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Guardian Technologies 004582-2 manual

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Table of contents for the manual

  • Page 1

    Owner’ s Man ual • SAFETY • ASSEMBL Y • OPERA TION • TR OUBLESHOO TING • ELECTRICAL D A T A • P AR TS • W ARRANTY 1-800-333-1322 UL TRA SOURCE P or table Generator COMMERCIAL • INDUSTRIAL • RESIDENTIAL MODEL: 004582-2 15,000 W att P or table Generator A UTHORIZED DEALER SUPPORT :[...]

  • Page 2

    T able of Contents Commercial-Industrial-Residential P or table Generator System Safety Rules .................................................................. 1 Section 1 – General Information ................................. 4 1.1 Unpacking ............................................................................. 4 1.1.1 Accessory Box ...[...]

  • Page 3

    INTRODUCTION Thank you f or purchasing this model by Generac P ower 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 a vailab le or in place of utility due to a power outage . READ THIS MANU AL THOROUGHL Y If any po[...]

  • Page 4

    2 Nev er star t or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON. Star t the engine and let it stabilize bef ore connecting electrical loads. Disconnect all electrical loads before shutting down the generator . Do not inser t objects through unit's cooling slots. Never operate generator: indo[...]

  • Page 5

     ELECTRICAL HAZARDS  All generators cov ered by this manual produce dangerous electrical voltages and can cause f atal electr ical shoc k. Utility power delivers extremely high and dangerous v oltages as does the generator when it is in operation. Av oid contact with bare wires, ter minals , connections, etc., while the unit is running. Ensur[...]

  • Page 6

    1.1 UNP A CKING Set the palleted car ton on a rigid flat surface . Remov e staples along bottom of car ton that f asten car ton to pallet. Open car ton from top . Remov e all packaging material. Remov e separate accessory box. Lift car ton off the generator . Remov e generator from shipping pallet by remo ving bolts through the shipping brack ets ([...]

  • Page 7

    5 1.2.3 B A TTER Y CONNECTION The battery shipped with the generator has been provided fully charged. Caution must be taken when connecting the battery . NO TE: A battery may lose some of it’ s charge when not in use for prolonged periods of time. Cut the tie wrap cable holding the RED and BLA CK batter y cables to the stator . Connect the RED ba[...]

  • Page 8

    6 Section 2 – Operation Commercial-Industrial-Residential P or table Generator System 2.1 KNO W THE GENERA T OR Read the Owner’ s Manual and Safety Rules before operating this generator . Compare the generator to Figures 4 through 6 to become f amiliarized with the locations of various controls and adjustments. Save this manual f or future refe[...]

  • Page 9

    2.2 CORD SETS AND CONNECTION PLUGS 2.2.1 120 V A C, 20 AMP , DUPLEX RECEPT A CLE This is a 120 V olt outlet protected against overload by a 20 Amp push-to-reset circuit breaker (Figure 7). Use each sock et to power 120 V olt AC , single phase, 60 Hz electrical loads requiring up to a combined 2400 watts (2.4 kW) or 20 Amps of current. Use only high[...]

  • Page 10

    Use this receptacle to operate 120 V olt 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 break er . 2.2.4 120/240 V A C, 30 AMP RECEPT A CLE Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4- wire grounded cord set to the plug and to t[...]

  • Page 11

    Proper gr ounding of the generator will help prevent electrical shock in the e vent of a ground f ault condition in the generator or in connected electrical devices. Proper grounding also helps dissipate static electricity , which often builds up in ungrounded de vices. 2.3.2 CONNECTING ELECTRICAL LO ADS DO NO T connect 240 V olt loads to 120 V olt[...]

  • Page 12

    2.6 BEFORE ST AR TING THE GENERA T OR Prior to operating the generator , engine oil and gasoline will need to be added, as follo ws: 2.6.1 ADDING ENGINE OIL NO TE: When adding oil to the engine crankcase in the future, use only high quality detergent oil rated with API service classification SG, SH or SL SAE 30 weight. Use no special additives. 5W-[...]

  • Page 13

    2.7 T O ST ART THE ENGINE  Never start or stop engine with electrical devices plug ged into the receptacles AND devices turned on. Unplug all electrical loads from the unit's receptacles before star ting the engine. Make sure the unit is in a le vel position. Open the fuel shut-off valv e (Figure 15). Figure 15 - Fuel Shut-off V alve Locate[...]

  • Page 14

    2.9 A UT OMA TIC IDLE CONTR OL This feature is designed to g reatly improv e fuel economy . When this switch is turned “ On , ” the engine will only run at its normal fast gov er ned engine speed when electrical load is connected. When the load is remov ed, the engine will run at a reduced speed of 2100 RPM. With the s witch “ Off , ” the e[...]

  • Page 15

    13 Section 3 — Maintenance Commercial-Industrial-Residential P or table Generator System 3.2.1 GENERA T OR SPECIFICA TIONS MODEL GPS 15,000 Model # 004582-2 Rated Max. Po wer 15.0 kW Surge Po wer 22.5 kW Rated AC V oltage 120/240 Rated Max A C Load Current @ 240V 62.5 Amps Current @ 120V 125.0 Amps Rated F requency 60 Hz @ 3600 RPM Phase Single P[...]

  • Page 16

    14 Section 3 — Maintenance Commercial-Industrial-Residential P or table Generator System 3.3 GENERAL RECOMMEND A TIONS The warranty of the gener ator does not cover items that ha ve been subjected to operator abuse or negligence . T o receive full v alue from the warranty , the operator must maintain the gener ator as instructed in this manual. S[...]

  • Page 17

    15 Section 3 — Maintenance Commercial-Industrial-Residential P or table Generator System 3.3.6 REPLA CING THE SP ARK PLUG Use Champion RC14YC spark plug or equivalent. The correct air gap is 1.01 mm (0.040 in.) (Figure 18). Replace the plug once each year . This will help the engine star t easier and run better . 1. Stop the engine and pull the s[...]

  • Page 18

    3.6 ADJUSTING V AL VE CLEARANCE After the first 50 hours of operation, check the v alve clearance in the engine and adjust if necessary . Important: If feeling uncomf or table about doing this procedure or the proper tools are not av ailable, please tak e the generator to the nearest service center to have the v alve clearance adjusted. This is a v[...]

  • Page 19

    Section 3 — Maintenance Commercial-Industrial-Residential P or table Generator System 17 3.8 LONG TERM ST ORA GE It is impor tant to pre vent gum deposits from f or ming in essential fuel system par ts such as the carb uretor , fuel hose or tank during storage. Also , experience indicates that alcohol-blended fuels (called gasohol, ethanol or met[...]

  • Page 20

    Section 4 — T roubleshooting Commercial-Industrial-Residential P or table Generator System 4.1 TROUBLESHOO TING GUIDE PROBLEM CA USE CORRECTION Engine is running, but no A C output is av ailable. 1. Circuit breaker is open. 2. Poor connection or def ective cord set. 3. Connected device is bad. 4. Fault in gener ator . 1. Reset circuit breaker . 2[...]

  • Page 21

    19 19 Section 5 — Electrical Data Electrical Schematic – Drawing No. 0G0733[...]

  • Page 22

    20 Section 5 — Electrical Data Wiring Diagram – Drawing No. 0G0731[...]

  • Page 23

    21 Section 5 — Electrical Data Wiring Diagram – Drawing No. 0G0731[...]

  • Page 24

    22 Section 6 — Exploded Views and Parts Lists Handle, Frame & Wheel Kit – Drawing No. 0E0695-B[...]

  • Page 25

    23 Section 6 — Exploded Views and Parts Lists Handle, Frame & Wheel Kit – Drawing No. 0E0695-B ITEM P AR T NO . QTY . DESCRIPTION 1 057058 4 SCREW HHC M6-1.0 X 55 2 0D5315 4 R UBBER T ANK MOUNT 3 0D4570 1 CAP , FUEL WITH GAUGE & VENT 4 0D22850SR V 1 KIT , FUEL T ANK 5 045771 4 NUT HEX M8-1.25 6 022129 10 W ASHER LOCK M8-5/16 7 022145 14[...]

  • Page 26

    24 Section 6 — Exploded Views and Parts Lists Control P anel – Drawing No. 0G0727-B[...]

  • Page 27

    25 Section 6 — Exploded Views and Parts Lists Control P anel – Drawing No. 0G0727-B ITEM P AR T NO . QTY . DESCRIPTION 1 087968 1 SWITCH, ROCKER -/0 2 090418 1 OUTLET , 12VDC SNAP 3 0D6640 1 CO VER, GOVERNOR CONTR OL 4 090987 6 SCREW PPHM M3-0.5 X 12 5 0D8740 1 P ANEL, SHEET MET AL (15 KW) 0G0309 1 P ANEL, SHEET MET AL (17.5 KW) 6 068868 2 OUTL[...]

  • Page 28

    26 Section 6 — Exploded Views and Parts Lists Generator – Drawing No. 0G0742-A[...]

  • Page 29

    27 Section 6 — Exploded Views and Parts Lists Generator – Drawing No. 0G0742-A ITEM P AR T NO . QTY . DESCRIPTION 1 0C6934 1 AD APTOR, ENGINE 2 0G1177 1 ST A T OR 15KW 0D2136 ST A TOR 17.5KW 3 0G11760SRV 1 ASSEMBL Y , ROT OR WITH F AN 15KW 0D21350SR V ASSEMBL Y , ROT OR WITH F AN 17.5KW 4 0C6043B 1 CARRIER, REAR BEARING 5 0D2492 1 EXHA UST MANI[...]

  • Page 30

    28 Section 6 — Exploded Views and Parts Lists GT -760/990 Engine – Drawing No. 0E8589-W - Part 1[...]

  • Page 31

    27 29 Section 6 — Exploded Views and Parts Lists GT -760/990 Engine – Drawing No. 0E8589-W - Part 1 ITEM P AR T NO . QTY . DESCRIPTION 1 0C5729 1 ASSEMBL Y , CRANKCASE HOUSING WITH SLEEVE 2 0E9843 1 SEAL, 38 I.D . CRANKSHAFT 3 090388 3 SCREW , T APTITE M6-1.0 X 12 BP 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER CO VER 6 0E3372[...]

  • Page 32

    30 Section 6 — Exploded Views and Parts Lists GT -760/990 Engine – Drawing No. 0E8589-W - Part 2[...]

  • Page 33

    31 Section 6 — Exploded Views and Parts Lists GT -760/990 Engine – Drawing No. 0E8589-W - Part 2 ITEM P AR T NO . QTY . DESCRIPTION 66 0D6592 1 WINGNUT , AIRBOX 67 0D4511 1 PRECLEANER, AIR 68 0D9723 1 ELEMENT , AIR CLEANER 69 0E5302 1 STUD M6-1.0 X 73 70 0D4183 1 AD APTOR, SPIT BA CK 71 0D6327 1 GASKET , SPITBACK 72 0D2774B 1 BASE, AIRBOX 73 0D[...]

  • Page 34

    32 CALIFORNIA EMISSION CONTROL W ARRANTY ST A TEMENT Y OUR W ARRANTY RIGHTS AND OBLIGA TIONS The Calif or nia Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to e xplain the Emission Control System warr anty on your ne w engine. In California, new off-road Large Spark-Ignition (LSI) engines must be designed, b uilt[...]

  • Page 35

    33 EMISSION CONTROL SYSTEM W ARRANTY Emission Control System W arranty (ECS warr anty) for 2001 and later model y ear LSI engines: (a) Applicability: This warranty shall apply to 2001 and later model y ear engines. The ECS W arranty period shall begin on the date the new engine or equipment is purchased by/deliv ered to its or iginal, end-use purch[...]

  • Page 36

    Section 7 – Warranty Commercial-Industrial-Residential P or table Generator System P ar t No . 0G1086 Rev . C Printed in U.S .A. 03/27/07 GENERA C PO WER SYSTEMS “TWO YEAR” LIMITED W ARRANTY FOR GU ARDIAN ® “15,000 W A TT POR T ABLE GENERA T OR” For a period of two y ears from the date of original sale, Generac P ower Systems, Inc. (Gene[...]