Instruction/ maintenance manual of the product 2.4L Generac Power Systems
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ST ANDBY GENERA T OR O WNER'S MANU AL This manual should remain with the unit. A ne w standar d of reliability Serial Number 2.4L 25kW Models N ot i nt ended for us e i n c r i t i c al l i f e s uppor t appl i c at i ons. ONL Y QU ALIFIED ELECTRICIANS OR CONTRA CT ORS SHOULD A TTEMPT INST ALLA TION! DEADL Y EXHA UST FUMES.
Standby Generator Sets T able of Contents SECTION P AGE SAFETY RULES ................................................ 1-1 INTRODUCTION ..................................................... 1-3 Read this Manual Thoroughly ..............................
Study these SAFETY RULES carefully before install- ing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely , efficiently and reli- ably only if it is properly installed, operated and maintained.
• Before performing any maintenance on the gen- erator , disconnect its battery cables to prevent accidental start -up. Disconnect the cable from the battery post indicated by a NEGA TIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step.
1-3 I NTRODUCTION Thank you for purchasing this model of the standby generator set product line. Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written.
I DENTI F ICA TION REC ORD D A T A LA BE L Every generator set has a DA T A LABEL that contains important information pertinent to the generator . The data label, which can be found attached to the ge.
E QUIPM ENT DE SCRI PTION This equipment is a revolving field, alternating cur - rent generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units.
ENGI N E P RO TECTIVE DEVICE S The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant tempera- ture, oil pressure or rpm.
F U E L SYST E M FUE L RE QUIRE MEN T S The standby generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (PV) fuel system The Manual Drawing .
SP E CI F ICA TIONS GEN ERA T OR T ype ............................................................................. Synchronous Rotor Insulation .................................................................... Class F Stator Insulation ..........
COLD WEA THER KIT F or cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: • Battery W armer • 4” Junction Box with hardware • 6 qt. pack 5W -30 synthetic oil (engine) R E C ON FIGU R I NG THE F U EL SY S TEM NOTE: All models are configured to run on natural gas from the factory .
GEN ER A T OR AC LEAD C ONN ECTIONS See “V oltage Codes”. This generator may be rated at any one of three voltages, either single -phase or three -phase. The electrical wires in the unit ’s AC con- nection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application.
I NS T ALLA TION Refer to the separate “Installation Guide” supplied with the unit. P R EP AR A TION B EFOR E ST ART -UP The instructions in this section assume that the standby generator has been properly installed, ser - viced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor .
• Battery charger connection to 120 V AC. • Communication wires connected between transfer switch and generator (HTS only). • Unit secured to pad. S T ART -U P CH E CKLIS T Before working on the generator , ensure the fol- lowing: • The AUTO/OFF/MANU AL switch is in the OFF position.
GEN ER A T OR CONTROL AND OP ER A TION Refer to the appropriate control panel operator’s manual for this unit. OP ER A TING U N IT WITH MAN UAL TR ANSF ER SWIT CH If the generator was installed in conjunction with a transfer switch capable of manual operation only , the following procedure applies.
MAI NTENANCE P ER FOR M ED B Y SERVICE F ACI LITIES Before working on the generator , ensure the fol- lowing: • The AUTO/OFF/MANU AL switch is in the OFF position. • The 15A fuse has been removed from the con- trol box. • The 120V AC supply to the battery charger is switched OFF .
• Remove oil dipstick and wipe dry with a clean, lint- free cloth. • Install oil dipstick, then remove again. • Oil should be between FULL and ADD marks. • If oil level is below the dipstick ADD mark, remove oil fill cap -. Add the recommended oil to bring oil level up to the FULL mark.
CHANGI NG ENGIN E OI L Refer to maintenance performed by service facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning . This means warm up the engine, shut it down and drain immediately as follows: 1.
M IS CELL AN E OUS MAI NTENANCE CLEAN ING TH E GEN ER A T OR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- erator windings have an adverse effect on insulation resistance. P eriodically clean generator exterior surfaces.
SERVICE S CH EDU LE 30 KW - 1 50 KW S T ANDBY GA S ENGI NE DR IVEN GEN ER A T OR SET S The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.
Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask Required T ask Required T ask T ask Required T ask mended Comp. to be done Comp.
Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask Required T ask Required T ask T ask Required T ask mended Comp. to be done Comp.
Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask Required T ask Required T ask T ask Required T ask mended Comp. to be done Comp.
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 blown. 1. Replace fuse. 2. Loose or corroded or defectiv e 2. Tighten, clean or replace batter y cables . batter y cables as necessary . 3. Defectiv e star ter contactor .
Standby Generator Sets Notes.
Standby Generator Sets Notes.
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1 0F3137 1 PAN CB CONN BOX 2 0F3188 1 STAND RH CONTROL 3 0F3189 1 STAND LH CONTROL 4 023484N 1 BUSHING SNAP SB-2. 5-31 5 0F6366B 1 XFM R DUAL 120V/16V (F OR 120/240V & 277/ 480V UNITS) 0F63 66A 1 XFMR DUAL 104V/ 16V (FOR 120/208V U NITS) 6 043180 2 WAS HER FLAT M4 7 022264 2 WAS HER LOCK #8-M4 8 0C3990 2 SCREW PHTT M4-0.
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5) UL CIRCU IT BREAKE R (QJ - 2P) A 0F8137 1 COVE R QJ 2P FRM CB C 0 E7994 - CB 0225A 240V 2P S QJ22 D 0F8136 1 COVE R QJ 2P CB DISH E 036261 4 RIVET POP .
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1 0G0056 1 ROTOR-239 0-35KD1 CPL 0 G1155 1 ROTO R-2390-35KD1 CPL (G2) 0F 9677 1 ROTOR-239 0-45KD1 CPL 0 G0959 1 ROTO R-2390-45KD1 CPL (G2) 0 G2101 1 ROTO R 25KW 1PH DIREC T 390 1800 0 G1931 1 ROTO R 2.
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CO MPON ENTS IN CLUDE D IN 0 G2283 D 1 0F1823 A 1 ENCL HSB CO NTROL P ANEL 2 0F3078 1 COVER CONTR OL PANE L 3 0F2606 1 HINGE C ONTIN UOUS H-PA NEL 4 03626 1 6 RIVET P O P .1 25 X .2 75 SS 5 0E7358 4 SCREW PPP H HI- LO # 4-24 X 3/8 6 0527 77 3 W ASHER F LAT M 3 7 0G130 3C 1 ASS Y P C B R-200 1800 RPM 2.
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1 0F9 5 17 1 WELDMENT FRAME 2.4 L C2 2 052860 4 NUT FLAN G ED HEX M12 -1.75 3 05225 1 5 D AMPENE R VI BRATIO N 40 B LUE 4 052257 5 SPACER . 49 X .62 X 1.87 PWDR /Z NC 5 05225 2 5 D AMPENE R VI BRATIO N 6 05225 9 5 W ASHE R FLAT M 12 7 05289 1 5 S CREW HHC M 12-1.
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1 0F3408 B 1 BATT ERY T RAY C1 CPL 2 0F3411 1 STRAP BA TT ERY RETAI NME NT 3 0255 07 REF WASHE R SH AKEP ROOF EXT 7/16 S TL 4 0522 12 REF SCREW HHC M 10- 1.
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1 0E6586 1 GASKET BOSCH 32 & 40 2 0E0519A 1 A DAPTER CARBUR ETOR W/PVC CONN 3 0C812 7 1 ELEMENT A IR CLEANE R 4 0526 19 4 SCRE W HH C M 5-0.8 X 20 G 8.8 5 022 127 1 N UT HEX 1 /4-20 S TEEL 6 0629 74 1 S TUD TH 1/4- 20 X 4-1/ 2 G2 ZNC 7 0G 0 1 90 1 P LAT E , AI R CLE A NE R TO P 2.
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1 0G0408 1 ENGINE 2.4L MITSUBISHI 4G64 2 046526 3 WASHER LO CK M10 3 039414 4 SCREW HH C M8-1.25 X 35 G8 .8 4 0G0149 1 SCREW SHC M14-1.5 X 35 G10 .9 5 0E9868A 1 ALTER NATOR DC W /OUT PULLEY (2) 6 0F32.
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1 0F9529 1 WELDMENT RADIATO R SUPPORT 2.4L 2 0F2608 1 RADIATOR 598 X 568 X 49 CPL RH 3 0F5263 1 V-BELT 31/64" X 57-3/8" 4 04652 6 5 WASHER LOCK M1 0 5 05998 1 4 SCREW HHC M10- 1.
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1 026915 2 NIPPLE CLOSE 3/4 X 1.375 2 075580 1 FLA NGE FUEL INLET 3 0F63 90C 1 REGUL ATOR ASSY 2 .4L (25KW) 0F6390B 1 REGULATOR ASS Y 2.4L (35KW & 4 5KW) 4 039253 2 SCREW HHC M8-1.2 5 X 20 G8.8 5 022145 2 WASHE R FLAT 5/16-M 8 ZINC 6 022129 2 WASHE R LOCK M8- 5/16 7 045771 2 NUT HEX M8-1.
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1 0G0045 (XX ) 1 REA R WRAP C2 CPL 2 0C2454 54 S CREW THF M6-1 X 16 N WA Z/JS 3 0F5849 (XX) 2 DOOR C2 4 0872 33 2 RIVET POP .187 5 X .450 SS 5 0E3257 4 S CREW TH-FRM M6 W/ CAP SHKPRF W 6 0F5852 (XX) 2 DISCHARGE DUCT LH & RH SIDE C2 7 0F9833 (XX) 2 FRONT CORNERS C2 8 0F5851 (XX) 1 DISCHARGE CENTE R DUCT C2 9 0498 13 2 NUT HEX M6 X 1.
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1 0F9794 2 MUFFLER 7" X 9" X 18-1/2" 2" IN/OUT 2 0G 0 1 13 1 EXHAUST ELB OW 2 1/ 4 OD 2 1/2 O D 3 0G 1007 1 BRACKET M UFFLE R 4 0 F2830 2 MUFFLER BR ACKET ST IFFENER 5 0F2962 2 MUFFLER STRAP 6 0807 6 2 5 BO LT U 3/8-16 X 2.
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1.) C2 U N ITS A 0F98 32 1 SHI ELD C ONN BOX C2 0F98 32GG S0R 1 SHIE LD CO NT ROL S TAND C2 B 0C 24 5 4 3 S CRE W T HF M6- 1 X 16 N WA Z/ JS 2.) C3 U N ITS A 0F98 32B 1 SHIELD CO NTROL STA ND C3 0F98 32KG S0R 1 S HIELD CO NTROL ST AND C3 B 0C 245 4 3 S CREW THF M6- 1 X 16 N WA Z/JS 3.
BackPg001 Re v . A 04/07.
An important point after buying a device Generac Power Systems 2.4L (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Generac Power Systems 2.4L yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Generac Power Systems 2.4L - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Generac Power Systems 2.4L you will learn all the available features of the product, as well as information on its operation. The information that you get Generac Power Systems 2.4L will certainly help you make a decision on the purchase.
If you already are a holder of Generac Power Systems 2.4L, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac Power Systems 2.4L.
However, one of the most important roles played by the user manual is to help in solving problems with Generac Power Systems 2.4L. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac Power Systems 2.4L along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
