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Generac 4582 manual

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Table of contents for the manual

  • Page 1

    Owner’ s Manual • SAFETY • ASSEMBLY • OPERATION • TROUBLESHOOTING • ELECTRICAL DATA • PARTS • WARRANTY 1-800-333-1322 UL TRA SOURCE Portable Generator COMMERCIAL • INDUSTRIAL • RESIDENTIAL MODELS: 004 4 51 (12,500 W A TT) 004582 (15,000 W A TT) AUTHORIZED DEALER SUPPORT: GENERAC POWER SYSTEMS, INC. P.O. Box 297 • Whitewater, W[...]

  • Page 2

    Table of Contents Commercial-Industrial-Residential Portable Generator System Safety Rules ..............................................1-3 Section 1 – General Information ................4 1.1 Unpacking ....................................................................4 1.1.1 Accessory Box ..................................................4 1[...]

  • Page 3

    INTRODUCTION Thank you for purchasing this model of the GUARDIAN ® product line by Generac Power Systems, Inc. This model is a compact, high performance, air-cooled, engine driven generator designed to supply electrical power to operate electrical loads where no utility power is available. READ THIS MANUAL THOROUGHLY If you do not understand any p[...]

  • Page 4

    2 • Never start or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON. Start the engine and let it stabilize before connecting electrical loads. Disconnect all electrical loads before shutting down the generator. • Do not insert objects through unit's cooling slots. • Never operate generator[...]

  • Page 5

    3  ELECTRICAL HAZARDS  • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages as does the generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure [...]

  • Page 6

    1.1 UNPACKING • Set the palleted carton on a rigid flat surface. • Remove staples along bottom of carton that fasten carton to pallet. Open carton from top. • Remove all packaging material. • Remove separate accessory box. • Lift carton off the generator. • Remove generator from shipping pallet by removing bolts through the shipping bra[...]

  • Page 7

    5 1.2.3 BATTERY CONNECTION • The battery shipped with the generator has been provided fully charged. Caution must be taken when connecting the battery. • Cut the tie wrap cable holding the RED and BLACK battery cables to the stator. • Connect the RED battery cable to the battery Positive terminal (+). After making sure that the connection is [...]

  • Page 8

    ITEM PART NO. QTY. DESCRIPTION 1 087968 1 SWITCH, ROCKER -/0 2 090418 1 OUTLET, 12VDC SNAP 3 0D6640 1 COVER, GOVERNOR CONTROL 4 090987 6 SCREW PPHM M3-0.5 X 12 5 0D2502 1 PANEL, SHEET METAL 6 068868 2 OUTLET 30A 120V RECEPT 7 022985 2 WASHER FLAT #6 8 043182 10 WASHER LOCK M3 9 051714 6 NUT HEX M3-0.5 G8 10 075207A 4 CIRCUIT BREAKER 30A 11 075207 2[...]

  • Page 9

    30 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No. 0E0227B 2.2 CORD SETS AND CONNECTION PLUGS 2.2.1 AC, 20 AMP, DUPLEX RECEPTACLE This is a 120 Volt outlet protected against overload by a 20 Amp push-to-reset circuit breaker. Use each socket to power 120 Volt AC,[...]

  • Page 10

    Figure 9 - 120 VAC, 30 Amp Receptacle Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker. 2.2.4 120/240V AC, 30 AMP RECEPTACLE Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4-wire grounded c[...]

  • Page 11

    2.3 HOW TO USE THE GENERATOR If you have any problems operating your generator, please call the generator helpline at 1-800-333-1322. 2.3.1 GROUNDING THE GENERATOR The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground . Local electrical cod[...]

  • Page 12

    10 2.5 WATTAGE REFERENCE GUIDE Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts *Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . .1700 *Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . .3800 *Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . .6000 Battery Charger (20 Amp) . . . . . . . . . . . . [...]

  • Page 13

    11 2.6.2 ADDING GASOLINE  WARNING: Never fill fuel tank indoors. Never fill fuel tank when engine is running or hot. DO NOT light a cigarette or smoke when filling the fuel tank.  Caution: Do not overfill the fuel tank. Always leave room for fuel expansion. • Use regular UNLEADED gasoline with the generator engine. Do not use premium gasoli[...]

  • Page 14

    12 • Move engine CHOKE knob to “Full Choke” position. Figure 17 - Full Choke Position • To start engine, press and hold the Start/Run/Stop switch in the “Start” position. The engine will crank and attempt to start. When the engine starts, release the switch to the run position. • When the engine starts, move choke knob to “1/2 Choke[...]

  • Page 15

    2.12 CHARGING A BATTERY  DANGER! Storage batteries give off explosive hydrogen gas while recharging. An explosive mixture will remain around the battery for a long time after it has been charged. The slightest spark can ignite the hydrogen and cause an explosion. Such an explosion can shatter the battery and cause blindness or other serious inju[...]

  • Page 16

    3.2.1 GENERATOR SPECIFICATIONS MODEL GPS 12500 GPS 15000 Model # 004451-1 004582-1 Rated Max. Power 12.5 kW 15.0 kW Surge Power 18.75 kW 22.5 kW Rated AC Voltage 120/240 120/240 Rated Max AC Load Current @ 240V 52.0 Amps 62.5 Amps Current @ 120V 104.0 Amps 125.0 Amps Rated Frequency 60 Hz @ 3600 RPM Phase Single Phase Rated DC Voltage 12 Volts Rate[...]

  • Page 17

    15 3.3 GENERAL RECOMMENDATIONS The warranty of the generator does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain the generator as instructed in this manual. Some adjustments will need to be made periodically to properly maintain the generator. All adjustm[...]

  • Page 18

    16 3.3.6 REPLACING THE SPARK PLUG Use Champion RC14YC spark plug or equivalent. The correct air gap is 0.76 mm (0.030 in.). Replace the plug once each year . This will help your engine start easier and run better. 1. Stop the engine and pull the spark plug wire off of the spark plug. 2. Clean the area around the spark plug and remove it from the cy[...]

  • Page 19

    Figure 21 - Spark Arrestor 3.6 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation, you should adjust the valve clearance in the engine. Important: If you feel uncomfortable about doing this procedure or you don't have the proper tools, please take your generator in to the nearest service center to have the valve clearance adjusted[...]

  • Page 20

    18 Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System 3.7 GENERAL The generator should be started at least once every seven days and be allowed to run at least 30 minutes. If this cannot be done and you must store the unit for more than 30 days, use the following information as a guide to prepare it for storage. ?[...]

  • Page 21

    18 Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System 3.7 GENERAL The generator should be started at least once every seven days and be allowed to run at least 30 minutes. If this cannot be done and you must store the unit for more than 30 days, use the following information as a guide to prepare it for storage. ?[...]

  • Page 22

    Figure 21 - Spark Arrestor 3.6 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation, you should adjust the valve clearance in the engine. Important: If you feel uncomfortable about doing this procedure or you don't have the proper tools, please take your generator in to the nearest service center to have the valve clearance adjusted[...]

  • Page 23

    16 3.3.6 REPLACING THE SPARK PLUG Use Champion RC14YC spark plug or equivalent. The correct air gap is 0.76 mm (0.030 in.). Replace the plug once each year . This will help your engine start easier and run better. 1. Stop the engine and pull the spark plug wire off of the spark plug. 2. Clean the area around the spark plug and remove it from the cy[...]

  • Page 24

    15 3.3 GENERAL RECOMMENDATIONS The warranty of the generator does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain the generator as instructed in this manual. Some adjustments will need to be made periodically to properly maintain the generator. All adjustm[...]

  • Page 25

    3.2.1 GENERATOR SPECIFICATIONS MODEL GPS 12500 GPS 15000 Model # 004451-1 004582-1 Rated Max. Power 12.5 kW 15.0 kW Surge Power 18.75 kW 22.5 kW Rated AC Voltage 120/240 120/240 Rated Max AC Load Current @ 240V 52.0 Amps 62.5 Amps Current @ 120V 104.0 Amps 125.0 Amps Rated Frequency 60 Hz @ 3600 RPM Phase Single Phase Rated DC Voltage 12 Volts Rate[...]

  • Page 26

    2.12 CHARGING A BATTERY  DANGER! Storage batteries give off explosive hydrogen gas while recharging. An explosive mixture will remain around the battery for a long time after it has been charged. The slightest spark can ignite the hydrogen and cause an explosion. Such an explosion can shatter the battery and cause blindness or other serious inju[...]

  • Page 27

    12 • Move engine CHOKE knob to “Full Choke” position. Figure 17 - Full Choke Position • To start engine, press and hold the Start/Run/Stop switch in the “Start” position. The engine will crank and attempt to start. When the engine starts, release the switch to the run position. • When the engine starts, move choke knob to “1/2 Choke[...]

  • Page 28

    11 2.6.2 ADDING GASOLINE  WARNING: Never fill fuel tank indoors. Never fill fuel tank when engine is running or hot. DO NOT light a cigarette or smoke when filling the fuel tank.  Caution: Do not overfill the fuel tank. Always leave room for fuel expansion. • Use regular UNLEADED gasoline with the generator engine. Do not use premium gasoli[...]

  • Page 29

    10 2.5 WATTAGE REFERENCE GUIDE Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts *Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . .1700 *Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . .3800 *Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . .6000 Battery Charger (20 Amp) . . . . . . . . . . . . [...]

  • Page 30

    2.3 HOW TO USE THE GENERATOR If you have any problems operating your generator, please call the generator helpline at 1-800-333-1322. 2.3.1 GROUNDING THE GENERATOR The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground . Local electrical cod[...]

  • Page 31

    Figure 9 - 120 VAC, 30 Amp Receptacle Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker. 2.2.4 120/240V AC, 30 AMP RECEPTACLE Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4-wire grounded c[...]

  • Page 32

    30 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No. 0E0227B 2.2 CORD SETS AND CONNECTION PLUGS 2.2.1 AC, 20 AMP, DUPLEX RECEPTACLE This is a 120 Volt outlet protected against overload by a 20 Amp push-to-reset circuit breaker. Use each socket to power 120 Volt AC,[...]

  • Page 33

    ITEM PART NO. QTY. DESCRIPTION 1 087968 1 SWITCH, ROCKER -/0 2 090418 1 OUTLET, 12VDC SNAP 3 0D6640 1 COVER, GOVERNOR CONTROL 4 090987 6 SCREW PPHM M3-0.5 X 12 5 0D2502 1 PANEL, SHEET METAL 6 068868 2 OUTLET 30A 120V RECEPT 7 022985 2 WASHER FLAT #6 8 043182 10 WASHER LOCK M3 9 051714 6 NUT HEX M3-0.5 G8 10 075207A 4 CIRCUIT BREAKER 30A 11 075207 2[...]

  • Page 34

    5 1.2.3 BATTERY CONNECTION • The battery shipped with the generator has been provided fully charged. Caution must be taken when connecting the battery. • Cut the tie wrap cable holding the RED and BLACK battery cables to the stator. • Connect the RED battery cable to the battery Positive terminal (+). After making sure that the connection is [...]

  • Page 35

    1.1 UNPACKING • Set the palleted carton on a rigid flat surface. • Remove staples along bottom of carton that fasten carton to pallet. Open carton from top. • Remove all packaging material. • Remove separate accessory box. • Lift carton off the generator. • Remove generator from shipping pallet by removing bolts through the shipping bra[...]

  • Page 36

    3  ELECTRICAL HAZARDS  • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages as does the generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure [...]

  • Page 37

    2 • Never start or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON. Start the engine and let it stabilize before connecting electrical loads. Disconnect all electrical loads before shutting down the generator. • Do not insert objects through unit's cooling slots. • Never operate generator[...]

  • Page 38

    INTRODUCTION Thank you for purchasing this model of the GUARDIAN ® product line by Generac Power Systems, Inc. This model is a compact, high performance, air-cooled, engine driven generator designed to supply electrical power to operate electrical loads where no utility power is available. READ THIS MANUAL THOROUGHLY If you do not understand any p[...]

  • Page 39

    Owner’ s Manual • SAFETY • ASSEMBLY • OPERATION • TROUBLESHOOTING • ELECTRICAL DATA • PARTS • WARRANTY 1-800-333-1322 UL TRA SOURCE Portable Generator COMMERCIAL • INDUSTRIAL • RESIDENTIAL MODELS: 004 4 51 (12,500 W A TT) 004582 (15,000 W A TT) AUTHORIZED DEALER SUPPORT: GENERAC POWER SYSTEMS, INC. P.O. Box 297 • Whitewater, W[...]

  • Page 40

    Owner’ s Manual • SAFETY • ASSEMBLY • OPERATION • TROUBLESHOOTING • ELECTRICAL DATA • PARTS • WARRANTY 1-800-333-1322 UL TRA SOURCE Portable Generator COMMERCIAL • INDUSTRIAL • RESIDENTIAL MODELS: 004 4 51 (12,500 W A TT) 004582 (15,000 W A TT) AUTHORIZED DEALER SUPPORT:[...]