Generac Power Systems RG02224 Owner's Manual

Spark-ignited stationary generators

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Spark-Ignited Stationary Generators

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Owner's Manual

WARNING

Loss of life. This product is not intended to

be used in a critical life support application.

Failure to adhere to this warning could result

in death or serious injury.

WWW.GENERAC.COM

1-888-GENERAC

(888-436-3722)

RG02224 - 2.4 L

RG02515 - 1.5 L

RG02724 - 2.4 L

RG03015 - 1.5 L

RG03224 - 2.4 L

RG03624 - 2.4 L

RG02824 - 2.4 L

RG04524 - 2.4 L

RG06024 - 2.4 L

019320

(W000209)

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Summary of Contents for Generac Power Systems RG02224

Page 1 Owner’s Manual Spark-Ignited Stationary Generators Residential and Commercial RG02224 - 2.4 L RG02515 - 1.5 L RG02724 - 2.4 L RG03015 - 1.5 L RG03224 - 2.4 L RG03624 - 2.4 L RG02824 - 2.4 L RG04524 - 2.4 L RG06024 - 2.4 L...
Page 2 Use this page to record important information about the generator set. GENERATOR UNIT For quick and easy reference, copy the information printed on the Unit Identification Label onto the sample la- GEN MODEL: MODEL: bel printed here. The Unit Identification Label is located SERIAL: on the base frame adjacent to the front engine mount on ALTERNATE NO:...
Page 3 Table of Contents Section 1: Safety Section 4: Operation Introduction ............5 Control Panel ............23 Read This Manual Thoroughly ........5 AUTO/MANUAL/OFF ........... 23 Safety Rules ............5 Menu Navigation..........24 How to Obtain Service .......... 5 Alarm / Warning Conditions ....... 26 General Hazards ............
Page 4 Removing Battery ..........37 Installing Battery..........37 Inspecting and Adjusting Accessory / Drive Belt ...............38 Inspecting Accessory / Drive Belt ......38 Adjusting Accessory / Drive Belt Tension ....38 Replacing Air Filter Element........38 Final Instructions ...........39 Schedule B Maintenance........39 Draining and Flushing Coolant System ....39 Schedule B Maintenance Item Locations ....41 Cleaning, Gapping, and Replacing Spark Plugs ..............41...
Page 5 Safety Section 1: Safety Introduction Safety Rules Thank you for purchasing this stationary automatic stand- The manufacturer cannot anticipate every possible cir- by generator set. It is designed to automatically supply cumstance that might involve a hazard. The alerts in this electrical power to operate critical loads during a utility manual, and on tags and decals affixed to the unit, are power failure.
Page 6 Safety General Hazards WARNING DANGER Accidental Start-up. Disconnect the negative battery ca- ble, then the positive battery cable when working on unit. Loss of life. Property damage. Installation must always Failure to do so could result in death or serious injury. comply with applicable codes, standards, laws and regu- (W000130) lations.
Page 7 Safety Fire Hazards DANGER WARNING Electrocution. In the event of electrical acci- dent, immediately shut power OFF. Use non- Fire and explosion. Installation must comply conductive implements to free victim from with all local, state, and national electrical live conductor. Apply first aid and get medical building codes.
Page 8 Safety WARNING Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or seri- ous injury. (W000138) WARNING Risk of burn. Do not open or mutilate bat- teries.
Page 9 General Information Section 2: General Information Emissions Emissions Data Plate A data plate is attached to the valve cover to verify com- The United States Environmental Protection Agency (US pliance with EPA emissions regulations. EPA) (and California Air Resources Board (CARB), for engines/equipment certified to California standards) re- Figure 2-1.
Page 10 General Information Specifications Model 22 kW 25 kW 27 kW 30 kW 32 kW 36 kW 38 kW 45 kW 60 kW Engine 2.4L 1.5L 2.4L 1.5L 2.4L 2.4L 2.4L 2.4L 2.4L Generator Set Rotor insulation Class H Class F Class H Class F Class H...
Page 11 General Information Model 22 kW 25 kW 27 kW 30 kW 32 kW 36 kW 38 kW 45 kW 60 kW Engine 2.4L 1.5L 2.4L 1.5L 2.4L 2.4L 2.4L 2.4L 2.4L Fan mode Pusher Puller Air flow — ft /min (m 2,400 2,490 2,400...
Page 12 General Information Model 22 kW 25 kW 27 kW 30 kW 32 kW 36 kW 38 kW 45 kW 60 kW Engine 2.4L 1.5L 2.4L 1.5L 2.4L 2.4L 2.4L 2.4L 2.4L Voltage Regulator Type Electronic Frequency regulation Single Steady state regulation +/- 1% Fuel System LP fuel pressure...
Page 13 General Information Battery Requirements • Stationary emergency generators installed with au- tomatic transfer switches will crank and start auto- matically when NORMAL (UTILITY) source voltage 1.5L, 2.4L Engines: For areas where tem- Group 26, 12 peratures regularly drop below 32 °F (0 °C). is removed or is below an acceptable preset level.
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Page 15 Activation and Startup Section 3: Activation and Startup Orientation Installing Battery NOTE: The 2.4L (32 kW) unit is depicted in the artwork WARNING used in this manual. The location and appearance of some components may vary between engine models. Explosion. Batteries emit explosive gases. Always connect positive battery cable first to Figure 3-1.
Page 16 Activation and Startup Opening Viewing Window Proceed as follows to open viewing window: 1. See Figure 3-4. Remove plastic film from both sides of viewing window. Figure 3-4. 006373 Figure 3-4. Viewing Window 2. Rotate viewing window upward to access control panel.
Page 17 Activation and Startup Activating Unit Display Reads: Generator Active is displayed on the LCD If the wrong language is selected, it may when the unit is first powered up. After dis- be changed later using the Edit menu. Up Arrow = (+) playing firmware and hardware version co- des, as well as other system information, Language...
Page 18 Activation and Startup Display Reads: Set Exercise Time. In AUTO mode, the engine starts and runs once each week at the time and day speci- Select Hour (0-23) - 1 + Use UP ARROW or DOWN ARROW to in- fied. During the exercise cycle, the unit crease or decrease the hour.
Page 19 Activation and Startup Checking Manual Transfer Switch Operation 12. Successively connect the AC voltmeter test leads across terminal lugs E1 and Neutral, then E2 and DANGER Neutral (and E3 and Neutral if 3-phase). Line-to- neutral reading in each case should match utility Electrocution.
Page 20 Activation and Startup 11. When testing under load is complete, turn OFF • If engine stops, set auxiliary shutdown switch electrical loads. to ON (I), clear alarm on controller, and re- start engine to verify generator is operating 12. Set generator MLCB (generator disconnect) to normally.
Page 21 Activation and Startup Securing the Generator Proceed as follows to secure generator: 1. Use key to install left and right side access panels. 2. Close viewing window. NOTE: See Figure 3-7. Obtain viewing window hasp, if not installed. With retaining tab at the bot- tom, insert square end of hasp into slot below view- ing window.
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Page 23 Operation Section 4: Operation Figure 4-1. Control Panel DANGER Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. (D000191) NOTE: The control panel is intended for use by qualified service personnel only.
Page 24 Operation Menu Navigation Figure 4-2. Feature Description System Menus HOME Screen The system will return to the HOME screen if the control panel is not used for five minutes. The screen nor- mally displays a status message, such as Ready to Run (AUTO mode) or Switched to OFF (OFF mode), and the total Hours of Protection.
Page 25 Operation Figure 4-2. 011127 Figure 4-2. Navigation Menu Spark-Ignited Stationary Generators Owner’s Manual...
Page 26 Operation Alarm / Warning Conditions Warning messages alert the operator to conditions which do not disable unit or require immediate correction. Possi- The owner / operator is alerted to Alarm and / or Warning ble Alarm / Warning messages are listed below. conditions via the control panel LCD.
Page 27 Operation Automatic Sequence of Operation NOTE: A warning message is displayed on the LCD when battery requires service. Utility Failure Transfer Switch Automatic Operation A ten second startup delay timer is started (user program- In AUTO, the generator starts automatically when utility mable) if control panel is set to AUTO when utility power source voltage drops below preset level.
Page 28 Operation Transfer Switch Manual Operation 7. Set generator MLCB (generator disconnect) to ON (CLOSED). DANGER Transferring Back to Utility Power Electrocution. Do not manually transfer under Proceed as follows to manually transfer back to utility load. Disconnect transfer switch from all power and shut down generator when utility power is power sources prior to manual transfer.
Page 29 Maintenance Section 5: Maintenance Component Locations The side of the enclosure with the viewing window is identified as the rear of the generator set. The right and left sides are identified by standing at the rear and looking towards the front of the unit. NOTE: The 2.4L (32 kW) unit is depicted in the artwork used in this manual.
Page 30 Figure 5-4. Regular maintenance will improve performance and ex- tend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emis- sions control devices and systems may be performed by any repair shop or person of the owner’s choosing.
Page 31 Maintenance Service Maintenance Schedule Observe the maintenance tasks and intervals shown in the table below. Schedule Schedule Schedule 30 Hours En- Daily If Running A Every B Every 2 C Every Service gine Break-In Continuously Year or 125 Years or 1000 Hours 250 Hours...
Page 32 Maintenance 8. Place a DO NOT OPERATE tag or placard on both control panel and transfer switch. 9. If unit has been running, wait five minutes for en- gine to cool. 30 Hour Break-In Perform the following task: • Replace Lubricating Oil and Oil Filter NOTE: See Replacing Lubricating Oil and Oil Filter under...
Page 33 Maintenance Schedule A Maintenance Figure 5-6 for the general location of components for all models. The 2.4L (32 kW) unit is depicted in the art- NOTE: Perform Schedule A maintenance once each year work used in this manual. or after 125 hours of service, whichever comes first. Figure 5-6.
Page 34 Maintenance Schedule A Maintenance Item Locations NOTE: The side of the enclosure with the viewing window is identified as the rear of the generator set. The right and left sides are identified by standing at the rear and looking towards the front of the unit. Model 22/27 kW 25/30 kW...
Page 35 Maintenance 2. Remove fill cap from overflow reservoir and add NOTE: Some oil dipsticks require more effort to coolant if coolant level is below COLD mark. See fully seat than others. Coolant Water Treatment. 5. Allow at least 10 seconds to elapse. 3.
Page 36 Maintenance Figure 5-10. Replacing Lubricating Oil and Oil Filter WARNING Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (W000139) WARNING Skin Irritation. Avoid prolonged or repeated contact with 019994 used motor oil.
Page 37 Maintenance Inspecting Battery Condition 2. Remove positive battery cable (red) from positive (+) battery terminal. 3. See Figure 5-11. Install rubber protective cover Inspecting Battery Condition and Cleaning over positive (+) battery terminal (A). Proceed as follows to inspect and clean battery: Figure 5-11.
Page 38 Maintenance Inspecting and Adjusting Accessory / Drive Belt Inspecting Accessory / Drive Belt Item Item Description Proceed as follows to inspect accessory / drive belt Belt deflection gauge condition: Water pump pulley 1. Perform visual inspection as follows: • Inspect belt for cracks, fraying, excessive Alternator pulley wear, or other damage.
Page 39 Maintenance 5. Install air cleaner cover (E) over threaded rod. In- 7. Use wrench to hold hex on hose fitting (to prevent stall flat washer, lock washer and wing nut. Tighten rotation), and use second wrench to remove drain wing nut until snug. plug.
Page 40 Maintenance 21. Repeat steps 4–12 to drain cooling system. 22. Obtain recommended quantity and type of coolant. Coolant Water Treatment. Slowly unscrew radiator cap. Slowly pour fresh coolant mixture into filler neck until radiator is full. 23. Add coolant to overflow reservoir. See Inspecting Coolant Level and Hoses.
Page 41 Maintenance Schedule B Maintenance Item Locations left sides are identified by standing at the rear and looking towards the front of the unit. NOTE: The side of the enclosure with the viewing window is identified as the rear of the generator set. The right and Model 22 / 27 kW 25 / 30 kW...
Page 42 Maintenance Final Instructions 8. Reset time and date. If only performing Schedule A and Schedule B mainte- Lube Oil Maintainer System nance procedures, proceed as follows: 1. Install battery negative cable (black) onto battery Description negative (-) terminal. 2. Install left and right side access panels. See NOTE: Oil reservoir is empty when shipped from factory.
Page 43 Maintenance Lube Oil Maintainer Components Figure 5-19. 012056 Figure 5-19. Lube Oil Maintainer Assembly and Function Diagram Item Description Item Description Item Description Item Item Item Regulator Oil inlet hose Test button Running engine Regulator viewing lens Shutoff valve crankcase 2.5 gal (9.46 L) Oil supply Center of green bar Oil level...
Page 44 Maintenance Filling Oil Supply Tank Removing From Service During Utility Outages Proceed as follows to fill oil supply tank: 1. See Figure 5-20. Rotate plastic cover counter- If, during prolonged utility outages, the user wishes to re- clockwise and remove from top of enclosure. move unit from service to conserve fuel, reduce run hours, or to perform maintenance tasks, then complete Figure 5-20.
Page 45 Maintenance Storage 19. Remove oil fill cap and fill engine with recommen- ded oil. See Engine Oil Recommendations. 20. Install oil fill cap. Preparing For Storage NOTE: Dispose of used oil and oil filter per nation- WARNING al, state, or local codes. 21.
Page 46 Maintenance 11. Set generator MLCB (generator disconnect) to ON (CLOSED). 12. Press MANUAL on control panel to start engine. A blue LED will illuminate to confirm system is in MANUAL mode. 13. Allow engine to run until it reaches normal operat- ing temperature.
Page 47 Troubleshooting Section 6: Troubleshooting Engine Troubleshooting Problem Cause Correction Fuse blown. Replace 7.5 amp fuse in generator con- trol panel. Correct short circuit condition if fuse blows again. Loose, corroded, or faulty battery cables. Engine will not crank. Tighten, clean, or replace as necessary. Faulty starter contact.
Page 48 Troubleshooting Controller Troubleshooting Active Alarm Problem Solution Unit will not start in AUTO Activating Unit NOT ACTIVATED with utility loss. Inspect generator MLCB (generator disconnect). Contact an Unit running in AUTO but IASD if generator MLCB (generator disconnect) is set to ON NONE no power in house.
Page 49 Troubleshooting Active Alarm Problem Solution Perform SERVICE SCHEDULE C maintenance; press ENTER Warning active. SERVICE SCHEDULE C to clear. Unit will not start in AUTO Figure Verify both auxiliary shutdown switches are ON (I). See AUXILIARY SHUTDOWN with utility loss. for the locations.
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Page 52 Part No. 0K8185 Rev. G 11/11/2024 Generac Power Systems, Inc. © 2024 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved Waukesha, WI 53189 Specifications are subject to change without notice. 1–888–GENERAC (1–888–436–3722) No reproduction allowed in any form without prior written www.generac.com...

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