Instruction/ maintenance manual of the product RD03024GDAE Generac
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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.
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.
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 .
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 .
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 ............ .................
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.
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 .
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.
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.
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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.
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 .
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 .
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.
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 ..
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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.
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.
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.
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.
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.
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.
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.
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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.
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.
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 .
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.
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.
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).
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.
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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.
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.
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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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 .
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.
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.
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 .
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 .
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.
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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.
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.
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 .
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.
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.
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T roubleshooting Owner ’s Manual for S tationary Diesel Generators 51 NOTES.
T r oubleshoot ing 52 Owner ’s Manual for S tationary Diesel Generators NOTES.
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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.
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