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Generac Power Systems 5209 Owner's Manual

Semi-automatic emergency generator
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See also: Repair Manual
ULTRA SOURCE
Semi-Automatic
Emergency Generator
Owner's
Manual
• SAFETY
• ASSEMBLY
• OPERATION

• TROUBLESHOOTING

• ELECTRICAL DATA
• PARTS
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
• WARRANTY
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 T T R R A A N N S S F F E E R R S S W W I I T T C C H H
AUTHORIZED DEALER SUPPORT:
W W I I T T H H B B U U I I L L T T - - I I N N L L O O A A D D C C E E N N T T E E R R
1-800-333-1322

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Summary of Contents for Generac Power Systems 5209

  • Page 1: Troubleshooting

    ULTRA SOURCE Semi-Automatic Emergency Generator Owner’s Manual • SAFETY • ASSEMBLY • OPERATION • TROUBLESHOOTING • ELECTRICAL DATA • PARTS COMMERCIAL • INDUSTRIAL • RESIDENTIAL • WARRANTY 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 T T R R A A N N S S F F E E R R S S W W I I T T C C H H AUTHORIZED DEALER SUPPORT: W W I I T T H H B B U U I I L L T T - - I I N N L L O O A A D D C C E E N N T T E E R R...

  • Page 2: Table Of Contents

    Table of Contents Residential Portable Generator System Safety Rules ...1-3 Section 1 – General Information ...4 Unpacking ...4 1.1.1 Accessory Box...4 Assembly ...4 1.2.1 Assembling the Wheel Kit ...4 1.2.2 Assembling the Handle ...5 1.2.3 Battery Connection ...5 Section 2 – Operation ...6 Know The Generator ...6...

  • Page 3: Safety Rules

    INTRODUCTION Thank you for purchasing this model of the GUARDIAN line by Generac Power Systems, Inc. This model is a compact, high performance, air-cooled, engine driven generator designed to supply electrical power to operate electrical loads when utility power is unavailable due to a power outage. READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual, contact your nearest GENERAC/GUARDIAN...
  • Page 4 IMPORTANT SAFETY INSTRUCTIONS Residential Portable Generator System SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's installation site. Safety should be stressed to all operators and potential operators of this equipment.

  • Page 5: Electrical Hazards

    If you have any question pertaining to fire extinguishers, consult your local fire department. IMPORTANT SAFETY INSTRUCTIONS Residential Portable Generator System • 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.

  • Page 6: Section 1 - General Information

    Section 1 – General Information Residential Portable Generator System 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.

  • Page 7: Battery Connection

    • Double check all connections to ensure they are in the correct location and secure. See Figure 3 at right. Section 1 - General Information Residential Portable Generator System Figure 2 - Handle Assembly Figure 3 - Battery Connections Negative...

  • Page 8: Section 2 - Operation

    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.

  • Page 9: Cord Sets And Connector Plugs

    For example, a defective appliance can cause a ground fault. Section 2 – Operation Residential Portable Generator System 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.

  • Page 10: 120/240V Ac, 30 A, Receptacle

    Section 2 – Operation Residential Portable Generator System 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.

  • Page 11: How To Use The Generator

    Section 2 – Operation Residential Portable Generator System 2.3.2 CONNECTING ELECTRICAL LOADS 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.

  • Page 12: Wattage Reference Chart

    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) .

  • Page 13: Adding Gasoline

    • Make sure the unit is in a level position. • Open the fuel shut-off valve. Residential Portable Generator System ------------- • Locate the Idle Control ON/OFF switch on the control panel and set it to the “OFF” position.

  • Page 14: Stopping The Engine

    Section 2 – Operation Residential Portable Generator System • 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.

  • Page 15: Charging A Battery

    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. Section 2 – Operation Residential Portable Generator System...

  • Page 16: Section 3 - Maintenance

    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 Check Oil Level Service Air Pre-Cleaner Change Oil and Oil Filter‡...

  • Page 17: General Recommendations

    Inspect cooling air slots and openings on the generator. These openings must be kept clean and unobstructed. Section 3 — Maintenance Residential Portable Generator System 3.3.3 ENGINE MAINTENANCE 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.

  • Page 18: Replacing The Spark Plug

    Section 3 — Maintenance Residential Portable Generator System 3.3.6 REPLACING THE SPARK PLUG Use Champion RC14YC spark plug or equivalent. The correct air gap is 0.76 mm (0.030 in.). Replace the plug once each year. This will help your engine start easier and run better.

  • Page 19: Adjusting Valve Clearance

    NOTE: You must hold the rocker arm jam nut in place as you turn the pivot ball stud. 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.

  • Page 20: General

    Section 3 — Maintenance Residential Portable Generator System 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.

  • Page 21: Section 4 - Troubleshooting

    Commercial-Industrial-Residential Portable Generator System 4.1 TROUBLESHOOTING SYMPTOM Engine is running, but no AC output is available. Engine runs good but bogs down when loads are connected. Engine will not crank. Engine will not start; or starts and runs rough. Engine shuts down during operation.

  • Page 22: Section 5 - Installation Guide For Generator Ready Kit

    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.
  • Page 23 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.
  • Page 24 SECTION 5 - INSTALLATION GUIDE FOR GENERATOR READY KIT Threaded Lock Nut The outer diameter of the threaded end is 15/16 inches. 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.
  • Page 25 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...

  • Page 26: Section 6 - Operation Of Generator With Generator Ready Kit

    At the other end is the male connector (NEMA 14-50) which plugs into the GUARDIAN 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.
  • Page 27 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.

  • Page 28: Generator Ready Kit

    SECTION 6 - OPERATION OF GENERATOR WITH GENERATOR READY KIT INTERCONNECTION DRAWING SEMI-AUTOMATIC TRANSFER SWITCH CONNECTED TO THE EXTERNAL CONNECTION BOX AND HOME’S MAIN ELECTRICAL DISTRIBUTION PANEL. TO HOUSE BRANCH TO HOUSE BRANCH CIRCUITS SPLICED CIRCUITS SPLICED USING WIRE NUTS USING WIRE NUTS GENERATOR READY GENERATOR READY...

  • Page 29: Section 7 - Notes

    Section 7 - Notes Residential Portable Generator System...

  • Page 30: Section 8 - Electrical Data

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

  • Page 31: Section 8 – Electrical Data

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

  • Page 32: Section 9 - Exploded Views And Parts Lists

    Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589-J...
  • Page 33 Commercial-Industrial-Residential Portable Generator System ITEM PART NO. QTY. DESCRIPTION 0C5729 ASSEMBLY, CRANKCASE HOUSING WITH SLEEVE 0E9843 SEAL, 38 I.D. CRANKSHAFT 090388 SCREW, TAPTITE M6-1.0 X 12 BP 0C5372 ASSEMBLY, BREATHER 0C3005 GASKET, BREATHER COVER 0E3372B SEPARATOR, OIL BREATHER 0D8067A ASSEMBLY, HEAD #1...
  • Page 34 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589-J...
  • Page 35 Commercial-Industrial-Residential Portable Generator System ITEM PART # QTY. DESCRIPTION 0D6592 WINGNUT, AIRBOX 0D4511 PRECLEANER, AIR 0D9723 ELEMENT, AIR CLEANER 0E5302 STUD M6-1.0 X 73 0D4183 ADAPTOR, SPIT BACK 0D6327 GASKET, SPITBACK 0D2774B BASE, AIRBOX 0D5125 SPRING, WINTER/SUMMER VALVE 0D2930 VALVE, SUMMER / WINTER...
  • Page 36 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator – Drawing No. 0D4488-D...
  • Page 37 Commercial-Industrial-Residential Portable Generator System ITEM PART NO. QTY. DESCRIPTION 0C6934 ADAPTOR, ENGINE 0D2123 STATOR 12.5KW 0D2134 STATOR 15KW 0D2136 STATOR 18KW 0D21320SRV 1 ASSEMBLY, ROTOR WITH FAN 12.5KW 0D21330SRV ASSEMBLY, ROTOR WITH FAN 15KW 0D2135 ROTOR 18KW 0C6043B CARRIER, REAR BEARING...
  • Page 38 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel – Drawing No. 0E0227-C...
  • Page 39 Commercial-Industrial-Residential Portable Generator System ITEM PART NO. QTY. DESCRIPTION 087968 SWITCH, ROCKER -/0 090418 OUTLET, 12VDC SNAP 0D6640 COVER, GOVERNOR CONTROL 090987 SCREW PPHM M3-0.5 X 12 0D8740 PANEL, SHEET METAL 068868 OUTLET 30A 120V RECEPT 022985 WASHER FLAT #6...
  • Page 40 Section 9 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit – Drawing No. 0E0695-A...

  • Page 41: Parts Lists

    Commercial-Industrial-Residential Portable Generator System ITEM PART NO. QTY. DESCRIPTION 057058 SCREW HHC M6-1.0 X 55 0D5315 RUBBER TANK MOUNT 0D4570 CAP, FUEL WITH GAUGE & VENT 0D22850SRV KIT, FUEL TANK 045771 NUT HEX M8-1.25 022129 WASHER LOCK M8-5/16 022145 WASHER FLAT 5/16...

  • Page 42: Section 108 - Warranty

    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.

  • Page 43: Emission Control System Warranty

    Commercial-Industrial-Residential Portable Generator System 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.

  • Page 44: Section 108 – Warranty

    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"...

This manual is also suitable for:

Ultra source 005209

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