ULTRA SOURCE Commercial, Industrial, Residential Portable Generator Owner’s Manual • Safety • Assembly • Operation • Maintenance • Troubleshooting • Electrical Data • Parts • Warranty by Generac Power Systems, Inc.
Table of Contents Commercial-Industrial-Residential Portable Generator System Safety Rules ..............................................1-3 Section 3 – Maintenance............................14 Section 1 – General Information ................4 3.1 Maintenance Schedule........................................................14 1.1 Unpacking ............................................................................4 1.1.1 Accessory Box ........................................................4 3.
INTRODUCTION Thank you for purchasing this model of the GUARDIAN® product line by Generac Power Systems, Inc. This model is a compact, high performance, air-cooled, engine driven generator designed to supply electrical power to operate electrical loads where no utility power is available. READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual, contact your nearest GENERAC/GUARDIAN® Authorized Dealer for starting, operating and servicing procedures.
IMPORTANT SAFETY INSTRUCTIONS Commercial-Industrial-Residential Portable Generator System THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted SAVE 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.
IMPORTANT SAFETY INSTRUCTIONS Commercial-Industrial-Residential Portable Generator System ELECTRICAL HAZARDS EXPLOSION HAZARDS All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages as does the generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running.
Section 1 – General Information Commercial-Industrial-Residential Portable Generator System 1.1 UNPACKING 1.2 ASSEMBLY • Set the palleted carton on a rigid flat surface. • Remove staples along bottom of carton that fasten carton to pallet. Open carton from top. 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. • Remove all packaging material. 1.2.
Section 1 - General Information Commercial-Industrial-Residential Portable Generator System Figure 2 - Handle Assembly CAPSCREW, 5/16 X 2-1/2 FLAT WASHER FLAT WASHER LOCK WASHER LOCK NUT SPACER WHEEL LOCK NUT FLAT WASHER RETAINING PIN AXLE HANDLE CARRIAGE BOLT, 3/8 X 1 FRONT FOOT ASSEMBLY CAPSCREW, 5/16 X 1 LOCK NUT 1.2.3 BATTERY CONNECTION • The battery shipped with the generator has been provided fully charged. Caution must be taken when connecting the battery.
Section 2 – Operation Commercial-Industrial-Residential Portable Generator System OPERATION 1) 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.
Section 2 – Operation Commercial-Industrial-Residential Portable Generator System Figure 8 - 120 VAC, 20 Amp GFCI Receptacle 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-toreset 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.
Section 2 – Operation Commercial-Industrial-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 12) before attempting to recharge a battery.
Section 2 – Operation Commercial-Industrial-Residential Portable Generator System 2.3.2 CONNECTING ELECTRICAL LOADS 2.3 HOW TO USE THE GENERATOR If you have any problems operating your generator, please call the generator helpline at 1-800-333-1322. 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. 2.3.
Section 2 – Operation Commercial-Industrial-Residential Portable Generator System 2.5 WATTAGE REFERENCE GUIDE Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Running Watts Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450 Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200 *Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2 — Operation Commercial-Industrial-Residential Portable Generator System 2.6.2 ADDING GASOLINE Figure 15 - Fuel Shut-off Valve ------------- WARNING ------------ ON WARNING: Never fill fuel tank indoors. Never fill fuel tank when engine is running or hot. DO NOT light a cigarette or smoke when filling the fuel tank. Caution: Do not overfill the fuel tank. OFF FUEL SHUTOFF Always leave room for fuel expansion. • Use regular UNLEADED gasoline with the generator engine.
Section 2 — Operation Commercial-Industrial-Residential Portable Generator System • Move engine CHOKE knob to “Full Choke” position. 17 - Full Choke Position 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.
Section 2 — Operation Commercial-Industrial-Residential Portable Generator System 2.12 CHARGING A BATTERY DANGER! Storage batteries give off explosive hydrogen gas while recharging. An explosive mixture will remain around the battery for a long time after it has been charged. The slightest spark can ignite the hydrogen and cause an explosion. Such an explosion can shatter the battery and cause blindness or other serious injury.
Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System 3.1 MAINTENANCE SCHEDULE Follow the calendar intervals. More frequent service is required when operating in adverse conditions noted below.
Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System 3.3.3 ENGINE MAINTENANCE 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. DANGER! When working on the generator, always disconnect negative cable from battery.
Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System Use Champion RC12YC spark plug or equivalent. The correct air gap is 0.76 mm (0.030 in.). Replace the plug once each year. This will help your engine start easier and run better. • Wash pre-cleaner in soapy water. Squeeze pre-filter dry in clean cloth (DO NOT TWIST). • Clean air cleaner cover before re-installing it. 1. Stop the engine and pull the spark plug wire off of the spark plug. 2.
Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System Figure 21 - Spark Arrestor the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change. Figure 22 - Valve Clearance Adjustment MUFFLER OUTLET TUBE Jam Nut RETAINER Pivot Ball Stud Rocker Arm Valve Stem SPARK ARRRESTOR SCREEN RETAINING SCREW 3.
Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System STORAGE 3.9 OTHER STORAGE TIPS: 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.
Section 4 — Troubleshooting Commercial-Industrial-Residential Portable Generator System 4.1 TROUBLESHOOTING PROBLEM CAUSE SOLUTION Engine is running, but no AC output is available. 1. Circuit breaker is open. 2. Poor connection or defective cord set. 3. Connected device is bad. 4. Fault in generator. 1. Reset circuit breaker. 2. Check and repair. 3. Connect another device that is in good condition. 4. Contact Authorized Service Facility. Engine runs good but bogs down when loads are connected. 1. 2.
Section 5 — Notes Commercial-Industrial-Residential Portable Generator System 20
Section 5 - Notes Commercial-Industrial-Residential Portable Generator System 21
0 0 44 SP2 D 22 G BLACK + D 12V BATTERY - IM2 IM1 0 LOP 11D 11 0 0 SM 14 86 STOP RUN (START) 0 SC GOVERNOR ACTUATOR IC RED FSS 30A C.B. 0 0 17 0 15 22 13 13 11C 16 0 0 15 PIN # 12 11 10 13 15 0 16 15 13 15 167 14 0 15 9 0 22 22 17 11 5 4 2 86 22 8 7 6 5 4 3 2 1 20A C.B. 167 3 1 HOT SP1 ENGINE WIRING 30A C.B. 22 G TWISTLOK WHITE 120V/20A DUPLEX 85 30 87a 87 LINE SCR 0 WHITE 11 20A C.B.
77 229 83 86 167 TR1 15B TR2 0 83 TB1 6 6 15B 4 44S 4 5 11S 3 0 162 1 2 C1-8 J1 J2 CONTROL PRINTED CIRCUIT BOARD 12 11 10 9 8 7 6 5 4 3 2 1 44S 15B 229 167 11S 0 ELECTRONIC VOLTAGE REGULATOR 77 86 77A TB2 229 0 0 86 44S 66 66A 5 0 15 15 12 10 9 4 6 18 14 15B 66 C1-4 C1-9 55 66A 77 10A BATTERY CHARGE WINDING C1-3 55A C1-10 C1-5 77A 15 13 SSR 14 229 66 77 15 14 83 167 15 4 18 162 66A BLK 13A 44 RED BCR1 I.C.T.
Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System 10 15 2 55 57 24 52 46 45 38 40 25 3 39 33 37 36 35 34 3 32 31 27 26 29 30 3 24 41 42 43 44 22 23 21 28 47 49 50 19 51 20 53 54 17 56 14 13 18 58 12 8 11 9 16 1 7 3 6 5 4 GT-990 & GT-760 Engine (Page 1) – Drawing No.
Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E0034 ITEM PART NO. QTY.
26 74 73 69 68 81 82 149 153 146 147 88 DETAIL "A" 87 86 67 66 80 85 143 144 37 150 75 71 72 145 89 70 83 143 140 151 79 142 84 141 100 77 92 90 91 78 139 107 101 93 76 92 93 136 135 110 137 103 104 102 105 138 109 106 152 108 94 97 98 99 95 96 129 130 131 134 108 147 108 132 157 121 117 133 158 128 122 123 125 126 108 127 156 157 114 115 114 DETAIL "A" 155 116 119 118 120 124 155 101 113 112 113 154 156 111 Sectio
Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E0034 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.
Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator – Drawing No.
Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator – Drawing No. 0D4488 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.
30 2 1 5 60 43 42 44 41 9 8 56 21 3 11 8 14 10 6 23 20 63 9 18 17 12 40 59 39 13 15 42 46 27 41 26 8 42 59 42 41 9 28 17 55 41 59 16 19 8 18 41 22 25 7 34 35 37 36 4 33 45 17 42 18 50 53 31 32 30 49 29 54 51 47,48 17 52 4 18 58 24 38 61 62 57 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No.
Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No. 0E0227 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.
32 6 7 11 12 13 9 14 15 35 50 POWER WIRE TO ENGINE Detail of Battery Tray 10 34 7 8 49 5 45 17 18 17 19 16 17 20 46 25 44 47 38 39 43 3 7 24 22 21 48 6 36 42 5 6 7 4 7 26 6 36 41 40 26 39 32 52 23 27 33 51 2 1 30 28 29 31 37 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No.
Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No. 0E0695 ITEM PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 QTY.
Section 8 – Warranty Commercial-Industrial-Residential Portable Generator System CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System warranty on your new engine. In California, new off-road Large Spark-Ignition (LSI) engines must be designed, built and equipped to meet the state's stringent anti-smog standards.
Section 8 – Warranty Commercial-Industrial-Residential Portable Generator System EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS warranty) for 2001 and later model year LSI engines: (a) Applicability: This warranty shall apply to 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.
Section 8 – Warranty Commercial-Industrial-Residential Portable Generator System GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR GUARDIAN® “12,500 WATT AND 15,000 WATT PORTABLE GENERATORS” For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its Guardian generator will be free from defects in materials and workmanship for the items and period set forth below.
Part No. 0E0226 06/01/02 Printed in U.S.A.