Guardian 004582-2 Owner's Manual
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Guardian 004582-2 Owner's Manual

Guardian 004582-2 Owner's Manual

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ULTRA SOURCE
Portable Generator
Owner's
Manual
• SAFETY
• ASSEMBLY
• OPERATION
• TROUBLESHOOTING
• ELECTRICAL DATA
• PARTS
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
• WARRANTY
MODEL: 004582-2
15,000 Watt Portable Generator
AUTHORIZED DEALER SUPPORT:
1-800-333-1322

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Summary of Contents for Guardian 004582-2

  • Page 1 ULTRA SOURCE Portable Generator Owner’s Manual • SAFETY • ASSEMBLY • OPERATION • TROUBLESHOOTING • ELECTRICAL DATA • PARTS COMMERCIAL • INDUSTRIAL • RESIDENTIAL • WARRANTY MODEL: 004582-2 15,000 Watt Portable Generator AUTHORIZED DEALER SUPPORT: 1-800-333-1322...

  • Page 2: Table Of Contents

    Table of Contents Commercial-Industrial-Residential Portable Generator System Safety Rules ..........1-3 Section 3 – Maintenance ......14 Section 1 – General Information ....4 Maintenance Schedule ..........14 Product Specifications ..........14 Unpacking ..............4 3.2.1 Generator Specifications ........14 1.1.1 Accessory Box..........4 3.2.2 Engine Specifications ........14 Assembly ..............4 General Recommendations ........15 1.2.1...

  • Page 3: Safety Rules

    INTRODUCTION We also strongly recommend instructing other users to properly start and operate the unit. This prepares them if they need to Thank you for purchasing this model of the GUARDIAN ® product operate the equipment in an emergency. line by Generac Power Systems, Inc. This model is a compact,...
  • Page 4 IMPORTANT SAFETY INSTRUCTIONS Commercial-Industrial-Residential Portable Generator System SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's installation site. Safety should be stressed to all operators and potential operators of this equipment. •...

  • Page 5: Electrical Hazards

    IMPORTANT SAFETY INSTRUCTIONS Commercial-Industrial-Residential Portable Generator System ELECTRICAL HAZARDS EXPLOSION HAZARDS • All generators covered by this manual produce dangerous • Do not smoke around the generator. Wipe up any fuel or oil electrical voltages and can cause fatal electrical shock. Utility spills immediately.

  • Page 6: Section 1 - General Information

    Section 1 – General Information Commercial-Industrial-Residential Portable Generator System 1.1 UNPACKING 1.2 ASSEMBLY • Set the palleted carton on a rigid flat surface. The generator requires some assembly prior to using it. If problems arise when assembling the generator, please call the •...

  • Page 7: Battery Connection

    Section 1 - General Information Commercial-Industrial-Residential Portable Generator System Figure 2 - Handle Assembly 1.2.3 BATTERY CONNECTION Figure 3 - Battery Connections • The battery shipped with the generator has been provided fully Negative Positive charged. Caution must be taken when connecting the battery. Cable Cable NOTE: A battery may lose some of it’s charge when not in use...

  • Page 8: Section 2 - Operation

    Section 2 – Operation Commercial-Industrial-Residential Portable Generator System OPERATION 12 Volt DC, 10 Amp Receptacle – This receptacle allows the capability to recharge a 12 volt DC storage battery with provided battery charge cables. 2.1 KNOW THE GENERATOR 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies electrical power for the operation of 120 Volt AC, 20 Amp, Read the Owner’s Manual and Safety Rules before operating single-phase, 60 Hz electrical lighting, appliance, tool and...

  • Page 9: Cord Sets And Connector Plugs

    Section 2 – Operation Commercial-Industrial-Residential Portable Generator System 14) Start/Run/Stop Switch – Controls the operation of the A GFCI receptacle does NOT protect against circuit overloads, generator. short circuits, or shocks. For example, electric shock can still occur if a person touches charged electrical wires while standing 15) Oil Fill –...

  • Page 10: 120/240V Ac, 30 A, Receptacle

    Section 2 – Operation Commercial-Industrial-Residential Portable Generator System Figure 9 - 120 VAC, 30 Amp Receptacle 2.2.5 12 VOLT DC, 10 AMP RECEPTACLE This receptacle allows you to recharge a 12 Volt automotive or utility style storage battery with the battery charge cables provided.

  • Page 11: How To Use The Generator

    Section 2 – Operation Commercial-Industrial-Residential Portable Generator System 2.3.2 CONNECTING ELECTRICAL LOADS 2.3 HOW TO USE THE GENERATOR DO NOT connect 240 Volt loads to 120 Volt receptacles. DO NOT If you have any problems operating your generator, please call the connect 3-phase loads to the generator.

  • Page 12: Wattage Reference Chart

    Section 2 – Operation Commercial-Industrial-Residential Portable Generator System 2.5 WATTAGE REFERENCE GUIDE Device ..... . .Running Watts Device ..... . .Running Watts *Air Conditioner (12,000 Btu) .

  • Page 13: Adding Gasoline

    Section 2 – Operation Commercial-Industrial-Residential Portable Generator System 2.6.2 ADDING GASOLINE 2.7 TO START THE ENGINE ------------- ------------- WARNING WARNING: Never start or stop engine with electrical devices WARNING: Never fill fuel tank indoors. Never fill fuel tank plugged into the receptacles AND devices turned on. when engine is running or hot.

  • Page 14: Stopping The Engine

    Section 2 – Operation Commercial-Industrial-Residential Portable Generator System • Move engine CHOKE knob outward to “Full Choke” position. 2.9 AUTOMATIC IDLE CONTROL Figure 17 - Full Choke Position This feature is designed to greatly improve fuel economy. When this switch is turned “On,” the engine will only run at its normal fast governed engine speed when electrical load is connected.

  • Page 15: Charging A Battery

    Section 2 – Operation Commercial-Industrial-Residential Portable Generator System Note: Use an automotive hydrometer to test battery state of charge and condition. Follow the hydrometer manufacturer's 2.12 CHARGING A BATTERY instructions carefully. Generally, a battery is considered to be at 100% state of charge when specific gravity of its fluid (as DANGER! Storage batteries give off explosive hydrogen gas measured by hydrometer) is 1.260 or higher.

  • Page 16: Section 3 - Maintenance

    *** Check valve clearance and adjust if necessary after first 50 hours of operation and every 100 hours thereafter. PRODUCT SPECIFICATIONS 3.2.1 GENERATOR SPECIFICATIONS MODEL GPS 15,000 Model # 004582-2 Rated Max. Power 15.0 kW Surge Power 22.5 kW Rated AC Voltage...

  • Page 17: General Recommendations

    Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System 3.3.3 ENGINE MAINTENANCE 3.3 GENERAL RECOMMENDATIONS DANGER! When working on the generator, always disconnect negative cable from battery. Also disconnect spark plug wires The warranty of the generator does not cover items that have from spark plug and keep wire away from spark plug.

  • Page 18: Replacing The Spark Plug

    Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System 3.3.6 REPLACING THE SPARK PLUG To clean or replace foam pre-cleaner: • Remove air cleaner cover, then foam pre-filter. Use Champion RC14YC spark plug or equivalent. The correct air gap is 1.01 mm (0.040 in.). Replace the plug once each year. •...

  • Page 19: Adjusting Valve Clearance

    Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System Figure 21 - Spark Arrestor To adjust valve clearance: • Loosen the rocker jam nut. Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge.

  • Page 20: General

    Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System 3.7 GENERAL 3.9 OTHER STORAGE TIPS: The generator should be started at least once every seven days • Do not store gasoline from one season to another. and be allowed to run at least 30 minutes. If this cannot be done •...

  • Page 21: Section 4 - Troubleshooting

    Section 4 — Troubleshooting Commercial-Industrial-Residential Portable Generator System 4.1 TROUBLESHOOTING SYMPTOM CAUSE SOLUTION Engine is running, but no AC 1. Circuit breaker is open. 1. Reset circuit breaker. output is available. 2. Poor connection or defective cord set. 2. Check and repair. 3.

  • Page 22: Section 5 - Electrical Data

    Section 5 — Electrical Data Commercial-Industrial-Residential Portable Generator System Wiring Diagram, UltraSource Portable Generator – Drawing No. 0G0731 120/240V 120/240V (50A/60A) OUTLET (50A/60A) OUTLET 120/240V 120/240V 120V/20A 120V/20A 120V/20A 120V/20A 30A TWISTLOK 30A TWISTLOK 120V/30A 120V/30A 120V/30A 120V/30A DUPLEX DUPLEX GFCI GFCI TWISTLOK...
  • Page 23 Section 5 — Electrical Data Commercial-Industrial-Residential Portable Generator System Wiring Diagram, UltraSource Portable Generator – Drawing No. 0G0731 OUTLET IDLE CONTROL IDLE CONTROL STATOR STATOR TRANSFORMERS TRANSFORMERS CLOSEST TO BEARING CLOSEST TO BEARING 11 11 PIN # PIN # ON/OFF ON/OFF 12 11 IDLE...

  • Page 24: Section 5 – Electrical Data

    Section 5 — Electrical Data Commercial-Industrial-Residential Portable Generator System Schematic, UltraSource Portable Generator – Drawing No. 0G0733 POWER WINDING POWER WINDING DPE WINDING DPE WINDING BATTERY CHARGE WINDING BATTERY CHARGE WINDING FIELD FIELD 66A 11S C1-5 C1-5 C1-4 C1-4 C1-1 C1-2 C1-2 C1-6...

  • Page 25: Section 6 - Notes

    Section 6 - Notes Commercial-Industrial-Residential Portable Generator System...
  • Page 26 Section 6 - Notes Commercial-Industrial-Residential Portable Generator System...
  • Page 27 Section 6 - Notes Commercial-Industrial-Residential Portable Generator System...

  • Page 28: Section 7 - Exploded Views And Parts Lists

    Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 Engine (Page 1) – Drawing No. 0E8589-R...
  • Page 29 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 Engine (Page 1) – Drawing No. 0E8589-R ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C5729 ASSEMBLY, CRANKCASE HOUSING WITH 0G1526 ASSY, GEAR COVER / ADAPTOR SLEEVE W/SLEEVE 0E9843...
  • Page 30 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 Engine (Page 2) – Drawing No. 0E8589-R...
  • Page 31 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 Engine (Page 2) – Drawing No. 0E8589-R ITEM PART # QTY. DESCRIPTION ITEM PART NO#. QTY. DESCRIPTION 0D6592 WINGNUT, AIRBOX 092079 SCREW TAPTITE M6-1.0 X 25 BP 0D4511 PRECLEANER, AIR 0F1338B...
  • Page 32 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator – Drawing No. 0G0742-A...
  • Page 33 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator – Drawing No. 0G0742-A ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C6934 ADAPTOR, ENGINE 0A2038 WASHER FLAT 3/8 ZINC 0G1177 STATOR 15KW 022237 WASHER LOCK 3/8 0D2136 STATOR 17.5KW 022511...
  • Page 34 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No. 0G0727-B...
  • Page 35 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No. 0G0727-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 065795 RECTIFIER-BATTERY CHARGER 087968 SWITCH, ROCKER -/0 0D4804 TRANSFORMER, IDLE CURRENT 090418 OUTLET, 12VDC SNAP 0C1085 SCREW PPHM M3-0.5 X 8...
  • Page 36 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No. 0E0695-B...

  • Page 37: Parts Lists

    Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No. 0E0695-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 045900 WASHER FLAT 3/4" (15 kW) 057058 SCREW HHC M6-1.0 X 55 0D7668 12.3"...

  • Page 38: Section 8 - Warranty

    Section 8 – Warranty Commercial-Industrial-Residential Portable Generator System CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System warranty on your new engine. In California, new off-road Large Spark-Ignition (LSI) engines must be designed, built and equipped to meet the state's stringent anti-smog standards.

  • Page 39: Emission Control System Warranty

    Section 8 – Warranty Commercial-Industrial-Residential Portable Generator System EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS warranty) for 2001 and later model year LSI engines: (a) Applicability: This warranty shall apply to 2001 and later model year engines.The ECS Warranty period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.

  • Page 40: Section 8 – Warranty

    “15,000 WATT PORTABLE GENERATOR” For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its Guardian generator will be free from defects in materials and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective.
  • Page 42 057058 SCREW HHC M6-1.0 X 55 0D5315 RUBBER TANK MOUNT 0D4570 CAP, FUEL WITH GAUGE & VENT 0D22850SRV KIT, FUEL TANK 045771 NUT HEX M8-1.25 022129 WASHER LOCK M8-5/16 022145 WASHER FLAT 5/16 0D4565 BRACKET BATTERY 0D3545 BOLT,BATTERY J-BOLT 022287 SCREW HHC 1/4-20 X 3/4 G5 022473 WASHER FLAT 1/4...

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