Generac Power Systems 004812-3 Owner's Manual
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Generac Power Systems 004812-3 Owner's Manual

Generac Power Systems 004812-3 Owner's Manual

Standby generator
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POWER SYSTEMS, INC.
Owner's Manual
Standby Generator
Models: 004812-3 & 004813-3
This manual should remain with the unit.

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Summary of Contents for Generac Power Systems 004812-3

  • Page 1 ® POWER SYSTEMS, INC. Owner’s Manual Standby Generator Models: 004812-3 & 004813-3 This manual should remain with the unit.

  • Page 2: Introduction

    INTRODUCTION The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recom- Thank you for purchasing this model of the stand- mends that the operator read this Owner's Manual by generator set product line by Generac Power and thoroughly understand all instructions before Systems.

  • Page 3: Table Of Contents

    Table of Contents Standby Generator Sets Introduction ....... Inside Front Cover Section 2 – Installation ........... 7 2.1 STANDBY GENERATOR INSTALLATION ....7 Read This Manual Thoroughly ........IFC Operation and Maintenance ........IFC 2.1.1 NFPA Standards ..........8 How to Obtain Service ..........IFC 2.1.2 Other Published Standards ......

  • Page 4: Safety Rules

    IMPORTANT SAFETY INSTRUCTIONS Standby Generator Sets   SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. ...
  • Page 5 IMPORTANT SAFETY INSTRUCTIONS Standby Generator Sets • Inspect the generator regularly, and promptly • Generators installed with an automatic transfer repair or replace all worn, damaged or defective switch will crank and start automatically when parts using only factory-approved parts. NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level.

  • Page 6: Section 1 - General Information

    Section 1 – General Information Standby Generator Sets IDENTIFICATION RECORD ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for 1.1.1 DATA LABEL long periods of time without an operator on hand to monitor such engine conditions as coolant tempera- Every generator set has a DATA LABEL that contains ture, oil pressure or rpm.-For that reason, the engine important information pertinent to the generator.

  • Page 7: Overcrank Shutdown

    Section 1 – General Information Standby Generator Sets 1.3.6 OVERCRANK SHUTDOWN SPECIFICATIONS After a prespecified duration of cranking, this func- 1.6.1 GENERATOR tion ends the cranking if the engine has failed to start. Refer to the data label on the particular generator for rated watts, amperes, frequency, voltage, phase and other pertinent information.

  • Page 8: Engine Oil Recommendations

    Section 1 – General Information Standby Generator Sets GENERATOR AC LEAD Engine Electrical System: DC Alternator Output ..........30 amps at 24 volts CONNECTIONS Starter Motor .................24-volt DC The electrical wires in the unit’s AC connection Recommended Battery ......... Two 12-volt, 90 Ah, 4 DLT (lower) panel should be installed according to the Ground Polarity ..............

  • Page 9: Starting Aids

    Section 2 – Installation Standby Generator Sets STARTING AIDS Figure 1.3 – Typical Dual-rate Battery Charger This standby generator is equipped with the follow- ing starting aids that serve to provide quicker, easier starts under varying climactic conditions. This generator has been mounted with an engine coolant heater and a battery charger.

  • Page 10: Nfpa Standards

    Section 2 – Installation Standby Generator Sets BASIC STANDBY ELECTRIC NOTE: For more information about the installation of a SYSTEM standby system, order Engine-Generator Standby Figure 2.1 shows a schematic diagram of a basic Electric Power Systems, Installer’s Guide and standby electric system.

  • Page 11: Total Circuit Isolation Method

    Section 2 – Installation Standby Generator Sets • It must have an ampere rating equal to, or greater Proper grounding helps protect personnel against than, the total amperage rating of the emergency electrical shock in the event of a ground fault condi- distribution panel circuit.

  • Page 12: Battery Installation

    Section 2 – Installation Standby Generator Sets BATTERY INSTALLATION When using maintenance-free batteries, it is not necessary to check the specific gravity or electrolyte DANGER level. Have these procedures performed at the inter- vals specified in Section 4, “Maintenance.” A nega- ...

  • Page 13: Start-Up Inspection

    Section 2 – Installation Standby Generator Sets 2.9.1.2 Fuel System Check to ensure that there are no loose electrical con- nections. Restrain any loose wires to keep them clear Make sure the fuel supply system to the genera- of any moving generator set components. tor (a) delivers the correct fuel at the correct pres- sure and (b) is properly purged and leak tested 2.9.1.7 Rodent Protection...

  • Page 14: Section 3 - Operation

    Section 3 – Operation Standby Generator Sets GENERATOR CONTROL AND OPERATION  Do not crank the engine continuously for longer Refer to the appropriate control panel operator’s than 30 seconds, or the heat may manual for this unit. damage the starter motor. •...

  • Page 15: Section 4 - Maintenance

    Section 4 – Maintenance Standby Generator Sets SERVICE SCHEDULE 4.1.2.3 Annually or Every 600 Hours (whichever comes first) 4.1.1 AUTHORIZED OPERATOR • Check engine valve clearance. MAINTENANCE FUNCTIONS • Test fuel injection nozzles. • Test injection timing. 4.1.1.1 Every Month or 100 Hours •...

  • Page 16: Test Standby Generator System Operation And Components

    Section 4 – Maintenance Standby Generator Sets 4.2.1 TEST STANDBY GENERATOR SYSTEM OPERATION AND COMPONENTS  Do not dispose of the battery in a fire. The An authorized operator should test the operation battery is capable of exploding. of the standby generator system and inspect its ...

  • Page 17: Inspect/Test Fuel Supply System

    Section 4 – Maintenance Standby Generator Sets 4.2.6 INSPECT/TEST FUEL SUPPLY SYSTEM 4.3.1 HOW TO ORDER PARTS Every three months (or 120 hours), an authorized To order a replacement part, locate the part in the operator should inspect and test the fuel supply sys- applicable exploded view.

  • Page 18: Section 5 - Installation Diagram

    Section 5 — Installation Standby Generator Sets Installation Diagram – Drawing No. 0F0652-B...
  • Page 19 Section 5 — Installation Standby Generator Sets Installation Diagram – Drawing No. 0F0652-B...

  • Page 20: Section 6 - Electrical Data

    Section 6 — Electrical Data Standby Generator Sets Wiring Diagram - E Panel – Drawing No. 0D2378A-C WIRE COLOR FUNCTION WIRE #'s LEGEND WHITE NEUTRAL 0,1,R15,591 BLACK/485+ NON-FUSED DC 4,13,29,218 ORANGE FUSED DC 14,15,219,220 CLEAR/485- 56,56A,57-59,67,89 BARE BROWN CONTROL 162,178,183,S1-3,590 2,49,150,A1-8,R1-9 BLUE SIGNAL/SENSING...
  • Page 21 Section 6 — Electrical Data Standby Generator Sets Wiring Diagram - E Panel – Drawing No. 0D2378A-C 14/219 CON1 CON3 SNDR RLY N/C PRG INPT 1 SNDR RLY N/O PRG INPT 2 SNDR RLY COM 15/220 PRG INPT 3 PRG RLY 3 NC PRG INPT 4 PRG RLY 3 NO PRG INPT 5...
  • Page 22 Section 6 — Electrical Data Standby Generator Sets Wiring Schematic - E Panel – Drawing No. 0D2379V-B LOWER PANEL CONNECTOR SEE DWG: 0D2483(390 ALTS.) OR 0D4225(520ALTS.) FIELD POWER SENSING BC3-10 CHARGE ALT. W/L CONN. PROG. INPUT 1 AUX. FUSED DC SUPPLY CON1-1 BATT CHRG FAIL BC3-1...
  • Page 23 Section 6 — Electrical Data Standby Generator Sets Wiring Schematic - E Panel – Drawing No. 0D2379V-B LEGEND AUDIBLE ALARM AMMETER AUTOMATIC VOLTAGE REGULATOR AVR CIRCUIT BREAKER FIELD BOOST DIODE CHARGE ALT EXCITER DIODE EMERGENCY STOP BUTTON ES1-3 NORMALLY CLOSED CONTACTS FREQUENCY METER PANEL LAMP E-PANEL CONTROLLER ASSEMBLY...
  • Page 24 Section 6 — Electrical Data Standby Generator Sets Wiring Diagram - Lower Panel – Drawing No. 0E4104-A K X X 178 & 183 2-WIRE START FROM TRANSFER SWITCH Q Q Q BRUSHLESS NB B (390mm) NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED...
  • Page 25 Section 6 — Electrical Data Standby Generator Sets Wiring Schematic - Lower Panel – Drawing No. 0E4105-A VOLTAGE CODE - A SERIES 4-WIRE BRUSHLESS DISPLACED PHASE WINDING THERMAL PROTECTOR BYPASS LEGEND: AR: ALTERNATOR ROTOR AS: ALTERNATOR STATOR CB1: CIRCUIT BREAKER (200A) CB2: CIRCUIT BREAKER (100A) CT1: CURRENT TRANSFORMER CT2: CURRENT TRANSFORMER...
  • Page 26 Section 6 — Electrical Data Standby Generator Sets Wiring Diagram - 3.9L – Drawing No. 0E2647A 79/CLEAR 0/BARE 0/BLACK 0/BLACK 79/CLEAR BLACK SM & SC LEGEND: ALT: ALTERNATOR - DC BAT: BATTERY BATTERY CHARGER CONTACTOR - CONTROL GREEN 120VAC EC1: CONNECTOR - ENGINE 1(BLACK) UTILITY WHITE...
  • Page 27 Section 6 — Electrical Data Standby Generator Sets Wiring Schematic - 3.9L Engine – Drawing No. 0E2648A 0/BLACK 0/BLACK 0/BARE 0/BARE 79/CLEAR 79/CLEAR 120VAC BLACK WHITE UTILITY ( + ) 12V BAT GREEN SUPPLY ( + ) 120VAC BLACK WHITE UTILITY GREEN BLACK...
  • Page 28 Section 6 — Electrical Data Standby Generator Sets Wiring Diagram - Battery Charger – Drawing No. 0D8610 COVER K6 K6 COVER ASSY # 67666 REV_G K1 K1 K4 K4 CHASSIS AC NEUT AC HOT 0D4698-T AC HOT AC NEUT LEGEND - DC AMMETER, 0-15A - FUSE, 250V, 4A (12V) OR 7A (24V)
  • Page 29 Section 6 — Electrical Data Standby Generator Sets Electrical Schematic - Battery Charger – Drawing No. 0D8611...

  • Page 30: Section 7 - Exploded Views And Parts Lists

    Section 7 — Exploded Views and Parts Lists Standby Generator Sets Mounting Base – Drawing No. 0E6626-A...
  • Page 31 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Mounting Base – Drawing No. 0E6626-A ITEM PART NO. QTY. DESCRIPTION 0E8714 ASSY MTG BASE 3.9L M 60-100KW 0E8715A ASSY MTG BASE 3.9L MITSU 125KW 055597 SCREW HHC M12-1.75 X 85 G8.8 (FRONT MOUNT ONLY) 052981 SCREW HHC M12-1.75 X 80 G8.8 (REAR MOUNT ONLY) 052259...
  • Page 32 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Tank – Drawing No. 0D5400V-F...
  • Page 33 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Tank – Drawing No. 0D5400V-F ITEM PART NO. QTY. DESCRIPTION 021075V TANK B GRP DW 210 GAL VERIZON 0C6789 SCREW HHC M12-1.75 X 30 SS FT 087171 WASHER FLAT 1/2 SS 051548 NUT HEX M12-1.75 G8 SS 0D3747V...
  • Page 34 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Radiator – Drawing No. 0F1599-D...
  • Page 35 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Radiator – Drawing No. 0F1599-D ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E1411B RADIATOR W703 X H749 L-IN L-OUT 33 * 0E2673 TOP/BOTTOM AIR DUCT 3.9L MITSU 0A5160 ASSEMBLY CAC 19 CORE 0A2110...
  • Page 36 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Exhaust – Drawing No. 0F0678 ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E7715 MUFFLER REWORK B GRP VERIZON 022129 WASHER LOCK M8-5/16 0E3170 EXHAUST PIPE 3.9L ENCLOSED 070264 WASHER FLAT M10 0A5215C...
  • Page 37 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Turbo – Drawing No. 0E4132-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 090625 AIR CLEANER 7 3/4 046526 WASHER LOCK M10 090624 MOUNTING CLAMP 7 3/4 0E2206 INSERT RUBBER REDUCER 3"...
  • Page 38 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Connection Box – Drawing No. 0E8213-B...
  • Page 39 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Connection Box – Drawing No. 0E8213-B ITEM PART NO. QTY. DESCRIPTION 0E6353 LOWER PANEL 390MM SHORT 0E6341 PANEL LOWER 390MM LONG 0D5489 COVER LOWER CONNECTION BOX 0E6427 PLATE GLAND 390S 0E6343 PLATE GLAND 390L 023484N...
  • Page 40 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Circuit Breakers – Drawing No. 0D6158-E APPLICATION FOR UNITS BUILT FROM 9/23/03 TO PRESENT LOWER CONNECTION PANEL (REF.) LEADS & ALT. SENSING LEADS & WIRE SENSING WIRE ALT. LEADS & SENSING WIRE ED 3 POLE...
  • Page 41 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Circuit Breakers – Drawing No. 0D6158-E ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION UL CIRCUIT BREAKER SIEMENS (BQ2) SEE TABLE SEE TABLE 0D5596B KIT CB MOUNT S (JD/LD 3P) 390L 0D5593A KIT CB MOUNT S (BQ 2P) 390S (B/D) (PME)
  • Page 42 Section 7 — Exploded Views and Parts Lists Standby Generator Sets QJ Circuit Breakers – Drawing No. 0E8214-B LEADS & SENSING ALT. QJ 2 POLE WIRE LEADS & (240V 60A-225A SENSING WIRE LOWER CONNECTION PANEL (REF.) ALT. LEADS & LEADS & SENSING QJ 3 POLE (240V 60A-225A...
  • Page 43 Section 7 — Exploded Views and Parts Lists Standby Generator Sets QJ Circuit Breakers – Drawing No. 0E8214-B ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION UL CIRCUIT BREAKER SIEMENS 390S UL CIRCUIT BREAKER SIEMENS 390L 2 POLE 3 POLE SEE TABLE P/N 0D8789 SEE TABLE P/N 0D8789...
  • Page 44 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Engine Parts – Drawing No. 0E6642-F...
  • Page 45 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Engine Parts – Drawing No. 0E6642-F ITEM PART NO. QTY. DESCRIPTION 0D5825 ENGINE 3.9L MITSUBISHI 0E1142 ADAPTER FLYWHEEL HSG. MACHINED 0A8240 FLEX PLATE SAE10 098184 FAN COOLING 26" 0D9220 SPACER FAN 3.9L 100K 0E2911 ARM THROTTLE CONTROL...
  • Page 46 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Generator – Drawing No. 0A4342-M...
  • Page 47 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Generator – Drawing No. 0A4342-M ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 055420 SCREW HHC M12-1.75 X 25 G10.9 020717B STATOR 390 35AP3 SAE 051769 WASHER LOCK M12 020718B STATOR 390 40AP3 SAE 046526...
  • Page 48 Section 7 — Exploded Views and Parts Lists Standby Generator Sets E Panel – Drawing No. 0E6893-E VIEW A HINGE ASSEMBLY SCALE: NONE TABLE A-FIELD BOOST RESISTOR DATA ALL DIRECTLY EXCITED MACHINES 5 OHM 25W P/N: 048352 ALL BRUSHLESS & PME MACHINES 25 OHM 25W UPTO 100KW WITH 12V DC SYSTEMS P/N: 057405...
  • Page 49 Section 7 — Exploded Views and Parts Lists Standby Generator Sets E Panel – Drawing No. 0E6893-E ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0E3681 PANEL BACK & BOTTOM E-PNL VRZN 022155 WASHER LOCK #6 0E3679 E-PANEL FRONT W/ SILK SCREEN 0C2428 SCREW TAPTITE PH 6-32 X 1/2 Z/YC 0E3683...
  • Page 50 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Exhaust (Model 004812) – Drawing No. 0E3755A-A CUSTOMER TO SUPPLY 3" NPT NIPPLE ITEM PART NO. QTY. DESCRIPTION 0E7611 MUFFLER,OPENSET 60KW VERIZON W 0E3603 BLANKET MUFFLER WRAP 3.9L L0SE 059940 RAIN CAP 3.50 / 3.69 059936...
  • Page 51 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Block Heater – Drawing No. 0E3354-A TO THERMOSTAT HOUSING TO LOWER RADIATOR HOSE MOUNTING BASE ITEM PART NO. QTY. DESCRIPTION 084918A BLOCK HEATER 1000W 100-200V. * 084918B BLOCK HEATER 1000W 200-240V. 084427 BRACKET HEATER W/WELDNUTS 050967...
  • Page 52 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Battery Charger – Drawing No. 0D3489-H REAR CUTAWAY VIEW OF PC BOARD MOUNTED TO BOTTOM OF INNER WALL COVER GND STRAP T.B. GND STRAP DETAIL A LOCATED ON OUTSIDE TOP FRONT VIEW OF INNER WALL WITH TERMINAL BLOCK &...
  • Page 53 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Battery Charger – Drawing No. 0D3489-H ITEM PART NO. QTY. DESCRIPTION 0C2943 BATT. CHARGER BOX 0D5255 SILKSCREEN/COVER DUAL METER 24 061526 AMMETER 0-15ADC 2-1/2" 061528 VOLTMETER 0-30VDC 2-1/2" 061525 LIGHT 120V NEON LAMP/HOLDER 032300 HOLDER FUSE...
  • Page 54 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Battery Charger – Drawing No. 0E3016C ITEM PART NO. QTY. DESCRIPTION 0D3489 ASSY. BATTERY CHARGER 24V 10A 0E6187 CORD, POWER SUPPLY 16 AWG X 9’ LONG 022206 FITTING, CONDUIT STRAIGHT 3/8”...
  • Page 55 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Baseframe Insulation – Drawing No. 0F0874 INSTALLED NEAR SIDE INSTALLED FAR SIDE ITEM PART NO. QTY. DESCRIPTION 0F0750 INSULATION LH REAR 0F0750A INSULATION LH MIDDLE 0F0750B INSULATION LH FRONT 0F0750C INSULATION RH FRONT 0F0750D...
  • Page 56 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Enclosure – Drawing No. 0F0679-C (Part 1) WELD STUDS UNDER STATES FOAM IS ON NEAR SIDE ROOF PANEL FOR ACCESS COVER CORDS STATES FOAM IS ON FAR SIDE 4 10 TYPICAL OF ALL FRONT DISCHARGE DUCT &...
  • Page 57 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Enclosure – Drawing No. 0F0679-C (Part 1) ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0C3594 ASSEMBLY M6 HINGE 0C3157N INSULATION FRONT CORNER POST 0F0548A INSULATION DISCHARGE ATTNTR BAFFLE 0C3157P INSULATION TOP &...
  • Page 58 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Enclosure – Drawing No. 0F0679-C (Part 2)
  • Page 59 Section 7 — Exploded Views and Parts Lists Standby Generator Sets Enclosure – Drawing No. 0F0679-C (Part 2) ITEM PART NO. QTY. DESCRIPTION 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 077992 NUT HEX LOCK M6-1.0 SS NY INS 0C9724 CAULK CLIMACEL CLEAR 0A5035A...

  • Page 60: Section 8 - Notes

    Section 8 — Notes Standby Generator Sets...
  • Page 61 Section 8 — Notes Standby Generator Sets...

  • Page 62: Section 9 - Warranty

    Warranty (ECS Warranty), which is provided to you by Generac pursuant to federal and California law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new non-road diesel engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circum- stances where the Generac Warranty may provide a longer warranty period.
  • Page 63 Section 9 – Warranty Standby Generator Sets EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1996 and later model year non-road diesel engines: (a) Applicability: This warranty shall apply to 1996 and later model year non-road diesel engines. The ECS Warranty shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 60 months, or 3,000 hours of use, thereafter, whichever occurs first.
  • Page 64 NOTE: ALL UNITS MUST HAVE A START-UP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER. For a period of two (2) years or two thousand (2,000) hours of operation from the date of sale, which ever occurs first, Generac Power Systems, Inc.
  • Page 66 055420 SCREW HHC M12-1.75 X 25 G10.9 020716D STATOR 390 35KB1 SAE 051769 WASHER LOCK M12 020728D STATOR 390 35KB2 SAE 046526 WASHER LOCK M10 020729D STATOR 390 40KB2 SAE 022237 WASHER LOCK 3/8 020730D STATOR 390 50KB2 SAE 052647 SCREW SHC M10-1.5 X 25 G12.9 020731D STATOR 390 60KB2 SAE...
  • Page 68 UL CIRCUIT BREAKER SIEMENS (BQ2) 0D5463 KIT NEUTRAL BLOCK 390/UPTO125A SEE TABLE PARTS SHOWN BELOW (I/N: A-I) 0D5593A KIT CB MOUNT S (BQ 2P) 390S (B/D) 0D5464 NEUTRAL BLOCK 390/UPTO125A 0D5593B KIT CB MOUNT S (BQ 2P) 390L (PME) 057073 JUNCTION BLOCK 3/8-16 PARTS SHOWN BELOW (I/N’S: C-P) 022152...
  • Page 70 0E6353 LOWER PANEL 390MM SHORT 0E6341 PANEL LOWER 390MM LONG 0D5489 COVER LOWER CONNECTION BOX 0E6427 PLATE GLAND 390S 0E6343 PLATE GLAND 390L 023484N BUSHING SNAP SB-2.5-31 0E6454 BRACKET NEUTRAL 056739 RELAY SOLENOID 12VDC PNL MNT 082982 RELAY CONTACTOR 24VDC 0C2454 SCREW THF M6-1X16 N WA Z/JS 051715...
  • Page 71 LEADS & SENSING ALT. QJ 2 POLE WIRE LEADS & (240V 60A-225A) SENSING WIRE LOWER CONNECTION PANEL (REF.) ALT. LEADS & LEADS & SENSING QJ 3 POLE (240V 60A-225A) SENSING WIRE WIRE ALT. LEADS & SENSING WIRE QJ 2 POLE (240V 60A-225A) LEADS &...
  • Page 72 UL CIRCUIT BREAKER SIEMENS 390S 2 POLE 0D5463A KIT NEUTRAL BLOCK 390/150-175A SEE TABLE P/N 0D8789 PARTS SHOWN BELOW (I/N : A-H) 0E5588 KIT CB MOUNT SIEMENS QJ 2P 390S 0D5464A NEUTRAL BLOCK 390/UP TO 125A PARTS ARE SHOWN BELOW 057073 JUNCTION BLOCK 3/8-16 0E5586...
  • Page 74 0E3681 PANEL BACK & BOTTOM E-PNL VRZN ---------- PANEL SPECIAL PARTS 0E3679 E-PANEL FRONT W/ SILK SCREEN 064733 BRACKET RESISTOR MNTNG FOR 25W 0E3683 PANEL RH SIDE E-PNL VERIZON RESISTOR #2 0E3682 PANEL LH SIDE E-PNL VERIZON TABLE A 0E3550 CHASSIS, UNIVERSAL FIELD CIRCUIT BREAKER 0D2382...
  • Page 76 021075V TANK B G RP DW 210 GAL VERIZO N 0C6789 SCREW HHC M12-1.75 X 30 SS FT 087171 W ASHER FLAT 1/2 SS 051548 NUT HEX M12-1.75 G8 SS 0D3747V COVER STUB-UP BGRP VERIZO N 050190 W ASHER FLAT .344 ID X 1.0 OD 051754 SCREW HHC M8-1.25 X 12 G 8.8 035472...
  • Page 77 TO THERMOSTAT HOUSING TO LOWER RADIATOR HOSE MOUNTING BASE...
  • Page 78 084918A BLOCK HEATER 1000W 100-200V. * 084918B BLOCK HEATER 1000W 200-240V. 084427 BRACKET HEATER W/WELDNUTS 050967 HOSE 5/8 ID RIA 250F (24” LG) 0A6283 HOSE PREFORMED BLOCK HEATER 057822 CLAMP HOSE #8 .53-1.00 047411 SCREW HHC M6-1.0 X 16 G8.8 022473 WASHER FLAT 1/4-M6 ZINC 022097...
  • Page 80 0E8714 ASSY MTG BASE 3.9L M 60-100KW 0E8715A ASSY MTG BASE 3.9L MITSU 125KW 055597 SCREW HHC M12-1.75 X 85 G8.8 (FRONT MOUNT ONLY) 052981 SCREW HHC M12-1.75 X 80 G8.8 (REAR MOUNT ONLY) 052259 WASHER FLAT M12 052257 SPACER .49 X .62 X 1.87 PWDR/ZINC 052252 DAMPENER VIBRATION 052251A...
  • Page 82 0F0750 INSULATION LH REAR 0F0750A INSULATION LH MIDDLE 0F0750B INSULATION LH FRONT 0F0750C INSULATION RH FRONT 0F0750D INSULATION RH MIDDLE 0F0750E INSULATION RH REAR 0F0750F INSULATION FRONT & ENDS...
  • Page 84 0E1411B RADIATOR W703 X H749 L-IN L-OUT 0A5160 ASSEMBLY CAC 19 CORE 0D9040A RADIATOR SUPPORT RH 3.9L 0D9040 RADIATOR SUPPORT LH 0D9041 VENTURI FAN 3.9 100KW 039253 SCREW HHC M8-1.25 X 20 G8.8 022129 WASHER LOCK M8-5/16 022145 WASHER FLAT 5/16-M8 ZINC 099305A VALVE 1/2 NPT BALL 090283...
  • Page 86 0C2943 BATT. CHARGER BOX 0D5255 SILKSCREEN/COVER DUAL METER 24 061526 AMMETER 0-15ADC 2-1/2" 061528 VOLTMETER 0-30VDC 2-1/2" 061525 LIGHT 120V NEON LAMP/HOLDER 032300 HOLDER FUSE 067682A FUSE 7A X 3AG SLO BLO GLASS 0D7178B FUSE 12AMP LITT 3AB-12 314012 067666A ASSY PCB 10A 24/120V 024911 SCREW HHTT #8-32 X 3/8 CZ...
  • Page 88 090625 AIR CLEANER 7 3/4 090624 MOUNTING CLAMP 7 3/4 0E4131 TUBE INTAKE W/ 1/8NPT 3.9L VZN 059668 HOSE RUBBER HUMP RDCR 4IN-3IN 0E2517 BRACKET AIR FILTER 3.9L MITSU 086133G CLAMP HI TORQUE 3.75 - 4.625 086133D CLAMP HI TORQUE 2.25 - 3.125 049814 SCREW HHC M10-1.5 X 25 G8.8 022131...
  • Page 90 0D5825 ENGINE 3.9L MITSUBISHI 0E1142 ADAPTER FLYWHEEL HSG. MACHINED 0A8240 FLEX PLATE SAE10 098184 FAN COOLING 26" 0D9220 SPACER FAN 3.9L 100K 0E2911 ARM THROTTLE CONTROL 049721 SCREW HHC M6-1.0 X 35 G8.8 BLK 022097 WASHER LOCK M6-1/4 0D58250526 REF. JOINT,ENG OIL PRESSURE GAUGE (COMES WITH ENGINE) 0D7034 REF.
  • Page 92 0E7611 MUFFLER,OPENSET 60KW VERIZON W 0E3603 BLANKET MUFFLER WRAP 3.9L L0SE 059940 RAIN CAP 3.50 / 3.69 059936 ELBOW 90 D 3 NPT 059941 NIPPLE TOE 3 NPT X 8 0E3298 REDUCER 2.5" TO 3" COUPLER 057646C FLEX EXH 2.5 X 15.44 LONG 0E2668 ELBOW EXHAUST TURBO OUTLET 0E3495...
  • Page 94 0E7715 MUFFLER REWORK B GRP VERIZON 0E3170 EXHAUST PIPE 3.9L ENCLOSED 0A5215C PIPE FLEX 3” 0C2933 BRACKET MUFFLER MTG 0C4114 CLAMP MUFFLER BAND 0F0669 U PIPE MUFFLER TO MUFFLER 3.9L 0C9645 3" TUBE 90 DEG ELBOW 'B' GROUP 0D8473 MUFFLER 6.8/8.1 (OPEN SET-G/B) 055978 BOLT U 3/8-16 X 3.25 0E4134...
  • Page 96 0C3594 ASSEMBLY M6 HINGE 0E1116 (A) RAD BLOCK-OFF RH/LH SIDE 3.9L 0F0548A INSULATION DISCHARGE ATTNTR BAFFLE 0E1117 (A) RAD BLOCK-OFF TOP 3.9L MITSU 0A3359 SCREW BHSC M6-1.0 X 16 SS 73 * 0F0774 (A) BLOCK OFF OVERHEAD MODULE FRONT 0F0425(A) BAFFLE DISCHARGE ATTENUATOR 0C3157W INSULATION REAR ROOF TOP #1...
  • Page 98 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 077992 NUT HEX LOCK M6-1.0 SS NY INS 0C9724 CAULK CLIMACEL CLEAR 0A5035A HANGER SELF ADHESIVE 3/4" 0F0130B INSULATION OVERHD MODULE FRONT/REAR 0F0130 INSULATION SPLITTER 0F0130A INSULATION OVERHD MODLE SIDE/BOTTOM 0F0048 (A) INTAKE OVERHEAD MODULE FRONT/REAR 0F1253 (A) INTAKE,OVER HEAD MODULE SIDE...
  • Page 99 WIRE COLOR FUNCTION WIRE #'s LEGEND WHITE NEUTRAL 0,1,R15,591 NON-FUSED DC 4,13,29,218 BLACK/485+ ORANGE FUSED DC 14,15,219,220 CLEAR/485- 56,56A,57-59,67,89 BARE BROWN CONTROL 162,178,183,S1-3,590 2,49,150,A1-8,R1-9 BLUE SIGNAL/SENSING S15,S16,64,65 BLACK AC/MISC 68,69,85,502,509, YELLOW UNIT STATUS 515,523,567,575,589 LEGEND 13/218 AVR = AUTOMATIC VOLTAGE REGULATOR CB1 = AVR CIRCUIT BREAKER 14/219 14/219...
  • Page 100 14/219 CON1 CON3 SNDR RLY N/C PRG INPT 1 SNDR RLY N/O PRG INPT 2 SNDR RLY COM 15/220 PRG INPT 3 PRG RLY 3 NC PRG INPT 4 PRG RLY 3 NO PRG INPT 5 PRG RLY 3 COM PRG INPT 6 PRG RLY 2 NC PRG INPT 7...
  • Page 101 LOWER PANEL CONNECTOR SEE DWG: 0D2483(390 ALTS.) OR 0D4225(520ALTS.) FIELD POWER SENSING BC3-10 CHARGE ALT. W/L CONN. TB4-5 PROG. INPUT 1 AUX. FUSED DC SUPPLY CON1-1 BATT CHRG FAIL BC3-1 POSITIVE DC FROM BATTERY CON4-1 CON1-2 PROG. INPUT 2 BC3-12 POSITIVE DC FROM BATTERY GEN.
  • Page 102 LEGEND AUDIBLE ALARM AMMETER AUTOMATIC VOLTAGE REGULATOR AVR CIRCUIT BREAKER FIELD BOOST DIODE CHARGE ALT EXCITER DIODE EMERGENCY STOP BUTTON ES1-3 NORMALLY CLOSED CONTACTS FREQUENCY METER PANEL LAMP E-PANEL CONTROLLER ASSEMBLY FIELD BOOST RESISTOR CHARGE ALT EXCITER RESISTOR VOLT/AMMETER SWITCH VOLTMETER VOLTS TRIM POTENTIOMETER XXX-X...
  • Page 103 COVER K6 K6 COVER ASSY # 67666 REV_G K1 K1 K4 K4 CHASSIS AC NEUT AC HOT 0D4698-T AC HOT AC NEUT LEGEND - DC AMMETER, 0-15A - FUSE, 250V, 4A (12V) OR 7A (24V) 4A (12V) OR 7A 4A (12V) OR 7A - FUSE, 32V, 12A GND - GROUND POST 46689-T...
  • Page 104 4A/7A 250V TB2-1 12 AMP SLOW-BLOW 0-15A TB1-3 TS5 5 TB2-2 AC HOT 0-15V 0-30V "POWER ON" TB1-2 TS6 6 TB2-3 AC NEUT TB1-1 TS7 7 TB2-4 LEGEND - DC AMMETER, 0-15A - FUSE, 250V, 4A (12V) OR 7A (24V) - FUSE, 32V, 12A - FUSE, 32V, 12A USE, 32V,...
  • Page 107 K X X 178 & 183 2-WIRE START FROM TRANSFER SWITCH Q Q Q BRUSHLESS NB B (390mm) NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED E1 E2 E3 LEGEND: CUSTOMER CONNECTION AS: ALTERNATOR STATOR 120/240V. 1-PHASE CB1: CIRCUIT BREAKER (200A) CB2: CIRCUIT BREAKER (100A) E1 TO E3 240V.
  • Page 108 VOLTAGE CODE - A SERIES 4-WIRE BRUSHLESS DISPLACED PHASE WINDING THERMAL PROTECTOR BYPASS LEGEND: AR: ALTERNATOR ROTOR AS: ALTERNATOR STATOR CB1: CIRCUIT BREAKER (200A) CB2: CIRCUIT BREAKER (100A) CT1: CURRENT TRANSFORMER CT2: CURRENT TRANSFORMER DPE: DISPLACED PHASE EXCIT. WINDING EA: BRUSHLESS EXCITER ARMATURE EF: EXCITER FIELD LPC: LOWER PANEL CONNECTION CUSTOMER CONNECTION...

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