Generac 04675-3, 04673-2, 04674-2 User Manual

POWER SYSTEMS, INC.

®

Installation and

Owner’s Manual

Air-cooled Automatic

Standby Generators

Models:
04673-2 (6 kW NG, 7 kW LP)
04674-2 (12 kW NG, 12 kW LP)
04675-3 (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.

*This manual should remain with the unit.*

GENERAC

POWER SYSTEMS, INC.

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Generac®Power Systems, Inc.

INTRODUCTION

Thank you for purchasing this model 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This generator will operate using either vapor withdrawn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, contact
the nearest Generac Authorized Dealer for starting,
operating and servicing procedures.

Throughout this publication, and on tags and
decals affixed to the generator, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert 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 is as 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:

• 04673-2 – 6 kW NG, 7 kW LP, single-cylinder GH­410 Engine

• 04674-2 – 12 kW NG, 12 kW LP, V-twin GT-990
Engine

• 04675-3 – 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 Generac
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 the Generac
Authorized Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

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

When contacting a Generac 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 1.4 for decal loca­tion.

Model No. ____________ Serial No. ______________

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AUTHORIZED

DEALER LOCATION

To locate the nearest GENERAC AUTHORIZED

DEALER, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

DANGER

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Table of Contents

Generac 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 System Set LED ............................................4

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

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

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

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

1.6 Fuel Requirements and Recommendations ....7

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

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

1.8.1 7 kW, 410CC ......................................7

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

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

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

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

1.10 Battery Installation ........................................9

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

Section 2 – Post Installation Start-up

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

2.1 Before Initial Start-up..................................10

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

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

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

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

2.6 Adjusting the Regulator (Natural Gas Only) ..12

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

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

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

2.7.3 Additional Corrosion Protection ......13

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

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

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

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

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

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

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

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

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

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

3.5.1 Transfer to Generator

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

3.5.2 Transfer Back to Utility

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

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

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

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

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

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

3.7.4 Overspeed ........................................17

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

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

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

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

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

4.3.2 Oil Change Procedure ......................18

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

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

4.5.1 7 kW, 12 kW and 15 kW

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

4.6 Spark Plug(s) ..............................................19

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

4.8 Adjusting Valve Clearance ............................20

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

4.10 Attention After Submersion ........................21

4.11 Corrosion Protection ..................................21

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

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

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

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

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..............50

Section 9 – Notes ............................................51

Section 10 – Warranty....................................52

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 anticipate every possible circum­stance that might involve a hazard. The warnings in
this manual, and on tags and decals affixed to the
unit are, therefore, not all-inclusive. If 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.

Please read all hazards carefully!

GENERAL HAZARDS

• For safety reasons, Generac recommends that the

installation, initial start-up and maintenance of
this equipment is carried out by a Generac
Authorized Dealer.

• The engine exhaust fumes contain carbon monox-

ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust 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 Generac 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.

!!!

IMPORTANT SAFETY INSTRUCTIONS

Generac 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 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. If there are any questions pertaining to fire
extinguishers, consult the local fire department.

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

Generac 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.

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 and 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 his or her signature under the
consignor's memo of loss or damage.

If there is loss or damage after delivery, separate the
damaged materials and contact the carrier for claim
procedures.

“Concealed damage” is understood to mean damage
to the contents of a package that is not in evidence at
the time of delivery, but is discovered later.

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 noti-

fy personnel that one of these faults has occurred.
There is also a “System Set” LED that is described
below.

1.3 SYSTEM SET LED

The “System Set” LED is lit when all of the following
conditions are true:

1. The AUTO/OFF/MANUAL switch is set to the
AUTO position.

2. The utility voltage being supplied to the unit is
being sensed by the Control 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.

Section 1 — General Information

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

4 Generac®Power Systems, Inc.

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Section 1 — General Information

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

Generac®Power Systems, Inc. 5

1.4 THE GENERATOR

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Figure 1.2 – 12 kW/15 kW, V-twin GT-990/760 Engine

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

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6 Generac®Power Systems, Inc.

Section 1 — General Information

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

1.5 SPECIFICATIONS

1.5.1 GENERATOR

Model 04673 Model 04674 Model 04675

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 NG/100.0 LP 108.3 NG/125.0 LP

240 Volts 25.0 NG/29.2 LP 50 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

at -17.8° C ( 0° F) 12 Volts and 12 Volts and 12 Volts and

350 Cold-cranking 525 Cold-cranking 525 Cold-cranking

Amperes Minimum Amperes Minimum Amperes Minimum

Weight 375 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 (42° F) above 16° C (60° F).

+ Total current in TWO separate curcuits. Current in each curcuit must not exceed the value stated for 240V.

1.5.2 ENGINE

Model 04673 Model 04674 Model 04675

Type of Engine GH-410 GT-990 GT-990
Number of Cylinders 1 2 2
Rated Horsepower 14.5 @ 3,600 rpm 30 @ 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 RC14YC 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 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.

Required fuel pressure for natural gas is 5 inches to

7 inches water colum (0.18 to 0.25 psi); and for
liquid propane, 11 inches to 14 inches of water
column (0.4 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the
fuel supply should be of adequate size to ensure
the fuel pressure NEVER drops below 4 inches
water colum for natural gas or 10 inches water col­umn for liquid propane for all load ranges.

1.7 FUEL CONSUMPTION

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

1.8 RECONFIGURING THE
FUEL SYSTEM

1.8.1 7 KW, 410CC

To reconfigure the fuel system from NG to LP,
follow these steps (Figure 1.3):

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 (0.4 to 0.5
psi) to the fuel inlet of the generator MUST BE
SUPPLIED.

1. Turn off the main gas supply (if connected).

2. Open the roof and remove the door.

3. Remove the battery (if installed).

4. Disconnect wire #0 and wire #14 from the gas
solenoid on top of the demand regulator.

5. Remove the carburetor fuel hose from the outlet
port of the demand regulator.

6. Remove the demand regulator by removing the
fastener that retains the regulator mounting
bracket.

7. Remove the square headed steel pipe plug from
outlet port #1 and the brass hose barb fitting
from outlet port #2.

8. Refit the brass hose barb fitting to outlet port #1
and the square headed steel pipe plug to outlet
port #2.

9. Reverse procedure steps 1-5 to reinstall demand
regulator.

10. Reverse the procedure to convert back to natural
gas.

Figure 1.3 – Demand Regulator

NOTE:

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

1.8.2 12KW AND 15KW, V-TWIN 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 (0.4 to 0.5
psi) to the fuel inlet of the generator MUST BE
SUPPLIED.

1. Turn off the gas supply. (if connected)

2. Open the roof and remove the door.

3. Remove the battery. (if installed)

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Section 1 — General Information

Generac 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

04673 66 119 0.82/30 1.47/54
04674 152 215 1.53/56 2.08/76
04675 156 220 1.58/58 2.40/88

HOSE & PL

WITCHED SIDE

FUEL H

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PL

FUEL H

BRASS HOSE

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NG FUEL SYSTE

LP FUEL SYSTE

4. Remove the engine air in baffle located on the left­hand 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.

5. 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 screwdriver to gen­tly lift up the hose edge.

6. Remove the small brass hose fitting from the reg­ulator casting.

7. Place the small fuel jet, thread side first, into the
threaded hole originally occupied by the brass
hose fitting (Figure 1.4).

Figure 1.4 - Demand Regulator

8. Using a short No. 2 Phillips screw driver, thread
the small fuel 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. The screw can be turned
with a long flat blade screwdriver.

13. To adjust the system to run on LP fuel, turn
BOTH adjuster screws 1/2 TURN CLOCKWISE.
The system should now be set for maximum
power and best perfomance. DO NOT, UNDER

ANY CIRCUMSTANCES, REMOVE THE SET
PINS FROM THE REGULATOR HOUSING.
THIS WILL VOID THE WARRANTY.

14. It may be necessary to make minor adjustments
to the preset adjustment screw settings to achieve
maximum power, particularly at higher altitudes.
If experiencing problems with the unit producing
maximum power, follow the procedure in Section

2.6 (Adjusting the Fuel Regulator).

1.9 LOCATION

1.9.1 GENERATOR

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

• 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.

1.9.2 TRANSFER SWITCH

1.9.2.1 7 kW, 12 kW and 15 kW Units

Transfer switches for use with these generators are
sold separately and can be purchased from Generac
Authorized Dealers.

• Install the transfer switch on a firm, sturdy sup-

porting structure.

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

essary. This can be done by placing washers
between the switch enclosure and mounting sur­face.

• Never install the switch where water or any corro-

sive substance might drip onto the enclosure.

• Protect the switch at all times against excessive

moisture, dust, dirt, lint, construction grit and cor­rosive vapors.

• Failure to utilize a Generac transfer switch with

this generator may void the warranty.

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T

T

U

T

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OSE

S

L

T

OR

OUSING PORT

JUSTER

SC

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Section 1 — General Information

Generac 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

1.10 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 5 amp fuse 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:

4. Connect the red battery cable (from starter con­tactor) 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 (—).

6. Replace the 5 amp fuse in the generator control
panel.

NOTE:

Damage will result if battery connections are made
in reverse.

Figure 1.5 – Battery Cable Connections

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.

1.11 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 battery with a rating of
350 cold-cranking amps minimum for 7 kW; 525
cold-cranking amps minimum for 12 and 15 kW at

-17.8º C (0º F) minimum. When using a maintenance­free 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 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.

!

!

Section 1 — General Information

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

DANGER

10 Generac®Power Systems, Inc.

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, immediately
flush thoroughly 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) or 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,
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. Check the engine crankcase oil level and, if nec-

essary, fill to the dipstick FULL mark with the
recommended oil. Do not fill above the FULL
mark.

5. 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. 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.

2. Use an accurate AC voltmeter to check utility

power source voltage across terminals N1 and
N2. Nominal line-to-line voltage should be 240
volts AC.

3. Check utility power source voltage across termi-

nals N1 and the transfer switch neutral lug; then
across terminal N2 and neutral. Nominal line-to­neutral voltage should be 120 volts AC.

4. When certain that utility supply voltage is com-

patible with transfer switch and load circuit rat­ings, turn OFF the utility power supply to the
transfer switch.

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

OFF (or open) position. Initial tests will be con­ducted at no-load condition.

6. On the generator panel, set the AUTO/OFF/MAN-

UAL switch to MANUAL. The engine should crank
and start.

7. 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.

Section 2 — Post Installation Start-up and Adjustments

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

!

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DANGER

DANGER

DANGER

Generac®Power Systems, Inc. 11

8. 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.

9. 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.

10. 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.

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

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 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.

4. 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.

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

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. Loads are now powered by
the standby generator.

8. Turn ON electrical loads. Apply an electrical load
equal to the full rated wattage/amperage capacity
of the installed generator.

9. 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.

10. 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.

11. When testing under load is complete, turn OFF
electrical loads.

12. Set the generator's main circuit breakers to their
OFF (or open) positions.

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

14. 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 the generator’s main circuit breaker to it’s
OFF (or open) position.

2. Check that the AUTO/OFF/MANUAL switch is set
to OFF.

3. Manually set the transfer switch to the UTILITY
position, i.e., load terminals connected to the util­ity power source side.

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

5. Set the AUTO/OFF/MANUAL switch to AUTO.
Then set the generator’s main circuit breaker to
its ON (or closed) position. The system is now
ready for automatic operation.

6. 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 15 seconds, the switch should transfer

loads back to the utility power source.

• About one minute after retransfer, the engine

should shut down.

Section 2 — Post Installation Start-up and Adjustments

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

12 Generac®Power Systems, Inc.

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 the no-load frequency with
the roof open and door off is set at 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 fre-

quency meter to the output lugs of the generator’s
main line circuit breaker.

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

(12 & 15 kW) adjustment screws. While watching
the frequency meter, slowly turn the adjustment
screw clockwise or counterclockwise one at a
time until highest frequency is read on the meter.
Only limited adjustment is available between the
set pins. 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. Then turn both adjustment
screws 1/4 turn counterclockwise. 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.

If this procedure or 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 (Figure 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 an AC frequency meter across the gener­ators AC output leads.

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

◆

!

Section 2 — Post Installation Start-up and Adjustments

Generac 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 83.3 amps 41.6 amps
15 kW 108.3 amps 54.1 amps

Adjustment Screw

V-twin

Adjustment
Screw

(Both Sides)

Set Pin

(Both Sides)

Adjustment
Screw

(One Side
Only)

410

Set
Pin

Generac®Power Systems, Inc. 13

Section 2 — Post Installation Start-up and Adjustments

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

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 — Single Cylinder Engine Governor

Adjustment

2.7.2 12 KW AND 15 KW UNITS

1. Loosen governor clamp bolt (See Figure 2.4).

Figure 2.4 — V-twin Engine Governor

Adjustment

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 2.5) to adjust frequency to
58 Hz.

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

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.

9. The governor is now set.

Figure 2.5 — V-twin Full Load Speed Adjust

Screw

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 62-63.5 Hertz, slowly
turn the slotted potentiometer (Figure 2.6) until line
voltage reads 244-252 volts.

NOTE:

Remove the access panel on top of the control
panel to adjust the voltage regulator.

Figure 2.6 – Voltage Adjustment Potentiometer

◆

◆

GOVERNOR

SHAFT

GOVERNOR

CLAMP

BOLT

ADJUST
SCREW

Full Load Speed Adjust Screw

Idle Spring

Governor
Shaft

(Rotate

Clockwise)

Governor Clamp Bolt

No Load Idle
Adjustment Screw

14 Generac®Power Systems, Inc.

Section 3 — Operation

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

NOTE:

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

3.1 BREAK-IN PROCEDURE

Once the unit has been installed, with utility power
connected to the transfer switch, 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. Run the unit for one hour at 25 percent load.

5. Run the unit for one hour at 50 percent load.

6. Run the unit for one hour at 75 percent load.

7. Run the unit for one hour at 100 percent 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. 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”.

11. 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 permits starting and exercising
of the engine every seven days with 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 both 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 voltage

is available to transfer switch terminal lugs N1
and N2.

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).

!

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EXERCISE

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POWER SYSTEMS, INC.

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Generac®Power Systems, Inc. 15

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 a 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 to 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 the 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 main circuit breaker to its
OFF (or open) position.

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

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).

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.

Figure 3.2 – Manual Transfer Switch Operation

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.



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Section 3 — Operation

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

DANGER

16 Generac®Power Systems, Inc.

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

The 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) allows
for selection of the day and time for system exercise.
To select the desired day and time of day, the follow­ing sequence must be done at that time.

1. Verify that the AUTO/OFF/MANUAL switch is set
to AUTO.

2. Hold down the set timer 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 (Remote Not Auto) on the controller
printed circuit board 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, and the AUTO/OFF/MANUAL switch must 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 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 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.

NOTE:

If the fault is not repaired, the overcrank feature
will continue to activate.







Section 3 — Operation

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

DANGER

Low Oil Switch

L

o

o

s

e

n

Oil
Drain
Hose

Oil Filter

High Temp Switch

Generac®Power Systems, Inc. 17

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 Generac 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, battery charging will not be possible.
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
(Figure 4.2):

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

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.





Section 4 — Maintenance

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

!

Oil Dipstick and Fill

Oil Dipstick

FUSE

5A

FUSE

15A

OFFAUTO

SET

EXERCISE

TIME

MAN.

Locat e your nearest dealer at :

R

POWER SYSTEMS, INC.

FLA SHING GR EEN L ED=

4FLASHINGREDLEDS=

R

SYSTEM SET
LOW OIL

HIGH TEMP.

OVER SPEED
OVER CRANK

N O U T IL IT Y S E N S E

EX ERCISER N OT S ET

Oil Fill

18 Generac®Power Systems, Inc.

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.

Figure 4.4 – Oil Drain Hose and Filter

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.

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

Figure 4.7 — 12 kW and 15 kW Engine

Air Cleaner





!

Section 4 — Maintenance

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

Air Cleaner

Fuel

Regulator

L

o

o

s

e

n

Oil
Drain
Hose

Oil Filter

Screw

Cover

Filter

Generac®Power Systems, Inc. 19

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 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, immediately
flush thoroughly 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) or 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 fuse is removed from the generator
control panel, or sparking may occur at the bat­tery posts as the cables are attached, causing
an explosion.

Section 4 — Maintenance

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

SET PLUG GAP AT 0.76 mm/0.50 mm

(0.030 inch/0.020 inch)

DANGER

!

!

!

20 Generac®Power Systems, Inc.

4.8 ADJUSTING 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, contact
the nearest 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.

• 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

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 48.9° C (104° F).

!

Section 4 — Maintenance

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

Rocker

Pivot Ball

Stud

Jam Nut

Arm

Valve

Stem

Generac®Power Systems, Inc. 21

4.10 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water,
it MUST NOT be started and operated. Following any sub­mersion in water, have a Generac 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 it is to 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 AUTO/OFF/MANUAL switch to OFF and turn

off the utility power to the transfer switch.

5. While the engine is still warm from running, drain

the oil completely. Refill the crankcase with oil. See
”Engine Oil Recommendations,” Section 4.3.1.

6. Attach a tag to the engine indicating the viscosity

and classification of the oil in the crankcase.

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

into the spark plug(s) threaded openings. Reinstall
and tighten the spark plug(s).

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

on a wooden board. Never store the battery on any
concrete or earthen floor.

9. Clean and wipe the entire generator.

4.12.2 RETURN TO SERVICE

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

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

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

3. 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.

4. 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.

5. Clean and wipe the entire generator.

6. Remove the 5A fuse from the generator control
panel.

7. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected incor­rectly. Replace the 5A fuse in the generator control
panel.

8. Open the fuel shutoff valve.

9. Start the unit by moving the AUTO/OFF/MANUAL
switch to MANUAL. Allow the unit to warm up thor­oughly.

10. Stop the unit and set the AUTO/OFF/MANUAL
switch to AUTO. Set the generator’s main circuit
breaker to its ON (or closed) position.

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

12. The generator is now ready for service.

NOTE:

If the battery was dead or disconnected, the exercise
timer must be reset.





Section 4 — Maintenance

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

22 Generac®Power Systems, Inc.

Section 4 — Maintenance

Generac 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 Generac 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 GENERAC Y

AUTHORIZED DEALER

Generac®Power Systems, Inc. 23

Section 5 — Troubleshooting

Generac 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 on 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 1. Check, replace air cleaner.
and runs rough. plugged 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 is at (0.4-

0.5 psi) for LP, and 5-7” water
colum (0.18-0.25 psi) for natural
gas.

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 2.1)

*Contact the nearest Generac Authorized Dealer for assistance.

24 Generac®Power Systems, Inc.

Section 6 — Electrical Data

Generac 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

C

C

3

6

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

86

8

56

3

0

56

8

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

I

HARGE

F

1

1

1

1

1

1

1

22

1

22

1

1

1

1

HT

L

BLA

MER SUPPLIE

1

1

L.E.D - ALARM INDICATOR

PRINTED CIRCUIT BOAR

NTR

D

2 - Remote Not Aut

3 - 50 Hz Operatio

4 - SPAR

1

1

1

2

1

2

1

1

22

Generac®Power Systems, Inc. 25

Section 6 — Electrical Data

Generac 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

NEUTRAL

NNE

TI

12Vdc TRAN

I

FE

UTILITY INPU

TOME

MANUA

NNECTI

26 Generac®Power Systems, Inc.

Section 6 — Electrical Data

Generac 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

O

G

3A

CR

OPW2225

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

22

22

1

B

2-

2-

ENGINE R

WINDIN

STATOR

HT

1-

2-

PRINTED CIRCUI

BOAR

NTR

1

L

1-

2

1

1

2

1

1

1

22

1

22

22

1

1

1

2

1

1

2

Generac®Power Systems, Inc. 27

Section 6 — Electrical Data

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

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

39

5

8

2

0V

94

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

240VA

TILIT
INP

12V

TRANSFE

I

TOME

NNECTION

2

1

W

BLA

12

12

24

TOME

PPLIE

1

1

2

1

1

2

1

1

1

1

1

1

1

1-

1

1

1

1-

1

1

2

F

WINDIN

STATOR

2-

POWE

B

P

P

28 Generac®Power Systems, Inc.

Section 6 — Electrical Data

Generac 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

39

5

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

22

Generac®Power Systems, Inc. 29

Section 6 — Electrical Data

Generac 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

Generac 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

0194

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

2

Generac®Power Systems, Inc. 31

Section 6 — Electrical Data

Generac 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.

Y

0

9

3

5

6

9

9

6

2

8

8

5

0

9

9

6

7

0

214

5

9

9

8

1

Section 7 — Exploded Views and Parts Lists

Generac Air-cooled 7 kW, 12 kW and 15 kW Generators
Enclosure – Drawing No. 0F0080-C

PRE PACKAGED UNITS ONL

4

4

7

7

4

4

2

4

2

1

4

2

4

4

7

2

4

4

1

2

2

1

1

Generac®Power Systems, Inc. 33

ITEM PART NO. QTY. DESCRIPTION

1 0C6140 1 ASSEMBLY, ENCLOSURE BASE

0D1901 1 ASSEMBLY, ENCLOSURE BASE (7KW)
2 0C6735 2 SUPPORT, ROOF FOLDING
3 0F0063 1 ENCLOSURE, FRONT
4 0C7062 1 ENCLOSURE, EXHAUST SIDE

0C7062A 1 ENCLOSURE, EXHAUST SIDE (7KW)
5 0E8811 1 ENCLOSURE, SIDE & BACK

0E8811A 1 ENCLOSURE, SIDE & BACK (7KW)
6 0E9873 1 ENCLOSURE, ROOF
7 0C7065 1 PANEL, ALTERNATOR DIVIDER

0C7065A 1 PANEL, ALTERNATOR DIVIDER (7KW)
8 0C8101A 1 PANEL, MUFFLER BOX SIDE

0C8861 1 PANEL, MUFFLER BOX SIDE (7KW)
9 0C8101B 1 COVER, MUFFLER BOX

0C8862 1 COVER, MUFFLER BOX (7KW)

10 0C8283 1 GASKET, DOOR SEAL
11 0C8284A 1 FOAM, BACK ENCLOSURE
12 0C8284B 1 FOAM, ROOF ENCLOSURE
13 0C8284C 1 FOAM, FRONT ENCLOSURE
14 0C8285 1 BRACKET, BATTERY SUPPORT
15 0C8899A 1 PAD, 24"X48" WITH MOUNTING HOLES
16 0D1128 1 PANEL, ENGINE DIVIDER

0D1128A 1 PANEL, ENGINE DIVIDER (7KW)

17 0E4244 1 BAFFLE, INTAKE

0D1605A 1 BAFFLE, INTAKE (7KW)

18 0D1606 1 HOUSING, FAN

0D5264 1 BAFFLE, EXHAUST (7KW)

19 0D1839 2 BRACKET, TOP SUPPORT
20 0D1840 2 BRACKET, BOTTOM SUPPORT
21 0D2425 1 DUCT, BASE AIR
22 0D2588 1 GASKET, FRONT DIVIDER

0D2588A 1 GASKET, FRONT DIVIDER (7KW)

23 0D2676 1 COVER, FRONT EXHAUST ENCLOSURE
24 0D2677 1 COVER, BACK EXHAUST ENCLOSURE
25 0D2979B 2 CLOTH, HARDWARE 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 1 FOAM, FRONT INTAKE BAFFLE (7KW)
29 0E4245A 1 FOAM, TOP INTAKE BAFFLE
30 0E4245B 1 FOAM, BACK INTAKE BAFFLE

0D3058C 1 FOAM, BACK INTAKE BAFFLE (7KW)
31 0D3057D 1 FOAM, BACK ENCL. STRIP
32 0D3059A 1 FOAM, EXHAUST SIDE ENCLOSURE END
33 0D3059B 1 FOAM, EXHAUST SIDE ENCL. FRONT
34 0D3059C 1 FOAM, EXHAUST FAN HOUSING
35 0D7176 24 WASHER, SELF LOCKING

22 WASHER, SELF LOCKING (7KW)
36 0D3059D 1 FOAM, FRONT EXHAUST ENCL. COVER
37 0D3059E 1 FOAM, BACK EXHAUST ENCL. COVER
38 0C7781A 2 DOOR, PAWL
39 0D3037 1 LATCH, QUARTER TURN LOCKING
40 0F0164 1 HINGE TYPE A WITH STUDS, PIN
41 0F0165 1 HINGE TYPE B WITH STUDS, PIN
42 0D3037A 1 LATCH, QUARTER TURN NON-LOCKING
43 0A2115 4 WASHER NYLON .250"
44 022097 1 WASHER LOCK M6-1/4"
46 0F0710 18 RIVET POP 0.125 X 0.337

ITEM PART NO. QTY. DESCRIPTION

47 047411 6 SCREW HHC M6-1.0 X 16 G8.8

047411 4 SCREW HHC M6-1.0 X 16 G8.8 (7KW)

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 0D3700 26 NUT, LOCKING FLANGE M6-1.0

0D3700 24 NUT, LOCKING FLANGE M6-1.0 (7KW)
50 0D4662 11 SCREW HHTT M8-1.2 X 20 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 SCREW TAPTITE M6-1.0X25 BP
58 0A1658 2 L/WASH SPECIAL ¼
59 0C2937 1 BRACKET, BATTERY HOLD DOWN (7KW)
60 086729 1 CONTACTOR, STARTER (7KW)
61 0388040AJ0 1 CABLE, #6 RED BATTERY 38.5"
62 022127 2 NUT HEX 1/4-20 STEEL (7KW)
63 022129 6 WASHER LOCK 5/16

022129 7 WASHER LOCK 5/16 (7KW)
64 074908 8 SCREW TAPTITE 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 0A7836 2 RIVET,1/8" X 0.126" - 0.375" LSH POP
69 0A8475 2 L/WASH 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 0E5968 11 GASKET, EXTRUDED TRIM
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)
79 036937 2 SCREW 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 0F0164A 1 HINGE TYPE A WITH STUDS, SOCKET
87 0F0165A 1 HINGE TYPE B WITH STUDS, SOCKET
89 0E2874 1 SCREW HHTR 1/4-20 X 3/4
90 043107 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
95 0E1330A 1 GROMMET, 38.1 CROSS SLIT WITH HOLE
96 0E9692 1 BRACKET, REGULATOR MOUNTING
97 042907 2 SCREW HHC M8-1.25 X 16mm
98 0F5241 1 PLATE, COVER
99 0F5943 1 GASKET, COVER

Section 7 — Exploded Views and Parts Lists

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

Enclosure – Drawing No. 0F0080-C

34 Generac®Power Systems, Inc.

2

Section 7 — Exploded Views and Parts Lists

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

1

9

7

Generac®Power Systems, Inc. 35

ITEM PART NO. QTY. DESCRIPTION

1 0E7886A 1 CIRCUIT 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)

2 0A1801 1 ASSEMBLY, BATTERY CHARGER ENGINE
3 083049 1 ASSEMBLY, POTTED REGULATOR
4 0C2174 1 RELAY, 12V 25A SPST
5 075210A 1 BLOCK 1 POSITION
6 0D3062 4 HEX STAND-OFF #6-32 x 3/8"
7 0D8615 1 ASSEMBLY, HOME STANDBY

CONTROLLER
0D8615A 1 ASSEMBLY, HOME STANDBY

CONTROLLER (7KW)

8 032300 2 HOLDER, FUSE

9 022676 1 FUSE, 15AMP X AGC15
10 0E4494 1 SWITCH, ROCKER DPDT ON-OFF-ON
11 0E7890 1 CIRCUIT BREAKER MOUNTING BRACKET
12 023484E 1 SNAP BUSHING
13 075476 4 SCREW PPHM M4-0.7 x 16mm
15 0E6480 6 NUT HEX LOCK M4-0.7 NYLON INSERT
17 0C1085 4 SCREW PPHM M3-0.5 X 8mm

0C1085 2 SCREW PPHM M3-0.5 X 8mm (7KW)
18 0D8443 1 DECAL, CONTROL PANEL (NOT SHOWN)
19 054502 1 CIRCUIT BREAKER 3 X 1 ETA 46-500-P

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

(7KW)

20 0E7870 1 CONTROL, PANEL BOTTOM

0E7871 1 CONTROL, PANEL BOTTOM (7KW)
21 075235 4 SCREW HHC M5-0.8 x 30mm
22 0D5240 1 SWITCH, SPST (ON)-ON N/O
23 0D9784 6 NUT HEX LOCK M3-0.5 NYLON INSERT

0D9784 4 NUT HEX LOCK M3-0.5 NYLON INSERT

(7KW)

ITEM PART NO. QTY. DESCRIPTION

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
29 082025 6 NUT HEX LOCK M5-0.8 NYLON INSERT
30 0C3910 1 TRANSFORMER
31 022507 2 SCREW HHC 1/4"-20 x 1/2"
32 099727 1 FUSE 5A X AGC5
33 046689 1 BLOCK TERMINAL STRIP 20A 4 X 6 X

1100V
34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC
35 075475 2 SCREW PPHM M4-0.7 x 10mm
36 043180 2 WASHER FLAT M4
37 0D8439 1 COVER, CONTROL PANEL COMPONENT

0E0119 1 COVER, CONTROL PANEL COMPONENT

(7KW)
38 092036 8 SCREW 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 8 NUT FLANGE M6-1.0 NYLOK
42 0912970069 1 ASSEMBLY, ROOF/DOOR GROUND WIRE
43 0E2874 1 SCREW HHTR 1/4"-20 X 3/4"
44 0A1658 2 WASHER LOCK SPECIAL 1/4"
45 022473 3 WASHER FLAT 1/4"-M6
46 038750 1 SCREW HHC M6-1.0 x 30mm
47 022097 3 WASHER LOCK M6-1/4"
48 049813 1 NUT HEX M6-1.0
49 031879 6 WASHER FLAT #4

031879 4 WASHER FLAT #4 (7KW)
50 023897 2 WASHER FLAT #10
51 0F4793 2 SCREW PPHM M3-0.5 x 10mm

Section 7 — Exploded Views and Parts Lists

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

Control Panel – Drawing No. 0E7974-G

36 Generac®Power Systems, Inc.

3

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

,

0

,

,

,

,

,

,

,

,
A,

B,

,

,

,

,

,

,

,

,

,

,

,

,

140

Section 7 — Exploded Views and Parts Lists

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

93
64
47
40
39
20
19

5

13
12
11

7

4

64

64

63

63

60

62

59

60

58

59

57

58

56

57

54

56
54
53
52
51
50
49
48

47

29
28

7

72
40
36
35
34
33
32

53
52
51

18

50

17

49
48

16

6

47

5

6

2

4

2

1

4

4

2

4

7

A

A

7

2

1

6

Generac®Power Systems, Inc. 37

ITEM PART NO. QTY. DESCRIPTION

1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH

SLEEVE
2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT
3 090388 3 SCREW, TAPTITE M6-1.0 X 12 YC
4 0C5372 1 ASSEMBLY, BREATHER
5 0C3005 1 GASKET, BREATHER COVER
6 0E3372B 3 SEPARATOR, 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 DRIVE
22 0E3223 2 ASSEMBLY, CONNECTING ROD
23 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8
24 0E6098 1 SCREEN, OIL PICKUP
25 0D4123A 1 ASSEMBLY, OIL PUMP
26 078699E 2 SLEEVE, SEAMED DOWEL 10 DIA.
27 0C3011 2 COVER, OIL RELIEF
28 0C3009 2 SPRING, OIL RELIEF
29 0C3010 2 BALL, 1/2D OIL RELIEF
30 093873 2 WASHER, LOCK RIB M6
31 0C5315 1 GEROTOR, OUTER
32 0C5998 1 CLAMP, OIL TUBE
33 0D1667 1 ARM, GOVERNOR
34 0C2991 2 E-RING, GOVERNOR ARM
35 0C2988 1 THRUST WASHER, GOVERNOR
36 0C2992 1 BUSHING, GOVERNOR LOWER

ITEM PART NO. QTY. DESCRIPTION

37 0C3971C 1 ASSEMBLY, DIPSTICK WITH HANDLE
38 0C5305 1 TUBE, DIPSTICK
39 0C3027 1 O-RING, OIL CLR 3/8 X 1/2
40 0E9842 1 SEAL, 42 I.D. CRANKSHAFT
41 0C5731 1 ASSEMBLY, HOUSING COVER WITH

SLEEVE
42 0C3006 9 SCREW, 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 0D2723B 1 ROCKER, COVER WITH OIL FILL
47 0C2979 2 GASKET, 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 072694 4 STUD, ROCKER ARM PIVOT
54 0D3998 4 NUT 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 2 VALVE, INTAKE
61 083897 4 TAPPET, SOLID
62 0D8067B 1 ASSEMBLY, HEAD #2 G&S
63 0D9853D 4 PUSHROD, 147
64 0C2978 2 GASKET, HEAD
65 043790 1 BARBED ELBOW 90 3/8NPT X 3/8
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

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

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

38 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

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

Generac®Power Systems, Inc. 39

ITEM PART NO. QTY. DESCRIPTION

74 0C5136A 2 KNOB, 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 0D2595 4 SCREW SHOULDER (8MM) M6-1.0 X 18
80 0D4417 4 WASHER,RUBBER 1/4" X 1/8" THICK
81 0C3025 1 SWITCH, OIL PRESS
82 0D3083 1 ASSEMBLY, OIL DRAIN HOSE
83 0C7292 1 NIPPLE, 3/4"-16 UNF
84 070185B 1 OIL FILTER
85 075281 1 SWITCH, THERMAL 284F
86 0F2094 2 SCREW, M3-0.5 X 6 SEMS
88 035461 2 BARBED STR 1/4NPT X 3/8
89 0C7649 4 CLAMP HOSE .38-.87
90 0C9806 2 HOSE, 3/8" I.D. X 6" LONG
91 0C3026 1 COOLER, OIL
92 0C9764 4 PLASTITE,1/4-15 X 3/4
93 0C3043 2 GASKET, MANIFOLD / PORT
94 0C7694 1 MANIFOLD CYLINDER 2
95 0C7693 1 MANIFOLD CYLINDER 1
96 0C3041A 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 0C3016A 1 PLATE, BACKING WITH OIL COOLER
101 0E4997 1 GROUND WIRE CONNECTOR
102 0C3725B 1 FLYWHEEL ASSEMBLY
103 0C3031 1 FAN, NYLON
104 0C3032 1 PLATE, FAN
105 0A5992 2 WASHER SHAKEPROOF INT M8 SS
106 051754 2 SCREW HHC M8-1.25 X 12 G8.8
107 0C3033 1 WASHER, 25mm I.D.
108 0C3034 1 NUT,HEX M24
109 0C8549A 1 SNORKEL, AIR INTAKE
110 0C3022A 1 HOUSING, BLOWER NG COOLER

ITEM PART NO. QTY. DESCRIPTION

111 0D1131 1 GUARD, FAN
112 045756 25 SCREW TAPTITE M6-1X10 YELLOW

CHROME
113 0C9763 4 NUT, GROMMET 1/4 PLUG
114 0C3036A 1 HOSE, 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 0F1177 1 ASSEMBLY, GROUND WIRE
123 0F1338B 1 ASSY, IGN COIL W/DIODE NO ADV
124 022097 4 WASHER 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
131 0E5343 1 NUT HEX LOCK M10-1.50
132 0C8468 1 SPRING, ANTI-LASH
133 0C3048 1 ROD, GOVERNOR CONTROL
134 0D3754 1 ASSEMBLY, GOVERNOR LEVER
135 0D3742 1 SPRING, GOVERNOR
136 0C8482 1 ASSEMBLY, GOVERNOR ADJUSTER
137 0E0486 1 SCREW SHC M10-1.5 X 75 G10.9
138 0D3743 1 SPRING, GOVERNOR IDLE
139 0D3705 1 ASSEMBLY, GOVERNOR ADJUSTER

BRACKET
140 0C2993 1 SEAL, GOVERNOR SHAFT
142 045771 1 NUT HEX M8-1.25 G8
143 0D6147 7 SCREW HHFC M6-1.0 X 10mm
144 0E8152 1 O-RING 0.49" I.D. X 0.07" THICK
145 0F1338A 1 ASSY, IGN COIL W/DIODE NO ADV

Section 7 — Exploded Views and Parts Lists

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

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

40 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Generac Air-cooled 7 kW, 12 kW and 15 kW Generators
7 kW Generator – Drawing No. 0D3504-D

4

2

2

1

4

1

2

1

2

1

1

Generac®Power Systems, Inc. 41

Section 7 — Exploded Views and Parts Lists

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

7 kW Generator – Drawing No. 0D3504-D

ITEM PART NO. QTY. DESCRIPTION

1 0C6934 1 ADAPTOR, ENGINE
2 0C9935H 1 STATOR
3 0C9934H 1 ROTOR
4 0C6043A 1 CARRIER, REAR BEARING
5 0C8096 1 FAN, 8" CURVED BLADE
6 0C9593 1 MUFFLER
7 0D3220 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, ALTERNATOR MOUNTING
14 0D1647 1 DUCT, ALTERNATOR AIR
15 0D2558 1 GASKET, ALTERNATOR AIR DUCT
16 0C7038B 1 BRACKET, ENGINE MOUNTING
17 0C7758 4 RUBBER MOUNT
18 0388050AE0 1 CABLE, #6 40" BLACK BATTERY
19 0C2417A 1 EARTH 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 022237 4 WASHER LOCK 3/8
25 022511 4 BOLT HHC 3/8-16 X 1-1/4 G5
26 022131 4 WASHER FLAT 3/8 ZINC
27 039287 4 SCREW HHC M8-1.25 X 45 G8.8
28 022145 12 WASHER FLAT 5/16 ZINC
29 049820 4 NUT LOCK HEX M8-1.25 NYL INSRT
30 090388 3 SCREW TAP M6-1.0X12 BP
31 022129 13 WASHER LOCK M8-5/16
32 022259 8 NUT HEX 5/16-18 STEEL
33 059637 2 SCREW TAPTITE 3/8-16X 3/4" BP
34 048031K 3 BAND, HOSE CLAMP 35.05 DIA.
35 0C9592 1 BELLOWS
36 057822 2 CLAMP HOSE #8 .53 - 1.00
37 040976 2 SCREW 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 1 GASKET, 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 CLEANER NG/LP
45 0D2273 1 TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG
46 055934N 1 CLAMP VINYL 1.31 X .281 Z
47 074994 1.25 FT HOSE 1\2ID PETROLEUM
48 0C5136A 2 KNOB, 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 0C8290 1 GASKET, PANEL
53 066849 2 SCREW HHTT M5-0.8 X 16

42 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Generac Air-cooled 7 kW, 12 kW and 15 kW Generators
12 kW and 15 kW Generator – Drawing No. 0D3417-J

2

1

4

1

2

1

Generac®Power Systems, Inc. 43

Section 7 — Exploded Views and Parts Lists

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

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

ITEM PART NO. QTY. DESCRIPTION

1 0C6934 1 ADAPTOR, ENGINE

2 0C7930 1 STATOR 12KW

0D2359 STATOR 13KW / 15KW

3 0C7944 1 ROTOR 12KW

0D2356 ROTOR 13KW / 15KW
4 0C6043 1 CARRIER, REAR BEARING
5 0D2336 1 FAN, 12" CURVED BLADE
6 0D6634 1 MUFFLER
7 0D3220 1 TAIL PIPE, MUFFLER
8 0C8101 1 PANEL, MUFFLER 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 0C7038 1 BRACKET, ALTERNATOR MOUNTING
14 0D1609 1 DUCT, ALTERNATOR AIR
15 0D2559 1 GASKET, ALTERNATOR AIR DUCT
16 0C7038A 1 BRACKET, ENGINE MOUNTING
17 0C7758 4 RUBBER MOUNT
18 0388050AD0 1 CABLE, #6 48" BLACK BATTERY
19 0C2417A 1 EARTH 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 022237 5 WASHER LOCK 3/8
25 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5
26 022131 4 WASHER FLAT 3/8 ZINC
27 051731 4 SCREW HHC M8-1.25 X 50 G8.8
28 022145 12 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 059637 2 SCREW TAPTITE 3/8-16 X 3/4 BP
34 0D4662 4 SCREW 5/16-18X3/4" HH THD ROLL
35 074994 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 0C4138 2 GASKET, EXHAUST PORT
41 048031C 2 CLAMP HOSE BAND ¼"
42 030340 1.33 FT HOSE 1/4 ID SAE 30R7
43 066849 2 SCREW HHTT M5-0.8 X 16

44 Generac®Power Systems, Inc.

9

Section 7 — Exploded Views and Parts Lists

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

4

2

2

4

1

1

7

7

2

4

Generac®Power Systems, Inc. 45

ITEM PART NO. QTY. DESCRIPTION

1 0E3221 1 ASSEMBLY, CONNECTING ROD
2 0E1466 1 PIN, PISTON D20
3 021533 1 SET, PISTON RING 90MM
4 0E2985 1 PISTON, HC
5 071983 2 RETAINER, PISTON PIN 20
6 0E8440 1 ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER
7 0A7628 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 021713B 1 GASKET, HEAD 410
18 078691 1 COVER, 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 0C4391 2 VALVE 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
30 0D9853B 2 PUSH ROD 174.9
31 083897 2 TAPPET
32 077158 1 ASSEMBLY, SCREEN OIL PICK-UP
33 0C3150 1 GASKET, ROCKER COVER 410
34 072694 2 STUD, D20 PIVOT BALL
35 083907 2 ROCKER ARM
36 072696 2 NUT, JAM (ROCKER ARM)
37 078694 1 PLATE, PUSH ROD GUIDE
38 021742 4 SCREW, HHFL M10-1.5 X 105
39 0D6094 1 ASSEMBLY, 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, STANDARD 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 SPRING
50 078699C 2 DOWEL, SEAMED SLEEVE
51 0A7627 1 SHAFT, GOVERNOR RC55
52 043790A 1 BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE
53 088590 1 DOWEL DIA 12 X 18L
54 078699B 1 DOWEL, SLEEVE SEAMED 12 DIA.

Section 7 — Exploded Views and Parts Lists

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

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

46 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

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

4

4

1

Generac®Power Systems, Inc. 47

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

4 0C9997 1 GUARD, FAN

5 088434 1 WRAPPER, BOTTOM

6 045756 11 SCREW, TAPTITE M6-1X10 YELLOW CHROME

7 0C4176A 1 WRAPPER, TOP

8 0D9004A 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 1 BACKPLATE, L/F D/F
12 083512 1 SCREW, TAPTITE M8-1.25 X 16 BP
13 0D1401A 1 BREATHER TUBE
14 091039 1 GASKET, INTAKE ADAPTER
15 0C9619 1 ASSEMBLY, PLASTIC CARB
16 049811 2 WASHER, FLAT M6
17 022097 4 WASHER, LOCK M6-1/4
18 040945 2 SCREW, SHC M6-1.0 X 20 G12.9
19 086999 1 GASKET,OIL FILTR ADAPTER
20 0D5667A 1 ADAPTER, OIL FILTER
21 049821 2 SCREW, SHC M8-1.25 X 30 G12.9
22 099236 1 SWITCH, 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 067890 1 NUT, HEX - FLYWHEEL
28 0E7585 1 SPARKPLUG
29 072734 1 ASSEMBLY,GOVERNOR LEVER 12 HP
30 072735 1 ROD,GOVERNOR CONTROL.
31 0C3978 1 SPRING, ANTI-LASH
32 0C6040 1 ASSEMBLY, WIRE
33 0D9760 1 ASSEMBLY, IGNITION COIL
34 092079 2 SCREW, TAPTITE M6-1.0 X 25 BP
35 073100 1 SPRING GOVERNOR
36 083502 1 BOLT, GOVERNOR ADJUST M5
37 082025 1 NUT HEX LOCK M5-0.8 NYINS ZINC
38 0D3083 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
43 0F2094 2 SCREW, M3-0.5 X 6 SEMS
44 0C4373 1 SPACER, ENDFRAME
45 022717B 1 GROMMET

Section 7 — Exploded Views and Parts Lists

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

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

48 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Generac Air-cooled 7 kW, 12 kW and 15 kW Generators
Gas Regulator – Drawing No. 0D8720-G

7

4

1

2

2

Generac®Power Systems, Inc. 49

ITEM PART NO. QTY. DESCRIPTION

1 0D5694 1 CASTING, TWIN REGULATOR HOUSING

2 0F5022 1 SOLENOID COIL, 12VDC

3 0C4647 1 GASKET , SOLENOID

4 0D4166 1 PLUNGER, LP REGULATOR ASSEMBLY

5 0C6070 1 SPRING-SOLENOID, PLUNGER

8 0F4795 4 SCREW PPHM SEMS M4-0.7 X 10

9 0C5760J 1 JET, GN 410 ENGINE LP (7KW)
10 0C6606 2* BARBED STRAIGHT 1/2NPT x 1/2
11 097934 2* O-RING, CHECK VALVE
12 0C4645 2* ADJUSTER SCREW, TWIN REGULATOR
13 0C5761 2 LEVER, REGULATOR
14 0C5968 2 SUPPORT, INLET SEAL
15 0C6066 2 SEAL, INLET
16 0C5759 2 PIN, PIVOT ARM
17 0C5764 2 SPRING, REGULATOR

0C5764A 2 SPRING, REGULATOR (7KW)
18 070728 4 SCREW, PFHMS M3-0.5 x 5
19 0C6069 2 GASKET, DIAPHRAGM
20 0C5762 2 COVER, TWIN REGULATOR
21 045764 16 SCREW, TAPTITE M4X8 BP
22 0C6731 2 RIVET, POP .118 X .125
23 0C6067 2 SUPPORT, DIAPHRAGM
24 0C4706 2 DIAPHRAGM, TWIN REGULATOR
25 0C6068 2 CAP, DIAPHRAGM SUPPORT
26 0C4643A 2 INLET, TWIN REGULATOR 11.11 DIA.
27 026073 1 PLUG, STANDARD PIPE 1/8" STEEL SQUARE HEAD

026073 2 PLUG, STANDARD PIPE 1/8" STEEL SQUARE HEAD (7KW)
28 0A4032 2* PIN, LIMITED ADJUSTMENT
29 0D3308 4 WASHER, FLAT M3 X 10mm O.D.
30 024310 1 PLUG, STANDARD PIPE 1/2" STEEL SQUARE HEAD (7KW)
31 028414A 1 BARBED STRAIGHT 1/8"NPT X 1/4"
32 0D5698A 1 JET IDLE PRIMER PHILLIPS HD (V-TWIN ONLY)
37 0D3973 1 PLUG, EXPANSION 16mm

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

Section 7 — Exploded Views and Parts Lists

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

Gas Regulator – Drawing No. 0D8720-G

50 Generac®Power Systems, Inc.

Section 8 — Mounting Dimensions

Generac 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

[

]

U

O
OU

U

[

8
[

]

[

]

]
9

]
]

3
9

[

]

]
[

]

[

]

[

]

[

CC

SS

O

S

)

NIT

36.0"

ND

PEN AREA

M

14mm

LL AR

INIM

.

LE

H

E

46.2"

172.3

UIRED

F 11-14"

RE

EL INLET

PRE

ATER COLUMN RE

4" NPT F

A

ABLE A

REMOVE PLUG FOR ACCESS

L

NDIN

R

INCHES

IN:
N

I

ILLIMETERS

*ALL DIMEN

10.2"

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"

4

23.5"

IF SUPPLIED

2

04

2

16

24.5"

22

IDE VIEW

EFT

Generac®Power Systems, Inc. 51

Section 9 — Notes

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

52 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 there are any questions regarding the warranty rights and responsibilities, contact Generac at the following address:

ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 340
EAGLE, WI 53119

Part 1

Section 10 – Warranty

Generac 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. 53

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

Generac 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. 0F0084 Revision H (03/28/05) Printed in U.S.A.

Section 10 – Warranty

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

GENERAC POWER SYSTEMS STANDARD TWO-YEAR LIMITED WARRANTY

FOR GENERAC RESIDENTIAL AND LIGHT COMMERCIAL UNITS

For a period of two (2) years or two thousand (2,000) hours of operation from the date of sale, which ever occurs first, Generac Power Systems, Inc.
will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or an Authorized/Certified
Generac Power Systems Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule
set forth below. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized/Certified Generac Power
Systems Dealer, or branch thereof. This warranty applies only to Generac Power Systems Generators used in "Standby" applications, as Generac
Power Systems, Inc. has defined Standby. Scheduled maintenance, as outlined by the generators owners manual, is highly recommended. This should
be performed by an Authorized/Certified Generac Power Systems Dealer, or branch thereof. This will verify service has been performed on the unit
throughout the warranty period.

WARRANTY SCHEDULE

YEAR ONE and TWO — one hundred percent (100%) coverage on mileage, labor, and parts listed (proof of purchase and maintenance required).

• Engine ALL COMPONENTS

• Alternator ALL COMPONENTS

• Transfer System ALL COMPONENTS

Guidelines:

Travel allowance for Air and Liquid cooled units is limited to 60 miles maximum, and 2.0 hours maximum or $100.00 maximum (per occurrence,
whichever is less), round trip, to the nearest authorized Generac Service Facility, and only applies to permanently wired and mounted units. Any and all
warranty repairs and/or concerns, must be performed and/or addressed by an Authorized/Certified Generac Power Systems Dealer, or branch thereof.

• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the generator set. If a Non-Generac Power
Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the generator set, no warranty coverage shall apply.

• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and Procedures Flat Rate
Manual.

• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.

• Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.

• Use of Non-Generac replacement part(s) will void the warranty in its entirety.

• Engine coolant heaters (block-heaters), heater controls and circulating pumps after the first year.

THIS

WARRANTY SHALL NOT APPLY

TO THE FOLLOWING:

1. Any unit built/manufactured prior to July 1, 2004.

2. Costs of normal maintenance (i.e. tune-ups, associated part(s), adjustments, loose/leaking clamps, installation and start-up).

3. Any failure caused by contaminated fuels, oils, coolants/antifreeze or lack of proper fuels, oils or coolants/antifreeze.

4. Units sold, rated or used for "Prime Power", "Trailer Mounted" or "Rental Unit" applications as Generac Power Systems have defined Prime Power,

Trailer Mounted or Rental Unit. Contact a Generac Power Systems Distributor for Prime Power, Trailer Mounted or Rental Unit definition and
warranty.

5. Failures caused by any external cause or act of God such as, but not limited to, collision, fire, theft, freezing, vandalism, riot or wars, lightning,

earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.

6. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.

7. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or sizing.

8. 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).

9. Damage related to rodent and/or insect infestation.

10. Failure due to misapplication, misrepresentation, or bi-fuel conversion.

11. Telephone, facsimile, cell phone, satellite, Internet, or any other communication expenses.

12. Rental equipment used while warranty repairs are being performed (i.e. rental generators, cranes, etc.).

13. Overtime, holiday, or emergency labor.

14. Modes of transportation deemed abnormal (refer to Generac Power Systems Warranty, Policies, Procedures and Flat Rate Manual).

15. Steel enclosures that are rusting due to improper installation, location in a harsh or saltwater environment or scratched where integrity of paint
applied is compromised.

16. Any and all expenses incurred investigating performance complaints unless defective Generac materials and/or workmanship were the direct
cause of the problem.

17. Starting batteries, fuses, light bulbs, engine fluids, and overnight freight cost for replacement part(s).

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS
MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.

GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/
owner. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner
specific legal rights. Purchaser/owner also may have other rights that vary from state to state.

Generac Power Systems, Inc. • P.O. Box 8 • Waukesha, WI 53187

Ph: [phone] • Fax: [phone]

Bulletin 0166550SBY / Printed in U.S.A. 6.04