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Generac Power Systems NP Series User's Manual

1. 6 1 1 Generator Location 6 1 2 Generator Supports 6 1 3 Suspended Mounting 6 1 4 Generator Restraint Generator Compartments 6 2 1 Compartment Size 6 2 2 Compartment Construction 6 2 3 Sound Insulating Materials 6 2 4 Acoustics essere m 6 2 5 Compartment Floor 25 Cooling and Ventilation sse 6 3 1 Generator Airflow 6 3 2 Cooling Air Inlet Openings ES 6 3 3 Compensating for Restrictions 27 6 3 4 Testing the Installation Gasoline Fuel System s 6 4 1 Fuel Tank 6 4 2 Generator Fuel Supply Line 6 4 2 1 Rigid Fuel Lines 6 4 2 2 Flexible Fuel Lines LP Gas Fuel System oet 6 5 1 Parts not included in Fuel System 28 6 5 2 Some Important Considerations 29 6 5 3 Vapor Withdrawal d 6 5 4 Primary Regulator sss eee 6 5 5 Gaseous Carburetion 22 6 5 6 Fuel Supply Lines 6 5 7 Excess Flow Valve 6 5 8 Leakage Exhaust 5 186 6 6 1 Mufflers and Spark Arrestors 6 6 2 Type of Exhaust System
2. 6 6 3 Exhaust System Safety Electrical Connections 6 7 1 Electrical Junction Box 6 7 2 a vae 6 7 3 Generator AC Connections 0 7 4 6 7 5 Isolating Different Power Sources 6 7 6 Power Supply 6 7 7 Ground Fault Circuit Interrupters Battery Installation 6 8 1 Recommended Battery 0 8 2 Battery Cables i ette us 6 8 3 Battery Cable Connections 6 8 4 Battery Compartment Optional 2 2 22 34 6 9 1 Remote Panel Models 35 Section 7 Post Installation 35 Section 8 Troubleshooting Post Installation Tests 35 Before Initial Start up Initial Testing Under 235 Installation Checklist 8 1 Troubleshooting Guide Troubleshooting Notes 38 Section 9 Electrical Data cesse 39 Section 10 Exploded Views and Parts Lists 40 50 Section 11 4 4 4 2 4 44 38 amp 51 Section 12 Warranty sese 52 Back Cover Ge
3. A Be sure to reinstall the muffler plug tightly Engine vibration could cause a loose plug to fall out Without the plug in place hot engine exhaust is directed out the opening This hot exhaust depending on the installation could be directed to areas not able to withstand the extreme heat such as wooden floor boards or other flammable material This could result in a fire 64 20 Section 3 Maintenance 25 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 caution A A Do NOT use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also cont aminate the generator fuel system
4. EXPLOSION HAZARDS 4 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 noi allow gas vapors to enter the vehicle Generac Power Systems inc 18 Section 5 General Information GENERAL INFORMATION PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners o
5. 40 Generac Power Systems inc ITEM Section 10 Exploded Views and Parts Lists Qi ums PRIMEPACT 55G and 55LP Recreational Vehicle Generators Sheet Metal Drawing No D3150 A 0 PART DESCRIPTION M 1 SEE ENGINE EXPLODED VIEW of ENGINE 099258 1 KEY NOODRUFF 6 x 22MM 067198N 1 BEVELLED WASHER 067890 1 HEX NUT 087865 1 PLUG FLYWHEEL ACCESS 0A4456 1 3 8 SPECIAL LOCK WASHER 086313 1 HOUSING ENGINE 056893 23 SCREW CRIMPTITE NO 10 24 x 1 2 087750 1 SCROLL FLYWHEEL 074916 1 COVER BASE CYL 2 074908 9 SCREW TAPTITE M5 x 10MM 073190 1 WRAPPER CYL 2 078858 1 COVER VALLEY 078859 1 WRAPPER CYL 1 074902 2 WRAPPER BARREL 066476 4 HHCS LW M6 x 1 0 x 12MM 073191 1 COVER BASE CYL 1 042907 2 CAPSCREW HEX HD M8 x 1 25 x 16MM 022129 2 LOCK WASHER M8 075246 4 SCREW TAPTITE 3 8 16 x 1 1 4 0742600133 1 WIRE ASSEMBLY NO 16 074900 1 STARTER COVER 073186 1 WRAPPER CRANKCASE 081108 1 BUSHING SNAP 022717B 1 GROMMET RUBBER 022717A 3 GROMMET RUBBER 067866A 1 O RING 077001A 1 PLUG OIL FILL 073132 2 BOOT SPARK PLUG 087858A 1 GROUND WIRE ASSEMBLY CYL 1 029289 2FT FOAM TAPE 087858B 1 GROUND WIRE ASSEMBLY CYL 2 050277 1 OIL DRAIN DECAL Generac Power Systems Inc 41 LISTS v Mh Section 10 Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators S 0 Base and Pulleys Drawing No D3151 A 42 Generac Power Systems Inc Section 10
6. 12 3 5 Checking the Engine Spark Plug 412 3 6 Fuel Filter Gasoline Only 13 3 7 Spark Arrestor Muffler 13 3 8 Cleaning the Generator 13 3 9 Battery Maintenance 2 2 100000 13 3 9 T Weekly aiite red ett hie QR E RT AREE ER 13 3 9 2 Every Six Months 2 13 3 10 Major Service Manual Sel Drive Belt cente Ser oou it tr eati sge 14 3 12 Exercising the Generator 14 3 13 Out of Service Procedure 3 13 1 Removal From Service 22 2 14 3 13 2 Return to Service 2 15 3 14 Wattage Reference Guide Section 4 422 1 21 2 7 1 1 0 8 4440 42 TABLE OF Table of Contents CONTENTS Part Installation Instructions sese 17 Safety Rules sees Section 5 General Information esses Purpose and Scope of the NE Standard Booklets Equipment Generator Engine Operating Speed Generator AC Connection System Major Dimensions and Features Section 6 Installation nn 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 Location and
7. 3 9 BATTERY MAINTENANCE All lead acid batteries will discharge when not in use The generator battery should be inspected as follows 3 9 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 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 Generac Power Systems Inc 13 E MAINTENANCE 2 9 Section 3 Maintenance A A 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 Dis
8. Exploded Views and Parts Lists Qo ums PRIMEPACT 55G and 55LP Recreational Vehicle Generators Base and Pulleys Drawing No D3151 A 0 ITEM QTY DESCRIPTION ITEM PARTNO DESCRIPTION 1 86318 1 BASE MOUNTING 50 5802 1 TINNERMAN CLIP 2 90141 1 GROUND CABLE 51 22237 8 WASHER LOCK 3 8 3 4691 4 MOUNT VIBR 1 50X1 38 X 3 8 16 52 22145 2 WASHER FLAT 5 16 ZINC 4 25017 8 SCREW HHC 3 8 16 X 1 2 G5 54 92120 2 NUTLOCK TRIC M6 X 1 0 Y ZNC 5 46526 2 WASHER LOCK M10 55 133 74260 1 CABLE STARTER 6 22129 8 WASHER LOCK M8 5 16 56 73179 1 OIL FILTER SUPPORT 7 72391 2 SKID RUBBER MOUNT 57 70185 1 FILTER OIL FRAM PH3614 8 77003 2 SAFETY BOLT 5 16 18 x 3 1 2 58 8584 1 10 PSI SWITCH OIL PRESSURE 9 22259 2 NUT HEX 5 16 18 STEEL 59 74948 3 FITTING COMP 5 16 X1 8 SLF ALGN 10 50858 6 NUT LOCK M8 60 74950 1 TUBE OUTER OIL 11 51730 2 SCREW HHC 8 1 25 X 60 G8 8 61 74951 1 TUBE INNER OIL 12 29459 2 SPRING BELT TENSION 62 73134 1 ADAPTOR OIL FILTER ADAPTER 13 75215 2 WASHER SPRING CNTR 63 38750 3 SCREW HHC M6 1 0 X 30 G8 8 14 73146 4 SLIDE NYLON 64 74949 1 ELBOW 90D TUBE CMP 5 16 X1 8NPT 15 75209 2 SUPPORT NYLON SLIDE 65 68548 1 GASKET OIL FILTER ADAPTER 16 73174 1 MANIFOLD EXHAUST 66 C4006 1 CABLE 30 LONG 17 79678 2 SEALING 67 29289 TAPE ELEC NON UL 1 16 1 2 18 40976 4 5 SHC 8 1 25 X 20 G12 9 68 22158 2 NUT HEX 10 32 STEEL 19 72383 2 GASKET COLLECTOR PAN 69 75281 1 SWITCH HIGH T
9. MINIMUM CLEARANCE 1 1 2 6 3 3 COMPENSATING FOR RESTRICTIONS Such materials as screening louvers or expanded metal can restrict the free flow of air 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 Section 6 Installation INSTALLATION 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 SYSTEM The installation of a gasoline fuel sys
10. Owner s Manual Air cooled Recreational Vehicle Generators Model 009592 4 and 009735 4 PRIMEPACT 55G and 55LP C VC lt 277 5 KE c cem Dy qe yp 5 FO T ERE ums Ac SE 785 i 2 21 xA 7 INTRODUCTION READ THIS MANUAL THOROUGHLY AXRM ALMAL 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 A A After this heading you can read instructions that if not strictly complied with will result in personal injury or property damage WARNING A After this heading you can read instructions that if not strictly complied with may result in person al injury or property damage Ak 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
11. 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 part s ONLY labor not included Labor removal and reinstallation is the 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 SERVICE 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 with all mechanical devices the GN Series engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust f
12. Rotor RPM 3600 3600 Rotor Poles 2 2 Engine RPM 2500 2500 Rated Max Continuous AC Output 5500 watts 5 5 kW 5200 watts 5 2 kW Voltage 120 120 Rated Max Continuous Current 45 8 AC ampst 43 3 AC amps N Phase 1 1 Frequenc 60 Hertz 60 Hertz Battery Charging Current Max 2 amps trickle charge 2 amps trickle charge Weight 211 pounds 214 pounds Length 25 inches 25 75 inches Width 18 5 inches 18 5 inches Height 16 13 inches 16 13 inches Allunits 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 amp Generac Power Systems inc OPERATION Section 2 Operation PRIMEPACT 55G and 55LP Recreational Vehicle Generators ix 2 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 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 sw
13. 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 Figure 3 3 Engine Air Cleaner PAPER FOAM FILTER PRE CLEANER 12 Generac Power Systems Inc PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 careful bending the ground electrode Figure 3 5 Figure 3 5 Setting the Spark Plug Ga
14. ENGINE SPECIFICATIONS Type of Engine PRIMEPACT 55G S5 LP GN 480 Cooling Method 2 0200 0 Air cooled Rated Horsepower PRIMEPACT 55G 55LP eee 15 at 3600 Displacement PRIMEPACT 55 55 2 480cc Compression 8 6to 1 Cylinder Block Aluminum w Cast Iron Sleeve Type of Governor sees Mechanical Fixed Speed Engine Governor Speed sss 2500 rpm Air Cleaner Paper Element w Foam Precleaner Starter cava cade AONO ies 12 volt DC Electric Ignition System Solid state w Flywheel Magneto Recommended Spark Plug Champion 2 RC12YC AQ uento ded inia ee n R45S FramiAutolite 2 65 Spark Plug Gap 0 030 inch 0 8 mm Recommended Min Battery 400 Cold Cranking Amps 1 6 4 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 1 6 5 GENERATOR SPECIFICATIONS SERIES PRIMEPACT 55G PRIMEPACT 55LP
15. Mach 44 40 X 1 4 22 087770 1 Line Fuel 5 16 I D 23 074946 1 Link Choke 25 030340 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 Flywheel Assembly 29 040173 2 Clamp Hose Screw Type 30 066829 2 Rivet 1 8 Diameter X 1 8 Long 31 075944 1 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 LISTS 00 49 ITEM PART NO QTY 1 A1662A 2 57822 3 74994 4 26307 5 26915 6 75211 7 2566 8 5198 9 49813 10 22097 11 47411 12 38750 13 37398 14 74961 15 56893 16 47227 1 2 1 4 1 1 1 1 4 4 2 2 1 1 5 1 Section 10 Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators LP Carburetor amp Air Cleaner Drawing No A4029 F DESCRIPTION CARB V TWIN UP HOSE CLAMP 1 2 LD X 10 LONG HOSE STREET ELBOWS 3 4 PIPE NIPPLE GASEOUS FUEL REGULATOR GASEOUS FUEL SOLENOID REGULATOR MOUNTING BRACKET M6 HEX NUT M6 LOCK WASHER 6 1 0 X 16MM HEX HD CAPSCR 6 1 0 X 30MM HEX HD CAPSCR HEX LOCK NUT NYLON GOVERNOR ADJUSTER BRACKET 810 24 X 1 2 SCREW GOVERNOR ADJUSTER SCREW 50 Generac Power Systems inc ITEM QTY 17 18 19 74962C 74962G 66476 2338 C2338C
16. PIPE 99 067897 2 EXHAUST GASKET NOT SHOWN GOVERNOR SHAFT SEAL 100 091481 1 GASKET AND CAP ASSEMBLY OIL PUMP O RING 101 091480 1 ROCKER ARM COVER OIL GALLEY O RING 102 001198 1 GOVERNOR CRANK CARBURETOR SPACER ROCKER ARM STUD Not Shown WASHER VALVE COVER SEAL Generac Power Systems Inc 47 Section 10 Exploded Views and Parts Lists 7 PRIMEPACT 55G and 55LP Recreational Vehicle Generators 0 Carburetor Drawing No 93753 G 48 Generac Power Systems Inc Section 10 Exploded Views and Parts Lists 50 PRIMEPACT 55G and 55LP Recreational Vehicle Generators Carburetor Drawing No 93755 G PARTS ITEM PART NO QTY DESCRIPTION 1 073112B 1 Carburetor Assembly 2 074962C 1 Spring Governor PP55 PP66 074962G 1 Spring Governer Q 70G 3 070155 1 Lever Governor 4 070108 1 Rod Governor to Carburetor 5 056893 5 Screw Crimptite 10 24 X 1 2 6 074961 1 Bracket Governor Adjuster 7 047227 1 Screw Governor Adjuster 8 037398 1 Nut Hex Lock Nylon 9 073131 1 Bracket Air Cleaner Support 10 066476 2 Screw Hex M6 1 0 X 12MM 11 070575 2 Screw Hex M6 1 0 X 25MM 12 070125 1 Spring Anti Lash 13 073374 1 Bracket Choke Support 14 074947 1 Rod Choke Control 15 089473 1 Bi Metal Assembly Choke 16 091306 1 Solenoid Choke 17 077091 1 Hair Pin Cotter 18 031879 4 Flat Washer 4 19 022159 4 Lock Washer 4 20 089870 1 Solenoid Fuel Shutoff Q 70G Only 21 072536 4 Screw Pan HD
17. 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 engine 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 74 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 availab
18. RECTIFIER 63 23897 3 10 M5 FLAT WASHER 33 90987 2 M3 0 5 x 12 LG PPHMS Generac Power Systems 45 i urs Section 10 Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators 0 Exploded View Engine Common Parts Drawing No 79216 F 98 VALVE OVERHAUL KIT 7 GRAPHCIL s 8 3 7 GRAPHOILS 46 Generac Power Systems inc ITEM PART NO QTY Oo Co ho 069331 069333 067805 079234 079235 070169 069332 0851100104 072315 089967 070596 069336 069325 067888 072334 075247 067924 067878 075248 075249 069327 075250 075251 072346 069316 069317 067816 069320 070513 070584 070530 072358 069379 067895 070594 067158 068574 068554A 068573 070506 070554 070568 075253 qe A a qe BO BO PO SO d d qm DO PO de BO DO d DO OQ a 2 ol ROLL Section 10 Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators PARTS Ce Or Exploded View Engine Common Parts Drawing No 79216 F DESCRIPTION ITEM PART NO QTY DESCRIPTION CYLINDER ASSEMBLY 44 067885 4 M6 NYLON NUT SLEEVE BEARING 45 075254 4 VALVE ADJUST SCREW OIL SEAL 46 070535 1 OIL SCREEN NO 1 CYLINDER HEAD ASSEMBLY 47 062881 1 STARTER MOTOR NOT SHOWN NO 2 CYLINDER HEAD ASSEMBLY 51 072536 4 IGNITION ARMATURE SCREW SEALING WASHER 52 072347 2 SPARK PLUG CYLIND
19. Systems inc 31 INSTALLATION Section 6 Installation PRIMEPACT 55G 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 f 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
20. Vehicle Generators Part Operating Instructions Introduction 24 4 4 Inside Front Cover Read This Manual Thoroughly 2 2 2 2 IFC Contents ese terrea ERANT Operation and Maintenance How to Obtain Service Authorized Service Dealer Locator Number IFC HV IAC 2 Section 1 General Information ee 4 1 1 Generator Identification 2 2 12 4 1 2 Generator Applicability 2 2 00 202 5 1 3 Installation cer ee eere Leg 5 1 4 Kril AME 5 1 5 Generator AC Connection 5 1 6 Sp cifications TR n 6 1 6 1 Fuel Requirements 2 00 00 6 1 6 2 Engine Oil Requirements sse 6 1 6 3 Engine Specifications 14 6 1 6 4 Emissions Compliance Period 6 1 6 5 Generator 6 Section 2 2 2 7 2 1 Generator Control Panel 2 0 0 7 DVL Buel PHIE utet rn rrr RH 7 2 1 2 Start Stop Switch 22 21 7 2 1 3 15 Amp Fuse 2 1 4 Eine Breakers 1
21. _ 22222204 Water in fuel _ _ Drain fuel tank and refill No AC output voltage 1 Main breaker s open Close main breaker s 2 Transfer switch if so equipped is Reset transfer switch set to wrong position 3 Failure in vehicle electrical system See vehicle manual 4 Generator component failure Contact an authorized service facility Generac Power Systems inc 37 00000 uU 00900 _ ELECTRICAL DATA Section 9 Electrical Data PRIMEPACT 55G and 55LP Recreational Vehicle Generators Electrical Schematic Drawing No D3148 A BATTERY 77 BATTERY CHARGE WINDING NEUTRAL CONNECTION BY CUSTDMER POWER WINDING DPE WINDING Ji 1 7 Ji e 3 Ji 3 gt Ji 4 gt 18 Ji 5 2 18 Ji 6 3 72 17 1 6 Ji 9 2 4 J1 102 66 Ji 11 2 85 41 122 0 21 132 REMOTE Ji 142 18 PANEL JI 155 18 CONNECTOR 0I 1 1 17 2 3 3 8 4 53 E w l rojJg 28 uu5 REMOTE PANEL e OPTIONAL Y 1814170 STUP 55 rae Mo M LEGEND BCR BATTERY CHARGE RECTIFIER CB CIRCUIT BREAKER 304 CALL MODELS ELECTRONIC Ch CB CIRCUIT BREAKER 20A 055 MODEL VULTAGE _ CIRCUIT BREAKER 30A Q70 NP66 MODEL CB3 25 055 MODEL REGULATOR RED 7 CIRCUIT BREAKER 3 0 NP66 070 MODELS CH CHOKE HEATER GASOLINE MODELS ONLY EA CS CHOKE SOLENOID GASOLINE
22. 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 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 ds OIL DIPSTICK OIL DRAIN PLUG Generac Power Systems Inc 11 C MAINTENANCE 2 9 Section 3 Maintenance Figure 3 2 Engine Oil Filter ENGINE OIL FILTER TWIST COUNTER CLOCKWISE TO LOOSEN 3 3 MAINTAINING THE ENGINE AIR 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
23. fuse 2 Loose or corroded or defective Tighten clean or replace battery cable s as necessary 3 Battery is discharged or defective 3 Recharge or replace battery 4 Defective starter contactor 4 Replace starter contactor 5 Defective starter motor 5 Replace starter motor 6 Defective Start Stop switch 6 Replace switch _ 7 Defective Engine Control Board 7 Contact an authorized service dealer Engine cranks wont start 1 Outoffuel 1 Refill fuel tank 2 Fuel shutoff valve is closed 2 Open fuel shutoff vaive s 3 Fuel pump not operating 3 Repair or replace pump 4 Automatic choke not operating properly 4 Repair replace or adjust 5 Engine is flooded 5 Wait 5 10 minutes try again 6 Fuel filter is clogged 6 Replace filter if clogged 7 Engine spark plugs defective 7 Clean regap or replace as needed 8 ignition magneto on engine 8 Replace if defective 9 Bad carburetor 9 Adjust repair or replace 10 Dirty air cleaner 10 Clean or replace as needed Engine starts hard runs rough 1 Dirty engine air cleaner 1 Clean or replace as needed 2 Automatic Choke sticking 2 Free choke linkage as needed 3 Defective spark plugs 3 Clean regap or replace 4 Defective ignition magneto 4 Replace it if defective Engine starts then shuts down 1 Engine oil level is low Add oil as needed 2 Badlow oil pressure switch Replace if bad 3 Defective High Temp Switch Replace Switch if bad E
24. 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 1 25 mm thick fiberglass having a 2 pound density When fiberglass is used its coated side should face toward the compartiment interior 24 Generac Power Systems Inc A A Do not install sound insulation or any absorbent material on the compartment floor interior Such materials will become soaked with combustible or explosive vapors and liquids and will become a fire hazard Using a combination of sound insulating materials can often reduce noise more effectively than a single mater ial For example a sheet of lead or visco elastic materi al along with a layer of other acoustical material is more effective than when a single material is used 6 2 4 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise compartment abatement NOTE Any method used to reduce noise must not adverse ly affect the flow of cooling and ventilating air into or out of the compartment In addition to the effective use of sound insulating mate rials construction of a special noise abatement com partment might be considered to reduce noise levels Such a compartment might be constructed as f
25. is 67 cubic feet per hour If an existing primary gas regulator does not have a sufficient flow capacity for the generator and other gas appliances in the circuit a install a primary regulator with adequate flow rate or b install a sep arate regulator only and rated at least 67 cubic feet per hour The inlet side of any primary regulator that supplies the generator must connect directly to a gas pressure tank Do NOT tee the generator line into a gas circuit feeding other areas 6 5 5 GASEOUS CARBURETION Eb Aad ER adosado te a in e 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 GAS AT FLOW POSITIVE PRESSURE 4 GAS AT ZERO PRESSURE LOW PRESSURE AREA Generac Power Systems inc 29 INSTALLATION Section 6 Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators The greater the airflow through the carburetor venturi the lower the pressure
26. ner nee ne 7 2 2 Optional Remote Start Stop 7 2 3 Automatic Choke 2 39 1 Ghoke Solenold e a eared Sa rues tees 7 2 3 2 Prechoke ehe ang re 2 4 Before Starting the Engine 2 41 Installation ie deer t 2 4 2 Engine Lubrication 2 4 3 Fuel Supply 2 4 4 Cooling and Ventilating Air 222 11 8 2 4 5 Engine Exhaust Gas 1 7 coc 8 2 5 Starting the Generator 2 6 Stopping the 2 2 2 22 2 2 7 Applying Loads to Generator 222 2 2 7 1 Letting the Engine Stabilize 2 7 2 Do Not Overload the Generator 9 2 8 Protection Systems eee epe reete tte 2 8 1 Low Oil Pressure Switch 2 8 2 High Temperature Switch 2 2 2 10 2 8 3 Field Bost egentes e e tege nee 2 8 4 Overvoltage Protection 2 8 5 25 Hour Break in Period 2 8 6 25 Hour Checkup 2 22 2 8 7 Operation in High Grass or Brush 11 Section 3 Maintenance 11 3 1 Checking the Engine Oil Level wll 3 2 Changing the Engine Oil and or Oil 11 3 3 Maintaining the Engine Air Cleaner 12 3 3 1 Cleaning the Foam Precleaner 12 3 4 Clean Air Intake Screen
27. 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 32 Generac Power Systems inc Line T1 red to T2 white is protected against overload by a 20 amp circuit breaker CB1 Use this line to neu tral 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 4 caution A Do NOT connect electrical loads in excess of any circuit breaker rating or you will develop prob lems with circuit breaker tripping which causes a loss of AC output Also do NOT exceed the gener ator s rated wattage capacity Add the watts or amperes of all lighting appliance tool and motor loads the generator will operate at one time This total should be less than the unit s rated wattage amperage capacity 6 7 4 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The fol
28. 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 Eb PUR Ii ccc CONES RENDERE 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
29. 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 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the purchaser owner Such use shall not reduce Generac s ECS Warra
30. 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 0 Section 5 Maintenance 32 CHANGING THE ENGINE OIL AND OR OIL FILTER Change the engine oil after the first 25 hours of operation after the 25 hour break in period see Section 2 8 5 Page 10 Thereafter change the oil every 100 operating hours Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures Change the engine oil filter after the first 25 hours of operation and every 100 operating hours there after To change the oil and or oil filter proceed as follows 1 Run the engine until it is thoroughly warmed up at least five minutes then shut OFF the engine 2 With 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
31. 004184 G EN ER A C 6 QUARTZH micin O HOURS Vo kK MOBILE GENSETS 2 3 AUTOMATIC 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 7 OPERATION Section 2 Operation al PRIMEPACT 55G and 55LP Recreational Vehicle Generators 2 5 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 pro
32. 4 both sides not shown o Q Oil Fill Oil Level Ee Fuel Filter Oil Drain Plug Fuel Pump c Starter Contactor Oil Filter Air Filter Ground Lug Generac Power Systems inc 21 INSTALLATION Section 6 Installation 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 s
33. A properly installed exhaust system must be vapor tight quiet and com pletely safe A 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 caution Ak A 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 INSTALLATION PRIMEPACT 55G and 55LP Recreational Vehicle Generators c 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
34. ATTERY 6 8 4 BATTERY COMPARTMENT Install the generator battery in its own vented compart ment Place the battery compariment 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 WIRES18 A PS WIRE 0 4 STOP d GROUND WIRE 14 WIRE 17 ENGINE RUN CRANK SIGNAL PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 I of this manual Model 004057 includes the remote panel and a 10 foot long 4 wire harness Model 004184 includes the remote panel and a 30 foot long 4 wire harness 71 POST INSTALLATION TESTS T
35. C XX CX 5 5 Ny 95 Nt 100 SQUARE INCHES UNRESTRICTED MINIMUM OPENINGS lt gt Ha lt gt o lt gt lt gt lt gt lt gt lt gt oo lt 2 e 2 lt 2 e 00 25 lt 5 09 000 X OX OO XX x 059506949606 06067 X069 0S X990 x 009 0 09 9 0 0 9 00 0 0 9 0 0 5 5555056 55 0 55 5 5 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 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 PRIMEPACT 55G and 55LP Recreational Vehicle Generators Figure 6 12 Air Inlet Using Ductwork ANTI SPLASH BAFFLE r i Vy 1 GENERATOR gt E s x i t 22 if AIR IN AIR OUT Figure 6 13 Air Inlet in Vehicle Skirt d VEHICLE FLOOR VEHICLE
36. C2338A 75944 A7782A 70155 76242 70125 70108 28739 55162 73131 61696 e 4d o e e me O NOT SHOWN 19 DESCRIPTION GOVERNOR SPRING PP55G LP PP66G LP GOVERNOR SPRING PP70G LP Q70G M6 1 0 X 12MM HEX SCREW W LOCK WASHER AIR CLEANER DECAL PRIMEPACT 7OLP AIR CLEANER DECAL PRIMEPACT 66LP AIR CLEANER DECAL PRIMEPACT 55LP GOVERNOR SPRING BRACKET FLYWHEEL ASSEMBLY GOVERNOR LEVER 1 8 1 D X 1 8 RIVET ANTI LASH SPRING GOVERNOR TO CARBURETOR ROD 4 LONG TIE WRAP PIPE SEALANT AIR CLEANER SUPPORT BRACKET BARBED 90 DEG 3 8 X 1 2 Section 11 Notes NOTES PRIMEPACT 55G and 55LP Recreational Vehicle Generators Generac Power Systems 51 Section 12 Warranty 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
37. EMPERATURE 20 90859 1 COVER PLATE EXTERNAL 70 1085 2 SCREW PPHM M3 0 5 X 8 21 75224B 1 PULLEY ENGINE 71 43182 2 WASHER LOCK 22 731068 1 PULLEY ALTERNATOR 72 22152 2 WASHER LOCK 10 23 175216 1 BELT POLY V 4L 40 73 75237 4 WASHER SPRING RETAINER 24 49451 1 WASHER FLAT SPECIAL 406 1 0 74 01624 1 BOOT OIL PRESSURE SWITCH 25 42633 1 SCREW HHC 3 8 24 X 1 G5 75 75474 i BOOT TEMPERATURE SWITCH 26 77017 1 GUIDE BLOWER HOUSING 76 90800 1 ELBOW EXHAUST 27 7318 1 SCREW 3 8 24 2 1 4 G8 77 94670 1 CLAMP EXHAUST 28 74906 7 SCREW TAPTITE M6 X 20 BP 78 175226 1 COVER AIR 29 91123 1 BRACKET FUEL PUMP 79 56893 23 SCREW CRIMPTITE 10 24 X 1 2 30 72375 1 HOUSING BLOWER 80 75229 1 SLIDE PAN GASKET 31 73185 1 SPACER ROLL 2 36 X 230 X 042 BRZ 81 D3158 1 SLIDE PAN 32 22097 7 WASHER LOCK M6 1 4 82 79246 6 CAPSCREW HEX HEAD M6 1 00 x 33 177682 1 SCREW HHC M5 0 8 X 80 G8 8 16mm WITH LOCK WASHER 34 75242 4 SPRING GENERATOR SET MT 83 22473 5 WASHER FLAT 1 4 ZINC 35 49813 2 NUT HEX M6 1 0 G8 YEL CHR 84 01741 1 BOOT BATTERY CABLE 36 45757 2 SCREW HHC M6 1 0 X 25 68 8 85 72384 1 COVER EXHAUST OUTLET 37 90475 1 FUEL PUMP 86 24114 2 NUT HEX 5 16 24 STEEL 38 87769 1 FUEL FILTER 87 77643 1 GASKET EXHAUST OUTLET 39 87768 1 FITTING COMP 1 4 1 8 SLF ALGN 88 01741 2 BOOT BATTERY CABLE 40 87770 1 FUEL LINE 89 1227 1 CONTACTOR STARTER 41 A8475 1 SPECIAL LOCK WASHER M5 90 1658 3 LOCKWASHER SPECIAL 42 26925 1 PLUG STD PIPE 3 8 STEEL
38. ER HEAD GASKET 53 075258 1 ENGINE GASKET KIT BREATHER ASSEMBLY 57 066480 1 AIR CLEANER GASKET BREATHER GASKET 59 072361 1 GOVERNOR SHAFT BUSHING BREATHER SCREW 60 072362 1 GOVERNOR SHAFT BUSHING BREATHER TUBE 61 070199 1 BREATHER BAFFLE OIL SUMP GASKET 62 072366 1 COTTER PIN CYLINDER HEAD BOLT 64 072365 1 GOVERNOR SHAFT WASHER 3 8 NPT OIL DRAIN PLUG 65 068555 2 CRANKCASE DOWEL CRANKSHAFT ASSEMBLY 66 067806 4 CYLINDER HEAD DOWEL OIL SUMP ASSEMBLY 73 068572 2 OIL PUMP SCREW OIL SEAL ASSEMBLY 74 075272 2 SPARK PLUG TERMINAL OIL SUMP BOLT 75 070122 4 VALVE STEM SEAL STANDARD PISTON ASSEMBLY 76 067910 2 INTAKE VALVE SEAT STANDARD PISTON RING SET 78 067813 4 VALVE GUIDE PISTON LOCKING RING 81 070592 1 AIR CLEANER BASE STANDARD PISTON RING 82 073123 1 AIR FILTER NOT SHOWN CONNECTING ROD ASSEMBLY 83 070593 1 AIR CLEANER COVER CONNECTING ROD BOLT 84 003633 1 AIR CLEANER COVER SCREW EXHAUST VALVE 85 067156 2 AIR CLEANER BASE SCREW INTAKE VALVE 86 069341 1 FOAM PRE CLEANER VALVE SPRING 88 070597 1 AIR INLET TUBE VALVE SPRING RETAINER 89 072305 1 BREATHER DEFLECTOR VALVE KEEPER 90 067920 2 VALVE COVER GASKET VALVE TAPPET 91 069328 2 VALVE COVER CAMSHAFT ASSEMBLY 92 070547 1 OIL PUMP ASSEMBLY INTAKE MANIFOLD 93 070536 1 GOVERNOR SLIDER CARBURETOR MOUNTING GASKET 94 070577 4 PUSH ROD INTAKE MANIFOLD GASKET 95 070599 4 ROCKER ARM CARBURETOR MOUNTING BOLT 97 070566 4 ROCKER ARM SUPPORT INTAKE MANIFOLD MOUNTING BOLT 98 075271 1 VALVE OVERHAUL KIT 1 8 NPT PLUG
39. FROM STATOR x EXCITATION WINDING ALTERNATING CURRENT S 6 Sy 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 OUR 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 PRIMEPACT 55G and 55LP Recreational Vehicle Generators 2 8 6 25 HOUR CHECK UP After the 25 hour break in period contact a Generac Authorized Service Dealer for the foll
40. 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 mya FOLD LOCKED STANDING DOUBLE LOCK DOUBLE SEAM i GORDON SEAM LOCK SEAM STANDARD LAP JOINT 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 A A Do not install any flammable material directly 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 62 5 SOUND INSULATING MATERIALS Once installers have determined that a compartment is properly constructed and metal lined they can add acoustical material This may
41. MODELS ONLY 3 Fl FUSE 15 BLACK 4 FP FUEL PUMP DR LPG SHUT OFF VALVE FS FUEL SOLENOID CIF SUPPLIED ON 9 GT TERMINAL GROUND 4 TAB 2 6 13 HM METER HOUR OPTIONAL SWITCH HIGH CLOSES ON HIGH TEMPO IM IGNITION MAGNETO CYL IGNITION MAGNETO Kt CYL CV TWIN UNITS ONLY 7 LIGHT RUN OPTIONAL toe SWITCH LOW DIL PRESSURE lt CLOSES ON LOW PRESSURED ENGINE CDNTRDLLE RESISTOR 1 DHM EN SC STARTER CONTACTOR SM STARTER MOTOR SW1 SWITCH START STOP SWe SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TC TERMINAL CONN 4 E CONNECTOR 120V 20 055 amp NP66 120V 30A 070 Generac Power Systems inc 9 Section 9 Electrical Data PRIMEPACT 55G and 55LP Recreational Vehicle Generators gt SLIND NIAL A ND ELECTRICAL DATA 4 P M CN RET M ORE aaa l AINOLSNI A8 2v7H NOLLOGNNUO JVNIn3N T NOLLISNNGO OV amaso Wiring Diagram Drawing D3148 A H3 DISn2 M Tal dds ei s3N lsno O O A8 3I lddhs 39 Generac Power Systems Inc Section 10 Exploded Views and Parts Lists PRIMEPACT 55G and 55LP Recreational Vehicle Generators Sheet Metal Drawing No D3150 A 13 See Carburetor _ Exploded View 7 woa A
42. S PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 n 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 vi
43. SQ HD 91 90088 1 CLAMP VINYL 25 X 28 Z 43 75710 1 TUBE OIL FILL AND DRAIN 92 22131 1 WASHER FLAT 3 8 ZINC 44 74958 1 CAP amp DIPSTICK ASSEMBLY 93 81105 2 FLANGE NUT SPECIAL 5 16 18 45 67871 1 O RING CAP 94 23897 6 WASHER FLAT 10 ZINC 46 5508 1 OIL FILL TUBE GASKET 95 67210 1 DECAL GROUND 47 75711 1 PIPE OIL DRAIN ADAPTOR 96 45756 9 SCREW M6X10 YEL CHR 49 22413 1 SCREW 1 4 20 X 1 G5 Generac Power Systems inc 43 Qi ums Section 10 Exploded Views and Parts Lists gt PRIMEPACT 55G and 55LP Recreational Vehicle Generators 0 Engine Drawing No D3149 A 44 Generac Power Systems Inc Section 10 Exploded Views and Parts Lists gs PRIMEPACT 55G and 55LP Recreational Vehicle Generators Engine Drawing No D3149 A 0 ITEM PARTNO QTY DESCRIPTION ITEM PARTNO QTY DESCRIPTION 1 C9675 1 LOWER BEARING CARRIER 34 86317A 1 PANEL SUPPORT BRACKET 2 77005 1 ROTOR ASSEM PP55 35 75235 2 M5 0 8 x 30 LG CAPSCREW 77004H 1 ROTOR ASSEM PP66 36 82737 4 VIBRATION MOUNT 3 87844H 1 STATOR ASSEM 55 37 49813 4 M6 1 0 HEX NUT 87845H 1 STATOR ASSEM 66 38 49815 1 M5 08 x 16 LG HEX HD CAPSCR 4 73159 1 BALL BEARING 39 43182 2 M3 LOCK WASHER 5 31971 1 BALL BEARING 40 8475 3 10 SPECIAL LOCK WASHER 6 C9674 1 UPPER BEARING CARRIER 41 53623 1 C BREAKER 2 5A PP55 7 77006 4 STUD STATOR 54502 1 C BREAKER 3 0A PP66 8 52858 4 M8 1 25 FLANGE LOCK NUT 42 D2724 2 BOOT ROCKER
44. SWITCH 9 66386 1 BRUSH HOLDER 43 83049 1 REGULATOR VOLTAGE 10 66849 2 M5 0 8 x 16 LG TAPTITE 44 22152 6 M5 LOCK WASHER 11 27756 4 NYLON WASHER 45 51716 4 M5 0 8 HEX NUT 12 86314 1 GENERATOR TOP HOUSING 46 90144 1 C BREAKER 20A PP55 13 75234 1 RESISTOR 90145 1 C BREAKER 30A PP66 14 22473 2 7 M6 FLAT WASHER 47 90145 i C BREAKER 30A ALL UNITS 15 22097 5 7 M6 LOCK WASHER 48 25105 4 86 32 4 SCREW W LOCK WASHER 16 74095 1 M6 1 0 x 60 LG CAPSCREW 49 86315 1 PANEL COVER 17 90141 2 GROUND CABLE 50 90734 4 M4 0 7 x 12 LG CAPSCR W LOCK 18 1658 2 SPECIAL LOCK WASHER 7 WASHER amp FLAT WASHER 19 74906 4 M6 1 0 x 20 LG TAPTITE 51 22985 1 6 FLAT WASHER 20 92234 1 CONTROLLER 52 32300 1 FUSE HOLDER 21 55440 2 M5 0 8 x 25mm CAPSCREW 53 22676 1 FUSE 15 22 22129 4 5 16 M8 LOCKWASHER 54 87798 1 SWITCH S P D T 6A START STOP 23 45771 4 M8 1 25 HEX NUT 55 92113 1 SWITCH S P D T FUEL PUMP 24 86316 1 PANEL SHEET METAL 56 75210 A 1 TERMINAL BLOCK 25 53650 1 4 57 8475 1 8 SPECIAL LOCK WASHER 26 4258 1 CONDUIT ASSEMBLY 58 51715 1 4 0 7 27 175244 1 ASSEMBLY REMOTE CABLE 59 90157 1 DECAL CB RATING 30A 28 23484 5 1 BUSHING 60 84867 4 U CHANNEL RUBBER 29 74908 1 5 0 8 x 10 LONG TAPTITE 61 89438 1 DECAL CUSTOMER 55 30 75476 3 M4 0 7 x 16 LG CAPSCREW 89438B 1 DECAL CUSTOMER CON 66 31 22264 4 8 M4 LOCK WASHER 62 31791 1 CLAMP HOSE 32 65795 1 BATTERY CHARGER
45. TE OF INSTALLATION PRIMEPACT 55G and 55LP Recreational Vehicle Generators EXHAUST SYSTEM Q Exhaust system complies with all applicable codes Q Exhaust system is properly and safely installed ELECTRICAL CONNECTIONS Q Connections comply with local code requirements and all National Electrical Codes Q Junction box is properly installed Wiring meets all standards connections are correct Q Conduit is properly installed and sealed Q Generator is properly bonded to the vehicle BATTERY INSTALLATION Recommended battery is installed 2 Recommended cables are installed J Cables are clean and tight Cables are connected properly d a Q Proper ventilation is provided d 1 Terminals are coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES Q Check that remote start stop panels if used are installed properly Q Check that hourmeter kit if used properly Q Check that any other options and accessories if used are installed properly is installed POST INSTALLATION TESTS Check that all tests are completed properly NAME OF INSTALLER SIGNATURE OF INSTALLER G6 Generac Power Systems Inc Section 8 Troubleshooting TROUBLESHOOTING PRIMEPACT 55G and 55LP Recreational Vehicle Generators 8 1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won t crank 1 15 amp fuse blown Replace blown
46. UDED IN FUEL SYSTEM The propane fuel system does NOT include such items as a gas tank b gas piping c fittings d valves and e primary regulator used to store the gaseous fuel and deliver it to the gaseous fuel solenoid Figure 2 15 Page 29 A A A 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 PRIMEPACT 55G and 55LP Recreational Vehicle Generators Figure 6 15 Typical Propane Gas Fuel System CARBURETOR REGULATOR Wl LOCKOFF SOLENOID PRIMARY REGULATOR VAPOR WIDTHDRAWAL ANK 6 5 2 SOME IMPORTANT CONSIDERATIONS Iberis dict A PRA When installing an LP gas system consider seriously the following items All fittings lines hoses and clamps must be tight and free of leaks Apply a pipe sealant to threads when assembling threaded connections This reduces the possibility of leakage Test the entire fuel system for leaks using approved test methods Optimum gas pressure at the inlet to the gaseous fuel solenoid valve and secondary regulator is 11 inches water column The installer s fuel supply connection p
47. 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 th
48. 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 non organic 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
49. 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 14 Generac Power Systems inc PRIMEPACT 55G and 55LP Recreational Vehicle Generators 3 10 MAJOR SERVICE MANUAL To obtain a service manual for your generator con tact Generac or your nearest Generac Authorized Service Dealer Make sure to identify your MODEL NUMBER and SERIES 3 11 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement The drive belt and pulleys are warranted for the life of the generator Drive belt tension was properly adjusted before the unit was shipped from the factory If you suspect that drive belt tension is incorrect contact a Generac Authorized Service Dealer 3 12 EXERCISING THE GENERATOR Generac recommends that you start and operate the generator at least once every seven days Let the unit run for at least 30 minutes to exercise the engine 3 13 OUT OF SERVICE PROCEDURE 3 13 1 REMOVAL FROM SERVICE If you cannot exercise the generator every seven days and it is to be out of service longer than 30 days pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 While the engine is still warm from running drain the oil completely Refill the crankcase w
50. charge static electricity from your body before touch ing the battery by first touching a grounded metal surface A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery Disconnect any charging source prior to connecting or disconnecting battery terminals and Do not use any jumper cables or booster battery to crank and start the generator engine If any battery has discharged remove it for recharging WARNING A Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic A The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing e 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
51. ctim 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 amp 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 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 EXPLOSION HAZARDS 4 Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible mat
52. e 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 insu lative 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 71 ELECTRICAL JUNCTION BOX a catio de audio rr 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 Generac Power
53. ed so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine manu facturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in tbe Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual
54. er or dealer for recommenda tions Figure 6 18 Transfer Switch Isolation Method 2ND AIR FROM 20 AMP HACR BREAKER CONDITIONER JUNCTION BOX VEHICLE FLEXIBLE WIRING CONDUIT 2 VEHICLE AC 15 SEE DISTRIBUTION 1 ES 6 THROW PANEL q SWITCHING 30 AMP f DEVICE MAIN BREAKER E lag f HACR e BREAKERS N 5 FOR AIR A es CONDITIONERS LIN bs BREAKERS POWER SUPPLY CORD Figure 6 19 Installation With Isolation Receptacle DOCKSIDE POWER RECEPTACLE FLEXIBLE CONDUIT re POWER SUPPLY CORD br ener Ll 2 Pam VEHICLE AC DISTRIBUTION PANEL Generac Power Systems Inc 33 INSTALLATION Section 6 Installation E PRIMEPACT 55G and 55LP Recreational Vehicle Generators 6 8 BATTERY INSTALLATION 2 8 1 RECOMMENDED BATTERY Install a battery that meets the requirements following 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
55. erials 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 3 Section 1 General Information INFORMATION PRIMEPACT 55G and 55LP Recreational Vehicle Generators GENERAL 11 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 1 55 6 E Lys gt anne Lim gt eee ae E J pene 13 12 11 10 REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake Screen 8 Starter Contactor 2 Data Plate 9 FuelInlet 3 Engine Start Stop Switch 10 Fuel Primer Switch 4 15 amp Fuse 11 Fuel Pump 5 20 amp 30 amp Circuit Breaker 12 Oil Filter 6 Optional Rem
56. ers 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 dock side 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 lor or serious injury or death to dockside utility power workers due to backfeed of electrical ener gy In case of accident caused by electric shock imme diately
57. f 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 5 1 Because of the different recreational vehicle models and the variations between the models it would be extremely difficult if not impractical to provide detailed instruc tions for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all applica ble codes standards and regulations pertaining to the installation and use of this product If any portion of this manual appears to be in conflict with such codes standards or regulations the applicable codes stan dards or regulations must take precedence over the manual 5 2 SAFETY Before handling installing operating or servicing this equipment carefully read the Notice to Installer and Safety Rules on Pages 18 and 19 Comply with all safe ty rules to prevent death personal injury or damage to equipment and or property Stress safety to all installers operators and service technicians who work on this equipment 5 5 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s rec
58. fficient 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 paris 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 SAFETY RULES Safety Rules PRIMEPACT 55G and 55LP Recreational Vehicle Generators ELECTRICAL HAZARDS FIRE HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal For fire safety the generator must be installed and electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate cov
59. fuel does not drip onto any electrical or exhaust system parts Use nonferrous metal straps without sharp edges to secure fuel lines 28 Generac Power Systems Inc 6 4 2 2 Flexible Fuel Line Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines This prevents breaking of the line caused by vibration shift ing settling or movement The following rules apply The flexible hose must comply with SAE 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 SYSTEM A DIE 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 INCL
60. he air cooled generator set was factory tested and adjusted You should not be required to adjust the unit any further except under special circumstances WARNING amp A Do not make any unnecessary adjustments Factory settings are correct for most applications When making adjustments however be careful to avoid overspeeding the engine 7 2 BEFORE INITIAL START UP Before starting complete the following 1 Check the engine crankcase oil level and if neces sary fill to the dipstick FULL mark cross hatched area with the recommended oil Do not fill above the FULL mark 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 A EIT A A 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 Section 7 Post Installation INSTALLATION 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 I Section 2 5 Starting the Generator
61. hicle living area PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION Figure 6 8 Compartment Floor Cutout 2 389 15 31 18007 09 57Le e4 20580101641 903 541 45 1 77 97 3 8271 4 45 ENGINE COOLING AIR DUTLETS MUST BE FREE OF OBSTRUCTIONS 194 7 647 60 2 3641 416 16 38 2 BOTTOM exhaust EW EROM gt CONNECTION OPTIONAL 50L01 97 366114 4171 183t7 20 013 90 5141 HOLES i FOR SECURING UNIT TO COACH 55 2 17 4 REQUIRED E 262 99 FRONT AIR FILTER SIDE 2210 87 p 581 22 87 Generac Power Systems inc 25 INSTALLATION Section 6 Installation 6 5 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 A EG A Never use discharged cooling air for heating
62. ire 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 part s Failure due to misapplication Telephone telegraph teletype or other communication expenses Living or travel expenses of person 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 part s 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 li
63. ire 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 A caution A A 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 Section 1 General Information PRIMEPACT 55G and 55LP Recreational Vehicle Generators GENERAL INFORMATION 1 5 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 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 Instal
64. 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 STATOR POWER WINDINGS 20 AMP GROUNDED NEUTRAL 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 Tl 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 breaker ratings in excess of circuit Section 5 General Information PRIMEPACT 55G and 55LP Recreational Vehicle Generators GENERAL INFORMATION Figure 5 2 Major Features and Dimensions PrimePact 55G and 55LP Control Panel Spark Plugs
65. itch 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 2 1 4 LINE BREAKERS Protects generators 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 MAIN START 15A BREAKER 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 22 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 hourme ter generator run lamp and a wire harness Figure 2 2 Optional Remote Panel Models 004057 and
66. ith SAE 10W 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 PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 2 Check the state of the battery Fill all cells of unsealed batteries to the proper level with distilled water DO NOT USE TAP WATER IN THE BAT TERY Recharge the battery to 100 percent state of charge or if defective replace the battery 3 Clean and wipe the entire generator 4 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 5 Turn OFF all electrical loads Add fuel if neces sary and then start the engine 6 Allow the unit to warm up thoroughly 7 Apply electrical loads to at least 50 percent of the uni
67. 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 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 9 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 Temperat
68. k 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 METAL LINED 1 2 INCH THICK BASE PIYWO0D t 6 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a com partment specifically manufactured to house a generator or inside a compartment that the installer constructs the compartment MUST meet certain specifications as out lined in the following sections 6 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a mini mum clearance of 1 2 inch 13 mm on the front and top 1 inch 25 mm on the sides and 1 2 inch 13 mm 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 Major Features and Figure 6 4 Clearances Plywood Compartment 1 1 2 Clearance on Top 1 Clearance in Back ZA 1 Each Side CETUR MCA Section 6 installation INSTALLATION qp 6 2 22 COMPARTMENT CONSTRUCTION The generator compartment should be either con structed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative t
69. l 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 71 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 72 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
70. l 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 OPERATION Section 2 Operation PRIMEPACT 55G and 55LP Recreational Vehicle Generators ap 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 crank and start the engine hold the start stop switch at START Release the switch when the engine starts caution A A 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 2 6 STOPPING THE GENERATOR 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 wil
71. 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 CABLE SIZE O 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 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 Figure 6 20 Connecting Battery Cables SIDE VIEW OF GENERATOR STARTER CONTACTOR GROUND LUG NEGATIVE CABLE B
72. lation 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 T1 O RR T O CB20 BLACK STATOR POWER WINDINGS GROUNDED NEUTRAL Generac Power Systems Inc 5 GENERAL INFORMATION 1 6 SPECIFICATIONS 1 61 FUEL REQUIREMENTS This generator is equipped with a gasoline fuel system as standard equipment Specific installations may pro vide either a se
73. le 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 35 Section 7 Post Installation GENERAL INFORMATION 75 INSTALLATION CHECKLIST LOCATION AND SUPPORT Q Generator is properly located Q Generator is properly supported Generator is properly restrained GENERATOR COMPARTMENT Q Compartment construction is proper Q Holes Openings are vapor sealed C Compartment size is correct Compartment is vapor sealed Q Sound insulation is correct Floor cutouts are properly completed COOLING AND VENTILATING AIR L Airflow is adequate M Air inlet opening is correct 2 Compensate for restrictions 2 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 1 Pressure at regulator inlet is correct Rated flow of primary regulator is correct All parts are properly installed Q Fuel system is properly tested adjusted DA
74. 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 pro
75. lowing 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 PRIMEPACT 55G and 55LP Recreational Vehicle Generators 6 7 6 POWER SUPPLY CORD ec l 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 Section 6 Installation INSTALLATION 677 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 manufactur
76. mita 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 GENERAC POWER SYSTEMS INC P O BOX 8 WAUKESHA WI 53187 Part No C2897 Revision 03 13 01 Printed in U S A
77. mp 1 1 2 2800 Submersible Pump 1 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 15 NOTES Section 4 Notes PRIMEPACT 55G and 55LP Recreational Vehicle Generators 1G Generac Power Systems Inc PART II INSTALLATION INSTRUCTIONS SAFETY RULES Safety Rules AN PRIMEPACT 55G 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 C1 1975 AND ANSI A119 2 1975 NFPA 501C Standard for Recreational Vehicles Part 3 Installation of Electrical Systems In addition installation must comply with the manufacturer s instructions and recommendations 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 s
78. nerac Power Systems Inc 1 AFETY R SEL Safety Rules PRIMEPACT 55G and 55LP 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 FN WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other rep roductive harm PN WARNING PN 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 procedu
79. nerator 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 caution Ak A Do NOT tee the generator fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not running generator operation may drain the vehicle engine supply line making it difficult to start the vehicle engine 6 4 2 GENERATOR FUEL SUPPLY LINE 6 4 2 1 Rigid Fuel Lines Those lines used to supply fuel from a tank to the gen erator must comply with applicable codes standards and regulations The following general rules apply to rigid fuel lines Rigid lines should be of annealed seamless drawn aluminum or steel Lines and fittings must comply with SAE J512E Standard Automotive Fittings or with ANSI B126 26 latest edition Route the fuel line so that at least 2 inches 51 mm of clearance is maintained between the line and any exhaust system parts Do not attach electrical wiring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so if they leak
80. nty 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 2 Air Induction System including 1 1 Gasoline carburetor assembly and its a Intake pipe manifold internal components if so equipped b Air cleaner a Fuel filter if so equipped 3 Ignition System including b Carburetor gaskets a Spark plug c Fuel pump if so equipped b Ignition module 1 2 LPG carburetion assembly and its 4 Catalytic Muffler Assembly if so equipped including internal components if so equipped a Muffler gasket a Fuel controller if so equipped b Exhaust manifold b Mixer and its gaskets if so equipped 5 Crankcase Breather Assembly including c Carburetor and its gaskets if so equipped a Breather connection tube 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 Generat
81. o 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 2 inch 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 METAL LINING FIREPROOF SOUND INSULATION METAL LINING PLYWOOD If constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel All seams splices and joints of the compartment walls unless vapor tight by design should be caulked to prevent poisonous flammable or explo sive vapors from entering the vehicle interior NOTE Caulking must be done so that the caulking material will stay in place permanently Pressing such materi als as putty tape onto joints and seams is not accept able A high quality silicone rubber base sealant is recommended Holes and openings made in the compartment walls to allow for the passage of electrical conduit conduc tors hoses cables etc into the vehicle living area must be sealed vapor tight with silicone rubber base sealant Generac Power Systems inc 23 INSTALLATION Section 6 Installation PRIMEPACT 55G and 55LP Recreational Vehicle Generators
82. oint is at the gaseous fuel solenoid valve This is a 3 4 inch female connection Provide a suitable 3 4 inch NPT male connector to attach to the fuel supply line Use a length of approved flexible fuel hose between the gaseous fuel solenoid valve and rigid gas piping The flexible line should be at least 6 inches longer than necessary 6 5 5 VAPOR WITHDRAWAL dodici Bo khair Se 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 Section 6 Installation INSTALLATION 6 5 4 PRIMARY REGULATOR diac eiae MR S Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regulator Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank The following rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column Do NOT exceed 14 inches water col umn The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommended MINIMUM gas flow rate for all air cooled PRIMEPACT series generators
83. ollows 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 A EX A A To prevent fire or explosion do not install any insulation or other absorbent materials on the interior or underside of the compartment floor Seal all compartment door edges to prevent noise leakage around the door perimeter Line the compartment door interior except for air openings with suitable fireproof sound insulation such as l inch 25 mm thick fiberglass with a 2 pound density Section 6 Installation INSTALLATION PRIMEPACT 55G and 55LP Recreational Vehicle Generators Figure 6 7 Typical Noise Abatement 6 2 5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compart ment for the following items Figure 2 8 PIYWOOD 5 8 3 8 THICK EXTERIOR 5 Ln Engine exhaust and cooling air outlets SO Generator cooling air inlet BS Four holes for passage of generator mounting bolts a ES See Section 2 1 4 Page 23 Fuel lines and exhaust piping must not penetrate into the ve
84. ommendations 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 C1 1975 and ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI 119 2 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 20 Generac Power Systems Inc PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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
85. or Part 2 Generac Power Systems inc 53 Section 12 Warranty 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 three years or 2 000 two thousand 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 Authorized Warranty Service Facility is found to be defective 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 se
86. or permit such air to enter the vehicle interior This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases 6 3 1 GENERATOR AIRFLOW Engine operation drives cooling fans for the two stage cooling air system A pressure fan draws cooling air into the top of the generator Figure 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 A Figure 6 9 Airflow Through Engine Generator 6 3 2 COOLING AIR INLET OPENINGS The minimum size of the air inlet opening whether the generator is housed in a conventional compartment or not is at least 100 square inches see Figure 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 26 Generac Power Systems Inc 28 PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 50000605 OC
87. ote Panel Receptacle 13 Oil Drain Plug 7 Generator AC Output Leads 14 Oil Dipstick and Filler Tube a Generac Power Systems Inc 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 A A A 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 Ill 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 requ
88. owing 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 warninc 4 amp Never operate the generator while the vehicle A is parked over high grass weeds brush leaves or any other combustible substance Such materials can ignite and burn from the heat of the exhaust system The generator exhaust system becomes extremely hot dur ing operation and remains hot for a long time after it has shut down 3 1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements see Engine Oil Requirements Section 1 6 2 Page 6 Check the engine crankcase oil level at least every eight hours of operation or before you use it To check the engine oil level proceed as follows see Figure 3 1 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 caution Never operate
89. p SET PLUG GAP AT 0 030 inch 0 76 mm A caution amp A 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 PRIMEPACT 55G and 55LP Recreational Vehicle Generators 3 6 FUEL FILTER casoLINE 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 7 SPARK 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 warning amp
90. parate 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 unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits caution amp A Generac does not recommend using any gasoline containing alcohol such as gasohol If you use any gasoline containing alcohol it must not contain more than 10 percent ethanol and it must be removed from the generator during storage Do NOT use any gasoline containing methanol If you use gasoline with alcohol inspect more frequently for fuel leaks and other abnormalities 1 6 2 ENGINE OIL REQUIREMENTS Use only high quality detergent oil classified For Service SF and with an oil viscosity rating of SAE 10W 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 Section 1 General information PRIMEPACT 55G and 55LP Recreational Vehicle Generators 1 6 5
91. pecial 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 A A A 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 A Potentially lethal voltages are generated by these machines Ensure all steps are
92. perator 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 GENERAC AUTHORIZED SERVICE DEALER nearest you please call this number 1 800 333 1322 ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER PRIMEPACT 55G and 55LP Recreational
93. perly 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 4 cauroN 4 Any attempt to crank or start the engine before you have properly serviced it with the recom mended oil may result in an engine failure 2 4 5 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 a Generac Power Systems Inc 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
94. pporting frame suffi cient strength Figure 6 1 Typical Horizontal Support Frame SUPPORT TUBING 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 tbe 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 SUPPORT SUPPORT FRAME The installer must make certain that the selected location will permit adequate cooling and ventilating airflow to be supplied PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 framewor
95. r 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 WI 53190 Part 1 Generac Power Systems Inc Section 12 Warranty PRIMEPACT 55G and 55LP Recreational Vehicle Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1997 and later model year engines a Applicability This warranty shall apply to 1997 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall contin ue for 24 consecutive months thereafter 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 15 1 Designed built and equipp
96. r 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 nspect 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 Safety Rules SAFETY RULE
97. re work method or operating technique that you choose does not render the generator unsafe A N A A 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 A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators 2 Generac Power Systems Inc Ay 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 Neve
98. rvice 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 All 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 6 one hundred percent only on selected part s and labor listed Any labor and part s not listed and removal and rein 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 Intake 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
99. 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 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
100. t s rated wattage capacity 8 When the engine is thoroughly warmed up shut it down 9 Your generator is now ready for service m MAINTENANCE O Section 3 Maintenance 3 14 WATTAGE REFERENCE GUIDE Running Watts Battery Charger aosi ereis a TKEK S 500 Belt Sander 3 Jania ienn aA 1000 en eenaa a aa a EE 1200 Circular Saw 6 12 800 to 1000 Disc Sander 9 2 1200 Hand Drill 1 ee HR Ine 1100 Hedge Trimmer tes dti mq es 450 Impact Wrench ore eed 500 Lawn MOWED etse PR x e ep T E 1200 Electric Range one 1500 Televisi n morora 05 ion p Rees 1750 to 2000 Coffee Maker 0 020222 1000 Electric Skillet eere 1250 Hair Dryer op co ser dere e 1200 Light Bulb eredi tid 100 Microwave Oven 1 700 Oil Burner on Furnace 300 Oil Fired Space Heater 140 000 400 Radio zeige rg eue e 50 to 200 Slow COOKer eite ect Ex rene EN RYE 200 Furnace Fan 1 3 2 1200 Refrigerator 2 2 600 Air Conditioner 12 000 1700 Compressor 1HP 2000 Deep Freeze eee xe p ein aas eene 500 MIIK COOI6E oe ERRAT ae 1100 Submersible Pu
101. 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 18 Generac Power Systems inc 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 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 su
102. tem 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 Fuel Line A EXE A 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 27 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 ge
103. 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 A This symbol points out important safety infor mation that if not followed could endanger personal safety and or property of you and others This symbol points out potential explosion hazard A This symbol points out potential fire hazard A This symbol points out potential electrical shock hazard Generac Power Systems Inc 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 o
104. to enter the vehicle EX A A 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 STARTING 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 contro
105. uch 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 ll 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 22 Generac Power Systems Inc PRIMEPACT 55G and 55LP Recreational Vehicle Generators 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 su
106. ure Switches HIGH TEMPERATURE ENGINE OIL OIL PRESSURE FILTER SWITCH 2 8 5 FIELD BOOST ALAAA 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 CONTROLLER CIRCUIT CLOSEST TO BOARD BEARING 4 FIELD 10 Generac Power Systems Inc 2 8 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 5 controls the generator s AC output voltage This regulator sup plies an excitation current to the rotor By regulating the rotor s excitation current the strength of its mag netic field is regulated and in turn the voltage deliv ered to connected electrical loads is controlled When the AC frequency is 50 Hertz voltage is regulated at 115 volts Figure 2 5 Solid State Voltage Regulator O S S Co seNsine EXE TOROTOR e Se meer curen C75 L
107. ved 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 se
108. when a fuel line is severed or broken Consult the Natural LP Gas Association for information and limita tions of excess flow valves Manual shutoff valves on the supply tank and elsewhere in the system must be fully open when operating the generator The excess flow valve functions properly only if all valves are fully open 6 5 8 LEAKAGE TESTS Do not place the generator into service until you have properly tested the gas system for leaks To test the sys tem you need a separate source of 12 volts DC to open the gaseous fuel solenoid valve Generac Power Systems inc 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 A EI 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

Generac Power Systems NP Series User's Manual

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