THE MANUFACTURER SUGGESTS THAT THESE "RULES” FOR SAFE OPERATION BE
COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE GENERATOR. SAFETY
A
SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF THIS
EQUIPMENT.
Study these SAFETY RULES carefully before operat
ing or servicing applicable equipment. Become familiar
with this Owner's Manual and with your generator.
Safe, efficient and reiiable operation can only be
achieved if generator is properly installed, operated
and maintained. Many accidents are caused by failing
to follow simple and fundamental rules or precautions.
The manufacturer suggests that these GENERAL
SAFETY RULES be copied and posted in potential
hazard areas of the generator. Safety should be
stressed to all operators and potential operators of
equipment.
The manufacturer cannot possibly anticipate every cir
cumstance that might involve a hazard. The \warnings
in this Manual and on tags and decals affixed to the
unit are, therefore, not all-inclusive. If you use a proce
dure, work method or operating technique Generac
does not specifically recommend, you must satisfy
yourself that it is safe for you and others. You must
also make sure the procedure, work method or operat
ing technique that you chose does not render the gen
erator to be unsafe.
For fire safety, the industrial mobile generator must be
A
properly installed and maintained. Installation must
always remain in compliance with applicable codes and
standards. In addition, the generator must be installed
in conformance to the manufacturer's detailed installa
tion instructions. Following installation, nothing must be
done that might render the generator in noncompliance
with such codes, standards and instructions.
The INDUSTRIAL MOBILE generator produces
A
extremely high and dangerous electrical voltages and
can cause dangerous, and possibly fatal, electrical
shock. Avoid contact with bare wires, terminals, etc.
while the unit is running. If you must work around an
operating generator, stand on an insulated, dry surface
to reduce shock hazard.
Never work on this equipment or handle any electrical
device while standing in water, while barefoot, or while
hands or feet are wet. Dangerous electrical shock will result.
Have the generator properly grounded (bonded) during
installation onto the vehicle, 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 conductor to any generator part that might
be removed or disassembled during routine mainte
nance. If the grounding conductor must be replaced,
use only a flexible conductor that is of No. 8 AWG cop
per wire minimum.
In case of accident caused by electric shock, shut
down the source of electrical power down at once. If
this cannot be done, free victim from live conductor.
AVOID DIRECT CONTACT WITH THE VICTIM. Use a
dry board, dry rope, or other non-conducting imple
ment to free the victim from live conductor.
Inspect fuel system frequently for leaks or damage.
Repair or replace any damaged or leaking component
immediately. Never attempt to change, alter or modify the
generator fuel system in any way that might affect safety
or compliance with applicable codes and standards.
The generator engine gives off DEADLY carbon
monoxide gas through its exhaust system. This dan
gerous gas, if breathed in sufficient concentrations,
can cause unconsciousness or even death. This
exhaust system must have been properly installed, in
strict compliance with applicable codes and standards.
Following installation, you must do nothing that might
render the system unsafe or in non-compliance with
such codes and standards. The generator compart
ment must be completely vapor sealed from vehicle
interior. There must be no possibility of exhaust fumes
entering the vehicle interior. Never operate this equip
ment with a leaking or defective exhaust system.
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, fuel leakage, oil leakage, etc.
Do not smoke around the generator. Wipe up any fuel,
and oil immediately. Never leave oily or fuel soaked
rags in the generator compartment or on the generator
itself. Keep the area around the generator clean and
free of debris.
Adequate ventilation is required to expel toxic fumes
and gasoline vapors from the generator compartment.
Do not alter the installation of this equipment in any
manner that might obstruct air and ventilation open
ings. Such openings must be kept clear and unob
structed.
Keep hands, feet, clothing, etc., away from drive belts,
fans and other moving parts of this equipment. Never
remove any drive belt or fan guards while the unit is
operating.
Inspect the generator periodically. Repair or replace all
damaged or defective parts immediately
These generators can be converted to use LP gas
(propane) as a fuel. Liquid Propane 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.
Before performing any maintenance on- the generator
set, disconnect its battery cables to prevent accidental
start up. Disconnect the cable from the battery post
indicated by a NEGATIVE, NEG or (-) first. Reconnect
that cable last.
IDENTIFICATION RECORD
Please record the following information from the generator DATA PLATE or information decal.
1.Model Number2.Serial Number
3.kW Ratina4. Rated Voltage
5. Phase6. Hertz
GENERATOR RPM [
FOR SERVICE CENTER LOCATION CALL
800-333-1322 24 HOURS A DAY
GENERAC CORPORATION
WAUKESHA, Wise.
— 1
TABLE OF CONTENTS
GENERAL SAFETY RULES
IDENTIFICATION RECORD....'
...........
inside cover
......................
READ THIS MANUAL THOROUGHLY
Operation and Maintenance
How to Obtain Service.................................................. 3
REPAIR PARTS.....................................15 to 23
6
6
7
7
7
7
7
8
CAL. EMISSIONS WARRANTY
WARRANTY
.......................................
..............
back page
24 - 25
— 2 —
READ THIS MANUAL THOROUGHLY
If you don't understand any portion of this manual,
contact Generac for a demonstration of actuai start
ing, operating and sen/icing procedures.
Throughout this publication and on tags and decals
affixed to the generator, DANGER and CAUTION
blocks are used to alert you to special instruction
about a particular operation that may be hazardous if
performed incorrectly or carelessly. Observe them
carefully.
These safety warnings cannot eliminate the hazards
that they indicate. Strict compliance with the special
instructions while performing the service plus "com
mon sense" are major measures to prevent acci
dents.
The foliowing definitions apply to DANGER, CAU
TION and NOTE blocks found throughout the manual.
[ DANGER: AFTER THIS HEADING YOU CAN READ
A HANDLING, INSTALLING, OPERATING OR SERVIC-
' ING INSTRUCTIONS THAT, IF NOT STRICTLY COM
PLIED WITH, MAY RESULT IN PERSONAL INJURY.
CAUTION: After this heading you can read instruc
tions for handling, installing, operating or servicing
the generator that, if not strictly complied with, may
result in damage to equipment and/or property.
NOTE: After this heading you can read explanatory
statements that require special emphasis.
These symbois indicate the following:
■ Points out important safety information and, if
not followed, could endanger personal safety
and/or property of yourself and others.
Potential explosion hazard
Potential fire hazard
A
The operator (driver) is responsible for proper and
safe use of the vehicle, equipment on the vehicle, and
the safety of all vehicle occupants. We strongly rec
ommend that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. We aiso strongly recommend
instructing other occupants in the vehicie to properiy
start and operate the generator. This prepares them if
they need to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibiiity to perform all safety
checks; to make sure that all maintenance for safe
operation is performed promptly; and to have the
equipment checked by an Authorized Dealer periodi
cally. Normal maintenance service and replacement
of parts are the responsibility of the Owner/Operator
and, as such, are not considered defects in materials
or workmanship within the terms of the warranty.
Individual operating habits and usage contribute to
the need for maintenance service.
Proper maintenance and care of your industrial
mobile generator assures a minimum number of prob
lems and keeps your operating expenses at a mini
mum. See your authorized Deaier/Distributor for ser
vice aids and accessories.
HOW TO OBTAIN SERVICE
When your industrial mobile generator set requires
servicing or repairs, simply contact an Authorized
Service Facility for assistance. Service technicians
are factory-trained and are capable of handling all of
your service needs.
When contacting an Authorized Service Facility or the
factory about parts and service, always supply the
complete model number and serial number of your
unit as given on its data decal.
The warranty on your generator is included in this
Owner's Manual, as well as listings for repair parts.
Potential electrical shock hazard
A
— 3-
GENERATOR FAMILIARIZATION
GENERATOR APPLICABILITY
These generators have been designed and manufac
tured for supplying electrical power for Industrial mobile
vehicles. You should not modify the generator or use it
for any application other than for what it was designed.
If there are questions pertaining to its application, write
or call the factory. Do not use the unit until you have
been advised by a competent authority.
DANGER; FOR FIRE SAFETY, THE GENERATOR
MUST HAVE BEEN PROPERLY INSTALLED IN COM
A
PLIANCE WITH INDUSTRY STANDARDS. THE GEN
ERATOR ALSO MUST HAVE BEEN INSTALLED IN
STRICT COMPLIANCE WITH THE MANUFACTUR
ER’S DETAILED INSTALLATION INSTRUCTIONS.
AFTER INSTALLATION, DO NOTHING THAT MIGHT
RENDER THE UNIT IN NON-COMPLIANCE WITH
SUCH CODES, STANDARDS AND INSTRUCTIONS.
You can use this generator to supply electrical power
for operating 120/240 volts, single phase, 60 Hertz, a-c
electrical loads requiring the following:
Industrial
Generator(wattage)120 Volts240 Volts
IM-52
IM-66
IM-7272006030
Power
520043.321.6
660055
Amps atAmps at
27.5
SAFETY
Before using the generator set, carefully read GENER
AL SAFETY RULES inside the cover. Comply with
these RULES to prevent accidents and damage to
equipment and/or property. Generac suggests copying
and posting the GENERAL SAFETY RULES in poten
tial hazard areas of the generator. Safety should be
stressed to all operators of this equipment.
GENERATOR AC CONNECTION
SYSTEM
This generator set is equipped with dual Stator a-c
power windings. These two stator windings supply
electrical power to customer electrical loads by means
of a dual 2-wire connection system. Note, however,
that neutral is grounded.
The generator may have been installed so that units
power 120/240 volts AC loads (Figure 1); or you can
wire them to connect only 120 volts AC electrical loads
(Figure 2). Be sure to install jumper wire between the
circuit breakers (C.B. in Figure 2) when reconnecting
for 120 volts.
Figure 1 —Connections for 120/Z40 Volts
CAUTION: Do not overload the generator. Some
installations may require that electrical loads be
alternated to avoid overloading. Applying exces
sively high electrical loads may damage the genera
tor 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 capaci
ty 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.
INSTALLATION
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 installa
tion.
Owners/Operators should make sure nothing is done
during installation that might render the unit unsafe or
in noncompliance with,applicable codes, standards
and instructions. They should be sure the unit has
been installed to allow adequate ventilation for cooling
and exhaust air.
Figure!—Connections for 120 Volts
GROUNDED
. NEUTIRAL
— 4 —
OPERATING INSTRUCTIONS
OPERATING PRECAUTIONS
WARNING: NEVER OPERATE THE GENERATOR
SET WHILE THE VEHICLE IS PARKED OVER DRY
LEAVES, DRY GRASS OR ANY OTHER COM
FUSE
Protects the engine 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 it, use only an identical replacement fuse.
BUSTIBLE SUBSTANCE. THE GENERATORS
EXHAUST SYSTEM BECOMES EXTREMELY HOT
AND CAN CAUSE FIRE IF IT IS TOO CLOSE TO
COMBUSTIBLE MATERIALS.
WARNING: THE GENERATORS EXHAUST SYSTEM
GIVES OFF DEADLY CARBON MONOXIDE GAS.
THIS DANGEROUS GAS, IF BREATHED IN SUFFI
CIENT CONCENTRATIONS CAN CAUSE UNCON
SCIOUSNESS AND EVEN DEATH. NEVER OPER
ATE THE GENERATOR SET WITH THE VEHICLE
INSIDE ANY GARAGE OR OTHER ENCLOSED
AREA. NEVER OPERATE THE GENERATOR WITH A
LEAKING EXHAUST SYSTEM. CLOSE WINDOWS IN
MAIN BREAKER
Protects generators AC output circuit against overload
and provides a method of turning OFF the generators
120/240 volts a-c output to vehicle circuits. The IM-52
units have 25 amp breakers while the IM-66 and IM-72
generators are equipped with 30 amp circuit breakers
(Figure 4).
NOTE: Refer to THE GENERATOR A-C CONNEC
TION SYSTEM on page 4. Individual installations will
differ. If an overload occurs, the dual breaker will open
the hot stator leads (11 and 44), When the generator
has been connected for 120 volts only, either of the
dual circuit breakers will open stator a-c output leads
No. 11 and No. 33.
THE VICINITY OF THE GENERATOR EXHAUST OUT
LET AND TAKE ANY OTHER STEPS THAT MAY BE
Figure 4—25 Amp Dual Circuit Breaker
NECESSARY TO PREVENT EXHAUST GASES FROM
ENTERING ROOMS OR AREAS OCCUPIED BY PEO
PLE OR ANIMALS.
LINE
BREAKERS
GENERATOR CONTROL PANEL
Mounted on the generator control panel.(Figure 3) are
the following features:
Figure 3 —Generator Control Panel
FUSE MAIN
START 15A BREAKER
STOP FUEL
PRIMER
FUEL PRIMER
Before starting a cold engine (it has not been started in
more than two weeks), you must press this switch to
bring fuel from the tank to the fuel pump. This rocker
type switch springs back into its original position when
you release it. •
START/STOP SWITCH
To crank and start the engine, hold this switch at its
START position. Release the switch when the engine
starts. To stop an operating engine, press and hold the
switch in its STOP position until the engine shuts off.
The switch center position is the RUN position.
— 5-
cm
REMOTE START/STOP PANEL
A remote mounted Start/Stop Panel is available, which
allows you to start and stop the generator engine con
veniently from inside the vehicle.
AUTOMATIC CHOKE
The engine is equipped with an automatic choke.
During engine cranking (Start/Stop switch at START),
a solid state choke module signals the choke solenoid
to acuate a cyclic rate dependent on ambient tempera
ture. The choke solenoid thus opens and closes the
carburetor choke valve only when the engine is crank
ing. When you start it and release the start/stop
switch, choke action stops. As the engine warms, the
carburetor choke valve then opens gradually.
BEFORE STARTING THE ENGINE
IMPORTANT: INSTRUCTIONS AND INFORMATION
IN THIS MANUAL ASSUME THE GENERATOR HAS
BEEN PROPERLY INSTALLED, CONNECTED, SER
VICED, TESTED AND ADJUSTED BY A QUALIFIED
INSTALLATION TECHNICIAN OF INSTALLATION
CONTRACTOR.
INSTALLATION
Generator installation must have been properly com
pleted so it complies with all applicable codes, stan
dards and regulations and with the manufacturer's rec
ommendations.
ENGINE LUBRIG\TION
Have engine crankcase properly serviced with recom
mended oil before starting. Refer to "Maintenance" and
"Specifications" sections for oil servicing procedures
and recommendations.
CAUTION: Any attempt to crank or start the engine
before you have properly serviced it with the recom
mended oil may result in engine failure.
FUEL SUPPLY
The engine must have adequate supply of proper fuel
to operate. Before starting, check that sufficient fuel is
available.
NOTE;
been provided with its own fuei tank. On other installa
tions, the generator may “share” with the vehicle’s fuel
tank. When the vehicle’s tank is shared, some
installers may have installed a generator fuel pick up
tube in the shared tank that is shared tank that is short
er than the vehicle’s pick up tube. When a shorter
generator fuel pick up tube is installed in the tank, the
generator will run out of gas while sufficient fuel
remains in the tank for vehicle engine operation.
On some installations, the generator may have
STARTING THE GENERATOR
To start the generator from either the generator control
panel or from the optional Remote Panel, proceed as
follows:
1. Turn OFF electrical loads, using whatever means provided
in your vehicle (such as a main line circuit breaker or trans
fer switch.
NOTE;
loads by setting the generators main circuit breaker to
“OFF” or “OPEN”. If starting from a Remote Panel,
turn OFF loads using whatever means is provided in
the vehicle (such as a main circuit breaker).
2. If you have not started the engine in more that two weeks,
3. To crank and start the engine, hold the start/stop switch at
4. Let the engine run at no-load for a few minutes to stabilize
5. Turn ON electrical loads, using whatever means provided
If starting from the generator panel, turn OFF
press the Fuel Pump Primer switch and hold it for about 30
seconds to activate the automatic shut-off function.
However, if the engine is warm, skip step 2.
START. Release the switch when the engine starts.
CAUTION: If the engine does not start after it has
been cranking for 15 seconds, release the start/stop
A
switch and try again. Holding the switch for longer
than 15 seconds can damage the starter motor.
and warm up the engine.
(such as a main circuit breaker or transfer switch).
■ COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compart
ment must be open and unobstructed for continued
proper operation. Without sufficient cooling and venti
lating air flow, the engine-generator quickly overheats,
which causes it to quickly shutdown. Overheating
could also damage the unit or your vehicle.
ENGINE EXHAUST GAS
Before starting the generator engine, you should be
sure there is no way for exhaust gases to enter the
vehicle interior and endangering people or animals.
Close windows, doors and other openings in the vehi
cle that, if open, might permit exhaust gases to enter
the vehicle.
DANGER: THE GENERATOR ENGINE GIVES OFF
DEADLY CARBON MONOXIDE GAS THROUGH ITS
EXHAUST SYSTEM. THIS DANGEROUS GAS, IF
BREATHED IN SUFFICIENT CONCENTRATIONS,
CAN CAUSE UNCONSCIOUSNESS OR EVEN
DEATH. DO NOT OPERATE THE GENERATOR IF ITS
EXHAUST SYSTEM IS LEAKING OR HAS BEEN
DAMAGED. SYMPTOMS OF CARBON MONOXIDE
POISONING ARE (A) INABILITY TO THINK COHER
ENTLY, (B) VOMITING, (C) TWITCHING MUSCLES,
(D) THROBBING TEMPLES, (E) DIZZINESS, (F)
HEADACHE, (G) WEAKNESS AND SLEEPINESS. IF
YOU FEEL ANY OF THESE SYMPTOMS, MOVE INTO
FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST,
GET MEDICAL HELP. .
STOPPING THE GENERATOR
1. Turn OFF all electrical loads, using whatever means pro
vided (such a main circuit breaker or transfer switch).
2. Place start/stop switch in its STOP position.
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 reducing oil consumption and enhancing
engine performance. During the break-in period,
observe the following rules:
• For the first 25 hours, run the generator at varying electri
cal loads, to help set the engine piston rings properly.
• Following the initial 25 hour break-in period, avoid light
electrical loads tor the next 75 hours of operation. The unit
should be loaded at 50% (or more) of its capacity during
those 75 hours. Repeated light loads during break-in peri
od may improperly seat the piston rings, resulting in blowby and high oil consumption.
• Check oil level frequently during the break-ln period. Add
oil if needed. It Is natural for the generator engine to con
sume more oil than is normal until the piston rings have
seated properly.
• When the 25 hour break-in period is done, complete the
tasks recommended under 25 HOUR CHECK-UP PERIOD.
— 6
25 HOUR CHECK-UP PERIOD
After the first 25 hours of operation have been com
pleted, contact an Authorized Service Facility for the
following maintenance. The Owner/Operator is
responsible for any changes.
• Change engine crankcase oil and oil filler.
• Check all cooling system ventilation openings on the vehicle.
• Check engine carburetor adjustments.
• Check engine ignition system.
• Inspect the entire electrical system.
• Inspect the engine exhaust system.
ATTENTION REQUIRED AFTER
SUBMERSION
If the generator has been submerged in water, it must
NOT be started or operated. Following any submersion
in water, have an authorized Generac Service Facility
thoroughly clean and dry the generator.
EFFECTS OF MOISTURE AND DIRT
Keep the generator set as clean,and dry as possible.
Protect unit against excessive dust, dirt, corrosive
vapors, road splash, etc. Permitting dirt and moisture
to accumulate on generator windings will have an
adverse effect on the insulation resistance of those
windings.
When moisture is allowed to remain in contact with
windings, some of the moisture will be retained in voids
and cracks in the insulation. This causes a reduced
insulation resistance and will eventually cause prob
lems. Dirt will make the problem worse, since dirt tends
to hold moisture in contact with windings. Salt (as from
sea air) will also worsen the problem since it tends to
absorb moisture from the air. Salt and moisture, when
combined, form a good electrical conductor.
AUTOMATIC LOW OIL PRESSURE
SHUTDOWN
The engine is equipped with a normally-closed (N.C.)
holds the switch open during cranking and operation.
Should oil pressure drop below about 8-10 psi, the
switch contacts close and the engine automatically
shuts down.
HIGH OIL TEMPERATURE
SHUTDOWN
An oil temperature switch (Figure 5) with normallyopen (N.O.) contacts is mounted on the engine.
Should engine oil temperature exceed about 284°F
(140°C), the switch contacts close and the engine
shuts down.
FIELD BOOST
The controller Circuit Board houses a field boost diodeand resistor. These two components are part of a
“field- boost” circuit (Figure 6).
Figure 6 — Field Boost Circuit,
During engine cranking only, a positive DC (battery)
voltage is delivered through the diode, resistor, brush
es and slip rings, and to 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 the
required “pick up" voltage in the stator windings.
OVER VOLTAGE PROTECTION
A solid state voltage regulator (Figure 7) controls the
generators AC output voltage. This regulator supplies
an excitation current to the rotor. By regulating the
rotor’s excitation current, the strength of its magnetic
field is regulated and, in turn, the voltage delivered to
connected electrical loads is controlled. When the AC
frequency is 60 Hz, voltage is regulated at 120 volts
(voltage-to-frequency ratio is 2-to-1).
Figure 7 — Solid State Voltage Regulator
Figure 5 — Oil Pressure and Temperature Switches
O—TO ROTOR
The voltage regulator also incorporates a “voltage
surge protection circuit." This circuit prevents trouble
some surges in the generator AC output voltage.
Voltage surge is a common cause of damage to elec
tronic equipment.
— 7 —
j (O'^eCT CURnÇNT)
FROM STATOR
eXCn'ATIONWINOINQ
{ALTERHATINO CURRENT)
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