ULTRA SOURCE Portable Generator Owner’s Manual • SAFETY • ASSEMBLY • OPERATION • TROUBLESHOOTING • ELECTRICAL DATA • PARTS COMMERCIAL • INDUSTRIAL • RESIDENTIAL • WARRANTY MODEL: 004583-0 AUTHORIZED DEALER SUPPORT: 1-800-333-1322 17,500 Watt Portable Generator and 60 amp manual transfer switch with built-in load center
Table of Contents 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 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.
IMPORTANT SAFETY INSTRUCTIONS Residential Portable Generator System THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's SAVE 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.
IMPORTANT SAFETY INSTRUCTIONS 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 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 ASSEMBLING THE WHEEL KIT • Remove separate accessory box.
Section 1 - General Information Residential Portable Generator System Figure 2 - Handle Assembly 1.2.3 BATTERY CONNECTION • 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. Figure 3 - Battery Connections Negative Cable Positive Cable • Connect the RED battery cable to the battery Positive terminal (+).
Section 2 – Operation Residential Portable Generator System 1) OPERATION 2.1 KNOW THE GENERATOR 2) 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 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 control 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 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 Residential Portable Generator System 2.3 HOW TO USE THE GENERATOR 2.3.2 CONNECTING ELECTRICAL LOADS 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. 2.3.1 GROUNDING THE GENERATOR • Let engine stabilize and warm up for a few minutes after starting.
Section 2 – Operation Residential Portable Generator System 2.5 WATTAGE REFERENCE GUIDE Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts *Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . .1700 *Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . .3800 *Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . .6000 Battery Charger (20 Amp) . . . . . . . . . . . . . . . . . . . . .500 Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2 – Operation Residential Portable Generator System 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. Do not mix oil with gasoline.
Section 2 – Operation 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 Residential Portable Generator System 2.12 CHARGING A BATTERY DANGER! Storage batteries give off explosive hydrogen gas while recharging. An explosive mixture will remain around the battery for a long time after it has been charged. The slightest spark can ignite the hydrogen and cause an explosion. Such an explosion can shatter the battery and cause blindness or other serious injury. DANGER! Do not permit smoking, open flame, sparks or any other source of heat around a battery.
Section 3 — Maintenance Residential Portable Generator System 3.1 MAINTENANCE SCHEDULE Follow the calendar intervals. More frequent service is required when operating in adverse conditions noted below. Operation Maintenance Daily Check Oil Level Service Air Pre-Cleaner ✓ Every Season Every Season ✓** ✓* Change Oil and Oil Filter‡ ✓ ✓ Clean Spark Arrestor Screen Adjust Valve Clearance Service Air Cleaner Replace Spark Plugs ‡ * ** Change oil after first 8 hours of operation then every season.
Section 3 — Maintenance 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. Also disconnect spark plug wires from spark plug and keep wire away from spark plug.
Section 3 — Maintenance Residential Portable Generator System 3.3.6 REPLACING THE SPARK PLUG To clean or replace foam pre-cleaner: 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. • Remove air cleaner cover, then foam pre-filter. 1. Stop the engine and pull the spark plug wire off of the spark plug. • Clean air cleaner cover before re-installing it. 2.
Section 3 — Maintenance 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 3.6 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation, you should adjust the valve clearance in the engine.
Section 3 — Maintenance Residential Portable Generator System 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—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. 1. 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.
Section 5—Installation for Manual Transfer Switch THESE INSTRUCTIONS ARE TO SERVE AS A GUIDE ONLY! ANY ELECTRICAL WORK PERFORMED MUST MEET NFPA 70-NEC AND ANY LOCAL CODES THAT APPLY. 1 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.
Section 5—Installation for Manual Transfer Switch 8. 7a 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/lbs. The green wire is to be stripped back 1/2”, inserted into the ground lug and torque lug screw to 25 in/lbs. Reinstall internal cover plate and screw. Close and lock cover.
Section 5—Installation for Manual Transfer Switch 9a. 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.
Section 6—Operation of Generator with Manual Transfer Switch ULTRA SOURCE PORTABLE COMPONENTS USING THE ULTRA SOURCE PORTABLE The GUARDIAN® ULTRA SOURCE with manual 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.
Section 6—Operation of Generator with Manual Transfer Switch TRANSFER TO GENERATOR POWER SOURCE WHEN UTILITY POWER FAILS TRANSFER BACK TO UTILITY POWER SOURCE 1. Move generator to within approximately 10 feet of the power inlet box. Connect ground strap to the generator’s grounding lug and to the grounding rod. When utility power has been restored, you will want to transfer back to that power source and shut down the generator. This can be accomplished as follows: 2.
Section 6—Operation of Generator with Manual Transfer Switch INTERCONNECTION DRAWING ULTRASOURCE GENERATOR CONNECTED TO THE EXTERNAL CONNECTION BOX, MANUAL TRANSFER SWITCH AND HOME’S MAIN ELECTRICAL DISTRIBUTION PANEL 26
Section 7 - Notes Residential Portable Generator System 27
Section 8 — Electrical Data Commercial-Industrial-Residential Portable Generator System Wiring Diagram, UltraSource Portable Generator – Drawing No. 0G0731 22 120V/30A 120V/30A TWISTLOK TWISTLOK 120V/20A GFCI 0 22 22 LINE G GREEN WHITE LOAD 2 WHITE 1 HOT 4 22 HOT 2 HOT G HOT G WHITE X 1 22 0 3 0 22 3 4 5 44D 11D 0 0 11C 0 WHITE Y 22 22 5 44C 0 22 0 22 22 0 0 22 0 11A 22 0 22 22 11B 44B 44A 44 44 44 30A 44 C.B. 11 0 30A C.B. 11D 30A C.B.
Section 8 — Electrical Data Commercial-Industrial-Residential Portable Generator System Wiring Diagram, UltraSource Portable Generator – Drawing No.
Section 8 — Electrical Data Commercial-Industrial-Residential Portable Generator System Schematic, UltraSource Portable Generator – Drawing No. 0G0733 POWER WINDING 77A 55A C1-5 66A 11S C1-4 C1-3 11 22S C1-1 44 C1-2 2 6 C1-6 22 10A BATTERY CHARGE WINDING BA FIELD DPE WINDING BATTERY CHARGE WINDING 0 4 C1-7 C1-11 C1-12 I.C. RED 77 66 55 C1-10 C1-9 C1-8 77 I.C.T. 66A 66 22S 11S 22 I.C.T.
Section 8 — Electrical Data Commercial-Industrial-Residential Portable Generator System Wiring Diagram, Manual Transfer Switch – Drawing No.
Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Manual Transfer Switch with Load Center – Drawing No.
Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Manual Transfer Switch with Load Center – Drawing No. 0G0939-B ITEM PART NO. QTY.
34 37 36 35 33 39 34 38 27 26 40 16 160 32 3 44 41 42 43 46 48 45 24 29 30 25 3 31 22 47 21 52 50 49 28 23 51 53 19 54 20 55 57 58 56 17 18 14 13 8 12 1 11 10 6 2 7 9 15 59 3, 30, 35, 65 60 2, 5, 17, 18, 34, 35, 40, 57, 139, 153 61 8, 11, 12, 13 62 4, 5, 6 63 7, 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, 53, 54, 57, 58 64 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, 53, 54, 56, 57, 58 65 25, 26, 27 4 160 5 Section 9 — Exploded Views and Parts Lists
Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589-N ITEM PART NO.
36 67 86 66 81 82 87 146 149 153 DETAIL "A" 74 73 69 68 80 85 143 144 37 150 75 71 72 145 70 83 143 140 151 79 142 77 92 141 100 90 91 160 84 78 139 107 101 93 76 92 93 136 135 108 138 109 106 152 108 110 137 89 103 104 94 97 98 99 102 105 95 96 160 147 108 132 131 133 129 130 134 155 111 128 154 157 114 155 122 123 125 126 108 127 157 115, 161 114 124 DETAIL "A" 113 121 112 113 120 118 116 119 162 Section 9 — Exploded Vie
Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 2) – Drawing No.
Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System 16 32 19 10 30 6 40 17 32 19 24 25 20 22 30 36 31 24 8 14 39 38 11 23 46 21 12 33 13 4 9 31 32 31 34 17 28 43 44 42 15 3 35 5 37 39 2 40 1 41 7 38 32 31 28 27 28 26 10 29 28 18 29 45 10 Generator – Drawing No.
Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator – Drawing No. 0D4488-F ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.
Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No.
Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No. 0G0727-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.
42 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 17 16 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 27 33 23 29/51 2 1 30 28 29 31 37 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No.
Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No. 0E0695-B 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 057058 0D5315 0D4570 0D22850SRV 045771 022129 022145 0D4565 0D3545 022287 022473 022097 022127 0388040AK0 0D4575 0D5202 0D5199 029809 0C3168 0D5198 0E0317 027007 0D5303 042909 090388 064101 039214 0D9165 QTY.
Section 10 – 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 10 – 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® 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.
