Generac Power Systems A-2624 User Manual
OWNER'S MANUAL
IM-72
AIR-COOLED
Manual No. A2624
INDUSTRIAL MOBILE
GENERATORS
Model No. 00843-0
POWER SYSTEMS. INC.
Revision 0 (9/29/98)
Printed in U.S.A.
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty ("ECS Warranty") for 1995 and Later Model Year Utility and Lawn and Garden Equipment
Engines;
A. Applicability: This warranty shall apply to 1995 and later model year utility and lawn and garden equipment engines. The
ECS Warranty Period (“ECS Warranty Period”) shall begin on the date the new engine or equipment is delivered to its origi
nal, end-use purchaser and shall continue for 24 consecutive months thereafter.
B. General Emissions Warranty Coverage: Generac Corporation warrants to the original, end-use purchaser of the new engine
or equipment and to each subsequent purchaser that each of its utility and lawn and garden equipment engines is:
1. Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pur
suant to its authority, and
2. Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, will cause a warrant
ed emissions - related part to fail to be identical in all material respects to the part as described in the engine manufac
turer's application for certification.
C. The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
1. Any warranted, emissions-related parts which are not scheduled for replacement as required maintenance in the Owner's
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be
repaired or replaced by Generac Corporation according to Subsection (4) below. Any such part repaired or replaced under
the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period.
2. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the Owner's Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary" shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for any remainder of the ECS Warranty Period.
3. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner's
Manual shall be warranted for the period of time prior to first scheduled replacement point for that part. If the part fails
prior to the first scheduled replacement, the part shall be repaired or replaced by Generac Corporation according to
Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted
for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related
part.
4. Repair or Replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge
to the owner at a Generac Corporation Authorized Service Outlet.
5. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS
Warranty is in fact defective, provided that such diagnostic work is performed at a Generac Corporation Authorized
Service Outlet.
6. Generac Corporation shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission-related part covered by the ECS Warranty.
7. Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to
meet the expected demand for such emission-related parts.
8. Any Generac Corporation authorized and approved emission-related replacement part may be used in the performance
of any ECS warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce
Generac Corporation ECS warranty obligations.
9. Unapproved add-on modified parts may not be used to modify or repair a Generac Corporation engine. Such use voids
this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac Corporation shall not
be liable hereunder for failures of any warranted parts of a Generac Corporation engine caused by the use of such an
unapproved add-on or modified part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1. Carburetor assembly and its internal components.
a. Fuel filter
b. Carburetor gaskets
c. Fuel pump (if so equipped)
2. Air cleaner assembly
a. Air filter element
b. Intake pipe/manifold
3. Ignition system including:
a. Spark plug
b. Ignition module
4. Catalytic muffler (if so equipped)
a. Muffler gasket (if so equipped)
b. Exhaust manifold (if so equipped)
5. Crankcase breather assembly and its components,
a. Breather connection tube
IDENTIFICATION RECORD
Please record the following information from the generator DATA PLATE or information decal.
1. Model Number______________________ 2. Serial Number___________________________
3.kW Rating.
5. Phase
_____
GENERATOR RPM
MODEL NO.
SERIAL NO.
FOR SERVICE CENTER LOCATION CALL
800-333-1322 24 HOURS A DAY
4. Rated Voltage.
6. Hertz
________
— 3 —
TABLE OF CONTENTS
GENERAL SAFETY RULES
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inside cover
IDENTIFICATION RECORD.................... 3
READ THIS MANUAL THOROUGHLY
Operation and Maintenance
How to Obtain Service.................................................. 5
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GENERATOR FAMILIARIZATION
Generator Applicability
Installation.....................................................................6
Safety........................................................................... 6
Generator AC Connection System
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OPERATING INSTRUCTIONS
Operating Precautions.................................................. 7
Generator Control Panel
Fuel Primer....................................................................7
Start/Stop Switch...........................................................7
Fuse..............................................................................7
Main Breaker.................................................................7
Remote Start/Stop Switch
Automatic Choke
Before Starting the Engine
Installation.....................................................................8
Engine Lubrication
Fuel Supply
Cooling and Ventilation Air
Engine Exhaust Gas
Starting the Generator.................................................. 8
Stopping the Generator
25 Hour Break-In Period................................................8
25 Hour Check-up Period..............................................9
Attention Required After Submersion
Effects of Moisture and Dirt...........................................9
Automatic Low Oil Pressure Shutdown
High Oil Temperature Shutdown
Field Boost
Over Voltage Protection
Engine Governed Speed.............................................10
Drive Belt.....................................................................10
Fuel Requirements......................................................10
Optional LP Gas Fuel System
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SPECIFICATIONS
Engine Oil Requirements........................................11
Engine Specifications
Generator Specifications
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MAINTENANCE
Checking Engine Oil Level
Change Engine Oil
Change oil filter
Engine Air Cleaner
Clean Air Intake Screen
Engine Spark Plugs
Fuel Filter
Spark Arrestor Muffler
Cleaning the Generator...........................................13
Battery............................................................... 13-14
Major Service Manual
Drive Belt.................................................................14
Exercising the Generator
Out of Service Protection
Return the Unit to Service after Storage
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TROUBLESHOOTING............................15
ELECTRICAL DATA
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REPAIR PARTS
CAL. EMISSIONS WARRANTY
WARRANTY
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READ THIS MANUAL THOROUGHLY
If you don't understand any portion of this manual,
contact Generac for a demonstration of actual start
ing, operating and servicing 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 following definitions apply to DANGER, WARN
ING, CAUTION and NOTE blocks found throughout
the manual.
DANGER: Indicates an immediately hazardous sit
uation which, if not avoided, will result in death or
A
serious injury. Danger is limited to the most
extreme situations.
WARNING: Indicates a potentially hazardous situ
ation which, if not avoided, could result in death or
serious injury.
CAUTION: Indicates a potentially hazardous situa
tion which, if not avoided, may result in minor or
moderate injury. Caution may also be used to alert
against unsafe practices.
NOTE: After this heading you can read explanatory
statements that require special emphasis.
These symbols indicate the following:
Points out important safety information and, if
not followed, could endanger personal safety
and/or property of yourself and others.
A
OPERATION AND MAINTENANCE
It is the operator's responsibility 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 Dealer/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.
SERVICE DEALER LOCATION
To locate the nearest Generac Servicing Dealer,
please call our 800 number.
Only dealer location information can be obtained
at this number.
Potential explosion hazard.
Potential fire hazard.
Potential electrical shock hazard.
A
1 -800-333-1322
WARNING:
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
______
or other reproductive harm.
________
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 compliance with industry
standards. The generator also must have been
installed in strict compliance with the manufactur
er’s detailed installation instructions. After installa
tion, do nothing that might render the unit in noncompliance with such codes, standards and
instructions.
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 name
plate 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.
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 CONNEaiON
SYSTEM
This generator is equipped with with a 3-phase, Y con
nected stator. The unit is capable of delivering 3phase and 1-phase voltage simultaneously. It is
extremely important that any single phase load is
applied to the correct winding, since this winding has
been designed to accept 1-phase load. The maximum
1 -phase load that can be applied is 3.0 kW.
Figure 1 — Connections for 1-Phase and 3-Phase
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.
— 6 —
OPERATING INSTRUCTIONS
OPERATING PRECAUTIONS
WARNING: Never operate the generator set while
the vehicle is parked over dry leaves, dry grass or
any other combustible 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 deadiy carbon monoxide gas. This dangerous
gas, if breathed in sufficient concentrations can
cause unconsciousness and even death. Never
operate 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 the vicinity of the generator exhaust
outlet and take any other steps that may be neces
sary to prevent exhaust gases from entering areas
occupied by people.
GENERATOR CONTROL PANEL
Mounted on the generator control panel (Figure 3) are
the following features;
Figure 3 — Generator Control Panel
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.
MAIN BREAKER
Protects generators AC output circuit against overload
and provides a method of turning OFF the generators
120/208 volts AC output to vehicle circuits. This unit is
fitted with a 25A 3-pole circuit breaker (Figure 4).
NOTE: Refer to THE GENERATOR AC CONNEC
TION SYSTEM on page 4. Individual installations may
differ. If an overload occurs, the breaker will open the
stator leads.
Figure 4 — 25 Amp-Dual Circuit Breaker
o
MAIN BREAKER
START SWrrCH
STOP SWITCH
----------
TV
FUEL PRIMER
Before starting r. 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 carburetor. This rocker
type switch springs back into its original position when
you release it.
m 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.
©
FUSE
PRIMER
8b
0
0
-TX
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 OUALIFIED
INSTALLATION TECHNICIAN OR INSTALLATION
CONTRACTOR. .
-7-
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 LUBRICATION
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 oii may resuit in engine failure.
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
transfer switch.
NOTE; If starting from the generator panel, turn OFF
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 the engine is warm, skip step 2. If you have not started
the engine in more that two weeks, press the Fuel Pump
Primer switch and hold it for about 30 seconds.
FUEL SUPPLY
The engine must have adequate supply of proper fuel
to operate. Before starting, check that sufficient fuel is
available.
NOTE: On some installations, the generator may have
been provided with its own fuel 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 shorter than the vehi
cle'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.
■ 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. Close win
dows, doors and other openings in the vehicle 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 con
centrations, 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 coherently, (b) vomiting, (c) twitching mus-
cies, (d) throbbing tempies, (e) dizziness, (f)
headache, (g) weakness and sleepiness. If you feel
any of these symptoms, move into fresh air immedi
ately. If symptoms persist, get medical help.
3. To crank and start the engine, hold the start/stop switch at
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
switch and try again. Holding the switch for longer
than 15 seconds can damage the starter motor.
4. Let the engine run at no-load for a few minutes to stabilize
and warm up the engine.
5. Turn ON electrical loads, using whatever means provided
(such as a main circuit breaker or transfer switch).
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 gerierator 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 for 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-in 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.
— 8 —
25 HOUR CHECK-UP PERtOD
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 filter.
• Check all cooling system ventilation openings.
• Check engine carburetor adjustments.
• Check engine ignition system.
• Inspect the entire electrical system.
• Inspect the engine exhaust system.
AHENTION REQUIRED AFTER
HIGH TEMPERATURE
SHUTDOWN
A temperature switch (Figure 5) with normally-open
(N.O.) contacts is mounted on the engine. Should
engine 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 diode
and resistor. These two components are part of a
“field boost" circuit (Figure 6).
Figure 6 — Field Boost Circuit
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.)
oil pressure switch (Figure 5). Engine oil pressure
holds the switch open during cranking and operation.
Should oil pressure drop below about 8-10 psi, the
switch contact? close and the engine automatically
shuts down.
Figure 5 — Oil Pressure and Temperature Switches
High
Temperature
Switch
CLOSEST TO
BEARING
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 ‘Hashes 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 208 volts, 3phase.
Figure 7 — Solid State Voltage Regulator
-SENStNO
-4<*Hj_TOROTOW
(DRECT CURRENT)
FROM STATOR
EXCITATION WWDtNO
(ALIERNATINO CURREKT]
Oii
Pressure
Switch
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.
— 9 —
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