Page 2 - INTRODUCTION; READ THIS MANUAL THOROUGHLY; This symbol points out potential fire hazard.; CONTENTS; AUTHORIZED SERVICE
Generac ® Power Systems, Inc. INTRODUCTION READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual,contact Generac or your nearest Generac AuthorizedService Dealer for starting, operating and servicingprocedures.Throughout this publication, and on tags and decals affixed to t...
Page 3 - Table of Contents
Table of Contents PRIMEPACT 66G and 66LP Recreational Vehicle Generators Generac ® Power Systems, Inc. 1 Part I — Operating InstructionsIntroduction ..................................................Inside Front Cover Read This Manual Thoroughly ..........................................IFCContents ...
Page 4 - GENERAL HAZARDS
2 Generac ® Power Systems, Inc. Study these SAFETY RULES carefully beforeinstalling, 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 andmaintained. Many acc...
Page 5 - ELECTRICAL HAZARDS; Safety Rules
Generac ® Power Systems, Inc. 3 ELECTRICAL HAZARDS • The generator covered by this manual produces dangerous electrical voltages and can cause fatalelectrical shock. Avoid contact with bare wires, ter-minals, connections, etc., while the unit is running.Ensure all appropriate covers, guards and barr...
Page 6 - Section 1 – General Information; IDENTIFICATION; REFERENCE NUMBER IDENTIFICATION
4 Generac ® Power Systems, Inc. Section 1 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators Please record the following information from the generator DATA DECAL or information decal. 1. Model Number ____________________ 2. Serial Number __________________ 3. kW Rating ___...
Page 7 - GENERATOR APPLICABILITY
Generac ® Power Systems, Inc. 5 Section 1 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators 1.2 GENERATOR APPLICABILITY These generators have been designed and manufac-tured for supplying electrical power for recreationalvehicles. You should not modify the generator or use...
Page 8 - Figure 1.1 – Connection for 120 Volts Only; SPECIFICATIONS; Fuel Consumption; NOTE; GENERATOR SPECIFICATIONS
6 Generac ® Power Systems, Inc. Section 1 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators Figure 1.1 – Connection for 120 Volts Only Figure 1.2 - Connection for 120/240 Volts 1.6 SPECIFICATIONS 1.6.1 FUEL REQUIREMENTS This generator is equipped with a gasoline fuel syste...
Page 9 - Section 2 – Operation; • For engines of 225 cc or more, Category C=250; GENERATOR CONTROL PANEL; Figure 2.1 – Typical Control Panel
Generac ® Power Systems, Inc. 7 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-c...
Page 10 - Figure 2.2 — Optional Remote Panel; AUTOMATIC CHOKE
8 Generac ® Power Systems, Inc. Section 2 – Operation PRIMEPACT 66G and 66LP Recreational Vehicle Generators NOTE: If this generator has been reconnected for dualvoltage AC output (120/240 volts), you can installline breakers having an amperage rating that isdifferent than that stated above. The rep...
Page 11 - STARTING THE GENERATOR
Generac ® Power Systems, Inc. 9 Section 2 – Operation PRIMEPACT 66G and 66LP Recreational Vehicle Generators 2.4.5 ENGINE EXHAUST GAS Before starting the generator engine, you should besure there is no way for exhaust gases to enter thevehicle interior and endanger people or animals.Close windows, d...
Page 12 - • If a load does not show its rated wattage, multiply; PROTECTION SYSTEMS; Figure 2.3 – Low Oil Pressure and
10 Generac ® Power Systems, Inc. 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 ofyour generator on the generator data decal (seeSection 1.1 on Page 4).Applying electrical loads in exce...
Page 13 - Section 3 – Maintenance; Figure 2.5 – Solid State Voltage Regulator; OR BRUSH
Generac ® Power Systems, Inc. 11 Section 3 – Maintenance PRIMEPACT 66G and 66LP Recreational Vehicle Generators 2.8.4 OVERVOLTAGE PROTECTION A solid-state voltage regulator (Figure 2.5) controlsthe generator’s AC output voltage. This regulator sup-plies an excitation current to the rotor. By regulat...
Page 14 - engine oil; Location of Oil Drain Plug
12 Generac ® Power Systems, Inc. Section 3 – Maintenance PRIMEPACT 66G and 66LP Recreational Vehicle Generators 3.2 CHANGING THE ENGINE OILAND/OR OIL FILTER • Change the engine oil after the first 25 hours of operation (after the 25-hour break-in period, seeSection 2.8.5, Page 10). Thereafter, chang...
Page 15 - filter must lock into slots on cover.; Figure 3.3 – Engine Air Cleaner; CLEAN AIR INTAKE SCREEN; Figure 3.4 – Cleaning Air Intake; Remove the spark plug and check the condition.; Figure 3.5 – Setting the Spark Plug Gap; FUEL FILTER; Figure 3.6 – Fuel Filter; SPARK ARRESTOR MUFFLER
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 3.3 – Engine Air Cleaner 3.4 CLEAN AIR INTAKE SCREEN Clean all foreign mat...
Page 16 - • Inspect the battery posts and cables for tightness
14 Generac ® Power Systems, Inc. Be sure to reinstall the muffler plug tightly.Engine vibration could cause a loose plug tofall out. Without the plug in place, hot engineexhaust is directed out the opening. This hotexhaust, depending on the installation, couldbe directed to areas not able to withsta...
Page 17 - MAJOR SERVICE MANUAL
Generac ® Power Systems, Inc. 15 3.10 MAJOR SERVICE MANUAL To obtain a service manual for your generator, con-tact Generac or your nearest Generac AuthorizedService Dealer. Make sure to identify your MODELNUMBER and SERIES. 3.11 DRIVE BELT The engine drives the generator rotor by means of apulley an...
Page 18 - Section 4 – Notes
16 Generac ® Power Systems, Inc. Section 4 – Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators
Page 19 - ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
Page 20 - NOTICE TO INSTALLER; Installation Instructions
18 Generac ® Power Systems, Inc. Safety Rules PRIMEPACT 66G and 66LP Recreational Vehicle Generators NOTICE TO INSTALLER These Installation Instructions have been published by Generac to aid in the installation of the productsdescribed in this manual. Generac assumes thatinstallation personnel are f...
Page 22 - Figure 5.1 – Connection for 120 Volts Only; Section 5 – General Information
20 Generac ® Power Systems, Inc. 5.1 PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS These Installation Instructions have been prepared especially for the purpose of familiarizing installers andowners of the applicable equipment with the product'sinstallation requirements. Give serious considerat...
Page 23 - Figure 5.2 - Major Features and Dimensions
Generac ® Power Systems, Inc. 21 Figure 5.2 - Major Features and Dimensions Section 5 – General Information PRIMEPACT 66G and 66LP Recreational Vehicle Generators Control Panel Fuel Filter Fuel Pump Oil Filter Oil Drain Plug Starter Contactor Oil Fill/Oil Level Spark Plugs (both sides,not shown) Air...
Page 24 - Figure 6.1 – Typical Horizontal Support Frame; Section 6 – Installation
22 Generac ® Power Systems, Inc. Figure 5.3 - Connection for 120/240 Volts • The AC connection system on all air- cooled PRIMEPACT series generators uses a GROUNDEDneutral. • A separate green ground wire is connected to the recreational vehicle’s junction box. • Loads connected across T1 (Red) to T2...
Page 25 - • Protect the generator against road splash and debris.; Figure 6.2 – Typical Suspended Mounting System; • The installer must make certain that the selected; Figure 6.3 – Typical Generator Restraint; COMPARTMENTS; Figure 6.4 – Clearances; • The generator compartment should be either con-; Figure 6.5 – Typical Compartment Construction
Generac ® Power Systems, Inc. 23 • Protect the generator against road splash and debris. Baffles or splash guards may be required to protect cer-tain areas of the generator. To make sure the generatoris adequately protected, road test the installationthrough mud, water and slush. Figure 6.2 – Typica...
Page 26 - Figure 6.6 – Types of Lock Seams
24 Generac ® Power Systems, Inc. • If constructing a compartment, line the exterior (underside) of the compartment floor with 26-gaugegalvanized steel. • All seams, splices and joints of the compartment walls (unless vapor tight by design) should becaulked to prevent poisonous, flammable or explo-si...
Page 27 - • Seal all compartment door edges to prevent noise; Figure 6.7 – Typical Noise Abatement
Generac ® Power Systems, Inc. 25 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. To prevent fire or explosion...
Page 28 - COOLING AND VENTILATING AIR; Figure 6.9 – Airflow Through Engine/Generator; at least 100 square inches; Figure 6.10 – Air Inlet in Compartment Door; • By providing an opening in the vehicle skirt and space
26 Generac ® Power Systems, Inc. 6.2.5 COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compart-ment 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 Sectio...
Page 29 - Figure 6.12 – Air Inlet Using Ductwork; If you plan to use screening with an 80; FUEL; Figure 6.14 – Generator Fuel System
Generac ® Power Systems, Inc. 27 behind the generator for cooling airflow (Figure 6.13 ). Recommended clearance behind theback of the generator is at least 1/2 inch (13 mm). Figure 6.12 – Air Inlet Using Ductwork Figure 6.13 – Air Inlet in Vehicle Skirt 6.3.3 COMPENSATING FOR RESTRICTIONS Such mater...
Page 30 - LP GAS FUEL SYSTEM
28 Generac ® Power Systems, Inc. 6.4.1 FUEL TANK Either the generator must share the vehicle engine's fueltank, or you must install a separate fuel tank for thegenerator set. All fuel tanks installed on the vehiclemust be constructed, installed and restrained so theycomply with applicable codes, sta...
Page 31 - Figure 6.15 – Typical Propane Gas Fuel System; • Test the entire fuel system for leaks using approved; Figure 6.16 – LP Gas Carburetion Diagram
Generac ® Power Systems, Inc. 29 Figure 6.15 – Typical Propane Gas Fuel System 6.5.2 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system, consider seriouslythe following items:• All fittings, lines, hoses and clamps must be tight and free of leaks. Apply a pipe sealant to threads whenasse...
Page 32 - SYSTEM
30 Generac ® Power Systems, Inc. The greater the airflow through the carburetor venturi,the lower the pressure at the venturi throat. The lowerthe pressure at the venturi throat, the greater thediaphragm movement, and the greater the movement ofthe regulator valve. The more the regulator valve opens...
Page 33 - CONNECTIONS
Generac ® Power Systems, Inc. 31 Failure to provide and maintain a spark arrestor may bein violation of the law. If this generator is used on anyforest covered, brush covered or grass covered unim-proved land, you must provide a spark arrestor. Thevehicle owner or operator must maintain this device ...
Page 34 - Figure 6.17 – Generator AC Output Leads; INSTALLATION
32 Generac ® Power Systems, Inc. • 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 orisolation receptacle must prevent vehicle electricalcircuits fr...
Page 35 - Figure 6.18 — Transfer Switch Isolation Method
Generac ® Power Systems, Inc. 33 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 indiameter may cause a drop in voltage, which causesstarting problems. For the best cold weather starting,the volt...
Page 36 - Figure 6.20 – Connecting Battery Cables; ACCESSORIES; Figure 6.21 – Remote Panel Plug-in Receptacle; CABLE LENGTH
34 Generac ® Power Systems, Inc. 6.8.3 BATTERY CABLE CONNECTIONS 1. Connect the battery cable from the battery post or terminal indicated by a POSITIVE, POS or (+) to thelug on the starter contactor (Figure 6.20). NOTE: Check to be sure the battery cable boot for thestarter cable has been installed....
Page 37 - Check the fuel supply. Gas fuel lines must have been; START; Let the engine warm up for about five minutes to; UNDER; Section 7 – Post Installation
Generac ® Power Systems, Inc. 35 7.1 POST INSTALLATION TESTS The air-cooled generator set was factory tested andadjusted. You should not be required to adjust the unitany further except under special circumstances. Do not make any unnecessary adjustments.Factory settings are correct for most applica...
Page 38 - CHECKLIST
36 Generac ® Power Systems, Inc. 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 i...
Page 39 - Section 8 – Troubleshooting; TROUBLESHOOTING GUIDE; PROBLEM
Generac ® Power Systems, Inc. 37 Section 8 – Troubleshooting PRIMEPACT 66G and 66LP Recreational Vehicle Generators 8.1 TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace blown fuse. 2. Loose, or corroded or defective 2. Tighten, clean or replace, bat...
Page 42 - Section 10 — Exploded Views and Parts Lists
40 Generac ® Power Systems, Inc. Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle GeneratorsSheet Metal – Drawing No. 0D3150-A
Page 43 - ITEM PART
Generac ® Power Systems, Inc. 41 Section 10 — Exploded Views and Parts Lists PRIMEPACT 66G and 66LP Recreational Vehicle Generators Sheet Metal – Drawing No. 0D3150-A ITEM PART NO. QTY. DESCRIPTION 1 --------- 1 SEE ENGINE EXPLODED VIEW of ENGINE 2 099258 1 KEY-WOODRUFF 6 x 22MM 3 067198N 1 BEVELLED...
Page 45 - DESCRIPTION
Generac ® Power Systems, Inc. 43 ITEM PART NO. QTY. DESCRIPTION 1 086318 1 BASE, MOUNTING 2 090141 1 GROUND CABLE 3 046911 4 MOUNT VIBR 1.50X1.38 X 3/8-16) 4 025017 8 SCREW HHC 3/8-16 X 1/2 G5 5 046526 2 WASHER LOCK M10 6 022129 8 WASHER LOCK M8-5/16 7 072391 2 SKID, RUBBER MOUNT 8 077603 2 SAFETY B...
Page 55 - Section 11 — Notes
Generac ® Power Systems, Inc. 53 Section 11 — Notes PRIMEPACT 66G and 66LP Recreational Vehicle Generators
Page 58 - Section 12 – Warranty; CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT
56 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 Agenc...
Page 59 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
Generac ® Power Systems, Inc. 57 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 y...
Page 60 - GENERAC; GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY; WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS
Part No. 0D7803 GENERAC ® POWER SYSTEMS, INC. P.O. BOX 8 • WAUKESHA, WI 53187 Revision 0 (11/14/01) Printed in U.S.A. Section 12 – Warranty PRIMEPACT 66G and 66LP Recreational Vehicle Generators GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS NOTE: ALL UNITS MU...
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