Generac Power Systems 004742-0 Owner'S Manual Download

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POWER SYSTEMS, INC.

Owner’s Manual

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

This manual should remain with the unit.

Liquid-cooled, Prepackaged

Standby Generators

Model Numbers

004742-0
004744-0
004746-0

Summary of Contents for 004742-0

Page 1: ...INC Owner s Manual ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION This manual should remain with the unit Liquid cooled Prepackaged Standby Generators Model Numbers 004742 0 004744 0 004746 0 ...

Page 2: ...d This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment We strongly recommend that the operator read this Owner s Manual and thoroughly understand all instructions before using this equip ment We also strongly recommend instructing other users to properly start and operate the unit ...

Page 3: ...ation Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 10 2 9 Transfer Switch Start Signal Connections 10 2 10 Battery Installation 11 2 11 Preparation Before Start Up 11 Section 3 OPERATION 12 3 1 Using a Standard GTS Transfer Switch 12 3 2 Control Console Components 12 3 3 Manual Transfer and Startup 13 3 4 Retransfer and Shutdow...

Page 4: ...ner ator is installed operated and serviced in accordance with the manufacturer s instructions and recommen dations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regula tions The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations c...

Page 5: ...ting Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when nor mal utility source voltage is removed or is below an acceptable prese...

Page 6: ...re 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 If a transfer switch is not included one may be pur chased separately from an Authorized Dealer 1 3 AUTOMATIC SYSTEM OPERATION When this generator along with its transfer switch has been installed and interconnected a c...

Page 7: ... N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 8 10 psi 55 68 kPa the switch contacts close and the engine shuts down automatically Figure 1 4 Figure 1 4 Low Oil Pressure Switch 1 7 2 HIGH COOLANT TEMPERATURE SWITCH Normally open N O thermostatic switch has sens ing tip which is immersed in captive coolant Should coolant temperatur...

Page 8: ...ING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping colli sion etc Store and unpack cartons with the proper side up as noted on the shipping carton 1 8 2 INSPECTION After unpacking carefully inspect the generator for any damage that may have occurred during ship ment If loss or damage is noted at the time of deliv ery have the person s making...

Page 9: ...inuous power output when using natural gas rated at 1000 Btu per cubic foot or LP gas rated 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine condi tions and other environmental factors 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas from the factory To reconfigure the fuel syst...

Page 10: ...he critical essential loads together and wire them into a separate emer gency distribution panel This generator can be installed in conjunction with a standard GTS type transfer switch if desired The standard transfer switch has no sensing or con trolling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which controls all phases of operation including en...

Page 11: ...t ing consider using a windbreak to protect 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 5 feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install ...

Page 12: ...o be properly connected to an approved earth ground and or grounding rods For that purpose a GROUND LUG Figure 2 2 is provided on the gener ator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may resul...

Page 13: ... bicarbon ate of soda to one gallon 4 liters of water The bicarbonate 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 fol lowing procedure are to be followed DO NOT SMOKE when near batteries DO NOT cause flame or spa...

Page 14: ...connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged prop erly installed and interconnected and ready for use Check to ensure that there are no loose electrical con nections Restrain any loose wires to keep them clear of any moving generator set components 3 1 USING A STANDARD GTS TRANSFER SWITCH When required the pre packaged standby generator c...

Page 15: ...se outputs NOTE This fuse will not remove the battery input power from the PCB when it opens This means the exercise timer will not be reset If this fuse does open carefully check the wiring to the start fuel field boost and transfer outputs before replacing the fuse 3 2 6 SET EXERCISE TIME SWITCH This switch permits programming the generator to start and exercise automatically See Weekly Exercise...

Page 16: ...ls are disconnected or control panel fuse is removed the exercise timer needs to be reset for correct automatic exercise operation Figure 3 2 Set Exercise Switch 3 7 ENGINE HEATER This standby generator comes equipped with a block heater Figure 3 3 similar to the block heaters used in automotive applications The block heater is wired to a grounded plug Figure 3 3 Engine Block Heater Refer to appli...

Page 17: ... fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 4 CHECKING FLUID LEVELS 4 4 1 CHECK ENGINE OIL Check engine crankcase oil level Figure 4 1 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If...

Page 18: ...uired 4 5 9 INSPECT ENGINE GOVERNOR Visually inspect electronic governor Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life Correct rated frequenc...

Page 19: ...HE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal gen erator windings have an adverse effect on insulation resistance Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather...

Page 20: ...an shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear...

Page 21: ...removing the battery cable to prevent an over current condi tion from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any po...

Page 22: ... level Correct as necessary 5 Check the natural gas delivery system on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit...

Page 23: ...ents and abnormal operating conditions Correct as necessary 14 Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Change the engine oil 16 Replace the engine oil filter s 17 Replace the engine air filter s 18 Replace the engine ...

Page 24: ...plugs 3 Clean regap or replace plugs Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 ...

Page 25: ...Section 6 Installation Diagram Liquid cooled 15 kW 20 kW and 25 kW Generators Installation Diagram Drawing No 0E1533 A 23 ...

Page 26: ...7 8 9 10 12 13 15 16 17 18 5 1 2 4 3 13 15 15 0 14 176 T1 T2 15C 178 23 85 4 S15 S16 229 176 4 229 56 162 S16 E1 TO E2 240 E1 TO 00 120V E2 TO 00 OUTPUT CONNECTION 120 240V 1 PHASE E1 E2 CLOSEST TO BEARING BRUSH HOLDER MOUNTING SCREW 23 178 183 183 183 FO SW 23 194 T2 15C 15 225A 94 BLUE BLUE RED BLACK BLACK BROWN YELLOW TO GOVERNOR 178 85 56 0 1 85 85 225 BLUE RED BLACK BLACK 15C 0 162 4 S16 ACTU...

Page 27: ...Section 7 Electrical Data Liquid cooled 15 kW 20 kW and 25 kW Generators Wiring Diagram 1 5L Engine Drawing No 0E0343 B 25 ...

Page 28: ...R ROTOR AS ALTERNATOR STATOR CB1 2 CIRCUIT BREAKERS DPE EXCITATION WINDING F FUSE 15 AMPS GCU GOVERNOR CONTROL UNIT PCB CIRCUIT BOARD CONTROLLER TS1 2 3 TERMINAL BOARDS VR VOLTAGE REGULATOR LEGEND AS F SA SUPRESSION ASSEMBLY TR1 TRANSFORMER UTILITY SENSING 183 178 183 PREPACKAGE N C 15 15C BLUE 225A SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH BLACK BLACK YELLOW USE BLUE WIRE FOR 240V L L SY...

Page 29: ...Section 7 Electrical Data Liquid cooled 15 kW 20 kW and 25 kW Generators Electrical Schematic 1 5L Drawing No 0A7182 C 27 ...

Page 30: ...Section 8 Exploded Views and Parts Liquid cooled 15 kW 20 kW and 25 kW Generators Mounting Base Drawing No 0E0768 B 28 8 13 15 15 9 17 10 20 14 4 22 3 10 20 5 16 7 18 7 6 9 6 1 22 15 7 11 6 2 6 5 ...

Page 31: ...5 12 WASHER FLAT 5 16 ZINC 7 022129 16 WASHER LOCK M8 5 16 8 045771 4 NUT HEX M8 1 25 G8 YEL CHR 9 071956 4 WASHER FLAT M8 10 051730 4 SCREW HHC M8 1 25 X 60 G8 8 11 021991 1 EARTH STRAP 13 0D9335 2 PANEL SUPPORT 14 0D9336 2 PANEL BRACKET 15 0C2454 16 SCREW TH FRM M6 1 X 16 N WA Z JS 16 047411 1 SCREW HHC M6 1 0 X 16 G8 8 17 022097 1 WASHER LOCK M6 1 4 18 022473 1 WASHER FLAT 1 4 M6 ZINC 19 055414...

Page 32: ...No 0E0771 H 15 NUTS ITEM 26 USE LOCTITE ON PANEL FOR ACCESS COVER CABLE WELD STUD UNDER ROOF GROUND WIRE FASTENER TO SECURE USE DOOR LATCH NOTE 11 25 24 7 30 10 4 9 24 17 26 25 26 19 15 18 8 5 11 12 10 5 NOTE 15 Y 19 26 6 10 4 26 18 19 18 17 10 Y 16 26 14 13 26 11 11 15 17 1 30 24 3 20 23 22 11 28 2 21 11 29 30 ...

Page 33: ...TEEL 21 0C2634A 1 ASSEMBLY COVER ACCESS 22 022473 1 WASHER FLAT 1 4 ZINC 23 022097 1 WASHER LOCK M6 1 4 24 0D2023 3 GASKET CLIP ON SELF GRIPPING 25 0F3390 1 LATCH AND CAM 26 037337 6 NUT HEX JAM 3 8 24 SS 27 0D2023 21 GASKET CLIP ON SELF GRIPPING 28 0D8664A E 1 DUCT LH SIDE 1 5L 29 0D8664B F 1 DUCT RH SIDE 1 5L 30 077992 20 NUT HEX LOCK M6 1 0 SS NY INS NOTE THE KEY FOR THIS LOCK IS P N 067042A NO...

Page 34: ... 4 19 39 15 18 33 6 22 23 32 11 12 45 34 33 11 37 41 41 5 40 25 42 1 15 49 11 26 19 45 4 35 10 18 32 45 11 Y 15 Y 13 16 14 17 19 18 17 34 29 31 11 10 3 29 22 24 23 11 46 28 48 30 27 2 21 NUT 037337 USE LOCTITE ON 15 NOTE STATES FOAM IS ON NEAR SIDE STATES FOAM IS ON FAR SIDE 11 47 20 Section 8 Exploded Views and Parts Liquid cooled 15 kW 20 kW and 25 kW Generators Acoustic Compartment Drawing No 0...

Page 35: ... 1 5L DUCT FNT PNL 31 0E0072A 1 ACSTC INSLTN 1 5L ROOF PANEL 32 0E0072M 2 ACSTC INSLTN 1 5L SIDE DR PNL 33 0E0072P 2 ACSTC INSLTN 1 5L SIDE DR PNL 34 0E0072L 2 ACSTC INSLTN 1 5L SIDE BRC PNL 35 0E0072N 2 ACSTC INSLTN 1 5L DR BAFFLE PL 36 0E0072G 2 ACSTC INSLTN 1 5L RR CRNR TOP 37 0E0072J 2 ACSTC INSLTN 1 5L RR CRNR BOTT 38 0E0072F 1 ACSTC INSLTN 1 5L REAR DR PNL 39 0E0072E 1 ACSTC INSLTN 1 5L REAR...

Page 36: ... 5 31 50 34 49 12 28 42 3 40 39 38 41 11 2 30 57 17 16 18 28 28 A 21 56 14 38 13 40 24 23 39 41 1 40 28 35 20 44 46 45 47 39 15 36 32 32 37 48 41 4 43 Section 8 Exploded Views and Parts Liquid cooled 15 kW 20 kW and 25 kW Generators Control Panel Drawing No 0E0778 G ...

Page 37: ... ZINC 28 0C2212 10 SCREW PHTT M4 0 7 X 16 ZYC 29 023762 2 WASHER SHAKEPROOF EXT 10 STL ITEM PART NO QTY DESCRIPTION 30 0C2267 14 SCREW HHTT M5 0 8 X 12 BP 31 023897 15 WASHER FLAT 10 ZINC 32 0C2454 4 SCREW TH FRM M6 1X16 N WA Z JS 33 054199 1 DECAL HIGH VOLTAGE 34 081988 1 DECAL EXERCISE INFO 35 0E2514 1 STRAIGHT WIRE CONNECTOR 1 1 2 36 0A1354A 1 REGULATOR DC ALT 37 074908 4 SCREW HHTT M5 0 8 X 10...

Page 38: ... 10 1 11 19 17 11 26 18 20 17 21 22 0 28 20 21 25 23 24 46 57 33 11 14 9 24 10 11 10 14 TO 24 44 35 34 36 45 14 71 46 10 11 12 48 47 70 24 43 74 51 55 66 69 73 56 59 52 54 58 65 64 63 2 62 60 7 32 Section 8 Exploded Views and Parts Liquid cooled 15 kW 20 kW and 25 kW Generators Engine Drawing No 0E1228 H ...

Page 39: ...1 026925 1 PLUG STD PIPE 3 8 STEEL SQ HD 42 061012 1 PLUG STD PIPE 1 8 SCKT HD 43 039253 5 SCREW HHC M8 1 25 X 20 G8 8 ITEM PART NO QTY DESCRIPTION 44 0A5110 1 PIPE WATER INLET 45 0A7006 1 O RING 1 1 16 X 1 5 16 X 1 8 46 025507 2 WASHER SHAKEPROOF EXT 7 16 STL 47 022500B 2 SPACER 41 X 75 X 25 ST ZNC 48 0A8584 1 SWITCH OIL PRESSURE 49 036277 1 ELBOW 90D STREET 1 8 50 042574 1 ADAPTOR 1 8 NPTF TO 1 ...

Page 40: ...an 050275 36 TO WATER INLET TUBE MIDWAY UP ENGINE BLOCK 14 TUBE ON BLOCK 31 10 23 26 20 8 TO BASE OF WATER INLET 8 19 8 8 6 TO THERMOSTAT ADAPTER 12 24 7 16 7 7 15 5 7 13 12 TO ENGINE BYPASS ON INTAKE MANIFOLD 36 33 34 11 12 Section 8 Exploded Views and Parts Liquid cooled 15 kW 20 kW and 25 kW Generators Radiator Drawing No 0E0769 K 38 ...

Page 41: ... 8 18 056892 4 SCREW CRIMPTITE 10 24 X 3 8 19 0A6284 1 HOSE LOWER RADIATR 20 0A6258 1 HOSE UPPER RADIATR 21 029032 1 HOSE 9 32 ID 36 LG 22 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 23 060035 4 SPACER 41 X 75 X 87 ST ZNC 24 022127 4 NUT HEX 1 4 20 STEEL 26 046627 1 CAP RADIATOR 27 0C7649 1 CLAMP HOSE 38 87 28 0C2454 4 SCREW TH FRM M6 1 X 16 N WA Z JS 29 076749 1 TANK COOLANT RECOVERY 30 0E0726 1 BRAC...

Page 42: ... 21 24 25 30 28 33 20 19 14 C 12 17 16 31 32 6 6 39 26 38 41 41 40 37 34 36 35 22 C 13 8 18 27 2 44 42 6 7 23 NATURAL GAS OUT 1 3 11 PORT 29 D Section 8 Exploded Views and Parts Liquid cooled 15 kW 20 kW and 25 kW Generators Fuel System Drawing No 0E0774 F ...

Page 43: ...OW 90D STREET 3 4 24 062522 1 STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 0D8492T 1 DECAL EMISSION CTRL 1 5 NG 2005 10 15KW NATURAL GAS 30 0E1104 1 GASKET AIR CLEANER ADAPTER 31 0E0668 1 O RING 2 028 1 38 X 1 50 X 06 32 0E0590 1 VENTURI 18MM 33 0C5133 1 O RING 29 82 X 2 62...

Page 44: ...9 15 14 17 To Blower Housing 32 23 24 35 1 21 28 7 22 1 29 16 30 18 6 19 20 31 21 4 To Engine Crankshaft 26 Section 8 Exploded Views and Parts Liquid cooled 15 kW 20 kW and 25 kW Generators Alternator Drawing No 0A9348 G ...

Page 45: ... 075476 4 SCREW PPHM M4 0 7 X 16 12 0A5601A 1 COVER REAR BEARING 13 075554B 4 BOLT STATOR X 16 LG 14 0A9375 4 SCREW RHM 10 24 X 2 15 022152 4 WASHER LOCK 10 16 097146 1 FAN RING GEAR ASSEM 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A5061 1 SPACER FLEX PLATE 19 0A4989 1 PLATE FLEX 20 053557 1 SCREW HHC M12 1 75 X 40 G8 8 21 051769 6 WASHER LOCK M12 22 049541 4 SCREW HHC M10 1 5 X 35 G8 8 23 046526 4 WASH...

Page 46: ...0 1 25 X 20 G8 8 8 075763 3 BOOT BATTERY CABLE 9 0D8668 1 BRACKET BATTERY HOLD DOWN 1 5 13 050331A 1 BATTERY POST COVER RED 14 050331 1 BATTERY POSTCOVER BLACK 15 0C2454 2 SCREW TH FRM M6 1X16 N WA Z JS 16 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 17 027482 2 WASHER SHAKEPROOF EXT 5 16 STL 15 SOLENOID 8 13 1 2 STARTER 14 8 8 TO ENGINE BLOCK 5 6 7 9 16 3 4 44 Section 8 Exploded Views and Parts Liquid...

Page 47: ...MITSU 7 0E0170 1 BLANKET EXHAUST 1 5L MITSU 8 0D9437 1 MUFFLER 1 5L ACOUSTIC STANDARD 9 060366 2 STRAP MUFFLER 6 DIA 10 039253 4 SCREW HHC M8 1 25 X 20 G8 8 11 022145 4 WASHER FLAT 5 16 ZINC 12 022129 4 WASHER LOCK M8 5 16 13 045771 4 NUT HEX M8 1 25 G8 YEL CHR 14 0A8974 1 CAP RAIN 2 15 027837 2 SCREW RHM 1 4 20 X 2 1 4 3 9 14 5 4 2 10 8 15 3 9 6 13 12 3 7 Section 8 Exploded Views and Parts Liquid...

Page 48: ... INS 11 0E1326 1 ASSY CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 10 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC 17 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 18 0E1694 1 SPRING ANTI LASH ITEM 13 NEOPRENE SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN CARBURETOR ARM REF 11 TO A 17 6 7 9 10 10 5 4 INTAK...

Page 49: ...47 Section 9 Notes Liquid cooled 15 kW 20 kW and 25 kW Generators ...

Page 50: ...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 prob lem occurs The warran...

Page 51: ...low 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 Fac...

Page 52: ...ng clamps installation and start up 3 Any failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze 4 Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted ...

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Page 54: ...IER REAR 10 075591 1 ASSY HOLDER BRUSH 11 075476 4 SCREW PPHM M4 0 7 X 16 12 0A5601A 1 COVER REAR BEARING 13 075554B 4 BOLT STATOR X 16 LG 14 0A9375 4 SCREW RHM 10 24 X 2 15 022152 4 WASHER LOCK 10 16 097146 1 FAN RING GEAR ASSEM 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0A5061 1 SPACER FLEX PLATE 19 0A4989 1 PLATE FLEX 20 053557 1 SCREW HHC M12 1 75 X 40 G8 8 21 051769 6 WASHER LOCK M12 22 049541 4 SCR...

Page 55: ...25 10 27 33 9 31 53 52 55 54 58 8 6 7 5 31 50 34 49 12 28 42 3 40 39 38 41 11 2 30 194 LOAD 1 LOAD 2 23 UTILITY 1 UTILITY 2 P N 0E1454 183 178 57 17 16 18 28 28 A 21 56 14 38 13 40 24 23 39 41 1 40 28 35 19 12 7 6 8 10 9 11 5 DEUTSCH 3 4 2 1 20 44 46 45 47 39 15 36 32 32 37 48 41 4 43 ...

Page 56: ...2097 3 WASHER LOCK M6 1 4 27 022473 2 WASHER FLAT 1 4 M6 ZINC 28 0C2212 10 SCREW PHTT M4 0 7 X 16 ZYC 29 023762 2 WASHER SHAKEPROOF EXT 10 STL 30 0C2267 14 SCREW HHTT M5 0 8 X 12 BP 31 023897 15 WASHER FLAT 10 ZINC 32 0C2454 4 SCREW TH FRM M6 1X16 N WA Z JS 33 054199 1 DECAL HIGH VOLTAGE 34 081988 1 DECAL EXERCISE INFO 35 0E2514 1 STRAIGHT WIRE CONNECTOR 1 1 2 36 0A1354A 1 REGULATOR DC ALT 37 0749...

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Page 58: ...HEX M8 1 25 G8 YEL CHR 9 071956 4 WASHER FLAT M8 10 051730 4 SCREW HHC M8 1 25 X 60 G8 8 11 021991 1 EARTH STRAP 13 0D9335 2 PANEL SUPPORT 14 0D9336 2 PANEL BRACKET 15 0C2454 16 SCREW TH FRM M6 1 X 16 N WA Z JS 16 047411 1 SCREW HHC M6 1 0 X 16 G8 8 17 022097 1 WASHER LOCK M6 1 4 18 022473 1 WASHER FLAT 1 4 M6 ZINC 19 055414 1 LUG SLDLSS 2 8 X 17 64 CU 20 049813 5 NUT HEX M6 X 1 0 G8 YEL CHR 21 02...

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Page 60: ...TUBING 5 8 ID X 18 LG 17 058443 6 SCREW CRIMPTITE 1 4 20 X 5 8 18 056892 4 SCREW CRIMPTITE 10 24 X 3 8 19 0A6284 1 HOSE LOWER RADIATR 20 0A6258 1 HOSE UPPER RADIATR 21 029032 1 HOSE 9 32 ID 36 LG 22 031669 4 BOLT CARR 1 4 20 X 1 3 4 JS500 23 060035 4 SPACER 41 X 75 X 87 ST ZNC 24 022127 4 NUT HEX 1 4 20 STEEL 26 046627 1 CAP RADIATOR 27 0C7649 1 CLAMP HOSE 38 87 28 0C2454 4 SCREW TH FRM M6 1 X 16 ...

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Page 62: ...31 1 WASHER FLAT 3 8 ZINC 6 046526 1 WASHER LOCK M10 7 052213 1 SCREW HHC M10 1 25 X 20 G8 8 8 075763 3 BOOT BATTERY CABLE 9 0D8668 1 BRACKET BATTERY HOLD DOWN 1 5 13 050331A 1 BATTERY POST COVER RED 14 050331 1 BATTERY POSTCOVER BLACK 15 0C2454 2 SCREW TH FRM M6 1X16 N WA Z JS 16 025507 1 WASHER SHAKEPROOF EXT 7 16 STL 17 027482 2 WASHER SHAKEPROOF EXT 5 16 STL ...

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Page 64: ...39 1 BARBED EL 90 3 8 NPT X 5 8 41 026925 1 PLUG STD PIPE 3 8 STEEL SQ HD 42 061012 1 PLUG STD PIPE 1 8 SCKT HD 43 039253 5 SCREW HHC M8 1 25 X 20 G8 8 44 0A5110 1 PIPE WATER INLET 45 0A7006 1 O RING 1 1 16 X 1 5 16 X 1 8 46 025507 2 WASHER SHAKEPROOF EXT 7 16 STL 47 022500B 2 SPACER 41 X 75 X 25 ST ZNC 48 0A8584 1 SWITCH OIL PRESSURE 49 036277 1 ELBOW 90D STREET 1 8 50 042574 1 ADAPTOR 1 8 NPTF T...

Page 65: ...ITEM 13 NEOPRENE SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN CARBURETOR ARM REF 11 TO A 17 6 7 9 10 10 5 4 INTAKE MANIFOLD REF 6 12 7 A 2 3 1 16 7 15 COATING WIRE HARNESS 14 ...

Page 66: ... 8 7 022097 5 WASHER LOCK M6 1 4 8 084543A 1 SCREW PHM M3 0 5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0E1326 1 ASSY CARBURETOR LINKAGE ROD 12 0A7106 1 BRACKET STEPPER MOTOR 13 074031 AR LIQUID NEOPRENE 14 029333A 10 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 022473 2 WASHER FLAT 1 4 ZINC 17 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 18 0E1...

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Page 68: ...22 049226 4 WASHER LOCK M5 23 026307 1 ELBOW 90D STREET 3 4 24 062522 1 STUD TH 1 4 20 X 3 G2 ZNC FULL 25 022127 1 NUT HEX 1 4 20 STEEL 26 022259 2 NUT HEX 5 16 18 STEEL 27 050279 1 DECAL FUEL INLET NG 28 0A6125 2 STUD 5 16 18 X 1 25 F THR 29 0D8492W 1 DECAL EMISSION CTRL 1 5NG 2006 10 15KW NATURAL GAS 30 0E1104 1 GASKET AIR CLEANER ADAPTER 31 0E0668 1 O RING 2 028 1 38 X 1 50 X 06 32 0E0590 1 VEN...

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Page 70: ...WASHER LOCK 8 M4 19 067035 6 SCREW PPHM 8 32 X 5 16 20 022127 1 NUT HEX 1 4 20 STEEL 21 0C2634A 1 ASSEMBLY COVER ACCESS 22 022473 1 WASHER FLAT 1 4 ZINC 23 022097 1 WASHER LOCK M6 1 4 24 0D2023 3 GASKET CLIP ON SELF GRIPPING 26 037337 6 NUT HEX JAM 3 8 24 SS 27 0D2023 21 GASKET CLIP ON SELF GRIPPING 28 0D8664A E 1 DUCT LH SIDE 1 5L 29 0D8664B F 1 DUCT RH SIDE 1 5L 30 077992 20 NUT HEX LOCK M6 1 0 ...

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Page 72: ...DUCT LH PNL 29 0E0072Q 2 ACSTC INSLTN 1 5L RAD SUPPORT 30 0E0072C 1 ACSTC INSLTN 1 5L DUCT FNT PNL 31 0E0072A 1 ACSTC INSLTN 1 5L ROOF PANEL 32 0E0072M 2 ACSTC INSLTN 1 5L SIDE DR PNL 33 0E0072P 2 ACSTC INSLTN 1 5L SIDE DR PNL 34 0E0072L 2 ACSTC INSLTN 1 5L SIDE BRC PNL 35 0E0072N 2 ACSTC INSLTN 1 5L DR BAFFLE PL 36 0E0072G 2 ACSTC INSLTN 1 5L RR CRNR TOP 37 0E0072J 2 ACSTC INSLTN 1 5L RR CRNR BOT...

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Page 74: ...E EXHAUST 1 5L STNDRD ACSTC 5 0C1318 1 FLEX PIPE EXHAUST 6 0D8657 1 SUPPORT RADIATOR 1 5L MITSU 7 027837 2 SCREW RHM 1 4 20 X 2 1 4 8 0D9437 1 MUFFLER 1 5L ACOUSTIC STANDARD 9 060366 2 STRAP MUFFLER 6 DIA 10 039253 4 SCREW HHC M8 1 25 X 20 G8 8 11 022145 4 WASHER FLAT 5 16 ZINC 12 022129 4 WASHER LOCK M8 5 16 13 045771 4 NUT HEX M8 1 25 G8 YEL CHR ...

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Page 78: ...1 PHASE TRANSFER SWITCH CONNECTION TS3 EC AR ALTERNATOR ROTOR AS ALTERNATOR STATOR CB1 2 CIRCUIT BREAKERS DPE EXCITATION WINDING F FUSE 15 AMPS GCU GOVERNOR CONTROL UNIT PCB CIRCUIT BOARD CONTROLLER TS1 2 3 TERMINAL BOARDS VR VOLTAGE REGULATOR LEGEND AS F SA SUPRESSION ASSEMBLY TR1 TRANSFORMER UTILITY SENSING 183 178 183 PREPACKAGE N C 15 15C BLUE 225A SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE S...

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