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OPERATING INSTRUCTIONS AND PARTS MANUAL
PORTABLE DIESEL GENERATOR
®
MODELS 3ZC06A AND 4W315A
FORM 5S3125
03430
1192/351/VP
READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR MAINTAIN
THE PRODUCT DESCRIBED. PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY INFORMA-
TION. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR
PROPERTY DAMAGE! KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE.
120
VO LTS
120 ON
LY
FU LL P
OW
ER
120
/24
0V
100
AC V
200
OU
TP UT
VO
OLT
LTA GE
30
120 /24
0 V OLT
Figure 1
MODEL 3ZC06A
120
VO
LTS
120 O
NLY
FU LL P
OW
ER
SE LE
OR 12 0/2
40
100
200
AC
VO
OU
TP UT
VO
LTS
LTA
GE
30
120
/24 0 V
OLT
Description
This Dayton Professional portable generator is rugged and compact. It provides dependable, trouble-free service. The alternator is brushless with revolving fields.
Yanmar diesel engine provides long life under heavy use. This engine is governed to maintain engine speed of 3600 RPM under load. 3600 RPM engine speed provides 120/240V, 60 Hz power.
This generator also includes circuit breaker protection, spark-arresting muffler, large fuel tank, oil alert system, electric starter (4W315A only), and a pressurized lubrication system.
Unpacking
E
F
MODEL 4W315A
RU N
ST
OP
1.
Remove generator from carton.
2.
Remove any protective packaging applied to generator for shipment.
3.
Check for loose or missing parts. Check for shipping damage. If any parts are missing or damaged, promptly inform dealer where you bought generator.
4.
Model 4W315A only: Battery cables are in a separate bag inside generator carton. You must install these cables to engine. See Battery, page 8 for installation instructions.
Table Of Contents
SECTION PAGE
Description ................................................................ 1
Unpacking ................................................................. 1
General Safety Information ....................................... 2
Warranty ................................................................... 4
Specifications ............................................................ 5
Generator Features .................................................. 6
Oil Alert System .................................................. 6
Battery Discharge Lamp ..................................... 6
Full Power Selector Switch ................................ 6
Voltmeter ............................................................ 6
Electric Start ....................................................... 6
Receptacle Circuit Breaker ................................ 7
Spark Arrester .................................................... 7
Pre-Installation .......................................................... 7
Engine Oil ........................................................... 7
Checking Oil Level and Adding Oil .................... 7
Fuel ..................................................................... 8
Installation ................................................................. 8
Battery ....................................................................... 8
Generator Grounding .............................................. 10
Ground Fault Protection .......................................... 10
Extension Cords ..................................................... 10
Standby Installation To Home or Building .............. 10
Operation ................................................................ 11
Determining Electrical Load For Generator ..... 11
Ventilation ......................................................... 12
Dust, Dirt, Rain, and Snow ............................... 12
High and Low Temperature Operation ............. 12
General Information .......................................... 12
Using Receptacle ............................................. 12
Power Cord and Plug Requirements ................ 12
Prestart ............................................................. 13
Starting ............................................................. 13
High Altitude Operation .................................... 15
Adding Electrical Loads .................................... 15
Disconnecting Electrical Loads ........................ 15
Stopping Engine ............................................... 15
Maintenance ........................................................... 16
Storage ................................................................... 18
Troubleshooting ...................................................... 19
Product Identification .............................................. 21
Wiring Diagrams ..................................................... 22
Replacement Parts Lists .................................... 23-27
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
General Safety Information
IMPORTANT: READ THESE INSTRUCTIONS AND
ENGINE OWNER’S MANUAL CAREFULLY. BECOME
FAMILIAR WITH GENERATOR BEFORE TRYING TO
OPERATE OR SERVICE IT. KNOW ITS USES, LIMI-
TATIONS, AND ANY HAZARDS INVOLVED. IM-
PROPER USE OF GENERATOR CAN CAUSE SE-
VERE INJURY OR DEATH FROM EXPLOSION, FIRE,
BURNS, ELECTRICAL SHOCK, OR CARBON MON-
OXIDE POISONING.
Make certain you read and understand all warnings.
Keep these instructions for reference. They are your guide to safe and proper operation of this generator.
Safety information appears throughout these instructions. Pay close attention to them. Below are definitions for the safety information listed throughout this manual.
!
DANGER
Under this heading, installation, operating and maintenance procedures or practices will be found that, if not carefully followed, WILL result in IMMEDIATE serious personal injury or death.
WARNING
Under this heading, installation, operating and maintenance procedures or practices will be found that, if not carefully followed, COULD result in severe personal injury or death.
SAFE FOR YOU AND OTHERS. YOU SHOULD ALSO
ENSURE THAT EQUIPMENT WILL NOT BE DAM-
AGED OR MADE UNSAFE BY THE OPERATING OR
MAINTENANCE METHOD YOU CHOOSE.
!
DANGER
ENGINE EXHAUST CONTAINS POISONOUS CAR-
BON MONOXIDE GAS. OVEREXPOSURE WILL
CAUSE LOSS OF CONSCIOUSNESS AND WILL LEAD
TO DEATH. USE ONLY IN WELL-VENTED AREAS.
MAKE SURE AREA HAS PLENTY OF FREE-MOV-
ING, FRESH, OUTSIDE AIR. NEVER RUN GENERA-
TOR IN AN ENCLOSED OR CONFINED AREA. NEVER
RUN GENERATOR INSIDE OCCUPIED BUILDING.
EARLY SIGNS OF CARBON MONOXIDE POISON-
ING RESEMBLE THE FLU, WITH HEADACHES, DIZ-
ZINESS, OR NAUSEA. IF YOU HAVE THESE SIGNS,
GET FRESH AIR AT ONCE! SOME PEOPLE ARE
MORE AFFECTED BY CARBON MONOXIDE THAN
OTHERS. THESE INCLUDE PREGNANT WOMEN,
PERSONS WITH HEART OR LUNG DISEASE OR
ANEMIA, THOSE UNDER THE INFLUENCE OF AL-
COHOL, AND THOSE AT HIGH ALTITUDES.
CAUTION
Under this heading, installation, operating and maintenance procedures or practices will be found that, if not carefully followed, COULD result in minor personal injury, product or property damage.
IMPORTANT
Used to draw special attention to a factor concerned with operation, installation, assembly or maintenance which COULD result in damage to the machine or equipment if ignored.
NOTE
Under this heading statements will be found emphasizing installation, operation, and maintenance procedures that either simplify procedures or increase efficiency.
IMPORTANT: EVERY POSSIBLE CIRCUMSTANCE
THAT MIGHT INVOLVE A HAZARD CANNOT BE AN-
TICIPATED. THE WARNINGS IN THESE INSTRUC-
TIONS AND ON TAGS OR DECALS AFFIXED TO THE
UNIT ARE THEREFORE NOT ALL-INCLUSIVE. IF A
PROCEDURE, WORK METHOD, OR OPERATING
TECHNIQUE NOT SPECIFICALLY RECOMMENDED
BY DAYTON IS USED, YOU MUST MAKE SURE IT IS
WARNING
DIESEL FUEL PRESENTS A HAZARD OF FIRE. DIE-
SEL FUEL IS FLAMMABLE.
• KEEP FUEL OUT OF CHILDREN’S REACH.
• REFUEL GENERATOR IN A WELL-VENTED AREA.
DO NOT FILL FUEL TANK IN THE DARK. DO NOT
REFUEL WHILE ENGINE IS RUNNING. UNHOOK
ALL ELECTRICAL LOADS AND SHUT OFF EN-
GINE BEFORE REFUELING.
• DO NOT OVERFILL FUEL TANK. ALWAYS AL-
LOW ROOM FOR FUEL TO EXPAND. IF YOU
OVERFILL TANK, FUEL CAN OVERFLOW ONTO
HOT GENERATOR. THIS CAN CAUSE FIRE. AF-
TER REFUELING, TIGHTLY CLOSE FUEL TANK
CAP.
• DO NOT SPILL FUEL. IF FUEL SPILLS, MAKE
SURE AREA IS DRY BEFORE STARTING EN-
GINE.
• NEVER SMOKE IN REFUELING AREA. NEVER
ALLOW OPEN FLAMES OR SPARKS IN AREA.
• STORE FUEL IN APPROVED CONTAINER. STORE
FUEL IN A WELL-VENTED AREA FREE OF OPEN
2
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
General Safety Information (Continued)
FLAMES OR SPARKS.
WARNING
GUARD AGAINST FIRE HAZARD. KEEP OPERA-
TION AREA WELL-VENTED. KEEP GENERATOR AT
LEAST THREE FEET AWAY FROM ANY OBJECT.
DO NOT PLACE FLAMMABLE OBJECTS NEAR GEN-
ERATOR.
• DO NOT USE GENERATOR WHERE FLAMMABLE
VAPORS ARE PRESENT. SOME VAPORS ARE
HEAVIER THAN AIR. THESE VAPORS SETTLE IN
LOW-LYING PLACES.
• DO NOT USE GENERATOR IN ENCLOSED
SPACES. THIS INCLUDES MOTOR HOME OR RV
GENERATOR COMPARTMENTS.
WARNING
GUARD AGAINST BURNS. HOT ENGINE PARTS
CAN CAUSE SEVERE INJURY. USE CAUTION AND
REMAIN ALERT WHEN USING GENERATOR.
• KEEP CHILDREN AND ANIMALS AWAY FROM
GENERATOR WHILE IT IS RUNNING OR HOT.
• KEEP ALL COVERS AND SHIELDS IN PLACE.
KEEP THEM TIGHTLY SECURED.
• THE MUFFLER BECOMES VERY HOT DURING
OPERATION. THE MUFFLER REMAINS HOT
FOR A WHILE AFTER SHUTDOWN. DO NOT
TOUCH MUFFLER WHILE IT IS HOT. DO NOT LET
MUFFLER TOUCH ANYTHING FLAMMABLE.
LET ENGINE COOL BEFORE TRANSPORTING
OR STORING.
WARNING
GUARD AGAINST ELECTRIC SHOCK. GENERA-
TOR PRODUCES HIGH VOLTAGE. THIS HIGH
VOLTAGE CAN CAUSE SEVERE ELECTRIC
SHOCK. ONLY RESPONSIBLE ADULTS SHOULD
USE THE GENERATOR.
• PROPERLY GROUND GENERATOR BEFORE
STARTING.
• NEVER LET ANYONE OPERATE OR SERVICE
GENERATOR WITHOUT PROPER INSTRUC-
TIONS.
• AVOID CONTACT WITH LIVE TERMINALS OR
BARE WIRES.
• DO NOT USE GENERATOR OUTDOORS IN RAIN
OR SNOW.
• DO NOT USE GENERATOR NEAR STANDING
WATER OR SNOW.
• DO NOT USE IF GENERATOR IS WET OR DAMP.
• DO NOT USE GENERATOR IN HIGHLY CONDUC-
TIVE AREAS. THESE AREAS INCLUDE METAL
DECKING AND STEELWORK.
• ONLY USE GROUNDED EXTENSION CORDS.
• DO NOT USE ANY WORN OR DAMAGED ELEC-
TRIC CORDS. ELECTRIC SHOCK OR DAMAGE
TO GENERATOR MAY RESULT.
• ON CONSTRUCTION SITES, YOU MUST USE A
GROUND FAULT CIRCUIT INTERRUPTER (GFCI).
THIS HELPS GUARD AGAINST ELECTRIC
SHOCK. OSHA AND THE NATIONAL ELECTRI-
CAL CODE REQUIRES THIS.
• DO NOT WEAR DAMP CLOTHING OR WET
SHOES WHEN USING GENERATOR.
3
WARNING
HAVE STANDBY INSTALLATION TO HOME OR
BUILDING PERFORMED BY A LICENSED ELECTRI-
CIAN. DO NOT LET ANYONE ELSE WIRE INTO A
UTILITY CIRCUIT. PERSONAL INJURY, EQUIP-
MENT DAMAGE, OR DAMAGE TO HOME COULD
OCCUR.
WARNING
NEVER CONNECT GENERATOR TO ANY EXISTING
ELECTRICAL CIRCUITS. THE GENERATOR OUT-
PUT WILL BACK-FEED INTO THE UTILITY POWER
LINE. THIS MAY ELECTROCUTE A POWER COM-
PANY LINE REPAIR PERSON. ALSO, IF GENERA-
TOR IS POWERING ELECTRICAL CIRCUITS, THE
CHANCE OF AN ELECTRICAL FIRE EXISTS.
WARNING
MODEL 4W315A ONLY: BATTERY GIVES OFF EX-
PLOSIVE GASES. KEEP SPARKS, FLAMES, AND
CIGARETTES AWAY. DO NOT REMOVE OR INSTALL
BATTERY CABLES WHEN ENGINE IS CRANKING
OR RUNNING. ONLY SERVICE OR USE BATTERY IN
A WELL-VENTED AREA.
WARNING
MODEL 4W315A ONLY: BATTERY CONTAINS SUL-
FURIC ACID. BATTERY ACID IS POISONOUS IF
SWALLOWED. CONTACT WITH SKIN OR EYES MAY
CAUSE SEVERE BURNS. DO NOT TILT GENERA-
TOR WITH BATTERY INSTALLED. TILTING COULD
CAUSE BATTERY ACID TO SPILL. WEAR PROTEC-
TIVE CLOTHING AND FACE SHIELD WHEN SERVIC-
ING. KEEP OUT OF CHILDREN’S REACH.
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
General Safety Information (Cont’d)
WARNING
ONLY A QUALIFIED ELECTRICAL SERVICE PER-
SON SHOULD SERVICE AND REPAIR GENERA-
TOR.
• GENERATOR PRODUCES HIGH VOLTAGE. USE
EXTREME CAUTION WHEN WORKING ON ELEC-
TRICAL PARTS.
• WHEN WORKING ON GENERATOR, AVOID HOT
MUFFLER, EXHAUST MANIFOLD, AND ENGINE
PARTS. SEVERE BURNS MAY OCCUR.
• DO NOT WORK ON GENERATOR WHEN TIRED.
• USE ONLY FACTORY APPROVED REPLACE-
MENT PARTS.
WARNING
STORE GENERATOR IN A WELL-VENTED AREA.
MAKE SURE FUEL TANK IS EMPTY. NEVER STORE
WITH FUEL IN TANK.
CAUTION
Never operate generator
• if engine speed changes greatly
• if engine misfires often
• if powered items overheat
• if electrical output drops
• if it is sparking
• if it produces smoke or flames
• if it vibrates at high levels
• if it has a damaged receptacle
CAUTION
Keep generator and nearby areas clean.
• Keep generator free of oil, mud, and other foreign matter.
• Remove anything that creates slippery areas around generator.
• Remove oily rags and other items that create fire hazards.
• Keep a fire extinguisher nearby. Make sure it is rated ABC by the NFPA. They are good for all uses. Consult your local fire department.
• Keep fire extinguisher well maintained. Be familiar with its use.
CAUTION
Know how to stop engine quickly. Know how to use all controls.
CAUTION
Prolonged exposure to loud noise can cause hearing loss.
• When working around generator, wear approved hearing protection.
• Remember neighbors when using generator.
NOTE: The five-year limited warranty below covers all non-engine parts of this generator including the alternator. Yanmar warrants the engine.
LIMITED WARRANTY
DAYTON FIVE-YEAR LIMITED WARRANTY. Professional-duty portable generator alternators, models 3ZC06A and 4W315A, are warranted by Dayton Electric Mfg. Co. (Dayton) to the original user against defects in workmanship or materials under normal use for five years after date of purchase. Any part which is determined by Dayton to be defective in material or workmanship and returned to an authorized service location, as Dayton designates, shipping costs prepaid, will be, as the exclusive remedy, repaired or replaced at Dayton’s option. For limited warranty claim procedures, see PROMPT DISPOSITION below.
This limited warranty gives purchasers specific legal rights which vary from state to state.
LIMITATION OF LIABILITY. To the extent allowable under applicable law, Dayton’s liability for consequential and incidental damages is expressly disclaimed. Dayton’s liability in all events is limited to, and shall not exceed, the purchase price paid.
WARRANTY DISCLAIMER. Dayton has made a diligent effort to illustrate and describe the products in this literature accurately; however, such illustrations and descriptions are for the sole purpose of identification, and do not express or imply a warranty that the products are merchantable, or fit for a particular purpose, or that the products will necessarily conform to the illustrations or descriptions.
Except as provided below, no warranty or affirmation of fact, expressed or implied, other than as stated in “LIMITED WARRANTY” above is made or authorized by Dayton.
PRODUCT SUITABILITY. Many states and localities have codes and regulations governing sales, construction, installation, and/or use of products for certain purposes, which may vary from those in neighboring areas. While Dayton attempts to assure that its products comply with such codes, it cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a product, please review the product application, and national and local codes and regulations, and be sure that the product, installation, and use will comply with them.
Certain aspects of disclaimers are not applicable to consumer products; e.g., (a) some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you; (b) also, some states do not allow limitations on how long an implied warranty lasts, consequently the above limitation may not apply to you; and (c) by law, during the period of this Limited Warranty, any implied warranties of merchantability or fitness for a particular purpose applicable to consumer products purchased by consumers, may not be excluded or otherwise disclaimed.
PROMPT DISPOSITION. Dayton will make a good faith effort for prompt correction or other adjustment with respect to any product which proves to be defective within limited warranty. For any product believed to be defective within limited warranty, first write or call dealer from whom product was purchased. Dealer will give additional directions. If unable to resolve satisfactorily, write to Dayton at address below, giving dealer’s name, address, date and number of dealer’s invoice, and describing the nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier. If product was damaged in transit to you, file claim with carrier.
Manufactured for Dayton Electric Mfg. Co.,
5959 W. Howard St., Chicago, IL 60648
4
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Specifications
YANMAR YANMAR
MODEL ENGINE H.P.
MODEL
3ZC06A 6 L60
4W315A 9 L90
GENERAL SPECIFICATIONS
FUEL
TYPE
Diesel
Diesel
FUEL TANK OIL ALERT ELECTRIC WEIGHT
CAPACITY SYSTEM
0.9 gal.
4.2 gal.
No
Yes
START
No
Yes
(POUNDS)
168.5
241
MODEL
3ZC06A
4W315A
120V
DUPLEX
Yes
Yes
RECEPTACLE SPECIFICATIONS
120V, 30-AMP
TWIST-LOCK
Yes
Yes
120/240V, 20-AMP
TWIST-LOCK
Yes
Yes
120V FULL
POWER SWITCH
Yes
Yes
MODEL
3ZC06A
4W315A
* Single-phase, 1.0 power factor
ELECTRICAL SPECIFICATIONS
RATED
WATTAGE*
3000
5000
120V
25.0
41.7
RATED AMPERAGE
240V
12.5
20.8
ELECTRICAL COMPONENT SPECIFICATIONS
MODEL
3ZC06A
4W315A
RESISTANCE IN OHMS
STATOR STATOR ROTOR ROTOR
MAIN AUXILIARY
WINDING * WINDING
PRIMARY SECONDARY
∆
WINDING † WINDING †
CAPACITOR,
MFD
450 VOLT
0.71
0.54
2.17
1.38
0.54
0.61
2.07
2.29
(*) Connect T2 (green) and T3 (black). Measure resistance between T1 (red) and T4 (yellow).
(
∆
) Resistance between brown and white leads.
(†) Remove diodes to check resistance.
5
40
50
DIODES (2)
800 VOLT
70 Amp
70 Amp
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Generator Features
OIL ALERT SYSTEM (Model 4W315A only)
The oil alert system protects the engine from low oil damage. This system automatically shuts down the engine and prevents engine restarting if the oil pressure falls too low.
If this system shuts down the engine, the engine will not start until you add oil. The oil alert lamp is near engine starter switch (see Figure 2). Add oil to engine (see
Engine Oil, page 7).
See engine owner’s manual for more information.
120 ONLY
FULL POWER
SELECTOR
120/240V
0
100 200
300
A C VOLTS
OIL
120 ONLY
FULL POWER
SELECTOR
120/240V
0
100 200
300
A C VOLTS
OUTPUT VOLTAGE OUTPUT VOLTAGE
120 VOLT ONLY
POSITION
Figure 3 - Full Power Selector Switch
120/240 VOLT
POSITION
CHARGE
OFF
OIL
ALERT
LAMP
IMPORTANT: DO NOT MOVE THE FULL POWER
SELECTOR SWITCH WHILE POWERING ELECTRI-
CAL ITEMS. UNPLUG ALL ITEMS BEFORE MOVING
SWITCH. FAILURE TO DO SO CAN DAMAGE
SWITCH.
BATTERY
DISCHARGE
LAMP
Figure 2 - Battery Discharge Lamp and Oil Alert
Lamp Location
VOLTMETER
The voltmeter is on the control panel. The voltmeter shows the generator output voltage (see Figure 4).
120 VOLT ONLY full power switch position: The voltmeter will show about 120V under load.
120/240 VOLT full power switch position: The voltmeter will show about 240V under load.
BATTERY DISCHARGE LAMP (Model 4W315A only)
The battery discharge lamp (see Figure 2, above) will light if battery charger is not operating while engine is running. If this happens, the battery will not charge and will eventually run down. Have battery charging circuit repaired by authorized service person.
0
100 200
300
A C VOLTS
FULL POWER SELECTOR SWITCH
The full power selector switch is on the control panel.
The switch has two positions: 120 VOLT ONLY, and
120/240 VOLT.
120 VOLT ONLY: This position sends full power to the
120V receptacles only. 240V power is not available.
Use this position when full power is needed for 120V items only.
120/240 VOLT: This position sends full power to the
120/240V receptacle. It also powers the 120V twist-lock receptacle at half wattage capacity.
6
Figure 4 - Voltmeter
ELECTRIC START (Model 4W315A only)
This model has an electric starter. A battery is not supplied with generator. You must provide a 12-volt, 45amp-hour battery. For more battery information, see
Battery, page 8.
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Generator Features (Cont’d)
RECEPTACLE CIRCUIT BREAKER
The circuit breakers protect the receptacles and alternator. Overloading generator will trip circuit breaker. A short circuit in item being powered will also trip breaker.
If this occurs, unplug electrical load from receptacle. Let circuit breaker cool down. Push circuit breaker button to reset.
Electric motors need higher starting current. They require up to three-times their rated wattage to start. The starting current needed may be too high. This can cause nuisance circuit breaker tripping. To help prevent this, start electric motors first. Connect additional items to generator after starting motors. If this continues to happen, reduce the total generator load.
20
NORMAL
20
TRIPPED
Figure 5 - Receptacle Circuit Breaker Button
SPARK ARRESTER
We ship a spark arrester with this generator. You must install spark arrester to muffler (see Figure 6).
A spark arrester is required if using generator in a national forest and other designated state and local areas. Check local codes.
The spark arrester needs periodic cleaning. A dirty spark arrester reduces engine output and increases fuel consumption. It also makes starting difficult. See engine owner’s manual for cleaning instructions.
Pre-Installation
ENGINE OIL
We ship the generator without oil in the engine crankcase. You must add oil before starting engine. See below for specific oil type.
CHECKING OIL LEVEL AND ADDING OIL
Follow steps below to check oil level. Make sure engine is level and stopped.
1. Remove either dipstick (see Figure 7). Wipe dipstick clean.
2. Insert dipstick into oil filler neck. Do not screw it in.
Oil level should be at top of filler neck. Oil should cover most of dipstick.
3. If level is low, fill to top of oil filler neck (see Figure 7).
Use proper lube oil to preserve your engine.
Nothing affects the performance and durability of your engine more than the lube oil you use. If inferior oil is used, or if your engine oil is not changed regularly, the risk of piston seizure, piston ring sticking, and accelerated wear of the cylinder liner, bearing and other moving components increases significantly. Your engine life may be seriously shortened. Yanmar recommends CC/
CD oil of API engine service classification, stock number 4ZF20.
Always use oil with the right viscosity for the ambient temperature in which your engine is being operated. Use the chart on this page when choosing your engine oil.
Lube Oil Capacity
3ZC06A
4W315A
1.16 qt.
1.74 qt.
20W 40
10W 30
MUFFLER
CLAMP
SPARK
AR-
RESTER
Figure 6 - Installing Spark Arrester
7
FORM 5S3125
03430
OIL LEVEL
AT TOP OF
FILLER
NECK
MODELS 3ZC06A AND 4W315A
Pre-Installation
NOTE: If oil level is too low, oil alert system will shutdown engine and prevent engine from restarting (Model
4W315A only).
Installation
BATTERY (MODEL 4W315A ONLY)
WARNING
BATTERY GIVES OFF EXPLOSIVE GASES. KEEP
SPARKS, FLAMES, AND CIGARETTES AWAY. DO
NOT REMOVE OR INSTALL BATTERY CABLES
WHEN ENGINE IS CRANKING OR RUNNING. ONLY
SERVICE OR USE BATTERY IN A WELL-VENTED
AREA.
DIPSTICK
Figure 7 - Checking Oil Level
OIL
FUEL
WARNING
DIESEL FUEL PRESENTS A HAZARD OF FIRE. DIE-
SEL FUEL IS FLAMMABLE.
• KEEP FUEL OUT OF CHILDREN’S REACH.
• REFUEL GENERATOR IN A WELL-VENTED AREA.
DO NOT FILL FUEL TANK IN THE DARK. DO NOT
REFUEL WHILE ENGINE IS RUNNING. UNHOOK
ALL ELECTRICAL LOADS AND SHUT OFF EN-
GINE BEFORE REFUELING.
• DO NOT OVERFILL FUEL TANK. ALWAYS AL-
LOW ROOM FOR FUEL TO EXPAND. IF YOU
OVERFILL TANK, FUEL CAN OVERFLOW ONTO
HOT ENGINE. THIS CAN CAUSE FIRE. AFTER
REFUELING, TIGHTLY CLOSE FUEL TANK CAP.
• DO NOT SPILL FUEL. IF FUEL SPILLS, MAKE
SURE AREA IS DRY BEFORE STARTING EN-
GINE.
• NEVER SMOKE IN REFUELING AREA. NEVER
ALLOW OPEN FLAMES OR SPARKS IN AREA.
• STORE FUEL IN APPROVED CONTAINER.
STORE FUEL IN A WELL-VENTED AREA FREE OF
OPEN FLAMES OR SPARKS.
Use clean, fresh, diesel fuel. Use diesel fuel with cetane rating of 45 or higher. Avoid getting dirt, dust, or water in fuel tank.
See engine owner’s manual for more information.
8
WARNING
BATTERY CONTAINS SULFURIC ACID. CONTACT
WITH SKIN OR EYES MAY CAUSE SEVERE
BURNS. DO NOT TILT GENERATOR WITH BAT-
TERY INSTALLED. TILTING COULD CAUSE BAT-
TERY ACID TO SPILL. WEAR PROTECTIVE
CLOTHING AND FACE SHIELD WHEN SERVICING.
KEEP OUT OF CHILDREN’S REACH.
• IF BATTERY ACID GETS ON YOUR SKIN,
WASH WITH WATER.
• IF BATTERY ACID GETS IN YOUR EYES,
FLUSH WITH WATER AT LEAST 15 MINUTES.
CALL A DOCTOR AT ONCE.
BATTERY ACID IS POISONOUS.
• IF SWALLOWED, DRINK LARGE AMOUNTS
OF WATER OR MILK. FOLLOW WITH MILK
OF MAGNESIA OR VEGETABLE OIL. CALL A
DOCTOR AT ONCE.
CAUTION
If you remove battery, insulate the red, positive (+) battery cable terminal. Insulate with electrical tape.
Exposed terminal may spark when generator runs.
IMPORTANT: MAKE SURE BATTERY CONNEC-
TIONS ARE THE CORRECT POLARITY. THIS GEN-
ERATOR USES NEGATIVE GROUND, 12-VOLT DC
STARTING SYSTEM.
This generator has an electric starter. A battery is not supplied with generator. You must provide a 12-volt, 45amp-hour battery. The positive and negative battery cables are supplied with generator. You must install these cables before mounting battery.
Always wear safety glasses when working with battery.
Make sure battery terminals are clean. Make sure cable connections are tight.
Always shut down engine before removing or attaching battery cables. Always remove the negative (–) cable first. Always attach negative (–) cable last.
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
STARTER
SOLENOID
Installation (Continued)
INSTALLING BATTERY CABLES TO ENGINE
1. Attach the red, positive (+) battery cable to the starter solenoid on engine (see Figure 8).
2. Attach the black, negative (–) battery cable to the engine block. Use the bolt, nut, and two washers provided with the battery cables. Attach cable as shown in Figure 9.
MOUNTING BATTERY TO GENERATOR
1. Secure battery to generator by battery hold-down system. This system consists of the battery mounting bracket, hook bolts, and nuts (see Figure 10).
2. Locate the red, positive (+) battery cable from starter solenoid. Connect it to the positive (+) battery terminal (see Figure 11).
3. Locate the black, negative (–) battery cable attached to engine block. Connect it to the negative (–
) battery terminal (see Figure 11).
4. Check battery before starting engine. Make sure fluid levels are full. Make sure battery is charged.
See engine owner’s manual for more information.
NUT
BATTERY
MOUNTING
BRACKET
BATTERY
RED, POSITIVE (+)
BATTERY CABLE
Figure 8 - Connecting Red, Positive (+) Battery Cable to Starter Solenoid on Engine
HOOK
BOLT
Figure 10 - Battery Hold-Down
System
RED, POSITIVE
CABLE FROM
STARTER SOLE-
NOID
BLACK, NEGATIVE (–)
BATTERY CABLE
Figure 9 - Connecting Black, Negative (–) Battery
Cable to Engine Block
BLACK, NEGATIVE
CABLE FROM
ENGINE BLOCK
9
Figure 11 - Connecting Positive and Negative Cables to Battery
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
GENERATOR GROUNDING
WARNING
Installation (Continued)
YOU MUST PROPERLY EARTH-GROUND GENERA-
TOR BEFORE STARTING. THIS WILL HELP GUARD
AGAINST DEADLY ELECTRIC SHOCK. ONLY USE
GROUNDED PLUGS WITH GENERATOR. ONLY USE
GROUNDED EXTENSION CORDS. ONLY USE
THREE-WIRE OR DOUBLE-INSULATED POWER
TOOLS.
Grounding generator helps prevent electric shock from a ground fault condition. Locate ground lug on end of generator housing (see Figure 12). Attach a #10 stranded-copper ground wire to ground lug. Drive grounding point into ground. Grounding point can be a stake, grounding rod, or pipe. Grounding point should be copper or brass. Attach ground wire to grounding point. You must supply the ground wire and grounding point. They do not come with generator. Follow the
National Electrical Code and all state and local codes.
Consult your power company or a licensed electrician.
EXTENSION CORDS
Only use grounded extension cords. Be sure to use extension cord with proper wire gauge size. See chart below.
Recommended Minimum Wire
Gauges (AWG) for Extension Cords
AMPERE AWG FOR LENGTH OF CORD (FT.)
LOAD 50' 100' 150'
6
8
10
12
4
5
2
3
14
16
20
16
16
16
14
18
18
16
16
14
12
10
16
14
14
14
18
18
16
16
12
12
10
14
12
12
12
18
18
16
16
10
10
8
STANDBY INSTALLATION TO HOME OR BUILDING
WARNING
WARNING
FOR A GROUNDING POINT, DO NOT USE METAL
PIPE BEING USED TO CARRY COMBUSTIBLE MA-
TERIALS OR GASES.
ALTERNATOR
HAVE STANDBY INSTALLATION PERFORMED BY
A SKILLED, LICENSED ELECTRICIAN. DO NOT LET
ANYONE ELSE WIRE INTO A UTILITY CIRCUIT.
PERSONAL INJURY, EQUIPMENT DAMAGE, OR
DAMAGE TO HOME COULD OCCUR.
GROUND LUG
COPPER OR BRASS
GROUNDING POINT
Figure 12 - Grounding Generator
GROUND WIRE
IMPORTANT:THIS GENERATOR WILL NOT POWER
YOUR ENTIRE HOME. MOST HOME UTILITY ELEC-
TRIC SERVICE IS MORE THAN 60 AMPS. THIS WILL
EXCEED GENERATOR OUTPUT. ONLY POWER
NEEDED ITEMS DURING A POWER OUTAGE.
MAKE SURE TOTAL WATTAGE OF ELECTRICAL
LOAD DOES NOT EXCEED RATED WATTAGE OF
GENERATOR.
You can use this generator as a standby power source.
During a power outage, the generator will power selected items in a building. Have generator and additional wiring installed by a skilled, licensed electrician.
This is not a do-it-yourself job. Follow all local codes.
GROUND FAULT PROTECTION
A Ground Fault Circuit Interrupter (GFCI) helps guard against electric shock. On construction sites, you must use a GFCI. OSHA and the National Electric Code requires this.
You must provide a separate, portable GFCI device which can be purchased at any electrical supply house.
Check the Yellow Pages for the nearest supply house.
WARNING
THE ELECTRICIAN MUST INSTALL A DOUBLE-
THROW TRANSFER SWITCH. THIS ISOLATES EX-
ISTING ELECTRICAL CIRCUITS FROM THE UTIL-
ITY POWER LINE. IF NOT ISOLATED, GENERATOR
OUTPUT WILL BACK-FEED INTO UTILITY POWER
LINE. THIS MAY ELECTROCUTE A POWER COM-
PANY LINE REPAIR PERSON.
10
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Operation
DETERMINING ELECTRICAL LOAD FOR
GENERATOR
You must decide what electrical load your generator can power. Do this before using generator. Use the following four-step method. It will help you select a load that is not too large. Make sure total wattage of all electrical loads does not exceed 3000 watts (Model
3ZC06A) or 5000 watts (Model 4W315A). Electric motors present a special problem when figuring load. Read
Step 3 carefully.
1. Make two lists of items you want powered by generator. List all motors and motor-powered appliances in one. List all lights, small appliances, etc. in the other. For standby service to home or building, only include items you must power.
age to run as to start. These items include saws, drills, hair dryers, and food mixers. See Chart 1 for typical appliance wattage examples.
4. Add watts and starting watts (maximum VA) of all items. This total must not be larger than 3000 watts
(Model 3ZC06A) or 5000 watts (Model 4W315A). It is a good idea to have up to 25% extra capacity for future needs or extra equipment.
Chart 1
2. Enter running watts of each item except motors. The light bulb or appliance nameplate lists its wattage.
Remember, 1KW = 1000 watts. NOTE: The nameplate may not list wattage. It may only list volts and amps. The formula for finding wattage is: Volts x
Amps = Watts. For example: An appliance nameplate states 3 amps at 120 volts. 3 amps x 120 volts
= 360 watts.
3. Electric motors present a special problem. They require up to 3-times their rated wattage to start.
Chart 2, below, shows starting watts (maximum voltamperes [VA]) for different size motors. For example: an electric motor nameplate states 5 amps at
120 volts. 5 amps x 120 volts = 600 watts running.
Multiply this figure by 3. This will show the starting watts (maximum VA) needed. 600 watts x 3 = 1800 watts (VA) to start. When figuring the generator load for motors, you must use the starting watts (maximum VA) figure. Do not use the running watts figure.
NOTE: Some motors require nearly the same watt-
Chart 2
TYPICAL ELECTRIC APPLIANCE WATTAGES
EQUIPMENT
STARTING
RUNNING WATTS
WATTS (MAX.VA)
Light bulb (100W)
Radio
Fan
Television
100
150
200
400
600 Furnace fan—1/3 HP with blower
Vacuum cleaner
Sump pump—1/3 HP
Refrigerator/freezer
6" Circular saw
Floodlight
1/2" Drill
Toaster/coffeemaker
Skillet
14" Chain saw
Water well pump—1/2 HP
600
700
800
800
1000
1000
1200
1200
1200
1000
Hot plate/range (per burner) 1500
Water heater (storage-type) 5000
100
150
600
400
1800
750
2100
2400
1000
1000
1250
1200
1200
1500
3000
1500
5000
MOTOR
HP
RATING
1/8
1/4
1/3
1/2
3/4
1
1 1/2
2
APPROXIMATE
RUNNING
WATTS
275
400
450
600
850
1000
1600
2000
APPROXIMATE STARTING WATTS* (MAX. VA)
UNIVERSAL
MOTORS
(SMALL APPLIANCE)
400
500
600
750
1000
1250
1750
2350
REPULSION
INDUCTION
MOTORS
600
850
975
1300
1900
2300
3200
3900
CAPACITOR
MOTORS
850
1050
1350
1800
2600
3000
4200
†
SPLIT
PHASE
MOTORS
†
†
†
†
1200
1700
1950
2600
(*) Always use starting watts (maximum VA), not running watts, when figuring correct electrical load.
(†) Motors of higher horsepower are not generally used.
11
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
VENTILATION
!
DANGER
Operation (Continued)
NOTE: We supply the engine owner’s manual with generator. Refer to that manual for questions concerning engine operation.
USE ONLY IN WELL-VENTED AREAS. MAKE SURE
AREA HAS PLENTY OF FREE-MOVING, FRESH,
OUTSIDE AIR. NEVER RUN GENERATOR IN AN
ENCLOSED OR CONFINED AREA. NEVER RUN GEN-
ERATOR INSIDE OCCUPIED BUILDING. ENGINE
EXHAUST CONTAINS POISONOUS CARBON MON-
OXIDE GAS. OVEREXPOSURE WILL CAUSE LOSS
OF CONSCIOUSNESS AND WILL LEAD TO DEATH.
This generator needs cooling air to run properly. Never block free-flowing, cooling air to generator. Overheating will occur without cooling air. This will damage the generator. Keep generator at least three feet away from any object.
USING RECEPTACLE
NOTE: Do not exceed amperage rating of receptacles.
Exceeding rating will trip receptacle circuit breaker.
Use receptacles properly. Improper use could damage generator. Use only grounded extension cords. Power only grounded or double-insulated items. Do not overload receptacles. This generator has the following receptacles (see Figure 13):
• 120V, 15-amp duplex receptacle
• 120V, 30-amp twist-lock receptacle
• 120/240V, 20-amp twist-lock receptacle
120V, 15-AMP DUPLEX
DUST, DIRT, RAIN, AND SNOW
WARNING
120/240V, 20-AMP
TWIST-LOCK
DO NOT USE GENERATOR OUTDOORS IN RAIN OR
SNOW. DO NOT USE GENERATOR NEAR STAND-
ING WATER OR SNOW. DO NOT USE IF GENERA-
TOR IS WET OR DAMP. OPERATING GENERATOR
IN THESE CONDITIONS INCREASES THE RISK OF
ELECTROCUTION. SEVERE INJURY OR DEATH
CAN OCCUR.
Do not use generator in extremely dusty or dirty conditions. This will severely affect its life. Keep generator clean. Do not allow dust, dirt, rain, or snow to collect on it. Protect generator from outdoor elements.
HIGH AND LOW TEMPERATURE OPERATION
Air temperature affects generator output. Output drops
1% for each 10
°
temperature rise above 60
°
F. Low temperatures may make the engine hard to start. See engine owner’s manual for more information.
120V, 30-AMP
TWIST-LOCK
120 Volt
30 Amp
120 VO
LTS
120 O
NLY
FULL P
OW
ER
0
SELEC
100
TO
R
200
AC VOLTS
30
120/240V
OU
TPUT
VO
LTA
GE
Figure 13 - Receptacle Locations
120/24
0 V
OLTS
POWER CORD AND PLUG REQUIREMENTS
120V, 30-amp twist-lock receptacle
• NEMA L5-30P plug
• Three-wire, 30-amp cord
120/240V, 20-amp twist-lock receptacle
• NEMA L14-20P (20-amp) plug
• Four-wire, 20-amp cord
GENERAL INFORMATION
This generator is not large enough to power your entire home. Do not connect generator to any existing electrical circuits. Plug items directly into generator receptacles. Do not exceed amperage rating of receptacles.
Only use grounded cords.
Ground
(Green)
Y
(Hot)
X
(Hot)
Y X
G
120/240 Volt
20 Amp
L5-30P
Plug
Neutral
120V 120V WARNING
NEVER CONNECT GENERATOR TO ANY EXISTING
ELECTRICAL CIRCUITS. THE GENERATOR OUT-
PUT WILL BACK-FEED INTO THE UTILITY POWER
LINE. THIS MAY ELECTROCUTE A POWER COM-
PANY LINE REPAIR PERSON. ALSO, IF GENERA-
TOR IS POWERING ELECTRICAL CIRCUITS, THE
CHANCE OF AN ELECTRICAL FIRE EXISTS.
Ground
(Green)
X
(Hot) w
Y X
G
Ground
Y
(Hot)
W
(Neutral)
Figure 14 - Cord and Plug Configurations
L14-20P
Plug
12
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Operation (Continued)
PRESTART
Operate generator on a firm, dry, and clean surface. The surface must be level. Protect generator from heavy dust, sand, dirt, rain, or snow. Do not locate generator near standing water and snow. Make sure area is well-vented.
FUEL VALVE LEVER
S
O
WARNING
Figure 15 - Fuel Valve Lever In “O” (open) Position
ONLY RESPONSIBLE ADULTS SHOULD USE GEN-
ERATOR. NEVER LET ANYONE OPERATE GEN-
ERATOR WITHOUT PROPER INSTRUCTIONS.
Make sure oil level is full before starting. See Engine Oil, page 7.
3. For Model 3ZC06A: Push engine run/stop knob down to the RUN position (see Figure 16). Turn engine run/stop knob clockwise to tighten. Tighten firmly.
NOTE: If oil level is too low, oil alert system will keep engine from starting (Model 4W315A only — see Oil Alert
System, page 6).
Before starting engine, disconnect all electric loads from generator.
You may need to bleed fuel line to remove trapped air
• if starting engine for first time
• if starting engine after allowing generator to run out of fuel
Follow the directions below to bleed fuel line.
Bleeding Fuel Line
1. Loosen fuel line clamp and remove fuel line from engine. Place open end of fuel line over a clean container to catch any fuel spilled in step 3, below.
2. Move fuel valve lever to the “O” (open) position (see
Figure 15).
3. Allow air to bleed from line. When fuel exits fuel line in a steady stream, reattach fuel line to engine.
4. Add spilled fuel back into fuel tank.
CAUTION
You must fully move engine run/stop knob to the
RUN position to run engine at 3600 RPM. Do not run engine at lower speeds. Running engine at lower speeds will damage generator and powered items.
For Model 4W315A: Move engine run lever to the
RUN position (see Figure 16).
MODEL
3ZC06A
STO
P
RUN
Start
ENGINE
RUN/STOP
KNOB
RUN
STOP
ENGINE
RUN LEVER
MODEL
4W315A
STARTING
CAUTION
You must always run the engine at full speed. Do not run engine at lower speeds. At full speed, the engine runs at 3600 RPM under load. The engine must maintain 3600 RPM for generator to create correct voltage. Running engine at lower speeds will damage generator and powered items.
IMPORTANT: NEVER START GENERATOR WITH
ELECTRICAL LOADS CONNECTED. START ENGINE
BEFORE ADDING ELECTRICAL LOADS.
1. Make sure fuel tank is full. See Fuel, page 8 for fuel information.
2. Move fuel valve lever to the “O” (open) position (see
Figure 15).
13
Figure 16 - Engine Run/Stop Knob (Model 3ZC06A) and Engine Run Lever (Model 4W315A)
4. Start the engine.
A. Electric Starter (Model 4W315A only)
I.
Push decompression lever all the way down
(see Figure 17). Decompression lever will stay in this position until you turn starting key.
II. Turn the starting key clockwise to the START position (see Figure 18). Hold it there until engine starts.
III. When engine starts, release key.
IMPORTANT: DO NOT USE ELECTRIC STARTER
MORE THAN TEN SECONDS. STARTER MOTOR
DAMAGE MAY OCCUR. IF ENGINE FAILS TO
START, RELEASE THE KEY AND WAIT 15 SEC-
ONDS. AFTER 15 SECONDS, TRY STARTING
AGAIN.
Continued
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
DECOMPRESSION
LEVER
OIL
OIL
Operation (Continued)
B. Recoil Starter (Models 3ZC06A and 4W315A)
I.
Slowly pull starter rope until you feel strong resistance. Gently return starter rope to engine.
II. Push decompression lever all the way down
(see Figure 20). Decompression lever will stay in this position until you pull starter rope.
DECOMPRESSION
LEVER Figure 17 - Decompression Lever
STARTING
KEY
OIL
CHARGE
OFF
OIL
OIL
Figure 18 - Starting Key (Model 4W315A only)
In cold weather, your engine may be hard to start. If so, remove the rubber plug on the rocker arm cover
(see Figure 19). Add 2 cc of engine oil in hole.
Replace rubber plug. Repeat starting procedure.
WARNING
NEVER USE GASOLINE, PAINT THINNER, OR ANY
OTHER FLAMMABLE LIQUID AS A STARTING AID.
AN EXPLOSION MAY OCCUR.
CAUTION
Keep rubber plug on rocker arm in place when not adding oil for starting. Rain, dirt, and other debris may enter the engine. This can damage the engine.
RUBBER
PLUG ENGINE
STARTING
OIL HOLE
OIL
OIL
Figure 19 - Rubber Plug On Rocker Arm Cover
Figure 20 - Decompression Lever
III. Firmly grasp starter grip with both hands. Remove slack from starter rope by lightly pulling starter grip.
IV. To start engine, pull starter rope briskly. You must pull the starter rope all the way out. If not, the engine will not start.
IMPORTANT: DO NOT LET STARTER GRIP SNAP
BACK AGAINST ENGINE. RETURN IT GENTLY.
THIS WILL PREVENT DAMAGE TO STARTER.
In cold weather, your engine may be hard to start. If so, remove the rubber plug on the rocker arm cover
(see Figure 19). Add 2 cc of engine oil in hole.
Replace rubber plug. Repeat starting procedure.
WARNING
NEVER USE GASOLINE, PAINT THINNER, OR ANY
OTHER FLAMMABLE LIQUID AS A STARTING AID.
AN EXPLOSION MAY OCCUR.
14
CAUTION
Keep rubber plug on rocker arm in place when not adding oil for starting. Rain, dirt, and other debris may enter the engine. This can damage the engine.
If engine does not start, repeat steps under B. Recoil
Starter on this page.
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Operation (Continued)
HIGH ALTITUDE OPERATION
This generator will not perform well at high altitudes without proper adjustment. Contact a Yanmar dealer for adjustment information.
MODEL
3ZC06A
STOP
RUN
Start
ADDING ELECTRICAL LOADS
IMPORTANT: DO NOT OVERLOAD GENERATOR.
MAKE SURE TOTAL WATTAGE OF ALL ELECTRI-
CAL LOADS DOES NOT EXCEED RATED WATTAGE
OF GENERATOR. OVERLOADING MAY SHORTEN
GENERATOR LIFE. IT COULD ALSO CAUSE INTER-
NAL DAMAGE TO GENERATOR. OVERLOADING
WILL TRIP CIRCUIT BREAKER.
IMPORTANT: KEEP FULL POWER SELECTOR
SWITCH IN THE 120 VOLT ONLY POSITION IF ONLY
POWERING 120V ITEMS. ONLY MOVE SWITCH TO
120/240 VOLT POSITION IF POWERING 240V ITEMS.
1. Check items to be powered. Their nameplate lists their wattage ratings.
NOTE: The wattage ratings for some electrical motors are misleading. They may require up to 3-times their rated wattage to start. You must figure total electrical load wattage. Make sure total wattage of all electrical loads does not exceed rated wattage of generator. See Determining Electrical Load For
Generator, page 11.
2. Start engine. Let engine reach full speed.
3. Connect electrical loads one at a time. If the load consists of electric motors, start them first. Always start the largest first. Start each motor individually.
RUN
STOP
ENGINE RUN/
STOPKNOB IN
STOP POSITION
MODEL
4W315A
ENGINE STOP
LEVER
Figure 21 - Releasing Engine Run/Stop Knob (Model
3ZC06A) and Pushing Down Engine Stop
Lever (Model 4W315A)
DISCONNECTING ELECTRIC LOADS
Remove electrical loads one at a time. Remove voltage sensitive items first. Voltage sensitive items include
TVs, VCRs, and other home electronic items.
STOPPING ENGINE
Follow the steps below to stop engine.
1. Remove all electrical loads from generator (see
Disconnecting Electrical Loads on this page). Remove electrical loads one at a time.
2. Let engine run for two or three minutes after removing electrical loads. This lets engine cool slightly.
3. For Model 3ZC06A: Turn engine run/stop knob counterclockwise to release. The run/stop knob will return to the STOP position automatically (see Figure 21).
For Model 4W315A: Push down engine stop lever
(see Figure 21). This releases engine run lever and stops engine. Do not stop engine with the decompression lever.
15
4. For Model 4W315A: Turn the starter key to the OFF position.
5. Turn fuel valve lever off. Do this by moving valve lever to the “S” position (see Figure 22).
6. Slowly pull starter rope until you feel strong resistance. Gently return starter rope to engine. This action closes the intake and exhaust valves. This prevents rust from forming while not using engine.
S
O
FUEL VALVE
LEVER
Figure 22 - Fuel Valve Lever In “S” Position
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Maintenance
WARNING
ONLY A QUALIFIED ELECTRICAL SERVICE PER-
SON SHOULD SERVICE AND REPAIR THE ALTER-
NATOR ON THIS GENERATOR. USE ONLY FAC-
TORY APPROVED REPLACEMENT PARTS.
CAUTION
You must always run the engine at full speed. Do not run engine at lower speeds. At full speed, the engine runs at 3600 RPM under load. The engine must maintain 3600 RPM for generator to create correct voltage. Running engine at lower speeds will damage generator and powered items.
CAUTION
• After the engine has been used, clean the engine immediately with a cloth to prevent corrosion and to remove sediment.
• Only use genuine Yanmar parts. The use of replacement parts which are not of equivalent quality may damage the engine.
Note: Items marked “•” should be serviced by an authorized Yanmar dealer, unless the owner has the proper tools and is mechanically proficient.
HOW TO CHANGE YOUR ENGINE OIL
Remove the oil filler cap. Remove the drain plug and drain the old oil while the engine is still warm. The plug is located on the bottom of the cylinder block. Tighten the drain plug and refill with the recommended oil. (See the section under “Preparations for starting” in the engine owner’s manual.)
CAUTION
Shut off generator before performing maintenance.
CLEANING THE OIL FILTER
Loosen the fixing bolt and then pull out the oil filter.
Cleaning time Every six months or 500 hours operation
IMPORTANT: KEEP GENERATOR LEVEL WHEN
SERVICING. NEVER TURN GENERATOR UPSIDE
DOWN OR STAND IT ON END TO SERVICE.
NOTE: We supply the engine owner’s manual with generator. Refer to that manual for questions concerning engine maintenance and repairs.
Non-engine parts require little maintenance. Keep generator clean. Use a damp cloth to clean outside surfaces. Never use water to clean generator. Water can cause damage to internal parts. Use vacuum to clean air inlet and outlet louvers of alternator.
CHANGING THE AIR CLEANER ELEMENT
Do not wash the air cleaner element with detergent because this is a wet type element.
Change Every six months or 500 hours operation (or earlier if dirty)
See the section for changing the air cleaner element under “Preparations for starting” in the engine owner’s manual.
ENGINE MAINTENANCE
Periodic checks and maintenance are very important for keeping the engine in good condition and durable.
The chart below indicates which checks to make and when to make them. The mark (•) indicates that special tools and skills are required.
Consult your Yanmar dealer.
CAUTION
Never run the engine without the air cleaner element or with a defective element.
Note: A clogged element hinders the flow of air to the combustion chamber. This reduces engine output, increases lube oil and fuel oil consumption and makes starting difficult. Make sure you clean your element regularly.
WARNING
SHUT OFF THE ENGINE BEFORE PERFORMING
ANY MAINTENANCE. IF THE ENGINE MUST BE
RUN, MAKE SURE THE AREA IS WELL VENTILATED.
THE EXHAUST CONTAINS POISONOUS CARBON
MONOXIDE GAS.
16
CLEANING AND REPLACING THE FUEL FILTER
The fuel filter also has to be cleaned regularly to insure maximum engine output.
Clean Every six months or 500 hours operation
Replace Every year or 1000 hours operation
1. Drain the fuel oil from the fuel tank.
2. loosen the nuts of the fuel cock and pull out the filter from the F.O. tank filler port. Wash the filter thoroughly with diesel fuel oil.
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Maintenance (Cont’d)
CLEANING THE SPARK ARRESTER
WARNING
IF THE ENGINE HAS BEEN RUNNING, THE MUF-
FLER AND THE SPARK ARRESTER WILL BE VERY
HOT. ALLOW THESE TO COOL BEFORE PROCEED-
ING.
Remove the lock nut, end cap and diffuser discs and clean off the carbon deposits.
Clean Every three months or 100 hours operation
(or earlier if dirty)
WARNING
DO NOT PERFORM THE INJECTION NOZZLE TEST
NEAR AN OPEN FIRE OR ANY OTHER KIND OF
FIRE. THE FUEL SPRAY MAY IGNITE. DO NOT EX-
POSE BARE SKIN TO THE FUEL SPRAY. THE FUEL
MAY PENETRATE THE SKIN AND CAUSE INJURY
TO THE BODY. ALWAYS KEEP YOUR BODY AWAY
FROM THE NOZZLE.
CHECKING AND REPLENISHING BATTERY FLUID
AND CHARGING THE BATTERY (MODEL 4W315A
ONLY)
The L-engine uses the 12V battery. Batter fluid will be lost through continuous charging and discharging.
Figure 23 - Spark Arrester
MUFFLER
CLAMP
SPARK
AR-
RESTER
END CAP
DIFFUSER
DISCS
LOCK
NUT
WARNING
• The battery electrolyte contains sulfuric acid.
Protect your eyes, skin, and clothing. In case of contact, flush thoroughly with water and get prompt medical attention, especially if your eyes are affected.
• Batteries generate hydrogen gas, which can be highly explosive. Do not smoke or allow flames or sparks near the battery, especially during charging.
Note: Much more fluid is lost during summer than in winter.
Before starting, check for physical damage to the battery and also the electrolyte levels, and replenish with distilled water up to the upper mark if necessary. When actual damage is discovered, replace the battery.
Battery fluid check Monthly
CAUTION
• A clogged spark arrester hinders the flow of exhaust gas. This reduces engine output, increases fuel consumption and makes starting difficult.
• Make sure you clean your spark arrester regularly.
Note: Spark arrester is an optional part.
TIGHTEN CYLINDER HEAD BOLTS
Tightening the cylinder head bolts requires a special tool. Don’t try it yourself. Consult your Yanmar dealer.
CHECKING THE INJECTION NOZZLE, INJECTION
PUMP, ETC.
• Adjusting the valve head clearance for the intake and exhaust valves.
• Lapping of intake and exhaust valves.
• Replacing piston ring.
All these require special tools and skills, so consult your
Yanmar dealer.
WARNING
• Before charging, remove the cap from each cell of the battery.
• Charge the battery in a place where there is plenty of ventilation.
• Discontinue charging if the electrolyte temperature exceeds 45
°
C (117
°
F).
17
CAUTION
• Do not charge the battery with the battery cable still connected. The diodes will be damaged by the high voltage.
• Connect the (+) lead of the charger to the (+) terminal of the battery, and the (–) lead to the (–) terminal. Reversed polarity will damage the charger rectifier or the battery.
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
ENGINE MAINTENANCE SCHEDULE
REGULAR SERVICE
PERIOD DAILY
ITEM
1 Check and replenish fuel oil
2 Drain fuel from F.O. tank
3 Check and replenish lube oil
4 Check for oil leakage
5 Check and tighten engine parts
CHECK
❍
❍
❍
❍
FIRST EVERY EVERY
MONTH 3 MONTHS 6 MONTHS
OR
20 HRS.
OR OR
EVERY
YEAR
OR
100 HRS.
500 HRS.
1000 HRS.
Monthly
●
Tighten head bolts
6 Change lube oil
❍
1st time
❍
2nd and thereafter
7 Clean oil filter
8
9
Air cleaner element replacement
Clean fuel filter
(Service more frequently when used in dusty areas)
❍
(Replace if necessary)
❍
(Replace)
❍ ●
(Change)
10 Clean spark arrester
11 Check fuel injection pump
12 Check fuel injection nozzle
13 Check fuel piping
14 Adjust valve head clearance for intake and exhaust valves
15 Lap intake and exhaust valves
16 Replace piston rings
17 Check battery fluid
●
20 Hrs
1st time
❍
(Monthly)
●
●
(Replace if necessary)
●
●
●
Storage
WARNING
WARNING
Cover and store generator in a clean, dry place. Do not expose generator to extreme high or low temperatures during storage.
REMOVE ALL FUEL FROM FUEL TANK BEFORE
STORING GENERATOR. STORE FUEL IN AP-
PROVED CONTAINER. STORE FUEL IN A WELL-
VENTED AREA FREE OF OPEN FLAMES OR
SPARKS.
THE MUFFLER BECOMES VERY HOT DURING OP-
ERATION. THE MUFFLER REMAINS HOT FOR A
WHILE AFTER SHUTDOWN. LET ENGINE COOL
BEFORE STORING.
IMPORTANT: KEEP GENERATOR LEVEL WHILE IN
STORAGE. NEVER STORE GENERATOR UPSIDE
DOWN OR STANDING ON END.
18
ENGINE STORAGE
If storing your engine for long periods, make the following preparations.
1. Operate the engine for about 3 minutes and then stop.
2. Stop the engine. Drain the engine lube oil while the engine is still warm and fill with new oil.
3. Remove the rubber plug on the rocker arm cover and add about 2cc of lube oil. Put the plug back in place (see Figure 24, page 19).
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
RUBBER
PLUG
OIL OIL
Storage (Cont’d)
“START” position, turn engine for 2 to 3 seconds.
(Do not start the engine.)
ENGINE
STARTING
OIL HOLE
DECOMPRESSION
LEVER
OIL
OIL
Figure 24 - Rubber Plug On Rocker Arm Cover
4. Recoil starting
Push the decompression lever down (non-compression position, see Figure 25) and hold it while you pull the recoil starter 2 or 3 times. (Do not start the engine.)
Electric starting
Push the decompression lever down (non-compression position, see Figure 25) and hold it. With key in
Figure 25 - Decompression Lever
5. Pull the decompression lever up. Pull the recoil starter slowly. Stop when it feels tight. This closes the intake and exhaust valves (in compression position) and helps prevent rust from forming.
6. Wipe the oil and dirt from the engine and store in a dry place.
WARNING
Troubleshooting
Note: Engine troubleshooting information is taken from engine owner’s manual. See engine owner’s manual.
ONLY A QUALIFIED ELECTRICAL SERVICE PER-
SON SHOULD SERVICE AND REPAIR GENERA-
TOR. USE ONLY FACTORY APPROVED REPLACE-
MENT PARTS.
SYMPTOM
No voltage when starting generator with no electrical load
POSSIBLE CAUSE(S)
1. Defective capacitor
2. Winding short circuit or loose connections
3. Defective rotor diode
4. Loss of residual magnetism
CORRECTIVE ACTION
1.
Replace capacitor
2.
Check resistance of coils (see Electrical Component Specifications, page
5)
3.
Replace both diodes on rotor
4.
Apply 12-volt battery to capacitor terminals for 2-3 seconds
Voltage is less than normal voltage with no electrical load
1. Engine speed too low
2. Clogged spark arrester
3. Defective rotor diode
4. Partial short circuit in winding
5. Defective capacitor
1.
Set engine speed to 3720 RPM (62
Hz) with no load
2.
Clean arrester. See engine owner’s manual
3.
Replace both diodes on rotor
4.
Check resistance of coils (see Electrical Component Specifications, page
5)
5.
Replace capacitor Voltmeter reading more than
10% high with no electrical load
Voltmeter reading correct with no electrical load, but more than 10% low when electrical load is added
1. Engine speed too high
1. Defective rotor diode
2. Electrical load too high
3. Engine not running properly
1.
Set engine speed to 3720 RPM (62
Hz) with no load
1.
Replace both diodes on rotor
2.
Do not overload generator
3.
Contact an authorized engine service center
Continued
19
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
SYMPTOM
Engine will not start.
ENGINE TROUBLESHOOTING
POSSIBLE CAUSE(S)
1. Fuel level too low
2. Fuel cock not in “OPEN” position
3. Diesel fuel not reaching the fuel injection pump or nozzle
4. Speed control lever not in
“START” position
5. Lube oil level not correct
CORRECTIVE ACTION
1.
Add fuel to fuel tank
2.
Move fuel cock to “OPEN” position
3.
See qualified Yanmar service person
4.
Move speed control lever to
“START” position
5.
Add lube oil to engine. See Engine
Oil, page 7
6.
See qualified Yanmar service person 6. Fuel injection nozzle not working properly
7. Recoil starter not pulled quickly and firmly enough
8. Spark arrester clogged by carbon
9. Battery not discharging
7.
When starting engine with recoil starter, pull starter rope quickly and firmly. You must pull starter rope all the way out
8.
Clean spark arrester. See Cleaning the Spark Arrester, page 17
9.
Loose battery connections, corrosion on batter terminals, or battery dead
WARNING
KEEP AWAY FROM THE INJECTION NOZZLE WHEN
PERFORMING THE INJECTION SPRAY TEST.
Note: Always pull the recoil starter quickly and firmly.
(See the section, “How to start you engine” in engine owner’s manual.)
UNCLEAR POINTS OR PROBLEMS
If any instructions are unclear or if problems occur during the operation of your engine, complete the following form and consult your Yanmar dealer.
(Make a note of your dealer’s name and telephone number on the inside cover of this manual.)
1. Diesel engine model and serial number.
Engine model: ___________________________
Engine serial number: _____________________
2. Condition when the problem occurred
At what stage of operation: _________________
At what rpm: ____________________________
3. Total operation hours since purchase
Approximately _______ hours
4. Other details of conditions at the time the problem occurred. _______________________________
______________________________________
______________________________________
______________________________________
20
YANMAR DIESEL ENGINE
REPLACEMENT FILTERS
HP OIL FILTER AIR FILTER FUEL FILTER
6 114250-35070 114250-12580 114350-55120
9 114250-35070 114650-12590 114650-55120
ORDER REPLACEMENT PARTS
BY CALLING TOLL FREE
1-800-323-0620
Please provide the following information:
• Model Number
• Serial Number (if any)
• Part Description and Number as shown in Parts List
Address parts correspondence to:
Parts Company of America
1657 Shermer Road
Northbrook, IL 60062-5362
SERVICING THE ENGINE
For Yanmar engine replacement parts, contact Parts
Company of America at 1-800-323-0620.
Yanmar engine servicing should be handled by your nearest authorized Yanmar engine service firm. Contact Yanmar at 1-714-630-9415 for nearest authorized Yanmar engine service firm.
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Product Identification
Control
Panel
120 Volt
Receptacles
Full Power
Selector
Switch
E
F
VO
LTS
120
LY
FU
LL P
OW
ER
SE
LEC
TO
R
0 100
200
OU
AC
V
OLT
S
TP
UT
LTA
GE
30
0V
120
/24
0 V
OLT
S
Voltmeter
120/240 Volt
Receptacle
Circuit
Breaker
Decompression
Lever
Roll Cage
F
E
Engine
Run Lever
Engine
Stop Lever
ST
OP
RU
N
Oil Alert Lamp
(4W315A only)
Battery Discharge
Lamp (4W315A only)
Electric Start Switch
(4W315A only)
Alternator
Fuel Gage
Fuel Valve
(under fuel tank)
Fuel Cap
Fuel Tank (Different size and location, Model
3ZC06A)
Starter Grip
Engine
Figure 26 - Portable Generator
21
Ground
Lug
Spark
Arrester
Oil Dipstick
Muffler
Battery
(Model 4W315A only - not included, must be purchased separately)
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
Wiring Diagrams
Green/Yellow
120/240V 20A
Receptacle
Red
White
Red
Green
120V, 15A
Receptacle
White
120V, 30A
Receptacle
T1
Circuit
Breaker
25A
Black
T2
Full Pwr
Selector
Switch
Red
Red
Circuit
Breaker
25A
T4
Yellow
Black
T3
Black
White
Black
Black
Red
Green
Yellow Voltmeter
Red
*
Red
Black
White
Green
* Remove Jumper Bar, This Side Only
Capacitor
White
White
T1 T4 T3 T2
Main
Windings
Auxiliary
Phase
Green
T2 T1
Red
Black
T3
Yellow
T4
Diode
Rotor
Diode
Stator
White
Brown
Black
Circuit
Breaker
20A
Black
Circuit
Breaker
20A
Stator
T1 T2 T3 T4
L1
220/240V
110/120V 110/120V
L2
Figure 27 - Alternator Wiring Diagram
Charge
Coil
Green/White
Green/White
Charge
Regulator
Green
Yellow
White
Fuse
White
2
3
4
1
Green
Green
Yellow
White
Red
Key
Switch
Charge
Lamp
White
Starter
Motor/
Solenoid
Red
Shutdown
Solenoid
Black
Green/White
Bridge
Red + -
Black
Yellow
Red
Battery
Red
30
86
Relay
87
85 White
P
Oil Pressure Switch
Black
Green/White
Red White
Low Oil
Pressure Lamp
Figure 28 - Engine Wiring Diagram (Model 4W315A only)
22
Black
FORM 5S3125
03430
1
MODELS 3ZC06A AND 4W315A
5
14
11
5
4
12
10
13
13
10
2
8
3
7
6
9
5
4
10
9
ORDER REPLACEMENT PARTS BY CALLING TOLL FREE
1-800-323-0620
Address parts correspondence to: Please provide the following information:
• Model Number
• Serial Number (if any)
• Part Description and Number as shown in Parts List
Parts Company of America
1657 Shermer Road
Northbrook, IL 60062-5362
Replacement Parts List for Fuel Tank and Roll Cage - Model 3ZC06A
5
6
7
8
REF.
NO.
DESCRIPTION
1
2
Roll cage
Spreader
3
4
5/16-18 x 1 1/2" Bolt
5/16" Washer
5/16-18 Nut
1/2-20 x 1" Screw
1/2" Lockwasher
Shock mounts
(
∆
) Not shown.
PART
NUMBER QTY.
100477-01AA 1
100475-01AA 1
04110002
WP-5C
2
5
NTC-5C
26302006
WLI-8
17529000
7
2
2
2
REF.
NO.
DESCRIPTION
PART
NUMBER QTY.
9 5/16-18 x 3/4" Bolt
10 5/16" Washer
11 Shock mount
12 Ground strap
13 1/4-20 x 1/2" Screw
26007004
WLE-5
26020000
14138000
M10908-74
14 #8-18 x 1/2" Sems screw 100410-01
∆
Safety information decal 099947-01
∆
Operation decal 100473-01
1
1
2
5
3
4
1
1
23
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
1
F
E
5
2
3
4
20
9
15
9
8
6
14
19
19
14
7
11
10
18
12
13
16
9
8
9 8
14
13
17
ORDER REPLACEMENT PARTS BY CALLING TOLL FREE
1-800-323-0620
Address parts correspondence to: Please provide the following information:
• Model Number
• Serial Number (if any)
• Part Description and Number as shown in Parts List
Parts Company of America
1657 Shermer Road
Northbrook, IL 60062-5362
Replacement Parts List for Fuel Tank and Roll Cage - Model 4W315A
5
6
7
8
9
REF.
NO.
DESCRIPTION
1
2
Fuel tank assembly
1/4-20 x 3/4" Screw
3
4
1/4" Washer
1/4-20 Nut
Roll cage
Spreader
5/16-18 x 1 1/2" Bolt
5/16" Washer
5/16-18 Nut
10 1/2-20 x 1" Screw
11 1/2" Lockwasher
12 Shock mounts
(
∆
) Not shown.
PART
NUMBER QTY.
099935-01
HC4-6C
1
4
WP-4C
NTC-4C
4
4
099942-01AA 1
099944-01AA 1
04110002 2
WP-5C
NTC-5C
5
9
26302006
WLI-8
17529000
2
2
2
REF.
NO.
DESCRIPTION
PART
NUMBER QTY.
13
14
17
5/16-18 x 3/4" Bolt
5/16" Washer
15 Shock mount
16 Battery bracket
Hook bolt
26007004
WLE-5
26020000 1
099774-01AA 1
099750-01 2
5
3
1
2
18 Ground strap
19 1/4-20 x 1/2" Screw
14138000
M10908-74
20 #8-18 x 1/2" Sems screw 100410-01
∆
Safety information decal 099947-01
∆
Operation decal 099948-01
∆
Battery cable (positive) 099873-01
∆
Battery cable (negative) 099873-02
1
1
4
1
1
24
FORM 5S3125
03430
MODELS 3ZC06A AND 4W315A
ORDER REPLACEMENT PARTS BY CALLING TOLL FREE
1-800-323-0620
Address parts correspondence to: Please provide the following information:
• Model Number
• Serial Number (if any)
• Part Description and Number as shown in Parts List
Parts Company of America
1657 Shermer Road
Northbrook, IL 60062-5362
14
9
18
19
20
8
7
5
6
9
10
12
13
15
16
17
22
21
23
24
1
2
18
19
20
21
22
14
15
16
17
23
24
25
10
11
12
13
8
9
6
7
REF.
NO.
∆
1
4
5
2
3
(
∆
) Not shown.
4
25
11
3
Replacement Parts List for Alternator Assembly
DESCRIPTION
Alternator assembly complete
End cover
M5 x 13 Screw
Bushing
Terminal block (4-block)
Terminal block (2-block)
Ground lug
#10-16 x 3/8" Screw
Stator bolt
5/16" Lockwasher
Bearing housing
Capacitor
Stator
Fan bracket
M8 x 20 Screw
Rotor nut
Washer
Draw bolt
Bearing
Diode
Rotor
Fan
Engine flange
3/8-16 x 5/8" Bolt
3/8" Lockwasher
Foam pad
PART NUMBER
3ZC064 4W315A
099723-01
099844-01
099701-01
099760-01
099863-01
099863-02
17587000
M11084-26
099847-01
WLE-5
099843-01
27004002S
099840-02S
27003002
27003015
27001010
27003013
099842-01
27003003
27003012S
099839-02S
27003008
27003007
26322006
WLE-6
099892-01
099723-02
099844-01
099701-01
099760-01
099863-01
099863-02
17587000
M11084-26
099847-02
WLE-5
099843-01
27005003S
099840-03S
27003002
27003015
27001010
27003013
099842-02
27003003
27003012S
099839-03
27003008
27003007
26322006
WLE-6
099892-01
25
QTY.
1
1
1
1
2
1
1
4
4
1
4
1
1
1
1
1
4
4
1
1
1
1
6
1
1
1
FORM 5S3125
03430
2
2
MODELS 3ZC06A AND 4W315A
11
1
5
3
7
RE
SE
T
RE
SE
T
120
V
OL
TS
4
6
120
O
NLY
FU
LL P
OW
ER
SE
LE
CT
OR
120
/24
0V
OU
TP
UT
V
OL
TA
GE
120
/24
0 V
OL
TS
6
12 12
RE
SE
T
RE
SE
T 0
100
200
AC VOLTS
30
10
8
9
ORDER REPLACEMENT PARTS BY CALLING TOLL FREE
1-800-323-0620
Address parts correspondence to: Please provide the following information:
• Model Number
• Serial Number (if any)
• Part Description and Number as shown in Parts List
Replacement Parts List for Control Panel
Parts Company of America
1657 Shermer Road
Northbrook, IL 60062-5362
REF.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
∆
DESCRIPTION
Control panel
20 Amp Circuit breaker *
120V, 30A Twist-lock
receptacle *
120V, 15A Duplex receptacle *
Full power selector switch *
20 Amp Circuit breaker *
25 Amp Circuit breaker *
120/240V, 20A Twist-lock
receptacle *
Voltmeter
Bushing
#8-18 x 1/2" Sems screw
Control box
U-nut
Panel schematic decal
(
∆
) Not shown.
(*) Includes fastening hardware.
26
PART NUMBER
3ZC06A 4W315A
099775-10
22616009
099775-05
22616009
099833-01
099836-01
099956-01
22616009
—
099833-01
099836-01
099956-01
—
22616011
099834-01 099834-01
099748-01
099760-01
099748-01
099760-01
100410-01 100410-01
099744-01AA 099744-01AA
22261000 22261000
099872-01 099872-01
QTY.
1
2
1
2
2
1
1
1
4
1
1
1
8
1
FORM 5S3125
03430
19
MODELS 3ZC06A AND 4W315A
18
17
16
5
20
4
13
15
13
14
12
11
6
10
22
9
23
3
ORDER REPLACEMENT PARTS BY CALLING TOLL FREE
1-800-323-0620
Address parts correspondence to: Please provide the following information:
• Model Number
• Serial Number (if any)
• Part Description and Number as shown in Parts List
Parts Company of America
1657 Shermer Road
Northbrook, IL 60062-5362
7
8
4
2
1
3
6
13
21
3
Replacement Parts List for Switch Control Box (Model 4W315A only)
REF
NO.
DESCRIPTION
PART
NUMBER QTY.
1 Switch control box
2 Low oil light
100131-01
22721000
3 Key switch, lamp, and harness assembly 099936-01
4 #8-18x 1/2" Sems screw 100410-01
5 Strain relief bushing
6 #8 Speed nut
7 Relay
8 #10-32 Hex locknut
9 Adhesive-backed PVC foam
099760-01
22261000
26498000
NTF-3C
10
11
Connector cover
Connector
12 #6-32 x 1/2" Hex tapping screw
RN12000100 1
24478004 1
24477004 1
M10908-3
1
1
1
1
4
1
4
1
1
27
REF
NO.
DESCRIPTION
PART
NUMBER QTY.
13 #6 Internal-tooth lockwasher
14 Full bridge
15 #10-32x 1/2" Hex
16
17 tapping screw
Grommet
#10 Flat washer
WLI-1C
26509000
M10908-27
15020000
WP-3C
18 #10-32 x 3/4" Hex-head screw
19 Solenoid
26499000
26490000
20 M4 x 8 Hex-head screw 26494000
21 M3 x 8 Hex-head screw 26492000
22 Switch control box bracket 100132-01
6
1
1
1
1
2
4
1
1
1
23 Female T-tap connector 100085-01 1
FORM 5S3125
03430
DATE
MODELS 3ZC06A AND 4W315A
Service Record
MAINTENANCE PERFORMED COMPONENTS REQUIRED
28
099946-
01
REV. C
12/92
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Table of contents
- 1 Description
- 1 Unpacking
- 2 General Safety Information
- 4 Warranty
- 5 Specifications
- 6 Generator Features
- 6 Oil Alert System
- 6 Battery Discharge Lamp
- 6 Full Power Selector Switch
- 6 Voltmeter
- 6 Electric Start
- 7 Receptacle Circuit Breaker
- 7 Spark Arrester
- 7 Pre-Installation
- 7 Engine Oil
- 7 Checking Oil Level and Adding Oil
- 8 Installation
- 8 Battery
- 10 Generator Grounding
- 10 Ground Fault Protection
- 10 Extension Cords
- 10 Standby Installation To Home or Building
- 11 Operation
- 11 Determining Electrical Load For Generator
- 12 Ventilation
- 12 Dust, Dirt, Rain, and Snow
- 12 High and Low Temperature Operation
- 12 General Information
- 12 Using Receptacle
- 12 Power Cord and Plug Requirements
- 13 Prestart
- 13 Starting
- 15 High Altitude Operation
- 15 Adding Electrical Loads
- 15 Disconnecting Electrical Loads
- 15 Stopping Engine
- 16 Maintenance
- 18 Storage
- 19 Troubleshooting
- 21 Product Identification
- 22 Wiring Diagrams
- 23 Replacement Parts Lists