Guardian Technologies Portable Generator 5209 User Manual

ULTRA SOURCE

Semi-Automatic

Emergency Generator

Owner’s

Manual

• SAFETY

• ASSEMBLY

• OPERATION

• TROUBLESHOOTING

• ELECTRICAL DATA

• PARTS

COMMERCIAL • INDUSTRIAL • RESIDENTIAL

• WARRANTY

MODEL: 005209

15,000 WATT GENERATOR

AND 100 AMP TRANSFER SWITCH

WITH BUILT-IN LOAD CENTER

AUTHORIZED DEALER SUPPORT:

1-800-333-1322

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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.

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.

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.

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.

• 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

to operate or service the generator.

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 a particular operation

that may be hazardous if performed incorrectly or carelessly.

Observe them carefully. Their definitions are as follows:

• 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.

-------------

ƽ DANGER ƽ

After this heading, you can read instructions that, if

not strictly complied with, will result in personal injury

or property damage.

• Use a ground fault circuit interrupter in any damp or highly

conductive area (such as metal decking or steel work).

-------------

ƽ WARNING ƽ

After this heading, you can read instructions that, if

not strictly complied with, may result in personal

injury or property damage.

• 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.

-------------

ƽ CAUTION ƽ

After this heading, you can read instructions that, if

not strictly complied with, could result in damage to

equipment and/or property.

• 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.

NOTE: After this heading, you can read explanatory statements

that require special emphasis. These safety warnings cannot

eliminate the hazards that they indicate. Common sense and

strict compliance with the special instructions while performing

the service are essential to preventing accidents.

• 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.

Four commonly used safety symbols accompany the DANGER,

WARNING and CAUTION blocks. The type of information each

indicates follows:

• Never store generator with fuel in tank where gasoline vapors

might reach an open flame, spark or pilot light (as on a

furnace, water heater or clothes dryer). FIRE or

EXPLOSION may result.

ƽ This symbol points out important safety

information that, if not followed, could endanger

personal safety and/or property of you and others.

• Generator exhaust gases contain DEADLY carbon monoxide

gas.This dangerous gas, if breathed in sufficient

concentrations, can cause unconsciousness or even death.

Operate this equipment only in the open air where adequate

ventilation is available.

Ʒ This symbol points out potential explosion hazard.

Ƹ This symbol points out potential fire hazard.

Ꮨ This symbol points out potential electrical shock

• 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.

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.

ƽ DANGER! NEVER operate your generator indoors,

in an attached garage or near an open window.

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IMPORTANT SAFETY INSTRUCTIONS

Residential Portable Generator System

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted

ƽ_{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

-------------

ƽ DANGER ƽ

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.

ƽ 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.

• Do not insert objects through unit's cooling slots.

• Never operate generator: in rain; in any enclosed

compartment; if connected electrical devices overheat; if

electrical output is lost; if engine or generator sparks; if flames

or smoke are observed while unit is running; if unit vibrates

excessively.

Ꮨ 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.

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.

ƽ Parts of the generator are rotating and/or hot during

operation. Exercise care near running generators.

ƽ GENERAL HAZARDS ƽ

• For safety reasons, GENERAC^®recommends that the

installation, initial start-up and maintenance of this equipment

is carried out by a GENERAC^®/GUARDIAN^®Authorized Dealer.

• The engine exhaust fumes contain carbon monoxide, which

can be DEADLY. This dangerous gas, if breathed in sufficient

concentrations, can cause unconsciousness or even death.

This exhaust system must be installed properly, in strict

compliance with applicable codes and standards. Following

installation, you must do nothing that might render the system

unsafe or in noncompliance with such codes and standards.

• Keep hands, feet, clothing, etc., away from drive belts, fans,

and other moving or hot parts. Never remove any drive belt or

fan guard while the unit is operating.

• Adequate, unobstructed flow of cooling and ventilating air is

critical to correct generator operation. Do not alter the

installation or permit even partial blockage of ventilation

provisions, as this can seriously affect safe operation of the

generator. The generator MUST be operated outdoors.

• When working on this equipment, remain alert at all times.

Never work on the equipment when you are physically or

mentally fatigued.

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:

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

• Inspect the generator regularly, and contact your nearest

GENERAC^®/GUARDIAN^®Authorized Dealer for parts needing

repair or replacement.

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 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.

• 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.

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IMPORTANT SAFETY INSTRUCTIONS

Residential Portable Generator System

Ꮨ ELECTRICAL HAZARDSᏘ

Ʒ EXPLOSION HAZARDS Ʒ

•

All generators covered by this manual produce dangerous

electrical voltages and can cause fatal electrical shock. Utility

power delivers extremely high and dangerous voltages as

does the generator when it is in operation. Avoid contact with

bare wires, terminals, connections, etc., while the unit is

running. Ensure all appropriate covers, guards and barriers

are in place before operating the generator. If you must work

around an operating unit, stand on an insulated, dry surface

to reduce shock hazard.

• Do not 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.

• 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.

1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL

ELECTRIC CODE.

• 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.

2. Article X, NATIONAL BUILDING CODE, available from the

American Insurance Association, 85 John Street, New York,

N.Y. 10038.

• 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.

3. AGRICULTURAL WIRING HANDBOOK, available from the Food

and Energy Council, 909 University Avenue, Columbia, MO

65201.

4. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM

STANDBY ELECTRICAL SYSTEMS, available from the

American Society of Agricultural Engineers, 2950 Niles Road,

St. Joseph, MI 49085.

• 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.

5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS

CODE.

Ƹ FIRE HAZARDS Ƹ

• For fire safety, the generator must be operated and maintained

properly. Operation always must

comply with applicable

codes, standards, laws and regulations. Adhere strictly to local,

state and national electrical and building codes. Comply with

regulations the Occupational Safety and Health Administration

(OSHA) has established. Also, ensure that the generator is

operated in accordance with the manufacturer’s instructions

and recommendations. Do not alter the construction of

generator or change controls which might create an unsafe

operating condition.

• Keep a fire extinguisher near the generator at all times.

Extinguishers rated “ABC” by the National Fire Protection

Association are appropriate for use on the standby electric

system. Keep the extinguisher properly charged and be familiar

with its use. If you have any question pertaining to fire

extinguishers, consult your local fire department.

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Section 1 – General Information

Residential Portable Generator System

1.1 UNPACKING

1.2 ASSEMBLY

• Set the palleted carton on a rigid flat surface.

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 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.

1.2.1 ASSEMBLING THE WHEEL KIT

The wheel kit is designed to greatly improve the portability of the

generator. A socket wrench with a 9/16” socket, a 1/2” socket, a

1/2” wrench and a pair of pliers are the tools that will be needed

for assembly of the wheel kit.

• Remove generator from shipping pallet by removing bolts

through the shipping brackets.

Note:The wheel kit is not intended for over-the-road use.

Figure 1 - Bracket Removal

• Refer to Figure 2 shown on opposite page and install the wheel

kit as follows:

• Place the generator on a hard flat surface.

• Stand at the engine end of the unit and gently tilt the generator

forward, high enough to place wooden blocks beneath the

cradle. This will allow space to install the wheel assemblies.

Shipping

Bracket

(x4)

• 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.

• Insert retaining pins and using pliers, bend out the ends to

prevent the pins from falling out of the axle. Remove the

wooden blocks.

1.1.1 ACCESSORY BOX

Check all contents. If any parts are missing or damaged locate an

authorized dealer at 1-800-333-1322.

1.2.2 ASSEMBLING THE HANDLE

Contents include:

• 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.

• Owner’s Manual

• Bolt-on tubular handle

• Wheel Axle

• 2 – Pneumatic Wheels

• 2 – Axle Bracket Assemblies

• 2 – Washers

• Using the handle, lift the unit high enough to place wooden

blocks under the unit. Attach the front support foot to the

underside of the cradle using the 3/8” carriage bolts provided.

• 2 – Wheel Spacers

• 2 – Cotter Pins

• Remove the shipping brackets from the cradle, if you have not

already done so.

• Bolt-on Foot

• 6 – Carriage Bolts, Washers, Nuts

• Battery Charge Cable

• Spark Plug Wrench

• 2 Spark Plugs.

• Air Filter

• Pre-cleaner

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Section 1 - General Information

Residential Portable Generator System

Figure 2 - Handle Assembly

Figure 3 - Battery Connections

1.2.3 BATTERY CONNECTION

• The battery shipped with the generator has been provided fully

charged. Caution must be taken when connecting the battery.

Negative

Cable

Positive

Cable

• 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 (–). 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.

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Section 2 – Operation

Residential Portable Generator System

1) 12 Volt DC, 10 Amp Receptacle – This receptacle

OPERATION

allows the capability to recharge a 12 volt DC storage battery

with provided battery charge cables.

2.1 KNOW THE GENERATOR

Read the Owner’s Manual and Safety Rules before

2) 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.

3) 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.

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

4) 120 Volt AC, 30 Amp Locking Receptacle – Supplies

electrical power for the operation of 120 Volt AC, 30 Amp,

single-phase, 60 Hz electrical lighting, appliance, tool and

motor loads.

5) 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.

6) 120/240 Volt AC, 50 Amp Receptacle – Supplies

electrical power for the operation of 120/240 Volt AC, 50

Amp, single-phase, 60 Hz, welder or motor loads.

7) Air Cleaner – Filters intake air as it is drawn into the engine.

8) Choke Knob – Used when starting a cold engine.

9) Winter / Summer Valve – See “Cold Weather Operation.”

(Section 2, page 12.)

10) 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)

11) Fuel Tank – Tank holds 16 U.S. gallons of fuel.

Figure 5 - Generator Controls

12) Grounding Lug – Ground the generator to an approved

earth ground here. See page 9 for details.

13) Idle Control Switch – The idle control runs the engine at

normal (high) speeds when there is an electrical load present

and runs the engine at idle (low) speeds when a load is not

present.

Figure 6 - Engine Control Panel

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Section 2 – Operation

Residential Portable Generator System

14) Start/Run/Stop Switch – Controls the operation of the

A GFCI receptacle does NOT protect against circuit overloads,

short circuits, or shocks. For example, electric shock can still

occur if a person touches charged electrical wires while standing

on a non-conducting surface, such as a wood floor.

generator.

15) Oil Fill – Use this point to add oil to engine.

16) Fuse - 10 Amp – Protects the DC control circuit from

overload. If this fuse element has melted open the engine will

not be able to crank and start.

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-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.

Testing the GFCI: Test the GFCI outlet every month as follows:

• Plug a test lamp into the receptacle.

Figure 7 - 120 Volt AC, 20 Amp, Duplex 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.

2.2.2 120V AC, 20 AMP, GFCI RECEPTACLE

2.2.3 120V AC, 30 AMP RECEPTACLE

This unit is equipped with a ground fault circuit interrupter (GFCI).

This device meets applicable federal, state and local codes.

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.

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.

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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 12) before attempting

to recharge a battery.

Figure 11 - 12 Volt DC, 10 Amp Receptacle

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.

2.2.6 120/240 VOLT AC, 50 AMP

RECEPTACLE

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).

Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire

cord set rated for 250 Volts AC at 50 Amps to the plug.

Figure 12 - 120/240 VAC, 50 Amp Receptacle

Figure 10 - 120/240 VAC, 30 Amp Receptacle

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 a 50 Amp 2-pole circuit breaker.

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.

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Section 2 – Operation

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.

2.3.1 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.

• 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:

Figure 13 - Grounding the Generator

• 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.

Generator Ground Lug

• 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.

• 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

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:

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.

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.)

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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") . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000

Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200

Circular Saw (6-1/2") . . . . . . . . . . . . . . . . . . .800 to 1000

*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . .5750

*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . . .700

*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . .1150

Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750

*Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . . . .2000

*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . . .1800

*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . .1400

Curling Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700

*Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650

Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200

Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500

Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400

Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200

Electric Range (per element) . . . . . . . . . . . . . . . . . .1500

Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250

*Freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700

*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . .875

*Garage Door Opener . . . . . . . . . . . . . . . . . . .500 to 750

Hair Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200

Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100

Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts

Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450

Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500

Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200

*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800

Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200

Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Microwave Oven . . . . . . . . . . . . . . . . . . . . . .700 to 1000

*Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1100

Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . .300

Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . .400

Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . . . .225

Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . .150

*Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . .600

Paint Sprayer, Airless (handheld) . . . . . . . . . . . . . . . .150

Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 200

*Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700

Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200

*Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . . .2800

*Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . . .2000

*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . .1500

*Sump Pump . . . . . . . . . . . . . . . . . . . . . . . .800 to 1050

*Table Saw (10") . . . . . . . . . . . . . . . . . . . . .1750 to 2000

Television . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500

Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650

Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500

*Allow 3 times the listed watts for starting these devices.

• Above 40°F, use SAE 10W-30 or SAE 30.

• Below 40°F, use synthetic 5W-20 or 5W-30.

2.6 BEFORE STARTING THE

GENERATOR

Although multi-viscosity oils (5W-30, 10W-30, etc.) improve

starting in cold weather, these multi-viscosity oils will result in

increased oil consumption when used above 32°F. Check your

engine oil level more frequently to avoid possible damage from

running low on oil.

Prior to operating the generator, engine oil and gasoline will need

to be added, as follows:

2.6.1 ADDING ENGINE OIL

• Place generator on a level surface.

NOTE: When adding oil to the engine crankcase in

the future, use only high quality detergent oil rated

with API service classification SF or SG SAE 30

weight. Use no special additives.

• Clean area around oil fill and remove oil fill cap and dipstick.

•

Wipe dipstick clean.

Slowly fill engine with oil through the oil fill opening until it

reaches the full mark on the dipstick. Stop filling occasionally

to check oil level. DO NOT OVERFILL.

Select the oil’s viscosity grade according to the expected

operating temperature. Do not use SAE 10W-40.

• Install dipstick. Install oil fill cap and finger tighten securely.

• Check engine oil level before starting each time thereafter.

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Section 2 – Operation

Residential Portable Generator System

Figure 15 - Fuel Shut-off Valve

2.6.2 ADDING GASOLINE

-------------

ƽ WARNING ƽ

Ʒ 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.

ƽ 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 cap.

• 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.

• Locate the Idle Control ON/OFF switch on the control panel and

set it to the “OFF” position.

•

Install fuel cap and wipe up any spilled gasoline.

Figure 16 - Idle Control Switch

Figure 14 - Fuel Tank

IMPORTANT: It is important to prevent gum deposits from

forming in fuel system parts such as the carburetor, fuel hose or

tank during storage. Alcohol-blended fuels (called gasohol,

ethanol or methanol) can attract moisture, which leads to

separation and formation of acids during storage. Acidic gas can

damage the fuel system of an engine while in storage. To avoid

engine problems, the fuel system should be emptied before

storage of 30 days or longer. See "Storage" on page 18. Never use

engine or carburetor cleaner products in the fuel tank as

permanent damage may occur.

2.7 TO START THE ENGINE

Ꮨ WARNING! Never start or stop engine with electrical

devices plugged into the receptacles AND devices turned on.

• Unplug all electrical loads from the unit's receptacles before

starting the engine.

• Make sure the unit is in a level position.

• Open the fuel shut-off valve.

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Section 2 – Operation

Residential Portable Generator System

• Move engine CHOKE knob to “Full Choke” position.

2.9 AUTOMATIC IDLE CONTROL

Figure 17 - Full Choke Position

This feature is designed to greatly improve fuel economy. When

this switch is turned “On,” the engine will only run at its normal

fast governed engine speed when electrical load is connected.

When the load is removed, the engine will run at a reduced speed

of 2100 RPM. With the switch “Off,” the engine runs at the

normal fast engine speed all the time. Always have the switch

OFF when starting and stopping the engine.

2.10 COLD WEATHER OPERATION/

DE-ICER

Under certain weather conditions (temperatures below 40° F (4°

C) and a high dew point), the engine may experience icing of the

carburetor and/or the crankcase breather system. To eliminate

this problem, this generator engine is fitted with a winter/summer

valve. this directs hot air into the carburetor during cold weather

operation. Always make sure the winter/summer valve is in the

correct location relative to the weather conditions.

• 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.

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.

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.

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.

• 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.

2.11.2 SENSING LOW OIL PRESSURE

• Move Start/Run/Stop switch to “Off” position.

• Close fuel valve.

If the system senses low oil pressure during operation, the engine

shuts down.

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.

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.

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Section 2 – Operation

Residential Portable Generator System

2.12 CHARGING A BATTERY

Ʒ 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.

ƽ 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.

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.

• If the battery is equipped with vent caps, make sure they are

installed and are tight.

• If necessary, clean battery terminals.

• Connect battery charge 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.

• 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.

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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

Every Season

Check Oil Level

✓

Service Air Pre-Cleaner

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.

Change oil and oil filter every month when operating under heavy load or in high temperatures.

** Clean more often under dirty or dusty operating conditions. Replace air cleaner parts if very dirty..

PRODUCT SPECIFICATIONS

3.2.1 GENERATOR SPECIFICATIONS

MODEL

GPS 15000

004582-1

15.0 kW

Model #

Rated Max. Power

Surge Power

22.5 kW

Rated AC Voltage

Rated Max AC Load

Current @ 240V

Current @ 120V

Rated Frequency

Phase

Rated DC Voltage

Rated Max DC Load

Current @ 12 Volts

120/240

62.5 Amps

125.0 Amps

60 Hz @ 3600 RPM

Single Phase

12 Volts

10 Amperes

3.2.2 ENGINE SPECIFICATIONS

Rated Horsepower

@ 3600 RPM

992cc

Displacement

Spark Plug Type

Spark Plug Gap

Champion RC14YC or Equivalent

0.030 inch or (0.76 mm)

Gasoline Capacity

Oil Type

Oil Capacity

16 U.S. gallons

Summer – SAE 30 or 10W-30 Winter – Synthetic 5W-20 or 5W-30

w/ Filter Change = 1.5 Qts. w/o Filter Change = 1.2 Qts.

10 Hours / 1.6 gallons per hour

Run Time/Fuel

Consumption-1/2 Load

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Section 3 — Maintenance

Residential Portable Generator System

3.3.3 ENGINE MAINTENANCE

3.3 GENERAL RECOMMENDATIONS

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.

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.

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.

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 page 14.

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.

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.

Use the following instructions to change the oil while

the engine is still warm:

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.

• Clean area around oil drain hose and plug.

• 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.

Check the cleanliness of the generator frequently and clean when

dust, dirt, oil, moisture or other foreign substances are visible on

its exterior surface.

• Place a suitable container beneath the oil filter and turn filter

counterclockwise to remove. Discard according to local

regulations.

• Coat gasket of new filter with clean engine oil. Turn filter

clockwise until gasket contacts lightly with filter adapter. Then

tighten an additional 3/4 turn.

ƽCAUTION! Never insert any object or tool through the air

cooling slots, even if the engine is not running.

• Fill oil sump with recommended oil. (See “Before Starting the

Generator” on page 10 for oil recommendations).

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.

• Wipe up any spilled oil.

3.3.2 TO CLEAN THE GENERATOR

• Use a damp cloth to wipe exterior surfaces clean.

• A soft, bristle brush may be used to loosen caked on dirt, oil, etc.

• A vacuum cleaner may be used to pick up loose dirt and debris.

• Low pressure air (not to exceed 25 psi) may be used to blow

away dirt. Inspect cooling air slots and openings on the

generator. These openings must be kept clean and

unobstructed.

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Section 3 — Maintenance

Residential Portable Generator System

To clean or replace foam pre-cleaner:

• Remove air cleaner cover, then foam pre-filter.

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.

•

Wash pre-cleaner in soapy water. Squeeze pre-filter dry in

clean cloth (DO NOT TWIST).

1. Stop the engine and pull the spark plug wire off of the spark

plug.

• Clean air cleaner cover before re-installing it.

To clean or replace paper air filter:

2. Clean the area around the spark plug and remove it from the

cylinder head.

• Remove air cleaner cover; then remove foam pre-filter (service

if necessary) and remove paper filter.

3. Set the spark plug's gap to 0.76 mm (0.030 in.). Install the

correctly gapped spark plug into the cylinder head.

• 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.

Figure 18 - Spark Plug Gap

• 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.

3.4 SERVICE AIR CLEANER

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.

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.

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.

Figure 20 - Air Cleaner

Cover

• 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.

Pre-Cleaner

• Replace the screen and the retaining bracket.

Base

Filter

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Section 3 — Maintenance

Residential Portable Generator System

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 21 - Spark Arrestor

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.

• Install new valve cover gasket.

• Re-attach the valve cover.

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.

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.

To adjust valve clearance:

• Re-attach the spark plug wire to the spark plug.

• Repeat the process for the other cylinder.

• Make sure the engine is at room temperature.

• Make sure that the spark plug wire is removed from the spark

plug and out of the way.

• Remove the four screws attaching the valve cover with a #2 or

#3 phillips screwdriver.

• Make sure the piston is at Top Dead Center (TDC) of its

compression stroke (both valves closed). To get the piston at

TDC, remove the intake screen at the front of the engine to gain

access to the flywheel nut. Use a large socket and socket

wrench to rotate the nut and hence the engine. While watching

the piston through the spark plug hole. The piston should

move up and down. The piston is at TDC when it is up as high

as it can go.

• Loosen the rocker jam nut. Use an 10mm allen wrench to turn

the pivot ball stud while checking clearance between the rocker

arm and the valve stem with a feeler gauge. Correct clearance

is 0.002-0.004 inch (0.05-0.1 mm).

NOTE: You must hold the rocker arm jam nut in place

as you turn the pivot ball stud.

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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.

• Replace your gasoline can if your can starts to rust. Rust

and/or dirt in your gasoline will cause problems with the

carburetor and fuel system.

• If possible, store your unit indoors and cover it to give

protection from dust and dirt. BE SURE TO EMPTY THE

FUEL TANK.

ƷƸDANGER! 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.

• If 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.

3.8 LONG TERM STORAGE

• Cover your unit with a suitable protective cover that does not

retain moisture.

It is important to prevent gum deposits from forming in essential

fuel system parts such as the carburetor, fuel hose or tank during

storage. Also, experience indicates that alcohol-blended fuels

(called gasohol, ethanol or methanol) can attract moisture, which

leads to separation and formation of acids during storage. Acidic

gas can damage the fuel system of an engine while in

storage.

ƽ DANGER! NEVER cover your generator while

engine and exhaust area are warm.

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.

ƷƸDANGER! 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.

ƽCAUTION! Avoid spray from spark plug holes

when cranking engine.

• Install 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.

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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. 2. Check and repair.

1. Reset circuit breaker.

3. Connected device is bad.

3. Connect another device that is in

good condition.

4. Fault in generator.

4. Contact Authorized Service Facility.

Engine runs good but bogs

down when loads are connected.

1. Short circuit in a connected load.

2. Generator is overloaded.

3. Engine speed is too slow.

4. Shorted generator circuit.

1. Disconnect shorted electrical load.

2. See “Don’t Overload the Generator” on page 9.

3. Contact Authorized Service Facility.

4. Contact Authorized Service Facility.

Engine will not crank.

10 amp fuse at rear of generator

control panel has melted open.

Replace fuse with only an identical

10-amp replacement fuse.

Engine will not start; or starts

and runs rough.

1. Dirty air cleaner.

2. Out of gasoline.

1. Clean or replace air cleaner.

2. Fill fuel tank.

3. Stale gasoline.

4. Spark plug wire not connected to

spark plug.

3. Drain fuel tank and fill with fresh fuel.

4. Connect wire to spark plug.

5. Bad spark plug.

6. Water in gasoline.

7. Overchoking.

5. Replace spark plug.

6. Drain fuel tank; fill with fresh fuel.

7. Put choke knob to No Choke position.

8. Fill crankcase to proper level.

9. Contact Authorized Service Facility.

10. Contact Authorized Service Facility.

11. Contact Authorized Service Facility.

8. Low oil level.

9. Excessive rich fuel mixture.

10. Intake valve stuck open or closed.

11. Engine has lost compression.

Engine shuts down during

operation.

1. Out of gasoline.

2. Low oil level.

3. Fault in engine.

1. Fill fuel tank.

2. Fill crankcase to proper level.

3. Contact Authorized Service Facility.

Engine lacks power.

1. Load is too high.

2. Dirty air filter.

1. See “Don’t Overload the Generator” on page 9.

2. Replace air filter.

3. Engine needs to be serviced.

3. Contact Authorized Service Facility.

Engine “hunts” or falters.

1. Choke is opened too soon.

1. Move choke to halfway position until

engine runs smoothly.

2. Carburetor is running too rich or too

lean.

2. Contact Authorized Service Facility.

No Battery Charge DC output.

1. Battery posts are corroded.

2. Battery cable is bad.

3. Battery is defective.

1. Clean battery posts.

2. Replace cable.

3. Check battery condition; replace if

defective.

4. Receptacle is bad.

4. Contact Authorized Service Facility.

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SECTION 5 - INSTALLATION GUIDE FOR GENERATOR READY KIT

MAKES A HOME GENERATOR READY!

GENERATOR READY KIT

KIT INCLUDES:

1. 50 AMP PLUG ON 5FT. POWER CORD

Use with ULTRA SOURCE portable generator to

supply power to load center.

2. THE EXTERNAL CONNECTION BOX

Located outside the home where the generator will be

operated.

3. 30’ FLEXIBLE CONDUIT

Pre-wired from the automatic transfer switch with built-

in 12 circuit load center for connection to the external

connection box.

4. PRE-WIRED AUTOMATIC TRANSFER SWITCH* AND

5. EMERGENCY LOAD CENTER WITH 12 CIRCUITS

Installed within 1 foot of the home’s main distribution

panel. This transfer switch will provide smooth and safe

transition between utility and generator power.

Eliminates the need to run extension cords.*When used

with a portable generator the transfer from utility to

generator power will require that some manual

connections are performed by the user. (See page 25)

6. 2’ PRE-WIRED CONDUIT FOR EASY CONNECTION TO

THE HOME’S MAIN DISTRIBUTION PANEL

ITEMS YOUR MUST PURCHASE:

8. 5’ DC SIGNAL HARNESS

70 AMP double pole circuit

breaker (must be the same type

as in your main electrical

distribution panel)

Provides signal from the ULTRA SOURCE portable

generator to the transfer switch.

9. 12 UL LISTED WIRE NUTS (not shown)

Ground rod (8 foot) with

grounding strap (No. 10 AWG

stranded copper)

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 and safety goggles.

Silicone caulk

Fasteners - to mount connection

box and automatic transfer

switch

Power cord clamp - to secure

power cord at the entrance point

to the external connection box

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Portable Generator Placement

SECTION 5 - INSTALLATION GUIDE

FOR GENERATOR READY KIT

Illustration at left shows the

Guardian Ultra Source 15,000

watt portable generator

placed outside the home and

connected to the weather

protective external box. The

ground rod and ground strap

show a suggested location

only. When fully installed the

ground rod will not protrude

above ground level.

1. PLAN THE LOCATION OF YOUR GENERATOR.

4. While adhering to all local electrical codes, route the

30 foot conduit along ceiling/floor joists and wall

studs to the location where the conduit will pass

through the wall to the exterior of the house.

NOTE: Do not place the generator directly under a

window.

Select an area outside of your home where you can

easily transport the portable generator to and from.

Keep in mind that the generator must have free air

flow for proper operation and to ensure there is no

possibility for exhaust gases to build up.

Drill Pass Through Hole

1-3/4”

Diameter Hole

2. Drive an 8-foot grounding rod into the ground to

grade (so that no part is exposed above ground).

3. Determine where the flexible conduit will pass

through the house from inside to outside. When you

are certain you have clearance on each side of the

wall, drill a small pilot hole through the wall to mark

the location.

Drill a 1-3/4” diameter hole through the sheathing

and siding with hole saw.

5. From the inside of the house, feed the end of the 30-

foot conduit (INCLUDED and pre-wired from transfer

switch) through the wall to outside.

Drill Hole Through House

Feed Conduit and Wires

Silicone

Caulk

1-3/4”

Diameter Hole

The outer diameter of the

conduit connector is 1-11/16”

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SECTION 5 - INSTALLATION GUIDE FOR GENERATOR READY KIT

--- ƽ WARNING ƽ ---

Threaded Lock Nut

The external connection box must be locked to ensure

safety and to discourage tampering.

The outer diameter

of the threaded end

is 15/16 inches.

Mounting Automatic Transfer Switch

1ft.

6. Remove the threaded lock nut from the conduit coupling.

7. Remove the knock out

Connect Wires

in the lower right corner of

the external connection

box. From the rear of the

connection box, feed wires

& 4 pin plug into box. Slip

the lock nut over wires and

plug and tighten securely

onto conduit coupling.

Connect the black, red,

and white wires to

separate threaded lugs

and tighten securely.

Fasten the green ground

wire securely beneath the

hex nut on the grounding

stud at the bottom of the

box. Tighten securely to

ensure good contact with

metal box.

9. Locate automatic transfer switch with built-in

emergency load center within one foot of main

distribution panel. The automatic transfer switch can

be located to the left or right of main distribution

panel. Hold transfer switch against the mounting

surface. Level the transfer switch and mark the

mounting holes. Drill the appropriate size pilot holes.

Mount the automatic transfer switch to mounting

surface with appropriate fasteners.

ƽDANGER: Although you may choose to perform

electrical connections yourself, Generac Power Systems,

Inc. recommends that a licensed electrician or individual

with complete knowledge of electricity perform the

procedures in sections 10a and 10b.

Knockout

ƽDANGER: 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.

NOTE: THE 4-PIN PLUG WILL not be connected to

any mating plug or other wires at this time.

8. Using appropriate

fasteners, mount

11b Mount External Connection Box

external connection

box over pre-drilled

hole to fully conceal

the hole. (Seal around

the hole and conduit

with

material

insulating

and/or

silicone caulk from

both outside and

inside of house.)

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SECTION 5 - INSTALLATION GUIDE FOR GENERATOR READY 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

installation differs from that described in this

guide, consult a licensed professional at this

time.

10b. In your main panel, remove the black (hot) wire from

a circuit breaker that protects a circuit you want to

have powered in the event of a power failure. Wire

nut the black wire to the matching circuit lead wire

from the emergency circuit breaker from load center

in the transfer switch. (All circuit wires are color

coded and labeled for easy identification). Repeat

this process with remaining circuits to be powered

by the generator. White wires (neutral) in your main

distribution panel should remain connected to

neutral bar. It is not necessary to move them. The

emergency load center in the transfer switch

supplies the following circuits: (5) 15A/120V, (3)

20A/120V, (1) 20A/240V and (1) 30A/240V.

10a. Remove the main electrical distribution panel cover.

Remove appropriate size knockout from the bottom

or side of the main panel. (A 2-foot flexible conduit

is pre-wired from the transfer switch with built-in

load center). Remove threaded lock nut from

conduit coupling. Feed all wires through knockout

into main panel. Slip lock nut over wires and tighten

securely onto conduit coupling.

11 Install 70 AMP Circuit Breaker

10a Connection of Emergency Circuits

11. Install the 70 Amp double pole circuit breaker that

you have purchased into main electrical distribution

panel. This circuit breaker must be compatible with

your main electrical distribution panel. It may be

necessary to reposition remaining circuit breakers

or remove circuit breakers that have been

disconnected to accommodate the insertion of the

70 Amp double pole circuit breaker. Connect white

wire to the main distribution panel neutral bar.

Connect solid green wire to main electrical panel

ground bar. Connect the black and red wires to the

70 Amp double pole circuit breaker. Replace

electrical distribution panel cover.

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.

10b Connection of Emergency Circuits

YOUR GUARDIAN^®

GENERATOR READY KIT

IS NOW INSTALLED!

UL approved wire nuts are included with installation kit.

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SECTION 6 - OPERATION OF GENERATOR WITH GENERATOR READY KIT

GENERATOR READY KIT

USING THE GENERATOR READY KIT WITH ULTRA SOURCE PORTABLE GENERATOR

The GUARDIAN^®Generator Ready Kit gives you the ability to hook up a GUARDIAN^®ULTRA SOURCE portable generator to provide

power safely and conveniently to vital items in your home including hard wired items. Included in the kit is a 5 foot electrical power

cord and a 5 foot DC signal harness. The power cord contains 4 wires (black & red), neutral (white) and ground (green) wires. At

one end are the terminal connectors. At the other end is the male connector (NEMA 14-50) which plugs into the GUARDIAN^®ULTRA

SOURCE portable generator’s control panel. To install this option, insert the terminal wire end of the power cord into the bottom

of the external connection box through the conduit clamp (not included) from the outside. Allow

about an inch of the power cord insulation to enter beyond the clamp to the inside of the box.

TIghten clamp securely. Attach ground wire (green) to the bottom of the box using the supplied

ground screw and pre-drilled hole. Connect red, black and white wires each to separate lug posts.

Make sure hold down nuts are tightened securely. The 5 foot DC signal harness allows semi-

automatic transfer switch operation. You simply attach the four-pin plug to its mating plug within

the external connection box. At the other end is a V-type connector that plugs into the 12-volt DC

receptacle on the portable generator control panel. Instructions for these items are detailed on the

following page (Page 25).

CAUTION: If you are connecting the 5 foot power cord after the 30 foot conduit has been connected inside of the external

connection box you must match the black, red and white wires to the lugs of the wires previously placed.

(For example: black to black; red to red, etc.) Failure to match wires may result in damage to generator and house wiring.

ULTRA SOURCE PORTABLE GENERATOR CONTROL PANEL

5 FOOT DC SIGNAL HARNESS

12 Volt DC

Receptacle

NEMA 14-50

Receptacle

EXTERNAL

CONNECTION BOX

50 AMP POWER PLUG

5 FOOT POWER CORD

WITH PLUG

Lug Posts

Bring power

cord through

here

Ground

Lug

NEMA

14-50 Plug

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SECTION 6 - OPERATION OF GENERATOR WITH GENERATOR READY KIT

SEMI-AUTOMATIC TRANSFER OPERATION USING GUARDIAN^®PORTABLE GENERATOR

TRANSFER TO GENERATOR POWER SOURCE WHEN

UTILITY POWER FAILS

TRANSFER BACK TO UTILITY POWER SOURCE

When utility power has been restored, you will want to

transfer back to that source and shut down the generator.

This can be accomplished as follows:

1. Connect ground strap to generator’s grounding lug

and to grounding rod.

2. Set the generator’s 50 amp circuit breaker to its OFF

1. Set the generator’s 50 amp circuit breaker to its OFF

(or open) position.

3. Insert the NEMA 14-50 plug (from the power cord that

you have installed) into the mating receptacle on the

generator control panel.

4. Start the generator.

5. Let the engine stabilize and warm up for a few minutes.

6. Insert the V-type plug (on the DC signal harness

you have connected within the external connection

box) into the 12 volt DC receptacle on the generator

control panel. The insertion of this plug will send a

signal to the transfer switch to shift the contactor to

the standby position.

2. Remove the V-type plug (on the DC signal harness

that was connected within the external connection

box) from the 12 volt DC receptacle on the generator

control panel. The removal of this plug will send a

signal to the transfer switch to shift the contactor

back to the utility position and allow the circuits of

the home to again be powered by the incoming utility.

3. Let the engine run for a minute or two at no-load to

stabilize the internal temperatures.

4. Turn off the generator.

After utilizing the 5 ft. electrical power cord, 5 ft. DC signal

harness and ground strap for operation with the GUARDIAN^®

ULTRA SOURCE portable generator you must disconnect and

remove them. Open the external connection box. Remove the

fasteners holding the Black, Red, White, and Green wires in

place. Remove wires from threaded lugs and from under

ground screw. Replace fasteners and ground screw. Loosen

the cable clamp and slide the power cord out of the external

connection box. Disconnect the 4-pin plug from its mating half

within the external connection box. Remove ground strap

from the generator’s ground lug and from the grounding rod.

Store the power cord, the DC signal harness and the ground

strap with your GUARDIAN^®ULTRA SOURCE portable

generator for future use.

7. Set the generator’s 50 amp circuit breaker to its’ ON

(or closed) position to send the generator power to

the load center in the transfer switch.

Choose a lamp or light fixture located in a frequently

occupied area of the house as a signal light to tell

you when utility power has returned. This light

should be on a utility powered circuit only so it

operates independent of the generator.

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SECTION 6 - OPERATION OF GENERATOR WITH GENERATOR READY KIT

GENERATOR READY KIT

INTERCONNECTION DRAWING

SEMI-AUTOMATIC TRANSFER SWITCH CONNECTED TO THE EXTERNAL CONNECTION BOX

AND HOME’S MAIN ELECTRICAL DISTRIBUTION PANEL.

GENERAC UUL LISTED

PANEL BBOARD

TO HOUSE BRANCH

CIRCUITS SPLICED

USING WIRE NUTS

GENERATOR READY

KIT - 12 CIRCUITS

70A 2-POLE

CIRCUIT BREAKER

1 2 3 4 5

NEUTRAL

BAR

100A OR 200A

HOUSE MAIN

SERVICE

GROUND

EXTERNAL CUSTOMER

CONNECTION PANEL

4 POSITION

DEUTSCH

CONNECTOR

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Section 7 - Notes

Residential Portable Generator System

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Section 8 — Electrical Data

Commercial-Industrial-Residential Portable Generator System

Wiring Diagram – Drawing No. 0E0228

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Section 8 — Electrical Data

Commercial-Industrial-Residential Portable Generator System

Schematic – Drawing No. 0E0229-A

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Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589-J

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Section 9 — 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.

DESCRIPTION

ITEM PART NO. QTY.

DESCRIPTION

0C5729

ASSEMBLY, CRANKCASE HOUSING 36

WITH SLEEVE

0C5731

ASSEMBLY, HOUSING COVER

WITH SLEEVE

0E9843

090388

0C5372

0C3005

0E3372B

0D8067A

071983

0D5269

043790

0E2950

0E2985

021533

0E1466

0D4041

0D4788

093064

0C2977

0C5943

0E4357E

SEAL, 38 I.D. CRANKSHAFT

SCREW, TAPTITE M6-1.0 X 12 BP

ASSEMBLY, BREATHER

GASKET, BREATHER COVER

SEPARATOR, OIL BREATHER

ASSEMBLY, HEAD #1

RETAINER, PISTON PIN 20

ROCKER, COVER

BARBED EL 90 3/8NPT X 3/8

PISTON, LC (GT-990)

PISTON, HC (GT-760)

SET, PISTON RING 90MM

PIN PISTON

ASSEMBLY, CAMSHAFT & GEAR

PLUG STD PIPE 3/8 STEEL SQ HD

ASSEMBLY, OIL FILL CAP

GASKET, CRANK CASE

SEAL, OIL PASSAGE

ASSEMBLY, CRANKSHAFT

HORIZONTAL DIRECT DRIVE

(GT-990)

ASSEMBLY, CRANKSHAFT

HORIZONTAL DIRECT DRIVE

(GT-760)

ASSEMBLY, CONNECTING ROD

(GT-990)

0C3006

080318

0C8808

0C2981C

0C2979

086515

0D2274

0D3867

078672

0C5371

072694

0C3027

0D5313

0D3998

SCREW, HHFC M10-1.5 X 55

SCREW HHFC M6-1.0 X 25

HOOK, LIFTING

ROCKER, COVER

GASKET, VALVE COVER

KEEPER, VALVE SPRING

RETAINER, VALVE SPRING

SPRING, VALVE

SEAL, VALVE STEM D7

WASHER, VALVE SPRING

STUD, ROCKER ARM PIVOT

O-RING, 3/8" X 1/2"

ROCKER ARM

NUT, HEX M8-1.0 GB YELLOW

CHROME

PLATE, PUSH ROD GUIDE

SCREW HHFC M8-1.25 X 65

VALVE, EXHAUST

0D6024

0C2976

086516

0C2229

083897

0D8067B

0D9853D

0C2978

0D6008

0D4010

0D6007

0D4012

0D8675A

0D8675B

0D4015

VALVE, INTAKE

TAPPET, SOLID

ASSEMBLY, HEAD #2

PUSHROD 147

GASKET, HEAD

0E4356E

KIT GEAR COVER

KIT GASKET

0E3223

0E3222

KIT PISTON & RINGS

KIT BREATHER ASSEMBLY

KIT HEAD ASSEMBLY CYLINDER 1

KIT HEAD ASSEMBLY CYLINDER 2

KIT OIL RELIEF

ASSEMBLY, CONNECTING ROD

(GT-760)

0D2157

0E6098

0D4123A

078699E

0C3011

0C3009

0C3010

093873

0C5315

0C5998

0D4497

SCREW SHC M6-1.0 X 50 G8.8

SCREEN, OIL PICKUP

ASSEMBLY, OIL PUMP

SLEEVE, SEAMED DOWEL 10 DIA.

COVER, OIL RELIEF

Item 59 (Kit) includes items 3, 30, 35, 65

Item 60 (Kit) includes items 2, 5, 17, 18, 34, 35, 40, 57, 139, 153.

Item 61 (Kit) includes items 8, 11, 12, 13

Item 62 (Kit) includes items 4, 5, 6

Item 63 (Kit) includes items 7, 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52,

53, 54, 57, 58

Item 64 (Kit) includes items 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, 53,

54, 56, 57, 58

Item 65 (Kit) includes items 25, 26, 27

SPRING, OIL RELIEF

BALL, 1/2D OIL RELIEF

WASHER, LOCK RIB M6

GEROTOR, OUTER

CLAMP, OIL TUBE

PLUG-CRANKCASE GOVERNOR

BORE

0C3971E

ASSEMBLY, DIPSTICK WITH

HANDLE

0D3745

0C3027

0E9842

TUBE, DIPSTICK

O-RING, OIL CLR

SEAL, 42 I.D. CRANKSHAFT

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Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589-J

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Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589-J

ITEM PART #

QTY. DESCRIPTION

ITEM PART NO#.QTY. DESCRIPTION

0D6592

0D4511

0D9723

0E5302

0D4183

0D6327

0D2774B

0D5125

0D2930

0D4612A

0D6143

0D2775

0D5014A

0D5014B

049721

022097

022473

0E8388

0D6021

0C9093A

0D4522

074908

0E3398

0E2548

0E5077

0D4026

WINGNUT, AIRBOX

PRECLEANER, AIR

ELEMENT, AIR CLEANER

STUD M6-1.0 X 73

ADAPTOR, SPIT BACK

GASKET, SPITBACK

114

115

116

117

118

119

120

121

122

123

124

125

126

127

092079

0F1338B

0C4147

022264

0D6142

0D5399A

0E7585

0E4271

022129

061906

022145

045771

0D1131

0F1169J

SCREW TAPTITE M6-1.0 X 25 BP

ASSY, IGN COIL W/DIODE NO ADV

PUMP, IMPULSE

WASHER LOCK M4

SCREW PPHM M4-0.7 X 40

ELBOW, RUBBER 90 DEG.

SPARKPLUG, CHAMPION RC14YC

STARTER, DELCO REMY SD80

WASHER LOCK M8-5/16

SCREW HHC M8-1.25 X 85 G8.8

WASHER, FLAT M8

NUT, HEX M8-1.25 YELLOW ZINC

GUARD,FAN

HOUSING, BLOWER REPOWER

L&G

BASE, AIRBOX

SPRING, WINTER/SUMMER VALVE

VALVE, SUMMER / WINTER

SNORKEL, AIR INTAKE

TUBE, HEAT RISER 50.8 I.D.

COVER, AIRBOX

KNOB, AIRBOX 17mm

KNOB, AIRBOX 95MM

SCREW HHC M6-1.0 X 35

WASHER LOCK M6-1/4

WASHER FLAT 1/4

NUT HEX FLANGE WHIZ M6-1.0

STUD, METRIC

HOSE, BREATHER

CONTROLLER ASSEMBLY

SCREW HHTT M5-0.8 X 10

ASSEMBLY, WIRE

CARBURETOR (GT-990)

CARBURETOR (GT-760)

GASKET, CARB TO SPACER

(GT-990)

GASKET, CARB/AIRBOX (GT-760)

CLAMP HOSE BAND 1/4

HOSE ¼ ID

GASKET, MANIFOLD TO CARB

(GT-990)

GASKET, MANIFOLD TO CARB

(GT-760)

SLEEVING 1/2" I.D.

FILTER, FUEL

WASHER FLAT M8

WASHER LOCK M8

SCREW SHC M8-1.25 X 30

MANIFOLD, INTAKE

128

129

130

131

132

133

134

135

136

0C9763

0C3034

0C3033

0C3032

0A5992

051754

0C3031

0E4997

045756

NUT, GROMMET 1/4 PLUG

NUT,HEX M24

WASHER, M24

PLATE, FAN

WASHER SHAKEPROOF INT M8 SS

SCREW HHC M8-1.25 X 12 G8.8

FAN, NYLON

ASSY,GROUND WIRE CONNECTOR

SCREW TAPTITE M6-1X10 YELLOW

CHROME

FLYWHEEL ASSEMBLY

PLATE, BACKING GT990 WITH REG.

CUTOUT

KEY, WOODRUFF 4 X 19D

GASKET, MANIFOLD / PORT

PLASTITE,1/4-15 X 3/4

137

138

0C3725A

0F1170C

0D4024

048031C

030340

0D4023

12"

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

082774

0C3043

0C9764

0C3026

0F6301

0C9806

035461

070185B

0C7292

0D3083

0C3025

0D4550

0C3018

0C3019

046964

0E0409

COOLER, OIL

0D5282

CLAMP, HOSE OETIKER 16.5mm

HOSE, 3/8" I.D. X 6" LONG

BARBED STR 1/4NPT X 3/8

OIL FILTER

NIPPLE, 3/4"-16 UNF

ASSEMBLY, OIL DRAIN HOSE

SWITCH, OIL PRESS

BRACKET, AIRBOX SUPPORT

WRAPPER, UPPER CYLINDER 1

WRAPPER, LOWER CYLINDER 1

BRASS ST ELBOW 1/4 NPT

ASSY, ROD, GOV. STEPPER

MOTOR

086061G

0D6313

070008

070006

049821

0C9911

051714

0D5411

0D5445

0D5416A

100

101

102

103

104

NUT HEX M3-0.5

ROD, SUMMER / WINTER VALVE

BUSHING, MINI CONTROL PANEL

KNOB, CONTROL SUMMER /

WINTER

105

106

107

108

0D5398

0E6043

0D3432

045756

CHOKE ASSEMBLY

155

157

0C8563

0D9784

0E4869

SCREW HHHC M6-1.0 X12

NUT, LOCK HEX M3-0.5 (GT-990)

NUT, HEX W/TOOTH WASHER M3-

0.5 (GT-760)

WASHER FLAT #4 (GT-990)

WASHER FLAT #4 (GT-760)

SPACER, ROD (GT-760 ONLY)

SCREW HHFC M6-1.0 X 10mm

ASSY, IGN COIL W/DIODE NO ADV

SCREW TAPTITE M5-0.8 X 8 ZP

PANEL, CONTROL FACE PLATE

SCREW TAPTITE M6-1.0X 10

YELLOW CHROME

158

031879

0E4868

0D6098

0D6147

0F1338A

109

110

111

112

113

0D4767

0D1142A

0D1143

0F1177

022097

SWITCH ROCKER

WRAPPER, LOWER CYLINDER 2

WRAPPER, UPPER CYLINDER 2

ASSEMBLY, GROUND WIRE

WASHER LOCK M6-1/4

159

160

161

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Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

Generator – Drawing No. 0D4488-D

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Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

Generator – Drawing No. 0D4488-D

ITEM PART NO. QTY. DESCRIPTION

0C6934

0D2123

0D2134

0D2136

0D21320SRV 1

0D21330SRV

0D2135

0C6043B

0D2492

0D2726

0C4138

0D3547

031971

0C3168

0D1838

0D3549

0C7038E

032712

0D4662

0C7038D

0C7758

ADAPTOR, ENGINE

STATOR 12.5KW

STATOR 15KW

STATOR 18KW

ASSEMBLY, ROTOR WITH FAN

12.5KW

ASSEMBLY, ROTOR WITH FAN

15KW

0A2038

022237

022511

022131

051731

022145

049820

WASHER FLAT 3/8 ZINC

WASHER LOCK 3/8

SCREW HHC 3/8-16 X 1-1/4 G5

WASHER FLAT 3/8-M10 ZINC

SCREW HHC M8-1.25 X 50 G8.8

WASHER FLAT 5/16 ZINC

NUT LOCK HEX M8-1.25 NYLON

INSERT

ROTOR 18KW

079246

SCREW HHC M6-1.0 X 16 WITH

LOCK WASHER

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 MOUNT

BATTERY CABLE, BLACK

EARTH STRAP 3/8X 3/8

CLIP-J VINYL COAT .625 ID

ASSEMBLY, BRUSH HOLDER

SCREW TAP-R #10-32 X 9/16

022129

022259

059637

0D5100

0D5823

0C8565

0D5833

0D5834

090388

022473

N/A

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 & 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

0D5133

0D5133A

SPARK ARRESTOR SCREEN

RETAINER, SPARK ARREST

SCREEN

SCREW HHTT M4-0.7 X 8

SHIELD, RUBBER MOUNT

SCREW HHTT M5-0.8 X 16

0388050AF0 1

0C2417A

082121C

066386

045764

0D6214

066849

0C2824

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Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

Control Panel – Drawing No. 0E0227-C

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Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

Control Panel – Drawing No. 0E0227-C

ITEM PART NO. QTY.DESCRIPTION

022158

023897

057405

022473

022097

049813

065795

0D4804

0C1085

051715

022264

048505

087962

NUT HEX #10-32

WASHER FLAT #10

RESISTOR 25R 5% 25W

WASHER FLAT 1/4

WASHER LOCK M6-1/4

NUT HEX M6-1.0 G8

RECTIFIER-BATTERY CHARGER

TRANSFORMER, IDLE CURRENT

SCREW PPHM M3-0.5 X 8

NUT HEX M4-0.7 G8

087968

090418

0D6640

090987

0D8740

068868

022985

043182

051714

075207A

075207

0D4969

043437

0D4968

0D4966

0D1004E

SWITCH, ROCKER -/0

OUTLET, 12VDC SNAP

COVER, GOVERNOR CONTROL

SCREW PPHM M3-0.5 X 12

PANEL, SHEET METAL

OUTLET 30A 120V RECEPT

WASHER FLAT #6

WASHER LOCK M3

NUT HEX M3-0.5 G8

CIRCUIT BREAKER 30A

CIRCUIT BREAKER 20A

OUTLET 50A 125/250V

OUTLET 30A 125/250V

OUTLET 20A 120V DPLX

OUTLET 20A 120V GFCI

CIRCUIT BREAKER 50A 400V

2POLE

WASHER LOCK M4

CIRCUIT BREAKER 6 X 1

CIRCUIT BREAKER 10 X 1 12VDC

1/4"QC

RIVET POP .125 X .129-.133 / #30

LUG GRND 8 TABS

HOLDER FUSE

FUSE 10A X AGC10

HEATSINK

SCREW PPHM M4-0.7 X 10

SCREW HHC M5-0.8 X 16 G8.8

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 1.5

SCREW HHTT M5-0.8 X 10

SCREW PPHM M5-0.8 X 30

SCREW PPHM M5-0.8 X 50

WASHER FLAT #8

036261

0A2769

032300

028578

055444

075475

049815

0A2053

055440

045770

0D5734

074908

075235

080823

038150

0D6140

051716

022152

0D5045

067680

NUT HEX M5-0.8 G8

WASHER LOCK #10

DIN RAIL 59.5mm LONG

ASSEMBLY VOLTAGE REGULATOR

60HZ

ELECTRONIC GOVERNOR / IDLE

CONTROLLER

RELAY PNL 12VDC SPST 30A

RELAY 3PDT 12VDC

CONTROL PANEL BOX

BUSHING SNAP

RIVET POP .156 X .160-.164 / #20

BLOCK TERMINAL 20A 2 X 6 X

1100V

BLOCK DOUBLE ROW TERMINAL 8

POSITION

RECTIFIER MSC 12A 600V

WASHER MICA .203

WASHER STEP NYLON .20

0D4409

052844

0F3100

0D2691

023484L

0A1661

048766

GASKET, PORTABLE CONTROL

PANEL

SCREW PPHM M4-0.7 X 16

075476

027565

058000K

0F3101

0D3550

A/R TAPE ELEC UL PERMACEL

NUT TRIC M5-0.8

RELAY BASE 3PDT 12VDC

049939

070370

030468

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Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

Frame, Handle & Wheel Kit – Drawing No. 0E0695-A

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Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

Frame, Handle & Wheel Kit – Drawing No. 0E0695-A

ITEM PART NO. QTY.

DESCRIPTION

ITEM PART NO. QTY.

DESCRIPTION

045900

0D7668

WASHER FLAT 3/4" (15 kW)

WASHER FLAT 3/4" (12.5 kW)

12.3" PNEUM WHEEL 3/4" AXLE

(15 kW)

10" PNEUM WHEEL 3/4" AXLE

(12.5 kW)

PIN COTTER 1/8 X 1-1/4

BRACKET, WHEEL SPACER

NUT FLANGE M6-1.0 NYLOK

HANDLE

SCREW HHC 5/16-18 X 2-1/2 G5

NUT LOCK HEX 5/16-18 NYLON

INSERT

057058

0D5315

0D4570

0D22850SRV

045771

022129

022145

0D4565

0D3545

022287

022473

022097

022127

0388040AK0

0D4575

0D5202

0D5199

029809

0C3168

0D5198

0E0317

0D2498

027007

0D5303

042909

090388

064101

039214

0D9165

0D2496

SCREW HHC M6-1.0 X 55

RUBBER TANK MOUNT

CAP, FUEL WITH GAUGE & VENT

KIT, FUEL TANK

0D2495

NUT HEX M8-1.25

10 WASHER LOCK M8-5/16

14 WASHER FLAT 5/16

0D4999

0D4044

0D3700

0D2497

022532

027028

BRACKET BATTERY

BOLT,BATTERY J-BOLT

SCREW HHC 1/4-20 X 3/4 G5

WASHER FLAT 1/4

WASHER LOCK M6-1/4

NUT HEX 1/4-20

0D2271

052762

051713

049226

051716

050190

078299

080270

0D5142

096021

048031C

030340

075763

075763A

0E0318

030795

FRAME

BATTERY CABLE, RED

BATTERY U1

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 ¼

NUT WING 5/16-18 BRASS

WASHER FLAT 5/16 BRASS

NUT HEX 5/16-18 BRASS

5/16 SPECIAL L/WASH

SCREW HHC 5/16-18 X 1.5 BRASS

BRACKET FRONT FOOT (15 kW)

BRACKET FRONT FOOT (12.5 kW)

VIB MOUNT

WASHER FLAT .25ID X 1"OD

SCREW HHC M8-1.25 X 30

SCREW HHTT M6-1.0 X 12

NUT LOCK FL 3/8-16

18" HOSE ¼ ID

BOOT BATTERY CABLE

BOOT STARTER CABLE

SPACER, AXLE (15 kW)

SCREW HHC 5/16"-18 X 1"

BOLT CARR 3/8-16 X 1

AXLE, 3/4"DIA X 30" (15 kW)

AXLE, 3/4"DIA X 27.25" (12.5 kW)

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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. 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, 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 Warranty Service Facility. When requesting warranty service, evidence

must be presented showing the date of the sale to the original purchaser/owner.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at one of the following

addresses:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, WI 53190

Part 1

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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.

(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 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 ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a Generac

Authorized Warranty Service Facility.

(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for diagnostic

costs if the repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications caused by a failure under warranty of any

emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand

for such emission-related parts.

(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS warranty maintenance or repairs

and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac RCS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts nay not be used to modify or repair a Generac engine. Such use voids this ECS

Warranty and 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 such an unapproved, add-on, modified, counterfeit and/or "grey market" part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

3) Ignition System including:

a) Spark plug

1.2) LPG/Natural Gas carburetion assembly and its internal components.

b) Ignition module

a) Fuel controller (if so equipped)

4) Catalytic Muffler Assembly (if so equipped) including:

a) Muffler gasket

b) Exhaust manifold

b) Mixer and its gaskets (if so equipped)

c) Carburetor and its gaskets (if so equipped)

d) Primary gas regulator (if so equipped)

e) LP liquid vaporizer (if so equipped)

5) Crankcase Breather Assembly including:

a) Breather connection tube

2) Air Induction System including:

a) Intake pipe/manifold

b) Air cleaner

* Generac engine types covered by this warranty statement include the following:

1) Prepackaged Standby Generator

2) Auxiliary Power Unit (APU) Generator

3) Standby Generator

Part 2

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Section 8 – Warranty

Commercial-Industrial-Residential Portable Generator System

GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR GUARDIAN^®

"ULTRA SOURCE 15,000 WATT GENERATOR WITH GENERATOR READY KIT"

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its 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 replace any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service

Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian

Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by

the purchaser/owner. This warranty applies only to Generac Guardian Ultra Source portable generator prepackaged with transfer switch sold

and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and maintenance

is required):

Engine - All Components

Alternator - All Components

Transfer System - All Components

All warranty expense allowances are subject to the conditions defined in Guardian's Warranty Policies, Procedures and Flat Rate Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

•

Guardian Ultra Source generators that utilize non-Guardian/Generac replacement parts.

Guardian Ultra Source generators utilizing non-Guardian/Generac automatic transfer switches.

Guardian Ultra Source generators used in commercial or rental applications.

Repairs or 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 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, cellular phone, facsimile, internet access or other communication expenses.

Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit

warranty period.

•

Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

Rental equipment used while warranty repairs are being performed.

Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)

Overnight freight costs for replacement part(s).

Overtime labor.

Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO

OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow

limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL

GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT

OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above

limitation 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 53190

Part No. 0F7573 Rev.*

Printed in U.S.A.

07.05

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