Installation and
Owner’s Manual
Air-cooled Automatic
Standby Generators
Models:
04758-0 (6 kW NG, 7 kW LP)
04759-0 (12 kW NG, 12 kW LP)
04760-0 (13 kW NG, 15 kW LP)
Not intended for use as Primary Power in place of utility
!
!
or in life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
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Table of Contents
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
3.2.2 “Off” Position....................................14
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
Introduction ........................Inside Front Cover
Read This Manual Thoroughly ........................IFC
Contents ..........................................................IFC
Operation and Maintenance ............................IFC
How to Obtain Service ....................................IFC
Authorized Dealer Locator Number ....................IFC
3.5.1 Transfer to Generator
Safety Rules ........................................................2
Standards Index..................................................3
Power Source......................................15
3.5.2 Transfer Back to Utility
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
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 ........................................16
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
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 5 – Troubleshooting ........................23
5.1 Troubleshooting Guide................................23
Section 6 – Electrical Data............................24
Section 7 – Exploded Views and
Parts Lists....................................32
Section 3 – Operation ....................................13
3.1 Break-in Procedure......................................13
3.2 Using the Auto/Off/Manual Switch ..............14
3.2.1 “Auto” Position..................................14
Section 8 – Mounting Dimensions..............50
Section 9 – Notes ............................................51
Section 10 – Warranty....................................52
1
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IMPORTANT SAFETY INSTRUCTIONS
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted near the unit’s installation site. Safety should be stressed to
all operators and potential operators of this equipment.
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!
!
!
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GENERAL HAZARDS
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
• For safety reasons, Generac recommends
that the installation, initial start-up and
maintenance of this equipment is carried out by 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 sys-
tem must be installed properly, in strict compli-
ance with applicable codes and standards.
Following installation, you must do nothing that
might render the system unsafe or in noncompli-
ance with such codes and standards.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit is
operating.
• Adequate, unobstructed flow of cooling and venti-
lating air is critical to correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seri-
ously affect safe operation of the generator. The
generator MUST be installed outdoors.
• When working on this equipment, remain alert at
all times. Never work on the equipment when you
are physically or mentally fatigued.
!
!
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before
installing, operating or servicing this equipment.
Become familiar with this Owner’s Manual and with
the unit. The generator can operate safely, efficiently
and reliably only if it is properly installed, operated
and maintained. Many accidents are caused by failing
to
follow
simple
and
fundamental
rules
or precautions.
Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals
affixed to the unit are, therefore, not all-inclusive. If
you use a procedure, work method or operating tech-
nique Generac does not specifically recommend, you
must satisfy yourself that it is safe for you and others.
You also must make sure the procedure, work
method or operating technique that you choose does
not render the generator unsafe.
• Inspect the generator regularly, and contact your
nearest Generac Authorized Dealer for parts need-
ing repair or replacement.
• Before performing any maintenance on the genera-
tor, disconnect its battery cables to prevent acci-
dental start up. Disconnect the cable from the bat-
tery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating con-
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
DANGER
Despite the safe design of this generator,
!
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
!
generators.
2
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IMPORTANT SAFETY INSTRUCTIONS
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
• Keep a fire extinguisher near the generator at all
times. Extinguishers rated “ABC” by the National
Fire Protection Association are appropriate for use
on the standby electric system. Keep the extin-
guisher properly charged and be familiar with its
use. If you have any question pertaining to fire
extinguishers, consult your local fire department.
ELECTRICAL HAZARDS
• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as does the standby generator when it is in opera-
tion. Avoid contact with bare wires, terminals, con-
nections, etc., while the unit is running. Ensure all
appropriate covers, guards and barriers are in
place before operating the generator. If you must
work around an operating unit, stand on an insu-
lated, dry surface to reduce shock hazard.
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no com-
bustible materials are left in the generator com-
partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing the generator clean and free from debris.
• Gaseous fluids such as natural gas and liquid
propane (LP) gas are extremely EXPLOSIVE.
Install the fuel supply system according to applica-
ble fuel-gas codes. Before placing the home stand-
by electric system into service, fuel system lines
must be properly purged and leak tested according
to applicable code. After installation, you must
inspect the fuel system periodically for leaks. No
leakage is permitted.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands
or feet are wet. DANGEROUS ELECTRICAL
SHOCK MAY RESULT.
• The National Electrical Code (NEC) requires the
frame and external electrically conductive parts of
the generator to be connected to an approved earth
ground. Local electrical codes also may require
proper grounding of the generator electrical system.
• After installing this home standby electrical sys-
tem, the generator may crank and start at any time
without warning. When this occurs, load circuits
are transferred to the STANDBY (generator) power
source. To prevent possible injury if such a start
and transfer occur, always set the generator’s
Auto/Off/Manual switch to its OFF position before
working on equipment and remove the 5A and 15A
fuses from the generator control panel.
STANDARDS INDEX
‹
In the absence of pertinent standards, codes, regula-
tions and laws, the published information listed
below may be used as installation guide for this
equipment.
• In case of accident caused by electric shock, imme-
diately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply
first aid and get immediate medical help.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.
1. NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES, available from
the National Fire Protection Association, 470
Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-
TEMS FOR HEALTH CARE FACILITIES, avail-
able same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE,
available same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD
FOR STORAGE AND HANDLING OF LIQUEFIED
PETROLEUM GAS, available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85
John Street, New York, N.Y. 10038.
7. AGRICULTURAL WIRING HANDBOOK, available
from the Food and Energy Council, 909
University Avenue, Columbia, MO 65201.
8. ASAE EP-3634, INSTALLATION AND MAINTE-
NANCE OF FARM STANDBY ELECTRICAL SYS-
TEMS, available from the American Society of
Agricultural Engineers, 2950 Niles Road, St.
Joseph, MI 49085.
FIRE HAZARDS
• For fire safety, the generator must be installed and
maintained properly. Installation always must
comply with applicable codes, standards, laws and
regulations. Adhere strictly to local, state and
national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installa-
tion, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regu-
lations.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.
3
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Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
1.2 PROTECTION SYSTEMS
DANGER
Unlike an automobile engine, the generator may have
to run for long periods of time with no operator pres-
ent to monitor engine conditions. For that reason, the
engine is equipped with the following systems that
protect it against potentially damaging conditions:
Only qualified electricians or contractors should
attempt such installations, which must comply
strictly with applicable codes, standards and
regulations.
!
1. Low Oil Pressure Sensor
2. High Temperature Sensor
There are LED readouts on the control panel to noti-
fy you that one of these faults has occurred. There is
also a “System Set” LED that is described below.
3. Overcrank
4. Overspeed
1.1 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents
for damage.
• This standby generator set has been factory sup-
plied with a weather protective enclosure that is
intended for outdoor installation only.
1.3 SYSTEM SET LED
The “System Set” LED is lit when all of the following
conditions are true:
If this generator is used to power electrical load
circuits normally powered by a utility power
source, you are required by code to install a
transfer switch. The transfer switch must effec-
tively isolate the electrical system from the util-
ity 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 work-
ers due to backfeed of electrical energy.
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 posi-
tion , the generator will start.
3. The “Not In Auto” dip switch is set to the OFF
position on the control board.
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.
4. No alarms are present, for example, low oil pres-
sure, high temperature, etc.
If you note loss or damage after delivery, separate the
damaged materials and contact the carrier for claim
procedures.
“Concealed damage” is understood to mean damage
to the contents of a package that is not in evidence at
the time of delivery, but is discovered later.
4
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Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
1.4 YOUR GENERATOR
Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine
Control Panel
Data Decal
Exhaust
Enclosure
Air Filter
Fuel Regulator
Battery Compartment
Oil Filter
Figure 1.2 – 12 kW/15 kW, V-twin GT-990 Engine
Data
Decal
Control
Panel
Oil Dipstick
Air Filter
Exhaust
Enclosure
Fuel Regulator
Battery Compartment
Oil Filter
5
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Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
1.5 SPECIFICATIONS
1.5.1 GENERATOR
‹
Model 04758
6,000 NG/7,000 LP
120/240
Model 04759
12,000 NG/12,000 LP 13,000 NG/15,000 LP†
Model 04760
Rated Max. Continuous Power Capacity (Watts*)
Rated Voltage
120/240
120/240
Rated Max. Continuous Load Current (Amps)
120 Volts +
50.0 NG/58.3 LP
100.0 NG/100.0 LP
108.3 NG/125.0 LP
240 Volts
25.0 NG/29.2 LP
50.0 NG/50.0 LP
54.2 NG/62.5 LP
Main Line Circuit Breaker
Phase
Number of Rotor Poles
Rated AC Frequency
Power Factor
30 Amp
50 Amp
70 Amp
1
2
1
2
1
2
60 Hz
1
60 Hz
1
60 Hz
1
Recommended Air Filter
Battery Requirement
Generac Part # C8127 Generac Part # C8127 Generac Part # C8127
Group 26/26R
12 Volts and
Group 26/26R
12 Volts and
Group 26/26R
12 Volts and
350 Cold-cranking
Amperes Minimum
550 Cold-cranking
Amperes Minimum
550 Cold-cranking
Amperes Minimum
Weight
452 Pounds
68 db (A)
470 Pounds
70.5db (A)
-20°F (-28.8°C) to 104°F (40°C)
487 Pounds
71.5 db (A)
Output Sound Level @ 23 ft (7m) at full load
Normal Operating Range
* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power
decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F).
+ Total current in TWO separate curcuits. Current in each curcuit must not exceed the value stated for 240V.
1.5.2 ENGINE
‹
Model 04758
GH-410
Model 04759
GT-990
Model 04760
GT-990
Type of Engine
Number of Cylinders
Rated Horsepower
Displacement
1
2
2
14.5 @ 3,600 rpm
410cc
30 @ 3,600 rpm
992cc
30 @ 3,600 rpm
992cc
Cylinder Block
Aluminum w/Cast
Iron Sleeve
Aluminum w/Cast
Iron Sleeve
Aluminum w/Cast
Iron Sleeve
Valve Arrangement
Ignition System
Recommended Spark Plug
Spark Plug Gap
Overhead Valves
Solid-state w/Magneto
RC12YC
Overhead Valves
Solid-state w/Magneto
RC12YC
Overhead Valves
Solid-state w/Magneto
RC12YC
0.76 mm (0.030 inch) 0.508 mm (0.020 inch) 0.508 mm (0.020 inch)
Compression Ratio
Starter
8.6:1
12 Vdc
9.5:1
12 Vdc
9.5:1
12Vdc
Oil Capacity Including Filter
Recommended Oil Filter
Recommended Air Filter
Operating RPM
Approx. 1.5 Qts
Approx. 2.5 Qts
Approx. 2.5 Qts
Generac Part # 70185 Generac Part # 70185 Generac Part # 70185
Generac Part # 0C8127 Generac Part # 0C8127 Generac Part # 0C8127
3,600
3,600
3,600
6
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Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
3. Disconnect wire #0 and wire #14 from the gas
1.6 FUEL REQUIREMENTS
solenoid located on the top of the demand regu-
lator.
AND RECOMMENDATIONS
With LP gas, use only the vapor withdrawal
system. This type of system uses the vapors formed
above the liquid fuel in the storage tank.
4. Remove the demand regulator by rotating coun-
terclockwise.
5. Remove the brass hose fitting from the outlet port
of the demand regulator.
The engine has been fitted with a fuel carburetion
system that meets the specifications of the 1997
California Air Resources Board for tamper-proof dual
fuel systems. The unit will run on natural gas or LP
gas, but it has been factory set to run on natural gas.
Should the primary fuel need to be changed to LP
gas, the fuel system needs to be reconfigured. See
Section 1.8 for instructions on reconfiguration of the
fuel system.
Recommended fuels should have a Btu content of at
least 1,000 BTU’s per cubic foot for natural gas; or at
least 2,520 BTU’s per cubic foot for LP gas. Ask your
fuel supplier for the BTU content of your fuel.
6. Remove the brass metering jet (loosen counter-
clockwise) from the housing port of the demand
regulator located on the side of the regulator.
7. Install new LP metering jet (tighten clockwise) in
the outlet port of the demand regulator.
8. Refit the brass hose fittings to the outlet port of
the demand regulator.
9. Reverse procedure steps 1-4 to reinstall demand
regulator.
10. Reverse the procedure to convert back to natural
gas.
Figure 1.3 – Demand Regulator
Fuel pressure for both natural gas and liquid
propane set ups should be 11 inches to 14 inches
of water column (0.6 psi) at all load ranges.
FUEL HOSE
FUEL HOSE
BRASS HOSE
FITTING
BRASS HOSE
FITTING
NOTE:
FUEL JET
HOUSING
PORTS
HOUSING
PORTS
A separate gas line and regulator may be needed
to assure proper gas pressure (11-14”) to the gen-
erator. Low gas pressure can cause hard starting
and could affect engine durability.
1.7 FUEL CONSUMPTION
Model #
Nat. Gas (*)
LP Vapor (**)
1/2 Load Full Load 1/2 Load
Full Load
1.21/44.1
2.17/79.0
2.80/102.3
NG FUEL SYSTEM
04758
04759
04760
74
105
185
240
0.91/33
1.34/48.9
1.73/63.2
LP FUEL SYSTEM
114
NOTE:
148.5
*Natural gas is in cubic feet per hour.
**LP is in gallons per hour/cubic feet per hour.
The natural gas adjustment screw is preset during
installation and should not need any further
adjustment.
DANGER
Gaseous fuels such as natural gas and liquid
propane (LP) gas are highly explosive. Even the
slightest spark can ignite such fuels and cause
an explosion. No leakage of fuel is permitted.
Natural gas, which is lighter than air, tends to
collect in high areas. LP gas is heavier than air
and tends to settle in low areas.
1.8.2 12KW AND 15KW, 990CC ENGINES
◆
To reconfigure the fuel system from NG to LP,
follow these steps:
NOTE:
The primary regulator for the propane supply is
NOT INCLUDED with the generator. You must sup-
ply a fuel pressure of 11 to 14 inches of water col-
umn (0.6 psi) to the fuel inlet of the generator.
1.8 RECONFIGURING THE
FUEL SYSTEM
1. Turn off the main gas supply.
2. Remove the three carburetor fuel hoses from the
outlet ports of the demand regulator.
3. Disconnect wire #0 and wire #14 from the gas
solenoid located on the top of the demand regu-
lator.
1.8.1 7 KW, 410CC
To reconfigure the fuel system from NG to LP,
follow these steps:
◆
1. Turn the main gas supply off.
2. Remove the carburetor fuel hose from the outlet
4. Remove the demand regulator from the enclosure
port of the demand regulator (Figure 1.3).
by rotating counterclockwise.
7
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Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
5. Remove the small brass hose fitting from the idle
1.9 LOCATION
◆
Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available. Consider these factors:
circuit port of the regulator housing.
6. Remove the small jet (0D5698A) located in the
side of the regulator housing and install it into the
small threaded hole in the idle circuit port on the
regulator.
1.9.1 GENERATOR
7. Refit the brass hose fitting to the idle circuit port
of the regulator. Use pipe thread sealant to reseal
the threads on the hose fitting.
8. Identify both adjustment screws.
NOTE:
• Install the unit where air inlet and outlet openings
will not become obstructed by leaves, grass, snow,
etc. If prevailing winds will cause blowing or drift-
ing, you may need to consider using a windbreak
to protect the unit.
One adjustment screw can be accessed from the
front of the unit and the second can be accessed
from the back of 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 3 feet of space on all sides.
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings to
the prevailing winds.
9. To adjust the system to run on LP fuel, turn the
adjuster screw that is accessed from inside the
front of the unit 1/4 turn clockwise. This will set
the system for max power and best performance
on LP fuel.
10. The fuel system will now allow the engine to run
on LP fuel. It may be necessary to make minor
adjustments to the preset screw settings to
achieve maximum power. If there are problems
with the unit producing maximum power, follow
the procedure in Section 2.6 “Adjusting the
Regulator”.
• Install the generator as close as possible to the fuel
supply, to reduce the length of piping.
• Install the generator as close as possible to the
transfer switch. HOWEVER, REMEMBER THAT
LAWS OR CODES MAY REGULATE THE DIS-
TANCE.
1.9.2 TRANSFER SWITCH
◆
11. Reverse procedure steps 1-4 to reinstall the
demand regulator.
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.
Figure 1.4 - Demand Regulator
FUEL HOSE
• 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 sur-
face.
BRASS HOSE
FITTING
BRASS HOSE
IDLE CIRCUIT
FITTING
SMALL
FUEL JET
PORT
RE
R
1
NP
REGULATOR
HOUSING PORT
ADJUSTER
SCREWS
• Never install the switch where water or any corro-
sive substance might drip onto the enclosure.
• Protect the switch at all times against excessive
moisture, dust, dirt, lint, construction grit and cor-
rosive vapors.
TURN CLOCKWISE
1/4 TURN TO SET
FOR LP FUEL.
• Failure to utilize a Generac/Guardian transfer
switch with this generator will void the warranty.
Transfer switches available for these generators are:
• Model 004678-0 — 100 Amp, 2 Pole, 250 Volt
NEMA 1 (indoor rated) or
• Model 004635-0 — 200 Amp, 2 Pole, 250 Volt
NEMA 3R (outdoor rated)
8
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Section 1 — General Information
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
NOTE:
1.10 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if nec-
essary and have the battery fully charged before
installing it.
Your generator is equipped with a battery trickle
charger that is active when your unit is set up for
automatic operation. With the battery installed
and utility power source voltage available to the
transfer switch, the battery receives a trickle
charge while the engine is not running, to prevent
self-discharge. The trickle charger is designed to
help extend the life of your battery by maintaining
the battery when the unit is not running. The
trickle charge feature cannot be used to recharge
a discharged battery.
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 and 15 amp fuses from the
generator control panel.
1.11 THE BATTERY
Servicing of the battery is to be performed or super-
vised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized person-
nel away from batteries.
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.
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; 550
cold-cranking amps minimum for 12 and 15 kW at
-18º C (0º F) minimum. When using a maintenance-
free battery, it is not necessary to check the specific
gravity or electrolyte level. Have these procedures
performed at the intervals specified in the “Service
Schedule.” A negative ground system is used. Battery
connections are shown on the wiring diagrams. Make
sure the battery is correctly connected and terminals
are tight. Observe battery polarity when connecting
the battery to the generator set.
Battery cables were factory connected at the genera-
tor (Figure 1.5). Connect cables to battery posts as
follows:
4. Connect the red battery cable (from starter con-
tactor) to the battery post indicated by a positive,
POS or (+).
5. Connect the black battery cable (from frame
ground) to the battery post indicated by a nega-
tive, NEG or (—).
6. Replace the 5 amp and 15 amp fuses in the gen-
erator control panel.
DANGER
Do not dispose of the battery in a fire. The
battery is capable of exploding.
NOTE:
Damage will result if battery connections are made
in reverse.
A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when working
on batteries:
Figure 1.5 – Battery Cable Connections
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
• Disconnect charging source prior to connecting or dis-
connecting battery terminals.
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
!
the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
!
conductive and corrosive.
9
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Section 2 — Post Installation Start-up and Adjustments
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
The following procedures are to be observed:
2.2 CHECK TRANSFER SWITCH
• 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
OPERATION
Refer to Section 3.5 (Page 15), of the owner’s manual
for manual operation procedures.
DANGER
• 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 bicar-
bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
2.3 ELECTRICAL CHECKS
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
Complete electrical checks as follows:
1. Turn on the utility power supply to the transfer
switch using the means provided (such as a utili-
ty main line circuit breaker).
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area; and
• Discharge static electricity from your body before
touching the battery by first touching a grounded
metal surface.
DANGER
The transfer switch is now electrically “hot.”
Contact with “hot” parts will result in extreme-
ly hazardous and possibly fatal electrical shock.
Proceed with caution.
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.
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-to-
neutral voltage should be 120 volts AC.
4. When certain that utility supply voltage is com-
patible with transfer switch and load circuit rat-
ings, turn OFF the utility power supply to the
transfer switch.
5. Set the generator's main circuit breaker to its
OFF (or open) position. Initial tests will be con-
ducted at no-load condition.
6. On the generator panel, set the Auto/Off/Manual
switch to MANUAL. The engine should crank and
start.
Be sure the utility power supply is turned off,
or sparking may occur at the battery posts as
you attach the cables 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.
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.
DANGER
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.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
!
this could damage the engine.
10
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Section 2 — Post Installation Start-up and Adjustments
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
8. Connect an accurate AC voltmeter and a frequen-
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 frequen-
cy 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.
cy meter across transfer switch terminal lugs E1
and E2. Voltage should be 242-252 volts; fre-
quency should read about 61-63 Hertz.
9. Connect the AC voltmeter test leads across termi-
nal lug E1 and neutral; then across E2 and neu-
tral. In both cases, voltage reading should be 121-
126 volts AC.
10. Set the generator’s main circuit breaker to its
OFF (or open) position. Let the engine run at no-
load for a few minutes to stabilize internal engine
generator temperatures.
11. Set the generator's Auto/Off/Manual switch to
OFF. The engine should shut down.
12. Set the generator's main circuit breakers to their
NOTE:
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.
It is important that you do not proceed until you
are certain that generator AC voltage and frequen-
cy are correct and within the stated limits.
Generally, if both AC frequency and voltage are
high or low, the engine governor requires adjust-
ment. If frequency is correct, but voltage is high or
low, the generator’s voltage regulator requires
adjustment.
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.
2.4 GENERATOR TESTS UNDER LOAD
To test the generator set with electrical loads applied,
proceed as follows:
2. Check that the Auto/Off/Manual switch is set to
OFF.
1. Set generator’s main circuit breaker to its OFF
(or open) position.
3. Turn OFF the utility power supply to the transfer
switch using the means provided (such as a utili-
ty main line circuit breaker).
4. Manually set the transfer switch to the UTILITY
position, i.e., load terminals connected to the util-
ity power source side.
5. Turn ON the utility power supply to the transfer
switch, using the means provided (such as a util-
ity main line circuit breaker).
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 util-
ity main line circuit breaker).
6. 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.
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
7. Turn OFF the utility power supply to the transfer
switch.
With the Auto/Off/Manual switch at AUTO, the engine
should crank and start when the utility source power
is turned OFF. After starting, the transfer switch
should connect load circuits to the standby side. Let
the system go through its entire automatic sequence
of operation.
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.
With the generator running and loads powered by gen-
erator AC output, turn ON the utility power supply to
the transfer switch. The following should occur:
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.
• After about six seconds, the switch should transfer
loads back to the utility power source.
• About one minute after retransfer, the engine
should shut down.
11
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Section 3 — Operation
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Figure 2.2 — Placement of Regulator
2.6 ADJUSTING THE REGULATOR
(NATURAL GAS ONLY)
Although the generator has been factory set to pro-
vide maximum power, it may be necessary in some
areas to adjust this setting. Because natural gas has
different BTU or power content across the country
the engine may not perform as designed.
If you experience engine problems at high or full load
conditions follow these steps. It will require a fre-
quency meter to perform this procedure.
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:
Adjustment Screw
7. Turn utility power to the main distribution panel
back on. This can be done by switching the serv-
ice main breaker to the on or closed position.
Allow the generator to shut down.
Unit
7 kW
12 kW
15 kW
120 Volts
50.0 amps
100.0 amps
108.3 amps
240 Volts
25.0 amps
50.0 amps
54.2 amps
Do not make any unnecessary adjustments.
Factory settings are correct for most applica-
tions. However, when making adjustments, be
careful to avoid overspeeding the engine.
!
If this procedure or equipment are not available to
you, locate the Generac Guardian Dealer nearest you
and they can perform the adjustments.
4. When full load has been achieved. Connect a fre-
quency meter to the output lugs of the generator’s
main line circuit breaker.
NOTE:
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).
A service fee may be charged for this adjustment.
2.7 ENGINE GOVERNOR ADJUSTMENT
If both AC frequency and voltage are correspondingly
high or low, adjust the engine governor as follows:
2.7.1 7 KW UNITS
◆
Figure 2.1 — Dual Fuel Regulators
1. Loosen the governor clamp bolt (Figure 2.3 on
6 and 7 kW
12, 13, and 15 kW
page 13).
2. Hold the governor lever at its wide open throttle
position, and rotate the governor shaft clockwise
as far as it will go. Then, tighten the governor
lever clamp bolt to 70 inch-pounds (8 N-m).
3. Start the generator; let it stabilize and warm up
at no-load.
Adjustment
Set
Pins
Adjustment
Screw
(Both sides)
Screw
(One Side
Only)
4. Connect a frequency meter across the generators
AC output leads.
5. Turn the speed adjust nut to obtain a frequency
reading of 63 Hz.
6. When frequency is correct at no load, check the
AC voltage reading. If voltage is incorrect, the volt-
age regulator may require adjustment.
6. When the highest frequency is reached maximum
power has been set. Then turn both adjustment
screws 1/4 turn counterclockwise. Regulator is
now set.
12
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Section 3 — Operation
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Figure 2.3 — Engine Governor Adjustment
2.7.3 ADDITIONAL CORROSION
PROTECTION
◆
Periodically spray all engine linkage parts and brack-
ets with corrosion inhibiting spray such as WD-40 or
a comparable product.
Idle Spring
2.8 VOLTAGE REGULATOR
Governor
Shaft
(Rotate
Clockwise)
ADJUSTMENT
With the frequency between 62-63.5 Hertz, slowly
turn the slotted potentiometer (Figure 2.5) until line
voltage reads 244-252 volts.
NOTE:
You must remove the access panel on top of the
control panel to adjust the voltage regulator.
No Load Idle
Adjustment Screw
Governor Clamp Bolt
Figure 2.5 – Voltage Adjustment Potentiometer
2.7.2 12 KW AND 15 KW UNITS
◆
1. Loosen governor clamp bolt (See Figure 2.3).
2. Completely remove the idle spring.
3. With governor arm at wide open throttle position,
rotate governor shaft fully clockwise. Tighten
clamp bolt to 84 inch-pounds.
4. Start unit and apply full load. Use full load speed
adjust screw (Figure 2.4) to adjust frequency to
58 Hz.
5. Remove load, stop engine, loosen the idle adjust
screw and reconnect the idle spring.
6. Using your hand, push the governor arm to the
closed throttle position. Make sure the idle spring
does not stretch at all.
NOTE:
7. Restart the unit.
The voltage regulator is housed above the genera-
tor's control panel. The regulator maintains a volt-
age in direct proportion to frequency. For example,
at 62 Hertz, line-to-neutral voltage will be 124 volts.
8. Slowly turn the idle adjust screw to adjust the no-
load idle frequency to 63-63.5 Hz.
9. The governor is now set.
Figure 2.4 — Full Load Speed Adjust Screw
3.1 BREAK-IN PROCEDURE
Full Load Speed Adjust Screw
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 utili-
ty 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.
13
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Section 3 — Operation
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
8. Turn ON the utility power supply to the transfer
3.3 AUTOMATIC TRANSFER
switch, which will allow the transfer switch to
transfer back to utility power. The unit will con-
tinue to run for one minute and then shut down.
9. Allow the unit to cool.
OPERATION
To select automatic operation, do the following:
1. Make sure the transfer switch main contacts are
set to their “Utility” position, i.e., loads connected
to the utility power source (Figure 3.2, Page 15).
2. Be sure that normal utility power source voltage
is available to transfer switch terminal lugs N1
and N2.
10. Drain the oil and remove the oil filter. Replace the
oil filter according to Section 4.4, “Changing the
Oil Filter” (Page 18). Replace the oil with synthet-
ic oil as recommended in Section 4.3, “Changing
the Engine Oil” (Page 17).
3. Set the generator’s Auto/Off/Manual switch to
11. The generator is now ready for service.
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.”
3.2 USING THE AUTO/OFF/MANUAL
SWITCH (FIGURE 3.1)
3.2.1 “AUTO” POSITION
‹
Selecting this switch position activates fully automatic
system operation. It also allows you to start and exercise
the engine every seven days with the setting of the exer-
cise timer (see Section 3.6, Page 16). This position also
is used for remote starting, when it is set up.
3.4 SEQUENCE OF AUTOMATIC
OPERATION
The generator’s control panel houses a control logic
circuit board. This board constantly monitors utility
power source voltage. Should that voltage drop below
a preset level, circuit board action will signal the
engine to crank and start. After the engine starts, the
circuit board signals the transfer switch to activate
and connect load circuits to the standby power sup-
ply (load terminal lugs T1/T2 connect to terminal
lugs E1/E2).
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.
Upon restoration of utility source voltage above a pre-
set level, generator circuit board action signals the
transfer switch to transfer loads back to that power
supply. After retransfer, the engine is signalled to shut
down.
Figure 3.1 – Generator Control Panel
FUSE
R
L o c a t
e
y o u r n e a r e s t
d e a le r a t
:
R
POWER SYSTEMS, INC.
The actual sequence of operation is controlled by
sensors and timers on a control logic circuit board,
as follows:
5A
AUTO OFF MAN.
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
FUSE
A.Utility Voltage Dropout Sensor
• This sensor monitors utility source voltage.
• If utility source voltage drops below about 70 per-
cent of the nominal supply voltage, the sensor
energizes a 15-second timer.
F L A
S
H
IN
N
H
G
O
IN
G R E E N L E D
=
SET
EXERCISE
TIME
15A
U
G
T
IL IT
E D L E D
IS E R
Y
S
E N
S
=
E
4
F L A
S
R
S
T
E X E R
C
N
O
S
E T
• 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.
With the switch set to AUTO, the engine may
crank and start at any time without warning.
Such automatic starting normally occurs when
utility power source voltage drops below a pre-
set level or during the normal exercise cycle. To
prevent possible injury that might be caused by
such sudden starts, always set the switch to
OFF and remove both fuses before working on
or around the generator or transfer switch.
Then, place a “Do Not Operate” tag on the gen-
erator panel and on the transfer switch.
!
C.Standby Voltage Sensor
• This sensor monitors generator AC output volt-
age. When the voltage has reached 50 percent of
the nominal rated voltage, transfer to standby
can occur.
14
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Section 3 — Operation
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
D.Utility Voltage Pickup Sensor
Figure 3.2 – Manual Transfer Switch Operation
• This sensor monitors utility power supply volt-
age. When that voltage is restored to above 70
percent of the nominal source voltage, a retrans-
fer 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.
3.5.2 TRANSFER BACK TO UTILITY POWER
SOURCE
‹
3.5 MANUAL TRANSFER OPERATION
When utility power has been restored, you will want
to transfer back to that source and shut down the
generator. This can be accomplished as follows:
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. 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.
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).
4. Check that utility power supply to the transfer
switch is turned OFF.
DANGER
DANGER
Do not attempt to activate the transfer switch
manually until all power voltage supplies to
the switch have been positively turned off.
Failure to turn off all power voltage supplies
may result in extremely hazardous and possibly
fatal electrical shock.
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 trans-
fer switch to move the main contacts to their
“Standby” position, i.e., loads connected to the
standby power source (Figure 3.2).
5. Use the manual transfer handle inside the trans-
fer switch to move the main contacts back to their
“Utility” position, i.e., loads connected to the util-
ity power source (Figure 3.2).
5. To crank and start the engine, set the
6. Turn ON the utility power supply to the transfer
Auto/Off/Manual switch to MANUAL.
switch using the means provided.
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.
7. Set the system to automatic operation as outlined
in “Automatic Transfer Operation,” Section 3.3
(Page 14).
15
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Section 3 — Operation
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Figure 3.3 – Low Oil Pressure and
High Temperature Switches
3.6 SETTING THE EXERCISE TIMER
Your generator is equipped with an exercise timer.
Once it is set, the generator will start and exercise
once every seven days, on the day of the week and at
the time of day you complete the following sequence.
During this exercise period, the unit runs for approx-
imately 12 minutes and then shuts down. Transfer of
loads to the generator output does not occur during
the exercise cycle.
Low Oil Switch
High Temp Switch
A switch on the control panel (see Figure 3.1, Page
14) allows you to select the day and time for system
exercise. To select the desired day and time of day,
you must perform the following sequence at that
time.
Oil
Drain
Hose
Oil Filter
1. Verify that the Auto/Off/Manual switch is set
to AUTO.
2. Hold down the set timer switch until the genera-
tor 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.
3.7.3 OVERCRANK
‹
This feature prevents the generator from damaging
itself when it continually attempts to start and anoth-
er problem, such as no fuel supply, prevents it from
starting. The unit will crank and rest for a preset time
limit. Then, it will stop cranking, and the LED 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:
The exerciser will only work in the AUTO mode
and will not work unless this procedure is per-
formed. 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.
NOTE:
If the fault is not repaired, the overcrank feature
will continue to activate.
3.7.3.1 Approximate Crank Cycle Times
• 15 seconds ON
3.7 PROTECTION SYSTEMS
• 7 seconds OFF
• 7 seconds ON
• 7 seconds OFF
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 crank-
ing and operating. Should oil pressure drop below the
8 psi range, switch contacts close, and the engine
shuts down. The unit should not be restarted until oil
is added, and the Auto/Off/Manual switch must be
turned to OFF and then back to AUTO.
• 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 gener-
ator from supplying an output that could potentially
damage appliances connected to the generator cir-
cuit. Contact your nearest Generac Authorized Dealer
if this failure occurs.
3.7.2 HIGH TEMPERATURE SWITCH
‹
This switch’s contacts (Figure 3.3) close if the tem-
perature should exceed approximately 140º C (284º
F), initiating an engine shutdown. Your generator will
automatically restart and the LED will reset once the
temperature has returned to a safe operating level.
16
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Figure 4.2 — Oil Dipstick and Fill, 7 kW
4.1 FUSE
The generator panel’s 15 amp fuse (Figure 4.1) protects
the DC control circuit against overload. The fuse is
wired in series with the battery output lead to the panel.
If the fuse element has melted open, you cannot crank
or start the engine. You should replace the fuse using
only an identical 15-amp replacement.
Oil Dipstick and Fill
The generator panel’s 5 amp fuse protects the battery
charge circuit against overload. If the fuse element has
melted open, you will not have battery charging capa-
bility. You should replace the fuse using only an identi-
cal 5 amp replacement. To remove fuse, push cap down
and rotate counterclockwise.
Figure 4.1 – Generator Control Panel
FUSE
R
Figure 4.3 — Oil Dipstick and Fill,
12 kW and 15 kW
L o c a t
e
y o u r n e a r e s t
d e a le r a t
:
R
POWER SYSTEMS, INC.
5A
AUTO OFF MAN.
SYSTEM SET
LOW OIL
Oil Dipstick
HIGH TEMP.
OVER SPEED
OVER CRANK
FUSE
F L A
S
H
IN
N
H
G
O
IN
G R E E N L E D
=
SET
EXERCISE
TIME
15A
U
G
T
IL IT
E D L E D
IS E R
Y
S
E N
S
=
E
4
F L A
S
R
S
T
E X E R
C
N
O
S
E T
Oil Fill
4.2 CHECKING THE ENGINE
OIL LEVEL
For oil capacities, see “Specifications,” Section 1.5
(Page 6). For engine oil recommendations, see
Section 4.3.1. To check the engine oil level, proceed
as follows (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 nec-
essary, add oil to the “Full” mark only. DO NOT
FILL ABOVE THE “FULL” MARK.
4.3 CHANGING THE ENGINE OIL
4.3.1 ENGINE OIL RECOMMENDATIONS
‹
Use oil of American Petroleum Institute (API) Service
Class SG, SH or SJ. Use all season SAE 5W-30
Synthetic oil. Organic break-in oil is required before
using synthetic oil.
NOTE:
The unit is supplied with “break-in” oil. See the
“Break-in Procedure,” Section 3.1 (Page 12), for
the first required oil change.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
!
this could damage the engine.
4. Install the dipstick.
5. Reset the Auto/Off/Manual switch to its original
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
!
position.
17
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
4.3.2 OIL CHANGE PROCEDURE
To change the oil, proceed as follows:
‹
4.5 CHANGING THE ENGINE
AIR CLEANER
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.
4.5.1 7 KW, 12 KW AND 15 KW
GENERATORS
‹
See Figures 1.1 and 1.2, (Page 5), for the location of
your air cleaner. Use the following procedure (Figure
4.6):
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover and air filter.
Figure 4.4 – Oil Drain Hose and 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 clock-
wise to tighten.
See the “Service Schedule,” Section 4.13 (Page 22) for
air cleaner maintenance. See Section 1.5.1 (Page 6)
for air filter replacement part number.
Oil
Drain
Hose
Figure 4.6 — 7 kW, Engine Air Cleaner Location
Fuel
Regulator
Oil Filter
Air Cleaner
3. After the oil has drained, replace the cap onto the
end of the oil drain hose. Retain the hose in the clip.
4. Refill with the proper recommended oil (see
Section 4.3.1). See Section 1.5.2 (Page 6) for oil
capacities.
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 gas-
ket of the new filter. See Section 1.5.1 (Page 6) for
recommended filter.
Figure 4.7 — 12 kW and 15 kW Engine
Air Cleaner
Screw
3. Screw the new filter on by hand until its gasket
lightly contacts the oil filter adapter. Then, tighten
the filter an additional 3/4 to one turn (Figure 4.4).
4. Refill with the proper recommended oil (see
Section 4.3.1, Page 17). See Section 1.5.2 (Page 6)
for oil capacities.
Cover
Filter
5. Start the engine and check for leaks.
18
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
• Remove watches, rings or other metal objects;
4.6 SPARK PLUG(S)
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
Reset the spark plug(s) gap or replace the spark
plug(s) as necessary. See Section 4.13 (Page 22) 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 condi-
tion. Replace the spark plug(s) if worn or if reuse
is questionable. See Section 4.13 (Page 22) 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).
• 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
Figure 4.8 – Setting the Spark Plug Gap
SET PLUG GAP AT 0.76 mm/0.50 mm
(0.030 inch/0.020 inch)
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or water. The bicar-
bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
4.7 BATTERY MAINTENANCE
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area; and
• Discharge static electricity from your body before
touching the battery by first touching a grounded
metal surface.
The battery should be inspected per the “Service
Schedule,” Section 4.13 (Page 22). The following pro-
cedure 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 bat-
tery hydrometer.
Be sure the Auto/Off/Manual switch is set to
the OFF position before connecting the battery
!
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as
the battery cables are connected.
Be sure the utility power supply is turned off,
and the 5A fuse is removed from the generator
control panel, or sparking may occur at the bat-
tery posts as you attach the cables causing an
explosion.
DANGER
Do not dispose of the battery in a fire. The
battery is capable of exploding.
A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when working
on batteries:
19
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
• Install new valve cover gasket.
• Re-attach the valve cover.
NOTE:
4.8 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, you should
adjust the valve clearance in the engine.
Start all four screws before tightening or you will not
be able to get all the screws in place. Make sure the
valve cover gasket is in place.
Important: If you feel uncomfortable about doing this
procedure or you don't have the proper tools, please
contact your Generac Authorized dealer for service
assistance. This is a very important step to insure
longest life for your engine.
• Re-attach the spark plug wire to the spark plug.
• Repeat the process for the other cylinder.
To adjust valve clearance:
4.9 COOLING SYSTEM
• 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.
Air inlet and outlet openings in the generator compart-
ment must be open and unobstructed for continued
proper operation. This includes such obstructions as
high grass, weeds, brush, leaves and snow.
• Remove the four screws attaching the valve cover with
a #2 or #3 phillips screwdriver.
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.)
• 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.
Figure 4.9 – Cooling Vent Locations
• Loosen the rocker jam nut. Use an 10mm allen
wrench to turn the pivot ball stud while checking
clearance between the rocker arm and the valve stem
with a feeler gauge. Correct clearance is 0.002-0.004
inch (0.05-0.1 mm).
NOTE:
You must hold the rocker arm jam nut in place as
you turn the pivot ball stud.
When valve clearance is correct, hold the pivot ball stud
in place with the allen wrench and tighten the rocker
arm jam nut. Tighten the jam nut to 174 in/lbs. torque.
After tightening the jam nut, recheck valve clearance to
make sure it did not change.
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.
Figure 4.10 - Valve Clearance Adjustment
Rocker
Pivot Ball
Stud
Arm
Jam Nut
Valve
Stem
The maximum ambient temperature for your
generator is 48.9° C (104° F).
!
20
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
4.12.2 RETURN TO SERVICE
To return the unit to service after storage, proceed
as follows:
‹
4.10 ATTENTION AFTER SUBMERSION
If the generator has been submerged in water,
it MUST NOT be started and operated. Following any sub-
mersion in water, have a Generac Authorized Dealer thor-
oughly clean and dry the generator.
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
4.11 CORROSION PROTECTION
Auto/Off/Manual switch is set to OFF.
Periodically wash and wax the enclosure using automo-
tive type products. Frequent washing is recommended
in salt water/coastal areas. Spray engine linkages with
a light oil such as WD-40.
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, Page 17).
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 (Page 6), for type and
size.
5. Clean and wipe the entire generator.
6. Remove both fuses from the generator control
panel.
7. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected incor-
rectly. Replace the fuses in the generator control
panel.
4.12 OUT OF SERVICE PROCEDURE
4.12.1 REMOVAL FROM SERVICE
‹
If you cannot exercise the generator every seven days,
and it is to be out of service longer than 90 days, pre-
pare the generator for storage as follows:
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
3. Once the unit has shut down, it will signal a low oil
fault.
4. Set the Auto/Off/Manual switch to OFF and turn off
the utility power to the transfer switch. Remove both
fuses from the generator control panel.
5. While the engine is still warm from running, drain
the oil completely. Refill the crankcase with oil. See
”Engine Oil Recommendations,” Section 4.3.1 (Page
17).
6. Attach a tag to the engine indicating the viscosity
and classification of the oil in the crankcase.
7. Remove the spark plug(s) and spray fogging agent
into the spark plug(s) threaded openings. Reinstall
and tighten the spark plug(s).
8. Remove the battery and store it in a cool, dry room
on a wooden board. Never store the battery on any
concrete or earthen floor.
8. 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. Your generator is now ready for service.
NOTE:
If the battery was dead or disconnected, you must
reset the exercise timer.
9. Clean and wipe the entire generator.
21
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Section 4 — Maintenance
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
4.13 SERVICE SCHEDULE
ATTENTION: It is recommended that all service work
be performed by your nearest Generac Authorized Dealer.
SYSTEM/COMPONENT
PROCEDURE
FREQUENCY
X = Action
Inspect
Change
Clean
W = Weekly
M = Monthly
Y = Yearly
R = Replace as Necessary
* = Notify Dealer
if Repair is Needed.
FUEL
Fuel lines and connections*
X
X
M
M
LUBRICATION
Oil level
Oil
X
X
AFTER BREAK-IN,
AND Y
Oil filter
AFTER BREAK-IN,
AND Y
COOLING
Enclosure louvers
BATTERY
X
X
W
Remove corrosion,
ensure dryness
X
X
X
X
M
M
Clean and tighten
battery terminals
Check charge state
X
X
R
R
EVERY 6 M
EVERY 6 M
Electrolyte level
(unsealed batteries only)*
ENGINE AND MOUNTING
Air cleaner
X
X
R
R
Y
Y
Spark plug(s)
GENERAL CONDITION
Vibration, Noise, Leakage,
Temperature*
X
M
Y
COMPLETE TUNE-UP*
TO BE COMPLETED BY A GENERAC
AUTHORIZED DEALER
22
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Section 5 — Troubleshooting
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
5.1 TROUBLESHOOTING GUIDE
PROBLEM
The engine will not crank.
CAUSE
1. Fuse blown
CORRECTION
1. Replace 15A fuse on generator
control panel.
2. Loose, corroded or defective
battery cables
2. Tighten, clean or replace
as necessary.
3. Defective starter contactor (7 kW) 3. *
4. Defective starter motor
5. Dead Battery
4. *
5. Charge or replace battery.
The engine cranks but
will not start.
1. Out of fuel
1. Replenish fuel.
2. *
3. *
2. Defective fuel solenoid (FS)
3. Open #14 wire from
engine control board
4. Defective spark plug(s)
5. Valve lash out of adjustment.
4. Clean, re-gap or replace plug(s).
5. Reset valve lash.
The engine starts hard
and runs rough.
1. Air cleaner
1. Check, replace air cleaner.
plugged or damaged
2. Defective spark plug(s)
3. Fuel regulator not set.
4. Fuel pressure incorrect.
2. Clean, re-gap or replace plug(s).
3. Set fuel regulator.
4. Confirm fuel pressure is at 11”-14”
water column (0.4 psi - 0.5 psi).
The Auto/Off/Manual switch
is set to OFF, but the engine
continues to run.
1. Defective switch
1. *
2. *
2. Auto/Off/Manual switch
wired incorrectly
3. Defective control board
3. *
There is no AC output from
the generator.
1. Main line circuit breaker open
2. Generator internal failure
1. Reset circuit breaker
to ON (or closed).
2. *
There is no transfer to
standby after utility
source failure.
1. Defective transfer switch coil
2. Defective transfer relay
3. Transfer relay circuit open
4. Defective control logic board
1. *
2. *
3. *
4. *
Unit consumes large
amounts of oil.
1. Break-in procedure
1. *
not followed (see Section 3.1)
*Contact your nearest Generac Authorized Dealer for assistance.
23
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Section 6 — Electrical Data
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500
3
2
1
BATTERY
CHARGER
DIAGRAM KEY
BA - BRUSH ASSEMBLY
BCR - BATTERY CHARGE RELAY
CB1 - MAIN OUTPUT BREAKER
14
2
1
0
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION
D
-
DIODE
225B
ENGINE WIRING
DSW - PCB MOUNTED DIP SWITCH
FS
224B
FS - FUEL SOLENOID
13A
0
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
GRD - CONTROL PANEL GROUND
HTO - HIGH OIL TEMPERATURE SWITCH
IC - INLINE CONNECTOR
0
ICT - INTERCONNECTION TERMINALS
IM1 - IGNITION MODULE, CYLINDER #1
IM2 - IGNITION MODULE, CYLINDER #2
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
0
SCR - STARTER CONTACTOR RELAY
SP1, SP2 - SPARK PLUGS
14
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
14
SM - STARTER MOTOR
TB - INSULATED TERMINAL BLOCK
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
IC
TB
D
SP1
6
5
0
0
14
IM1
18
85
4
3
86
2
1
13
13
D
16
IC
IC
SP2
C1
16
SCR
IM2
13
18
85
A
B
86
351
HTO
0
14
86
56
0
85
56
1
16
13
86
2
3
4
5
J2
LOP
0
J1
CONTROL
PRINTED CIRCUIT BOARD
RED
BLACK
DSW
1
2
3
4
ON
ON - INDICATES
1 - 20 Vac Sense Transformer
2 - Remote Not Auto
3 - 50 Hz Operation
4 - SPARE
SM
- +
12V
BATTERY
SC
CUSTOMER SUPPLIED
L.E.D - ALARM INDICATORS
24
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Section 6 — Electrical Data
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Wiring Diagram – 12 & 15 kW – Drawing No. 0D8500
CONTROL PANEL BOX
225
224
224A
225A
CLOSEST TO BEARING
BA
224A
4
0
225A
TX
BCR
CB2
1 3
4 6
7 9
STATOR
N1 N2
162
77
A B
66
2
225B
4
10
9
224B
0
2
11
6
77
8
2
14
55
4
7
6
22
6
66A
11
0
11
11
22
5
4
3
22
77
11
66
66
13A
225
22
4
77
0
4
0
6
0
2
6
44
1
224
162
162
55
C2
VOLTAGE
REGULATOR
66A
0
0
66A
4
55
N2
33
N1
13
13
22
13
225
GRD
351
224
194
23
N2
4
N1
13
44
351
23
56
11
13
13A
351
CUSTOMER
CONNECTION
194
15A
23
22
N2
18
13
33
N1
194
0
14
13
66A
F2
F1
239
CB1
0
15A
17
OFF
17
15
13
239
17
0
SW1
225
15
224
1a
1
15
1b
SW2
240V GENERATOR
AUTO
OUTPUT TO TRANSFER
SWITCH CONTACTOR
MANUAL
25
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Section 6 — Electrical Data
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501
11
22
3
2
1
225A
224A
BATTERY
CHARGER
225B
F2
13A
13
224B
13A
2
1
F1
7
7
9
9
BCR
1
4
3
6
11
0
13A
77
C2-1
0
77
14
BATTERY CHARGE
WINDING
66
0
66
C2-2
22
0
0
0
C2-4
55
HTO
0
C2-11
0
LOP
11
22
ENGINE RUN
WINDING
BA
FIELD
SW2
C1-4
0
14
(STATOR)
C1-3
0
C2-9
C2-3
4
0
ELECTRONIC
VOLTAGE
REGULATOR
C2-10
4
4
66A
0
85
6
86
162
C1-6
4
6
CB2
0
351
225
224
C2-7
C2-8
66A
2
DPE WINDING
(STATOR)
1
2
3
4
5
J2
23
18
1
2
4
J1
194
86
3
4
5
6
7
8
9
23
194
56
DIAGRAM KEY
BA - BRUSH ASSEMBLY
14
BCR - BATTERY CHARGE RELAY
CB1 - CIRCUIT BREAKER, MAIN OUTPUT
CB2 - CIRCUIT BREAKER, ALT. EXCITATION
D - DIODE
66A
239
15A
17
CONTROL
PRINTED CIRCUIT
BOARD
10
11
12
13
14
15
16
17
FS - FUEL SOLENOID
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
15
0
225
224
HTO - HIGH OIL TEMPERATURE SWITCH
IM1 - IGNITION MODULE, CYLINDER #1
IM2 - IGNITION MODULE, CYLINDER #2
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTER
SCR - STARTER CONTACTOR RELAY
SP1, SP2 - SPARK PLUGS
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
SM - STARTER MOTOR
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
26
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Section 6 — Electrical Data
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Electrical Schematic – 12 & 15 kW – Drawing No. 0D8501
11
C2-6
22
C2-5
TX
225A
N2
56VA
1VA
224A
225
224
N1
194
23
CUSTOMER
CONNECTIONS
N2
N2
N1
13
N1
15
17
11
NEUTRAL
17
23
0
22
33
15A
0
SW1
194
120V
15
120V
POWER WINDING
(STATOR)
239
15
44
CB1
23
15
194
239
11
14
0
240V
14
15A
15
239
13
RED
0
C2-1
66A
17
13
SC
SCR
56
16
16
0
14
C1-1
BATTERY
12V
0
SC
0
FS
0
SM
BLACK
CUSTOMER
SUPPLIED
IM1
IM2
SP1
SP2
D
18
C1-5
D
27
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Section 6 — Electrical Data
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Wiring Diagram – 7 kW – Drawing No. 0D9013
ENGINE WIRING
3
2
1
DIAGRAM KEY
BATTERY
CHARGER
(UTILITY)
BA - BRUSH ASSEMBLY
BCR - BATTERY CHARGE RELAY
CB1 - MAIN OUTPUT BREAKER
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION
14
2
1
0
D
-
DIODE
DSW - PCB MOUNTED DIP SWITCH
225A
224A
FS - FUEL SOLENOID
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
GRD - CONTROL PANEL GROUND
FS
13A
0
HTO - HIGH OIL TEMPERATURE SWITCH
IC - INLINE CONNECTOR
ICT - INTERCONNECTION TERMINALS
0
IM - IGNITION MODULE
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SP - SPARK PLUG
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
14
SM - STARTER MOTOR
TB - INSULATED TERMINAL BLOCK
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
14
IC
TB
0
D
SP
14
0
6
5
0
IM
18
14
85
4
3
86
85
IC
IC
2
HTO
13
0
1
C1
86
18
56
56
LOP
86
351
0
13
14
86
56
85
56
1
4
2
3
4
5
J2
4
J1
86
23
194
SC
56
CONTROL
18
PRINTED CIRCUIT BOARD
14
66A
RED
239
BLACK
DSW
15A
1
2
3
4
ON
17
15
16
0
ON - INDICATES
225
1 - 20 Vac Sense Transformer
2 - Remote Not Auto
3 - 50 Hz Operation
4 - SPARE
224
- +
12V
SM
BATTERY
CUSTOMER SUPPLIED
L.E.D - ALARM INDICATORS
28
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Section 6 — Electrical Data
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Wiring Diagram – 7 kW – Drawing No. 0D9013
224A
CLOSEST TO BEARING
225A
CONTROL PANEL BOX
225
224
BA
4
0
224A
225A
TX
BCR
STATOR
CB2
162
1 3
4 6
7 9
N2
N1
77
A B
66
2
4
225A
10
9
224A
0
2
11
6
77
2
8
14
55
66A
4
6
7
22
6
11
22
11
11
22
5
4
3
77
11
66
66
13A
225
22
4
0
77
0
4
N2
0
6
0
2
6
44
N1
1
224
162
162
55
C2
VOLTAGE
REGULATOR
4
66A
0
0
0
66A
4
55
N2
33
N1
0
13
22
225
0
GRD
351
224
0
194
23
N2
N1
13
44
351
15A
23
56
11
13A
351
CUSTOMER
CONNECTION
194
22
18
33
0
23
N2
14
13
N1
194
F2
F1
CB1
0
OFF
13
239
17
15
SW1
SW2
15
AUTO
240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR
MANUAL
29
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Section 6 — Electrical Data
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Electrical Schematic – 7 kW – Drawing No. 0D9014
11
22
225A
3
2
1
BATTERY
CHARGER
225B
F2
13A
13
224B
13A
2
1
F1
7
7
9
9
BCR
1
4
3
6
11
0
0
13A
77
C2-1
0
15
77
14
BATTERY CHARGE
WINDING
66
66
C2-2
22
0
0
0
0
C2-4
55
HTO
0
LOP
11
22
ENGINE RUN
WINDING
BA
FIELD
SW2
C1-4
0
14
(STATOR)
C1-3
0
C2-9
C2-3
4
0
ELECTRONIC
VOLTAGE
REGULATOR
C2-10
4
4
66A
0
85
6
86
162
C2-11
4
6
6
CB2
351
225
14
0
224
C2-7
2
66A
C2-8
2
1
2
3
4
5
DPE WINDING
(STATOR)
J2
23
1
2
4
J1
194
86
3
4
5
6
7
8
9
23
194
56
DIAGRAM KEY
18
BA - BRUSH ASSEMBLY
BCR - BATTERY CHARGE RELAY
CB1 - CIRCUIT BREAKER, MAIN OUTPUT
CB2 - CIRCUIT BREAKER, ALT. EXCITATION
D - DIODE
14
66A
239
15A
17
CONTROL
PRINTED CIRCUIT
BOARD
10
FS - FUEL SOLENOID
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
11
12
13
14
15
16
17
15
0
HTO - HIGH OIL TEMPERATURE SWITCH
HM - HOUR RUN METER
IM - IGNITION MODULE
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTER
SP - SPARK PLUG
225
224
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
SM - STARTER MOTOR
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
30
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Section 6 — Electrical Data
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Electrical Schematic – 7 kW – Drawing No. 0D9014
11
C2-6
22
C2-5
TX
N2
56VA
1VA
224A
225
224
N1
194
23
CUSTOMER
CONNECTIONS
N2
N2
N1
13
N1
17
11
NEUTRAL
17
23
22
33
15A
0
SW1
120V
194
15
120V
POWER WINDING
(STATOR)
239
15
44
CB1
23
15
194
239
11
240V
66A
15A
15
13
239
RED
SC
C1-2
14
17
0
14
56
C1-1
BATTERY
12V
SM
SC
0
FS
0
0
C1-6
0
BLACK
CUSTOMER
SUPPLIED
18
IM
D
C1-5
SP
31
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Enclosure – Drawing No. 0D3416-K
76
85
44
71
40
68
69
82
48
77
84
80
82
41
73
78
81
80
30
17
79
72
51
86
72
5
52
87
A
6
29
45
12
60
49
47
44
16
19
66
47
28
55
75
64
65
88
54
31
11
50
44
62
35
46
74
25
49
51
48
51
14
8
61
57
49
50
9
35
27
22
89
67
56
63
59
49
49
90
58
1
93
49
91
13
35
93
38
26
3
51
70
39
23
58
37
42
24
43
48
51
36
51
A
21
49
43
46
47
7
34
33
2
32
10
50
49
18
52
20
51
4
15
91
63
92
71
69
35
25
68
32
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Enclosure – Drawing No. 0D3416-K
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0C6140
0D1901
0C6735
0C7061
0C7062
0C7062A
0C7063
0C7063A
0C7063B
0C7064
0C7065
0C7065A
0C8101A
0C8861
0C8101B
0C8862
0C8283
0C8284A
0C8284B
0C8284C
0C8285
0C8899A
0D1128
0D1128A
0D1605
0D1605A
0D1606
0D5264
0D1839
0D1840
0D2425
0D2588
0D2676
0D2677
0D2979B
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
ASSEMBLY, ENCLOSURE BASE (12KW / 15KW)
ASSEMBLY, ENCLOSURE BASE (7KW)
SUPPORT, ROOF FOLDING
44
45
46
47
48
022097
022473
036261
047411
043116
043116
0D3700
083512
090388
9
4
14
12
5
WASHER LOCK M6-1/4"
WASHER FLAT ¼" ZINC
2
3
4
RIVET POP .125 X .129-.133/#30
SCREW HHC M6-1.0 X 16 G8.8
SCREW HHC M6-1.0 X 12 G8.8 (12KW / 15KW)
SCREW HHC M6-1.0 X 12 G8.8 (7KW)
NUT, LOCKING FLANGE M6-1.0
SCREW TAPTITE M8-1.20 X 16 BP
SCREW TAPTITE M6-1.0 X 12 BP
(12KW / 15KW)
SCREW TAPTITE M6-1.0 X 12 BP (7KW)
NUT LOCK TRIC M6 X 1.0 Y/ZNC
GASKET, BATTERY SUPPORT BRACKET
PLUG, PLASTIC 0.593 HEYCO 1675
LUG SLDLSS #2-#8X17/64 CU
SCREW TAPTITE M6-1.0X25 BP
L/WASH SPECIAL ¼
BRACKET, BATTERY HOLD DOWN (7KW)
CONTACTOR, STARTER (7KW)
CABLE, #6 RED BATTERY 38.5"
NUT HEX 1/4-20 STEEL (7KW)
WASHER LOCK 5/16 (12KW / /15KW)
WASHER LOCK 5/16 (7KW)
SCREW TAPTITE M5-0.8 X 10 BP
HARNESS, ENGINE (12KW / 15KW)
HARNESS, ENGINE (7KW)
BUSHING, SNAP SB-1000-12
SCREW HHC 5/16-18 X 3/4 G5 (7KW)
RIVET,1/8" X 0.126" - 0.375" LSH POP
L/WASH SPECIAL #10
ASSEMBLY, ROOF/DOOR GROUND WIRE
ASSEMBLY, ROOF/DOOR GROUND WIRE
PLUG PLASTIC 1.375 (12KW / 15KW)
GASKET, CLIP-ON SELF GRIPPING
PLATE, "HOT"
GROMMET 2.75 X 1/16
EXTERNAL CONNECTION BOX
POWER BLOCK
HARNESS GENERATOR TO EXTERNAL
CONNECTION BOX (12KW / 15KW)
HARNESS GENERATOR TO EXTERNAL
CONNECTION BOX (7KW)
HARNESS GENERATOR TO EXTERNAL
CONNECTION BOX (16KW)
ENCLOSURE, FRONT
ENCLOSURE, EXHAUST SIDE (12KW / 15KW)
ENCLOSURE, EXHAUST SIDE (7KW)
ENCLOSURE, SIDE & BACK (12KW / 15KW)
ENCLOSURE, SIDE & BACK (7KW)
ENCLOSURE, SIDE & BACK (16KW)
ENCLOSURE, ROOF
PANEL, ALTERNATOR DIVIDER (12KW / 15KW)
PANEL, ALTERNATOR DIVIDER (7KW)
PANEL, MUFFLER BOX SIDE (12KW / 15KW)
PANEL, MUFFLER BOX SIDE (7KW)
COVER, MUFFLER BOX (12KW / 15KW)
COVER, MUFFLER BOX (7KW)
GASKET, DOOR SEAL
FOAM, BACK ENCLOSURE
FOAM, ROOF ENCLOSURE
FOAM, FRONT ENCLOSURE
BRACKET, BATTERY SUPPORT (12KW / 15KW)
PAD, 24"X48" WITH MOUNTING HOLES
PANEL, ENGINE DIVIDER (12KW / 15KW)
PANEL, ENGINE DIVIDER (7KW)
BAFFLE, INTAKE (12KW / 15KW)
BAFFLE, INTAKE (7KW)
6
5
49
50
51
18
11
34
6
7
22
2
1
1
1
1
2
1
1
1
2
4
5
8
1
1
1
1
2
2
1
2
2
10.5
1
1
52
54
55
56
57
58
59
60
61
62
63
092120
8
9
0D3167
0A3328
055414
092079
10
11
12
13
14
15
16
0A1658
0C2937
086729
0388040AJ0
022127
022129
022129
074908
0D2346
0D2345
023484F
022142
0A7836
0A8475
0912970069
0912970070
055450
0D2023
0D3701
0D3472
0C8742
0C8911
0D3338
64
65
17
18
HOUSING, FAN (12KW / 15KW)
BAFFLE, EXHAUST (7KW)
BRACKET, TOP SUPPORT
BRACKET, BOTTOM SUPPORT
66
67
68
69
70
71
72
73
74
75
76
77
78
19
20
21
22
23
24
25
DUCT, BASE AIR (12KW / 15KW)
GASKET, FRONT DIVIDER
COVER, FRONT EXHAUST ENCLOSURE
COVER, BACK EXHAUST ENCLOSURE
CLOTH, HARDWARE 266.7mm x 146mm
(12KW / 15KW)
CLOTH, HARDWARE 266.7mm x 146mm
(7KW)
CLOTH, HARDWARE 543mm x 146mm
CLOTH, HARDWARE 266.7mm x 387.4mm
CLOTH, HARDWARE (7KW)
FOAM, FRONT INTAKE BAFFLE (12KW / 15KW)
FOAM, FRONT INTAKE BAFFLE (7KW)
FOAM, TOP INTAKE BAFFLE (12KW / 15KW)
FOAM, BACK INTAKE BAFFLE (12KW / 15KW)
FOAM, BACK INTAKE BAFFLE (7KW)
FOAM, BACK ENCL. STRIP (12KW / 15KW)
FOAM, EXHAUST SIDE ENCLOSURE END
FOAM, EXHAUST SIDE ENCLOSURE FRONT
FOAM, EXHAUST FAN HOUSING
(12KW / 15KW)
WASHER, SELF LOCKING (12KW / 15KW)
WASHER, SELF LOCKING (7KW)
FOAM, FRONT EXHAUST ENCLOSURE COVER
FOAM, BACK EXHAUST ENCLOSURE COVER
DOOR, PAWL
0D2979B
3
1
1
1
26
27
0D2979C
0D2979D
0D2979E
0D3057A
0D3058A
0D3057B
0D3057C
0D3058C
0D3057D
0D3059A
0D3059B
0D3059C
1
1
1
1
1
1
1
1
1
1
1
1
0D3419
0D3928
1
1
28
29
30
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
036937
022152
023897
022158
0D3031
026850
049813
0D2537A
0D2538A
047411
0A2311
043107
022145
045771
0C3906
2
5
2
5
1
1
1
1
1
2
1
4
8
4
2
SCREW PPHM #10-32 X 1
WASHER LOCK #10
WASHER FLAT #10 ZINC
NUT HEX #10-32 STEEL
FUEL LINE, 3/4"OUTDOOR (NOT SHOWN)
WASHER SHAKPROOF EXT 1/4 STEEL
NUT HEX M6-1.0 G8 YELLOW CHROME
HINGE, LIFT OFF, TYPE A KNUCKLE
HINGE, LIFT OFF, TYPE B KNUCKLE
SCREW HHC M6-1.0 X 16 G8.8
SCREW SWAGE 1/4-20 X 1
31
32
33
34
35
0D7176
24
22
1
1
2
1
1
1
1
36
37
38
39
40
41
42
43
0D3059D
0D3059E
0C7781
0D3037
0D2537
0D2538
0D3037A
0A2115
SCREW HHC M8-1.25 X 25
WASHER FLAT 5/16
NUT HEX M8-1.25
SELF-ALIGN SCREW M6 HH
LATCH, QUARTER TURN LOCKING
HINGE, LIFT OFF, TYPE A PIN
HINGE, LIFT OFF, TYPE B PIN
LATCH, QUARTER TURN NON-LOCKING
WASHER NYLON .250"
4
33
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Control Panel – Drawing No. 0D8503-E
34
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Control Panel – Drawing No. 0D8503-E
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0A9947E
0A9947G
0A9947F
0A9947C
0A9947D
1
1
1
1
1
CIRCUIT BREAKER 30 X 2 240V SQD
QOU230 (7KW)
CIRCUIT BREAKER 40 X 2 240V SQD
QOU240 (8.5KW)
CIRCUIT BREAKER 50 X 2 240V SQD
QOU250 (12KW)
CIRCUIT BREAKER 60 X 2 240V SQD
QOU260 (13KW)
CIRCUIT BREAKER 70 X 2 240V SQD
QOU260 (15KW)
ASSEMBLY, BATTERY CHARGER ENGINE
ASSEMBLY, POTTED REGULATOR
RELAY, 12V 25A SPST (8.5KW/ 12KW/ 13KW)
BLOCK 1 POSITION
HEX STAND-OFF #6-32 x 3/8"
ASSEMBLY, HOME STANDBY CONTROLLER
HOLDER, FUSE
23
051714
051714
0D8502
0D8441
4
2
1
1
NUT HEX M3-0.5 (8.5KW/ 12KW/ 13KW)
NUT HEX M3-0.5 (7KW)
NEUTRAL ISOLATOR
HARNESS, CONTROL PANEL WIRE (NOT
SHOWN) (8.5KW/ 12KW/ 13KW)
HARNESS, CONTROL PANEL WIRE (NOT
SHOWN) (7KW)
SCREW TAPTITE, M5-0.8 x 10 BP
WASHER LOCK M5
NUT HEX M5-0.8
TRANSFORMER
SCREW HHC 1/4"-20 x 1/2"
FUSE 5A X AGC5
TERMINAL STRIP
RELAY PANEL 12VDC DPDT 10A 240VAC
SCREW PPHM M4-0.7 x 10mm
WASHER FLAT M4
COVER, CONTROL PANEL COMPONENT
(8.5KW/ 12KW/ 13KW)
COVER, CONTROL PANEL COMPONENT
(7KW)
SCREW PPHMS/LW #6-32 x 1/4"
SCREW HHC M5-0.8 x10mm
COVER, CONTROL PANEL (8.5KW/ 12KW/
13KW)
COVER, CONTROL PANEL (7KW)
NUT FLANGE M6-1.0 NYLOCK
ASSEMBLY, ROOF/DOOR GROUND WIRE
SCREW SWAGE 1/4"-20 x 1"
LOCKWASHER SPECIAL 1/4"
WASHER FLAT 1/4"
SCREW HHC M6-1.0 x 30mm
WASHER LOCK M6-1/4"
NUT HEX M6-1.0
24
26
0E0120
1
27
28
29
30
31
32
33
34
35
36
37
074908
049226
051716
0C3910
022507
099727
046689
063617
075475
043180
0D8439
4
6
6
1
2
1
1
1
4
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
0A1801
083049
0C2174
075210A
0D3062
0D8615
032300
022676
033873
0D5045
023484E
075476
022264
051715
043182
043182
043181
0D8443
054502
1
1
1
1
4
1
2
1
1
1
1
4
8
8
4
2
4
1
1
FUSE, 15AMP X AGC15
SWITCH, ROCKER
DIN RAIL
SNAP BUSHING SB-687-8
SCREW PPHM M4-0.7 x 16mm
WASHER LOCK M4
0E0119
1
38
39
40
092036
045770
0C7171
8
2
1
NUT HEX M4-0.7
WASHER LOCK M3 (8.5KW/ 12KW/ 13KW)
WASHER LOCK M3 (7KW)
SCREW PHM M3-0.5 x 10mm
DECAL, CONTROL PANEL (NOT SHOWN)
CIRCUIT BREAKER 3 X 1 ETA 46-500-P
(8.5KW/ 12KW/ 13KW)
CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P
(7KW)
CONTROL, PANEL BOTTOM (8.5KW/ 12KW/
13KW)
0D2989
0D3700
0912970069
0A2311
0A1658
022473
038750
022097
049813
031879
031879
023897
1
10
1
1
2
3
1
3
1
17
18
19
41
42
43
44
45
46
47
48
49
053623
0D8438
1
1
20
0E0118
075235
0D5240
1
4
1
CONTROL, PANEL BOTTOM (7KW)
SCREW HHC M5-0.8 x 30mm
SWITCH, SPDT ON-MOM-ON
4
2
2
WASHER FLAT #4 (8.5KW/ 12KW/ 13KW)
WASHER FLAT #4 (7KW)
WASHER FLAT #10
21
22
50
35
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990 Engine – Drawing No. 0D8674-C Part 1
Kit Contains:
66 2, 5, 19, 20, 39, 40, 47, 64, 93, 140
67 8, 11, 12, 13
68 4, 5, 6
34
69 16A, 16B, 17, 18
37
36
35
70 7, 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59, 60
71 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59, 60, 62
72 27, 28, 29
3
38
140
39
73 3, 32, 33, 34, 35, 36, 40, 72
34
22
40
33
32
9
41
3
21
12
10
31
13
42
29
43
25
30
28
27
11
3
26
15
16A
14
16B
23
24
44
16A
8
53
55
56
54
17
7
18
45
20
19
6
57
46
5
4
47
48
49
62
63
50
3
64
51
52
1
2
65
58
59
60
61
36
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990 Engine – Drawing No. 0D8674-C Part 1
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0C5729
1
ASSEMBLY, CRANKCASE HOUSING WITH
SLEEVE
SEAL, 38 I.D. CRANKSHAFT
SCREW, TAPTITE M6-1.0 X 12 YC
ASSEMBLY, BREATHER
GASKET, BREATHER COVER
SEPARATOR, OIL BREATHER
ASSEMBLY, HEAD #1 G&S
RETAINER, PISTON PIN 20
ROCKER, COVER NO OIL FILL
STUD M8-1.25/10MM X 30 G5 ZINC
PISTON, HC
SET, PISTON RING 90MM
PIN PISTON D20
ASSEMBLY, CAMSHAFT & GEAR
SHAFT, GOVERNOR
ROLLER BEARING, GOVERNOR PLATE
ROLLER BEARING, GOVERNOR
ASSEMBLY,GOVERNOR GEAR
SPOOL, GOVERNOR MACHINED
GASKET, CRANK CASE
SEAL, OIL PASSAGE
ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE (GT-990)
ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE (GT-760)
ASSEMBLY, CONNECTING ROD (GT-990)
ASSEMBLY, CONNECTING ROD (GT-760)
SCREW SHC M6-1.0 X 50 G8.8
SCREEN, OIL PICKUP
ASSEMBLY, OIL PUMP
SLEEVE, SEAMED DOWEL 10 DIA.
COVER, OIL RELIEF
SPRING, OIL RELIEF
BALL, 1/2D OIL RELIEF
35
36
37
38
39
40
41
0C2988
0C2992
0C3971C
0C5305
0C3027
0C3007
0C5731
1
1
1
1
1
1
1
THRUST WASHER, GOVERNOR
BUSHING, GOVERNOR LOWER
ASSEMBLY, DIPSTICK WITH HANDLE
TUBE, DIPSTICK
O-RING, OIL CLR 3/8 X 1/2
SEAL, 42 I.D. CRANKSHAFT
ASSEMBLY, HOUSING COVER WITH
SLEEVE
SCREW, HHFC M10-1.5 X 55
SCREW HHFC M6-1.0 X 20
ASSEMBLY, OIL FILL CAP
HOOK, LIFTING
ROCKER, COVER WITH OIL FILL
GASKET, VALVE COVER
KEEPER, VALVE SPRING
RETAINER, VALVE SPRING
SPRING, VALVE
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16A
16B
17
18
19
20
21
0C3008
090388
0C5372
0C3005
0C3003
0D8067A
071983
0C2981C
045761A
0C5848
021533
071980
0D4041
0C2983
0C2985A
0C2985B
0D4042
0A7811
0C2977
0C5943
0D4040E
1
8
1
1
3
1
4
1
4
2
2
2
1
1
2
1
1
1
1
1
1
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
0C3006
0C8566
093064
0C8808
0D2723B
0C2979
086515
0D2274
0D3867
078672
0C5371
0D5326
0D6023
0D5354
0D5313
0D6024
0C2976
086516
0C2229
083897
0D8067B
088396D
0C2978
043790A
0D4010
0D4011
0D4012
0D4013
0D8675A
0D8675B
0D4015
0D4016
9
8
1
2
1
2
8
4
4
2
4
4
4
4
4
2
12
2
2
4
1
4
2
1
1
1
1
1
1
1
1
1
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
NUT, JAM ROCKER ARM
STUD, ROCKER ARM M8-1.0 x 57mm
PIVOT, ROCKER ARM
ROCKER ARM
PLATE, PUSH ROD GUIDE
SCREW HHFC M8-1.25 X 65
VALVE, EXHAUST
VALVE, INTAKE
TAPPET, SOLID
ASSEMBLY, HEAD #2 G&S
PUSHROD, 144.6
GASKET, HEAD
BARBED ELBOW 90 3/8NPT X 3/8 L0CKTITE
KIT GASKET
KIT PISTON & RINGS
KIT BREATHER ASSEMBLY
KIT GOVERNOR ASSEMBLY
KIT HEAD ASSEMBLY CYLINDER 1
KIT HEAD ASSEMBLY CYLINDER 2
KIT OIL RELIEF
21
22
0D4122E
1
0C2969
0D3961
0D2157
0C5313
0D4123
078699E
0C3011
0C3009
0C3010
093873
0C5315
0C5998
0D1667
0C2991
2
2
2
1
1
2
2
2
2
2
1
1
1
2
23
24
25
26
27
28
29
30
31
32
33
34
WASHER, LOCK RIB M6
GEROTOR, OUTER
CLAMP, OIL TUBE
ARM, GOVERNOR
E-RING, GOVERNOR ARM
KIT GEAR COVER
37
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990/760 Engine – Drawing No. 0D8674-C Part 2
74
138
75
139
135
122
124
125
123
76
77
136
137
120
125
79
124
133
134
78
132
131
119
80
116
115
127
114
117
121
118
97
128
129
81
98
130
126
99
82
96
95
83
100
102
84
109
103
105
104
93
87
86
85
88
94
91
110
97
98
99
106
112
89
90
101
89
107
108
112
92
112
113
111
38
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990/760 Engine – Drawing No. 0D8674-C Part 2
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
74
75
76
77
78
0C5136A
0C3024
0C3040
0C8127
0D8564A
0D8564B
0D2595
0D4417
0C3025
0D3083
0C7292
070185
075281
0C1085
043182
035461A
2
1
1
1
1
1
4
4
1
1
1
1
1
2
2
2
KNOB, AIR CLEANER
COVER, AIRBOX NG/LP
PRE-CLEANER,
ELEMENT, AIR CLEANER
ASSEMBLY, MIXER/AIRBOX 990
ASSEMBLY, MIXER/AIRBOX 760
SCREW SHOULDER (8MM) M6-1.0 X 18
WASHER,RUBBER 1/4" X 1/8" THICK
SWITCH, OIL PRESS
ASSEMBLY, OIL DRAIN HOSE
NIPPLE, 3/4"-16 UNF
FILTER, OIL D 69 X 64 LONG
SWITCH, THERMAL 284F
SCREW PPHM M3-0.5 X 8
WASHER LOCK M3
BARBED STR 1/4NPT X 3/8 WITH VIBRA
SEAL
CLAMP HOSE #5.5 .62 - .62
HOSE, 3/8" I.D. X 6" LONG
COOLER, OIL
108
109
110
111
112
0C3034
0C8549
0C3022A
0D1131
045756
1
1
1
1
27
NUT,HEX M24
SNORKEL, AIR INTAKE
HOUSING, BLOWER NG COOLER
GUARD, FAN
SCREW TAPTITE M6-1X10 YELLOW
CHROME
NUT, GROMMET 1/4 PLUG
HOSE, BREATHER
BRACKET, STARTER
SCREW HHC M6-1.0 x 16 WITH LOCK-
WASHER
WRAPPER, UPPER CYLINDER 1
WRAPPER, LOWER CYLINDER 1
WRAPPER, LOWER CYLINDER 2
WRAPPER, UPPER CYLINDER 2
SCREW TAPTITE M5-0.8 X 8 BP
ASSEMBLY, GROUND WIRE
ASSEMBLY, IGNITION COIL
WASHER LOCK M6-1/4
79
80
81
82
83
84
85
86
87
88
113
114
115
116
0C9763
0C3036
0C8919
079246
4
1
1
1
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
0C3018
0C3019
0D1142A
0D1143
066849B
0C3053
0C3052
022097
092079
0C3017
0D4529
022129
061906
082774
052859
0C8468
0C3048
0D3754
0D3742
0C8482
0D2576
0D3743
0D3705
1
1
1
1
2
1
2
4
4
1
2
2
2
1
1
1
1
1
1
1
1
1
1
89
90
91
92
93
94
95
96
97
040173
0C9806
0C3026
0C9764
0C3043
0C7694
0C7693
0C3041
070008
070006
040976
0C3016A
085011
0C3725B
0C3031
0C3032
0A5992
051754
0C3033
4
2
1
4
2
1
1
2
4
4
4
1
1
1
1
1
2
2
1
SCREW TAPTITE M6-1.0 X 25 BP
STARTER
SPARKPLUG
PLASTITE,1/4-15 X 3/4
GASKET, MANIFOLD / PORT
MANIFOLD CYLINDER 2
MANIFOLD CYLINDER 1
SLEEVE, RUBBER
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 85 G8.8
KEY, WOODRFF 4 X 19D
NUT HEX LOCK M10-1.50
SPRING, ANTI-LASH
ROD, GOVERNOR CONTROL
ASSEMBLY, GOVERNOR LEVER
SPRING, GOVERNOR
ASSEMBLY, GOVERNOR ADJUSTER
SCREW SHC M10-1.5 X 70 G10.9
SPRING, GOVERNOR IDLE
ASSEMBLY, GOVERNOR ADJUSTER
BRACKET
WASHER FLAT M8 SS
98
99
WASHER LOCK M8 SSTL
SCREW SHC M8-1.25 X 20 G12.9
PLATE, BACKING GT990 WITH OIL COOL
INSULATOR ASSEMBLY IGNITION
FLYWHEEL ASSEMBLY
FAN, NYLON
PLATE, FAN
WASHER SHAKEPROOF INT M8 SS
SCREW HHC M8-1.25 X 12 G8.8
WASHER, 25mm I.D.
100
101
102
103
104
105
106
107
140
0C2993
1
SEAL, GOVERNOR SHAFT
39
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
7 kW Generator – Drawing No. 0D3504-B
36
45
30
47
49
50
48
34
46
44
34
40
43
42
41
6
51
35
34
7
29
1
31
37
18
28
2
39
3
26
21
38
8
24
25
4
9
22
32
19
30
10
10
14
20
12
17
10
28
27
38
5
31
32
31
16
23
11
52
33
28
15
19
17
32
13
31
28
31
32
40
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
7 kW Generator – Drawing No. 0D3504-B
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0C6934
0C9935H
0C9934H
0C6043A
0C8096
0C9593
0D3220
0C8860
031971
0C3168
056147
0D1847
0C7038C
0D1647
0D2558
0C7038B
0C7758
0388050AE0
0C2417A
082121C
066386
029451
049451
022237
022511
022131
039287
022145
049820
090388
022129
022259
059637
048031K
0C9592
057822
040976
0C2824
025145
090239
0C6989
0D1214
0C8127
0C3024
0D2273
055934N
074994
0C5136A
074906
022473
0D4662
0C8290
1
1
1
1
1
1
1
1
1
3
1
4
1
1
1
1
ADAPTOR, ENGINE
STATOR
ROTOR
CARRIER, REAR BEARING
FAN, 8" CURVED BLADE
MUFFLER
TAIL PIPE, MUFFLER
PANEL, MUFFLER BASE
BEARING #6205-2NSE-C3
5/16 SPECIAL L/WASH
BOLT ROTOR HHCS 5/16"-24 X 13-1/2" G5
BOLT STATOR IHHC M8-1.25 x 305mm
BRACKET, ALTERNATOR MOUNTING
DUCT, ALTERNATOR AIR
GASKET, ALTERNATOR AIR DUCT
BRACKET, ENGINE MOUNTING
RUBBER MOUNT
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
4
1
1
1
CABLE, #6 40" BLACK BATTERY
EARTH STRAP 3/8X 3/8
CLIP-J VINYL COAT .625 ID
ASSEMBLY BRUSH HOLDER
TAPE ELEC UL FOAM 1/8 X 1/2
WASHER FLAT .406ID X 1.62OD
WASHER LOCK 3/8
BOLT HHC 3/8-16 X 1-1/4 G5
WASHER FLAT 3/8 ZINC
SCREW HHC M8-1.25 X 45 G8.8
WASHER FLAT 5/16 ZINC
NUT LOCK HEX M8-1.25 NYL INSRT
SCREW TAP M6-1.0X12 BP
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW TAPTITE 3/8-16X 3/4" BP
BAND, HOSE CLAMP 35.05 DIA.
BELLOWS
1
1.8 FT
1
4
4
4
4
14
4
3
13
8
2
3
1
2
2
3
1
1
1
1
1
1
1
CLAMP HOSE #8 .53 - 1.00
SCREW SHC M8-1.25 X 20 G12.9
SCREW TAPR #10-32 X 9/16
U-BOLT 5/16"-18 X 1.25" W/ SADDLE
GASKET, EXHAUST
STINGER, ENGINE AIR IN
BASE, AIR CLEANER
ELEMENT, AIR CLEANER
COVER, AIR CLEANER NG/LP
TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG
CLAMP VINYL 1.31 X .281 Z
HOSE 1\2ID LP GAS
1
1.25 FT
2
4
4
6
1
KNOB, AIR CLEANER
SCREW TAPTITE M6-1 X 20 BP
WASHER FLAT 1/4 ZINC
SCREW HHTT M8-1.2 X 20 BP
GASKET, PANEL
41
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
12 kW and 15 kW Generator – Drawing No. 0D3417-B
42
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
12 kW and 15 kW Generator – Drawing No. 0D3417-B
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0C6934
0C7930
0D2359
0C7944
0D2356
0C6043
0D2336
0C6042
0D3220
0C8101
056482
0C3168
0D1838
0D1846
0C7038
0D1609
0D2559
0C7038A
0C7758
0388050AD0
0C2417A
082121C
066386
029451
049451
022237
022511
022131
039288
022145
049820
045756
022129
022259
059637
083512
074994
057822
052858
0C2824
025145
0C4138
048031C
030340
1
1
ADAPTOR, ENGINE
STATOR 12KW
STATOR 15KW
ROTOR 12KW
3
1
ROTOR 15KW
4
5
6
7
8
1
1
1
1
1
1
3
1
4
1
1
1
1
4
1
1
CARRIER, REAR BEARING
FAN, 12" CURVED BLADE
MUFFLER
TAIL PIPE, MUFFLER
PANEL, MUFFLER BASE
BEARING 1.1811-2.8346
5/16 SPECIAL LOCK WASHER
BOLT, HHCS 3/8"-24 x 15.50"
BOLT, HHCS M8-1.25 x 345mm
BRACKET, ALTERNATOR MOUNTING
DUCT, ALTERNATOR AIR
GASKET, ALTERNATOR AIR DUCT
BRACKET, ENGINE MOUNTING
RUBBER MOUNT
CABLE, #6 48" BLACK BATTERY
EARTH STRAP 3/8X 3/8
CLIP-J, VYNL COAT 0.625" ID
ASSEMBLY BRUSH HOLDER
TAPE ELEC UL FOAM 1/8 X 1/2
WASHER FLAT .406ID X 1.62OD
WASHER LOCK 3/8
SCREW HHC 3/8-16 X 1-1/4 G5
WASHER FLAT 3/8 ZINC
SCREW HHC M8-1.25 x 55 G8.8
WASHER FLAT 5/16 ZINC
NUT LOCK HEX M8-1.25 NYL INSERT
SCREW TAPTITE M6-1.0X10 BP
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW TAPTITE 3/8-16 X 3/4 BP
SCREW TAPTITE M8-1.25 X 16 BP
HOSE RES 1/2 LP GAS
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
1
1
2.6 FT
1
5
4
4
4
14
4
2
10
8
2
4
2.83 FT
4
4
3
1
2
2
CLAMP HOSE #8 .53 - 1.00
NUT LOCK M8
SCREW TAP-R #10-32 x 9/16
U-BOLT 5/16"-18 X 1.25" WITH SADDLE
GASKET, EXHAUST PORT
CLAMP HOSE BAND ¼"
HOSE 1/4 ID SAE 30R7
1.33 FT
43
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GN410 Engine – Drawing No. 0D3539-B Part 1
44
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GN410 Engine – Drawing No. 0D3539-B Part 1
ITEM
PART NO. QTY. DESCRIPTION
ITEM
PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
071978
071980
021533
0C5848
071983
0D4287
1
1
1
1
2
1
ASSEMBLY, CONNECTING ROD
PIN, PISTON D20
SET, PISTON RING 90MM
PISTON, HC
RETAINER, PISTON PIN 20
ASSEMBLY, CRANKSHAFT
GH410 SMALL TAPER
ARM, GOVERNOR RC45
PIN, "R" GOVERNOR ARM
WASHER, GOVERNOR ARM THRUST
CRANKCASE, SUBASSEMBLY
WITH PLUGS GH410
SEAL, 35 I.D. CRANKSHAFT
ASSEMBLY, GOVERNOR GEAR
C-RING, GOVERNOR GEAR RETAINER
SPOOL, GOVERNOR- MACHINE
ASSEMBLY, CAMSHAFT & GEAR
GASKET , CRANKCASE
GASKET, HEAD 410
COVER, OIL PRESSURE RELIEF
SPRING, OIL RELIEF 360
BALL, DIA 11/32 PRESSURE RELIEF
WASHER, THRUST GOVERNOR GEAR
ASSEMBLY, COVER, GEAR TOP
CHECK / FILL
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
086516
086517
088396B
083897
077158
0C3150
072694
083907
072696
078694
021742
0D6094
076329
086254
0D4788
1
1
2
2
1
1
2
2
2
1
4
1
1
1
1
VALVE, EXHAUST
VALVE, INTAKE
PUSH ROD
TAPPET
ASSEMBLY, SCREEN OIL PICK-UP
GASKET, ROCKER COVER 410
STUD, D20 PIVOT BALL
ROCKER ARM
NUT, JAM (ROCKER ARM)
PLATE, PUSH ROD GUIDE
SCREW, HHFL M10-1.5 X 105
ASSEMBLY, ROCKER COVER BREATHER
PLUG, OIL FILL PLASTIC
O-RING 17.8 I.D. x 2.4
7
8
9
0A7628
078658
078659
088261E
1
1
2
1
10
11
12
13
14
15
16
17
18
19
20
21
22
072655
0A7975
078645
0A7811
0A9877
076701
021713B
078691
0A5771
0A5776
076361
0A8898D
2
1
1
1
1
1
1
1
1
1
1
1
PLUG, STANDARD PIPE 3/8 STEEL
SQUARE HEAD
43
44
45
46
47
48
49
50
51
52
074908
086515
078606
0A1442
078672
089673
0B2104
078699C
0A7627
043790A
1
4
4
8
1
2
1
2
1
1
SCREW, TAPTITE M5-0.8 X 10 BP
KEEPER, VALVE SPRING
SCREW & LOCKWASHER M6-1 X 12
SCREW, HHFC M8-1.25 X 42
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
WASHER, LARGE SPRING
DOWEL, SEAMED SLEEVE
SHAFT, GOVERNOR RC55
BARBED ELBOW 90 3/8NPT X 3/8
LOCKTITE
23
24
25
26
27
0D2274
0C4391
086025
0C7393
021714
2
2
1
1
1
RETAINER, VALVE SPRING
VALVE SPRING LF
SET,GEROTOR 12 THK
BALANCER
ASSEMBLY,CYLINDER HEAD
SEATS & GUIDES
53
54
088590
078699B
1
1
DOWEL DIA 12 X 18L
DOWEL, SLEEVE SEAMED 12 DIA.
45
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GN410 Engine – Drawing No. 0D3539-B Part 2
46
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GN410 Engine – Drawing No. 0D3539-B Part 2
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0C1069
0D2922
0C8435
0C9997
088434
045756
088433B
0C3794
021544
040976
022129
0C2458A
083512
0D1401
091039
0C9619
049811
022097
040945
086999
0D5667A
049821
099236
070185
082774
091222ESRV
067198N
067890
072347
072734
072735
0C3978
0C6040
084542
092079
0A8222
083502
083503
0D3083
0C8434
090072
075281
043182
0C1085
5
1
1
1
1
11
1
1
1
2
2
1
1
1
1
1
2
4
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
2
SCREW, TAPTITE M6-1.0X8 YELLOW CHROME
HOUSING, BLOWER
TUBE, DIPSTICK
GUARD, FAN
WRAPPER, BOTTOM
SCREW, TAPTITE M6-1X10 YELLOW CHROME
WRAPPER, TOP
BUMPER, NEOPRENE
STARTER ASSEMBLY, EATON
SCREW, SHC M8-1.25 X 20 G12.9
WASHER, LOCK M8-5/16
BACKPLATE, L/F D/F
SCREW, TAPTITE M8-1.2 X 16 YC
BREATHER TUBE
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
GASKET, INTAKE ADAPTER
ASSEMBLY, PLASTIC CARB
WASHER, FLAT M6
WASHER, LOCK M6-1/4
SCREW, SHC M6-1.0 X 20 G12.9
GASKET,OIL FILTR ADAPTER
ADAPTER, OIL FILTER
SCREW, SHC M8-1.25 X 30 G12.9
SWITCH, OIL 8.0 PSI
FILTER, OIL DIA. 69 X 64 LG
KEY, WOODRFF 4 X 19D
FLYWHEEL WITH RING GEAR 32DEG.
WASHER,BELV-20 X 2.2
NUT, HEX - FLYWHEEL
SPARKPLUG
ASSEMBLY,GOVERNOR LEVER 12 HP
ROD,GOVERNOR CONTROL.
SPRING, ANTI-LASH
ASSEMBLY, WIRE
ASSEMBLY, IGNITION COIL - GN LF
SCREW, TAPTITE M6-1.0 X 25 BP
SPRING, GOVERNOR 8#
BOLT, GOVERNOR ADJUST M5
NUT, M5-0.8 METAL LOCK
ASSEMBLY, OIL DRAIN HOSE
ASSEMBLY, CAP & DIPSTICK
O-RING 9/16 X 3/4 X 3/32
SWITCH, THERMAL
WASHER LOCK M3
SCREW PPHM M3-0.5 X 8
47
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Gas Regulator – Drawing No. 0D8720-B
48
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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Gas Regulator – Drawing No. 0D8720-B
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
0D5694
0C5765
0C4647
0C4680
0C6070
022985
022264
075475
0C5760A
0C6606
097934
0C4645
0C5761
0C5968
0C6066
0C5759
0C5764
0C5764A
070728
070728
0C6069
0C5762
045764
045764
0C6731
0C6067
0C4706
0C6068
0C4643A
026073
0A4032
0D3308
0D3308
0C4643
028414A
0D5698A
0C5760B
0C5760C
0C5760D
0C5760E
0D3973
1
1
1
1
1
4
4
4
1
2*
2*
2*
2*
2*
2*
2*
2
CASTING, TWIN REGULATOR HOUSING
SOLENOID, TWIN REGULATOR
GASKET , SOLENOID
PLUNGER, LP REGULATOR ASSEMBLY
SPRING-SOLENOID, PLUNGER
WASHER, FLAT #6
WASHER, LOCK M4
SCREW PPHM M4-0.7 X 10
JET, GN 410 ENGINE LP (7KW)
BARBED STRAIGHT 1/2NPT x 1/2
O-RING, CHECK VALVE
ADJUSTER SCREW, TWIN REGULATOR
LEVER, REGULATOR
SUPPORT, INLET SEAL
SEAL, INLET
PIN, PIVOT ARM
SPRING, REGULATOR
SPRING, REGULATOR (7KW)
SCREW, PFHMS M3-0.5 x 5
SCREW, PFHMS M3-0.5 x 5 (7KW)
GASKET, DIAPHRAGM
COVER, TWIN REGULATOR
SCREW, TAPTITE M4X8 BP
SCREW, TAPTITE M4X8 BP (7KW)
RIVET, POP .118 X .125
1
4
2
18
19
20
21
2*
2*
16
8
2*
2*
2*
2*
2*
1
2*
4
2
1
1
22
23
24
25
26
27
28
29
SUPPORT, DIAPHRAGM
DIAPHRAGM, TWIN REGULATOR
CAP, DIAPHRAGM SUPPORT
INLET, TWIN REGULATOR 11.11 DIA.
PLUG, STANDARD PIPE 1/8 STEEL SQUARE HEAD
PIN, LIMITED ADJUSTMENT
WASHER, FLAT M3 X 10mm O.D.
WASHER, FLAT M3 X 10mm O.D. (7KW)
INLET, TWIN REGULATOR NO HOLE - NOT SHOWN (7KW)
BARBED STRAIGHT 1/8"NPT X 1/4"
JET IDLE PRIMER PHILLIPS HD
JET, GT760 CYL 1 NAT GAS
JET, GT760 CYL 2 NAT GAS
JET, GT 760 LP CYL 1
30
31
32
33
34
35
36
37
1
1
1
1
1
2
JET, GT760 LP CYL 2
PLUG, EXPANSION 16mm
* A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY
49
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Section 8 — Mounting Dimensions
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Drawing No. 0D3739-B
50
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Section 9 — Notes
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
51
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Section 10 – Warranty
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below.
CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with
Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.*
New (small off road) engines must be designed, built and equipped to meet stringent anti-smog standards for the state of
California and the federal government. 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 and exhaust systems. 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 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 because of the lack of receipts or for your failure to ensure the
completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or
responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unap-
proved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.
You are responsible for presenting your engine to 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 and federal 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 serv-
ice, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner shall be
responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the
inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or losses incurred while
the engine is being transported/shipped for inspection or warranty repairs.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the
following address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part 1
52
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Section 10 – Warranty
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:
(a) Applicability: This warranty shall apply to 1997 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 EPA and CARB pursuant to
their respective 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 manu-
facturer’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 responsible
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 purchaser/owner. Such use shall not reduce
Generac’s ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac
shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an
unapproved, add-on, modified, counterfeit and/or “grey market” part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
1.1) Gasoline carburetor assembly and its
internal components (if so equipped).
a) Fuel filter (if so equipped)
b) Carburetor gaskets
c) Fuel pump (if so equipped)
3) Ignition System including:
a) Spark plug
b) Ignition module
1.2) LPG carburetion assembly and its
internal components (if so equipped).
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)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
5) Crankcase Breather Assembly including:
a) Breather connection tube
*Generac engine types covered by this warranty statement include the following:
1) Utility
2) Lawn and Garden Equipment
3) Recreational Vehicle (RV) Generator
4) Industrial Mobile (IM) Generator
Part 2
53
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Section 10 – Warranty
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GENERAC POWER SYSTEMS STANDARD "TWO YEAR" LIMITED WARRANTY FOR
GUARDIAN “EMERGENCY AUTOMATIC STANDBY GENERATORS”
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or
replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer,
is found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equip-
ment that the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized
Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and pre-
paid by the purchaser/owner. This warranty applies only to Generac emergency automatic standby generators sold and rated
for use in "Standby" applications.
WARRANTY SCHEDULE
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and
maintenance is required):
• Engine - All Components
• Alternator - All Components
• Transfer System - All Components
All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate
Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Generac generators that utilize non-Generac replacement parts.
• Generac/Guardian generators utilizing non-Generac/Guardian automatic transfer switches.
• Any Generac generators used as rental or trailer mounted applications.
• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where
utility power service does not normally exist.
• Costs of normal maintenance, adjustments, installation and start-up.
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with
all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty
will not cover repair when normal use has exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit
warranty period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
USE OF NON-GENERAC/GUARDIAN TRANSFER SWITCHES SHALL VOID THIS WARRANTY WITH RESPECT TO ALL
GENERAC PRODUCT.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES
NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or conse-
quential damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
P.O. BOX 297
WHITEWATER, WI 53190
Part No. 0E1370
Revision A (07/31/02)
Printed in U.S.A.
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