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Generac Power Systems 2.4L manual

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Table of contents for the manual

  • Page 1

    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. OUTDOOR[...]

  • Page 2

    Standby Generator Sets T able of Contents SECTION P AGE SAFETY RULES ................................................ 1-1 INTRODUCTION ..................................................... 1-3 Read this Manual Thoroughly ................................... 1-3 Operation and Maintenance ...................................... 1-3 How to Obtain Servic[...]

  • Page 3

    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. Many accidents are caused by failing to follow simple and fundamental ru[...]

  • Page 4

    • 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. Stepping on the unit can stress and break parts, and [...]

  • Page 5

    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. However , the manufacturer reserves the right to change, alter or otherwise improve this produ[...]

  • Page 6

    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 gen- erator’s lower connection box, lists the unit ’s serial number and its rated voltage, amps, wattage capacity , phase, frequency , rpm, power fa[...]

  • Page 7

    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. See the Specifications section for exact numbers. The unit comes com[...]

  • Page 8

    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 or that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shuttin[...]

  • Page 9

    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 Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the uni[...]

  • Page 10

    SP E CI F ICA TIONS GEN ERA T OR T ype ............................................................................. Synchronous Rotor Insulation .................................................................... Class F Stator Insulation .................................................................. Class H T otal Har monic Distor tion .....[...]

  • Page 11

    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 . T o reconfigure [...]

  • Page 12

    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. If there are any qu[...]

  • Page 13

    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 . Be sure to read [...]

  • Page 14

    • 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. • The 120V AC supply to the battery charger is swit[...]

  • Page 15

    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. A manually operated transfer switch is one that [...]

  • Page 16

    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 . EVER Y TH R EE MONTHS 1. Check battery condition. 2. Inspe[...]

  • Page 17

    • 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. DO NOT FILL ABOVE THE “FULL ” MARK. See “Engine [...]

  • Page 18

    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. Remove OIL DRAIN HOSE from its retaining clip. 2. Loosen and remove OIL DRAIN HOSE CA[...]

  • Page 19

    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. A soft brush may be used to loosen caked on dirt. Use a vacuum system o[...]

  • Page 20

    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. They will [...]

  • Page 21

    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. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Init[...]

  • Page 22

    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. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Init[...]

  • Page 23

    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. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Init[...]

  • Page 24

    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 . 3. Replace contactor.* 4. Defectiv e star ter motor . 4. Replace star ter motor.*[...]

  • Page 25

    Standby Generator Sets Notes[...]

  • Page 26

    Standby Generator Sets Notes[...]

  • Page 27

    [...]

  • Page 28

    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 M4-0.7 X 10 ZYC (1) 9 057701 [...]

  • Page 29

    [...]

  • Page 30

    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 .125 X .275 SS F 0224 73 2 WASHER FLAT 1/4-M6 ZINC G 022097 2 WASHER LO CK M6- 1/4 H 022127 2 NUT HEX 1/4-20 STEEL J 0F81 39 1 INSUL CB 2P Q J K 0C2454 7 SCREW THF M6- 1 X 16 N W A Z/JS L 0222 37 [...]

  • Page 31

    [...]

  • Page 32

    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 25KW 3PH DIREC T 390 1800 2 0G0057 1 STATOR-2 390-35AD1 CPL 0F 9664 1 STATOR-3 90 45K 2P 1PH DIRE CT 0 G0058 1 STATO R-2390-35KD1 CPL 0 G0184 1 STATO R[...]

  • Page 33

    [...]

  • Page 34

    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. 4L 8 0F1262 4 HOLDE R FUSE WIC KMANN 178. 6150[...]

  • Page 35

    [...]

  • Page 36

    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. 75 X 80 G8.8 8 053 6210410 1 ASSY WIR E 14.0 0" 9 04290 9 1 S CREW HHC M 8-1.25 X[...]

  • Page 37

    [...]

  • Page 38

    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- 1.25 X 25 G8. 8 5 0465 26 REF WASHE R LO CK M1 0 6 0221 31 REF WASHE R FL AT 3/ 8-M 10 ZI NC 7 05 033 1A REF BAT TERY P OST COVE R RE D + 8 0503 31 REF BATTE RY POS T CO VER BLA CK - 9 038 805Y 1 [...]

  • Page 39

    [...]

  • Page 40

    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. 4L 8 037561 1 N UT WIN G 1/4 -20 NY LK 9 0220 97 1 WAS HER LO CK[...]

  • Page 41

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  • Page 42

    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 0F3217 1 SPACER DC A LTERNATOR PUL LEY 7 042574 1 ADAPTOR 1 /8 NPTF TO 1/8 BSP T 8 0A858 4 1 SWITCH OI L PRESSURE 1 0 PSI 2 POL (R-P ANEL) 0F4612 1 SENDER[...]

  • Page 43

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  • Page 44

    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- 1.5 X 30 G10.9 6 0F2776A 1 BRAC KET, SIGNAL CONDITI ONER (USED O NLY WITH QTA PRODU CT) 7 0F5050A 1 SHIELD R ADIATOR C4 9 0F2573 1 PULLEY FAN V-GRO OVE 9" 10 0[...]

  • Page 45

    [...]

  • Page 46

    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 M8-1.25 G 8 CLEAR ZINC 9 0 E8286 1 STREET EL 4 5D 1/2 NPT BRAS[...]

  • Page 47

    [...]

  • Page 48

    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 1.0 G8 YEL CHR[...]

  • Page 49

    [...]

  • Page 50

    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. 6 2 7 0E0170A 1 EXHAU ST BLA NKET 9 88MM (C2) 8 0C24 54 4 SCREW THF M6-1 X 16 N WA Z/ JS 9 0G0776 1 PI PE [...]

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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.) C4 U N ITS A 0F98 32A 1 SHIELD CO NTROL STA ND C4 B 0C 245 4 2 [...]

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