Guardian ULTRA SOURCE 004451, ULTRA SOURCE 004582 Owner's Manual

Owner’s

1-800-333-1322

Manual

• SAFETY

• ASSEMBLY

• OPERATION

ULTRA SOURCE

Portable Generator

• TROUBLESHOOTING

• ELECTRICAL DATA

• PARTS

• WARRANTY

AUTHORIZED DEALER SUPPORT:

COMMERCIAL • INDUSTRIAL • RESIDENTIAL

MODELS:
004451 (12,500 WATT)
004582 (15,000 WATT)

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 where no
utility power is available.

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.

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:

After this heading, you can read instructions that, if
not strictly complied with, will result in personal injury
or property damage.

After this heading, you can read instructions that, if
not strictly complied with, may result in personal
injury or property damage.

After this heading, you can read instructions that, if
not strictly complied with, could result in damage to
equipment and/or property.

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.

Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTIONblocks. The type of information each
indicates follows:

 This symbol points out important safety

information that, if not followed, could endanger
personal safety and/or property of you and others.

 This symbol points out potential explosion hazard.
 This symbol points out potential fire hazard.
 This symbol points out potential electrical shock

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. 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.

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.

• 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.

• 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.

• Use a ground fault circuit interrupter in any damp or highly
conductive area (such as metal decking or steel work).

• 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.

• 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.

• Never add fuel while unit is running.

• Do not overfill the fuel tank. Always allow room for fuel
expansion. If tank is overfilled, fuel can overflow onto a hot
engine and cause FIRE or an EXPLOSION.

• 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.

• 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.

• 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.

1

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 DANGER 

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 WARNING 

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 CAUTION 

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3

 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 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 handle any kind of electrical device while standing in

water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• 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.

• 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 non­conducting 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.

• 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.

 FIRE HAZARDS 

• 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.

 EXPLOSION HAZARDS 

• 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.

1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE.

2. Article X, NATIONAL BUILDING CODE, available from the
American Insurance Association, 85 John Street, New York,
N.Y. 10038.

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.

5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS
CODE.

IMPORTANT SAFETY INSTRUCTIONS

Commercial-Industrial-Residential Portable Generator System

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 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.

Figure 3 - Battery Connections

Section 1 - General Information

Commercial-Industrial-Residential Portable Generator System

Negative

Cable

Positive

Cable

Figure 2 - Handle Assembly

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, well­insulated, 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.

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

2.2.2 120V AC, 20 AMP, GFCI RECEPTACLE

This unit is equipped with a ground fault circuit interrupter (GFCI).
This device meets applicable federal, state and local codes.

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.

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.

Figure 8 - 120 VAC, 20 Amp GFCI Receptacle

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

• Plug a test lamp into the 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-to­reset circuit breaker. Use the outlet to power 120V AC, single­phase, 60 Hz, electrical loads requiring up to a combined 2400
watts (2.4 kW) or 20 amps of current.

2.2.3 120V AC, 30 AMP RECEPTACLE

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.

7

Section 2 – Operation

Commercial-Industrial-Residential Portable Generator System

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 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.

Figure 13 - Grounding the 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.

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.

• Let engine stabilize and warm up for a few minutes after
starting.

• 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:

• 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.

• 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:

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.)

9

Section 2 – Operation

Commercial-Industrial-Residential Portable Generator System

Generator Ground Lug