Generac Power Systems 009592-4 User Manual

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POWER SYSTEMS, INC
Air-cooled Recreational
Vehicle Generators
• Model: 009592-4 and 009735-4
PRIMEPACT 55G and 55LP
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INTRODUCTION
♦ READ THIS MANUAL THOROUGHLY
If you do not understand any portion of this manual, contact Generac or your nearest Generac Authorized Service Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or care lessly. Observe them carefully. Their definitions are as follows:
______________
DANCER
After this heading, you can read instructions that, if not strictly complied with, will result in personal injury or property damage.
--------Mk WARNING ik
After this heading, you can read instructions that, if not strictly complied with, may result in person al injury or property damage.
------
Jk CAUTION ik
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 special instructions while performing the service are essential to preventing accidents.
Four commonly used safety symbols accompany the Danger, Warning and Caution blocks. The type of information each indicates follows:
This symbol points out important safety infor
A
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.
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-----------
A
^ 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 009592-4 and 009735-4. 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
Generac* Power Systems, Inc.
To locate the GENERAC AUTHORIZED SERVICE
DEALER nearest you, please call this number:
1-800-333-022
ONLY DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
Table of Contents
PRIMEPACT 55C and 55LP 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
Authorized Service Dealer Locator Number
Safety Rules...................................................................................................2
Section 1 - General Information
.........................................................
........................
................................................................
IFC IFC
1.1 Generator Identification ....................................................4
1.2 Generator Applicability
1.3 Installation
........................................................................
.....................................................
1.4 Safety ................................................................................. 5
1.5 Generator AC Connection System.....................................5
1.6 Specifications ....................................................................6
1.6.1 Fuel Requirements
1.6.2 Engine Oil Requirements
.................................................
.......................................
1.6.3 Engine Specifications .............................................6
1.6.4 Emissions Compliance Period
1.6.5 Generator Specifications
Section 2 - Operation...................................................................................7
...............................
.........................................
2.1 Generator Control Panel.....................................................7
2.1.1 Fuel Primer..............................................................7
2.1.2 StartyStop Switch....................................................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 ......................................................7
2.3.2 Prechoke..................................................................8
2.4 Before Starting the Engine ................................................8
2.4.1 Installation...............................................................8
2.4.2 Engine Lubrication .................................................8
2.4.3 Fuel Supply
.............................................................
2.4.4 Cooling and Ventilating Air ...................................8
2.4.5 Engine Exhaust Gas
2.5 Starting the Generator
...............................................
.......................................................
2.6 Stopping the Generator...................................................... 9
2.7 Applying Loads to Generator ............................................9
2.7.1 Letting the Engine Stabilize ...................................9
2.7.2 Do Not Overload the Generator
.............................
2.8 Protection Systems.............................................................9
2.8.1 Low Oil Pressure Switch
2.8.2 High Temperature Switch
........................................
.....................................
10
2.8.3 Field Boost............................................................10
2.8.4 Overvoltage Protection
2.8.5 25-Hour Break-in Period
2.8.6 25-Hour Checkup
2.8.7 Operation in High Grass or Brush
Section 3 - Maintenance
........................................................................
3.1 Checking the Engine Oil Level
3.2 Changing the Engine Oil and/or Oil Filter
3.3 Maintaining the Engine /Ur Cleaner
3.3.1 Cleaning the Foam Precleaner
........................................
......................................
.................................................
........................
.......................................
......................
...............................
..............................
10
10 11 11
....11
11 11 12
12
3.4 Clean Air Intake Screen ..................................................12
3.5 Checking the Engine Spark Plug
.....................................
12
3.6 Fuel Filter (Gasoline Only) .............................................13
3.7 Spark /U-restor Muffler
3.8 Cleaning the Generator
3.9 Battery Maintenance
...................................................
....................................................
.........................................................
13
13
13
3.9.1 Weekly ................................................................. 13
3.9.2 Every Six Months
.................................................
13
3.10 Major Service Manual......................................................14
3.11 Drive Belt.........................................................................14
3.12 Exercising the Generator .................................................14
3.13 Out of Service Procedure
3.13.1 Removal From Service
3.13.2 Return to Service
3.14 Wattage Reference Guide
Section 4 - Notes.........................................................................................16
................................................
......................................
...............................................
................................................
14
15
15
14
Part II — Installation Instructions...........................................................17
Safety Rules...........................................................................................18-19
Section 5 — General Information
...........................................................
20
5.1 Purpose and Scope of the Manual....................................20
5.2 Safety ................................................................................20
5.3 Standard Booklets
5.4 Equipment Description
5.5 Generator Engine Operating Speed
4
5 5
5.6 Generator AC Connection System...................................20
Major Dimensions and Features
Section 6 - Installation.......................................................................22
6.1 Location and Support.......................................................22
6.1.1 Generator Location
6.1.2 Generator Supports
6.1.3 Suspended Mounting
............................................................
....................................................
.................................
......................................
...............................................
..............................................
...........................................
20 20 20
21
22 22 22
6.1.4 Generator Restraint ..............................................23
6 6
6 6
6.2 Generator Compartments.................................................23
6.2.1 Compartment Size
6.2.2 Compartment Construction
6.2.3 Sound Insulating Materials
6.2.4 Acoustics
...............................................................
6.2.5 Compartment Floor Cutouts
.................................................
...................................
...................................
.................................
24 25
23 23
24
6.3 Cooling and Ventilation...................................................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
7 7
6.4 Gasoline Fuel System .......................................................27
6.4.1 Fuel Tank
.............................................................
28
6.4.2 Generator Fuel Supply Line .................................28
6.4.2.1 Rigid Fuel Lines............................................28
6.5 LP Gas Fuel System
6.4.2.2 Flexible Fuel Lines
.........................................................
.......................................
28
28
6.5.1 Parts not included in Fuel System ........................28
6.5.2 Some Important Considerations............................29
8
6.5.3 Vapor Withdrawal.................................................29
6.5.4 Primary Regulator.................................................29
8 8
6.5.5 Gaseous Carburetion ............................................29
6.5.6 Fuel Supply Lines
.................................................
30
6.5.7 Excess Flow Valve................................................30
6.5.8 Leakage Tests........................................................30
6.6 Exhaust Systems
9 9
6.6.1 Mufflers and Spark /Wrestors...............................31
6.6.2 Type of Exhaust System
6.6.3 Exhaust System Safety
6.7 Electrical Connections ......................................................31
6.7.1 Electrical Junction Box
6.7.2 Wiring
6.7.3 Generator AC Connections
..............................................................
.......................................
.........................................
.........................................
...................................................................
...................................
30 31
31
31 32 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 ..........................33
6.8 Battery Installation...........................................................34
6.8.1 Recommended Battery..........................................34
6.8.2 Battery Cables ......................................................34
6.8.3 Battery Cable Connections
..................................
34
6.8.4 Battery Compartment............................................34
6.9 Optional Accessories
.......................................................
34
6.9.1 Remote Panel Models .........................................35
Section 7 — Post Installation
7.1 Post Installation Tests
7.2 Before Initial Start-up
7.3 Initial Start
.......................................................................
7.4 Testing Under Load
7.5 Installation Checklist
Section 8 - Troubleshooting
.................................................................
......................................................
......................................................
.........................................................
......................................................
.............................................................
35
35 35 35 35 36
37
8.1 Troubleshooting Guide......................................................37
Troubleshooting Notes ....................................................38
Section 9 - Electrical Data
Section 10 - Exploded Views and Parts Lists
Section 11 - Notes............................................................................38 & 51
Section 12 - Warranty
........................................................................39
.......................................................
Generac® Power Systems, Inc. 1
................................
52-Back Cover
40-50
SAFETY RULES
operation be copied and posted in potential hazard areas of the recreational vehicle,
Safety should be stressed to all operators and potential operators of this equipment.
A
Safety Rules
PRIMERACT 55C and 55LP Recreational Vehicle Generators
SAVE THESE INSTRUCTIONS - The manufacturer suggests that these rules for safe
■n

WARNING:

The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.

WARNING:

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 you use a procedure, work method or operating tech nique Generac does not specifically recommend, you must satisfy yourself that it is safe for you and others. You also must make sure the procedure, work method or operating technique that you choose does not render the generator unsafe.
DANCER
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
A
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.
GENERAL HAZARDS
For safety reasons, Generac recommends
that the installation, initial star.t-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.
A
tSenerac” Power Systems, Inc.
Safety Rules
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
SAFETY RULES
A
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, 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.
A
A
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 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.
A
A EXPLOSION HAZARDS A
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. 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 I - General Information
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
1.1 GENERATOR IDENTIFIGITION
Please record the following information from the generator DATA DECAL or information decal.
1. Model Number
3. kW Rating
5. Phase________________________________ 6. Hertz
________________________
____________________________
2. Serial Number
4. Rated Voltage ___________________________________
____________________________
____________________________
REFERENCE NUMBER IDENTIFICATION
1. Generator Air Intake Screen
2. Data Plate
8. Starter Contactor
9. Fuel Inlet
3. Engine StartyStop Switch 10. Fuel Primer Switch
4. 15 amp FUse
5. 20 & 30 amp Circuit Breaker
6. Optional Remote Panel Receptacle
7. Generator AC Output Leads
Generac* Power Systems, Inc.
11. Fuel Pump
12. Oil Filter
13. Oil Drain Plug
14. Oil Dipstick and Filler Tube
Section 1 - General Information
PRIMEPACT 55G and 55LP 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.
DANCER
For fire safety, the generator must have been
A
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 55G: 120 and/or 240 volts, single phase, 60 Hz electrical loads. These loads can require up to 5500 watts (5.5 kW) of power, but cannot exceed 45.8 AC amperes of current at 120 volts or exceed 22.9 AC amperes at 240 volts.
• PRIMEPACT 55LP: 120 and/or 240 volts, single phase, 60 Hz electrical loads. These loads can require up to 5200 watts (5.2 kW) of power, but cannot exceed 43.3 AC amperes of current at 120 volts or exceed 21.6 AC amperes at 240 volts.
------
Ml caution
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.
---------------
1.3 INSTALLATION
This Owner’s Manual has been prepared under the
assumption that a competent, qualified technician installed the generator into an industrial vehicle. We also assume the installer complied with all applicable codes, standards and regulations pertaining to instal lation.
An INSTALLATION MANU/VL was shipped with the generator. That Manual contains manufacturer’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-compliance with applicable 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 SAFETY 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.
The generator may have been installed so that units
only power 120 volts AC loads (Figure 1); or you can wire them to connect both 120 and/or 240 volts AC electrical loads. Be sure to remove the Jumper between the circuit breakers when connecting for
120/240 volts.
Figure 1.1 - Connection for 120 Volts Only
Generac® Power 5yst:ems, Inc.
GENERAL
INFORMATION
Section 1 - General Information
PRIMEPAa 55C and 55LP Recreational Vehicle Generators
1.6 SPECIFICATIONS
♦ 1.6.1 FUEL REQUIREMENTS
This generator is equipped with a gasoline fuel system
as standard equipment. Specific installations may pro vide either a separate fuel tank for the generator, or the generator may “share” the vehicle engine’s fuel tank.
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 imleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits.
------
Jk CAUTION Jk
Generac does not recommend using any
gasoline containing alcohol (such as "gasohol").
A
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.
-----------
_______________
♦ 1.6.5 ENGINE SPECIFICATIONS_________________
Type of Engine
PRIMEPACT 55G/55LP................................................GN-480
CooUng Method Rated Horsepower
PRIMEPACT 55G/55LP Displacement
PRIMEPACT 55G/55LP
Compression Ratio............................................................8.6 to 1
Cylinder Block.............................Aluminum w/Cast Iron Sleeve
туре of Governor ................................Mechanical, Fixed Speed
Engine Governor Speed................................................2500 rpm
Air Cleaner Starter
............................................................
Ignition System Recommended Spark Plug
Champion
AC......................................................................................R45S
FfamAutollte
Spark Plug Gap
Recommended Min. Battery...............400 Cold Cranking Amps
♦ 1.6.4 EMISSIONS COMPLIANCE PERIOD
.........................................................
.........................................
..................................................
..........................
........................
....................................................................
.........................................................................
...........................................
Paper Element w/Foam Precleaner
12-volt DC Electric
Solid-state w/Flywheel Magneto
0.030 inch (0.8 mm)
Air-cooled
15 at 3600
480cc
RC12YC
65
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, В=500 hours, and A=1000 hours.
♦ 1.6.5 GENERATOR SPECIFICATIONS
SERIES
Rotor RPM 3600 Rotor Poles Engine RPM 2500 Rated Max. Continuous AC Output* * Voltage* Rated Max. Continuous Current* 45.8 AC ampsf 43.3 AC amps N Phase 1 Freguencv 60 Hertz Battery Charging Current (Max.) 2 amps (trickle charge) 2 amps (trickle charge) Weight Length 25 inches Width 18.5 inches Height 16.13 inches 16.13 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 I Rated maximum continuous current at 240 volts is 22.9 amps. N Rated maximum continuous current at 240 volts is 21.6 amps.
B Generac* Power Systems, !nc.
PRIMEPACT 55G
2 2
5500 watts (5.5 kW) 5200 watts (5.2 kW)
120 120
211 pounds
PRIMEPACT 55LP
3600 2500
1
60 Hertz
214 pounds
25.75 inches
18.5 inches
Section 2 - Operation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
OPERATION
фо
2.1 GENERATOR CONTROL PANEL
The following features are mounted 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 10 seconds to bring fuel from the tank to the fuel pump. This rocker type switch springs back into its original position when
you release it.
♦ 2.T.2 START/STOP SWITCH
To crank and start the engine, hold this switch in the START position. Release the switch 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 RUN position.
♦ 2.1.5 15 AMP FUSE____________________________
The fuse protects the engine’s DC control circuit 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.
___________________________
____________________
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 me ter, generator run lamp and a wire harness.
Figure 2.2Optional Remote Panel
(Models 004057 and 004184)
♦ 2.1.4 LINE BREAKERS
Protects generator’s AC output circuit against overload, i.e., prevents unit from exceeding wattage/amperage capacity. This unit has one 20-amp and one 30-amp breaker.
Figure 2.1 - Typical Control Panel
FUSE
ISA
STOP FUEL
PRilVIER
IVIAII4I
BREAKER
2.3 AUTOIVIATiC CHOKE
This engine is equipped with an automatic choke that consists of two main components: a choke solenoid and prechoke.
♦ 2.3.1 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/choke off) until the engine starts. The choke solenoid thus opens and closes the carburetor choke valve only
when the engine is cranking. When the engine starts,
the choke stops cycling.
________________________
Generac* Power Systems, Inc.
OPERATION
Section 2 - Operation
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
♦ 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.
♦ 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.
------
-Jk CAUTION Jk
Any attempt to crank or start the engine before
you have properly serviced it with the recom
A
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:
----------
♦ 2.4.5 ENGINE EXHAUST GAS
Before starting the generator engine, you should be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals. Close windows, doors and other openings in the vehi cle that, if open, might permit exhaust gases to enter the vehicle.
____________________
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:
Generac* Power Systems, Inc.
Section 2 - Operation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
OPERATION
(Six
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.
--------
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.
4.
Let the engine run at no-load for a few minutes to stabilize and warm up.
5.
Turn ON electrical loads using the means provided (such as a main circuit breaker or transfer switch).
A
2.6 STOPPING THE GENERATOR
1. Turn OFF all electrical loads using the means provided (such as a main circuit breaker or transfer switch).
2. Let generator run at no-load for a few minutes, to stabilize internal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position. 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.
• 2.7.2 DO NOT OVERLOAD THE GENERATOR
You can read the rated wattage/amperage capacity of your generator on the generator data decal (see
Section 1.1 on Page 4).
Applying electrical loads in excess of the unit’s rated capacity will cause the engine/generator to automati
cally shut down.
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 starting). 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 that will be operated by the generator.
• Do not apply heavy electrical loads for the first two
or three hours of operation.
2.8 PROTECTION SYSTEMS
• 2.8.1 LOW OIL PRESSURE SWITCH______________
This switch (Figure 2.3 on page 10) has normally open (N.O.) contacts that are held open by engine oil pressure during cranking and operating. Should oil
pressure drop below a preset level, switch contacts
close, and the engine automatically shuts down. The
unit should not be restarted until oil is added.
Generac* Power Systems, Inc.
OPERATION
Section 2 - Operation PRIMEPACT 55G and 55LP Recreational Vehicle Generators
♦ 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
CLOSEST TO
BEARINO
♦ 2.8.4 OVERVOLTAGE PROTEQION
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
I
----
a-iH—^(IIRECr 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 25­hour break-in period, follow this procedure:
• Run the unit at var^ng 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.
-SENSIH6
(+) -iTfl ROIDR
-----
hfROMSTRTOR
^ EXCITATION WINBiNG
(ALTERNATING CURRENT)
_______________
T O Qenerao* Power Systems, Inc.
Section 3 - Maintenance
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
MAINTENANCE
♦ 2.8.6 25-HOUR CHECK-UP
After the 25-hour break-in period, contact a Generac Authorized Service Dealer for the following mainte
nance. The vehicle owner is responsible for any charges:
• 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
-------
-ik WARNING Æ k-------------
Never operate the generator while the vehicle is parked over high grass, weeds, brush,
A
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.
1.
Remove the dipstick and wipe it dry with a clean,
2.
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 add oil until it reaches the dip stick “Full” mark. DO NOT FILL ABOVE THE “FULL’ MARK.
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:
Run the engine until it is thoroughly warmed up
1.
(at least five minutes) then shut OFF the engine.
With the engine still warm from running, remove
2.
the oil drain plug (Figure 3.1). Drain the oil into a suitable container. After the oil has drained, replace the oil drain
3. plug. (If only changing the oil, go to step 7.)
With the oil drained, remove the old oil filter by turning it counterclockwise (Figure 3.2 on page 12).
Apply a light coating of clean engine oil to the gas
5. ket of the new filter. Screw the new filter on by hand until its gasket
6.
lightly contacts the oil filter adapter. Then, tight en the filter an additional 3/4 to one turn.
Remove the dipstick and fill crankcase with the proper type and amount of recommended oil (see Section 1.6.2, Page 6). The engine crankcase can hold about 1.4 liters. DO NOT FILL ABOVE THE “FULL’ MARK. Install and tighten the dipstick before operating
8.
the engine. Start the engine and check for leaks.
9.
NOTE:
Check the oil level and fill to the “FULL” mark after checking for leaks. The filter will retain some oil.
Figure 3.1Oil Dipstick/Fill Tube and
Location of Oil Drain Plug
CAUTION
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.
11
MAINTENANCE
Section 3 - Maintenance
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
Figure 3.2Engine Oil Filter
3.3 iVIAINTAINING THE ENGINE
AIH CLEANER
♦ 3.3.1 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. Gently 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 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.
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 3.4 - 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).
Figure 3.5 - Setting the Spark Plug Gap
SET PLUG GAP AT 0.030 inch
Figure 3.3 - Engine Air Cleaner
PAPER FILTER
1 a Generac* Power Systems, Inc.
FOAM PRE-CLEANER
------
ik CAUTION Jk------------
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.
Section 3 - Maintenance
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
MAINTENANCE
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
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 are spark
arrestor types. Generac exhaust mufflers for recre ational vehicle generators do not have a spark arrestor screen, but are of the more efficient “toroid” 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.
-A WARNING A-
Be sure to reinstall the muffler plug tightly.
A
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.
--------
M. CAUTION M.
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
A
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:
♦ 5.9.1 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.
♦ 3.9.2 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.
Damage will result if the battery connections are made in reverse.
_________________________________
NOTE:
Generac® Power Systems, Inc. 1 3
MAINTENANCE
Section 3 - Maintenance PRIMEPACT 55C and 55LP Recreational Vehicle Generators
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
A
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.
--------Jk WARNING Jk
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
A
the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
A
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.
--------------
3.10 iVlAJOR SERVICE lyiANUAL
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
♦ 5.15.1 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. Close the fuel shutoff valve in the fuel supply line
2.
and allow the unit to shut down.
While the engine is still warm from running,
3. drain the oil completely. Refill the crankcase with SAE lOW-30 oil having API classification “For Service SE”
Attach a tag to the engine indicating the viscosity
4. and classification of the oil in the crankcase.
Remove the spark plug and pour two or three
5. tablespoons of clean, fresh engine oil into the spark plug threaded openings. Reinstall and tighten the spark plug.
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.
Clean and wipe the entire generator.
7.
1 4 Generac* Power Systems, Inc.
Section 3 - Maintenance
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
MAINTENANCE
♦ 3.13.2 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.
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.
Clean and wipe the entire generator.
3. Reconnect the battery. Observe battery polarity.
4. Damage may occur if the battery is connected incorrectly.
Turn OFF all electrical loads. Add fuel if neces
5. sary and then start the engine.
Allow the unit to warm up thoroughly.
6.
Apply electrical loads to at least 50 percent of the
7. unit’s rated wattage capacity.
When the engine is thoroughly warmed up, shut
8.
it down.
9. Your generator is now ready for service.
3.14 WATTAGE REFERENCE GUIDE
Running
Watts
Battery Charger.................................................................500
Belt Sander (3”)..............................................................1000
Chain Saw.......................................................................1200
Circular Saw (6-12”) ........................................800 to 1000
Disc Sander (9”)
Hand Drill (1”) ...............................................................1100
Hedge Trimmer.................................................................450
Impact Wrench .................................................................500
Lawn Mower ..................................................................1200
Electric Range (one element)..........................................1500
Television........................................................1750 to 2000
Coffee Maker..................................................................1000
Electric Skillet.................................................................1250
Hair Dryer.......................................................................1200
Light Bulb.........................................................................100
Microwave Oven
Oil Burner on Furnace
Oil Fired Space Heater (140,000 Btu)
Radio......................................................................50 to 200
Slow Cooker
♦Furnace Fan (1/3 HP)
♦Refrigerator.....................................................................600
♦Air Conditioner (12,000 Btu)
♦Compressor (IHP).........................................................2000
♦Deep Freeze....................................................................500
♦Milk Cooler
♦Submersible Pump (1-1/2 HP)......................................2800
♦Submersible Pump (1 HP) ♦Paint Sprayer, Airless (1/3 HP)
♦Table Saw (10”) ...........................................1750 to 2000
............................................................
.............................................................
.....................................................
..............................
....................................................................
...................................................
.......................................
..................................................................
............................................
.....................................
1200
700 300 400
200
1200
1700
1100
2000
600
♦ Allow 2-1/2 times the listed watts for starting these devices.
Generac’ Power Systems, Inc. 1 5
NOTES
Section 4 - Notes PRIMEPACT 55C and 55LP Recreational Vehicle Generators
1 6 Generac* Power Systems, Inc.
PART II -
INSTALLATION
INSTRUCTIONS
DANGER
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
SAFETY RULES
Safety Rules
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
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
A
Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the manufacturer’s instructions and recommendations.
NOTICE TO INSTALLER
These Installation Instructions have been published by Generac to aid in the installation of the products described in this manual. Generac assumes that installation personnel are familiar with the proce dures for installing such products, or similar prod ucts that Generac manufactures. 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 (c) use of any tools and/or equipment from other sup
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 Installation Instructions are based on the latest information available at the time of publi cation. Every effort 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
A
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.
^ 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 eidiaust 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 55G and 55LP Recreational Vehicle Generators
SAFETY RULES
A
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
A
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.
A
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.
A
Oenerac* Power Systems, Inc. 1 3
GENERAL
INFORMATION
Section 5 - General Information
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
5.1 PURPOSE ÄND SCOPE
OF THE MANUAL
These Installation Instructions have been prepared
especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to
all information and 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.
6. CSA Electrical Bulletin 946, available from the Canadian Standards Association, Housing and Constructions Materials Section, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3.
5.4 EQUiPMENT 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 40.0 amps (gasoline) or
37.5 amps (LP fuel) at 120 volts.
5.5 GENERATOR ENGINE
OPERATING SPEED
The generator’s revolving field (rotor) is driven by a sin gle-cylinder, 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 SYSTEM
The generator is equipped with dual stator power wind ings as shown in Figure 1.1.
Figure 5.1 - 120-volt Single Voltage Connection
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 booklets (latest revision) are available from the sources indicated:
1. NFPA Standard 501C, “Standard for Recreational Vehicles,” available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
2. NFPA 70, "NFPA Handbook of the National Electric Code,” available same as Item 1.
3. ANSI Cl-1975 and ANSI 119.2-1975, available from the American National Standards Institute, 1430 Broadway, New York, NY 10018.
4. ANSI A119.2/NFPA 501C, available from the Recreational Vehicle Association, 1896 Preston White Drive, Reston, VA 22090.
5. California Administrative Code, Title 25, available from the State of California, Documents Section, PO. Box 1015, North Highlands, CA 95660.
so Generac* Power Systems, Inc.
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.
• For these PRIMEPACT units, loads connected across T1 (red) to T2 (white), MUST NOT exceed 30
amperes or 3,600 watts, and loads connected across
T3 (black) and T2 (white) MUST NOT exceed 20
amperes or 2,400 watts each at 120 volts. The com
bined loading of the two breakers should not exceed
5,500 watts.
NOTE:
Do NOT connect loads in excess of circuit breaker ratings.
Section 5 - General Information
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
Figure 5.2 - Major Features and Dimensions
PrimePact 55G and 55LP
GENERAL
INFORMATION
Air Filter
16.13”
Ground Lug
18.5’
Generac* Power Systems, Inc. S1
INSTALLATION
Section 6 - Installation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
6.1 LOCATION AND SUPPORT
• 6.1.1 GENERATOR LOCATION
The most desirable location for the generator set is between the vehicle's main frame members. However, this is seldom possible. 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 2.1.2.
• 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 2.2. 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 2.1.
The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle 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 2.2. The location of a suspended mounting system must be carefully planned, keeping the following general rules in mind:
• Protect the generator against road splash and debris. Baffles or splash guards may be required to protect cer tain areas of the generator. To make sure the generator is adequately protected, road test the installation through mud, water and slush.
Figure 6.2 - 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.
22 Generac* Power Systems, Inc.
Section 6 - installation
PRiMEPACT 55C and 55LP Recreational Vehicle Generators
INSTALLATION
♦ 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
2.3). All bolts must be long enough so that when tight, at least three threads are visible past the retaining lock nuts. Refer to Section 2.2 for the location of the generator mounting holes.
Figure 6.3 ~ Typical Generator Restraint
6.2 GENERATOR COlVIPARTiVIENTS
Wliether 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:
• 6.2.2 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 2,5).
Figure 6.5 - Typical Compartment Construction
CROSS-SECTION VIEW „ETAL LINING
♦ 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) from the back for air circulation AFTER the compart
ment has been lined with metal and sound insulation
(Figure 2.4).
NOTE:
Refer to “Figure 1.2 ­Dimensions” on Page 21.
Figure 6.4 - Clearances
Major Features and
If constructing a compartment, line the exterior (underside) of the compartment floor with 26-gauge galvanized steel.
• /\11 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.
Generac* Power Systems, Inc. 23
INSTALLATION
Section 6 - Installation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
• 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 2.6.
Installer constructed compartments typically utilize a standard lap joint.
Figure 6.6 - Types of Lock Seams
SL B T H
LOCKED STANDING I wT
mmmufMm
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 2.2.3.
■ I OFF SI
DOUBLE LOCK DQÜBU!
[j^
DANGER
Do not install any flammable material directly
A
above or around the compartment. Heat, 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.
♦ 6.2.5 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 l-inch (25 mm) thick fiberglass having a 2-pound density.
When fiberglass is used, its coated side should face
toward the compartment interior.
ACMELOCt
LOCK SEAM
______________
DANGER
Do not install sound insulation or any absorbent
material on the compartment floor interior. Such
A
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 compartment.
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 2.7):
• 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.
• Vapor seal all compartment seams and joints.
• Over the galvanized steel lining, install a combination
of acoustical materials as mentioned in Section 2.2.3.
____________
NOTE:
DANGER
To prevent fire or explosion, do not install any
insulation or other absorbent materials on the
A
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 2-
pound density).
S<4 Generac® Power Systems, Inc.
Section 6 - Installation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
INSTALLATION
Figure 6.7 - Typical Noise Abatement
Figure 6.8Compartment Floor Cutout
• 6.2.5 COMPARTMENT FLOOR CUTOUTS
You must provide openings in the generator compart ment for the following items (Figure 2.8):
• Engine exhaust and cooling air outlets
• Generator cooling air inlet
• Four holes for passage of generator mounting bolts. See Section 2.1.4 (Page 23).
DANGER
-A
Fuel lines and exhaust piping must not penetrate
into the vehicle living area.
__________
INSTALLATION
Section 6 - Installation
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
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.
DANGER
A Never use discharged cooling air for heating or
aia 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 2.9). 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:
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 2.3.3 (Page 27).
Figure 6.10 - Air Inlet in Compartment Door
100 SQUARE INCHES UNRESTRICTED MINIMUM OPENINGS
NOTE:
Be sure to meet the minimum clearances illustrated in Figure 2.4 (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 2.11).
♦ 6.5.2 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 2.10). 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.
S6 Generao* Power Systems, Inc.
Figure 6.11 - Suspended Mount: Inlet Door
Using ductwork (Figure 2.12, 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
behind the generator for cooling airflow (Figure 2.13
Page 27). Recommended clearance behind the back
of the generator is at least 1/2 inch (13 mm).
Section 6 - Installation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
INSTALLATION
Figure 6.12 - Air Inlet Using Ductwork
ANTI-SPLASH
Figure 6.13 - Air Inlet in Vehicle Skirt
♦ 6.3.4 TESTING THE INSTALLATION
_________________
Generac recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, you will need to enlarge the air openings. 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 SYSTEIVi
The installation of a gasoline fuel system (Figure 2.14) 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
♦ 6.3.3 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
A 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. H7
INSTALLATION
Section 6 - installation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
♦ 6.4.1 FUEL TANK
Either the generator must share the vehicle engine's fuel tank, or you must install a separate fuel tank for the
generator set. All fuel tanks installed on the vehicle
must be constructed, installed and restrained so they comply with applicable codes, standards and regula tions.
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.
------
M. CAUTION Jk
Do NOT tee the generator fuel supply line into
A
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 J512E “Standard Automotive Fittings,” or with ANSI B 126.26 (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.
6.4.2.I 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.
• 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 GAS FUEL SYSTEIVI
—A Era A—
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 SYSTEIVI
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.
SB Generac* Power Systems, Inc.
Section 6 - Installation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
Figure 6.15 - Typical Propane Gas Fuel 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.
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
• 6.5.2 SOME IMPORTANT CONSIDERATIONS
When installing an LP gas system, consider seriously
pressure tank. Do NOT tee the generator line into a gas circuit feeding other areas.
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
• 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 2.16). 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
AIR
than necessary.
INSTALLATION
NOTE:
___________________
GAS AT
• 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.
Generac* Power Systems, Inc. 23
INSTALLATION
Section 6 - installation
PRIMEPACT 55C and 55LP 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, non­organic 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.
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
A 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 m
• 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.
30 Generac* Power Systems, inc.
_
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.
Section 6 - Installation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
INSTALLATION
• 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.
Failure to provide and maintain a spark arrestor may be in violation of the law. If this generator is used on any
forest covered, brush covered or grass covered unim proved land, you must provide a spark arrestor. The vehicle owner or operator must maintain this device in good condition. In the state of California, the preceding
is required by law (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 type 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.
• 6,6.5 EXHAUST SYSTEM SAFETY
* •
• Maintain a clearance of at least 3 inches (76 mm) between exhaust system parts and any combustible material (such as wood, felt, cotton, organic fibers or other like material). If you cannot maintain the 3-inch (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 1.6 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, have approved insu­lative qualities and be properly supported.
• Conduit and wire openings into the generator com partment (if used) must be vapor-sealed to prevent entry of flammable, 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). Route 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.
Benerac® Power Systems, Inc. 31
INSTALLATION
Section 6 - Installation
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
♦ 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.
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
2.17. 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
Line T1 (red) to T2 (white) is protected against overload by a 20-amp circuit breaker (CBl). Use this line-to-neu­tral connection separately to operate 120-volt, single phase, 60 Hertz, AC loads requiring up to 2,400 watts
(3.6 kW) of power. Line T3 (black) to T2 (white) also is
protected against overload by a 30-amp 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.
--------
ii CAUTION il
Do NOT connect electrical loads in excess of any
A
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.
• 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 vapor proof 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 2.18, Page 33). An alternate method for isolating different power sources is by using an isolating receptacle
(Figure 2.19, Page 33). Whichever method you use, you must be certain that both power sources are NOT con
nected at the same time.
32 Generac* Power Systems, Inc.
Section 6 - Installation
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
INSTALLATION
♦ 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.
Figure 6.18Transfer Switch Isolation Method
♦ 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.
FROM 20 AMP HACR BREAKER
DOUBLE POLE DOUBLE
THROW SWITCHING
DEVICE
2ND AIR CONDITIONER
VEHICLE AC
DISTRIBUTION PANEL
30 AMP MAIN BREAKER
HACR BREAKERS FOR AIR CONDITIONERS
POWER SUPPLY CORD
Figure 6.19Installation With Isolation Receptacle
DOCKSIDE POWER RECEPTACLE
POWER SUPPLY
CORD
Qenerac* Power Systems, Inc. 33
INSTALLATION
Section 6 - Installation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
6.8 BATTERY INSTALLATION
♦ 2.8.1 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.
• 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.
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.
CABLE LENGTH
in Feet (meters)
0 to 10 (0 to 3) 2*
11 to 15 (3.4 to 4.5)
16 to 20 (4,5 to 6)
*For warm weather, use No. 2 cable up to 20 feet.
CABLE SIZE
0
000
Figure 6.20 - Connecting Battery Cables
SIDE VIEW OF GENERATOR
♦ 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 flame.
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.
6.9 OPTIONAL ACCESSORIES
A plug-in receptacle (Figure 2.21) 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, ©, © 0.
♦ 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 2.20).
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 2.20).
3.
Connect cables so the connectors are clean and tight.
34 Generac* Power Systems, Inc.
WIRE #14 (ENGINE RUN SIGNAL)
' WIRE #0
(GROUND)
WIRE #17 (CRANK)
Section 7 - Post Installation
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
INSTALLATION
• 6.9.1 REMOTE PANEL MODELS
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 1 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.
__________________
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.
A
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.
2. Check the fuel supply. Gas fuel lines must have been properly purged and leak tested in accordance with
applicable fuel codes. All fuel shutoff valves in the
fuel supply lines must be open.
_
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 next 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 3.4. 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.
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.
DANGER
If 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.
7.4 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.
Generac* Power Systems, Inc. 3B
GENERAL
INFORMATION
Section 7 - Post Installation
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
7.5 INSTALLATION CHECKLIST
♦ LOCATION AND SUPPORT
□ Generator is properly located, □ Generator is properly supported. □ Generator is properly restrained.
♦ GENERATOR COMPARTMENT
□ Compartment construction is proper. □ Holes/Openings are vapor-sealed. □ 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 CONNEQIONS
□ 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 starVstop 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 55G and 55LP Recreational Vehicle Generators
TROUBLESHOOTING
PROBLEM
Engine won't crank.
Engine cranks, won't start.
Engine starts hard, runs rough.
CAUSE
1. 15 amp fuse biown.
2. Loose, or corroded or defective battery cable(s).
3. Battery is discharged or defective.
4. Defective starter contactor.
5. Defective starter motor.
6. Defective Start/Stop switch
7. Defective Engine Control Board
1. Out of fuel.
2. Fuel shutoff valve is closed.
3. Fuel pump not operating. Automatic choke not operating properiy.
4.
5. Engine is fiooded.
6. Fuei fiiter is clogged. Engine spark plugs defective.
7.
8. Bad ignition magneto on engine. Bad carburetor. 9.
9.
10. Dirty air cieaner.
1. Dirty engine air cieaner.
2. Automatic Choke sticking.
3. Defective spark piugs.
4. Defective ignition magneto.
CORREQION
1. Replace blown fuse. Tighten, clean or replace.
2.
as necessary. Recharge or replace battery.
3.
Replace starter contactor.
4.
5. Replace starter motor.
6. Replace switch Contact an authorized service dealer.
7.
Refill fuel tank.
1. Open fuel shutoff valve(s).
2.
Repair or replace pump.
3.
4. Repair, replace or adjust. Wait 5-10 minutes; try again.
5. Replace filter if clogged.
6.
7. Clean, regap or replace as needed. Replace if defective.
8. Adjust, repair or replace.
10. Clean or replace as needed.
1. Clean or replace as needed. Free choke linkage as needed.
2. Clean, regap or replace.
3. Replace it if defective.
4.
Engine starts, then shuts down.
No AC output voitage.
1. Engine oii ievei is low. Bad low oil pressure switch.
2. Defective Fligh Temp Switch 3.
3.
4. Water in fuel.
1. Main breaker(s) open.
Transfer switch (if so equipped) is
2. set to wrong position.
3. Failure in vehicle electrical system.
4.
Generator component failure.
1. Add oil as needed.
2. Replace, if bad. Replace Switch, if bad.
4. Drain fuel tank and refill.
1. Close main breaker(s). Reset transfer switch.
2.
See vehicle manual.
3. Contact an authorized service facility.
4.
Generac* Power Systems, Inc. 37
ELECTRICAL
DATA
Section 9 — Electrical Data
6
PRIA/IEPACT 55G and 55LP Recreational Vehicle Generators
Electrical Schematic - Drawing No. D3148-A
-NEUTRAL CONNECTION BY CUSTOMER
за Generac* Power Systems, Inc.
120V 20A - Q55 S. NP66 120V 30A - Q70
- BATTERY CHARGE RECTIFIER
- CIRCUIT BREAKER, 30A (ALL №DELS)
- CIRCUIT BREAKER, 20A <055 MDMIL) CIRCUIT BREAKER, 30A (Q70-NP66 MDBEL)
- CIRCUIT BREAKER, 2.5 (Q55 MODEL) CIRCUIT BREAKER, 3.0 <NP66-Q70 MODELS)
- CHCKE ^CATER (GASDLIhE MDICLS DW-Y)
- СШ<Е SDLEhffllD CGASOLI^«: MODELS ONLY)
- FUSE, 15A
- FUEL PUMP-DR-LPG SHUT OFF VALVE
- FUEL SOLENOID CIF SUPPLIED)
- TERMINAL, GROUND 4-TAB
- METER, HOUR (CPTIDNAL)
- SWITCH, HIGH TEMP. OIL (CLOSES ON HIGH TEMP.)
- IGNITION MAG^TO - #1 CYL.
- IGNITION MAGNETO - «2 CYL.(V-TVIN UNITS ONLY)
- LIGHT, RUN (iPTIDW^)
- SWITCH, LOW OIL PRESSURE (CLOSES ON LOW PRESSURE)
- Et^INE CONTROLLER
- RESISTOR, 1 OHM 25W
- STARTER CmTACTDR
- STARTER mim
- SWITCH, START/STQP
- SWITCH FUEL PRIMER
- SPARK PLUG #1 CYL
- SPARK PLUG «2 CYL.
- TERMINAL, CONN. 4-TAB
— CmNECTOR
LEGEND
Section 9 — Electrical Data
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
Wiring Diagram - Drawing No. D3148-A
S «A
0CZ3
h-U
D
ELECTRICAL
DATA
fi 1 ooooooooooooooo
Generac* Power Systems, Inc. 3S
PAFiTS
LISTS
Section 10 — Exploded Views and Parts Lists
PRIMEPACT 55G and 55LP Recreational Vehicle Generators Sheet Metal - Drawing No. D3150-A
^ See Carburetor
Exploded View
40 Generac* Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
ITEM PART NO. QTY. DESCRIPTION
^PARTS
LISTS
Sheet Metal - Drawing No. D3150-A
1 2 3 4 5 087865 6 0A4456 7 8 056893 23
10 087750 11
12 13 073190 14 15 078859
16 17 19 073191 20 21 022129
22 075246 23 24 25 073186 26 081108 27 28 29 30 31 33 34 029289 35
36
...........
099258 067198N 1 067890
086313
074916 074908 9
078858
074902 2 WRAPPER, BARREL 066476
042907 2
0742600133 074900
022717B 1 GROMMET-RUBBER 022717A 067866A 1 077001A 073132 2 BOOT, SPARK PLUG 087858A 1 GROUND WIRE ASSEMBLY-CYL. #1
087858B 050277
1 SEE ENGINE EXPLODED VIEW of ENGINE 1 KEY-WOODRUFF 6 x 22MM
BEVELLED WASHER 1 1 PLUG, FLYWHEEL ACCESS 1 3/8" SPECIAL LOCK WASHER 1 HOUSING, ENGINE TOP
1 1 COVER, BASE CYL. #2
1 1 1 WRAPPER, CYL. #1
4 1
2 4 SCREW (TAPTITE) 3/8"-16 x 1-1/4" 1 WIRE ASSEMBLY-NO, 16 1 STARTER COVER 1 1 BUSHING, SNAP
3
1
2FT. FOAM TAPE
1 GROUND WIRE ASSEMBLY-CYL. #2 1 OIL DRAIN DECAL
HEX NUT
SCREW (CRIMPTITE) NO. 10-24 x 1/2“
SCROLL, FLYWHEEL
SCREW (TAPTITE) M5 x 10MM
WRAPPER CYL. #2
COVER, VALLEY
HHCS/LW-M6x1.0x12MM
COVER, BASE CYL. #1
CAPSCREW, HEX HD.-M8 X 1.25x16MM
LOCKWASHER-M8
WRAPPER, CRANKCASE
GROMMET-RUBBER
0-RING
PLUG, OIL FILL
Oenerac* Power Systems, Inc. 41
^PARTS
LISTS
Section TO — Exploded Views and Parts Lists
PRIMEPACT 55C and 55LP Recreational Vehicle Generators Base and Pulleys - Drawing No. D3151-A
4a Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists
PRiMEPACT 55C and 55LP Recreational Vehicle Generators
Base and Pulleys - Drawing No. D3151-A
^PARTS
LISTS
ITEM
PART NO. QTY.
1
86318 1
2 90141
46911 4
3
25017
4 5 46526 2 WASHER LOCK M10 55 6 22129 7
72391 2 SKID, RUBBER MOUNT 77603 2
8 9 22259 2
52858
10 11
51730 2
12 29459
75215 2
13 14
73146 4
15 75209 2 SUPPORT, NYLON SLIDE 65 68548
73174 1 MANIFOLD, EXHAUST 66
16 17
79678 2
18 40976 4 SCREW SHC M8-1,25 X20G12,9 68 22158
72383 2 GASKET, COLLECTOR PAN 69
19 20 90859 1 21
75224B 22 73106B 23 75216 1 BELT (POLY V 4L)-40" 73 24
49451 1 WASHER FLAT SPECIAL .406 I.D. 25 42633 1 SCREW HHC 3/8-24 X 1 G5 75 75474 1
77017
26 27 73118 28 74906 7 SCREW TAPTITE M6 X 20 BP 78 75226
91123 1
29 30 72375 31 73185 1 SPACER ROLL 2.36 X.230 X.042 BRZ 81 D3158
22097
32
77682
33 34 75242
49813 2 NUT HEX M6-1.0 G8YEL CHR
35
45757
36 37
90475 1 38 87769 1 FUEL FILTER 39 87768 1 40 87770 1 FUEL LINE 89 41
A8475 1 SPECIAL LOCK WASHER, M5 90 42
26925 1 PLUG STD PIPE 3/8 STEEL SO HD 91
7571OA 1 TUBE, OIL FILL AND DRAIN 92 22131
43 44
74958 1 CAP & DIPSTICK ASSEMBLY 93 81105 45 67871 1 46 A5508 1 OIL FILL TUBE GASKET 95 47 75711 49 22413 1 SCREW HHC 1/4-20 X 1 G5
DESCRIPTION ITEM
BASE, MOUNTING
1 GROUND CABLE 51
MOUNT VIBR 1,50X1,38 X 3/8-16)
8
SCREW HHC 3/8-16 X 1/2 G5
WASHER LOCK M8-5/16 56 73179
8
SAFETY BOLT 5/16-18x3 1/2" NUT HEX 5/16-18 STEEL 59 NUT LOCK M8 60 74950 1
6
SCREW HHC M8-1,25X60 G8,8
2 SPRING, BELT TENSION
WASHER, SPRING CNTR SLIDE (NYLON) 64 74949 1 ELBOW 90D TUBE CMP 5/16 X1/8NPT
RING, SEALING 67
COVER PLATE -EXTERNAL 1 PULLEY, ENGINE 71 43182 2 WASHER LOCK M3 1 PULLEY, ALTERNATOR
GUIDE, BLOWER HOUSING
1 1
SCREW HHC 3/8-24 X2-1/4G8
BRACKET-FUEL PUMP
1
HOUSING, BLOWER
7 WASHER LOCK M6-1/4 1
SCREW HHC M5-0.8 X 80 G8.8
4
SPRING. GENERATOR SET MT
2
SCREW HHC M6-1.0X25 G8.8
FUEL PUMP 86 24114
FITTING COMP 1/4X1/8 SLF-ALGN
0-RING, CAP
PIPE, OIL DRAIN ADAPTOR
1
PART NO.
50 A5802
22237
52
22145
54
92120
133-74260
57
70185
58 A8584
74948 3
74951 1 TUBE, INNER OIL
61
62 73134 63
38750
C4006 29289
75281 1 SWITCH, HIGH TEMPERATURE
70 Cl 085
72
22152 75237 4
74 D1624 1 BOOT, OIL PRESSURE SWITCH
76 90800
77
94670
79
56893
80
75229
82
79246
83 22473 5
84
D1741A
85 72384C
87
77643
D1741 2 BOOT, BAHERY CABLE
88
D1227 1 A1658 90088
94
23897 6 WASHER FLAT #10 ZINC 67210
96 45756 9
QTY. DESCRIPTION
1 TINNERMAN CLIP
WASHER LOCK 3/8
8 2
WASHER FLAT 5/16 ZINC
2 NUT LOCK TRIC M6X 1.0Y/ZNC 1 CABLE, STARTER 1 OIL FILTER SUPPORT 1
FILTER, OIL(FRAM#PH3614)
1 10PSI-SWITCH, OIL PRESSURE
FITTING COMP 5/16X1/8 SLF-ALGN TUBE, OUTER OIL
1
ADAPTOR, OIL FILTER ADAPTER
3 SCREW HHC M6-1.0X30 G8.8
1 GASKET, OIL FILTER ADAPTER 1
CABLE, 30" LONG
-
TAPE ELEC NON-UL FOAM 1/16X1/2 NUT HEX #10-32 STEEL
2
2
SCREW PPHM M3-0.5 X 8
2
WASHER LOCK #10 WASHER. SPRING RETAINER
BOOT, TEMPERATURE SWITCH
1
ELBOW, EXHAUST 1 CLAMP, EXHAUST 1 COVER, AIR
23 SCREW CRIMPTITE #10-24 X 1/2
SLIDE PAN, GASKET
1
SLIDE PAN
1
CAPSCREW, HEX HEAD- M6-1.00 x
6
16mm WITH LOCK WASHER
WASHER FLAT 1/4 ZINC 1 BOOT, BATTERY CABLE 1 COVER, EXHAUST OUTLET 2 NUT HEX 5/16-24 STEEL 1 GASKET, EXHAUST OUTLET
CONTACTOR, STARTER
LOCKWASHER, SPECIAL 'A"
3
CLAMP VINYL .25 X .28 Z
1 1
WASHER FLAT 3/8 ZINC 2 FLANGE NUT, (SPECIAL) 5/16"-18
1 DECAL-GROUND
SCREW TAPTITE M6X10YEL CHR
Generac* Power Systems, Inc. 43
PARTS
LISTS
Section 10 — Exploded Views and Parts Lists
PRIMEPACT 55C and 55LP Recreational Vehicle Generators Engine - Drawing No. D3149-A
44 Generac* Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
Engine - Drawing No. D3149-A
j>ms
LISTS
TEM PART NO. QTY.
1
C9675 77005H
2
77004H 1 87844H
3
87845H
4
73159
31971 1
5
C9674
6 7
77006 4 8 52858 4 M8-1.25 FLANGE LOCK NUT 42 D2724 2 9 66386 1 BRUSH HOLDER
10 66849 2 M5-0.8X 16LG.TAPTITE 44 22152 11
27756
12 86314
75234 1
13 14
22473 2 '/47 M6-FLAT WASHER 47 22097
15 16 74095 1 M6-1.0X60 LG. CAPSCREW 17
90141 2 GROUND CABLE 18 A1658 19 74906 4
92234 1
20 21
55440 2 M5-0.8 X 25mm CAPSCREW
22
22129 4 5/167 M8 LOCKWASHER
23 45771 4 24
86316
25 53650 1 4-PIN CONNECTOR 26 C4258 1 27
75244 1 28 23484-S 1 29 74908 1 M5-0.8X10LONGTAPTITE 30 75476 3 M4-0.7X 16 LG. CAPSCREW 89438B 1 DECAL, CUSTOMER CON. PP66 31 22264 32
65795 1 BAHERY CHARGER RECTIFIER
90987 2
33
DESCRIPTION ITEM PART NO. QTY.
1 LOWER BEARING CARRIER
1
ROTOR ASSEM. PP55 35 75235
ROTOR ASSEM. PP66 1 STATOR ASSEM. 55 1 STATOR ASSEM. 66
1
BALL BEARING BALL BEARING
1 UPPER BEARING CARRIER
STUD-STATOR 54502 1 C/BREAKER 3.0A PP66
4 NYLON WASHER 1
GENERATOR TOP HOUSING 46 RESISTOR 90145
5 '/4 7 M6-LOCK WASHER
2
SPECIAL LOCK WASHER, '/4" WASHERS FLAT WASHER M6-1.0X20 LG.TAPTITE 51 22985 CONTROLLER P.C.B. 52
M8-1.25 HEX NUT 55 92113
1
PANEL SHEET METAL
CONDUIT ASSEMBLY ASSEMBLY, REMOTE CABLE BUSHING 60
4
#8/ M4-LOCK WASHER 62
M3-0.5X12LG.PPHMS
34 86317A 1 PANEL SUPPORT BRACKET
82737 4 VIBRATION MOUNT
36 37 49813
38 49815
43182 2
39 40 A8475 3
41 53623
83049
43
45 51716
90144 1
90145
48 25105
49 86315
90734
50
32300 22676 1
53 54 87798
75210-A 1
56
A8475-A 1
57 58 51715
90157 1 DECAL, CB RATING 30A.
59
84867 4" U- CHANNEL, RUBBER
89438A
61
31791 23897 3 #10/M5-FLAT WASHER
63
DESCRIPTION
2
M5-0.8 X 30 LG. CAPSCREW
4
M6-1.0HEX NUT
1 M5-08X16LG.HEX HD. CAPSCR.
M3-LOCK WASHER
#10-SPECIAL LOCKWASHER
1
C/BREAKER 2.5A PP55
BOOT, ROCKER SWITCH
1
REGULATOR VOLTAGE M5-LOCK WASHER
6 4
M5-0.8 HEX NUT C/BREAKER 20A. PP55
1
C/BREAKER 30A. PP66
1
C/BREAKER 30A. (ALL UNITS)
4 #6-32 X '/4" SCREW W/LOCK WASHER 1 PANEL COVER 4
M4-0.7X 12 LG. CAPSCR.W/LOCK-
1
#6-FLAT WASHER
1 FUSE HOLDER
FUSE AGC-15A.
1
SWITCH S.P.D.T. 6A.-(START-STOP)
1
SWITCH S.P.D.T.-(FUEL PUMP) TERMINAL BLOCK #8 SPECIAL LOCKWASHER
1
M4-0.7 HEX NUT
1 DECAL, CUSTOMER CON. PP55
1 CLAMP, HOSE
Generac* Power Systems, Inc. «45
PARTS
LISTS
Section 10 — Exploded Views and Parts Lists
PRIMEPACT 55C and 55LP Recreational Vehicle Generators Exploded View - Engine Common Parts - Drawing No. 79216-F
[H
II ]'i
\\ \ A
i' U
"V i'> C/
\ ^
Qj
/ ' h4
.smc:®
4B Generac* Power Systems, Inc.
(>
•I
Section 10 — Exploded Views and Parts Lists
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
Exploded View - Engine Common Parts - Drawing No. 79216-F
^PARTS
LISTS
PART NO.
FEM
1 069331 1 CYLINDER ASSEMBLY
*2 069333 1 SLEEVE BEARING
3 067805 1 OIL SEAL
4 079234 1 NO, 1 CYLINDER HEAD ASSEMBLY 5 079235 6 070169 7 069332 2 CYLINDER HEAD GASKET
0851100104
8
072315
9
089967 1 BREATHER SCREW
10 11 070596 1 BREATHER TUBE
069336 1 OIL SUMP GASKET
12 13 069325 8 14 067888 2
072334
15
075247 1
16
067924 1 OIL SEAL ASSEMBLY
17 18 067878 9
075248 2 STANDARD PISTON ASSEMBLY
19 20 075249 2
069327 4
21
075250 2 STANDARD PISTON RING
22
075251 2
23 24 072346 4
069316 2
25 26 069317 2
067816 4 VALVE SPRING
27 28 069320 4
070513 4 VALVE KEEPER
29
070584 4 VALVE TAPPET
30 31 070530 1
072358 1
32
069379
33 34 067895 2
070594 2
35
067158 4 INTAKE MANIFOLD MOUNTING BOLT
36
068574
37
068554A
38 39 068573 1
070506 1 OIL GALLEY 0-RING
40
070554
41 42 070568 4
075253 4 WASHER VALVE COVER SEAL
43
QTY. DESCRIPTION
1 NO. 2 CYLINDER HEAD ASSEMBLY 4 SEALING WASHER
BREATHER ASSEMBLY
1 1 BREATHER GASKET
CYLINDER HEAD BOLT 3/8" NPT OIL DRAIN PLUG CRANKSHAFT ASSEMBLY
1
OIL SUMP ASSEMBLY
OIL SUMP BOLT
STANDARD PISTON RING SET PISTON LOCKING RING
CONNECTING ROD ASSEMBLY CONNECTING ROD BOLT EXHAUST VALVE 85 INTAKE VALVE
VALVE SPRING RETAINER
CAMSHAF ASSEMBLY INTAKE MANIFOLD CARBURETOR MOUNTING GASKET
2
INTAKE MANIFOLD GASKET CARBURETOR MOUNTING BOLT
1/8” NPT PLUG PIPE
1
GOVERNOR SHAFT SEAL
1
OIL PUMP 0-RING
CARBURETOR SPACER
1
ROCKER ARM STUD
ITEM PART NO. QTY. DESCRIPTION
44
067885 4 45 075254 4 46
070535 47 0C2881 1
51 072536 4
52 072347 2 53
075258 1 57 066480 1 59
072361 60 072362 1
070199
61
62 072366 1 64
072365 1 65 068555 2 66 067806 73 068572 2 74 075272 2 75 070122 4 76 067910 78 067813
81 070592 1
82
073123 83 070593 1 84 0C3633 1
067156 2 86 069341
070597 1
88 89 072305 90 067920 2
91 069328
070547
92 93
070536 94 070577 95 070599 4 97
070566
075271 1
98 99 067897
100 091481 1
101
091480
102 0D1198 1
'Not Shown
M6 NYLON NUT
VALVE ADJUST SCREW
OIL SCREEN
1
STARTER MOTOR (NOT SHOWN) IGNITION ARMATURE SCREW
SPARK PLUG
ENGINE GASKET KIT AIR CLEANER GASKET GOVERNOR SHAFT BUSHING
1
GOVERNOR SHAFT BUSHING
BREATHER BAFFLE
1
COTTER PIN GOVERNOR SHAFT WASHER CRANKCASE DOWEL CYLINDER HEAD DOWEL
4
OIL PUMP SCREW SPARK PLUG TERMINAL VALVE STEM SEAL INTAKE VALVE SEAT
2 4 VALVE GUIDE
AIR CLEANER BASE AIR FILTER (NOT SHOWN)
1
AIR CLEANER COVER AIR CLEANER COVER SCREW AIR CLEANER BASE SCREW FOAM PRE-CLEANER
1
AIR INLET TUBE BREATHER DEFLECTOR
1
VALVE COVER GASKET VALVE COVER
2
OIL PUMP ASSEMBLY
1
GOVERNOR SLIDER
1
PUSH ROD
4
ROCKER ARM ROCKER ARM SUPPORT
4
VALVE OVERHAUL KIT EXHAUST GASKET (NOT SHOWN)
2
GASKET AND CAP ASSEMBLY ROCKER ARM COVER
1
GOVERNOR CRANK
Generac® Power Systems, Inc. 47
PARTS
LISTS
Section 10 — Exploded Views and Parts Lists
PRIMEPACT 55G and 55LP Recreational Vehicle Generators Carburetor - Drawing No. 93753-G
4S Generac* Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
Carburetor - Drawing No. 93753-C
^PARTS
LISTS
ITEM
1
2
3 4 5 6 7 8
9 073131 10 11 12 13
PART NO. QTY. DESCRIPTION
073112B 1 Carburetor Assembly 074962C 074962G 070155 070108
1 Spring, Governor (PP55, PP66) 1 Spring, Governor (Q-70G) 1
Lever, Governor
1 Rod, Governor to Carburetor 056893 5 Screw, (Crimptite) - #10-24 X 1/2” 074961 047227 1 037398
1
1 Nut, Hex Lock (Nylon)
Bracket, Governor Adjuster
Screw, Governor Adjuster
1 Bracket, Air Cleaner Support 066476 070575
2 Screw, Hex - M6-1.0 X 12MM
2
Screw, Hex - M6-1.0 X 25MM 070125 1 Spring, Anti-Lash 073374
1
Bracket, Choke Support
14 074947 1 Rod, Choke Control 15
089473 16 091306 17
077091
18 031879
19
20 21 22 23 25
022159 089870 072536 087770 074946 030340
1 1
Bi-Metal Assembly, Choke
Solenoid, Choke 1 Hair Pin, Cotter 4 Flat Washer - #4 4 Lock Washer - #4 1
Solenoid, Fuel Shutoff (Q-70G Only) 4 Screw, Pan HD. Mach. - #4-40 X 1/4” 1
Line, Fuel-5/16” I.D. 1 Link, Choke 1 Hose, Fuel, 4.5” LG.
26 0C2338B 1 Decal, Air Cleaner Primepact 66G
0C2338
1
Decal, Air Cleaner Primepact 55G
091352C 1 Decal, Air Cleaner Q-70G 27 075252 1 Kit, Carburetor Overhaul - Not Shown 28 0A7782A 1 29 040173 30
066829 31 075944
2 2 Rivet -1/8” Diameter X 1/8” Long 1
Flywheel Assembly
Clamp, Hose (Screw Type)
Bracket, Governor Spring 32 070594 2 Capscrew, Hex HD. - M6-1.0 X 93 LG. w/washer 33 077075
1
Cover, Choke Coil
Generac* Power Systems, Inc. 43
^PARTS
LISTS
Section 10 — Exploded Views and Parts Lists
PRIMEPACT 55G and 55LP Recreational Vehicle Generators LP Carburetor & Air Cleaner - Drawing No. A4029-F
TEM PART NO.
1 A1662A 1 GARB, V-TWIN U P 2 57822 2 HOSE CLAMP 3 74994
26307
4
5 26915 1 3/4“ PIPE NIPPLE 6 75211 1 GASEOUS FUEL REGULATOR
QTY. DESCRIPTION
1/2" I.D, X10"LONG HOSE 18 66476
1
STREET ELBOWS 19
4
7 A2666 1 GASEOUS FUEL SOLENOID
8 A5198 1
9
49813 22097
10 11 47411 2 M6-1.0X16MMHEXHD.CAPSCR. 12
38750 2 13 37398 1 14 74961 1 GOVERNOR ADJUSTER BRACKET 15 56893 5 #10-24 X 1/2" SCREW 16 47227 1 GOVERNOR ADJUSTER SCREW 28 61696
REGULATOR MOUNTING BRACKET 21 A7782A
4 M6 HEX NUT
4 M6 LOCK WASHER
M6-1.0 X 30MM HEX HD. CAPSCR. 25 70108 1
HEX LOCK NUT (NYLON) + 28739
PART NO. QTY. DESCRIPTION
ITEM
17 74962C 1
74962G 1 GOVERNOR SPRING (PP70G/LP, Q70G)
C2338E 1 C2338C 1 C2338A 1
20 75944 1
22
70155 23 76242 24
70125
+ 55162 9CC
27 73131 1 AIR CLEANER SUPPORT BRACKET
{+ ) NOT SHOWN
50 Oenerac” Power Systems, Inc.
GOVERNOR SPRING (PP55G/LR PP66G/LP)
M6-1.0X 12MM HEX SCREW W/LOCK WASHER
2
AIR CLEANER DECAL-PRIMEPACT 70LP AIR CLEANER DECAL-PRIMEPACT 66LP AIR CLEANER DECAL-PRIMEPACT 55LP
GOVERNOR SPRING BRACKET 1 FLYWHEEL ASSEMBLY 1 GOVERNOR LEVER
2 1/8“ I.D X 1/8" RIVET
1 ANTI-LASH SPRING
GOVERNOR-TO-CARBURETOR ROD
4 4" LONG TIE WRAP
PIPE SEALANT
1 BARBED 90 DEG. 3/8" X 1/2"
Section 11 — Notes
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
NOTES
Generac* Power Systems, Inc. 51
Section 12 - Warranty PRIMEPACT 55G and 55LP Recreational Vehicle Generators
CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.*
New utility, and lawn and garden equipment 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
S2 Generac® Power Systems, Inc.
Section 12 - Warranty
PRIMEPACT 55C and 55LP Recreational Vehicle Generators
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:
(a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on
the date the new engine or equipment is purchased by/dellvered to its original, end-use purchaser/owner and shall 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 emlssions-related part to fall to be Identical in all material respects to the part as described in the engine manu
facturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) /'my 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 falls 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) /Wiy 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 part.
(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) /Iny 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’ part.
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) 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
2) Air Induction System including: a) Intake plpe/manifold
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
Generac* Power Systems, Inc. 53
Section 12 - Warranty
PRIMEPACT 55G and 55LP 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 period of 3 (tliree) years or 2,000 (two tliousand) hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc, (Generac) will, at its option, repair or replace any part which, upon examination. Inspection and testing by Generac or a Generac Auttiorized Warranty Service Facility, is found to be detective under normal use and service, in accordance with the warranty
schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest
Generac Authorized Warranty Service Facility. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac generators sold and rated for “Recreational Vehicle” (RV) appli cations, as Generac has defined Recreational Vehicle generator applications. This warranty is effective only upon Generac's receipt, from the original purchaser/owner, of a completed Warranty Registration Card. This card is the only valid registration identification and must be presented 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 reinstallation listed:
• Engine - All components
• Alternator - Ail components
• Transfer System - All components
WARRANTY SCHEDULE - CONSUMER/PERSONAL APPLICATIONS
YEARS ONE AND TWO - 100% (one hundred percent) 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 partis) and labor listed (Any labor and partis) not listed, and removal and réin
stallation are the owner’s responsibility):
• Rotor, Stator, Computer Control Board, (if applicable with regard to the generator) Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Valve,
Valve Lifter(s), hitake and Exhaust Manifolds
FOR THE LIFE OF THE RECREATIONAL VEHICLE GENERATOR (IF SO EQUIPPED)
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 the life of the generator. For the original purchaser/owner, this drive train 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 the original purchaser/owner. For subsequent purchaser/owner, this drive train warranty shall cover belt and pulley partis) ONLY (labor not included). Labor, removal and reinstallation is tiie responsibility of the subsequent purchaser/owner.
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 the 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 Warranty 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 wltli all mechanical devices, the GN-Series engines need periodic parfis) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a parfis) 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 that 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 the defective parfis).
• Failure due to misapplication.
• Telephone, telegraph, teletype or other communication expenses.
• Living or travel expenses of persoti(s) performing service, except as specifically included within, the terms of a specific unit warranty period.
• Rental equipment used while warranty repairs are being performed.
• Overnight freight costs for replacement parfis),
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids. THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER
WARRANTIES AS TO THE MERCHANTABILITY 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 DAMAGES ARE A DIRECT RESULT OF GEN ERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the 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.
GEISIERAC* POWER SYSTEMS, INC.
P.O. BOX
Part No. CSaS7
S
• WAUKESHA, Wl
Revision Q (03/1 3/01] Printed in U.S.A..
531 S7
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