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Generac 004583-0 Portable Generator User Manual

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1. HOlH31X3 Q Y a SLIHM H ES i 3O AH3S NIVW LD A 1 5 37002 HO WOOL H j SO I Sa lt gt OG gt ew aaridans uawoisno inl l n H 3104 097 Adiswovd 13110 E 55 5 8 A r mm ID 9 NMOHS SV 3OV1d OLNI L UD ES H3NIVL3H 25 e gt Fd 30V1d303H HOJVH3N39 2116 OLNI 9n1d 09 B um un SHOLONGNOD iH 1 un Sinodo F T N UD AONADH I SLNN 3HIM ONISN f XQ8 LJINI S1InOHIS ISNOH OL p A 3GO2 1v201 3009 219199719 WNOLLWN 02 VddN LIIW 15 Jos 5 HAWOLSNO OLLON ALVIGSWHYALNI MOTI TIIM H LON31 QHOO H3MOd SV SV 38 5 HOLIVH3N39 3HVS HOA Section 7 Notes Residential Portable Generator System NOTES 27 Section 8 Electrical Data ELECTRICAL Commercial Industrial Residential Portable Generator System DATA Wiring Diagram UltraSource Portable Generator Drawing 060731 180 840V 120 240V 504 604 OUTLET 120V 30A 120V 30A 30A TWISTLOK TWISTLOK TWISTLOK
2. NEUTRAL BAR CIRCUIT 16 CPNK YEL z CIRCUIT 14 gt CIRCUIT 12 CDRG YEL CIRCUIT 10 CGRY YEL CIRCUIT 8 VID YEL I CIRCUIT 6 VID gt CIRCUIT 4 DRG WHT CIRCUIT 2 e CRED gt IN 1 BLK UTRA lt WHT iei i UTROL CWT MEX TROC WHT UTRAL Chie um Seis mc ade Se cu IT 1 CWHT UT RAL m RII Tama Us CIRC or CIR gt suu rrr om Cr cm cm mm C gt 31 CG urs Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System 0 Manual Transfer Switch with Load Center Drawing 0G0939 B 2 Qn WEN 10 32 Section 9 Exploded Views Parts Lists i usss Commercial Industrial Residential Portable Generator System Manual Transfer Switch with Load Center Drawing No 0G0939 B 0 0 QTY DESCRIPTION 1 0G0749 1 BOX LOAD CENTER W HARDWARE 2 0G0748 1 CIRCUIT BREAKER INTERLOCK 3 0E7888 1 CIRCUIT BREAKER 20A 2P 4 0E7888B 5
3. Mg 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 if on Let engine run at no load for several minutes to stabilize the internal temperatures of engine and generator Move Start Run Stop switch to Off position Close 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 If 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 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 engi
4. ENGINE WIRING 1 Y 7 158 2 18 1 1 229 15 2 1 2 14 Y 167 0 3 2 167 4 167 ym SP2 1 Lt is 8 5 1 F1 eee OTT 1 1 15 0 1 1 lt 7 lt 14 Section 8 Electrical Data Commercial Industrial Residential Portable Generator System Wiring Diagram UltraSource Portable Generator Drawing No 0G0731 ELECTRICAL DATA IDLE CONTROL TRANSFORMERS ON OFF IDLE CONTROL SWITCH ELECTRONIC GOVERNOR 15 ENGINE SHUTDOWN P R1 VOLTAGE REGULATOR RECTIFIER 0 10A AUTO LEGEND 14 RESET BKR 774 BRUSH ASSEMBLY BATTERY 6AMP AUTO RESET BREAKER RECTIFIER D ENGINE SHUTDOWN DIODE D2 600V 12A DIODE F1 104 FUSE FSS FUEL SHUT OFF SOLENOID GND GROUND BAR IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 LOP LOW OIL PRESSURE Ri 25 OHM 25W RESISTOR SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SP1 SPARK PLUG CYL 1 SP2 SPARK PLUG CYL 2 SSR START STOP RELAY TB2 TERMINAL BLOCK 77 10 BATTERY CHARGE WINDING 77 Section 8 Electrical Data LECTRICAL DATA POWER WINDING BATTERY CHARGE WINDING Y Y Y Ye 7 55 66A 1 2es C1 3
5. 700 Table Saw 109 1750 10 2000 Furnace Fan 3 5 HP 875 TeleVi8l8R inesse oes ex ma 200 to 500 Door Opener 500 10 750 Toaster 1000 1650 HairDryer 1200 Weed Trimmer 500 Hand Drill 250 to 1100 Allow times the listed watts for starting these devices 2 6 BEFORE STARTING THE Above 40 F use SAE 10W 30 or SAE 30 GENERATOR Below 40 F use synthetic 5W 20 or 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 2 6 1 ADDING ENGINE OIL NOTE When adding oil to the engine crankcase in the future Place generator on a level surface use only high quality detergent oil rated with API service classification SG SH or SL SAE 30 weight Use no special Prior to operating the generator engine oil and gasoline will need to be added as follows lean area around oil fill and remove oil fill cap and dipstick additives Wipe dipstick clean Select the oils viscosity grade according to the expected Slowly fill engine with oil through the oil fill opening until it operating temperature Do not use SAE 10W 40 reaches the full mark on th
6. GUARDIAN by Generac Power Systems Inc U RA S 0 R C Owner s Manual SAFETY ASSEMBLY OPERATION TROUBLESHOOTING ELECTRICAL DATA PARTS COMMERCIAL INDUSTRIAL RESIDENTIAL WARRANTY MODEL 004583 0 17 500 Watt Portable Generator and 60 amp manual transfer switch AUTHORIZED DEALER SUPPORT with built in load center 1 800 333 1322 TABLE Table of Contents CONTENTS Residential Portable Generator System Safety Rules 1 3 Section 1 General Information 4 1 1 4 1 11 Accessory BOX u u 4 521 uc 4 1 24 Assembling the Wheel Kit 4 1 2 2 Assembling the Handle 5 1 2 3 Battery Connection 5 Section 2 Operation 6 2 1 Know The Generator 6 2 2 Sets and Connector 5 7 221 120V AC 20 A Duplex Receptacle 7 222 120V AC 20 A GFCI Receptacle 7 223 120V AC 30 Receptacle 7 8 2 2 4 120 240 AC 30 A Receptacle 8 2 2 5 12 VDC 10 Amp Receptacle 8 2 2 6 120 240V AC
7. Ot Section 2 Operation Figure 9 120 VAC 30 Amp Receptacle 120V 30A Use this receptacle to operate 120 Volt AC 60 Hz single phase loads requiring up to 3600 watts 3 6 kW of power at 30 Amps The outlet is protected by a 30 Amp push to reset circuit breaker 2 2 4 120 240V AC 30 AMP RECEPTACLE Use a NEMA L14 30 plug with this receptacle Connect a suitable 4 wire grounded cord set to the plug and to the desired load The cord set should be rated for 250 Volts AC at 30 Amps or greater Figure 10 120 240 VAC 30 Amp Receptacle 120V 240V 30A 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 or 240 Volt AC 60 Hz single phase loads requiring up to 7200 watts 7 2 kW of power at 30 Amps The outlet is protected by two 30 Amp push to reset circuit breakers Residential Portable Generator System 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 13 before attempting to recharge a battery Figure 11 12 Volt DC 10 Amp Receptacle N 2 2 6 120 240 VOLT AC 50 AMP RECEPTACLE Use the supplied NEMA 14 50 plug with this receptacle Connect a 4 wire cord s
8. neutral wire from the emergency load center Repeat for each circuit See page 31 The emergency load center in the transfer switch supplies the following circuits 5 15A 120V 5 20A 120V 1 20A 240V 1 40A 240V and 1 50A 240V ME NUS Install 60 AMP Breaker 2 x nr ry 2 11 Installthe 60 Amp double pole circuit that you have purchased into main electrical distribution panel This circuit breaker must be compatible with your main electrical distribution panel may be necessary to reposition remaining circuit breakers or remove circuit breakers that have been disconnected to accommodate the insertion of the 60 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 60 Amp double pole circuit breaker Replace electrical distribution panel cover Your GUARDIAN Ultra Source Manual Transfer Switch is now installed NOTE If additional circuits are required to be protected Generac offers and additional 30A manual transfer switch and 30A Power Inlet Kit Model 5341 This kit can be ordered direct from the factory 1 800 747 1530 Option 2 23 GUARDIAN Section 6 Operation of Generator with Manual Transfer Switch USING THE ULTRA SOURCE PORTABLE ULTRA SOURCE PORTABLE COMPONENTS The GUARDIAN ULTRA SOURCE with manu
9. 004024 0480316 0 9176 004023 005282 0860616 006313 070008 070006 049821 009911 051714 005411 005445 0D5416A 0D5398 0E6043 0D3432 045756 0D4767 0D1142A 0D1143 0F1177 022097 QTY 5 5 5 5 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System PARTS Ce LISTS GT 990 amp GT 760 Engine Page 2 Drawing No 0E8589 N 0 DESCRIPTION ITEM PART NO QTY DESCRIPTION WINGNUT AIRBOX 114 092070 4 SCREW TAPTITE M6 1 0 X 25 PRECLEANER AIR 115 0F1338B 1 ASSY IGN COIL W DIODE NO ADV ELEMENT AIR CLEANER 116 066263 1 PUMP IMPULSE STUD 6 1 0 X 73 118 0G0926 2 SCREW HHFCS M6 1 0 X 16 68 8 ADAPTOR SPIT BACK 119 060832 7 ELBOW RUBBER 90 DEG GASOLINE GASKET SPITBACK 120 07585 2 SPARKPLUG CHAMPION RC14YC BASE AIRBOX 121 0 4271 1 STARTER DELCO REMY 5080 SPRING WINTER SUMMER VALVE 122 022129 3 LOCK M8 5 16 VALVE SUMMER WINTER 123 061906 2 SCREW HHC M8 1 25 X 85 68 8 SNORKEL AIR INTAKE 124 022145 1 WASHER FLAT M8 TUBE HEAT RISER 50 8 1 125 OF5467 1 NUT HEX M8 1 25 YELLOW ZINC COVER AIRBOX 126 001131 1 GUARD FAN KNOB AIRBOX 17mm 127 0FW169B 1 HOUSING BLOWER GAS COOLER KNOB AIRBOX 95MM 128 0697635 4 GROMMET 1 4 PLUG SCREW HHC M6 1 0 X 35 129 003034 1 NUTHEX M24 WASHER LOCK M6 1 4 130 003033 1 WASHE
10. 060309 1 6 068868 2 7 061093 4 8 043182 4 9 009784 6 10 075207 4 11 075207 2 12 061493 1 13 043437 1 14 004968 1 15 004966 1 16 001004 1 17 0 6480 4 18 022471 4 19 005045 1 20 0 9719 1 21 004409 1 22 052844 1 23 0 3100 1 24 060503 1 0 7424 1 25 0234845 1 26 0 1661 2 27 048766 1 28 003550 1 29 049939 1 30 070370 1 31 030468 1 32 022158 1 33 023897 1 34 057405 1 35 022473 1 36 022097 1 37 049813 1 Section 9 Exploded Views Parts Lists Commercial Industrial Residential Portable Generator System Control Panel Drawing No 0G0727 B DESCRIPTION SWITCH ROCKER 0 OUTLET 12VDC SNAP COVER GOVERNOR CONTROL SCREW PPHM M3 0 5 X 12 PANEL SHEET METAL 15 KW PANEL SHEET METAL 17 5 KW OUTLET 30 120V RECEPT SCREW SFILHM 8 32 X 5 8 LG 17 5 KW ONLY WASHER LOCK M3 NUT HEX LOCK M3 0 5 NY INS CIRCUIT BREAKER 30A CIRCUIT BREAKER 20A OUTLET 504 250V 17 5 KW ONLY OUTLET 30A 125 250V OUTLET 20A 120V DPLX OUTLET 204 120V CIRCUIT BREAKER 50A 400V 2POLE NUT HEX M4 0 5 NYINS NUT HEX 8 32 17 5 KW ONLY DIN RAIL 59 5mm LONG ASSY PCB VREG AIR COOLED ELECTRONIC GOVERNOR IDLE CONTROLLER RELAY PNL 12VDC SPST 30A RELAY 3PDT 12VDC CONTROL PANEL BOX 15 KW CONTROL PANEL BOX 17 5 KW 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 NUT HEX
11. 50 A Receptacle 8 23 How To Use The Generator 9 2 51 Grounding The Generator 9 2 3 2 Connecting Electric 1 0 0 9 24 Don t Overload The Generator 9 25 Wattage Reference 10 26 Before Starting The Generator 10 2 6 1 Adding Engine Oil 10 2 6 2 Adding Gasoline 11 27 ToStart The Engine 11 2 8 Stopping The Engine 12 2 9 Automatic Idle 12 2 10 Cold Weather Operation De lcer 12 2 11 Low Oil Pressure 12 2111 Initial Start up 12 2 11 2 Sensing Low Oil Pressure 12 2 11 3 ite 12 2 12 Charging a Battery 13 Section 3 Maintenance 14 31 Maintenance 14 3 2 Product Specifications 14 3 2 1
12. OIL PUMP 62 004012 1 KIT BREATHER ASSEMBLY O RING 0 49 ID X 0 07 THICK 63 0D8675A 1 KITHEAD ASSEMBLY CYLINDER 1 COVER OIL RELIEF 64 0086758 1 KITHEAD ASSEMBLY CYLINDER 2 SPRING OIL RELIEF 65 004015 1 KIT OIL RELIEF BALL 1 2D OIL RELIEF WASHER LOCK RIB M6 SCREW PLASTITE HI LOW 10 CLAMP OIL TUBE PLUG CRANKCASE GOVERNOR BORE ASSEMBLY DIPSTICK WITH HANDLE TUBE DIPSTICK O RING OIL CLR SEAL 42 1 0 CRANKSHAFT Item 59 Kit includes Item 60 Kit includes Item 61 Kit includes Item 62 Kit includes Item 63 Kit includes Item 64 Kit includes Item 65 Kit includes items 3 30 35 65 items 2 5 17 18 34 35 40 57 139 153 items 8 11 12 13 items 4 5 6 items 7 41 42 43 44 45 46 47 49 50 51 52 53 54 57 58 items 41 42 43 44 45 46 47 49 50 51 52 53 54 56 57 58 items 25 26 27 35 CG urs Section 9 Exploded Views and Parts Lists 0 Commercial Industrial Residential Portable Generator System 0 07 990 amp GT 760 Engine Page 2 Drawing No 0E8589 N 80 67 68 73 74 DETAIL OF 87 36 91 92 93 94 95 97 98 99 100 102 103 104 105 106 107 108 109 110 111 112 113 PART 006592 004511 009723 0 5302 004183 006327 002774 005125 002930 0D4612A 0D6143 0D2775 0D5014A 005014 049721 022097 022473 0 8388 006021 0C9093A 0D4522 074908 0E3398 0 9035 0 8603 004026
13. SHOWN HARNESS CONTROL PANEL FRONT NOT SHOWN HARNESS TERMINAL STRIP TO PCB NOT SHOWN SPRING RETAINER PARTS Ce LISTS Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System 0 Frame Handle amp Wheel Kit Drawing No 0 0695 Detail of Battery Tray 42 ITEM NO 057058 005315 004570 0D22850SRV 045771 022129 022145 0D4565 0D3545 022287 022473 022097 022127 0388040 0 004575 005202 005199 029809 063168 005198 0 0317 027007 005303 042909 090388 064101 039214 009165 k O HHH pn DESCRIPTION SCREW 6 1 0 X 55 RUBBER TANK MOUNT CAP FUEL WITH GAUGE amp VENT KIT FUEL TANK NUT HEX 8 1 25 WASHER LOCK M8 5 16 WASHER FLAT 5 16 BRACKET BATTERY BOLT BATTERY J BOLT SCREW HHC 1 4 20 3 4 65 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 LWASH SCREW HHC 5 16 18 X 1 5 BRASS BRACKET FRONT FOOT 15 kW VIB MOUNT WASHER FLAT 2510 X 1 0D 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 Section 9 Exploded Views and Parts Lists Commercial Industrial Resi
14. You must hold the rocker arm jam nut in place as you turn the pivot ball stud Residential Portable Generator System MAINTENANCE 2S 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 Install 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 Re attach the spark plug wire to the spark plug Repeat the process for the other cylinder 17 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 AXA 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 essent
15. 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 NOTE Do not place the generator directly under a window Select an area outside of your home about 10 feet away 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 3 Hole Through House Determine where the user supplied 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 and wiring along ceiling floor joists and wall studs to the location where the conduit will pass through the wall to the exterior of the house Feed Conduit and Wires 5 From the inside of the house feed the end of the customer supplied conduit through the wall to outside Threaded Lock Nut 6 Remove the threaded lock nut from the conduit coupling 21 GUARDIAN Section 5 Installation for Manual Transfer Switch Prepare Box For Connections Knockout 7a Lift cover of the power inlet box and remove the internal cover plate screws and interna
16. operation Out of gasoline Low oil level Fault in engine Engine lacks power Load is too high Dirty air filter Engine needs to be serviced Engine hunts or falters Choke is opened too soon Carburetor is running too rich or too lean No Battery Charge DC output Battery posts are corroded Battery cable is bad Battery is defective Receptacle is bad Poor connection or defective cord set SOLUTION Reset circuit breaker Check and repair Connect another device that is in good condition Contact Authorized Service Facility Disconnect shorted electrical load See Don t Overload the Generator on 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 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 See Don t Overload the Generator page 9 Replace air filter Contact Authorized Service Facility Move choke to halfway position until engine run
17. 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 one time Note All figures are approximate See data plate on appliance for wattage requirements OPERATION Section 2 Operation Residential Portable Generator System 2 5 WATTAGE REFERENCE GUIDE i RR Running Watts Air Conditioner 12 000 Btu 1700 Device Running Watts Air Conditioner 24 000 Btu 3800 Hedge 450 Air Conditioner 40 000 Btu 6000 Impact 500 Battery Charger 20 Amp 500 Iron LT 1200 Belt Sander 3 1000 Jet PUMP 800 Chain Saw 1200 Lawn 1200 Circular Saw OBI pana 800 to 1000 Light s sassa sa San eros 100 Clothes Dryer Electric 5750 Mi
18. 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 and 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 e 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 EXPLOSION Never store generator with fuel in tank where gasoline vapors might reach an open flame spark or pilot light as on a furnace
19. 10 32 WASHER FLAT 10 RESISTOR 25R 5 25W WASHER FLAT 1 4 WASHER LOCK M6 1 4 NUT HEX M6 1 0 G8 ITEM PART NO QTY 38 065795 2 39 0D4804 2 40 001085 4 41 051715 12 8 42 022264 14 43 048505 1 44 087962 1 45 036261 2 46 0 2769 1 47 032300 1 48 028578 1 49 055444 1 50 075475 2 51 082025 6 52 0A2053 1 53 055440 2 54 045770 1 55 060923 2 005734 2 56 074908 10 57 075235 3 58 077682 2 080823 2 59 038150 14 10 60 006140 1 61 075476 2 62 027565 A R 63 058000K 2 64 0 3101 1 65 004969 1 66 0 5483 1 67 003546 1 68 005809 1 69 000615 1 PARTS LISTS er DESCRIPTION RECTIFIER BATTERY CHARGER TRANSFORMER IDLE CURRENT SCREW PPHM 3 0 5 X 8 NUT HEX M4 0 7 G8 15 KW NUT HEX M4 0 7 G8 17 5 KW WASHER LOCK M4 CIRCUIT BREAKER 6 X 1 CIRCUIT BREAKER 10 X 1 12VDC 1 4 0C RIVET POP 125 X 250 SS LUG GROUND 8 TABS HOLDER FUSE FUSE 10A X AGC10 HEATSINK SCREW PPHM M4 0 7 X 10 NUT HEX LOCK M5 0 8 NYINS SCREW HHC M6 1 0 X 65 G8 8 SCREW HHC M5 0 8 X 25 G8 8 SCREW HHC M5 0 8 X 10 G8 8 SPACER 25 X 50 X 2 5 17 5 KW SPACER 25 X 50 X 1 5 15 KW SCREW HHTT M5 0 8 X 10 SCREW PPHM M5 0 8 X 30 SCREW PPHM M5 0 8 X 80 17 5 KW SCREW PPHM M5 0 8 X 50 15 KW WASHER FLAT 8 15 KW WASHER FLAT 8 17 5 KW GASKET PORTABLE CONTROL PANEL SCREW PPHM 4 0 7 X 16 TAPE ELEC UL PERMACEL NUT TRIC M5 0 8 RELAY BASE 3PDT 12VDC OUTLET 50A 125 250V 15 KW ONLY HARNESS CONTROL PANEL BACK NOT
20. 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 take 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 e Make sure the engine is at room temperature 60 80 F Make sure that the spark plug wire is removed from the spark plug and out of the way e Remove the four screws attaching the valve cover with a 2 or 3 phillips screwdriver e 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
21. CIRCUIT BREAKER 15A 1P 5 0E7888C 5 CIRCUIT BREAKER 20A 1P 6 0E7888D 1 CIRCUIT BREAKER 40A 2P 7 0 7888 2 CIRCUIT BREAKER 504 2 8 0 7888 1 CIRCUIT 60 2 9 000863 1 HARNESS 50 AMP PLUGS 10 0G0750 1 HARNESS LOAD CENTER TO MAIN PANEL 11 061494 1 POWER INLET BOX 33 LISTS Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System GT 990 amp GT 760 Engine Page 1 Drawing No 0E8589 N 58 44 45 46 47 49 50 51 52 53 54 57 58 7 41 42 43 64 41 42 43 44 45 46 47 49 50 51 52 53 54 56 57 012 5 17 18 34 35 40 57 139 153 9 3 30 35 65 5 6 BWP PART 005729 0 9843 090388 005372 003005 0E3372B 0D8067A 071983 060693 043790A 0E2950 0E2985 021533 0E1466 0D4041 0D4788 093064 002977 005943 0 4357 0 4356 0E3223 0E3222 0D2157 0 6098 004123 0 8152 003011 003009 003010 093873 0 5458 005998 004497 0C3971E 0D3745 003027 0 9842 0 la la ap sp Section 9 Exploded Views Parts Lists Ce usss Commercial Industrial Residential Portable Generator System GT 990 8 GT 760 Engine Page 1 Drawing No 0E8589 N 0 DESCRIPTION ITEM PARTNO QTY DESCRIPTION ASSEMBLY CRANKCASE HOUSING WITH 36 005731 1 ASSEMBLY HOUSING COVE
22. EXTERNAL CONNECTION BOX MANUAL TRANSFER SWITCH AND HOME S MAIN ELECTRICAL DISTRIBUTION PANEL HOLIMS H34SNVH1 qalsi11n H3XV3H8 5 uaxvdua q3l1ddnS H3MOd HOIVH3N39 5 uawoisno 148 HOS SHIM NHH1 OMVOL 3NIT 3NIT 3HIM NHH1 DAVV8 SONILLIS LINGNOO v E HT8IX3 1 31VIQ3AH3INI HOH TVIH3 IVIW 31539905
23. 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 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 A GENERAL HAZARDS A Never operate an enclosed area or indoors For safety reasons GENERAC recommends that the maintenance of this equipment is carried out by a GENERAC 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 properly maintained You must do nothing that might render the exhaust system unsafe or in noncompliance with any local codes and or 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 cooli
24. 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 up any spilled oil 15 Section 3 Maintenance 3 3 6 REPLACING THE SPARK PLUG Use Champion RC14YC spark plug or equivalent The correct air gap is 1 01 mm 0 040 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 1 01 mm 0 040 in Install the correctly gapped spark plug into the cylinder head Figure 18 Spark Plug Gap 3 4 SERVICE AIR CLEANER Your engine will 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 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 cl
25. 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 Both 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 W
26. 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 Located on underside of control panel 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 Section 2 page 12 Circuit Breakers AC Each receptacle is provided with a push to reset circuit breaker to protect the generator against electrical overload 50 amp uses toggle reset Fuel Tank Tank holds 16 U S gallons of fuel Grounding Lug Ground the generator to an approved earth ground here See page 9 for details 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 Figure 6 Engine Control Panel ENGINE START UP START ER bol PUS UMMER above 40 F amp LIT 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 Located at rear of control pan
27. power source and shut down the generator This can be accomplished as follows 1 Switch the 50 Amp circuit breaker on the generator control panel to the OFF or Open position Release the retainer clip from the NEMA 14 50 plug and remove the plug from the outlet on the generator Twist and remove the 50 Amp female receptacle from the power inlet box Close and lock the box Coil the power cord and place it with the generator After the generator has run for a couple minutes to cool down turn off the generator Open the door of the Manual Transfer Switch and slide the mechanical interlock to turn OFF the STANDBY circuit breaker Both circuit breakers will be in the OFF position Flip the UTILITY circuit breaker handle to the ON position Close the door of the Manual Transfer Switch The Utility is now supplying power Disconnect the ground strap from the grounding rod and the generator s grounding lug Retain the ground strap with the generator Return the generator to its storage location Choose a lamp or light fixture located in a frequently occupied area of the building as a signal light to tell you when utility power has been restored This light should be on a utility powered circuit only so it operates independent of the generator Operation of Generator with Manual Transfer Switch Section 6 GUARDIAN INTERCONNECTION DRAWING ULTRASOURCE GENERATOR CONNECTED TO THE
28. 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 consequential 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 cellula
29. water heater or clothes dryer FIRE or EXPLOSION may result e Generator exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed 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 NEVER operate your generator indoors in an attached garage or near an open window SAFETY RULES AN IMPORTANT SAFETY INSTRUCTIONS Residential Portable Generator System SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted near the unit s installation site Safety should be stressed to all operators and potential operators of this equipment Never start or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON Start the engine and let it stabilize before connecting electrical loads Disconnect all electrical loads before shutting down the generator Do not insert objects through unit s cooling slots e Never operate generator in rain indoors or in any enclosed compartment if connected electrical devices overheat if electrical output is lo
30. ASAE 3634 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE Section 1 General Information INFORMATION Residential Portable Generator System GENERAL 1 1 UNPACKING Set the palleted carton on a rigid flat surface Remove staples along bottom of carton that fasten carton to pallet Open carton from top Remove all packaging material Remove separate accessory box Lift carton off the generator Remove generator from shipping pallet by removing bolts through the shipping brackets Figure 1 Bracket Removal Shipping cket x4 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 Wheel Axle e Bolt on tubular handle 2 Washers 2 Pneumatic Wheels 2 Wheel Spacers 2 Axle Bracket Assemblies e 2 Cotter Pins Foot Battery Charge Cable Spark Plug Wrench Air Filter Filter Pre cleaner e 2 Quarts Oil 26 Wire Nuts 6 Carriage Bolts Washers Nuts 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 W
31. CS 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 ECS 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 shall 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 su
32. Commercial Industrial Residential Portable Generator System Schematic UltraSource Portable Generator Drawing 0G0733 DPE WINDING 44 2 55 Ae C1 9 77 777 44 22 0 11 BCR2 Z 134 6_9 154 ELECTRONIC 1 VOLTAGE REGULATOR 5 LUP 0 rh c2 12 0 0 0 gt 0 0 F1 6 CY 13 9 1 sc 15 BATTERY c2 11 13 13 86 15B 167 T ce 9 BLACK 16 16 59 15 0 167 15 c2 8 D 17 gt 17 83 CONTROL Ll PRINTED CIRCUIT 555 0 BOARD 170 167 s 5 4 86 167 gt 167 0 22944 Ce 10 15 GOVERNOR J1 ACTUATOR 15 15 ce 2 gt 5 7 120V 120V 14 _ k 0 GFCI DUPLEX FSS J 22 22 1185 Q 120 240V 1207240V 120V 30A 120V 30A 30A 304 60 TWISTLDK TWISTLDK TWISTLOK 11 11 44A 0 L B 504 604 11 22 0 4 LEGEND BA BRUSH ASSEMBLY FSS FUEL SHUT OFF SOLENOID SCR STARTER RELAY 1 BATTERY CHARGE RECTIFIER 10A GROUND BAR SM STARTER MOTOR BCRe BATTERY CHARGE RECTIFIER LC T IDLE CONTROL TRANSFORMER SP1 SPAR
33. GER Although you may choose to perform electrical connections yourself Generac Power Systems recommends that a licensed electrician or individual with complete knowledge of electricity perform the procedures in sections 10a and 10h A DANGER Switch service main circuit breaker to OFF or 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 these wires and the service main circuit breaker connection lugs Section 5 Installation for Manual Transfer Switch GUARDIAN 9 The 2 foot conduit that is pre wired into the manual transfer switch is not fastened to the side of the enclosure when shipped To secure the conduit to the manual switch enclosure proceed as follows Remove the cover panel of the manual transfer switch with emergency load center Insert the 2 foot conduit into the knockout and tighten the lock nut securely on the inside of the enclosure UL approved wire nuts are included with installation kit 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 instal
34. Generator Specifications 14 3 2 2 Engine Specifications 14 3 8 General Recommendations 15 3 3 1 General Maintenance 15 3 3 2 Clean The 15 3 3 3 Engine Maintenance 15 3 3 4 Checking Oil Level 15 3 3 5 Changing The Oil amp Oil Filter 15 3 3 6 Replacing The Spark Plug 16 34 Service Air 16 3 5 Clean Spark Arrestor Screen 16 3 6 Adjusting Valve Clearance 17 Ort General 18 3 8 Long Term Storage 18 3 9 Other Storage 18 Section 4 Troubleshooting 19 41 Troubleshooting 19 Section 5 Installation Guide For Manual Transfer Switch 20 23 Section 6 Operation Of Generator With Manual Transfer Switch 24 26 Section 7 Notes 27 Section 9 Electrical Data 28 31 Section 9 Exploded Vie
35. HEEL 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 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 Refer to Figure 2 shown on opposite page and install the wheel kit as follows Place the generator on 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 pla
36. K PLUG CYL 1 10AMP AUTO RESET BREAKER IGNITION MODULE CYL 1 SP2 SPARK PLUG CYL 2 6AMP AUTO RESET BREAKER IGNITION MODULE CYL 2 SSR START STOP RELAY 600V DIODE LOP LOW GIL PRESSURE SW1 START RUN STOP RELAY D3 ENGINE SHUTDOWN DIODE 25 OHM 25W RESISTOR SW2 IDLE CONTROL SWITCH F1 10 FUSE SC STARTER CONTACTOR TBi TB2 TERMINAL BLOCK Section 8 Electrical Data Commercial Industrial Residential Portable Generator System Wiring Diagram Manual Transfer Switch Drawing No 061065 GROUND GRN E CIRCUIT 9 YHD x EUTRAL CIRCUIT ii CIRCUIT 1g YHP EUTRAL CIRCUIT 15 FP CIRCUIT 1 BRN CIRCUIT BRN WHT mus GROUND GRND CIRCUIT 5 CYEL2 GEN2 RED CIRCUIT 7 GEN1 BLK x CIRCUIT 9 BLU IX CIRCUIT 11 ORG CUSTOMER SUPPLIED CIRCUIT 13 BLU CIRCUIT 15 GROUND BAR mC iC iC EUTRAL BAR LOAD CENTER
37. OCK HEX M3 0 5 GT 990 SCREW M5 0 8 X 8 ZP 0E4869 2 HEX W TOOTH WASHER M3 0 5 PANEL CONTROL FACE PLATE GT 760 SCREW TAPTITE M6 1 0X 10 YELLOW 160 006147 SCREW M6 1 0 X 10mm CHROME 161 0F1338A 1 ASSY IGN COIL W DIODE NO ADV SWITCH ROCKER 162 0480316 1 HOSE BAND GREEN WRAPPER LOWER CYLINDER 2 WRAPPER UPPER CYLINDER 2 ASSEMBLY GROUND WIRE WASHER LOCK M6 1 4 37 38 PARTS Ce LISTS V V 29 ve PS Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Generator Drawing No 0D4488 F V 35 De QA lt s PEON 2 59 28 31 39 32 006934 002123 002134 002136 0D21320SRV 0D21330SRV 0D2135 006043 002492 002726 04138 0D3547 031971 003168 0D1838 0D3549 0C7038E 032712 0D4662 0070380 007758 0388050 0 0C2417A 0821216 066386 002824 0 DESCRIPTION 1 1 1 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 IHHC M8 1 25 X 400 G8 8 BRACKET ALT MOUNTING SCREW HHTT 10 32 X 1 75 SCREW HHTT M8 1 2 X 20 ENGINE MOUNTING PLATE RUBBER MO
38. R M24 WASHER FLAT 1 4 131 003032 1 PLATE FAN NUT HEX FLANGE WHIZ 6 1 0 132 0A5992 2 WASHER SHAKEPROOF INT M8 SS STUD METRIC 133 051754 2 SCREW HHC 8 1 25 X 12 08 8 HOSE BREATHER 134 003031 1 FAN NYLON CONTROLLER ASSEMBLY 135 0 4997 10 ASSYGROUND WIRE CONNECTOR SCREW M5 0 8 X 10 136 045756 4 SCREW TAPTITE M6 1X10 YELLOW ASSEMBLY WIRE CHROME CARBURETOR GT 990 137 0C3725A 1 FLYWHEEL ASSEMBLY CARBURETOR GT 760 138 70 __ 1 PLATE BACKING 07990 W OIL COOL GASKET CARB TO SPACER GT 990 139 082774 1 KEY WOODRFF 4 X 19D GASKET CARB AIRBOX GT 760 140 0030437 2 GASKET MANIFOLD PORT CLAMP HOSE BAND 1 4 141 009764 4 PLASTITE 1 4 15 X 3 4 HOSE ID 142 003026 1 COOLER OIL GASKET MANIFOLD TO CARB GT 990 143 06301 4 CLAMP HOSE OETIKER 16 5mm GASKET MANIFOLD TO CARB GT 760 144 0008066 2 HOSE 3 8 10 X 6 LONG SLEEVING 1 2 L D 145 035461 2 BARBED STR 1 4NPT X 3 8 FILTER FUEL 146 0701858 1 FILTER WASHER FLAT 8 148 003083 1 ASSEMBLY OIL DRAIN HOSE WASHER LOCK M8 149 003025 1 SWITCH OIL PRESS SCREW SHC M8 1 25 X 30 150 004550 1 BRACKET AIRBOX SUPPORT MANIFOLD INTAKE 151 003018 1 WRAPPER UPPER CYLINDER 1 NUT HEX M3 0 5 152 003019 1 WRAPPER LOWER CYLINDER 1 ROD SUMMER WINTER VALVE 153 046964 1 BRASS ST ELBOW 1 4 BUSHING MINI CONTROL PANEL 154 0 0409 1 ASSY ROD GOV STEPPER MOTOR KNOB CONTROL SUMMER WINTER 155 008568 6 SCREW 6 1 0 X12 ASSEMBLY 157 009784 2 NUT L
39. R WITH SLEEVE SLEEVE SEAL 38 1 0 CRANKSHAFT 37 003006 10 SCREW HHFC 10 1 5 X 55 SCREW TAPTITE M6 1 0 X 12 BP 38 080318 8 SCREW HHFC M6 1 0 X 25 ASSEMBLY BREATHER 39 06808 2 HOOK LIFTING GASKET BREATHER COVER 40 0027280 1 COVER ROCKER W OIL FILL GENERAC SEPARATOR OIL BREATHER TEXT ASSEMBLY HEAD 1 41 002979 2 GASKET VALVE COVER RETAINER PISTON PIN 20 42 086515 KEEPER VALVE SPRING ASSY ROCKER COVER W BARB 43 002274 4 RETAINER VALVE SPRING BARBED EL 90 3 8NPT X 3 8 W VS 44 003867 4 SPRING VALVE PISTON LC GT 990 45 078672 2 SEAL VALVE STEM 07 PISTON GT 760 46 005371 4 WASHER VALVE SPRING SET PISTON RING 90MM 47 072694 4 STUD ROCKER ARM PIVOT PIN PISTON 48 063007 2 O RING 3 8 X 1 2 ASSEMBLY CAMSHAFT amp GEAR 49 005313 4 ROCKER ARM PLUG STD PIPE 3 8 STEEL SQ HD 50 003998 4 M8 1 0 GB YELLOW CHROM ASSEMBLY OIL FILL CAP 51 006024 2 PLATE PUSH ROD GUIDE GASKET CRANK CASE 52 062976 12 SCREW M8 1 25 X 65 SEAL OIL PASSAGE 53 086516 2 VALVE EXHAUST ASSEMBLY CRANKSHAFT HORIZONTAL 54 002229 2 VALVE INTAKE DIRECT DRIVE 67 990 55 083897 4 TAPPET SOLID ASSEMBLY CRANKSHAFT HORIZONTAL 56 0080678 1 ASSEMBLY HEAD 2 DIRECT DRIVE GT 760 57 0098520 4 PUSHROD 147 ASSEMBLY CONNECTING ROD 6 990 58 0029 8 2 GASKET HEAD ASSEMBLY CONNECTING ROD 6 760 59 006008 1 KIT GEAR COVER SCREW SHC M6 1 0 X 50 68 8 60 0040100 1 KIT GASKET SCREEN OIL PICKUP 61 006007 1 KIT PISTON amp RINGS ASSEMBLY
40. Rust and or dirt in your gasoline will cause problems with the carburetor and fuel system f possible store your unit indoors and cover it to give protection from dust and dirt BE SURE TO EMPTY THE FUEL TANK lf it is 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 A DANGER NEVER cover your generator while engine and exhaust area are warm Section 4 Troubleshooting TROUBLESHOOTING Commercial Industrial Residential Portable Generator System 4 1 TROUBLESHOOTING SYMPTOM Engine is running but no AC output is available Circuit breaker is open Connected device is bad Fault in generator Short circuit in a connected load Generator is overloaded Engine speed is too slow Shorted generator circuit Engine runs good but bogs down when loads are connected Engine will not crank 10 amp fuse at rear of generator control panel has melted open Engine will not start or starts and runs rough 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 9 Excessive rich fuel mixture 10 Intake valve stuck open or closed 11 Engine has lost compression Engine shuts down during
41. UNT 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 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Generator Drawing No 0D4488 F PART NO 0A2038 022237 022511 022131 051731 022145 049820 079246 022129 022259 059637 0D5100 0D5823 008565 005833 005834 090388 022473 N A 0D5133 0D5133A 045764 0D6214 066849 PARTS 00 DESCRIPTION ANA ROA 18 12 6j WASHER FLAT 3 8 ZINC WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 1 4 65 WASHER FLAT 3 8 M10 ZINC SCREW HHC 8 1 25 X 50 68 8 WASHER FLAT 5 16 ZINC NUT LOCK HEX 8 1 25 NYLON INSERT SCREW HHC M6 1 0 X 16 WITH LOCK WASHER WASHER LOCK M8 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 M8 1 25 X 18 PANEL MUFFLER BOX BACK PANEL MUFFLER BOX END SCREW HHTT M6 1 0 X 12 WASHER FLAT 1 4 NOT USED SPARK ARRESTOR SCREEN RETAINER SPARK ARREST SCREEN SCREW M4 0 7 X 8 SHIELD RUBBER MOUNT SCREW M5 0 8 X 16 39 Commercial Industrial Residential Portable Generator System Section 9 Exploded Views and Parts Lists Control Panel Drawing No 0G0727 B LISTS 00 PARTS AX e ITEM PART NO QTY 1 087968 1 2 090418 1 3 006640 1 4 090987 6 5 008740 1
42. age 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 A 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 enters 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 e Usea damp cloth to wipe exterior surfaces clean Asoft bristle brush may be used to loosen caked on dirt oil etc Avacuum cleaner be used to pick up loose dirt and debris Low pressu
43. age 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 A 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 battery Do not use the unit to charge any 6 Volt batteries Do not use the unit to crank an engine having a discharged battery This battery charger is a pulse type designed to provide a quality charge current into the battery The voltage measured at the outlet should be 8 12 VDC This is normal and does not indicate a faulty charging system To recharge 12 Volt batteries proceed as follows 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 If the battery is equipped with vent caps make sure they are installed and are tight f necessary clean battery terminals e Connect battery charge
44. al transfer switch gives you the ability to provide power safely and conveniently to vital items in your home including hard wired items Included in the kit is a power Inlet box with built in 50 Amp twistlock male receptacle and a 15 foot electrical power cord The power cord is made up of 4 wires power black amp red neutral white and ground green At one end is the 50 Amp female receptacle which is inserted and twist locked into the power inlet box At the other end is the male connector NEMA 14 50 which plugs into the portable generator s control panel and is locked in place by the supplied spring retainer The power inlet box must be locked to ensure safety and to discourage tampering Power Inlet Box with 50 Amp Male Receptacle 12 Volt DC 2 ae Receptacle i a E E 26250 Surge Watts 9 0 UI Is CU NOM pice Wa 0 COUMERCI oJ 0 Whoo Rina p Mier Westin SOLOW SENERAS POWER SYSTEMS INC 30 w Oo NEMA 14 50 Receptacle 15 Foot Power Cord with E NEMA 14 50 90 Amp Plug and Receptacle 50 Receptacle NEMA 14 50 50 Amp Plug Section 6 of Generator with Manual Transfer Switch TRANSFER T0 GENERATOR POWER SOURCE WHEN UTILITY POWER FAILS 1 Move generator to within approximately 10 feet of the p
45. ample electric shock can still occur if a person touches charged electrical wires while standing non conducting surface such as a wood floor Section 2 Operation Figure 8 120 VAC 20 Amp GFCI Receptacle Receptacle W Outlet s B Iu Correct wiring 1 Indicator N L A 1531 TEST button t N RESET button SNOWONALSNI m AIHINOW N Outlet Testing the GFCI Test the GFCI outlet every month as follows Plug atest lamp into the receptacle 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 should 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
46. arranty 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 P O BOX 297 WHITEWATER WI 53190 Part 1 gA 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 b 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 workmanship 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
47. art No 000726 Rev 0 Printed in U S A 4 24 06
48. cable connector plug to panel receptacle identified by the words 12 VOLT D C Connect battery charge cable clamp with red handle to the positive battery terminal e 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 Section 2 Operation Residential Portable Generator System OPERATION Ot 13 Section 3 Maintenance MAINTENANCE Residential Portable Generator System gt 3 1 MAINTENANCE SCHEDULE Follow the calendar intervals More frequent service is required when operating in adverse conditions noted below Operation Maintenance Every Season Every Season Every Season Check Oil Level 4 Service Air Pre Cleaner vii Change Oil and Oil Filter Z Clean Spark Arrestor Screen 4 Adjust Valve Clearance 4 Service Air Cleaner Replace Spark Plugs 4 t Change oil after first 8 hours of operation then every season A Change oil and oil filter every month when operating under
49. ce wooden blocks under the unit Attach the front support foot to the underside of the cradle using the 3 8 carriage bolts provided Remove the shipping brackets from the cradle if you have not already done so Section 1 General Information TENET GENERAL Residential Portable Generator System INFORMATION Figure 2 Handle Assembly CAPSCREW 5 16 X 2 1 2 e FLATWASHER ISS ae A FLAT WASHER T D LOCKWASHER 5 lt SQ JAK LOCK NUT SOK 24 SPACER 15kW vl K WHEEL di x KS Ce CM _ T NS d FLAT WASHER S BW hoe 6 2 A RETAINING PIN k 2 27 Se u e UI LA ie 2d SS HANDLE J ST N ae T V CARRIAGE BOLT 3 8 X 1 ASSEMBLY CAPSCREW 5 16 X 1 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 m charged Caution must taken when connecting the battery Cut the tie wrap cable holding the RED and BLACK battery cables to the stator Negative Positive Connect the RED battery cable to the battery Positive terminal 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 termi
50. ch 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 b Ignition module Fuel controller if so equipped Mixer and its gaskets if so equipped Carburetor and its gaskets if so equipped 4 Catalytic Muffler Assembly if so equipped including Primary gas regulator if so equipped R Muffler gasket d b Exhaust manifold e LP liquid vaporizer if so equipped 5 Crankcase Breather Assembly including 2 Air Induction System including a Breather connectontube a Intake pipe manifold GenpAaclemgine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 45 Section 8 Warranty WARRANTY Commercial Industrial Residential Portable Generator System GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GUARDIAN ULTRA SOURCE 17 500 WATT GENERATOR WITH MANUAL TRANSFER SWITCH For a period of two years from the date of original sale Generac Power Systems Inc Generac warrants that its Guardian 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 rep
51. commendations 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 IMPORTANT SAFETY INSTRUCTIONS SAFETY RULES Residential Portable Generator System 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 Always reference the latest revision available for the standards listed 1 NFPA 70 ELECTRIC CODE NFPA HANDBOOK OF NATIONAL 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
52. crowave Oven 700 to 1000 Clothes Dryer Gas i eran PK MEE 700 Milk Cooler rem 1100 Clothes Washer 1150 Oil Burner on Furnace 300 Coffee Maker 1750 Oil Fired Space Heater 140 000 400 Compressor 1 HP 2000 Oil Fired Space Heater 85 000 225 Compressor 3 4 1800 Oil Fired Space Heater 30 000 Btu 150 Compressor 1 2 HP 000 1400 Paint Sprayer Airless 1 8 HP 600 Curling WOR 700 Paint Sprayer Airless handheld 150 Dehumidifier 650 0 50 10 200 Disc Sander 9 1200 Refrigerator QS 700 Edge Trinmer 500 Slow 200 Electric 400 Submersible Pump 1 1 2 2800 Electric Gun 1200 Submersible Pump 1 HP 2000 Electric Range per element 1500 Submersible Pump 1 2 HP 1500 Electric 5 1250 Sump Pump 800 to 1050 8
53. dential Portable Generator System Frame Handle amp Wheel Kit Drawing No 0 0695 ITEM PARTNO 29 30 81 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 045900 2 0D7668 2 0D4999 2 0D4044 2 0D3700 4 0D2497 1 022532 4 027028 6 0D2271 1 052762 4 051713 8 049226 4 051716 4 050190 2 078299 1 080270 1 0D5142 1 096021 2 048031C 2 0F9176 18 075763 1 075763A 1 0E0318 2 030795 2 PARTS LISTS a DESCRIPTION WASHER FLAT 3 4 15 kW 12 3 PNEUM WHEEL 3 4 AXLE 15 kW PIN COTTER 1 8 X 1 1 4 BRACKET WHEEL SPACER NUT FLANGE M6 1 0 NYLOK HANDLE SCREW HHC 5 16 18 X 2 1 2 G5 NUT LOCK HEX 5 16 18 NYLON INSERT FRAME SCREW HHC M5 0 8 X 45 G8 8 WASHER FLAT M5 WASHER LOCK M5 NUT HEX M5 0 8 WASHER FLAT 1 BUSHING TANK DEXTOR VALVE PLASTIC TANK AIR DEFLECTOR GROMMET 75 X 06 X 50 CLAMP HOSE BAND 1 4 HOSE ID BOOT BATTERY CABLE BOOT STARTER CABLE SPACER AXLE 15 kW SCREW HHC 5 16 18 X 1 43 Section 10 Warranty m Commercial Industrial Residential Portable Generator System CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System warranty on your new engine In California new off road Large Spark Ignition LSI engines must be designed built and equipped to meet the state s stringent an
54. 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 a non 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 jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury 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 re
55. e dipstick Stop filling occasionally to check oil level DO NOT OVERFILL Install dipstick Install oil fill cap and finger tighten securely 10W 30 SAE 30 Check engine oil level before starting each time thereafter Synthetic 5W 20 5W 30 F 20 0 20 32 40 60 80 100 C 30 20 10 0 10 20 30 40 Temperature Range of Expected Use 10 2 6 2 ADDING GASOLINE WARNING Never fill fuel tank indoors Never fill fuel tank when engine is running or hot DO NOT light a cigarette or smoke when filling the fuel tank A Caution Do not overfill the fuel tank Always leave room for fuel expansion Use regular UNLEADED gasoline with the generator engine Do not use premium 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 1 2 inch 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 sto
56. ean 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 authorized 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 Remove the screen retaining bracket by removing the screw Slide the spark arrestor screen out from the tail pipe Inspect 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 Figure
57. el 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 and possible overheating of wires Figure 7 120 Volt AC 20 Amp Duplex Receptacle 120V 20A 2 2 2 120V 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 Residential Portable Generator System OPERATION SEB A GFCI receptacle does NOT protect against circuit overloads short circuits or shocks For ex
58. et rated for 250 Volts AC at 50 Amps to the plug N Figure 12 120 240 VAC 50 Amp Receptacle O 120V 240V 50A Use this receptacle to operate 120 240 Volt AC 60 Hz electrical loads requiring up to 12 000 watts 12 0 kW of power This receptacle is protected by 50 Amp 2 pole circuit breaker 2 3 HOW 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 Generator Ground Lug 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 Residential Portable Generator Syste
59. 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 17 500 Model 004583 0 Rated Max Power 17 5 kW Surge Power 26 2 kW Rated AC Voltage 120 240 Rated Max AC Load Current 240V 72 9 Amps Current 120V 145 8 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 33 Displacement 992cc Spark Plug Type Champion RC14YC or Equivalent Spark Plug Gap 0 040 inch or 1 01 mm Gasoline Capacity 16 U S gallons Oil Type Summer SAE 30 or 10W 30 Winter Synthetic 5W 20 or 5W 30 Oil Capacity w Filter Change 1 5 Qts w o Filter Change 1 2 Qts Run Time Fuel 10 Hours 1 6 gallons per hour Consumption 1 2 Load 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 in the Maintenance Schedule chart on p
60. ial 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 system should be emptied before storage of 30 days or longer as follows Remove all gasoline from the fuel tank A NDANGER 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 ANCAUTION Avoid spray from spark plug holes when cranking engine nstall and tighten spark plugs Do not connect spark plug wires Clean the generator outer surfaces Check that cooling air slots and openings on generator are open and unobstructed Store the unit in a clean dry place Residential Portable Generator System 3 9 OTHER STORAGE TIPS Do not store gasoline from one season to another Replace your gasoline can if your can starts to rust
61. installation is complete Silicone caulk Fasteners to mount transfer switch connection box and plug house cord hanger Intermediate wiring from Manual Transfer Switch to the Power Inlet Box Individual wires in conduit or wiring in a jacketed cable must be sized for 50 Amp service and of construction approved by the National Electric Code and other applicable local codes 20 Section 5 Installation for Manual Transfer Switch GUARDIAN THESE INSTRUCTIONS ARE TO SERVE AS A GUIDE ONLY ANY ELECTRICAL WORK PERFORMED MUST MEET NFPA 70 NEC AND ANY LOCAL CODES THAT APPLY ll Portable Generator Placement Drill Pass Through Hole Generator should be placed as far away from house as power cord will allow It is understood that the cord should not be pulled tight and it will lay along the ground between the external connection box and generator panel External Connection 1 3 4 Diameter Hole drill hole through the sheathing and siding Fowor ord with Plu A W V ith hole saw 4 Measure the lengths of wire and conduit needed to reach the Manual Transfer Switch Allow extra length to clear the joists studs While adhering to all local electrical codes route the customer supplied conduit Ground Rod with Strap FIGURE A 1 PLAN THE LOCATION OF YOUR GENERATOR Fig A shows the GUARDIAN Ultra Source 17 5000 watt portable generator placed outside the home and
62. l cover plate Remove the knock out in the lower center of the box From the rear of the connection box feed wires into box Slip the lock nut over wires tighten securely onto conduit coupling 7b Using appropriate fasteners mount power inlet 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 Receptacle Green 4 Existing Wire 8 Connect the black red and white wires to the same color coded lugs on the back of the receptacle Failure to match wires may result in damage to generator and house wiring Strip wire insulation back 1 2 and torque lug screws to 25 in Ibs The green wire is to be stripped back 1 2 inserted into the ground lug and torque lug screw to 25 in Ibs Reinstall internal cover plate and screw Close and lock cover The power inlet box must be locked to ensure safety and to discourage tampering 9 Mounting Manual Transfer Switch 9 Locate manual transfer switch with built in emergency load center within one foot of main distribution panel The manual transfer switch should be located to the right of the 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 manual transfer switch to mounting surface with appropriate fasteners A DAN
63. lace 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 diagnostics 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
64. lation 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 manual 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 NOTE Circuits to be moved must be protected by same size breaker For example a 15 amp 120V circuit in emergency load center will replace a 15 amp 120V circuit in main panel NOTE Both grounded and ungrounded conductors for each circuit must be moved to the emergency panel and connected to to the new wiring from the emergency panel using supplied locknuts 10b 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 Trace each black hot wire connected and wire nut the white neutral wire from the same Romex cable circuit to the matching circuit number on the white
65. m OPERATION SEB 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 not 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 e If the 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
66. 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 in 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 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 E
67. nal 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 Section 2 Operation ix Residential Portable Generator System OPERATION 2 1 KNOW THE GENERATOR Read the Owner s Manual and Safety Rules before operating this generator 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 f 1 Wa H 12Vde IDLE 1 coNTRoL 110 2 a 9 50 f dok ON 120V 120V E CIRCUIT BREAKERS PUSH TO RESET 1 2 3 4 5 6 7 8 9 10 11 12 13 12 DC 10 Amp Receptacle This receptacle allows the capability to recharge a 12 volt DC storage battery with provided battery charge cables 120 Volt 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 tools and motor loads 120 Volt AC 30 Amp Locking Receptacle Supplies electrical power for the operation of 120 Volt AC 30 Amp single
68. ne 2 10 COLD WEATHER OPERATION DE ICER Under certain weather conditions temperatures below 409 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 for 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 2 12 CHARGING A BATTERY DANGER Stor
69. ng 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 he operated outdoors e When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued nspect the generator regularly and contact your nearest GENERAC Authorized Dealer for parts needing repair or replacement 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 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
70. ower inlet box Connect ground strap to the generator s grounding lug and to the grounding rod Open the door of the Manual Transfer Switch Slide the mechanical interlock connecting the 60 Amp and 50 Amp circuit breakers at the top of the panel to turn Off the Utility circuit breaker Both circuits will be in the position Flip the Standby circuit breaker handle to the On position Close the door of the Manual Transfer Switch Open the power inlet box Insert and lock the 50 Amp female receptacle into the receptacle in the external connection box Insert the 50 Amp plug into the 50 Amp NEMA 14 50 receptacle located on the underside of the generator s control panel A retaining clip is supplied on the control panel Secure the retaining clip over the end of the plug The retaining clip ensures that the plug remains in place during generator operation Before starting the generator verify the 50 Amp circuit breaker on the generator s control panel is in the Off or Open position Start the generator and allow it to warm up for a couple of minutes Switch the 50 Amp circuit breaker on the generator control panel to the ON or Closed position The generator is now supplying power to the load center circuits in the manual transfer switch GUARDIAN TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored you will want to transfer back to that
71. r 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 may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53130 P
72. rage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer See Storage page 18 Never use engine or carburetor cleaner products in the fuel tank as permanent damage may occur OPERATION BPP Section 2 Operation Residential Portable Generator System 2 7 TO START THE ENGINE A 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 e Make sure the unit is in a level position Open the fuel shut off valve Figure 15 Fuel Shut off Valve _ FUEL SHUTOFF _ Locate the Idle Control ON OFF switch on the control panel and set it to the OFF position Figure 16 Idle Control Switch IDLE CONTROL ON OFF 11 OPERATION Ot Section 2 Operation Move engine CHOKE knob to Full Choke position Figure 17 Full Choke Position 1 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
73. re 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 MAINTENANCE 2 9 Section 3 Maintenance 3 3 3 ENGINE MAINTENANCE DANGER When working on the generator always disconnect 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 Clean 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 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
74. s smoothly Contact Authorized Service Facility Clean battery posts Replace cable Check battery condition replace if defective Contact Authorized Service Facility 19 GUARDIAN Section 5 Installation for Manual Transfer Switch KIT INCLUDES 1 Power Inlet Box Pre wired with the 50 amp male receptacle this box is located outside the home where the generator will be operated 2 Pre wired Manual Transfer Switch and Emergency Load Center with 16 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 to every item requiring back up power 3 2 Pre wired Conduit for Easy Connection to the Home s Main Distribution Panel 26 UL listed wire nuts not shown TOOLS REQUIRED Drill drill bits hole saw type and length will be determined by the materials you will be drilling and cutting open end wrenches or adjustable wrenches socket wrenches or nut drivers standard and Phillips screwdrivers sledge hammer level pencil channel lock pliers wire cutters strippers and safety goggles ITEMS YOU MUST PURCHASE 60 AMP double pole circuit breaker must be the same type as in your main electrical distribution panel Ground rod 8 foot with grounding strap No 10 AWG stranded copper Padlock To lock external connection box after
75. st 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 WARNING engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm A WARNING A 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 might 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
76. 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 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 Manual and thoroughly understand all instructions before using this equipment 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 voltage that can cause extremely hazardous electrical shock Avoid contact with bare wires terminals etc Never permit any unqualified person
77. ti 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 on 2001 and later model year LSI 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 completion 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
78. ws and Parts Lists 32 43 Section 10 Warranty 44 46 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 you to special instruction about 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 serious personal injury severe property damage and or including without limitation death After this heading you can read instructions that if not strictly complied with may result in serious personal injury and 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

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