Generac Portable Generator 04389 1 04456 1 04390 1 User Manual

POWER SYSTEMS, INC.

Installation and

Owner’s Manual

Air-cooled, Prepackaged

Automatic Standby Generators

Models:

04389-1 (6 kW NG, 7 kW LP)

04456-1 (12 kW NG, 12 kW LP)

04390-1 (13 kW NG, 15 kW LP)

GENERAC

POWER SYSTEMS, INC.

Not intended for use as Primary Power in place of utility or in

life-support applications.

DANGER

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

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Table of Contents

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

3.2.2 “Off” Position....................................14

Introduction ........................Inside Front Cover

Read This Manual Thoroughly ........................IFC

Contents ..........................................................IFC

Operation and Maintenance ............................IFC

How to Obtain Service ....................................IFC

Authorized Dealer Locator Number ....................IFC

3.2.3 “Manual” Position ............................14

3.3 Automatic Transfer Operation ....................14

3.4 Sequence of Automatic Operation................14

3.5 Manual Transfer Operation ........................15

3.5.1 Transfer to Generator

Safety Rules ........................................................2

Power Source......................................15

Standards Index..................................................3

3.5.2 Transfer Back to Utility

Power Source......................................15

Section 1 – General Information ..................4

1.1 Unpacking/Inspection ....................................4

1.2 Protection Systems ........................................4

1.3 System Set LED ............................................4

1.4 Your Generator ..............................................5

1.5 Specifications ................................................6

1.5.1 Generator ..........................................6

1.5.2 Engine ................................................6

1.6 Fuel Requirements and Recommendations....7

1.7 Fuel Consumption ........................................7

1.8 Reconfiguring the Fuel System ......................7

1.8.1 7 kW, 410cc Engine ............................7

1.8.2 12 kW and 15 kW, 990cc Engine........7

1.9 Location ........................................................8

1.9.1 Generator ..........................................8

1.9.2 Transfer Switch..................................8

1.10 Battery Installation ........................................8

1.11 The Battery....................................................9

Section 2 – Post Installation Start-up

3.6 Setting the Exercise Timer ..........................15

3.7 Protection Systems ......................................16

3.7.1 Low Oil Pressure Switch ..................16

3.7.2 High Temperature Switch ................16

3.7.3 Overcrank ........................................16

3.7.4 Overspeed ........................................16

Section 4 – Maintenance ..............................16

4.1 Fuse ............................................................16

4.2 Checking the Engine Oil Level ....................17

4.3 Changing the Engine Oil ..............................17

4.3.1 Engine Oil Recommendations ..........17

4.3.2 Oil Change Procedure ......................17

4.4 Changing the Oil Filter ................................18

4.5 Changing the Engine Air Cleaner ................18

4.5.1 7 kW, 12 kW and 15 kW

Generators........................................18

4.6 Spark Plug(s) ..............................................18

4.7 Battery Maintenance....................................19

4.8 Adjusting GH-410/GT-990 Valve Clearance ..19

4.9 Cooling System............................................20

4.10 Attention After Submersion ........................20

4.11 Corrosion Protection ..................................20

4.12 Out of Service Procedure ............................21

4.12.1 Removal From Service......................21

4.12.2 Return to Service..............................21

4.13 Service Schedule ........................................22

and Adjustments ......................10

2.1 Before Initial Startup ..................................10

2.2 Check Transfer Switch Operation................10

2.3 Electrical Checks ........................................10

2.4 Generator Tests Under Load ......................11

2.5 Checking Automatic Operation....................11

2.6 Adjusting the Regulator (Natural Gas Only) ..11

2.7 Engine Governor Adjustment ......................12

2.7.1 7 kW Units ......................................12

2.7.2 12 kW and 15 kW Units ..................13

2.7.3 Additional Corrosion Protection ......13

2.8 Voltage Regulator Adjustment......................13

Section 5 – Troubleshooting ........................23

5.1 Troubleshooting Guide................................23

Section 6 – Electrical Data............................24

Section 7 – Exploded Views and

Parts Lists....................................32

Section 3 – Operation ....................................13

3.1 Break-in Procedure......................................13

3.2 Using the Auto/Off/Manual Switch ..............14

3.2.1 “Auto” Position..................................14

Section 8 – Mounting Dimensions..............53

Section 9 – Notes ............................................54

Section 10 – Warranty....................................56

Generac Power Systems, Inc.

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IMPORTANT SAFETY INSTRUCTIONS

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

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.

GENERAL HAZARDS

WARNING:

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

• 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 monox-

ide, which can be DEADLY. This dangerous gas, if

breathed in sufficient concentrations, can cause

unconsciousness or even death. This exhaust sys-

tem must be installed properly, in strict compli-

ance with applicable codes and standards.

Following installation, you must do nothing that

might render the system unsafe or in noncompli-

ance 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 venti-

lating air is critical to correct generator operation.

Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seri-

ously affect safe operation of the generator. The

generator MUST be installed outdoors.

• When working on this equipment, remain alert at

all times. Never work on the equipment when you

are physically or mentally fatigued.

WARNING:

This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

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

simple

and

fundamental

rules

or precautions.

Generac cannot possibly anticipate every possible

circumstance that might involve a hazard. The warn-

ings 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 tech-

nique 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.

• Inspect the generator regularly, and contact your

nearest Generac/Guardian Authorized Dealer for

parts needing repair or replacement.

• Before performing any maintenance on the genera-

tor, disconnect its battery cables to prevent acci-

dental start up. Disconnect the cable from the bat-

tery 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 con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

DANGER

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.

Generac Power Systems, Inc.

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IMPORTANT SAFETY INSTRUCTIONS

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

• 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 extin-

guisher properly charged and be familiar with its

use. If you have any question pertaining to fire

extinguishers, consult your local fire department.

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 to the transfer switch

as does the standby generator when it is in opera-

tion. Avoid contact with bare wires, terminals, con-

nections, 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 insu-

lated, dry surface to reduce shock hazard.

EXPLOSION HAZARDS

• Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no com-

bustible materials are left in the generator com-

partment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surround-

ing the generator clean and free from debris.

• Gaseous fluids such as natural gas and liquid

propane (LP) gas are extremely EXPLOSIVE.

Install the fuel supply system according to applica-

ble fuel-gas codes. Before placing the home stand-

by electric system into service, fuel system lines

must be properly purged and leak tested according

to applicable code. After installation, you must

inspect the fuel system periodically for leaks. No

leakage is permitted.

• 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.

• After installing this home standby electrical sys-

tem, the generator may crank and start at any time

without warning. When this occurs, load circuits

are transferred to the STANDBY (generator) power

source. To prevent possible injury if such a start

and transfer occur, always set the generator’s

Auto/Off/Manual switch to its OFF position before

working on equipment and remove the 5A and 15A

fuses from the generator control panel.

STANDARDS INDEX

‹

In the absence of pertinent standards, codes, regula-

tions and laws, the published information listed

below may be used as installation guide for this

equipment.

• In case of accident caused by electric shock, imme-

diately 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 equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

1. NFPA No. 37, STATIONARY COMBUSTION

ENGINES AND GAS TURBINES, available from

the National Fire Protection Association, 470

Atlantic Avenue, Boston, MA 02210.

2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-

TEMS FOR HEALTH CARE FACILITIES, avail-

able same as Item 1.

3. NFPA No. 54, NATIONAL FUEL GAS CODE,

available same as Item 1.

4. NFPA No. 58, AMERICAN NATIONAL STANDARD

FOR STORAGE AND HANDLING OF LIQUEFIED

PETROLEUM GAS, available same as Item 1.

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL

ELECTRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available

from the American Insurance Association, 85

John Street, New York, N.Y. 10038.

7. AGRICULTURAL WIRING HANDBOOK, available

from the Food and Energy Council, 909

University Avenue, Columbia, MO 65201.

8. ASAE EP-3634, INSTALLATION AND MAINTE-

NANCE OF FARM STANDBY ELECTRICAL SYS-

TEMS, available from the American Society of

Agricultural Engineers, 2950 Niles Road, St.

Joseph, MI 49085.

FIRE HAZARDS

• For fire safety, the generator must be installed and

maintained properly. Installation 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 installed in

accordance with the manufacturer’s instructions

and recommendations. Following proper installa-

tion, do nothing that might alter a safe installation

and render the unit in noncompliance with the

aforementioned codes, standards, laws and regu-

lations.

9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE

LIQUIDS CODE, available same as Item 1.

Generac Power Systems, Inc.

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Section 1 — General Information

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

1.2 PROTECTION SYSTEMS

DANGER

Unlike an automobile engine, the generator may have to

run for long periods of time with no operator present to

monitor engine conditions. For that reason, the engine is

equipped with the following systems that protect it

against potentially damaging conditions:

Only qualified electricians or contractors should

attempt such installations, which must comply strictly

with applicable codes, standards and regulations.

1.1 UNPACKING/INSPECTION

After unpacking, carefully inspect the contents

for damage.

1. Low Oil Pressure Sensor

2. High Temperature Sensor

There are LED readouts on the control panel to noti-

fy you that one of these faults has occurred. There is

also a “System Set” LED that is lit when all of the con-

ditions describe in Section 1.3 are true.

3. Overcrank

4. Overspeed

• This standby generator set has been factory sup-

plied with a weather protective enclosure that is

intended for outdoor installation only.

• This standby generator set is packaged with an

automatic transfer switch with built in load center.

The combination transfer switch and load center is

pre-wired with a 2 foot and 30 foot conduit. Circuit

breakers for emergency circuit connections are

included.

• This UL listed, 2-pole switch is rated at 100 AC

amperes at 250 volts maximum. This transfer

switch is for indoor use only.

1.3 SYSTEM SET LED

The “System Set” LED is lit when all of the following

conditions are true:

1. The Auto/Off/Manual switch is set to the AUTO

position.

2. The utility voltage being supplied to the unit is

being sensed by the PCB. If the utility sense volt-

age is not connected to the unit or if it is below

168 volts AC, then the system set light will flash

rapidly. This indicates that if the Auto/Off/Manual

switch is placed in the Auto position , the genera-

tor will start.

If this generator is used to power electrical load

circuits normally powered by a utility power

source, you are required by code to install a trans-

fer switch. The transfer switch must effectively iso-

late the electrical system from the utility distribu-

tion system when the generator is operating (NEC

700, 701 & 702). Failure to isolate an electrical sys-

tem by such means will result in damage to the

generator and also may result in injury or death to

utility power workers due to backfeed of electrical

energy.

3. The “Not In Auto” dip switch is set to the OFF

position on the control board.

4. No alarms are present, for example, low oil pres-

sure, high temperature, etc.

If any loss or damage is noted at time of delivery, have

the person(s) making the delivery note all damage on

the freight bill or affix his or her signature under the

consignor's memo of loss or damage.

If you note loss or damage after delivery, separate the

damaged materials and contact the carrier for claim

procedures.

“Concealed damage” is understood to mean damage

to the contents of a package that is not in evidence at

the time of delivery, but is discovered later.

Generac Power Systems, Inc.

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Section 1 — General Information

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

1.4 YOUR GENERATOR

Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine

Control Panel

Data Decal

Exhaust

Enclosure

Air Filter

Fuel Regulator

Battery Compartment

Oil Filter

Figure 1.2 – 12 kW and 15 kW, V-twin GT-990 Engine

Data

Decal

Control

Panel

Oil Dipstick

Air Filter

Exhaust

Enclosure

Fuel Regulator

Battery Compartment

Oil Filter

Generac Power Systems, Inc.

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Section 1 — General Information

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

1.5 SPECIFICATIONS

1.5.1 GENERATOR

‹

Model 04389-1

6,000 NG/7,000 LP

120/240

Model 04456-1

12,000 NG/12,000 LP 13,000 NG/15,000 LP†

Model 04390-1

Rated Max. Continuous Power Capacity (Watts*)

Rated Voltage

120/240

Rated Max. Continuous Load Current (Amps)

120 Volts**

50.0 NG/58.3 LP

100.0 NG/100.0 LP

108.3 NG/125.0 LP

240 Volts

25.0 NG/29.2 LP

50.0 NG/50.0 LP

54.2 NG/62.5 LP

Main Line Circuit Breaker

Phase

Number of Rotor Poles

Rated AC Frequency

Power Factor

30 Amp

50 Amp

60 Amp/70 Amp†

60 Hz

Recommended Air Filter

Battery Requirement

Generac Part # C8127 Generac Part # C8127 Generac Part # C8127

Group 26/26R

12 Volts and

Group 26/26R

12 Volts and

Group 26/26R

12 Volts and

350 Cold-cranking

Amperes Minimum

550 Cold-cranking

Amperes Minimum

550 Cold-cranking

Amperes Minimum

Weight

452 Pounds

68 db (A)

470 Pounds

70.5db (A)

-20°F (-28.8°C) to 104°F (40°C)

487 Pounds

71.5 db (A)

Output Sound Level @ 23 ft (7m) at full load

Normal Operating Range

* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power

decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.

** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240 volts.

† 15,000 watt with upgrade kit 04578-0. Kit includes power harnesses and 70 amp 2-pole circuit breaker.

1.5.2 ENGINE

‹

Model 04389-1

GH-410

Model 04456-1

GT-990

Model 04390-1

GT-990

Type of Engine

Number of Cylinders

Rated Horsepower

Displacement

14.5 @ 3,600 rpm

410cc

26 @ 3,600 rpm

992cc

30 @ 3,600 rpm

992cc

Cylinder Block

Aluminum w/Cast

Iron Sleeve

Aluminum w/Cast

Iron Sleeve

Aluminum w/Cast

Iron Sleeve

Valve Arrangement

Ignition System

Recommended Spark Plug

Spark Plug Gap

Compression Ratio

Starter

Overhead Valves

Solid-state w/Magneto

RC12YC

0.76 mm (0.030 inch)

8.6:1

Overhead Valves

Solid-state w/Magneto

RC12YC

0.76 mm (0.020 inch)

9.5:1

Overhead Valves

Solid-state w/Magneto

RC12YC

0.76 mm (0.020 inch)

9.5:1

12 Vdc

12Vdc

Oil Capacity Including Filter

Recommended Oil Filter

Recommended Air Filter

Operating RPM

Approx. 1.5 Qts

Approx. 1.7 Qts

Generac Part # 70185 Generac Part # 70185 Generac Part # 70185

Generac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127

3,600

Generac Power Systems, Inc.

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Section 1 — General Information

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

3. Disconnect wire #0 and wire #14 from the gas

1.6 FUEL REQUIREMENTS

solenoid located on the top of the demand regu-

lator.

AND RECOMMENDATIONS

With LP gas, use only the vapor withdrawal

system. This type of system uses the vapors formed

above the liquid fuel in the storage tank.

4. Remove the demand regulator by rotating coun-

terclockwise.

5. Remove the brass hose fitting from the outlet port

of the demand regulator.

The engine has been fitted with a fuel carburetion

system that meets the specifications of the 1997

California Air Resources Board for tamper-proof dual

fuel systems. The unit will run on natural gas or LP

gas, but it has been factory set to run on natural gas.

Should the primary fuel need to be changed to LP

gas, the fuel system needs to be reconfigured. See

Section 1.8 for instructions on reconfiguration of the

fuel system.

Recommended fuels should have a Btu content of at

least 1,000 Btus per cubic foot for natural gas; or at

least 2,520 Btus per cubic foot for LP gas. Ask your

fuel supplier for the Btu content of your fuel.

6. Remove the brass metering jet (loosen counter-

clockwise) from the housing port of the demand

regulator located on the side of the regulator.

7. Install new LP metering jet (tighten clockwise) in

the outlet port of the demand regulator.

8. Refit the brass hose fittings to the outlet port of

the demand regulator.

9. Reverse procedure steps 1-4 to reinstall demand

regulator.

10. Reverse the procedure to convert back to natural

gas.

Figure 1.3 – Demand Regulator

Fuel pressure for both natural gas and liquid

propane set ups should be 11 inches to 14 inches

of water column (0.6 psi) at all load ranges.

FUEL HOSE

BRASS HOSE

FITTING

BRASS HOSE

FITTING

NOTE:

FUEL JET

HOUSING

PORTS

HOUSING

PORTS

A seperate gas line and regulator may be needed

to assure proper gas pressure (11-14”) to the gen-

erator. Low gas pressure can cause hard starting

and could affect engine durability.

1.7 FUEL CONSUMPTION

Model #

Nat. Gas (*)

LP Vapor (**)

1/2 Load Full Load 1/2 Load

Full Load

1.21/44.1

2.17/79.0

2.80/102.3

04389

04456

04390

105

185

240

0.91/33

1.34/48.9

1.73/63.2

NG FUEL SYSTEM

LP FUEL SYSTEM

114

NOTE:

148.5

*Natural gas is in cubic feet per hour.

**LP is in gallons per hour/cubic feet per hour.

The natural gas adjustment screw is preset during

installation and should not need any further

adjustment.

DANGER

Gaseous fuels such as natural gas and liquid

propane (LP) gas are highly explosive. Even the

slightest spark can ignite such fuels and cause

an explosion. No leakage of fuel is permitted.

Natural gas, which is lighter than air, tends to

collect in high areas. LP gas is heavier than air

and tends to settle in low areas.

1.8.2 12 KW AND 15 KW, 990CC ENGINES

◆

To reconfigure the fuel system from NG to LP,

follow these steps:

NOTE:

The primary regulator for the propane supply is

NOT INCLUDED with the generator. You must sup-

ply a fuel pressure of 11 to 14 inches of water col-

umn (0.6 psi) to the fuel inlet of the generator.

1.8 RECONFIGURING THE

FUEL SYSTEM

1. Turn off the main gas supply.

2. Remove the three carburetor fuel hoses from the

outlet ports of the demand regulator.

3. Disconnect wire #0 and wire #14 from the gas

solenoid located on the top of the demand regu-

lator.

1.8.1 7 KW, 410CC ENGINE

To reconfigure the fuel system from NG to LP,

follow these steps:

◆

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet

4. Remove the demand regulator from the enclosure

port of the demand regulator (Figure 1.3).

by rotating counterclockwise.

Generac Power Systems, Inc.

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Section 1 — General Information

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

5. Remove the small brass hose fitting from the idle

• Install the generator on high ground where water

levels will not rise and endanger it.

• Allow sufficient room on all sides of the generator

for maintenance and servicing. A good rule is to

allow 5 feet of space on all sides.

• Where strong prevailing winds blow from one

direction, face the generator air inlet openings to

the prevailing winds.

circuit port of the regulator housing.

6. Remove the small jet (0D5698A) located in the

side of the regulator housing and install it into the

small threaded hole in the idle circuit port on the

regulator.

7. Refit the brass hose fitting to the idle circuit port

of the regulator. Use pipe thread sealant to reseal

the threads on the hose fitting.

8. Identify both adjustment screws.

NOTE:

• Install the generator as close as possible to the fuel

supply, to reduce the length of piping.

• Install the generator as close as possible to the

transfer switch. HOWEVER, REMEMBER THAT

LAWS OR CODES MAY REGULATE THE DIS-

TANCE.

One adjustment screw can be accessed from the

front of the unit and the second can be accessed

from the back of the unit.

9. Reverse procedure steps 1-4 to re-install the

demand regulator.

10. To adjust the system to run on LP fuel, simply

turn the adjuster screw that is accessed from

inside the front of the unit, 1/4 turn clockwise.

This will now set the system for maximum power

and best performance on LP fuel.

1.9.2 TRANSFER SWITCH

◆

1.9.2.1 7 kW, 12 kW and 15 kW Units

The transfer switch shipped with this generator is

enclosed in a NEMA 1 enclosure. This type of enclo-

sure is intended for indoor use only. Follow these

rules:

11. The fuel system will now allow the engine to run

on LP fuel. It may be necessary to make minor

adjustments to the preset screw settings to

achieve maximum power. If you experience prob-

lems with the unit producing maximum power,

follow the procedure in Section 2.6 (Adjusting the

Regulator).

• Install the transfer switch indoors on a firm, stur-

dy supporting structure.

• To prevent switch distortion, level the switch if nec-

essary. This can be done by placing washers

between the switch enclosure and mounting sur-

face.

• Never install the switch where water or any corro-

sive substance might drip onto the enclosure.

• Protect the switch at all times against excessive

moisture, dust, dirt, lint, construction grit and

corrosive vapors.

Figure 1.4 - Demand Regulator

FUEL HOSE

BRASS HOSE

FITTING

1.10 BATTERY INSTALLATION

Fill the battery with the proper electrolyte fluid if nec-

essary and have the battery fully charged before

installing it.

IDLE CIRCUIT

BRASS HOSE

PRESSURE

FITTING

1/8 NPT

SMALL

FUEL JET

PORT

TAP

REGULATOR

HOUSING PORT

ADJUSTER

SCREWS

Before installing and connecting the battery, complete

the following steps:

1. Set the generator's Auto/Off/Manual switch to

OFF.

2. Turn off utility power supply to the transfer

switch.

1.9 LOCATION

◆

3. Remove the 5A and 15A fuses from the generator

1.9.1 GENERATOR

control panel.

Install the generator set, in its protective enclosure,

outdoors, where adequate cooling and ventilating air

is always available. Consider these factors:

If the Auto/Off/Manual switch is not set to its

OFF position, the generator can crank and start

as soon as the battery cables are connected. If

the utility power supply is not turned off,

sparking can occur at the battery posts and

cause an explosion.

• Install the unit where air inlet and outlet openings

will not become obstructed by leaves, grass, snow,

etc. If prevailing winds will cause blowing or drift-

ing, you may need to consider using a windbreak

to protect the unit.

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Section 1 — General Information

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Battery cables were factory connected at the genera-

DANGER

Do not dispose of the battery in a fire. The

battery is capable of exploding.

tor (Figure 1.5). Connect cables to battery posts as

follows:

4. Connect the red battery cable (from starter con-

tactor) to the battery post indicated by a positive,

POS or (+).

5. Connect the black battery cable (from frame

ground) to the battery post indicated by a nega-

tive, NEG or (—).

A battery presents a risk of electrical shock

and high short circuit current. The following

precautions are to be observed when working

on batteries:

• Remove the 5A and 15A fuses from the generator

control panel.

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the

battery; and

NOTE:

Damage will result if battery connections are made

in reverse.

Figure 1.5 – Battery Cable Connections

• Disconnect charging source prior to connecting or dis-

connecting battery terminals.

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to

the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive.

NOTE:

The following procedures are to be observed:

Your generator is equipped with a battery trickle

charger that is active when your unit is set up for

automatic operation. With the battery installed

and utility power source voltage available to the

transfer switch, the battery receives a trickle

charge while the engine is not running, to prevent

self-discharge. The trickle charger is designed to

help extend the life of your battery by maintaining

the battery when the unit is not running. The

trickle charge feature cannot be used to recharge

a discharged battery.

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and seek

medical attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) of water. The bicar-

bonate of soda solution is to be added until the

evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the

area dried.

1.11 THE BATTERY

Servicing of the battery is to be performed or super-

vised by personnel knowledgeable of batteries and

the required precautions. Keep unauthorized person-

nel away from batteries.

Lead-acid batteries present a risk of fire

because they generate hydrogen gas. The

following procedures are to be followed:

When replacing the battery, use the following type of

battery: Group 26/26R 12-volt DC, negative ground

battery with a rating of 350 cold-cranking amps min-

imum for 7 kW; 550 cold-cranking amps minimum

for 12 and 15 kW at -17.8º C (0º F) minimum. When

using a maintenance-free battery, it is not necessary

to check the specific gravity or electrolyte level. Have

these procedures performed at the intervals specified

in the “Service Schedule.” A negative ground system

is used. Battery connections are shown on the wiring

diagrams. Make sure the battery is correctly connect-

ed and terminals are tight. Observe battery polarity

when connecting the battery to the generator set.

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from your body before

touching the battery by first touching a grounded

metal surface.

Be sure the Auto/Off/Manual switch is set to

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as

the battery cables are connected.

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Section 2 — Post Installation Start-up and Adjustments

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Be sure the utility power supply is turned off

DANGER

and the 5A and 15A fuses are removed from

the generator control panel, or sparking may

occur at the battery posts as you attach the

cables and cause an explosion.

The transfer switch is now electrically “hot.”

Contact with “hot” parts will result in extreme-

ly hazardous and possibly fatal electrical shock.

Proceed with caution.

2.1 BEFORE INITIAL START-UP

5. Use an accurate AC voltmeter to check utility

power source voltage across transfer switch ter-

minals N1 and N2. Nominal line-to-line voltage

should be 240 volts AC.

Before starting, complete the following:

1. Set the generator’s main circuit breaker to its

OFF (or open) position.

2. Set the generator's Auto/Off/Manual switch to the

6. Check utility power source voltage across termi-

nals N1 and the transfer switch neutral lug; then

across terminal N2 and neutral. Nominal line-to-

neutral voltage should be 120 volts AC.

7. When certain that utility supply voltage is com-

patible with transfer switch and load circuit rat-

ings, turn OFF the utility power supply to the

transfer switch.

8. On the generator panel, set the Auto/Off/Manual

switch to MANUAL. The engine should crank and

start.

9. Let the engine warm up for about five minutes to

allow internal temperatures to stabilize. Then, set

the generator’s main circuit breaker to its ON (or

closed) position.

OFF position.

3. Turn OFF the utility power supply to the transfer

switch using the means provided (such as the

utility main line circuit breaker).

4. Turn OFF all loads connected to the transfer

switch terminals T1 and T2.

5. Check the engine crankcase oil level and, if neces-

sary, fill to the dipstick FULL mark with the rec-

ommended oil. Do not fill above the FULL mark.

6. Check the fuel supply. Gaseous fuel lines must have

been properly purged and leak tested in accor-

dance with applicable fuel-gas codes. All fuel shut-

off valves in the fuel supply lines must be open.

DANGER

Never operate the engine with the oil level

Proceed with caution! Generator power voltage

is now supplied to the transfer switch. Contact

with live transfer switch parts will result in

dangerous and possibly fatal electrical shock.

below the “Add” mark on the dipstick. Doing

this could damage the engine.

2.2 CHECK TRANSFER SWITCH

10. Connect an accurate AC voltmeter and a frequen-

cy meter across transfer switch terminal lugs E1

and E2. Voltage should be 242-252 volts; fre-

quency should read about 61-63 Hertz.

11. Connect the AC voltmeter test leads across termi-

nal lug E1 and neutral; then across E2 and neu-

tral. In both cases, voltage reading should be 121-

126 volts AC.

12. Set the generator’s main circuit breaker to its

OFF (or open) position. Let the engine run at no-

load for a few minutes to stabilize internal engine

generator temperatures.

OPERATION

Refer to Section 3.5 (Page 15), of the owner’s manual

for manual operation procedures.

DANGER

Do not attempt manual transfer switch opera-

tion until all power voltage supplies to the

transfer switch have been positively turned off.

Failure to turn off all power voltage supplies

will result in extremely hazardous and possibly

fatal electrical shock.

13. Set the generator's Auto/Off/Manual switch to

OFF. The engine should shut down.

2.3 ELECTRICAL CHECKS

NOTE:

Complete electrical checks as follows:

It is important that you do not proceed until you

are certain that generator AC voltage and frequen-

cy are correct and within the stated limits.

Generally, if both AC frequency and voltage are

high or low, the engine governor requires adjust-

ment. If frequency is correct, but voltage is high or

low, the generator’s voltage regulator requires

adjustment.

1. Set the generator's main circuit breaker to its

OFF (or open) position.

2. Set the generator's Auto/Off/Manual switch to the

OFF position.

3. Turn OFF all loads connected to the transfer

switch terminals T1 and T2.

4. Turn on the utility power supply to the transfer

switch using the means provided (such as a utili-

ty main line circuit breaker).

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Section 2 — Post Installation Start-up and Adjustments

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

2.4 GENERATOR TESTS UNDER LOAD

2.5 CHECKING AUTOMATIC

To test the generator set with electrical loads applied,

proceed as follows:

OPERATION

To check the system for proper automatic operation,

proceed as follows:

1. Set generator’s main circuit breaker to its OFF

(or open) position.

1. Set generator’s main circuit breaker to its OFF

(or open) position.

2. Turn OFF all loads connected to the transfer

switch terminals T1 and T2.

2. Check that the Auto/Off/Manual switch is set to

3. Set the generator's Auto/Off/Manual switch

to OFF.

4. Turn OFF the utility power supply to the transfer

switch, using the means provided (such as a util-

ity main line circuit breaker).

OFF.

3. Turn OFF the utility power supply to the transfer

switch, using means provided (such as a utility

main line circuit breaker).

4. Manually set the transfer switch to the UTILITY

position, i.e., load terminals connected to the util-

ity power source side.

Do not attempt manual transfer switch opera-

tion until all power voltage supplies to the

transfer switch have been positively turned off.

Failure to turn off all power voltage supplies

will result in extremely hazardous and possibly

fatal electrical shock.

5. Turn ON the utility power supply to the transfer

switch, using the means provided (such as a util-

ity main line circuit breaker).

6. Set the Auto/Off/Manual switch to AUTO. The sys-

tem is now ready for automatic operation.

7. Turn OFF the utility power supply to the transfer

switch.

With the Auto/Off/Manual switch at AUTO, the engine

should crank and start when the utility source power

is turned OFF. After starting, the transfer switch

should connect load circuits to the standby side. Let

the system go through its entire automatic sequence

of operation.

5. Manually set the transfer switch to the STANDBY

position, i.e., load terminals connected to the

generator's E1/E2 terminals. The transfer switch

operating lever should be down.

6. Set the generator's Auto/Off/Manual switch to

MANUAL. The engine should crank and start

immediately.

7. Let the engine stabilize and warm up for a few

With the generator running and loads powered by gen-

erator AC output, turn ON the utility power supply to

the transfer switch. The following should occur:

minutes.

8. Set the generator’s main circuit breaker to its ON

(or closed) position. Loads are now powered by

the standby generator.

9. Turn ON electrical loads connected to transfer

switch T1 and T2. Apply an electrical load equal

to the full rated wattage/amperage capacity of the

installed generator.

10. Connect an accurate AC voltmeter and a frequen-

cy meter across terminal lugs E1 and E2. Voltage

should be greater than 230 volts; frequency

should be greater than 58 Hertz.

11. Let the generator run at full rated load for 20-30

minutes. Listen for unusual noises, vibration or

other indications of abnormal operation. Check

for oil leaks, evidence of overheating, etc.

12. When testing under load is complete, turn OFF

electrical loads.

• After about six seconds, the switch should transfer

loads back to the utility power source.

• About one minute after retransfer, the engine

should shut down.

2.6 ADJUSTING THE REGULATOR

(NATURAL GAS ONLY)

Although the generator has been factory set to pro-

vide maximum power, it may be necessary in some

areas to adjust this setting. Because natural gas has

different BTU or power content across the country

the engine may not perform as designed.

If you experience engine problems at high or full load

conditions follow these steps. It will require a fre-

quency meter to perform this procedure.

13. Set the generator's main circuit breaker to its

1. Turn off utility power to the main distribution

panel in the house. This can be done by switching

the service main breaker to the off or open posi-

tion.

2. Allow the generator to start. Before loading the

generator, confirm that the No Load Frequency,

with the roof open and door off, is set to 63-63.5

Hz. Transfer load to emergency circuits.

OFF (or open) position.

14. Let the engine run at no-load for a few minutes.

15. Set the Auto/Off/Manual switch to OFF. The

engine should shut down.

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Section 2 — Post Installation Start-up and Adjustments

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

3. Turn on appliances, lights, pumps, etc., that are

7. Turn utility power to the main distribution panel

back on. This can be done by switching the serv-

ice main breaker to the on or closed position.

Allow the generator to shut down.

on the emergency circuits in an attempt to fully

load the generator. Be cautious not to overload

the generator. Use the following chart as a guide:

Unit

7 kW

12 kW

15 kW

120 Volts

50.0 amps

100.0 amps

108.3 amps

240 Volts

25.0 amps

50.0 amps

54.1 amps

Do not make any unnecessary adjustments.

Factory settings are correct for most applica-

tions. However, when making adjustments, be

careful to avoid overspeeding the engine.

4. When full load has been achieved. Connect a fre-

quency meter to the output lugs of the generator’s

main line circuit breaker.

If this procedure or equipment are not available to

you, locate the Generac Guardian Dealer nearest you

and they can perform the adjustments.

5. The fuel regulator is fitted with one (7 kW), or two

(12 & 15 kW) adjustment screws. While watching

the frequency meter, slowly turn the adjustment

screws clockwise or counterclockwise one at a

time until the highest frequency is read on the

meter. Only limited adjustment is available

between the set pins (7 kW only). Under no cir-

cumstances should any of the pins be removed

(Figures 2.1 and 2.2).

NOTE:

A service fee may be charged for this adjustment.

2.7 ENGINE GOVERNOR ADJUSTMENT

If both AC frequency and voltage are correspondingly

high or low, adjust the engine governor as follows:

2.7.1 7 KW UNITS

◆

Figure 2.1 — Dual Fuel Regulators

1. Loosen the governor clamp bolt (Figures 2.3 on

990

410

page 13).

2. Hold the governor lever at its wide open throttle

position, and rotate the governor shaft clockwise

as far as it will go. Then, tighten the governor

lever clamp bolt to 70 inch-pounds (8 N-m).

3. Start the generator; let it stabilize and warm up

at no-load.

Adjustment

Set

Pins

Adjustment

Screw

(Both sides)

Screw

(One Side

Only)

4. Connect a frequency meter across the generators

AC output leads.

5. Turn the speed adjust nut to obtain a frequency

reading of 63 Hz.

6. When frequency is correct at no load, check the

AC voltage reading. If voltage is incorrect, the volt-

age regulator may require adjustment.

6. When the highest frequency is reached maximum

power has been set. From this point turn both

adjustment screws 1/4 turn counterclockwise.

The regulator is now set.

Figure 2.3 — Engine Governor Adjustment

Figure 2.2 — Placement of Regulator

Idle Spring

Governor

Shaft

(Rotate

Clockwise)

No Load Idle

Adjustment Screw

Governor Clamp Bolt

Adjustment Screw

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Section 3 — Operation

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Figure 2.5 – Voltage Adjustment Potentiometer

2.7.2 12 KW AND 15 KW UNITS

◆

1. Loosen governor clamp bolt (See Figure 2.3).

2. Completely remove the idle spring.

3. With governor arm at wide open throttle position,

rotate governor shaft fully clockwise. Tighten

clamp bolt to 84 inch-pounds.

4. Start unit and apply full load. Use full load speed

adjust screw (Figure 2.4) to adjust frequency to

58 Hz.

5. Remove load, stop engine, loosen the idle adjust

screw and reconnect the idle spring.

6. Using your hand, push the governor arm to the

closed throttle position. Make sure the idle spring

does not stretch at all.

7. Restart the unit.

8. Slowly turn the idle adjust screw to adjust the no-

load idle frequency to 63-63.5 Hz (with door

open).

9. The governor is now set.

NOTE:

The voltage regulator is housed above the genera-

tor's control panel. The regulator maintains a volt-

age in direct proportion to frequency at a 2-to-1

ratio. For example, at 62 Hertz, line-to-neutral

voltage will be 124 volts.

Figure 2.4 — Full Load Speed Adjust Screw

Full Load Speed Adjust Screw

3.1 BREAK-IN PROCEDURE

Once the unit has been installed and all electrical

checks have been made, it is strongly recommended

that the following “Break-in Procedure” be completed

to ensure correct generator operation in the future.

1. Set the generator’s Auto/Off/Manual switch to

AUTO.

2. Turn OFF the utility power supply to the transfer

switch using the means provided (such as a utili-

ty main line circuit breaker).

3. The unit will start, and the transfer switch will

2.7.3 ADDITIONAL CORROSION

PROTECTION

Periodically spray all engine linkage parts and brack-

ets with corrosion inhibiting spray such as WD-40 or

a comparable product.

◆

transfer to standby.

4. Using the transfer switch’s built-in emergency

load center, turn on circuits to load the generator

to approximately 25% rated load and run the unit

for one hour.

5. Run the unit for one hour at 50% rated load.

6. Run the unit for one hour at 75% rated load.

7. Run the unit for one hour at 100% rated load.

8. Turn ON the utility power supply to the transfer

switch, which will allow the transfer switch to

transfer back to utility power. The unit will con-

tinue to run for one minute and then shut down.

9. Allow the unit to cool.

10. Set the generator's Auto/Off/Manual switch to

OFF. Remove the 5A and 15A fuses from the gen-

erator control panel. Disconnect the battery

cables as outlined in “General Hazards” (page 2).

2.8 VOLTAGE REGULATOR

ADJUSTMENT

With the frequency between 62-63 Hertz, slowly turn

the slotted potentiometer (Figure 2.5) until line volt-

age reads 247-252 volts.

NOTE:

You must remove the access panel on top of the

control panel to adjust the voltage regulator.

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Section 3 — Operation

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

11. Drain the oil and remove the oil filter. Replace the

3.3 AUTOMATIC TRANSFER

oil filter according to Section 4.4, “Changing the

Oil Filter” (Page 18). Replace the oil with synthet-

ic oil as recommended in Section 4.3, “Changing

the Engine Oil” (Page 17).

OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are

set to their “Utility” position, i.e., loads connected

to the utility power source (Figure 3.2, Page 15).

2. Be sure that normal utility power source voltage

is available to transfer switch terminal lugs N1

and N2.

12. Reconnect the battery cables as outlined in

“General Hazards” (page 2) and insert the 5A and

15A fuses into the generator control panel. The

generator is now ready for service.

3.2 USING THE AUTO/OFF/MANUAL

SWITCH (FIGURE 3.1)

3. Set the generator’s Auto/Off/Manual switch to

AUTO.

4. Set the generator’s main circuit breaker to its ON

(or closed) position.

3.2.1 “AUTO” POSITION

‹

With the preceding steps complete, the generator will

start automatically when utility source voltage drops

below a preset level. After the unit starts, loads are

transferred to the standby power source. Refer to

Section 3.4, “Sequence of Automatic Operation.”

Selecting this switch position activates fully automat-

ic system operation. It also allows you to start and

exercise the engine every seven days with the setting

of the exercise timer (see Section 3.6, Page 16). This

position also is used for remote starting, when it is

set up.

3.4 SEQUENCE OF AUTOMATIC

3.2.2 “OFF” POSITION

This switch position shuts down the engine. This

position also prevents automatic operation.

‹

OPERATION

The generator’s control panel houses a control logic

circuit board. This board constantly monitors utility

power source voltage. Should that voltage drop below

a preset level, circuit board action will signal the

engine to crank and start. After the engine starts, the

circuit board signals the transfer switch to activate

and connect load circuits to the standby power sup-

ply (load terminal lugs T1/T2 connect to terminal

lugs E1/E2).

Upon restoration of utility source voltage above a pre-

set level, generator circuit board action signals the

transfer switch to transfer loads back to that power

supply. After retransfer, the engine is signalled to shut

down.

3.2.3 “MANUAL” POSITION

Set the switch to Manual to crank and start the

engine. Transfer to standby power will not occur

unless there is a utility failure.

‹

Figure 3.1 – Generator Control Panel

FUSE

L o c a t

y o u r n e a r e s t

d e a le r a t

POWER SYSTEMS, INC.

AUTO OFF MAN.

SYSTEM SET

LOW OIL

The actual sequence of operation is controlled by

sensors and timers on a control logic circuit board,

as follows:

HIGH TEMP.

OVER SPEED

OVER CRANK

FUSE

F L A

G R E E N L E D

SET

EXERCISE

TIME

15A

IL IT

E D L E D

IS E R

E N

A.Utility Voltage Dropout Sensor

F L A

E X E R

E T

• This sensor monitors utility source voltage.

• If utility source voltage drops below about 70 per-

cent of the nominal supply voltage, the sensor

energizes a 15-second timer.

With the switch set to AUTO, the engine may

crank and start at any time without warning.

Such automatic starting normally occurs when

utility power source voltage drops below a pre-

set level or during the normal exercise cycle. To

prevent possible injury that might be caused by

such sudden starts, always set the switch to

OFF and remove the fuses before working on

or around the generator or transfer switch.

Then, place a “Do Not Operate” tag on the gen-

erator panel and on the transfer switch.

• Once the timer has expired, the engine will crank

and start.

B.Engine Warm-up Time Delay

• This mechanism lets the engine warm up for

about 10 seconds before the load is transferred

to the standby source.

C.Standby Voltage Sensor

• This sensor monitors generator AC output volt-

age. When the voltage has reached 50 percent of

the nominal rated voltage, transfer to standby

can occur.

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Section 3 — Operation

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

D.Utility Voltage Pickup Sensor

5. To crank and start the engine, set the

Auto/Off/Manual switch to MANUAL.

6. Let the engine stabilize and warm up for a few

minutes.

• This sensor monitors utility power supply volt-

age. When that voltage is restored above 70 per-

cent of the nominal source voltage, a retransfer

time delay starts timing.

7. Set the generator’s main circuit breaker to its ON

(or closed) position. The standby power source

now powers the loads.

E.Retransfer Time Delay

• This timer runs for about 15 seconds.

• At end of a 15-second delay, circuit board action

de-energizes transfer relay in the transfer switch.

• Retransfer to utility power source then occurs.

F. Engine Cool-down Timer

• When the load is transferred back to utility power

source, the engine cool-down timer starts timing.

• The timer will run for about one minute, and the

generator will then shut down.

3.5.2 TRANSFER BACK TO UTILITY POWER

SOURCE

‹

When utility power has been restored, you will want

to transfer back to that source and shut down the

generator. This can be accomplished as follows:

1. Set the generator’s main circuit breaker to its

OFF (or open) position.

2. Let the engine run for a minute or two at no-load

to stabilize the internal temperatures.

3. Set the generator’s Auto/Off/Manual switch to

its OFF (or open) position. The engine should

shut down.

3.5 MANUAL TRANSFER OPERATION

3.5.1 TRANSFER TO GENERATOR

‹

POWER SOURCE

To start the generator and activate the transfer switch

manually, proceed as follows:

4. Check that utility power supply to the transfer

switch is turned OFF.

1. Set the generator’s Auto/Off/Manual switch

to OFF.

DANGER

2. Set the generator’s main circuit breaker to its

Do not attempt to activate the transfer switch

manually until all power voltage supplies

to the switch have been positively turned off.

Failure to turn off all power voltage supplies

may result in extremely hazardous and possibly

fatal electrical shock.

OFF (or open) position.

3. Turn OFF the utility power supply to the transfer

switch using the means provided (such as a

utility main line circuit breaker).

DANGER

5. Use the manual transfer handle inside the trans-

fer switch to move the main contacts back to their

“Utility” position, i.e., loads connected to the util-

ity power source (Figure 3.2).

Do not attempt to activate the transfer switch

manually until all power voltage supplies to

the switch have been positively turned off.

Failure to turn off all power voltage supplies

may result in extremely hazardous and possibly

fatal electrical shock.

6. Turn ON the utility power supply to the transfer

switch using the means provided.

7. Set the system to automatic operation as outlined

in “Automatic Transfer Operation,” Section 3.3

(Page 14).

4. Use the manual transfer handle inside the trans-

fer switch to move the main contacts to their

“Standby” position, i.e., loads connected to the

standby power source (Figure 3.2).

3.6 SETTING THE EXERCISE TIMER

Your generator is equipped with an exercise timer.

Once it is set, the generator will start and exercise

once every seven days, on the day of the week and at

the time of day you complete the following sequence.

During this exercise period, the unit runs for approx-

imately 12 minutes and then shuts down. Transfer of

loads to the generator output does not occur during

the exercise cycle.

Figure 3.2 – Manual Transfer Switch Operation

A switch on the control panel (see Figure 3.1, Page 14)

allows you to select the day and time for system exer-

cise. To select the desired day and time of day, you

must perform the following sequence at that time.

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Section 4 — Maintenance

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

1. Verify that the Auto/Off/Manual switch is set

3.7.3 OVERCRANK

‹

to AUTO.

This feature prevents the generator from damaging

itself when it continually attempts to start and anoth-

er problem, such as no fuel supply, prevents it from

starting. The unit will crank and rest for a preset time

limit. Then, it will stop cranking, and the LED on the

generator control panel will light indicating an over-

crank failure. The Auto/Off/Manual switch will need

to be set to OFF and then back to AUTO to reset the

generator control board.

2. Hold down the “Set Exercise Time” switch until

the generator starts (approximately 10 seconds)

and then release.

3. The generator will start and run for approximately

12 minutes and then shut down on its own. The

exerciser will then be set to run at that time of day

every week.

NOTE:

The exerciser will only work in the AUTO mode

and will not work unless this procedure

is performed. The exerciser will need to be reset

every time the 12-volt battery is disconnected and

then reconnected. The exerciser WILL NOT work

if dip switch 2 on the controller printed circuit

board (Remote Not Auto) is ON.

If the fault is not repaired, the overcrank feature

will continue to activate.

3.7.3.1 Approximate Crank Cycle Times

• 15 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

3.7 PROTECTION SYSTEMS

3.7.1 LOW OIL PRESSURE SWITCH

‹

• Repeat for 45 seconds

Approximately 90 seconds total

This switch (Figure 3.3) has normally closed contacts

that are held open by engine oil pressure during crank-

ing and operating. Should oil pressure drop below the

8 psi range, switch contacts close, and the engine

shuts down. The unit should not be restarted until oil

is added. The Auto/Off/Manual switch must then be

turned to OFF and then back to AUTO.

3.7.4 OVERSPEED

‹

This feature protects the generator from damage by

shutting it down if it happens to run faster than the

preset limit. This protection also prevents the gener-

ator from supplying an output that could potentially

damage appliances connected to the generator cir-

cuit. Contact your nearest Generac/Guardian

Authorized Dealer if this failure occurs.

3.7.2 HIGH TEMPERATURE SWITCH

‹

This switch’s contacts (Figure 3.3) close if the tem-

perature should exceed approximately 140º C (284º

F), initiating an engine shutdown. Your generator will

automatically restart and the LED on the generator

control panel will reset once the temperature has

returned to a safe operating level.

4.1 FUSE

The generator panel’s 15 amp fuse (Figure 4.1) protects

the DC control circuit against overload. The fuse is

wired in series with the battery output lead to the panel.

If the fuse element has melted open, you cannot crank

or start the engine. You should replace the fuse using

only an identical 15-amp replacement.

Figure 3.3 – Low Oil Pressure and

High Temperature Switches

The generator panel’s 5 amp fuse protects the battery

charge circuit against overload. If the fuse element has

melted open, you will not have battery charging capa-

bility. You should replace the fuse using only an identi-

cal 5 amp replacement. To remove fuse, push cap down

and rotate counterclockwise.

Low Oil Switch

High Temp Switch

Oil

Drain

Hose

Oil Filter

16 Generac Power Systems, Inc.

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Section 4 — Maintenance

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Figure 4.1 – Generator Control Panel

Figure 4.3 — Oil Dipstick and Fill,

12 kW and 15 kW

FUSE

L o c a t

y o u r n e a r e s t

d e a le r a t

Oil Dipstick

POWER SYSTEMS, INC.

AUTO OFF MAN.

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

FUSE

Oil Fill

F L A

G R E E N L E D

SET

EXERCISE

TIME

15A

IL IT

E D L E D

IS E R

E N

F L A

E X E R

E T

4.2 CHECKING THE ENGINE

OIL LEVEL

For oil capacities, see “Specifications,” Section 1.5

(Page 6). For engine oil recommendations, see

Section 4.3.1. To check the engine oil level, proceed

as follows (Figures 4.2 and 4.3):

4.3 CHANGING THE ENGINE OIL

1. Start the generator by moving the Auto/

Off/Manual switch to the MANUAL position. Allow

it to run for a short while and then shut it down

by moving the switch to the OFF position.

2. Remove the dipstick and wipe it dry with a

clean cloth.

4.3.1 ENGINE OIL RECOMMENDATIONS

‹

Use oil of American Petroleum Institute (API) Service

Class SG, SH or SJ. Use all season SAE 5W-30

Synthetic oil. Organic break-in oil is required before

using synthetic oil.

3. Install the dipstick; then, remove it again. The oil

level should be at the dipstick “Full” mark. If nec-

essary, add oil to the “Full” mark only. DO NOT

FILL ABOVE THE “FULL” MARK.

NOTE:

The unit is supplied with “break-in” oil. See the

“Break-in Procedure,” Section 3.1 (Page 14), for

the first required oil change.

Never operate the engine with the oil level

below the “Add” mark on the dipstick. Doing

this could damage the engine.

Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

4. Install the dipstick.

5. Reset the Auto/Off/Manual switch to its original

4.3.2 OIL CHANGE PROCEDURE

To change the oil, proceed as follows:

‹

position.

Figure 4.2 — Oil Dipstick and Fill, 7 kW

1. Run the engine until it is thoroughly warmed up

then shut OFF the engine.

2. Immediately after the engine shuts OFF, pull the

oil drain hose (Figure 4.4 on page 18) free of its

retaining clip. Remove the cap from the hose and

drain the oil into a suitable container.

Oil Dipstick and Fill

3. After the oil has drained, replace the cap onto the

end of the oil drain hose. Retain the hose in the clip.

4. Refill with the proper recommended oil (see

Section 4.3.1). See Section 1.5.2 (Page 6) for oil

capacities.

Generac Power Systems, Inc. 17

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Section 4 — Maintenance

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Figure 4.4 – Oil Drain Hose and Filter

Figure 4.6 — 7 kW, Engine Air Cleaner Location

Low Oil Switch

High Temp Switch

Fuel

Regulator

Air Cleaner

Oil

Drain

Hose

Oil Filter

Figure 4.7 — 12 kW and 15 kW Engine

Air Cleaner

4.4 CHANGING THE OIL FILTER

Change the engine oil filter as follows:

1. With the oil drained, remove the old oil filter by

turning it counterclockwise.

Screw

2. Apply a light coating of clean engine oil to the gas-

ket of the new filter. See Section 1.5.1 (Page 6) for

recommended filter.

3. Screw the new filter on by hand until its gasket

lightly contacts the oil filter adapter. Then, tighten

the filter an additional 3/4 to one turn (Figure 4.4).

4. Refill with the proper recommended oil (see

Section 4.3.1, Page 17). See Section 1.5.2 (Page 6)

for oil capacities.

Cover

Filter

5. Start the engine and check for leaks.

4.5 CHANGING THE ENGINE

AIR CLEANER

4.5.1 7 KW, 12 KW AND 15 KW

GENERATORS

‹

See Figures 1.1 and 1.2, (Page 5), for the location of

your air cleaner. Use the following procedure (Figure

4.6):

4.6 SPARK PLUG(S)

1. Turn the two screws counterclockwise to loosen.

2. Remove the cover and air filter.

Reset the spark plug(s) gap or replace the spark

plug(s) as necessary. See Section 4.13 (Page 22) for

maintenance requirements.

3. Wipe away dust or debris from inside of the air

box and around edges.

1. Clean the area around the base of the spark

plug(s) to keep dirt and debris out of the engine.

Clean by scraping or washing using a wire brush

and commercial solvent. Do not blast the spark

plug(s) to clean.

2. Remove the spark plug(s) and check the condi-

tion. Replace the spark plug(s) if worn or if reuse

is questionable. See Section 4.13 (Page 22) for

recommended inspection.

4. Install the new air cleaner into the air box.

5. Install the cover. Turn the two cover screws clock-

wise to tighten.

See the “Service Schedule,” Section 4.13 (Page 22) for

air cleaner maintenance. See Section 1.5.1 (Page 6)

for air filter replacement part number.

18 Generac Power Systems, Inc.

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Section 4 — Maintenance

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

3. Check the spark plug gap using a wire feeler

The electrolyte is a dilute sulfuric acid that is

gauge. Adjust the gap to 0.76 mm (0.030 inch) for

7 kW and 0.50 mm (0.020 inch) for 12/15 kW by

carefully bending the ground electrode (Figure

4.8).

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following

procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and seek

medical attention; and

Figure 4.8 – Setting the Spark Plug Gap

SET PLUG GAP AT 0.76 mm / 0.50 mm

(0.030 inch / 0.020 inch)

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) of water. The bicar-

bonate of soda solution is to be added until the

evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the

area dried.

Lead-acid batteries present a risk of fire

because they generate hydrogen gas. The

following procedures are to be followed:

4.7 BATTERY MAINTENANCE

The battery should be inspected per the “Service

Schedule,” Section 4.13 (Page 22). The following pro-

cedure should be followed for inspection:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from your body before

touching the battery by first touching a grounded

metal surface.

1. Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries

and, if necessary, fill with DISTILLED WATER

ONLY. DO NOT USE TAP WATER IN BATTERIES.

3. Have the state of charge and condition checked.

This should be done with an automotive-type bat-

tery hydrometer.

Be sure the Auto/Off/Manual switch is set to

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as

the battery cables are connected.

Be sure the utility power supply is turned off

and the 5A and 15A fuses are removed from

the generator control panel, or sparking may

occur at the battery posts as you attach the

cables and cause an explosion.

DANGER

Do not dispose of the battery in a fire. The

battery is capable of exploding.

A battery presents a risk of electrical shock

and high short circuit current. The following

precautions are to be observed when working

on batteries:

4.8 ADJUSTING GH-410/GT-990 VALVE

CLEARANCE

After the first 50 hours of operation, you should

adjust the valve clearance in the engine.

• Remove the 5A and 15A fuses from the generator

control panel.

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the

battery; and

Important: If you feel uncomfortable about doing this

procedure or you don't have the proper tools, please

contact your Generac Authorized dealer for service

assistance. This is a very important step to insure

longest life for your engine.

To adjust valve clearance:

• Disconnect charging source prior to connecting or dis-

connecting battery terminals.

• Make sure the engine is at room temperature.

• Make sure that the spark plug wire is removed

from the spark plug and out of the way.

• Remove the four screws attaching the valve cover

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to

with a #2 or #3 phillips screwdriver.

the skin and eyes, and to be toxic.

Generac Power Systems, Inc. 19

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Section 4 — Maintenance

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

• Make sure the piston is at Top Dead Center (TDC)

4.9 COOLING SYSTEM

of its compression stroke (both valves closed). To

get the piston at TDC, remove the intake screen at

the front of the engine to gain access to the flywheel

nut. Use a large socket and socket wrench to rotate

the nut and hence the engine. While watching the

piston through the spark plug hole. The piston

should move up and down. The piston is at TDC

when it is up as high as it can go.

Air inlet and outlet openings in the generator com-

partment must be open and unobstructed for contin-

ued proper operation. This includes such obstruc-

tions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the

engine/generator quickly overheats, which causes it to

quickly shut down. (See Figure 4.9 for vent locations.)

• Loosen the rocker jam nut. Use an 10mm allen

wrench to turn the pivot ball stud while checking

clearance between the rocker arm and the valve

stem with a feeler gauge. Correct clearance is

0.002-0.004 inch (0.05-0.1 mm).

Figure 4.9 – Cooling Vent Locations

NOTE:

You must hold the rocker arm jam nut in place as

you turn the pivot ball stud.

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. torque. After tightening the jam nut, recheck

valve clearance to make sure it did not change.

Figure 4.10 - Valve Clearance Adjustment

Rocker

Pivot Ball

Stud

Arm

The exhaust from this product gets extremely

hot and remains hot after shutdown. High

grass, weeds, brush, leaves, etc. must remain

clear of the exhaust. Such materials may ignite

and burn from the heat of the exhaust system.

Jam Nut

Valve

Stem

The maximum ambient temperature for your

generator is 40° C (104° F).

4.10 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water,

it MUST NOT be started and operated. Following any

submersion in water, have a Generac/Guardian

Authorized Dealer thoroughly clean and dry the gener-

ator.

• Install new valve cover gasket.

• Re-attach the valve cover.

NOTE:

Start all four screws before tightening or you will

not be able to get all the screws in place. Make

sure the valve cover gasket is in place.

4.11 CORROSION PROTECTION

Periodically wash and wax the enclosure using auto-

motive type products. Frequent washing is recom-

mended in salt water/coastal areas. Spray engine

linkages with a light oil such as WD-40.

• Re-attach the spark plug wire to the spark plug.

• On GT-990, Repeat the process for the other cylinder.

20 Generac Power Systems, Inc.

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Section 4 — Maintenance

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

4.12.2 RETURN TO SERVICE

To return the unit to service after storage, proceed

as follows:

‹

4.12 OUT OF SERVICE PROCEDURE

4.12.1 REMOVAL FROM SERVICE

‹

If you cannot exercise the generator every seven days,

and it is to be out of service longer than 90 days, pre-

pare the generator for storage as follows:

1. Verify that utility power is turned off and that the

Auto/Off/Manual switch is set to OFF.

2. Check the tag on the engine for oil viscosity and

classification. Verify that the correct recommend-

ed oil is used in the engine (see Section 4.3.1,

Page 17). If necessary, drain and refill with the

proper oil.

3. Check the state of the battery. Fill all cells of

unsealed batteries to the proper level with dis-

tilled water. DO NOT USE TAP WATER IN THE

BATTERY. Recharge the battery to 100 percent

state of charge, or, if defective, replace the battery.

See “Specifications,” Section 1.5 (Page 6), for type

and size.

4. Clean and wipe the entire generator.

5. Remove the 5A and 15A fuses from the generator

control panel. Reconnect the battery. Observe bat-

tery polarity. Damage may occur if the battery is

connected incorrectly.

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line

and allow the unit to shut down.

3. Once the unit has shut down, it will signal a low

oil fault.

4. Set the Auto/Off/Manual switch to OFF and turn

off the utility power to the transfer switch.

Remove the 5A and 15A fuses from the generator

control panel. Disconnect the battery cables as

outlined in “General Hazards” (page 2).

5. While the engine is still warm from running,

drain the oil completely. Refill the crankcase with

oil. See ”Engine Oil Recommendations,” Section

4.3.1 (Page 17).

6. Attach a tag to the engine indicating the viscosity

and classification of the oil in the crankcase.

7. Remove the spark plug(s) and spray fogging agent

into the spark plug(s) threaded openings.

Reinstall and tighten the spark plug(s).

6. Open the fuel shutoff valve.

7. Insert the 5A and 15A fuses into the generator

control panel. Start the unit by moving the

Auto/Off/Manual switch to MANUAL. Allow the

unit to warm up thoroughly.

8. Remove the battery and store it in a cool, dry

room on a wooden board. Never store the battery

on any concrete or earthen floor.

8. Stop the unit by setting the Auto/Off/Manual

switch to OFF.

9. Clean and wipe the entire generator.

9. Turn on the utility power to the transfer switch.

10. Set the Auto/Off/Manual switch to AUTO.

11. Your generator is now ready for service.

NOTE:

If the battery was dead or disconnected, you must

reset the exercise timer.

Generac Power Systems, Inc. 21

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Section 4 — Maintenance

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

4.13 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by your nearest Generac/Guardian Authorized Dealer.

SYSTEM/COMPONENT

PROCEDURE

FREQUENCY

X = Action

Inspect

Change

Clean

W = Weekly

M = Monthly

Y = Yearly

R = Replace as Necessary

* = Notify Dealer

if Repair is Needed.

FUEL

Fuel lines and connections*

LUBRICATION

Oil level

Oil

AFTER BREAK-IN,

AND Y

Oil filter

AFTER BREAK-IN,

AND Y

COOLING

Enclosure louvers

BATTERY

Remove corrosion,

ensure dryness

Clean and tighten

battery terminals

Check charge state

EVERY 6 M

Electrolyte level

(unsealed batteries only)*

ENGINE AND MOUNTING

Air cleaner

Spark plug(s)

GENERAL CONDITION

Vibration, Noise, Leakage,

Temperature*

COMPLETE TUNE-UP*

TO BE COMPLETED BY A GENERAC/

GUARDIAN AUTHORIZED DEALER

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Section 5 — Troubleshooting

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

5.1 TROUBLESHOOTING GUIDE

PROBLEM

The engine will not crank.

CAUSE

1. Fuse blown.

CORRECTION

1. Replace 15A fuse in generator

control panel.

2. Loose, corroded or defective

battery cables.

2. Tighten, clean or replace

as necessary.

3. Defective starter contactor. (7 kW) 3. *

4. Defective starter motor.

5. Dead Battery.

4. *

5. Charge or replace battery.

The engine cranks but

will not start.

1. Out of fuel.

1. Replenish fuel.

2. *

3. *

2. Defective fuel solenoid (FS).

3. Open #14 wire from

engine control board.

4. Defective spark plug(s).

5. Valve lash out of adjustment.

4. Clean, re-gap or replace plug(s).

5. Reset valve lash.

The engine starts hard

and runs rough.

1. Air cleaner plugged

or damaged.

1. Check, replace air cleaner.

2. Defective spark plug(s).

3. Fuel Regulator not set.

4. Fuel Pressure incorrect.

2. Clean, re-gap or replace plug(s).

3. Set Fuel Regulator.

4. Confirm fuel pressure to regulator

is 11-14” water column (0.6 psi).

The Auto/Off/Manual switch

is set to OFF, but the engine

continues to run.

1. Defective switch.

1. *

2. *

2. Auto/Off/Manual switch

wired incorrectly.

3. Defective control board.

3. *

There is no AC output from

the generator.

1. Main line circuit breaker open. 1. Reset circuit breaker

to ON (or closed).

2. Generator internal failure.

2. *

There is no transfer to

standby after utility

source failure.

1. Defective transfer switch coil.

2. Defective transfer relay.

3. Transfer relay circuit open.

4. Defective control logic board.

1. *

2. *

3. *

4. *

Unit consumes large

amounts of oil.

1. Break-in procedure

1. *

not followed (see Section 2.1).

*Contact your nearest Generac/Guardian Authorized Dealer for assistance.

Generac Power Systems, Inc. 23

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Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-A

DIAGRAM KEY

BA - BRUSH ASSEMBLY

BCR - BATTERY CHARGE RELAY

CB1 - MAIN OUTPUT BREAKER

CHARGER

CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION

DSW - PCB MOUNTED DIP SWITCH

FS - FUEL SOLENOID

F1 - FUSE 15 AMP

F2 - FUSE 5 AMP

GRD - CONTROL PANEL GROUND

HTO - HIGH OIL TEMPERATURE SWITCH

225B

ENGINE WIRING

224B

13A

ICT - INTERCONNECTION TERMINALS

IM1 - IGNITION MODULE, CYLINDER #1

LOP - LOW OIL PRESSURE SWITCH

SC - STARTER CONTACTOR

SCR - STARTER CONTACTOR RELAY

SP1, SP2 - SPARK PLUGS

SW1 - AUTO / OFF / MANUAL SWITCH

SW2 - SET EXERCISE SWITCH

SM - STARTER MOTOR

TB - INSULATED TERMINAL BLOCK

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

SP1

IM1

SP2

SCR

IM2

351

HTO

LOP

CONTROL

PRINTED CIRCUIT BOARD

RED

BLACK

2 - Remote Not Auto

3 - 50 Hz Operation

4 - SPARE

12V

BATTERY

CUSTOMER SUPPLIED

L.E.D - ALARM INDICATORS

24 Generac Power Systems, Inc.

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Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-A

CONTROL PANEL BOX

225

224

224A

225A

CLOSEST TO BEARING

224A

225A

BCR

CB2

STATOR

N1 N2

162

225B

224B

66A

13A

225

224

162

VOLTAGE

REGULATOR

66A

225

GRD

351

224

194

351

13A

351

CUSTOMER

CONNECTION

194

15A

194

66A

239

CB1

15A

OFF

239

225

224

SW2

AUTO

OUTPUT TO TRANSFER

SWITCH CONTACTOR

MANUAL

Generac Power Systems, Inc. 25

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Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-A

225A

224A

BATTERY

CHARGER

225B

13A

224B

13A

BCR

13A

C2-1

BATTERY CHARGE

WINDING

C2-2

C2-4

HTO

C2-11

LOP

ENGINE RUN

WINDING

FIELD

SW2

C1-4

(STATOR)

C1-3

C2-9

C2-3

ELECTRONIC

VOLTAGE

REGULATOR

66A

162

C1-6

CB2

C2-8

351

225

224

C2-7

66A

(STATOR)

DIAGRAM KEY

194

BA - BRUSH ASSEMBLY

BCR - BATTERY CHARGE RELAY

CB1 - CIRCUIT BREAKER, MAIN OUTPUT

CB2 - CIRCUIT BREAKER, ALT. EXCITATION

D - DIODE

FS - FUEL SOLENOID

F1 - FUSE 15 AMP

F2 - FUSE 5 AMP

HTO - HIGH OIL TEMPERATURE SWITCH

IM1 - IGNITION MODULE, CYLINDER #1

IM2 - IGNITION MODULE, CYLINDER #2

LOP - LOW OIL PRESSURE SWITCH

SC - STARTER CONTACTER

194

66A

CONTROL

PRINTED CIRCUIT

BOARD

15A

225

224

SCR - STARTER CONTACTOR RELAY

SP1, SP2 - SPARK PLUGS

SW1 - AUTO / OFF / MANUAL SWITCH

SW2 - SET EXERCISE SWITCH

SM - STARTER MOTOR

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

26 Generac Power Systems, Inc.

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Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-A

C2-6

C2-5

225A

56VA

1VA

224A

225

224

194

CUSTOMER

CONNECTIONS

NEUTRAL

15A

SW1

120V

194

120V

POWER WINDING

(STATOR)

239

CB1

194

239

240V

15A

239

RED

C2-1

66A

SCR

C1-1

BATTERY

12V

BLACK

CUSTOMER

SUPPLIED

IM1

IM2

SP1

SP2

C1-5

Generac Power Systems, Inc. 27

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Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Wiring Diagram – 7 kW – Drawing No. 0D9013-A

ENGINE WIRING

DIAGRAM KEY

BA - BRUSH ASSEMBLY

BCR - BATTERY CHARGE RELAY

CB1 - MAIN OUTPUT BREAKER

225A

224A

DIODE

DSW - PCB MOUNTED DIP SWITCH

FS - FUEL SOLENOID

13A

F2 - FUSE 5 AMP

GRD - CONTROL PANEL GROUND

HTO - HIGH OIL TEMPERATURE SWITCH

IC - INLINE CONNECTOR

ICT - INTERCONNECTION TERMINALS

IM - IGNITION MODULE

LOP - LOW OIL PRESSURE SWITCH

SC - STARTER CONTACTOR

SP - SPARK PLUG

SW1 - AUTO / OFF / MANUAL SWITCH

SM - STARTER MOTOR

TB - INSULATED TERMINAL BLOCK

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

HTO

LOP

351

194

CONTROL

PRINTED CIRCUIT BOARD

66A

RED

239

BLACK

DSW

15A

225

224

12V

BATTERY

CUSTOMER SUPPLIED

L.E.D - ALARM INDICATORS

28 Generac Power Systems, Inc.

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Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Wiring Diagram – 7 kW – Drawing No. 0D9013-A

224A

CLOSEST TO BEA

225A

CONTROL PANEL BOX

225

224

224A

225A

BCR

STATOR

162

225A

224A

66A

13A

225

224

162

VOLTAGE

REGULATOR

66A

225

GRD

351

224

194

351

15A

13A

351

CUSTOMER

CONNECTION

194

CB1

OFF

239

SW2

AUTO

240V GENERATOR

OUTPUT TO TRANSFER

SWITCH CONTACTOR

MANUAL

Generac Power Systems, Inc. 29

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Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Electrical Schematic – 7 kW – Drawing No. 0D9014-A

225A

BATTERY

CHARGER

225B

13A

224B

13A

BCR

13A

C2-1

BATTERY CHARGE

WINDING

C2-2

C2-4

HTO

LOP

ENGINE RUN

WINDING

FIELD

SW2

C1-4

(STATOR)

C1-3

C2-9

C2-3

ELECTRONIC

VOLTAGE

REGULATOR

C2-10

66A

162

C2-11

CB2

351

225

224

C2-7

66A

C2-8

DPE WINDING

(STATOR)

194

DIAGRAM KEY

194

BA - BRUSH ASSEMBLY

BCR - BATTERY CHARGE RELAY

CB1 - CIRCUIT BREAKER, MAIN OUTPUT

CB2 - CIRCUIT BREAKER, ALT. EXCITATION

D - DIODE

66A

CONTROL

PRINTED CIRCUIT

BOARD

FS - FUEL SOLENOID

F1 - FUSE 15 AMP

F2 - FUSE 5 AMP

15A

HTO - HIGH OIL TEMPERATURE SWITCH

HM - HOUR RUN METER

IM - IGNITION MODULE

LOP - LOW OIL PRESSURE SWITCH

SC - STARTER CONTACTER

SP - SPARK PLUG

SW1 - AUTO / OFF / MANUAL SWITCH

SW2 - SET EXERCISE SWITCH

SM - STARTER MOTOR

225

224

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)

30 Generac Power Systems, Inc.

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Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Electrical Schematic – 7 kW – Drawing No. 0D9014-A

C2-6

C2-5

56VA

1VA

224A

225

224

194

CUSTOMER

CONNECTIONS

15A

SW1

120V

194

120V

POWER WINDING

(STATOR)

239

CB1

194

239

240V

66A

15A

239

RED

C1-2

C1-1

BATTERY

12V

C1-6

BLACK

CUSTOMER

SUPPLIED

C1-5

Generac Power Systems, Inc. 31

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Enclosure – Drawing No. 0D3416-K

32 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Enclosure – Drawing No. 0D3416-K

ITEM PART NO.QTY. DESCRIPTION

0C6140

0D1901

0C6735

0C7061

0C7062

0C7062A

0C7063

0C7063A

0C7063B

0C7064

0C7065

0C7065A

0C8101A

0C8861

0C8101B

0C8862

0C8283

0C8284A

0C8284B

0C8284C

0C8285

0C8899A

0D1128

0D1128A

0D1605

0D1605A

0D1606

0D5264

0D1839

0D1840

0D2425

0D2588

0D2676

0D2677

0D2979B

ASSEMBLY, ENCLOSURE BASE (12KW / 15KW)

ASSEMBLY, ENCLOSURE BASE (7KW)

SUPPORT, ROOF FOLDING

022097

022473

036261

047411

043116

0D3700

083512

090388

WASHER LOCK M6-1/4"

WASHER FLAT ¼" ZINC

RIVET POP .125 X .129-.133/#30

SCREW HHC M6-1.0 X 16 G8.8

SCREW HHC M6-1.0 X 12 G8.8 (12KW / 15KW)

SCREW HHC M6-1.0 X 12 G8.8 (7KW)

NUT, LOCKING FLANGE M6-1.0

SCREW TAPTITE M8-1.20 X 16 BP

SCREW TAPTITE M6-1.0 X 12 BP

(12KW / 15KW)

SCREW TAPTITE M6-1.0 X 12 BP (7KW)

NUT LOCK TRIC M6 X 1.0 Y/ZNC

GASKET, BATTERY SUPPORT BRACKET

PLUG, PLASTIC 0.593 HEYCO 1675

LUG SLDLSS #2-#8X17/64 CU

SCREW TAPTITE M6-1.0X25 BP

L/WASH SPECIAL ¼

BRACKET, BATTERY HOLD DOWN (7KW)

CONTACTOR, STARTER (7KW)

CABLE, #6 RED BATTERY 38.5"

NUT HEX 1/4-20 STEEL (7KW)

WASHER LOCK 5/16 (12KW / /15KW)

WASHER LOCK 5/16 (7KW)

SCREW TAPTITE M5-0.8 X 10 BP

HARNESS, ENGINE (12KW / 15KW)

HARNESS, ENGINE (7KW)

BUSHING, SNAP SB-1000-12

SCREW HHC 5/16-18 X 3/4 G5 (7KW)

RIVET,1/8" X 0.126" - 0.375" LSH POP

L/WASH SPECIAL #10

ASSEMBLY, ROOF/DOOR GROUND WIRE

PLUG PLASTIC 1.375 (12KW / 15KW)

GASKET, CLIP-ON SELF GRIPPING

PLATE, "HOT"

GROMMET 2.75 X 1/16

EXTERNAL CONNECTION BOX

POWER BLOCK

HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (12KW / 15KW)

HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (7KW)

HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (16KW)

ENCLOSURE, FRONT

ENCLOSURE, EXHAUST SIDE (12KW / 15KW)

ENCLOSURE, EXHAUST SIDE (7KW)

ENCLOSURE, SIDE & BACK (12KW / 15KW)

ENCLOSURE, SIDE & BACK (7KW)

ENCLOSURE, SIDE & BACK (16KW)

ENCLOSURE, ROOF

PANEL, ALTERNATOR DIVIDER (12KW / 15KW)

PANEL, ALTERNATOR DIVIDER (7KW)

PANEL, MUFFLER BOX SIDE (12KW / 15KW)

PANEL, MUFFLER BOX SIDE (7KW)

COVER, MUFFLER BOX (12KW / 15KW)

COVER, MUFFLER BOX (7KW)

GASKET, DOOR SEAL

FOAM, BACK ENCLOSURE

FOAM, ROOF ENCLOSURE

FOAM, FRONT ENCLOSURE

BRACKET, BATTERY SUPPORT (12KW / 15KW)

PAD, 24"X48" WITH MOUNTING HOLES

PANEL, ENGINE DIVIDER (12KW / 15KW)

PANEL, ENGINE DIVIDER (7KW)

BAFFLE, INTAKE (12KW / 15KW)

BAFFLE, INTAKE (7KW)

10.5

092120

0D3167

0A3328

055414

092079

0A1658

0C2937

086729

0388040AJ0

022127

022129

074908

0D2346

0D2345

023484F

022142

0A7836

0A8475

0912970069

0912970070

055450

0D2023

0D3701

0D3472

0C8742

0C8911

0D3338

HOUSING, FAN (12KW / 15KW)

BAFFLE, EXHAUST (7KW)

BRACKET, TOP SUPPORT

BRACKET, BOTTOM SUPPORT

DUCT, BASE AIR (12KW / 15KW)

GASKET, FRONT DIVIDER

COVER, FRONT EXHAUST ENCLOSURE

COVER, BACK EXHAUST ENCLOSURE

CLOTH, HARDWARE 266.7mm x 146mm

(12KW / 15KW)

CLOTH, HARDWARE 266.7mm x 146mm

(7KW)

CLOTH, HARDWARE 543mm x 146mm

CLOTH, HARDWARE 266.7mm x 387.4mm

CLOTH, HARDWARE (7KW)

FOAM, FRONT INTAKE BAFFLE (12KW / 15KW)

FOAM, FRONT INTAKE BAFFLE (7KW)

FOAM, TOP INTAKE BAFFLE (12KW / 15KW)

FOAM, BACK INTAKE BAFFLE (12KW / 15KW)

FOAM, BACK INTAKE BAFFLE (7KW)

FOAM, BACK ENCL. STRIP (12KW / 15KW)

FOAM, EXHAUST SIDE ENCLOSURE END

FOAM, EXHAUST SIDE ENCLOSURE FRONT

FOAM, EXHAUST FAN HOUSING

(12KW / 15KW)

WASHER, SELF LOCKING (12KW / 15KW)

WASHER, SELF LOCKING (7KW)

FOAM, FRONT EXHAUST ENCLOSURE COVER

FOAM, BACK EXHAUST ENCLOSURE COVER

DOOR, PAWL

0D2979B

0D2979C

0D2979D

0D2979E

0D3057A

0D3058A

0D3057B

0D3057C

0D3058C

0D3057D

0D3059A

0D3059B

0D3059C

0D3419

0D3928

036937

022152

023897

022158

0D3031

026850

049813

0D2537A

0D2538A

047411

0A2311

043107

022145

045771

0C3906

SCREW PPHM #10-32 X 1

WASHER LOCK #10

WASHER FLAT #10 ZINC

NUT HEX #10-32 STEEL

FUEL LINE, 3/4"OUTDOOR (NOT SHOWN)

WASHER SHAKPROOF EXT 1/4 STEEL

NUT HEX M6-1.0 G8 YELLOW CHROME

HINGE, LIFT OFF, TYPE A KNUCKLE

HINGE, LIFT OFF, TYPE B KNUCKLE

SCREW HHC M6-1.0 X 16 G8.8

SCREW SWAGE 1/4-20 X 1

0D7176

0D3059D

0D3059E

0C7781

0D3037

0D2537

0D2538

0D3037A

0A2115

SCREW HHC M8-1.25 X 25

WASHER FLAT 5/16

NUT HEX M8-1.25

SELF-ALIGN SCREW M6 HH

LATCH, QUARTER TURN LOCKING

HINGE, LIFT OFF, TYPE A PIN

HINGE, LIFT OFF, TYPE B PIN

LATCH, QUARTER TURN NON-LOCKING

WASHER NYLON .250"

Generac Power Systems, Inc. 33

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Control Panel – Drawing No. 0D8503-E

34 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Control Panel – Drawing No. 0D8503-E

ITEM PART NO. QTY. DESCRIPTION

0A9947E

0A9947G

0A9947F

0A9947C

0A9947D

CIRCUIT BREAKER 30 X 2 240V SQD

QOU230 (7KW)

CIRCUIT BREAKER 40 X 2 240V SQD

QOU240 (8.5KW)

CIRCUIT BREAKER 50 X 2 240V SQD

QOU250 (12KW)

CIRCUIT BREAKER 60 X 2 240V SQD

QOU260 (13KW)

CIRCUIT BREAKER 70 X 2 240V SQD

QOU260 (15KW)

ASSEMBLY, BATTERY CHARGER ENGINE

ASSEMBLY, POTTED REGULATOR

RELAY, 12V 25A SPST (8.5KW/ 12KW/

13KW)

0D5240

051714

0D8502

0D8441

SWITCH, SPDT ON-MOM-ON

NUT HEX M3-0.5 (8.5KW/ 12KW/ 13KW)

NUT HEX M3-0.5 (7KW)

NEUTRAL ISOLATOR

HARNESS, CONTROL PANEL WIRE (NOT

SHOWN) (8.5KW/ 12KW/ 13KW)

HARNESS, CONTROL PANEL WIRE (NOT

SHOWN) (7KW)

SCREW TAPTITE, M5-0.8 x 10 BP

WASHER LOCK M5

NUT HEX M5-0.8

TRANSFORMER

SCREW HHC 1/4"-20 x 1/2"

FUSE 5A X AGC5

TERMINAL STRIP

RELAY PANEL 12VDC DPDT 10A 240VAC

SCREW PPHM M4-0.7 x 10mm

WASHER FLAT M4

COVER, CONTROL PANEL COMPONENT

(8.5KW/ 12KW/ 13KW)

COVER, CONTROL PANEL COMPONENT

(7KW)

SCREW PPHMS/LW #6-32 x 1/4"

SCREW HHC M5-0.8 x10mm

COVER, CONTROL PANEL (8.5KW/ 12KW/

13KW)

COVER, CONTROL PANEL (7KW)

NUT FLANGE M6-1.0 NYLOCK

ASSEMBLY, ROOF/DOOR GROUND WIRE

SCREW SWAGE 1/4"-20 x 1"

LOCKWASHER SPECIAL 1/4"

WASHER FLAT 1/4"

SCREW HHC M6-1.0 x 30mm

WASHER LOCK M6-1/4"

NUT HEX M6-1.0

0E0120

074908

049226

051716

0C3910

022507

099727

046689

063617

075475

043180

0D8439

0A1801

083049

0C2174

075210A

0D3062

0D8615

BLOCK 1 POSITION

HEX STAND-OFF #6-32 x 3/8"

ASSEMBLY, HOME STANDBY

CONTROLLER

HOLDER, FUSE

FUSE, 15AMP X AGC15

SWITCH, ROCKER

DIN RAIL

SNAP BUSHING SB-687-8

SCREW PPHM M4-0.7 x 16mm

WASHER LOCK M4

032300

022676

033873

0D5045

023484E

075476

022264

051715

043182

043181

0D8443

054502

0E0119

092036

045770

0C7171

NUT HEX M4-0.7

WASHER LOCK M3 (8.5KW/ 12KW/ 13KW)

WASHER LOCK M3 (7KW)

SCREW PHM M3-0.5 x 10mm

DECAL, CONTROL PANEL (NOT SHOWN)

CIRCUIT BREAKER 3 X 1 ETA 46-500-P

(8.5KW/ 12KW/ 13KW)

CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P

(7KW)

CONTROL, PANEL BOTTOM (8.5KW

/12KW/ 13KW)

0D2989

0D3700

0912970069

0A2311

0A1658

022473

038750

022097

049813

031879

023897

053623

0D8438

WASHER FLAT #4 (8.5KW/ 12KW/ 13KW)

WASHER FLAT #4 (7KW)

WASHER FLAT #10

0E0118

075235

CONTROL, PANEL BOTTOM (7KW)

SCREW HHC M5-0.8 x 30mm

Generac Power Systems, Inc. 35

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

7 kW GTS Load Center Assembly – Drawing No. 0D3997-E

36 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

7 kW GTS Load Center Assembly – Drawing No. 0D3997-E

ITEM

PART NO.

QTY.

DESCRIPTION

0D4801

0D4800

0C2237

077220

077220A

082574

084464

074908

024912

0A1658

063617

0D3030A

0A1495

0A1661

022473

0D3094

0D4684A

0D3319

056326

022152

087680

077441

063378

074138

036933

077033

048850

028739

038150

0D3191

0D3088

073591

073590A

040213B

0C8037

075475

0C8036

0C8035

0D3320

0D4802

022264

0A7215

0A2110

1 FT

BOX GTS LOAD CENTER

COVER, 8 POSITION GTS LOAD CENTER

TRANSFER SWITCH HOME STANDBY 100A2P250V

COIL UTILITY

COIL STANDBY

INSULATOR-SIDEWALL (NOT SHOWN)

LIMIT SWITCH OPERATION (NOT SHOWN)

SCREW TAPTITE M5-0.8 X 10 BP

SCREW TAPTITE 1/4-20 X 5/8 BP

LOCK WASHER, SPECIAL-1/4"

RELAY PANEL 12VDC DPDT 10A@240VAC

BASE, MOUNTING 6 POLE 125A/240V

SCREW TAPTITE M4-0.7X10 BP

RIVET POP .156 X .160-.164/#20

WASHER FLAT 1/4 ZINC

HARNESS,GTS TO MAIN PANEL

HARNESS ADAPTER PLATE

PANEL-SUB BREAKER BASE

TRIM VINYL BLACK 1/8GP

WASHER LOCK #10

NUT WING M6-1.0

HANDLE, TRANSFER SWITCH HOME STANDBY

HOLDER CABLE TIE

LUG DIS QK NI-S 10X45 DEG BR/T

SCREW PPHM #10-32 X 3/8"

LUG SLDLSS 1/0-#14X9/16 AL/CU

BLOCK TERMINAL 20A 5 X 6 X 1100V

TIE WRAP 3.9" X .10" NAT'L UL

WASHER FLAT #8 ZINC

COVER, RELAY & TERM BLOCK

WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)

FUSE HOLDER

ASSEMBLY FUSE 5A X BUSS HLDR73591

PCB SUPPORT SNAP-IN 1-3/8"

CIRCT BRK 20 X 1 HOM120

SCREW PPHM M4-0.7 X 10

CIRCT BRK 15 X 1 HOM115

CIRCT BRK 30 X 2 HOM230

COVER - HARNESS ENTRY

HARNESS, GTS TO EXT CONN BOX

WASHER LOCK M4

SCREW SW 1/4-20X5/8 N WA JS500

SCREW SWAGE 1/4-20 X 1/2 ZINC

Generac Power Systems, Inc. 37

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

12 kW and 15 kW GTS Load Center Assembly – Drawing No. 0D3996-D

38 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

12 kW and 15 kW GTS Load Center Assembly – Drawing No. 0D3996-D

ITEM

PART NO.

QTY.

DESCRIPTION

0D3086

0D3092

0C2237

077220

077220A

082574

084464

074908

024912

0A1658

063617

0D3030

0A1495

0A1661

022473

055450

025034

0D4684

0D3319

056326

022152

087680

077441

063378

074138

036933

077033

048850

028739

038150

0D3191

0D3088

073591

073590A

040213B

0C8037

0D3190

0C8036

0C8035

0D3320

0D3093

0D3926

022264

0A7215

0A2110

075475

0D3094

1 FT

BOX GTS LOAD CENTER

COVER, 12 POSITION GTS LOAD CENTER

TRANSFER SWITCH HOME STANDBY 100A2P250V

COIL UTILITY

COIL STANDBY

INSULATOR-SIDEWALL (NOT SHOWN)

LIMIT SWITCH OPERATION (NOT SHOWN)

SCREW TAPTITE M5-0.8 X 10 BP

SCREW TAPTITE 1/4-20 X 5/8 BP

LOCK WASHER, SPECIAL-1/4"

RELAY PANEL 12VDC DPDT 10A@240VAC

BASE, MOUNTING 6 POLE 125A/240V

SCREW TAPTITE M4-0.7X10 BP

RIVET POP .156 X .160-.164/#20

WASHER FLAT 1/4 ZINC

PLUG HEYMAN DP1375 (10KW / 12KW / 13KW)

PLUG STEEL 1.0625 STMPSN 3811 (14KW / 15KW / 16KW)

HARNESS ADAPTER PLATE

PANEL-SUB BREAKER BASE

TRIM VINYL BLACK 1/8GP

WASHER LOCK #10

NUT WING M6-1.0

HANDLE, TRANSFER SWITCH HOME STANDBY

HOLDER CABLE TIE

LUG DIS QK NI-S 10X45 DEG BR/T

SCREW PPHM #10-32 X 3/8"

LUG SLDLSS 1/0-#14X9/16 AL/CU

BLOCK TERMINAL 20A 5 X 6 X 1100V

TIE WRAP 3.9" X .10" NAT'L UL

WASHER FLAT #8 ZINC

COVER, RELAY & TERM BLOCK

WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)

FUSE HOLDER

ASSEMBLY FUSE 5A X BUSS HLDR73591

PCB SUPPORT SNAP-IN 1-3/8"

CIRCT BRK 20 X 1 HOM120

CIRCT BRK 20 X 2 HOM220

CIRCT BRK 15 X 1 HOM115

CIRCT BRK 30 X 2 HOM230

COVER - HARNESS ENTRY

HARNESS, GTS TO EXT CONN BOX (10KW / 12KW / 13KW)

HARNESS, GTS TO EXT CONN BOX (14KW / 15KW / 16KW)

WASHER LOCK M4

SCREW SW 1/4-20X5/8 N WA JS500

SCREW SWAGE 1/4-20 X 1/2 ZINC

SCREW PPHM M4-0.7 X 10

HARNESS,GTS TO MAIN PANEL

Generac Power Systems, Inc. 39

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

GT-990 Engine – Drawing No. 0D8674-C Part 1

Kit Contains:

66 2, 5, 19, 20, 39, 40, 47, 64, 93, 140

67 8, 11, 12, 13

68 4, 5, 6

69 16A, 16B, 17, 18

70 7, 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59, 60

71 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59, 60, 62

72 27, 28, 29

140

73 3, 32, 33, 34, 35, 36, 40, 72

16A

16B

16A

40 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

GT-990 Engine – Drawing No. 0D8674-C Part 1

ITEM PART NO. QTY. DESCRIPTION

0C5729

ASSEMBLY, CRANKCASE HOUSING WITH

SLEEVE

SEAL, 38 I.D. CRANKSHAFT

SCREW, TAPTITE M6-1.0 X 12 YC

ASSEMBLY, BREATHER

GASKET, BREATHER COVER

SEPARATOR, OIL BREATHER

ASSEMBLY, HEAD #1 G&S

RETAINER, PISTON PIN 20

ROCKER, COVER NO OIL FILL

STUD M8-1.25/10MM X 30 G5 ZINC

PISTON, HC

SET, PISTON RING 90MM

PIN PISTON D20

ASSEMBLY, CAMSHAFT & GEAR

SHAFT, GOVERNOR

ROLLER BEARING, GOVERNOR PLATE

ROLLER BEARING, GOVERNOR

ASSEMBLY,GOVERNOR GEAR

SPOOL, GOVERNOR MACHINED

GASKET, CRANK CASE

SEAL, OIL PASSAGE

ASSEMBLY, CRANKSHAFT HORIZONTAL

DIRECT DRIVE (GT-990)

ASSEMBLY, CRANKSHAFT HORIZONTAL

DIRECT DRIVE (GT-760)

ASSEMBLY, CONNECTING ROD (GT-990)

ASSEMBLY, CONNECTING ROD (GT-760)

SCREW SHC M6-1.0 X 50 G8.8

SCREEN, OIL PICKUP

ASSEMBLY, OIL PUMP

SLEEVE, SEAMED DOWEL 10 DIA.

COVER, OIL RELIEF

SPRING, OIL RELIEF

BALL, 1/2D OIL RELIEF

0C2988

0C2992

0C3971C

0C5305

0C3027

0C3007

0C5731

THRUST WASHER, GOVERNOR

BUSHING, GOVERNOR LOWER

ASSEMBLY, DIPSTICK WITH HANDLE

TUBE, DIPSTICK

O-RING, OIL CLR 3/8 X 1/2

SEAL, 42 I.D. CRANKSHAFT

ASSEMBLY, HOUSING COVER WITH

SLEEVE

SCREW, HHFC M10-1.5 X 55

SCREW HHFC M6-1.0 X 20

ASSEMBLY, OIL FILL CAP

HOOK, LIFTING

ROCKER, COVER WITH OIL FILL

GASKET, VALVE COVER

KEEPER, VALVE SPRING

RETAINER, VALVE SPRING

SPRING, VALVE

16A

16B

0C3008

090388

0C5372

0C3005

0C3003

0D8067A

071983

0C2981C

045761A

0C5848

021533

071980

0D4041

0C2983

0C2985A

0C2985B

0D4042

0A7811

0C2977

0C5943

0D4040E

0C3006

0C8566

093064

0C8808

0D2723B

0C2979

086515

0D2274

0D3867

078672

0C5371

0D5326

0D6023

0D5354

0D5313

0D6024

0C2976

086516

0C2229

083897

0D8067B

088396D

0C2978

043790A

SEAL, VALVE STEM D7

WASHER, VALVE SPRING

NUT, JAM ROCKER ARM

STUD, ROCKER ARM M8-1.0 x 57mm

PIVOT, ROCKER ARM

ROCKER ARM

PLATE, PUSH ROD GUIDE

SCREW HHFC M8-1.25 X 65

VALVE, EXHAUST

VALVE, INTAKE

TAPPET, SOLID

ASSEMBLY, HEAD #2 G&S

PUSHROD, 144.6

GASKET, HEAD

0D4122E

0C2969

0D3961

0D2157

0C5313

0D4123

078699E

0C3011

0C3009

0C3010

093873

0C5315

0C5998

0D1667

0C2991

BARBED ELBOW 90 3/8NPT X 3/8

L0CKTITE

0D4010

KIT GASKET

KIT PISTON & RINGS

0D4011

0D4012

0D4013

0D8675A

0D8675B

0D4015

WASHER, LOCK RIB M6

GEROTOR, OUTER

CLAMP, OIL TUBE

ARM, GOVERNOR

KIT BREATHER ASSEMBLY

KIT GOVERNOR ASSEMBLY

KIT HEAD ASSEMBLY CYLINDER 1

KIT HEAD ASSEMBLY CYLINDER 2

KIT OIL RELIEF

E-RING, GOVERNOR ARM

Generac Power Systems, Inc. 41

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

GT-990/760 Engine – Drawing No. 0D8674-C Part 2

138

139

135

122

124

125

123

136

137

120

125

124

133

134

132

131

119

116

115

127

114

117

121

118

128

129

130

126

100

102

109

103

105

104

110

106

112

101

107

108

112

113

111

42 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

GT-990/760 Engine – Drawing No. 0D8674-C Part 2

ITEM PART NO. QTY. DESCRIPTION

0C5136A

0C3024

0C3040

0C8127

0D8564A

0D8564B

0D2595

0D4417

0C3025

0D3083

0C7292

070185

075281

0C1085

043182

035461A

KNOB, AIR CLEANER

COVER, AIRBOX NG/LP

PRE-CLEANER,

ELEMENT, AIR CLEANER

ASSEMBLY, MIXER/AIRBOX 990

ASSEMBLY, MIXER/AIRBOX 760

SCREW SHOULDER (8MM) M6-1.0 X 18

WASHER,RUBBER 1/4" X 1/8" THICK

SWITCH, OIL PRESS

ASSEMBLY, OIL DRAIN HOSE

NIPPLE, 3/4"-16 UNF

FILTER, OIL D 69 X 64 LONG

SWITCH, THERMAL 284F

SCREW PPHM M3-0.5 X 8

WASHER LOCK M3

BARBED STR 1/4NPT X 3/8 WITH VIBRA

SEAL

CLAMP HOSE #5.5 .62 - .62

HOSE, 3/8" I.D. X 6" LONG

COOLER, OIL

108

109

110

111

112

0C3034

0C8549

0C3022A

0D1131

045756

NUT,HEX M24

SNORKEL, AIR INTAKE

HOUSING, BLOWER NG COOLER

GUARD, FAN

SCREW TAPTITE M6-1X10 YELLOW

CHROME

NUT, GROMMET 1/4 PLUG

HOSE, BREATHER

BRACKET, STARTER

SCREW HHC M6-1.0 x 16 WITH LOCK-

WASHER

WRAPPER, UPPER CYLINDER 1

WRAPPER, LOWER CYLINDER 1

WRAPPER, LOWER CYLINDER 2

WRAPPER, UPPER CYLINDER 2

SCREW TAPTITE M5-0.8 X 8 BP

ASSEMBLY, GROUND WIRE

ASSEMBLY, IGNITION COIL

WASHER LOCK M6-1/4

113

114

115

116

0C9763

0C3036

0C8919

079246

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

0C3018

0C3019

0D1142A

0D1143

066849B

0C3053

0C3052

022097

092079

0C3017

0D4529

022129

061906

082774

052859

0C8468

0C3048

0D3754

0D3742

0C8482

0D2576

0D3743

0D3705

040173

0C9806

0C3026

0C9764

0C3043

0C7694

0C7693

0C3041

070008

070006

040976

0C3016A

085011

0C3725B

0C3031

0C3032

0A5992

051754

0C3033

SCREW TAPTITE M6-1.0 X 25 BP

STARTER

SPARKPLUG

PLASTITE,1/4-15 X 3/4

GASKET, MANIFOLD / PORT

MANIFOLD CYLINDER 2

MANIFOLD CYLINDER 1

SLEEVE, RUBBER

WASHER LOCK M8-5/16

SCREW HHC M8-1.25 X 85 G8.8

KEY, WOODRFF 4 X 19D

NUT HEX LOCK M10-1.50

SPRING, ANTI-LASH

ROD, GOVERNOR CONTROL

ASSEMBLY, GOVERNOR LEVER

SPRING, GOVERNOR

ASSEMBLY, GOVERNOR ADJUSTER

SCREW SHC M10-1.5 X 70 G10.9

SPRING, GOVERNOR IDLE

ASSEMBLY, GOVERNOR ADJUSTER

BRACKET

WASHER FLAT M8 SS

WASHER LOCK M8 SSTL

SCREW SHC M8-1.25 X 20 G12.9

PLATE, BACKING GT990 WITH OIL COOL

INSULATOR ASSEMBLY IGNITION

FLYWHEEL ASSEMBLY

FAN, NYLON

PLATE, FAN

WASHER SHAKEPROOF INT M8 SS

SCREW HHC M8-1.25 X 12 G8.8

WASHER, 25mm I.D.

100

101

102

103

104

105

106

107

140

0C2993

SEAL, GOVERNOR SHAFT

Generac Power Systems, Inc. 43

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

7 kW Generator – Drawing No. 0D3504-B

44 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

7 kW Generator – Drawing No. 0D3504-B

ITEM

PART NO.

QTY.

DESCRIPTION

0C6934

0C9935H

0C9934H

0C6043A

0C8096

0C9593

0D3220

0C8860

031971

0C3168

056147

0D1847

0C7038C

0D1647

0D2558

0C7038B

0C7758

0388050AE0

0C2417A

082121C

066386

029451

049451

022237

022511

022131

039287

022145

049820

090388

022129

022259

059637

048031K

0C9592

057822

040976

0C2824

025145

090239

0C6989

0D1214

0C8127

0C3024

0D2273

055934N

074994

0C5136A

074906

022473

0D4662

0C8290

ADAPTOR, ENGINE

STATOR

ROTOR

CARRIER, REAR BEARING

FAN, 8" CURVED BLADE

MUFFLER

TAIL PIPE, MUFFLER

PANEL, MUFFLER BASE

BEARING #6205-2NSE-C3

5/16 SPECIAL L/WASH

BOLT ROTOR HHCS 5/16"-24 X 13-1/2" G5

BOLT STATOR IHHC M8-1.25 x 305mm

BRACKET, ALTERNATOR MOUNTING

DUCT, ALTERNATOR AIR

GASKET, ALTERNATOR AIR DUCT

BRACKET, ENGINE MOUNTING

RUBBER MOUNT

CABLE, #6 40" BLACK BATTERY

EARTH STRAP 3/8X 3/8

CLIP-J VINYL COAT .625 ID

ASSEMBLY BRUSH HOLDER

TAPE ELEC UL FOAM 1/8 X 1/2

WASHER FLAT .406ID X 1.62OD

WASHER LOCK 3/8

BOLT HHC 3/8-16 X 1-1/4 G5

WASHER FLAT 3/8 ZINC

SCREW HHC M8-1.25 X 45 G8.8

WASHER FLAT 5/16 ZINC

NUT LOCK HEX M8-1.25 NYL INSRT

SCREW TAP M6-1.0X12 BP

WASHER LOCK M8-5/16

NUT HEX 5/16-18 STEEL

SCREW TAPTITE 3/8-16X 3/4" BP

BAND, HOSE CLAMP 35.05 DIA.

BELLOWS

1.8 FT

CLAMP HOSE #8 .53 - 1.00

SCREW SHC M8-1.25 X 20 G12.9

SCREW TAPR #10-32 X 9/16

U-BOLT 5/16"-18 X 1.25" W/ SADDLE

GASKET, EXHAUST

STINGER, ENGINE AIR IN

BASE, AIR CLEANER

ELEMENT, AIR CLEANER

COVER, AIR CLEANER NG/LP

TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG

CLAMP VINYL 1.31 X .281 Z

HOSE 1\2ID LP GAS

1.25 FT

KNOB, AIR CLEANER

SCREW TAPTITE M6-1 X 20 BP

WASHER FLAT 1/4 ZINC

SCREW HHTT M8-1.2 X 20 BP

GASKET, PANEL

Generac Power Systems, Inc. 45

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

12 kW and 15 kW Generator – Drawing No. 0D3417-B

46 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

12 kW and 15 kW Generator – Drawing No. 0D3417-B

ITEM

PART NO.

QTY.

DESCRIPTION

0C6934

0C7930

0D2359

0C7944

0D2356

0C6043

0D2336

0C6042

0D3220

0C8101

056482

0C3168

0D1838

0D1846

0C7038

0D1609

0D2559

0C7038A

0C7758

0388050AD0

0C2417A

082121C

066386

029451

049451

022237

022511

022131

039288

022145

049820

045756

022129

022259

059637

083512

074994

057822

052858

0C2824

025145

0C4138

048031C

030340

ADAPTOR, ENGINE

STATOR 12KW

STATOR 15KW

ROTOR 12KW

ROTOR 15KW

CARRIER, REAR BEARING

FAN, 12" CURVED BLADE

MUFFLER

TAIL PIPE, MUFFLER

PANEL, MUFFLER BASE

BEARING 1.1811-2.8346

5/16 SPECIAL LOCK WASHER

BOLT, HHCS 3/8"-24 x 15.50"

BOLT, HHCS M8-1.25 x 345mm

BRACKET, ALTERNATOR MOUNTING

DUCT, ALTERNATOR AIR

GASKET, ALTERNATOR AIR DUCT

BRACKET, ENGINE MOUNTING

RUBBER MOUNT

CABLE, #6 48" BLACK BATTERY

EARTH STRAP 3/8X 3/8

CLIP-J, VYNL COAT 0.625" ID

ASSEMBLY BRUSH HOLDER

TAPE ELEC UL FOAM 1/8 X 1/2

WASHER FLAT .406ID X 1.62OD

WASHER LOCK 3/8

SCREW HHC 3/8-16 X 1-1/4 G5

WASHER FLAT 3/8 ZINC

SCREW HHC M8-1.25 x 55 G8.8

WASHER FLAT 5/16 ZINC

NUT LOCK HEX M8-1.25 NYL INSERT

SCREW TAPTITE M6-1.0X10 BP

WASHER LOCK M8-5/16

NUT HEX 5/16-18 STEEL

SCREW TAPTITE 3/8-16 X 3/4 BP

SCREW TAPTITE M8-1.25 X 16 BP

HOSE RES 1/2 LP GAS

2.6 FT

2.83 FT

CLAMP HOSE #8 .53 - 1.00

NUT LOCK M8

SCREW TAP-R #10-32 x 9/16

U-BOLT 5/16"-18 X 1.25" WITH SADDLE

GASKET, EXHAUST PORT

CLAMP HOSE BAND ¼"

HOSE 1/4 ID SAE 30R7

1.33 FT

Generac Power Systems, Inc. 47

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

GN410 Engine – Drawing No. 0D3539-B Part 1

48 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

GN410 Engine – Drawing No. 0D3539-B Part 1

ITEM

PART NO.

QTY.

DESCRIPTION

071978

071980

021533

0C5848

071983

0D4287

0A7628

078658

078659

088261E

072655

0A7975

078645

0A7811

0A9877

076701

021713B

078691

0A5771

0A5776

076361

0A8898D

0D2274

0C4391

086025

0C7393

021714

086516

086517

088396B

083897

077158

0C3150

072694

083907

072696

078694

021742

0D6094

076329

086254

0D4788

074908

086515

078606

0A1442

078672

089673

0B2104

078699C

0A7627

043790A

088590

078699B

ASSEMBLY, CONNECTING ROD

PIN, PISTON D20

SET, PISTON RING 90MM

PISTON, HC

RETAINER, PISTON PIN 20

ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER

ARM, GOVERNOR RC45

PIN, "R" GOVERNOR ARM

WASHER, GOVERNOR ARM THRUST

CRANKCASE, SUBASSEMBLY WITH PLUGS GH410

SEAL, 35 I.D. CRANKSHAFT

ASSEMBLY, GOVERNOR GEAR

C-RING, GOVERNOR GEAR RETAINER

SPOOL, GOVERNOR- MACHINE

ASSEMBLY, CAMSHAFT & GEAR

GASKET , CRANKCASE

GASKET, HEAD 410

COVER, OIL PRESSURE RELIEF

SPRING, OIL RELIEF 360

BALL, DIA 11/32 PRESSURE RELIEF

WASHER, THRUST GOVERNOR GEAR

ASSEMBLY, COVER, GEAR TOP CHECK / FILL

RETAINER, VALVE SPRING

VALVE SPRING LF

SET,GEROTOR 12 THK

BALANCER

ASSEMBLY,CYLINDER HEAD SEATS & GUIDES

VALVE, EXHAUST

VALVE, INTAKE

PUSH ROD

TAPPET

ASSEMBLY, SCREEN OIL PICK-UP

GASKET, ROCKER COVER 410

STUD, D20 PIVOT BALL

ROCKER ARM

NUT, JAM (ROCKER ARM)

PLATE, PUSH ROD GUIDE

SCREW, HHFL M10-1.5 X 105

ASSEMBLY, ROCKER COVER BREATHER

PLUG, OIL FILL PLASTIC

O-RING 17.8 I.D. x 2.4

PLUG, STANDARD PIPE 3/8 STEEL SQUARE HEAD

SCREW, TAPTITE M5-0.8 X 10 BP

KEEPER, VALVE SPRING

SCREW & LOCKWASHER M6-1 X 12

SCREW, HHFC M8-1.25 X 42

SEAL, VALVE STEM D7

WASHER, VALVE SPRING

WASHER, LARGE SPRING

DOWEL, SEAMED SLEEVE

SHAFT, GOVERNOR RC55

BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE

DOWEL DIA 12 X 18L

DOWEL, SLEEVE SEAMED 12 DIA.

Generac Power Systems, Inc. 49

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

GN410 Engine – Drawing No. 0D3539-B Part 2

50 Generac Power Systems, Inc.

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

GN410 Engine – Drawing No. 0D3539-B Part 2

ITEM

PART NO.

QTY.

DESCRIPTION

0C1069

SCREW, TAPTITE M6-1.0X8

YELLOW CHROME

0D2922

0C8435

0C9997

088434

045756

088433B

0C3794

021544

040976

022129

0C2458A

083512

0D1401

091039

0C9619

049811

022097

040945

086999

0D5667A

049821

099236

070185

082774

091222ESRV

067198N

067890

072347

072734

072735

0C3978

0C6040

084542

092079

0A8222

083502

083503

0D3083

0C8434

090072

075281

043182

0C1085

HOUSING, BLOWER

TUBE, DIPSTICK

GUARD, FAN

WRAPPER, BOTTOM

SCREW, TAPTITE M6-1X10 YELLOW CHROME

WRAPPER, TOP

BUMPER, NEOPRENE

STARTER ASSEMBLY, EATON

SCREW, SHC M8-1.25 X 20 G12.9

WASHER, LOCK M8-5/16

BACKPLATE, L/F D/F

SCREW, TAPTITE M8-1.2 X 16 YC

BREATHER TUBE

GASKET, INTAKE ADAPTER

ASSEMBLY, PLASTIC CARB

WASHER, FLAT M6

WASHER, LOCK M6-1/4

SCREW, SHC M6-1.0 X 20 G12.9

GASKET,OIL FILTR ADAPTER

ADAPTER, OIL FILTER

SCREW, SHC M8-1.25 X 30 G12.9

SWITCH, OIL 8.0 PSI

FILTER, OIL DIA. 69 X 64 LG

KEY, WOODRFF 4 X 19D

FLYWHEEL WITH RING GEAR 32DEG.

WASHER,BELV-20 X 2.2

NUT, HEX - FLYWHEEL

SPARKPLUG

ASSEMBLY,GOVERNOR LEVER 12 HP

ROD,GOVERNOR CONTROL.

SPRING, ANTI-LASH

ASSEMBLY, WIRE

ASSEMBLY, IGNITION COIL - GN LF

SCREW, TAPTITE M6-1.0 X 25 BP

SPRING, GOVERNOR 8#

BOLT, GOVERNOR ADJUST M5

NUT, M5-0.8 METAL LOCK

ASSEMBLY, OIL DRAIN HOSE

ASSEMBLY, CAP & DIPSTICK

O-RING 9/16 X 3/4 X 3/32

SWITCH, THERMAL

WASHER LOCK M3

SCREW PPHM M3-0.5 X 8

Generac Power Systems, Inc. 51

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Gas Regulator – Drawing No. 0D8720-B

FOR GT 760

ENGINE ONLY

ITEM PART NO. QTY. DESCRIPTION

0D5694

0C5765

0C4647

0C4680

0C6070

022985

022264

075475

0C5760A

0C6606

097934

0C4645

0C5761

0C5968

0C6066

0C5759

0C5764

0C5764A

070728

0C6069

0C5762

CASTING, TWIN REGULATOR HOUSING

SOLENOID, TWIN REGULATOR

GASKET , SOLENOID

PLUNGER, LP REGULATOR ASSEMBLY

SPRING-SOLENOID, PLUNGER

WASHER, FLAT #6

045764

0C6731

0C6067

0C4706

0C6068

0C4643A

026073

SCREW, TAPTITE M4X8 BP

SCREW, TAPTITE M4X8 BP (7KW)

RIVET, POP .118 X .125

SUPPORT, DIAPHRAGM

DIAPHRAGM, TWIN REGULATOR

CAP, DIAPHRAGM SUPPORT

INLET, TWIN REGULATOR 11.11 DIA.

PLUG, STANDARD PIPE 1/8 STEEL

SQUARE HEAD

PIN, LIMITED ADJUSTMENT

WASHER, FLAT M3 X 10mm O.D.

WASHER, FLAT M3 X 10mm O.D. (7KW)

INLET, TWIN REGULATOR NO HOLE -

NOT SHOWN (7KW)

BARBED STRAIGHT 1/8"NPT X 1/4"

JET IDLE PRIMER PHILLIPS HD

JET, GT760 CYL 1 NAT GAS

JET, GT760 CYL 2 NAT GAS

JET, GT 760 LP CYL 1

WASHER, LOCK M4

SCREW PPHM M4-0.7 X 10

JET, GN 410 ENGINE LP (7KW)

BARBED STRAIGHT 1/2NPT x 1/2

O-RING, CHECK VALVE

ADJUSTER SCREW, TWIN REGULATOR

LEVER, REGULATOR

SUPPORT, INLET SEAL

SEAL, INLET

PIN, PIVOT ARM

SPRING, REGULATOR

0A4032

0D3308

0C4643

028414A

0D5698A

0C5760B

0C5760C

0C5760D

0C5760E

0D3973

SPRING, REGULATOR (7KW)

SCREW, PFHMS M3-0.5 x 5

SCREW, PFHMS M3-0.5 x 5 (7KW)

GASKET, DIAPHRAGM

JET, GT760 LP CYL 2

PLUG, EXPANSION 16mm

COVER, TWIN REGULATOR

* A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY

52 Generac Power Systems, Inc.

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Section 8 — Mounting Dimensions

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Drawing No. 0D3739-B

Generac Power Systems, Inc. 53

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Section 9 — Notes

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

54 Generac Power Systems, Inc.

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Section 9 — Notes

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

Generac Power Systems, Inc. 55

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Section 10 – Warranty

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below.

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 utility, and lawn and garden equipment engines must be

designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control

system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifi-

cation or improper maintenance of your engine.

Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will

repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, dur-

ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or

workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory

supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance

on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the

completion of all scheduled maintenance.

As the engine purchaser/owner, you should, however, be aware that Generac may 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 unap-

proved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.

You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The

warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.

To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System

Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited

Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by

Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms

between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the

Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe impor-

tant rights and obligations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty serv-

ice, evidence must be presented showing the date of the sale to the original purchaser/owner.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at one of

the following addresses:

For Air-cooled Product ...

For Liquid-cooled Product ...

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

211 MURPHY DRIVE

WHITEWATER, WI 53190

EAGLE, WI 53119

Part 1

56 Generac Power Systems, Inc.

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Section 10 – Warranty

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1995 and later model year 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 con-

tinue for 24 consecutive months thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or

equipment and to each subsequent purchaser/owner that each of its engines is ...

(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its

authority, and

(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a war-

ranted emissions-related part to fail to be identical in all material respects to the part as described in the engine man-

ufacturer’s application for certification.

(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s

Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall

be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the

ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual

shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or

replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS

Warranty shall be warranted for the remainder of the ECS Warranty Period.

(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s

Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part

fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection

(4) below. Any such 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-related part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no

charge to the owner at a Generac Authorized Warranty Service Facility.

(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsi-

ble for diagnostic costs if the repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused

by a failure under warranty of any emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient

to meet the expected demand for such emission-related parts.

(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS

Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac

ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac

engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.

Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of

such an unapproved, add-on, modified, counterfeit and/or “grey market” part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

3) Ignition System including:

a) Spark plug

b) Ignition module

1.2) LPG/Natural Gas carburetion assembly and its internal

components.

a) Fuel controller (if so equipped)

4) Catalytic Muffler Assembly (if so equipped) including:

a) Muffler gasket

b) Exhaust manifold

b) Mixer and its gaskets (if so equipped)

c) Carburetor and its gaskets (if so equipped)

d) Primary gas regulator (if so equipped)

e) LP liquid vaporizer (if so equipped)

5) Crankcase Breather Assembly including:

a) Breather connection tube

2) Air Induction System including:

a) Intake pipe/manifold

b) Air cleaner

*Generac engine types covered by this warranty statement include the following:

1) Prepackaged Standby Generator

2) Auxiliary Power Unit (APU) Generator

3) Standby Generator

Part 2

Generac Power Systems, Inc. 57

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Section 10 – Warranty

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

GENERAC POWER SYSTEMS STANDARD "TWO YEAR" LIMITED WARRANTY FOR

GUARDIAN^®"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon

examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective under

normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner

claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer. All trans-

portation 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 prepackaged emergency automatic standby generators sold and rated for use in

"Standby" applications.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and

maintenance is required):

• Engine - All Components

• Alternator - All Components

• Transfer System - All Components

All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate

Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Generac Guardian generators that utilize non-Generac replacement parts.

• Generac Guardian generators utilizing non-Generac/Guardian automatic transfer switches.

• Any Generac Guardian generators used as rental or trailer mounted applications.

• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where

utility power service does not normally exist.

• Costs of normal maintenance, adjustments, installation and start-up.

• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with

all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty

will not cover repair when normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,

freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Damage related to rodent infestation.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or

replacement of the defective part(s).

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit

warranty period.

• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES

NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not

allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT

SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A

DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or conse-

quential damages, so the above limitation may not apply to you.

This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC^®POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, WI 53190

Part No. 0D8846

Revision B (08/26/02)

Printed in U.S.A.

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