User Manual

Table of Contents
PRIMEPACT 55G and 55LP Recreational Vehicle Generators
Generac
®
Power Systems, Inc. 1
Part I — Operating Instructions
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
1.1 Generator Identification ................................................4
1.2 Generator Applicability ..................................................5
1.3 Installation ....................................................................5
1.4 Safety ............................................................................5
1.5 Generator AC Connection System..................................5
1.6 Specifications ................................................................6
1.6.1 Fuel Requirements ..............................................6
1.6.2 Engine Oil Requirements ....................................6
1.6.3 Engine Specifications ..........................................6
1.6.4 Emissions Compliance Period ............................6
1.6.5 Generator Specifications......................................6
Section 2 – Operation................................................................7
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
2.2 Optional Remote Start/Stop Panel..................................7
2.3 Automatic Choke ..........................................................7
2.3.1 Choke Solenoid ..................................................7
2.3.2 Prechoke..............................................................8
2.4 Before Starting the Engine ............................................8
2.4.1 Installation..............................................................8
2.4.2 Engine Lubrication ................................................8
2.4.3 Fuel Supply ............................................................8
2.4.4 Cooling and Ventilating Air ....................................8
2.4.5 Engine Exhaust Gas ..............................................8
2.5 Starting the Generator ..................................................8
2.6 Stopping the Generator..................................................9
2.7 Applying Loads to Generator ........................................9
2.7.1 Letting the Engine Stabilize ................................9
2.7.2 Do Not Overload the Generator ..........................9
2.8 Protection Systems ........................................................9
2.8.1 Low Oil Pressure Switch......................................9
2.8.2 High Temperature Switch ..................................10
2.8.3 Field Boost ........................................................10
2.8.4 Overvoltage Protection ......................................10
2.8.5 25-Hour Break-in Period....................................10
2.8.6 25-Hour Checkup ..............................................11
2.8.7 Operation in High Grass or Brush ....................11
Section 3 – Maintenance ........................................................11
3.1 Checking the Engine Oil Level......................................11
3.2 Changing the Engine Oil and/or Oil Filter ....................11
3.3 Maintaining the Engine Air Cleaner ............................12
3.3.1 Cleaning the Foam Precleaner............................12
3.4 Clean Air Intake Screen ..............................................12
3.5 Checking the Engine Spark Plug..................................12
3.6 Fuel Filter (Gasoline Only) ..........................................13
3.7 Spark Arrestor Muffler ................................................13
3.8 Cleaning the Generator ................................................13
3.9 Battery Maintenance ....................................................13
3.9.1 Weekly ..............................................................13
3.9.2 Every Six Months ..............................................13
3.10 Major Service Manual ..................................................14
3.11 Drive Belt ....................................................................14
3.12 Exercising the Generator ............................................14
3.13 Out of Service Procedure ............................................14
3.13.1 Removal From Service ....................................14
3.13.2 Return to Service ............................................15
3.14 Wattage Reference Guide..............................................15
Section 4 – Notes......................................................................16
Part II — Installation Instructions
Safety Rules..........................................................................18-19
Section 5 — General Information..........................................20
5.1 Purpose and Scope of the Manual................................20
5.2 Safety ..........................................................................20
5.3 Standard Booklets ......................................................20
5.4 Equipment Description................................................20
5.5 Generator Engine Operating Speed..............................20
5.6 Generator AC Connection System................................20
Major Dimensions and Features ..................................21
Section 6 — Installation ..........................................................22
6.1 Location and Support ..................................................22
6.1.1 Generator Location............................................22
6.1.2 Generator Supports ..........................................22
6.1.3 Suspended Mounting ........................................22
6.1.4 Generator Restraint ..........................................23
6.2 Generator 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
6.3 Cooling and Ventilation ................................................26
6.3.1 Generator Airflow ..............................................26
6.3.2 Cooling Air Inlet Openings ................................26
6.3.3 Compensating for Restrictions ..........................27
6.3.4 Testing the Installation ......................................27
6.4 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
6.5 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
6.6 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
6.7 Electrical Connections ................................................31
6.7.1 Electrical Junction Box ....................................31
6.7.2 Wiring ................................................................32
6.7.3 Generator AC Connections ................................32
6.7.4 Conduit..............................................................32
6.7.5 Isolating Different Power Sources ......................32
6.7.6 Power Supply Cord............................................33
6.7.7 Ground Fault Circuit Interrupters ....................33
6.8 Battery Installation ......................................................34
6.8.1 Recommended Battery ......................................34
6.8.2 Battery Cables ..................................................34
6.8.3 Battery Cable Connections ................................34
6.8.4 Battery Compartment ........................................34
6.9 Optional Accessories....................................................34
6.9.1 Remote Panel Models ........................................35
Section 7 — Post Installation ................................................35
7.1 Post Installation Tests ..................................................35
7.2 Before Initial Start-up ..................................................35
7.3 Initial Start ..................................................................35
7.4 Testing Under Load......................................................35
7.5 Installation Checklist ..................................................36
Section 8 – Troubleshooting ..................................................37
8.1 Troubleshooting Guide ................................................37
Section 9 – Electrical Data......................................................38
Section 10 – Exploded Views and Parts Lists....................40
Section 11 – Notes....................................................................53
Section 12 – Warranty ............................................................56