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Generac Power Systems 009592-5, 009735-5 manual

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Table of contents for the manual

  • Page 1

    PRIMEP A CT 55G[...]

  • 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 procedures. Throughout this publication, and on tags and decals affixed to the generator , DANGER, W ARNING , CA UTI[...]

  • Page 3

    T able of Cont ents PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators Generac ® Pow er Systems, Inc. 1 Part I — Operating Instructions Introduction ..................................................Inside Front 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 maintained. Many accidents are caused by failing to follow sim[...]

  • 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 AC T 5 5G and 5 5LP 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 V olt[...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 Section 1 – General Information PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators 1.2 GEN ER A T OR APP 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 other [...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. Section 1 – General Information PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators 1.6 SP E CI F ICA TIONS 1.6.1 F UEL R EQ UIRE MEN T S 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 th[...]

  • Page 9

    Generac ® Pow er Systems, Inc. 7 Section 2 – Operation PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators • F or engines of 225 cc or more, Category C=250 hours, B=500 hours, and A=1000 hours. 2.1 GEN ER A T OR C ONTROL P AN EL The following features are mounted on the generator control panel (Figure 2.1): 2.1.1 F UEL PRIME R Before s[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. Section 2 – Operation PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators 2.3.2 P RECHOKE 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[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 Section 2 – Operation PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators 2. If you have not started the engine in more than two weeks, press the F uel Pump Primer switch and hold it for about 10 seconds. However , if the engine is warm, skip Step 2. 3. T o crank and start the engine, hold the start/stop [...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. Section 2 – Operation PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators 2.8.2 H IGH TEMP ER A TU R E SWIT CH 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), initiat[...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 Section 3 – Maintenance PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators 2.8.6 25-HOUR CH E CK-U P 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 [...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. Section 3 – Maintenance PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators Figure 3.2 — Engine Oil Filter 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 R E CLEAN ER Clean and re - oil the foam precleaner every three months or every 25 hours of operation, whichever occur[...]

  • Page 15

    Section 3 – Maintenance PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators 3.6 F U EL F I L TER (GAS OLI N E ONL 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 MUFFLE R If the generator is not equipped with a sp[...]

  • 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 R N 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. Section 4 – Notes PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators[...]

  • Page 19

    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 AC T 5 5G and 5 5LP Recreational V ehicle Generators NO TICE T O I NST 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 for ins[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 Safety Rules PRIMEP AC T 5 5G and 5 5LP 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 . Ensure a[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. 5.1 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 5.2 – Major Features and Dimensions Section 5 – General Information PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators PrimePact 55G and 55LP 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 Ground [...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. 6.1 L OCA TION AN D SU P PORT 6.1.1 GEN ERA T OR L OCA 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 [...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 6.1.4 GEN ERA T OR RES TR AI NT Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tub- ing . These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compart- ment is used) and (c) the supporting framework (Figu[...]

  • 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 construc- tion, 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 6 – Installation PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators Figure 6.7 – T ypical Noise Abatement 6.2.5 COMP ARTMENT 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 • Generator[...]

  • Page 28

    26 Generac ® Pow er Systems, Inc. 6.3 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 airflow , the engine/generator quickly overheats. Such overheating can cause serious operating difficulties and also m[...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 Figure 6.12 – Air Inlet Using Ductwork Figure 6.13 – Air Inlet in V ehicle Skirt 6.3.3 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 propor- tionately larger . Some [...]

  • Page 30

    28 Generac ® Pow er Systems, Inc. 6.4.1 F UEL T ANK 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 regula- tions. If the gene[...]

  • Page 31

    Generac ® Pow er Systems, Inc. 29 Figure 6.15 – T ypical Propane Gas Fuel System 6.5.2 SOME I MPORT ANT C ONSI DER A TIONS When installing an LP gas system, consider seriously the following items: • All fittings, lines, hoses and clamps must be tight and free of leaks. Apply a pipe sealant to threads when assembling threaded connections. This [...]

  • Page 32

    30 Generac ® Pow er Systems, Inc. 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 proportio[...]

  • Page 33

    Generac ® Pow er Systems, Inc. 31 6.6.1 MUFF LERS AN D SP ARK AR R ES 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 unap- proved muffler , or an unapproved exhaust system part, or modifying an exhaust system in any way that might ca[...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. 6 .7 . 2 WIRIN 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[...]

  • Page 35

    Generac ® Pow er Systems, Inc. 33 Section 6 – Installation PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators 6.7 .6 POWER SUP PL Y CORD The power supply cord must comply with all applicable codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected. 6.7 .7 GROU ND F AU L T CI RCU[...]

  • Page 36

    34 Generac ® Pow er Systems, Inc. 6.8 B A T TER Y I NST ALL A TION 2.8.1 R E COMM EN DED BA T TER Y Install a battery that meets the following requirements: • 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 delivering [...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 6.9.1 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 conjunc- tion with the maintenance operations found in P art I of this manual. • Model 004057 includes the remote panel and a 10 foot lon[...]

  • Page 38

    36 Generac ® Pow er Systems, Inc. 7 .5 INST ALL A TION CH E CKLIST L OCA TION AND SU P PORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GEN ERA T OR COM P ARTMENT ❑ Compartment construction is proper . ❑ Holes/Openings are vapor - sealed. ❑ Compartment size is correct. ❑ Com[...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 Section 8 – T roubleshooting PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators 8.1 TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R ECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace blown fuse . 2. Loose, or corroded or def ective 2. Tighten, clean or replace, battery cable(s). as necess[...]

  • Page 40

    12 0 V 30A DPE WINDIN G V O LTA GE RE GU LAT OR ELE C TR O NI C 120V 20A - Q 55 & NP6 6 120V 30A - Q 7 0 BY CUS T O ME R NE U TRAL CO NNE C TI ON T2 0F FIELD C B 3 0N 0K 0 2 2A 22P 44 22 S 0N 0N R1 55 S P1 - S PARK PL UG #1 C YL . S P2 - S PARK PL UG #2 C YL . TC - TERMINAL , CONN. 4-TA B - CO NNE C T OR C IR C UIT BREAKER, 3.0 ( NP66- Q 70 M O[...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 MT G SC RE W 1 8A S) T EMP. ) S ES ON LOW PRESSURE ) 85 1 8A 1 8 0 RED RED FP CH CS 0 1 5 14 14 0B 0 GT 1 8 C B 1 11 0 I 33 T2 11P T2 14 GT 1 8 17 0I 4 4 2 0 2A 66 1 5 B CR 1 3 14 1 5 0 K 4 2 17 0N 33 11P P 44 55 44 4 55 22P R1 FIELD C L OS E S T T O BEARIN G 90 0F 0F[...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. Section 1 0 — Exploded Views and P ar ts Lists PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators Sheet Metal – Drawing No. D31 50-A[...]

  • Page 43

    Generac ® Pow er Systems, Inc. 41 Section 1 0 — Exploded Views and P ar ts Lists PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators Sheet Metal – Drawing No. D31 50-A ITEM P ART NO . QTY . DESCRIPTION 1 --------- 1 SEE ENGINE EXPLODED VIEW of ENGINE 2 099258 1 KEY -W OODRUFF 6 x 22MM 3 067198N 1 BEVELLED WASHER 4 067890 1 HEX NUT 5 08[...]

  • Page 44

    42 Generac ® Pow er Systems, Inc.[...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P ART 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 BOL T 5/16-18 x 3 1/2" 9 022259 2 NUT HE[...]

  • Page 46

    44 Generac ® Pow er Systems, Inc. 30 1 7 9 85 33 32 72 67 67 27 2 3 24 7 88 9 10 7 3 34 1 5 14 7 3 14 6 2 8 4 0 4 11 1 0 1 3 12[...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 ITEM P ART NO . QTY . DESCRIPTION 1 86318 1 BASE, MOUNTING 2 90141 1 GROUND CABLE 3 46911 4 MOUNT , (R UBBER) 4 25017 8 SCREW HHC 3/8-16 X 1/2 G5 5 46526 2 W ASHER LOCK M10 6 22129 8 W ASHER LOCK M8-5/16 7 72391 2 SKID , R UBBER MOUNT 8 77603 2 SAFETY BOL T 5/16"-18 x 3-1/2" 9 22259 2 NUT HEX 5/16-18 STE[...]

  • Page 48

    46 Generac ® Pow er Systems, Inc. 51 18 7 9 3 2 9 8 10 11 2 3 1 31 30 39 33 2 8 50 19 34 4 5 2 17 6 17 38 12 24 4 0 36 45 4 4 3 15 37 35 4 8 44 57 2, 5 3 31 4 9 40 63 4 5 44 58 31 30 56 2 6 27 2 6 2 5 59 4 6 55 62 4 5 44 2 0 21 61 T O EN G IN E G R OU N D 63 13 15 16 14 47 22 60 18 14 40[...]

  • Page 49

    Generac ® Pow er Systems, Inc. 47 ITEL4686.6(P)996.8AR NO TY DESCRIPTION7[...]

  • Page 50

    48 Generac ® Pow er Systems, Inc. Section 1 0 — Exploded Views and P ar ts Lists PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators Exploded View - Engine Common Parts – Drawing No. 0 7 921 6-G[...]

  • Page 51

    Generac ® Pow er Systems, Inc. 49 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 THER[...]

  • Page 52

    50 Generac ® Pow er Systems, Inc. Section 1 0 — Exploded Views and P ar ts Lists PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators Carburetor – Drawing No. 093 7 53-H[...]

  • Page 53

    Generac ® Pow er Systems, Inc. 51 ITEM P ART NO . QTY . DESCRIPTION 1 073112B 1 CARBURET OR ASSEMBY 2 074962C 1 SPRING, GOVERNOR - GREEN (PP55G/LP , PP66G/LP) 074962G 1 SPRING, GOVERNOR - BR OWN (PP70G/LP , Q70G) 3 070155 1 LEVER, GOVERNOR 4 070108 1 ROD , GO VERNOR TO CARBURET OR 5 056893 5 SCREW CRMPTIT 10-24 X ½ 6 074961 1 BRACKET , GOVERNOR A[...]

  • Page 54

    52 Generac ® Pow er Systems, Inc. 21 27 11 9 10 9 4 3 2 28 18 2 23 17 6 3 2 5 4 1 19 12 4 7 29 11 13 15 25 8[...]

  • Page 55

    Generac ® Pow er Systems, Inc. 53 Section 1 1 — Notes PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators[...]

  • Page 56

    54 Generac ® Pow er Systems, Inc. Section 1 1 — Notes PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators[...]

  • Page 57

    Generac ® Pow er Systems, Inc. 55 Section 1 1 — Notes PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators[...]

  • Page 58

    56 Generac ® Pow er Systems, Inc. Section 1 2 – W arranty PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators CALI FOR N IA AND F EDER AL EM ISSION C ONTROL W AR R ANT Y ST A TEM ENT Y OUR W AR R ANT Y RIGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EP A), together[...]

  • Page 59

    Generac ® Pow er Systems, Inc. 57 Section 1 2 – W arranty PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators EM IS SION CONTROL S YS TEM W ARR 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 ECS W arranty[...]

  • Page 60

    Part No. 0D4889 GENERAC ® POWER SY STEMS, INC. P.O. BO X 8 • W AUKESHA, WI 53187 Revision 0 (11/09/01) Printed in U.S.A. Section 1 2 – W arranty PRIMEP AC T 5 5G and 5 5LP Recreational V ehicle Generators GEN ERAC PO WER SY STEMS’ THR EE- YEAR LI MITED W AR R ANT Y FOR R E CR EA TIONAL VEH ICLE GEN ER A T ORS NOTE: ALL UNITS MUST BE INST ALL[...]