Guardian Technologies 5209 User Manual
Owner’s
Manual
• SAFETY
• ASSEMBLY
• OPERATION
• TROUBLESHOOTING
• ELECTRICAL DATA
• PARTS
• WARRANTY
1-800-333-1322
ULTRA SOURCE
Semi-Automatic
Emergency Generator
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODEL: 005209
1155,,000000 WWAATTTT GGEENNEERRAATTOORR
AANNDD 110000 AAMMPP TTRRAANNSSFFEERR SSWWIITTCCHH
WWIITTHH BBUUIILLTT--IINN LLOOAADD CCEENNTTEERR
AUTHORIZED DEALER SUPPORT:
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 ......................................................................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
2.1 Know The Generator ....................................................6
2.2 Cord Sets and Connector Plugs....................................7
2.2.1 120V AC, 20 A, Duplex Receptacle ..................7
2.2.2 120V AC, 20 A, GFCI Receptacle ......................7
2.2.3 120V AC, 30 A Receptacle ............................7-8
2.2.4 120/240V AC, 30 A, Receptacle........................8
2.2.5 12 VDC, 10 Amp Receptacle ............................8
2.2.6 120/240V AC, 50 A, Receptacle........................8
2.3 How To Use The Generator ..........................................9
2.3.1 Grounding The Generator ................................9
2.3.2 Connecting Electric Loads ................................9
2.4 Don’t Overload The Generator ......................................9
2.5 Wattage Reference Chart ............................................10
2.6 Before Starting The Generator ....................................10
2.6.1 Adding Engine Oil ..........................................10
2.6.2 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-up ................................................12
2.11.2 Sensing Low Oil Pressure ..............................12
2.11.3 Restarting ......................................................12
2.12 Charging a Battery ......................................................13
Section 3 – Maintenance............................14
3.1 Maintenance Schedule ................................................14
3.2 Product Specifications ................................................14
3.2.1 Generator Specifications ................................14
3.2.2 Engine Specifications ....................................14
3.3 General Recommendations ........................................15
3.3.1 General Maintenance......................................15
3.3.2 To Clean The Generator..................................15
3.3.3 Engine Maintenance ......................................15
3.3.4 Checking Oil Level ..........................................15
3.3.5 Changing The Oil & Oil Filter ..........................15
3.3.6 Replacing The Spark Plug .............................16
3.4 Service Air Cleaner......................................................16
3.5 Clean Spark Arrestor Screen ......................................16
3.6 Adjusting Valve Clearance ..........................................17
3.7 General ......................................................................18
3.8 Long Term Storage ....................................................18
3.9 Other Storage Tips......................................................18
Section 4 – Troubleshooting ....................19
4.1 Troubleshooting Guide................................................19
Section 5 – Installation Guide For
Generator Ready Kit ........20-23
Section 6 – Operation Of Generator With
Generator Ready Kit ........24-26
Section 7 – Notes ......................................27
Section 8 – Electrical Data ..................28-29
Section 9 – Exploded Views and
Parts Lists..........................30-39
Section 108 – Warranty ........................40-42
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 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 CAUTION blocks. 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 over-filled, 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
-------------
DANGER
-------------
-------------
WARNING
-------------
-------------
CAUTION
-------------
DANGER! NEVER operate your generator indoors,
in an attached garage or near an open window.
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: in rain; in any enclosed
compartment; if connected electrical devices overheat; if
electrical output is lost; if engine or generator sparks; if flames
or smoke are observed while unit is running; if unit vibrates
excessively.
Note: Your generator is equipped with a spark arrestor
muffler. The spark arrestor must be maintained in
effective working order by the owner/ operator. In the
State of California, a spark arrestor is required by law
(Section 4442 of the California Public Resources
Code). Other states may have similar laws. Federal
laws apply on federal lands.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar with this
Owner’s Manual and with the unit. The generator can operate
safely, efficiently and reliably only if it is properly installed,
operated and maintained. Many accidents are caused by failing to
follow simple and fundamental rules or precautions.
GENERAC
®
cannot possibly anticipate every possible
circumstance that might involve a hazard. The warnings in this
manual, and on tags and decals affixed to the unit are, therefore,
not all-inclusive. If you use a procedure, work method or
operating technique GENERAC
®
does not specifically recommend,
you must satisfy yourself that it is safe for you and others. You
also must make sure the procedure, work method or operating
technique that you choose does not render the generator unsafe.
Despite the safe design of this generator, operating
this equipment imprudently, neglecting its
maintenance or being careless can cause possible
injury or death. Permit only responsible and capable
persons to operate or maintain this equipment.
Potentially lethal voltages are generated by these
machines. Ensure all steps are taken to render
the machine safe before attempting to work on
the generator.
Parts of the generator are rotating and/or hot during
operation. Exercise care near running generators.
GENERAL HAZARDS
• For safety reasons, GENERAC®recommends that the
installation, initial start-up and maintenance of this equipment
is carried out by a GENERAC®/GUARDIAN®Authorized Dealer.
• The engine exhaust fumes contain carbon monoxide, which
can be DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death.
This exhaust system must be installed properly, in strict
compliance with applicable codes and standards. Following
installation, you must do nothing that might render the system
unsafe or in noncompliance with such codes and standards.
• Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating air is
critical to correct generator operation. Do not alter the
installation or permit even partial blockage of ventilation
provisions, as this can seriously affect safe operation of the
generator. The generator MUST be operated outdoors.
• When working on this equipment, remain alert at all times.
Never work on the equipment when you are physically or
mentally fatigued.
• Inspect the generator regularly, and contact your nearest
GENERAC
®
/GUARDIAN®Authorized Dealer for parts needing
repair or replacement.
• Before performing any maintenance on the generator,
disconnect its battery cables to prevent accidental start up.
Disconnect the cable from the battery post indicated by a
NEGATIVE, NEG or (–) first. Reconnect that cable last.
• Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in
dangerous operating conditions from leaking exhaust gases,
fuel leakage, oil leakage, etc.
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.
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:
-------------
DANGER
-------------
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.
3
IMPORTANT SAFETY INSTRUCTIONS
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.
• Remove separate accessory box.
• Lift carton off the generator.
• Remove generator from shipping pallet by removing bolts
through the shipping brackets.
Figure 1 - Bracket Removal
1.1.1 ACCESSORY BOX
Check all contents. If any parts are missing or damaged locate an
authorized dealer at 1-800-333-1322.
Contents include:
• Owner’s Manual
• Bolt-on tubular handle
• Wheel Axle
• 2 – Pneumatic Wheels
• 2 – Axle Bracket Assemblies
• 2 – Washers
• 2 – Wheel Spacers
• 2 – Cotter Pins
• Bolt-on Foot
• 6 – Carriage Bolts, Washers, Nuts
• Battery Charge Cable
• Spark Plug Wrench
• 2 Spark Plugs.
• Air Filter
• Pre-cleaner
1.2 ASSEMBLY
The generator requires some assembly prior to using it. If
problems arise when assembling the generator, please call the
Generator Helpline at 1-800-333-1322.
1.2.1 ASSEMBLING THE WHEEL KIT
The wheel kit is designed to greatly improve the portability of the
generator. A socket wrench with a 9/16” socket, a 1/2” socket, a
1/2” wrench and a pair of pliers are the tools that will be needed
for assembly of the wheel kit.
Note:The wheel kit is not intended for over-the-road use.
• Refer 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 enough to place wooden blocks beneath the
cradle. This will allow space to install the wheel assemblies.
• Attach an axle bracket assembly with attached sleeve to either
side of the frame. Ensure the sleeve faces outward.
• Slide the axle through the sleeves on the axle brackets.
• Slide one wheel with flat washer to the outside and a spacer to
the inside onto each end of the axle. Make sure the air inflation
valve on the wheel is facing outward.
• Insert retaining pins and using pliers, bend out the ends to
prevent the pins from falling out of the axle. Remove the
wooden blocks.
1.2.2 ASSEMBLING THE HANDLE
• Attach the handle by aligning one side of the handle on the
cradle, then spread the handle around the cradle and let it
spring into place. Secure the handle to the frame using the
5/16’ hex head bolts provided. Check each fastener to ensure
that it is secure.
• Using the handle, lift the unit high enough to place wooden
blocks under the unit. Attach the front support foot to the
underside of the cradle using the 3/8” carriage bolts provided.
• Remove the shipping brackets from the cradle, if you have not
already done so.
4
Section 1 – General Information
Residential Portable Generator System
Shipping
Bracket
(x4)
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
Residential Portable Generator System
Negative
Cable
Positive
Cable
Figure 2 - Handle Assembly
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, 10 Amp Receptacle – This receptacle
allows the capability to recharge a 12 volt DC storage battery
with provided battery charge cables.
2) 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies
electrical power for the operation of 120 Volt AC, 20 Amp,
single-phase, 60 Hz electrical lighting, appliance, tool and
motor loads.
3) 120 Volt AC, 20A Duplex GFCI Receptacle –
Supplies ground fault protected electrical power for
operation of 120 volt AC 20 amp, single-phase, 60 Hz electric
lighting, appliances, tools and motor loads.
4) 120 Volt AC, 30 Amp Locking Receptacle – Supplies
electrical power for the operation of 120 Volt AC, 30 Amp,
single-phase, 60 Hz electrical 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 lighting,
appliance, tool and motor loads.
6) 120/240 Volt AC, 50 Amp Receptacle – Supplies
electrical power for the operation of 120/240 Volt AC, 50
Amp, single-phase, 60 Hz, welder or motor loads.
7) Air Cleaner – Filters intake air as it is drawn into the engine.
8) Choke Knob – Used when starting a cold engine.
9) Winter / Summer Valve – See “Cold Weather Operation.”
(Section 2, page 12.)
10) Circuit Breakers (AC) – Each receptacle is provided with
a push-to-reset circuit breaker to protect the generator
against electrical overload. (50 amp uses toggle reset)
11) Fuel Tank – Tank holds 16 U.S. gallons of fuel.
12) Grounding Lug – Ground the generator to an approved
earth ground here. See page 9 for details.
13) Idle Control Switch – The idle control runs the engine at
normal (high) speeds when there is an electrical load present
and runs the engine at idle (low) speeds when a load is not
present.
7
11
12
15
9
8
14
Figure 5 - Generator Controls
Figure 6 - Engine Control Panel
Figure 4 - Control Panel
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
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-to-
reset 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
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.
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 cord set to the plug and to the desired load. The
cord set should be rated for 250 Volts AC at 30 Amps (or greater).
Figure 10 - 120/240 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
or 240 Volt AC, 60 Hz, single phase loads requiring up to 7200
watts (7.2 kW) of power at 30 Amps. The outlet is protected 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 cables
provided. This receptacle can not recharge 6 Volt batteries and
can not be used to crank an engine having a discharged battery.
See the section "Charging a Battery" (page 12) before attempting
to recharge a battery.
Figure 11 - 12 Volt DC, 10 Amp Receptacle
2.2.6 120/240 VOLT AC, 50 AMP
RECEPTACLE
Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire
cord set rated for 250 Volts AC at 50 Amps to the plug.
Figure 12 - 120/240 VAC, 50 Amp Receptacle
Use this receptacle to operate 120/240 Volt AC, 60 Hz electrical
loads requiring up to 12,000 watts (12.0 kW) of power. This
receptacle is protected by a 50 Amp 2-pole circuit breaker.
8
Section 2 – Operation
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.)
Generator Ground Lug
9
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) . . . . . . . . . . . . . . . . .3800
*Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . .6000
Battery Charger (20 Amp) . . . . . . . . . . . . . . . . . . . . .500
Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000
Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Circular Saw (6-1/2") . . . . . . . . . . . . . . . . . . .800 to 1000
*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . .5750
*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . . .700
*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . .1150
Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750
*Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . . . .2000
*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . . .1800
*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . .1400
Curling Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
*Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650
Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500
Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Electric Range (per element) . . . . . . . . . . . . . . . . . .1500
Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250
*Freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . .875
*Garage Door Opener . . . . . . . . . . . . . . . . . . .500 to 750
Hair Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100
Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts
Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450
Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800
Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Microwave Oven . . . . . . . . . . . . . . . . . . . . . .700 to 1000
*Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1100
Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . .300
Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . .400
Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . . . .225
Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . .150
*Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . .600
Paint Sprayer, Airless (handheld) . . . . . . . . . . . . . . . .150
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 200
*Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
*Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . . .2800
*Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . . .2000
*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . .1500
*Sump Pump . . . . . . . . . . . . . . . . . . . . . . . .800 to 1050
*Table Saw (10") . . . . . . . . . . . . . . . . . . . . .1750 to 2000
Television . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500
Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650
Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500
*Allow 3 times the listed watts for starting these devices.
10
Section 2 – Operation
Residential Portable Generator System
2.6 BEFORE STARTING THE
GENERATOR
Prior to operating the generator, engine oil and gasoline will need
to be added, as follows:
2.6.1 ADDING ENGINE OIL
NOTE: When adding oil to the engine crankcase in
the future, use only high quality detergent oil rated
with API service classification SF or SG SAE 30
weight. Use no special additives.
Select the oil’s viscosity grade according to the expected
operating temperature. Do not use SAE 10W-40.
• Above 40°F, use SAE 10W-30 or SAE 30.
• Below 40°F, use synthetic 5W-20 or 5W-30.
Although multi-viscosity oils (5W-30, 10W-30, etc.) improve
starting in cold weather, these multi-viscosity oils will result in
increased oil consumption when used above 32°F. Check your
engine oil level more frequently to avoid possible damage from
running low on oil.
• Place generator on a level surface.
• Clean area around oil fill and remove oil fill cap and dipstick.
• Wipe dipstick clean.
• Slowly fill engine with oil through the oil fill opening until it
reaches the full mark on the dipstick. Stop filling occasionally
to check oil level. DO NOT OVERFILL.
• Install dipstick. Install oil fill cap and finger tighten securely.
• Check engine oil level before starting each time thereafter.
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. Do not mix oil with gasoline.
• Clean area around fuel fill cap, remove cap.
• Slowly add unleaded regular gasoline to fuel tank. Be careful
not to overfill. Allow about 1/2" of tank space for fuel
expansion, as shown here.
• Install fuel cap and wipe up any spilled gasoline.
Figure 14 - Fuel Tank
IMPORTANT: It is important to prevent gum deposits from
forming in fuel system parts such as the carburetor, fuel hose or
tank during storage. 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 in storage. To avoid
engine problems, the fuel system should be emptied before
storage of 30 days or longer. See "Storage" on page 18. Never use
engine or carburetor cleaner products in the fuel tank as
permanent damage may occur.
2.7 TO START THE ENGINE
WARNING! Never start or stop engine with electrical
devices plugged into the receptacles AND devices turned on.
• Unplug all electrical loads from the unit's receptacles before
starting the engine.
• Make sure the unit is in a level position.
• Open the fuel shut-off valve.
Figure 15 - Fuel Shut-off Valve
• Locate the Idle Control ON/OFF switch on the control panel and
set it to the “OFF” position.
Figure 16 - Idle Control Switch
Section 2 – Operation
Residential Portable Generator System
11
-------------
WARNING
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• 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” position until
the engine runs smoothly and then to “Run” position. If engine falters,
move choke knob to “1/2 Choke” position until the engine runs
smoothly and then to “Run” position.
Note: If engine fires, but does not continue to run,
move choke lever to “Full Choke” and repeat starting
instructions.
2.8 STOPPING THE ENGINE
• Shut off all loads, then unplug the electrical loads from
generator panel receptacles. Never start or stop the engine
with electrical devices plugged in and turned on.
• Turn “Off” the Idle Control switch (if on).
• Let engine run at no-load for several minutes to stabilize the
internal temperatures of engine and generator.
• Move Start/Run/Stop switch to “Off” position.
• Close fuel valve.
IMPORTANT: Do not overload the generator. Also, do not
overload individual panel receptacles. These outlets are protected
against overload with push-to-reset-type circuit breakers. If
amperage rating of any circuit breaker is exceeded, that breaker
opens and electrical output to that receptacle is lost. Read “Don’t
Overload the Generator” on page 9 carefully.
2.9 AUTOMATIC IDLE CONTROL
This feature is designed to greatly improve fuel economy. When
this switch is turned “On,” the engine will only run at its normal
fast governed engine speed when electrical load is connected.
When the load is removed, the engine will run at a reduced speed
of 2100 RPM. With the switch “Off,” the engine runs at the
normal fast engine speed all the time. Always have the switch
OFF when starting and stopping the engine.
2.10 COLD WEATHER OPERATION/
DE-ICER
Under certain weather conditions (temperatures below 40° F (4°
C) and a high dew point), the engine may experience icing of the
carburetor and/or the crankcase breather system. To eliminate
this problem, this generator engine is fitted with a winter/summer
valve. this directs hot air into the carburetor during cold weather
operation. Always make sure the winter/summer valve is in the
correct location relative to the weather conditions.
2.11 LOW OIL PRESSURE SHUTDOWN
SYSTEM
The engine is equipped with a low oil pressure sensor that shuts
down the engine automatically when the oil pressure drops below
10 psi. If the engine shuts down by itself and the fuel tank has
enough gasoline, check engine oil level.
2.11.1 INITIAL START-UP
A delay built into the low oil shutdown system allows oil pressure
to build during starting. The delay allows the engine to run for
about 10 seconds before sensing oil pressure.
2.11.2 SENSING LOW OIL PRESSURE
If the system senses low oil pressure during operation, the engine
shuts down.
2.11.3 RESTARTING
If you try to restart the engine within 10 seconds after it shuts
down, the engine may NOT start. The system needs 5 to 10
seconds to reset.
If you do restart the engine after such a shutdown and have not
corrected the low oil pressure, the engine runs for about 10
seconds as described above and then stops.
Section 2 – Operation
Residential Portable Generator System
12
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