Guardian 04389-1 Installation instructions

GENERAC
POWER SYSTEMS, INC.
R
R
Installation and
Owner’s Manual
Air-cooled, Prepackaged
Automatic Standby Generators
Models:
04389-1 (6 kW NG, 7 kW LP)
04456-1 (12 kW NG, 12 kW LP)
04390-1 (13 kW NG, 15 kW LP)
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
DANGER
Not intended for use as Primary Power in place of utility or in
life-support applications.
!!

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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Enclosure – Drawing No. 0D3416-Q

Generac®Power Systems, Inc. 33
ITEM PART NO.QTY. DESCRIPTION
1 0C6140 1 ASSEMBLY, ENCLOSURE BASE (12KW/15KW)
0D1901 1 ASSEMBLY, ENCLOSURE BASE (7KW)
2 0C6735 2 SUPPORT, ROOF FOLDING
3 0C7061 1 ENCLOSURE, FRONT
4 0C7062 1 ENCLOSURE, EXHAUST SIDE (12KW / 15KW)
0C7062A 1 ENCLOSURE, EXHAUST SIDE (7KW)
5 0C7063 1 ENCLOSURE, SIDE & BACK (12KW / 15KW)
0C7063A 1 ENCLOSURE, SIDE & BACK (7KW)
0C7063B 1 ENCLOSURE, SIDE & BACK (16KW)
6 0C7064 1 ENCLOSURE, ROOF
7 0C7065 1 PANEL, ALTERNATOR DIVIDER (12KW / 15KW)
0C7065A 1 PANEL, ALTERNATOR DIVIDER (7KW)
8 0C8101A 1 PANEL, MUFFLER BOX SIDE (12KW / 15KW)
0C8861 1 PANEL, MUFFLER BOX SIDE (7KW)
9 0C8101B 1 COVER, MUFFLER BOX (12KW / 15KW)
0C8862 1 COVER, MUFFLER BOX (7KW)
10 0C8283 1 GASKET, DOOR SEAL
11 0C8284A 1 FOAM, BACK ENCLOSURE
12 0C8284B 1 FOAM, ROOF ENCLOSURE
13 0C8284C 1 FOAM, FRONT ENCLOSURE
14 0C8285 1 BRACKET, BATTERY SUPPORT (12KW/15KW)
15 0C8899A 1 PAD, 24"X48" WITH MOUNTING HOLES
16 0D1128 1 PANEL, ENGINE DIVIDER (12KW / 15KW)
0D1128A 1 PANEL, ENGINE DIVIDER (7KW)
17 0E4244 1 BAFFLE, INTAKE (12KW / 15KW)
0D1605A 1 BAFFLE, INTAKE (7KW)
18 0D1606 1 HOUSING, FAN (12KW / 15KW)
0D5264 1 BAFFLE, EXHAUST (7KW)
19 0D1839 2 BRACKET, TOP SUPPORT
20 0D1840 2 BRACKET, BOTTOM SUPPORT
21 0D2425 1 DUCT, BASE AIR (12KW / 15KW)
22 0D2588 1 GASKET, FRONT DIVIDER (12KW / 15KW)
0D2588A 1 GASKET, FRONT DIVIDER (7KW)
23 0D2676 1 COVER, FRONT EXHAUST ENCLOSURE
24 0D2677 1 COVER, BACK EXHAUST ENCLOSURE
25 0D2979B 2 CLOTH, HARDWARE 266.7mm x 146mm
(12KW / 15KW)
0D2979B 3 CLOTH, HARDWARE 266.7mm x 146mm (7KW)
26 0D2979C 1 CLOTH, HARDWARE 543mm x 146mm
27 0D2979D 1 CLOTH, HARDWARE 266.7mm x 387.4mm
0D2979E 1 CLOTH, HARDWARE (7KW)
28 0E4245 1 FOAM, FRONT INTAKE BAFFLE (12KW/15KW)
0D3058A 1 FOAM, FRONT INTAKE BAFFLE (7KW)
29 0E4245A 1 FOAM, TOP INTAKE BAFFLE (12KW / 15KW)
30 0E4245B 1 FOAM, BACK INTAKE BAFFLE (12KW / 15KW)
0D3058C 1 FOAM, BACK INTAKE BAFFLE (7KW)
31 0D3057D 1 FOAM, BACK ENCL. STRIP (12KW / 15KW)
32 0D3059A 1 FOAM, EXHAUST SIDE ENCLOSURE END
33 0D3059B 1 FOAM, EXHAUST SIDE ENCLOSURE FRONT
34 0D3059C 1 FOAM, EXHAUST FAN HOUSING (12KW/15KW)
35 0D7176 24 WASHER, SELF LOCKING (12KW / 15KW)
22 WASHER, SELF LOCKING (7KW)
36 0D3059D 1 FOAM, FRONT EXHAUST ENCLSURE COVER
37 0D3059E 1 FOAM, BACK EXHAUST ENCLOSURE COVER
38 0C7781 2 DOOR, PAWL
39 0D3037 1 LATCH, QUARTER TURN LOCKING
40 0D2537 1 HINGE, LIFT OFF, TYPE A PIN
41 0D2538 1 HINGE, LIFT OFF, TYPE B PIN
42 0D3037A 1 LATCH, QUARTER TURN NON-LOCKING
43 0A2115 4 WASHER NYLON .250"
ITEM PART NO.QTY. DESCRIPTION
44 022097 9 WASHER LOCK M6-1/4"
45 022473 4 WASHER FLAT ¼" ZINC
46 036261 14 RIVET POP .125 X .129-.133/#30
47 047411 12 SCREW HHC M6-1.0 X 16 G8.8
48 043116 5 SCREW HHC M6-1.0 X 12 G8.8 (12KW / 15KW)
043116 6 SCREW HHC M6-1.0 X 12 G8.8 (7KW)
49 0D3700 18 NUT, LOCKING FLANGE M6-1.0
50 083512 11 SCREW TAPTITE M8-1.25 X 16 BP
51 090388 36 SCREW TAPTITE M6-1.0 X 12 BP (12KW/15KW)
24 SCREW TAPTITE M6-1.0 X 12 BP (7KW)
52 092120 2 NUT LOCK TRIC M6 X 1.0 Y/ZNC
54 0D3167 1 GASKET, BATTERY SUPPORT BRACKET
55 0A3328 1 PLUG, PLASTIC 0.593 HEYCO 1675
56 055414 1 LUG SLDLSS #2-#8X17/64 CU
57 092079 1 SCREW TAPTITE M6-1.0X25 BP
58 0A1658 2 L/WASH SPECIAL ¼
59 0C2937 1 BRACKET, BATTERY HOLD DOWN (7KW)
60 086729 1 CONTACTOR, STARTER (7KW)
61 0388040AJ0 1 CABLE, #6 RED BATTERY 38.5"
62 022127 2 NUT HEX 1/4-20 STEEL (7KW)
63 022129 4 WASHER LOCK 5/16 (12KW / /15KW)
022129 5 WASHER LOCK 5/16 (7KW)
64 074908 8 SCREW TAPTITE M5-0.8 X 10 BP
65 0D2346 1 HARNESS, ENGINE (12KW / 15KW)
0D2345 1 HARNESS, ENGINE (7KW)
66 023484F 1 BUSHING, SNAP SB-1000-12
67 022142 1 SCREW HHC 5/16-18 X 3/4 G5 (7KW)
68 0A7836 2 RIVET,1/8" X 0.126" - 0.375" LSH POP
69 0A8475 2 L/WASH SPECIAL #10
70 0912970069 1 ASSEMBLY, ROOF / DOOR GROUND WIRE
71 0912970070 2 ASSEMBLY, ROOF / DOOR GROUND WIRE
72 055450 2 PLUG PLASTIC 1.375 (12KW / 15KW)
73 0D2023 10.5 GASKET, CLIP-ON SELF GRIPPING
74 0D3701 1 PLATE, "HOT"
75 0D3472 1 GROMMET 2.75 X 1/16
76 0C8742 1 EXTERNAL CONNECTION BOX
77 0C8911 1 POWER BLOCK
78 0D8442 1 HARNESS GENERATOR TO EXTERNAL CON-
NECTION BOX (12KW / 15KW)
0D8652 1 HARNESS GENERATOR TO EXTERNAL CON-
NECTION BOX (7KW)
0D3928 1 HARNESS GENERATOR TO EXTERNAL CON-
NECTION BOX (16KW)
79 036937 2 SCREW PPHM #10-32 X 1
80 022152 5 WASHER LOCK #10
81 051713 2 WASHER FLAT M5
82 022158 5 NUT HEX #10-32 STEEL
83 0D3031 1 FUEL LINE, 3/4"OUTDOOR (NOT SHOWN)
84 026850 1 WASHER SHAKPROOF EXT 1/4 STEEL
85 049813 1 NUT HEX M6-1.0 G8 YELLOW CHROME
86 0D2537A 1 HINGE, LIFT OFF, TYPE A KNUCKLE
87 0D2538A 1 HINGE, LIFT OFF, TYPE B KNUCKLE
88 047411 2 SCREW HHC M6-1.0 X 16 G8.8
89 0A2311 1 SCREW SWAGE 1/4-20 X 1
90 043107 4 SCREW HHC M8-1.25 X 25
91 022145 8 WASHER FLAT 5/16
92 045771 4 NUT HEX M8-1.25
93 0C3906 2 SELF-ALIGN SCREW M6 HH
94 0E4321 1 PANEL, EXHAUST ALIGNMENT
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Enclosure – Drawing No. 0D3416-Q

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Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Control Panel – Drawing No. 0D8503-F

Generac®Power Systems, Inc. 35
ITEM PART NO. QTY. DESCRIPTION
1 0A9947E 1 CIRCUIT BREAKER 30 X 2 240V SQD
QOU230 (7KW)
0A9947G 1 CIRCUIT BREAKER 40 X 2 240V SQD
QOU240 (8.5KW)
0A9947F 1 CIRCUIT BREAKER 50 X 2 240V SQD
QOU250 (12KW)
0A9947C 1 CIRCUIT BREAKER 60 X 2 240V SQD
QOU260 (13KW)
0A9947D 1 CIRCUIT BREAKER 70 X 2 240V SQD
QOU260 (15KW)
2 0A1801 1 ASSEMBLY, BATTERY CHARGER ENGINE
3 083049 1 ASSEMBLY, POTTED REGULATOR
4 0C2174 1 RELAY, 12V 25A SPST (8.5KW/ 12KW/
13KW)
5 075210A 1 BLOCK 1 POSITION
6 0D3062 4 HEX STAND-OFF #6-32 x 3/8"
7 0D8615 1 ASSEMBLY, HOME STANDBY
CONTROLLER
8 032300 2 HOLDER, FUSE
9 022676 1 FUSE, 15AMP X AGC15
10 0E4494 1 SWITCH, ROCKER
11 0D5045 1 DIN RAIL
12 023484E 1 SNAP BUSHING SB-687-8
13 075476 4 SCREW PPHM M4-0.7 x 16mm
14 022264 8 WASHER LOCK M4
15 051715 8 NUT HEX M4-0.7
16 043182 4 WASHER LOCK M3 (8.5KW/ 12KW/ 13KW)
043182 2 WASHER LOCK M3 (7KW)
17 043181 4 SCREW PHM M3-0.5 x 10mm
18 0D8443 1 DECAL, CONTROL PANEL (NOT SHOWN)
19 054502 1 CIRCUIT BREAKER 3 X 1 ETA 46-500-P
(8.5KW/ 12KW/ 13KW)
053623 1 CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P
(7KW)
20 0D8438 1 CONTROL, PANEL BOTTOM (8.5KW/
12KW/ 13KW)
0E0118 1 CONTROL, PANEL BOTTOM (7KW)
21 075235 4 SCREW HHC M5-0.8 x 30mm
ITEM PART NO. QTY. DESCRIPTION
22 0D5240 1 SWITCH, SPDT ON-MOM-ON
23 051714 4 NUT HEX M3-0.5 (8.5KW/ 12KW/ 13KW)
051714 2 NUT HEX M3-0.5 (7KW)
24 0D8502 1 NEUTRAL ISOLATOR
26 0D8441 1 HARNESS, CONTROL PANEL WIRE (NOT
SHOWN) (8.5KW/ 12KW/ 13KW)
0E0120 1 HARNESS, CONTROL PANEL WIRE (NOT
SHOWN) (7KW)
27 074908 4 SCREW TAPTITE, M5-0.8 x 10 BP
28 049226 6 WASHER LOCK M5
29 051716 6 NUT HEX M5-0.8
30 0C3910 1 TRANSFORMER
31 022507 2 SCREW HHC 1/4"-20 x 1/2"
32 099727 1 FUSE 5A X AGC5
33 046689 1 TERMINAL STRIP
34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC
35 075475 4 SCREW PPHM M4-0.7 x 10mm
36 043180 2 WASHER FLAT M4
37 0D8439 1 COVER, CONTROL PANEL COMPONENT
(8.5KW/ 12KW/ 13KW)
0E0119 1 COVER, CONTROL PANEL COMPONENT
(7KW)
38 092036 8 SCREW PPHMS/LW #6-32 x 1/4"
39 045770 2 SCREW HHC M5-0.8 x10mm
40 0C7171 1 COVER, CONTROL PANEL (8.5KW/ 12KW/
13KW)
0D2989 1 COVER, CONTROL PANEL (7KW)
41 0D3700 10 NUT FLANGE M6-1.0 NYLOCK
42 0912970069 1 ASSEMBLY, ROOF/DOOR GROUND WIRE
43 0A2311 1 SCREW SWAGE 1/4"-20 x 1"
44 0A1658 2 LOCKWASHER SPECIAL 1/4"
45 022473 3 WASHER FLAT 1/4"
46 038750 1 SCREW HHC M6-1.0 x 30mm
47 022097 3 WASHER LOCK M6-1/4"
48 049813 1 NUT HEX M6-1.0
49 031879 4 WASHER FLAT #4 (8.5KW/ 12KW/ 13KW)
031879 2 WASHER FLAT #4 (7KW)
50 023897 2 WASHER FLAT #10
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
Control Panel – Drawing No. 0D8503-F

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3A
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
7 kW GTS Load Center Assembly – Drawing No. 0D3997-E

Generac®Power Systems, Inc. 37
ITEM PART NO. QTY. DESCRIPTION
1 0D4801 1 BOX GTS LOAD CENTER
2 0D4800 1 COVER, 8 POSITION GTS LOAD CENTER
3 0C2237 1 TRANSFER SWITCH HOME STANDBY 100A2P250V
3A 077220 1 COIL UTILITY
3B 077220A 1 COIL STANDBY
3C 082574 1 INSULATOR-SIDEWALL (NOT SHOWN)
3D 084464 1 LIMIT SWITCH OPERATION (NOT SHOWN)
4 074908 6 SCREW TAPTITE M5-0.8 X 10 BP
5 024912 1 SCREW TAPTITE 1/4-20 X 5/8 BP
6 0A1658 1 LOCK WASHER, SPECIAL-1/4"
7 063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC
8 0D3030A 1 BASE, MOUNTING 6 POLE 125A/240V
9 0A1495 4 SCREW TAPTITE M4-0.7X10 BP
10 0A1661 2 RIVET POP .156 X .160-.164/#20
11 022473 1 WASHER FLAT 1/4 ZINC
12 0D3094 1 HARNESS,GTS TO MAIN PANEL
13 0D4684A 1 HARNESS ADAPTER PLATE
14 0D3319 1 PANEL-SUB BREAKER BASE
15 056326 1 FT TRIM VINYL BLACK 1/8GP
16 022152 6 WASHER LOCK #10
17 087680 1 NUT WING M6-1.0
18 077441 1 HANDLE, TRANSFER SWITCH HOME STANDBY
19 063378 4 HOLDER CABLE TIE
21 074138 2 LUG DIS QK NI-S 10X45 DEG BR/T
22 036933 6 SCREW PPHM #10-32 X 3/8"
23 077033 6 LUG SLDLSS 1/0-#14X9/16 AL/CU
24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V
25 028739 4 TIE WRAP 3.9" X .10" NAT'L UL
26 038150 2 WASHER FLAT #8 ZINC
27 0D3191 1 COVER, RELAY & TERM BLOCK
28 0D3088 1 WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)
29 073591 2 FUSE HOLDER
30 073590A 2 ASSEMBLY FUSE 5A X BUSS HLDR73591
31 040213B 4 PCB SUPPORT SNAP-IN 1-3/8"
32 0C8037 1 CIRCT BRK 20 X 1 HOM120
33 075475 2 SCREW PPHM M4-0.7 X 10
34 0C8036 5 CIRCT BRK 15 X 1 HOM115
35 0C8035 1 CIRCT BRK 30 X 2 HOM230
36 0D3320 1 COVER - HARNESS ENTRY
37 0D4802 1 HARNESS, GTS TO EXT CONN BOX
38 022264 2 WASHER LOCK M4
39 0A7215 4 SCREW SW 1/4-20X5/8 N WA JS500
40 0A2110 4 SCREW SWAGE 1/4-20 X 1/2 ZINC
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
7 kW GTS Load Center Assembly – Drawing No. 0D3997-E

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1
3
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B
3A
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
12 kW and 15 kW GTS Load Center Assembly – Drawing No. 0D3996-D

Generac®Power Systems, Inc. 39
ITEM PART NO. QTY. DESCRIPTION
1 0D3086 1 BOX GTS LOAD CENTER
2 0D3092 1 COVER, 12 POSITION GTS LOAD CENTER
3 0C2237 1 TRANSFER SWITCH HOME STANDBY 100A2P250V
3A 077220 1 COIL UTILITY
3B 077220A 1 COIL STANDBY
3C 082574 1 INSULATOR-SIDEWALL (NOT SHOWN)
3D 084464 1 LIMIT SWITCH OPERATION (NOT SHOWN)
4 074908 6 SCREW TAPTITE M5-0.8 X 10 BP
5 024912 1 SCREW TAPTITE 1/4-20 X 5/8 BP
6 0A1658 1 LOCK WASHER, SPECIAL-1/4"
7 063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC
8 0D3030 1 BASE, MOUNTING 6 POLE 125A/240V
9 0A1495 4 SCREW TAPTITE M4-0.7X10 BP
10 0A1661 2 RIVET POP .156 X .160-.164/#20
11 022473 1 WASHER FLAT 1/4 ZINC
12 055450 1 PLUG HEYMAN DP1375 (10KW / 12KW / 13KW)
025034 1 PLUG STEEL 1.0625 STMPSN 3811 (14KW / 15KW / 16KW)
13 0D4684 1 HARNESS ADAPTER PLATE
14 0D3319 1 PANEL-SUB BREAKER BASE
15 056326 1 FT TRIM VINYL BLACK 1/8GP
16 022152 6 WASHER LOCK #10
17 087680 1 NUT WING M6-1.0
18 077441 1 HANDLE, TRANSFER SWITCH HOME STANDBY
19 063378 4 HOLDER CABLE TIE
21 074138 2 LUG DIS QK NI-S 10X45 DEG BR/T
22 036933 6 SCREW PPHM #10-32 X 3/8"
23 077033 6 LUG SLDLSS 1/0-#14X9/16 AL/CU
24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V
25 028739 4 TIE WRAP 3.9" X .10" NAT'L UL
26 038150 2 WASHER FLAT #8 ZINC
27 0D3191 1 COVER, RELAY & TERM BLOCK
28 0D3088 1 WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)
29 073591 2 FUSE HOLDER
30 073590A 2 ASSEMBLY FUSE 5A X BUSS HLDR73591
31 040213B 4 PCB SUPPORT SNAP-IN 1-3/8"
32 0C8037 3 CIRCT BRK 20 X 1 HOM120
33 0D3190 1 CIRCT BRK 20 X 2 HOM220
34 0C8036 5 CIRCT BRK 15 X 1 HOM115
35 0C8035 1 CIRCT BRK 30 X 2 HOM230
36 0D3320 1 COVER - HARNESS ENTRY
37 0D3093 1 HARNESS, GTS TO EXT CONN BOX (10KW / 12KW / 13KW)
0D3926 1 HARNESS, GTS TO EXT CONN BOX (14KW / 15KW / 16KW)
38 022264 2 WASHER LOCK M4
39 0A7215 4 SCREW SW 1/4-20X5/8 N WA JS500
40 0A2110 4 SCREW SWAGE 1/4-20 X 1/2 ZINC
41 075475 2 SCREW PPHM M4-0.7 X 10
42 0D3094 1 HARNESS,GTS TO MAIN PANEL
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
12 kW and 15 kW GTS Load Center Assembly – Drawing No. 0D3996-D

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it
C
ontains:
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990 Engine – Drawing No. 0D8674-E Part 1

Generac®Power Systems, Inc. 41
ITEM PART NO. QTY. DESCRIPTION
1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH
SLEEVE
2 0C3008 1 SEAL, 38 I.D. CRANKSHAFT
3 090388 8 SCREW, TAPTITE M6-1.0 X 12 YC
4 0C5372 1 ASSEMBLY, BREATHER
5 0C3005 1 GASKET, BREATHER COVER
6 0E1684 3 SEPARATOR, OIL BREATHER
7 0D8067A 1 ASSEMBLY, HEAD #1 G&S
8 071983 4 RETAINER, PISTON PIN 20
9 0C2981C 1 ROCKER, COVER NO OIL FILL
10 045761A 4 STUD M8-1.25/10MM X 30 G5 ZINC
11 0C5848 2 PISTON, HC
12 021533 2 SET, PISTON RING 90MM
13 071980 2 PIN PISTON D20
14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR
15 0C2983 1 SHAFT, GOVERNOR
16A 0C2985A 2 ROLLER BEARING, GOVERNOR PLATE
16B 0C2985B 1 ROLLER BEARING, GOVERNOR
17 0D4042 1 ASSEMBLY,GOVERNOR GEAR
18 0A7811 1 SPOOL, GOVERNOR MACHINED
19 0C2977 1 GASKET, CRANK CASE
20 0C5943 1 SEAL, OIL PASSAGE
21 0D4040E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE (GT-990)
0D4122E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE (GT-760)
22 0C2969 2 ASSEMBLY, CONNECTING ROD (GT-990)
0D3961 2 ASSEMBLY, CONNECTING ROD (GT-760)
23 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8
24 0C5313 1 SCREEN, OIL PICKUP
25 0D4123 1 ASSEMBLY, OIL PUMP
26 078699E 2 SLEEVE, SEAMED DOWEL 10 DIA.
27 0C3011 2 COVER, OIL RELIEF
28 0C3009 2 SPRING, OIL RELIEF
29 0C3010 2 BALL, 1/2D OIL RELIEF
30 093873 2 WASHER, LOCK RIB M6
31 0C5315 1 GEROTOR, OUTER
32 0C5998 1 CLAMP, OIL TUBE
33 0D1667 1 ARM, GOVERNOR
34 0C2991 2 E-RING, GOVERNOR ARM
35 0C2988 1 THRUST WASHER, GOVERNOR
ITEM PART NO. QTY. DESCRIPTION
36 0C2992 1 BUSHING, GOVERNOR LOWER
37 0C3971C 1 ASSEMBLY, DIPSTICK WITH HANDLE
38 0C5305 1 TUBE, DIPSTICK
39 0C3027 1 O-RING, OIL CLR 3/8 X 1/2
40 0C3007 1 SEAL, 42 I.D. CRANKSHAFT
41 0C5731 1 ASSEMBLY, HOUSING COVER WITH
SLEEVE
42 0C3006 9 SCREW, HHFC M10-1.5 X 55
43 080318 8 SCREW HHFC M6-1.0 X 25
44 093064 1 ASSEMBLY, OIL FILL CAP
45 0C8808 2 HOOK, LIFTING
46 0D2723B 1 ROCKER, COVER WITH OIL FILL
47 0C2979 2 GASKET, VALVE COVER
48 086515 8 KEEPER, VALVE SPRING
49 0D2274 4 RETAINER, VALVE SPRING
50 0D3867 4 SPRING, VALVE
51 078672 2 SEAL, VALVE STEM D7
52 0C5371 4 WASHER, VALVE SPRING
53 072694 4 STUD, ROCKER ARM PIVOT
54 0D3998 4 NUT HEX M8-1.0 G8 YEL CHR
55 0C3027 2 O-RING, 3/8" X 1/2"
56 0D5313 4 ROCKER ARM
57 0D6024 2 PLATE, PUSH ROD GUIDE
58 0C2976 12 SCREW HHFC M8-1.25 X 65
59 086516 2 VALVE, EXHAUST
60 0C2229 2 VALVE, INTAKE
61 083897 4 TAPPET, SOLID
62 0D8067B 1 ASSEMBLY, HEAD #2 G&S
63 0D9853D 4 PUSHROD, 147
64 0C2978 2 GASKET, HEAD
65 043790A 1 BARBED ELBOW 90 3/8NPT X 3/8
L0CKTITE
66 0D4010 1 KIT GASKET
67 0D4011 1 KIT PISTON & RINGS
68 0D4012 1 KIT BREATHER ASSEMBLY
69 0D4013 1 KIT GOVERNOR ASSEMBLY
70 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1
71 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2
72 0D4015 1 KIT OIL RELIEF
73 0D4016 1 KIT GEAR COVER
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990 Engine – Drawing No. 0D8674-E Part 1

42 Generac®Power Systems, Inc.
112
112
111
1
07
1
06
1
05
1
04
1
03
1
02
1
09
99
92
95
96
91
89
90
89
88
86
85
83
84
82
81
1
30
99
11
8
12
6
94
7
9
7
8
7
6
77
7
5
74
122
12
5
12
3
12
5
11
9
12
0
1
37
1
36
1
34
1
33
1
32
127
2
9
1
35
11
3
1
01
11
0
121
112
12
8
124
24
80
87
98
97
1
38
1
39
1
1
116
141
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990/760 Engine – Drawing No. 0D8674-E Part 2

Generac®Power Systems, Inc. 43
ITEM PART NO. QTY. DESCRIPTION
74 0C5136A 2 KNOB, AIR CLEANER
75 0C3024 1 COVER, AIRBOX NG/LP
76 0C3040 1 PRE-CLEANER,
77 0C8127 1 ELEMENT, AIR CLEANER
78 0D8564A 1 ASSEMBLY, MIXER/AIRBOX 990
0D8564B 1 ASSEMBLY, MIXER/AIRBOX 760
79 0D2595 4 SCREW SHOULDER (8MM) M6-1.0 X 18
80 0D4417 4 WASHER,RUBBER 1/4" X 1/8" THICK
81 0C3025 1 SWITCH, OIL PRESS
82 0D3083 1 ASSEMBLY, OIL DRAIN HOSE
83 0C7292 1 NIPPLE, 3/4"-16 UNF
84 070185 1 FILTER, OIL D 69 X 64 LONG
85 075281 1 SWITCH, THERMAL 284F
86 0C1085 2 SCREW PPHM M3-0.5 X 8
87 043182 2 WASHER LOCK M3
88 035461A 2 BARBED STR 1/4NPT X 3/8 WITH VIBRA
SEAL
89 0C7649 4 CLAMP HOSE .38-.87
90 0C9806 2 HOSE, 3/8" I.D. X 6" LONG
91 0C3026 1 COOLER, OIL
92 0C9764 4 PLASTITE,1/4-15 X 3/4
93 0C3043 2 GASKET, MANIFOLD / PORT
94 0C7694 1 MANIFOLD CYLINDER 2
95 0C7693 1 MANIFOLD CYLINDER 1
96 0C3041 2 SLEEVE, RUBBER
97 070008 4 WASHER FLAT M8 SS
98 070006 4 WASHER LOCK M8 SSTL
99 040976 4 SCREW SHC M8-1.25 X 20 G12.9
100 0C3016A 1 PLATE, BACKING GT990 WITH OIL COOL
101 085011 1 INSULATOR ASSEMBLY IGNITION
102 0C3725B 1 FLYWHEEL ASSEMBLY
103 0C3031 1 FAN, NYLON
104 0C3032 1 PLATE, FAN
105 0A5992 2 WASHER SHAKEPROOF INT M8 SS
106 051754 2 SCREW HHC M8-1.25 X 12 G8.8
107 0C3033 1 WASHER, 25mm I.D.
108 0C3034 1 NUT,HEX M24
ITEM PART NO. QTY. DESCRIPTION
109 0C8549 1 SNORKEL, AIR INTAKE
110 0C3022A 1 HOUSING, BLOWER NG COOLER
111 0D1131 1 GUARD, FAN
112 045756 27 SCREW TAPTITE M6-1X10 YELLOW
CHROME
113 0C9763 4 NUT, GROMMET 1/4 PLUG
114 0C3036 1 HOSE, BREATHER
115 0C8919 1 BRACKET, STARTER
116 079246 1 SCREW HHC M6-1.0 x 16 WITH LOCK-
WASHER
117 0C3018 1 WRAPPER, UPPER CYLINDER 1
118 0C3019 1 WRAPPER, LOWER CYLINDER 1
119 0D1142A 1 WRAPPER, LOWER CYLINDER 2
120 0D1143 1 WRAPPER, UPPER CYLINDER 2
121 066849B 2 SCREW TAPTITE M5-0.8 X 8 BP
122 0C3053 1 ASSEMBLY, GROUND WIRE
123 0C3052 2 ASSEMBLY, IGNITION COIL
124 022097 4 WASHER LOCK M6-1/4
125 092079 4 SCREW TAPTITE M6-1.0 X 25 BP
126 0C3017 1 STARTER
127 0D4529 2 SPARKPLUG
128 022129 2 WASHER LOCK M8-5/16
129 061906 2 SCREW HHC M8-1.25 X 85 G8.8
130 082774 1 KEY, WOODRFF 4 X 19D
131 052859 1 NUT HEX LOCK M10-1.50
132 0C8468 1 SPRING, ANTI-LASH
133 0C3048 1 ROD, GOVERNOR CONTROL
134 0D3754 1 ASSEMBLY, GOVERNOR LEVER
135 0D3742 1 SPRING, GOVERNOR
136 0C8482 1 ASSEMBLY, GOVERNOR ADJUSTER
137 0D2576 1 SCREW SHC M10-1.5 X 70 G10.9
138 0D3743 1 SPRING, GOVERNOR IDLE
139 0D3705 1 ASSEMBLY, GOVERNOR ADJUSTER
BRACKET
140 0C2993 1 SEAL, GOVERNOR SHAFT
141 0E1552 4 SCREW FHHC M6-1.0 X12 W/M5 HEX
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GT-990/760 Engine – Drawing No. 0D8674-E Part 2

44 Generac®Power Systems, Inc.
3
7
6
51
7
8
21
53
9
3
2
1
4
5
23
11
3
1
3
1
12
5
22
14
20
38
15
3
0
24
26
32
10
19
16
28
27
17
10
1
28
3
1
3
2
17
3
2
3
1
33
28
13
39
18
4
0
28
3
4
35
3
4
44
48
30
45
46
3
4
36
47
5
2
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
7 kW Generator – Drawing No. 0D3504-C

Generac®Power Systems, Inc. 45
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
7 kW Generator – Drawing No. 0D3504-C
ITEM PART NO. QTY. DESCRIPTION
1 0C6934 1 ADAPTOR, ENGINE
2 0C9935H 1 STATOR
3 0C9934H 1 ROTOR
4 0C6043A 1 CARRIER, REAR BEARING
5 0C8096 1 FAN, 8" CURVED BLADE
6 0C9593 1 MUFFLER
7 0D3220 1 TAIL PIPE, MUFFLER
8 0C8860 1 PANEL, MUFFLER BASE
9 031971 1 BEARING #6205-2RS-C3
10 0C3168 3 5/16 SPECIAL L/WASH
11 056147 1 BOLT ROTOR HHCS 5/16"-24 X 13-1/2" G5
12 0D1847 4 BOLT STATOR HHCS M8-1.25 x 305mm
13 0C7038C 1 BRACKET, ALTERNATOR MOUNTING
14 0D1647 1 DUCT, ALTERNATOR AIR
15 0D2558 1 GASKET, ALTERNATOR AIR DUCT
16 0C7038B 1 BRACKET, ENGINE MOUNTING
17 0C7758 4 RUBBER MOUNT
18 0388050AE0 1 CABLE, #6 40" BLACK BATTERY
19 0C2417A 1 EARTH STRAP 3/8X 3/8
20 082121C 1 CLIP-J VINYL COAT .625 ID
21 066386 1 ASSEMBLY BRUSH HOLDER
22 029451 1.8 FT TAPE ELEC UL FOAM 1/8 X 1/2
23 049451 1 WASHER FLAT .406ID X 1.62OD
24 022237 4 WASHER LOCK 3/8
25 022511 4 BOLT HHC 3/8-16 X 1-1/4 G5
26 022131 4 WASHER FLAT 3/8 ZINC
27 039287 4 SCREW HHC M8-1.25 X 45 G8.8
28 022145 14 WASHER FLAT 5/16 ZINC
29 049820 4 NUT LOCK HEX M8-1.25 NYL INSRT
30 090388 3 SCREW TAP M6-1.0X12 BP
31 022129 13 WASHER LOCK M8-5/16
32 022259 8 NUT HEX 5/16-18 STEEL
33 059637 2 SCREW TAPTITE 3/8-16X 3/4" BP
34 048031K 3 BAND, HOSE CLAMP 35.05 DIA.
35 0C9592 1 BELLOWS
36 057822 2 CLAMP HOSE #8 .53 - 1.00
37 040976 2 SCREW SHC M8-1.25 X 20 G12.9
38 0C2824 1 SCREW TAPR #10-32 X 9/16
39 025145 1 U-BOLT 5/16"-18 X 1.25" W/ SADDLE
40 090239 1 GASKET, EXHAUST
41 0C6989 1 STINGER, ENGINE AIR IN
42 0D1214 1 BASE, AIR CLEANER
43 0C8127 1 ELEMENT, AIR CLEANER
44 0C3024 1 COVER, AIR CLEANER NG/LP
45 0D2273 1 TUBE, 1.25"O.D. x 20Ga. x 12.125" LONG
46 055934N 1 CLAMP VINYL 1.31 X .281 Z
47 074994 1.25 FT HOSE 1\2ID PETROLEUM
48 0C5136A 2 KNOB, AIR CLEANER
49 074906 4 SCREW TAPTITE M6-1 X 20 BP
50 022473 4 WASHER FLAT 1/4 ZINC
51 0D4662 6 SCREW HHTT M8-1.2 X 20 BP
52 0C8290 1 GASKET, PANEL
53 066849 2 SCREW HHTT M5-0.8 X 16

46 Generac®Power Systems, Inc.
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3
4
11
2
5
24
43
21
7
13
33
12
38
17
3
2
3
1
28
3
1
20
19
10
17
15
3
2
16
22
39
8
6
37
14
3
2
40
32
24
25
10
30
19
26
28
27
28
3
2
3
1
41
10
18
36
35
29
41
42
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
12 kW and 15 kW Generator – Drawing No. 0D3417-D

Generac®Power Systems, Inc. 47
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
12 kW and 15 kW Generator – Drawing No. 0D3417-D
ITEM PART NO. QTY. DESCRIPTION
1 0C6934 1 ADAPTOR, ENGINE
2 0C7930 1 STATOR 12KW
0D2359 STATOR 15KW
3 0C7944 1 ROTOR 12KW
0D2356 ROTOR 15KW
4 0C6043 1 CARRIER, REAR BEARING
5 0D2336 1 FAN, 12" CURVED BLADE
6 0D6634 1 MUFFLER
7 0D3220 1 TAIL PIPE, MUFFLER
8 0C8101 1 PANEL, MUFFLER BASE
9 056482 1 BEARING 1.1811-2.8346
10 0C3168 3 5/16 SPECIAL LOCK WASHER
11 0D1838 1 BOLT, HHCS 3/8"-24 x 15.50"
12 0D1846 4 BOLT, HHCS M8-1.25 x 345mm
13 0C7038 1 BRACKET, ALTERNATOR MOUNTING
14 0D1609 1 DUCT, ALTERNATOR AIR
15 0D2559 1 GASKET, ALTERNATOR AIR DUCT
16 0C7038A 1 BRACKET, ENGINE MOUNTING
17 0C7758 4 RUBBER MOUNT
18 0388050AD0 1 CABLE, #6 48" BLACK BATTERY
19 0C2417A 1 EARTH STRAP 3/8X 3/8
20 082121C 1 CLIP-J, VYNL COAT 0.625" ID
21 066386 1 ASSEMBLY BRUSH HOLDER
22 029451 2.6 FT TAPE ELEC UL FOAM 1/8 X 1/2
23 049451 1 WASHER FLAT .406ID X 1.62OD
24 022237 5 WASHER LOCK 3/8
25 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5
26 022131 4 WASHER FLAT 3/8 ZINC
27 039288 4 SCREW HHC M8-1.25 x 55 G8.8
28 022145 14 WASHER FLAT 5/16 ZINC
29 049820 4 NUT LOCK HEX M8-1.25 NYL INSERT
30 045756 2 SCREW TAPTITE M6-1.0X10 BP
31 022129 10 WASHER LOCK M8-5/16
32 022259 8 NUT HEX 5/16-18 STEEL
33 059637 2 SCREW TAPTITE 3/8-16 X 3/4 BP
34 083512 4 SCREW TAPTITE M8-1.25 X 16 BP
35 074994 2.83 FT HOSE RES 1/2 LP GAS
36 057822 4 CLAMP HOSE #8 .53 - 1.00
37 052858 4 NUT LOCK M8
38 0C2824 1 SCREW TAP-R #10-32 x 9/16
39 025145 1 U-BOLT 5/16"-18 X 1.25" WITH SADDLE
40 0C4138 2 GASKET, EXHAUST PORT
41 048031C 2 CLAMP HOSE BAND ¼"
42 030340 1.33 FT HOSE 1/4 ID SAE 30R7
43 066849 2 SCREW HHTT M5-0.8 X 16

48 Generac®Power Systems, Inc.
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47
33
3
4
36
35
37
27
45
43
39
18
19
20
23
3
2
44
48
24
46
11
22
29
28
3
1
30
17
5
2
1
14
13
26
38
25
25
40
41
21
15
16
6
1
2
4
42
10
5
7
3
8
9
49
5
1
50
5
4
53

Generac®Power Systems, Inc. 49
ITEM PART NO. QTY. DESCRIPTION
1 071978 1 ASSEMBLY, CONNECTING ROD
2 071980 1 PIN, PISTON D20
3 021533 1 SET, PISTON RING 90MM
4 0C5848 1 PISTON, HC
5 071983 2 RETAINER, PISTON PIN 20
6 0D4287 1 ASSEMBLY, CRANKSHAFT GH410 SMALL TAPER
7 0A7628 1 ARM, GOVERNOR RC45
8 078658 1 PIN, "R" GOVERNOR ARM
9 078659 2 WASHER, GOVERNOR ARM THRUST
10 088261E 1 CRANKCASE, SUBASSEMBLY WITH PLUGS GH410
11 072655 2 SEAL, 35 I.D. CRANKSHAFT
12 0A7975 1 ASSEMBLY, GOVERNOR GEAR
13 078645 1 C-RING, GOVERNOR GEAR RETAINER
14 0A7811 1 SPOOL, GOVERNOR- MACHINE
15 0A9877 1 ASSEMBLY, CAMSHAFT & GEAR
16 076701 1 GASKET , CRANKCASE
17 021713B 1 GASKET, HEAD 410
18 078691 1 COVER, OIL PRESSURE RELIEF
19 0A5771 1 SPRING, OIL RELIEF 360
20 0A5776 1 BALL, DIA 11/32 PRESSURE RELIEF
21 076361 1 WASHER, THRUST GOVERNOR GEAR
22 0A8898D 1 ASSEMBLY, COVER, GEAR TOP CHECK / FILL
23 0D2274 2 RETAINER, VALVE SPRING
24 0C4391 2 VALVE SPRING LF
25 086025 1 SET,GEROTOR 12 THK
26 0C7393 1 BALANCER
27 021714 1 ASSEMBLY,CYLINDER HEAD SEATS & GUIDES
28 086516 1 VALVE, EXHAUST
29 086517 1 VALVE, INTAKE
30 088396B 2 PUSH ROD
31 083897 2 TAPPET
32 077158 1 ASSEMBLY, SCREEN OIL PICK-UP
33 0C3150 1 GASKET, ROCKER COVER 410
34 072694 2 STUD, D20 PIVOT BALL
35 083907 2 ROCKER ARM
36 072696 2 NUT, JAM (ROCKER ARM)
37 078694 1 PLATE, PUSH ROD GUIDE
38 021742 4 SCREW, HHFL M10-1.5 X 105
39 0C3972 1 ASSEMBLY, ROCKER COVER BREATHER
40 076329 1 PLUG, OIL FILL PLASTIC
41 086254 1 O-RING 17.8 I.D. x 2.4
42 0D4788 1 PLUG, STANDARD PIPE 3/8 STEEL SQUARE HEAD
43 074908 1 SCREW, TAPTITE M5-0.8 X 10 BP
44 086515 4 KEEPER, VALVE SPRING
45 078606 4 SCREW & LOCKWASHER M6-1 X 12
46 0A1442 8 SCREW, HHFC M8-1.25 X 42
47 078672 1 SEAL, VALVE STEM D7
48 089673 2 WASHER, VALVE SPRING
49 0B2104 1 WASHER, LARGE SPRING
50 078699C 2 DOWEL, SEAMED SLEEVE
51 0A7627 1 SHAFT, GOVERNOR RC55
52 043790A 1 BARBED ELBOW 90 3/8NPT X 3/8 LOCKTITE
53 088590 1 DOWEL DIA 12 X 18L
54 078699B 1 DOWEL, SLEEVE SEAMED 12 DIA.
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GN410 Engine – Drawing No. 0D3539-D Part 1

50 Generac®Power Systems, Inc.
19
21
6
2
20
28
24
3
40
40
41
44
2
4
6
6
5
12
7
8
9
10
13
14
1
16
18
11
6
37
36
35
27
17
18
3
4
33
3
4
18
29
30
3
1
38
6
Section 7 — Exploded Views and Parts Lists
Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators
GN410 Engine – Drawing No. 0D3539-D Part 2