Exploded Views and Parts Lists | Generac 04389-1, 04456-1, 04390-1

				Section 7 — Exploded Views and Parts Lists
				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
	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	0D6094	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.

Generac® Power Systems, Inc. 49

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Generac 04389-1, 04456-1, 04390-1 Exploded Views and Parts Lists, Description, GN410 Engine - Drawing No. 0D3539-BPart

Contents

DANGER POWER SYSTEMS, INCDEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY POWER SYSTEMS ‹CONTENTS INTRODUCTIONAUTHORIZED DEALER LOCATION DANGER Introduction GENERAL HAZARDS Despite the safe design of this generatorParts of the generator are rotating and/or hot ‹STANDARDS INDEX ELECTRICAL HAZARDSFIRE HAZARDS EXPLOSION HAZARDS 1.1UNPACKING/INSPECTION 1.2PROTECTION SYSTEMS1.3SYSTEM SET LED 1.4YOUR GENERATOR Figure 1.1 - 7 kW, Single Cylinder GH-410EngineFigure 1.2 - 12 kW and 15 kW, V-twin GT-990Engine 1.5 SPECIFICATIONS ‹ 1.5.1 GENERATOR‹1.5.2 ENGINE DANGER 1.8RECONFIGURING THE FUEL SYSTEM1.6FUEL REQUIREMENTS AND RECOMMENDATIONS 1.7FUEL CONSUMPTION 1.9.1 GENERATOR 1.10 BATTERY INSTALLATION1.9LOCATION 1.9.2 TRANSFER SWITCH Do not open or mutilate the battery. Released 1.11 THE BATTERYFigure 1.5 - Battery Cable Connections Wear rubber gloves and boots Never operate the engine with the oil level 2.2CHECK TRANSFER SWITCH OPERATION2.1BEFORE INITIAL START-UP 2.3ELECTRICAL CHECKS 2.6ADJUSTING THE REGULATOR NATURAL GAS ONLY 2.4GENERATOR TESTS UNDER LOAD2.5CHECKING AUTOMATIC OPERATION Do not make any unnecessary adjustments 2.7ENGINE GOVERNOR ADJUSTMENTFigure 2.2 - Placement of Regulator Figure 2.3 - Engine Governor Adjustment Figure 2.5 - Voltage Adjustment Potentiometer 2.8VOLTAGE REGULATOR ADJUSTMENT3.1BREAK-INPROCEDURE Figure 2.4 - Full Load Speed Adjust Screw 3.4SEQUENCE OF AUTOMATIC OPERATION 3.3AUTOMATIC TRANSFER OPERATION3.2USING THE AUTO/OFF/MANUAL SWITCH FIGURE With the switch set to AUTO, the engine may Figure 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 PROCEDURE Figure 4.6 - 7 kW, Engine Air Cleaner Location 4.5CHANGING THE ENGINE AIR CLEANER4.4CHANGING THE OIL FILTER 4.6SPARK PLUGS 4.7BATTERY MAINTENANCE 4.8ADJUSTING GH-410/GT-990VALVE CLEARANCEFigure 4.8 - Setting the Spark Plug Gap Figure 4.10 - Valve Clearance Adjustment 4.9COOLING SYSTEM4.10 ATTENTION AFTER SUBMERSION 4.11 CORROSION PROTECTION 4.12 OUT OF SERVICE PROCEDURE ‹4.12.1 REMOVAL FROM SERVICE‹4.12.2 RETURN TO SERVICE 4.13 SERVICE SCHEDULE CORRECTION 5.1TROUBLESHOOTING GUIDEPROBLEM CAUSE Section 6 - Electrical Data 24 Generac Power Systems, Inc CONTROL PANEL BOX CUSTOMERCONNECTION 26 Generac Power Systems, Inc C2-6 28 Generac Power Systems, Inc Wiring Diagram - 7 kW - Drawing No. 0D9013-A CLOSEST TO BEA 4 0 STATOR CUSTOMER CONNECTION 30 Generac Power Systems, Inc Generac Power Systems, Inc 32 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists PART NO.QTY. DESCRIPTION Control Panel - Drawing No. 0D8503-E DESCRIPTION Section 7 - Exploded Views and Parts Lists 0D4801 37 17 24 0D3086 Kit Contains Section 7 - Exploded Views and Parts Lists 42 Generac Power Systems, Inc Section 7 - Exploded Views and Parts Lists 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 Air 54 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 RESPONSIBILITIES EMISSION RELATED PARTS INCLUDE THE FOLLOWING EMISSION CONTROL SYSTEM WARRANTY WARRANTY SCHEDULE GENERAC POWER SYSTEMS, INCP.O. BOX WHITEWATER, WI