconnected for dual voltage output f Rated maximum continuous current at 240 volts is 29,2 amps, N Rated maximum continuous current at 240 volts is 27.5 amps.

B Generac^ Power Systems, Inc.

PRIMEPACT 70G PRIMEPACT 70LP

3600 3600

2900 2900

7000 waits (7.0 kW) 6600 watts (6,6 kW)

120 120

1 1

60 Hertz 60 Hertz

10 amps (regulated) 10 amps (regulated)

221 pounds 224 pounds

25 inches 25,75 inches

18.5 inches 18.5 inches

55.0 AC amps N

Section 2 - Operation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

♦ 1.6.4 ENGINE SPECIFICATIONS

_________________

'lype of Engine

PRIMEPACT 70G/70LP

Cooling Metliod

....................................................

...........................................

Air-coolcd

GNG80

Rated Horsepower

PRIMEPACT 70G/70LP .....................................16 at 3600

Displacement

PRIMEPACT 70G/70LP

............................................

480cc

Compression Ratio.......................................................8.6 to 1

Cylinder Block .........................Aluminum w/Cast Iron Sleeve

Type of Governor

............................

Mechanical, Fixed Speed

Engine Governor Speed...........................................2900 rpni

Air Cleaner

.......................

Paper Element w/Foam Pi'ecleaner

Starter ........................................................12-volt DC Electric

Ignition System

.....................

Solid-state w/Flywheel Magneto

Recommended Spark Plug

Champion

..............................................................

RC12YC

AC................................................................................R45S

Fram AutoUte ..................................................................65

Spark Plug Gap Recommended Min. Battery

♦ 1.6.5 EMISSIONS COMPLIANCE PERIOD

.......................................

...........

400 Cold Cranking Amps

0.030 inch (0.8 mm)

* •

For nonhandled engines the Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal emission requirements.

• For engines less than 225 cc displacement, Category C=125 hours, B = 250 hours, and A=500 hours.

• For engines of 225 cc or more. Category C = 250 hours, B = 500 hours, and A= 1000 hours.

2.1 GENERATOR CONTROL PANEL

The following features are mouiiied on the generator

control panel (Figure 2,1):

♦ 2.1.1 FUEL PRIMER

Before starting a cold engine (if it has not been start ed in more than two weeks), you must press this switch for approximately ten seconds to bring fuel

from the tank to the fuel pump. This rocker ty[3C

switch springs back into its original ¡rosition when

you release it.

♦ 2.1.2 START/STOP SWITCH

To crank and start the engine, hold this switch in the

START position. Release the .switcli when the engine starts. To stop an operating engine, press and hold the switch in the STOP position until the engine shuts off. The switch center position is the ItlJN position.

♦ 2.1.5 15 AMP FUSE

The fuse protects the engine's DC control circaill against electrical overload. If the fuse element has melted open due to overloading, the engine cannot be cranked. If you must replace the fuse, use only an identical 15 amp replacement fuse.

♦ 2.1.4 LINE BREAKERS

Protects generator’s AC output circiut against overload, i.e., prevents unit from exceeding wattage/amperage capacity. This unit has two iiO-ang:) breakers.

Figure 2.1 - Typical Control Panel

START T5A BREAKER

__________________________

____________________

__________________________

FUSE IVIAIIM

STOP FUEL

PRilVlER

Generac* Power Systems, Inc.

OPERATION

Section 2 - Operation

PRIMEPACT 70C and 70LP 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 time). If the unit is reconnected for dual voltage, it is no longer RVIA listed.

2.2 OPTIONAL REMOTE

START/STOP PANEL

A remote mounted Start/Stop Panel (Figure 2.2) is

available that allows you to start and stop the gener

ator engine conveniently from inside the vehicle. The

remote panel includes a Start/Stop switch,

hour meter, generator run lamp and a wire harness.

Figure 2.2 — Optional Remote Panel

(Models 004057 and 004184)

♦ 2.3.2 PRECHOKE

The choke system also has a temperature-sensitive metal strip that adjusts choke valve angle according to ambient temperatures (i.e., in cold ambient tem peratures, choke valve closes more). Once the engine starts, an element heats the temperature-sensitive strip to a normal operating condition, opening the choke valve. This may take about three minutes in cooler weather.

2.4 BEFORE STARTING THE ENGINE

NOTE:

Instructions and information in this manual assume the generator has been properly installed, connected, serviced, tested and adjusted by a qualified installation technician or installation contractor.

♦ 2.4.1 INSTALLATION___________________________

Generator installation must have been properly com pleted so it complies with all applicable codes, stan dards and regulations and with the manufacturer's recommendations.

____

(For drawing, see Instruction Sheet P/N A9579)

' 1 J ^l T q]

....,.......

2.3 AUTOMATIC CHOKE

This engine is equipped with an automatic choke that consists of two main components: a choke solenoid and irrechoke.

♦ 2.5.1 CHOKE SOLENOID

During engine cranking (Start/Stop switch at START), a solid-state choke module signals the choke solenoid to activate and cycle (choke on/chokc off) until the engine starts. The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking. When (he engine starts, (he choke sto[3S cycling.

________________________

♦ 2.4.2 ENGINE LUBRICATION

Have the engine crankcase properly serviced with the recommended oil before starting. Refer to Section

1.6.3 (Page 6) and Sections 3.1 and 3.2 (Page 11) for

oil servicing procedures and recommendations.

-------

M. CAUTION ik

Any attempt to crank or start the engine before

you have properly serviced it with the recom mended oil may result in an engine failure.

♦ 2.4.3 FUEL SUPPLY____________________________

The engine must have an adequate supply of proper fuel to operate. Before starting it, check that sufficient fuel is available.

Depending on the installation, the generator may have either a separate fuel tank, or it may “share” the vehicle engine’s fuel tank.

♦ 2.4.4 COOLING AND VENTILATING AIR

Air inlet and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation. Without sufficient cooling and ventilating airflow, the engine/generator quickly over heats. which causes it to shut down and may damage the generator.

-----------------

NOTE:

Generac' Power Systems, Inc.

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

♦ 2.4.5 ENGINE EXHAUST GAS_____________________

Before starting the generator engine, you should be sure there is no way for exhaust gases to enter tlie 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.

DANGER

The generator engine gives off DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concen trations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED. SYMPTOMS OF CARBON MONOX IDE POISONING ARE (a) inability to think coher ently; (b) vomiting; (c) twitching muscles; (d) throbbing temples; (e) dizziness; (f) headaches; (g) weakness; and (h) sleepiness. IF YOU FEEL ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET MEDICAL HELP.

2.5

Read the vehicle manufacturer’s instructions. The

owner/operator should become familiar with the vehicle in which this generator is installed. Differences exist between vehicles. For example,

some vehicles may use a transfer switch to isolate

dockside power from the generator, while other vehicles may use an isolating receptacle. Some vehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads.

To crank and start the generator engine, proceed as follows:

1. Turn OFF electrical loads using the means pro

If starting from the generator control panel, turn OFF loads by setting the generator’s main circuit breaker to the OFF (or open) position. If starting from a remote panel, turn OFF loads using the means provided in the vehicle (such as a main cir cuit breaker). Electrical load circuits will be turned ON after the generator has started, stabi lized and warmed up.

STARTING THE GENERATOR

NOTE:

vided in your vehicle (such as a main line circuit breaker or transfer switch).

NOTE:

Section 2 - Operation

If you have not started the engine in more than two weeks, press the Fuel Pump Primer switch and hold it for about 10 seconds. However, if the engine is warm, skip Step 2.

To crank and start the engine, hold the start/stop switch at START. Release the switch when the engine starts.

-------

Mk CAUTION

If the engine does not start after it has been

^ cranking for 15 seconds, release the Start/Stop

switch and wait 1 minute before trying again. Holding the switch for longer than 15 seconds can damage the starter motor.

Let the engine run at no-load for a few minutes to stabilize and warm up.

Turn ON electrical loads using the means provided (such as a main circuit bicaker oitransfer switch).

---------------

OPERATION

2.6 STOPPING THE GENERATOR

1. Turn OFF all electrical loads using the means provided (such as a main circuit breaker or transfer switch).

Let generator run at no-load for a few minutes, to

stabilize internal engine generator temperatures. Place the Start/Stop switch in its STOP position.

3. The engine will come to a complete stop.

2.7 APPLYING LOADS TO GENERATOR

When applying electrical loads to the generator, observe these guidelines:

• Before applying electrical loads, let the generator stabilize and warm up for a minute or two.

“ DO NOT overload the generator.

♦ 2.7.1 LETTING THE ENGINE STABILIZE

The generator supplies correct rated voltage only at the proper governed speed. Some electrical appli ances may be extremely sensitive to voltage. Incorrect voltages can damage such appliances.

If electrical loads are applied at reduced operating speeds, such loads imposed on the engine when suf ficient power is not available may shorten engine life. Never turn ON electrical loads until after the genera tor engine has started and stabilized at no-load.

Generac* Power Systems, Inc.

OPERATION

Section 2 - Operation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

• 2.7.2 DO NOT OVERLOAD THE GENERATOR

You can read the rat- ’ waltage/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.

To avoid overloading, add up the wattage of all con nected electrical lighting, appliance, tool and motor loads. This total should not be greater than the gen erator’s rated wattage capacity.

• Most lighting, appliance, tool and motor loads indi cate their required watts on their nameplate or

data plate. For light bulbs, simply note the wattage rating of the bulb.

• If a load does not show its rated wattage, multiply

that load’s rated VOLTS times AMPS to obtain WATTS.

• Induction type motors (such as those that run the

vehicle’s furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2 times more watts of power for starting than for running (for a few seconds during motor starling). Be sure to allow for this when connecting electrical loads to the generator. First, figure the watts needed to start electric motors in the system. To that figure, add the run ning wattages of other items lliat will be operated by the generator.

• Do not apply heavy electrical loads for the first two

or three hours of operation.

2.8 PROTECTION SYSTEfVIS

• 2.8.1 LOW OIL PRESSURE SWITCH

I'his switch (Figure 2.3 on page 10) has normally closed (N.C.) contacts that arc held open by engine oil l)i essure during cranking and operating. Should oil j^ressure drop below a ¡preset level, switch contacts close, and the engine automatically shuts down. The unit should not be restarted until oil is added.

_______________

♦ 2.8.2 HIGH TEMPERATURE SWITCH

_______________

This switch (Figure 2.3), which has normally open

(N.O.) contacts, is mounted near the oil filter. The contacts close if the temperature should exceed approximately 284° F (140° C), initiating an engine shutdown.

Figure 2.3 - Low Oil Pressure and

High Temperature Switches

HIGH

♦ 2.8.3 FIELD BOOST

The Controller Circuit Board houses a field boost diode and resistor that are not part of the automatic choke circuit. These two components are part of a “field boost” circuit (Figure 2.4). During engine cranking only, a positive DC (battery) voltage is deliv ered through the diode, resistor, brushes and slip rings, and the generator rotor. Application of this voltage to the rotor “flashes the field” whenever it is started. Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce “pickup” voltage in the stator windings.

Figure 2.4 - Field Boost Circuit

1 O Generac’ Power Systems, Inc.

CLOSEST TO BEARING

Section 3 - Maintenance

PRIMEPACT 70C and 70LP Recreational Vehicle Generators

MAINTENANCE

♦ 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. When the AC frequency is 50 Hertz, voltage is regulated at

115 volts.

Figure 2.5 - Solid State Voltage Regulator

'yy-SENSING

+)t_to rotor

)—T(DIRECT CURRENT)

----

hEROM STATOR

EXCITATION WINDING (ALTERNATING CURRENT)

The voltage regulator also incorporates a “voltage surge protection circuit.” This circuit prevents trou blesome surges in the generator AC output voltage. Voltage surge is a common cause of damage to elec tronic equipment.

• 2.8.5 25-HOUR BREAK-IN PERIOD

_____________

The first 25 hours of operation is the break-in period for the generator. Properly breaking in the generator is essential to minimize fuel consumption and pro

vide maximum engine performance. During this 25-

hour break-in period, follow this procedure:

• Run the unit at varying electrical loads to help seat the engine piston rings properly.

• Check the engine oil level frequently. Add oil if needed. It is normal for the generator engine to consume more oil than is normal until the piston rings have properly seated.

• For the 75-hour operation following the break-in period, avoid light electrical loads. Load the generator at 50 percent (or more) of its rated wattage capacity. Repeated light loads during these

75 hours can cause improper seating of engine pis ton rings, resulting in blowby and high oil con sumption.

• After operating the unit for 25 hours, complete the tasks recommended under Section 2.8.6.

♦ 2.8.6 25-HOUR CHECK-UP

After the 25-hour break-in period, contact a Gcncrac Authorized Service Dealer for the following mainte nance. The vehicle owner is responsible for any charges:

• Change the engine crankcase oil and oil filter.

• Check all fluid levels.

• Inspect the cooling and ventilation openings.

• Check the engine ignition system.

• Inspect the entire electrical system.

• Inspect the engine exhaust system.

• 2.8.7 OPERATION IN HIGH GRASS OR BRUSH

-------

M. WARNING Ék

-----------------

Never operate the generator while the vehicle is parked over high grass, weeds, brush,

leaves or any other combustible substance. Such materials can ignite and burn from the heat of the exhaust system. The generator exhaust system becomes extremely hot dur ing operation and remains hot for a long time after it has shut down.

3.1

CHECKING THE ENGINE OIL LEVEL

For oil capacities and requirements, see “Engine Oil Requirements,” Section 1.6.2 (Page 6). Check the engine crankcase oil level at least every eight hours of operation, or before you use it. To check the engine

oil level, proceed as follows (see Figure 3.1):

Be sure the generator is as level as possible.

Remove the dipstick and wipe it dry with a clean,

lint-free cloth. Install and tighten the dipstick cap; then, remove

3. it again. The oil level should be at the dipstick “Full” mark.

If necessary, remove the oil fill cap on the rocker

4. cover and slowly adcf oil until it reaches the dip stick “Full” mark. DO NOT FILL ABOVE THE

“FULL’ MARK.

-------

ik CAUTION Mk---------------

Never operate the engine with the oil level

below the "Add" mark on the dipstick. Doing this could damage the engine.

5. Install and tighten the oil fill cap and the dipstick before operating the engine.

Generac® Power Systems, Inc. 1 1

MAINTENANCE

Section 3 - Maintenance

PRIMEPACT 70C and 70LP Recreational Vehicle Generators

3.2 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. Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures.

• Change the engine oil filter after the first 25 hours

of operation, and every 100 operating hours there after.

To change the oil and/or oil filter, proceed as follows:

1. Run the engine until it is thoroughly warmed up (at least five minutes) then shut OFF

the engine.

2. With (he engine still warm from running, remove the oil drain plug (Figure 3.1). Drain the oil into a suitable conlainer.

3. After the oil lias drained, replace the oil drain plug. (II only changing the oil, go to step 7.)

4. With the oil drained, remove the old oil filter by ¡uming it counterclockwise (Figure 3.2 on page 12).

5. Apply a light coating of clean engine oil to the gas ket of the new filter.

6. Screw the new filter on by hand until its gasket lightly c'onlacts the oil filter adapter. Then, tight en the filter an additional 3/4 to one turn.

7. Remove the dipstick and fill crankcase with the jn oper type and amount of recommended oil (see Seedion 1.6.2. Page 6). Tlie engine crankcase can hold aboul 1.4 liters. DO NOT FILL ABOVE THE d^TJLi: MARK.

c8. Install and lighten the dipstick before operating

tlu' engiiK'.

9. Start the engine and check for leaks.

NOTE:

Check the oil level and fill to the “FULE’ mark after checking for leaks. The filter will retain some oil.

Figure 3.1 — Oil Dipstick/FiU Tube and

Location of Oil Drain Plug

3.3

MAINTAINING THE ENGINE

AIR CLEANER

♦ 3.5.1 CLEANING THE FOAM PRECLEANER

Clean and re-oil the foam precleaner every three months or every 25 hours of operation, whichever occurs first. Service the foam precleaner more fre quently if operating the generator in extremely dusty or dirty conditions. Use the following procedure (Figure 3.3):

1. Turn the knob counterclockwise to loosen.

2. Remove the cover, foam precleaner and paper fil ter.

3. Remove the foam precleaner from the cover.

4. Wash the foam precleaner in liquid detergent and

water.

5. Wrap the foam precleaner in a clean cloth and

gently squeeze it dry.

6. Saturate the foam precleaner in clean engine oil. Genllv squeeze it in a clean cloth to remove

excess oil and to distribute oil (DO NOT TWIST).

7. Install the foam precleaner into the cover, fol lowed by the paper filter. Tabs at edges of paper

1 H Generac’ Power Systems, Inc.

Section 3 - Maintenance

PRIMEPACT TOG and 70LP Recreational Vehicle Generators

MAINTENANCE

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 FILTER

FOAM PRE-CLEANER

3.4 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.

Inspect the area around the generator exhaust muf

fler periodically and remove all grass, leaves, dirt,

etc., from this area.

Figure 3.5 - Setting the Spark Plug Gap

-------

ik CAUTION Mk

Sparking can occur if the wire terminal does

not fit firmly on the spark plug terminal end. If necessary, re-form the wire terminal to obtain a

tight fit.

------------

3.6 FUEL FILTER (gasoline only)

Remove and replace the fuel filter (Figure 3.6) once each year or every 100 hours of operation, whichever comes first.

Figure 3.6 - Fuel Filter

FUEL FILTER

TO FUEL PUMP

Figure 3.4 - Cleaning Air Intake

CLEAN THESE AREAS

3.5 CHECKING THE ENGINE

SPARK PLUG

Clean the spark plug and reset the spark plug gap

every 100 hours of operation.

1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and com mercial solvent. Do not blast the spark plug to clean.

2. Remove the spark plug and check the condition. Replace the spark plug if worn or if reuse is ques tionable.

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.030 inch (0.76 mm) by carefully bending the ground electrode (Figure 3.5).

CUSTOMER FUEL CONNECTION

3.7 SPARK ARRESTOR IVlUFFLER

If the generator is not equipped with a spark arrestor exhaust muffler and is to be used on any forest cov ered, brush covered or grass covered unimproved land, you may have to install a spark arrestor. The spark arrestor must be maintained in effective work

ing order by the vehicle owner/operator. For assistance in ordering, installing and maintaining

spark arrestor exhaust mufflers, contact your nearest Generac Authorized Service Dealer.

Exhaust mufflers supplied by Generac arc 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" or “swirl" type. To remove carbon and combustion deposits from such mufflers, remove the plug from the muffler and run the engine for approximately 15 minutes. Shut down the engine, let the muffler cool and install the plug.

Generac® Power Systems, Inc. 1 3

iX>=

MAINTENANCE

Section 3 - Maintenance

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

-----

ik WARNING Ék

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 other flammable material. This could result in a

fire.

------

3.8 CLEANING THE GENERATOR

Keep the generator set as clean and dry as possible.

Protect the unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and mois ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings.

When moisture is allowed to remain in contact with windings, some of the moisture will be retained in voids and cracks in the insulation. This causes a reduced insulation resistance and will eventually cause problems. Dirt will make the problem worse, since dirt tends to hold moisture in contact with windings. Salt (as from sea air) also will worsen the problem since it tends to absorb moisture from the air. Salt and moisture, when combined, form a good electrical conductor.

---------

Ml caution M

Do NOT use a forceful spray of water to clean

the generator. Water will enter the generator interior and cause problems, and may also cont aminate the generator fuel system.

-------------------

3.9 BATTERY MAINTENANCE

All lead-acid batteries will discharge when not in use. The generator battery should be inspected as follows:

♦ 3.9.1 WEEKLY________________________________

• Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.

• Check the battery fluid level of unsealed batteries and, if necessary, fill with Distilled Water Only. Do not use tap water in batteries.

♦ 5.9.2 EVERY SIX MONTHS

• Have the state of charge and condition checked.

This should be done with an automotive-type bat

tery hydrometer.

Servicing of the battery is to be performed or supervised by personnel knowledgeable of batter ies and the required precautions. Keep unautho rized personnel away from batteries.

1 «4 Generac’ Power Systems, Inc.

_______________________

NOTE:

Damage will result if the battery connections are made in reverse.

DANGER

Do not dispose of the battery in a fire. The battery is capable of exploding. Storage batter ies give off explosive hydrogen gas. This gas

can form an explosive mixture around the bat tery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks, or any spark producing

tools or equipment near the battery. Discharge

static electricity from your body before touch ing the battery by first touching a grounded metal surface.

A battery presents a risk of electrical shock

and high short circuit current. The following precautions are to be observed when working

on batteries:

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the

battery;

• Disconnect any charging source prior to connecting

or disconnecting battery terminals; and

• Do not use any jumper cables or booster battery to crank and start the generator engine. If any battery has discharged, remove it for recharging.

-----

LL WARNING ik

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention; and

• Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) or water. The bicar

bonate of soda solution is to be added until the

evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the area dried.

------

Section 3 - Maintenance

PRIMEPACT TOG and 70LP Recreational Vehicle Generators

MAINTENANCE

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. The drive belt and pulleys are warranted for the life of the generator. Drive belt tension was properly adjusted before the unit was shipped from the factory. If you suspect that drive belt tension is incorrect, contact a 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.

3.13 OUT OF SERVICE PROCEDURE

♦ 5.13.1 REMOVAL FROM SERVICE

If you cannot exercise the generator every seven days, and it is to be out of service longer than 30 days, pre pare the generator for storage as follows:

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down.

3. While the engine is still warm from running, drain the oil completely Refill the crankcase with SAE lOW-30 oil having API classification “For Service SE”

4. Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase.

5. Remove the spark plug and pour two or three tablespoons of clean, fresh engine oil into the spark plug threaded openings. Reinstall and tighten the spark plug.

6. Remove the battery and store it in a cool, dry room on a wooden board. Never store the battery on any concrete or earthen floor.

7. Clean and wipe the entire generator.

♦ 5.15.2 RETURN TO SERVICE____________________

To return the unit to service after storage, proceed as follows:

1. Check the tag on the engine for oil viscosity and

classification. Verify that the correct recommend ed oil is used in the engine (see Section 1.5.4, Page 6). If necessary, drain and refill with the proper oil.

________________

2. Check the state of the battery. Fill all cells of unsealed batteries to the proper level with distilled

water. DO NOT USE TAP WATER IN THE BAT TERY. Recharge the battery to 100 percent state of charge, or, if defective, replace the battery.

3. Clean and wipe the entire generator.

4. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly.

5. Turn OFF all electrical loads. Add fuel if neces sary and then start the engine.

6. Allow the unit to warm up thoroughly.

7. Apply electrical loads to at least 50 percent of the unit’s rated wattage capacity.

8. When the engine is thoroughly warmed up, shut it down.

9. Your generator is now ready for service.

3.14 WATTAGE REFERENCE GUIDE

Running Watts

Battery Charger.................................................................500

Belt Sander (3")

Chain Saw.......................................................................1200

Circular Saw (6-12”)

Disc Sander (9”) .............................................................1200

Hand Drill (1”) ...............................................................1100

Hedge Trimmer.................................................................450

Impact Wrench .................................................................500

Lawn Mower ..................................................................1200

Electric Range (one element)..........................................1500

Television........................................................1750 to 2000

Coffee Maker

Electric Skillet.................................................................1250

Hair Dryer

Light Bulb.........................................................................100

Microwave Oven ..............................................................700

Oil Burner on Furnace Oil Fired Space Heater (140,000 Btu)

Radio......................................................................50 to 200

Slow Cooker .....................................................................200

♦Furnace Fan (1/3 HP)....................................................1200

♦Refrigerator.....................................................................600

♦Air Conditioner (12,000 Btu)........................................1700

♦Compressor (IHP).........................................................2000

♦Deep Freeze

♦Milk Cooler ..................................................................1100

♦Submersible Pump (1-1/2 HP) ♦Submersible Pump (1 HP) ♦Paint Sprayer, Airless (1/3 HP)

♦Table Saw (10”) ...........................................1750 to 2000

♦ Allow 2-1/2 times the listed watts for starting these

devices.

..............................................................

........................................

..................................................................

.......................................................................

.....................................................

..............................

....................................................................

.............................

............................................

..............................

Generac* Power Systems, Inc. 1 5

800 to 1000

1000

1200

300 400

500

2800 2000

600

NOTES

Section 4 - Notes PRIMEPACT 70G and 70LP Recreational Vehicle Generators

1 B Generac* Power Systems, Inc.

PART II -

INSTALLATION

INSTRUCTIONS

DANGER

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

SAFETY RULES

DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly

with article 551, NFPA 70; ANSI Cl-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.

Safety Rules PRIMEPACT 70G and 70LP Recreational Vehicle Generators

NOTICE TO INSTALLER

These I ns tal lat ion In str uc tio ns 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. Generac also assumes that personnel have been trained in the rec ommended installation procedures for these prod ucts and that such training includes (a) use of com

mon hand tools, (b) use of special Generac tools, and

pliers. Generac cannot possibly know of and advise the

recreational vehicle trade of all conceivable methods, procedures or techniques by which to perform an installation. Nor can Generac anticipate every possi ble hazard that might result from each installation

method, procedure or technique. Generac has not undertaken any such wide evaluation. Therefore, people who use a method, procedure or technique that Generac does not specifically recommend must first completely satisfy themselves that their safety, the safety of the vehicle's occupants and the product's safety is not endangered by the method, procedure or technique selected.

Information, illustrations, specifications, etc., con tained in these In sta lla tio n In str uc tio ns are based on the latest information available at the time of publi cation. Every efforl has been expended to be sure that such data is both accurate and current. However, the manufacturer reserves the right to change, alter or otherwise improve this product at any time without prior notice.

DANGER

Despite the safe design of this generator,

operating this equipment imprudently, neglecting

its maintenance or being careless can cause possible injury or death. Permit only responsible

and capable persons to operate or maintain this equipment.

Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

Parts of the generator are rotating and/or hot

during operation. Exercise care near running generators.

A GENERAL HAZARDS A

For safety reasons, Generac recommends

that the installation, initial start-up and mainte nance of this equipment is carried out by a Generac Authorized Service Dealer.

The engine exhaust fumes contain carbon monox

ide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust sys tem must be installed properly, in strict compli ance with applicable codes and standards. Following installation, you must do nothing that might render the system unsafe or in noncompli ance with such codes and standards. The genera tor compartment must be completely vapor sealed from the vehicle interior. There must be no possi bility of exhaust fumes entering the vehicle interi or. Never operate this equipment with a leaking or defective exhaust system.

Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and venti

lating air is critical to correct generator operation and is required to expel toxic fumes and fuel

vapors from the generator compartment. Without

sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to the generator. Do not alter the installation or per mit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the

generator.

When working on this equipment, remain alert at

all times. Never work on the equipment when you are physically or mentally fatigued.

Before performing any maintenance on the genera

tor, disconnect its battery cables to prevent acci dental start up. Disconnect the cable from the bat tery post indicated by a NEGATIVE, NEG or (-) first. Reconnect that cable last.

Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break parts, and may result in dangerous operating con ditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

Never insert any tool or other object through open

ings in the generator interior, even if the unit is not running. You might seriously Injure yourself or damage the equipment.

1 S Generac* Power Systems, Inc.

Safety Rules

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

SAFETY RULES

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. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

During installation onto the vehicle, properly ground (bond) the generator either by solid mount

ing to the vehicle frame or chassis, or by means of an approved bonding conductor. DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 American Wire Gauge (AWG) copper wire minimum.

If the vehicle electrical circuits can be powered by

any other source of electricity (such as a "dockside” power receptacle), there must be no possibil ity of connecting the different power sources to the vehicle circuits at the same time. The dockside (utility) power source must be positively isolated

from the vehicle circuits whenever the generator is

operating. Failure to isolate the vehicle circuits

from the dockside power supply when the genera

tor is running may result in damage to the genera tor or serious injury or death to dockside (utility) power workers due to backfeed of electrical ener

gy-

In case of accident caused by electric shock, imme

diately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting imple ment, such as a rope or board, to free the victim from the live conductor. If the victim is uncon scious, apply first aid and get immediate medical help.

Never wear jewelry when working on this equip

ment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving com ponents causing injury.

FIRE HAZARDS

For fire safety, the generator must be installed and maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installa tion, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regu lations.

Keep a fire extinguisher in the vehicle at all times. Extinguishers rated “ABC" by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system. Keep the extinguisher properly charged and be familiar with its use. If you have any question per taining to fire extinguishers, consult your local fire department.

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no com bustible materials are left in the generator com partment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surround ing the generator clean and free from debris.

Gasoline is extremely FLAMMABLE and its vapors

are 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.

Fuel lines must be properly installed and

fastened, and free of leaks. There must be no possibility of gasoline vapors entering the vehi cle interior.

You are required to install an approved, flexible,

nonconductive fuel line between the generator fuel connection point and rigid fuel lines.

If the generator is equipped with a liquid propane

(LP) gas fuel system, install the unit so it complies with all codes, standards and regulations pertain ing to such systems. LP gas is highly explosive. The

gas tends to settle in low areas where even the

slightest spark can ignite it and cause an explo sion. Do not allow gas vapors to enter the vehicle.

Generac* Power Systems, Inc. 1 3

GENERAL

INFORMATION

Section 5 - General Information PRIMEPACT 70G and 70LP Recreational Vehicle Generators

5.1 PURPOSE AND SCOPE OF THE

INSTALLATION INSTRUCTIONS

These Inst al lat ion In st ru cti on s 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 instructions in the manual, both for safety and for continued reliable operation of the equip ment.

Because of the different recreational vehicle models and

the variations between the models, it would be extremely difficult, if not impractical, to provide detailed instruc

tions for every possible installation. For that reason, instructions and illustrations in this manual are general in nature. Illustrations are not intended to serve as detailed installation blueprints.

The installation should comply strictly with all applica ble codes, standards and regulations pertaining to the installation and use of this product. If any portion of this manual appears to be in conflict with such codes, standards or regulations, the applicable codes, stan dards or regulations must take precedence over the manual.

5.2 SAFETY

Before handling, installing, operating or servicing this equipment, carefully read the “Notice to Installer” and “Safety Rules” on Pages 18 and 19. Comply with all safe ty rules to prevent death, personal injury or damage to equipment and/or property. Stress safety to all installers, operators and service technicians who work on this equipment.

5.3 STANDARDS BOOKLETS

Installation, use and servicing of this equipment should comply strictly with published standards, as well as the manufacturer's recommendations. The following stan dards Irooklets (latest revision) are available from the sources indicated:

NFPA Standard 501C, “Standard for Recreational Vehicles,” available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

NFPA 70, “NFPA Handbook of the National Electric Code," available same as Item 1.

ANSI Cl-1975 and ANSI 119.2-1975, available from the American National Standards Institute, 1430 Broadway, New York, NY 10018,

ANSI A119.2/NFPA 501C, available from the

Recreational Vehicle Association, 1896 Preston White Drive, Reston, VA 22090.

California Administrative Code, Title 25, available from the State of California, Documents Section, PO. Box 1015, North Highlands, CA 95660.

6. eSA Electrical Bulletin 946, available from the Canadian Standards Association, Housing and Constructions Materials Section, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3.

5.4 EQUIPIVIENT DESCRIPTION

Instructions and information in this section pertain to

Generac air-cooled generators. These generators are designed specifically for installing in recreational vehi cles. They operate 120-volt, single-phase, 60-Hertz, AC electrical loads that require 58.3 amps (gasoline) or

55.0 amps (LP fuel) at 120 volts.

5.5 GENERATOR ENGINE

OPERATING SPEED

The generator’s revolving field (rotor) is driven by a twocylinder, four-cycle engine through a pulley and drive belt arrangement. The generator supplies 120 volts AC at 60 Hertz when the rotor is operating at 3,600 rpm.The drive belt arrangement allows the engine to operate at a lower speed than the rotor.

5.6 GENERATOR AC

CONNECTION SYSTEIVi

These air-cooled generator sets are equipped with dual stator AC power windings. These two stator windings supply electrical power to customer electrical loads by means of a dual 2-wire connection system.

Generators may be installed to provide the following outputs:

1) 120 VAC loads only — one load with a maximum total

wattage requirement equal to the generator’s rated power output (in watts), and 120V across the generator output terminals.

2) 120/240 VAC loads — one load with a maximum total wattage requirement equal to the generator’s rated power output, and 240 V across the generator output terminals: or two seperate loads, each with a maximum total wattage requirement equal to half of the genera tor’s rated power output (in watts), and 120 V across the generator output terminals.

Figure 5.1 - Connection for 120 Volts Only

S.O Generac* Power Systems, Inc.

Section 5 - General Information

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

Figure 5.2 - Major Features and Dimensions

PRIMEPACT 70G and 70LP

GENERAL

INFORMATION

Air Filter

Ground Lug

Generao* Power Systems, Inc. 21

INSTALLATION

Section 6 - Installation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

Figure 5.3 - Connection for 120/240 Volts

• 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.

• Loads connected across T1 (Red) to T2 (White), and

T3 (Black) to T2 (White), must not exceed 58.3 amps for PriinePact 70G, or 55 amps for PrimePact 70LP with a voltage of 120V across each set of terminals.

NOTE:

Do NOT connect loads in excess of circuit

breaker ratings.

6.1 LOCATION AND SUPPORT

• 6.1.1 GENERATOR LOCATION

I'lie most desirable location for the generator set is

between the veliicle's main frame members. However, this is seldom jjossilrle. Most units must be installed on the side of the vehicle and are difficult to reinforce.

Many recreational vehicles have been factory equipped

with an area for the generator set. Some vehicles may

even have a generator compartment provided by the vehicle manufacturer.

Plan the generator location based on the following:

• The generator set must be installed on a framework

that is part of the recreational vehicle, as outlined in Section 6.1.2.

• The location must provide an access opening that is

large enough to permit generator removal (unless the generator is to be removed from underneath the sup porting framework).

• The location must provide easy access to frequently serviced components, such as filters, oil drains, spark plugs and other common maintenance parts.

• The location must provide sufficient room to allow minimum clearances as outlined in Section 6.2. If sound insulation is to be used on the compartment

___________________

walls and ceiling, the minimum recommended applies to the space between the generator and such insulation.

• The location must provide adequate cooling and ven tilating airflow for the generator without a great deal of work and expense.

• 6.1.2 GENERATOR SUPPORT

_____________________

The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding. The metal framework on which the generator will rest and which will restrain the generator set should consist of at least two horizon tal beams. These beams should consist of (a) 1-1/2-inch square, 11-gauge steel tubing OR (b) 1-1/2-inch, 11-

gauge angle iron. A typical supporting frame with hori

zontal support tubing, is shown in Figure 6,1,

The generator can be installed so that it sits on top of

the horizontal support tubing if the vehiele design per mits. Another method is to suspend the generator below

the horizontal support tubing by means of suitable,

structurally sound metal framework. The following gen eral rules apply:

“ Vehicle construction MUST be capable of supporting

the weight of the generator.

• 'Whether the generator is mounted above the horizon tal support tubing or suspended below the tubing, the supporting frame used must be structurally sound.

' If the generator cannot be bolted directly to

the supporting frame or support tubing, consider using additional tubing, angle brackets or other supports to give the supporting frame suffi cient strength.

Figure 6.1 - Typical Horizontal Support Frame

♦ 6.1.5 SUSPENDED MOUNTING

______________________

If you are going to suspend the generator below the hor izontal support tubing, the suspension method you use with the vehicle frame members must (a) be able to sup port the weight of the generator AND (b) provide suffi cient restraint for the generator. One typical suspended mounting system is shown in Figure 6.2. The location of a suspended mounting system must be carefully planned, keeping the following general rules in mind:

SS Generac* Power Systems, Inc.

Section 6 - Installation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

INSTALLATION

Protect the generator against road splash and debris. Baffles or splash guards may be required to protect cer

tain ai'eas of the generator. To make sure the generator is adequately protected, road test the installation through mud, water and slush.

Figure 6.2 - Typical Suspended Mounting System

GENERATOR MOUNTING

HOLES FOR 3/8" -16

BOLTS (BOTH SIDES)

• The installer must make certain that the selected location will permit adequate cooling and ventilating airflow to be supplied.

♦ 6.1.4 GENERATOR RESTRAINT

____________________

Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten

the generator to the supporting frame or the support tub ing. These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compart ment is used) and (c) the supporting framework

(Figure 6.3). /Ml bolts must be long enough so that when tight, at least three threads are visible past the retaining lock nuts. Refer to Section 6.2 for the location of the gen erator mounting holes.

Figure 6.3 - Typical Generator Restraint

1/2 INCH THICK

from ilic back lor air circulation AFTER the compart ment has been lined with metal and sound insulalioii (Figure 6.4).

NOTE:

Refer to “Figure 5.2 -

Major Features and

Dimensions” on Page 21.

Figure 6.4 - Clearances

• 6.2.2 COMPARTMENT CONSTRUaiON

_______________

• The generator compartment should be either con structed of, or lined with, 26-gauge galvanized steel.

NOTE:

Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum’s low melting point.

• If the compartment is lined with galvanized steel, it

may be constructed of any material. Generac recom mends that the compartment be constructed of 1/2inch thick plywood (not strandboard), with the floor made of a double thickness of 1/2-inch plywood with the grain of the wood at cross section for added strength (Figure 6.5).

6.2 GENERATOR COIVIPARTIViENTS

Wlrether the generator set is being installed inside a com partment specifically manufactured to house a generator or inside a compartment that the installer constructs, the compartment MUST meet certain specifications as out lined in the following sections:

♦ 6.2.1 COMPARTMENT SIZE

Plan the compartment size carefully. Provide a mini mum clearance of 1/2 inch (13 mm) on the front and top, 1 inch (25 mm) on the sides, and 1/2 inch (13 mm)

________________________

Figure 6.5 - Typical Compartment Construction

CROSS SECTION VIEW

Generac* Power Systems, Inc. 23

METAL LINING

INSTALLATION

Section 6 - Installation PRIMEPACT 70G and 70LP 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.

NOTE:

Caulking must be done so that the caulking material will stay in place permanently. Pressing such materi als as putty tape onto joints and seams is not accept able. A high quality silicone rubber base sealant is recommended.

• Holes and openings made in the compartment walls to allow for the passage of electrical conduit, conduc tors, hoses, cables, etc., into the vehicle living area must be sealed vapor tight with silicone rubber base sealant.

• If flexible metal conduit is used, it must be sealed internally at the end where it terminates inside the compartment’s electrical junction box.

NOTE:

Flexible metal conduit, due to its unique construc tion, is NOT vapor tight along its entire length.

• Seams and joints of the galvanized steel (whether used as a liner or for the compartment itself) must be lapped and mechanically secured. Such seams may be manufactured, welded, bolted, riveted or screwed. Manufactured lock seams are shown in Figure 6.6. Installer constructed compartments t3q3ically utilize a standard lap joint.

Figure 6.6 - Types of Lock Seams

. w p

FOLD LOCKED STANDING

I I

* ■ OFF SET

DOUBLE LOCK DOUBLE SEAM

STANDARD LAP JOINT

OFF SET

ACME LOCK

LOCK SEAM

After the compartment has been metal lined and

vapor sealed, line the compartment interior walls and ceiling with an approved, nonflammable sound insu lating material. See Section 6.2.3.

DANGER

Do not install any flammable material directly

above or around the compartment. Heat,

24 Qenerac* Power Systems, !nc.

transferred through the compartment structure, may be sufficient to ignite, char or discolor seat cushions, fiberboard and other flammable materials. You may need to use approved nonflammable insulating materials in high temperature areas.

♦ 6.2.3 SOUND INSULATING MATERIALS

______________

Once installers have determined that a compartment is properly constructed and metal lined, they can add acoustical material. This may include additional sealant or insulating material, to reflect noise away from the

vehicle Interior.

Sound insulating materials should be of a nonflamma

ble type. One excellent insulating material is a 1-inch

(25 mm) thick fiberglass having a 2-pound density. When fiberglass is used, its coated side should face toward the compartment interior.

DANGER

Do not install sound insulation or any absorbent

material on the compartment floor interior. Such materials will become soaked with combustible or

explosive vapors and liquids and will become a fire hazard.

Using a combination of sound insulating materials can often reduce noise more effectively than a single mater ial. For example, a sheet of lead or visco-elastic materi al, along with a layer of other acoustical material, is more effective than when a single material is used.

• 6.2.4 ACOUSTICS _____________

For additional noise abatement, the installer may wish to consider the following:

• Using special sound insulating materials,

• Construction of a special noise abatement compart ment.

NOTE:

Any method used to reduce noise must not adverse ly affect the flow of cooling and ventilating air into or

out of the compartment.

In addition to the effective use of sound insulating mate rials, construction of a special noise abatement com partment might be considered to reduce noise levels. Such a compartment might be constructed as follows

(Figure 6.7, page 25):

• Use 5/8-inch thick or 3/4-inch thick plywood in the compartment.

• Construct the compartment floor of a double thick ness of 5/8-inch or 3/4-inch plywood.

• Line the compartment interior walls and floor, as well as the underside of the floor, with 26-gauge galva nized steel.

Section 6 - Installation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

INSTALLATION

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.

DANGER

To prevent fire or explosion, do not install any

insulation or other absorbent materials on the interior or underside of the compartment floor.

• Seal all compartment door edges to prevent noise leakage around the door perimeter.

• Line the compartment door interior (except for air openings) with suitable, fireproof sound insulation (such as 1-inch (25 mm) thick fiberglass with a 2pound density).

Figure 6.8 — Compartment Floor Cutout

Figure 6.7 - Typical Noise Abatement

INSTALLATION

Section 6 - installation PRIMEPACT 70G and 70LP 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 exliaust and cooling air outlets

• Generator cooling air inlet

• Four holes for passage of generator mounting bolts. See Section 6.1.4 (Page 23).

_____________

E2ANGER

Fuel lines and exhaust piping must not penetrate

into the vehicle living area.

6.3 COOLING AND VENTILATING AIR

It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. Without sufficient airflow, the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also may cause fire and personal injury. The installer must make sure that sufficient air is available to the generator for cooling, ventilating and combustion. The installer also must provide for a path for exhausting the cooling air to the exterior of a compartment, if so equipped.

♦ 6.3.2 COOLING AIR INLET OPENINGS

The minimum size of the air inlet opening, whether the generator is housed in a conventional compartment or not, is at least 100 square inches (see Figure 6.10). This rule applies whether inlet air is brought in through an opening in the compartment door, an opening in the vehicle skirt, through ductwork, or by any other means.

NOTE:

Screening, louvers or expanded metal that cover air openings restrict airflow. You must compensate for

this by making the actual air opening proportionate

ly larger. See Section 6.3.3 (Page 27).

Figure 6.10 - Air Inlet in Compartment Door

100 SQUARE INCHES UNRESTRICTED MINIMUM OPENINGS

________________

DANGER

Never use discharged cooling air for heating or

permit such air to enter the vehicle interior. This air contains deadly carbon monoxide gas and other poisonous, flammable or explosive gases.

♦ 6.3.1 GENERATOR AIRFLOW

Engine operation drives cooling fans for the two-stage cooling air system. A pressure fan draws cooling air into the top of the generator (Figure 6.9). This airflow cools the engine/generator and electronic components. The second part of the cooling system, a suction fan, draws air that is heated from a hot engine into a collector pan at the base of the unit. This heated air (although cooler than exhaust muffler) is then deflected out the bottom toward the ground.

Figure 6.9 - Airflow Through Engine/Generator

NOTE:

Be sure to meet the minimum clearances illustrated in Figure 6.4 (Page 23).

When the unit is installed on a suspended mounting

system, one of several different methods of supplying airflow may be used as follows:

• Provide a door in the vehicle skirt having an air inlet opening (Figure 6.11).

Figure 6.11 - Suspended Mount: Inlet Door

Using ductwork (Figure 6.12, Page 27). The installer

must be sure air is available to the top of the genera tor since air inlets are located at the top.

By providing an opening in the vehicle skirt and space

Section 6 - Installation

PRIMEPACT TOG and 70LP Recreational Vehicle Generators

INSTALLATION

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

ANTI-SPLASH

Figure 6.13 - Air Inlet in Vehicle Skirt

♦ 63.4 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. Never place a unit into service until absolutely certain that cooling and ventilation is adequate.

NOTE:

You must test the installation, especially if you bring

in air from below the generator set.

6.4 GASOLINE FUEL SYSTEIV!

The installation of a gasoline fuel system (Figure 6.14) for a recreational vehicle generator set must comply

with applicable codes, standards and regulations. The

entire fuel system must be completely free of leaks.

There must be no possibility of gasoline vapors entering

the vehicle interior.

Figure 6.14 - Generator Fuel System

♦ 6.3.5 COMPENSATING FOR RESTRICTIONS

Such materials as screening, louvers or expanded metal

can restrict the free flow of air. Compensate for this

restriction by making the actual air opening propor

tionately larger.

Some materials may offer only a 60 percent “free air inlet area.” Other more efficient materials may provide up to a 90 percent free air inlet area. The percentage of free air inlet opening is usually available from the mate

rial supplier or manufacturer.

To determine the actual air inlet opening size required, divide 100 square inches by the percent

age of free air inlet area for the material you will use. For example: If you plan to use screening with an 80

percent free air inlet area, divide 100 by 0.8, which

results in 125 square inches. Minimum actual size of

air inlet opening in this case is 125 square inches.

DANGER

Gasoline is highly flammable, and its vapors are explosive. Comply with all codes, standards and regulations pertaining to gasoline fuel systems used in recreational vehicle generators. Properly install and maintain the fuel system and keep it entirely free of leaks. Gasoline vapors must not enter the vehicle interior.

Factory installed generator fuel system components

include (a) fuel filter, (b) 12-volt DC electric pump, (c)

engine carburetor, and (d) interconnecting lines and fit

tings. Connect a fuel supply line to the fuel filter inlet. Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines.

Generac* Power Systems, Inc. S.7

INSTALLATION

Section 6 - Installation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

♦ 6.4.1 FUEL TANK

Either tlie 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 generator is to share the vehicle engine's tank, sep arate 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. This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods.

-------

-Jk CAUTION

Do NOT tee the generator fuel supply line into

the vehicle engine fuel supply line. If this is done, the generator will be starved of fuel when both engines are operating at the same time. Also, while the vehicle engine is not running, generator operation may drain the vehicle engine supply line, making it difficult to start the vehicle engine.

♦ 6.4.2 GENERATOR FUEL SUPPLY LINE

6.4.2.1 Rigid Fuel Lines

Those lines used to supply fuel from a tank to the gen

erator must comply with applicable codes, standards

and regulations. The following general rules apply to rigid fuel lines:

• Rigid lines should be of annealed, seamless, drawn aluminum or steel.

• Lines and fittings must comply with SAE J512F, “Standard Automotive Fittings,” or with ANSI B126.26 (latest edition).

• Route the fuel line so that at least 2 inches (51 mm) of clearance is maintained between the line and any exhaust system parts.

• Do not attach electrical wiring to fuel lines. Route the wiring so it cannot come into contact with any fuel line.

• Route fuel lines so if they leak, fuel does not drip onto any electrical or exhaust system parts.

• Use nonferrous metal straps without sharp edges to secure fuel lines.

--------------

_______________

• The hose should be at least 6 inches (152 mm) longer than is needed to prevent the hose from rupturing if the generator shifts or settles,

6.5 LP CAS FUEL SYSTEM

—AEaEia A—

lp gas is highly EXPLOSIVE. The gas is heavier

than air and tends to settle in low areas. Even the slightest spark can ignite it and cause and explo sion. Only competent, qualified people should be allowed to install, test, adjust or service an LP gas fuel system. Install the optional fuel system in compliance with applicable codes, standards and regulations. After the installation, do not do any

thing that might render the system in noncompli

ance with applicable codes and standards.

The LP powered range of generators are fitted with a nonadjustable, factory set system. These systems are tamper-proof to meet 1997 California Air Resources Board requirements for engine emission.

♦ 6.5.1 PARTS NOT INCLUDED IN FUEL SYSTEM

The propane fuel system does NOT include such items as (a) gas tank, (b) gas piping, (c) fittings, (d) valves, and (e) primary regulator, used to store the gaseous fuel and deliver it to the gaseous fuel solenoid (Figure 2.15, Page

29).

DANGER

Use only approved components in the fuel supply

system. All components must be properly installed

in accordance with applicable codes. Improper installation or use of unauthorized components may result in fire or an explosion. Follow

approved methods to test the system for leaks. No leakage is permitted. Do not allow fuel vapors to enter the vehicle interior.

6.4.2.2 Flexible Fuel Line

Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines. This prevents breaking of the line caused by vibration, shift ing, settling or movement. The following rules apply:

• The flexible hose must comply with SAE J30B, “Standard for Fuel and Oil Hose.” It must be

approved for use with gasoline.

2S Generac® Power Systems, Inc.

Section 6 - Installation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

INSTALLATION

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. This reduces the possibility of leakage.

• Test the entire fuel system for leaks using approved

test methods.

• Optimum gas pressure at the inlet to the gaseous fuel

solenoid valve and secondary regulator is 11 inches

water column.

• The installer’s fuel supply connection point is at the gaseous fuel solenoid valve. This is a 3/4-inch

(female) connection. Provide a suitable 3/4-inch NPT (male) connector to attach to the fuel supply line.

• Use a length of approved flexible fuel hose between

the gaseous fuel solenoid valve and rigid gas piping. The flexible line should be at least 6 inches longer than necessary.

• 6.5.3 VAPOR WITHDRAWAL

__________________

___

LP gas is stored in pressure tanks as a liquid. The gas

systems used with these generators were designed only

for vapor withdrawal type systems. Vapor withdrawal

systems use the gas vapors that form above the liquid fuel in the tank. Do NOT attempt to use the generator with any liquid withdrawal type system.

♦ 6.5.4 PRIMARY REGULATOR

Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regulator. Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank. The following rules apply:

• For best results, the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column. Do NOT exceed 14 inches water col umn.

• The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit.

NOTE:

Recommended MINIMUM gas flow rate for all air cooled PRIMEPACT series generators is 67 cubic feet per hour.

If an existing primary gas regulator does not have a sufficient flow capacity for the generator and other gas appliances in the circuit, (a) install a primary regulator with adequate flow rate, or (b) install a sep arate regulator only and rated at least 67 cubic feet per hour. The inlet side of any primary regulator that supplies the generator must connect directly to a gas pressure tank. Do NOT tee the generator line into a gas circuit feeding other areas.

• 6.5.5 GASEOUS CARBURETION

___________________

LP gas vapors should be supplied to the secondary reg ulator inlet at about 11 inches water column (positive pressure). The engine pistons draw air in during the intake stroke (Figure 6.16). This air passes through a carburetor venturi, which creates a low pressure that is proportional to the quantity of air being pumped. The low pressure from the carburetor venturi acts on the regulator diaphragm to pull the diaphragm toward the source of low pressure. A lever attached to the diaphragm opens a valve to permit gas glow through the carburetor.

Figure 6.16 - LP Gas Carburetion Diagram

GAS AT

POSITIVE

PRESSURE

GASAI

LOW PRESSURE

AREA

ZERO PRESSURE

Generac* Power Systems, Inc. 2S

INSTALLATION

Section 6 - Installation

PRIMEPACT 70G and 70LP 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. The more the regulator valve opens, the greater the gas flow that is proportional to airflow

through the generator. The following facts about the secondary regulator must

be emphasized:

• The regulator must be sensitive to venturi throat pressure changes throughout the operating range.

• The regulator must be properly adjusted so it will stop the flow of gas when the engine is not running (no air flow through the carburetor).

• The slightest airflow (and vacuum in the venturi throat) should move the regulator valve off its seat and permit gas to flow.

• 6.5.6 FUEL SUPPLY LINES

• LP gas lines must be accessible, but protected against possible damage.

• Do NOT connect electrical wiring to any LP gas fuel line or run wiring alongside the lines.

• Route gas lines away from hot engine exhausts.

• Retain gas lines with metal clamps that do not have sharp edges.

• Install an approved length of flexible hose between the gaseous fuel solenoid valve and rigid fuel supply lines. The flexible line must be nonmetallic, nonor-

ganic and nonconductive. It must be approved for use

with LP gas.

• 6.5.7 EXCESS FLOW VALVE

LP gas tanks should have an excess flow valve, accord ing to NFPA 501C, Paragraph 3-4.4, This valve and the gas lines must be carefully sized so the valve will close when a fuel line is severed or broken. Consult the Natural-LP Gas Association for information and limita tions of excess flow valves.

Manual shutoff valves on the supply tank and elsewhere in the system must be fully open when operating the generator. The excess flow valve functions properly only if all valves are fully open.

• 6.5.8 LEAKAGE TESTS

Do not place the generator into service until you have properly tested the gas system for leaks. To test the sys tem, you need a separate source of 12 volts DC to open the gaseous fuel solenoid valve.

The leak test must comply fully with NFPA, Paragraph

318. All connections, hoses, valve regulators, fittings, and other fuel system parts must be tested under gas or air pressure of not less than 90 psi (620 kPa), while using soap and water or an equivalent solution to check

_______________________

______________________

__________________________

for leaks. Other approved methods of testing for leaks

may be used, if appropriate. DO NOT USE ANY FLAME

TO TEST FOR LEAKS.

DANGER

Gaseous fuel lines between the tank and the sec

ondary regulator are under a positive pressure (about 11 inches water column). Gas pressure at

the outlet side of the secondary regulator, howev er, is a negative pressure and can draw flame

inside a line or fitting and cause an explosion.

6.6 EXHAUST SYSTEM

The generator exhaust system must be safely and prop

erly installed. Only approved mufflers and other exhaust system parts must be used. A properly installed exhaust system must be vapor tight, quiet and com pletely safe.

DANGER

The generator engine gives off DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentra tions, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT

OPERATE THE GENERATOR IF THE EXHAUST SYS TEM IS LEAKING OR HAS BEEN DAMAGED. SYMP TOMS OF CARBON MONOXIDE POISONING ARE

(a) inability to think coherently; (b) vomiting; (c) twitching muscles; (d) throbbing temples; (e) dizziness; (f) headaches; (g) weakness; and (h)

sleepiness. IF YOU FEEL ANY OF THESE SYMP TOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF

SYMPTOMS PERSIST, GET MEDICAL HELP. Do not operate the generator until its exhaust system has

been inspected and properly repaired.

-------

M. CAUTION Jk

Never tee the generator engine exhaust pipe into

the vehicle engine exhaust piping. This causes

excessive back pressure on the generator engine.

Also, water from one engine can damage the other engine.

♦ 6.6.1 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 unap proved muffler, or an unapproved exhaust system part, or modifying an exhaust system in any way that might cause a hazard, is liable for any damage, injury or war ranty expense that might be caused by such unapproved installation or modification.

------------

30 Generac* Power Systems, Inc.

Section 6 - Installation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

INSTALLATION

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 cov^ered 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 California, the preceding is required bylaw (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.

• 6.6.2 TYPE OF EXHAUST SYSTEM

______________

Two types of exhaust systems for PRIMEPACT series generators are available from Generac. They include the

following;

• “Out-the-bottom" exhaust system dimensions are 1 5/16” O.D., model 9742.

• “Out-the-side” exhaust system dimensions are 1” O.D., 18 gauge, modelS 9743 and 9326.

NOTE:

No matter what tjqje of exhaust kit best fits your recreational vehicle, the mounting base has open ings for either “bottom-out” or “side-out” exhaust

systems. Use the cover plate provided with the gen

erator to cover the opening you do NOT use.

• 6.6.3 EXHAUST SYSTEM SAFETY

• *•

• Maintain a clearance of at least 3 indies (76 n un ] between exhaust system parts and any combustible material (such as wood, felt, cotton, organic fiber.s or other like material). If you cannot maintain the 3-incli (76 mm) clearance, locate, insulate or shield the exhaust part(s) so that the temperature of any com

bustible material is not raised more than 117° F' (65°

C) above the ambient air temperature.

• Extend the exhaust system at least 1 inch (25 mm) past the outer edge of the vehicle. Do not terminate the exhaust system under the vehicle.

• Terminate the exhaust tailpipe such that exhaust

gases will not be drawn back into the generator com

partment and recirculated.

• If there is any possibility of the tailpipe or muffler being damaged, protect these damage-prone areas by

means of a protective device (such as a skid bar).

• Install the generator exhaust system according to safe automotive practices.

• Use enough exhaust system hangers to prevent any part of the system from being dislocated.

® Use exhaust system parts recommended by Generac.

Using unapproved exhaust mufflers and exhaust sys

tem parts is the responsibility of the person(s) installing such unauthorized parts.

• Do not terminate the exhaust system under any open ing, window or vent that can be opened or is not per manently sealed from the vehicle interior.

*• Exhaust piping must be large enough to prevent

excessive back pressure on the generator engine.

• Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping. This causes excessive

back pressure on the generator engine. Also, water

from one engine can damage the other engine.

• Plan exhaust system installation carefully. Comply

with all applicable codes, standards and regulations,

6.7 ELECTRICAL CONNECTIONS

Be sure to read Section 5.6 on Page 20.

The following general rules apply to electrical connec

tions in a recreational vehicle:

• Qualified electricians who are familiar with applica

ble codes, standards and regulations should install electrical wiring.

• The wiring should comply with codes, standards and regulations. The National Electrical Code (NFPA 70), and state and local codes apply.

• Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent damage from road shock.

• Wiring must be of adequate size, liave approved insii-

lalive qualities and be properly supported.

• Conduit and wire openings into the generator com partment (if used) must be vapor-sealed to prevent entry of flammabic. explosive or poisonous gases into the vehicle.

• 6.7.1 ELECTRICAL JUNCTION BOX

Install an approved, square electrical junction box with a blank cover on the interior or exterior wall of the area you plan to install the generator (NOT on the generator). F/oute the generator's AC output leads into this junction box through approved flexible conduit. This is the point of first termination for generator AC output leads.

• 6.7.2 WIRING__________________________________

• Wiring should be of stranded copper to reduce the chance that vibration may cause breakage.

• Wire gauge size should be large enough to handle at least 115 percent of the installed generator's rated maximum current.

• If neutral conductors are used, they must be the same size as other leg wires.

• Route power supply conductors from generator AC output leads T1 (red), T2 (white), T3 (black) and the green ground wire through approved flexible conduit to the electrical junction box on the compartment wall.

If flexible metal conduit is used between the genera

tor and the compartment junction box, the conduit end that terminates the compartment junction box must be vapor-sealed. Flexible metal conduit is NOT vapor tight along its entire length.

Generac* Power Systems, Inc. 31

___

INSTALLATION

Section 6 - Installation PRIMEPACT 70C and 70LP 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 dockside power).

• Conductors must be rated 221° F (105° C) or must be of a larger conductor size.

• 6.7.3 GENERATOR AC CONNECTIONS

Generator AC output leads T1 (red), T2 (white) and T3 (black) come out of the generator as shown in Figure 6.17. Leads T1 (red) and T3 (black) are “hot,”

while T2 (white) is the grounded neutral lead. There is

also a green lead that connects to ground in the Junction

box of the recreational vehicle.

Figure 6.17 - Generator AC Output Leads

_______________

♦ 6.7.4 CONDUIT

Route the connections between the generator and the

junction box through approved, flexible conduit. The

following general rules apply:

• Cut wiring to the required length and allow extra wire for junction box connections.

• Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation.

• Route conduit so it does not interfere with generator movement.

• If you use metallic conduit, vapor seal the end of the conduit where it enters the junction box. Do this because flexible metallic conduit is not vaporproof along its entire length.

• 6.7.5 ISOLATING DIFFERENT POWER SOURCES

Connections from the junction box must terminate in a double-pole, double-throw transfer switch (Figure 6.18, Page 33). An alternate method for isolating different power sources is by using an isolating receptacle

(Figure 6.19, Page 33). Whichever method you use, you must be certain that both power sources are NOT con nected at the same time.

♦ 6.7.6 POWER SUPPLY CORD

The power supply cord must comply with all applicable codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected. (See page 33 for illustration.)

Line T1 (red) to T2 (white) is protected against overload by a 30-amp circuit breaker (CBl). Use this line-to-neutral connection separately to operate 120-volt, singlephase, 60 Hertz, AC loads requiring up to 3,300 watts of power for PrimePact 66G or 3,100 watts for PrimePacl 66LR Line T3 (black) to T2 (white) also is protected against overload by a 30-anip circuit breaker (CB2). Use this line-to-neutral connection separately to operate similar loads. However, be sure the total unit load does not exceed the maximum rating of the gener ator. The neutral line (T2, white) on all units is a

grounded neutral.

-------

'ik CAUTION ii-------------------

Do NOT connect electrical loads in excess of any

circuit breaker rating or you will develop prob lems with circuit breaker tripping, which causes a loss of AC output. Also, do NOT exceed the gener

ator's rated wattage capacity. Add the watts or amperes of all lighting, appliance, tool and motor

loads the generator will operate at one time. This

total should be less than the unit's rated wattage/amperage capacity.

3a Generao® Power Systems, Inc.

• 6.7.7 GROUND FAULT CIRCUIT INTERRUPTERS

The National Electrical Code (NFPA 70, 551-7) requires that you install ground fault circuit interrupters (GFCIs) on all external and some internal electrical receptacles. Contact your manufacturer or dealer for recommenda tions.

6.8 BATTERY INSTALLATION

• 6.8.1 RECOMMENDED BATTERY__________________

Install a battery that meets the following requirements:

• The battery must be a 12-volt, automotive type

storage battery.

• For prevailing ambient temperatures above 32° F (0°

C), use a battery rated 70 amp-hours and capable of

delivering 400 cold-cranking amperes.

• For prevailing ambient temperatures below 32° F (0°

C), use a battery rated 95 amp-hours and capable of delivering 400 cold-cranking amperes.

NOTE:

If the battery is to be used to power other vehicle accessories, as well as start the generator, you may need a battery with a larger capacity.

Section 6 - Installation

PRIMEPACT TOG and 70LP Recreational Vehicle Generators

INSTALLATION

♦ 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.

Figure 6.18 — Transfer Switch Isolation Method

PRIMEPACT generators are rated at about 100 DC amperes of cranking current.

Select battery cables based on (a) cable length and (b)

prevailing ambient temperatures. Generally, the longer

the cable and the colder the weather, the larger the cable size must be, as shown in the chart.

2ND AIR

Figure 6.19 — Installation With Isolation Receptacle

DOCKSIDE POWER RECEPTACLE

INSTALLATION

Section 6 - Installation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

CABLE LENGTH

in Feet (meters)

0 to 10 (0 to 3)

CABLE SIZE

11 to 15 (3.4 to 4.5) 0

16 to 20 (4.5 to 6) 000

*For warm weather, use No. 2 cable up to 20 feet.

♦ 6.8.3 BATTERY CABLE CONNECTIONS________________

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 battery post indi cated by a NEGATIVE, NEG or (-) to the frame ground connection (Figure 6.20).

3. Connect cables so the connectors are clean and tight.

Figure 6.20 - Connecting Battery Cables

SIDE VIEW OF GENERATOR

6.9 OPTIONAL ACCESSORIES

A plug-in receptacle (Figure 6.21) is provided on the generator set, above the muffler enclosure. Use this

receptacle to connect an optional remote-mounted start/stop panel to the generator. Installation of such a

panel will permit you to start and stop the generator

engine from any convenient location inside the vehicle.

Figure 6.21 - Remote Panel Plug-in Receptacle

r r

WIRE #18 (STOP)

WIRE #14

(ENGINE RUN SIGNAL)

• 6.9.1 REMOTE PANEL MODELS

WIRE #17 (CRANK)

____________________

The remote panels mount a rocker type start/stop switch, a “Generator Run” advisory lamp and an hourmeter. The hourmeter should be used in conjunc tion with the maintenance operations found in Part I of this manual.

• Model 004057 includes the remote panel and a 10 foot long, 4 wire harness.

• Model 004184 includes the remote panel and a 30 foot long, 4 wire harness.

WIRE #0 (GROUND)

♦ 6.8.4 BATTERY COMPARTMENT

____________________

Install the generator battery in its own, vented compart ment. Place the battery compartment away from any source of heat, sparks or ñame.

Provide ventilation openings in the battery compart ment. The minimum size of openings should be 2 square inches at the top of the compartment. Mount the battery on a strong, rigid supporting structure, where leaks and spills of battery fluid will not cause damage.

34 Generac* Power Systems, Inc.

Section 7 - Post installation

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

INSTALLATION

7.1 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.

-A WARNING A~

Do not make any unnecessary adjustments.

Factory settings are correct for most applications.

When making adjustments, however, be careful to avoid overspeeding the engine.

7.2 BEFORE INITIAL START-UP

Before starting, complete the following:

1. Check the engine crankcase oil level and, if neces sary, fill to the dipstick “FULL’ mark (cross-hatched area) with the recommended oil. Do not fill above the FULL mark.

Check the fuel supply. Gas fuel lines must have been

properly purged and leak tested in accordance with

applicalale fuel codes. All fuel shutoff valves in the

fuel supply lines must be open.

A-

lf a liquid propane (LP) gas fuel system has been

installed, it must be properly tested for leaks

before operating the system in compliance with ANSI A119.2/NFPA 501C. No leakage is permitted. You must be sure no gasoline fuel vapors enter the vehicle interior.

7. Let the unit run at no-load for a few minutes to sta bilize internal engineZ-generator temperatures. Then, shut down the engine.

NOTE:

The generator set was thoroughly tested and adjust ed at the factory before shipping. No additional adjustment should be necessary. Only qualified ser vice technicians who have been trained should per form adjustments outlined in this manual.

7.4 TESTING UNDER LOAD

Apply electrical loads equal to about 75 to 100 percent of the unit's rated wattage/amperage capacity.

Let the unit run at least 30 minutes with load applied. During this part of the test, check that the unit is not running excessively hot and that adequate cooling air flow is available. You must not allow the unit to overheat during prolonged operation.

NOTE:

The generator engine is equipped with a high tem

perature switch. 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.

7.3 INITIAL START

When you are absolutely certain that the unit has been properly installed and prepared for use, start the engine as follows:

1. Turn off all electrical loads. Do this by setting the generator’s main circuit breakers to their “OFF” (or open) position.

2. Refer to Part 1. Section 2.5, “Starting the Generator” (Page 8), for cranking and starting instructions. The

engine may require more cranking for initial start ing since the fuel lines have to be primed (use of the primer switch will shorten this time).

3. Let the engine warm up for about five minutes to

allow Internal temperatures to stabilize.

4. Carefully inspect the engine/generator for fuel, oil

and exhaust system leaks. Before proceeding to the ne.xt step, correct any leakage immediately.

5, When all tests and adjustments at no-load are com

pleted, apply electrical loads and check for proper operation under load. See Section 7.4. Run the unit

at least 30 minutes with loads applied.

6. Turn off all electrical loads by setting the generator’s

main circuit breakers to their “OFF” (or open) posi tion.

Generac® Power Systems, Inc. 35

INSTALLATION

Section 7 - Post Installation PRIMEPACT 70G and 70LP Recreational Vehicle Generators

7.5 INSTALLATION CHECKLIST

♦ LOCATION AND SUPPORT

U Generator is properly located. J Generator is properly supported. □ Generator is properly restrained.

♦ GENERATOR COMPARTMENT______________________

□ Compartment construction is proper. □ Holes/Openings are vapor-sealed. □ Compartment size is correct. □ Compartment is vapor-sealed. □ Sound insulation is correct. □ Floor cutouts are properly completed.

♦ COOLING AND VENTILATING AIR___________________

□ Airflow is adequate. □ Air inlet opening is correct. □ Compensate for restrictions.

□ Check that installation has been tested.

♦ GASOLINE FUEL SYSTEM____________

□ Fuel tank complies with all applicable codes. □ Fuel system is properly installed and checked

for leaks.

♦ OPTIONAL LP GAS FUEL SYSTEM

□ Fuel system is properly installed and checked

for leaks. □ Pressure at regulator inlet is correct. □ Rated flow of primary regulator is correct. □ All parts are properly installed. □ Fuel system is properly tested/adjusted.

________________________

____________

_________________

♦ EXHAUST SYSTEM

□ Exhaust system complies with all applicable codes. □ Exhaust system is properly and safely installed.

♦ ELECTRICAL CONNECTIONS

□ Connections comply with local code requirements

and all National Electrical Codes. □ Junction box is properly installed. □ Wiring meets all standards. □ All connections are correct. □ Conduit is properly installed and sealed. □ Generator is properly bonded to the vehicle.

♦ BATTERY INSTALLATION

□ Recommended battery is installed. □ Recommended cables are installed. □ Cables are clean and tight. □ Cables are connected properly. □ Proper ventilation is provided. □ Terminals are coated with anti-corrosion grease, and

terminal covers are positioned.

♦ OPTIONAL ACCESSORIES

□ Check that remote starRstop panels (if used) are

installed properly.

□ Check that hourmeter kit (if used) is installed

properly.

□ Check that any other options and accessories (if

used) are Installed properly.

♦ POST INSTALLATION TESTS

□ Check that all tests are completed properly.

DATE OF INSTALLATION

NAME OF INSTALLER

SIGNATURE OF INSTALLER

36 Generac’ Power Systems, Inc.

8.1 TROUBLESHOOTING GUIDE

Section 8 - Troubleshooting

PRIMEPACT TOG and 70LP Recreational Vehicle Generators

TROUBLESHOOTING

PROBLEM CAUSE

15 amp fuse blown.

Engine won’t crank.

Engine cranks, won't start.

Engine starts hard, runs rough.

Loose, or corroded or defective

2. battery cable(s).

Battery is discharged or defective.

4. Defective starter contactor.

5, Defective starter motor.

Defective Start/Stop switch.

7. Defective Engine Control Board

1. Out of fuel.

Fuel

3. Fuel pump not operating.

4. Automatic choke not operating properly.

5. Engine is flooded.

6. Fuel filter is clogged. Engine spark plugs defective..

7. Bad ignition magneto on engine.

9. Bad carburetor.

10. Dirty air cleaner.

1. Dirty engine air cleaner.

2, Automatic choke is sticking.

3. Defective spark plugs.

4. Defective ignition magneto.

shutoff

valve

is closed.

CORRECTION

Replace blown fuse.

2. Tighten, clean or replace, as necessary.

Recharge or replace battery.

Replace starter contactor.

Replace starter motor.

6. Replace switch.

7. Contact an authorized service dealer.

1. Refill fuel tank.

2. Open fuel shutoff valve(s).

3. Repair or replace pump.

4. Repair, replace or adjust. Wait 5-10 minutes; try again.

6. Replace filter if clogged.

7. Clean, regap or replace as needed.

8. Replace if defective. Adjust, repair or replace.

Clean or replace as needed.

10.

1. Clean or replace as needed.

2. Free choke linkage as needed.

Clean, regap or replace.

Replace it if defective.

Engine starts, then shuts down.

No AC output voltage.

1, Engine oil level is low.

Bad low oil pressure switch.

3. Defective high temp switch.

4. Water in fuel.

1. Main breaker(s) open.

2. Transfer switch (if so equipped) is set to wrong position.

Failure in vehicle electrical system.

3. Generator component failure.

Add oil as needed.

2, Replace, if bad.

3. Replace, if bad.

4. Drain fuel tank and refill.

1. Close main breaker(s). Reset transfer switch.

See vehicle manual.

4, Contact an authorized service facility.

Generac® Power Systems, Inc. 37

'MÌTÌÌ"'! ('(Ti (J'(i

ELECTRICAL

DATA

Section 9 — Electrical Data

PRIMEPACT 70G and 70LP Recreational Vehicle Generators Electrical Schematic - Drawing No. 0D3459

/ GREEN i

■ neutral CONNECnON BY CUSTDMtLR

VHITE

I T2

за Generac* Power Systems, Inc.

BAfrt'.Ri' CHAR Lit VlNiJiNL

PLIWCR V/INDINC

......

—

EES IIS

1 1

ELECTRONIC

vqlt age

REGULATOR

-J

DPE V[NU[NG

120V

-120V

?' 9

BLACK

BLACK RED

1.^

BC - BATTERY CHARGE

CBi - CIRCUIT BREAKER,

- CIRCUIT BREAKER,

СВР

CIRCUIT BREAKER,

- CIRCUIT BREAKER,

CB3

- CHOKE HEATER

* CH * CS

- CHOKE SOLENOID

- FUSE, 15A

ГР

- FUEL PUMP-OR-LPG SHUT OFF VALVE

- TERMINAL, GROUND 4-TAB

- METER, HOUR COPTiONAL)

НТО - SWITCH, HIGH TEMP, OIL (CLOSES ON HIGH TEMP,)

IMl - IGNITION MAGNETO - 4] CYi

[М2 - IGNITION MAGNETO - 42 CYL,(V-TV!N UNITS ONLY) LI - LIGHT, RUN (OPTIONAL)

LDP - SWITCH, LOW OIL PRESSURE (CLOSES ON LOW PRESSURE) PCB - ENGINE CONTROLLER

■ STARTER CONTACTOR

^ 240V-

STARTER MOTOR SWITCH, START/STDP

SVI

SW2 ■

SWITCH ruEL PRIMER

SP]

SPARK PLUG 41 CYL,

SPB

- SPARK PLUG 42 CYL,

TERMINAL, CONN. 4-TA3

CONNECTOR

-THESE ITEMS ON GASOLINE POWERED UNITS ONLY

GEND

25A

30A

2.5

3.0

15A

-----

----

------

-----

......

IMb2

IM66 L IM7E

IM52

iM6tS &, IM72

Section 9 — Electrical Data

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

Wiring Diagram - Drawing No. 0D3459

(T)

ELECTRICAL

DATA

Generac* Power Systems, Inc. 33

^PARTS

LISTS

Section 10 — Exploded Views and Parts Lists

PRIlVIEPACT 70G and 70LP Recreational Vehicle Generators Sheet Metal - Drawing No. 0D3465

See Carburetor Exploded View

37 \

40 Generac® Power Systems, Inc.

Section 10 — Exploded Views and Parts Lists

PRiWlEPACT 70G and 70LP Recreational Vehicle Generators

Sheet Metal - Drawing No. 0D3465

^PARTS

LISTS

ITEM

1 2 099258 1

3 4 067890 5

6 0A4456 7 8

10 11 074916 12 13 14 078858 15 16 17 19 20

22 75246 4

23 0742600133 24 088290 1 25 26 081108 27 022717B 28 29 30 077001 31 33 34 029289 35 087858B 36 37 38 39 033469 40 41 092934 1 REGULATOR-10A. 42

PART NO. QTY. DESCRIPTION

067198N

087865

086313 056893 23 087750

074908 073190

078859 074902 2 066476 073191 048571 022129

073186

022717A 2 067866

073132 2 087858A 1

050277 038153 022152 2 NO. 10 LOCK WASHER

023897 2

022158

1 1 HEX NUT 1 PLUG, FLYWHEEL ACCESS 1 3/8" SPECIAL LOCK WASHER

1 HOUSING, ENGINE TOP

1 SCROLL, FLYWHEEL

1 COVER, BASECYL#2

1 WRAPPER CYL. #2 1 COVER, VALLEY 1 WRAPPER, CYL #1

4 1 COVER, BASE CYL. #1

2 CAPSCREW, HEX HD.-IV18 x 1.25 x 15MM

2 LOCK WASHER-MS

1 WIRE ASSEMBLY-NO, 16

1 WRAPPER, CRANKCASE 1 BUSHING, SNAP 1

1 O-RING 1 PLUG, OIL FILL

2FT, FOAM TAPE

1 GROUND WIRE ASSEMBLY-CYL. #1 1 2 N0.10-32x1-1/2" SCREW

SEE ENGINE EXPLODED VIEW of ENGINE KEY-WOODRUFF 6 x 25MM BEVELLED WASHER

SCREW (CRIMPTITE) NO. 10-24 x 1/2"

SCREW (TAPTITE) MSxIOMM

WRAPPER, BARREL HHCS/LW-M6x1,0x12MM

SCREW (TAPTITE) 3/8"-16 x 1-1/4"

STARTER COVER

GROMMET-RUBBER

GROMMET -RUBBER

BOOT SPARK PLUG

GROUND WIRE ASEMBLY-CYL. #2

OIL DRAIN DECAL

0.22 INCH I.D. SPACER NO. 10 FLAT WASHER

NO. 10-32 HEX NUT

Generac* Power Systems, Inc. 4T

^PARTS

id),

LISTS

Section 10 — Exploded Views and Parts Lists

PRIMEPACT 70G and 70LP Recreational Vehicle Generators Base and Pulleys - Drawing No. 0D3464A

42 Generac* Power Systems, Inc.

Section 10 — Exploded Views and Parts Lists

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

Base and Pulleys - Drawing No. 0D3464A

FEM PART NO. QTY. DESCRIPTION

086318

2 022145

046911

3 4 025017 8 CAPSCREW, HEX HD.-3/8"-6 x 1/2" 5 022237 6 6 022129 8 LOCKWASHER5/16" -M8 7 072391 2

077603 2

8 9 022259

052858 6 NUT FLANGED LOCK-M8-1.25

10 11 051730 12 029459 2 13 075215 14 073146 15 075209

073174

16 17 079678 18 040976

072383

023897 6

20 21 075224-G 22 073106-G 1

075216

23 24 049451

25 042633 26 077017 27 073118 1 28 074906

022152

29 30 072375 31 073185

022097 6 LOCKWASHER

077682 1

33 34 075242

049813 2

35 36 045757 37

090859 048031-E 2 CLAMP, HOSE-3/8"

38 39 091123 40 045756 41 081105

087768

07571OA 1 TUBE, OIL FILL AND DRAIN

43 44 074958

067871 1 O-RING, CAP

45 46 0A5508 47

075711

48 022413

0A5802 1 TINNERMAN CLIP

1 BASE, MOUNTING 4 FLAT WASHER 5/16" -M8 4

MOUNT, (RUBBER)

LOCKWASHER-3/8"

SKID, RUBBER MOUNT 56 073179 SAFETY BOLT, 5/16"-18x 3-1/2" 57 070185

2 NUT, HEX -5/16--18

2 CAPSCR, HEX HD.-M8-1.25 x 60mm

SPRING, BELT TENSION 61 2 WASHER, SPRING CNTR, 4

SLIDE (NYLON) 2 SUPPORT, NYLON SLIDE 1 MANIFOLD, EXHAUST

2 RING, SEALING 4 SHCS, M8-1,25 x 20mm 2 GASKET, COLLECTOR PAN

FLAT WASHER #10-M5 68 087770

1 PULLEY, ENGINE

PULLEY, ALTERNATOR 1 BELT (POLY V 4L)-40” 1 WASHER, PULLEY RETAINER

7GA, ,41"x1,62" 1 HHCS, 3/8”-24x1" (GRADES) 1 GUIDE, BLOWER HOUSING

CAPSCR,, HEX HD,-3/8"-24 x 2-1/4" TAPTITE, M6-1,00x20mm

WASHER, LOCK #10 1 HOUSING, BLOWER 1 SPACER, BLOWER HOUSING 2-3/8”

'A"

-M6

CAPSCR. HEX HD.-M5-0.80 x 80mm 4 SPRING, GENERATOR SET MT

NUT, HEX M6-1.0 83 022473

2 CAPSCREW, HEX HEAD- M6-1.0 x 25mm

COVER PLATE

1 BRACKET, FUEL PUMP 9 TAPTITE, M6-1,0x10mm

5/16-18 FLANGE NUT, SPECIAL 89

2 1 FITTING, 1/8" PIPE TO

1 CAP & DIPSTICK ASSEMBLY

OIL FILL TUBE GASKET 1 PIPE, OIL DRAIN ADAPTOR 1

CAPSCR., HEX HD.-1/4-20X1"

'A"

TUBE

ITEM PART NO.

50 043790A 1

047290 52 035461 1 53 069811

54 092120 2

087769 1

58 0A8584 59

074948

60 074950

074951 1 073134 1

62 63

038750

074949 65 068548 66 0C4006 67 029289

075281 1

69 70 OC1085 2

71 043182

090088 73 075237 74

0D1624 75 075474

76 090800 77

094670 78 075226 79

056893 80 075229

81 0D3158

079246

090475

85 072384-C 1

022131 1 FLATWASHER, 3/8" -M10

077643

88 0A8475

090141 1 GROUND CABLE

0A1658

91 045756

92 ODI 227 1 CONTACTOR, STARTER

0133-74260 1

94 024414

0D1741A 1 BOOT, BATTERY CABLE

95 96 0D1741 2 BOOT, BATTERY CABLE 97

022158

QTY. DESCRIPTION

ELBOW-3/8" NPT x 3/8"

1 HOSE-3/8" I.D. #6L0LA

FITTING, BARBED-1/4" NPT

1 CAP, HEX-1/4" NPT

NUT LOCK TRIG M6-1.0Y/ZNC FILTER, FUEL

1 OIL FILTER SUPPORT

FILTER, OIL(FRAM#PH3614)

10 PSI-SWITCH, OIL PRESSURE

1 3 FiniNG-5/16" 1 TUBE, OUTER OIL

TUBE, INNER OIL ADAPTOR, OIL FILTER ADAPTER CAPSCREW, HEX HEAD

M6-1.00 X 30mm 1 FITTING, 90-DEGREE-5/16” 1 GASKET, OIL FILTER ADAPTER

CABLE, BATTERY

TAPE, FOAM-1/16”THICKx8’ LINE, FUEL

SWITCH, HIGH TEMPERATURE SCREW, PAN HEAD-M3-0.50 x 8mm

2 LOCKWASHER-M3

CLAMP, VINYL COATED

1 4 WASHER, SPRING RETAINER

BOOT, OIL PRESSURE SWITCH

BOOT, TEMPERATURE SWITCH

1 1 ELBOW, EXHAUST -UNIVERSAL

CLAMP, EXHAUST

1 COVER, AIR

22 CRIMPTITE, NO. 10-24 X 1/2"

GASKET, SLIDE PAN

1 1 SLIDE PAN

CAPSCREW, HEX HEAD

M6-1.00X 16mmWITH LOCKWASHER

7 FLATWASHER, H" -M6

! PUMP FUEL

COVER, EXHAUST OUTLET

GASKET, EXHAUST OUTLET

SPECIAL LOCKWASHER, M5

SPECIAL LOCK WASHER, W"

TAPTITE, M6-1.00x10mm

CABLE, STARTER

2 HEX NUT, 5/16”-24 STEEL

HEX NUT, #10-32 STEEL

Generac® Power Systems, Inc. 43

.PARTS

LISTS

Section 10 — Exploded Views and Parts Lists PRIMEPACT TOG and 70LP Recreational Vehicle Generators

Alternator and Panel - Drawing No. 0D3463

10 13

lA-

. TO ENGINE 20

GROUND

"fV r

44 ' 14/ '"'

45 54 "

-J ;■■■

48 44

44 45

<44 Generac* Power Systems, Inc.

0\„

27 26

I K

V, 30

0*.

52,53

Section 10 — Exploded Views and Parts Lists

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

Alternator and Panel - Drawing No. 0D3463

PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION

TEM

C9675

80095H 3 92848H 1 4

73159

31971

5 6 C9674

77006

8 52858

66386 10 66849 11

27756 12 86314 13

A8475 14

D2724

15 22097 4 '/47 M6-LOCK WASHER 44

1 LOWER BEARING CARRIER 30 75476 1 ROTOR ASSEMBLY

STATOR ASSEMBLY 1 BALL BEARING 33 1

BALL BEARING 1

UPPER BEARING CARRIER 35 75235 4

STUD-STATOR 4 M8-1.25 FLANGE LOCK NUT 1

BRUSH HOLDER 38 49815

2 M5-0.8X 16LG.TAPT1TE 39 43182 2

4 NYLON WASHER 40 1

GENERATOR TOP HOUSING

3 M5-SPECIAL LOCK WASHER 42

2 BOOT, ROCKER SWITCH

22264 6 #8/ M4-LOCK WASHER

38077

90987 2 M3-0.5X 12LG. PPHMS 86317A 1 PANEL SUPPORT BRACKET

82737

36 37

49813 4

45771 4

41 54502

90157 83049

22152 6 16 31791 1 CLAMP, HOSE 45 51716 17

90141

A1658

74906 92234 1

20 21

93846

22129 23 23484-S 24

86316A 1 25

53650

C4887 1 SEALTITE CONDUIT ASSEMBLY 54 87798

26 27

75244 1 ASSEMBLY, REMOTE CABLE 55 92113 28 74908 29 23897 1 #10/M5-FLAT WASHER

GROUND CABLE 46

1 M6-SPECIAL LOCK WASHER

51715 82081

4 M6-1.0X20 LG.TAPTITE 48 25105

CONTROLLER P.C.B.

1 DECAL, CUSTOMER CONN. 50

5/167 M8 LOCKWASHER

BUSHING

49 86315 1

90734 4

51 22985 3

PANEL SHEET METAL 52 32300 1

4-PIN CONNECTOR 53

1 M5-0.8X10LONGTAPTITE 56

22676

75210-A 1

57 A8475-A 1

M4-0.7X 16LG. CAPSCREW

CIRCUIT BRACKER 15A.

M5-0.8X30 LG. CAPSCREW

4 4 VIBRATION MOUNT

M6-1.0 HEX NUT

1 M5-08X 16LG.HEX HD. CAPSCR.

M3-LOCK WASHER M8-1.25 HEX NUT

1 C/BREAKER 3.0A

1 DECAL, CB RATING 30A.

1 REGULATOR VOLTAGE

M5-LOCK WASHER

4 M5-0.8 HEX NUT

1 M4-0.7 HEX NUT

C/BREAKER 30A.

4 #6-32 X 'A" SCREW W/LOCK WASHER

PANEL COVER M4-0.7 X 12 LG, CAPSCR.W/LOCK-

WASHERS FLAT WASHER

#6-FLAT WASHER FUSE HOLDER FUSE AGC-15A,

1 1 SWITCH S.P.D.T. 6A.-(START-STOP)

SWITCH S.PD.T.-(FUEL PUMP)

TERMINAL BLOCK #8 SPECIAL LOCK WASHER

Generac* Power Systems, Inc. 45

^PARTS

LISTS

Section 10 — Exploded Views and Parts Lists

PRiMEPACT 70G and 70LP Recreational Vehicle Generators Exploded View - Engine Common Parts - Drawing No. 079216-F

46 Benerac® Power Systems, Inc.

Section 10 — Exploded Views and Parts Lists

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

Exploded View - Engine Common Parts - Drawing No. 079216-F

.^PARTS

LISTS

PART NO.

TEM

069331 1 CYLINDER ASSEMBLY

*2 069333 1

067805

079234 1 NO, 1 CYLINDER HEAD ASSEMBLY

079235

6 070169

7 069332 2 CYLINDER HEAD GASKET 8 0851100104 1 BREATHER ASSEMBLY 9 072315 1 BREATHER GASKET

10 089967 11 070596 12 069336 13 069325 8 CYLINDER HEAD BOLT 14 067888 2 3/8" NPT OIL DRAIN PLUG

072334 1

15 16 075247 1 OIL SUMP ASSEMBLY 73 17

067924 18 067878 9 OIL SUMP BOLT 19

075248 20 075249 2 STANDARD PISTON RING SET 21 069327 4 PISTON LOCKING RING

22 075250 23 075251 2 CONNECTING ROD ASSEMBLY 24 072346 25 069316 2 EXHAUST VALVE 26 069317 2 INTAKE VALVE 86 069341 27 067816 4 28 069320 4 VALVE SPRING RETAINER 89 29 070513 4 30 070584 31 070530 1 CAMSHAFT ASSEMBLY 92 070547

32 072358 1 INTAKE MANIFOLD 93 33 069379 2 CARBURETOR MOUNTING GASKET 94 070577 34

067895 070594 2 CARBURETOR MOUNTING BOLT 97 070566 4

36 067158 4 INTAKE MANIFOLD MOUNTING BOLT 37 068574 1 38

068554A 39 068573 40 070506 1 OIL GALLEY 0-RING 41 070554 1 42 070568 4 ROCKER ARM STUD 43 075253 4

QTY. DESCRIPTION

SLEEVE BEARING

OIL SEAL

1 NO, 2 CYLINDER HEAD ASSEMBLY 51 4

SEALING WASHER

BREATHER SCREW

BREATHER TUBE

OIL SUMP GASKET

CRANKSHAFT ASSEMBLY

1 OIL SEAL ASSEMBLY 74

STANDARD PISTON ASSEMBLY

STANDARD PISTON RING

CONNECTING ROD BOLT

VALVE SPRING

VALVE KEEPER

VALVE TAPPET

INTAKE MANIFOLD GASKET

1/8" NPT PLUG PIPE 1 GOVERNOR SHAFT SEAL 100 091481 1 1

OIL PUMP 0-RING

CARBURETOR SPACER

WASHER VALVE COVER SEAL

ITEM PART NO.

067885

45 075254

070535 1

46 47 0C2881

072536 072347 2 SPARK PLUG

52 53 075258 57

066480 59 072361 60 072362 1

070199 1 BREATHER BAFFLE

62 072366 64 072365 65 068555 66 067806

068572

075272 2 75 070122

76 067910 78 067813

81 070592 1 AIR CLEANER BASE

073123 83 070593 84 0C3633

85 067156

070597 1 AIR INLET TUBE

072305 90 067920

91 069328

070536 1 GOVERNOR SLIDER

95 070599

98 075271 1 VALVE OVERHAUL KIT

067897 2 EXHAUST GASKET (NOT SHOWN)

101 091480

102 0D1198

'Not Shown

QTY.

DESCRIPTION

4 M6 NYLON NUT 4 VALVE ADJUST SCREW

OIL SCREEN STARTER MOTOR (NOT SHOWN)

4 IGNITION ARMATURE SCREW

1 ENGINE GASKET KIT

1 AIR CLEANER GASKET

1 GOVERNOR SHAFT BUSHING

GOVERNOR SHAFT BUSHING

1 COTTER PIN

GOVERNOR SHAFT WASHER

2 CRANKCASE DOWEL

CYLINDER HEAD DOWEL

4 2

OIL PUMP SCREW SPARK PLUG TERMINAL

4 VALVE STEM SEAL

2 INTAKE VALVE SEAT

4 VALVE GUIDE

1 AIR FILTER (NOT SHOWN) 1 AIR CLEANER COVER 1

AIR CLEANER COVER SCREW

AIR CLEANER BASE SCREW

1 FOAM PRE-CLEANER

BREATHER DEFLECTOR

2 VALVE COVER GASKET 2 VALVE COVER 1 OIL PUMP ASSEMBLY

4 PUSH ROD 4 ROCKER ARM

ROCKER ARM SUPPORT

GASKET AND CAP ASSEMBLY

ROCKER ARM COVER

GOVERNOR CRANK

Generac^ Power Systems, Inc. ‘4“7

^PARTS

LISTS

Section 10 — Exploded Views and Parts Lists

PRIMEPACT TOG and 70LP Recreational Vehicle Generators Carburetor - Drawing No. 093753-G

<4S Generac® Power Systems, Inc.

Section 10 — Exploded Views and Parts Lists

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

Carburetor - Drawing No. 093753-G

^PARTS

LISTS

ITEM

PART NO.

073112B 1 Carburetor Assembly 074962C 074962G 1

3 4 5

070155 1 070108 1

056893 5 6 074961 1 7 047227 8

037398 9 073131 1

10 11 12 13

066476

070575

070125

073374 1

14 074947 15 089473 1 16 17 18

091306

077091 1

031879

19 022159 4

*20

21 22

089870

072536

087770

23 074946 1 25

030340

26 0C2338B 1

0C2338 1

091352C

27 075252 28 0A7782A 1 29 30 31

040173

066829

075944 1

32 070594 33 077075

QTY.

1 1

2 2 1

4 1

1 1

2 2

DESCRIPTION

Spring, Governor (PP55, PP66) Spring, Governer (Q-70G) Lever, Governor

Rod, Governor to Carburetor Screw, (Crimptite) - #10-24 X 1/2” Bracket, Governor Adjuster Screw, Governor Adjuster Nut, Hex Lock (Nylon) Bracket, Air Cleaner Support Screw, Hex - M6-1.0 X 12MM Screw, Hex - M6-1.0 X 25MM Spring, Anti-Lash Bracket, Choke Support Rod, Choke Control Bi-Metal Assembly, Choke Solenoid, Choke Hair Pin, Cotter Flat Washer - #4 Lock Washer - #4 Solenoid, Fuel Shutoff (Q-70G Only) Screw, Pan HD. Mach. - #4-40 X 1/4” Line, Fuel - 5/16” I.D. Link, Choke Hose, Fuel, 4.5” LG. Decal, Air Cleaner Primepact 66G Decal, Air Cleaner Primepact 55G Decal, Air Cleaner Q-70G Kit, Carburetor Overhaul - Not Shown Flywheel Assembly

Clamp, Hose (Screw Type)

Rivet - 1/8” Diameter X 1/8” Long Bracket, Governor Spring

Capscrew, Hex HD. - M6-1.0 X 93 LG. w/washer Cover, Choke Coil

* Not Shown

Cenerac* Power Systems, Inc. 43

Section 10 — Exploded Views and Parts Lists

PRIMEPACT 70G and 70LP Recreational Vehicle Generators LP Regulator, LP Carburetor & Air Cleaner - Drawing No. 0A4029-F

ITEM PART NO. QTY.

1 0A1662A 2

057822 2 HOSE CLAMP 074962G 1

074994 1

026307 4 5 026915 6

075211 1 GASEOUS FUEL REGULATOR 0C2338A 1 7

0A2666 1

1 GARB, V-TWIN L7P

1 3/4" PIPE NIPPLE 0C2338C 1

8 0A5198 1 9 049813

022097 4

11 047411 12

038750 2

13 037398 14

074961 1

056893

047227 1

50 Generac® Power Systems, Inc.

4 M6 HEX NUT 22 070155 1 GOVERNOR LEVER

2 M6-1.0X16MM HEX HD. CAPSCR. 24

1 HEX LOCK NUT (NYLON) +

5 #10-24X1/2" SCREW 27 073131 1 AIR CLEANER SUPPORT BRACKET

DESCRIPTION

1/2" I.D.X 10" LONG HOSE 18 STREET ELBOWS 19 0C2338E

GASEOUS FUEL SOLENOID REGULATOR MOUNTING BRACKET 21

M6 LOCK WASHER 23 076242 2

M6-1.0 X 30MM HEX HD CAPSCR. 25 070108 1

GOVERNOR ADJUSTER BRACKET

GOVERNOR ADJUSTER SCREW

ITEM PART NO. QTY.

20 075944 1 GOVERNOR SPRING BRACKET

28 061696 1

074962C

066476 2

0A7782A

070125

028739

1 ANTI-LASH SPRING

4 4" LONG TIE WRAP

055162 9CC

(-^) NOT SHOWN

DESCRIPTION

GOVERNOR SPRING (PP55G/LR PP66G/LP) GOVERNOR SPRING (PP70G/LR Q70G) M6-1.0 X 12MM HEX SCREW W/LOCK WASHER AIR CLEANER DECAL-PRIMEPACT 70LP AIR CLEANER DECAL-PRIMEPACT 66LP AIR CLEANER DECAL-PRIMEPACT 55LP

FLYWHEEL ASSEMBLY

1/8" I.D. X 1/8” RIVET

GOVERNOR-TO-CARBURETOR ROD

PIPE SEALANT

BARBED 90 DEG. 3/8" X 1/2"

Section 11 — Notes

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

NOTES

Generac* Power Systems, Inc. 51

Section 12 - Warranty

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

Tlic California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power Systems. Inc. (Cfcnerac). are pleased to explain the Emission Control System Warranty on your new engine.* New utility, and lawn and garden cciuipment engines must be designed, built and equipped to meet stringent anti-smog stan dards for the state of California and the federal government. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improp er maintenance of your engine.

Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair

your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted. If, dur ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or

workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory

supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure

the completion of all scheduled maintenance. As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or

responsibility if your engine, or a part/component thereof has failed due to abuse, neglect, improper maintenance or unap proved modifications, or the use of counterfeit and/or ‘grey market’ parts not made, supplied or approved by Generac.

You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a prob lem occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System 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. Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty ser vice, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner shall

be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the

inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the fol lowing address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, Wl 53190

Part 1

52 Generac® Power Systems, Inc.

Section 12 - Warranty

PRIMEPACT 70G and 70LP Recreational Vehicle Generators

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Wai-ranty) 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 sliall contin ue for 24 consecutive months thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or

equipment, and to each subsequent purchaser/owner, that each of its engines is ... (1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant

to their respective authority, and

(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a war

ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine manu facturer's application for certification,

(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner's

Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted, emissions-related part that is scheduled only for regular inspection as .specified in the Owner's Manual

shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner's

Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related paid.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no

charge to the owner at a Generac Authorized Warranty Service Facility,

(5) When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsi

ble for diagnostic costs if the repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused

by a failure under warranty of any emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient

to meet the expected demand for such emission-related parts,

(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS

Warranty maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac's ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or ‘grey market' parts may not be used to modify or repair a Generac

engine. 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' paid.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

1.1) Gasoline carburetor assembly and its internal components (if so equipped).

a) Fuel filter (if so equipped) b) Carburetor gaskets c) Fuel pump (if so equipped)

1.2) LPG carburetion assembly and its internal components (if so equipped).

a) Fuel controller (if so equipped) b) Mixer and its gaskets (if so equipped) c) Carburetor and its gaskets (if so equipped) d) Primary gas regulator (if so equipped)

2) Air Induction System including; a) Intake pipe/rnanifold b) Air cleaner

3) Ignition System including: a) Spark plug b) Ignition module

4) Catalytic Muffler Assembly (if so equipped) including: a) Muffler gasket b) Exhaust manifold

5) Crankcase Breather Assembly including; a) Breather connection tube

e) LP liquid vaporizer (if so equipped)

‘Generac engine types covered by this warranty statement include the following:

1) Utility

2} Lawn and Garden Equipment

3) Recreational Vehicle (RV) Generator

4) Industrial Mobile (IM) Generator

Part 2

Generac* Power Systems, Inc. 53

Section 12 - Warranty PRIMEPACT 70G and 70LP Recreational Vehicle Generators

GENERAC POWER SYSTEMS' THREE-YEAR LIMITED WARRANTY

FOR RECREATIONAL VEHICLE GENERATORS

NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a i)eriod of 3 (iJirec) years or 2.000 (two tliousand) liours of operation from the date of original sale, wliichever occurs first. Generar Power Systems, Inc, (Generar) will, at Us option, rejrair or replace any part which, upon examination, inspection and testing by Generac or :i Generttc Authorized Warranly Service Fticility, is found to be defective under normal use and service, in accordance with the warranty schedule sel forth below. Any ecjuipment that the purchaser/owner claims to be defective must be returned to and examined by tlie nearest Generac Antlioi ized Warranty Service Facility. All transportation costs under the warranty, including return to die factory, are to be borne and prepaid by the purchaser/owner, 'Phis warranty applies only to Generac generators sold and rated for “Recreational Vehicle" (RV) appli cations, as Generac luis defined Recreational Vehicle generator applications. This warranty is effective only upon Generac’s receipt, from the original purchaser/owner. of a completed Warranty Regislration Card. This card is the only valid registration identification and must Ire irresenled at time of request for warranty service. Claims will not be accepted without presentation of the Warranty Registration Card. The factory recommends exercising the unit one half-hour every season.

WARRANTY SCHEDULE - COMMERCIAL APPLICATIONS

YEAR ONE - 100% (one hundred percent) coverage on part(s), labor, removal and réinstallation listed:

’ Engine - All components

• Alternator - All components

• Transfer System - All components

WARRANTY SCHEDULE - CONSUMER/PERSONAL APPLICATIONS

YEARS ONE AND TWO - 100% (one hundred yrercent) coverage on part(s), labor, removal and reinstallation listed:

• Engine - All components

• Alternator - All components

• Transfer System - All components YEAR Three - 100% (one hundred percent) only on selected part(s) and labor listed (Any labor and part(s) not listed, and removal and réin

• Rotor, Stator, Conijiuter Control Board, (if applicable with regard to Üie generator) Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Valve,

Valve Lifler(s), Intake and Exliaust Manifolds

The drive train belt and pulleys (if so equipped) on generators used in recreational vehicles shall be warranted against failure due to defec

tive materials or normal usage for tire life of the generator. For the original purchaser/owner. this drive ti'ain warranty shall include part(s) and labor (removal and reinstallation are not included) plus $50 (fifty dollars - U.S.) payment upon return of the failed belt or pulley by Die original purcliaser/owner. For subsequent purchaser/owner, this drive train warranly sliall cover belt and pulley part(s) ONLY (labor not included). Labor, removal and reinstallation is the responsibility of the subsequent purchaser/owier.

Generac RV generators manufactured prior to December 31, 1997. DO NOT have a transferable warranty. Generac RV generators manu factured after January 1, 1998, have a transferable warranty to tlie second owner ONLY for the remainder of the three-year limited war ranty. Proof-of-purchase is required and must be presented to a Generac Authorized Warranly Service Facility prior to the performance of any warranty service.

All warranty expense allowances are subject to the conditions defined in Generac's super se^'^ice information manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING;

• Costs of normal maintenance, adjustments, installation and start-up.

• Failures caused by any contaminated fuels or oils.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As wiUi all mechanical devices, the GN-Series engines need periodic part(s) service and replacement to perform well. This warranty will not cover

repair when normal use has exhausted the life of a part(s) or engine.

“ Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing,

lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane,

• Products tliat are modified or altered in a manner not authorized by Generac in writing,

• Any' incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replace

ment of die defective part(s),

• Failure due to misapplication.

• Teleplione, telegraph, teletype or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within tlie terms of a specific unit warranty period.

• Rental equipment used while warranty repairs are being performed.

• Overnight freight costs for replacement parfls).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

i'HIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC MAKES NO OTHER WARI/ANTIES AS TO THE MERCHANI'ABILITY OR FITNESS FOR A PARTICULAR PURPOSE, -Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE, IN NO EVENT SHALL GEN ERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAIMAGES ARE A DIRECT RESULT OF GEN

ERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so Uie above limita tion may not apply to you. Purchaser/owner agrees to make no claims against Generac based on negligence.

This warranty gives you specific legal rights. You also may have other rights that vary from state to state.

Part No. CSBO-l

stallation are the owner's responsibility):

FOR THE LIFE OF THE RECREATIONAL VEHICLE GENERATOR (IF SO EQUIPPED)

GEMERAC®

P.O.

BOX

POWER SYSTEMS, INC.

S • WAUKESHA, Wi

Revision O (04/16/01) Printed in U.S.A.

531 S7

Generac Power Systems 000595-1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual