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Generac Power Systems 66781, Owner'S Manual

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Generac Power Systems 66781 Owner'S Manual Download Page 42

Maintenance

36

Owner’s Manual for Stationary Diesel Generators

Installation

Always connect the positive battery cable first. If the positive cable should contact ground with the 
negative cable installed, the resulting sparks may cause a battery explosion which could result in seri-
ous injury.

1.

Install rubber protective cover over battery posi-
tive (+) terminal. See A of Figure 5-12.

2.

Grasp battery strap next to battery positive (+) 
terminal, and lift battery. 

3.

When battery tilts sideways, insert into opening. 
See B of Figure 5-12.

4.

Return battery to the horizontal position while 
sliding it onto battery tray. 

5.

Tighten two screws with nylon washers to 
secure hold-down clamp to battery tray.

6.

Remove rubber protective cover from battery 
positive (+) terminal.

7.

Install battery positive cable (red) to battery 
positive (+) terminal.

8.

Install battery negative cable (black) to battery 
negative (-) terminal.

$

Figure 5-12. Install Battery (2.3L Models)

 A = Protective

 

Cover

 B = Battery Strap

A

B

Summary of Contents for 66781

Page 1: ...on with the appropriate installation manual NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY Model RD015 15 kW 60 Hz RD020 20 kW 60 Hz RD030 30 kW 60 Hz RD048 48 kW 60 Hz Single Phase Only RD050 50 kW 60 Hz Three Phase Only 0066781 30 kW 60 Hz ...

Page 2: ...nger service life while also keeping operating expenses to a minimum It is the operator s responsibility to perform all safety checks to make sure that all maintenance is per formed promptly and to have the equipment checked periodically by an Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and are not considered defects in...

Page 3: ...ne 6 2 3 Engine Oil Recommendations 7 2 4 Coolant Water Treatment 7 2 5 Fuel Requirements 7 2 5 1 Fuel Maintenance 8 2 5 2 Fuel Maintenance 8 2 6 Battery Requirements 8 2 6 1 Battery Charger 8 2 7 Corrosion Protection 8 2 8 Accessories 8 Section 3 Activation and Startup 3 1 Orientation 11 3 2 Remove Side Access Panels 11 3 3 Prime Fuel System 12 3 4 Install Battery 12 3 5 Open Viewing Window 13 3 ...

Page 4: ...4 6 2 User Programmable 23 4 6 2 1 Start Up Delay Timer 23 4 6 2 2 Warm Up Delay Timer 23 4 7 USB Port for Firmware Updates 23 4 8 Battery Charger 23 4 9 Transfer Switch Automatic Operation 23 4 9 1 Automatic Sequence of Operation 24 4 9 1 1 Utility Failure 24 4 9 1 2 Cranking 24 4 9 1 3 Load Transfer 24 4 10 Transfer Switch Manual Operation 24 4 10 1 Transfer to Generator Power 25 4 10 2 Transfer...

Page 5: ...t V Belt 37 5 7 8 1 Check 37 5 7 8 2 Adjust 38 5 7 9 Replace Air Filter Element 38 5 7 10 Drain Breather Canister and Replace Filter 38 5 7 11 Lubricate Governor Rod Linkage 39 5 7 12 Final Instructions 39 5 8 Schedule B Maintenance 40 5 8 1 Replace Lubricating Oil and Oil Filter 40 5 8 2 Replace Fuel Filter 41 5 8 2 1 Prime Fuel System 41 5 8 3 Drain Flush Coolant System 41 5 8 4 Final Instructio...

Page 6: ...This product contains or emits chemicals known to the state of California to cause cancer birth defects and other reproductive harm 000004 WARNING California Proposition 65 Engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm ...

Page 7: ...manufacturer suggests that this manual and the rules for safe operation be cop ied and posted near the generator installation site Safety should be stressed to all operators and potential operators of this equipment SAFETY Throughout this manual and on tags and decals affixed to the unit DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular o...

Page 8: ...rsonnel only 1 3 General Hazards For safety reasons this equipment should only be installed serviced and repaired by a Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards regula tions and product Installation Manual guidelines The operator also must comply with all such codes standards regulations and product Installati...

Page 9: ...VOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving parts resulting in injury 1 6 Fire Hazards For fi...

Page 10: ...Safety 4 Owner s Manual for Stationary Diesel Generators This page intentionally left blank ...

Page 11: ... for standby power generation Any other use may be a violation of federal and or local laws To ensure that the engine complies with the applicable emission standards for the duration of the engine s life it is important to follow the mainte nance specifications in Section 5 This generator is certified to operate on Diesel Fuel No 2 KSM2610 2 1 1 Emissions Data Plate A data plate is riveted to the ...

Page 12: ... 185 F 85 C System Coolant Capacity 2 8 gal 10 6 liter 2 8 gal 10 6 liter 2 8 gal 10 6 liter Coolant Flow Rate 10 gal 38 liter min at 1800 RPM 10 gal 38 liter min at 1800 RPM 12 2 gal 46 liter min at 1800 RPM Lubricating System Oil Pump Type Gear Gear Gear Oil Filter Type Full Flow Spin On Canister Full Flow Spin On Canister Full Flow Spin On Canister Oil Cooler Not Applicable Installed Installed ...

Page 13: ...event rot in summer and anti freeze to prevent freezing in winter Dilute the anti freeze based on a theoretical temperature that is 9 18 F 5 10 C below the lowest temperature expected in the area A ratio of 40 60 is most common range NOTE Use only Peak Fleet Charge 50 50 ethylene glycol type coolant available from any authorized dealer Do not use propylene glycol type coolant Using the wrong coola...

Page 14: ...cts Frequent washing is recommended in salt water coastal areas 2 8 Accessories The following product accessories are available Contact a Dealer for additional information Group 27F 12 Volt 2 3L Engine For areas where temperatures regularly drop below 32 F 0 C NOTE Battery dimensions L x W x H for Group 27F battery must not exceed 12 1 2 x 6 13 16 x 8 15 16 318 mm x 173 mm x 227 mm Group 31 12 Vol...

Page 15: ...Specifications Owner s Manual for Stationary Diesel Generators 9 Figure 2 3 Product Accessories 1 2 6 7 8 3 4 5 9 10 12 13 14 11 ...

Page 16: ...Specifications 10 Owner s Manual for Stationary Diesel Generators This page intentionally left blank ...

Page 17: ...earance of some components may vary between engine models 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 Figure 3 1 Enclosure Rear Left View 3 2 Remove Side Access Panels NOTE Access panels are located at both the front and sides of the enclosu...

Page 18: ...s may cause a battery explosion which could result in serious injury 2 4L 3 4L Models NOTE On 2 3L models remove ten screws to release lou vered air intake panel on left side of enclosure 1 Loosen two screws with nylon washers to release hold down clamp from battery tray 2 Install battery onto tray 3 Install two screws with nylon washers to secure hold down clamp to battery tray 4 Install battery ...

Page 19: ...A of Figure 3 6 2 Move the Main Circuit Breaker switch down to the OFF Open position See B of Figure 3 6 3 Press MANUAL on the control pad to start the engine A blue LED illuminates to confirm that the system is in the MANUAL mode See C of Figure 3 6 4 Allow the engine to run until it reaches normal operating temperature 5 Press OFF on the control pad to stop the engine A red LED illuminates to co...

Page 20: ... 8482 US CA only if activation passcode is not avail able If activation pass code is available wait a few seconds for the next display Display Reads Use UP ARROW or DOWN ARROW to increment or decrement the digit to correspond to the first number of the pass code Press ENTER Repeat step to enter remaining digits Press ESCAPE to return to preceding digits if a correction becomes necessary If attempt...

Page 21: ...ting oil level See Subsections 5 7 2 5 7 4 and 5 7 6 respectively During initial start up only the generator may exceed the normal number of start attempts and experience an over crank fault This is due to accumulated air in the fuel system during installation Reset the control board and restart up to two more times if necessary If unit fails to start contact the local dealer for assistance 3 8 2 ...

Page 22: ...ed to the transfer switch Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock 10 Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 E2 and E3 if three phase 11 Successively connect the AC voltmeter test leads across terminal lugs E1 E2 and E3 if three phase and neu tral then across E2 and neutral Voltage r...

Page 23: ... control pad illuminates to confirm that the system is in the OFF mode 2 Install front cover of the transfer switch 3 Turn ON the utility power supply to the transfer switch using the means provided such as a utility main line cir cuit breaker NOTE Transfer Switch will transfer back to utility position 4 Move the Main Circuit Breaker switch on the generator control panel up to the ON or closed pos...

Page 24: ...Activation and Startup 18 Owner s Manual for Stationary Diesel Generators This page intentionally left blank ...

Page 25: ...added security place a DO NOT OPERATE tag or placard on both the con trol panel and transfer switch Figure 4 1 Generator Control Panel 4 2 Auto Manual Off Feature Description AUTO Press to activate fully automatic operation Green LED illuminates to confirm that system is in AUTO mode Transfer to standby power occurs if utility power fails Functionality of exercise timer is enabled if set MANUAL Pr...

Page 26: ...always displayed first MAIN MENU Enables the operator to navigate the software using UP ARROW DOWN ARROW ENTER and ESCAPE The Main Menu can be accessed from any sub menu by consecutively pressing ESCAPE Each time ESCAPE is pressed the preceding menu is displayed The Main Menu is reached when the System Date Time Battery and Sub Menus are displayed Navigation ESCAPE Used to abort a routine or back ...

Page 27: ...ntrollerFault IgnitionFaultCode WIRINGERROR OverVoltage UnderVoltage OverloadRemoveLoad CanbusError GovernorFault MissingCamPulse MissingCrankPulse RupturedTank LowFuel 10 E Stop FuseProblem Note E CodesNotShown WARNINGMESSAGE S LowBattery ExerciseSetError FIRMWAREERROR 9 ScheduleAMaint ScheduleBMaint ScheduleCMaint BatteryProblem ChargerWarning ChargerMissingAC OverloadWarning OverloadCooldown SE...

Page 28: ... retained in memory 4 6 Programmable Timers 4 6 1 Dealer Programmable 4 6 1 1 Exercise Time A programmable exercise time is provided In the AUTO mode the engine starts and runs once each week at the time and day specified During the exercise cycle the unit runs approximately 12 minutes and then shuts down Transfer of loads to the generator does not occur unless utility power fails NOTE A Dealer pa...

Page 29: ...or Firmware Updates A USB port is located beneath the rubber flap on the control panel and is provided for firmware updates Firmware updates must be performed by an Authorized Service Dealer NOTE The USB port is intended for use with a USB thumb drive only The USB port is not intended for charging devices such as phones or laptops Do not connect any consumer electronics to the USB port 4 8 Battery...

Page 30: ...ely turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock Prior to automatic operation manually exercise the transfer switch to verify that there is no binding or interference with proper operation of the mechanism Manual operation of the transfer switch is required if automatic operation fails AUTO Starts and runs if utilit...

Page 31: ... to bring it up to normal operating temperature 7 Move the Main Circuit Breaker switch up to the ON Closed position Figure 4 4 Manual Transfer Switch Operation Typical 4 10 2 Transfer Back to Utility Power When utility power is restored manually transfer back to utility power and shut down the generator as follows NOTE Verify that utility voltage has returned and is at the proper value 1 Move the ...

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Page 33: ...e 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 Figure 5 1 Rear View Figure 5 2 Right Side View Main Circuit Breaker Viewing Window Control Pad and LCD Screen 7 5 Amp Fuse and USB Port Right Side Left Side Oil Level Dipstick Oil Filter V Belt Air Filter Oil Drain Hose Oil Fill Cap ...

Page 34: ... in this manual The location and appearance of some components may vary between engine models Fuel Filter Air Bleed Battery Governor Linkage Coolant Overflow Reservoir Coolant Drain Hose Fuel Supply Hose Fuel Return Hose Breather Canister and Filter Fuel Filler Spout Fuel Level Gauge Emergency Vent Primary Tank Fuel Tank Primary Vent Emergency Vent Secondary Tank ...

Page 35: ...e front and sides of the enclosure 5 2 1 Removal 1 Insert key into latch and rotate counterclockwise 1 2 turn See Figure 5 5 2 Raise panel using thumb latch 5 2 2 Installation 1 Lower panel into position using thumb latch 2 Insert key into latch and rotate clockwise 1 2 turn Figure 5 5 Access Panel Key Key Thumb Latch ...

Page 36: ...aintenance interval with 900 to 999 total hours have an authorized service provider perform the Schedule C maintenance tasks as well and reset the A B C Year maintenance schedule counter Service 30 Hours Engine Break In Daily If Running Continuously Schedule A Every Year or 125 Hours Schedule B Every 2 Years or 250 Hours Schedule C Every 1000 Hours Check Fuel Level and Fill Drain Fuel Filter Check...

Page 37: ...ll up rubber flap covering fuse holder and remove 7 5 amp fuse See C of Figure 5 6 6 Place a DO NOT OPERATE tag or placard on both the control panel and transfer switch 7 If the unit has been running wait five minutes for the engine to cool Figure 5 6 Generator Control Panel 5 5 30 Hour Break In Perform the following task Replace Lubricating Oil and Oil Filter NOTE See Subsection 5 8 1 under Sched...

Page 38: ...k Fuel Level and Fill 1 Observe fuel gauge to note level of fuel in tank See Figure 5 7 2 Remove fuel fill cap from filler pipe 3 Add fuel until needle on fuel gauge approaches the F ull mark 4 Install fuel fill cap onto filler pipe Figure 5 7 Check Fuel Level Gauge and Fill 5 7 3 Drain Fuel Filter and Check Fuel Lines Hoses 1 Slowly loosen water drain plug See Figure 5 8 2 Place a shop rag under ...

Page 39: ...ant expands when hot so the level may be higher than the HOT mark Do not add coolant higher than the HOT mark 2 If the coolant level is below the COLD mark remove fill cap from overflow reservoir and add coolant See Sub section 2 4 Coolant Water Treatment 3 Check coolant hoses for leaks Tighten hose clamps if necessary 4 Check hoses for nicks cuts tears or general deterioration Replace as necessar...

Page 40: ...fasten fan guard to radiator shroud 9 Install coolant hoses into holding clamps 10 Install clamps and rubber couplings onto each end of air intake pipe Install pipe to air heater and radiator shroud Tighten clamps 11 On right side of enclosure install four screws with nylon washers to fasten fan guard to radiator shroud 12 Install oil drain hose into holding clamp 13 Install clamps and rubber coup...

Page 41: ...ction 5 7 7 3 Check State of Charge 9 Replace battery if necessary See Subsection 5 7 7 4 Battery Replacement NOTE On 2 3L models start ten screws to install louvered air intake panel Alternately tighten screws to 90 in lbs 10 N m using a crosswise pattern 5 7 7 2 Check Fluid Level Check the fluid level of unsealed batteries If necessary fill with distilled water only DO NOT use tap water 5 7 7 3 ...

Page 42: ... Grasp battery strap next to battery positive terminal and lift battery 3 When battery tilts sideways insert into opening See B of Figure 5 12 4 Return battery to the horizontal position while sliding it onto battery tray 5 Tighten two screws with nylon washers to secure hold down clamp to battery tray 6 Remove rubber protective cover from battery positive terminal 7 Install battery positive cable...

Page 43: ...er damage Verify that belt is free of grease and oil Replace belt if contaminated NOTE Use a solution of soap and warm water to clean pulleys if necessary Avoid use of solvents but if used always follow by a soap and water wash 5 Using a suitable gauge apply 22 Ibs 10 kgf force midway between the crankshaft and alternator pulleys See Figure 5 13 6 Take note of gauge reading If belt deflection is n...

Page 44: ... against adapter flange NOTE The air filter element is not directional 5 Install air cleaner cover over threaded rod Install wing nut and tighten until snug Figure 5 14 Air Cleaner Cover and Filter Element 5 7 10 Drain Breather Canister and Replace Filter NOTE This procedure only applies to turbocharged engines 2 4L 3 4L models 1 Observe sight glass for level of oil in canister See Figure 5 15 2 W...

Page 45: ...icone spray See Figure 5 16 2 Verify that rod moves freely without binding Figure 5 16 Lubricate Governor Rod Ends 5 7 12 Final Instructions 1 Install battery negative cable black onto battery negative terminal 2 Install access panels at the front and both sides of the enclosure See Subsection 5 2 Access Panels 3 See Subsection 5 10 Return To Service Filter Element Clamp Sight Glass Drain Plug ...

Page 46: ...y a light coat of clean engine oil to gasket of new oil filter 8 Install oil filter by hand until gasket just contacts oil filter adapter Tighten oil filter an additional 3 4 to one full turn 9 Remove fill cap and fill engine with the recommended oil See Subsection 2 3 Engine Oil Recommendations 10 Install fill cap 11 Install battery negative cable black onto battery negative terminal 12 Pull up r...

Page 47: ...d screw and work priming pump until bubbles are observed 3 When all bubbles are purged and replaced by a solid stream of fuel depress pump handle and tighten the air bleed screw 4 Check for leaks 5 8 3 Drain Flush Coolant System NOTE On 2 3L models remove ten screws to release louvered air discharge panel on left side of enclosure 1 Disconnect and empty coolant overflow reservoir 2 Install and con...

Page 48: ...e engine A blue LED illuminates to confirm that the system is in the MANUAL mode 16 Allow engine to run until the thermostat opens as indicated by heating of the top radiator hose 17 Check coolant hoses for leaks Tighten clamps if necessary 18 Press OFF on the control pad to shut the engine down 19 Wait five minutes for the engine to cool 20 Repeat steps 4 20 to drain and refill cooling system 21 ...

Page 49: ...enance schedule counter using the Dealer Sub Menu password required 5 10 Return To Service After inspection maintenance or service of the generator return the unit to service following the steps below 1 Pull up rubber flap covering fuse holder and install 7 5 amp fuse See A of Figure 5 20 2 Install T1 fuse in transfer switch 3 Press AUTO on the control pad A green LED illuminates to confirm that t...

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Page 51: ...s again Defective fuel system No fuel to pump Prime fuel system The engine starts hard and runs rough Air cleaner plugged or damaged Check replace air cleaner The generator is set to OFF but the engine continues to run Defective keypad Defective control board There is no AC output from the generator Main line circuit breaker is in the OFF OPEN position Reset circuit breaker to ON CLOSED position G...

Page 52: ...arm From the MAIN menu on the control panel navi gate to the BATTERY MENU Contact servicing dealer if battery is GOOD Replace battery If CHECK BATTERY is displayed OVERCRANK Unit will not start in AUTO with utility loss Clear alarm Attempt to start the unit in MANUAL If it does not start or starts and runs rough contact servicing dealer FUSE PROBLEM Unit will not start in AUTO with utility loss Ch...

Page 53: ...conserve fuel or to reduce run hours start at step 5 1 Install battery negative cable black onto battery negative terminal 2 Pull up rubber flap covering fuse holder and install 7 5 amp fuse 3 Install T1 fuse in transfer switch 4 Remove the DO NOT OPERATE tag or placard from both the control panel and transfer switch 5 Press AUTO on the control pad A green LED illuminates to confirm that the syste...

Page 54: ...jury 23 Remove battery negative cable black from battery negative terminal 24 Remove battery positive cable red from battery positive terminal 25 Remove two screws to release battery hold down clamp from platform 26 Remove battery and store on a wooden board in a cool dry room Do not store the battery on a concrete or earthen floor 27 Install left side access panel See Subsection 5 2 Access Panels...

Page 55: ...gine is run ning 16 Press OFF on the control pad A red LED illuminates to confirm that the system is in the OFF mode 17 Install right side access panel See Subsection 5 2 Access Panels 18 Turn on utility power to the transfer switch 19 Press AUTO on the control pad A green LED illuminates to confirm that the system is in the AUTO mode 20 Reset the time and date 21 Close the viewing window 6 5 Atte...

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Page 57: ...Troubleshooting Owner s Manual for Stationary Diesel Generators 51 NOTES ...

Page 58: ...Troubleshooting 52 Owner s Manual for Stationary Diesel Generators NOTES ...

Page 59: ......

Page 60: ...c All rights reserved Specifications are 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 Waukesha WI 53189 1 888 GENERAC 1 888 436 3722 generac com ...

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