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Generac RD03024JDAE manual

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  • Page 1

    Owner ’ s Manual For S t ationary Diesel Generators Residential and Commercial Protector ™ Series This manual should re main with the unit. This manual must be used in conjunction with the appropriate inst allation manual. * NOT INTENDED FOR USE IN CRITICAL LIFE SUPPOR T APPLICA TIONS. * ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEM[...]

  • Page 2

    ii Owner ’s Manual for S tationary Diesel Generators Use this p age to record import ant information about the generator set. For quick and easy re ferenc e, copy the information printed on the Unit Identification Label onto the sample label printed here. The Unit Identification Label is located at the re ar of the alternator on 15/20 kW (2.3L) u[...]

  • Page 3

    T able of Conten ts Owner ’s Manual for S tationary Diesel Generators iii Section 1 Safety 1.1 Introduction ............ ................................. ................................................. ................ ............ 1 1.2 Safety Information ....... .................................................................. .............[...]

  • Page 4

    T able of Content s iv Owner ’s Manual for S tationary Diesel Generators 3.8.3 Electrical Checks .................................................... ................................................... ................. 16 3.8.4 Test Generator Under Load .............................................. ........................................... ..[...]

  • Page 5

    T able of Conten ts Owner ’s Manual for S tationary Diesel Generators v 5.6 Daily Maintenance (If R unning Continuously) ...... ............................................... ............ 31 5.7 Schedule A Maintenance ............ ............................................................. .............. ............ 3 2 5.7.1 Preliminary Inst[...]

  • Page 6

    T able of Content s vi Owner ’s Manual for S tationary Diesel Generators (000005) W ARNING California P roposition 65. This product contains or emits chemicals known to the state of California t o cause cancer , birth defects, and other reproductive harm. (000004) W ARNING California P roposition 65. Engine exhaust and some of its constituents ar[...]

  • Page 7

    Owner ’s Manual for S tationary Diesel Generators 1 Section 1 Safety 1.1 — Introduction Thank you for purchasing this st ationary automatic st andby generator se t. Every effort was made to ensure that the information in this manual was both accurate and co mplete at the time it was released . Howe ver , the manufact urer reserves the right to [...]

  • Page 8

    Safety 2 Owner ’s Manual for S tationary Diesel Generators 1.2 — Safety Information S tudy these safety rules carefully before operating or servicing th is equipment. Become fam iliar with this Owner ’s Man- ual and with the unit. The gener ator can operate safely , efficien tly and reliably o nly if it is properly inst alled, operated and ma[...]

  • Page 9

    Safety Owner ’s Manual for S tationary Diesel Generators 3 1.4 — Exhaust Hazards • Generator eng ine exhaust cont ains DEADL Y carbon monoxi de, an odorles s, colorless, poison ous gas. Breathin g carbon monoxide can cause dizziness, throbbin g temples, nausea , mu scular twitching, heada che, vomiting, weakness, slee piness, inabi lity to th[...]

  • Page 10

    Safety 4 Owner ’s Manual for S tationary Diesel Generators This p age intentionally lef t blank.[...]

  • Page 11

    Owner ’s Manual for S tationary Diesel Generators 5 Section 2 Specifications 2.1 — Emission Information The U.S. Environmental Protection Agency (EP A) requires th at the generator comply with exhaust emission stand ards. The generator is cert ified to meet the applicable EP A emission levels, and is certified for use as a stationary eng ine fo[...]

  • Page 12

    S pecifications 6 Owner ’s Manual for S tationary Diesel Generators 2.2 — S pecifications 2.2.1— Engine A complete specification sheet is included in the do cumentat ion provided with the unit at the time of purchase. For additional copies, consult your local Authorized Service Dealer . General 2.3L Engin e 2.4L-49 Engine 3.4L Engine Engine S[...]

  • Page 13

    S pecifications Owner ’s Manual for S tationary Diesel Generators 7 2.3 — Engine Oil Recommendations T o maintain the product warranty , use only genuine Gene rac replacement p arts. Generac maintena nce kits includ e both the oil filter and air filter , and can be obt ained through any Author ized Dealer . All Generac maintenance kit s meet mi[...]

  • Page 14

    S pecifications 8 Owner ’s Manual for S tationary Diesel Generators NOTE: Low ambient temperature s as well as engine operation at hig h altitudes may require the use of fuels with higher Cet ane ratings. Allow at least 5 percent of the t ank capacity for fuel exp ansion. DO NOT OVERFILL! 2.5.1— Fuel Maintenance Always treat diesel fuel for lon[...]

  • Page 15

    S pecifications Owner ’s Manual for S tationary Diesel Generators 9 Figure 2-3. Product Accessories 1. 2. 6. 7. 8. 3. 4. 5. 9. 10. 12. 13. 14. 11 .[...]

  • Page 16

    S pecifications 10 Owner ’s Manual for S tationary Diesel Generators This p age intentionally lef t blank.[...]

  • Page 17

    Owner ’s Manual for S tationary Diesel Generators 11 Section 3 Activation and S t artup IMPORT ANT NOTE: The unit fuel t ank has been inspected by AHJ (authorit y having local jurisdiction) or fire marshal and meet s all requirement s. Unit is fueled and the fuel is treated as per additive direct ions. 3.1 — Orient ation NOTE: The 3.4L engine i[...]

  • Page 18

    Activation and S tartup 12 Owner ’s Manual for S tationary Diesel Generators 3.3 — Prime Fuel System 1. See Figure 3-3. Loosen the air b leed screw and work priming pump until bubb les are observed. Place a shop rag around the air bleed scr ew to catch any loss of fu el. 2. When all bubbles are purged and replaced by a so lid stream of fuel, ti[...]

  • Page 19

    Activation and S t artup Owner ’s Manual for S tationary Diesel Generators 13 3.5 — Open Viewing Window 1. Rotate viewing window upward to access control panel. 2. T o hold viewing window in the open position , remove rod from clip at back of window a nd insert into hole in frame. See Figure 3-5 . 3.6 — S t art and Run Engine 1. Pull up rubbe[...]

  • Page 20

    Activation and S tartup 14 Owner ’s Manual for S tationary Diesel Generators 3.7 — Activate Unit Display Reads: Generato r Active is displayed on the LCD screen when the unit is first powered up. After displaying firmware and hardware version codes, as well as other system information, the Installation Wizard is launched, and the Language scree[...]

  • Page 21

    Activation and S t artup Owner ’s Manual for S tationary Diesel Generators 15 3.8 — Operational Checks The following procedure s require special tools and skills. Cont act a Generac Dealer or an authorized service provider t o perform these t asks. 3.8.1— Self T est Upon power up, the controller goes thro ugh a system self te st which checks [...]

  • Page 22

    Activation and S tartup 16 Owner ’s Manual for S tationary Diesel Generators 3.8.3— Electrical Checks Complete electrical checks as follows: 1. V erify that the generator is OFF . A r ed LED on the control pa d illu minates to confirm that the system is in the OFF mode. 2. V erify that the Main Circuit Breaker switch on the generator contro l p[...]

  • Page 23

    Activation and S tartup Owner ’s Manual for S tationary Diesel Generators 17 5. Press MANUAL on the control pad. The engine will crank and start. 6. Allow the engine to warm up for a few minutes. 7. Move the Main Circuit Breaker switch on the generator control pa nel up to the ON (or closed) position. The switch is now powered by the standby g en[...]

  • Page 24

    Activation and S tartup 18 Owner ’s Manual for S tationary Diesel Generators This p age intentionally lef t blank.[...]

  • Page 25

    Owner ’s Manual for S tationary Diesel Generators 19 Section 4 Operation 4.1 — Control Panel NOTE: The control p a nel is intende d for use by qualified service personnel on ly . The control pane l is located behind the vi ewing window at the rear of the unit. With the control p ad set to AUTO, the engine may cran k and st art at any time witho[...]

  • Page 26

    Operation 20 Owner ’s Manual for S tationary Diesel Generators Figure 4-2. Contro l Pad and LCD Screen 4.3 — Menu Navigation See Figure 4-3. Feature Descr iption System Menus HOME Screen The system returns to the Home screen if the control pad is not used for five minu tes. The screen normally displays a S tatus message, such as Ready to R un ([...]

  • Page 27

    Operation Owner ’s Manual for S tationary Diesel Generators 21 Figure 4-3. Navigation Menu “Run Log” ESC ENTER ENTER ESC SYSTEM BA TTERY DA TE/TIME SUB MENUS HISTOR Y EDIT MAINT DEALER Exercise T ime Å 14:00 Wednesday Æ ESC ESC ENTER ESC ENTER Current Date/T ime Å 9/12/13 12:22 Æ ESC ESC ESC ESC ENTER ENTER ESC ESC ESC ENTER ENTER ENTER E[...]

  • Page 28

    Operation 22 Owner ’s Manual for S tationary Diesel Generators 4.4 — Alarm/W arning Conditions The owner/operator is alerted to Alar m and/or W arning conditions via the cont rol panel LCD screen. All Alarm condi- tions cause the gene rator to shut down. The W arning messages alert the oper ator to conditions that do not disable the unit or req[...]

  • Page 29

    Operation Owner ’s Manual for S tationary Diesel Generators 23 4.6.2— User Programmable 4.6.2.1—St art-Up D elay Timer A programmable line inte rrupt delay (or S tart-Up Delay) timer is provided. When utility vo ltage fails (falls below 60% of nominal), the start-up delay timer is started. If the volt age rises above the Utility V olts Low th[...]

  • Page 30

    Operation 24 Owner ’s Manual for S tationary Diesel Generators 4.9.1— Automatic Sequence of Operation 4.9.1.1—Utility Failure If the control pad is set to AUTO when the utility power fails (falls below 60% of nominal, dealer programmable), a ten second S tart-Up Delay timer is started (user pr ogrammable). If utility power is still absent whe[...]

  • Page 31

    Operation Owner ’s Manual for S tationary Diesel Generators 25 IMPORT ANT NOTE: Always use the applicable transf er switch owner's manual for actual manual t ransfer switch operation instructions. The in formation presented her e describes a typical V -style transfer switch, which is not used for three phase applicat ions. 4.10.1— T ransfe[...]

  • Page 32

    Operation 26 Owner ’s Manual for S tationary Diesel Generators This p age intentionally lef t blank.[...]

  • Page 33

    Owner ’s Manual for S tationary Diesel Generators 27 Section 5 Maintenance 5.1 — Component Locations The side of the enclo sure with the v iewing window is identified as the rear of the generator set. The r ight and lef t sides are identified by st anding at the rear an d looking towards the front of the unit. Figure 5-1. Rear V iew Figure 5-2.[...]

  • Page 34

    Maintenance 28 Owner ’s Manual for S tationary Diesel Generators Figure 5-3. Left Side V iew Figure 5-4. Front V iew NOTE: The 3.4L engine is depicted in the artwor k used in this manual. The location and ap pearance of some component s may vary between engine models. Fuel Filter/A ir Bleed Battery Governor Linkage Coolant Overflow Reservoir Cool[...]

  • Page 35

    Maintenance Owner ’s Manual for S tationary Diesel Generators 29 5.2 — Access Panels Access panels are locate d at both the front and sides of the enclosure. 5.2.1— Removal 1. Insert key into latch and rot ate counterclockwise 1/2 turn. See Figure 5-5. 2. Raise panel using thumb latch. 5.2.2— Inst allation 1. Lower panel into p osition usin[...]

  • Page 36

    Maintenance 30 Owner ’s Manual for S tationary Diesel Generators 5.3 — Service Maintenance Intervals NOTE: Use only Genu ine Generac parts to ensure warrant y coverage. All generator service must be performed by a qualified service person only . It is important to perform all mainte nance at the interval specified in the Service Maintenance Sch[...]

  • Page 37

    Maintenance Owner ’s Manual for S tationary Diesel Generators 31 5.4 — Remove From Service T o ensure sa fety , follow the ste ps below pr ior to inspection, maintena nce or service. IMPORT ANT NOTE: If curre ntly experiencing a utility out age, see Subsection 6.3 —Removal Fr om Service During Utility Out ages for special instructions. 1. Ope[...]

  • Page 38

    Maintenance 32 Owner ’s Manual for S tationary Diesel Generators 5.7 — Schedule A Maintenance NOTE: Perform Schedule A mainten ance once each year or af ter 125 hours of service, whichever comes first. 5.7.1— Preliminary Instructions 1. See Subsection 5 .4 —Remove From Service. 2. Remove access panels at the front and both sides of the encl[...]

  • Page 39

    Maintenance Owner ’s Manual for S tationary Diesel Generators 33 Figure 5-8. Drain Wa ter From Fuel Filter 5.7.4— Check Coolant Level and Hoses Do not add coolant when the engine is hot. S team and scalding fluids can cause severe burns. N O T E : On 2.3L models, remove ten screws to release louvered air discharge p anel on left side of en clos[...]

  • Page 40

    Maintenance 34 Owner ’s Manual for S tationary Diesel Generators 5.7.5— Check Radiator for Clogging Direct beam of flashlight thro ugh openings in fan guard to inspect the radiator fins. Carefu lly look for debris, accumula- tions of dirt or other deposit s. If necessary , clean as follows: 1. On right side of enclosure, loosen two clamp s at e[...]

  • Page 41

    Maintenance Owner ’s Manual for S tationary Diesel Generators 35 5.7.7— Check Battery Condition/Fluid Level 5.7.7.1— Check Co ndition an d Clean N O T E : On 2.3L models, remove ten sc rews to release louvered air int ake p anel on lef t side of enclosure. 1. V erify that top of battery is clean a nd dry . Dirt and electro- lyte on top of the[...]

  • Page 42

    Maintenance 36 Owner ’s Manual for S tationary Diesel Generators Inst allation Always connect the posit ive battery cable first. If the positive cable should co nt act ground with the negative cable inst alled, the resulting sp arks may cause a batter y explosion which could result in seri- ous injury . 1. Install rubber pro tective cover over ba[...]

  • Page 43

    Maintenance Owner ’s Manual for S tationary Diesel Generators 37 5.7.8— Check and Adjust V -Belt 5.7.8.1— Check Check the V -belt deflection. T oo little belt deflec tion accele rates belt wear , while too much deflection leaves the pulley idle, overheat s the engine, and no-load is ge ner ated. Adjust the belt deflection as follows: 1. On ri[...]

  • Page 44

    Maintenance 38 Owner ’s Manual for S tationary Diesel Generators 5.7.8.2— Adjust 1. Loosen tension adjuster screw (top). Loosen hex nut on pivot screw (bottom). Rotate alterna tor outward to reduce belt de flection, rota te inward to in crease belt deflection . 2. T ighten tension adjuster screw (top) to 17-22 ft- lbs (23-30 N-m). T ighten hex [...]

  • Page 45

    Maintenance Owner ’s Manual for S tationary Diesel Generators 39 Figure 5-15. Drain Breather Canister and Replace Filter 5.7.1 1— Lubricate Go vernor Rod Linkage 1. Lubricate both ends of rod with a silicone spray . See Figure 5-16. 2. V erify that rod moves freely without binding. Figure 5-16. Lubricate Governor Rod Ends 5.7.12— Final Instru[...]

  • Page 46

    Maintenance 40 Owner ’s Manual for S tationary Diesel Generators 5.8 — Schedule B Maintenance NOTE: Perform Schedule B maintenance e very two years o r af ter 250 hours of service, whic hever comes firs t. Before proceedin g below , first perform all tas ks listed under Schedule A Main tenance. NOTE: For general locatio n of component s, see Su[...]

  • Page 47

    Maintenance Owner ’s Manual for S tationary Diesel Generators 41 5.8.2— Replace Fuel Filter 1. Slowly loosen water drain pl ug. See Figure 5-18. 2. Rotate filter counterclockwise to remove fro m filter adapter . 3. Install new fi lter by hand until gasket just cont acts filter adap ter . T ighten filter an additional 3/4 to one full turn. 4. T [...]

  • Page 48

    Maintenance 42 Owner ’s Manual for S tationary Diesel Generators 5. Remove coo lant drain ho se from holdin g clamp. 6. Use wrench to hold hex on hose fitting (to prevent rot a tion), and use second wrench to remove dra in plug. 7. Drain coolant into a suitab le conta iner . 8. Install plug at end of drain hose. 9. Install drain hose in holding c[...]

  • Page 49

    Maintenance Owner ’s Manual for S tationary Diesel Generators 43 5.9 — Schedule C Maintenance NOTE: Perform Sched ule C maintenance af ter 1000 hours of service. Before pr oceeding below , first perform all t asks listed under Sch edule A Maintenance and Schedule B Maintenance. The following procedure s require special tools and skills. Cont ac[...]

  • Page 50

    Maintenance 44 Owner ’s Manual for S tationary Diesel Generators This p age intentionally lef t blank.[...]

  • Page 51

    Owner ’s Manual for S tationary Diesel Generators 45 Section 6 T roubleshooting 6.1 — Engine T roubleshooting Problem Cause Correction The engine will not crank. Fuse blow n. Replace 7.5 a mp fuse in gene rator con- trol panel. Cor rect short circuit condi- tion if fuse blows again. Loose, co rroded or de fective bat- tery cables. T ighten, cle[...]

  • Page 52

    T r oubleshoot ing 46 Owner ’s Manual for S tationary Diesel Generators 6.2 — Controller T roubleshooting Active Alarm Problem Solution NOT ACTIV A TED Unit will not start in AUTO with utility loss. Refer to activation sectio n in Owner ’s Manual. NONE Unit running in AUTO but no power in house. Check MLCB. Contact servicing deale r if MLCB i[...]

  • Page 53

    T roubleshooting Owner ’s Manual for S tationary Diesel Generators 47 6.3 — Removal From Servic e During Utility Out ages If, during prolonged utility outages, the us er wishes to remove the unit from serv ice to conserve fuel, reduce run hours, or to perform main tenanc e tasks, then comple te the steps listed b elow . IMPORT ANT NOTE: Failure[...]

  • Page 54

    T r oubleshoot ing 48 Owner ’s Manual for S tationary Diesel Generators 10. Remove right side access panel. See Subsection 5.2 —Access Panels. 11 . Remove oil drain hose from holding clamp. 12. Use one wrench to hold hex on hose fitting (to prevent rot ation), and use second wrench to remove drain plug. 13. Drain oil into a su itable container [...]

  • Page 55

    T roubleshooting Owner ’s Manual for S tationary Diesel Generators 49 8. Install lef t side access panel. S ee Subsec tion 5.2 —Acc ess Panels. N O TE : On 2.3L models, st art ten screws to ins t all louvered air in t ake p anel. Alternately t ighten screws to 90 in- lbs. 9. Remove right side access panel. See Subsection 5.2 —Access Panels. 1[...]

  • Page 56

    T r oubleshoot ing 50 Owner ’s Manual for S tationary Diesel Generators This p age intentionally lef t blank.[...]

  • Page 57

    T roubleshooting Owner ’s Manual for S tationary Diesel Generators 51 NOTES[...]

  • Page 58

    T r oubleshoot ing 52 Owner ’s Manual for S tationary Diesel Generators NOTES[...]

  • Page 59

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  • Page 60

    Part No. 0K3220 Rev . J 05/07/2015 Printed in USA © Generac Power Systems, Inc. All righ ts reserved S pecifications a re subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy . 59 W a ukesha, WI 53189 1-888-GENERAC (1-888-436-[...]