Protector™ Series Owner’s Manual For Stationary Diesel Generators Residential and Commercial Model RD015 RD020 RD030 RD048 RD050 0066781 - * * NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS. * DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY! ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! This manual should remain with the unit. This manual must be used in conjunction with the appropriate installation manual.
Use this page to record important information about the generator set. For quick and easy reference, copy the information printed on the Unit Identification Label onto the sample label printed here. The Unit Identification Label is located at the rear of the alternator on 15/20 kW (2.3L) units, and on the front engine mount on 30 kW (2.4L) and 50 kW (3.4L) models.
Table of Contents Table of Contents Section 1 Safety 1.1 Introduction .......................................................................................................................... 1 1.2 Safety Information ................................................................................................................ 2 1.3 General Hazards ................................................................................................................... 2 1.4 Exhaust Hazards ...................
Table of Contents 3.8.3 Electrical Checks ........................................................................................................................ 16 3.8.4 Test Generator Under Load ........................................................................................................ 16 3.8.5 Check Automatic Operation ........................................................................................................ 17 3.9 Final Instructions .........................................
Table of Contents 5.6 Daily Maintenance (If Running Continuously) ................................................................. 31 5.7 Schedule A Maintenance ................................................................................................... 32 5.7.1 Preliminary Instructions .............................................................................................................. 32 5.7.2 Check Fuel Level and Fill .....................................................................
Table of Contents 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. (000004) WARNING California Proposition 65. This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm.
Section 1 Safety 1.1 — Introduction Thank you for purchasing this stationary automatic standby generator set. Every effort was made to ensure that the information in this manual was both accurate and complete at the time it was released. However, the manufacturer reserves the right to change, alter or otherwise improve this product at any time without prior notice. This generator is designed to automatically supply electrical power to operate critical loads during a utility power failure.
Safety 1.2 — Safety Information Study these safety rules carefully before operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple rules or precautions. The manufacturer cannot anticipate every possible circumstance that might involve a hazard.
Safety 1.4 — Exhaust Hazards • Generator engine exhaust contains DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, weakness, sleepiness, inability to think clearly, fainting, unconsciousness or even death. If any carbon monoxide poisoning symptom is experienced, move into fresh air and immediately seek medical attention. • This generator is designed for OUTDOOR installation ONLY.
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Section 2 Specifications 2.1 — Emission Information The U.S. Environmental Protection Agency (EPA) requires that the generator comply with exhaust emission standards. The generator is certified to meet the 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 2.2 — Specifications 2.2.1— Engine General 2.3L Engine 2.4L-49 Engine 3.4L Engine 4 cylinder, in-line, 4 cycle 4 cylinder, in-line, 4 cycle Engine System Type 4 cylinder, in-line, 4 cycle Fuel Type Ultra Low Sulfur Diesel Ultra Low Sulfur Diesel Ultra Low Sulfur Diesel Fuel Filtering 5 Microns 5 Microns 10 Microns Bore and Stroke 3.46 in x 3.70 in (88 mm x 94 mm) 3.54 in x 3.70 in (90 mm x 94 mm) 3.86 in x 4.45 in (98 mm x 113 mm) Displacement 139.5 cubic inches (2.
Specifications 2.3 — Engine Oil Recommendations To maintain the product warranty, use only genuine Generac replacement parts. Generac maintenance kits include both the oil filter and air filter, and can be obtained through any Authorized Dealer. All Generac maintenance kits meet minimum American Petroleum Institute (API) Service Class CD or better. Select the appropriate viscosity oil grade according to the expected operating temperature.
Specifications NOTE: Low ambient temperatures as well as engine operation at high altitudes may require the use of fuels with higher Cetane ratings. Allow at least 5 percent of the tank capacity for fuel expansion. DO NOT OVERFILL! 2.5.1— Fuel Maintenance Always treat diesel fuel for long term storage. Use the approved fuel additive and water abatement material. Test stored fuel every 90 days and provide additional treatment if required. Periodically check and dry abatement material as necessary. 2.5.
Specifications 1. 2. 3. 5. 6. 4. 7. 8. 9. 10. 11. 12. 13. 14. Figure 2-3.
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Section 3 Activation and Startup IMPORTANT NOTE: The unit fuel tank has been inspected by AHJ (authority having local jurisdiction) or fire marshal and meets all requirements. Unit is fueled and the fuel is treated as per additive directions. 3.1 — Orientation NOTE: The 3.4L engine is depicted in the artwork used in this manual. The location and appearance 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.
Activation and Startup 3.3 — Prime Fuel System 1. See Figure 3-3. Loosen the air bleed screw and work priming pump until bubbles are observed. Place a shop rag around the air bleed screw to catch any loss of fuel. 2. When all bubbles are purged and replaced by a solid stream of fuel, tighten the air bleed screw. 3. Check for leaks. Priming Pump Air Bleed Screw Figure 3-3. Prime Fuel System 3.4 — Install Battery $ CAUTION: Always connect the positive battery cable first.
Activation and Startup 3.5 — Open Viewing Window 1. Rotate viewing window upward to access control panel. 2. To hold viewing window in the open position, remove rod from clip at back of window and insert into hole in frame. See Figure 3-5. Figure 3-5. Viewing Window 3.6 — Start and Run Engine 1. Pull up rubber flap covering fuse holder and verify installation of 7.5 amp fuse. See 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.
Activation and Startup 3.7 — Activate Unit Display Reads: Up Arrow = (+) Language - English + Generator 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 screen is displayed. If the wrong language is selected, it may be changed later using the Edit menu. Use UP ARROW or DOWN ARROW to scroll to desired language. Press ENTER.
Activation and Startup Display Reads: Quite Test Mode? Yes No Display Reads: 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 the hour. Press ENTER. In the AUTO mode, the engine starts and runs once each week at the time and day specified.
Activation and Startup 3.8.3— Electrical Checks Complete electrical checks as follows: 1. Verify that the generator is OFF. A red LED on the control pad illuminates to confirm that the system is in the OFF mode. 2. Verify that the Main Circuit Breaker switch on the generator control panel is in the OFF (Open) position. 3. Turn OFF all circuit breakers/electrical loads that will be powered by the generator. 4.
Activation and Startup 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 panel up to the ON (or closed) position. The switch is now powered by the standby generator. 8. Turn ON the circuit breaker/electrical loads powered by the generator. 9. Connect a calibrated AC voltmeter and a frequency meter across terminal lugs E1, E2, and E3 (if three phase).
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Section 4 Operation 4.1 — Control Panel NOTE: The control panel is intended for use by qualified service personnel only. The control panel is located behind the viewing window at the rear of the unit. * With the control pad set to AUTO, the 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 the configured level.
Operation LCD Screen UP ARROW Green LED Blue LED Red LED ENTER AUTO MANUAL OFF DOWN ARROW ESCAPE Figure 4-2. Control Pad and LCD Screen 4.3 — Menu Navigation See Figure 4-3. Feature Description System Menus HOME Screen The system returns to the Home screen if the control pad is not used for five minutes. The screen normally displays a Status message, such as Ready to Run (Auto mode) or Switched to OFF (Off mode), and the total Hours of Protection.
Operation Switched to “OFF” Hours of Protection 0 (H) Home Screen Up Arrow = (+) Current Date/Time 02/14/13 07:40 ESC Running Manual Running-Utility Lost Running-Remote Start Running-2 Wire Start Running - Exercise Switched Off Stopped - Auto Stopped - Alarm SYSTEM ENTER ESC DATE/TIME Down Arrow = (-) ENTER Battery Condition Run Hours (H) ENTER “Good” “Inspect Battery” or “Check Battery” BATTERY SUB MENUS 0.
Operation 4.4 — Alarm/Warning Conditions The owner/operator is alerted to Alarm and/or Warning conditions via the control panel LCD screen. All Alarm conditions cause the generator to shut down. The Warning messages alert the operator to conditions that do not disable the unit or require immediate correction. The possible Alarm/Warning messages are listed below.
Operation 4.6.2— User Programmable 4.6.2.1—Start-Up Delay Timer A programmable line interrupt delay (or Start-Up Delay) timer is provided. When utility voltage fails (falls below 60% of nominal), the start-up delay timer is started. If the voltage rises above the Utility Volts Low threshold, the timer is reset. If the utility voltage remains below the threshold during the duration of the timer, the unit cranks and starts.
Operation 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 Start-Up Delay timer is started (user programmable). If utility power is still absent when the time expires, the engine cranks and starts. Once started, a five second engine Warm-Up Delay timer starts (user programmable). When the time has elapsed, the load is transferred to the generator.
Operation IMPORTANT NOTE: Always use the applicable transfer switch owner's manual for actual manual transfer switch operation instructions. The information presented here describes a typical V-style transfer switch, which is not used for three phase applications. 4.10.1— Transfer to Generator Power When utility power fails, manually transfer to standby power and start the generator as follows: 1. Press OFF on the control pad. A red LED illuminates to confirm that the system is in the OFF mode. 2.
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Section 5 Maintenance 5.1 — 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. Viewing Window 7.5 Amp Fuse and USB Port Main Circuit Breaker Control Pad and LCD Screen Left Side Right Side Figure 5-1. Rear View V-Belt Air Filter Oil Filter Oil Level Dipstick Oil Fill Cap Oil Drain Hose Figure 5-2.
Maintenance Fuel Return Hose Fuel Filter/Air Bleed Coolant Overflow Reservoir Coolant Drain Hose Fuel Supply Hose Breather Canister and Filter Governor Linkage Battery Figure 5-3. Left Side View Fuel Tank Primary Vent Emergency Vent Primary Tank Fuel Filler Spout Emergency Vent Fuel Level Gauge Secondary Tank Figure 5-4. Front View NOTE: The 3.4L engine is depicted in the artwork used in this manual. The location and appearance of some components may vary between engine models.
Maintenance 5.2 — Access Panels Access panels are located at both the 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. Key Thumb Latch Figure 5-5.
Maintenance 5.3 — Service Maintenance Intervals NOTE: Use only Genuine Generac parts to ensure warranty coverage. * It is important to perform all maintenance at the interval specified in the Service Maintenance Schedule. This All generator service must be performed by a qualified service person only. ensures safe and proper operation, as well as compliance with applicable emissions standards. Critical emissions maintenance must be performed for the Emissions Warranty to remain valid.
Maintenance 5.4 — Remove From Service To ensure safety, follow the steps below prior to inspection, maintenance or service. IMPORTANT NOTE: If currently experiencing a utility outage, see Subsection 6.3 —Removal From Service During Utility Outages for special instructions. 1. Open the viewing window. See Subsection 3.5 —Open Viewing Window. 2. Move the Main Circuit Breaker switch down to the OFF (Open) position. See A of Figure 5-6. 3. Press OFF on the control pad.
Maintenance 5.7 — Schedule A Maintenance NOTE: Perform Schedule A maintenance once each year or after 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 enclosure. See Subsection 5.2 —Access Panels. 3. Remove battery negative cable (black) from battery negative (-) terminal. NOTE: For general location of components, see Subsection 5.1 —Component Locations. 5.7.
Maintenance Priming Pump Fuel Filter Water Drain Plug Figure 5-8. Drain Water From Fuel Filter 5.7.4— Check Coolant Level and Hoses * Do not add coolant when the engine is hot. Steam and scalding fluids can cause severe burns. NOTE: On 2.3L models, remove ten screws to release louvered air discharge panel on left side of enclosure. 1. Verify that the coolant level is between the HOT and COLD marks on the overflow reservoir. See Figure 5-9.
Maintenance 5.7.5— Check Radiator for Clogging Direct beam of flashlight through openings in fan guard to inspect the radiator fins. Carefully look for debris, accumulations of dirt or other deposits. If necessary, clean as follows: 1. On right side of enclosure, loosen two clamps at each end of turbocharger exhaust outlet pipe. Remove pipe, clamps and rubber couplings from engine. 2. Remove oil drain hose from holding clamp. 3.
Maintenance 5.7.7— Check Battery Condition/Fluid Level 5.7.7.1— Check Condition and Clean NOTE: On 2.3L models, remove ten screws to release louvered air intake panel on left side of enclosure. 1. Verify that top of battery is clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-discharge. Clean battery top with a solution of baking soda (sodium bicarbonate) and water (5 teaspoons baking soda per quart or liter of water).
Maintenance 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 serious injury. 1. Install rubber protective cover over battery positive (+) 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.
Maintenance 5.7.8— Check and Adjust V-Belt 5.7.8.1— Check Check the V-belt deflection. Too little belt deflection accelerates belt wear, while too much deflection leaves the pulley idle, overheats the engine, and no-load is generated. Adjust the belt deflection as follows: 1. On right side of enclosure, loosen two clamps at each end of turbocharger exhaust outlet pipe. Remove pipe, clamps and rubber couplings from engine. 2. Remove oil drain hose from holding clamp. 3.
Maintenance 5.7.8.2— Adjust 1. Loosen tension adjuster screw (top). Loosen hex nut on pivot screw (bottom). Rotate alternator outward to reduce belt deflection, rotate inward to increase belt deflection. 2. Tighten tension adjuster screw (top) to 17-22 ft-lbs (23-30 N-m). Tighten hex nut on pivot screw (bottom) to 33-43 ft-lbs (45-58 N-m). 3. Recheck belt deflection and repeat steps as necessary. 5.7.9— Replace Air Filter Element 1. Remove wing nut from threaded rod to release air cleaner cover.
Maintenance Filter Element Clamp Drain Plug Sight Glass Figure 5-15. Drain Breather Canister and Replace Filter 5.7.11— Lubricate Governor Rod Linkage 1. Lubricate both ends of rod with a silicone 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.
Maintenance 5.8 — Schedule B Maintenance NOTE: Perform Schedule B maintenance every two years or after 250 hours of service, whichever comes first. Before proceeding below, first perform all tasks listed under Schedule A Maintenance. NOTE: For general location of components, see Subsection 5.1 —Component Locations. 5.8.1— Replace Lubricating Oil and Oil Filter 1. Remove oil drain hose from holding clamp. See Figure 5-17. 2.
Maintenance 5.8.2— Replace Fuel Filter 1. Slowly loosen water drain plug. See Figure 5-18. 2. Rotate filter counterclockwise to remove from filter adapter. 3. Install new filter by hand until gasket just contacts filter adapter. Tighten filter an additional 3/4 to one full turn. 4. Tighten water drain plug. NOTE: Dispose of used fuel filter at a proper collection center. 5. See Subsection 5.8.2.1—Prime Fuel System. Priming Pump Fuel Filter Water Drain Plug Air Bleed Screw Figure 5-18.
Maintenance 5. Remove coolant drain hose from holding clamp. 6. Use wrench to hold hex on hose fitting (to prevent rotation), and use second wrench to remove drain plug. 7. Drain coolant into a suitable container. 8. Install plug at end of drain hose. 9. Install drain hose in holding clamp. 10. Rotate hex fitting to close radiator drain cock. 11. Obtain at least 2.8 gallons (10.6 liters) of coolant. See Subsection 2.4 —Coolant Water Treatment. 12.
Maintenance 5.9 — Schedule C Maintenance NOTE: Perform Schedule C maintenance after 1000 hours of service. Before proceeding below, first perform all tasks listed under Schedule A Maintenance and Schedule B Maintenance. * The following procedures require special tools and skills. Contact a Generac Dealer or an authorized service provider to perform these tasks.
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Section 6 Troubleshooting 6.1 — Engine Troubleshooting Problem The engine will not crank. The engine cranks but will not start. The engine starts hard and runs rough. The generator is set to OFF, but the engine continues to run. There is no AC output from the generator. There is no transfer to standby after utility source failure. Unit consumes large amounts of oil. Cause Correction Fuse blown. Replace 7.5 amp fuse in generator control panel. Correct short circuit condition if fuse blows again.
Troubleshooting 6.2 — Controller Troubleshooting Active Alarm NOT ACTIVATED Solution Unit will not start in AUTO with utility loss. Refer to activation section in Owner’s Manual. NONE Unit running in AUTO but no power in house. Check MLCB. Contact servicing dealer if MLCB is in the ON position. NONE Unit will not start in AUTO with utility loss. Check screen for start delay countdown. If the start up delay is greater than expected, contact servicing dealer to adjust from 2 to 1500 seconds.
Troubleshooting 6.3 — Removal From Service During Utility Outages If, during prolonged utility outages, the 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. To remove the generator from service while running in AUTO and online, proceed as follows: 1. Turn the main utility disconnect to OFF (Open). 2.
Troubleshooting 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 rotation), and use second wrench to remove drain plug. 13. Drain oil into a suitable container. 14. Install drain plug onto end of oil drain hose. 15. Install oil drain hose into holding clamp. 16. Rotate oil filter counterclockwise to remove from oil filter adapter. 17.
Troubleshooting 8. Install left side access panel. See Subsection 5.2 —Access Panels. NOTE: On 2.3L models, start ten screws to install louvered air intake panel. Alternately tighten screws to 90 inlbs. 9. Remove right side access panel. See Subsection 5.2 —Access Panels. 10. Check oil level and add oil as necessary. DO NOT OVERFILL. 11. Open the viewing window. See Subsection 3.5 —Open Viewing Window. 12. Pull up rubber flap covering fuse holder and install 7.5 amp fuse. 13.
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Troubleshooting NOTES Owner’s Manual for Stationary Diesel Generators 51
Troubleshooting NOTES 52 Owner’s Manual for Stationary Diesel Generators
Part No. 0K3220 Rev. J 05/07/2015 Printed in USA © 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) generac.