Generac 04389-2, 04456-2, 04390-2 User Manual

Installation and

Owner’s Manual

Air-cooled, Prepackaged

Automatic Standby Generators

Models:
04389-2 (6 kW NG, 7 kW LP)
04456-2 (12 kW NG, 12 kW LP)
04390-2 (13 kW NG, 15 kW LP)

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

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

in life-support applications.

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*This manual should remain with the unit.

GENERAC

POWER SYSTEMS, INC.

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DANGER

Generac®Power Systems, Inc.

INTRODUCTION

Thank you for purchasing this model of the Guardian
product line by Generac Power Systems, Inc.. This
model is a compact, high performance, air-cooled,
engine-driven generator designed to automatically
supply electrical power to operate critical loads dur­ing a utility power failure.

This unit is factory installed in an all-weather, metal
enclosure that is intended exclusively for outdoor
installation. This generator will operate using either
vapor withdrawn liquid propane (LP) or natural gas
(NG).

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, the
nearest Guardian Authorized Dealer for starting, oper­ating and servicing procedures.

NOTE:

A service call may involve a fee if adjustments are
required following self-installation.

Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert per­sonnel to special instructions about a particular
operation that may be hazardous if performed incor­rectly or carelessly. Observe them carefully. Their def­initions are as follows:

After this heading, read instructions that, if not
strictly complied with, will result in serious person­al injury, including death, in addition to property
damage.

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

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

NOTE:

After this heading, read explanatory statements
that require special emphasis.

These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compli­ance with the special instructions while performing the
service are essential to preventing accidents.

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

This symbol points out important safety informa­tion that, if not followed, could endanger personal
safety and/or property of others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock
hazard.

The operator is responsible for proper and safe use
of the equipment. Generac strongly recommends that
the operator read this Owner's Manual and thor­oughly understand all instructions before using this
equipment. Generac also strongly recommends
instructing other users to properly start and operate
the unit. This prepares them if they need to operate
the equipment in an emergency.

CONTENTS

This manual contains pertinent owner’s information,
including warranty, electrical diagrams, exploded
views and lists of repair parts, for three different
Guardian models:

• 04389-2 – 6 kW NG, 7 kW LP, single-cylinder GH­410 Engine

• 04456-2 – 12 kW NG, 12 kW LP, V-twin GT-990
Engine

• 04390-2 – 13 kW NG, 15 kW LP, V-twin GT-990
Engine

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by a Guardian
Authorized Dealer. Normal maintenance service and
replacement of parts are the responsibility of the
owner/operator and, as such, are not considered
defects in materials or workmanship within the terms
of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.

Proper maintenance and care of the generator
ensures a minimum number of problems and keep
operating expenses at a minimum. See a Guardian
Authorized Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,
contact a Guardian Authorized Dealer for assistance.
Service technicians are factory-trained and are capa­ble of handling all service needs.

When contacting a Guardian Authorized Dealer about
parts and service, always supply the complete model
number and serial number of the unit as given on its
data decal, which is located on the generator. See
Figure 1.1 or Figure 1.2 in Section 1.6 for decal loca­tion.

Model No. ____________ Serial No. ______________

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AUTHORIZED

DEALER LOCATION

To locate the nearest GUARDIAN AUTHORIZED

DEALER, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

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Table of Contents

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

Generac®Power Systems, Inc. 1

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

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

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

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

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

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

1.3 NEC Requirement for Arc Fault Circuit

Interruption Breaker for Bedrooms ..............4

1.4 The Generator ..............................................5

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

1.6 System Set LED ............................................7

1.7 Fuel Requirements and Recommendations....7

1.8 Fuel Consumption ........................................7

1.9 Reconfiguring the Fuel System ......................7

1.10 Location ........................................................8

1.11 Battery Installation ........................................9

1.12 The Battery ....................................................9

Section 2 – Post Installation Start-up

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 ......................13

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

Section 3 – Operation ....................................14

3.1 Break-in Procedure......................................14

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

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

3.4 Sequence of Automatic Operation................15

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

3.6 Setting the Exercise Timer ..........................16

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

Section 4 – Maintenance ..............................17

4.1 Fuse ............................................................17

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

4.3 Changing the Engine Oil ..............................18

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

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

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

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

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

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

Section 7 – Exploded Views and

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

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

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

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

2 Generac®Power Systems, Inc.

Study these SAFETY RULES carefully before
installing, operating or servicing this equipment.
Become familiar with this Owner’s Manual and with
the unit. The generator can operate safely, efficiently
and reliably only if it is properly installed, operated
and maintained. Many accidents are caused by failing
to follow simple and fundamental rules or precau­tions.

Generac cannot possibly anticipate any or all
circumstances that might involve a hazard. The
warnings in this manual, and on tags and decals
affixed to the unit are, therefore, not all-inclusive. If
using a procedure, work method or operating tech­nique Generac does not specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique cho­sen does not render the generator unsafe.

Despite the safe design of this generator,
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.

Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.

Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.

GENERAL HAZAR

DS

• For safety reasons, Generac recommends that the

installation, initial start-up and maintenance of
this equipment is carried out by an Authorized
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 sys­tem must be installed properly, in strict compli­ance with applicable codes and standards.
Following installation, do nothing that might ren­der the system unsafe or in noncompliance with
such codes and standards.

• Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit is
operating.

• Adequate, unobstructed flow of cooling and 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 seri­ously 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 Guardian Authorized Dealer for parts
needing repair or replacement.

• Before performing any maintenance on the genera-

tor, disconnect its battery cables to prevent acci­dental start up. Disconnect the cable from the bat­tery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.

• Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break
parts, and may result in dangerous operating con­ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.

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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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The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

This product contains or emits chemicals
known to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:

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Generac®Power Systems, Inc. 3

ELECTRICAL HAZARDS

• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as does the standby generator when it is in opera­tion. Avoid contact with bare wires, terminals, con­nections, etc., while the unit is running. Ensure all
appropriate covers, guards and barriers are in
place before operating the generator. If 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 sys­tem, 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.

• In case of accident caused by electric shock, imme­diately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
such as a 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 equip­ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com­ponents causing injury.

FIRE HAZARDS

• For fire safety, the generator must be 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 installa­tion, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regu­lations.

• Keep a fire extinguisher near the generator at all
times. Extinguishers rated “ABC” by the National
Fire Protection Association are appropriate for use
on the standby electric system. Keep the extin­guisher properly charged and be familiar with its
use. Consult the local fire department with any
questions pertaining to fire extinguishers.

EXPL

OSION HAZARDS

• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no com­bustible materials are left in the generator com­partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround­ing 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 applica­ble fuel-gas codes. Before placing the home stand­by 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, regula­tions and laws, the published information listed
below may be used as installation guide for this
equipment.

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, avail­able 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 SYS­TEMS, available from the American Society of
Agricultural Engineers, 2950 Niles Road, St.
Joseph, MI 49085.

9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE

LIQUIDS CODE, available same as Item 1.

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IMPORTANT SAFETY INSTRUCTIONS

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

Only qualified electricians or contractors should
attempt such installations, which must comply
strictly with applicable codes, standards and
regulations.

1.1 UNPACKING/INSPECTION

After unpacking, carefully inspect the contents
for damage.

• This standby generator set has been factory sup­plied 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.

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 trans­fer switch. The transfer switch must effectively
isolate the electrical system from the utility dis­tribution system when the generator is operat­ing (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.

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 con­signor'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.

1.2 PROTECTION SYSTEMS

Unlike an automobile engine, the generator may have
to run for long periods of time with no operator pres­ent to monitor engine conditions. For that reason, the
engine is equipped with the following systems that
protect it against potentially damaging conditions:

1. Low Oil Pressure Sensor 3. Overcrank

2. High Temperature Sensor 4. Overspeed

There are LED readouts on the control panel to noti­fy personnel that one of these faults has occurred.
There is also a “System Set” LED that is lit when all
of the conditions describe in Section 1.3 are true.

1.3 NEC REQUIREMENT FOR ARC
FAULT CIRCUIT INTERRUPTION
BREAKER FOR BEDROOMS

In 2001, the National Electric Code (NEC) introduced
a requirement for new construction. This new
requirement indicates the need for Arc Fault Circuit
Interrupters to be used to protect the complete
branch circuit that feeds a dwelling bedroom. The
actual NEC requirement is indicated below.

1.3.1 SECTION 210.12 ARC FAULT CIRCUIT
INTERRUPTER PROTECTION

1. Definition: An arc fault circuit interrupter is a
device intended to provide protection from the
effects of arc faults by recognizing characteristics
unique to arcing and by functioning to de-ener­gize the circuit when an arc fault is detected.

2. Dwelling Unit Bedrooms: All branch circuits that
supply 125 volt, single-phase, 15 and 20 ampere
outlets installed in dwelling unit bedrooms shall
be protected by an arc fault circuit interrupter
listed to provide protection of the entire branch
circuit.

Section 210.12 requires that AFCI protection be pro­vided on branch circuits that supply outlets (recepta­cle, lighting, etc.) in dwelling bedrooms. The require­ment is limited to 15 and 20 ampere, 125 volt cir­cuits. There is no prohibition against providing AFCI
protection on other circuits or in locations other than
bedrooms. Because circuits are often shared between
a bedroom and other areas such as closets and hall­ways, providing AFCI protection on the complete cir­cuit would comply with 210.12.

If during the installation of the Guardian Home
Standby system the decision is made to provide back
up power to a bedroom branch circuit, then the cir­cuit breaker in the Guardian Transfer Switch should
be replaced with an Arc Fault Circuit Interrupter.

It is most important that breakers only be switched
like for like. For instance, if replacing a 15A breaker,
it MUST be replaced with a 15A AFCI breaker.
Likewise, a 20A breaker MUST be replaced with a
20A AFCI.

These AFCI breakers are available at the nearest
Home Depot or hardware store.

Siemens Item # Description

Q115AF 15A Single Pole AFCI

Q120AF 20A Single Pole AFCI

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Section 1 — General Information

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

4 Generac®Power Systems, Inc.

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Section 1 — General Information

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

Generac®Power Systems, Inc. 5

1.4 THE GENERATOR

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

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

Exhaust
Enclosure

Oil Check/Fill

Data Decal

Control Panel

Air Filter

Fuel Regulator

Oil Filter

Oil Dipstick

Exhaust
Enclosure

Air Filter

Battery Compartment

Data
Decal

Control
Panel

Fuel Inlet

Fuel Regulator

Oil Filter

Fuel Inlet

Battery Compartment

6 Generac®Power Systems, Inc.

Section 1 — General Information

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

1.5 SPECIFICATIONS

1.5.1 GENERATOR

Model 04389-2 Model 04456-2 Model 04390-2

Rated Max. Continuous Power Capacity (Watts*) 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP†
Rated Voltage 120/240 120/240 120/240
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 30 Amp 50 Amp 60 Amp/70 Amp†
Phase 1 1 1
Number of Rotor Poles 2 2 2
Rated AC Frequency 60 Hz 60 Hz 60 Hz
Power Factor 1 1 1
Recommended Air Filter Generac Part # C8127 Generac Part # C8127 Generac Part # C8127
Battery Requirement Group 26/26R Group 26/26R Group 26/26R

12 Volts and 12 Volts and 12 Volts and

350 Cold-cranking 550 Cold-cranking 550 Cold-cranking

Amperes Minimum Amperes Minimum Amperes Minimum

Weight 452 Pounds 470 Pounds 487 Pounds

Output Sound Level @ 23 ft (7m) at full load 68 db (A) 70.5db (A) 71.5 db (A)

Normal Operating Range -20°F (-28.8°C) to 104°F (40°C)

* 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 04578-1. Kit includes power harnesses and 70 amp 2-pole circuit breaker.

1.5.2 ENGINE

Model 04389-2 Model 04456-2 Model 04390-2

Type of Engine GH-410 GT-990 GT-990
Number of Cylinders 1 2 2
Rated Horsepower 14.5 @ 3,600 rpm 26 @ 3,600 rpm 30 @ 3,600 rpm
Displacement 410cc 992cc 992cc
Cylinder Block Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast

Iron Sleeve Iron Sleeve Iron Sleeve
Valve Arrangement Overhead Valves Overhead Valves Overhead Valves
Ignition System Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto
Recommended Spark Plug RC12YC RC12YC RC12YC
Spark Plug Gap 0.76 mm (0.030 inch) 0.508 mm (0.020 inch) 0.508 mm (0.020 inch)
Compression Ratio 8.6:1 9.5:1 9.5:1
Starter 12 Vdc 12 Vdc 12Vdc
Oil Capacity Including Filter Approx. 1.5 Qts Approx. 1.7 Qts Approx. 1.7 Qts
Recommended Oil Filter Generac Part # 70185 Generac Part # 70185 Generac Part # 70185
Recommended Air Filter Generac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127
Operating RPM 3,600 3,600 3,600

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Generac®Power Systems, Inc. 7

1.6 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 volt­age 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 generator will start.

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 pres­sure, high temperature, etc.

1.7 FUEL REQUIREMENTS

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.

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 1.9 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 the fuel.

Fuel pressure for both natural gas and liquid
propane set ups should be 11 inches to 14 inches

of water column (0.4 to 0.5 psi) at all load ranges.

NOTE:

A separate gas line and regulator may be needed
to assure proper gas pressure (11-14”) to the gen­erator. Low gas pressure can cause hard starting
and could affect engine durability.

1.8 FUEL CONSUMPTION

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

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.

1.9 RECONFIGURING THE
FUEL SYSTEM

1.9.1 7 KW, 410CC ENGINE

To reconfigure the fuel system from NG to LP,
follow these steps:

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet

port of the demand regulator (Figure 1.3).

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

solenoid located on the top of the demand regu­lator.

4. Remove the demand regulator by rotating coun-

terclockwise.

5. Remove the brass hose fitting from the outlet port

of the demand regulator.

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

T

M

M

OSE

G

OSE

OSE

OSE

G

OR

OUSING PORT

OU

T

T

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Section 1 — General Information

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

Model # Nat. Gas (*) LP Vapor (**)

1/2 Load Full Load 1/2 Load Full Load

04389 74 105 0.91/33 1.21/44.1
04456 114 185 1.34/48.9 2.17/79.0
04390 148.5 240 1.73/63.2 2.80/102.3

DANGER

FUEL H

FUEL H

BRASS H

FITTIN

BRASS H

FUEL JE

REGULAT
H

FITTIN

POR

TLE

NG FUEL SYSTE

LP FUEL SYSTE

NOTE:

The natural gas adjustment screw is preset during
installation and should not need any further
adjustment.

1.9.2 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 pres­sure of 11 to 14 inches of water column (0.6 psi)
to the fuel inlet of the generator MUST BE SUP­PLIED.

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.

3. Remove the small hose clamp and hose from the
fuel regulator. It may be necessary to pry the hose
off of the brass fitting using a screw driver to gen­tly lift up the hose edge.

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.

8. Using a short No. 2 Phillips screw driver, thread
the idle jet into the regulator casting. DO NOT
OVER TIGHTEN.

9. Apply thread sealant to the threads of the hose fit­ting and replace it into the regulator body.

10. Re-attach the small hose and hose clamp and
tighten as necessary.

11. Replace the engine air in baffle using the four M6
screws.

12. Identify both brass adjustment screws on the reg­ulator.

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.

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).

Figure 1.4 - Demand Regulator

1.10 LOCATION

1.10.1 GENERATOR

Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available. Consider these factors:

• 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 drift­ing, 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.

• Where strong prevailing winds blow from one

direction, face the generator air inlet openings to
the prevailing winds.

• Install the generator as close as possible to the fuel

supply, to reduce the length of piping.

• Install the generator as close as possible to the

transfer switch. HOWEVER, REMEMBER THAT
LAWS OR CODES MAY REGULATE THE DIS­TANCE.

The genset must be installed on a level surface. The
base frame must be level within two (2) inches all
around.

1.10.2 TRANSFER SWITCH

1.10.2.1 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:

◆

◆

G

T

T

U

T

G

OSE

S

L

T

OR

OUSING PORT

JUSTER

SC

S

OU

S

◆

Section 1 — General Information

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

8 Generac®Power Systems, Inc.

TLET PORT

FUEL H

BRASS HOSE
FITTIN

IDLE CIRCUI

POR

1/8 NP

BRASS HOSE

FITTIN

AD

REW

REGULAT
H

MAL

FUEL JE

Generac®Power Systems, Inc. 9

• Install the transfer switch indoors on a firm, stur­dy supporting structure.

• To prevent switch distortion, level the switch if nec­essary. This can be done by placing washers
between the switch enclosure and mounting sur­face.

• Never install the switch where water or any corro­sive substance might drip onto the enclosure.

• Protect the switch at all times against excessive
moisture, dust, dirt, lint, construction grit and
corrosive vapors.

1.11 BATTERY INSTALLATION

Fill the battery with the proper electrolyte fluid if nec­essary and have the battery fully charged before
installing it.

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.

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

control panel.

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 genera­tor (Figure 1.5). Connect cables to battery posts as
follows:

Figure 1.5 – Battery Cable Connections

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 nega­tive, NEG or (—).

NOTE:

Damage will result if battery connections are made
in reverse.

NOTE:

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
charge while the engine is not running, to prevent
self-discharge. The trickle charger is designed to
help extend the life of the battery by maintaining
the battery when the unit is not running. The
trickle charge feature cannot be used to recharge
a discharged battery.

1.12 THE BATTERY

Servicing of the battery is to be performed or super­vised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized person­nel away from batteries.

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 min­imum 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 connect­ed and terminals are tight. Observe battery polarity
when connecting the battery to the generator set.

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

• Disconnect charging source prior to connecting or dis-

connecting battery terminals.

Section 1 — General Information

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

DANGER

10 Generac®Power Systems, Inc.

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;

• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and

• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) of water. The bicar­bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.

Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:

• DO NOT SMOKE when near the battery;

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

• Discharge static electricity from body before touch­ing the battery by first touching a grounded metal
surface.

Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as
the battery cables are connected.

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.

2.1 BEFORE INITIAL START-UP

Before starting, complete the following:

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

OFF (or open) position.

2. Set the generator's AUTO/OFF/MANUAL switch to

the 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 nec­essary, 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
accordance with applicable fuel-gas codes. All
fuel shutoff valves in the fuel supply lines must be
open.

Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.

2.2 CHECK TRANSFER SWITCH

OPERATION

Refer to Section 3.5, of the owner’s manual for man­ual operation procedures.

Do not attempt manual transfer switch opera­tion 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.

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 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 utili­ty main line circuit breaker).

The transfer switch is now electrically “hot.”
Contact with “hot” parts will result in extreme­ly hazardous and possibly fatal electrical shock.
Proceed with caution.

5. Use an accurate AC voltmeter to check utility
power source voltage across transfer switch ter­minals N1 and N2. Nominal line-to-line voltage
should be 240 volts AC.

6. Check utility power source voltage across termi­nals N1 and the transfer switch neutral lug; then
across terminal N2 and neutral. Nominal line-to­neutral voltage should be 120 volts AC.

Section 2 — Post Installation Start-up and Adjustments

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

!

!

!

!

DANGER

DANGER

Generac®Power Systems, Inc. 11

7. When certain that utility supply voltage is com­patible with transfer switch and load circuit rat­ings, 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.

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.

10. Connect an accurate AC voltmeter and a frequen­cy meter across transfer switch terminal lugs E1
and E2. Voltage should be 242-252 volts; fre­quency should read about 61-63 Hertz.

11. Connect the AC voltmeter test leads across termi­nal lug E1 and neutral; then across E2 and neu­tral. In both cases, voltage reading should be 121­126 volts AC.

12. Set the generator’s main circuit breaker to its
OFF (or open) position. Let the engine run at no­load for a few minutes to stabilize internal engine
generator temperatures.

13. Set the generator's AUTO/OFF/MANUAL switch to
OFF. The engine should shut down.

NOTE:

It is important not to proceed until certain that
generator AC voltage and frequency are correct
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 generator’s
voltage regulator requires adjustment.

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.

2. Turn OFF all loads connected to the transfer
switch terminals T1 and T2.

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 util­ity main line circuit breaker).

Do not attempt manual transfer switch opera­tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.

5. Manually set the transfer switch to the STANDBY
position, i.e., load terminals connected to the
generator's E1/E2 terminals. The transfer switch
operating lever should be down.

6. Set the generator's AUTO/OFF/MANUAL switch to
MANUAL. The engine should crank and start
immediately.

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

8. Set the generator’s main circuit breaker to its ON
(or closed) position. Loads are now powered by
the standby generator.

9. Turn ON electrical loads connected to transfer
switch T1 and T2. Apply an electrical load equal
to the full rated wattage/amperage capacity of the
installed generator.

10. Connect an accurate AC voltmeter and a frequen­cy 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 main circuit breaker to its
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:

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.

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 util­ity power source side.

Section 2 — Post Installation Start-up and Adjustments

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

DANGER

12 Generac®Power Systems, Inc.

5. Turn ON the utility power supply to the transfer
switch, using the means provided (such as a util­ity main line circuit breaker).

6. Set the AUTO/OFF/MANUAL switch to AUTO. The
system is now ready for automatic operation.

7. Turn OFF the utility power supply to the transfer
switch.

With the AUTO/OFF/MANUAL switch at AUTO, the
engine should crank and start when the utility source
power is turned OFF. After starting, the transfer
switch should connect load circuits to the standby
side. Let the system go through its entire automatic
sequence of operation.

With the generator running and loads powered by
generator AC output, turn ON the utility power sup­ply to the transfer switch. The following should
occur:

• After about six seconds, the switch should transfer

loads back to the utility power source.

• About one minute after retransfer, the engine

should shut down.

2.6 ADJUSTING THE REGULATOR

(NATURAL GAS ONLY)

Although the generator has been factory set to pro­vide maximum power, it may be necessary in some
areas to adjust this setting. Because natural gas has
different BTU or power content across the country
the engine may not perform as designed.

If experiencing engine problems at high or full load
conditions follow these steps. It will require a fre­quency 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 posi­tion.

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:

4. When full load has been achieved. Connect a fre­quency 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 cir­cumstances should any of the pins be removed
(Figures 2.1 and 2.2).

Figure 2.1 — Dual Fuel Regulators

6. When the highest frequency is reached maximum
power has been set. From this point turn both
adjustment screws 1/4 turn counterclockwise.
The regulator is now set.

Figure 2.2 — Placement of Regulator

7. Turn utility power to the main distribution panel
back on. This can be done by switching the serv­ice main breaker to the on or closed position.
Allow the generator to shut down.

Do not make any unnecessary adjustments.
Factory settings are correct for most applica­tions. However, when making adjustments, be
careful to avoid overspeeding the engine.

!

Section 2 — Post Installation Start-up and Adjustments

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

Unit 120 Volts 240 Volts

7 kW 50.0 amps 25.0 amps
12 kW 100.0 amps 50.0 amps
13 kW 108.3 amps 54.1 amps

990

Adjustment

Screw

(Both sides)

Adjustment

Screw

(One Side
Only)

410

Set

Pins

Adjustment Screw

Generac®Power Systems, Inc. 13

Section 2 — Post Installation Start-up and Adjustments

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

If this procedure or the equipment are not available,
locate the nearest Generac Guardian Dealer 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:

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.

4. Connect a frequency meter across the generators
AC output leads.

5. Turn the speed adjust nut to obtain a frequency
reading of 63 Hertz.

6. When frequency is correct at no load, check the
AC voltage reading. If voltage is incorrect, the volt­age regulator may require adjustment.

Figure 2.3 — Engine Governor Adjustment

2.7.2 12 KW AND 15 KW UNITS

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

2. Completely remove the idle spring.

3. With governor arm at wide open throttle position,
rotate governor shaft fully clockwise. Tighten
clamp bolt to 84 inch-pounds.

4. Start unit and apply full load. Use full load speed
adjust screw (Figure 2.4) to adjust frequency to
58 Hz.

5. Remove load, stop engine, loosen the idle adjust
screw and reconnect the idle spring.

Figure 2.4 — Full Load Speed Adjust Screw

6. Using a hand, push the governor arm to the
closed throttle position. Make sure the idle spring
does not stretch at all.

7. Restart the unit.

8. Slowly turn the idle adjust screw to adjust the no­load idle frequency to 63-63.5 Hz (with door
open).

9. The governor is now set.

2.7.3 ADDITIONAL CORROSION

PROTECTION

Periodically spray all engine linkage parts and brack­ets with corrosion inhibiting spray such as WD-40 or
a comparable product.

2.8 VOLTAGE REGULATOR

ADJUSTMENT

With the frequency between 62-63 Hertz, slowly turn
the slotted potentiometer (Figure 2.5) until line volt­age reads 247-252 volts.

Figure 2.5 – Voltage Adjustment Potentiometer

◆

◆

◆

Idle Spring

Governor
Shaft

(Rotate

Clockwise)

Full Load Speed Adjust Screw

Governor Clamp Bolt

No Load Idle
Adjustment Screw

14 Generac®Power Systems, Inc.

Section 3 — Operation

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

NOTE:

The access panel on top of the control panel must
be removed to adjust the voltage regulator.

NOTE:

The voltage regulator is housed above the genera­tor's control panel. The regulator maintains a volt­age in direct proportion to frequency at a 2-to-1
ratio. For example, at 62 Hertz, line-to-neutral
voltage will be 124 volts.

3.1 BREAK-IN PROCEDURE

Once the unit has been installed and all electrical
checks have been made, it is strongly recommended
that the following “Break-in Procedure” be completed
to ensure correct generator operation in the future.

1. Set the generator’s AUTO/OFF/MANUAL switch to
AUTO.

2. Turn OFF the utility power supply to the transfer
switch using the means provided (such as a utili­ty main line circuit breaker).

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

4. Using the transfer switch’s built-in emergency
load center, turn on circuits to load the generator
to approximately 25% rated load and run the unit
for one hour.

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

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

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

8. Turn ON the utility power supply to the transfer
switch, which will allow the transfer switch to
transfer back to utility power. The unit will con­tinue to run for one minute and then shut down.

9. Allow the unit to cool.

10. Set the generator’s main circuit breaker to its
OFF (or open) position.

11. Set the generator's AUTO/OFF/MANUAL switch to
OFF. Remove the 5A and 15A fuses from the gen­erator control panel. Disconnect the battery
cables as outlined in “General Hazards” (page 2).

12. 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”.

13. Reconnect the battery cables as outlined in
“General Hazards” (page 2) and insert the 5A and
15A fuses into the generator control panel. The
generator is now ready for service.

3.2 USING THE AUTO/OFF/MANUAL
SWITCH (FIGURE 3.1)

3.2.1 “AUTO” POSITION

Selecting this switch position activates fully automat­ic system operation. It also allows personnel to start
and exercise the engine every seven days with the set­ting of the exercise timer (see Section 3.6). This posi­tion 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.

3.2.3 “MANUAL” POSITION

Set the switch to MANUAL to crank and start the
engine. Transfer to standby power will not occur
unless there is a utility failure.

Figure 3.1 – Generator Control Panel

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 pre­set 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:

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 volt-

age is available to transfer switch terminal lugs
N1 and N2.

!







FUSE

5A

FUSE

15A

OFFAUTO

SET

EXERCISE

TIME

MAN.

Locat e your nearest dealer at :

R

POWER SYSTEMS, INC.

FLASHINGGREEN LED=

4FLASHIN G RED LEDS =

R

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

N OUTILITYS E NSE

EX ER CIS E RNOT SET

Generac®Power Systems, Inc. 15

3. Set the generator’s AUTO/OFF/MANUAL switch to
AUTO.

4. Set the generator’s main circuit breaker to its ON
(or closed) position.

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.”

3.4 SEQUENCE OF AUTOMATIC

OPERATION

The generator’s control panel houses a control logic
circuit board. This board constantly monitors utility
power source voltage. Should that voltage drop below
a preset level, circuit board action will signal the
engine to crank and start. After the engine starts, the
circuit board signals the transfer switch to activate
and connect load circuits to the standby power sup­ply (load terminal lugs T1/T2 connect to terminal
lugs E1/E2).

Upon restoration of utility source voltage above a pre­set 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.

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 per­cent of the nominal supply voltage, the sensor
energizes a 15-second timer.

• Once the timer has expired, the engine will crank
and start.

B.Engine Warm-up Time Delay

• This mechanism lets the engine warm up for
about 10 seconds before the load is transferred
to the standby source.

C.Standby Voltage Sensor

• This sensor monitors generator AC output volt­age. 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 volt­age. When that voltage is restored above 70 per­cent 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.

3.5 MANUAL TRANSFER OPERATION

3.5.1 TRANSFER TO GENERATOR
POWER SOURCE

To start the generator and activate the transfer switch
manually, proceed as follows:

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).

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.

4. Use the manual transfer handle inside the trans­fer 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

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.



Section 3 — Operation

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

DANGER

16 Generac®Power Systems, Inc.

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:

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.

4. Check that utility power supply to the transfer
switch is turned OFF.

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.

5. Use the manual transfer handle inside the trans­fer switch to move the main contacts back to their
UTILITY position, i.e., loads connected to the util­ity power source (Figure 3.2).

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.

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 approx­imately 12 minutes and then shuts down. Transfer of
loads to the generator output does not occur during
the exercise cycle.

A switch on the control panel (see Figure 3.1) permits
selection of the day and time for the system to exer­cise. At the chosen time, perform the following
sequence to select the desired day and time of day the
system will exercise.

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 approximate­ly 12 minutes and then shut down on its own.
The exerciser will then be set to run at that time
of day every week.

NOTE:

The exerciser will only work in the AUTO mode
and will not work unless this procedure
is performed. The exerciser will need to be reset
every time the 12-volt battery is disconnected and
then reconnected. The exerciser WILL NOT work
if dip switch 2 on the controller printed circuit
board (Remote Not Auto) is ON.

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.

3.7.2 HIGH TEMPERATURE SWITCH

This switch’s contacts (Figure 3.3) close if the tem­perature 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.

Figure 3.3 – Low Oil Pressure and

High Temperature Switches

3.7.3 OVERCRANK

This feature prevents the generator from damaging
itself when it continually attempts to start and anoth­er 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 over­crank failure. The AUTO/OFF/MANUAL switch will
need to be set to OFF and then back to AUTO to reset
the generator control board.

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Section 3 — Operation

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

DANGER

Low Oil Switch

High Temp Switch

L

o

o

s

e

n

Oil
Drain
Hose

Oil Filter

Generac®Power Systems, Inc. 17

NOTE:

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

• Repeat for 45 seconds

Approximately 90 seconds total

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 gener­ator from supplying an output that could potentially
damage appliances connected to the generator
circuit. Contact the nearest Guardian Authorized
Dealer if this failure occurs.

4.1 FUSE

The generator panel’s 15 amp fuse (Figure 4.1) pro­tects the DC control circuit against overload. The fuse
is wired in series with the battery output lead to the
panel. If the fuse element has melted open, 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

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):

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.

3. Install the dipstick; then, remove it again. The oil
level should be at the dipstick “Full” mark. If nec­essary, add oil to the “Full” mark only. DO NOT
FILL ABOVE THE “FULL” MARK.

Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
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

Figure 4.3 — Oil Dipstick and Fill,

12 kW and 15 kW



Section 4 — Maintenance

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

!

Oil Dipstick and Fill

FUSE

5A

FUSE

15A

OFFAUTO

SET

EXERCISE

TIME

MAN.

Locat e your nearest dealer at :

R

POWER SYSTEMS, INC.

FLASHINGGREEN LED=

4FLASHIN G RED LEDS =

R

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

N OUTILITYS E NSE

EX ER CIS E RNOT SET

Oil Dipstick

Oil Fill

18 Generac®Power Systems, Inc.

4.3 CHANGING THE ENGINE OIL

4.3.1 ENGINE OIL RECOMMENDATIONS

Use oil of American Petroleum Institute (API) Service
Class SG, SH or SJ. Use all season SAE 5W-30
Synthetic oil. Organic break-in oil is required before
using synthetic oil.

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 recom­mended oil may result in an engine failure.

4.3.2 OIL CHANGE PROCEDURE

To change the oil, proceed as follows:

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.

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 capaci­ties.

Figure 4.4 – Oil Drain Hose and Filter

4.4 CHANGING THE OIL FILTER

Change the engine oil filter as follows:

1. With the oil drained, remove the old oil filter by
turning it counterclockwise.

2. Apply a light coating of clean engine oil to the gas­ket of the new filter. See Section 1.5.1 for recom­mended filter.

3. Screw the new filter on by hand until its gasket
lightly contacts the oil filter adapter. Then, tight­en the filter an additional 3/4 to one turn (Figure

4.4).

4. Refill with the proper recommended oil (see
Section 4.3.1). See Section 1.5.2 for oil capaci­ties.

5. Start the engine and check for leaks.

4.5 CHANGING THE ENGINE

AIR CLEANER

4.5.1 7 KW, 12 KW AND 15 KW

GENERATORS

See Figures 1.1 and 1.2, for the location of the air
cleaner. Use the following procedure (Figure 4.6):

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
box and around edges.

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

5. Install the cover. Turn the two cover screws clock­wise 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 4.6 — 7 kW, Engine Air Cleaner Location

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!



Section 4 — Maintenance

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

Low Oil Switch

High Temp Switch

Fuel

L

o

o

s

e

n

Oil
Drain
Hose

Oil Filter

Air Cleaner

Regulator

Generac®Power Systems, Inc. 19

Figure 4.7 — 12 kW and 15 kW Engine

Air Cleaner

4.6 SPARK PLUG(S)

Reset the spark plug(s) gap or replace the spark
plug(s) as necessary. See Section 4.13 for mainte­nance 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.

2. Remove the spark plug(s) and check the condi­tion. Replace the spark plug(s) if worn or if reuse
is questionable. See Section 4.13 for recom­mended 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).

Figure 4.8 – Setting the Spark Plug Gap

4.7 BATTERY MAINTENANCE

The battery should be inspected per the “Service
Schedule,” Section 4.13. The following procedure
should be followed for inspection:

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 bat­tery hydrometer.

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

• Disconnect charging source prior to connecting or dis-

connecting battery terminals.

Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following
procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and seek
medical attention; and

• 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 bicar­bonate 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.

!

!

Section 4 — Maintenance

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

SET PLUG GAP AT 0.76 mm (.030 inch)

Screw

Cover

Filter

DANGER

20 Generac®Power Systems, Inc.

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 body before touch­ing the battery by first touching a grounded metal
surface.

Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as
the battery cables are connected.

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

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.

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.

• 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.

• 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 the pivot
ball stud is turned.

When valve clearance is correct, hold the pivot ball
stud in place with the allen wrench and tighten the
rocker arm jam nut. Tighten the jam nut to 174
in/lbs. torque. After tightening the jam nut, recheck
valve clearance to make sure it did not change.

Figure 4.10 - Valve Clearance Adjustment

• Install new valve cover gasket.

• Re-attach the valve cover.

NOTE:

Start all four screws before tightening or it will not
be possible 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.

4.9 COOLING SYSTEM

Air inlet and outlet openings in the generator com­partment must be open and unobstructed for contin­ued proper operation. This includes such obstruc­tions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to quickly shut down. (See Figure 4.9 for vent loca­tions.)

Figure 4.9 – Cooling Vent Locations

Section 4 — Maintenance

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

!

Pivot Ball

Jam Nut

Stud

Rocker

Arm

Valve
Stem

Generac®Power Systems, Inc. 21

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.

The maximum ambient temperature for the
generator is 40° C (104° F).

4.10 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water,
it MUST NOT be started and operated. Following any
submersion in water, have a Guardian Authorized
Dealer thoroughly clean and dry the generator.

4.11 CORROSION PROTECTION

Periodically wash and wax the enclosure using auto­motive type products. Frequent washing is recom­mended 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, pre­pare the generator for storage as follows:

1. Start the engine and let it warm up.

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

and allow the unit to shut down.

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

oil fault.

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

OFF (or open) position.

5. 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).

6. 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.

7. Attach a tag to the engine indicating the viscosity
and classification of the oil in the crankcase.

8. Remove the spark plug(s) and spray fogging agent
into the spark plug(s) threaded openings.
Reinstall and tighten the spark plug(s).

9. 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.

10. Clean and wipe the entire generator.

4.12.2 RETURN TO SERVICE

To return the unit to service after storage, proceed
as follows:

1. Verify that utility power is turned off and that the
AUTO/OFF/MANUAL switch is set to OFF.

2. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recommend­ed 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 dis­tilled 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 bat­tery polarity. Damage may occur if the battery is
connected incorrectly.

6. Open the fuel shutoff valve.

7. Insert the 5A and 15A fuses into the generator
control panel. Start the unit by moving the
AUTO/OFF/MANUAL switch to MANUAL. Allow
the unit to warm up thoroughly.

8. Stop the unit by setting the AUTO/OFF/MANUAL
switch to OFF.

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 exer­cise timer must be reset.



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!

Section 4 — Maintenance

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

22 Generac®Power Systems, Inc.

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 the nearest Guardian Authorized Dealer.

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action Inspect Change Clean W = Weekly
R = Replace as Necessary M = Monthly
* = Notify Dealer Y = Yearly

if Repair is Needed.

FUEL

Fuel lines and connections* XM

LUBRICATION

Oil level XM

Oil X AFTER BREAK-IN,

AND Y

Oil filter X AFTER BREAK-IN,

AND Y

COOLING

Enclosure louvers XXW

BATTERY

Remove corrosion, XXM

ensure dryness

Clean and tighten

XXM

battery terminals

Check charge state X R EVERY 6 M

Electrolyte level X R EVERY 6 M
(unsealed batteries only)*

ENGINE AND MOUNTING

Air cleaner XR Y

Spark plug(s) XR Y

GENERAL CONDITION

Vibration, Noise, Leakage, XM
Temperature*

COMPLETE TUNE-UP* TO BE COMPLETED BY A Y

GUARDIAN AUTHORIZED DEALER

Generac®Power Systems, Inc. 23

Section 5 — Troubleshooting

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

5.1 TROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

The engine will not crank. 1. Fuse blown. 1. Replace 15A fuse in generator

control panel.

2. Loose, corroded or defective 2. Tighten, clean or replace
battery cables. as necessary.

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

4. Defective starter motor. 4. *

5. Dead Battery. 5. Charge or replace battery.

The engine cranks but 1. Out of fuel. 1. Replenish fuel.
will not start. 2. Defective fuel solenoid (FS). 2. *

3. Open #14 wire from 3. *
engine control board.

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

5. Valve lash out of adjustment. 5. Reset valve lash.

The engine starts hard 1. Air cleaner plugged 1. Check, replace air cleaner.
and runs rough. or damaged.

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

3. Fuel Regulator not set. 3. Set Fuel Regulator.

4. Fuel Pressure incorrect. 4. Confirm fuel pressure to regulator

is 11-14” water column (0.6 psi).

The Auto/Off/Manual switch 1. Defective switch. 1. *
is set to OFF, but the engine 2. Auto/Off/Manual switch 2. *

continues to run. wired incorrectly.

3. Defective control board. 3. *

There is no AC output from 1. Main line circuit breaker open. 1. Reset circuit breaker
the generator. to ON (or closed).

2. Generator internal failure. 2. *

There is no transfer to 1. Defective transfer switch coil. 1. *
standby after utility 2. Defective transfer relay. 2. *
source failure. 3. Transfer relay circuit open. 3. *

4. Defective control logic board. 4. *

Unit consumes large 1. Break-in procedure 1. *
amounts of oil. not followed (see Section 3.1).

*Contact the nearest Guardian Authorized Dealer for assistance.

24 Generac®Power Systems, Inc.

Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500-B

)

0

CUSTO

D

CK

OP

O

0

SP2

SP1

86

85

Y

CH

N

C

R

Y

CH

G

D

S

OCK

S

CH

S

CH

SSU

CH

2

1

SC

Y

D

S

SC

OR

OR

P

P

S

OR

E

Y

S

n

E

D

1 - 20 Vac Sense Transformer

o

SM

SC

C

CIC

316

C1

56

85

86

0

SCR

85

8618

3

3

0

6

6

3

86

J1

39

CO

OL

SW

0

3

56

5

5

5A

66A

94

18

56

3J25

8

3

6

351

4

86

8

56

3

0

5618

351

3

3

C

R

G

0

S

0

0

3A

0

5B

5B

4

0

3A

0

DIAGRAM KE

BA - BRUSH ASSEMBL
BCR - BATTERY CHARGE RELA

B1 - MAIN OUTPUT BREAKE
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATIO
D - DIOD
DSW - PCB MOUNTED DIP SWIT
FS - FUEL SOLENOI
F1 - FUSE 15 AM
F2 - FUSE 5 AM

RD - CONTROL PANEL GROUN
HTO - HIGH OIL TEMPERATURE SWIT
IC - INLINE CONNECT
ICT - INTERCONNECTION TERMINAL
IM1 - IGNITION MODULE, CYLINDER #
IM2 - IGNITION MODULE, CYLINDER #
LOP - LOW OIL PRE

- STARTER CONTACT
R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT

W2 - SET EXERCISE SWIT

M - STARTER MOT
TB - INSULATED TERMINAL BL
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

RE SWIT

ENGINE WIRIN

I

I

HARGE

F

1

1

1

1

1

1

1

22

1

22

1

1

1

1

HT

L

BLA

MER SUPPLIE

1

L.E.D - ALARM INDICATOR

NTR

PRINTED CIRCUIT BOAR

D

2 - Remote Not Aut

3 - 50 Hz Operatio

4 - SPAR

1

1

2

1

2

1

1

22

Generac®Power Systems, Inc. 25

Section 6 — Electrical Data

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

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

G

D

OR

94

5

5

5

5

R

L

5A

39

3

5

313

5

GE

OR

5A

3

313

3

3A

62

62

39

O

1

b

a

2

ON

R

OR

OR

1

94

OX

5B

3A

5B

3A

5

5A

CR

5A

2

62

0

CO

C

ON

C

T

94

CO

L

S

R

3

F

22

22

22

NTROL PANEL B

LOSEST TO BEARIN

B

B

1

22

22

22

1

1

VOLTA

REGULAT

1

1

1

TAT

22

1

2

1

1

1

1

22

1

2

1

1

1

1

1

1

2

W

AUT

R

2

1

B

1

1

W

240V GENERAT
TPUT TO TRANSFE
WITCH CONTACT

F

240VA

RELAY

I

12Vdc TRAN

UTILITY INPU

FE

NEUTRAL

NNE

TI

TOME

MANUA

NNECTI

26 Generac®Power Systems, Inc.

Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501-B

1

2

SSU

CH

S

CH

CH

OR

)

T

D

P

CH

Y

Y

R

6

0

P

Y

N

E

5

3

7

OR

C

GE

3A

6

O

G

3A

CR

OP

2

5

0

3A

R

5B

5A

5

3

OL

D

T

39

5

5

5A

9423

8194

5A

5

2

0

UN

G

GE

3

39

1

4

02-9

)

6

72-8

)

3

4

3

1

2

5A

94

3

1

2-

7

2-1

ELECTRONI

VOLTA

REGULAT

BA - BRUSH ASSEMBL
BCR - BATTERY CHARGE RELA
CB1 - CIRCUIT BREAKER, MAIN OUTPU
CB2 - CIRCUIT BREAKER, ALT. EXCITATIO
D - DIOD
FS - FUEL SOLENOI
F1 - FUSE 15 AM
F2 - FUSE 5 AM
HTO - HIGH OIL TEMPERATURE SWIT
IM1 - IGNITION MODULE, CYLINDER #
IM2 - IGNITION MODULE, CYLINDER #
LOP - LOW OIL PRE

- STARTER CONTACTE
R - STARTER CONTACTOR RELAY

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT
W2 - SET EXERCISE SWIT
M - STARTER MOT

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

2-1

B

2-

STATOR

DIAGRAM KE

RE SWIT

HARGE

1

BATTERY CHAR

1-

WINDIN

2-

22

ENGINE R

WINDIN

STATOR

6

2-

PRINTED CIRCUI

22

2-

HT

1-

BOAR

1

B

W

NTR

1

L

1-

22

2

1

1

2

1

1

1

1

22

22

22

1

1

1

2

1

1

2

Generac®Power Systems, Inc. 27

Section 6 — Electrical Data

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

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

39

5

8

2

0V194

5

3

5

39

1

94

5A

3

1

G

0V

0V

3

R

S

94

S

6

R

D

3

A

6

5

1

)

CK

1

1

5

6

3

R

Y

C

UT

R

dc

L

5

5

5A

5

3

3

5A

8

8

2-

22

V

22

1

2-

2

1

2

240VA

TILIT
INP

12V

TRANSFE

I

TOME

NNECTION

1

W

BLA

12

12

24

TOME

PPLIE

1

1

2

1

2

1

1

1

1

1

1

1

1-

1

1-

1

2

1

1

1

F

POWE
WINDIN
STATOR

2-

B

P

P

28 Generac®Power Systems, Inc.

Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Wiring Diagram – 7 kW – Drawing No. 0D9013-C

)

N

CK

D

OP

O

CH

R

Y

Y

E

OR

S

OR

CH

D

D

CH

SSU

CH

E

P

P

UG

OCK

OR

CH

Y

D

SW

OL

E

o

n

S

6

8

3

C

C

C

3

8

3

5

8

94

39225

5A

313

G

S

3A

R

)

5B

5B

3A

DIAGRAM KE

BA - BRUSH ASSEMBL
BCR - BATTERY CHARGE RELA

B1 - MAIN OUTPUT BREAKE
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATIO
D - DIOD
DSW - PCB MOUNTED DIP SWIT
FS - FUEL SOLENOI
F1 - FUSE 15 AM
F2 - FUSE 5 AM

RD - CONTROL PANEL GROUN
HTO - HIGH OIL TEMPERATURE SWIT
IC - INLINE CONNECT
ICT - INTERCONNECTION TERMINAL
IM - IGNITION MODUL

LOP - LOW OIL PRE

- STARTER CONTACT
P - SPARK PL
W1 - AUTO / OFF / MANUAL SWIT
W2 - SET EXERCISE SWIT
M - STARTER MOT

TB - INSULATED TERMINAL BL
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

RE SWIT

HT

I

I

ENGINE WIRIN

HARGE

UTILITY

F

1

1

1

1

22

1

22

I

L

1

BLA

1

TOMER SUPPLIE

L.E.D - ALARM INDICATOR

1

PRINTED CIRCUIT BOAR

NTR

D

2 - Remote Not Aut

3 - 50 Hz Operatio

4 - SPAR

2

1

1

2

1

1

Generac®Power Systems, Inc. 29

Section 6 — Electrical Data

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

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

N

D

OR

R

OR

OR

94

5

5A

3923

515A

3A

3

3

3

4

5

3

5

3A

GE

OR

62

222

L

O

7

5

1

39

2

ON

R

1

3

2

62

OX

5B

5B

3A

5

5A

5A

2

62

0

CO

L

S

R

N

CO

C

ON

3

94

C

T

2

F

22

22

NTROL PANEL B

LOSEST TO BEARI

22

B

TAT

1

22

22

1

22

22

1

VOLTA

REGULAT

2

1

1

1

1

2

22

R

2

N

1

1

2

1

1

1

2

1

1

B

1

1

1

1

AUT

MANUA

2

W

W

240V GENERAT
TPUT TO TRANSFE

WITCH CONTACT

TOME

NNECTI

F

EUTRAL

RELAY

12Vdc TRAN

240VA

NNE

TI

UTILITY INPU

I

FE

30 Generac®Power Systems, Inc.

Section 6 — Electrical Data

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Electrical Schematic – 7 kW – Drawing No. 0D9014-C

T

CH

CH

N

)

Y

Y

P

P

UG

D

E

R

R

CH

OR

SSU

CH

E

Y

0

6

5

3

G

GE

OR

C

2

8

62

0

OL

D

T

4

7

)

9

1

3

UN

G

)

0

2

O

4

5A

5

5

OP

3

8

39

94

3

2

3

5

94

39

0

94

3

5

5B

GE

G

R

1

3A

3ABCR

3A13

5A

5

5

3

5A

22

ELECTRONI

VOLTA

REGULAT

HARGE

1

1

2-

BATTERY CHAR

WINDIN

2-1

1

B

2-

2-

DPE WINDIN

STATOR

2-

2-1

DIAGRAM KE

BA - BRUSH ASSEMBL
BCR - BATTERY CHARGE RELA
CB1 - CIRCUIT BREAKER, MAIN OUTPU
CB2 - CIRCUIT BREAKER, ALT. EXCITATIO
D - DIOD
FS - FUEL SOLENOI
F1 - FUSE 15 AM
F2 - FUSE 5 AM
HTO - HIGH OIL TEMPERATURE SWIT
HM - HOUR RUN METE

IM - IGNITION MODUL
LOP - LOW OIL PRE

- STARTER CONTACTE

RE SWIT

P - SPARK PL

W1 - AUTO / OFF / MANUAL SWIT
W2 - SET EXERCISE SWIT
M - STARTER MOT

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

2-

22

ENGINE R

WINDIN

STATOR

22

2-

PRINTED CIRCUI

2-

HT

1-

BOAR

NTR

1

L

W

1-

22

2

1

2

1

1

2

1

1

1

1

1

1

22

22

1

1

1

2

1

2

Generac®Power Systems, Inc. 31

Section 6 — Electrical Data

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

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

UT

dc

Y

L

R

L

V

C

R

D

3

1

39

6

5

8

5

8

8

5A

5

1

39

3

5

5A

94

3

5

CK

R

G

)

S

2

94

0V

1

0V

5

5A

A

5

3

6

3

94

R

S

0

2-

22

2-

V

22

2

1

1

240VA

TILIT
INP

12V

TRANSFE

I

TOME

NNECTION

2

NEUTRA

1

W

1

POWE
WINDIN
STATOR

12

120

2

1

B

2

1

1

2

1

1

1

1

1-

1-

24

F

1

1

1-

BLA

1-

1

TOME

PPLIE

32 Generac®Power Systems, Inc.

3

9

6

6

9

3

9

3

8

5

8

3

0

5

9

6

9

928

0

3

5

6

9

8

9

Y

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Enclosure – Drawing No. 0D3416-R

PRE PACKAGED UNITS ONL

7

4

4

7

2

1

1

4

7

4

7

4

2

4

2

4

4

4

4

4

1

4

1

1

1

2

Generac®Power Systems, Inc. 33

ITEM PART NO. QTY. DESCRIPTION

1 0C6140 1 ASSEMBLY, ENCLOSURE BASE

0D1901 1 ASSEMBLY, ENCLOSURE BASE (7KW)
2 0C67352SUPPORT, ROOF FOLDING
3 0C7061 1 ENCLOSURE, FRONT
4 0C7062 1 ENCLOSURE, EXHAUST SIDE

0C7062A 1ENCLOSURE, EXHAUST SIDE (7KW)
5 0C7063 1ENCLOSURE, SIDE & BACK

0C7063A 1ENCLO

SURE, SIDE & BACK (7KW)
6 0C7064 1 ENCLOSURE, ROOF
7 0C7065 1 PANEL, ALT ERNATOR DIVIDER

0C7065A 1PANEL, ALT ERNATOR DIVIDER (7KW)

8 0C8101A 1PANEL, MUFFLER BOX SIDE

0C8861 1 PANEL, MUFFLER BOX SIDE (7KW)

9 0C8101B 1 COVER, MUFFLER BOX

0C8862 1 COVER, MUFFLER BOX (7KW)
10 0C8283 1GASKET, DOOR SEAL
11 0C8284A 1FOAM, BA

CK ENCLOSURE
12 0C8284B 1 FOAM, ROOF ENCLOSURE
13 0C8284C 1 FOAM, FRONT ENCLOSURE
14 0C8285 1 BRACKET, BATTERY SUPPORT
15 0C8899A 1PAD, 24"X48" WITH MOUNTING HOLES
16 0D1128 1 PANEL, ENGINE DIVIDER

0D1128A 1PANEL, ENGINE DIVIDER (7KW)

17 0E4244 1 BAFFLE, INTAKE

0D1605A 1BAFFLE, INTAKE (7KW)

18 0D1606 1 HOUS

ING, FAN

0D5264 1 BAFFLE, EXHAUST (7KW)
19 0D1839 2BRACKET, TOP SUPPORT
20 0D1840 2 BRACKET, BOTTOM SUPPORT
21 0D2425 1 DUCT, BASE AIR
22 0D2588 1 GASKET, FRONT DIVIDER

0D2588A 1GASKET, FRONT DIVIDER (7KW)
23 0D2676 1 COVER, FRONT EXHAUST ENCLOSURE
24 0D2677 1 COVER, BACK EXHAUST ENCLOSURE
25 0D2979B 2 CLOTH, HAR

DWARE 266.7mm x 146mm

0D2979B 3 CLOTH, HARDWARE 266.7mm x 146mm

(7KW)
26 0D2979C 1 CLOTH, HARDWARE 543mm x 146mm
27 0D2979D 1 CLOTH, HARDWARE 266.7mm x 387.4mm

0D2979E 1 CLOTH, HARDWARE (7KW)

28 0E4245 1 FOAM, FRONT INTAKE BAFFLE

0D3058A 1FOAM, FRONT INTAKE BAFFLE (7KW)

29 0E4245A 1FOAM, TOP INTAKE BAFFLE

30 0E4245B 1 FOAM, BACK I

NTAKE BAFFLE

0D3058C 1 FOAM, BACK INTAKE BAFFLE (7KW)
310D3057D 1 FOAM, BACK ENCL. STRIP
320D3059A 1FOAM, EXHAUST SIDE ENCLOSURE END
33 0D3059B1FOAM, EXHAUST SIDE ENCLOSURE

FRONT
340D3059C1FOAM, EXHAUST FAN HOUSING
3

5 0D7176 24 WA SHER, SELF LOCKING

22 WASHER, SELF LOCKING (7KW)

360D3059D1FOAM, FRONT EXHAUST ENCLOSURE

COVER
370D3059E1FOAM, BACK EXHAUST ENCLOSURE

COVER

38 0C7781 2 DOOR, PAWL
39 0D30371LATCH, QUARTER TURN LOCKING

40 0D25371HINGE, LIFT OFF, TYPE A PIN
41 0D25381HINGE, LIFT OFF, TYPE B PI

N

ITEM PART NO. QTY. DESCRIPTION

42 0D3037A 1LATCH, QUARTER TURN NON-LOCKING
43 0A2115 4 WA SHER NYLON .250"
44 022097 9WASHER LOCK M6-1/4"
45 022473 4 WASHER FLAT ¼" ZINC
46 036261 14 RIVET POP .125 X .129-.133/#30
47 047411 12 SCREW HHC M6-1.0 X 16 G8.8
48 043116 5 SCREW HHC M6-1.0 X 12 G8.8

043116 6 SCREW HHC M6-1.0 X 12 G8.8 (7KW)

49 0D

3700 18 NUT, LOCKING FLANGE M6-1.0
50 083512 11 SCREW TAPTITE M8-1.25 X 16 BP
51 090388 36 SCREW TAPTITE M6-1.0 X 12 BP

24 SCREW TAPTITE M6-1.0 X 12 BP (7KW)
52 092120 2 NUT LOCK TRIC M6 X 1.0 Y/ZNC
54 0D3167 1 GASKET, BATTERY SUPPORT BRACKET
55 0A3328 1 PLUG, PLASTIC 0.593
56 055414 1 LUG SLDLSS #2-#8X17/64 CU
57 092079 1 SC

REW TAPTITE M6-1.0X25 BP
58 0A1658 2 L/WA SH SPECIAL ¼
59 0C29371BRACKET, BATTERY HOLD DOWN (7KW)
60 086729 1CONTACTOR, STARTER (7KW)
61 0388040AJ0 1 CABLE, #6 RED BATTERY 38.5"
62 022127 2 NUT HEX 1/4-20 STEEL (7KW)
63 022129 4 WASHER LOCK 5/16

022129 5 WASHER LOCK 5/16 (7KW)

64 074908 8 SCREW TA

PTITE M5-0.8 X 10 BP

65 0D2346 1 HARNESS, ENGINE

0D2345 1 HARNESS, ENGINE (7KW)
66 023484F 1 BUSHING, SNAP SB-1000-12
67 022142 1 SCREW HHC 5/16-18 X 3/4 G5 (7KW)
68 0A78362RIVET,1/8" X 0.126" - 0.375" LSH POP
69 0A8475 2 L/WA SH SPECIAL #10
70 0912970069 1 ASSEMBLY, ROOF / DOOR GROUND WIRE
71 0912970070 2

ASSEMBLY, ROOF / DOOR GROUND WIRE
72 055450 2 PLUG PLASTIC 1.375
73 0D2023 10.5 GASKET, CLIP-ON SELF GRIPPING
74 0D3701 1 PLATE, "HOT"
75 0D3472 1 GROMMET 2.75 X 1/16
76 0C8742 1 EXTERNAL CONNECTION BOX
77 0C8911 1 POWER BLOCK
78 0D8442 1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX

0D8652 1 HARNESS GENERATOR TO EXTERNAL

CONNECTION BOX (7KW)
7

9 0369372SCREW PPHM #10-32 X 1
80 022152 5 WASHER LOCK #10
81 051713 2 WASHER FLAT M5
82 022158 5 NUT HEX #10-32 STEEL
83 0D3031 1 FUEL LINE, 3/4"OUTDOOR (NOT SHOWN)
84 026850 1 WASHER SHAKPROOF EXT 1/4 STEEL
85 049813 1 NUT HEX M6-1.0 G8 YELLOW CHROME
86 0D2537A 1HINGE, LIFT OFF, TYPE A K

NUCKLE
87 0D2538A 1HINGE, LIFT OFF, TYPE B KNUCKLE
88 047411 2 SCREW HHC M6-1.0 X 16 G8.8
89 0A2311 1 SCREW SWAGE 1/4-20 X 1

90043107 4 SCREW HHC M8-1.25 X 25
91 022145 8 WASHER FLAT 5/16
92 045771 4 NUT HEX M8-1.25
93 0C3906 2 SELF-ALIGN SCREW M6 HH
94 0E4321 1 PANEL, EXHAUST ALIGNMENT

Section 7 — Exploded Views and Parts Lists

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

Enclosure – Drawing No. 0D3416-R

34 Generac®Power Systems, Inc.

2

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Control Panel – Drawing No. 0E7974-B

5

9

7

Generac®Power Systems, Inc. 35

ITEM PART NO. QTY. DESCRIPTION

1 0E7886A 1CIRCUIT BREAKER 30A X 2P 240V (7KW)

0E7886C 1 CIRCUIT BREAKER 40A X 2P 240V

(8.5KW)

0E7886D 1 CIRCUIT BREAKER 45A X 2P 240V

(11KW)

0E7886E 1 CIRCUIT BREAKER 50A X 2P 240V

(12KW)

0E7886F 1 CIRCUIT BREAKER 60A X 2P 240V

(13KW)

0E7886G 1 CIRCUIT BREAKER 70A X 2P 240V

(15KW)

20A1801 1 ASSEMBLY, BATTERY CHAR

GER ENGINE
3 083049 1 ASSEMBLY, POTTED REGULATOR
4 0C2174 1 RELAY, 12V 25A SPST
5 075210A 1 BLOCK 1 POSITION
60D3062 4 HEX STAND-OFF #6-32 x 3/8"
7 0D8615 1 ASSEMBLY, HOME STANDBY CON-

TROLLER

0D8615A 1 ASSEMBLY, HOME STANDBY

CONTROLLER (7KW)

8032300 2 HOLDER, FUSE

9

022676 1 FUSE, 15AMP X AGC15
10 0E44941SWITCH, ROCKER DPDT ON-OFF-ON
11 0E78901CIRCUIT BREAKER MOUNTING

BRACKET
12 023484E 1 SNAP BUSHING
13 075476 4 SCREW PPHM M4-0.7 x 16mm
14 022264 8 WASHER LOCK #8-M4
15 051715 8 NUT HEX M4-0.7
16 043182 4 WASHER LOCK M3

043182 2 WAS HER LOCK M3 (7KW)

17 043181 4 SCR

EW PHM M3-0.5 x 10mm
18 0D8443 1 DECAL, CONTROL PANEL (NOT SHOWN)
19 054502 1 CIRCUIT BREAKER 3 X 1 ETA 46-500-P

053623 1CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P

(7KW)

20 0E7870 1 CONTROL, PANEL BOTTOM

0E7871 1 CONTROL, PANEL BOTTOM (7KW)

ITEM PART NO. QTY. DESCRIPTION

21 0752354SCREW HHC M5-0.8 x 30mm
22 0D5240 1 SWITCH, SPST (ON)-ON N/O
23 051714 4 NUT HEX M3-0.5

051714 2 NUT HEX M3-0.5 (7KW)
24 0D8502 1 NEUTRAL CONNECTOR
26 0D8441 1 HARNESS, CONTROL PANEL (NOT

SHOWN)

0E0120 1 HARNESS, CONTROL PANEL WIRE (NOT

SHOWN) (7KW)
27 074908 4 SCREW TAPTITE, M5-0.8 x 10 BP
28 049226 6 WASHER LOCK M5
29 051716 6 NUT HEX M5-0.8

300C3910 1 TRANSFORMER
31 022507 2 SCREW HHC 1/4"-20 x 1/2"
32099727 1 FUSE 5A X AGC5
33 046689 1 BLOCK TERMINAL STRIP 20A 4 X 6 X

1100V

34063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC
35 075475 4 SCREW PPHM M4-0.7 x 10mm
36043180 2 WASHER FLAT M4
37 0D8439 1COVER

, CONTROL PANEL COMPONENT

0E0119 1COVER, CONTROL PANEL COMPONENT

(7KW)

380920368SCREW PPHMS/LW #6-32 x 1/4"
39 045770 2 SCREW HHC M5-0.8 x10mm

40 0E7866 1 COVER, CONTROL PANEL

0E7867 1 COVER, CONTROL PANEL (7KW)
41 0D3700 10 NUT FLANGE M6-1.0 NYLOK
42 0912970069 1

ASSEMBLY, ROOF/DOOR GROUND WIRE
43 0A2311 1 SCREW SWAGE 1/4"-20 x 1"
44 0A1658 2 WASHER LOCK SPECIAL 1/4"
45 0224733WASHER FLAT 1/4"-M6
46 038750 1 SCREW HHC M6-1.0 x 30mm
47 022097 3WASHER LOCK M6-1/4"
48 049813 1 NUT HEX M6-1.0
49 031879 4 WASHER FLAT #4

031879

2 WASHER FLAT #4 (7KW)

50 0238972WAS HER FLAT #10

Section 7 — Exploded Views and Parts Lists

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

Control Panel – Drawing No. 0E7974-B

36 Generac®Power Systems, Inc.

8

0

5

9

6

0

3

3

5

9

6

6

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. 0E7975-A

2

2

1

1

1

1

1

2

1

2

2

1

Generac®Power Systems, Inc. 37

ITEM PART NO. QTY. DESCRIPTION

1 0D4801 1 BOX GTS LOAD CENTER
2 0D4800 1 COVER, 8 POSITION GTS LOAD CENTER

3 0C22371TRANSFER SWITCH HOME STANDBY 100A 2P 250V
3A 077220 1 COIL UTILITY
3B 077220A 1 COIL STANDBY
3C 082574 1 INSULATOR-SIDEWALL (NOT SHOWN)
3D 084464 1 LIMIT SWITCH OPERATION (NOT SHOWN)

4 074908 8 SCREW TAPTITE M5-0.8 X 10 BP

5 024912 1 S

CREW TAPTITE 1/4-20 X 5/8 BP
60A1658 1 LOCK WASHER, SPECIAL-1/4"
7063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC
8 0E7889A 18 CIRCUIT LOAD CENTER 125A/240V
9 0A14954SCREW HHTT M4-0.7 X 10

10 0A1661 2 RIVET POP 0.156" X 0.675"
11 022473 1 WASHER FLAT 1/4-M6
12 0D30941HARNESS,GTS TO MAIN PANEL
13 0D4684A 1PLATE HARNESS

ADAPTER
14 0E7900 1 SUBPLATE, LOAD CENTER
15 056326 10.5" TRIM VINYL BLACK 1/8GP
16 022152 6 WASHER LOCK #10
17 064526 2 SCREW HWHS #6-25 X 3/8
18 0E6155 1 ARM EXTENDER PIN
19 063378 4 HOLDER CABLE TIE
20 0A2110 4 SCREW SWAGE 1/4-20 X 1/2 ZINC
21 074138 2 LUG QUICK DISCONNECT NI-S 10X45 DEG BRASS / TIN

22 036933 6 S

CREW PPHM #10-32 X 3/8"
23 077033 6 LUG SLDLSS 1/0-#14X9/16 AL/CU
24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V
25 028739 4 TIE WRAP UL 3.9" X .10" NAT'L
26 0D4802 1 HARNESS, GTS TO EXTERNAL CONNECTION BOX
27 0D31911COVER, RELAY & TERM BLOCK
28 0D3088 1 WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)
29 0735912FUSE HOLDER

30073590A 2FUSE 5A X BUSS
31 040213B 4 PCB SUPPORT SNAP-IN 1-3/8"
32 0E7888C 1 CIRCUIT BREAKER 20A X 1P
33 0A7215 4 SCREW SW 1/4-20X5/8 WITH WASHER
34 0E7888B 5 CIRCUIT BREAKER 15A X 1P

35 0E7888A 1CIRCUIT BREAKER 30A X 2P
360D3320 1 COVER - HARN

ESS ENTRY

370E6193 1BRACKET, ARM EXTENDER

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. 0E7975-A

38 Generac®Power Systems, Inc.

0

8

0

0

9

6

3

3

5

6

1

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. 0E7973-B

1

1

1

1

1

1

2

4

2

2

1

Generac®Power Systems, Inc. 39

ITEM PART NO. QTY. DESCRIPTION

10D3086 1 BOX GTS LOAD CENTER
20D30921COVER, 12 POSITION GTS LOAD CENTER

3 0C22371TRANSFER SWITCH HOME STANDBY 100A 2P 250V
3A 077220 1 COIL UTILITY
3B 077220A 1 COIL STANDBY
3C 082574 1 INSULATOR-SIDEWALL (NOT SHOWN)
3D 084464 1 LIMIT SWITCH OPERATION (NOT SHOWN)

4 074908 6 SCREW HHTT M5-0.8 X 10

5 024912 1 SCREW HHTT 1/4-20 X 5/8

60A1658 1 LOCK WASHER, SPECIAL-1/4"

7063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC

8 0E7889 1 12 CIRCUIT LOAD CENTER 125A/240V

9 0A14954SCREW HHTT M4-0.7 X 10

10 0A1661 2 RIVET POP .156" X .675"
11 022473 1 WASHER FLAT 1/4-M6 ZINC
12 055450 1 PLUG PLASTIC 1.375
13 0D4684 1 HARNESS ADAPTER PLATE
14 0E7900 1

SUBPLATE, LOAD CENTER
15 056326 10.5" TRIM VINYL BLACK 1/8"GP
16 022152 6 WASHER LOCK #10
17 064526 2 SCREW HWHS #6-25 X 3/8"
18 0E6155 1 ARM EXTENDER PIN
19 063378 4 HOLDER CABLE TIE
20 0D30941HARNESS,GTS TO MAIN PANEL
21 074138 2 LUG QUICK DISCONNECT NI-S 10X45 DEG BRASS / TIN
22 036933 6 SCREW PPH

M #10-32 X 3/8"
23 077033 6 LUG SLDLSS 1/0-#14X9/16 AL/CU
24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V
25 028739 4 TIE WRAP 3.9" X .10"
26 0A2110 4 SCREW SWAGE 1/4-20 X 1/2" ZINC
27 0D31911COVER, RELAY & TERMINAL BLOCK
28 0D3088 1 WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)
29 0735

912FUSE HOLDER
30073590A 2FUSE 5A X BUSS
31 040213B 4 PCB SUPPORT SNAP-IN 1-3/8"
32 0E7888C 3 CIRCUIT BREAKER 20A 1P
33 0E7888 1 CIRCUIT BREAKER 20A 2P
34 0E7888B 5 CIRCUIT BREAKER 15A 1P
35 0E7888A 1CIRCUIT BREAKER 30A 2P

360D3320 1 COVER - HARNESS ENTRY

370D3093 1HARNESS, GTS TO EXT CONN BOX

0D85971HARNESS, GTS TO EXT CONN BOX (8.5KW)
38 075475 2 SCREW PPHM M4-0.7 X 10
39 0A7215 4 SCREW SW 1/4"-20 X 5/8" WITH WASHER
40 0E6193 1BRACKET, ARM EXTENDER

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. 0E7973-B

40 Generac®Power Systems, Inc.

3

0

,

,

,

,

,

,

,

,

,

,

,

,

,

,

140

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990 Engine – Drawing No. 0E8774-B Part 1

93
64
47
40
39
20
19

5

72
40
36
35
34
33
32

4

4

2

1

A

A

7

4

4

4

2

1

2

1

6

4

7

Generac®Power Systems, Inc. 41

ITEM PART NO. QTY. DESCRIPTION

1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH

SLEEVE
20C3008 1 SEAL, 38 I.D. CRANKSHAFT
3 090388 4 SCREW, TAPTITE M6-1.0 X 12 YC

4 0C5372 1 ASSEMBLY, BREATHER
50C3005 1 GASKET, BREATHER COVER
60E3372B 3SEPARATOR, OIL BREATHER
7 0D8067A 1 ASSEMBLY, HEAD #1 G&S
8 071983 4 RETAINER, PISTON PIN 20
9 0C2981C 1 ROCKER, COVER NO OIL FILL

10 045761A 4 STUD M8-1.25/10MM X 30 G5 ZINC
11 0E2985 2 PISTON, HC
12 021533 2 SET, PISTON RING 90MM
13 0E1466 2 PIN PISTON
14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR
15 0C2983 1 SHAFT, GOVERNOR

16A

0C2985A 2 ROLLER BEARING, GOVERNOR PLATE

16B 0C2985B 1 ROLLER BEARING, GOVERNOR

17 0D4042 1 ASSEMBLY,GOVERNOR GEAR
18 0A7811 1 SPOOL, GOVERNOR MACHINED
19 0C2977 1 GASKET, CRANK CASE
20 0C5943 1 SEAL, OIL PASSAGE
21 0E4357E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL

DIRECT DR

IVE
22 0E3223 2 ASSEMBLY, CONNECTING ROD
23 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8
24 0E60981SCREEN, OIL PICKUP
25 0D4123A 1 ASSEMBLY, OIL PUMP
26 078699E2SLEEVE, SEAMED DOWEL 10 DIA.
27 0C3011 2 COVER, OIL RELIEF
28 0C3009 2 SPRING, OIL RELIEF
29 0C3010 2 BALL, 1/2D OIL RELIEF

30093873 2 WASHER, LOCK RIB

M6
31 0C5315 1 GEROTOR, OUTER
32 0C59981CLAMP, OIL TUBE
33 0D1667 1 ARM, GOVERNOR
34 0C29912E-RING, GOVERNOR ARM
35 0C2988 1 THRUST WASHER, GOVERNOR
36 0C29921BUSHING, GOVERNOR LOWER

ITEM PART NO. QTY. DESCRIPTION

370C3971C 1 ASSEMBLY, DIPSTICK WITH HANDLE
38 0C5305 1 TUBE, DIPSTICK
39 0C3027 1 O-RING, OIL CLR 3/8 X 1/2

40 0C3007 1 SEAL, 42 I.D. CRANKSHAFT
41 0C57311ASSEMBLY, HOUSING COVER WITH

SLEEVE
42 0C3006 9SCREW, HHFC M10-1.5 X 55
43 080318 8 SCREW HHFC M6-1.0 X 25
44 093064 1 ASSEMBLY, OIL FILL CAP
45 0C8808 2 HOOK, LIFTING
46 0D2723B1

ROCKER, COVER WITH OIL FILL
47 0C2979 2GASKET, VALVE COVER
48 086515 8 KEEPER, VALVE SPRING
49 0D2274 4 RETAINER, VALVE SPRING
50 0D3867 4 SPRING, VALVE
51 078672 2 SEAL, VALVE STEM D7
52 0C5371 4 WASHER, VALVE SPRING
53 0726944STUD, ROCKER ARM PIVOT
54 0D399

84NUT HEX M8-1.0 G8 YEL CHR
55 0C3027 2 O-RING, 3/8" X 1/2"
56 0D5313 4 ROCKER ARM
57 0D6024 2 PLATE, PUSH ROD GUIDE
58 0C2976 12 SCREW HHFC M8-1.25 X 65
59 086516 2 VALVE, EXHAUST
60 0C2229 2VALVE, INTAKE
61 0838974TAPPET, SOLID
62 0D8067B 1 ASSEMBLY, HEAD #2 G&S
63 0D9853D4PUSHROD, 147
64 0C2978 2 GASKET, HEAD
65 043

790A 1BARBED ELBOW 90 3/8NPT X 3/8

L0CKTITE
66 0D4010 1 KIT GASKET
67 0D4011 1 KIT PISTON & RINGS
68 0D4012 1 KIT BREATHER ASSEMBLY
69 0D4013 1 KIT GOVERNOR ASSEMBLY
70 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1
71 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2
72 0D4015 1 KIT OIL RELIEF
73 0D4016 1 KIT GEAR COVER

Section 7 — Exploded Views and Parts Lists

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

GT-990 Engine – Drawing No. 0E8774-B Part 1

42 Generac®Power Systems, Inc.

0

33

9

01

3

07

08

09

5

3

3

30

5

8

6

8

9

5

37

0

6

5

6

36

38

32

9

34

39

35

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990/760 Engine – Drawing No. 0E8774-B Part 2

7

1

1

7

12

12

12

1

1

1

12

7

7

1

1

11

14

11

11

11

1

12

2

1

11

1

1

1

11

Generac®Power Systems, Inc. 43

ITEM PART NO. QTY. DESCRIPTION

74 0C5136A 2KNOB, AIR CLEANER
75 0C3024 1 COVER, AIRBOX NG/LP
76 0C3040 1 PRE-CLEANER,
77 0C8127 1 ELEMENT, AIR CLEANER
78 0D8564A 1 ASSEMBLY, MIXER/AIRBOX 990

0D8564B 1 ASSEMBLY, MIXER/AIRBOX 760
79 0D25954SCREW SHOULDER (8MM) M6-1.0 X 18
80 0D4417 4 WASHER,R

UBBER 1/4" X 1/8" THICK
81 0C3025 1 SWITCH, OIL PRESS
82 0D3083 1 ASSEMBLY, OIL DRAIN HOSE
83 0C72921NIPPLE, 3/4"-16 UNF
84 070185B 1 OIL FILTER
85 075281 1 SWITCH, THERMAL 284F
86 0C1085 2 SCREW PPHM M3-0.5 X 8
87 043182 2 WASHER LOCK M3
88 035461A 2BARBED STR 1/4NPT X 3/8 WITH VIBRA

SEAL
89 0C7649 4CLAMP HOSE .38-.87
900C9

806 2 HOSE, 3/8" I.D. X 6" LONG

910C3026 1 COOLER, OIL
920C9764 4 PLASTITE,1/4-15 X 3/4
93 0C3043 2GASKET, MANIFOLD / PORT
94 0C76941MANIFOLD CYLINDER 2
95 0C7693 1 MANIFOLD CYLINDER 1
960C3041A 2 SLEEVE, RUBBER
97 070008 4 WASHER FLAT M8 SS
98 070006 4 WASHER LOCK M8 SSTL
99 040976 4 SCREW SHC M8-1.25 X 20 G12.9

100 0E4

9971ASSY, G ROUND WIRE CONNECTOR
101 0E49971GROUND WIRE CONNECTOR
102 0C3725B 1 FLYWHEEL ASSEMBLY
103 0C30311FAN, NYLON
104 0C30321PLATE, FAN
105 0A59922WASHER SHAKEPROOF INT M8 SS
106 051754 2 SCREW HHC M8-1.25 X 12 G8.8
107 0C3033 1 WASHER, 25mm I.D.
108 0C303

41NUT,HEX M24

109 0C8549A 1 SNORKEL, AIR INTAKE

ITEM PART NO. QTY. DESCRIPTION

110 0C3022A 1 HOUSING, BLOWER NG COOLER
111 0D11311GUARD, FAN
112 045756 25 SCREW TAPTITE M6-1X10 YELLOW

CHROME
113 0C9763 4 NUT, GROMMET 1/4 PLUG
114 0C3036A 1HOSE, BREATHER
115 022145 1 WASHER FLAT 5/16-M8 ZINC
116 022129 1 WASHER LOCK M8-5/16
117 0C3018 1 WRAPPER, UPPER CYLINDER 1
118 0C3019 1 WRAPPER, LOWER CYLINDER 1
119 0D1142A 1 WRAPPER, LOWER CYLINDER 2
120 0D1143 1 WRAPPER, UPPER CYLINDER 2
121 0E6043 2 SCREW TAPTITE M5-0.8 X 8 ZP
122 0E7209 1 ASSEMBLY, GROUND WIRE
123 0C3052 2 ASSEMBLY, IGNITION COIL
124 0220974WASHER LOCK M6-1/4
125 092079

4 SCREW TAPTITE M6-1.0 X 25 BP
126 0E4271 1 STARTER
127 0D4529 2 SPARKPLUG
128 022129 2 WASHER LOCK M8-5/16
129 061906 2 SCREW HHC M8-1.25 X 85 G8.8
130 082774 1 KEY, WOODRFF 4 X 19D
1310E5343 1 NUT HEX LOCK M10-1.50
132 0C8468 1 SPRING, ANTI-LASH
133 0C3048 1 ROD, GOVERNOR CONTROL
1340D3754 1 ASSE

MBLY, GOVERNOR LEVER
1350D3742 1 SPRING, GOVERNOR
136 0C8482 1 ASSEMBLY, GOVERNOR ADJUSTER
137 0E0486 1 SCREW SHC M10-1.5 X 75 G10.9
1380D3743 1 SPRING, GOVERNOR IDLE
139 0D3705 1 ASSEMBLY, GOVERNOR ADJUSTER

BRACKET

140 0C2993 1 SEAL, GOVERNOR S

HAFT
141 0C8563 4 SCREW HHFC M6-1.0 X 12
142 045771 1 NUT HEX M8-1.25 G8
143 0D6147 6 SCREW HHFC M6-1.0 X 10mm
144 0E8152 1 O-RING 0.49" I.D. X 0.07" THICK

Section 7 — Exploded Views and Parts Lists

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

GT-990/760 Engine – Drawing No. 0E8774-B Part 2

44 Generac®Power Systems, Inc.

5

0

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

4

2

1

4

4

4

7

0

1

2

1

2

1

Generac®Power Systems, Inc. 45

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 0C69341ADAPTOR, ENGINE
20C9935H 1 STATOR
3 0C9934H 1 ROTOR
4 0C6043A 1CARRIER, REAR BEARING
5 0C80961FAN, 8" CURVED BLADE
60C9593 1 MUFFLER
70D3220 1 TAIL PIPE, MUFFLER
8 0C8860 1 PANEL, MUFFLER BASE
9 031971 1 BEARING #6205-2RS-C3

10 0C3168 3 5/16 SPECIAL L/

WASH
11 056147 1 BOLT ROTOR HHCS 5/16"-24 X 13-1/2" G5
12 0D1847 4 BOLT STATOR HHCS M8-1.25 x 305mm
13 0C7038C 1 BRACKET, ALT ERNATOR MOUNTING
14 0D1647 1 DUCT, ALT ERNATOR AIR
15 0D2558 1 GASKET, ALT ERNATOR AIR DUCT
16 0C7038B 1 BRACKET, ENGINE MOUNTING
17 0C7758 4 RUBBER MOUNT
18 0388050AE0 1 CABLE, #6 40" BLACK B

ATTERY
19 0C2417A 1EARTH STRAP 3/8X 3/8
20 082121C 1 CLIP-J VINYL COAT .625 ID
21 066386 1 ASSEMBLY BRUSH HOLDER
22 029451 1.8 FT TAPE ELEC UL FOAM 1/8 X 1/2
23 049451 1 WASHER FLAT .406ID X 1.62OD
24 0222374WASHER LOCK 3/8
25 022511 4 BOLT HHC 3/8-16 X 1-1/4 G5
26 0221314WASHER FLAT 3/8 ZINC
27 039287 4 SCREW HHC M8-1.25 X 45 G8.8
28 022145 14 WASHER FLAT 5/16 ZINC
29

049820 4 NUT LOCK HEX M8-1.25 NYL INSRT

30090388 3SCREW TAP M6-1.0X12 BP
31 022129 13WASHER LOCK M8-5/16
32 022259 8 NUT HEX 5/16-18 STEEL
33 0596372SCREW TAPTITE 3/8-16X 3/4" BP
34 048031K 3 BAND, HOSE CLAMP 35.05 DIA.
350C9592 1 BELLOWS
36 057822 2 CLAMP HOSE #8 .53 - 1.00
37 040976 2 S

CREW SHC M8-1.25 X 20 G12.9
38 0C2824 1 SCREW TAPR #10-32 X 9/16
39 025145 1 U-BOLT 5/16"-18 X 1.25" W/ SADDLE

40 090239 1GASKET, EXHAUST
41 0C6989 1 STINGER, ENGINE AIR IN
42 0D1214 1 BASE, AIR CLEANER
43 0C8127 1 ELEMENT, AIR CLEANER
44 0C3024 1 COVER, AIR CLEANE

R NG/LP
45 0D2273 1 TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG
46 055934N 1CLAMP VINYL 1.31 X .281 Z
47 074994 1.25 FT HOSE 1\2ID PETROLEUM
48 0C5136A 2KNOB, AIR CLEANER
49 074906 4 SCREW TAPTITE M6-1 X 20 BP
50 022473 4 WASHER FLAT 1/4 ZINC
51 0D4662 6 SCREW HHTT M8-1.2 X 20 BP
52 0C82901GASKET, PANEL
53 066849 2 SCREW HHTT M5-0.8 X 16

46 Generac®Power Systems, Inc.

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-H

2

1

2

4

1

2

1

Generac®Power Systems, Inc. 47

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-H

ITEM PART NO. QTY. DESCRIPTION

1 0C69341ADAPTOR, ENGINE
2 0C79301STATOR 12KW

0D2359STATOR 13KW / 15KW

3 0C7944 1 ROTOR 12KW

0D2356 ROTOR 13KW / 15KW
4 0C6043 1CARRIER, REAR BEARING
5 0D23361FAN, 12" CURVED BLADE
6 0D66341MUFFLER
70D3220 1 TAIL PIPE, MUFFLER
8 0C8101 1 PANEL, MUFFLE

R BASE

9 056482 1 BEARING 1.1811-2.8346

10 0C3168 3 5/16 SPECIAL LOCK WASHER
11 0D1838 1 BOLT, HHCS 3/8"-24 x 15.50"
12 0D1846 4 BOLT, HHCS M8-1.25 x 345mm
13 0C70381BRACKET, ALTE RNATOR MOUNTING
14 0D1609 1 DUCT, ALT ERNATOR AIR
15 0D2559 1GASKET, ALT ERNATOR AIR DUCT
16 0C7038A 1BRACKET, ENGINE MOUNTING
17 0C7758 4 RUBBER MOUNT
18 0388050AD0 1 CABLE, #6 48" BLACK BATTERY
19 0C2417A 1EARTH STRAP 3/8X 3/8
20 082121C 1 CLIP-J, VYNL COAT 0.625" ID
21 066386 1 ASSEMBLY BRUSH HOLDER
22 029451 2.6 FT TAPE ELEC UL FOAM 1/8 X 1/2
23 049451 1 WASHER FLAT .406ID X 1.62OD
24 0222375WASHER LOCK 3/8
25 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5
26 0221314WASHER FLAT

3/8 ZINC
27 039288 4 SCREW HHC M8-1.25 x 55 G8.8
28 022145 14 WASHER FLAT 5/16 ZINC
29 049820 4 NUT LOCK HEX M8-1.25 NYL INSERT

30 045756 2 SCREW TAPTITE M6-1.0X10 BP
31 022129 10 WASHER LOCK M8-5/16
32 022259 8 NUT HEX 5/16-18 STEEL
33 0596372SCREW TAPTITE 3/8-16 X 3/4 BP
34 0D4662 4 SCREW 5/16-18X3/4" HH THD ROLL
35 074

994 3 FT HOSE RES 1/2 LP GAS
36 057822 4 CLAMP HOSE #8 .53 - 1.00
37 0F0462 4 NUT HEX W/TOOTH WSHR M8-1.25
38 0C2824 1 SCREW TAP-R #10-32 x 9/16
39 025145 1 U-BOLT 5/16"-18 X 1.25" WITH SADDLE

40 0C41382GASKET, EXHAUST PORT
41 048031C 2 CLAMP HOSE BAND ¼"
42 030340 1.33 FT HOSE 1/4 ID SAE 30R7
43 066849 2 SCRE

W HHTT M5-0.8 X 16

48 Generac®Power Systems, Inc.

9

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GN410 Engine – Drawing No. 0E9180-A Part 1

4

2

2

4

1

1

7

7

2

4

Generac®Power Systems, Inc. 49

ITEM PART NO. QTY. DESCRIPTION

10E3221 1 ASSEMBLY, CONNECTING ROD
2 0E1466 1 PIN, PISTON D20
3 021533 1 SET, PISTON RING 90MM
40E2985 1 PISTON, HC
5 071983 2 RETAINER, PISTON PIN 20
6 0E8440 1 ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER
70A7628 1 ARM, GOVERNOR RC45
8 078658 1 PIN, "R" GOVERNOR ARM

9

078659 2 WASHER, GOVERNOR ARM THRUST
10 088261E 1 CRANKCASE, SUBASSEMBLY WITH PLUGS GH410
11 0E3812 2 SEAL, 35 I.D. CRANKSHAFT
12 0E6519 1 ASSEMBLY, GOVERNOR GEAR
13 078645 1 C-RING, GOVERNOR GEAR RETAINER
14 0A7811 1 SPOOL, GOVERNOR- MACHINE
15 0A9877 1 ASSEMBLY, CAMSHAFT & GEAR
16 076701 1 GASKET , CRANKCASE
17 021713B1GASKET, HEAD 410
18 0786911COVER, OIL PRESSURE RELIEF
19 0A5771 1 SPRING, OIL RELIEF 360

20 0A5776 1 BALL, DIA 11/32 PRESSURE RELIEF
21 076361 1 WASHER, THRUST GOVERNOR GEAR
22 0A8898D 1 ASSEMBLY, COVER, GEAR TOP CHECK / FILL
23 0D2274 2 RETAINER

, VALVE SPRING
24 0C43912VALVE SPRING LF
25 086025 1 SET,GEROTOR 12 THK
26 0E3341 1 BALANCER
27 021714 1 ASSEMBLY,CYLINDER HEAD SEATS & GUIDES
28 086516 1 VALVE, EXHAUST
29 086517 1 VALVE, INTAKE

300D9853B2PUSH ROD 174.9
310838972TAPPET

32 077158 1 ASSEMBLY, SCREEN

OIL PICK-UP

33 0C3150 1 GASKET, ROCKER COVER 410
34 0726942STUD, D20 PIVOT BALL
35083907 2 ROCKER ARM
36 0726962NUT, JAM (ROCKER ARM)
37 0786941PLATE, PUSH ROD GUIDE
38 021742 4 SCREW, HHFL M10-1.5 X 105
39 0D60941ASSEMBLY, ROCKER COVER BREATHER

40 076329 1 PLUG, OIL FILL PLASTIC
41 0E0057 1 O-RING 17.8 I.D. x 2.4
42 0D4788 1 PLUG, STAN

DARD PIPE 3/8 STEEL SQUARE HEAD
43 074908 1 SCREW, TAPTITE M5-0.8 X 10 BP
44 086515 4 KEEPER, VALVE SPRING
45 078606 4 SCREW & LOCKWASHER M6-1 X 12
46 0A1442 8 SCREW, HHFC M8-1.25 X 42
47 078672 1 SEAL, VALVE STEM D7
48 089673 2 WASHER, VALVE SPRING
49 0B2104 1 WASHER, LARGE S

PRING
50 078699C2DOWEL, SEAMED SLEEVE
51 0A7627 1 SHAFT, GOVERNOR RC55
52 043790A 1BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE
53 0885901DOWEL DIA 12 X 18L
54 078699B1DOWEL, SLEEVE SEAMED 12 DIA.

Section 7 — Exploded Views and Parts Lists

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

GN410 Engine – Drawing No. 0E9180-A Part 1

50 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GN410 Engine – Drawing No. 0E9180-A Part 2

7

4

2

4

1

Generac®Power Systems, Inc. 51

ITEM PART NO. QTY. DESCRIPTION

1 0C1069 5 SCREW, TAPTITE M6-1.0X8 YELLOW CHROME
2 0D2922 1 HOUSING, BLOWER
3 0C8435 1 TUBE, DIPSTICK
40C99971GUARD, FAN
5 0884341WRAPPER, BOTTOM
6 045756 11 SCREW, TAPTITE M6-1X10 YELLOW CHROME
7 0C4176A 1 WRAPPER, TOP
80D9004A 1 ASSY, STARTER

9 059985 2 SCREW, SHC M8-1.25 X 45 G12.9
10 022129 2 WASHER, LOCK M8-5/16
11 0C2458A 1BACKPLATE, L/F D/F
12 083512 1 SCREW, TAPTITE M8-1.25 X 16 BP
13 0D1401A 1BREATHER TUBE
14 091039 1GASKET, INTAKE ADAPTER
15 0C9619 1 ASSEMBLY, PLASTIC CARB
16 049811 2 WASHER, FLAT M6
17 0220974WASHER, LOCK M6-1/4
18 040945 2 SCREW, SHC M

6-1.0 X 20 G12.9
19 086999 1GASKET,OIL FILTR ADAPTER
20 0D5667A 1 ADAPTER, OIL FILTER
21 049821 2 SCREW, SHC M8-1.25 X 30 G12.9
22 0992361SWITCH, OIL 8.0 PSI
23 070185B 1 OIL FILTER
24 082774 1 KEY, WOODRFF 4 X 19D
25 091222E 1 FLYWHEEL WITH RING GEAR 32DEG.
26 067198N 1 WASHER,BELV-20 X 2.2
27 0678901NUT, HEX - FLYWHEEL
28 0E7585 1 SPARKPLUG
29

0727341ASSEMBLY,GOVERNOR LEVER 12 HP

30 0727351ROD,GOVERNOR CONTROL.
310C3978 1 SPRING, ANTI-LASH
32 0C6040 1 ASSEMBLY, WIRE
33 0D9760 1 ASSEMBLY, IGNITION COIL
34092079 2 SCREW, TAPTITE M6-1.0 X 25 BP
35073100 1 SPRING GOVERNOR
36083502 1 BOLT, GOVERNOR A

DJUST M5
37 082025 1 NUT HEX LOCK M5-0.8 NYINS ZINC
380D3083 1 ASSEMBLY, OIL DRAIN HOSE
39 0E7887C 1 ASSEMBLY, CAP & DIPSTICK

40 090072 1 O-RING 9/16 X 3/4 X 3/32

41 075281 1 SWITCH, THERMAL
42 043182 2 WASHER LOCK M3
43 0C4739 2 SCREW PPHM M3-0.5 X 6
44 0C4373 1 SPACER, ENDFRAME

45 022717B 1 GROMMET

Section 7 — Exploded Views and Parts Lists

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

GN410 Engine – Drawing No. 0E9180-A Part 2

ITEM PART NO. QTY. DESCRIPTION

1 0D56941CASTING, TWIN REGULATOR HOUSING
2 0C5765 1 SOLENOID, TWIN REGULATOR
3 0C4647 1 GASKET , SOLENOID
4 0C4680 1 PLUNGER, LP REGULATOR ASSEMBLY
5 0C6070 1 SPRING-SOLENOID, PLUNGER
6 022985 4 WASHER, FLAT #6
7 022264 4 WASHER, LOCK M4
8 075475 4 SCREW PPHM M4-0.7 X 10

9 0C5760A 1 JET, GN 410 ENGINE LP (7KW)
10 0C6606 2* BARBED STRAIGHT 1/2NPT x 1/2
11 0979342*O-RING, CHECK VALVE
12 0C4645 2* ADJUSTER SCREW, TWIN REGULATOR

13 0C5761 2* LEVER, REGULATOR
14 0C5968 2* SUPPORT, I NLET SEAL
15 0C6066 2* SEAL, INLET
16 0C5759 2* PIN, PIVOT ARM
17 0C5764 2 SPRING, REGULATO

R

0C5764A 1 SPRING, REGULATOR (7KW)

18 070728 4 SCREW, PFHMS M3-0.5 x 5

070728 2 SCREW, PFHMS M3-0.5 x 5 (7KW)
19 0C6069 2* GASKET, DIAPHRAGM
20 0C5762 2* COVER, TWIN REGULATOR

ITEM PART NO. QTY. DESCRIPTION

21 045764 16 SCREW, TAPTITE M4X8 BP

045764 8 SCREW, TAPTITE M4X8 BP (7KW)
22 0C67312*RIVET, POP .118 X .125
23 0C6067 2* SUPPORT, D I APHRAGM
24 0C4706 2* DIAPHRAGM, TWIN REGULATOR
25 0C6068 2* CAP, D I APHRAGM SUPPORT
26 0C4643A 2* INLET, TWIN REGULATOR 11.11 DIA.
27 026073 1 PLUG, STANDARD PIPE 1/8 STEEL

SQU

ARE HEAD

28 0A40322*PIN, LIMITED ADJUSTMENT
29 0D3308 4 WASHER, FLAT M3 X 10mm O.D.

0D3308 2 WA SHER, FLAT M3 X 10mm O.D. (7KW)

30 0C4643 1INLET, TWIN REGULATOR NO HOLE -

NOT SHOWN (7KW)
31 028414A 1BARBED STRAIGHT 1/8"NPT X 1/4"
32 0D5698A 1 JET IDLE PRIMER PHILLIPS HD
33 0C5760B 1 JET, GT760 CYL 1

NAT GAS
34 0C5760C 1 JET, GT760 CYL 2 NAT GAS
35 0C5760D 1 JET, GT 760 LP CYL 1
36 0C5760E 1 JET, GT760 LP CYL 2
370D3973 2 PLUG, EXPANSION 16mm

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

52 Generac®Power Systems, Inc.

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

21

10

20

25

24

22

10

32

12

28

23

19

12

28

26

15

11

17

9

5

4

3

11

27
31

14

16

13

6

37

1

26

17

29

18

16

15

14

13

33

32

35

19

22

10

34

FOR GT 760

ENGINE ONLY

29

18

23

24

25

36

37

20

21

Generac®Power Systems, Inc. 53

Section 8 — Mounting Dimensions

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

Drawing No. 0D3739-B

S

G

S

O

)

O

O

OO

G

O

S

CO

S

[

]
OU

G

UG

U

S

SSU

O

Q

S

O

S

[

]

[

]

G
U

U

[

36.0"

]

U

O
OU

U

[

8
[

]

[

]

]

9

]
]

3

9

[

]

]
[

]

[

]

[

]

[

CC

SS

O

S

)

PEN AREA

M

14mm

INIM

NIT

ND

LL AR

.

LE

46.2"

172.3

UIRED

F 11-14"

RE

EL INLET

PRE

ATER COLUMN RE

4" NPT F

A

H

E

ABLE A

L

NDIN

R

REMOVE PLUG FOR ACCESS

10.2"

INCHES

IN:
N

I

ILLIMETERS

*ALL DIMEN

IDE VIEW

14

5.9"

HT
I

90.7

.19"

0.2mm

F"

47"

193

RNER

4-

T LIFT BY THE R

LE

H

N

IFTIN

D

4

27.7"

8.14"

07

48.5"

232

NT VIEW

R

M

3.00"
M

RAVEL

IN

EA

6.2mm

12"

IF SUPPLIED

4

2

23.5"

04

24.5"

IDE VIEW

22

EFT

2

16

54 Generac®Power Systems, Inc.

Section 9 — Notes

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

Generac®Power Systems, Inc. 55

Section 9 — Notes

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

56 Generac®Power Systems, Inc.

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 modifi­cation 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, dur­ing 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 unap­proved 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 impor­tant 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 serv­ice, 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 ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC. GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 211 MURPHY DRIVE
WHITEWATER, WI 53190 EAGLE, WI 53119

Part 1

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.

Generac®Power Systems, Inc. 57

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 con­tinue 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 man­ufacturer’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:

*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

Section 10 – Warranty

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

1) Fuel Metering System:

1.2) LPG/Natural Gas carburetion assembly and its internal
components.

a) Fuel controller (if so equipped)
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)

2) Air Induction System including:

a) Intake pipe/manifold
b) Air cleaner

3) Ignition System including:
a) Spark plug
b) Ignition module

4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold

5) Crankcase Breather Assembly including:
a) Breather connection tube

Part No. 0E8012 Revision D (02/25/04) Printed in U.S.A.

Section 10 – Warranty

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

GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR GUARDIAN

®

“PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS”

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Guardian generator
will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair or replace
any part which, upon examination, inspection and testing by Generac or a Guardian Authorized Warranty Service Dealer, is found to be
defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Guardian Authorized
Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the
purchaser/owner. This warranty applies only to Generac Guardian prepackaged emergency automatic standby generators sold and
rated for use in “Standby” applications.

WARRANTY SCHEDULE

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

tenance is required):

ENGINE – All Components
ALTERNATOR – All Components
TRANSFER SYSTEM – All Components

Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the
responsibility of the owner and is not covered by this warranty. Nicks, srapes, dents or scratches to the painted enclosure should be
repaired promptly by the owner.

All warranty expense allowances are subject to the conditions defined in Guardian’s

Warranty Policies, Procedures and Flat Rate Manual

.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

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

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

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

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

power service does not normally exist.

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

• Steel enclosures that are rusting due to the improper installation or location in a harsh or saltwater environment.

• 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 and/or insect 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.

• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)

• Overnight freight costs for replacement part(s).

• Overtime labor.

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

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESS

ED OR IMPLIED. SPECIFICALLY, GE NERAC MAKES NO
OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow lim-
itations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC’S ONLY L IABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED A

BOVE. 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 consequential 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

Revision (01/01/04)