Generac Power Systems 009600-4 User Manual

POWER SYSTEMS, INC

Owner’s Manual

Air-cooled Recreational

Vehicle Generators

• Model: 009600-4 and 009734-4

PRIMEPACT 66G and 66LP

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:

DANGER

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

--------ik WARNING Jk---------------

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

------ ik CAUTION Jk-----------

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.

AThishazard.symbol points out potential explosion

This symbol points out potential fire hazard.

This symbol points out potential electrical A 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		009600-4		and 009734-4. 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

To locate the GENEPiAC AUTHORIZED SERVICE

DEALER nearest you, please call this number:

1-800-333-1322

ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER.

Generac* Power Systems, Inc.

Table of Contents

PRIMEPACT 66C and 66LP 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 ................................................................			IFC
AuUiorized Service Dealer Locator Number ..............................			IFC
Safety Rules..................		...........................................................................	...2
Section 1 - General Information ...............................................................			4
1.1	Generator Identification ..........................................................		4
1.2	Generator Applicability............................................................		5
1.3	Installation ...............................................................................		5
1.4	Safety .......................................................................................		5
1.5	Generator AC Connection System...........................................		5
1.6	Specifications ...........................................................................		6
	1.6.1 Fuel Requirements & ConsurnpLion ..........................		6
	1.6.2	Engine Oil Requirements ............................................	6
	1.6.3	Generator Specifications..............................................	6
	1.6.4	Engine Specifications ..................................................	7
	1.6.5	Emissions Compliance Period .....................................	7
Section 2 -		Operation.....................................................................	7
2.1	Generator Conixol Panel..........................................................		7
	2.1.1	Fhel Primer...................................................................	7
	2.1.2	Staii/Stop Switch .........................................................	7
	2.1.3	15 Amp Fuse................................................................	7
	2.1.4	Line Breakers................................................................	7
2.2	Optional Remote Start/Stop Panel............................................		8
2.3	Automatic Choke .....................................................................		8
	2.3.1	Choke Solenoid ............................................................	8
	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 ..................................................................	8
	2.4.4 Cooling and Ventilating Air ........................................		8
	2.4.5	Engine Exhaust Gas .....................................................	9
2.5	Starting the Generator .............................................................		9
2.6	Stopping lire 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 ................................		10
2.8	Protection Systems.................................................................		10
	2.8.1 Low Oil Pressure Switch............................................		10
	2.8.2	High Temperature Swatcli..........................................	10
	2.8.3	Field Boo.st.................................................................	10
	2.8.4	Overvoltage Protection .............................................	11
	2.8.5	25-Hour Break-in Period............................................	11
	2.8.6	25-Hour Checkup.......................................................	11
	2.8.7 Operation in High Grass or Brush ............................		11
Section 3 -		Maintenance...............................................................	11
3.1	Checking the Engine Oil Level...............................................		11
3.2	Changing the Engine Oil and/orOil Pdlter.............................		12
3.3	Maintaining the Engine Air Cleaner .....................................		12
	3.3.1 Cleaning tire Foam Precleaner...................................		12
3.4	Clean Air Intake Screen ........................................................		13
3.5	Checking the Engine Spark Plug...........................................		13
3.6	Fuel Filter (Gasoline Only) ...................................................		13
3.7	Spark Arrestor Muffler...........................................................		13
3.8	Cleaning the Generator............................................................		14
3.9	Battery Maintenance...............................................................		14
	3.9.1	Weekly .......................................................................	14
	3.9.2	Every Six Months.......................................................	14
3.10	Major Service Manual............................................................		15
3.11	Drive Belt ..............................................................................		15
3.12	Exercising the Generator .......................................................		15
3.13 Out of Service Procedure ......................................................			15
	3.13.1	Removal From Service ...........................................	15
	3.13.2	Return to Service .....................................................	15
3.14	Wattage Reference Guide.......................................................		15
Section 4 - Notes...........................................................................................			16

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 ..................................................................			20
5.4	Equipment Description...........................................................			20
5.5	Generator Engine Operating Speed........................................			20
5.6	Generator AC Connection System.........................................			20
	Major Dimensions and Features.............................................			2i
Section 6 - Installation.................................................				....22
6.1	Location ..............................................................and Support			22
	6.1.1 .....................................................	Generator Location		22
	6.1.2 .....................................................	Generator Supports		22
	6.1.3 .................................................	Suspended Mounting		22
	6.1.4 ....................................................	Generator Restraint		23
6.2	Generator ........................................................Conipartmeuts			23
	6.2.1 .....................................................	Compartment Size		23
	6.2.2 .......................................	Compartment Construction		23
	6.2.3 .........................................	Sound Insulating Materials		24
	6.2.4 ....................................................................	Acoustics		24
	6.2.5 .......................................	Compartment Floor Cutouts		25
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 file Installation		27
6.4	Gasoline ............................................................Fuel System			27
	6.4.1 ...................................................................	fWelTank		28
	6.4.2 ......................................Generator Fuel Supply Line			28
	6.4.2.1 .................................................		Rigid Fuel Lines	28
	6.4.2.2 .............................................		Flexible Fuel Lines	28
6.5	LP Gas ..............................................................Fuel System			28
	6.5.1 ...........................Parts not mcUrded is\ Fuel System			28
	6.5.2 .................................	Some Important Considerations		29
	6.5.3 ......................................................	Vapor Withdrawal		29
	6.5.4 .......................................................	Primary Regulator		29
	6.5.5 ..................................................	Gaseous Carburetion		29
	6.5.6 .......................................................	Riel Supply Lines		30
	6.5.7 ....................................................	Elxcess Flow Valve		30
	6.5.8 .............................................................	Leakage Tests		30
6.6	Exliaust .....................................................................Systems			30
	6.6.1 ....................................Mufflers and Spark Arrestors			31
	6.6.2 ...........................................IVpe of Exliaust System			31
	6.6.3 ...............................................	Exliaust System Safety		31
6.7	Electrical ..........................................................Connections			31
	6.7.1 .............................................	Electrical Junction Box		31
	6.7.2 .........................................................................	Wiring		32
	6.7.3 .........................................	Generator AC Connections		32
	6.7.4 ........................................................................	Conduit		32
	6.7.5 ..............................Isolating Different Power Sources			32
	6.7.6 .....................................................	Power Supply Cord		33
	6.7.7 ..............................Ground Fault Circuit Interrupters			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				35
7.1	Post Installation .............................................................Tests			35
7.2	Before .............................................................Initial Start-up			35
7.3	Initial ..............................................................................Start			35
7.4	Testing ................................................................Under Load			35
7.5	Installation .............................................................Checklist			36
Section 8 - ...........................................Troubleshooting				37
8.1	Troubleshooting ............................................................Guide			37
Section 9 - ...............................................Electrical Data				39
Section 10 - ...............Exploded Views and Parts Lists				40
Section 11 - .........................................................Notes				51
Section 12 - .....................................................Warranty				52

Generac* Power Systems, Inc.

SAFETY RULES

Safety Rules

PRIMEPACT 66C and 66LP Recreational Vehicle Generators

SAVE THESE INSTRUCTIONS - The manufacturer suggests that these rules for safe . operation be copied and posted in potential hazard areas of the recreational vehicle.

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

WARNING:

The engine exhaust from this product contains chemicals known to the state

of California to cause cancer, birth defects or other reproductive harm.

WARNING:

This product contains or emits chemicals I 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.

DANGER

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

Athese machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

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

A GENERAL HAZARDS ^

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 exliaust system.

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

Adequate,

unobstructed

flow

of

cooling

and

venti­

lating

air is

critical

to

correct

generator

operation

and

is

required

to expel toxic fumes and fuel

vapors

from

the

generator

compartment.

Without

sufficient

cooling

airflow,

the

engine/generator

quickly

overheats,

which

causes

serious

damage to

the

generator.

Do

not

alter

the

installation

or

per­

mit

even

partial blockage

of ventilation

provisions,

as this can seriously affect safe operation of the generator.

When	working	on this	equipment, remain alert at
all times. Never		work	on the equipment when you
are physically or mentally fatigued.
Inspect	the generator		regularly, and contact your

nearest Generac Authorized Service Dealer imme­

diately		for parts needing repair or replacement.
Before		performing		any maintenance on the genera­
tor,	disconnect		its	battery cables	to prevent	acci­
dental		start up. Disconnect the cable from the				bat­
tery	post indicated			by a NEGATIVE, NEG or (-)
first. Reconnect that cable last.
Never		use the generator or any of its parts as a
step.		Stepping	on	the unit can	stress and	break

parts, and may result in dangerous operating con­ ditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

Generac* Power Systems, Inc.

SAFETY RULES

Safety Rules

PRIMEPACT 66C and 66LP Recreational Vehicle Generators

A	ELECTRICAL HAZARDS	A
• 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 FIRE HAZARDS A

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			iSafety		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	tlie

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 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	Section 1 - General Information
		PRIMEPACT 66G and 66LP Recreational Vehicle Generators
	INFORMATION

1.1 GENERATOR IDENTIFICATION

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

1.Model Number ________________________ 2. Serial Number ____________________________

3.kW Rating____________________________ 4. Rated Voltage ____________________________

5.Phase________________________________ 6. Hertz ____________________________________

	REFERENCE NUMBER IDENTIFICATION
1.	Generator Air Intake Screen	8.	Starter Contactor
2.	Data Plate	9,	Fuel Inlet
3.	Engine StarPStop Switch	10.	Fuel Primer Switch
4.	15 amp Fuse	11.	Fuel Pump
5,	30 amp Circuit Breaker	12.	Oil Filter
6,	Optional Remote Panel Receptacle	13.	Oil Drain Plug
7.	Generator AC Output Leads	14.	Oil Dipstick and Filler Tube

Generac* Power Systems, Inc.

	Section 1 - General Information	GENERAL
	PRIMEPACT 66C and 66LP Recreational Vehicle Generators
		INFORMATION

1.2 GENERATOR APPLICABILITY

1.3 INSTALLATION

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.

IMiNCilR

For fire safety, the generator must have been properly installed in compliance with ANSI 119.2-1975/NFPA 501C-1974, "Standard for Recreational Vehicles, Part III - Installation of Electrical Systems." The generator also must have been installed in strict compliance with the manufacturer's detailed installation instruc­ tions. After installation, do nothing that might render the unit in noncompliance with such codes, standards and instructions.

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

•PRIMEPACT 66G: 120 and/or 240 volts, single

phase,	60 Hz	electrical loads.	These loads	can
require up to 6600 watts (6.6 kW) of power,				but
cannot	exceed	55 AC amperes	of current at	120
volts or exceed 27.5 AC amperes at 240 volts.

•PRIMEPACT 66LP: 120 and/or 240 volts, single

phase,	60 Hz electrical loads. These loads	can
require up to 6200 watts (6.2 kW) of power,		but
cannot	exceed 51.7 AC amperes of current at	120
volts or exceed 25.8 AC amperes at 240 volts.
	------M. CAUTION M.----------

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

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 MANUAL 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 informaiion.

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.

1.4SAFETY

Before using the generator set, carefully read GEN­ ERAL SJAFETY 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.

1.5GENERATOR AC CONNECTION

SYSTEIVi

These air-cooled generator sets are equipped with dual stator AC power windings. These two stator

windings supply electrical	power to	customer electri­
cal loads by means of a	dual 2-wire	connection sys­
tem.

Generators may be installed to provide the following outputs:

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

generator	output terminals.	Figure	1.1, page	6,
shows	the generator lead	wire	connections	for
120VAC ONLY.

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

total	wattage	requirement	equal	to	the	generator’s
rated	power	output, and	240V	across	the	generator

output terminals; or two seperate loads, each with a

maximum total		wattage requirement			equal	to half of
the generator’s		rated	power	output	(in	watts),	and
120V	across	the	generator		output	terminals.
Figure	1.2, page 6,		shows	the generator		lead	wire

connections for 120/240 VAC loads.

Generac* Power Systems, Inc.

Section 1 - General Information

	GENERAL	PRIMEPACT 66G and 66LP Recreational Vehicle Generators
	INFORMATION

Figure 1.1 - Connection for 120 Volts Only	Fuel Consumption (gph/ibs.ph)
	Model	No Load	1/2 Load	Full Load
	PrimePact 66G	0.33	0.59	0.99
	PrimePact 66LP	0,47/2.01	0.85/3.62	1,66/7.05

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:

Figure 1.2 - Connection for 120/240 Volts

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

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.

------ Jk CAUTION Jk-----------

Generac does not recommend using any

A gasoline containing alcohol (such as "gasohol"). If you use any gasoline containing alcohol, it must not contain more than 10 percent ethanol, and it must be removed from the generator during storage. Do NOT use any gasoline containing methanol. If you use gasoline with alcohol, inspect more frequently for fuel leaks and other abnormalities.

♦ 1.6.2 ENGINE OIL REQUIREMENTS_______________

Use only	high	quality	detergent oil	classified	“For
Service SF”	and	with an	oil viscosity	rating of	SAE

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

ommended oil. Engine	crankcase	capacity is	1.4
liters. See Section 3.2 on	page 11	for oil level	check
and filing procedures.

♦ 1.6.3 GENERATOR SPECIFICATIONS

SERIES		PRIMEPACT 66G		PRIMEPACT 66LP
Rotor RPM		3600		3600
Rotor Poles		2		2
Engine RPM		2700		2700
Rated Max. Continuous AC Output*		6600 watts (6.6 kW)		6200 watts (6.2 kW)
Voltage*		120		120
Rated Max. Continuous Current*		55.0 AC ampst		51.7 AC amps N
Phase		1		1
Frequency		60 Hertz		60 Hertz
Battery Charging Current (Max.)		2 amps (trickle charge)		2 amps (trickle charge)
Weight		213 pounds		216 pounds
Length		25 inches		25.75 inches
Width		18,5 inches		18.5 inches
Height		15.75 inches		15.75 inches
* All units are reconnectable to 120 and/or 240 volts, dual voltage		output. Units are not listed	per RVIA/ANSI when reconnected for dual voltage output
t Rated maximum continuous current at 240 volts is 27,5 amps,
N Rated maximum continuous current at 240 volts is 25,8 amps.

6 Generac* Power Systems, Inc.

Section 2 - Operation	OPERATION
PRIMEPACT 66G and 66LP Recreational Vehicle Generators

♦1,6.4 ENGINE SPECIFICATIONS_________________

Type of Engine
PRIMEPACT 66G/66LP...........................................		GN-480
Cooling Method .....................................................		Air-cooled
Rated Horsepower
PRIMEPACT 66G/66LP .....................................		16 at 3600
Displacement
PRIMEPACT 66G/66LP...........................................		480CC
Compression Ratio.......................................................		8.6 to 1
Cylinder Block..........................		Almiiinum w/Cast Iron Sleeve
Type of Governor ............................		Mechanical. Fixed Speed
Engine Governor Speed...........................................		2700 rpm
Air Cleaner .......................	Paper Element w/Foarn Precleaner
Starter .......................................................		12-volt DC Electric
Ignition System .....................		Solid-state w/Flywheel Magneto
Recommended Spark Plug
Champion...............................................................		RC12YC
AC................................................................................		R45S
Fram Autolite ...................................................................		65
Spark Plug Gap.......................................		0.030 inch (0.8 mm)
Recommended Min. Battery		........... 400 Cold Cranking Amps

♦1.6.5 EMISSIONS COMPLIANCE PERIOD * •

For	nonhandled		engines		the	Emissions		Compliance
Period		referred	to	on	the	Emissions		Compliance
Label indicates			the	number		of operating hours for
which the engine has been						shown	to	meet Federal
emission requirements.
•	For	engines	less		than	225	cc	displacement,

Category C= 125 hours, B=250 hours, and A=500 hours.

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

2.1GENERATOR 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	ten	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.
♦	2.1.2 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 tlie RUN position.

♦2.1.3 15 AMP FUSE ______________________

The fuse protects the engine’s	DC	control circuit
against electrical overload. If the	fuse	elenieni lias

melted open due to overloading, the engine cannot be cranked. If you must replace the fuse, use only an identical 15 amp replacement fuse.

♦ 2.1.4 LINE BREAKERS

Protects generator’s AC output circiut against overload, i.e,, prevents unit from exceeding wattage/amperage capacity. This unit has two 30-amp breakers.

Figure 2.1 - Typical Control Panel

FUSE IVIAiN

STAFTF ^SA BREAKER

PRIMER

Generac* Power Systems, Inc. "7

OPERATION	Section 2 - Operation

0CX	PRIMEPACT 66C and 66LP Recreational Vehicle Generators
	NOTE:	♦ 2.3.2 PRECHOKE

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.

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.

2.2OPTIONAL 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 2.2 — Optional Remote Panel

(Models 004057 and 004184)

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

2.3AUTOMATIC 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.

2.4BEFORE 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 recom.mendations,

♦ 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.

------ ik CAUTION Jk-----------

Any attempt to crank or start the engine before A you have properly serviced it with the recom­

mended oil may result in an engine failure.

♦ 2.4.3 FUEL SUPPLY____________________________

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

CSenerac* Power Systems, Inc.

Section 2 - Operation	OPERATION
PRIMEPACT 66G and 66LP Recreational Vehicle Generators

♦ 2.4.5 ENGINE EXHAUST GAS____________________

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

2.5STARTING THE GENERATOR

NOTE:

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

2.	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.
3.	To	crank and start	the	engine, hold		the starf/stop

switch at START. Release the switch when the engine starts.

--------M.CAUTION ¿k--------------

If the engine does not start after it has been

^cranking for 15 seconds, release the Start/Stop switch and wait 1 minute before trying again. Holding the switch for longer than 15 seconds can damage the starter motor.

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

5. Turn ON electrical loads	using	the means
provided (such as a main	circuit	breaker or
transfer switch).

2.6STOPPING 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.

2J APPLYING LOADS TO GENERATOR

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

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

•DO NOT overload the generator.

•2.7.1 LETTING THE ENGINE STABILIZE

The	generator supplies	correct rated voltage only at
the	proper governed	speed. Some electrical appli­

ances may be extremely sensitive to voltage. Incorrect voltages can damage such appliances.

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

Generac® Power Systems, Inc.

OPERATION	Section 2- Operation

0Ìi	PRIMEPACT 66C and 66LP Recreational Vehicle Generators
• 2.7.2 DO NOT OVERLOAD THE GENERATOR		♦ 2.8.2 HIGH TEMPERATURE SWITCH______________

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.

2.8PROTECTION 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.

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 BEARING

1 O Generac* Power Systems, Inc.

Section 3 - Maintenance	MAINTENANCE
PRIMEPACT 66C and 66LP Recreational Vehicle Generators

♦ 2.8.4 OVERVOLTAGE PROTECTION___________

♦ 2.8.6 25-HOUR CHECK-UP

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

		it)V
	©			©
					-SENSING
					TO ROTOR
	©			=	^(DIRECT CURRENT)
					>FR0M STATOR
					EXCITATION WINDING
				B	(ALTERNATING CURRENT)
				B
	©			©
The voltage regulator				also	incorporates a “voltage

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

•2.8.5 25-HOUR BREAK-IN PERIOD _______________

The first 25		hours of operation	is the break-in		period
for	the generator. Properly breaking in the			generator
is	essential	to minimize fuel	consumption	and		pro­
vide maximum engine performance. During				this		25-
hour break-in period, follow this procedure:
•	Run the	unit at varying electrical loads to		help		seat
	the engine piston rings properly.
•	Check the engine oil level frequently. Add				oil if
	needed. It is normal for the generator engine to
	consume	more oil than is normal until		the	piston
	rings have properly seated.

•For the 75-hour operation following the break-in

period, avoid light electrical loads. Load						the
generator at 50 percent (or more)					of its	rated
wattage	capacity.	Repeated	light	loads	during	these
75 hours can cause improper seating of engine						pis­
ton rings, resulting in blowby and high oil con­
sumption.
• After	operating	the unit for	25	hours,	complete the

tasks recommended under Section 2.8.6.

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

-------JàWARNING ML--------------

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

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

3.1CHECKING THE ENGINE OIL

LEVEL

For oil capacities and reciuirements, 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):
1. Be sure the generator is as level as possible.
2.	Remove the dipstick and wipe it dry with a clean,
	lint-free cloth.
3.	Install	and tighten the dipstick	cap; then,		remove
	it again. The oil level should		be at	the	dipstick
	“Full” mark.

4.If necessary, remove the oil fill cap on the rocker

cover and slowly add oil until it reaches the dip­ stick “Full” mark. DO NOT FILL ABOVE THE “FULL MARK.

-------ML CAUTION Jk------------

Never operate the engine with the oil level A below the "Add" mark on the dipstick. Doing

this could damage the engine.

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

Generac* Power Systems, Inc. 1 1

(¿XSgiagM^ "' ' Z. '

MAINTENANCE

Section 3 - Maintenance

PRIMEPACT 66G and 66LP Recreational Vehicle Generators

3.2CHANCING THE ENGINE OIL

AND/OR OIL FILTER

•Change the engine oil after the first 25 hours of

operation (after the 25-hour break-in

period,

see

Section

2.8.5,

Page

10).

Thereafter,

change

the

oil every 100 operating hours. Change the oil more

frequently

if

operating

consistently

under

heavy

load or at high ambient temperatures.

•

Change

the

engine oil filter

after the

first

25

hours

of operation, and every 100 operating

hours

there­

after.

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

follows:

1.

Run

the

engine

until

it is

thoroughly warmed up

(at

least

five

minutes)

then

shut

OFF

the engine.

2.

With

the

engine still warm from running,

remove

the oil drain

plug

(Figure

3.1). Drain the

oil

into

a suitable container.

3.

After

the

oil

has

drained,

replace

the

oil

drain

plug. (If only changing the oil, go to step 7.)

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

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

6.Screw the new filter on by hand until its gasket

lightly contacts the oil filter adapter. Then, tight­ en the filter an additional 3/4 to one turn.

7.	Remove the dipstick and fill crankcase with the
	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 /\BOVE THE
	‘TULL’ MARK.
8.	Install	and	tighten	the dipstick before operating

the engine.

9.Start the engine and check for leaks.

NOTE:

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

Figure 3.1 — Oil Dipstick/Fill Tube and

Location of Oil Drain Plug

3.3MAINTAINING THE ENGINE AIR CLEANER

♦ 5.5.1 CLEANING THE FOAM PRECLEANER
Clean and re-oil the					foam	precleaner every				three
months		or	every	25	hours	of	operation,		whichever
occurs first. Service the foam precleaner more										fre­
quently		if	operating the generator				in	extremely		dusty
or	dirty		conditions.		Use	the	following		procedure
(Figure 3.3):
1. Turn the knob counterclockwise to loosen.
2.	Remove the			cover,	foam	precleaner		and	paper	fil­
	ter.

3.Remove the foam precleaner from the cover.

4.Wash the foam precleaner in liquid detergent and water.

5.	Wrap the foam precleaner in a clean cloth and
	gently squeeze it dry.

6.Saturate the foam precleaner in clean engine oil.

	Gently	squeeze it	in a clean cloth to remove
	excess oil and to distribute oil (DO NOT T’WIST).
7.	Install	the foam	precleaner into the cover, fol­
	lowed by the paper filter. Tabs at edges of paper

1 a Generac* Power Systems, Inc.

Section 3 - Maintenance
PRIMEPACT 66G and 66LP Recreational Vehicle Generators	MAINTENANCE

filter must lock into slots on cover.

8.Install the cover, foam precleaner and paper filter.

9.Replace knob to retain the filter in place.

Figure 3.3 - Engine Air Cleaner

PAPER FOAM

FILTER PRE-CLEANER

Figure 3.5 - Setting the Spark Plug Gap

SET PLUG GAP AT 0.030 inch

3.4CLEAN 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

3.5CHECKING 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).

—ik CAUTiON ik----------------

Sparking can occur if the wire terminal does A not fit firmly on the spark plug terminal end. If

necessary, re-form the wire terminal to obtain a tight fit.

3.6 FUEL FILTER (GASOLINE ONLY)

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

Figure 3.6 - Fuel Filter

FUEL FILTER

TO FUEL PUMP

---------------- ►

CUSTOMER FUEL CONNECTION

3.7SPARK ARRESTOR MUFFLER

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.

Generac* Power Systems, Inc. 1 3

	Section 3 - Maintenance
MAINTENANCE	PRIMEPACT 66C and 66LP Recreational Vehicle Generators

WARNING

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.

3.8CLEANING 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.

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

Do NOT use a forceful spray of water to clean A the generator. Water will enter the generator

interior and cause problems, and may also cont­ aminate the generator fuel system.

3.9BATTERY MAINTENANCE

All lead-acid batteries				will	discharge			when	not	in	use.
The generator battery should be inspected as follows:
♦ 3.9.1 WEEKLY_________________________________
•	Inspect	the	battery	posts		and	cables		for	tightness
	and corrosion. Tighten and clean as necessary.
•	Check	the	battery	fluid	level		of	unsealed		batteries
	and. if necessary, fill with					Distilled Water Only.					Do
	not use tap water in batteries.
♦ 5.9.2 EVERY SIX MONTHS_______________________
•	Have	the	state of	charge		and		condition		checked.
	This should be done with					an	automotive-type				bat­
	tery hydrometer.			NOTE:

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.

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 A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when working on batteries:

•Remove watches, rings or other metal objects;

•Use tools with insulated handles;

•Wear rubber gloves and boots;

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

•Disconnect any charging source prior to connecting or disconnecting battery terminals; and

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

--------A WARNING A-----------

Do not open or mutilate the battery. Released A electrolyte has been known to be harmful to

the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is 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.

1 Generac* Power Systems, Ino.

Section 3 - Maintenance
PRIMEPACT 66G and 66LP Recreational Vehicle Generators	MAINTENANCE

3.10IVIAJOR SERVICE MANUAL

To	obtain a service manual for your generator, con­
tact	Generac or your nearest Generac Authorized

Service Dealer. Make sure to identify your MODEL NUMBER and SERIES.

3.11DRIVE 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.

3.12EXERCISING 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.

3.13OUT 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.

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

3.	While	the	engine	is still	warm from	running,
	drain the oil completely. Refill the crankcase with
	SAE 1OW-30 oil having API classification “For
	Service SF.”
4.	Attach	a tag	to the	engine	indicating the	viscosity

and classification of the oil in the crankcase.

5.Remove the spark plug and pour two or three

	tablespoons of	clean,	fresh engine		oil	into	the
	spark plug	threaded	openings.	Reinstall			and
	tighten the spark plug.
6.	Remove the	battery and store it		in	a	cool,	dry
	room on a wooden board. Never			store		the battery
	on any concrete or earthen floor.

7.Clean and wipe the entire generator.

♦5.15.2 RETURN TO SERVICE_______________

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

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

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

2.Check the state of the battery. Fill all cells of unsealed batteries to die proper level wltli distilled water. DO NOT USE TAP WATER IN THE BAT­ TERY. Recharge the battery to 100 percent state of charge, or, if defective, replace the battery.

3.Clean and wipe the entire generator.

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

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

6.Allow the unit to warm up thoroughly

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

v8. When the eirgine is thoroughly warmed up, shut it down.

9.Your generator is now ready for service.

3.14WATTAGE REFERENCE GUIDE

	Running Watts
Battery Charger.................................................................	500
Belt Sander (3”)..............................................................	1000
Chain Saw.......................................................................	1200
Circular Saw (6-12”) ........................................	800 to 1000
Disc Sander (9”) .............................................................	1200
Hand Drill (1”) ...............................................................	1100
Hedge Trimmer.................................................................	450
Impact Wrench .................................................................	500
Lawn Mower ..................................................................	1200
Electric Range (one element)..........................................	1500
Television.......................................................	1750 to 2000
Coffee Maker..................................................................	1000
Electric Skillet.................................................................	1250
Hair Dryer.......................................................................	1200
Light Bulb.........................................................................	100
Microwave Oven ..............................................................	700
Oil Burner on Furnace .....................................................	300
Oil Fired Space Heater (140,000 Btu)..............................	400
Radio......................................................................	50 to 200
Slow Cooker .....................................................................	200
♦Furnace Fan (1/3 HP)....................................................	1200
♦Refrigerator.....................................................................	600
♦Air Conditioner (12,000 Btu).......................................	1700
♦Compressor (IHP).........................................................	2000
♦Deep Freeze....................................................................	500
♦Milk Cooler ..................................................................	1100
♦Submersible Pump (1-1/2 HP)......................................	2800
♦Submersible Pump (1 HP)............................................	2000
♦Paint Sprayer, Airless (1/3 HP) .....................................	600
♦Table Saw (10”) ..........................................	1750 to 2000
♦ Allow 2-1/2 times the listed watts for starting these
devices.

Generac* Power Systems, Inc. 1 5