Generac Power Systems 5209 manual

Owner’ s Manual • SAFETY • ASSEMBLY • OPERATION • TROUBLESHOOTING • ELECTRICAL DATA • PARTS • WARRANTY 1-800-333-1322 UL TRA SOURCE Semi-Automatic Emergency Generator COMMERCIAL • INDUSTRIAL • RESIDENTIAL MODEL: 005209 1 1 5 5 , , 0 0 0 0 0 0 W W A A T T T T G G E E N N E E R R A A T T O O R R A A N N D D 1 1 0 0 0 0 A A M M P P[...]

Table of Contents Residential Portable Generator System Safety Rules ..............................................1-3 Section 1 – General Information ................4 1.1 Unpacking ....................................................................4 1.1.1 Accessory Box ..................................................4 1.2 Assembly ..........[...]

INTRODUCTION Thank you for purchasing this model of the GUARDIAN ® product line by Generac Power Systems, Inc. This model is a compact, high performance, air-cooled, engine driven generator designed to supply electrical power to operate electrical loads when utility power is unavailable due to a power outage. READ THIS MANUAL THOROUGHLY If you do [...]

2 • Never start or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON. Start the engine and let it stabilize before connecting electrical loads. Disconnect all electrical loads before shutting down the generator. • Do not insert objects through unit's cooling slots. • Never operate generator[...]

 ELECTRICAL HAZARDS  • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages as does the generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure al[...]

1.1 UNPACKING • Set the palleted carton on a rigid flat surface. • Remove staples along bottom of carton that fasten carton to pallet. Open carton from top. • Remove all packaging material. • Remove separate accessory box. • Lift carton off the generator. • Remove generator from shipping pallet by removing bolts through the shipping bra[...]

5 1.2.3 BATTERY CONNECTION • The battery shipped with the generator has been provided fully charged. Caution must be taken when connecting the battery. • Cut the tie wrap cable holding the RED and BLACK battery cables to the stator. • Connect the RED battery cable to the battery Positive terminal (+). After making sure that the connection is [...]

6 Section 2 – Operation Residential Portable Generator System OPERATION 2.1 KNOW THE GENERATOR Read the Owner’s Manual and Safety Rules before operating this generator. Compare the generator to this illustration to become familiarized with the locations of various controls and adjustments. Save this manual for future reference. 1) 12 Volt DC, 1[...]

14) Start/Run/Stop Switch – Controls the operation of the generator. 15) Oil Fill – Use this point to add oil to engine. 16) Fuse - 10 Amp – Protects the DC control circuit from overload. If this fuse element has melted open the engine will not be able to crank and start. 2.2 CORD SETS AND CONNECTION PLUGS 2.2.1 AC, 20 AMP, DUPLEX RECEPTACLE [...]

Figure 9 - 120 VAC, 30 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. 2.2.4 120/240V AC, 30 AMP RECEPTACLE Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4-wire grounded c[...]

2.3 HOW TO USE THE GENERATOR If you have any problems operating your generator, please call the generator helpline at 1-800-333-1322. 2.3.1 GROUNDING THE GENERATOR The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground . Local electrical cod[...]

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) . . . . . . . . . . . . . .[...]

2.6.2 ADDING GASOLINE  WARNING: Never fill fuel tank indoors. Never fill fuel tank when engine is running or hot. DO NOT light a cigarette or smoke when filling the fuel tank.  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.[...]

• Move engine CHOKE knob to “Full Choke” position. Figure 17 - Full Choke Position • 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”[...]

2.12 CHARGING A BATTERY  DANGER! Storage batteries give off explosive hydrogen gas while recharging. An explosive mixture will remain around the battery for a long time after it has been charged. The slightest spark can ignite the hydrogen and cause an explosion. Such an explosion can shatter the battery and cause blindness or other serious inju[...]

3.2.1 GENERATOR SPECIFICATIONS MODEL GPS 15000 Model # 004582-1 Rated Max. Power 15.0 kW Surge Power 22.5 kW Rated AC Voltage 120/240 Rated Max AC Load Current @ 240V 62.5 Amps Current @ 120V 125.0 Amps Rated Frequency 60 Hz @ 3600 RPM Phase Single Phase Rated DC Voltage 12 Volts Rated Max DC Load Current @ 12 Volts 10 Amperes 3.2.2 ENGINE SPECIFIC[...]

15 3.3 GENERAL RECOMMENDATIONS The warranty of the generator does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain the generator as instructed in this manual. Some adjustments will need to be made periodically to properly maintain the generator. All adjustm[...]

3.3.6 REPLACING THE SPARK PLUG Use Champion RC14YC spark plug or equivalent. The correct air gap is 0.76 mm (0.030 in.). Replace the plug once each year . This will help your engine start easier and run better. 1. Stop the engine and pull the spark plug wire off of the spark plug. 2. Clean the area around the spark plug and remove it from the cylin[...]

Figure 21 - Spark Arrestor 3.6 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation, you should adjust the valve clearance in the engine. Important: If you feel uncomfortable about doing this procedure or you don't have the proper tools, please take your generator in to the nearest service center to have the valve clearance adjusted[...]

3.7 GENERAL The generator should be started at least once every seven days and be allowed to run at least 30 minutes. If this cannot be done and you must store the unit for more than 30 days, use the following information as a guide to prepare it for storage.  DANGER! NEVER store engine with fuel in tank indoors or in enclosed, poorly ventila[...]

19 4.1 TROUBLESHOOTING Engine is running, but no AC 1. Circuit breaker is open. 1. Reset circuit breaker. output is available. 2. Poor connection or defective cord set. 2. Check and repair. 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[...]

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 exte[...]

1. PLAN THE LOCATION OF YOUR GENERATOR. 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. 2. [...]

6. R emove the threaded lock nut from the conduit coupling. 7. Remove the knock out 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[...]

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 [...]

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), n[...]

TRANSFER TO GENERATOR POWER SOURCE WHEN UTILITY POWER FAILS 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 (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.[...]

TO HOUSE BRANCH TO HOUSE BRANCH CIRCUITS SPLICED CIRCUITS SPLICED USING WIRE NUTS USING WIRE NUTS A 11 11 3 3 9 9 7 7 5 5 1 1 N B 12 12 4 4 10 10 8 8 6 6 2 2 3 4 12 120/240v CBHOM-F TYPE HOM 120/240v CBHOM-F TYPE HOM 120/240v CBHOM-F TYPE HOM 120/240v CBHOM-F TYPE HOM 120/240v CBHOM-F TYPE HOM 120/240v CBHOM-F TYPE HOM 120/240v CBHOM-F TYPE HOM 120[...]

27 Section 7 - Notes Residential Portable Generator System[...]

28 Section 8 — Electrical Data Commercial-Industrial-Residential Portable Generator System Wiring Diagram – Drawing No. 0E0228[...]

29 Section 8 — Electrical Data Commercial-Industrial-Residential Portable Generator System Schematic – Drawing No. 0E0229-A[...]

30 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589-J 22 39 40 44 43 41 42 46 45 35 37 36 38 27 3 3 32 34 160 3 29 24 3 25 26 48 31 30 47 58 53 50 52 49 51 54 55 57 17 56 18 10 1 15 2 6 7 4, 5, 6 8, 11, 12, 13 25, 26, 27 3, 30, 35, 65 [...]

31 ITEM PART NO. QTY. DESCRIPTION 1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH SLEEVE 2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT 3 090388 3 SCREW, TAPTITE M6-1.0 X 12 BP 4 0C5372 1 ASSEMBLY, BREATHER 5 0C3005 1 GASKET, BREATHER COVER 6 0E3372B 1 SEPARATOR, OIL BREATHER 7 0D8067A 1 ASSEMBLY, HEAD #1 8 071983 4 RETAINER, PISTON PIN 20 9 0D5269 1 ROCKER, COVE[...]

32 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589-J 108 136 125 127 122 78 84 149 143 147 146 145 143 140 144 142 67 86 66 80 71 37 72 74 75 DETAIL "A" 153 87 69 81 73 68 70 82 83 151 150 85 79 158 135 141 138 137 154 128 1[...]

ITEM PART # QTY. DESCRIPTION 66 0D6592 1 WINGNUT, AIRBOX 67 0D4511 1 PRECLEANER, AIR 68 0D9723 1 ELEMENT, AIR CLEANER 69 0E5302 1 STUD M6-1.0 X 73 70 0D4183 1 ADAPTOR, SPIT BACK 71 0D6327 1 GASKET, SPITBACK 72 0D2774B 1 BASE, AIRBOX 73 0D5125 1 SPRING, WINTER/SUMMER VALVE 74 0D2930 1 VALVE, SUMMER / WINTER 75 0D4612A 1 SNORKEL, AIR INTAKE 76 0D6143[...]

34 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator – Drawing No. 0D4488-D[...]

35 ITEM PART NO. QTY. DESCRIPTION 1 0C6934 1 ADAPTOR, ENGINE 2 0D2123 1 STATOR 12.5KW 0D2134 STATOR 15KW 0D2136 STATOR 18KW 3 0D21320SRV 1 ASSEMBLY, ROTOR WITH FAN 12.5KW 0D21330SRV ASSEMBLY, ROTOR WITH FAN 15KW 0D2135 ROTOR 18KW 4 0C6043B 1 CARRIER, REAR BEARING 5 0D2492 1 EXHAUST MANIFOLD 6 0D2726 1 MUFFLER 7 0C4138 2 GASKET, EXHAUST 8 0D3547 1 C[...]

36 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No. 0E0227-C 61 1 2 56 5 60 9 44 8 43 42 41 21 3 22 59 6 14 15 13 41 42 59 29 32 31 25 42 41 33 7 35 34 37 36 18 49 30 17 38 8 18 10 11 12 64 18 63 8 9 17 20 23 40 42 59 41 46 26 27 42 41 28 9 8 39 16 17 19 55 47,48 [...]

ITEM PART NO. QTY. DESCRIPTION 1 087968 1 SWITCH, ROCKER -/0 2 090418 1 OUTLET, 12VDC SNAP 3 0D6640 1 COVER, GOVERNOR CONTROL 4 090987 6 SCREW PPHM M3-0.5 X 12 5 0D8740 1 PANEL, SHEET METAL 6 068868 2 OUTLET 30A 120V RECEPT 7 022985 2 WASHER FLAT #6 8 043182 10 WASHER LOCK M3 9 051714 6 NUT HEX M3-0.5 G8 10 075207A 4 CIRCUIT BREAKER 30A 11 075207 2[...]

Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No. 0E0695-A 38[...]

39 ITEM PART NO. QTY. DESCRIPTION 1 057058 4 SCREW HHC M6-1.0 X 55 2 0D5315 4 RUBBER TANK MOUNT 3 0D4570 1 CAP, FUEL WITH GAUGE & VENT 4 0D22850SRV 1 KIT, FUEL TANK 5 045771 4 NUT HEX M8-1.25 6 022129 10 WASHER LOCK M8-5/16 7 022145 14 WASHER FLAT 5/16 8 0D4565 1 BRACKET BATTERY 9 0D3545 2 BOLT,BATTERY J-BOLT 10 022287 2 SCREW HHC 1/4-20 X 3/4 [...]

40 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[...]

41 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/own[...]

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 materia[...]