PARTS MANUAL. Generator Models RC185D

Transcription

1 PARTS MANUAL Generator Models RC185D This manual contains important safety information. Do not destroy this manual. This manual must be available to the personnel who operate and maintain this machine. Clarke Power Generation, Inc Piedmont Triad Parkway Greensboro, N.C Book: G (6-2015) Rev A

2 2

3 TABLE OF CONTENTS Parts Book TITLE Parts Ordering PAGE Parts List Engine and Engine Mounting Engine and Engine Mounting Alternator, Alternator Mounting Alternator Internal Parts Alternator J Box Fan Belt Guards Cooling System Parts Cooling System Parts Exhaust Assembly Engine Air Intake Fuel Tank & Hardware Fuel Tank Piping Fuel Tank Canada Only Fuel Tank Canada Only Central Drains Battery Control Panel Assembly - Digital Control Panel Assembly - Digital Control Panel Assembly - Digital Control Panel Assembly - Digital Control Panel Assembly - Digital Control Panel - Digital Receptacles & Circuit Breakers Circuit Breaker Assembly Frame Assembly Drawbar, Standard Electric Brake Running Gear Assembly Running Gear, Standard Electric Brake Running Gear Lighting and Break-Away Switch Page Blank Intentionally Enclosure Assembly Enclosure Assembly Intake Baffles Foam Assembly Decal Location Recommended Spares & Service Kits Recommended Spares & Service Kits Option Parts List Option - Manual Oil Pump Frame and Skid Assembly Camlock Assembly Battery Charger Block Heater Battery Heater Way Fuel Valve Way Fuel Valve

4 Parts Book Wiring Diagrams Tail Lights Wiring Diagram

5 Parts Ordering

6 GENERAL This publication, which contains an illustrated parts breakdown, has been prepared as an aid in locating those parts which may be required in the maintenance of the unit. Always insist on genuine Clarke parts for your unit. Clarke Power Generation can bear no responsibility for injury or damages resulting directly from the use of non-approved repair parts. Clarke Power Generation service facilities and parts are available worldwide. Consult local yellow pages or visit: Special order parts may not be included in this manual. Contact the Clarke Power Generation Parts Department with the unit serial number for assistance with these special parts. Description The illustrated parts breakdown illustrates and lists the various assemblies, subassemblies and detailed parts which make up this particular machine. This covers the standard models and the more popular options that are available. In referring to the rear, the front or to either side of the unit, always consider the drawbar end of the unit as the front. Standing at the rear of the unit facing the drawbar (front) will determine the right and left sides. Fasteners Both SAE/inch and ISO/metric hardware have been used in the design and assembly of these units. In the disassembly and reassembly of parts, extreme care must be taken to avoid damaging threads by the use of wrong fasteners. How To Order Always specify the model and serial number of the unit. Specify the part number and description.

7 Parts List 5

8 6 Engine and Engine Mounting

9 Engine and Engine Mounting 1 M Bracket, Engine Mounting, RH 1 2 M Bracket, Engine Mounting, LH 1 3 M Crossmember Engine 1 4 M Engine, 6068HF M Fan, 736.6mm Dia. 1 6 M Isolator 2 7 M Nut, Locking 2 8 M Screw, Hex Head M X M Spacer, Fan 1 10 M Washer 4 11 M Washer, Snubber 4 12 M Screw, Tapping M X M Screw, Hex Flange M X M Nut, Hex Flange M12 X M Screw, Hex M X M Harness, Engine Wiring Not Shown C02775 Filter, Fuel 1 C02776 Filter, Fuel Primary 1 C04521 Oil Filter 1 G Fan Belt 1 G Thermostat 1 G Starter 1 G Alternator, Charging 1 7

10 Alternator, Alternator Mounting 1 M Alternator, LSA 442L12-60Hz 1 2 M Support, Alternator 1 3 M Screw, Hex Cap 3/4-1 X 1-3/4 2 4 M Washer, Flat Plain Type A Narrow 3/4 2 5 M Washer, Snubbing (Top of Mount) 2 M Washer, Snubbing (Bottom of Mount) 2 6 M Isolator 2 7 M Screw, Tapping M X M Nut, Locking 3/ M Bolt, Engine-Generator M X M Bolt, Drive Disk 8 11 M Harness, J Box 1 12 M Cover, Transformer 1 13 M Screw, Tapping M6-1.0 X M Transformer 1 15 M Bracket, Transformer Mounting 1 16 M Screw, Tapping M6-1.0 X M Nut, Hex Flange M M Harness, Transformer 1 Not Shown 8

11 Alternator Internal Parts 1 M Bearing, NDE 1 2 M Wavy Washer 1 3 M Wound Exciter Field 1 4 M Voltage Regulator 1 5 M Drive Disc 1 6 M Surge Suppressor 1 7 M Seal, O-Ring 1 8 M Diode Bridge LSA M Nut, Stud 1 10 M Fuse, AVR 1 Not Shown 11 M Fan 1 12 M Tie Rods 1 13 M Terminal Block 1 9

12 Alternator J Box 1 M Cover, J Box 1 2 M Back, J Box 1 3 M Side, J Box - Street 1 4 M Side, J Box - Curb 1 5 M Front, J Box 1 6 M Plate, J Box 2 7 M Box, Voltage Selector Switch 1 8 M Screw, Phillips Pan Head #10-32 X 1/2 2 9 M Nut, Hex Light Locking # M Switch, Interlock 1 11 M Switch, Voltage Selector 1 12 M Mount, Voltage Selector Switch 1 13 M Screw, Cap Socket Head 1/4-20 X M Nut, Hex 1/ M Washer, Flat Plain Type A Narrow 1/ M Rubber, Cable Entry 1 17 M Plate, J Box Rubber 2 18 M Screw, Tapping M6-1.0 X M Kit, Power Wiring 1 Not Shown 20 M Transformer, Current 600:5 3 Not Shown 10

13 Fan Belt Guards 1 M Guard, Top Belt 1 2 M Bracket, Fan Guard 1 3 M Guard, Belt- LH 1 4 M Bracket, Belt Guard 1 5 M Guard, Belt - RH 1 6 M Screw, Hex Flange M X M Nut, Hex Flange M M Screw, Hex M X M Screw, Tapping M6-1.0 X M Screw, Hex M X

14 12 Cooling System Parts

15 Cooling System Parts 1 M Baffle, Radiator, Top 1 1A M Screw, Tapping M6-1.0 X M Bracket, Coolant Bottle 1 3 M Connector, 2 Flexible 2 4 M Cooler, Charge Air 1 5 M Clamp, Hose 1 6 M Hose, Overflow 34 Length 1 7 M Guard, Fan 7 8 M Panel, Radiator Mount 1 9 M Hose, Radiator Lower 1 10 M Hose, Radiator Upper 1 11 M Screw, Tapping M X M Plate, Support, Cooler 2 13 M Radiator Assembly 1 14 M Reducer, 76.2mm x 50.8mm 2 15 M Screw, Hex Flange M X M Cap, Radiator 14 psi 1 M Cap, Radiator 16 psi 1 16 M Screw, Hex. Flange 1 17 M Screw, Tpg Hex Washer Head M X M Screw, Tapping M6-1.0 X M Serial Number Plate 1 20 M Shroud, Fan 1 21 M Spring-Loaded, T-Bolt Clamp 2 22 M Spring-Loaded, T-Bolt Clamp 6 23 M Support, Cooler 2 24 M Support, Cooler, Bottom 1 25 M Screw, Tapping M6-1.0 X M Inlet Tube 1 27 M Outlet Tube 1 28 M Tank, Radiator Overflow 1 29 M Rivet, SS.187 Dia M Nutsert, Hex M M Clamp, Hose 4 13

16 Exhaust Assembly 1 M Bracket, Muffler 1 2 M Clamp, 14" Muffler Mounting 2 3 M Muffler, Exhaust 1 4 M Tube, Air Intake 1 5 M Clamp Saddle 3 6 M Pipe, 90 Elbow 1 7 M Pipe, Engine Exhaust 1 8 M Pipe, Extension 1 9 M Cap, 5 Rain 1 10 M Screw, Hex Head M X M Nut, Hex Flange M M Screw, Tapping M X M Nut, Hex Flange M M Screw, Hex M X M Clamp, Band 5 Dia M Clamp, Band 4 Dia M Clamp, V-Band 4.75 Dia. 1 14

17 Engine Air Intake 1 G Bracket, Air Cleaner Mtg, RC185D-RC240D 1 2 G Air Filter Mounting Band, RC D 1 3 G Air Filter Assy, RC D (includes items 1 9,10,11,13 w/clips) 4 G Elbow, Rubber, 90 degree 130mm ID 1 5 G Hose, Hump - 5 to 4, 6 LG 1 6 G Pipe, Aluminum, 5 OD, 7 Long 1 7 C12652 Clamp, Hose 4 8 C12650 Clamp, Hose 4 9 G Ejector, Dust, RC185D-RC240D 3 10 G Primary Element, RC185D-RC240D 1 11 G Safety Element, RC185D-RC240D 1 12 G Restriction Indicator, 65 MBAR, M G Cover, Air Cleaner, RC185D-RC240D (W/O 1 Not Shown Clips) 14 G Spacer, 29mm (RC185D Only) 4 Not Shown (Place between G & G030099) 15 NPN Washer, Steel, Zinc Plated Flat- M NPN Nut, Nylon Insert, M8x NPN Bolt, Steel, Hex Head M8 x1.25 x NPN Bolt, Tapping M8 x 1.25 x

18 Fuel Tank & Hardware 1 M Tank, Fuel Assembly 1 2 M Strainer, Fuel Tank 1 3 M Cap, Fuel Fill 4 M Bracket, Tank Mounting, Front 2 5 M Bracket, Tank Mounting Left Rear 1 6 M Screw, Hex Flange M X M Nut, Hex Flange M M Screw, Tapping M X M Pad, Fuel Tank 8.7 Length 3 10 M Bracket, Tank Mounting Right Rear 1 11 M Sensor, Containment Level 1 12 M U-Bolt, 1/4 X 1 X 1-1/ M Nut, Hex Locking 1/ M Bracket, Sensor 1 15 M Screw, Tapping M X M Bracket, Tank 4 17 M Sender, Fuel 1 18 M Screw, Hex #10-32 X

19 Fuel Tank Piping 1 M Plug, Square Head 1/2 NPT 1 2 M Silencer, Pneumatic 1/4 NPT 2 3 M Clamp, Hose 2 4 M Valve, Check 3/8 NPT 1 5 M Adapter, 3/8 Hose X 3/8 NPT 1 6 M Adapter, 1/4 NPT X 5/16 I.D. Hose 3 7 M Hose, Fuel 5/16 I.D. X 60 Length 1 8 M Clamp, Hose 8 9 M Hose, Vent 3/8 O.D. X 25 Length 2 10 M Screw, Tapping M6-1.0 X M Connector, 1/4 NPT X 3/8 Tubing 2 12 M Connector, 1/4 NPTF X 3/8 Tubing 2 13 M Hose, Fuel 3/8 I.D. 17

20 18 Fuel Tank Canada Only

21 Fuel Tank Canada Only 1 M Assembly, Fuel Tank Canada Only 1 2 M Cap, Fuel Filler 1 3 M Strainer, Fuel Tank 1 4 M Cap, Vent 1 5 M Sender, Fuel Level 1 6 M Sensor, Containment Level 1 7 M Pad, Fuel Tank 3 8 M Bracket, Tank Adjustable Left Side 1 9 M Bracket, Tank Adjustable Right Side 1 10 M Bracket, Tank Mounting Front 2 11 M Hose, 5/16 I.D. x 26 Length 1 12 M Hose, 3/8 I.D. x 60 Length 1 13 M Clamp, Hose 1/4 I.D M Adapter, Barbeb 1/4 NPT x 5/16 I.D. Hose 1 15 M Reducer, 1/4 O.D. x 5/16 O.D M Adapter, Barbed 3/8 NPT x 3/8 I.D. Hose 1 17 M Valve, Check 3/8 NPT 1 18 M Bracket, Sensor 1 19 M Screw, Tapping M x M Screw, Hex Flange M x M U-Bolt, 1/4 x 1 I.D. x 1-1/4 Leg 2 22 M Screw, Tapping M6-1.0 x M Nut, Hex Locking 1/ M Nut, Hex Flange M

22 Central Drains 1 M Adapter, 1/4 NPT X 3/8 Hose 1 2 M Hose, Fuel 3/8 I.D. X 24.8 Length 1 3 M Clamp, Hose 1/4 I.D. 2 4 M Adapter, 3/8 NPT X 3/8 Hose 1 5 M Valve, T-Handle Ball 3/8 1 6 M Nipple, Extra Strong 3/4 NPT X 3 Length 1 7 M Connector, Bulkhead 2 8 M Valve, Drain M X 5/8 Hose 1 20

23 Battery 1 M Battery 12V 1 2 M Tray, Battery 1 3 M Angle 1 4 M J-Bolt 2 5 M Washer, Plastic 1 O.D. 2 6 M Nut, Hex 1/ M Screw, Tapping M X M Cable, Battery Positive 475mm 1 9 M Cable, Battery Negative 450mm 1 To Starter Negative Stud 10 M Cable, Jumper 625mm (From Switch to Starter) 1 11 M Screw, Tapping M X M Switch, Battery Cut-Off 1 13 M Bracket, Disconnect 1 21

24 22 Control Panel Assembly - Digital

25 Control Panel Assembly - Digital 1 M Label, Remote Start 1 2 M Standoff, Insulator 4 3 M Block Terminal 1 4 M Screw, Tapping Black M6-1.0 X M Screw, Button Socket Hd M X M Latch, Cable Door 2 7 M Hinge, Cable Door 1 8 M Bracket, Bus Bar Mounting 1 9 M Rubber, Cable Entry 1 10 M Bracket, Cable Entry Bracket 2 11 M Bus Bar, Ground 1 12 M Bus Bar, Neutral 1 13 M Angle, Gasket 2 14 M Cable, Rubber Entry 1 15 M Breaker, Sub Assembly 1 16 M Decal, Direct Connect 1 17 M Screw, Whiz Lock Flange 5/16-18 X 3/ M Signal, Audible 1 19 M Door, Rubber 1 20 M Nut, Hex Flange M M Screw, Hex M X M Nut, Hex Locking 5/ M Nut, Hex Nylon Insert # M Washer, Lock 3/ M Screw, Phillips Pan Head #6-32 X 1/ M Nut, Hex Nylon Insert # M Screw, Hex M X

26 24 Control Panel Assembly - Digital

27 Control Panel Assembly - Digital 1 M Terminal End 4 2 M Hinge, Control Panel 1 3 M Fuse, Terminal 2 4 M Plate, Fuse End 1 5 M Grommet, Blind/Plug 1 6 M Receptacle, 1/4 Turn 2 7 M Block, 4 Pole Terminal 1 8 M Alarm, Coolant Level 1 9 M Block, Terminal - Red 1 10 M Block, Terminal - Gray 6 11 M Block, Terminal - Yellow 3 12 M Connector, 3 position 1 13 M Connector, 4 position 1 14 M Rail, DIN 35mm 1 15 M Connector 4 16 M Clamp, Cable 1 17 M Support, Clamp 3 18 M Screw, Tapping M6-1.0 X M Nut, Hex Flange M M Screw, Hex Flange M X M Rail, DIN 35mm 1 22 M Fuseholder, 3 Pole 1 23 M Decal, Fuse Label 1 24 M Screw, Tapping M6-1.0 X M Nut, Hex Nylon Insert # M Screw, Phillips Pan Head #10-32 X 1/

28 Control Panel Assembly - Digital 1 M Rivet, Aluminum.187 Dia. Black Dia 2 M Enclosure, Power Pedestal 1 3 M Door, Cable Hook-Up 1 4 M Cover, Top Left 1 5 M Stud, Self Ejecting 2 6 M Plexiglass, Cable Door 1 7 M Retainer 2 8 M Sub-assembly, Breaker/Receptacle 1 9 M Cover, Circuit Breaker 1 10 M Panel, Digital Control 1 11 M Screw, Hex Flange M6-1.0 X M Washer, Flat Plain Type A Narrow #

29 Control Panel - Digital 1 M Bulb, Lamp 1 2 M Switch, Pushbutton - Green 1 3 M Panel, Pedestal Control 1 4 M Decal, Voltage Output Adjust 1 5 M Panel, Pedestal 1 6 G Controller, GSC1 1 7 G Label, Sensing Warning 1 8 M Potentiometer, Voltage Adjust 1 Not Shown 9 M Knob, Voltage Adjust 1 Not Shown 27

30 Receptacles & Circuit Breakers 1 M Receptacle, 125V 20A 2 2 M Cover, Recptacle 2 3 M Receptacle, 125/250V 50A 3 4 M Cover, Weatherproof 3 5 M Screw, Phillips Pan Head #8-32 X 5/ M Nut, Hex Nylon Insert # M Breaker, Circuit, 50A 3 8 M Breaker, Circuit, 20A 2 9 M Screw, Phillips Pan Head #6-32 X 1/ M Cover, Receptacle 1 11 M Screw, Hex Flange M6-1.0 X M Decal, Breaker 1 13 M Panel, Receptacle 1 14 M Decal, Receptacle 1 15 M Harness, Receptacle 1 Not Shown 28

31 Circuit Breaker Assembly 1 M Base, Breaker 1 2 M Screw, Tapping M6-1.0 X M Decal, Direct Connect 1 4 M Circuit Breaker 1 5 M Screw, Socket Head M X M Washer,Flat Plain Type A Narrow 9/ M Nut, Hex Flange M M Bar, Bus 1 9 M Screw, Hex Flange 1/4-20 X M Plate, Bus Bar 1 11 M Screw, Hex M X M Standoff, Plastic 4 13 M Bracket, Bus Bar 1 14 M Bar, Bus 3 15 M Bar, Bus 2 16 M Lugs, Panelboard 4 17 M Screw, Hex M X M Nut, Hex Prevailing Torque M

32 Frame Assembly 1 REF Frame 1 2 M Lifting Bail Assembly 1 3 M Screw Hex Flange M X M Nut, Hex Flange M

33 Drawbar, Standard Electric Brake 1 M Drawbar, STD Electric Brake 1 2 M Screw, Hex 4 M X 60 3 M Washer 4 4 M Nut, Hex 4 M20 X M Screw, Jack 1 6 M Pin X M Pintle Eye M Screw 4 M X 70 9 M Washer 4 10 M Nut 4 M M Chain, Safety 2 12 M Link, Chain Coupling 2 31

34 Running Gear Assembly 1 M Frame, G M Bracket, Chock 2 3 M Strap, Tie-Down 2 4 M Screw, Tapping Black M6-1.0 X M Chock, Wheel 2 6 M Screw, Hex M X 20 7 M Tire, 9.50 X 16.5 LT E 2 8 M Fender, LH 1 9 M Fender, RH 1 10 M Screw, Tapping M X M Bracket, Left Fender 1 12 M Bracket, Right Fender 1 13 M Support, Fender 2 14 M Support, Fender 2 15 M Screw, Tapping M6-1.0 X Fender to Support 16 M Running Gear, Complete 2 17 M Bracket, Wiring Harness 2 32

35 Running Gear, Standard Electric Brake 1 M Axle Beam 2 2 M Screw, Brake Mounting 20 3 M Washer, Lock 20 4 M Nut, Brake Mounting Hex 20 5 M Bearing, Inner 4 6 M Seal, Grease 4 7 M Cup, Inner Bearing 4 8 M LH Electric Brake Assembly 2 8A M RH Electric Brake Assembly 2 9 M Nut, Wheel M Wheel, 16.5 X A M Stem, Valve 4 11 M Dust Cap,E-Z Lube Fitting 4 11A M Rubber Boot, E-Z Lube 4 12 M Washer, Spindle 4 13 M Nut, Spindle 4 14 M Bearing, Outer 4 15 M Cup, Outer Bearing 4 16 M Hub Assembly 4 17 M Stud, Wheel M Bolt, Hex Flange M16-2 X M Nut, Hex Flange M M Washer, Tang 4 Not Shown 33

36 Running Gear Lighting and Break-Away Switch 1 M Lamp, Yellow 2 M Lamp, Red 2 2 M Grommet, Narrow Groove 4 3 M Lamp, Combo 2 4 M Grommet, Reflector 2 5 M Light, License 1 6 M Screw, Tapping M6-1.0 X M Switch, Breakaway 1 8 M Screw, Tapping Black M6-1.0 X

37 Page Blank Intentionally 35

38 36 Enclosure Assembly

39 Enclosure Assembly 1 M Panel, Top Rear Roof 1 2 M Panel, Top Middle Roof 1 3 M Panel, Top Front Roof 1 4 M Cover, Radiator Fill 1 5 M Panel, Exhaust Grille Left 1 6 M Panel, Exhaust Grille Right 1 7 M Strap, Foam Retention 8 8 M Panel, Front Top 1 9 M Panel, Front Bottom 1 10 M Panel, Side Front 2 11 M Panel, Side Middle 2 12 M Door, Side 4 13 M Latch, Door 5 14 M Hinge, Side Door M Rivet, Aluminum.187 Dia. Black Oxide M Nut, Hex Nylon Insert M M Holder, Door - Male 5 18 M Screw, Hex Button Head M6-1.0 X M Angle, Door 4 20 M Panel, Bottom Right Front 1 21 M Panel, Side Top & Bottom 7 22 M Panel, Right Rear Bottom 2 23 M Louver 2 24 M Holder, Door - Female 5 25 M Panel, Right Rear Corner 1 26 M Switch, E-Stop 1 27 M Plate, E-Stop 1 28 M Box, E-Stop 1 29 M Bracket, Latch 1 30 M Door, Rear 1 31 M Window, Plexiglass 1 32 M Seal, Window 1 33 M Seal, Door 30 Length 1 34 M Screw, Tapping M6-1.0 X M Nutsert, Hex M M Nutsert, Hex M M Panel, Top Rear 1 38 M Bottle, Engine Vent 1 39 M Bracket, Vent Bottle 2 40 M Hose, 3/4 I.D. 30 Length (Engine to Bottle) 1 41 M Hose, 5/8 I.D.48 L (Bottle to Containment) 1 42 M Clamp, Hose M Seal, Latch Side Door 4 44 M Seal, Door 1135 Length AR M Molding, Strip 31-1/2 Length 2 37

40 Intake Baffles 1 M Baffle, Rear Top 1 2 M Baffle, Rear Lh 1 3 M Baffle, Rear Rh 1 4 M Baffle, Intake 4 5 M Bracket, Baffle Top 2 6 M Nutsert, Hex M M Screw, Tapping M6-1.0 X M Nutsert, Hex M M Screw, Tapping M X

41 Foam Assembly 1 M Fiberglass 1 2 M Fiberglass, Exhaust Plenum 1 3 M Fiberglass, Roof 1 4 M Foam, Baffle, Rear 4 5 M Foam, Channel Vertical 2 6 M Foam, Radiator Baffle Top 1 7 M Foam, Side Door 8 8 M Foam, Door Panel 7 9 M Foam, Panel Rear 2 10 M Foam, Panel Front 2 11 M Foam, Panel Roof 2 12 M Foam, Panel Roof Center 1 13 M Foam, Panel Roof Rear 1 14 M Foam, Panel Side 3 15 M Foam, Roof Access 1 16 M Foam, Top Rear Door Panel 1 17 M Panel - Insulation End 1 18 M Foam, Door Panel 1 39

42 Decal Location 1 M Decal, Rotating Fan 2 Both Sides 2 M Decal, General Shock 1 3 M Decal, Improper Ground 1 4 M Decal, Hazardous Voltage 1 5 M Decal, Battery Disconnect 1 6 M Decal, ISO Improper Operation 1 7 G Decal, Capacity Diagram 1 8 G Decal, Quick Start, Digital Control 1 Not Shown 40

43 Recommended Spares & Service Kits RECOMMENDED SPARE PARTS CLASS 1: RECOMMENDED MAINTENANCE AND REPAIR ITEMS G Oil 15W40 1 Gallon C02776 Primary Fuel Filter C02775 Fuel Water Separator Filter C04521 Oil Filter G Element, Air Filter Primary G Element, Air Filter Safety M Hose, Radiator Lower M Hose, Radiator Upper M Cap, Radiator G Fan Belt G Thermostat C Rocker Gasket Cover Emergency Stop Switch G Hr. Maintenance Kit - With Fluids G Hr. Maintenance Kit - Without Fluids G Hr. Maintenance Kit - With Fluids G Hr. Maintenance Kit - Without Fluids CLASS 2: PARTS REQUIRED TO PREVENT EXTENDED DOWNTIME IN REMOTE LOCATIONS G Starter G Alternator, Charging G Water Pump M AC Alternator Assembly M Fuse Voltage Regulator M Automatic Voltage Regulator M Wound Exciter Field M Bearing, LSA 442 M Diode Bridge M Surge Suppressor M Tie Rods M Stud Terminal Block M Stud Nuts M Switch, Voltage Selector M Voltage Transformer G Controller, Clarke Digital M Voltage Adjust Potentiometer R ohm 41

44 Recommended Spares & Service Kits...Continued CLASS 2: PARTS REQUIRED TO PREVENT EXTENDED DOWNTIME IN REMOTE LOCATIONS M Fuse F1, F2, F3 1 Amp M Fuse F01, 20 Amp M Fuse F5, 10 Amp M Fuse, F6 5 Amp M GFI Duplex Receptacle 20 Amp 120 VAC M Twist-Lock Receptacle 50 Amp 120/240 VAC M Breaker 20 Amp CB2, CB3 M Breaker 50 Amp CB4, CB5 M Breaker CB1 M Relay K1 M Relay K2 M Relay K3, K4 M Fuel Sender U1 42

45 Option Parts List 43

46 Option - Manual Oil Pump 1 M Pump, Oil Manual 1 2 M Bracket, Pump Mounting 1 3 M Screw, Tapping 1/4-20 X 1/2 4 4 M Clamp, Hose 9/ M Bushing, Reducer 1 NPT X 1/2 FNPT 2 6 M Elbow, 90 1/2 NPT x 5/8 Hose 1 7 M Hose, 3/8 I.D. X 16 Length 1 to Bottom of Pump 8 M Screw, Tapping M X

47 Frame and Skid Assembly 1 M Skid, Fork Lift 2 2 M Screw, Hex Flange M X M Nut, Hex Flange M M Screw, Hex Flange M X M Nut, Hex Flange M

48 Camlock Assembly 1 G Connector, Green Camlock 1 2 G Connector, White Camlock 1 3 G Connector, Red Camlock 1 4 G Connector, Black Camlock 1 5 G Connector, Blue Camlock 1 6 NPN Screw, Hex Flange 3/8-16 X NPN Washer, Flat 3/ NPN Washer, Spring Lock 3/8 5 9 NPN Nut, Hex 3/

49 Battery Charger 1 G Charger, Battery 5 amp 1 2 NPN Screw, Tapping M X G Cord, Power Charger 1 4 M Cord, Heater/Charger Power AR Not Shown 5 M Grommet, 3/4 I.D. X 1/8 Gap 1 6 G Charger, Battery 10 amp 1 7 G Harness, Battery Charger 1 Not Shown 47

50 Block Heater 1 G Heater 1 2 G Bracket, Mounting Heater 1 3 C05941 Adapter, Block 1 4 C O-Ring 1 5 C05142 Connector NPT x Hose 2 6 C Clamp, Hose 4 7 G Hose, Oil Drain G Hose, Oil Drain G Elbow, Street 90 degree 1/2 NPT 1 10 C12A128 Adapter, M18 to 1/2 NPT 1 11 NPN Screw, Hex Flange M6-1x NPN Nut, Hex Flange M

51 Battery Heater 1 G Pad, Battery Heater 1 2 M Cord, Heater/Charger Power AR Not Shown 49

52 50 3-Way Fuel Valve

53 3-Way Fuel Valve 1 M Valve, 3-Way 1 2 M U-Bolt, 1/4-20 X 1-1/4 I.D. 1 3 M Screw, Tapping M6-1.0 X M Nut, Hex Nylon Insert 1/ M Bracket, Valve Mounting 1 6 M Bushing, Reducing 1/2 NPT X 1/4 NPT 2 7 M Bushing, Reducing 1/2 NPT X 3/8 NPT 1 8 M Adapter, Barbed 3/8 NPT X 3/8 Hose 2 9 M Bushing, Reducing 3/8 NPT X 1/4 NPT 2 10 M Elbow, 90 1/4 NPT x 5/16 Barbed 2 11 M Connector, Bulkhead 2 1/2 NPT X 1-1/8-14 UNF 12 M Connector, Str. Male 1 3/4 NPT to 1/2 NPT 13 M Coupler, Quick Disconn. Female 3/ M Plug, Quick Disconnect 1 15 M Coupler, Quick Disconn. Female 1/ M Plug, Quick Disconnect 1 17 M Nipple, Close 1/2 NPT X 1-1/ M Hose, Fuel 5/16 X 35 Length 1 19 M Hose, Fuel 5/16 X 28 Length 1 20 M Hose, Fuel 5/16 X 26 Length 1 21 M Clamp, Hose 1/4 Dia M Hose, Fuel 3/8 X 33 Length 1 23 M Hose, Fuel 3/8 X 55 Length 1 24 M Hose, Fuel 3/8 X 22 Length 1 25 M Clamp, Hose 6 26 M Elbow, 90 1/4 NPT x 3/8 Barbed 2 51

54 52

55 Wiring Diagrams 53

56 54

57 Tail Lights Wiring Diagram DS1 AMBER SIDE DS2 RED SIDE DS3 RIGHT TAIL JUNCTION BOX DS3 RIGHT STOP / TURN RED N/C WHITE WHITE DS4 LICENSE BROWN BROWN GREEN GREEN YELLOW YELLOW BLUE N/C DS3 LEFT STOP / TURN DS1 AMBER SIDE DS2 RED SIDE FRAME DS3 LEFT TAIL PLUG / SOCKET WIRING CONNECTIONS WHITE - GROUND 2 YELLOW - LEFT STOP/TURN SIGNAL 3 4 GREEN - RIGHT STOP/TURN SIGNAL 5 BROWN - TAIL / CLEARANCE LIGHTS 6 BLUE - ELECTRIC BRAKES

58 Battery Heater Wiring Diagram Power Cord Wiring Diagram Block Heater Wiring Diagram Camlock Option Battery Charging Wiring Diagram

59 L3 VSS VOLTAGE SELECTOR SWITCH A 3A 5A 7A 9A 11A 2A 4A 6A 8A 10A 12A CT N L2 CT2 CT1 L1 L3 CT3 VSS VOLTAGE SELECTOR SWITCH A 3A 5A 7A 9A 11A 2A 4A 6A 8A 10A 12A L CT N CT1 L1 VSS VOLTAGE SELECTOR SWITCH A 3A 5A 7A 9A 11A 2A 4A 6A 8A 10A 12A L2 CT2 6 1 N L1 7 2 CT

60

61 ORN 2A PNK 3C ECU J B 2C ORN ORN RED 30C 1 4 CAN HI A1 CAN LO B1 20 YEL SP SP20 GRN 905 SP30 SP1 18 SP A 905A RED ENGINE DIAGNOSTIC CONNECTOR 30D 14 SP3 2A 3C A B EM 1B RED C D ORN 2D 2 3 BLU BLU SW BATT B2 +5V G2 LOW COOLANT G4 ISOC GOV H4 CAN SHIELD K2 012 RED B 905B C 905C PB1 LOW COOL PROBE 21 VIO YEL 50 1 RED B F01 A 30C 30B RED 2D RED UNSW BATT L1 UNTERM GND L2 UNTERM GND L3 UNSW BATT L4 UNSW BATT M1 UNTERM GND M2 UNSW BATT M4 A F02 20A B RED A 050A 050B 022B 022C 050C 022D 022E BRN BRN SP4 BRN D A B A B C 5 BLU 20 WHT 78 BRN 31 ORN YEL 11 GRY 80 BLU 057 LOW FUEL P8 SHUTDOWN A A (CLOSED BRN WHEN DRY) 31B B B C C BRN LEVEL D D 31C U1 FUEL SENDER S4 BASIN FLUID LEVEL (CLOSED WHEN WET) 11 A B BRN 31A 30A YEL RED 020B RED 8 RED S6 BATTERY 2/0 RED 2/0 RED BLU 30D BT1 BATTERY S POS 022 B1 STARTER MOTOR RED 050D 050C D+ B+ B- 31D BRN G1 ALTERNATOR ORN W A A B 2B ORN 80 GRY 905C 904C 12V 2/0 BLK 050B BRN 050A 31 BRN 12

62 B P12 A P9-1 ALTERNATOR BOX S5 RECON} DOOR SW (SHOWN DOOR CLOSED) 16 NO 108NO 130A 97NC COM NC 16 P9-2 P9-3 C09-H C09-W C09-F C09-C P3-H P3-W P3-F P3-C RED (2B1) 228 W091 BLK W102 W027 BLU W103 W036 BLU W IN CTR IN CTR K7 120V CT SWAPPING RELAY OUT OUT 0 8 BLU W010 WHT CTE2 BLK W024 B A W100 RED 231 WHT 234 F1 202B 221 F2 203B W002 F3 213B W BLK 204J W038 W B CTE3 A BLK RED WHT W233 BLU 91 91A D B C A 130B 91C W127 W IN CTR IN CTR K8 120V VOLTAGE SWAPPING OUT OUT RELAY BLK D3 W124 W138 C A 94A 18 YEL A 94B 97C F 131H 110D A 131E 131G 94B 97C 110A 110B RED BRN F5 8A 101 B A TB1 BAT 1(R) (Y) 9(Y) 10(Y) GND R1 680 R2 680 ORN 110 SWITCHED BAT C09-A C09-L P3-A P3-L C09-J P3-J 115 C09-V P3-V (3C2) C09-G C09-M C09-N C09-K C09-U C09-S C09-P C09-B C09-E C09-D P3-G P3-M P3-N P3-K P3-U P3-S P3-P P3-B P3-E P3-D BRN CONTROL PANEL DOOR 020A CAN J4 COM COM CT1 CT2 CT3 C U R R E N T CAN - 0 TO 5A J7 AI1 OIL J3 AI2 TEMP N VL1 VL2 V O L T A G E 3 X 48O V J6 VL3 CONTROLLER MRS 19 AI3 FUEL RPM GND J8 RPM IN START B01 FUEL B02 FUEL PULL B03 J2 PREHEAT B04 SLEEP OFF B05 HORN B06 OVER LOAD B07 B11 REMOTE S/S B12 LOW COOLANT B13 EMERG STOP B14 LOW FUEL J5 BATT B15 HI BASIN J1 D B16 VOLTS HI/LO BATT B17 VSS DOOR C09-R C09-T C09-X P3-R P3-T P3-X 020 YEL GRN 904D 905D S8 CONTROL POWER ON A 105B A C D A K6 POWER RELAY ORN B A K5 PREHEAT RELAY 131E K4 OVERLOAD RELAY C 91A 87 ORN 131A 108 K3 FUEL 108A RELAY B A 110D A 131F 131H + - TB2 ALARM DS2 REMOTE START DS1 PANEL LAMP 131G 303A 109 RED ORN

63 WORD INDEX CPN 250 Hr. Maintenance Kit - With Fluids Hr. Maintenance Kit - Without Fluids Hr. Maintenance Kit - With Fluids Hr. Maintenance Kit - Without Fluids A AC Alternator Assembly Adapter 1/4 NPT X 3/8 Hose /4 NPT X 5/16 I.D. Hose /8 Hose X 3/8 NPT /8 NPT X 3/8 Hose Barbeb 1/4 NPT x 5/16 I.D. Hose Barbed 3/8 NPT X 3/8 Hose Barbed 3/8 NPT x 3/8 I.D. Hose Alarm Coolant Level Alternator Charging , 41 LSA 442L12-60Hz Angle Door Gasket Assembly Air Cleaner Fuel Tank Canada Only Automatic Voltage Regulator Axle Beam B Back J Box Baffle Intake Radiator Top Rear Lh Rear Rh Rear Top Bar Bus Base Breaker Battery 12V Bearing Inner LSA NDE Outer Block 4 Pole Terminal Terminal - Gray Terminal - Red Terminal - Yellow Block Terminal Body Air Cleaner Bolt Drive Disk Engine-Generator M X Hex Flange M16-2 X Bottle Engine Vent Box E-Stop Voltage Selector Switch Bracket Air Filter Baffle Top Belt Guard Block Heater Bus Bar Bus Bar Mounting Cable Entry Bracket Chock Coolant Bottle Disconnect Engine Mounting LH RH Fan Guard Latch Left Fender Muffler Pump Mounting Right Fender Sensor , 19 Tank Tank Adjustable Left Side Tank Adjustable Right Side Tank Mounting Front Tank Mounting Front Tank Mounting Left Rear Tank Mounting Right Rear Transformer Mounting Valve Mounting Vent Bottle Wiring Harness Breaker Circuit 20A A Sub Assembly Breaker 20 Amp CB2 CB Breaker 50 Amp CB4 CB Breaker CB Bulb Lamp Parts Book 63

64 WORD INDEX Bus Bar Ground Neutral Bushing Reducer 1 NPT X 1/2 FNPT Reducing 1/2 NPT X 1/4 NPT Reducing 1/2 NPT X 3/8 NPT Reducing 3/8 NPT X 1/4 NPT C Cable Battery Negative 450mm Battery Positive 475mm Jumper 625mm (From Switch to Starter) Rubber Entry Cap 5 Rain Fuel Fill Fuel Filler Radiator Radiator 14 psi Radiator 16 psi Vent Chain Safety Charger Battery 10 amp Battery 5 amp Chock Wheel Circuit Breaker Clamp 14" Muffler Mounting Band 4 Dia Band 5 Dia Cable Hose , 17, 51 Hose 1/4 Dia Hose 1/4 I.D , 20 Hose Hose 9/ V-Band 4.75 Dia Clamp Saddle CLASS 1 RECOMMENDED MAINTENANCE AND REPAIR ITEMS CLASS 2 PARTS REQUIRED TO PREVENT EXTENDED DOWNTIME IN REMOTE LOCATIONS.. 41, 42 Connector 1/4 NPT X 3/8 Tubing /4 NPTF X 3/8 Tubing Flexible position position Black Camlock Blue Camlock Bulkhead , 51 Green Camlock Red Camlock Str. Male White Camlock Controller Auto-Start 60Hz ECU Engine Digital Cooler Charge Air Cord Heater/Charger Power , 49 Power Charger Coupler Quick Disconn. Female 1/ Quick Disconn. Female 3/ Cover Circuit Breaker J Box Radiator Fill Receptacle Recptacle Top Left Transformer Weatherproof Cover Assembly Air Crossmember Engine Cup Inner Bearing Outer Bearing D Decal Battery Disconnect Breaker Capacity Diagram Direct Connect , 29 Fuse Label General Shock Hazardous Voltage Improper Ground ISO Improper Operation Logo Receptacle Rotating Fan Voltage Output Adjust Diode Bridge Diode Bridge LSA Parts Book

65 WORD INDEX Door Cable Hook-Up Rear Rubber Side Drawbar STD Electric Brake Drive Disc Dust Cap E-Z Lube Fitting E Elbow 90 1/2 NPT x 5/8 Hose /4 NPT x 3/8 Barbed /4 NPT x 5/16 Barbed Element Air Filter Primary Air Filter Safety Emergency Stop Switch Enclosure Power Pedestal Engine 6068HF285 ( C28 ) F Fan mm Dia Fan Belt , 41 Fender LH RH Fiberglass Exhaust Plenum Roof Filter Fuel Fuel Primary Foam Baffle Rear Channel Vertical Door Panel Panel Front Panel Rear Panel Roof Panel Roof Center Panel Roof Rear Panel Side Radiator Baffle Top Roof Access Side Door Top Rear Door Panel Frame G Front J Box Fuel Filter Primary Fuel Sender U Fuse AVR (Not Shown) F6 5 Amp Terminal Fuse F01 20 Amp Fuse F1 F2 F3 1 Amp Fuse F5 10 Amp Fuse Voltage Regulator Fuseholder 3 Pole G GFI Duplex Receptacle 20 Amp 120 VAC Grommet 3/4 I.D. X 1/8 Gap Blind/Plug Narrow Groove Reflector Guard Belt - RH Belt- LH Fan Top Belt H Harness J Box Battery Charger Engine Wiring Receptacle (Not Shown) Transformer (Not Shown) Heater Block Hinge Cable Door Control Panel Side Door Holder Door - Female Door - Male Parts Book 65

66 WORD INDEX Hose 3/4 I.D. 30 Length (Engine to Bottle) /8 I.D. X 16 Length /8 I.D. x 60 Length /16 I.D. x 26 Length /8 I.D.48 L (Bottle to Containment) Fuel 3/8 I.D Fuel 3/8 I.D. X 24.8 Length Fuel 3/8 X 22 Length Fuel 3/8 X 33 Length Fuel 3/8 X 55 Length Fuel 5/16 I.D. X 60 Length Fuel 5/16 X 26 Length Fuel 5/16 X 28 Length Fuel 5/16 X 35 Length Overflow 34 Length Radiator Lower , 41 Radiator Upper , 41 Vent 3/8 O.D. X 25 Length Hub Assembly I Inlet Tube Isolator , 8 J J-Bolt K Kit Power Wiring L Label Remote Start Lamp Combo Minature Red Yellow Latch Cable Door Door LH Electric Brake Assembly Lifting Bail Assembly Light License Link Chain Coupling Louver Lugs Panelboard Mount Voltage Selector Switch Muffler Exhaust N Nipple Close 1/2 NPT X 1-1/ Extra Strong 3/4 NPT X 3 Length Nut Brake Mounting Hex Hex Hex 1/ , 21 Hex 3/ Hex Flange M Hex Flange M Hex Flange M12 X Hex Flange M Hex Flange M Hex Flange M Hex Flange M Hex Flange M , 11, 14, 16, 19, 25, 29 Hex Light Locking # Hex Locking 1/ , 19 Hex Locking 5/ Hex Nylon Insert # Hex Nylon Insert # Hex Nylon Insert # , 28 Hex Nylon Insert 1/ Hex Nylon Insert M Hex Prevailing Torque M Locking Locking 3/ Spindle Stud Wheel Nutsert Hex M , 37, 38 Hex M , 38 O Oil Filter , 41 Oil Protec 15W Outlet Tube P Pad Battery Heater Fuel Tank Fuel Tank 8.7 Length M Molding Strip 31-1/2 Length Parts Book

67 WORD INDEX Panel Bottom Right Front Digital Control Exhaust Grille Left Exhaust Grille Right Front Bottom Front Top Pedestal Radiator Mount Receptacle Right Rear Bottom Right Rear Corner Side Front Side Middle Side Top & Bottom Top Front Roof Top Middle Roof Top Rear Top Rear Roof Panel - Insulation End Pin Pintle Eye Pipe 90 Elbow Engine Exhaust Extension Plate Bus Bar E-Stop Fuse End J Box J Box Rubber Support Cooler Plexiglass Cable Door Plug Quick Disconnect Square Head 1/2 NPT Pump Oil Manual Retainer RH Electric Brake Assembly Rivet Aluminum.187 Dia. Black Aluminum.187 Dia. Black Oxide SS.187 Dia Rocker Gasket Cover Rubber Cable Entry , 23 Rubber Boot E-Z Lube Running Gear Complete R Radiator Assembly Rail DIN 35mm Receptacle 1/4 Turn /250V 50A V 20A RECOMMENDED SPARE PARTS Reducer 1/4 O.D. x 5/16 O.D mm x 50.8mm Relay K Relay K Relay K3 K Parts Book 67

68 WORD INDEX S Screw Brake Mounting Button Socket Hd M X Cap Socket Head 1/4-20 X Hex Hex #10-32 X Hex Button Head M6-1.0 X Hex Cap 3/4-1 X 1-3/ Hex Flange 1/4-20 X Hex Flange 3/8-16 X Hex Flange M X Hex Flange M X , 45 Hex Flange M X Hex Flange M6-1.0 X , 28 Hex Flange M6-1.0 X Hex Flange M x Hex Flange M X , 16, 25 Hex Head M X Hex Head M X Hex M X Hex M X Hex M X Hex M X Hex M X Hex M X Hex M X Hex M X Hex M X Hex M8 X Hex. Flange Jack Phillips Pan Head #10-32 X 1/ , 25 Phillips Pan Head #6-32 X 1/ , 28 Phillips Pan Head #8-32 X 5/ Socket Head M X Tapping 1/4-20 X 1/ Tapping Black M6-1.0 X Tapping Black M6-1.0 X , 34 Tapping M X Tapping M X Tapping M6-1.0 X , 11, 37, 38 Tapping M6-1.0 x Tapping M6-1.0 X , 13, 17, 25, 29, 32 Tapping M6-1.0 X , 25, 34 Tapping M6-1.0 X Tapping M X 20 7, 8, 14, 16, 21, 32, 38, 44 Tapping M x Tpg Hex Washer Head M X Whiz Lock Flange 5/16-18 X 3/ Screw Hex Flange M X Seal Door 1135 Length Door 30 Length Grease Latch Side Door O-Ring Window Sender Fuel Fuel Level Sensor Containment Level , 19 Serial Number Plate Shroud Fan Side J Box - Curb J Box - Street Signal Audible Silencer Pneumatic 1/4 NPT Skid Fork Lift Spacer Fan Spring-Loaded T-Bolt Clamp Standoff Insulator Plastic Starter , 41 Stem Valve Strainer Fuel Tank , 19 Strap Foam Retention Tie-Down Stud Self Ejecting Wheel Stud Nuts Stud Terminal Block Sub-assembly Breaker/Receptacle Support Alternator Clamp Cooler Bottom Fender Surge Suppressor , Parts Book