® POWER SYSTEMS, INC.
INTRODUCTION ◆ READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual, contact Generac or your nearest Generac Authorized Service Dealer for starting, operating and servicing procedures. Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
Table of Contents PRIMEPACT 66G and 66LP Recreational Vehicle Generators Part I — Operating Instructions Introduction ..................................................Inside Front Cover Read This Manual Thoroughly ..........................................IFC Contents ............................................................................IFC Operation and Maintenance ..............................................IFC How to Obtain Service ......................................................
Safety Rules PRIMEPACT 66G and 66LP Recreational Vehicle Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment. WARNING: The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
Safety Rules PRIMEPACT 66G and 66LP Recreational Vehicle Generators ELECTRICAL HAZARDS FIRE HAZARDS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, 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.
Section 1 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators 1.1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal. 1. Model Number ____________________ 2. Serial Number __________________ 3. kW Rating__________________________ 4. Rated Voltage __________________ 5. Phase ______________________________ 6.
Section 1 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators 1.2 GENERATOR APPLICABILITY These generators have been designed and manufactured 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.
Section 1 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators Figure 1.1 – Connection for 120 Volts Only Fuel Consumption (gph/lbs.ph) Model PrimePact 66G PrimePact 66LP No Load 0.33 0.47/2.01 1/2 Load 0.59 0.85/3.62 Full Load 0.99 1.66/7.05 NOTE Some installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine’s pickup tube.
Section 2 – Operation PRIMEPACT 66G and 66LP Recreational Vehicle Generators ◆ 1.6.4 ENGINE SPECIFICATIONS Type of Engine PRIMEPACT 66G/66LP ..............................................GN-480 Cooling Method ........................................................Air-cooled Rated Horsepower PRIMEPACT 66G/66LP ........................................16 at 3600 Displacement PRIMEPACT 66G/66LP..................................................480cc Compression Ratio............................................
Section 2 – Operation PRIMEPACT 66G and 66LP Recreational Vehicle Generators NOTE: If this generator has been reconnected for dual voltage AC output (120/240 volts), you can install line breakers having an amperage rating that is different than that stated above. The replacement line breakers consist of two separate breakers with a connecting piece between the breaker handles (so that both breakers will operate at the same time). If the unit is reconnected for dual voltage, it is no longer RVIA listed. 2.
Section 2 – Operation PRIMEPACT 66G and 66LP Recreational Vehicle Generators ◆ 2.4.5 ENGINE EXHAUST GAS Before starting the generator engine, you should be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals. Close windows, doors and other openings in the vehicle that, if open, might permit exhaust gases to enter the vehicle. The generator engine gives off DEADLY carbon monoxide gas through its exhaust system.
Section 2 – Operation PRIMEPACT 66G and 66LP Recreational Vehicle Generators ◆ 2.7.2 DO NOT OVERLOAD THE GENERATOR You can read the rated wattage/amperage capacity of your generator on the generator data decal (see Section 1.1 on Page 4). Applying electrical loads in excess of the unit’s rated capacity will cause the engine/generator to automatically shut down. To avoid overloading, add up the wattage of all connected electrical lighting, appliance, tool and motor loads.
Section 3 – Maintenance PRIMEPACT 66G and 66LP Recreational Vehicle Generators ◆ 2.8.4 OVERVOLTAGE PROTECTION A solid-state voltage regulator (Figure 2.5) controls the generator’s AC output voltage. This regulator supplies an excitation current to the rotor. By regulating the rotor’s excitation current, the strength of its magnetic field is regulated and, in turn, the voltage delivered to connected electrical loads is controlled. When the AC frequency is 50 Hertz, voltage is regulated at 115 volts.
Section 3 – Maintenance PRIMEPACT 66G and 66LP Recreational Vehicle Generators 3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER Figure 3.1 — Oil Dipstick/Fill Tube and Location of Oil Drain Plug • 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.
Section 3 – Maintenance PRIMEPACT 66G and 66LP Recreational Vehicle Generators filter must lock into slots on cover. 8. Install the cover, foam precleaner and paper filter. 9. Replace knob to retain the filter in place. Figure 3.5 – Setting the Spark Plug Gap Figure 3.3 – Engine Air Cleaner PAPER FILTER FOAM PRE-CLEANER KNOB 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. COVER 3.
Section 3 – Maintenance PRIMEPACT 66G and 66LP Recreational Vehicle Generators Damage will result if the battery connections are made in reverse. 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.
Section 3 – Maintenance PRIMEPACT 66G and 66LP Recreational Vehicle Generators 3.10 MAJOR SERVICE MANUAL To obtain a service manual for your generator, contact 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.
Section 4 – Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators 16 Generac® Power Systems, Inc.
PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
Safety Rules PRIMEPACT 66G and 66LP 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.
Safety Rules PRIMEPACT 66G and 66LP Recreational Vehicle Generators ELECTRICAL HAZARDS FIRE HAZARDS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, 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.
Section 5 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators 5.1 PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to all information and instructions in the manual, both for safety and for continued reliable operation of the equipment.
Section 5 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators Figure 5.2 - Major Features and Dimensions PrimePact 66G and 66LP Control Panel Spark Plugs (both sides, not shown) Oil Fill/Oil Level Fuel Filter Oil Drain Plug Fuel Pump Starter Contactor Oil Filter Air Filter Ground Lug Generac® Power Systems, Inc.
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators Figure 5.3 - Connection for 120/240 Volts CB1 T1 RED walls and ceiling, the minimum recommended applies to the space between the generator and such insulation. • The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense. ◆ 6.1.
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators • Protect the generator against road splash and debris. Baffles or splash guards may be required to protect certain areas of the generator. To make sure the generator is adequately protected, road test the installation through mud, water and slush. Figure 6.2 – Typical Suspended Mounting System from the back for air circulation AFTER the compartment has been lined with metal and sound insulation (Figure 6.4).
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators • If constructing a compartment, line the exterior (underside) of the compartment floor with 26-gauge galvanized steel. • All seams, splices and joints of the compartment walls (unless vapor tight by design) should be caulked to prevent poisonous, flammable or explosive vapors from entering the vehicle interior.
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators • Vapor seal all compartment seams and joints. • Over the galvanized steel lining, install a combination of acoustical materials as mentioned in Section 6.2.3. Figure 6.7 – Typical Noise Abatement 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.
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators ◆ 6.2.5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compartment for the following items (Figure 6.8, Page 25): • Engine exhaust and cooling air outlets • Generator cooling air inlet • Four holes for passage of generator mounting bolts. See Section 6.1.4 (Page 23). Fuel lines and exhaust piping must not penetrate into the vehicle living area. 6.
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators behind the generator for cooling airflow (Figure 6.13 ). Recommended clearance behind the back of the generator is at least 1/2 inch (13 mm). Figure 6.12 – Air Inlet Using Ductwork ◆ 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.
Section 6 – Installation PRIMEPACT 66G and 66LP 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 regulations. If the generator is to share the vehicle engine's tank, separate fuel pickup tubes are required for the engine and the generator.
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators Figure 6.15 – Typical Propane Gas Fuel System ◆ 6.5.4 PRIMARY REGULATOR Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regulator. Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank. The following rules apply: • For best results, the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column.
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators The greater the airflow through the carburetor venturi, the lower the pressure at the venturi throat. The lower the pressure at the venturi throat, the greater the diaphragm movement, and the greater the movement of the regulator valve. The more the regulator valve opens, the greater the gas flow that is proportional to airflow through the generator. for leaks.
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators 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 unimproved 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).
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators • From the junction box, route power supply wires through approved conduit to either (a) double-pole, double-throw transfer switch, or (b) approved isolation 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).
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators ◆ 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 generator 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.
Section 6 – Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators CABLE LENGTH in Feet (meters) 0 to 10 (0 to 3) 11 to 15 (3.4 to 4.5) 16 to 20 (4.5 to 6) CABLE SIZE 2* 0 000 *For warm weather, use No. 2 cable up to 20 feet. ◆ 6.8.3 BATTERY CABLE CONNECTIONS 6.9 OPTIONAL ACCESSORIES A plug-in receptacle (Figure 6.21) is provided on the generator set, above the muffler enclosure. Use this receptacle to connect an optional remote-mounted start/stop panel to the generator.
Section 7 – Post Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators 7.1 POST INSTALLATION TESTS The air-cooled generator set was factory tested and adjusted. You should not be required to adjust the unit any further except under special circumstances. 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.
Section 7 – Post Installation PRIMEPACT 66G and 66LP Recreational Vehicle Generators 7.5 INSTALLATION CHECKLIST ◆ LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. ◆ GENERATOR COMPARTMENT ❑ Compartment construction is proper. ❑ Holes/Openings are vapor-sealed. ❑ Compartment size is correct. ❑ Compartment is vapor-sealed. ❑ Sound insulation is correct. ❑ Floor cutouts are properly completed.
Section 8 – Troubleshooting PRIMEPACT 66G and 66LP Recreational Vehicle Generators 8.1 TROUBLESHOOTING GUIDE PROBLEM Engine won’t crank. CAUSE 1. 2. CORRECTION 3. 4. 5. 6. 7. 15 amp fuse blown. Loose, or corroded or defective battery cable(s). Battery is discharged or defective. Defective starter contactor. Defective starter motor. Defective Start/Stop switch. Defective Engine Control Board 3. 4. 5. 6. 7. Replace blown fuse. Tighten, clean or replace, as necessary. Recharge or replace battery.
Section 9 — Electrical Data PRIMEPACT 66G and 66LP Recreational Vehicle Generators Electrical Schematic and Wiring Diagram – Drawing No. D3148-A 38 Generac® Power Systems, Inc.
Section 9 — Electrical Data PRIMEPACT 66G and 66LP Recreational Vehicle Generators Electrical Schematic and Wiring Diagram – Drawing No. 0D3148-A Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Sheet Metal – Drawing No. 0D3150-A 40 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Sheet Metal – Drawing No. 0D3150-A ITEM PART NO. QTY.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Base and Pulleys – Drawing No. 0D3151-A 50 12 13 10 28 66 4 29 2 1 28 51 14 6 28 38 95 52 7 52 91 90 9 49 93 TO ENGINE 83 47 44 14 15 7 35 34 73 45 3 96 10 6 46 84 86 88 68 43 36 41 19 89 92 94 23 54 5 5 18 25 76 67 61 60 77 28 32 87 30 33 79 3 20 82 80 83 81 64 85 79 65 62 69 59 5 6 28 74 57 42 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Base and Pulleys – Drawing No. 0D3151-A ITEM PART NO. QTY.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Base and Pulleys – Drawing No. 0D3154-A 37 12 13 11 10 28 4 66 2 1 40 14 84 39 3 6 7 3 50 9 38 88 TO ENGINE 54 53 41 83 47 79 44 14 15 7 35 34 73 10 45 32 49 48 46 43 36 24 17 8 23 5 61 60 76 16 27 67 67 77 28 72 32 32 87 30 33 79 20 80 64 2 78 81 61 60 85 70 79 69 71 58 59 56 28 74 57 44 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Base and Pulleys – Drawing No. 0D3154-A ITEM PART NO. QTY.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Alternator and Control Panel – Drawing No. 0D3149-C 44 45 51 57 8 29 22 TO ENGINE GROUND 38 23 6 45 21 40 17 36 15 61 34 9 18 14 60 40 10 58 20 12 11 31 37 18 43 24 3 14 35 55 4 45 47 5 1 16 63 19 2 13 15 62 17 4 44 40 63 44 48 49 42 46 50 7 2,53 25 28 27 26 26 56 39 30 31 31 46 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Alternator and Control Panel – Drawing No. 0D3149-C ITEM PART NO. QTY.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Exploded View - Engine Common Parts – Drawing No. 079216-G 48 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Exploded View - Engine Common Parts – Drawing No. 079216-G ITEM PART NO. QTY.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Carburetor – Drawing No. 093753-H 50 Generac® Power Systems, Inc.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Carburetor – Drawing No. 093753-H ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 25 26 27 28 29 30 31 32 33 PART NO. 073112B 074962C 074962G 070155 070108 056893 074961 047227 037398 073131 066476 070575 070125 073374 074947 089473 091306 077091 031879 022159 072536 087770 074946 030340 0C2338B 0C2338 0C2338D 075252 0A7782A 040173 066829 075944 070594 077075 QTY.
Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators LP Carburetor & Air Cleaner – Drawing No. 0A4029-G 13 25 1 11 22 18 27 29 19 4 21 3 2 5 2 7 3 4 28 4 12 9 8 10 9 11 10 ITEM PART NO. QTY. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0A1662A 057822 074994 026307 026915 075211 0A2666 0A5198 049813 022097 047411 038750 037398 074961 056893 047227 074962C 074962G 1 2 1 3 1 1 1 1 4 4 2 2 1 1 5 1 1 1 DESCRIPTION CARB. V-TWIN L/P HOSE CLAMP 1/2 I.
Section 11 — Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators Generac® Power Systems, Inc.
Section 11 — Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators 54 Generac® Power Systems, Inc.
Section 11 — Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators Generac® Power Systems, Inc.
Section 12 – Warranty PRIMEPACT 66G and 66LP 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.
Section 12 – Warranty PRIMEPACT 66G and 66LP Recreational Vehicle Generators EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Section 12 – Warranty PRIMEPACT 66G and 66LP 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.
