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Guardian ULTRA SOURCE 004582-2, Owner'S Manual

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29

Section 7 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

GT-990 Engine (Page 2) – Drawing No. 0E8589-R

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

1

TUBE, HEAT RISER 50.8 I.D.

77

0D2775

1

COVER, AIRBOX

78

0D5014A

1

KNOB, AIRBOX 17mm

79

0D5014B

1

KNOB, AIRBOX 95MM

80

049721

1

SCREW HHC M6-1.0 X 35

81

022097

1

WASHER LOCK M6-1/4

82

022473

1

WASHER FLAT 1/4

83

0E8388

4

NUT, HEX FLANGE WHIZ M6-1.0

84

0D6021

4

STUD, METRIC

85

0C9093A

1

HOSE, BREATHER 

86

0D4522

1

CONTROLLER ASSEMBLY

87

074908

2

SCREW HHTT M5-0.8 X 10

89

0E3398

1

ASSEMBLY, WIRE

90

0F9035

1

CARBURETOR (GT-990)

0F8603

1

CARBURETOR (GT-760)

91

0D4026

1

GASKET, CARB TO SPACER (GT-990)

0D4024

1

GASKET, CARB/AIRBOX (GT-760)

92

048031C

4

CLAMP HOSE BAND 1/4

93

0F9176

12"

HOSE ¼  ID

94

0D4023

1

GASKET, MANIFOLD TO CARB (GT-990)

0D5282

1

GASKET, MANIFOLD TO CARB (GT-760)

95

084409D

1

SLEEVING, FLEXO HW ¾ 3"

96

0D6313

1

FILTER, FUEL

97

070008

4

WASHER FLAT M8 

98

070006

4

WASHER LOCK M8

99

049821

4

SCREW SHC M8-1.25 X 30

100

0C9911

1

MANIFOLD, INTAKE

101

051714

1

NUT HEX M3-0.5

102

0D5411

1

ROD, SUMMER / WINTER VALVE

103

0D5445

1

BUSHING, MINI CONTROL PANEL

104

0D5416A

1

KNOB, CONTROL SUMMER / WINTER

105

0D5398

1

CHOKE ASSEMBLY

106

0E6043

2

SCREW TAPTITE M5-0.8 X 8 ZP

107

0D3432

1

PANEL, CONTROL FACE PLATE

108

045756

24

SCREW TAPTITE M6-1.0X 10 YELLOW 

CHROME

109

0D4767

1

SWITCH ROCKER

110

0D1142A

1

WRAPPER, LOWER CYLINDER 2 

111

0D1143

1

WRAPPER, UPPER CYLINDER 2

112

0F1177

1

ASSEMBLY, GROUND WIRE

113

022097

4

WASHER LOCK M6-1/4

ITEM PART NO#. QTY.

DESCRIPTION

114

092079

4

SCREW TAPTITE M6-1.0 X 25 BP

115

0F1338B

1

ASSY, IGN COIL W/DIODE NO ADV

116

0F6263

1

PUMP, IMPULSE

118

0G0926

2

SCREW, HHFCS M6-1.0 X 16 G8.8

119

0G0832

1

ELBOW, RUBBER 90 DEG. GASOLINE

120

0E7585A

2

SPARKPLUG, CHAMPION RC14YC

121

0E4271

1

STARTER, DELCO REMY SD80

122

022129

3

WASHER LOCK M8-5/16

123

061906

2

SCREW HHC M8-1.25 X 85 G8.8

124

022145

1

WASHER, FLAT M8

125

0F5467

1

NUT, HEX M8-1.25 YELLOW ZINC

126

0D1131

1

GUARD,FAN

127

0F1169B

1

HOUSING, BLOWER GAS COOLER

128

0C9763

4

NUT, GROMMET 1/4 PLUG

129

0C3034

1

NUT,HEX M24

130

0C3033

1

WASHER, M24

131

0C3032

1

PLATE, FAN 

132

0A5992

2

WASHER SHAKEPROOF INT M8 SS

133

051754

2

SCREW HHC M8-1.25 X 12 G8.8

134

0C3031

1

FAN, NYLON

135

0E4997

1

ASSY,GROUND WIRE CONNECTOR

136

045756

4

SCREW TAPTITE M6-1X10 YELLOW 

CHROME

137

0C3725A

1

FLYWHEEL ASSEMBLY

138

0F1170A

1

PLATE, BACKING GT990 W/OIL COOL

139

082774

1

KEY, WOODRFF 4 X 19D

140

0C3043

2

GASKET, MANIFOLD / PORT 

141

0C9764

4

PLASTITE,1/4-15 X 3/4

142

0C3026

1

COOLER, OIL 

143

0F6301

4

CLAMP, HOSE OETIKER 16.5mm

144

0C9806

2

HOSE, 3/8" I.D. X 6" LONG 

145

035461

2

BARBED STR 1/4NPT X 3/8 

146

070185B

1

OIL FILTER 

147

0D3083

1

ASSEMBLY, OIL DRAIN HOSE

149

0C3025

1

SWITCH, OIL PRESS 

150

0D4550

1

BRACKET, AIRBOX SUPPORT

151

0C3018

1

WRAPPER, UPPER CYLINDER 1 

152

0C3019

1

WRAPPER, LOWER CYLINDER 1 

153

046964

1

BRASS ST ELBOW 1/4 NPT

154

0E0409

1

ASSY, ROD, GOV. STEPPER MOTOR

155

0C8563

6

SCREW HHHC M6-1.0 X12 

157

0D9784

2

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

0E4869

2

NUT, HEX W/TOOTH WASHER M3-0.5 

(GT-760)

160

0D6147

7

SCREW HHFC M6-1.0 X 10mm

161

0F1338A

1

ASSY, IGN COIL W/DIODE NO ADV

162

048031G

1

CLAMP, HOSE BAND GREEN

Summary of Contents for ULTRA SOURCE 004582-2

Page 1: ...Y ASSEMBLY OPERATION TROUBLESHOOTING ELECTRICAL DATA PARTS WARRANTY 1 800 333 1322 ULTRA SOURCE Portable Generator COMMERCIAL INDUSTRIAL RESIDENTIAL MODEL 004582 2 15 000 Watt Portable Generator AUTHO...

Page 2: ...2 Adding Gasoline 11 2 7 To Start The Engine 11 2 8 Stopping The Engine 12 2 9 Automatic Idle Control 12 2 10 Cold Weather Operation De Icer 12 2 11 Low Oil Pressure Shutdown 12 2 11 1 Initial Start...

Page 3: ...d to operate the equipment in an emergency CAUTION Always disconnect spark plug wires and place the wires where they cannot contact the spark plugs to prevent accidental starting when setting up trans...

Page 4: ...rator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS Never operate in an enclosed area or indoors For safety reasons GENERAC recommends that the mainten...

Page 5: ...nd 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 t...

Page 6: ...efer 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 e...

Page 7: ...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 Nega...

Page 8: ...ctrical 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 l...

Page 9: ...tion 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 A GFCI receptacle does NOT prote...

Page 10: ...ed by two 30 Amp push to reset circuit breakers 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...

Page 11: ...e 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 b...

Page 12: ...llow 3 times the listed watts for starting these devices 10 Section 2 Operation Commercial Industrial Residential Portable Generator System 2 6 BEFORE STARTING THE GENERATOR Prior to operating the gen...

Page 13: ...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 i...

Page 14: ...al fast governed engine speed when electrical load is connected When the load is removed the engine will run at a reduced speed of 2100RPM With the switch Off the engine runs at the normal fast engine...

Page 15: ...ge measured at the outlet should be 8 12 VDC This is normal and does not indicate a faulty charging system To recharge 12 Volt batteries proceed as follows Check fluid level in all battery cells If ne...

Page 16: ...tion 1 2 Load 10 Hours 1 6 gallons per hour Check Oil Level Service Air Pre Cleaner Change Oil and Oil Filter Clean Spark Arrestor Screen Check Valve Clearance Service Air Cleaner Replace Spark Plugs...

Page 17: ...erior 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...

Page 18: ...ce if necessary and remove paper filter 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 Clean air cle...

Page 19: ...as high as it can go Insert a 0 002 0 004 inch 0 05 0 1mm feeler gauge between the rocker arm and valve stem Correct clearance is when a slight drag is felt when sliding the gauge back and forth If th...

Page 20: ...gine 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...

Page 21: ...spark plug 5 Replace spark plug 6 Water in gasoline 6 Drain fuel tank fill with fresh fuel 7 Overchoking 7 Put choke knob to No Choke position 8 Low oil level 8 Fill crankcase to proper level 9 Exces...

Page 22: ...30A TWISTLOK WHITE WHITE 0 4 5 WHITE WHITE 2 WHITE WHITE 120V 20A 120V 20A GFCI GFCI X Y G C B C B CONTRO SWITC IDL ON OF 60A 60A 50A 60A OUTLET 50A 60A OUTLET 120 240V 120 240V 50A 50A 22 11 44 15B 2...

Page 23: ...HARGE CHARGE BATTERY BATTERY CHARGE CHARGE BATTERY BATTERY RECTIFIER RECTIFIER D2 D2 R1 R1 22 22 ENGINE SHUTDOWN P C B ENGINE SHUTDOWN P C B ELECTRONIC GOVERNOR ELECTRONIC GOVERNOR CONTROL CONTROL SWI...

Page 24: ...ULATOR ELECTRONIC ELECTRONIC C1 10 C1 10 77A 77A 77 77 77 77 C1 8 C1 8 55 55 C1 5 C1 5 77A 77A C1 3 C1 3 55A 55A CONTROL CONTROL PRINTED CIRCUIT PRINTED CIRCUIT 167 167 5 229 229 TR2 TR2 86 86 22S 22S...

Page 25: ...23 Section 6 Notes Commercial Industrial Residential Portable Generator System...

Page 26: ...Section 6 Notes Commercial Industrial Residential Portable Generator System 24...

Page 27: ...Section 6 Notes Commercial Industrial Residential Portable Generator System 25...

Page 28: ...8 11 12 13 25 26 27 3 30 35 65 7 41 42 43 44 45 46 47 49 50 51 52 53 54 57 58 41 42 43 44 45 46 47 49 50 51 52 53 54 56 57 58 2 5 17 18 34 35 40 57 139 153 59 60 61 63 65 62 64 14 18 45 40 43 44 42 41...

Page 29: ...1 CLAMP OIL TUBE 31 0D4497 1 PLUG CRANKCASE GOVERNOR BORE 32 0C3971E 1 ASSEMBLY DIPSTICK WITH HANDLE 33 0D3745 1 TUBE DIPSTICK 34 0C3027 3 O RING OIL CLR 35 0E9842 1 SEAL 42 I D CRANKSHAFT ITEM PART N...

Page 30: ...116 125 127 122 78 84 149 143 146 145 143 140 144 142 67 86 66 80 71 37 72 74 75 DETAIL A 153 87 69 81 73 68 70 82 83 151 150 85 79 135 141 138 137 154 128 129 108 132 131 130 134 133 126 155 DETAIL A...

Page 31: ...HROME 109 0D4767 1 SWITCH ROCKER 110 0D1142A 1 WRAPPER LOWER CYLINDER 2 111 0D1143 1 WRAPPER UPPER CYLINDER 2 112 0F1177 1 ASSEMBLY GROUND WIRE 113 022097 4 WASHER LOCK M6 1 4 ITEM PART NO QTY DESCRIP...

Page 32: ...ustrial Residential Portable Generator System Generator Drawing No 0G0742 A 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 3...

Page 33: ...2417A 1 EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VINYL COAT 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 0C2824 1 SCREW TAP R 10 32 X 9 16 ITEM PART NO QTY DESCRIPTION 23 0A2038 1 WASHER FLAT 3 8 ZINC...

Page 34: ...32 Section 7 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Control Panel Drawing No 0G0727 B...

Page 35: ...097 1 WASHER LOCK M6 1 4 37 049813 1 NUT HEX M6 1 0 G8 ITEM PART NO QTY DESCRIPTION 38 065795 2 RECTIFIER BATTERY CHARGER 39 0D4804 2 TRANSFORMER IDLE CURRENT 40 0C1085 4 SCREW PPHM M3 0 5 X 8 41 0517...

Page 36: ...nerator System Frame Handle Wheel Kit Drawing No 0E0695 B 34 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...

Page 37: ...12 26 064101 6 NUT LOCK FL 3 8 16 27 039214 6 BOLT CARR 3 8 16 X 1 28 0D9165 1 AXLE 3 4 DIA X 30 15 kW ITEM PART NO QTY DESCRIPTION 29 045900 2 WASHER FLAT 3 4 15 kW 30 0D7668 2 12 3 PNEUM WHEEL 3 4 A...

Page 38: ...y 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 coun...

Page 39: ...h 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 r...

Page 40: ...res caused by any contaminated fuels oils or lack of proper oil levels Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper use As with all mechanical devi...

Page 41: ......

Page 42: ...8 4 SCREW HHTT M6 1 0 X 12 26 064101 6 NUT LOCK FL 3 8 16 27 039214 6 BOLT CARR 3 8 16 X 1 28 0D9165 1 AXLE 3 4 DIA X 30 15 kW 0D2496 1 AXLE 3 4 DIA X 27 25 12 5 kW 29 045900 2 WASHER FLAT 3 4 15 kW 0...

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