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)
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................15
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......................................16
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 ........................................9
1.11 The Battery....................................................9
Section 2 – Post Installation Start-up
3.6 Setting the Exercise Timer ..........................16
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 ........................................17
Section 4 – Maintenance ..............................17
4.1 Fuse ............................................................17
4.2 Checking the Engine Oil Level ....................17
4.3 Changing the Engine Oil ..............................18
4.3.1 Engine Oil Recommendations ..........18
4.3.2 Oil Change Procedure ......................18
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) ..............................................19
4.7 Battery Maintenance....................................19
4.8 Adjusting GH-410/GT-990 Valve Clearance ..20
4.9 Cooling System............................................20
4.10 Attention After Submersion ........................21
4.11 Corrosion Protection ..................................21
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) ..12
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 ....................................14
3.1 Break-in Procedure......................................14
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
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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.
!
!
!
!
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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 an Authorized
Generac/Guardian 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, do nothing that might ren-
der the system unsafe or in noncompliance with
such codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit is
operating.
• Adequate, unobstructed flow of cooling and 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
physically or mentally fatigued.
• Inspect the generator regularly, and contact the
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.
!
!
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
to follow simple and fundamental rules or precau-
tions.
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
using a procedure, work method or operating tech-
nique Generac does not specifically recommend, sat-
isfy yourself that it is safe for others. Also make sure
the procedure, work method or operating technique
chosen does not render the generator unsafe.
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.
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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. Consult the local fire department with any
questions pertaining to fire extinguishers.
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 work must
be done around an operating unit, stand on an
insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands
or feet are wet. DANGEROUS ELECTRICAL
SHOCK MAY RESULT.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts of
the generator to be connected to an approved earth
ground. Local electrical codes also may require
proper grounding of the generator electrical system.
• 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.
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, inspect the
fuel system periodically for leaks. No leakage is
permitted.
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 dry 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.
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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 pres-
ent 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. 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
1.1 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents
for damage.
• 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 two 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, it is required by code to install a trans-
fer switch. The transfer switch must effectively
isolate the electrical system from the utility dis-
tribution system when the generator is operat-
ing (NEC 700, 701 & 702). Failure to isolate an
electrical system 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 their signature under the con-
signor's memo of loss or damage.
If a loss or damage is noted 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.
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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
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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
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†
1
2
1
2
1
2
60 Hz
1
60 Hz
1
60 Hz
1
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
1
2
2
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
Overhead Valves
Solid-state w/Magneto
RC12YC
Overhead Valves
Solid-state w/Magneto
RC12YC
Overhead Valves
Solid-state w/Magneto
RC12YC
0.76 mm (0.030 inch) 0.508 mm (0.020 inch) 0.508 mm (0.020 inch)
Compression Ratio
Starter
8.6:1
12 Vdc
9.5:1
12 Vdc
9.5:1
12Vdc
Oil Capacity Including Filter
Recommended Oil Filter
Recommended Air Filter
Operating RPM
Approx. 1.5 Qts
Approx. 1.7 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
3,600
3,600
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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 the
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
FUEL HOSE
BRASS HOSE
FITTING
BRASS HOSE
FITTING
NOTE:
FUEL JET
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.
HOUSING
PORTS
HOUSING
PORTS
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
74
105
185
240
0.91/33
1.34/48.9
1.73/63.2
NG FUEL SYSTEM
LP FUEL SYSTEM
114
148.5
NOTE:
*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 12KW AND 15KW, 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. A fuel pres-
sure of 11 to 14 inches of water column (0.6 psi)
to the fuel inlet of the generator MUST BE SUP-
PLIED.
1.8 RECONFIGURING THE
FUEL SYSTEM
1.8.1 7 KW, 410CC ENGINE
To reconfigure the fuel system from NG to LP,
follow these steps:
◆
1. Turn OFF the main gas supply.
2. Remove the engine air in baffle located on the left
hand side of the battery compartment. Two M6
screws are located on top of the baffle and two
M6 screws are located on the inside of the baffle
towards the back.
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet
port of the demand regulator (Figure 1.3).
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Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
3. Remove the small hose clamp and hose from the
1.9 LOCATION
fuel regulator. It may be necessary to pry the hose
off of the brass fitting using a screw driver to gen-
tly lift up the hose edge.
1.9.1 GENERATOR
◆
Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available. Consider these factors:
4. Remove the brass hose fitting screwed into the
fuel regulator.
5. Locate and identify the brass idle jet. This will be
located in the fuel regulator casting facing the
front of the unit.
6. Remove the idle jet from its holding location.
7. Place the idle jet, thread side first, into the
threaded hole originally occupied by the brass
hose fitting.
• 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, consider using a windbreak to protect the unit.
• 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 three feet of space on all sides.
8. Using a short No. 2 Phillips screw driver, thread
the idle jet into the regulator casting. DO NOT
OVER TIGHTEN.
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings to
the prevailing winds.
9. Apply thread sealant to the threads of the hose fit-
ting and replace it into the regulator body.
10. Re-attach the small hose and hose clamp and
tighten as necessary.
• Install the generator as close as possible to the fuel
supply, to reduce the length of piping.
11. Replace the engine air in baffle using the four M6
• Install the generator as close as possible to the
transfer switch. HOWEVER, REMEMBER THAT
LAWS OR CODES MAY REGULATE THE DIS-
TANCE.
The genset must be installed on a level surface. The
base frame must be level within two (2) inches all
around.
screws.
12. Identify both brass adjustment screws on the reg-
ulator.
NOTE:
One adjustment screw can be accessed from the
front of the unit and the second can be accessed
from the back of the unit enclosure by removing
the plastic hole plug.
1.9.2 TRANSFER SWITCH
◆
13. To adjust the system to run on LP fuel, turn the
adjuster screw that can be accessed from inside
the front of the unit, ¼ TURN CLOCKWISE. This
should now set the system for maximum power
and best performance.
14. It may be necessary to make minor adjustments
to the preset adjustment screw settings to achieve
maximum power. If experiencing problems with
the unit producing maximum power, follow the
procedure in Section 2.6 (Adjusting the Fuel
Regulator).
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:
• 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.
Figure 1.4 - Demand Regulator
• 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 cor-
rosive vapors.
FUEL HOSE
BRASS HOSE
FITTING
IDLE CIRCUIT
PORT
BRASS HOSE
FITTING
SMALL
FUEL JET
PRE
R
1
NP
REGULATOR
HOUSING PORT
ADJUSTER
SCREWS
®
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Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
charge while the engine is not running, to prevent
1.10 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if nec-
essary and have the battery fully charged before
installing it.
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.
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.
1.11 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.
3. Remove the 5A and 15A fuses from the generator
control panel.
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.
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.
Battery cables were factory connected at the genera-
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 (—).
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:
NOTE:
Damage will result if battery connections are made
in reverse.
• Remove the 5A and 15A fuses from the generator
control panel.
Figure 1.5 – Battery Cable Connections
• 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
• 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
!
NOTE:
conductive and corrosive.
The generator is equipped with a battery trickle
charger that is active when the 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
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;
®
Generac Power Systems, Inc.
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Section 2 — Post Installation Start-up and Adjustments
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
2.2 CHECK TRANSFER SWITCH
OPERATION
Refer to Section 3.5, of the owner’s manual for man-
ual operation procedures.
• 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.
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.
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
• 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.
2.3 ELECTRICAL CHECKS
Complete electrical checks as follows:
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
Be sure the Auto/Off/Manual switch is set to
the OFF position before connecting the battery
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).
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 the cables are
attached and cause an explosion.
DANGER
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
Before starting, complete the following:
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.
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.
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 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 nec-
essary, fill to the dipstick FULL mark with the
recommended 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.
®
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Section 2 — Post Installation Start-up and Adjustments
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
10. Connect an accurate AC voltmeter and a frequen-
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.
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.
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.
13. Set the generator's Auto/Off/Manual switch to
OFF. The engine should shut down.
NOTE:
13. Set the generator's main circuit breaker to its
It is important not to proceed until you are certain
that generator AC voltage and frequency are cor-
rect and within the stated limits. Generally, if both
AC frequency and voltage are high or low, the
engine governor requires adjustment. If frequency
is correct, but voltage is high or low, the genera-
tor’s voltage regulator requires adjustment.
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.
2.5 CHECKING AUTOMATIC
OPERATION
To check the system for proper automatic operation,
proceed as follows:
2.4 GENERATOR TESTS UNDER LOAD
To test the generator set with electrical loads applied,
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. Check that the Auto/Off/Manual switch is set to
OFF.
2. Turn OFF all loads connected to the transfer
switch terminals T1 and T2.
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.
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).
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.
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.
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.
With the generator running and loads powered by
generator AC output, turn ON the utility power sup-
ply to the transfer switch. The following should
occur:
7. Let the engine stabilize and warm up for a few
minutes.
8. Set the generator’s main circuit breaker to its ON
(or closed) position. Loads are now powered by
the standby generator.
• 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.
®
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Section 2 — Post Installation Start-up and Adjustments
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
6. When the highest frequency is reached maximum
2.6 ADJUSTING THE REGULATOR
power has been set. From this point turn both
adjustment screws 1/4 turn counterclockwise.
The regulator is now set.
(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.
Figure 2.2 — Placement of Regulator
If experiencing engine problems at high or full load
conditions follow these steps. It will require a fre-
quency meter to perform this procedure.
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.
3. Turn on appliances, lights, pumps, etc., that are
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:
Adjustment Screw
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.
Unit
7 kW
120 Volts
50.0 amps
100.0 amps
108.3 amps
240 Volts
25.0 amps
50.0 amps
54.1 amps
12 kW
15 kW
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.
!
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).
If this procedure or equipment are not available to
you, locate the nearest Generac Guardian Dealer
nearest and they can perform the adjustments.
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:
Figure 2.1 — Dual Fuel Regulators
990
410
2.7.1 7 KW UNITS
◆
1. Loosen the governor clamp bolt (Figures 2.3).
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.
®
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Section 2 — Post Installation Start-up and Adjustments
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
5. Turn the speed adjust nut to obtain a frequency
6. Using a hand, push the governor arm to the
closed throttle position. Make sure the idle spring
does not stretch at all.
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.
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).
Figure 2.3 — Engine Governor Adjustment
9. The governor is now set.
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.
◆
Idle Spring
Governor
Shaft
(Rotate
Clockwise)
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:
No Load Idle
Adjustment Screw
Governor Clamp Bolt
The access panel on top of the control panel must
be removed to adjust the voltage regulator.
2.7.2 12 KW AND 15 KW UNITS
◆
Figure 2.5 – Voltage Adjustment Potentiometer
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.
Figure 2.4 — Full Load Speed Adjust Screw
Full Load Speed Adjust Screw
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.
®
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Section 3 — Operation
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
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.
‹
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.
Figure 3.1 – Generator Control Panel
1. Set the generator’s Auto/Off/Manual switch to
AUTO.
FUSE
R
L o c a t
e
y o u r n e a r e s t
d e a le r a t
:
2. Turn OFF the utility power supply to the transfer
switch using the means provided (such as a utili-
ty main line circuit breaker).
R
POWER SYSTEMS, INC.
5A
AUTO OFF MAN.
SYSTEM SET
LOW OIL
3. The unit will start, and the transfer switch will
HIGH TEMP.
OVER SPEED
OVER CRANK
FUSE
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.
F L A
S
H
IN
N
H
G
O
IN
G R E E N L E D
=
E N
S
T
SET
EXERCISE
TIME
15A
U
G
T
IL IT
E D L E D
IS E R
Y
S
S
=
E
4
F L A
S
R
E X E R
C
N
O
S
E T
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).
11. Drain the oil and remove the oil filter. Replace the
oil filter according to Section 4.4, “Changing the
Oil Filter”. Replace the oil with synthetic oil as
recommended in Section 4.3, “Changing the
Engine Oil”.
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
generator panel and on the transfer switch.
!
3.3 AUTOMATIC TRANSFER
OPERATION
To select automatic operation, do the following:
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.
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).
2. Be sure that normal utility power source voltage
is available to transfer switch terminal lugs N1
and N2.
3.2 USING THE AUTO/OFF/MANUAL
SWITCH (FIGURE 3.1)
3. Set the generator’s Auto/Off/Manual switch to
AUTO.
3.2.1 “AUTO” POSITION
‹
4. Set the generator’s main circuit breaker to its ON
(or closed) 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 personnel to start
and exercise the engine every seven days with the set-
ting of the exercise timer (see Section 3.6). This posi-
tion also is used for remote starting, when it is set up.
3.2.2 “OFF” POSITION
‹
This switch position shuts down the engine. This
position also prevents automatic operation.
®
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Section 3 — Operation
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
3.4 SEQUENCE OF AUTOMATIC
3.5 MANUAL TRANSFER OPERATION
OPERATION
3.5.1 TRANSFER TO GENERATOR
POWER SOURCE
‹
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).
To start the generator and activate the transfer switch
manually, proceed as follows:
1. Set the generator’s Auto/Off/Manual switch
to OFF.
2. Set the generator’s main circuit breaker to its
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).
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.
DANGER
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.
The actual sequence of operation is controlled by
sensors and timers on a control logic circuit board,
as follows:
A.Utility Voltage Dropout Sensor
• 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.
• Once the timer has expired, the engine will crank
and start.
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).
Figure 3.2 – Manual Transfer Switch Operation
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.
D.Utility Voltage Pickup Sensor
• 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.
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.
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.
7. Set the generator’s main circuit breaker to its ON
(or closed) position. The standby power source
now powers the loads.
®
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Section 3 — Operation
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
NOTE:
3.5.2 TRANSFER BACK TO UTILITY POWER
SOURCE
When utility power has been restored, transfer back
to that source and shut down the generator. This can
be accomplished as follows:
‹
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.
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.
3.7 PROTECTION SYSTEMS
3.7.1 LOW OIL PRESSURE SWITCH
‹
This switch (Figure 3.3) has normally closed contacts
that are held open by engine oil pressure during
cranking 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.
4. Check that utility power supply to the transfer
switch is turned OFF.
DANGER
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.
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. The generator will
automatically restart and the LED on the generator
control panel will reset once the temperature has
returned to a safe operating level.
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).
Figure 3.3 – Low Oil Pressure and
High Temperature Switches
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.
Low Oil Switch
High Temp Switch
3.6 SETTING THE EXERCISE TIMER
This 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 the following sequence is completed.
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.
Oil
Drain
Hose
A switch on the control panel (see Figure 3.1) permits
selection of the day and time for the system to exer-
cise. At the chosen time, perform the following
sequence to select the desired day and time of day the
system will exercise.
Oil Filter
3.7.3 OVERCRANK
‹
1. Verify that the Auto/Off/Manual switch is set
to AUTO.
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 approximate-
ly 12 minutes and then shut down on its own.
The exerciser will then be set to run at that time
of day every week.
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.
®
16 Generac Power Systems, Inc.
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
NOTE:
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.
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. 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.
• Repeat for 45 seconds
Approximately 90 seconds total
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
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
circuit. Contact the nearest Generac/Guardian
Authorized Dealer if this failure occurs.
this could damage the engine.
4. Install the dipstick.
5. Reset the Auto/Off/Manual switch to its original
position.
Figure 4.2 — Oil Dipstick and Fill, 7 kW
Oil Dipstick and Fill
4.1 FUSE
The generator panel’s 15 amp fuse (Figure 4.1) pro-
tects 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, the engine
cannot crank or start. Replace the fuse using only an
identical 15-amp replacement.
The generator panel’s 5 amp fuse protects the battery
charge circuit against overload. If the fuse element
has melted open, there will not be battery charging
capabilities. Replace the fuse using only an identical
5 amp replacement. To remove fuse, push cap down
and rotate counterclockwise.
Figure 4.1 – Generator Control Panel
Figure 4.3 — Oil Dipstick and Fill,
12 kW and 15 kW
FUSE
R
L o c a t
e
y o u r n e a r e s t
d e a le r a t
:
Oil Dipstick
R
POWER SYSTEMS, INC.
5A
AUTO OFF MAN.
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
FUSE
Oil Fill
F L A
S
H
IN
N
H
G
O
IN
G R E E N L E D
=
SET
EXERCISE
TIME
15A
U
G
T
IL IT
E D L E D
IS E R
Y
S
E N
S
=
E
4
F L A
S
R
S
T
E X E R
C
N
O
S
E T
4.2 CHECKING THE ENGINE
OIL LEVEL
For oil capacities, see “Specifications,” Section 1.5.
For engine oil recommendations, see Section 4.3.1.
To check the engine oil level, proceed as follows
(Figures 4.2 and 4.3):
®
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
4.3 CHANGING THE ENGINE OIL
4.4 CHANGING THE OIL FILTER
Change the engine oil filter as follows:
4.3.1 ENGINE OIL RECOMMENDATIONS
‹
1. With the oil drained, remove the old oil filter by
turning it counterclockwise.
2. Apply a light coating of clean engine oil to the gas-
ket of the new filter. See Section 1.5.1 for recom-
mended filter.
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. Screw the new filter on by hand until its gasket
lightly contacts the oil filter adapter. Then, tight-
en the filter an additional 3/4 to one turn (Figure
4.4).
4. Refill with the proper recommended oil (see
Section 4.3.1). See Section 1.5.2 for oil capaci-
ties.
NOTE:
The unit is supplied with “break-in” oil. See the
“Break-in Procedure,” Section 3.1, for the first
required oil change.
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
5. Start the engine and check for leaks.
!
mended oil may result in an engine failure.
4.5 CHANGING THE ENGINE
AIR CLEANER
4.3.2 OIL CHANGE PROCEDURE
‹
To change the oil, proceed as follows:
4.5.1 7 KW, 12 KW AND 15 KW
GENERATORS
See Figures 1.1 and 1.2, for the location of your air
cleaner. Use the following procedure (Figure 4.6):
‹
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) free of its retaining
clip. Remove the cap from the hose and drain the
oil into a suitable container.
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover and air filter.
3. Wipe away dust or debris from inside of the air
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 for oil capaci-
ties.
box and around edges.
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, for air
cleaner maintenance. See Section 1.5.1 for air filter
replacement part number.
Figure 4.4 – Oil Drain Hose and Filter
Low Oil Switch
High Temp Switch
Figure 4.6 — 7 kW, Engine Air Cleaner Location
Fuel
Regulator
Air Cleaner
Oil
Drain
Hose
Oil Filter
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Figure 4.7 — 12 kW and 15 kW Engine
4.7 BATTERY MAINTENANCE
Air Cleaner
The battery should be inspected per the “Service
Schedule,” Section 4.13. The following procedure
should be followed for inspection:
Screw
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.
Cover
Filter
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:
• 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
4.6 SPARK PLUG(S)
Reset the spark plug(s) gap or replace the spark
plug(s) as necessary. See Section 4.13 for mainte-
nance requirements.
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.
• Disconnect charging source prior to connecting or dis-
connecting battery terminals.
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 for recom-
mended inspection.
3. Check the spark plug gap using a wire feeler
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).
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. 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;
Figure 4.8 – Setting the Spark Plug Gap
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
SET PLUG GAP AT 0.76 mm (.030 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.
®
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
When valve clearance is correct, hold the pivot ball
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
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.
• 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.
Figure 4.10 - Valve Clearance Adjustment
Rocker
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.
Pivot Ball
Stud
Arm
!
Jam Nut
Valve
Stem
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 the cables are
attached and cause an explosion.
4.8 ADJUSTING GH-410/GT-990 VALVE
CLEARANCE
• Install new valve cover gasket.
• Re-attach the valve cover.
NOTE:
After the first 50 hours of operation, adjust the
valve clearance in the engine.
Important: If feeling uncomfortable about doing this
procedure or the proper tools are not available,
please contact the Generac Authorized dealer for
service assistance. This is a very important step to
insure longest life for the engine.
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.
• Re-attach the spark plug wire to the spark plug.
• On GT-990, Repeat the process for the other cylinder.
To adjust valve clearance:
• 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.
4.9 COOLING SYSTEM
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.
• Remove the four screws attaching the valve cover
with a #2 or #3 phillips screwdriver.
• Make sure the piston is at Top Dead Center (TDC)
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.
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 loca-
tions.)
Figure 4.9 – Cooling 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).
NOTE:
Hold the rocker arm jam nut in place as you turn
the pivot ball stud.
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
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).
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.
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.
9. Clean and wipe the entire generator.
The maximum ambient temperature for the
generator is 40° C (104° F).
4.12.2 RETURN TO SERVICE
To return the unit to service after storage, proceed
as follows:
‹
!
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.
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). 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, 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.
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.
4.12 OUT OF SERVICE PROCEDURE
4.12.1 REMOVAL FROM SERVICE
If the generator cannot be exercised every seven days,
and will be out of service longer than 90 days, pre-
pare the generator for storage as follows:
‹
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.
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
8. Stop the unit by setting the Auto/Off/Manual
oil fault.
switch to OFF.
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.
9. Turn on the utility power to the transfer switch.
10. Set the Auto/Off/Manual switch to AUTO.
11. The generator is now ready for service.
NOTE:
If the battery was dead or disconnected, the exer-
cise timer must be reset.
®
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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*
X
X
M
M
LUBRICATION
Oil level
Oil
X
X
AFTER BREAK-IN,
AND Y
Oil filter
AFTER BREAK-IN,
AND Y
COOLING
Enclosure louvers
BATTERY
X
X
W
Remove corrosion,
ensure dryness
X
X
X
X
M
M
Clean and tighten
battery terminals
Check charge state
X
X
R
R
EVERY 6 M
EVERY 6 M
Electrolyte level
(unsealed batteries only)*
ENGINE AND MOUNTING
Air cleaner
X
X
R
R
Y
Y
Spark plug(s)
GENERAL CONDITION
Vibration, Noise, Leakage,
Temperature*
X
M
Y
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.
®
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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-B
ENGINE WIRING
DIAGRAM KEY
3
2
1
BA - BRUSH ASSEMBLY
BCR - BATTERY CHARGE RELAY
BATTERY
CHARGER
CB1 - MAIN OUTPUT BREAKER
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION
14
2
1
D
-
DIODE
0
DSW - PCB MOUNTED DIP SWITCH
FS - FUEL SOLENOID
225B
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
GRD - CONTROL PANEL GROUND
HTO - HIGH OIL TEMPERATURE SWITCH
IC - INLINE CONNECTOR
ICT - INTERCONNECTION TERMINALS
FS
224B
13A
0
13A
0
225B
IM1 - IGNITION MODULE, CYLINDER #1
IM2 - IGNITION MODULE, CYLINDER #2
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
0
224B
SCR - STARTER CONTACTOR RELAY
SP1, SP2 - SPARK PLUGS
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
14
0
0
14
SM - STARTER MOTOR
TB - INSULATED TERMINAL BLOCK
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
14
IC
TB
D
SP1
6
0
0
14
IM1
18
85
4
3
86
13
13
16
13
13
13
D
1
IC
IC
SP2
C1
16
SCR
IM2
13
18
351
85
A
B
86
351
HTO
0
0
14
86
56
18
85
56
1
56
16
13
18
86
2
3
4
5
J2
56
14
4
LOP
0
J1
86
23
56
14
239
17
0
194
18
CONTROL
PRINTED CIRCUIT BOARD
66A
15A
15
RED
BLACK
DSW
225
1 - 20 Vac Sense Transformer
2 - Remote Not Auto
3 - 50 Hz Operation
4 - SPARE
SM
224
+
12V
BATTERY
SC
CUSTOMER SUPPLIED
L.E.D - ALARM INDICATORS
®
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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-B
CONTROL PANEL BOX
225
224
224A
225A
224A
225A
CLOSEST TO BEARING
TX
BCR
CB2
1
4
7
3
6
9
4
0
N1 N2
STATOR
162
66
13A
A
B
77
2
0
225B
225B
4
10
9
224B
224B
0
2
11
6
66
8
2
14
55
4
6
22
0
6
5
66A
11
0
11
11
22
22
77
11
66
66
13A
225
22
4
0
4
3
2
0
6
0
77
6
44
1
224
162
162
55
C2
VOLTAGE
REGULATOR
66A
0
0
0
33
66A
4
55
22
N2
N1
13
13
225
GRD
13
351
224
194
23
N2
4
23
N1
13
44
351
11
13
13A
351
15A
194
N2
22
23
13
33
194
N1
0
13
66A
F2
F1
239
CB1
0
15A
17
OFF
17
15
13
239
17
0
SW1
225
224
15
1a
1
15
1b
SW2
240V GENERATOR
AUTO
OUTPUT TO TRANSFER
SWITCH CONTACTOR
CUSTOMER
CONNECTION
MANUAL
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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-B
11
22
225A
3
225A
2
224A
1
224A
BATTERY
CHARGER
225B
F2
225
13A
13
224B
13A
2
1
224
F1
7
7
9
BCR
6
3
4
11
0
13A
13
77
C2-1
0
15
77
14
BATTERY CHARGE
WINDING
66
0
66
C2-2
22
0
0
C2-4
55
HTO
0
C2-11
0
LOP
11
22
ENGINE RUN
WINDING
BA
FIELD
SW2
C1-4
0
14
(STATOR)
15
C1-3
0
C2-9
C2-3
4
0
ELECTRONIC
VOLTAGE
REGULATOR
C2-10
4
4
66A
0
85
23
194
6
86
162
C1-6
4
6
CB2
0
351
225
14
224
C2-7
C2-8
66A
2
(STATOR)
1
2
3
4
5
15A
J2
239
23
18
2
4
66A
J1
DIAGRAM KEY
194
86
3
5
7
23
194
56
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
SCR - STARTER CONTACTOR RELAY
SP1, SP2 - SPARK PLUGS
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
SM - STARTER MOTOR
14
66A
239
15A
17
CONTROL
PRINTED CIRCUIT
BOARD
9
10
12
15
0
225
224
16
17
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-B
11
C2-6
22
C2-5
TX
240VAC
UTILITY
INPUT
225A
224A
N2
N1
N2
56VA
1VA
N2
N1
12Vdc
TRANSFER
RELAY
225
224
23
194
COIL
N1
CUSTOMER
CONNECTIONS
13
17
11
NEUTRAL
23
22
33
15A
0
SW1
194
120V
120V
POWER
WINDING
(STATOR)
15A
239
13
15
17
44
CB1
23
15
194
239
11
0
240V
14
15
13
RED
0
C2-1
13
SC
SCR
15
56
16
16
0
14
C1-1
18
BATTERY
12V
0
SC
0
FS
0
SM
17
BLACK
15
CUSTOMER
SUPPLIED
IM1
IM2
0
SP1
18
D
18
C1-5
D
SP2
®
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-C
ENGINE WIRING
3
DIAGRAM KEY
BATTERY
CHARGER
(UTILITY)
1
BA - BRUSH ASSEMBLY
BCR - BATTERY CHARGE RELAY
14
CB1 - MAIN OUTPUT BREAKER
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION
2
1
0
D
-
DIODE
DSW - PCB MOUNTED DIP SWITCH
225B
224B
FS - FUEL SOLENOID
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
GRD - CONTROL PANEL GROUND
HTO - HIGH OIL TEMPERATURE SWITCH
IC - INLINE CONNECTOR
13A
0
13A
0
225B
ICT - INTERCONNECTION TERMINALS
IM - IGNITION MODULE
LOP - LOW OIL PRESSURE SWITCH
0
224B
SC - STARTER CONTACTOR
SP - SPARK PLUG
14
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
14
SM - STARTER MOTOR
TB - INSULATED TERMINAL BLOCK
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
14
IC
0
0
D
SP
14
0
6
5
0
IM
18
14
85
4
3
86
85
IC
IC
2
1
13
13
HTO
13
0
C1
86
18
56
56
LOP
86
351
0
13
56
85
56
4
1
2
3
4
5
J2
4
J1
23
56
14
194
SC
CONTROL
PRINTED CIRCUIT BOARD
18
66A
RED
239
BLACK
DSW
15A
ON
17
15
16
0
225
1 - 20 Vac Sense Transformer
2 - Remote Not Auto
3 - 50 Hz Operation
4 - SPARE
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-C
CONTROL PANEL BOX
225
224
224A
225A
CLOSEST TO BEARIN
4
224A
225A
TX
0
CB2
STATOR
N2
N1
162
66
13A
77
2
0
225B
224B
4
225B
10
224B
0
2
11
6
66
2
8
7
14
14
55
66A
4
6
22
11
11
11
22
5
4
22
77
11
66
66
13A
225
22
4
0
77
0
4
N2
0
6
0
2
6
44
N1
1
224
162
162
55
C2
VOLTAGE
REGULATOR
4
66A
0
0
0
4
66A
4
55
N2
33
N1
0
13
22
225
0
GRD
351
224
0
194
23
N2
N1
66A
13
44
351
15A
23
11
13A
351
194
N2
22
23
33
194
N1
0
13
66A
239
F2
F1
CB1
0
15A
OFF
13
239
17
15
0
SW1
15
SW2
15
AUTO
240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR
CUSTOMER
CONNECTION
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-B
11
11
22
22
225A
3
2
1
224A
BATTERY
CHARGER
225B
F2
225
13A
13
224B
13A
2
1
224
F1
7
7
9
9
BCR
6
3
4
11
0
0
13A
13
77
C2-1
0
15
77
14
BATTERY CHARGE
WINDING
66
66
C2-2
22
0
0
C2-4
55
HTO
0
LOP
11
22
ENGINE RUN
WINDING
BA
FIELD
SW2
C1-4
0
14
(STATOR)
15
C1-3
0
C2-9
C2-3
4
0
ELECTRONIC
VOLTAGE
REGULATOR
C2-10
4
4
66A
0
85
23
6
86
194
14
162
C2-11
4
6
6
CB2
351
225
0
224
C2-7
2
66A
C2-8
2
66A
1
2
3
4
5
DPE WINDING
(STATOR)
J2
239
23
1
4
J1
194
86
DIAGRAM KEY
3
4
5
6
23
194
56
BA - BRUSH ASSEMBLY
BCR - BATTERY CHARGE RELAY
CB1 - CIRCUIT BREAKER, MAIN OUTPUT
CB2 - CIRCUIT BREAKER, ALT. EXCITATION
D - DIODE
18
8
66A
CONTROL
PRINTED CIRCUIT
BOARD
239
15A
17
FS - FUEL SOLENOID
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
10
11
12
13
15
HTO - HIGH OIL TEMPERATURE SWITCH
HM - HOUR RUN METER
0
225
224
IM - IGNITION MODULE
15
16
17
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTER
SP - SPARK PLUG
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
SM - STARTER MOTOR
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-B
11
C2-6
22
C2-5
TX
240VAC
UTILITY
INPUT
225A
N2
N1
N2
56VA
1VA
N2
224A
225
N1
12Vdc
TRANSFER
RELAY
23
194
COIL
224
N1
CUSTOMER
CONNECTIONS
13
11
17
NEUTRAL
23
17
22
33
15A
0
SW1
194
120V
120V
POWER
WINDING
(STATOR)
239
15
44
CB1
23
15
11
194
239
240V
15A
15
13
RED
C1-2
17
0
SC
14
14
56
18
56
14
C1-1
BATTERY
12V
SM
SC
0
FS
0
0
17
18
C1-6
15
0
0
BLACK
CUSTOMER
SUPPLIED
18
IM
D
C1-5
SP
®
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-Q
PRE PACKAGED UNITS ONLY
4
71
40
68
69
77
80
82
41
73
48
30
17
79
80
72
1
86
72
5
52
87
6
29
12
60
49
44
16
28
55
75
6
65
88
54
31
50
9
44
35
46
11
49
51
25
14
8
74
57
35
27
1
22
56
49
49
5
93
49
91
35
26
3
51
39
37
42
3
51
21
49
43
34
33
2
94
10
18
52
20
4
15
91
71
69
35
63
92
25
68
®
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-Q
ITEM PART NO.QTY. DESCRIPTION
ITEM PART NO.QTY. DESCRIPTION
1
0C6140
0D1901
0C6735
0C7061
0C7062
0C7062A
0C7063
0C7063A
0C7063B
0C7064
0C7065
0C7065A
0C8101A
0C8861
0C8101B
0C8862
0C8283
0C8284A
0C8284B
0C8284C
0C8285
0C8899A
0D1128
0D1128A
0E4244
0D1605A
0D1606
0D5264
0D1839
0D1840
0D2425
0D2588
0D2588A
0D2676
0D2677
0D2979B
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
ASSEMBLY, ENCLOSURE BASE (12KW/15KW)
ASSEMBLY, ENCLOSURE BASE (7KW)
SUPPORT, ROOF FOLDING
44
45
46
47
48
022097
022473
036261
047411
043116
043116
0D3700
083512
090388
9
4
14
12
5
WASHER LOCK M6-1/4"
WASHER FLAT ¼" ZINC
2
3
4
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 M8-1.25 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)
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)
6
5
49
50
51
18
11
36
24
2
1
1
1
1
2
1
1
1
2
4
5
8
1
1
1
1
2
2
1
2
2
10.5
1
1
1
6
7
52
54
55
56
57
58
59
60
61
62
63
092120
0D3167
0A3328
055414
8
9
092079
0A1658
0C2937
086729
0388040AJ0
022127
022129
022129
074908
0D2346
0D2345
023484F
022142
0A7836
0A8475
0912970069
0912970070
055450
0D2023
0D3701
0D3472
0C8742
0C8911
0D8442
10
11
12
13
14
15
16
64
65
SCREW TAPTITE M5-0.8 X 10 BP
HARNESS, ENGINE (12KW / 15KW)
HARNESS, ENGINE (7KW)
17
18
66
67
68
69
70
71
72
73
74
75
76
77
78
BUSHING, SNAP SB-1000-12
HOUSING, FAN (12KW / 15KW)
BAFFLE, EXHAUST (7KW)
BRACKET, TOP SUPPORT
BRACKET, BOTTOM SUPPORT
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
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 CON-
NECTION BOX (12KW / 15KW)
HARNESS GENERATOR TO EXTERNAL CON-
NECTION BOX (7KW)
HARNESS GENERATOR TO EXTERNAL CON-
NECTION BOX (16KW)
SCREW PPHM #10-32 X 1
WASHER LOCK #10
WASHER FLAT M5
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
19
20
21
22
DUCT, BASE AIR (12KW / 15KW)
GASKET, FRONT DIVIDER (12KW / 15KW)
GASKET, FRONT DIVIDER (7KW)
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 ENCLSURE COVER
FOAM, BACK EXHAUST ENCLOSURE COVER
DOOR, PAWL
23
24
25
1
1
0D2979B
0D2979C
0D2979D
0D2979E
0E4245
0D3058A
0E4245A
0E4245B
0D3058C
0D3057D
0D3059A
0D3059B
0D3059C
0D7176
3
1
1
1
1
1
1
1
1
1
1
1
1
24
22
1
1
2
26
27
0D8652
0D3928
1
1
28
29
30
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
036937
022152
051713
022158
0D3031
026850
049813
0D2537A
0D2538A
047411
0A2311
043107
022145
045771
0C3906
0E4321
2
5
2
5
1
1
1
1
1
2
1
4
8
4
2
1
31
32
33
34
35
36
37
38
39
40
41
42
43
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
1
1
1
1
LATCH, QUARTER TURN LOCKING
HINGE, LIFT OFF, TYPE A PIN
HINGE, LIFT OFF, TYPE B PIN
LATCH, QUARTER TURN NON-LOCKING
WASHER NYLON .250"
PANEL, EXHAUST ALIGNMENT
4
®
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-F
®
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-F
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0A9947E
0A9947G
0A9947F
0A9947C
0A9947D
1
1
1
1
1
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)
22
23
0D5240
051714
051714
0D8502
0D8441
1
4
2
1
1
SWITCH, SPDT ON-MOM-ON
NUT HEX M3-0.5 (8.5KW/ 12KW/ 13KW)
NUT HEX M3-0.5 (7KW)
24
26
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
1
27
28
29
30
31
32
33
34
35
36
37
074908
049226
051716
0C3910
022507
099727
046689
063617
075475
043180
0D8439
4
6
6
1
2
1
1
1
4
2
1
2
3
4
0A1801
083049
0C2174
1
1
1
5
6
7
075210A
0D3062
0D8615
1
4
1
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
8
9
032300
022676
0E4494
0D5045
023484E
075476
022264
051715
043182
043182
043181
0D8443
054502
2
1
1
1
1
4
8
8
4
2
4
1
1
10
11
12
13
14
15
16
0E0119
1
38
39
40
092036
045770
0C7171
8
2
1
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
031879
023897
1
10
1
1
2
3
1
3
1
41
42
43
44
45
46
47
48
49
17
18
19
053623
0D8438
1
1
20
21
4
2
2
WASHER FLAT #4 (8.5KW/ 12KW/ 13KW)
WASHER FLAT #4 (7KW)
WASHER FLAT #10
0E0118
075235
1
4
CONTROL, PANEL BOTTOM (7KW)
SCREW HHC M5-0.8 x 30mm
50
®
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
31
7
37
9
11
5
2
17
18
3A
3
39
22
16
29
9
30
27
36
15
24
12
10
13
1
19
25
16
3B
22
40
21
23
26
38
14
33
32
34
8
35
34
®
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
1
2
3
3A
3B
3C
3D
4
5
6
7
8
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
1
1
1
1
1
1
6
1
1
1
1
4
2
1
1
1
1
1 FT
6
1
1
4
2
6
6
1
4
2
1
1
2
2
4
1
2
5
1
1
1
2
4
4
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
9
10
11
12
13
14
15
16
17
18
19
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
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
12
31
7
37
9
6
11
5
2
17
18
3A
3
39
22
9
27
36
15
24
42
10
13
1
19
25
3B
16
22
40
21
23
26
38
14
41
8
33
32
35
34
34
®
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
1
2
3
3A
3B
3C
3D
4
5
6
7
8
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
1
1
1
1
1
1
6
1
1
1
1
4
2
1
1
1
1
1
1 FT
6
1
1
4
2
6
6
1
4
2
1
1
2
2
4
3
1
5
1
1
1
1
2
4
4
2
1
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
9
10
11
12
13
14
15
16
17
18
19
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
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
38
39
40
41
42
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-E Part 1
®
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-E Part 1
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0C5729
1
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
36
37
38
39
40
41
0C2992
0C3971C
0C5305
0C3027
0C3007
0C5731
1
1
1
1
1
1
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 25
ASSEMBLY, OIL FILL CAP
HOOK, LIFTING
ROCKER, COVER WITH OIL FILL
GASKET, VALVE COVER
KEEPER, VALVE SPRING
RETAINER, VALVE SPRING
SPRING, VALVE
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16A
16B
17
18
19
20
21
0C3008
090388
0C5372
0C3005
0E1684
0D8067A
071983
0C2981C
045761A
0C5848
021533
071980
0D4041
0C2983
0C2985A
0C2985B
0D4042
0A7811
0C2977
0C5943
0D4040E
1
8
1
1
3
1
4
1
4
2
2
2
1
1
2
1
1
1
1
1
1
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
0C3006
080318
093064
0C8808
0D2723B
0C2979
086515
0D2274
0D3867
078672
0C5371
072694
0D3998
0C3027
0D5313
0D6024
0C2976
086516
0C2229
083897
0D8067B
0D9853D
0C2978
043790A
9
8
1
2
1
2
8
4
4
2
4
4
4
2
4
2
12
2
2
4
1
4
2
1
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
STUD, ROCKER ARM PIVOT
NUT HEX M8-1.0 G8 YEL CHR
O-RING, 3/8" X 1/2"
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, 147
GASKET, HEAD
BARBED ELBOW 90 3/8NPT X 3/8
L0CKTITE
KIT GASKET
0D4122E
1
22
0C2969
0D3961
0D2157
0C5313
0D4123
078699E
0C3011
0C3009
0C3010
093873
0C5315
0C5998
0D1667
0C2991
0C2988
2
2
2
1
1
2
2
2
2
2
1
1
1
2
1
23
24
25
26
27
28
29
30
31
32
33
34
35
66
67
68
69
70
71
72
73
0D4010
0D4011
0D4012
0D4013
0D8675A
0D8675B
0D4015
0D4016
1
1
1
1
1
1
1
1
KIT PISTON & RINGS
KIT BREATHER ASSEMBLY
KIT GOVERNOR ASSEMBLY
KIT HEAD ASSEMBLY CYLINDER 1
KIT HEAD ASSEMBLY CYLINDER 2
KIT OIL RELIEF
WASHER, LOCK RIB M6
GEROTOR, OUTER
CLAMP, OIL TUBE
ARM, GOVERNOR
E-RING, GOVERNOR ARM
THRUST WASHER, GOVERNOR
KIT GEAR COVER
®
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-E Part 2
74
138
75
139
135
122
124
125
123
76
77
136
137
120
125
79
24
133
134
78
132
11
119
80
127
121
118
128
81
29
97
98
130
126
99
82
96
95
83
102
84
109
141
103
104
87
105
86
85
88
94
110
99
106
112
89
90
101
89
91
107
112
92
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-E Part 2
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
74
75
76
77
78
0C5136A
0C3024
0C3040
0C8127
0D8564A
0D8564B
0D2595
0D4417
0C3025
0D3083
0C7292
070185
075281
0C1085
043182
035461A
2
1
1
1
1
1
4
4
1
1
1
1
1
2
2
2
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 .38-.87
109
110
111
112
0C8549
0C3022A
0D1131
045756
1
1
1
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
27
113
114
115
116
0C9763
0C3036
0C8919
079246
4
1
1
1
79
80
81
82
83
84
85
86
87
88
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
1
1
1
1
2
1
2
4
4
1
2
2
2
1
1
1
1
1
1
1
1
1
1
89
90
91
92
93
94
95
96
97
0C7649
0C9806
0C3026
0C9764
0C3043
0C7694
0C7693
0C3041
070008
070006
040976
0C3016A
085011
0C3725B
0C3031
0C3032
0A5992
051754
0C3033
0C3034
4
2
1
4
2
1
1
2
4
4
4
1
1
1
1
1
2
2
1
1
HOSE, 3/8" I.D. X 6" LONG
COOLER, OIL
PLASTITE,1/4-15 X 3/4
GASKET, MANIFOLD / PORT
MANIFOLD CYLINDER 2
MANIFOLD CYLINDER 1
SLEEVE, RUBBER
SCREW TAPTITE M6-1.0 X 25 BP
STARTER
SPARKPLUG
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
98
99
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
100
101
102
103
104
105
106
107
108
PLATE, FAN
WASHER SHAKEPROOF INT M8 SS
SCREW HHC M8-1.25 X 12 G8.8
WASHER, 25mm I.D.
140
141
0C2993
0E1552
1
4
SEAL, GOVERNOR SHAFT
SCREW FHHC M6-1.0 X12 W/M5 HEX
NUT,HEX M24
®
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-C
®
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-C
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
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
066849
1
1
1
1
1
1
1
1
1
3
1
4
1
1
1
1
ADAPTOR, ENGINE
STATOR
ROTOR
CARRIER, REAR BEARING
FAN, 8" CURVED BLADE
MUFFLER
TAIL PIPE, MUFFLER
PANEL, MUFFLER BASE
BEARING #6205-2RS-C3
5/16 SPECIAL L/WASH
BOLT ROTOR HHCS 5/16"-24 X 13-1/2" G5
BOLT STATOR HHCS M8-1.25 x 305mm
BRACKET, ALTERNATOR MOUNTING
DUCT, ALTERNATOR AIR
GASKET, ALTERNATOR AIR DUCT
BRACKET, ENGINE MOUNTING
RUBBER MOUNT
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
4
1
1
1
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
1.8 FT
1
4
4
4
4
14
4
3
13
8
2
3
1
2
2
1
1
1
1
1
1
1
1
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 PETROLEUM
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
1
1.25 FT
2
4
4
6
1
2
SCREW HHTT M5-0.8 X 16
®
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-D
®
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-D
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0C6934
0C7930
0D2359
0C7944
0D2356
0C6043
0D2336
0D6634
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
066849
1
1
ADAPTOR, ENGINE
STATOR 12KW
STATOR 15KW
ROTOR 12KW
3
1
ROTOR 15KW
4
5
6
7
8
1
1
1
1
1
1
3
1
4
1
1
1
1
4
1
1
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
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
CABLE, #6 48" BLACK BATTERY
EARTH STRAP 3/8X 3/8
1
1
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
1
5
4
4
4
14
4
2
10
8
2
4
2.83 FT
4
4
1
1
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
2
2
1.33 FT
2
SCREW HHTT M5-0.8 X 16
®
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-D 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-D Part 1
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
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
0C3972
076329
086254
0D4788
074908
086515
078606
0A1442
078672
089673
0B2104
078699C
0A7627
043790A
088590
078699B
1
1
1
1
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
1
2
2
2
1
4
1
1
1
1
1
4
4
8
1
2
1
2
1
1
1
1
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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
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-D 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-D Part 2
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0C1069
0D2922
0C8435
0C9997
088434
045756
088433B
0D9004A
059985
022129
0C2458A
083512
0D1401
091039
0C9619
049811
022097
040945
086999
0D5667A
049821
099236
070185
082774
091222E
067198N
067890
072347
072734
072735
0C3978
0C6040
084542
092079
0A8222
083502
083503
0D3083
0C8434
090072
075281
043182
0C4739
0C4373
5
1
1
1
1
11
1
1
2
2
1
1
1
1
1
2
4
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
2
1
SCREW, TAPTITE M6-1.0X8 YELLOW CHROME
HOUSING, BLOWER
TUBE, DIPSTICK
GUARD, FAN
WRAPPER, BOTTOM
SCREW, TAPTITE M6-1X10 YELLOW CHROME
WRAPPER, TOP
ASSY, STARTER
SCREW, SHC M8-1.25 X 45 G12.9
WASHER, LOCK M8-5/16
BACKPLATE, L/F D/F
SCREW, TAPTITE M8-1.25 X 16 BP
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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
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 6
SPACER, ENDFRAME
®
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
8
7
2
6
21
5
4
10
20
3
25
24
1
22
19
23
10
16
29
18
26
15
14
12
19
11
17
28
13
27
31
32
23
24
22
12
26
20
25
15
14
29
18
11
16
17
28
13
9
21
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
0D5694
0C5765
0C4647
0C4680
0C6070
022985
022264
075475
0C5760A
0C6606
097934
0C4645
0C5761
0C5968
0C6066
0C5759
0C5764
0C5764A
070728
070728
0C6069
0C5762
1
1
1
1
1
4
4
4
1
2*
2*
2*
2*
2*
2*
2*
2
1
4
2
2*
2*
CASTING, TWIN REGULATOR HOUSING
SOLENOID, TWIN REGULATOR
GASKET , SOLENOID
PLUNGER, LP REGULATOR ASSEMBLY
SPRING-SOLENOID, PLUNGER
WASHER, FLAT #6
21
045764
045764
0C6731
0C6067
0C4706
0C6068
0C4643A
026073
16
8
SCREW, TAPTITE M4X8 BP
SCREW, TAPTITE M4X8 BP (7KW)
RIVET, POP .118 X .125
22
23
24
25
26
27
2*
2*
2*
2*
2*
1
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
28
29
0A4032
0D3308
0D3308
0C4643
2*
4
2
30
1
31
32
33
34
35
36
37
028414A
0D5698A
0C5760B
0C5760C
0C5760D
0C5760E
0D3973
1
1
1
1
1
1
2
SPRING, REGULATOR (7KW)
SCREW, PFHMS M3-0.5 x 5
SCREW, PFHMS M3-0.5 x 5 (7KW)
GASKET, DIAPHRAGM
18
JET, GT760 LP CYL 2
PLUG, EXPANSION 16mm
19
20
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.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(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 “EMERGENCY AUTOMATIC STANDBY GENERATORS”
For a period of two years from the date of original sale, 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 equip-
ment that the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized
Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and pre-
paid by the purchaser/owner. This warranty applies only to Generac 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 generators that utilize non-Generac replacement parts.
• Generac/Guardian generators utilizing non-Generac/Guardian automatic transfer switches.
• Any Generac 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.
USE OF NON-GENERAC/GUARDIAN TRANSFER SWITCHES SHALL VOID THIS WARRANTY WITH RESPECT TO ALL
GENERAC PRODUCT.
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 H (08/07/03)
Printed in U.S.A.
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