Generac 04389-1, 04456-1, 04390-1 Exploded Views and Parts Lists, Part No.Qty. Description

Page 35
ITEM

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

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

0D1605

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

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

0D3057A

1

FOAM, FRONT INTAKE BAFFLE (12KW / 15KW)

 

0D3058A

1

FOAM, FRONT INTAKE BAFFLE (7KW)

29

0D3057B

1

FOAM, TOP INTAKE BAFFLE (12KW / 15KW)

30

0D3057C

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 ENCLOSURE 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 M8-1.20 X 16 BP

51

090388

34

SCREW TAPTITE M6-1.0 X 12 BP

 

 

 

(12KW / 15KW)

 

 

22

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

0D3338

1

HARNESS GENERATOR TO EXTERNAL

 

 

 

CONNECTION BOX (12KW / 15KW)

 

0D3419

1

HARNESS GENERATOR TO EXTERNAL

 

 

 

CONNECTION BOX (7KW)

 

0D3928

1

HARNESS GENERATOR TO EXTERNAL

 

 

 

CONNECTION BOX (16KW)

79

036937

2

SCREW PPHM #10-32 X 1

80

022152

5

WASHER LOCK #10

81

023897

2

WASHER FLAT #10 ZINC

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

Generac® Power Systems, Inc. 33

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Page 34 Page 36
Contents DANGER POWER SYSTEMS, INCDEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY POWER SYSTEMS‹CONTENTS INTRODUCTIONAUTHORIZED DEALER LOCATION DANGERIntroduction Parts of the generator are rotating and/or hot GENERAL HAZARDSDespite the safe design of this generator ‹STANDARDS INDEX ELECTRICAL HAZARDSFIRE HAZARDS EXPLOSION HAZARDS1.3SYSTEM SET LED 1.1UNPACKING/INSPECTION1.2PROTECTION SYSTEMS Figure 1.2 - 12 kW and 15 kW, V-twin GT-990Engine 1.4YOUR GENERATORFigure 1.1 - 7 kW, Single Cylinder GH-410Engine ‹1.5.2 ENGINE 1.5 SPECIFICATIONS‹ 1.5.1 GENERATOR DANGER 1.8RECONFIGURING THE FUEL SYSTEM1.6FUEL REQUIREMENTS AND RECOMMENDATIONS 1.7FUEL CONSUMPTION1.9.1 GENERATOR 1.10 BATTERY INSTALLATION1.9LOCATION 1.9.2 TRANSFER SWITCHDo not open or mutilate the battery. Released 1.11 THE BATTERYFigure 1.5 - Battery Cable Connections Wear rubber gloves and bootsNever operate the engine with the oil level 2.2CHECK TRANSFER SWITCH OPERATION2.1BEFORE INITIAL START-UP 2.3ELECTRICAL CHECKS2.5CHECKING AUTOMATIC OPERATION 2.6ADJUSTING THE REGULATOR NATURAL GAS ONLY2.4GENERATOR TESTS UNDER LOAD Do not make any unnecessary adjustments 2.7ENGINE GOVERNOR ADJUSTMENTFigure 2.2 - Placement of Regulator Figure 2.3 - Engine Governor AdjustmentFigure 2.5 - Voltage Adjustment Potentiometer 2.8VOLTAGE REGULATOR ADJUSTMENT3.1BREAK-INPROCEDURE Figure 2.4 - Full Load Speed Adjust Screw3.4SEQUENCE OF AUTOMATIC OPERATION 3.3AUTOMATIC TRANSFER OPERATION3.2USING THE AUTO/OFF/MANUAL SWITCH FIGURE With the switch set to AUTO, the engine mayFigure 3.2 - Manual Transfer Switch Operation 3.6SETTING THE EXERCISE TIMER3.5MANUAL TRANSFER OPERATION ‹3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE‹3.7.2 HIGH TEMPERATURE SWITCH 3.7PROTECTION SYSTEMS4.1FUSE ‹3.7.1 LOW OIL PRESSURE SWITCH‹4.3.1 ENGINE OIL RECOMMENDATIONS 4.2CHECKING THE ENGINE OIL LEVEL4.3CHANGING THE ENGINE OIL ‹ 4.3.2 OIL CHANGE PROCEDUREFigure 4.6 - 7 kW, Engine Air Cleaner Location 4.5CHANGING THE ENGINE AIR CLEANER4.4CHANGING THE OIL FILTER 4.6SPARK PLUGSFigure 4.8 - Setting the Spark Plug Gap 4.7BATTERY MAINTENANCE4.8ADJUSTING GH-410/GT-990VALVE CLEARANCE Figure 4.10 - Valve Clearance Adjustment 4.9COOLING SYSTEM4.10 ATTENTION AFTER SUBMERSION 4.11 CORROSION PROTECTION‹4.12.2 RETURN TO SERVICE 4.12 OUT OF SERVICE PROCEDURE‹4.12.1 REMOVAL FROM SERVICE 4.13 SERVICE SCHEDULE CORRECTION 5.1TROUBLESHOOTING GUIDEPROBLEM CAUSESection 6 - Electrical Data 24 Generac Power Systems, IncCONNECTION CONTROL PANEL BOXCUSTOMER 26 Generac Power Systems, Inc C2-6 28 Generac Power Systems, Inc Wiring Diagram - 7 kW - Drawing No. 0D9013-ACLOSEST TO BEA 4 0 STATOR CUSTOMER CONNECTION30 Generac Power Systems, Inc C2-6 32 Generac Power Systems, Inc Section 7 - Exploded Views and Parts ListsPART NO.QTY. DESCRIPTION Control Panel - Drawing No. 0D8503-E DESCRIPTION Section 7 - Exploded Views and Parts Lists 0D4801 37 17 24 0D3086 Kit Contains DESCRIPTION 42 Generac Power Systems, Inc DESCRIPTION 44 Generac Power Systems, Inc 7 kW Generator - Drawing No. 0D3504-B 46 Generac Power Systems, Inc 12 kW and 15 kW Generator - Drawing No. 0D3417-B 48 Generac Power Systems, Inc GN410 Engine - Drawing No. 0D3539-BPart 50 Generac Power Systems, Inc 0C1069 PART NO. QTY NTAKE Section 8 - Mounting DimensionsTRANSFER SWITCH Guardian Air54 Generac Power Systems, Inc Generac Power Systems, Inc Section 10 - Warranty CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIESEMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTYP.O. BOX WHITEWATER, WI WARRANTY SCHEDULEGENERAC POWER SYSTEMS, INC
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