Generac 004583-0 manual

Owner’ s Manual • SAFETY • ASSEMBL Y • OPERA TION • TROUBLESHOOTING • ELECTRICAL DA T A • P AR TS • W ARRANTY 1-800-333-1322 UL TRA SOURCE Portable Generator COMMERCIAL • INDUSTRIAL • RESIDENTIAL MODEL: 004583-0 17,500 W att Portable Generator and 60 amp manual transfer switch with built-in load center AUTHORIZED DEALER SUPPORT [...]

T able 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 THOROUGHL Y 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 generato[...]

 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 UNP ACKING • 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 b[...]

5 1.2.3 BA TTERY 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 batter y cables to the stator . • Connect the RED batter y cable to the battery Positive terminal (+). After making sure that the connectio[...]

6 Section 2 – Operation Residential Portable Generator System OPERA TION 2.1 KNOW THE GENERA TOR 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 D[...]

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

Figure 9 - 120 V AC, 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 RECEPT ACLE Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4-wire grounde[...]

2.3 HOW TO USE THE GENERA TOR If you have any problems operating your generator , please call the generator helpline at 1-800-333-1322. 2.3.1 GROUNDING THE GENERA TOR 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 [...]

2.5 WA TT AGE 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 • T o 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 BA TTER Y  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 in[...]

3.2.1 GENERA TOR SPECIFICA TIONS MODEL GPS 17,500 Model # 004583-0 Rated Max. Power 17.5 kW Surge Power 26.2 kW Rated AC Voltage 120/240 Rated Max AC Load Current @ 240V 72.9 Amps Current @ 120V 145.8 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 SPECI[...]

15 3.3 GENERAL RECOMMENDA TIONS The warranty of the generator does not cover items that have been subjected to operator abuse or negligence. T o 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 adj[...]

3.3.6 REPLACING THE SP ARK PLUG Use Champion RC14YC spark plug or equivalent. The correct air gap is 1.01 mm (0.040 in.). Replace the plug once each year . This will help your engine start easier and run better . 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 cyl[...]

Figure 21 - Spark Arrestor 3.6 ADJUSTING V AL VE 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 adjust[...]

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 Ser vice Facility . Engine runs[...]

2. 3. 20 Section 5—Installation for Manual T ransfer Switch KIT INCLUDES: 1. Power Inlet Box Pre-wired with the 50 amp male receptacle, this box is located outside the home where the generator will be operated. 2. Pre-wired Manual T ransfer Switch and Emergency Load Center with 16 Circuits Installed within 1 foot of the home’ s main distributio[...]

21 Section 5—Installation for Manual T ransfer Switch 1. PLAN THE LOCA TION OF YOUR GENERA TOR (Fig. A) shows the GUARDIAN Ultra Source 17,5000 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 w[...]

7a. Lift cover of the power inlet box and remove the internal cover plate screws and internal cover plate. Remove the knock out in the lower center of the box. From the rear of the connection box, feed wires into box. Slip the lock nut over wires tighten securely onto conduit coupling. 7b. Using appropriate fasteners, mount power inlet box over pre[...]

9a. The 2 foot conduit that is pre-wired into the manual transfer switch is not fastened to the side of the enclosure when shipped. T o secure the conduit to the manual switch enclosure proceed as follows. Remove the cover panel of the manual transfer switch with emergency load center . Insert the 2 foot conduit into the knockout and tighten the lo[...]

USING THE UL TRA SOURCE PORT ABLE The GUARDIAN ® UL TRA SOURCE with manual transfer switch gives you the ability to provide power safely and conveniently to vital items in your home including hard wired items. Included in the kit is a power Inlet box with built-in 50 Amp twistlock male receptacle and a 15 foot electrical power cord. The power cord[...]

TRANSFER TO GENERA TOR POWER SOURCE WHEN UTILITY POWER F AILS 1. Move generator to within approximately 10 feet of the power inlet box. Connect ground strap to the generator’ s grounding lug and to the grounding rod. 2. Open the door of the Manual T ransfer Switch. Slide the mechanical interlock connecting the 60 Amp and 50 Amp circuit breakers a[...]

26 Section 6—Operation of Generator with Manual T ransfer Switch INTERCONNECTION DRA WING UL TRASOURCE GENERA TOR CONNECTED T O THE EXTERNAL CONNECTION BOX, MANUAL TRANSFER SWITCH AND HOME’S MAIN ELECTRICAL DISTRIBUTION P ANEL[...]

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

28 Section 8 — Electrical Data Commercial-Industrial-Residential Portable Generator System Wiring Diagram, UltraSource Portable Generator – Drawing No. 0G0731 ACTUATOR ACTUATOR GOVERNOR GOVERNOR 4 0 CLOSEST TO BEARING STATOR 30 30 85 85 87a 87a 86 86 87 87 SC SC BLACK BLACK 12V 12V BATTERY BATTERY SM SM RED RED SP2 SP2 SP1 SP1 IM2 IM2 FSS FSS L[...]

29 ACTUATOR GOVERNOR 4 0 CLOSEST TO BEARING CLOSEST TO BEARING STATOR STATOR 30 85 87a 86 87 SC BLACK 12V BATTERY SM RED SP2 SP1 IM2 FSS LOP D D IM1 STOP RUN (START) 0 IC PIN # 12 11 10 8 9 7 6 SCR 5 4 3 0 2 1 F1 GND SSR ENGINE WIRING 30A C.B. 22 C.B. 30A 0 22 22 G 0 0 TWISTLOK 120V/30A WHITE 22 0 0 G WHITE TWISTLOK 120V/30A 20A C.B. C.B. 20A C.B. [...]

Section 8 — Electrical Data Commercial-Industrial-Residential Portable Generator System Schematic, UltraSource Portable Generator – Drawing No. 0G0733 86 86 0 14 14 15 15 15 15 167 167 0 17 17 16 16 13 13 13 13 22 22 44 44 ACTUATOR ACTUATOR J1 J1 44C 44C 0 RESET RESET TEST TEST GFCI GFCI 120V 120V 120V/30A 120V/30A TWISTLOK TWISTLOK CB1 - 10AMP[...]

Section 8 — Electrical Data Commercial-Industrial-Residential Portable Generator System Wiring Diagram, Manual T ransfer Switch – Drawing No. 0G1065 CIRCUIT 16 CIRCUIT 16 CIRCUIT 14 CIRCUIT 14 CIRCUIT 12 CIRCUIT 12 CIRCUIT 8 CIRCUIT 8 CIRCUIT 6 CIRCUIT 6 MAIN 2 MAIN 2 CIRCUIT 2 CIRCUIT 2 CIRCUIT 4 CIRCUIT 4 CIRCUIT 10 CIRCUIT 10 NEUTRAL NEUTRAL[...]

32 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Manual T ransfer Switch with Load Center – Drawing No. 0G0939-B[...]

33 ITEM P ART NO. QTY . DESCRIPTION 1 0G0749 1 BOX LOAD CENTER W/HARDWARE 2 0G0748 1 CIRCUIT BREAKER INTERLOCK 3 0E7888 1 CIRCUIT BREAKER 20A 2P 4 0E7888B 5 CIRCUIT BREAKER 15A 1P 5 0E7888C 5 CIRCUIT BREAKER 20A 1P 6 0E7888D 1 CIRCUIT BREAKER 40A 2P 7 0E7888E 2 CIRCUIT BREAKER 50A 2P 8 0E7888F 1 CIRCUIT BREAKER 60A 2P 9 0G0863 1 HARNESS, 50 AMP PLU[...]

34 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT -990 & GT -760 Engine (Page 1) – Drawing No. 0E8589-N 22 39 40 44 43 41 42 46 45 35 37 36 38 27 33 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[...]

35 ITEM P ART NO. QTY . DESCRIPTION 1 0C5729 1 ASSEMBL Y , CRANKCASE HOUSING WITH SLEEVE 2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT 3 090388 3 SCREW , T APTITE M6-1.0 X 12 BP 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER COVER 6 0E3372B 1 SEP ARA TOR, OIL BREA THER 7 0D8067A 1 ASSEMBL Y , HEAD #1 8 071983 4 RET AINER, PISTON PIN 20 9 0G06[...]

36 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT -990 & GT -760 Engine (Page 2) – Drawing No. 0E8589-N 108 136 118 162 120 119 116 125 127 122 78 84 149 143 146 145 143 140 144 142 67 86 66 80 71 37 72 74 75 DET AIL "A" 153 87 69 81 73 68 70 82 83 151 150 85 79 135 141 13[...]

ITEM P ART # 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 V AL VE 74 0D2930 1 V AL VE, SUMMER / WINTER 75 0D4612A 1 SNORKEL, AIR INT AKE[...]

38 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator – Drawing No. 0D4488-F 10 33 11 38 8 39 24 12 14 23 21 46 34 31 13 32 31 39 17 28 42 43 44 19 32 10 17 16 2 4 9 3 15 37 35 5 30 20 6 1 7 25 40 19 32 22 24 26 31 36 28 32 31 28 27 45 29 29 18 28 10 40 41 30[...]

39 ITEM P ART NO. QTY . DESCRIPTION 1 0C6934 1 ADAPTOR, ENGINE 2 0D2123 1 ST A TOR 12.5KW 0D2134 ST A TOR 15KW 0D2136 ST A TOR 18KW 3 0D21320SRV 1 ASSEMBL Y , ROTOR WITH F AN 12.5KW 0D21330SRV ASSEMBL Y , ROTOR WITH F AN 15KW 0D2135 ROTOR 18KW 4 0C6043B 1 CARRIER, REAR BEARING 5 0D2492 1 EXHAUST MANIFOLD 6 0D2726 1 MUFFLER 7 0C4138 2 GASKET , EXHAU[...]

40 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No. 0G0727-B[...]

ITEM P ART 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 MET AL (15 KW) 0G0309 1 P ANEL, SHEET MET AL (17.5 KW) 6 068868 2 OUTLET 30A 120V RECEPT 7 0G1093 4 SCREW SFILHM #8-32 X 5/8 LG (17.5 KW ONL Y) 8 043182 4 WASHER L[...]

Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No. 0E0695-B 42 33 14 15 7 34 6 11 35 10 49 8 5 7 9 12 13 39 40 26 24 38 39 20 17 19 22 21 36 6 7 42 6 5 7 26 32 52 47 46 45 50 25 17 17 18 16 44 43 48 3 7 6 36 41 4 23 29/51 30 29 27 28 2 31 37 1 ENGINE[...]

43 ITEM P ART NO. QTY . DESCRIPTION 1 057058 4 SCREW HHC M6-1.0 X 55 2 0D5315 4 RUBBER T ANK MOUNT 3 0D4570 1 CAP , FUEL WITH GAUGE & VENT 4 0D22850SRV 1 KIT , FUEL T ANK 5 045771 4 NUT HEX M8-1.25 6 022129 10 W ASHER LOCK M8-5/16 7 022145 14 WASHER FLA T 5/16 8 0D4565 1 BRACKET BA TTERY 9 0D3545 2 BOL T ,BA TTERY J-BOL T 10 022287 2 SCREW HHC [...]

44 CALIFORNIA EMISSION CONTROL W ARRANTY ST A TEMENT Y OUR W ARRANTY RIGHTS AND OBLIGA TIONS The Calif or nia Air Resources Board (CARB) and Generac P ower Systems , Inc. (Generac) are pleased to e xplain the Emission Control System warranty on y our ne w engine. In California, new off-road Large Spark-Ignition (LSI) engines must be designed, built[...]

45 EMISSION CONTROL SYSTEM W ARRANTY Emission Control System W arranty (ECS warr anty) for 2001 and later model y ear LSI engines: (a) Applicability: This warranty shall apply to 1995 and later model y ear engines. The ECS W arranty per iod shall begin on the date the ne w engine or equipment is purchased by/deliv ered to its original, end-use purc[...]

GENERA C PO WER SYSTEMS "TWO YEAR" LIMITED W ARRANTY FOR GU ARDIAN ® UL TRA SOURCE 17,500 W A TT GENERA T OR WITH MANU AL TRANSFER SWITCH F or a period of two years from the date of original sale, Generac P ower Systems, Inc. (Generac) warrants that its Guardian gener ator and accompanying transf er s witch will be free from def ects in [...]