® Protector™ Series Owner’s Manual Stationary Diesel Generators Residential and Commercial 15–50 kW, 12–40 kVA 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. (000209b) Register your Generac product at: WWW.GENERAC.COM 1-888-GENERAC (888-436-3722) Para español , visita: http://www.generac.com/service-support/product-support-lookup Pour le français, visiter : http://www.generac.
Use this page to record important information about the generator. For quick and easy reference, copy the information printed on the Unit Identification Label into the table provided below. The Unit Identification Label is located on the left engine mount on 15/20 kW (2.5L) models, on the left side of the radiator shroud on 30 kW (2.2L) models, and on the left side of the engine support rail on 48/50 kW (3.4L) models.
Table of Contents Introduction ..........................................................1 Electrical Checks .......................................................15 Test Generator Under Load ......................................16 Check Automatic Operation ......................................16 Read This Manual Thoroughly ....................................1 Final Instructions ............................................... 17 Safety Rules .........................................................
Table of Contents Check and Adjust V-Belt ........................................... 32 Adjust V-Belt Tension ............................................... 33 Replace Air Filter Element—2.5L Engine ........34 Replace Air Filter Element—2.2L Engine ........34 Replace Air Filter Element—3.4L Engine ........35 Lubricate Governor Rod Linkage (2.5L and 3.4L Engines) ..............................................35 Final Instructions .......................................................
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction Thank you for purchasing this stationary automatic standby generator. This generator is designed to automatically supply electrical power to operate critical loads during a utility power failure. The unit is factory installed in an all-weather metal enclosure and is intended exclusively for outdoor installation using only diesel fuel.
Safety Rules & General Information General Hazards WARNING DANGER Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury. (000190) Equipment damage. This unit is not intended for use as a prime power source. It is intended for use as an intermediate power supply in the event of temporary power outage only. Doing so could result in death, serious injury, and equipment damage.
Safety Rules & General Information Explosion Hazards DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) DANGER Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury. (000192) DANGER Electrocution. In the event of electrical accident, immediately shut power OFF.
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Specifications Section 2: Specifications Emission Information Emissions Data Plate The U.S. Environmental Protection Agency (EPA) requires generators to comply with exhaust emission standards. The generator is certified to meet applicable EPA emission levels, and is certified for use as a stationary engine for standby power generation. Any other use may be a violation of federal and/or local laws.
Specifications Specifications Engine General 2.5L Engine 2.2L Engine 3.4L Engine Engine System Type 4 cylinder, in-line, 4 cycle Fuel type Ultra low sulfur diesel Fuel filtering 6 Microns 25 Microns (maximum) 10 Microns Bore and stroke 3.3 in x 3.9 in (84 mm x 100 mm) 3.3 in x 3.9 in (84 mm x 100 mm) 3.86 in x 4.45 in (98 mm x 113 mm) Displacement 152.9 in3 (2.51 L) 135.2 in3 (2.22 L) 208.3 in3 (3.
Specifications Engine Oil Recommendations To maintain the product warranty, the engine oil should be serviced in accordance with the recommendations of this manual. For your convenience, maintenance kits designed and intended for use on this product are available from the manufacturer that include engine oil, oil filter, air filter, spark plug(s), a shop towel and funnel. These kits can be obtained from an Independent Authorized Service Dealer (IASD).
Specifications Battery Requirements Group 27F, 12 Volt 2.5L & 2.2L 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 in x 6-13/16 in x 8-15/16 in (31.8 cm x 17.3 cm x 22.7 cm). 3.4L engine and upgrade option for 2.2L engine: For areas where temperatures regularly drop below 32 °F (0 °C).
Specifications 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 006368a Figure 2-3.
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Activation and Startup Section 3: Activation and Startup Introduction NOTE: Before startup, unit fuel tank may need to be inspected by the local authority having jurisdiction (AHJ) or fire marshal to meet all requirements. User must fill fuel tank and treat the fuel according to additive specifications. A B Orientation NOTE: The 2.2L unit is depicted in most of the artwork used in this manual. Location and appearance of some components may vary between engine models. See Figure 3-1.
Activation and Startup 5. Connect negative battery cable (black) (B) to negative (-) battery terminal. 6. Thread 10 screws into louvered air intake panel. Alternately tighten screws to 90 in-lbs (10 Nm) using a crosswise pattern. B A B 006371 Figure 3-4. Prime Fuel System (2.5L Engines) 2. When all bubbles are purged and replaced by a solid stream of fuel, lower pump handle (or release priming bulb) and tighten the fuel filter air bleed screw. C 006372 Figure 3-5.
Activation and Startup Open Viewing Window 1. Turn viewing window upward to access control panel. 2. See Figure 3-6. To hold viewing window open, remove rod from clip at back of window and insert into hole in frame (A). Test Auxiliary Shutdown Switch Operation The generator is equipped with an independent means of shutting down prime mover (engine) for use in emergency situations. The shutdown mechanism, when activated, requires a mechanical reset. See Figure 3-8.
Activation and Startup Activate Unit Display Reads Up Arrow = (+) Language - English + Troubleshooting Generator Active is displayed on the LCD screen during initial startup. After displaying firmware and hardware version codes, as well as other system information, Install Wizard is launched and Language screen is displayed. If wrong language is selected, it may be changed later using the EDIT menu. Use UP ARROW or DOWN ARROW to scroll to desired language. Down Arrow = (-) Press ENTER. Press ENTER.
Activation and Startup Quiet Test Mode? Yes No Select Hour (0-23) -1+ Use UP ARROW or DOWN ARROW to select either YES or NO. Select YES to perform exercise at low speed. Select NO to perform exercise at normal operating speed. Press ENTER. • Set Exercise Time. • Use UP ARROW or DOWN ARROW to increment or decrement hour. Press ENTER. • Use UP ARROW or DOWN In AUTO, engine starts and runs once each week at the time and day specified.
Activation and Startup 7. Turn off utility power supply to transfer switch when utility supply voltage is compatible with transfer switch and load circuit ratings. 8. Press MANUAL on control panel to crank and start engine. 9. Allow engine to warm up for approximately five minutes. Set MLCB switch on generator control panel to ON (CLOSED). 10. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1, E2, and E3 (if three-phase). 11.
Activation and Startup Final Instructions 1. Use key to install side access panels. 2. Close viewing window. NOTE: See Figure 3-9. Obtain viewing window hasp, if not installed. With retaining tab at the bottom, insert square end of viewing window hasp into slot below viewing window. Push on viewing window hasp until it snaps in place. Gently pull on viewing window hasp to verify it will not come free. 4. Generator will start and run. Allow generator to run and warm up for a few minutes. 5.
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Operation Section 4: Operation Control Panel IMPORTANT NOTE: With control panel set to AUTO, engine may crank and start at any time without warning. Such automatic starting occurs during the programmed exercise cycle or when utility power source voltage drops below configured level. To prevent possible injury that might occur during sudden starts, always set control panel to OFF and remove the 7.5 amp fuse before working on or around the generator or transfer switch.
Operation AUTO/MANUAL/OFF Feature Description AUTO Activates fully automatic operation. Green LED illuminates to verify system is in AUTO. Transfer to standby power occurs if utility power fails. Functionality of exercise timer is enabled, if set. MANUAL Cranks and starts engine. Blue LED illuminates to verify system is in MANUAL. Transfer to standby power occurs if utility power fails. Functionality of exercise timer is disabled. OFF Shuts down engine, if running.
Owner’s Manual for Stationary Diesel Generators *Note: E-Codes Not Shown ALARM MESSAGE(S)* "High Engine Temp.
Operation Alarm/Warning Conditions Programmable Timers The owner/operator is alerted to Alarm and/or Warning conditions via the control panel LCD. All Alarm conditions cause generator to shut down. Warning messages alert operator to conditions that do not disable unit or require immediate correction. Dealer Programmable The possible Alarm/Warning messages are listed below.
Operation Battery Charger Automatic Sequence of Operation NOTE: Battery charger is integrated into control panel module. Utility Failure If control panel is set to AUTO when utility power fails (falls below 65% of nominal, dealer programmable), a ten second startup delay timer is started (user programmable). If utility power is still absent when time expires, engine cranks and starts. Once started, a five second engine warm-up delay timer starts (user programmable).
Operation Transfer Switch Manual Operation DANGER Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage. (000132) Prior to automatic operation, manually exercise transfer switch to verify there is no binding or interference with correct operation of the mechanism. Manual operation of transfer switch is required if automatic operation fails.
Maintenance Section 5: Maintenance Component Locations The side of enclosure with the viewing window is identified as the rear of the generator. The right and left sides are identified by standing at the rear and looking towards the front of the unit. D NOTE: The 2.2L engine is depicted in the artwork used in this manual. The location and appearance of some components may vary between engine models. A B C F E A 7.
Maintenance A C D A Governor linkage (2.5L engines; not shown) B Battery C Coolant drain hose D Coolant overflow reservoir 006380 B Figure 5-3. Left Side View A C E D A Fuel tank (primary vent) B Fuel filler spout C Fuel level gauge D Emergency vent (secondary tank) E Emergency vent (primary tank) B 006381 Figure 5-4.
Maintenance Access Panels Access panels are located at both the front and sides of the enclosure. Removal 1. See Figure 5-5. Insert key (B) into latch (A) and turn counterclockwise one-half turn. A B 006370 Figure 5-5. Access Panel Key 2. Raise panel using thumb latch. Installation 1. Lower panel into position using thumb latch. 2. Insert key into latch and turn clockwise one-half turn. Service Maintenance Intervals WARNING Equipment damage.
Maintenance Service Maintenance Schedule Observe maintenance tasks and intervals shown in the table below.
Maintenance A C o OFF PUSH TO TRIP B 006374 Figure 5-6. Generator Control Panel 30 Hour Break-In Perform the following task: • Replace Lubricating Oil and Oil Filter NOTE: See Replace Lubricating Oil and Oil Filter under Schedule B Maintenance. NOTE: For general location of components, see Component Locations. Check Fuel Level and Fill 1. See Figure 5-7. Observe fuel gauge to note level of fuel in tank.
Maintenance Drain Fuel Filter and Check Fuel Lines/Hoses 1. See Figure 5-8. Place a shop rag beneath fuel filter (A) to catch water or fuel drips. NOTE: On 2.5L models, install louvered air discharge panel. Alternately tighten ten screws to 90 in-lbs (10 Nm) using a crosswise pattern. A A 006187 Figure 5-8. Drain Fuel Filter (2.5L Engine) 2. Turn fuel filter counterclockwise to remove from filter adapter. 3. Install new fuel filter by hand until gasket just contacts filter adapter.
Maintenance turbocharger outlet and radiator shroud. Tighten clamps. Check Battery Condition/Fluid Level Check Condition and Clean Check Lubricating Oil Level 1. See Figure 5-10. Remove dipstick (A) and wipe with a clean cloth. NOTE: On 2.5L models, remove ten screws to release louvered air intake panel on left side of enclosure. B A 006384 Figure 5-10. Oil Level Dipstick (3.4L Engine) 2. Completely insert oil dipstick and then remove it. 3. Verify oil level is at or near H(igh) mark (B).
Maintenance 8. Check battery state of charge. See Check State of Charge. 9. Replace battery if necessary. See Battery Replacement. NOTE: On 2.5L models, start ten screws to install louvered air intake panel. Alternately tighten screws to 90 in-lbs (10 Nm) using a crosswise pattern. Check Fluid Level Check fluid level of unsealed batteries. If necessary, fill with distilled water only. DO NOT use tap water. Check State of Charge Check state of charge using a digital multimeter.
Maintenance 5. See Figure 5-13. Using a suitable belt deflection gauge (A), apply 22 Ibs (10 kg) force midway between the crankshaft (B) and alternator pulleys (C). 6. Take note of gauge reading. If belt deflection is not within specification, see Adjust V-Belt Tension. Belt Condition Deflection New 0.31–0.47 in (8–12 mm) Used 0.39–0.59 in (10–15 mm) 7. Install four screws with nylon washers to fasten fan guard to radiator shroud. 8.
Maintenance Replace Air Filter Element—2.5L Engine Replace Air Filter Element—2.2L Engine 1. See Figure 5-14. Remove wing nut (A), flat washer (B), and lock washer (C) from threaded rod to release air cleaner cover (D). NOTE: The 2.2L engine is equipped with an alternatestyle air cleaner. 1. See Figure 5-16. Release three buckle clasps from end cap (A) of air cleaner canister (B). Remove end cap. D A B C A 006183 Figure 5-14. Remove Air Cleaner Cover—2.5L Engine B 006185 2. See Figure 5-15.
Maintenance Replace Air Filter Element—3.4L Engine 2. Verify rod moves freely without binding. NOTE: 3.4L engine air filter element is not compatible with 2.5/2.2L engines. 1. See Figure 5-18. Use flathead screwdriver to hold slotted bolt (A) while loosening square nut to expand air filter element clamp (B). Final Instructions 1. Install negative battery cable (black) onto negative (-) battery terminal. 2. Install access panels at the front and both sides of the enclosure. See Access Panels. 3.
Maintenance 12. Press MANUAL on control panel to start engine. 13. Allow engine to run for one minute. Inspect for leaks while engine is running. 14. Press OFF on control panel. A red LED illuminates to verify system is OFF. 15. Wait a few minutes for engine to cool and to allow oil to drain back to the oil pan. 16. Check oil level and add oil as necessary. DO NOT OVERFILL. 17. Install oil fill cap. NOTE: Dispose of used oil and oil filter at an authorized collection center.
Maintenance A RADIATOR DRAIN A 001493 001497 NOTE: Drain hose removed for illustration purposes. Figure 5-22. Drain/Fill Coolant System Final Instructions 1. Install left and right side access panels. See Access Panels. 2. See Return To Service. Schedule C Maintenance NOTE: Perform Schedule C maintenance after 1,000 hours of service. Before proceeding below, first perform all tasks listed under Schedule A Maintenance and Schedule B Maintenance.
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Troubleshooting Section 6: Troubleshooting Engine Troubleshooting Problem Cause Blown fuse. Engine will not crank Loose, corroded, or faulty battery cables. Faulty starter contact. Correction Replace 7.5 amp fuse in generator control panel. Correct short circuit condition if fuse blows again. Tighten, clean or replace as necessary. Contact an IASD. Faulty starter motor. Engine cranks but will not start Engine starts hard and runs rough Discharged battery. Charge or replace battery. No fuel.
Troubleshooting Controller Troubleshooting Active Alarm Problem Solution NOT ACTIVATED Unit will not start in AUTO with utility loss. See Activate Unit. AUXILIARY SHUTDOWN Unit will not start in AUTO with utility loss. Verify both auxiliary shutdown switches are ON (I). NONE Unit running in AUTO but no power in house. Check MLCB. Contact an IASD if MLCB is ON. NONE Unit will not start in AUTO with utility loss. Check screen for start delay countdown.
Troubleshooting Removal From Service During Utility Outages If, during prolonged utility outages, user wishes to remove the unit from service to conserve fuel, reduce run hours, or to perform maintenance tasks, then complete the steps listed below. IMPORTANT NOTE: Failure to abide by this procedure can result in equipment damage. Remove From Service Proceed as follows to remove generator from service while running in AUTO and Online: 1. Turn main utility disconnect to OFF (OPEN). 2. Open viewing window.
Troubleshooting WARNING Explosion. Batteries emit explosive gases. Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury. (000238) 23. Remove negative battery cable (black) from negative (-) battery terminal. 24. Remove positive battery cable (red) from positive (+) battery terminal. 25. Remove two screws to release battery hold-down clamp from platform, or loosen strap and position away from tray. 26.
Troubleshooting Attention After Submersion Do NOT start and operate generator if it has been submerged in water. Have an IASD thoroughly clean, dry, and inspect generator following any submersion. If structure (home) has been flooded, it should be inspected by a certified electrician to verify there won’t be any electrical problems during generator operation or when utility power is returned. Attention After Fuel Spillage Contact reputable local company that performs clean up and disposal services.
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Part No. 10000019179 Rev. B 03/20/19 ©2019 Generac Power Systems, Inc. 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) www.generac.
