Guardian 04389-1, 04456-1, 04390-1 Installation And Owner's Manual

Installation and

Owner’s Manual

Air-cooled, Prepackaged

Automatic Standby Generators

Models:
04389-1 (6 kW NG, 7 kW LP)
04456-1 (12 kW NG, 12 kW LP)
04390-1 (13 kW NG, 15 kW LP)

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

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

life-support applications.

GENERAC

POWER SYSTEMS, INC.

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Section 7 — Exploded Views and Parts Lists

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

PRE PACKAGED UNITS ONL

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ITEM PART NO.QTY. DESCRIPTION

1 0C6140 1 ASSEMBLY, ENCLOSURE BASE (12KW/15KW)

0D1901 1 ASSEMBLY, ENCLOSURE BASE (7KW)
2 0C6735 2 SUPPORT, ROOF FOLDING
3 0C7061 1 ENCLOSURE, FRONT
4 0C7062 1 ENCLOSURE, EXHAUST SIDE (12KW / 15KW)

0C7062A 1 ENCLOSURE, EXHAUST SIDE (7KW)
5 0C7063 1 ENCLOSURE, SIDE & BACK (12KW / 15KW)

0C7063A 1 ENCLOSURE, SIDE & BACK (7KW)

0C7063B 1 ENCLOSURE, SIDE & BACK (16KW)
6 0C7064 1 ENCLOSURE, ROOF
7 0C7065 1 PANEL, ALTERNATOR DIVIDER (12KW / 15KW)

0C7065A 1 PANEL, ALTERNATOR DIVIDER (7KW)
8 0C8101A 1 PANEL, MUFFLER BOX SIDE (12KW / 15KW)

0C8861 1 PANEL, MUFFLER BOX SIDE (7KW)
9 0C8101B 1 COVER, MUFFLER BOX (12KW / 15KW)

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 (12KW/15KW)
15 0C8899A 1 PAD, 24"X48" WITH MOUNTING HOLES
16 0D1128 1 PANEL, ENGINE DIVIDER (12KW / 15KW)

0D1128A 1 PANEL, ENGINE DIVIDER (7KW)

17 0E4244 1 BAFFLE, INTAKE (12KW / 15KW)

0D1605A 1 BAFFLE, INTAKE (7KW)

18 0D1606 1 HOUSING, FAN (12KW / 15KW)

0D5264 1 BAFFLE, EXHAUST (7KW)

19 0D1839 2 BRACKET, T OP SUPPORT
20 0D1840 2 BRACKET, BOTTOM SUPPORT
21 0D2425 1 DUCT, BASE AIR (12KW / 15KW)
22 0D2588 1 GASKET, FRONT DIVIDER (12KW / 15KW)

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

(12KW / 15KW)

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 (12KW/15KW)

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

29 0E4245A 1 FOAM, TOP INTAKE BAFFLE (12KW / 15KW)
30 0E4245B 1 FOAM, BACK INTAKE BAFFLE (12KW / 15KW)

0D3058C 1 FOAM, BACK INTAKE BAFFLE (7KW)

31 0D3057D 1 FOAM, BACK ENCL. STRIP (12KW / 15KW)
32 0D3059A 1 FOAM, EXHAUST SIDE ENCLOSURE END
33 0D3059B 1 FOAM, EXHAUST SIDE ENCLOSURE FRONT
34 0D3059C 1 FOAM, EXHAUST FAN HOUSING (12KW/15KW)
35 0D7176 24 WASHER, SELF LOCKING (12KW / 15KW)

22 WASHER, SELF LOCKING (7KW)
36 0D3059D 1 FOAM, FRONT EXHAUST ENCLSURE COVER
37 0D3059E 1 FOAM, BACK EXHAUST ENCLOSURE COVER
38 0C7781 2 DOOR, PAWL
39 0D3037 1 LATCH, QUARTER TURN LOCKING
40 0D2537 1 HINGE, LIFT OFF, TYPE A PIN
41 0D2538 1 HINGE, LIFT OFF, TYPE B PIN
42 0D3037A 1 LATCH, QUARTER TURN NON-LOCKING
43 0A2115 4 WASHER NYLON .250"

ITEM PART NO.QTY. DESCRIPTION

44 022097 9 WASHER LOCK M6-1/4"
45 022473 4 WASHER FLAT ¼" ZINC
46 036261 14 RIVET POP .125 X .129-.133/#30
47 047411 12 SCREW HHC M6-1.0 X 16 G8.8
48 043116 5 SCREW HHC M6-1.0 X 12 G8.8 (12KW / 15KW)

043116 6 SCREW HHC M6-1.0 X 12 G8.8 (7KW)
49 0D3700 18 NUT, LOCKING FLANGE M6-1.0
50 083512 11 SCREW TAPTITE M8-1.25 X 16 BP
51 090388 36 SCREW TAPTITE M6-1.0 X 12 BP (12KW/15KW)

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 HEYCO 1675
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 4 WASHER LOCK 5/16 (12KW / /15KW)

022129 5 WASHER LOCK 5/16 (7KW)
64 074908 8 SCREW TAPTITE M5-0.8 X 10 BP
65 0D2346 1 HARNESS, ENGINE (12KW / 15KW)

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 (12KW / 15KW)
73 0D2023 10.5 GASKET, CLIP-ON SELF GRIPPING
74 0D3701 1 PLATE, "HOT"
75 0D3472 1 GROMMET 2.75 X 1/16
76 0C8742 1 EXTERNAL CONNECTION BOX
77 0C8911 1 POWER BLOCK
78 0D8442 1 HARNESS GENERATOR TO EXTERNAL CON-

NECTION BOX (12KW / 15KW)

0D8652 1 HARNESS GENERATOR TO EXTERNAL CON-

NECTION BOX (7KW)

0D3928 1 HARNESS GENERATOR TO EXTERNAL CON-

NECTION BOX (16KW)
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 0D2537A 1 HINGE, LIFT OFF, TYPE A KNUCKLE
87 0D2538A 1 HINGE, LIFT OFF, TYPE B KNUCKLE
88 047411 2 SCREW HHC M6-1.0 X 16 G8.8
89 0A2311 1 SCREW SWAGE 1/4-20 X 1
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

Section 7 — Exploded Views and Parts Lists

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

Enclosure – Drawing No. 0D3416-Q

34 Generac®Power Systems, Inc.

Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Control Panel – Drawing No. 0D8503-F

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ITEM PART NO. QTY. DESCRIPTION

1 0A9947E 1 CIRCUIT BREAKER 30 X 2 240V SQD

QOU230 (7KW)

0A9947G 1 CIRCUIT BREAKER 40 X 2 240V SQD

QOU240 (8.5KW)

0A9947F 1 CIRCUIT BREAKER 50 X 2 240V SQD

QOU250 (12KW)

0A9947C 1 CIRCUIT BREAKER 60 X 2 240V SQD

QOU260 (13KW)

0A9947D 1 CIRCUIT BREAKER 70 X 2 240V SQD

QOU260 (15KW)
2 0A1801 1 ASSEMBLY, BATTERY CHARGER ENGINE
3 083049 1 ASSEMBLY, POTTED REGULATOR
4 0C2174 1 RELAY, 12V 25A SPST (8.5KW/ 12KW/

13KW)
5 075210A 1 BLOCK 1 POSITION
6 0D3062 4 HEX STAND-OFF #6-32 x 3/8"
7 0D8615 1 ASSEMBLY, HOME STANDBY

CONTROLLER
8 032300 2 HOLDER, FUSE
9 022676 1 FUSE, 15AMP X AGC15

10 0E4494 1 SWITCH, ROCKER
11 0D5045 1 DIN RAIL
12 023484E 1 SNAP BUSHING SB-687-8
13 075476 4 SCREW PPHM M4-0.7 x 16mm
14 022264 8 WASHER LOCK M4
15 051715 8 NUT HEX M4-0.7
16 043182 4 WASHER LOCK M3 (8.5KW/ 12KW/ 13KW)

043182 2 WASHER LOCK M3 (7KW)
17 043181 4 SCREW PHM M3-0.5 x 10mm
18 0D8443 1 DECAL, CONTROL PANEL (NOT SHOWN)
19 054502 1 CIRCUIT BREAKER 3 X 1 ETA 46-500-P

(8.5KW/ 12KW/ 13KW)

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

(7KW)

20 0D8438 1 CONTROL, PANEL BOTTOM (8.5KW/

12KW/ 13KW)

0E0118 1 CONTROL, PANEL BOTTOM (7KW)
21 075235 4 SCREW HHC M5-0.8 x 30mm

ITEM PART NO. QTY. DESCRIPTION

22 0D5240 1 SWITCH, SPDT ON-MOM-ON
23 051714 4 NUT HEX M3-0.5 (8.5KW/ 12KW/ 13KW)

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

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

0E0120 1 HARNESS, CONTROL PANEL WIRE (NOT

SHOWN) (7KW)
27 074908 4 SCREW TAPTITE, M5-0.8 x 10 BP
28 049226 6 WASHER LOCK M5
29 051716 6 NUT HEX M5-0.8
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 TERMINAL STRIP
34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC
35 075475 4 SCREW PPHM M4-0.7 x 10mm
36 043180 2 WASHER FLAT M4
37 0D8439 1 COVER, CONTROL PANEL COMPONENT

(8.5KW/ 12KW/ 13KW)

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 0C7171 1 COVER, CONTROL PANEL (8.5KW/ 12KW/

13KW)

0D2989 1 COVER, CONTROL PANEL (7KW)
41 0D3700 10 NUT FLANGE M6-1.0 NYLOCK
42 0912970069 1 ASSEMBLY, ROOF/DOOR GROUND WIRE
43 0A2311 1 SCREW SWAGE 1/4"-20 x 1"
44 0A1658 2 LOCKWASHER SPECIAL 1/4"
45 022473 3 WASHER FLAT 1/4"
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 4 WASHER FLAT #4 (8.5KW/ 12KW/ 13KW)

031879 2 WASHER FLAT #4 (7KW)
50 023897 2 WASHER FLAT #10

Section 7 — Exploded Views and Parts Lists

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

Control Panel – Drawing No. 0D8503-F

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Section 7 — Exploded Views and Parts Lists

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
7 kW GTS Load Center Assembly – Drawing No. 0D3997-E

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ITEM PART NO. QTY. DESCRIPTION

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

3 0C2237 1 TRANSFER SWITCH HOME STANDBY 100A2P250V
3A 077220 1 COIL UTILITY
3B 077220A 1 COIL STANDBY
3C 082574 1 INSULATOR-SIDEWALL (NOT SHOWN)
3D 084464 1 LIMIT SWITCH OPERATION (NOT SHOWN)

4 074908 6 SCREW TAPTITE M5-0.8 X 10 BP

5 024912 1 SCREW TAPTITE 1/4-20 X 5/8 BP

6 0A1658 1 LOCK WASHER, SPECIAL-1/4"

7 063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC

8 0D3030A 1 BASE, MOUNTING 6 POLE 125A/240V

9 0A1495 4 SCREW TAPTITE M4-0.7X10 BP

10 0A1661 2 RIVET POP .156 X .160-.164/#20
11 022473 1 WASHER FLAT 1/4 ZINC
12 0D3094 1 HARNESS,GTS TO MAIN PANEL
13 0D4684A 1 HARNESS ADAPTER PLATE
14 0D3319 1 PANEL-SUB BREAKER BASE
15 056326 1 FT TRIM VINYL BLACK 1/8GP
16 022152 6 WASHER LOCK #10
17 087680 1 NUT WING M6-1.0
18 077441 1 HANDLE, TRANSFER SWITCH HOME STANDBY
19 063378 4 HOLDER CABLE TIE
21 074138 2 LUG DIS QK NI-S 10X45 DEG BR/T
22 036933 6 SCREW PPHM #10-32 X 3/8"
23 077033 6 LUG SLDLSS 1/0-#14X9/16 AL/CU
24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V
25 028739 4 TIE WRAP 3.9" X .10" NAT'L UL
26 038150 2 WASHER FLAT #8 ZINC
27 0D3191 1 COVER, RELAY & TERM BLOCK
28 0D3088 1 WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)
29 073591 2 FUSE HOLDER
30 073590A 2 ASSEMBLY FUSE 5A X BUSS HLDR73591
31 040213B 4 PCB SUPPORT SNAP-IN 1-3/8"
32 0C8037 1 CIRCT BRK 20 X 1 HOM120
33 075475 2 SCREW PPHM M4-0.7 X 10
34 0C8036 5 CIRCT BRK 15 X 1 HOM115
35 0C8035 1 CIRCT BRK 30 X 2 HOM230
36 0D3320 1 COVER - HARNESS ENTRY
37 0D4802 1 HARNESS, GTS TO EXT CONN BOX
38 022264 2 WASHER LOCK M4
39 0A7215 4 SCREW SW 1/4-20X5/8 N WA JS500
40 0A2110 4 SCREW SWAGE 1/4-20 X 1/2 ZINC

Section 7 — Exploded Views and Parts Lists

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

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