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Generac Power Systems Guardian 04758-2, Installation And Owner'S Manual

Get the Generac Power Systems Guardian 04758-2 Installation and Owner's Manual for free download on our website. This manual provides step-by-step instructions on installing and maintaining your generator, ensuring reliable power backup when you need it most. Download the manual today at manualshive.com.

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Section 7 — Exploded Views and Parts Lists

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

7 kW Generator – Drawing No. 0D3504-E

ITEM PART 

NO.  QTY.  DESCRIPTION

 1 

0C6

93

4 1 

ADAPTOR, 

ENGINE

 2 

0C

993

5H 1 

S

TATOR

 

3

 0C

993

4H 1 

ROTOR

 4 

0C604

3

A 

1 

CARRIER, REAR BEARING

 5 

0C

8

0

9

6 1 

FAN, 

8

” CURVED BLADE

 6 

0C

9

5

93

 1 

MUFFLER

 7 

0D

3

220 

1 

TAIL PIPE, MUFFLER

 

8

 0C

88

60 

1 

PANEL, MUFFLER BA

S

E

 

9

 

0

3

1

9

71 1 

BEARING 

#6205-2R

S

-C

3

 10 

0C

3

16

8

 

3

 5/16 

S

PECIAL L/WA

S

H

 11 

056147 

1 

BOLT 

ROTOR 

HHC

S

 5/16”-24 X 1

3

-1/2” G5

 12 

0D1

8

47 4 

BOLT 

S

TATOR HHC

S

 M

8

-1.25 x 

3

05mm

  1

3

 0C70

38

C 

1 

BRACKET, ALTERNATOR MOUNTING 

  14 

0D1647 

1 

DUCT, ALTERNATOR AIR

 15 

0D255

8

 1 

GA

S

KET, ALTERNATOR AIR DUCT

 16 

0C70

38

B 

1 

BRACKET, ENGINE MOUNTING

 17 

0C775

8

 4 

RUBBER 

MOUNT

  1

8

 

0

388

050AE0 

1 

CABLE, #6 40” BLACK BATTERY

  1

9

 0C2417A 

1  EARTH 

S

TRAP 

3

/

8

X 

3

/

8

 20 

0

8

2121C 

1 

CLIP-J VINYL COAT .625 ID

 21 

066

38

6 1 

A

SS

EMBLY  BRU

S

H HOLDER

 22 

02

9

451 1.

8

 FT 

TAPE ELEC UL FOAM 1/

8

 X 1/2

  2

3

 04

9

451 1 

WA

S

HER FLAT .406ID X 1.62OD

 24 

0222

3

7 4 

WA

S

HER LOCK 

3

/

8

 25 

022511 

4 

BOLT 

HHC 

3

/

8

-16 X 1-1/4 G5

 26 

0221

3

1 4 

WA

S

HER FLAT 

3

/

8

 ZINC

 27 

0

39

2

8

7 4 

S

CREW HHC M

8

-1.25 X 45 G

8

.

8

  2

8

 022145 

12  WA

S

HER FLAT 5/16 ZINC

  2

9

 04

98

20 

4 

NUT LOCK HEX M

8

-1.25 NYL IN

S

RT

 

3

0 0

9

0

388

 

3

 

S

CREW TAP M6-1.0X12 BP

 

3

1 02212

9

 

1

3

 WA

S

HER LOCK M

8

-5/16

 

3

2 02225

9

 

8

 

NUT HEX 5/16-1

8

 

S

TEEL

 

33

 05

9

6

3

7 2 

S

CREW TAPTITE 

3

/

8

-16X 

3

/4” BP

 

3

4 04

8

0

3

1K 

3

 BAND, 

HO

S

E CLAMP 

3

5.05 DIA.

 

3

5 0C

9

5

9

2 1 

BELLOW

S

 

3

6 04

8

0

3

1M 2 

HO

S

E CLAMP 

3

/4”

 

3

7 040

9

76 2 

S

CREW 

S

HC M

8

-1.25 X 20 G12.

9

 

38

 0C2

8

24 1 

S

CREW TAPR #10-

3

2 X 

9

/16

 

39

 025145 

1  U-BOLT 

5/16”-1

8

 X 1.25” W/ 

S

ADDLE

 40 

0

9

02

39

 1 

GA

S

KET, EXHAU

S

T

 41 

0C6

989

 1 

S

TINGER, ENGINE AIR IN 

 42 

0D1214 

1 

BA

S

E, AIR CLEANER

  4

3

 0C

8

127 1 

ELEMENT, 

AIR 

CLEANER

 44 

0C

3

024 

1 

COVER, AIR CLEANER NG/LP

 45 

0D227

3

 

1 

TUBE, 1.25”O.D. x 20G

a

. x 12.125” LONG

 46 

055

93

4N 1 

CLAMP 

VINYL 

1.

3

1 X .2

8

1 Z

 47 

0F7065 

1.25 

FT 

HO

S

E LP 1/2” I.D.

  4

8

 0C51

3

6A 2 

KNOB, 

AIR 

CLEANER

  4

9

 074

9

06 4 

S

CREW TAPTITE M6-1 X 20 BP

 50 

02247

3

 4 

WA

S

HER FLAT 1/4 ZINC

 51 

0D4662 

6 

S

CREW HHTT M

8

-1.2 X 20 BP

 52 

0C

8

2

9

0 1 

GA

S

KET, PANEL

  5

3

 066

8

4

9

 2 

S

CREW HHTT M5-0.

8

 X 16

  

41

Summary of Contents for Guardian 04758-2

Page 1: ...2 6 kW NG 7 kW LP 04759 2 12 kW NG 12 kW LP 04760 2 13 kW NG 15 kW LP DANGER DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY Not intended for use as Primary Power in place of utility or in life suppor...

Page 2: ...service are essen tial to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows This symbol points out...

Page 3: ...Regulator Adjustment 14 Section 3 Operation 14 3 1 Break in Procedure 14 3 2 Using the Auto Off Manual Switch 14 3 2 1 Auto Position 14 3 2 2 Off Position 14 3 2 3 Manual Position 14 3 3 Automatic Tra...

Page 4: ...d properly in strict com pliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards Keep hands...

Page 5: ...cordance 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 aforement...

Page 6: ...ier 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 1 2 PROTECTION SYSTEMS Unlik...

Page 7: ...Decal Control Panel Fuel Regulator Fuel Inlet GFCI Outlet Oil Filter Battery Compartment Exhaust Enclosure Oil Filter Battery Compartment Fuel Inlet GFCI Outlet Control Panel Data Decal Oil Dipstick...

Page 8: ...ubject 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...

Page 9: ...ch 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 RECONFIGURING THE FUEL SYSTEM 1 8 1 7 KW 410CC To reconfigure the fuel system from...

Page 10: ...losure by removing the plastic hole plug The screw can be turned with a long flat blade screwdriver 13 To adjust the system to run on LP fuel turn BOTH adjuster screws 1 2 TURN CLOCKWISE The system sh...

Page 11: ...a tive NEG or 6 Replace the 5 amp and 15 amp fuses in the gen erator control panel NOTE Damage will result if battery connections are made in reverse Figure 1 5 Battery Cable Connections NOTE The gene...

Page 12: ...ply is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion 2 1 BEFORE INITIAL START UP Before starting complete the following 1 Set the generator s...

Page 13: ...1 Set 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 provid...

Page 14: ...o the main distribution panel in the house This can be done by switching the service main breaker to the off or open posi tion 2 Allow the generator to start before loading the generator Confirm the n...

Page 15: ...ize and warm up at no load 4 Connect a frequency meter across the generators AC output leads Figure 2 3 Single Cylinder Engine Governor Adjustment GOVERNOR SHAFT PRIMARY ADJUST SCREW GOVERNOR CLAMP BO...

Page 16: ...ch as a utility 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 percen...

Page 17: ...signalled to shut down The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility s...

Page 18: ...omatic Transfer Operation Section 3 3 3 6 SETTING THE EXERCISE TIMER The generator is equipped with an exercise timer Once it is set the generator will start and exercise once every seven days on the...

Page 19: ...ircuit Contact the nearest Authorized Dealer if this failure occurs 4 1 FUSE The generator panel s 15 amp fuse Figure 4 1 pro tects the DC control circuit against overload The fuse is wired in series...

Page 20: ...s 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 3 After the oil has drained replace the cap onto the end of...

Page 21: ...kW and 0 50 mm 0 020 inch for 12 15 kW by carefully bending the ground electrode Figure 4 8 Figure 4 8 Setting the Spark Plug Gap 4 7 BATTERY MAINTENANCE The battery should be inspected per the Servi...

Page 22: ...ot available please contact the Authorized dealer for service assistance This is a very important step to insure longest life for the engine To adjust valve clearance Make sure the engine is at room t...

Page 23: ...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 b...

Page 24: ...air is Needed FUEL Fuel lines and connections X M LUBRICATION Oil level X M Oil X AFTER BREAK IN AND Y Oil filter X AFTER BREAK IN AND Y COOLING Enclosure louvers X X W BATTERY Remove corrosion X X M...

Page 25: ...r and runs rough plugged or damaged 2 Defective spark plug s 2 Clean re gap or replace plug s 3 Fuel regulator not set 3 Set fuel regulator 4 Fuel pressure incorrect 4 Confirm fuel pressure is at 0 4...

Page 26: ...OP LOW OIL PRESSURE SWITCH IM2 IGNITION MODULE CYLINDER 2 IM1 IGNITION MODULE CYLINDER 1 SCR STARTER CONTACTOR RELAY FS FUEL SOLENOID SP1 SP2 SPARK PLUGS SC STARTER CONTACTOR IC INLINE CONNECTOR F1 FU...

Page 27: ...5A 23 13 351 13 13 13A 13 13 0 0 N2 N1 351 0 66A 4 162 0 4 6 0 4 162 6 239 AUTO SW1 1 1b 1a SW2 CONNECTION CUSTOMER SWITCH CONTACTOR 240V GENERATOR 0 CB1 23 N1 N2 194 351 66A 55 77 44 11 55 0 C2 3 1 2...

Page 28: ...KEY SC STARTER CONTACTER 2 1 5 3 4 J2 2 1 3 2 1 14 16 17 12 10 9 J1 7 5 3 2 1 F2 FUSE 5 AMP BA BRUSH ASSEMBLY CB2 CIRCUIT BREAKER ALT EXCITATION D DIODE SCR STARTER CONTACTOR RELAY 15 2 23 224 77 FIEL...

Page 29: ...5 239 SW1 194 15A 22 11 23 11 22 11 SP1 44 WINDING 120V 120V 33 NEUTRAL N2 N1 23 CUSTOMER CONNECTIONS 194 0 0 SC FS 16 14 BATTERY CUSTOMER SUPPLIED SM 12V SC N2 N1 13 TX 56VA 1VA C2 6 C2 5 CB1 STATOR...

Page 30: ...ODULE F2 FUSE 5 AMP F1 FUSE 15 AMP SP SPARK PLUG TB INSULATED TERMINAL BLOCK SM STARTER MOTOR SW2 SET EXERCISE SWITCH DIAGRAM KEY PRINTED CIRCUIT BOARD DSW CONTROL 4 SPARE 2 Remote Not Auto 3 50 Hz Op...

Page 31: ...UTO 17 15 SW1 239 SW2 CONNECTION CUSTOMER 0 351 CB1 11 66 N1 194 0 23 N2 162 6 4 66A 0 77 55 55 22 6 11 0 1 C2 4 2 7 5 CONTROL PANEL BOX 224A 225B 224B 225B 224B 0 13A 225 224 N2 N1 224A 66 TX 225A 66...

Page 32: ...5 3 J2 4 6 8 3 5 4 1 3 1 2 2 1 DPE WINDING 0 VOLTAGE REGULATOR ELECTRONIC CB2 C2 8 2 2 22 162 0 4 C2 10 6 4 0 11 22 11 0 0 85 CONTROL BOARD PRINTED CIRCUIT C2 4 C2 7 STATOR 6 0 FIELD 6 BA C2 9 C2 11...

Page 33: ...239 13 15 SC 14 15A 194 23 15 IM 0 D BLACK SP POWER WINDING STATOR FS 14 C1 2 194 22 RED SC SM 240V 44 11 CB1 33 120V C2 5 N2 225A 56VA 1VA 224A 225 224 13 N1 TX 17 N2 22 11 C2 6 N1 11 23 194 N1 N2 B...

Page 34: ...87 5 86 76 48 39 92 18 94 91 63 21 15 51 71 42 69 10 52 49 35 51 49 11 31 9 50 99 98 72 46 41 57 27 91 1 56 5 44 60 40 19 12 71 6 97 22 65 68 63 16 69 14 54 47 55 75 49 30 17 3 93 25 29 28 1 Section...

Page 35: ...0F0710 18 RIVET POP 0 125 X 0 337 ITEM PART NO QTY DESCRIPTION 47 047411 6 SCREW HHC M6 1 0 X 16 G8 8 047411 4 SCREW HHC M6 1 0 X 16 G8 8 7KW 48 043116 5 SCREW HHC M6 1 0 X 12 G8 8 043116 6 SCREW HHC...

Page 36: ...7 10 3 49 51 13 17 5 21 35 23 49 29 21 17 4 2 38 6 7 33 2 20 27 15 40 41 39 45 44 43 1 30 15 11 47 45 24 45 47 49 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators Co...

Page 37: ...SWITCH SPST ON ON N O 23 0D9784 6 NUT HEX LOCK M3 0 5 NYLON INSERT 0D9784 4 NUT HEX LOCK M3 0 5 NYLON INSERT 7KW ITEM PART NO QTY DESCRIPTION 24 0D8502 1 NEUTRAL CONNECTOR 26 0D8441 1 HARNESS CONTROL...

Page 38: ...140 32 3 35 55 33 36 20 57 19 58 59 61 60 64 62 63 65 1 2 6 3 32 33 34 35 36 40 72 27 28 29 16A 16B 17 18 4 5 6 8 11 12 13 2 5 19 20 39 40 47 64 93 140 16B 56 54 23 25 30 16A 34 34 21 15 16A 17 18 22...

Page 39: ...0C2988 1 THRUST WASHER GOVERNOR 36 0C2992 1 BUSHING GOVERNOR LOWER ITEM PART NO QTY DESCRIPTION 37 0C3971C 1 ASSEMBLY DIPSTICK WITH HANDLE 38 0C5305 1 TUBE DIPSTICK 39 0C3027 1 O RING OIL CLR 3 8 X 1...

Page 40: ...07 108 104 103 106 111 109 143 125 123 145 96 95 143 130 114 75 78 77 76 99 100 118 98 97 121 124 124 119 122 125 137 120 127 126 115 116 131 136 138 132 142 129 134 139 135 Section 7 Exploded Views a...

Page 41: ...A 1 HOUSING BLOWER NG COOLER ITEM PART NO QTY DESCRIPTION 111 0D1131 1 GUARD FAN 112 045756 25 SCREW TAPTITE M6 1X10 YELLOW CHROME 113 0C9763 4 NUT GROMMET 1 4 PLUG 114 0C3036A 1 HOSE BREATHER 115 022...

Page 42: ...19 10 17 15 32 10 19 16 22 39 4 8 9 6 31 37 3 2 34 30 40 46 45 47 36 42 41 1 50 49 32 24 25 26 44 43 34 35 34 48 10 28 27 28 32 31 29 18 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW...

Page 43: ...451 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 12 WASHER FLAT 5...

Page 44: ...20 19 10 17 15 32 16 22 39 4 9 8 6 37 14 3 2 40 1 32 24 25 10 30 19 26 28 27 28 32 31 41 10 18 36 28 35 41 29 42 36 36 35 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Gener...

Page 45: ...8 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...

Page 46: ...46 11 49 29 37 27 28 30 31 17 52 47 48 24 38 26 22 40 41 25 25 50 14 12 51 13 54 16 1 6 1 2 11 10 42 5 7 9 8 3 4 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators GN4...

Page 47: ...E3341 1 BALANCER 27 021714 1 ASSEMBLY CYLINDER HEAD SEATS GUIDES 28 086516 1 VALVE EXHAUST 29 086517 1 VALVE INTAKE 30 0D9853B 2 PUSH ROD 174 9 31 083897 2 TAPPET 32 077158 1 ASSEMBLY SCREEN OIL PICK...

Page 48: ...28 4 24 6 12 7 6 1 14 18 17 27 31 30 2 45 5 13 8 52 6 11 9 48 42 10 25 26 18 32 18 34 6 34 33 6 37 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators GN410 Engine Draw...

Page 49: ...ING GEAR 32DEG 26 067198N 1 WASHER BELV 20 X 2 2 27 067890 1 NUT HEX FLYWHEEL 28 0E7585 1 SPARKPLUG 29 072734 1 ASSEMBLY GOVERNOR LEVER 12 HP 30 072735 1 ROD GOVERNOR CONTROL 31 0C3978 1 SPRING ANTI L...

Page 50: ...22 15 26 14 13 16 29 18 28 12 10 11 27 31 4 5 3 2 10 17 1 26 15 14 16 13 37 19 9 30 21 25 20 24 29 18 23 11 12 28 8 Section 7 Exploded Views and Parts Lists Air cooled 7 kW 12 kW and 15 kW Generators...

Page 51: ...069 2 GASKET DIAPHRAGM 20 0C5762 2 COVER TWIN REGULATOR 21 045764 16 SCREW TAPTITE M4X8 BP 22 0C6731 2 RIVET POP 118 X 125 23 0C6067 2 SUPPORT DIAPHRAGM 24 0C4706 2 DIAPHRAGM TWIN REGULATOR 25 0C6068...

Page 52: ...DO NOT LIFT BY THE ROOF LIFTING HOLES 4 CORNERS 30 2mm 1 19 ROUNDING LUG 3 4 NPT FUEL INLET GAS PRESSURE OF 11 14 WATER COLUMN REQUIRED ALL DIMENSIONS IN MILLIMETERS INCHES 76 2mm 3 00 PEA GRAVEL MIN...

Page 53: ...Section 9 Notes Air cooled 7 kW 12 kW and 15 kW Generators 51...

Page 54: ...sibility 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 suppli...

Page 55: ...s 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 par...

Page 56: ...nclosures that are rusting due to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised Failures caused by any contaminate...

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