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Generac Power Systems 00784-2, 09290-4 manual

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Table of contents for the manual

  • Page 1

    PO WER SY STEMS, INC. ® Owner ’ s Manual and Installation Instructions Air-cooled Recreational V ehicle Generators • Model Nos: 00784-2 and 09290-4[...]

  • Page 2

    Generac ® Pow er Systems, Inc. I NTRODUCTION R EAD THIS MAN UAL THOROUGHL Y If you do not understand any portion of this manual, contact Generac or your nearest Generac Authorized Service Dealer for starting, operating and servicing pro- cedures. Throughout this publication, and on tags and decals affixed to the generator , DANGER, W ARNING , CA U[...]

  • Page 3

    T able of Contents PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generatorss Generac ® Pow er Systems, Inc. 1 P ar t I — Owner’s Manual Introduction ........................................Inside F ront Cover Read This Manual Thoroughly ..................................IFC Contents .....................................................[...]

  • Page 4

    2 Generac ® Pow er Systems, Inc. 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 main- tained. Many accidents are caused by failing to follow s[...]

  • Page 5

    Generac ® Pow er Systems, Inc. 3 ELE CTR ICAL HA Z AR DS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. A void 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 t[...]

  • Page 6

    4 Generac ® Pow er Systems, Inc. Section 1 – General Information PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Please recor d the following information from the generator DA T A DECAL or information decal. 1. Model Number ____________________ 2. Serial Number __________________ 3. kW Rating __________________________ 4. Rated [...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 Section 1 – General Information PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators 1.2 GEN ER A T OR AP P LICAB I LIT Y These generators have been designed and manufac- tured for supplying electrical power for recreational vehicles. Y ou should not modify the generator or use it for any application [...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. Section 1 – General Information PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators 1.6 SP E CI F ICA TIONS 1.6.1 F UEL R EQ UIRE MEN T S These generators are equipped with a gasoline fuel sys- tem. Depending on the installation, the generator may have either a separate fuel tank, or it may “share?[...]

  • Page 9

    Generac ® Pow er Systems, Inc. 7 Section 2 – Operation PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators 2.1 GEN ER A T OR CONTROL P AN EL The following features are mounted on the generator control panel (Figure 2.1): Figure 2.1 – Generator Control Panel 2.1.1 F UEL PRIMER Before starting a cold engine (if it has not been start[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. Section 2 – Operation PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators 2.4 B EFOR E S T ARTI NG TH E ENGI N E NOTE: Instructions and information in this manual assume the generator has been properly installed, connected, serviced, tested and adjusted by a qualified installation technician or insta[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 Section 2 – Operation PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators 2 . 6 S T OPPIN G THE G E NERA T O R 1. T urn 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 engi[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. Section 2 – Operation PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Figure 2.4 – Field Boost Circuit 2.8.4 OVERV OL T AGE PRO TECTION 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 [...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 Sectio n 3 – Maintenance PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators 3.1 CH E CKI NG TH E ENGI N E OI L LEVEL F or oil capacities and requirements, see “Engine Oil Requirements,” Section 1.6.2 (P age 6). Check the engine crankcase oil level at least every eight hours of operation, or bef[...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. Sectio n 3 – Maintenance PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators 3.3 MAI NT AI N I NG TH E ENGI N E AI R CLEAN ER 3.3.1 CLEAN ING TH E FO AM P RECLEANER Clean and re - oil the foam precleaner every three months or every 25 hours of operation, whichever occurs first. Service the foam prec[...]

  • Page 15

    Sectio n 3 – Maintenance PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators 3 . 6 FUE L FIL T ER (GA SOLINE ON L Y) Remove and replace the fuel filter (Figure 3.6) once each year or every 100 hours of operation, whichever comes first. Figure 3.6 – Fuel Filter 3 . 7 S P ARK A RRE S T OR MUFFL ER If the generator is not equipped wit[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. Do not dispose of the battery in a fire. The battery is capable of exploding. Storage batter- ies give off explosive hydr ogen gas. This gas can form an explosive mixture ar ound the bat- tery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can sha[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 3.1 3.2 R E TU RN T O SERVICE T o return the unit to service after storage, proceed as follows: 1. Check the tag on the engine for oil viscosity and classification. V erify that the correct recommend- ed oil is used in the engine (see Section 1.5.4, P age 6). If necessary , drain and refill with the proper oil. 2.[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. Notes PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators[...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 P ART I I – I NS T ALL A TION I NS TR UCTIONS ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA TION!![...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. Safety Rules PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators NO TICE T O I NS T ALLER These Installation Instructions have been published by Generac to aid in the installation of the products described in this manual. Generac assumes that installation personnel are familiar with the proce- dures f[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 Safety Rules PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators ELE CTR ICAL HA Z AR DS • The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. A void contact with bare wires, ter- minals, connections, etc., while the unit is running . Ens[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. 1.1 P U R POSE AN D S COPE OF TH E MAN U AL 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 manua[...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Figure 1.2 – Major Features and Dimensions Section 1 – General Information PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators PrimePact 50 and 70 Control Panel Fuel Filter Fuel Pump Oil Filter Oil Drain Plug Starter Contactor Oil Fill/Oil Level Spark Plugs (both sides, not shown) Air Filter Groun[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. 2.1 L OCA TION AN D SU P PORT 2.1.1 GEN ERA T OR LOCA TION The most desirable location for the generator set is between the vehicle's main frame members. However , this is seldom possible. Most units must be installed on the side of the vehicle and are difficult to reinforce. Many recreational vehicles have b[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 2.1.4 GEN ERA T OR R ES TR AINT Use four 3/8"-16 hardened steel bolts (Grade 5) to fas- ten the generator to the supporting frame or the sup- port tubing . These bolts must pass through (a) the gen- erator mounting base, (b) the compartment floor (if a compartment is used) and (c) the supporting frame- work ([...]

  • Page 26

    24 Generac ® Pow er Systems, Inc. • If flexible metal conduit is used, it must be sealed internally at the end where it terminates inside the compartment ’s electrical junction box. NOTE: Flexible metal conduit, due to its unique con- struction, is NOT vapor tight along its entire length. • Seams and joints of the galvanized steel (whether u[...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 Section 2 – Installation PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Figure 2.7 – T ypical Noise Abatement 2.2.5 COMP ARTM ENT F L OOR CUT OUTS Y ou must provide openings in the generator compart- ment for the following items (Figure 2.8): • Engine exhaust and cooling air outlets • Gen[...]

  • Page 28

    26 Generac ® Pow er Systems, Inc. 2.3 C OOLI NG AN D VENTI L A TI NG AI R It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. W ithout sufficient air- flow , the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also[...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 Figure 2.12 – Air Inlet Using Ductwork Figure 2.13 – Air Inlet in V ehicle Skirt 2.3.3 COMP ENS A TING FOR R ES TR ICTIONS Such materials as screening, louvers or expanded metal can restrict the free flow of air . Compensate for this restriction by making the actual air opening pro- portionately larger . Some [...]

  • Page 30

    28 Generac ® Pow er Systems, Inc. 2.4.1 F UEL T AN K 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 vehi- cle must be constructed, installed and restrained so they comply with applicable codes, standards and regulations. If the gen[...]

  • Page 31

    Generac ® Pow er Systems, Inc. 29 2.5.1 MUFF LERS AN D SP AR K AR RES T ORS This muffler meets code and standard requirements of the U .S. F orest Service. Use only mufflers and parts approved by Generac. Any person(s) installing an unapproved muffler , or an unapproved exhaust system part, or modifying an exhaust system in any way that might caus[...]

  • Page 32

    30 Generac ® Pow er Systems, Inc. 2.6.2 W IRIN G • Wiring should be of stranded copper to reduce the chance that vibration may cause breakage. • Wire gauge size should be large enough to handle at least 115 percent of the installed generator's rated maximum current. • If neutral conductors are used, they must be the same size as other l[...]

  • Page 33

    Generac ® Pow er Systems, Inc. 31 Section 2 – Installation PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Figure 2.18 — T ransfer Switch Isolation Method Figure 2.19 — Installation With Isolation Receptacle[...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. 2.7 B A T TER Y I NST ALL A TION 2.7 .1 R E COMM EN DED B A TTER Y Install a battery that meets the following require- ments: • The battery must be a 12-volt, automotive type storage battery . • F or prevailing ambient temperatures above 32° F (0° C), use a battery rated 70 amp -hours and capable of deliveri[...]

  • Page 35

    Generac ® Pow er Systems, Inc. 33 2.8.1 R EMO TE P AN EL MODEL S The remote panels mount a rocker type start/stop switch, a “Generator Run ” advisory lamp and an hourmeter . The hourmeter should be used in con- junction with the maintenance operations found in P art I of this manual. • Model 004057 includes the remote panel and a 10 foot lon[...]

  • Page 36

    34 Generac ® Pow er Systems, Inc. 3.5 I NS T ALL A TION CHECKLIS T L OCA TION AN D SUP PORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GEN ERA T OR COM P ARTM ENT ❑ Compartment construction is proper . ❑ Holes/Openings are vapor - sealed. ❑ Compartment size is correct. ❑ Co[...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 Sectio n4–T roubleshooting PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators 4.1 TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION Engine won’t crank. 1. 15 amp fuse blo wn. 1. Replace blo wn fuse. 2. Loose, or corroded or def ective 2. Tighten, clean or replace , batter y cable(s). as[...]

  • Page 38

    36 Generac ® Pow er Systems, Inc. Section 5 – Electrical Data PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Wiring Diagram & Electrical Schematic — Drawing No. 0D65 7 9[...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 Section 5 – Electrical Data PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Wiring Diagram & Electrical Schematic — Drawing No. 0D65 7 9[...]

  • Page 40

    38 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P ar ts Lists PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Base and Pulleys – Drawing No. 0D65 77 -A[...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 ITEM P ART NO . QTY . DESCRIPTION 1 086318 1 BASE, MOUNTING 2 090141 1 GROUND CABLE 3 046911 4 MOUNT , (R UBBER) 4 025017 8 CAPSCREW , HEX HD .3/8"-16 X 1/2" 5 046526 2 LOCKW ASHER-M10 6 022129 8 LOCKW ASHER, 5/16" -M8 7 072391 2 SKID , R UBBER MOUNT 8 077603 2 SAFETY BOL T 5/16"-1 8 x 3 1/2&qu[...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P ar ts Lists PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Alternator and Control P anel – Drawing No. 0D65 78-A[...]

  • Page 43

    Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 0C9675 1 LO WER BEARING CARRIER 2 073163H 1 RO T OR ASSEMBL Y (PP70) 093940H 1 RO T OR ASSEMBL Y (PP50) 3 021441H 1 ST A TOR ASSEMBL Y (PP70) 080095H 1 ST A TOR ASSEMBL Y (PP50) 4 073159 1 BALL BEARING 5 031971 1 BALL BEARING 6 0C9674 1 UPPER BEARING CARRIER 7 077006 4 STUD-ST A[...]

  • Page 44

    42 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P ar ts Lists PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Engine Sheet Metal – Drawing No. 0D31 50-A[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P ART NO . QTY . DESCRIPTION 1 --------- 1 SEE ENGINE EXPLODED VIEW of ENGINE 2 99258 1 KEY -WOODR UFF 6 x 22MM 3 67198N 1 BEVELLED W ASHER 4 67890 1 HEX NUT 5 87865 1 PLUG, FL YWHEEL ACCESS 6 A4456 1 3/8" SPECIAL LOCK W ASHER 7 86313 1 HOUSING, ENGINE T OP 8 56893 23 SCREW (CRIMPTITE) NO . 10-24 x 1/2&q[...]

  • Page 46

    44 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P ar ts Lists PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Engine – Drawing No. 792 1 6-G[...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 ITEM P ART NO . QTY . DESCRIPTION 1 069331 1 CYLINDER ASSEMBL Y 2 069333 1 SLEEVE BEARING 3 067805 1 OIL SEAL 4 0851100101 1 NO . 1 CYLINDER HEAD ASSEMBL Y 5 0851100102 1 NO . 2 CYLINDER HEAD ASSEMBL Y 6 070169 4 SEALING W ASHER 7 069332 2 CYLINDER HEAD GASKET 8 0851100104 1 BREA THER ASSEMBL Y 9 072315 1 BREA THE[...]

  • Page 48

    46 Generac ® Pow er Systems, Inc. Section 6 — Exploded Views and P ar ts Lists PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators Carburetor – Drawing No. 0D65 76-A[...]

  • Page 49

    Generac ® Pow er Systems, Inc. 47 ITEM P ART NO . QTY . DESCRIPTION 1 073112B 1 CARBURET OR ASSEMBY 2 074962C 1 SPRING, GO VERNOR - GREEN (PP55G/LP , PP66G/LP) 074962E 1 SPRING, GO VERNOR - PURPLE (PP50G-50Hz) 074962G 1 SPRING, GO VERNOR - BROWN (PP70G/LP , PP70G-50Hz) 3 070155 1 LEVER, GO VERNOR 4 070108 1 R OD , GO VERNOR T O CARBURET OR 5 05689[...]

  • Page 50

    48 Generac ® Pow er Systems, Inc. Sectio n7–W a r r a n t y PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators CALI FOR N IA AND F EDER AL EM ISSION C ONTROL W AR R ANTY ST A TEMENT Y OU R W AR R ANT Y R IGHT S AN D OB LIGA TIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EP A),[...]

  • Page 51

    Generac ® Pow er Systems, Inc. 49 S e c t i o n7–W a r r a n t y PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators EM IS SION CONTROL S YS TEM W AR R ANT Y Emission Control System W arranty (ECS W arranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The [...]

  • Page 52

    Part No. 0D6583 Revision 0 (10/26/01) Printed in U.S.A. Sectio n7–W a r r a n t y PRIMEP A CT 5 0 and 7 0 (5 0Hz) Recreational V ehicle Generators GEN ERAC PO WER SY STEMS THR EE- YEAR LI MITED W AR R ANTY FOR R E CR EA TIONAL VEHICLE GEN ER A T ORS NOTE: ALL UNITS MUST BE INST ALLED BY GENERAC POWER SYSTEMS AUTHORIZED SER VICE F ACILITIES. F or [...]