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Guardian Technologies 5209 User's Manual

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2. 10 Section 5 Installation Guide For 2 6 1 Adding Engine Oil 10 Generator Ready Kit 20 23 2 6 2 Adding Gasoline 11 27 To Start The 6 ctc Drei 11 Section 6 Operation Of Generator With 2 8 Stopping The 0906 12 Generator Ready Kit 24 26 2 9 Automatic Idle Control 12 Section 7 Notes 27 2 10 Cold Weather Operation De Icer 12 2 11 Low DII Pressure 12 Section 8 Electrical Data 28 29 2 11 1 Initial Start up 12 2 11 2 Sensing Low Oil Pressure 12 241 3 Restarting eenia 12 Section 9 Views and 2 12 Charging a 13 0 39 Section 108 Warranty 40 42 We also strongly recommend instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency CAUTION Always disconnect spark plug wire and place the wire where it cannot contact the spark plug to prevent accidental starting when setting up transporting adjusting or making repairs to your generator The generator produces dangerously high voltag
3. X is M m vor K YOTISIML vor 2671971 0231 2981 1 HOLIMS 10H1NOO 3701 ZMS AVIY dOLS NDE LHVIS IMS AYTAY 4015 18618 HSS 246 oma 145 3 18015 WS AVT3H HOLOVINOO 310 18 HOS HOIOVINOO 0S HOISIS3H MSZ WHO 58 18 3unss3ud 401 NOLLINSI ZI 2110011 0 1800 0012705 440 1nHS 136 554 3sna VOL ld 30010 NMOGLNHS 3NISN3 3001A A009 OLNY dWYS 280 13939 13539 dAVOL L89 9 9 Y31411934 311 8 1HOS A18W3ssv va anaon voz 9 voz ol 0 9 G EN 65 1 0 0 5 1949 xaana d 5 f oa l gt 4 Section 8 Electrical Data Schematic Drawing No 0E0229 A Commercial Industrial Residential Portable Generator System Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System GT 990 8 GT 760 Engine Page 1 Drawing No 0E8589 J 0
4. 400 Electric 1200 Electric Range element 1500 Electric 5 1250 8261 ad ede 700 Furnace Fan 3 5 HP 875 Garage Door Opener 500 10 750 Halt Bonnets eee 1200 Hand Drill crei eat at ctt 250 to 1100 2 6 BEFORE STARTING THE GENERATOR Prior to operating the generator engine oil and gasoline will need to be added as follows 2 6 1 ADDING ENGINE OIL NOTE When adding oil to the engine crankcase in the future use only high quality detergent oil rated with API service classification SF or SG SAE 30 weight Use no special additives Select the oil s viscosity grade according to the expected operating temperature Do not use SAE 10W 40 F 20 0 20 32 40 60 80 100 30 20 10 0 10 20 30 40 Temperature Range of Expected Use 10 OPERATION BPP Section 2 Operation Figure 15 Fuel Shut off Valve onc OFF FUEL SHUTOFF Locate the Idle Control ON OFF switch the control panel and set it to the OFF position Figure 16 Idle Control Switch IDLE CONTROL ON OFF 11 Residential Portable Generator System 2 6 2 ADDING GASOLINE WARNING Never fill fuel tank indoors Never fill fuel ta
5. 6317 41 42 43 44 45 46 47 40 50 51 52 53 24 27 58 64 41 42 43 44 45 46 47 49 50 51 52 53 54 56 57 58 6214 5 6 65 25 26 27 PARTS 66 LISTS 60 2 5 17 18 34 35 40 57 139 153 59 3 30 35 65 61 8 11 12 13 30 PARTS 96 DESCRIPTION ASSEMBLY HOUSING COVER WITH SLEEVE SCREW HHFC M10 1 5 X 55 SCREW M6 1 0 X 25 HOOK LIFTING ROCKER COVER GASKET VALVE COVER KEEPER VALVE SPRING RETAINER VALVE SPRING SPRING VALVE SEAL VALVE STEM D7 WASHER VALVE SPRING STUD ROCKER ARM PIVOT O RING 3 8 X 1 2 ROCKER ARM NUT HEX M8 1 0 GB YELLOW CHROME PLATE PUSH ROD GUIDE SCREW 8 1 25 65 VALVE EXHAUST VALVE INTAKE TAPPET SOLID ASSEMBLY HEAD 2 PUSHROD 147 GASKET HEAD KIT GEAR COVER KIT GASKET KIT PISTON amp RINGS KIT BREATHER ASSEMBLY KIT HEAD ASSEMBLY CYLINDER 1 KIT HEAD ASSEMBLY CYLINDER 2 KIT OIL RELIEF 1 5 0 2 065731 0C3006 080318 0C8808 0 2981 0 2979 086515 0D2274 0D3867 078672 0C5371 072694 0 3027 005313 003998 006024 0 2976 086516 0 2229 083897 0D8067B 010985310 0C2978 0D6008 0D4010 0D6007 0D4012 0D8675A 0D8675B 0D4015 ITEM PART NO QTY 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 Item 59 Kit includ
6. GUARDIAN 277 ULTRA SOURCE Semi Automatic Emergency Generator Owner s Manual SAFETY ASSEMBLY e OPERATION e TROUBLESHOOTING e ELECTRICAL DATA 2 WARRANTY WARRANTY COMMERCIAL gt INDUSTRIAL RESIDENTIAL MODEL 005209 15 000 WATT GENERATOR AND 100 AMP TRANSFER SWITCH WITH BUILT IN LOAD CENTER AUTHORIZED DEALER SUPPORT 1 800 333 1322 Table of Contents TABLE OF CONTENTS Residential Portable Generator System Safety 65 1 3 Section 3 Maintenance 14 Section 1 General Information 4 3 1 Maintenance Schedule 14 13 Unpacking 4 3 2 Product 14 1 311 Accessory 00 4 3 2 1 Generator Specifications 14 4 1 2 1 Assembling the Wheel 4 3 3 General Recommendations 15 12 2 Assembling the Handle 5 3 31 General 15 1 23 Battery Connection 5 3 3 2 To Clean The 15 3 3 3 Engine Maintenance 15 Section 2 Operation 6 3 3 4 Checking Oil Level 0 15 3
7. 12 G8 8 FAN NYLON ASSY GROUND WIRE CONNECTOR SCREW TAPTITE 6 1 10 YELLOW CHROME FLYWHEEL ASSEMBLY PLATE BACKING GT990 WITH REG CUTOUT KEY WOODRUFF 4 X 19D GASKET MANIFOLD PORT PLASTITE 1 4 15 X 3 4 COOLER OIL CLAMP HOSE OETIKER 16 5mm HOSE 3 8 I D X 6 LONG BARBED STR 1 4NPT X 3 8 OIL FILTER NIPPLE 3 4 16 UNF ASSEMBLY OIL DRAIN HOSE SWITCH OIL PRESS BRACKET AIRBOX SUPPORT WRAPPER UPPER CYLINDER 1 WRAPPER LOWER CYLINDER 1 BRASS ST ELBOW 1 4 NPT ASSY ROD GOV STEPPER MOTOR SCREW 6 1 0 X12 NUT LOCK HEX M3 0 5 GT 990 NUT HEX W TOOTH WASHER M3 0 5 GT 760 WASHER FLAT 44 GT 990 WASHER FLAT 44 GT 760 SPACER ROD GT 760 ONLY SCREW HHFC M6 1 0 X 10mm ASSY IGN COIL W DIODE NO ADV 33 PART NO QTY 4 1 1 2 2 1 2 1 3 2 1 1 1 1 A gt RD gt N 092079 0 1338 0 4147 022264 006142 005399 0 7585 0 4271 022129 061906 022145 045771 001131 0 1169 0 9763 0 3034 3 02 0A5992 051754 0 3031 07 045756 0 3725 0F1170C 082774 003043 0C9764 0 3026 0 6301 0 9806 035461 070185B 0 7292 003083 0 3025 004550 0 3018 0 3019 046964 0 0409 0 8563 009784 0 4869 031879 0 4868 006098 006147 0 1338 114 115 116 117 118 119 120 121 122 123 124 125
8. 21 22 23 24 25 26 27 28 29 30 31 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System 0 Frame Handle amp Wheel Kit Drawing 0 0695 Detail of Battery Tray 38 PARTS wor 6 DESCRIPTION WASHER FLAT 3 4 15 kW WASHER FLAT 3 4 12 5 kW 12 3 PNEUM WHEEL 3 4 AXLE 15 kW 10 PNEUM WHEEL 3 4 AXLE 12 5 kW PIN COTTER 1 8 X 1 1 4 BRACKET WHEEL SPACER NUT FLANGE 6 1 0 NYLOK HANDLE SCREW HHC 5 16 18 X 2 1 2 G5 NUT LOCK HEX 5 16 18 NYLON INSERT FRAME SCREW 5 0 8 45 8 WASHER FLAT M5 WASHER LOCK M5 NUT HEX 5 0 8 WASHER FLAT 1 BUSHING TANK DEXTOR VALVE PLASTIC TANK AIR DEFLECTOR GROMMET 75 X 06 X 50 CLAMP HOSE BAND HOSE ID BOOT BATTERY CABLE BOOT STARTER CABLE SPACER AXLE 15 kW SCREW HHC 5 16 18 X 1 39 2 N 5 045900 045900 007668 002495 004999 004044 003700 002497 022532 027028 002271 052762 051713 049226 051716 050190 078299 080270 005142 096021 048031 030340 1 075763 0757638 08 030795 ITEM PART 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Frame H
9. 0D3547 1 031971 1 0 3168 3 001838 1 003549 4 0 7038 1 032712 4 0D4662 1 0C7038D 1 067758 6 0388050 1 2417 1 082121 1 066386 1 0 2824 1 1 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Control Panel Drawing No 0E0227 C 36 PARTS 20 ITEM PART NO QTY DESCRIPTION NUT HEX 10 32 WASHER FLAT 0 RESISTOR 25R 5 25W WASHER FLAT 1 4 WASHER LOCK M6 1 4 NUT HEX M6 1 0 G8 RECTIFIER BATTERY CHARGER TRANSFORMER IDLE CURRENT SCREW 0 5 X 8 NUT HEX M4 0 7 G8 WASHER LOCK M4 CIRCUIT BREAKER 6 X 1 CIRCUIT BREAKER 10 X 1 12VDC 1 4 QC RIVET POP 125 X 129 133 30 LUG GRND 8 TABS HOLDER FUSE FUSE 10A X AGC10 HEATSINK SCREW 4 0 7 X 10 SCREW HHC 5 0 8 X 16 8 SCREW HHC M6 1 0 X 65 G8 8 SCREW 5 0 8 X 25 8 SCREW HHC 5 0 8 X 10 G8 8 SPACER 25 X 50 X 1 5 SCREW HHTT 5 0 8 X 10 SCREW PPHM 5 0 8 X 30 SCREW PPHM 5 0 8 X 50 WASHER FLAT 8 GASKET PORTABLE CONTROL PANEL SCREW 4 0 7 X 16 TAPE ELEC UL PERMACEL NUT TRIC 5 0 8 RELAY BASE 3PDT 12VDC 37 022158 023897 057405 022473 022097 049813 065795 0D4804 0C1085 051715 022264 048505 087962 AH aco 036261 0 2769 032300 028578 055444 075475 049815 0A2053 055440 045770 0D5734 074908 075235
10. 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 157 158 159 160 161 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System GT 990 amp GT 760 Engine Page 2 Drawing No 0E8589 J DESCRIPTION WINGNUT AIRBOX PRECLEANER AIR ELEMENT AIR CLEANER STUD M6 1 0 X 73 ADAPTOR SPIT BACK GASKET SPITBACK BASE AIRBOX SPRING WINTER SUMMER VALVE VALVE SUMMER WINTER SNORKEL AIR INTAKE TUBE HEAT RISER 50 8 COVER AIRBOX KNOB AIRBOX 17mm KNOB AIRBOX 95MM SCREW HHC 6 1 0 35 WASHER LOCK 6 1 4 WASHER FLAT 1 4 NUT HEX FLANGE WHIZ 6 1 0 STUD METRIC HOSE BREATHER CONTROLLER ASSEMBLY SCREW HHTT M5 0 8 X 10 ASSEMBLY WIRE CARBURETOR GT 990 CARBURETOR GT 760 GASKET CARB TO SPACER GT 990 GASKET CARB AIRBOX GT 760 CLAMP HOSE BAND 1 4 HOSE ID GASKET MANIFOLD TO CARB GT 990 GASKET MANIFOLD TO CARB GT 760 SLEEVING 1 2 FILTER FUEL WASHER FLAT M8 WASHER LOCK M8 SCREW SHC 8 1 25 30 MANIFOLD INTAKE NUT HEX M3 0 5 ROD SUMMER WINTER VALVE BUSHING MINI CONTROL PANEL KNOB CONTROL SUMMER WINTER CHOKE ASSEMBLY SCREW 5 0 8 X 8 ZP PANEL CONTROL FACE PLATE SCREW TAPTITE M6 1 0X 10 YELLOW CHROME SWITCH ROCKER WRAPPER LOWER CYLINDER 2 WRAPPER UPPER CYLINDER 2 ASSE
11. PCR 1 fo J AXLE m 0 4 aw lt HANDLE j FRONT FOOT x CARRIAGE BOLT 3 8 X 1 CAPSCREW 5 16 X 1 1 1 ASSEMBLY JN gt LOCK WASHER LOCK NUT FLAT WASHER 1 2 3 BATTERY CONNECTION Figure 3 Battery Connections The battery shipped with the generator has been provided fully charged Caution must be taken when connecting the battery Negative Positive e Cut the tie wrap cable holding the RED and BLACK battery Cable cables to the stator 1 75 Connect the RED battery cable to the battery Positive terminal 2 After making sure that the connection is tight slip the rubber boot over the terminal connection Connect the BLACK battery cable to the battery Negative terminal Make sure the connection is tight Double check all connections to ensure they are in the correct location and secure See Figure 3 at right 12 Volt DC 10 Amp Receptacle This receptacle allows the capability to recharge a 12 volt DC storage battery with provided battery charge cables 120 Volt AC 20 Amp Duplex Receptacle Supplies electrical power for the operation of 120 Volt AC 20 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 120 Volt AC 20A Duplex GFCI Receptacle Supplies ground fault protected electrical power for operation of 120 volt AC 20 amp single phase 60 Hz electric lighting appliances
12. cece REC CR Re 800 Lawn MOWER 1200 Light Bulb RE E TCR E s 100 Microwave Oven 700 to 1000 Milk 1100 Oil Burner on Furnace 300 Oil Fired Space Heater 140 000 400 Oil Fired Space Heater 85 000 225 Oil Fired Space Heater 30 000 150 Paint Sprayer Airless 1 3 HP 600 Paint Sprayer Airless handheld 150 beaded Shaw eed 50 to 200 ole Sce s 700 Slow 200 Submersible Pump 1 1 2 HP 2800 Submersible Pump 1 HP 2000 Submersible Pump 1 2 HP 1500 Sump Pump 800 to 1050 Table Saw 10 1750 to 2000 Television 200 to 500 TOASTER 1000 to 1650 Weed Trimmer 500 Allow 3 times the listed watts for starting these devices Above 40 F use SAE 10W 30 or SAE 30 Below 40 F use synthetic 5W 20 5W 30 Although multi viscosity oils 5W 30 10W 30 etc improve starting in cold weather these multi viscosity oils will result in increased oil consumption when used above 32 F Check your engine oil level more frequently to avoid possible damage from running low on oil Pla
13. 240 VOLT AC 50 AMP RECEPTACLE Use a NEMA L14 30 plug with this receptacle Connect a suitable se 4 wire grounded cord set to the plug and to the desired load The Use a NEMA 14 50 plug with this receptacle Connect a 4 wire cord set should be rated for 250 Volts AC at 30 Amps or greater cord set rated for 250 Volts AC at 50 Amps to the plug Figure 10 120 240 VAC 30 Amp Receptacle Figure 12 120 240 VAC 50 Amp Receptacle 1 120V 240V a Use this receptacle to operate 120 Volt 60 Hz single phase Use this receptacle to operate 120 240 Volt AC 60 Hz electrical loads requiring up to 3600 watts 3 6 of power at 30 Amps 10805 requiring up to 12 000 watts 12 0 kW of power This or 240 Volt AC 60 Hz single phase loads requiring up to 7200 receptacle is protected by a 50 Amp 2 pole circuit breaker watts 7 2 kW of power at 30 Amps The outlet is protected by two 30 Amp push to reset circuit breakers OPERATION eps Section 2 Operation 2 3 2 CONNECTING ELECTRICAL LOADS DO NOT connect 240 Volt loads to 120 Volt receptacles DO NOT connect 3 phase loads to the generator DO NOT connect 50 Hz loads to the generator Let engine stabilize and warm up for a few minutes after starting Plug in and turn on the desired 120 or 240 Volt AC single phase 60 Hz electrical loads Add up the rated watts or amps of all loads to be connected at one time This total should no
14. 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 adjustments in the Maintenance section 3 of this manual should be made at least once each season Follow the requirements the Maintenance Schedule chart on page 14 NOTE Once a year you should replace the spark plug and replace the air filter A new spark plug and clean air filter assure proper fuel air mixture and help your engine run better and last longer 3 3 1 GENERATOR MAINTENANCE Generator maintenance consists of keeping the unit clean and dry Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust dirt moisture or any corrosive vapors Cooling air slots in the generator must not become clogged with snow leaves or any other foreign material Check the cleanliness of the generator frequently and clean when dust dirt oil moisture or other foreign substances are visible on its exterior surface CAUTION Never insert any object or tool through the air cooling slots even if the engine is not running Note DO NOT use a garden hose to clean generator Water can enter the engine fuel system and cause problems In addition if water en
15. 3 5 Changing The Oil amp Oil 15 2 1 Know The Generator 6 3 3 6 Replacing The Spark Plug 16 2 2 Cord Sets and Connector Plugs 7 34 Service Air 16 221 120V AC 20 A Duplex Receptacle 7 222 120 AC 20 A GFCI Receptacle 7 3 5 Clean Spark Arrestor Sereen 16 2 2 3 120V AC 30 A 1 8 3 6 Adjusting Valve Clearance 17 224 120 240 30 A Receptacle 8 225 12 VDC 10 Amp Receptacle 8 3 18 226 120 240V AC 50 A 8 3 8 Long Term 51018306 18 2 3 How To Use The 9 3 9 Other Storage Tips 18 2 3 1 Grounding The Generator 9 2 3 2 Connecting Electric 10808 9 Section 4 Troubleshooting 19 2 4 Don t Overload The Generator 9 41 Troubleshooting Guide 9000 19 2 5 Wattage Reference 10 2 6 Before Starting The
16. Open the fuel shut off valve Residential Portable Generator System 2 9 AUTOMATIC IDLE CONTROL 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 When the load is removed the engine will run at a reduced speed of 2100 RPM With the switch Off the engine runs at the normal fast engine speed all the time Always have the switch OFF when starting and stopping the engine 2 10 COLD WEATHER OPERATION DE ICER Under certain weather conditions temperatures below 40 F 4 C and a high dew point the engine may experience icing of the carburetor and or the crankcase breather system To eliminate this problem this generator engine is fitted with a winter summer valve this directs hot air into the carburetor during cold weather operation Always make sure the winter summer valve is in the correct location relative to the weather conditions 2 11 LOW OIL PRESSURE SHUTDOWN SYSTEM The engine is equipped with a low oil pressure sensor that shuts down the engine automatically when the oil pressure drops below 10 psi If the engine shuts down by itself and the fuel tank has enough gasoline check engine oil level 2 11 1 INITIAL START UP A delay built into the low oil shutdown system allows oil pressure to build during starting The delay allows the engine to run fo
17. disconnected to accommodate the insertion of the 70 Amp double pole circuit breaker Connect white wire to the main distribution panel neutral bar Connect solid green wire to main electrical panel ground bar Connect the black and red wires to the 70 Amp double pole circuit breaker Replace electrical distribution panel cover YOUR GUARDIAN GENERATOR READY KIT IS NOW INSTALLED 23 10b 11 NOTE Balance must be maintained when moving circuit locations from main electrical distribution panel to emergency load center Circuit breaker positions alternate buss bars vertically Circuits sharing a neutral wire should either be moved together to adjacent positions in emergency load center or not moved If you are unsure of proper procedure or if your installation differs from that described in this guide consult a licensed professional at this time 10a Remove the main electrical distribution panel cover Remove appropriate size knockout from the bottom or side of the main panel A 2 foot flexible conduit is pre wired from the transfer switch with built in load center Remove threaded lock nut from conduit coupling Feed all wires through knockout into main panel Slip lock nut over wires and tighten securely onto conduit coupling eZ WM Connection of Circuits NOTE Circuits to be moved must be protected by same size breaker For example a 15 amp 120 circuit in emergency load cent
18. socket a 1 2 wrench and a pair of pliers are the tools that will be needed for assembly of the wheel kit Note The wheel kit is not intended for over the road use e Refer to Figure 2 shown on opposite page and install the wheel kit as follows Place the generator on a hard flat surface Stand at the engine end of the unit and gently tilt the generator forward high enough to place wooden blocks beneath the cradle This will allow space to install the wheel assemblies Attach an axle bracket assembly with attached sleeve to either side of the frame Ensure the sleeve faces outward Slide the axle through the sleeves on the axle brackets Slide one wheel with flat washer to the outside and a spacer to the inside onto each end of the axle Make sure the air inflation valve on the wheel is facing outward nsert retaining pins and using pliers bend out the ends to prevent the pins from falling out of the axle Remove the wooden blocks 1 2 2 ASSEMBLING THE HANDLE Attach the handle by aligning one side of the handle on the cradle then spread the handle around the cradle and let it spring into place Secure the handle to the frame using the 5 16 hex head bolts provided Check each fastener to ensure that it is secure Using the handle lift the unit high enough to place wooden blocks under the unit Attach the front support foot to the underside of the cradle using the 3 8 carriage bolts provided e Rem
19. these wires and the service main circuit breaker connection lugs any mating plug or other wires at this time 8 Using appropriate fasteners mount external connection box over pre drilled hole to fully conceal the hole Seal around the hole and conduit with insulating material and or silicone caulk from both outside and inside of house 11b Mount External Connection Box SECTION 5 INSTALLATION GUIDE FOR GENERATOR READY KIT In your main panel remove the black hot wire from a circuit breaker that protects a circuit you want to have powered in the event of a power failure Wire nut the black wire to the matching circuit lead wire from the emergency circuit breaker from load center in the transfer switch All circuit wires are color coded and labeled for easy identification Repeat this process with remaining circuits to be powered by the generator White wires neutral in your main distribution panel should remain connected to neutral bar It is not necessary to move them The emergency load center in the transfer switch supplies the following circuits 5 15A 120V 3 20A 120V 1 20A 240V and 1 30A 240V 5 Install the 70 Amp double pole circuit breaker that you have purchased into main electrical distribution panel This circuit breaker must be compatible with your main electrical distribution panel It may be necessary to reposition remaining circuit breakers Or remove circuit breakers that have been
20. tools and motor loads 120 Volt AC 30 Amp Locking Receptacle Supplies electrical power for the operation of 120 Volt AC 30 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 120 240 Volt AC 30 Amp Locking Receptacle Supplies electrical power for the operation of 120 and or 240 Volt AC 30 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 120 240 Volt AC 50 Amp Receptacle Supplies electrical power for the operation of 120 240 Volt AC 50 Amp single phase 60 Hz welder or motor loads Air Cleaner Filters intake air as it is drawn into the engine Choke Knob Used when starting a cold engine Winter Summer Valve See Cold Weather Operation Residential Portable Generator System 1 2 3 4 5 6 7 8 9 OPERATION Ot OPERATION 2 1 KNOW THE GENERATOR Read the Owner s Manual and Safety Rules before operating this generator Section 2 Operation Compare the generator to this illustration to become familiarized with the locations of various controls and adjustments Save this manual for future reference Figure 4 Control Panel 4 6 GFCI contro 20 ON OFF 120V 120V s 20A 20A CIRCUIT BREAKERS PUSH TO RESET Section 2 page 12 10 Circuit Breakers AC Each receptacle is provided with a push to reset ci
21. 080823 038150 14 0D6140 1 a gt 075476 2 027565 A R 058000K 2 101 1 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Control Panel Drawing No 0E0227 C ITEM PART NO QTY DESCRIPTION SWITCH ROCKER 0 OUTLET 12VDC SNAP COVER GOVERNOR CONTROL SCREW PPHM M3 0 5 X 12 PANEL SHEET METAL OUTLET 30A 120V RECEPT WASHER FLAT 6 WASHER LOCK M3 NUT HEX 0 5 G8 CIRCUIT BREAKER 30A CIRCUIT BREAKER 20A OUTLET 50A 125 250V OUTLET 30A 125 250V OUTLET 20A 120V DPLX OUTLET 20 120 CIRCUIT BREAKER 50A 400V 2POLE NUT HEX 5 0 8 G8 WASHER LOCK 10 DIN RAIL 59 5mm LONG ASSEMBLY VOLTAGE REGULATOR 60HZ ELECTRONIC GOVERNOR IDLE CONTROLLER RELAY PNL 12VDC SPST 30A RELAY 3PDT 12VDC CONTROL PANEL BOX BUSHING SNAP RIVET POP 156 X 160 164 20 BLOCK TERMINAL 20A 2 X 6 X 1100V BLOCK DOUBLE ROW TERMINAL 8 POSITION RECTIFIER MSC 12A 600V WASHER MICA 203 WASHER STEP NYLON 20 087968 090418 006640 090987 008740 068868 022985 043182 051714 075207 075207 004969 043437 004968 004966 001004 051716 022152 005045 067680 004409 052844 0 0D2691 023484L 0A1661 048766 0D3550 049939 070370 030468
22. ASY CONNECTION TO THE HOME S MAIN DISTRIBUTION PANEL ITEMS YOUR MUST PURCHASE 5 DC SIGNAL HARNESS 70 AMP double pole circuit Provides signal from the ULTRA SOURCE portable breaker must be the same type generator to the transfer switch as in your main electrical 12 UL LISTED WIRE NUTS not shown Ground rod 8 foot with grounding strap No 10 AWG TOOLS REQUIRED stranded copper Drill drill bits hole saw type and length will be determined Silicone caulk by the materials you will be drilling and cutting open end wrenches or adjustable wrenches Fasteners to mount connection socket wrenches or nut drivers standard and box and automatic transfer Phillips screwdrivers sledge hammer level pencil channel lock pliers and safety goggles Power cord clamp to secure power cord at the entrance point to the external connection box SECTION 5 INSTALLATION GUIDE FOR GENERATOR READY KIT Illustration at left shows the Guardian Ultra Source 15 000 watt portable generator placed outside the home and connected to the weather protective external box The ground rod and ground strap show a suggested location only When fully installed the ground rod will not protrude above ground level 4 While adhering to all local electrical codes route the 30 foot conduit along ceiling floor joists and wall studs to the location where the conduit will pass through the wall to the exterior of the house 3 D
23. Battery is defective Receptacle is bad 9 10 Intake valve stuck open or closed 11 Engine has lost compression 4 1 TROUBLESHOOTING SYMPTOM Engine is running but no AC output is available Engine runs good but bogs down when loads are connected Engine will not crank Engine will not start or starts and runs rough Engine shuts down during operation Engine lacks power Engine hunts or falters No Battery Charge DC output SECTION 5 INSTALLATION GUIDE FOR GENERATOR READY KIT MAKES A HOME GENERATOR READY GUARDIAN GENERATOR READY KIT KIT INCLUDES 1 50 AMP PLUG ON 5FT POWER CORD Use with ULTRA SOURCE portable generator to supply power to load center THE EXTERNAL CONNECTION BOX Located outside the home where the generator will be Operated 30 FLEXIBLE CONDUIT Pre wired from the automatic transfer switch with built in 12 circuit load center for connection to the external connection box PRE WIRED AUTOMATIC TRANSFER SWITCH AND EMERGENCY LOAD CENTER WITH 12 CIRCUITS Installed within 1 foot of the home s main distribution panel This transfer switch will provide smooth and safe transition between utility and generator power Eliminates the need to run extension cords When used with a portable generator the transfer from utility to generator power will require that some manual connections are performed by the user See page 25 2 PRE WIRED CONDUIT FOR E
24. CH CONNECTOR NOTES 27 Section 7 Notes Residential Portable Generator System Section 8 Electrical Data Commercial Industrial Residential Portable Generator System Wiring Diagram Drawing No 0E0228 ELECTRICAL DATA e CLOSEST TO BEARING 4 0 STATOR 77 Lesa 15 1 15 RESET BKR E 1 OUTLET 1 4 1 20 89 4895 Ne 5 E H 1 8 ol 84811 0 2 9 HS 2 5 4 2 J 4 N 2 1 5 ax 8 55 Bs ges 8 8 38 2 A Ham 1 Dr BATTERY 4 TH Li
25. EL MUFFLER BOX BACK PANEL MUFFLER BOX END SCREW M6 1 0 12 WASHER FLAT 1 4 NOT USED SPARK ARRESTOR SCREEN RETAINER SPARK ARREST SCREEN SCREW HHTT M4 0 7 X 8 SHIELD RUBBER MOUNT SCREW HHTT M5 0 8 X 16 35 ANA RA Ga 18 12 gt ITEM PART 23 0A2038 24 022237 25 022511 26 022131 27 051731 28 022145 29 049820 30 079246 31 022129 32 022259 33 059637 34 0D5100 35 0D5823 36 0 8565 37 0D5833 38 0D5834 39 090388 40 022473 41 N A 42 0D5133 43 0D5133A 44 045764 45 0D6214 46 066849 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Generator Drawing No 0D4488 D ITEM PARTNO QTY DESCRIPTION ADAPTOR ENGINE STATOR 12 5KW STATOR 15KW STATOR 18KW ASSEMBLY ROTOR WITH FAN 12 5KW ASSEMBLY ROTOR WITH FAN 15KW ROTOR 18KW CARRIER REAR BEARING EXHAUST MANIFOLD MUFFLER GASKET EXHAUST COVER ALTERNATOR AIR IN BEARING 5 16 SPECIAL LOCK WASHER SCREW IHHC 3 8 24 X 15 50 G5 SCREW 8 1 25 400 G8 8 BRACKET ALT MOUNTING SCREW 10 32 X 1 75 SCREW 8 1 2 0 ENGINE MOUNTING PLATE RUBBER MOUNT BATTERY CABLE BLACK EARTH STRAP 3 8X 3 8 CLIP J VINYL COAT 625 ID ASSEMBLY BRUSH HOLDER SCREW TAP R 10 32 X 9 16 0C6934 1 0D2123 1 0D2134 0D2136 0D21320SRV 1 0D21330SRV 0D2135 0C6043B 1 0D2492 1 0D2726 1 004138 2
26. ERNOR BORE ASSEMBLY DIPSTICK WITH HANDLE TUBE DIPSTICK O RING OIL CLR SEAL 42 1 0 CRANKSHAFT 1 AB WO 2 2 0 6 0 5729 0 9843 090388 0 5372 0 3005 0E3372B 008067 071983 005269 043790 0 2950 0 2985 021533 0 1466 004041 004788 093064 0 2977 0 5943 0E4357E 0 4356 223 222 002157 0 6098 0D4123A 078699E 0 3011 0 3009 0 3010 093873 0 5315 0 5998 0D4497 0C3971E 0D3745 0 3027 0E9842 ITEM CI 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System GT 990 8 GT 760 Engine Page 2 Drawing No 0E8589 J PARTS Qor 32 PARTS deb 00 DESCRIPTION SCREW TAPTITE 6 1 0 25 BP ASSY IGN COIL W DIODE NO ADV PUMP IMPULSE WASHER LOCK M4 SCREW 4 0 7 X 40 ELBOW RUBBER 90 DEG SPARKPLUG CHAMPION RC14YC STARTER DELCO REMY SD80 WASHER LOCK 8 5 16 SCREW 8 1 25 X 85 G8 8 WASHER FLAT M8 NUT HEX M8 1 25 YELLOW ZINC GUARD FAN HOUSING BLOWER REPOWER L amp G NUT GROMMET 1 4 PLUG NUT HEX M24 WASHER M24 PLATE FAN WASHER SHAKEPROOF INT M8 SS SCREW HHC 8 1 25
27. MA 14 50 plug from the power cord that you have installed into the mating receptacle on the generator control panel Start the generator Let the engine stabilize and warm up for a few minutes 6 Insert the V type plug on the DC signal harness you have connected within the external connection box into the 12 volt DC receptacle on the generator control panel The insertion of this plug will send a signal to the transfer switch to shift the contactor to the standby position 7 Set the generator s 50 amp circuit breaker to its ON or closed position to send the generator power to the load center in the transfer switch Choose a lamp or light fixture located in a frequently occupied area of the house as a signal light to tell you when utility power has returned This light should be on a utility powered circuit only so it operates independent of the generator SECTION 6 OPERATION OF GENERATOR WITH GENERATOR READY KIT INTERCONNECTION DRAWING SEMI AUTOMATIC TRANSFER SWITCH CONNECTED TO THE EXTERNAL CONNECTION BOX AND HOME S MAIN ELECTRICAL DISTRIBUTION PANEL GENERAC UL LISTED PANEL BOARD TO HOUSE BRANCH CIRCUITS SPLICED USING WIRE NUTS GENERATOR READY KIT 12 CIRCUITS 708 2 POLE CIRCUIT BREAKER NEUTRAL BAR 100A OR 200A HOUSE MAIN SERVICE o GROUND EXTERNAL CUSTOMER CONNECTION PANEL 4 POSITION DEUTS
28. MBLY GROUND WIRE WASHER LOCK M6 1 4 QTY PRS gt A gt ITEM 66 006592 67 004511 68 009723 69 0 5302 70 0D4183 71 006327 72 0D2774B 73 0D5125 74 0D2930 75 0D4612A 76 0D6143 7 0D2775 78 0D5014A 79 0D5014B 80 049721 81 022097 82 022473 83 0E8388 84 006021 85 0090933 6 0D4522 87 074908 89 0 3398 90 0 2548 0 5077 91 004026 004024 92 048031C 93 030340 94 0D4023 0D5282 95 086061G 96 0D6313 97 070008 98 070006 99 049821 100 1 101 051714 102 05411 103 005445 104 0D5416A 105 8 106 3 107 2 108 045756 109 004767 110 001142 111 43 112 7 113 022097 Commercial Industrial Residential Portable Generator System Y 1 NNS o Section 9 Exploded Views and Parts Lists Generator Drawing No 0D4488 D PARTS 6 PARTS QTY DESCRIPTION WASHER FLAT 3 8 ZINC WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 1 4 G5 WASHER FLAT 3 8 M10 ZINC SCREW HHC 8 1 25 50 G8 8 WASHER FLAT 5 16 ZINC NUT LOCK HEX 8 1 25 NYLON INSERT SCREW 6 1 0 16 WITH LOCK WASHER WASHER LOCK 8 5 16 NUT HEX 5 16 18 STEEL SCREW TAPTITE 3 8 16 X 3 4 BP SHIELD MUFFLER HEAT U BOLT amp SADDLE SCREW SHC 8 1 25 X 18 PAN
29. ON Never store generator with fuel in tank where gasoline vapors might reach an open flame spark or pilot light as on a furnace water heater or clothes dryer FIRE or EXPLOSION may result Generator exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Operate this equipment only in the open air where adequate ventilation is available Allow at least 2 feet of clearance on all sides of generator or you could damage the unit Never operate the unit inside any room or enclosure where the free flow of cooling air into and out of the unit might be obstructed Review Cold Weather Operation on page 12 DANGER NEVER operate your generator indoors in an attached garage or near an open window 1 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 when utility power is unavailable due to a power outage READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual contact your nearest GENERAC GUARDIAN Authorized Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert
30. al and thoroughly understand all instructions before using this equipment IMPORTANT SAFETY INSTRUCTIONS Residential Portable Generator System SAFETY RULES AN 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 A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator A Parts of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS A For safety reasons GENERAC recommends that the installation initial start up and maintenance of this equipment is carried out by a GENERAC GUARDIAN Authorized Dealer The engine exhaust fumes contain carbon monoxide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust system must be installed properly in strict compliance with applicable codes and standards Following installation you must do nothing that might rend
31. and possible overheating of wires Figure 7 120 Volt AC 20 Amp Duplex Receptacle 120V 20A 2 2 2 120V AC 20 AMP GFCI RECEPTACLE This unit is equipped with a ground fault circuit interrupter GFCI This device meets applicable federal state and local codes A GFCI receptacle is different from conventional receptacles In the event of a ground fault a GFCI will trip and quickly stop the flow of electricity to prevent serious injury Definition Instead of following its normal safe path electricity passes through a persons body to reach the ground For example a defective appliance can cause a ground fault OPERATION Section 2 Operation 17 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 This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery See the section Charging a Battery page 12 before attempting to recharge a battery Figure 11 12 Volt DC 10 Amp Receptacle 120V 1 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 2 2 6 120
32. andle amp Wheel Kit Drawing No 0 0695 DESCRIPTION SCREW 6 1 0 55 RUBBER TANK MOUNT CAP FUEL WITH GAUGE amp VENT KIT FUEL TANK NUT HEX 8 1 25 WASHER LOCK 8 5 16 WASHER FLAT 5 16 BRACKET BATTERY BOLT BATTERY J BOLT SCREW HHC 1 4 20 X 3 4 G5 WASHER FLAT 1 4 WASHER LOCK 6 1 4 NUT HEX 1 4 20 BATTERY CABLE RED BATTERY U1 NUT WING 5 16 18 BRASS WASHER FLAT 5 16 BRASS NUT HEX 5 16 18 BRASS 5 16 SPECIAL L WASH SCREW HHC 5 16 18 X 1 5 BRASS BRACKET FRONT FOOT 15 kW BRACKET FRONT FOOT 12 5 kW VIB MOUNT WASHER FLAT 25ID X 1 OD SCREW HHC 8 1 25 X 30 SCREW HHTT M6 1 0 X 12 NUT LOCK FL 3 8 16 BOLT CARR 3 8 16 X 1 AXLE 3 4 DIA X 30 15 kW AXLE 3 4 DIA X 27 25 12 5 kW QTY AA gt gt 0 0 5 A ITEM PART 1 057058 2 0D5315 3 0D4570 4 0D22850SRV 5 045771 6 022129 7 022145 8 004565 9 003545 10 022287 11 022473 12 022097 13 022127 14 0388040 15 0D4575 16 0D5202 17 0D5199 18 029809 19 8 20 005198 21 0 0317 002498 22 027007 23 005303 24 042909 25 090388 26 064101 27 039214 28 009165 002496 Section 10 Warranty e 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 t
33. ay not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC BOX 297 WHITEWATER WI 53190 Part No 0F7573 Rev Printed in U S A 07 05
34. ce generator on a level surface Clean area around oil fill and remove oil fill cap and dipstick Wipe dipstick clean Slowly fill engine with oil through the oil fill opening until it reaches the full mark on the dipstick Stop filling occasionally to check oil level DO NOT OVERFILL Install dipstick Install oil fill cap and finger tighten securely Check engine oil level before starting each time thereafter 2 5 WATTAGE REFERENCE GUIDE Device Running Watts Air Conditioner 12 000 Btu 1700 Conditioner 24 000 Btu 3800 Conditioner 40 000 Btu 6000 Battery Charger 20 500 Belt Sander 3 cane 1000 Chain Saw 1200 Circular Saw 6 1 2 800 to 1000 Clothes Dryer Electric 5750 Clothes Dryer Gas 700 Clothes Washer 1150 Coffee Maker 1750 Compressor 1 2000 Compressor 3 4 HP 10 Compressor 1 2 HP 1400 Curling Iron 700 650 Disc Sander 99 1200 Edge Trimmer 500 Electric
35. cs performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Any Guardian Ultra Source generators used as rental or trailer mounted applications Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist Costs of normal maintenance adjustments installation and start up Steel components that are rusting due to the improper use location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequentia
36. e that can cause extremely hazardous electrical shock Avoid contact with bare wires terminals etc Never permit any unqualified person to operate or service the generator Never handle any kind of electrical cord or device while standing in water while barefoot or while hands or feet are wet Dangerous electrical shock will result The National Electric Code requires the frame and external electrically conductive parts of the generator be properly connected to an approved earth ground Local electrical codes may also require proper grounding of the generator Consult with a local electrician for grounding requirements in your area Use a ground fault circuit interrupter in any damp or highly conductive area such as metal decking or steel work Do not use worn bare frayed or otherwise damaged electrical cord sets with the generator Operate generator only on level surfaces and where it will not be exposed to excessive moisture dirt dust or corrosive vapors Gasoline is highly FLAMMABLE its vapors are EXPLOSIVE Do not permit smoking open flames sparks or heat in the vicinity while handling gasoline Avoid spilling gasoline on a hot engine Comply with all laws regulating storage and handling of gasoline Never add fuel while unit is running Do not overfill the fuel tank Always allow room for fuel expansion If tank is over filled fuel can overflow onto a hot engine and cause FIRE or an EXPLOSI
37. e time Note figures are approximate See data plate on appliance for wattage requirements Residential Portable Generator System 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 codes may also require proper grounding of the unit For that purpose generally connecting a No 10 AWG American Wire Gauge stranded copper wire to the grounding wing nut and to an earth driven copper or brass grounding rod electrode provides adequate protection against electrical shock However local codes may vary widely Consult with a local electrician for grounding requirements in your area Figure 13 Grounding the Generator Proper grounding of the generator will help prevent electrical shock in the event of a ground fault condition in the generator or in connected electrical devices Proper grounding also helps dissipate static electricity which often builds up in ungrounded devices OPERATION Section 2 Operation Residential Portable Generator System 061166 c ERR E s Running Watts Hedge Trimmer 450 Impact Wrench 500 OM e RR RR RIA X RR 1200
38. e your generator in to the nearest service center to have the valve clearance adjusted This is a very important step to insure longest life for your engine To adjust valve clearance Make sure the engine is at room temperature Make sure that the spark plug wire is removed from the spark plug and out of the way Remove the four screws attaching the valve cover with a 2 or 3 phillips screwdriver Make sure the piston is at Top Dead Center TDC of its compression stroke both valves closed To get the piston at TDC remove the intake screen at the front of the engine to gain access to the flywheel nut Use a large socket and socket wrench to rotate the nut and hence the engine While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is up as high as it can go 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 Correct clearance is 0 002 0 004 inch 0 05 0 1 mm NOTE You must hold the rocker arm jam nut in place as you turn the pivot ball stud Residential Portable Generator System 3 9 OTHER STORAGE TIPS Do not store gasoline from one season to another e Replace your gasoline can if your can starts to rust Rust and or dirt in your gasoline will cause problems with the carburetor and fuel system f possible store you
39. em should be emptied before storage of 30 days or longer as follows Remove all gasoline from the fuel tank ADANGER Drain fuel into approved container outdoors away from open flame Be sure engine is cool Do not smoke Start and run engine until engine stops from lack of fuel While engine is still warm drain oil from crankcase Refill with recommended grade Remove spark plugs and pour about 1 2 ounce 15 ml of engine oil into the cylinders Cover spark plug hole with rag Press the Start button and allow engine to crank for 2 seconds Then press the Stop button A CAUTION Avoid spray from spark plug holes when cranking engine Install and tighten spark plugs Do not connect spark plug wires lean the generator outer surfaces Check that cooling air slots and openings on generator are open and unobstructed e Store the unit in a clean dry place 18 Section 4 Troubleshooting TROUBLESHOOTING Commercial Industrial Residential Portable Generator System SOLUTION Circuit breaker is open Poor connection or defective cord set Connected device is bad Reset circuit breaker Check and repair Connect another device that is in good condition Fault in generator Contact Authorized Service Facility Short circuit in a connected load Generator is overloaded Engine speed is too slow Shorted generator circuit Disconnect shorted electrical load Don t O
40. er the system unsafe or in noncompliance with such codes and standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical to correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator The generator MUST be operated outdoors When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued Inspect the generator regularly and contact your nearest GENERAC GUARDIAN Authorized Dealer for parts needing repair or replacement e Before performing any maintenance on the generator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc 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 elec
41. er will replace a 15 amp 120V circuit in main panel cum UL approved wire nuts are included with installation kit SECTION 6 OPERATION OF GENERATOR WITH GENERATOR READY KIT GUARDIAN USING THE GENERATOR READY KIT WITH ULTRA SOURCE PORTABLE GENERATOR The GUARDIAN Generator Ready Kit gives you the ability to hook up a GUARDIAN ULTRA SOURCE portable generator to provide power Safely and conveniently to vital items in your home including hard wired items Included in the kit is a 5 foot electrical power cord and a 5 foot DC signal harness The power cord contains 4 wires black amp red neutral white and ground green wires At end are the terminal connectors At the other end is the male connector NEMA 14 50 which plugs into the GUARDIAN ULTRA SOURCE portable generator s control panel To install this option insert the terminal wire end of the power cord into the bottom of the external connection box through the conduit clamp not included from the outside Allow about an inch of the power cord insulation to enter beyond the clamp to the inside of the box Tighten clamp securely Attach ground wire green to the bottom of the box using the supplied ground screw and pre drilled hole Connect red black and white wires each to separate lug posts Make sure hold down nuts are tightened securely The 5 foot DC signal harness allows semi automatic transfer switch operation You simply attach the four pin pl
42. ers 2950 Niles Road St Joseph 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE 1 A ELECTRICAL HAZARDSA 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 all appropriate covers guards and barriers are in place before operating the generator If you must work around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local electrical codes also may require proper grounding of the generator electrical system In case of accident caused by electric shock immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use conducting implement such as a rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear
43. es items 3 30 35 65 Item 60 Kit includes items 2 5 17 18 34 35 40 57 139 153 Kit includes items 8 11 12 3 Item 61 Item 62 Kit includes items 4 5 6 Item 63 Kit includes items 7 41 42 43 44 45 46 47 49 50 51 52 58 54 57 58 Item 64 Kit includes items 41 42 43 44 45 46 47 49 50 51 52 53 54 56 57 58 Item 65 Kit includes items 25 26 27 31 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System GT 990 amp GT 760 Engine Page 1 Drawing No 0E8589 J DESCRIPTION ASSEMBLY CRANKCASE HOUSING WITH SLEEVE SEAL 38 I D CRANKSHAFT SCREW TAPTITE M6 1 0 X 12 BP ASSEMBLY BREATHER GASKET BREATHER COVER SEPARATOR OIL BREATHER ASSEMBLY HEAD 1 RETAINER PISTON PIN 20 ROCKER COVER BARBED EL 90 3 8NPT X 3 8 PISTON LC GT 990 PISTON HC GT 760 SET PISTON RING 90MM PIN PISTON ASSEMBLY CAMSHAFT amp GEAR PLUG STD PIPE 3 8 STEEL SQ HD ASSEMBLY OIL FILL CAP GASKET CRANK CASE SEAL OIL PASSAGE ASSEMBLY CRANKSHAFT HORIZONTAL DIRECT DRIVE GT 990 ASSEMBLY CRANKSHAFT HORIZONTAL DIRECT DRIVE GT 760 ASSEMBLY CONNECTING ROD GT 990 ASSEMBLY CONNECTING ROD GT 760 SCREW SHC M6 1 0 X 50 8 SCREEN OIL PICKUP ASSEMBLY OIL PUMP SLEEVE SEAMED DOWEL 10 DIA COVER OIL RELIEF SPRING OIL RELIEF BALL 1 2D OIL RELIEF WASHER LOCK RIB M6 GEROTOR OUTER CLAMP OIL TUBE PLUG CRANKCASE GOV
44. f on Let engine run at no load for several minutes to stabilize the internal temperatures of engine and generator e Move Start Run Stop switch to Off position lose fuel valve IMPORTANT Do not overload the generator Also do not overload individual panel receptacles These outlets are protected against overload with push to reset type circuit breakers amperage rating of any circuit breaker is exceeded that breaker opens and electrical output to that receptacle is lost Read Don t Overload the Generator on page 9 carefully 12 OPERATION JL 13 Section 2 Operation Residential Portable Generator System 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 injury DANGER Do not permit smoking open flame sparks or any other source of heat around a battery Wear protective goggles rubber apron and rubber gloves when working around a battery Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns If spill occurs flush area with clear water immediately Your generator has the capability of recharging a discharged 12 Volt automotive or utility style storage bat
45. hall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal components a Spark plug 1 Ignition module Fuel controller if so equipped Mixer and its gaskets if so equipped Carburetor and its gaskets if so equipped Catalytic Muffler Assembly if so equipped including Primary gas regulator if so equipped b 4 9 a Muffler gasket 0 b Exhaust manifold 5 Crankcase Breather Assembly including a Breather connection tube e LP liquid vaporizer if so equipped 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 Section 8 Warranty WARRANTY Commercial Industrial Residential Portable Generator System GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN ULTRA SOURCE 15 000 WATT GENERATOR WITH GENERATOR READY KIT For a period of two years from the date of original sale Generac Power Systems Inc Generac warrants that its Gua
46. he 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 Generac will warrant the emission control system on your engine one for the periods of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Generac will repair your engine at no cost to you for diagnosis replacement parts arid labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems 2001 and later model year 151 engines are warranted for two years as hereinafter noted If during such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the comp
47. hip which at any time during the ECS Warranty Period may cause a warranted emissions related part to fail to be identical in all material respects to the part as described in the engine manufacturer s application for certification The ECS Warranty pertains only to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be
48. ht corner of the external connection box From the rear of the connection box feed wires amp 4 pin plug into box Slip the lock nut over wires and plug and tighten securely onto conduit coupling Connect the black red and white wires to separate threaded lugs and tighten securely Fasten the green ground wire securely beneath the hex nut on the grounding A DANGER Although you may choose to perform stud at the bottom of the electrical connections yourself Generac Power Systems box Tighten securely to Inc recommends that a licensed electrician or individual ensure good contact with with complete knowledge of electricity perform the procedures in sections 10a and 10b 9 Locate automatic transfer switch with built in emergency load center within one foot of main distribution panel The automatic transfer switch can be located to the left or right of main distribution panel Hold transfer switch against the mounting surface Level the transfer switch and mark the mounting holes Drill the appropriate size pilot holes Mount the automatic transfer switch to mounting surface with appropriate fasteners Knockout ANDANGER Switch service main circuit breaker to off or NOTE THE 4 PIN PLUG WILL not be connected to open position prior to removal of cover or removal of any wiring of the main electrical distribution panel The wires connected to the service main circuit breaker remain live or hot Avoid contact with
49. ight involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If you use a procedure work method or operating technique GENERAC does not specifically recommend you must satisfy yourself that it is safe for you and others You also must make sure the procedure work method or operating technique that you choose does not render the generator unsafe SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Residential Portable Generator System 4 EXPLOSION HAZARDS A Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Gasoline is extremely EXPLOSIVE STANDARDS INDEX In the absence of pertinent standards codes regulations and laws the published information listed below may be used as a guideline for operation of this equipment NFPA 70 NFPA HANDBOOK NATIONAL ELECTRIC CODE Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE 3634 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS available from the American Society of Agricultural Engine
50. isconnect negative cable from battery Also disconnect spark plug wires from spark plug and keep wire away from spark plug 3 3 4 CHECKING OIL LEVEL See the BEFORE STARTING THE GENERATOR section on page 10 for information on checking the oil level The oil level should be checked before each use or at least every eight hours of operation Keep the oil level maintained 3 3 5 CHANGING THE OIL AND OIL FILTER Change the oil and filter after the first eight hours of operation Change the oil every 100 hours thereafter If you are running this unit under dirty or dusty conditions or in extremely hot weather change the oil more often Use the following instructions to change the oil while the engine is still warm lean area around oil drain hose and plug e Remove oil drain plug from end of hose and oil fill plug to drain oil completely into a suitable container e When oil has completely drained install oil drain plug and tighten securely Place a suitable container beneath the oil filter and turn filter counterclockwise to remove Discard according to local regulations oat gasket of new filter with clean engine oil Turn filter clockwise until gasket contacts lightly with filter adapter Then tighten an additional 3 4 turn Fill oil sump with recommended oil See Before Starting the Generator on page 10 for oil recommendations Wipe any spilled oil 15 Residential Portable Generator System
51. jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury A FIRE HAZARDS A For fire safety the generator must be operated and maintained properly Operation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is operated in accordance with the manufacturer s instructions and recommendations Do not alter the construction of generator or change controls which might create an unsafe operating condition Keep a fire extinguisher near the generator at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the standby electric system Keep the extinguisher properly charged and be familiar with its use If you have any question pertaining to fire extinguishers consult your local fire department Residential Portable Generator System 1 2 ASSEMBLY The generator requires some assembly prior to using it If problems arise when assembling the generator please call the Generator Helpline at 1 800 333 1322 1 2 1 ASSEMBLING THE WHEEL KIT The wheel kit is designed to greatly improve the portability of the generator A socket wrench with a 9 16 socket a 1 2
52. l not run properly and may be damaged if you run it using a dirty air cleaner Clean or replace the air cleaner paper filter once a year Clean or replace more often if operating under dusty conditions Clean foam pre cleaner every month or more often under dusty conditions Figure 20 Air Cleaner Pre Cleaner Base Filter 16 MAINTENANCE 2 0 Section 3 Maintenance When valve clearance is correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in Ibs torque After tightening the jam nut recheck valve clearance to make sure it did not change Figure 22 Valve Clearance Adjustment Rocker Pivot Ball Jam Nut nstall new valve cover gasket Re attach the valve cover NOTE Start all four screws before tightening or you will not be able to get all the screws in place Make sure the valve cover gasket is in place e Re attach the spark plug wire to the spark plug Repeat the process for the other cylinder 17 Residential Portable Generator System Figure 21 Spark Arrestor MUFFLER OUTLET TUBE RETAINER SPARK ARRRESTOR SCREEN RETAINING amp SCREW 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 tak
53. l or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation m
54. ld now be on To restore the flow of electricity press the Reset button on the front of the receptacle If the GFCI does not perform in this manner do not use the receptacle Contact a local service dealer This outlet is protected against overload by a 20A push to reset circuit breaker Use the outlet to power 120V AC single phase 60 Hz electrical loads requiring up to a combined 2400 watts 2 4 kW or 20 amps of current 2 2 3 120V AC 30 AMP RECEPTACLE Use a NEMA L5 30 plug with this receptacle Connect a 3 wire cord set rated for 125 Volts AC at 30 Amps or greater to the plug Residential Portable Generator System 14 Start Run Stop Switch Controls the operation of the generator 15 Oil Fill Use this point to add oil to engine 16 Fuse 10 Amp Protects the DC control circuit from overload If this fuse element has melted open the engine will not be able to crank and start 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 single phase 60 Hz electrical loads requiring up to a combined 2400 watts 2 4 kW or 20 Amps of current Use only high quality well insulated 3 wire grounded cord sets rated for 125 Volts at 20 Amps or greater Keep extension cords as short as possible preferably less than 15 feet long to prevent voltage drop
55. letion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unapproved modifications or the use of counterfeit and ox grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period B
56. nk when engine is running or hot DO NOT light a cigarette or smoke when filling the fuel tank A Caution Do not overfill the fuel tank Always leave room for fuel expansion e Use regular UNLEADED gasoline with the generator engine Do not use premium gasoline Do not mix oil with gasoline Clean area around fuel fill cap remove Slowly add unleaded regular gasoline to fuel tank Be careful not to overfill Allow about 1 2 of tank space for fuel expansion as shown here Install fuel cap and wipe up any spilled gasoline Figure 14 Fuel Tank Fuel Fuel Tank a IMPORTANT It is important to prevent gum deposits from forming in fuel system parts such as the carburetor fuel hose or tank during storage Alcohol blended fuels called gasohol ethanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer See Storage on page 18 Never use engine or carburetor cleaner products in the fuel tank as permanent damage may occur 2 7 TO START THE ENGINE WARNING Never start or stop engine with electrical devices plugged into the receptacles AND devices turned on e Unplug all electrical loads from the unit s receptacles before starting the engine Make sure the unit is in a level position
57. noted below Every Season Every Season Operation Maintenance 10 Hours 1 6 gallons per hour Check Oil Level Service Air Pre Cleaner Change Oil and Oil Filtert Clean Spark Arrestor Screen 4 Adjust Valve Clearance J Service Air Cleaner Replace Spark Plugs 4 t Change oil after first 8 hours of operation then every season Change oil and oil filter every month when operating under heavy load or in high temperatures Clean more often under dirty or dusty operating conditions Replace air cleaner parts if very dirty PRODUCT SPECIFICATIONS 3 2 1 GENERATOR SPECIFICATIONS MODEL GPS 15000 Model 004582 1 Rated Max Power 15 0 kW Surge Power 22 5 kW Rated AC Voltage 120 240 Rated Max AC Load Current 240V 62 5 Amps Current 120V 125 0 Amps Rated Frequency 60 Hz 3600 RPM Phase Single Phase Rated DC Voltage 12 Volts Rated Max DC Load Current 12 Volts 10 Amperes 3 2 2 ENGINE SPECIFICATIONS Rated Horsepower 3600 RPM 30 Displacement 992cc Spark Plug Type Champion RC14YC or Equivalent Spark Plug Gap 0 030 inch or 0 76 mm Gasoline Capacity 16 gallons Oil Type Summer SAE 30 or 10W 30 Winter Synthetic 5W 20 0 Oil Capacity w Filter Change 1 5 Qts w o Filter Change 1 2 015 Run Time Fuel Consumption 1 2 Load 14 MAINTENANCE 2 9 Section 3 Maintenance 3 3 3 ENGINE MAINTENANCE DANGER When working on the generator always d
58. orized service center at 1 800 333 1322 3 5 CLEAN SPARK ARRESTOR SCREEN The engine exhaust muffler has a spark arrestor screen Inspect and clean the screen at least once each year If unit is used regularly inspect and clean more often NOTE If you use your generator on any forest covered brush covered or grass covered unimproved land it must equipped with a spark arrestor The spark arrestor must be maintained in good condition by the owner operator Clean and inspect the spark arrestor as follows e Remove the screen retaining bracket by removing the screw e Slide the spark arrestor screen out from the tail pipe nspect screen and replace if torn perforated or otherwise damaged DO NOT USE a defective screen If screen is not damaged clean it with commercial solvent Replace the screen and the retaining bracket MAINTENANCE 2 0 Section 3 Maintenance 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 cylinder head 3 Set the spark plug s gap to 0 76 mm 0 030 in Install the correctly gapped spark plug into the cylinder head Figure 18 Spark Plug Gap 3 4 SERVICE AIR CLEANER Your engine wil
59. oth the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty service evidence must be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at one of the following addresses ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC BOX 297 WHITEWATER WI 53190 Part 1 40 Section 10 Warranty Commercial Industrial Residential Portable Generator System WARRANTY 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 1995 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 0 General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmans
60. ove the shipping brackets from the cradle if you have not already done so Section 1 General Information GENERAL INFORMATION 1 1 UNPACKING e 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 e Remove separate accessory box Lift carton off the generator Remove generator from shipping pallet by removing bolts through the shipping brackets Figure 1 Bracket Removal 1 1 1 ACCESSORY BOX Check all contents If any parts are missing or damaged locate an authorized dealer at 1 800 333 1322 Contents include e Owner s Manual Bolt on tubular handle Wheel Axle e 2 Pneumatic Wheels e 2 Axle Bracket Assemblies e 2 Washers e 2 Wheel Spacers e 2 Cotter Pins e Bolt on Foot 6 Carriage Bolts Washers Nuts Battery Charge Cable Spark Plug Wrench e 2 Spark Plugs e Air Filter e Pre cleaner Section 1 General Information GENERAL Residential Portable Generator System INFORMATION Figure 2 Handle Assembly ON CAPSCREW SWR 5 16 X 2 1 2 FLATWASHER d AN 4 4 SPACER 15kW WASHER 12 5kW 45 2 J PAS 1 WHEEL tee Ne NOT 4 FLAT WASHER 223 RETAINING PIN 20 AE do v5 KA A
61. r about 10 seconds before sensing oil pressure 2 11 2 SENSING LOW OIL PRESSURE If the system senses low oil pressure during operation the engine shuts down 2 11 3 RESTARTING If you try to restart the engine within 10 seconds after it shuts down the engine may NOT start The system needs 5 to 10 seconds to reset If you do restart the engine after such a shutdown and have not corrected the low oil pressure the engine runs for about 10 seconds as described above and then stops OPERATION Section 2 Operation 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 position until the engine runs smoothly and then to Run position If engine falters move choke knob to 1 2 Choke position until the engine runs smoothly and then to Run position Note If engine fires but does not continue to run move choke lever to Full Choke and repeat starting instructions 2 8 STOPPING THE ENGINE Shut off all loads then unplug the electrical loads from generator panel receptacles Never start or stop the engine with electrical devices plugged in and turned on Turn Off the Idle Control switch i
62. r unit indoors and cover it to give protection from dust and dirt BE SURE TO EMPTY THE FUEL TANK fitis not practical to empty the fuel tank and the unit is to be stored for some time use a commercially available fuel stabilizer added to the gasoline to increase the life of the gasoline Cover your unit with a suitable protective cover that does not retain moisture DANGER NEVER cover your generator while 4 engine and exhaust area are warm MAINTENANCE 0 9 Section 3 Maintenance 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 AA DANGER NEVER store engine with fuel in tank indoors or in enclosed poorly ventilated areas where fumes may reach an open flame spark or pilot light as on a furnace water heater clothes dryer or other gas appliance 3 8 LONG TERM STORAGE It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor fuel hose or tank during storage Also experience indicates that alcohol blended fuels called gasohol ethanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in storage To avoid engine problems the fuel syst
63. rcuit breaker to protect the generator against electrical overload 50 amp uses toggle reset 11 Fuel Tank Tank holds 16 U S gallons of fuel 12 Grounding Lug Ground the generator to an approved earth ground here See page 9 for details 13 Idle Control Switch The idle control runs the engine at normal high speeds when there is an electrical load present and runs the engine at idle low speeds when a load is not present e 12 120V 240V 50A Figure 6 Engine Control Panel ENGINE START UP START N ZONE o0 OPERATION orp A GFCI receptacle does NOT protect against circuit overloads short circuits or shocks For example electric shock can still occur if a person touches charged electrical wires while standing on a non conducting surface such as a wood floor Figure 8 120 VAC 20 Amp GFCI Receptacle Section 2 Operation Receptacle M Outlet gt Correct wiring 1 Trip Indicator 8 1531 TEST button RESET m RESET button E 5 Outlet Testing the GFCI Test the GFCI outlet every month as follows e Plug a test lamp into the receptacle e Start the generator the test lamp should be on Press the Test button located on the front of the receptacle to trip the device This should stop the flow of electricity making the lamp shut off The yellow trip indicator shou
64. rdian generator and accompanying transfer switch will be free from defects in material 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 Guardian Authorized Warranty Service Dealer is found to be defective Any equipment that the purchaser owner claims to be defective must be examined by the nearest Guardian Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Guardian Ultra Source portable generator prepackaged with transfer switch sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 100 one hundred percent transferable coverage on Labor and Part s listed proof of purchase and maintenance is required Engine All Components Alternator All Components Transfer System All Components All warranty expense allowances are subject to the conditions defined in Guardian s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Guardian Ultra Source generators that utilize non Guardian Generac replacement parts Guardian Ultra Source generators utilizing non Guardian Generac automatic transfer switches Guardian Ultra Source generators used in commercial or rental applications Repairs or diagnosti
65. repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the purchaser owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS warranty maintenance or repairs and will be provided without charge to the purchaser owner Such use shall not reduce Generac RCS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts nay not be used to modify or repair a Generac engine Such use voids this ECS Warranty and s
66. rill Pass Through Hole 1 3 4 Diameter Hole 5 From the inside of the house feed the end of the 30 foot conduit INCLUDED and pre wired from transfer switch through the wall to outside Feed Conduit and Wires 21 Portable Generator Placement p PLAN THE LOCATION OF YOUR GENERATOR NOTE Do not place the generator directly under a window Select an area outside of your home where you can easily transport the portable generator to and from Keep in mind that the generator must have free air flow for proper operation and to ensure there is no possibility for exhaust gases to build up Drive an 8 foot grounding rod into the ground to grade so that no part is exposed above ground Determine where the flexible conduit will pass through the house from inside to outside When you are certain you have clearance on each side of the wall drill a small pilot hole through the wall to mark the location Drill a 1 3 4 diameter hole through the sheathing and siding with hole saw 3 Drill Hole Through House 1 1 3 4 ia Diameter Hol B SECTION 5 INSTALLATION GUIDE FOR GENERATOR READY KIT The external connection box must be locked to ensure g Threaded Lock Nut The outer diameter safety and to discourage tampering of the threaded end is 15 16 inches pae 6 Remove the threaded lock nut from the conduit coupling 7 Remove the knock out in the lower rig
67. s that was connected within the external connection box from the 12 volt DC receptacle on the generator control panel The removal of this plug will send a signal to the transfer switch to shift the contactor back to the utility position and allow the circuits of the home to again be powered by the incoming utility Let the engine run for a minute or two at no load to stabilize the internal temperatures 4 Turn off the generator After utilizing the 5 ft electrical power cord 5 ft DC signal harness and ground strap for operation with the GUARDIAN ULTRA SOURCE portable generator you must disconnect and remove them Open the external connection box Remove the fasteners holding the Black Red White and Green wires in place Remove wires from threaded lugs and from under ground screw Replace fasteners and ground screw Loosen the cable clamp and slide the power cord out of the external connection box Disconnect the 4 pin plug from its mating half within the external connection box Remove ground strap from the generator s ground lug and from the grounding rod Store the power cord the DC signal harness and the ground strap with your GUARDIAN ULTRA SOURCE portable generator for future use TRANSFER TO GENERATOR POWER SOURCE WHEN UTILITY POWER FAILS 1 Connect ground strap 10 generator s grounding 110 and to grounding rod 2 Set the generator s 50 amp circuit breaker to its OFF Or open position 3 Insert the NE
68. t be greater than a the rated wattage amperage capacity of the generator or b circuit breaker rating of the receptacle supplying the power See Don t Overload the Generator below 2 4 DON T OVERLOAD THE GENERATOR Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and to connected electrical devices Observe the following to prevent overloading the unit Add up the total wattage of all electrical devices to be connected at one time This total should NOT be greater than the generator s wattage capacity The rated wattage of lights can be taken from light bulbs The rated wattage of tools appliances and motors can usually be found on a data plate or decal affixed to the device fthe appliance tool or motor does not give wattage multiply volts times ampere rating to determine watts volts x amps watts Some electric motors such as induction types require about three times more watts of power for starting than for running This surge of power lasts only a few seconds when starting such motors Make sure you allow for this high starting wattage when selecting electrical devices to connect to your generator 1 Figure the watts needed to start the largest motor 2 Add to that figure the running watts of all other connected loads The Wattage Reference Guide on page 10 is provided to assist you in determining how many items your generator can operate at on
69. ters the generator through cooling air slots some water will be retained in voids and crevices of the rotor and stator winding insulation Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings 3 3 2 TO CLEAN THE GENERATOR Usea damp cloth to wipe exterior surfaces clean e Asoft bristle brush may be used loosen caked on dirt oil etc Avacuum cleaner may be used to pick up loose dirt and debris Low pressure air not to exceed 25 psi may be used to blow away dirt Inspect cooling air slots and openings on the generator These openings must be kept clean and unobstructed Residential Portable Generator System To clean or replace foam pre cleaner Remove air cleaner cover then foam pre filter e Wash pre cleaner in soapy water Squeeze pre filter dry in clean cloth DO NOT TWIST Clean air cleaner cover before re installing it To clean or replace paper air filter Remove air cleaner cover then remove foam pre filter service if necessary and remove paper filter Clean paper filter by tapping it gently on a solid surface If the filter is too dirty replace it with a new one Dispose of the old filter properly Clean air cleaner cover then slip pre cleaner over filter Next insert new paper filter into the base of the air cleaner Re install air cleaner cover Note To order a new air filter please contact the nearest auth
70. tery Do not use the unit to charge any 6 Volt batteries Do not use the unit to crank an engine having a discharged battery To recharge 12 Volt batteries proceed as follows e Check fluid level in all battery cells If necessary add ONLY distilled water to cover separators in battery cells Do not use tap water e lf the battery is equipped with vent caps make sure they are installed and are tight e f necessary clean battery terminals Connect battery charge cable connector plug to panel receptacle identified by the words 12 VOLT D C e Connect battery charge cable clamp with red handle to the positive battery terminal Connect battery charge cable clamp with black handle to the negative battery terminal Start engine Let the engine run while battery recharges Engine idle control switch must be in off position for battery charging When battery has charged shut down engine Note Use an automotive hydrometer to test battery state of charge and condition Follow the hydrometer manufacturer s instructions carefully Generally a battery is considered to be at 100 state of charge when specific gravity of its fluid as measured by hydrometer is 1 260 or higher Every Season Residential Portable Generator System MAINTENANCE 2 0 3 1 MAINTENANCE SCHEDULE Section 3 Maintenance Follow the calendar intervals More frequent service is required when operating in adverse conditions
71. trical loads before shutting down the generator Do not insert objects through unit s cooling slots Never operate generator in rain in any enclosed compartment if connected electrical devices overheat if electrical output is lost if engine or generator sparks if flames or smoke are observed while unit is running if unit vibrates excessively Note Your generator is equipped with a spark arrestor muffler The spark arrestor must be maintained in effective working order by the owner operator In the State of California a spark arrestor is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands Study these SAFETY RULES carefully before installing 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 and fundamental rules or precautions 4 WARNING engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING VY This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm GENERAC cannot possibly anticipate every possible circumstance that m
72. ug to its mating plug within the external connection box At the other end is a V type connector that plugs into the 12 volt DC receptacle on the portable generator control panel Instructions for these items are detailed on the following page Page 25 CAUTION If you are connecting the 5 foot power cord after the 30 foot conduit has been connected inside of the external connection box you must match the black red and white wires to the lugs of the wires previously placed For example black to black red to red etc Failure to match wires may result in damage to generator and house wiring 5 FOOT DC SIGNAL HARNESS ULTRA SOURCE PORTABLE GENERATOR CONTROL PANEL 12 Volt DC 1111111111 T BA 125 CIRCUIT BREAKERS PUSH TO RESET 0 NEMA 14 50 lt Po Receptacle ud 9 9 iur ud EXTERNAL 90 AMP POWER PLUG 9 FOOT POWER CORD CONNECTION BOX WITH PLUG Lug Posts Bring power cord through here NEMA 14 50 Plug SECTION 6 OPERATION OF GENERATOR WITH GENERATOR READY KIT SEMI AUTOMATIC TRANSFER OPERATION USING GUARDIAN PORTABLE GENERATOR TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored you will want to transfer back to that source and shut down the generator This can be accomplished as follows 1 Set the generator s 50 amp circuit breaker to its OFF Or open position 2 Remove the V type plug on the DC signal harnes
73. verload the Generator page 9 Contact Authorized Service Facility Contact Authorized Service Facility Replace fuse with only an identical 10 amp replacement fuse Clean or replace air cleaner Fill fuel tank Drain fuel tank and fill with fresh fuel Connect wire to spark plug Dirty air cleaner Out of gasoline Stale gasoline Spark plug wire not connected to spark plug Bad spark plug Water in gasoline Overchoking Low oil level Excessive rich fuel mixture Replace spark plug Drain fuel tank fill with fresh fuel Put choke knob to No Choke position Fill crankcase to proper level Contact Authorized Service Facility 10 Contact Authorized Service Facility 11 Contact Authorized Service Facility Fill fuel tank Fill crankcase to proper level Contact Authorized Service Facility Out of gasoline Low oil level Fault in engine Load is too high Dirty air filter Engine needs to be serviced See Don t Overload the Generator page 9 Replace air filter Contact Authorized Service Facility Choke is opened too soon Move choke to halfway position until engine runs smoothly Carburetor is running too rich or too Contact Authorized Service Facility lean Clean battery posts Replace cable Check battery condition replace if defective Contact Authorized Service Facility Battery posts are corroded Battery cable is bad
74. you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows After this heading you can read instructions that if not strictly complied with will result in personal injury or property damage After this heading you can read instructions that if not strictly complied with may result in personal injury or property damage After this heading you can read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading you can read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows A This symbol points out important safety information that if not followed could endanger personal safety and or property of you and others A This symbol points out potential explosion hazard A This symbol points out potential fire hazard A This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment We strongly recommend that the operator read this Owner s Manu

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