DIESEL GENERATOR MMG170

Transcription

1 DIESEL GENERATOR MMG0 www m-p-llc com 0 PARTS MANUAL

2 INTRODUCTION Before servicing this machine, make sure the engine start switch is turned to off O, the circuit breakers are open (off, O ), the emergency stop switch is closed (pushed in), and the negative (-) terminal on battery is disconnected. Attach a DO NOT START sign to the control panel. This will notify everyone that the unit is being serviced and will reduce the chance of someone inadvertently trying to start the unit. If the unit is connected to a remote start or transfer switch, make sure the remote switch is also off and tagged. NEVER open the radiator cap or oil drain plug while the engine is running or before the engine has cooled down. Pressurized coolant and hot engine oil can cause severe burns. Allow the engine to cool completely before attempting any service work. DO NOT allow water to accumulate around the base of the generator set. If water is present, move the generator and allow the generator to dry before servicing. DO NOT service generator if clothing or skin is wet. DO NOT service generator without reading and fully understanding the operating manual. DO NOT allow untrained personnel to service this equipment. Only trained electrical technicians should be allowed to service the electrical components of this equipment. DO NOT attempt to modify the engine, generator or related components in any way. DO NOT pressure wash the control panel, generator end, or any other electrical components. ALWAYS keep hands, feet, and loose clothing away from moving parts on generator and engine. Stay especially clear of fan blade areas and use care to avoid allowing any debris to fall into the blade areas. Replace all guards, fasten doors and make sure all safety devices operate properly after making repairs or servicing the equipment. MAGNUM PRODUCTS LLC Power Drive Berlin, WI 9 U.S.A. Phone: 90-- FAX: 90-- Toll Free: For technical or parts QUESTIONS, please contact Magnum Products Customer Support or Technical Support team at 90-- or toll free at Please have your serial number available. To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call Magnum Products to locate a dealer in your area. Supplemental information may be available for your unit; when ordering parts ALWAYS check for a supplement that applies to your unit. A supplement may have been provided with your unit and can be found on the Magnum Products LLC website. Engine Make: Engine Serial Number: Engine Model Number: Generator Make: Generator Model Number: Generator Serial Number: Unit Model Number: Unit Serial Number: WARNING CALIFORNIA PROPOSITION WARNING: Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.

3 TABLE OF CONTENTS Page INTRODUCTION... TABLE OF CONTENTS... ENCLOSURE PANELS... UNIT DECALS... - LUG BOX DOOR... LUG PLATE ASSEMBLY... 9 LUG BOX ASSEMBLY... 0 LEFT CONTROL PANEL ASSEMBLY... RIGHT CONTROL PANEL ASSEMBLY... - CONTROL BOX ASSEMBLY... - OUTLET PANEL ASSEMBLY... OUTLET PANEL ASSEMBLY FOR CAM LOCK OPTIONS... CAM LOCK PANEL ASSEMBLY OPTIONS... CAM LOCK DOOR ASSEMBLY (OPTIONAL)... 9 AIR FILTER ASSEMBLY... 0 EXHAUST SYSTEM ASSEMBLY... ENGINE MOUNT ASSEMBLY... FUEL LEVEL SENDING UNIT ASSEMBLY... FUEL TANK ASSEMBLY... EXTENDED RUN OPTIONS... COOLING SYSTEM HOSES... - GENERATOR TO ENGINE ASSEMBLY... GENERATOR BOX ASSEMBLY ENGINE ASSEMBLY... - OIL RECIRCULATION KIT ASSEMBLY FUEL TANK AND SKID ASSEMBLY ENGINE TO SKID ASSEMBLY... - COOLING SYSTEM ASSEMBLY... - LEFT FRONT DOOR ASSEMBLY... - LEFT REAR DOOR ASSEMBLY RIGHT FRONT DOOR ASSEMBLY CONTROL DOOR ASSEMBLY... - LEFT SIDE CENTER PANEL ASSEMBLY... RIGHT SIDE CENTER PANEL ASSEMBLY... LEFT FRONT CORNER ASSEMBLY... RIGHT FRONT CORNER ASSEMBLY... FRONT PANEL ASSEMBLY... REAR PANEL ASSEMBLY... 9 FRONT ROOF PANEL ASSEMBLY... 0 REAR ROOF PANEL ASSEMBLY... LEFT REAR CORNER ASSEMBLY... - RIGHT REAR CORNER ASSEMBLY... - END AND LOWER SIDE PANEL ASSEMBLY... UPPER SIDE PANEL ASSEMBLY... TRAILER ASSEMBLY TRAILER BRAKE LINES... 0 RECOMMENDED SPARE PARTS LIST... ELECTRIC BRAKE WIRING HARNESS... TRAILER LIGHT WIRING DIAGRAM... AC WIRING DIAGRAM... DC WIRING DIAGRAM... AC WIRING DIAGRAM - FOUR POSITION OPTION...

4 ENCLOSURE PANELS

5 ITEM PART NO. QTY DESCRIPTION Page End panel assembly Page Front panel assembly Page Left front corner assembly Page Upper side panel assembly Page Left front door assembly Page Lower side panel assembly Page Left side center panel assembly Page Right side center panel assembly 9 Page Upper side panel assembly 0 Page Lower side panel assembly Page Left rear door assembly Page Left rear corner assembly Page 0 Front roof panel assembly Page Rear roof panel assembly Page 9 Rear panel assembly Page Right rear corner assembly Page Upper side panel assembly Page Right front corner assembly 9 Page Control door assembly 0 Page 0 Right front door assembly

6 Generator can automatically start which can cause serious injury. Disconnect battery before servicing. Aggregat kann automatisch starten und körperliche verletzung verursachen. Vor servicearbeit batterie abklemmen. Generador puede arrancar automaticamente y causar lesiones personales. Desconecte la bateria antes de prestar servicio. Generateur puet demarrer automatiquement resultant en des accidents de personne. Deconnecter batterie avant tout entretien. UNIT DECALS DANGER PN: Decal, Red Stripe PN: Decal, Magnum Logo PN: Decal, Mobile 0 0 Lock doors. Access can cause electric shock or injury. GEFAHR Türen schliessen! Zugang kann elektrischen schlag oder verletzung verursachen. PELIGRO Cierre las puertas. Ya que de orto modo existe el peligro de una descarga electrica o de lesiones personales. DANGER Fermer les portes d acces ou il pourrait en resulter risque d electrocution ou accidents de personne. WARNING Never change switch position with engine running. Results in damage to machine. WARNUNG Niemals schlter unstellen wenn motor läuft. Verursacht beschädigung des gerätes. ADVERTENCIA PN: 0 Decal, Magnum M Large Nunca cambie la posicion del interruptor al estar marchando el motor. Ya que esto podria conducir a daños en el equipo. AVERTISSEMENT Ne jamais changer la position de l interrupteur pendant que le moteur est en marche. Il pourrait en resulter risque de dommages a la machine. DANGER GEFAHR PELIGRO DANGER DANGER GEFAHR PELIGRO DIESEL DANGER WARNING WARNING WARNING WARNUNG WARNUNG ADVERTENCIA PN: Decal, Ground WARNUNG ADVERTENCIA AVERTISSEMENT ADVERTENCIA AVERTISSEMENT PN: Decal, Ground AVERTISSEMENT Located on tongue of trailered units. Note: All safety and operating decals are located on decal sheet 99, unless otherwise noted.

7 Generator can automatically start which can cause serious injury. Disconnect battery before servicing. Aggregat kann automatisch starten und körperliche verletzung verursachen. Vor servicearbeit batterie abklemmen. Generador puede arrancar automaticamente y causar lesiones personales. Desconecte la bateria antes de prestar servicio. Generateur puet demarrer automatiquement resultant en des accidents de personne. Deconnecter batterie avant tout entretien. DAS STARTEN DES GENERATORS COMIENZO DEL GENERADOR COMMENCEMENT DU GÉNÉRATEUR. TURN CONTROL SWITCH ON. PUSH ENGINE START ENGINE START CONTROL ON CONTROL OFF DAS AUFHÖREN DES GENERATORS PARADA DEL GENERADOR ARRÊT DU GÉNÉRATEUR ENGINE STOP CONTROL ON CONTROL OFF UNIT DECALS WARNING PN: Decal, Magnum Logo PN: Decal, Red Stripe WARNUNG ADVERTENCIA AVERTISSEMENT PN: 0 Decal, Magnum M Large PN: Decal, Mobile 0 0 DANGER Lock doors. Access can cause electric shock or injury. GEFAHR Türen schliessen! Zugang kann elektrischen schlag oder verletzung verursachen. PELIGRO Cierre las puertas. Ya que de orto modo existe el peligro de una descarga electrica o de lesiones personales. DANGER Fermer les portes d acces ou il pourrait en resulter risque d electrocution ou accidents de personne. WARNING WARNUNG ADVERTENCIA AVERTISSEMENT STARTING THE GENERATOR STOPPING THE GENERATOR. PUSH ENGINE STOP. TURN CONTROL SWITCH OFF PN: Decal, Controller Instructions CONTROL ON CONTROL OFF PN: Decal, Controller Switches PN: 9 Decal, Panel Light Switch (Optional) CAUTION Not for use when generator is operated at 0 volts. PN: 0 Decal, Caution for 0V CSA Located behind lug box door. Note: All safety and operating decals are located on decal sheet 99, unless otherwise noted.

8 LUG BOX DOOR ITEM PART NO. QTY DESCRIPTION NOTES 09 Screw, 0-X.00 pan phil 0W Door, lug box 0 Hinge, continuous Nut, 0- ser flg 0 Washer, split lock #0 00 Screw, 0-X.00 pan phil Assembly, cam lock, qrtr. turn 9 Handle, lug door

9 LUG PLATE ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES 0 Nut,.- ser flg lock Panel, lug box glastic Bus, lug extension 90 Lug, terminal dual #-0mcm 0 0 Screw,.-X.000 hx hd Bus, main breaker out 00 Screw,.-X std hex Bus, grounding link 9

10 LUG BOX ASSEMBLY 0 9 TO CONTROL BOX ITEM PART NO. QTY DESCRIPTION NOTES 0 Rivet,. dia W Angle, top lug box W Box, lug enclosure Switch, trigger safety, N.O. & N.C. 00 Nut, U-clip,.- 0 Nut,.- ser flg lock 00 Screw,.-X.000 hx hd 0 Washer, flat. X. 9 Page Assembly, lug door 0 09 Screw, 0-X.00 pan phil 9W Panel, lug box outlet 0 Screw,.-X.0 hx hd Page 9 Assembly, lug plate 00 Screw,.-X.000 hx hd 0 Nut, 0- ser flg 0

11 LEFT CONTROL PANEL ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES Holder, manual 09 Screw, 0-X.00 pan phil W Panel, control left 0 Hinge, left control panel 0 Nut, 0- sflg G 0 Rivet, /", closed end, alu. 00 Nut, U-clip,.-

12 On Off RIGHT CONTROL PANEL ASSEMBLY A B 0 9 C D E

13 ITEM PART NO. QTY DESCRIPTION NOTES 09 Kit, air filter minder Regulator, voltage - SE 0 00 Nut, - nylock 0 Screw, -X.00 pan phil 0 Switch, toggle - 0A VAC 9 Kit, voltage adjustment pot. 0 Hinge, control panel - 09 Screw, 0-X.00 pan phil 9 0 Nut, 0- ser flg G 0 9 Controller, eng/gen - prog. W Panel, digital control -- 9 Guard, potentiometer Not shown A 0 Light, interior control panel Option B 0 Switch, toggle - 0A VAC Option C W Panel, dig. cntrl - sngl brkr Option D W Panel, dig. cntrl - dual brkr Option E or Breaker, 0A, pole Option

14 On Off A B D F 0 H 0 J 9 0 K L E C C G CONTROL BOX ASSEMBLY

15 ITEM PART NO. QTY DESCRIPTION NOTES B Weldment, control box 0 Screw,.0-0X.00 sflg hex Transformer, current 0 Relay, ignition solenoid 00 Screw, 0-X.0 pan phil 0 Kit, ground bar 0 Nut,.0-0 sflg G ZC 0 Nut, 0- sflg G ZC 9 0 Block, terminal - 0 pos Nut, M-. sflg lock 09 Connector, pin, deutsch B Spacer, breaker." long Block, terminal - pole, Bussman 09 Screw,.0-0X.00 std hex 09 Screw, 0-X.00 pan phil Page Assembly, right control panel Nut,.- cage G ZC 00 Screw,.-X.000 std hex 9 0 Washer,. flat./ 0 B Panel, cable guard Page Assembly, outlet panel 0 Screw, M-.X0 sflg hex Page Assembly, lug box 009 Washer, M ext star ZC 99 Stud, ground Screw,.0-0X. pan phil Breaker, 00A, pole Page Assembly, left control panel 9 0 Plug, Deutsch connector hole A Stop, MM din rail end Option B Relay, voltage sensing Option C Base, relay - pos. Option D Relay, overload/current Option E Base, relay - pos. Option F 9 Relay, DPDT, VDC, pos. Option G 00 Rail, din MM X.00" Option H 9 Fitting, bushing Option -.00ODX.ID J Charger, battery Option K Transformer,.: -phase Option: buck transformer L Relay, 0A 0VAC power Option

16 OUTLET PANEL ASSEMBLY 0 9 A B ITEM PART NO. QTY DESCRIPTION NOTES 0 Receptacle, 0V/0A GFI 0 Nut, 0- nylock 09 Receptacle, 0/0V 0A twist lock 09 Breaker, 0A, 0V, -pole 09 Breaker, 0A, 0V, -pole 00 Screw, 0-X.00 pan phil 00 Screw, -X.0 pan phil 00 Nut, - nylock 9 00 Screw, -X.0 pan phil 0 0 Screw, -X.00 pan phil 90 Block, terminal - pos W Panel, outlets 00 Washer, split lock # OPTIONAL FEATURES: A Receptacle, 0V/A inlet Option: Edison plug B 00 Screw, 0-X.0 pan phil Option: Edison plug

17 OUTLET PANEL ASSEMBLY FOR CAM LOCK OPTIONS 0 9 ITEM PART NO. QTY DESCRIPTION NOTES 09 Breaker, 0A, 0V, -pole 0 Receptacle, 0V/0A GFI 09 Breaker, 0A, 0V, -pole 0 Nut, 0- nylock 09 Receptacle, 0/0V 0A twist lock W Panel, outlets 00 0 Washer, split lock # 00 Screw, -X.0 pan phil 9 0 Screw, -X.00 pan phil 0 90 Block, terminal - pos 00 Screw, 0-X.00 pan phil 00 Screw, -X.0 pan phil 00 Nut, - nylock W Panel, cam lock box

18 CAM LOCK PANEL ASSEMBLY OPTIONS 0 9 ITEM PART NO. QTY DESCRIPTION NOTES 009 Nut,.00- ser flg Bus, cam lock mount Connector, cam lock - white Connector, cam lock - green Connector, cam lock - black Connector, cam lock - red Connector, cam lock - blue 0 0 Screw, -X.0 pan phil 9 9W Panel, cam lock mounting Single Washer, #0 flat.9/ Nut, 0- nylk G Switch, trigger safety, N.O. & N.C. W Panel, cam lock mounting Dual

19 CAM LOCK DOOR ASSEMBLY (OPTIONAL) ITEM PART NO. QTY DESCRIPTION NOTES 09 Screw, 0-X.00 pan phil W Panel, cam lock door 0 Hinge, continuous Nut, 0- ser flg 0 Washer, split lock #0 00 Screw, 0-X.00 pan phil Assembly, cam lock, qrtr turn 9 Handle, lug door 9

20 AIR FILTER ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES Assembly, air filter Element, air filter Element, air filter - safety 0 Knob, air filter housing, end 0 Cap, dust ejector 9 Knob, air filter housing 0

21 EXHAUST SYSTEM ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES 090 Cap, rain.00 Pipe, exhaust up -.00 Clamp, muffler.00 Muffler,.00 Pipe, exhaust - down Pipe, exhaust 0 Clamp, V-band B Bracket, muffler mounting

22 ENGINE MOUNT ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES 00 Nut,. - hx hd 0 Washer,. split lock 0 Washer,. flat 9B Weldment, engine mount 0 Shock mount, rubber 0 Washer, snubber 09 Screw,. - x.00 hx

23 FUEL LEVEL SENDING UNIT ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES 0 Sender, fuel 0 Washer, split lock #0 00 Screw, 0-X.0 pan phil Gasket, fuel sending unit

24 FUEL TANK ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES 90 Fitting, hose barb.mnpt x. 9 Fitting, 90 barb brs.0npt x. 9 Vent, / NPT 9 Nipple, pipe / NPTX Page Assembly, fuel level sender 0B Tank, fuel - 0 gallon 9 Nipple, pipe -.00 NPT X 9 Plug,.00NPT X hex socket

25 EXTENDED RUN OPTIONS ITEM PART NO. QTY DESCRIPTION NOTES 00 Screw, 0-X.0 pan phil 0 Washer, split lock #0 0 Sender, fuel -.-" Gasket, fuel sending unit 0B Tank, fuel - 0 gal. B Weldment, containment pan

26 COOLING SYSTEM HOSES Units built before SN: ITEM PART NO. QTY DESCRIPTION NOTES 9 Assembly, radiator 0 Clamp, hose - const. trq Hose, C.A.C. - - X. 0 Clamp, hose - const. trq Pipe, C.A.C. in. 00 Clamp, hose - const. trq Hose, C.A.C. - X long 09 ft. Hose,.00" 9 9 Clamp, hose Clamp, hose Hose, radiator - upper 0 Hose, radiator - lower 00 Hose, C.A.C X Pipe, C.A.C. out - -0 Hose, C.A.C X. 9 Clamp, hose ft. Hose, fuel -.0 ID 0 psi 0999 Fitting, barb straight brass.00mnpt x.

27 COOLING SYSTEM HOSES Units built after SN: ITEM PART NO. QTY DESCRIPTION NOTES 9 Assembly, radiator 0 Clamp, hose - const. trq..-. Hose, C.A.C. -. x Pipe, C.A.C. inlet 00 Clamp, hose - const. trq ft. Hose, " Goodyear 9 Clamp, hose Clamp, hose Hose, radiator - upper 0 0 Hose, radiator - lower 00 Hose, C.A.C x Pipe, C.A.C. outlet 0 Hose, C.A.C. - x 9 Clamp, hose ft. Hose, fuel -.0 ID 0 psi 0999 Fitting, barb straight brass.00mnptx.

28 GENERATOR TO ENGINE ASSEMBLY GENERATOR TO ENGINE CONNECTION TO ENGINE BLOCK 0 9 ITEM PART NO. QTY DESCRIPTION NOTES 90 Generator, PSL0 00 Nut,.- hex 0 Washer,. split lock 09 Washer, flat M 0 Washer, flat M0 09 Screw,.-X.0 hx 00 Screw, M0X.X hx 0 Shock mount, rubber 9 0 Washer, snubber 0 B Anti-turn bolt. X Generator, PSL0 Option: Super start Note: Engine and generator parts used in all Magnum Products LLC equipment carry the Original Equipment Manufacturer (OEM) warranty unless otherwise stated. OEM warranty parts must be purchased through an OEM dealer. Please contact Magnum Products LLC with questions.

29 GENERATOR BOX ASSEMBLY Standard Generator, -position voltage selector switch ITEM PART NO. QTY DESCRIPTION NOTES B Panel, generator box top B Panel, generator box right 0 Screw, MX.0X hx ser flg 00 Insert, M threaded Block, terminal - lug type 0 Screw, MX0.X pan phil 00 Washer, flat M 00 Nut, M hx nylock 9 9B Panel, generator box front 0 0 Switch, phase - A, -pos 0 Screw, MX0.X pan phil 0B Panel, generator box left 0B Bracket, phase switch B Panel, generator box rear 9

30 GENERATOR BOX ASSEMBLY Standard Generator, -position voltage selector switch

31 ITEM PART NO. QTY DESCRIPTION NOTES B Panel, generator box top B Panel, generator box right 0 Screw, MX.0X hx ser flg 00 Insert, M threaded 0 Screw, MX0.X pan phil 00 Washer, flat M 00 Nut, M hx nylock 9B Panel, generator box front 9 Switch, phase - A, -pos 0 0 Screw, MX0.X pan phil 90 Seal, generator box 0B Panel, generator box left 00 Screw, M-0. x pan phil 0B Panel, generator box rear 9B Bracket, phase switch B Box, rear generator extension 0 Lug block, pos 9 Lug, switch extension terminal

32 GENERATOR BOX ASSEMBLY Super Start Generator, -position voltage selector switch 0 0 9

33 ITEM PART NO. QTY DESCRIPTION NOTES B Panel, generator box top B Panel, generator box right 0 0 Screw, MX.0X hx ser flg 00 0 Insert, M threaded Block, terminal - pole 0 Screw, MX0.X pan phil 00 Washer, flat M 00 Nut, M hx nylock 9 9B Panel, generator box front 0 0 Switch, phase - A, -pos 0 Screw, MX0.X pan phil 90 Seal, generator box 0B Panel, generator box left 00 Screw, MX0.X0 pan phil 0B Bracket, phase switch B Panel, generator box rear

34 GENERATOR BOX ASSEMBLY Super Start Generator, -position voltage selector switch

35 ITEM PART NO. QTY DESCRIPTION NOTES B Panel, generator box top B Panel, generator box right 0 Screw, MX.0X hx ser flg 00 Insert, M threaded 0 Screw, MX0.X pan phil 00 Washer, flat M 00 Nut, M hx nylock 9B Panel, generator box front 9 Switch, phase - A, -pos 0 0 Screw, MX0.X pan phil 90 Seal, generator box 0B Panel, generator box left 00 Screw, M-0.X0 pan phil 0B Panel, generator box rear 9B Bracket, phase switch B Box, rear generator extension 0 Lug block, pos 9 Lug, switch ext. terminal 9 Generator, PSL0 Super start

36 G F D B C A F E M L K B A M L K J H 9 ENGINE ASSEMBLY

37 ITEM PART NO. QTY DESCRIPTION NOTES 000 Nut, M hx ser flg lock B Weldment, air cleaner brckt Page 0 Assembly, air filter 0 Clamp, hose Elbow, -molded rubber 9B Tube, " steel, air filter Clamp, hose -.-. Elbow, molded rubber 9 0 Sensor, oil pressure 0 0 Sensor, temperature.00 NPT Page Assembly, engine mount 00 Screw, MX hx ser flg Fan, engine - " 0 Screw, M0X.X0 hx 00 Washer, flat M0 9 Spacer, fan G0-G 9 Fitting, hose barb.0nptm x Fitting,.00NPTM x.0npt 9 Fitting,.00NPTF x Fitting, oring seal.00mnpt x M 9 Seal, M 90 Fitting,.00FNPT X MX. 0 Nipple, pipe -.00 NPT 99 Valve, ball NPT 00. ft. Hose, -. I.D. 00 Fitting, hose barb.00mnpt x. 0 Clamp, hose Engine, Deere 0HF 9 0 Sensor, magnetic pickup 0 Fitting, MX. -.0 barb 0009 Screw, MX.X hx ser flg 9 Belt, fan/alternator Filter, oil 9 Filter, fuel - primary Filter, fuel - secondary Alternator, engine Cap, engine oil fill With gasket Assembly, engine Items - A 00 Fitting, hose barb Option: coolant heater B 0 Clamp, hose Option: coolant heater C 00 ft. Hose, coolant -. I.D. Option: coolant heater D 00 ft. Hose, coolant -. I.D. Option: coolant heater E 99 Heater, 0V, 00W Option: coolant heater F 00 Screw, MX.0X hx ser flg Option: coolant heater G 00 Nut, M hx ser flg lock Option: coolant heater H 9 O ring,." Option: coolant heater J Fitting, O ring seal Option: coolant heater -. x M K 9 Seal, M Option: coolant heater L 9 Fitting, O ring seal Option: coolant heater -.00MNPT M Fitting, 90 - brass Option: coolant heater -.00NPTF Note: Engine and generator parts used in all Magnum Products LLC equipment carry the Original Equipment Manufacturer (OEM) warranty unless otherwise stated. OEM warranty parts must be purchased through an OEM dealer. Please contact Magnum Products LLC with questions.

38 OIL RECIRCULATION KIT ASSEMBLY 0 9

39 ITEM PART NO. QTY DESCRIPTION NOTES Page Assembly, engine 000 Nut, M hx ser flg lock 9B Bracket, OCV system 00 Screw, MX.0X hx ser 00 Screw, hx ser flg M x. x 0 Kit, oil recirculation 0 Hose, OCV vent 9 Clamp, hose Clamp, hose ft. Hose, fuel -.00 ID 0 psi 90 Fitting, hose barb 9 Drain, check valve 90 Fitting, 90.0MNPT X.0FNPT 90 Fitting, straight.0fnpt X.00MNPT 90 Fitting, straight.00fnpt X MX. 9 Seal, M Filter, oil recirculation 9

40 FUEL TANK AND SKID ASSEMBLY A C D B 9 0 0

41 ITEM PART NO. QTY DESCRIPTION NOTES 0B Weldment, lift structure 00 Screw,.0-0X.000 flg 00 Screw, M0X.X0 ser flg 0B Weldment, skid 0 Washer, flat.0 0 Washer, split lock.0 09 Nut,.0-0 hx hd Clamp, hose 9 9 Hose, fuel -. ID X ft. Hose, fuel -. ID 0 psi Page Assembly, fuel tank 9 Clamp, hose Hose, fuel fill 00 Nut, U-clip -.- A B Bracket, interior light Option: interior light B 9 Light, interior with switch Option: interior light C 09 Screw,.- x ser flg Option: interior light D 009 Nut,.- ser flg Option: interior light

42 ENGINE TO SKID ASSEMBLY D E H A B C F G L J K Trailer Mounting Hardware

43 ITEM PART NO. QTY DESCRIPTION NOTES Page Assembly, engine 90 Strap, ground - 0 in. 0 Cable - assy, grd 09 Washer, flat. 0 Screw,.-X.00 hx Bracket, battery hold-down 0090 Nut,.0-0 wing 009 Washer, fender. 9 Bolt, J x Cable, battery - " /0 red 0 Cable, battery - " /0 blk Page 0 Assembly, skid 00 Screw, hx ser flg M0X.X0 00 Screw,.-X hx hd 0 Clamp, tubing -.0 lt duty 0 Nut,.- hx hd 0 Washer, split lock. 09 Washer, flat. 9 B Aux line bracket 0 0 Nut,.- hx ser flg lock 0 Screw,.-x hx flg 00 Washer, flat. 00 Nut,.- hx nylock A 0 Nut,.- hx hd Option B 0 Washer, split lock. Option C 09 Washer, flat. Option D 9 Light, interior with switch Option E B Bracket, interior light Option F 0 Nut,.0-0 hx ser flg Option G 9 Battery disconnect switch Option H 9B Bracket, battery disconnect Option J 09 Screw,.0-0X.000 hx Option K 0 Screw,.-X.00 hx Option L 09 Washer, flat.0 Option

44 COOLING SYSTEM ASSEMBLY

45 ITEM PART NO. QTY DESCRIPTION NOTES 9B Panel, bulkhead Built before SN: 090 9B Panel, bulkhead Built after SN:090 0 Nut,.0-0 hx ser flg 0 Screw,.0-0X.00 hx 9 Clamp, overflow bottle 0 Nut,.0-0 nylock 0 Screw, hx ser flg.0-0x. 9 Cap, overflow bottle 0 Jug, overflow ( qt) 9 0B Support, overflow jug 0 Clamp, hose mini 90 Hose, overflow -- 0 Assembly, overflow jug Items - 0 Panel, foam - right radiator 90B Bracket, upper radiator Radiator, Tier III Built before SN: Radiator, Tier III vers. Built after SN: Screw,.-X. hx flg 0 Screw, hx ser flg.0-0 x Clamp, tubing -.0 0B Weldment, fan guard - right 9 0B Weldment, fan guard - left 0 00 Fitting, hose barb.00mnpt x. 0 Clamp, hose ft. Hose, coolant -. I.D. 99 Valve, ball NPT 0 Nipple, pipe.00 NPT x close 99B Radiator shroud 00 Nut, M0 hx ser flg lock B Weldment, radiator support 00 Screw, hx ser flg M0X.X0 9 0B Panel, muffler mount 0 00 Nut, U-clip,.- 0 Screw,.-X.0 hx 0 Washer, split lock. 09 Washer, flat. 09 Screw,.-X hx ser flg 00 Washer, flat. 00 Washer, split lock. 00 Screw,.-X.000 hx hd 0 Panel, foam - left radiator Nut,.- ser flg 0 0 Nut,.- Lhex B Bracket, muffler pipe support 0 Screw,.-X.0 flat hex Cap, radiator 9 Sensor, low coolant

46 LEFT FRONT DOOR ASSEMBLY 9 0

47 ITEM PART NO. QTY DESCRIPTION NOTES Foam, small duct rht 9 Foam, front lft door upper 09W Duct, front door Foam, front duct face - lft Foam, door duct lft Foam, small duct lower 9 Foam, front lft door lower 900 Rod, door prop 9 00 Pin, roll. X. 0 09Z Bracket, prop rod 0 Rivet,. dia 0W Door, front left 9 Latch, T-handle right - ccw 0 Screw,.-X carriage 9 Hinge, left (male) 0 Washer,.0 flat./.00 0 Washer,. split lock 0 Nut,.- hx G Assy, front left door Items -

48 LEFT REAR DOOR ASSEMBLY 9 0 0

49 ITEM PART NO. QTY DESCRIPTION NOTES 9 Foam, small duct rght 9W Duct, rear door 9 Foam, rear lft duct face 90 Foam, door duct lft 9 Foam, rear lft duct lower 9 Foam, rear lft door upper 9 Foam, rear lft door lower 900 Rod, door prop 9 00 Roll pin,. x Rivet,. dia 09Z Bracket, prop rod 0 Washer,.0 flat./.00 0 Washer,. split lock 0 Nut,.- hx G Hinge, right (male) 0 Screw,.-X carriage W Door, rear left 9 Latch, T-handle - left cw -- Assy, rear left door Items - 9

50 RIGHT FRONT DOOR ASSEMBLY

51 ITEM PART NO. QTY DESCRIPTION NOTES Foam, small duct rght W Duct, front door Foam, front duct face - lft Foam, door duct lft Foam, small duct lower 9 Foam, front right door upper 9 Foam, front right door lower 900 Rod, door prop 9 00 Pin, roll. X. 0 0 Rivet,. dia 09Z Bracket, prop rod 0 Washer,.0 flat./.00 0 Washer,. split lock 0 Nut,.- hx G Hinge, right (male) 0 Screw,.-X carriage 9W Door, front right 9 Latch, T-handle - left cw lock Assy, front right door Items -

52 CONTROL DOOR ASSEMBLY 0 9 9

53 ITEM PART NO. QTY DESCRIPTION NOTES B Brace, control door 0 0 Rivet,. dia 0 Washer,.0 flat./.00 0 Washer,. split lock 0 Nut,.- hx G 9 Hinge, left (male) 0 Screw,.-X carriage 09 Screw, 0-X. pan phil 9 9 Latch, T-handle right - ccw 0 W Door, control Foam, panel - control door Gasket, control door Window, control door 0 Washer, flat #0 0 Nut, 0- nylock Flap, control door 0W Bracket, door flap 0 Latch, door - spring loaded 9 00 Washer, flat #0X.0 -- Assy, control door Items - 9

54 LEFT SIDE CENTER PANEL ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES W Panel, left/middle/front 0W Panel, right/middle/front 00 Nut, U-clip,.- 0 Washer, flat. 00 Screw,.-X std hex

55 RIGHT SIDE CENTER PANEL ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES 9W Panel, right/middle/rear 0W Panel, right/middle/front 00 Nut, U-clip,.- 0 Washer, flat. 00 Screw,.-X std hex

56 LEFT FRONT CORNER ASSEMBLY 9 ITEM PART NO. QTY DESCRIPTION NOTES 0W Panel, front left 9 Foam, front left 9 Foam, corner 00 Nut, U-clip,.- 0 Screw,.-X carriage Hinge, left (female) 0 Washer,.0 flat./.00 0 Washer,. split lock 9 0 Nut,.- hx G Assy, left front corner Items - 9

57 RIGHT FRONT CORNER ASSEMBLY 9 ITEM PART NO. QTY DESCRIPTION NOTES 0W Panel, front right 9 Foam, front right 9 Foam, corner 00 Nut, U-clip,.- 0 Screw,.-X carriage 0 Hinge, right (female) 0 Washer,.0 flat./.00 0 Washer,. split lock 9 0 Nut,.- hx G Assy, right front corner Items - 9

58 FRONT PANEL ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES 0W Panel, front Foam, front panel Assy, front panel Items -

59 REAR PANEL ASSEMBLY 9 ITEM PART NO. QTY DESCRIPTION NOTES Foam, panel - rear duct face W Duct, rear 9 Foam, duct (L) Foam, rear duct lower 9 Foam, duct (R) 99 Foam, panel long Foam, rear panel short 0 Rivet,. dia 9 0W Panel, rear -- Assy, rear panel Items - 9 9

60 FRONT ROOF PANEL ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES 00 Screw,.-X std hex 0 Washer, flat. 00 Nut, U-clip,.- W Panel, roof insert 9 Insulation, ceramic roof 0W Panel, access 0W Panel, roof front Foam, roof front Assy, front roof Items - 0

61 REAR ROOF PANEL ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES 0W Panel, roof rear Foam, rear roof panel Assy, rear roof Items -

62 LEFT REAR CORNER ASSEMBLY

63 ITEM PART NO. QTY DESCRIPTION NOTES 90 Foam, small duct right 9 Foam, small duct face W Duct, side air Foam, rear left corner 0 Washer,.0 flat./.00 0 Washer,. split lock 0 Nut,.- hx G 99 Foam, small duct lower 9 00 Nut, nylock 0 0W Panel, left rear 0 Port, fuel fill 00 Washer, flat #0 SS 09 Screw, 0-X. pan phil B Tube, filler 9 Gasket, fuel fill Cap, fuel fill 0 Rivet, /", closed end, alu. 0 Screw,.-X carriage 9 0 Hinge, right (female) 0 9 Foam, corner 00 Nut, U-clip, Assy, left rear corner Items -

64 RIGHT REAR CORNER ASSEMBLY

65 ITEM PART NO. QTY DESCRIPTION NOTES 0 Switch, e-stop, assy N.O./N.C. 0 Block, e-stop contactor N.C. Block, e-stop contactor N.O./N.O. 0 Switch, e-stop operator B Panel, emergency stop 0 Rivet,. dia 0W Panel, rear right 9 Foam, corner 9 0 Screw,.-X carriage 0 Hinge, left (female) 0 Washer,.0 flat./.00 0 Washer,. split lock 0 Nut,.- hx G 9 Foam, duct (L) Foam, rear right corner W Duct, side 9 Foam, duct face 99 Foam, duct lower 9 00 Nut, U-clip, Latch, door - spring loaded -- 0 Assy, right rear corner Items - 0

66 END AND LOWER SIDE PANEL ASSEMBLY 9 ITEM PART NO. QTY DESCRIPTION NOTES 0W Panel, end Foam, end panel -- 0 Assy, front/rear panel Items - 00 Nut, U-clip,.- 0 Foam, lower side panel W Panel, lower side -- 0 Assy, front lower panel Items - Foam, lower side panel W Panel, side -- Assy, rear lower panel Items - 09Z Bracket, prop rod 9 0 Rivet,. dia

67 UPPER SIDE PANEL ASSEMBLY ITEM PART NO. QTY DESCRIPTION NOTES W Panel, left rear upper Foam, right rear upper -- Assy, rear/left upper panel Items - W Panel, right front upper 9 Foam, right front upper -- 9 Assy, front upper panel Items - W Panel, right rear upper -- Assy, rear/right upper panel Items & 00 Nut, U-clip,.-

68 TRAILER ASSEMBLY A B C TO FRAME 0 TO FENDER TO FRAME TO FENDER 0 0 D ITEM PART NO. QTY DESCRIPTION NOTES B Weldment, trailer frame B Weldment, rear step rh 0 0 Screw,.00-X.0 hx 0 Washer, flat.00 fender 00 Nut,.00- nylock B Fender shield, large trailer 0 Screw,.-X.0 hx

69 ITEM PART NO. QTY DESCRIPTION NOTES 0 Washer, flat. 9 0 Nut,.- nylock 0 B Weldment, fender 00 Screw,.-X.0 hx 0 Light, clearance marker Red 0 Screw, 0-X.00 pan phil 00 Nut, 0- nylock 0 Light, clearance marker Amber 9 Pad, slip resistant 0 x 0B Weldment, front step rh B Weldment, jack 9 9B Weldment, front step lh 0 B Weldment, rear step lh 9 Light, stop/turn/tail - lh Light, stop/turn/tail - rh Light bar - lights 0 Light, license plate - V 0 Plug, wire, license light 0B Cover, brake guard 0 Screw,.0-0X. std hex 0 Washer, split lock Nut,.0-0 nylock 0 09 Chain, trailer safety, hi test 0 Screw,.00-X.00 hx hd 009 Washer, flat.00 SAE Actuator, trailer 9B Hitch, pintle eye (adj) - ID 09 Screw,.-X.000 hx 00 Washer, flat Nut,.- nylock 0 Screw,.-X.00 flg hex 9 0 Washer, sqr. bevel structural. galvanized 0 00 Washer, flat. 0 Nut,. - ser flg Axle 000# - frame Hydraulic brake Axle 000# - frame Option: Electric brake Surge free-backing brake Left Surge free-backing brake Right Electric brake assy Option: Left Electric brake assy Option: Right Inner grease seal." Inner hub bearing Inner bearing cup Drum, large trailer brake 000# axle Outer bearing cup 9 Outer hub bearing 0 Spindle washer 0 Spindle nut Spindle nut - cotter pin Dust cap 009 Nut, wheel lug 0 Wheel, 0- LTE A B Weldment, spare tire carrier Option: spare tire carrier B 9 Breakaway kit Option C 9B Weldment, hitch elec. Option: -pos adjustable D 99 Coupler,. ball Option: Adjustable hitch 9

70 TRAILER BRAKE LINES ITEM PART NO. QTY DESCRIPTION NOTES 09 Brake line, / x 0 9 Fitting, T w/bracket Brake line, / x 0 9 Connector, brake line 09 Fitting, T 09 Brake line, / x 0 09 Hose, brake 099 Clip, brake hose 0

71 RECOMMENDED SPARE PARTS LIST Lug Door Safety Swtiches()... Voltage Regulator... Digital Controller... 9 Voltage Potentiometer... 9 Starter Relay Hour Service Kit... SK0 Hose, Radiator - Upper... 9 Hose, Radiator - Lower... 0 Sensor, Low Coolant... 9 E-Stop Assembly... 0 Overflow Jug Assembly... 0 Engine Alternator... ELECTRIC BRAKE WIRING HARNESS BREAK AWAY SW + BATT - BLU GREEN YELLOW BROWN WHITE TO BRAKES RIGHT TURN/STOP LEFT TURN/STOP TAIL/MARKER GROUND

72 TRAILER LIGHT WIRING DIAGRAM TRAILER PLUG AMBER MARKER LAMP AMBER MARKER LAMP AMBER MARKER LAMP AMBER MARKER LAMP FENDER FENDER RED MARKER LAMP IDENTIFICATION LIGHT BAR RED MARKER LAMP PLATE LAMP STOP-TURN SIGNAL LAMP (LEFT) STOP-TURN SIGNAL LAMP (RIGHT)

73 AC WIRING DIAGRAM L CT- L L L0 CT- CT- (.K, WATT) VOLTAGE ADJUSTMENT GROUND TO GEN FRAME (T) PAIR PAIR (T9) PAIR T GRN/YEL GRN/YEL GRN/YEL GRN/YEL GRN/YEL BRN T 9 0 BRN 0V 0A BREAKER 0V 0A BREAKER 0V 0A BREAKER BRN/WHT BRN/WHT VDC SHUNT LUG DOOR SAFETY SWITCH NO SE0 VOLTAGE REGULATOR AMP FUSE ON REGULATOR F+ F- 0HZ 0HZ BRN/WHT RED F+ F- WHT BRN MECHANICAL LUGS GND PAIR (L0) L0 L L L RED 0V GFCI RECPT 0V 0A BRKER LT BLU LT BLU LT BLU LT BLU LT BLU T V GFCI RECPT 0V 0A BRKER 0V 0A RCPT. 0V 0A RCPT. 0V 0A RCPT. T T T0 T T T T T T GENERATOR F+ F- GROUND TO FRAME COM NC NO H H X X H WHT WHT QTY BRN RELAY RED BUCK XFORMER H X X WIRES NOT USED IN BUCK BOOST OPTION () JUMPER WIRES ON PHASE SWITCH -0, -, 0- WHT BUCK BOOST OPTION MAIN CIRCUIT BREAKER VOLTAGE SENSING RELAY SEE DC WIRING DIAGRAM FOR CT CONNECTIONS P N P N PIN PLUG

74 PIN PLUG (RPM) PLUG LOCATION BOTTOM MAG IN MAG REF PIN LOCATION RPM IN RPM GND LARGE PIN PLUG (GEN VOLTAGE) PLUG LOCATION TOP PHASE A VOLTAGE PHASE B VOLTAGE PHASE C VOLTAGE NEUTRAL PIN LOCATION L L L N PIN PLUG (GEN CURRENT) PLUG LOCATION TOP PIN LOCATION PHASE A CURRENT L PHASE B CURRENT L PHASE C CURRENT L PHASE GND COM RELAY BOARD PLUG LOCATION PIN BOTTOM LOCATION POWER + DC + D+ D+ POWER - DC - BO C +VDC PIN PLUG (BINARY INPUTS) PLUG LOCATION BOTTOM PIN LOCATION E STOP BI CONTROL POWER SWITCH RD/BK RD/BK RD/VI ORN GTB GROUND TERMINAL BLOCK YEL BRN GN/YL /B 0 /B GN/YL STARTER RELAY 9 B+ RED C+ YEL GROUND TO ENGINE BLOCK 0 MJB V BATTERY SHLD GRY RD/VI ORN WT/VI GY/BK RED GRY GN/YL ORN RD/WT RED RED RED ORG A WT/VI BRN YEL ORN WHT BR/WT YL/WT OR/WT GRN GRY GY/OR TB REMOTE START CONTACTS GRN RED YEL DC WIRING DIAGRAM RD/VI ORN WT/VI RD/YL ORN F+ DEUTSCH -PIN J ALT. EXCITE DEUTSCH -PIN G "RUN" FUEL LEVEL GROUND TO TANK LUG DOOR SAFETY SWITCH C NC RED PIN PLUG (ANALOG INPUTS) PLUG LOCATION BOTTOM OIL IN WATER IN FUEL IN PIN LOCATION AI (OIL) AI (TEMP) AI (FUEL) SRT BO FUE OPEN OPEN OPEN OPEN OPEN BO START C +VDC BO FUEL BO BO BO BO REMOTE START BI LOW COOLANT OPTION BI OPEN OPEN BI BI BI PIN PLUG PLUG LOCATION LEFT SIDE ECU H ECU L ECU COM PIN LOCATION H L COM GND ON BOARD GRY SHIELD WHT DEUTSCH -PIN F CAN-SHLD DEUTSCH -PIN U CAN-L DEUTSCH -PIN V CAN-H NC B+ MOTOR STARTER GY/BK RED GY/BK Shield not connected Cut back and Tape CT- WHT CT- WHT CT- L L L WHT SPLICE WHT GRN LOW COOLANT TO GEN FIELD B+ RED ALT SHUNT MAIN BREAKER GRN SPLICE YEL GN/YL L0 ORN ORN ORN RD/WT RD/WT RD/WT RD/WT H J K L M N P R S T U V W X A B C D E F G GRY GN/YL ORN RD/WT SHLD GRY RED RED RED RED RED TO VOLTAGE REGULATOR F- GEN F- GEN F+ NO NO OPTIONAL BATTERY DISCONNECT VIO MDC CONTROLLER BO OPEN OPEN BI *NOT REQUIRED WITH JOHN DEERE ECU ENGINE RD/YL RD/WT E-STOP SWITCH E-STOP SWITCH 900, ORG..0

75 L CT- L L CT- CT- (T) GRN/YEL GRN/YEL BRN BRN 9 0 T BRN/WHT BRN/WHT VDC SHUNT CIRCUIT BREAKER COM L CT CT COMMON CT CT OR/WT CT- GN/YL YL/WT BR/WT CT- CT- AMP FUSE ON REGULATOR F+ F- 0HZ 0HZ BRN/WHT F+ F- WHT BRN MECHANICAL LUGS L0 (.K, WATT) VOLTAGE ADJUSTMENT GROUND TO GEN FRAME GRN/YEL GRN/YEL GRN/YEL T T ELECTRONIC CONTROL BOARD PIN PLUG PIN PLUG GENERATOR CURRENT GEN VOLTAGE INPUTS INPUTS L L T9 L 0V 0V GFCI GFCI RECPT RECPT 0V 0A 0V 0A BREAKER RCPT. 0V 0A 0V 0A BREAKER RCPT. T 9 0 T T T T T T T9 T0 GENERATOR F+ F- GROUND TO FRAME GA GA GA SE0 VOLTAGE REGULATOR GND (T9) 0V 0V 0A 0A BRKER BRKER RED N N PIN PLUG () JUMPER WIRES (DASHED) ON PHASE SWITCH 0GA AWG LUG DOOR BRN SAFETY SWITCH NC RELAY L L ORN N WHT YEL L BRN NO LT BLU LT BLU LT BLU LT BLU LT BLU YEL WHT/BR ORN BRN/W BRN GRN RELAY VOLT REGULATION RED P P WHT WHT BUCK BOOST OPTION COM NC NO RED H H X X BUCK XFORMER H WHT VOLTAGE RELAY H X X L L T LO TO PLUG POS X SEE DC PRINT RED WIRES NOT USED IN BUCK BOOST OPTION (L0) 0V 0A 0V 0A BREAKER RCPT. TO PIN PLUG "W" SEE DC PRINT TP0 TPA TPA TP GEN BOX AC WIRING DIAGRAM For units equipped with a position voltage selector switch.

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