Generac Power Systems Portable Generator 009600 5 009734 5 User Manual

®
POWER SYSTEMS, INC.  
Owner’s Manual  
Air-cooled Recreational  
Vehicle Generators  
• Model: 009600-5 and 009734-5  
PRIMEPACT 66G and 66LP  
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Table of Contents  
PRIMEPACT 66G and 66LP Recreational Vehicle Generators  
Part I — Operating Instructions  
Part II — Installation Instructions ........................................17  
Safety Rules..........................................................................18-19  
Section 5 — General Information..........................................20  
Introduction..................................................Inside Front Cover  
Read This Manual Thoroughly ..........................................IFC  
Contents ............................................................................IFC  
Operation and Maintenance ..............................................IFC  
How to Obtain Service ......................................................IFC  
Authorized Service Dealer Locator Number ..........................IFC  
Safety Rules..................................................................................2  
Section 1 – General Information ............................................4  
5.1  
5.2  
5.3  
5.4  
5.5  
5.6  
Purpose and Scope of the Manual................................20  
Safety ..........................................................................20  
Standard Booklets ......................................................20  
Equipment Description................................................20  
Generator Engine Operating Speed..............................20  
Generator AC Connection System................................20  
Major Dimensions and Features ..................................21  
1.1  
1.2  
1.3  
1.4  
1.5  
1.6  
Generator Identification ................................................4  
Generator Applicability..................................................5  
Installation ....................................................................5  
Safety ............................................................................5  
Generator AC Connection System..................................5  
Specifications ................................................................6  
1.6.1 Fuel Requirements & Consumption ....................6  
1.6.2 Engine Oil Requirements ....................................6  
1.6.3 Generator Specifications......................................6  
1.6.4 Engine Specifications ..........................................7  
1.6.5 Emissions Compliance Period ............................7  
Section 6 — Installation ..........................................................22  
6.1  
Location and Support..................................................22  
6.1.1 Generator Location............................................22  
6.1.2 Generator Supports ..........................................22  
6.1.3 Suspended Mounting ........................................22  
6.1.4 Generator Restraint ..........................................23  
Generator Compartments ............................................23  
6.2.1 Compartment Size ............................................23  
6.2.2 Compartment Construction ..............................23  
6.2.3 Sound Insulating Materials................................24  
6.2.4 Acoustics ..........................................................24  
6.2.5 Compartment Floor Cutouts..............................25  
Cooling and Ventilation................................................26  
6.3.1 Generator Airflow ..............................................26  
6.3.2 Cooling Air Inlet Openings ................................26  
6.3.3 Compensating for Restrictions ..........................27  
6.3.4 Testing the Installation ......................................27  
Gasoline Fuel System ..................................................27  
6.4.1 Fuel Tank ..........................................................28  
6.4.2 Generator Fuel Supply Line ..............................28  
6.4.2.1 Rigid Fuel Lines..........................................28  
6.4.2.2 Flexible Fuel Lines......................................28  
LP Gas Fuel System ....................................................28  
6.5.1 Parts not included in Fuel System ....................28  
6.5.2 Some Important Considerations........................29  
6.5.3 Vapor Withdrawal ..............................................29  
6.5.4 Primary Regulator..............................................29  
6.5.5 Gaseous Carburetion ........................................29  
6.5.6 Fuel Supply Lines ..............................................30  
6.5.7 Excess Flow Valve..............................................30  
6.5.8 Leakage Tests ....................................................30  
Exhaust Systems..........................................................30  
6.6.1 Mufflers and Spark Arrestors............................31  
6.6.2 Type of Exhaust System ....................................31  
6.6.3 Exhaust System Safety ......................................31  
Electrical Connections ................................................31  
6.7.1 Electrical Junction Box ....................................31  
6.7.2 Wiring................................................................32  
6.7.3 Generator AC Connections ................................32  
6.7.4 Conduit..............................................................32  
6.7.5 Isolating Different Power Sources......................32  
6.7.6 Power Supply Cord............................................33  
6.7.7 Ground Fault Circuit Interrupters ....................33  
Battery Installation ......................................................34  
6.8.1 Recommended Battery ......................................34  
6.8.2 Battery Cables ..................................................34  
6.8.3 Battery Cable Connections ................................34  
6.8.4 Battery Compartment ........................................34  
Optional Accessories....................................................34  
6.9.1 Remote Panel Models ........................................35  
6.2  
Section 2 – Operation................................................................7  
6.3  
6.4  
6.5  
2.1  
Generator Control Panel ................................................7  
2.1.1 Fuel Primer..........................................................7  
2.1.2 Start/Stop Switch ................................................7  
2.1.3 15 Amp Fuse........................................................7  
2.1.4 Line Breakers ......................................................7  
Optional Remote Start/Stop Panel..................................8  
Automatic Choke ..........................................................8  
2.3.1 Choke Solenoid ..................................................8  
2.3.2 Prechoke..............................................................8  
Before Starting the Engine ............................................8  
2.4.1 Installation..............................................................8  
2.4.2 Engine Lubrication ................................................8  
2.4.3 Fuel Supply ............................................................8  
2.4.4 Cooling and Ventilating Air ....................................8  
2.4.5 Engine Exhaust Gas ..............................................9  
Starting the Generator ..................................................9  
Stopping the Generator..................................................9  
Applying Loads to Generator ........................................9  
2.7.1 Letting the Engine Stabilize ................................9  
2.7.2 Do Not Overload the Generator ........................10  
Protection Systems ......................................................10  
2.8.1 Low Oil Pressure Switch....................................10  
2.8.2 High Temperature Switch ..................................10  
2.8.3 Field Boost ........................................................10  
2.8.4 Overvoltage Protection ......................................11  
2.8.5 25-Hour Break-in Period....................................11  
2.8.6 25-Hour Checkup ..............................................11  
2.8.7 Operation in High Grass or Brush ....................11  
2.2  
2.3  
2.4  
2.5  
2.6  
2.7  
6.6  
6.7  
2.8  
Section 3 – Maintenance ........................................................11  
3.1  
3.2  
3.3  
Checking the Engine Oil Level......................................11  
Changing the Engine Oil and/or Oil Filter ....................12  
Maintaining the Engine Air Cleaner ............................12  
3.3.1 Cleaning the Foam Precleaner............................12  
Clean Air Intake Screen ..............................................13  
Checking the Engine Spark Plug..................................13  
Fuel Filter (Gasoline Only) ..........................................13  
Spark Arrestor Muffler ................................................13  
Cleaning the Generator................................................14  
Battery Maintenance ....................................................14  
3.9.1 Weekly ..............................................................14  
3.9.2 Every Six Months ..............................................14  
6.8  
6.9  
3.4  
3.5  
3.6  
3.7  
3.8  
3.9  
Section 7 — Post Installation ................................................35  
7.1  
7.2  
7.3  
7.4  
7.5  
Post Installation Tests..................................................35  
Before Initial Start-up ..................................................35  
Initial Start ..................................................................35  
Testing Under Load......................................................35  
Installation Checklist ..................................................36  
3.10 Major Service Manual ..................................................15  
3.11 Drive Belt ....................................................................15  
3.12 Exercising the Generator ............................................15  
3.13 Out of Service Procedure ............................................15  
3.13.1 Removal From Service ....................................15  
3.13.2 Return to Service ............................................15  
3.14 Wattage Reference Guide..............................................15  
Section 4 – Notes......................................................................16  
Section 8 – Troubleshooting ..................................................37  
8.1  
Troubleshooting Guide ................................................37  
Section 9 – Electrical Data......................................................38  
Section 10 – Exploded Views and Parts Lists....................40  
Section 11 – Notes....................................................................53  
Section 12 – Warranty ............................................................56  
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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.  
GENERAL HAZARDS  
WARNING:  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
The engine exhaust from this product  
• For safety reasons, Generac recommends  
that the installation, initial start-up and mainte-  
nance of this equipment is carried out by a  
Generac Authorized Service Dealer.  
• The engine exhaust fumes contain carbon monox-  
ide, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. This exhaust sys-  
tem must be installed properly, in strict compli-  
ance with applicable codes and standards.  
Following installation, you must do nothing that  
might render the system unsafe or in noncompli-  
ance with such codes and standards. The genera-  
tor compartment must be completely vapor sealed  
from the vehicle interior. There must be no possi-  
bility of exhaust fumes entering the vehicle interi-  
or. Never operate this equipment with a leaking or  
defective exhaust system.  
• Keep hands, feet, clothing, etc., away from drive  
belts, fans, and other moving or hot parts. Never  
remove any drive belt or fan guard while the unit is  
operating.  
• Adequate, unobstructed flow of cooling and venti-  
lating air is critical to correct generator operation  
and is required to expel toxic fumes and fuel  
vapors from the generator compartment. Without  
sufficient cooling airflow, the engine/generator  
quickly overheats, which causes serious damage to  
the generator. Do not alter the installation or per-  
mit even partial blockage of ventilation provisions,  
as this can seriously affect safe operation of the  
generator.  
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
Study these SAFETY RULES carefully before  
installing, operating or servicing this equipment.  
Become familiar with this manual and with the unit.  
The generator can operate safely, efficiently and reli-  
ably only if it is properly installed, operated and  
maintained. Many accidents are caused by failing to  
follow simple and fundamental rules or precautions.  
Generac cannot possibly anticipate every possible  
circumstance that might involve a hazard. The warn-  
ings in this manual, and on tags and decals  
affixed to the unit, are, therefore, not all-inclusive. If  
you use a procedure, work method or operating tech-  
nique Generac does not specifically recommend, you  
must satisfy yourself that it is safe for you and others.  
You also must make sure the procedure, work  
method or operating technique that you choose does  
not render the generator unsafe.  
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.  
• When working on this equipment, remain alert at  
all times. Never work on the equipment when you  
are physically or mentally fatigued.  
• Inspect the generator regularly, and contact your  
nearest Generac Authorized Service Dealer imme-  
diately for parts needing repair or replacement.  
• Before performing any maintenance on the genera-  
tor, disconnect its battery cables to prevent acci-  
dental start up. Disconnect the cable from the bat-  
tery post indicated by a NEGATIVE, NEG or (–)  
first. Reconnect that cable last.  
• Never use the generator or any of its parts as a  
step. Stepping on the unit can stress and break  
parts, and may result in dangerous operating con-  
ditions from leaking exhaust gases, fuel leakage,  
oil leakage, etc.  
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.  
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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, 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.  
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.  
• In case of accident caused by electric shock, imme-  
diately shut down the source of electrical power. If  
this is not possible, attempt to free the victim from  
the live conductor. AVOID DIRECT CONTACT  
WITH THE VICTIM. Use a nonconducting imple-  
ment, such as a rope or board, to free the victim  
from the live conductor. If the victim is uncon-  
scious, apply first aid and get immediate medical  
help.  
• Never wear jewelry when working on this equip-  
ment. Jewelry can conduct electricity resulting in  
electric shock, or may get caught in moving com-  
ponents causing injury.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any  
fuel or oil spills immediately. Ensure that no com-  
bustible materials are left in the generator com-  
partment, or on or near the generator, as FIRE or  
EXPLOSION may result. Keep the area surround-  
ing the generator clean and free from debris.  
• Gasoline is extremely FLAMMABLE and its vapors  
are EXPLOSIVE. Do not permit smoking, open  
flame, sparks or any source of heat in the vicinity  
while handling gasoline. Comply with all laws gov-  
erning the storage and handling of gasoline.  
• 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.  
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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 ____________________  
3. kW Rating__________________________  
5. Phase ______________________________  
2. Serial Number __________________  
4. Rated Voltage __________________  
6. Hertz __________________________  
1
3
2
4
5
6
7
14  
9
10  
11  
12  
13  
8
REFERENCE NUMBER IDENTIFICATION  
1. Generator Air Intake Screen  
2. Data Plate  
8. Starter Contactor  
9. Fuel Inlet  
3. Engine Start/Stop Switch  
4. 15 amp Fuse  
10. Fuel Primer Switch  
11. Fuel Pump  
5. 30 amp Circuit Breaker  
6. Optional Remote Panel Receptacle  
7. Generator AC Output Leads  
12. Oil Filter  
13. Oil Drain Plug  
14. Oil Dipstick and Filler Tube  
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Section 1 – General Information  
PRIMEPACT 66G and 66LP Recreational Vehicle Generators  
1.2 GENERATOR APPLICABILITY  
1.3 INSTALLATION  
These generators have been designed and manufac-  
tured for supplying electrical power for recreational  
vehicles. You should not modify the generator or use  
it for any application other than for what it was  
designed. If there are any questions pertaining to its  
application, write or call the factory. Do not use the  
unit until you have been advised by competent  
authority.  
This Owner’s Manual has been prepared under the  
assumption that a competent, qualified technician  
installed the generator into an industrial vehicle. We  
also assume the installer complied with all applicable  
codes, standards and regulations pertaining to instal-  
lation.  
An INSTALLATION MANUAL was shipped with the  
generator. That Manual contains manufacturer’s  
instructions and recommendations for installing the  
unit into an industrial vehicle. After installation,  
installers should forward the Installation Manual to  
Owners/Operators for their information.  
For fire safety, the generator must have been  
properly installed in compliance with ANSI  
119.2-1975/NFPA 501C-1974, “Standard for  
Recreational Vehicles, Part III – Installation of  
Electrical Systems.” The generator also must  
have been installed in strict compliance with  
the manufacturer’s detailed installation instruc-  
tions. After installation, do nothing that might  
render the unit in noncompliance with such  
codes, standards and instructions.  
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.  
You can use your generator set to supply electrical  
power for operating one of the following electrical  
loads:  
• PRIMEPACT 66G: 120 and/or 240 volts, single  
phase, 60 Hz electrical loads. These loads can  
require up to 6600 watts (6.6 kW) of power, but  
cannot exceed 55 AC amperes of current at 120  
volts or exceed 27.5 AC amperes at 240 volts.  
• PRIMEPACT 66LP: 120 and/or 240 volts, single  
phase, 60 Hz electrical loads. These loads can  
require up to 6200 watts (6.2 kW) of power, but  
cannot exceed 51.7 AC amperes of current at 120  
volts or exceed 25.8 AC amperes at 240 volts.  
1.5 GENERATOR AC CONNECTION  
SYSTEM  
These air-cooled generator sets are equipped with  
dual stator AC power windings. These two stator  
windings supply electrical power to customer electri-  
cal loads by means of a dual 2-wire connection sys-  
tem.  
Generators may be installed to provide the following  
outputs:  
1) 120 VAC loads only — one load with a maximum  
total wattage requirement equal to the generator’s  
rated power output (in watts), and 120V across the  
generator output terminals. Figure 1.1, page 6,  
shows the generator lead wire connections for  
120VAC ONLY.  
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.  
2) 120/240 VAC loads — one load with a maximum  
total wattage requirement equal to the generator’s  
rated power output, and 240V across the generator  
output terminals; or two seperate loads, each with a  
maximum total wattage requirement equal to half of  
the generator’s rated power output (in watts), and  
120V across the generator output terminals.  
Figure 1.2, page 6, shows the generator lead wire  
connections for 120/240 VAC loads.  
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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  
No Load  
0.33  
1/2 Load  
0.59  
Full Load  
0.99  
1.66/7.05  
PrimePact 66G  
PrimePact 66LP  
0.47/2.01  
0.85/3.62  
NOTE  
Some installations using a “shared” fuel tank may  
have a generator fuel pickup tube that is shorter  
than the vehicle engine’s pickup tube. Such an  
arrangement causes the generator engine to “run  
out of gas” while adequate fuel for the vehicle  
remains in the tank.  
To reduce lead and carbon deposits use high quality  
UNLEADED gasoline with the generator. Leaded  
REGULAR grade gasoline is an acceptable substitute.  
NOTE:  
Figure 1.2 - Connection for 120/240 Volts  
Using unleaded gasoline contributes to longer engine  
valve life by reducing lead and carbon deposits.  
T1  
RED  
CB1  
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.  
T2  
WHITE  
CB2  
T3  
1.6.2 ENGINE OIL REQUIREMENTS  
BLACK  
GROUNDED NEUTRAL  
STATOR WINDINGS  
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.  
1.6 SPECIFICATIONS  
1.6.1 FUEL REQUIREMENTS  
This generator is equipped with a gasoline fuel system  
as standard equipment. Specific installations may pro-  
vide either a separate fuel tank for the generator, or the  
generator may “share” the vehicle engine’s fuel tank.  
1.6.3 GENERATOR SPECIFICATIONS  
PRIMEPACT 66G  
SERIES  
Rotor RPM  
PRIMEPACT 66LP  
3600  
3600  
2
Rotor Poles  
Engine RPM  
2
2700  
2700  
6600 watts (6.6 kW)  
120  
Rated Max. Continuous AC Output*  
Voltage*  
6200 watts (6.2 kW)  
120  
Rated Max. Continuous Current*  
Phase  
55.0 AC amps‡  
1
60 Hertz  
51.7 AC amps Ñ  
1
60 Hertz  
Frequency  
Battery Charging Current (Max.)  
2 amps (trickle charge)  
213 pounds  
25 inches  
2 amps (trickle charge)  
216 pounds  
25.75 inches  
18.5 inches  
15.75 inches  
Weight  
Length  
Width  
18.5 inches  
15.75 inches  
Height  
*
Ñ
All units are reconnectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output  
Rated maximum continuous current at 240 volts is 27.5 amps.  
Rated maximum continuous current at 240 volts is 25.8 amps.  
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Section 2 – Operation  
PRIMEPACT 66G and 66LP Recreational Vehicle Generators  
1.6.4 ENGINE SPECIFICATIONS  
Type of Engine  
PRIMEPACT 66G/66LP ..............................................GN-480  
2.1 GENERATOR CONTROL PANEL  
The following features are mounted on the generator  
control panel (Figure 2.1):  
Cooling Method ........................................................Air-cooled  
Rated Horsepower  
2.1.1 FUEL PRIMER  
PRIMEPACT 66G/66LP ........................................16 at 3600  
Displacement  
PRIMEPACT 66G/66LP..................................................480cc  
Before starting a cold engine (if it has not been start-  
ed in more than two weeks), you must press this  
switch for approximately ten seconds to bring fuel  
from the tank to the fuel pump. This rocker type  
switch springs back into its original position when  
you release it.  
Compression Ratio........................................................8.6 to 1  
Cylinder Block ..........................Aluminum w/Cast Iron Sleeve  
Type of Governor ..............................Mechanical, Fixed Speed  
Engine Governor Speed............................................2700 rpm  
Air Cleaner ........................Paper Element w/Foam Precleaner  
Starter ........................................................12-volt DC Electric  
Ignition System ......................Solid-state w/Flywheel Magneto  
Recommended Spark Plug  
Champion ..................................................................RC12YC  
AC....................................................................................R45S  
Fram Autolite ......................................................................65  
Spark Plug Gap........................................0.030 inch (0.8 mm)  
Recommended Min. Battery............400 Cold Cranking Amps  
2.1.2 START/STOP SWITCH  
To crank and start the engine, hold this switch in the  
START position. Release the switch when the engine  
starts. To stop an operating engine, press and hold  
the switch in the STOP position until the engine shuts  
off. The switch center position is the RUN position.  
2.1.3 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.  
1.6.5 EMISSIONS COMPLIANCE PERIOD  
For nonhandled engines the Emissions Compliance  
Period referred to on the Emissions Compliance  
Label indicates the number of operating hours for  
which the engine has been shown to meet Federal  
emission requirements.  
2.1.4 LINE BREAKERS  
Protects generator’s AC output circiut against  
overload, i.e., prevents unit from exceeding  
wattage/amperage capacity. This unit has two 30-amp  
breakers.  
• 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  
Figure 2.1 – Typical Control Panel  
hours, B=500 hours, and A=1000 hours.  
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Section 2 – Operation  
PRIMEPACT 66G and 66LP Recreational Vehicle Generators  
NOTE:  
2.3.2 PRECHOKE  
If this generator has been reconnected for dual  
voltage AC output (120/240 volts), you can install  
line breakers having an amperage rating that is  
different than that stated above. The replacement  
line breakers consist of two separate breakers with  
a connecting piece between the breaker handles  
(so that both breakers will operate at the same  
time). If the unit is reconnected for dual voltage,  
it is no longer RVIA listed.  
The choke system also has a temperature-sensitive  
metal strip that adjusts choke valve angle according  
to ambient temperatures (i.e., in cold ambient tem-  
peratures, choke valve closes more). Once the engine  
starts, an element heats the temperature-sensitive  
strip to a normal operating condition, opening the  
choke valve. This may take about three minutes in  
cooler weather.  
2.4 BEFORE STARTING THE ENGINE  
2.2 OPTIONAL REMOTE  
NOTE:  
START/STOP PANEL  
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.  
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.  
2.4.1 INSTALLATION  
Figure 2.2 — Optional Remote Panel  
(Models 004057 and 004184)  
Generator installation must have been properly com-  
pleted so it complies with all applicable codes, stan-  
dards and regulations and with the manufacturer's  
recommendations.  
2.4.2 ENGINE LUBRICATION  
Have the engine crankcase properly serviced with the  
recommended oil before starting. Refer to Section  
1.6.3 (Page 6) and Sections 3.1 and 3.2 (Page 11) for  
oil servicing procedures and recommendations.  
2.3 AUTOMATIC CHOKE  
This engine is equipped with an automatic choke that  
consists of two main components: a choke solenoid  
and prechoke.  
Any attempt to crank or start the engine before  
you have properly serviced it with the recom-  
mended oil may result in an engine failure.  
2.4.3 FUEL SUPPLY  
2.3.1 CHOKE SOLENOID  
The engine must have an adequate supply of proper  
fuel to operate. Before starting it, check that sufficient  
fuel is available.  
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.  
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.  
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Section 2 – Operation  
PRIMEPACT 66G and 66LP Recreational Vehicle Generators  
2. If you have not started the engine in more than  
2.4.5 ENGINE EXHAUST GAS  
two weeks, press the Fuel Pump Primer switch  
and hold it for about 10 seconds. However, if the  
engine is warm, skip Step 2.  
Before starting the generator engine, you should be  
sure there is no way for exhaust gases to enter the  
vehicle interior and endanger people or animals.  
Close windows, doors and other openings in the vehi-  
cle that, if open, might permit exhaust gases to enter  
the vehicle.  
3. To crank and start the engine, hold the start/stop  
switch at START. Release the switch when the  
engine starts.  
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.  
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.  
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  
1. Turn OFF all electrical loads using the means  
provided (such as a main circuit breaker or  
transfer switch).  
2. Let generator run at no-load for a few minutes, to  
stabilize internal engine generator temperatures.  
3. Place the Start/Stop switch in its STOP position.  
The engine will come to a complete stop.  
2.5 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.  
2.7 APPLYING LOADS TO GENERATOR  
When applying electrical loads to the generator,  
observe these guidelines:  
• Before applying electrical loads, let the generator  
stabilize and warm up for a minute or two.  
• DO NOT overload the generator.  
2.7.1 LETTING THE ENGINE STABILIZE  
The generator supplies correct rated voltage only at  
the proper governed speed. Some electrical appli-  
ances may be extremely sensitive to voltage. Incorrect  
voltages can damage such appliances.  
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).  
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.  
NOTE:  
If starting from the generator control panel, turn  
OFF loads by setting the generator’s main circuit  
breaker to the OFF (or open) position. If starting  
from a remote panel, turn OFF loads using the  
means provided in the vehicle (such as a main cir-  
cuit breaker). Electrical load circuits will be  
turned ON after the generator has started, stabi-  
lized and warmed up.  
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Section 2 – Operation  
PRIMEPACT 66G and 66LP Recreational Vehicle Generators  
2.7.2 DO NOT OVERLOAD THE GENERATOR  
2.8.2 HIGH TEMPERATURE SWITCH  
You can read the rated wattage/amperage capacity of  
your generator on the generator data decal (see  
Section 1.1 on Page 4).  
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 284º F (140º C), initiating an engine  
shutdown.  
Applying electrical loads in excess of the unit’s rated  
capacity will cause the engine/generator to automati-  
cally shut down.  
Figure 2.3 – Low Oil Pressure and  
High Temperature Switches  
To avoid overloading, add up the wattage of all con-  
nected electrical lighting, appliance, tool and motor  
loads. This total should not be greater than the gen-  
erator’s rated wattage capacity.  
• Most lighting, appliance, tool and motor loads indi-  
cate their required watts on their nameplate or  
data plate. For light bulbs, simply note the wattage  
rating of the bulb.  
• If a load does not show its rated wattage, multiply  
that load’s rated VOLTS times AMPS to obtain  
WATTS.  
• Induction type motors (such as those that run the  
vehicle’s furnace fan, refrigerator, air conditioner,  
etc.) need about 2-1/2 times more watts of power  
for starting than for running (for a few seconds  
during motor starting). Be sure to allow for this  
when connecting electrical loads to the generator.  
First, figure the watts needed to start electric  
motors in the system. To that figure, add the run-  
ning wattages of other items that will be operated  
by the generator.  
2.8.3 FIELD BOOST  
The Controller Circuit Board houses a field boost  
diode and resistor that are not part of the automatic  
choke circuit. These two components are part of a  
“field boost” circuit (Figure 2.4). During engine  
cranking only, a positive DC (battery) voltage is deliv-  
ered through the diode, resistor, brushes and slip  
rings, and the generator rotor. Application of this  
voltage to the rotor “flashes the field” whenever it is  
started. Flashing of the field each time the generator  
starts makes sure that a sufficiently strong magnetic  
field is available to produce “pickup” voltage in the  
stator windings.  
• Do not apply heavy electrical loads for the first two  
or three hours of operation.  
2.8 PROTECTION SYSTEMS  
2.8.1 LOW OIL PRESSURE SWITCH  
This switch (Figure 2.3 on page 10) has normally  
open (N.O.) contacts that are held open by engine oil  
pressure during cranking and operating. Should oil  
pressure drop below a preset level, switch contacts  
close, and the engine automatically shuts down. The  
unit should not be restarted until oil is added.  
Figure 2.4 – Field Boost Circuit  
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Section 3 – Maintenance  
PRIMEPACT 66G and 66LP Recreational Vehicle Generators  
2.8.4 OVERVOLTAGE PROTECTION  
2.8.6 25-HOUR CHECK-UP  
A solid-state voltage regulator (Figure 2.5) controls  
the generator’s AC output voltage. This regulator sup-  
plies an excitation current to the rotor. By regulating  
the rotor’s excitation current, the strength of its mag-  
netic field is regulated and, in turn, the voltage deliv-  
ered to connected electrical loads is controlled. When  
the AC frequency is 50 Hertz, voltage is regulated at  
115 volts.  
After the 25-hour break-in period, contact a Generac  
Authorized Service Dealer for the following mainte-  
nance. The vehicle owner is responsible for any  
charges:  
• Change the engine crankcase oil and oil filter.  
• Check all fluid levels.  
• Inspect the cooling and ventilation openings.  
• Check the engine ignition system.  
• Inspect the entire electrical system.  
• Inspect the engine exhaust system.  
Figure 2.5 – Solid State Voltage Regulator  
2.8.7 OPERATION IN HIGH GRASS  
OR BRUSH  
Never operate the generator while the vehicle  
is parked over high grass, weeds, brush,  
leaves or any other combustible substance.  
Such materials can ignite and burn from the  
heat of the exhaust system. The generator  
exhaust system becomes extremely hot dur-  
ing operation and remains hot for a long time  
after it has shut down.  
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.  
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):  
2.8.5 25-HOUR BREAK-IN PERIOD  
The first 25 hours of operation is the break-in period  
for the generator. Properly breaking in the generator  
is essential to minimize fuel consumption and pro-  
vide maximum engine performance. During this 25-  
hour break-in period, follow this procedure:  
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  
“FULLMARK.  
• 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.  
Never operate the engine with the oil level  
below the “Add” mark on the dipstick. Doing  
this could damage the engine.  
• After operating the unit for 25 hours, complete the  
5. Install and tighten the oil fill cap and the dipstick  
before operating the engine.  
tasks recommended under Section 2.8.6.  
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