ULTRA SOURCE Portable Generator Owner’s Manual • SAFETY • ASSEMBLY • OPERATION • TROUBLESHOOTING • ELECTRICAL DATA • PARTS • WARRANTY AUTHORIZED DEALER SUPPORT: 1-800-333-1322 COMMERCIAL • INDUSTRIAL • RESIDENTIAL MODELS: 004451 (12,500 WATT) 004582 (15,000 WATT)
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 3.2 1.2 Assembly .........
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.
1.2.3 BATTERY CONNECTION Figure 3 - Battery Connections • The battery shipped with the generator has been provided fully charged. Caution must be taken when connecting the battery. • Cut the tie wrap cable holding the RED and BLACK battery cables to the stator. • Connect the RED battery cable to the battery Positive terminal (+). After making sure that the connection is tight, slip the rubber boot over the terminal connection. • Connect the BLACK battery cable to the battery Negative terminal (–).
Section 2 – Operation Commercial-Industrial-Residential Portable Generator System OPERATION 7) 12 Volt DC, 10 Amp Receptacle – This receptacle allows the capability to recharge a 12 volt DC storage battery with provided battery charge cables. 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies electrical power for the operation of 120 Volt AC, 20 Amp, single-phase, 60 Hz electrical lighting, appliance, tool and motor loads.
Section 2 – Operation Commercial-Industrial-Residential Portable Generator System 14) Start/Run/Stop Switch – Controls the operation of the generator. 15) Oil Fill – Use this point to add oil to engine. 16) Fuse - 10 Amp (Located at rear of panel)– Protects the DC control circuit from overload. If this fuse element has melted open the engine will not be able to crank and start. A GFCI receptacle does NOT protect against circuit overloads, short circuits, or shocks.
Section 2 – Operation Commercial-Industrial-Residential Portable Generator System Figure 9 - 120 VAC, 30 Amp Receptacle 2.2.5 12 VOLT DC, 10 AMP RECEPTACLE This receptacle allows you to recharge a 12 Volt automotive or utility style storage battery with the battery charge cables provided. This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery. See the section "Charging a Battery" (page 13) 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. 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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 Lawn Mower . . . .
Section 2 — Operation Commercial-Industrial-Residential Portable Generator System Figure 15 - Fuel Shut-off Valve 2.6.2 ADDING GASOLINE ------------- WARNING ------------ WARNING: Never fill fuel tank indoors. Never fill fuel tank when engine is running or hot. DO NOT light a cigarette or smoke when filling the fuel tank. Caution: Do not overfill the fuel tank. Always leave room for fuel expansion. • Use regular UNLEADED gasoline with the generator engine. Do not use premium gasoline.
Section 2 — Operation Commercial-Industrial-Residential Portable Generator System • Move engine CHOKE knob to “Full Choke” position. Figure 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 of 2100 RPM.
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 GENERAL RECOMMENDATIONS 3.3.3 ENGINE MAINTENANCE 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 3.3.6 REPLACING THE SPARK PLUG Use Champion RC14YC spark plug or equivalent. The correct air gap is 0.76 mm (0.030 in.). Replace the plug once each year. This will help your engine start easier and run better. 1. Stop the engine and pull the spark plug wire off of the spark plug. 2. Clean the area around the spark plug and remove it from the cylinder head.
Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System Figure 21 - Spark Arrestor 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/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change. Figure 22 - Valve Clearance Adjustment 3.
Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System STORAGE 3.7 GENERAL 3.9 OTHER STORAGE TIPS: 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. • Do not store gasoline from one season to another.
Section 4 — Troubleshooting Commercial-Industrial-Residential Portable Generator System 4.1 TROUBLESHOOTING SYMPTOM 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. 1. 2. 3. 4. 1. 2. 3. 4.
Section 5 — Notes Commercial-Industrial-Residential Portable Generator System 20
Section 5 - Notes Commercial-Industrial-Residential Portable Generator System 21
Section 6 — Electrical Data Commercial-Industrial-Residential Portable Generator System Wiring Diagram – Drawing No.
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Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System 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. 0E8589-J ITEM PART NO. QTY.
Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 2) – Drawing No.
Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589-J ITEM PART # 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 89 90 QTY.
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Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator – Drawing No. 0D4488-D ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.
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-C ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.
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Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No. 0E0695-A 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 28 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.
GENERAC POWER SYSTEMS, INC. P.O. Box 297 • Whitewater, WI 53190 Part No. 0E0226 Rev. G Printed in USA 5.04, 10.04, 5.
