Dayton 4W315A Operating instructions

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Dayton 4W315A Operating instructions | Manualzz

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

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120

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100

AC V

200

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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

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SE LE

OR 12 0/2

40

100

200

AC

VO

OU

TP UT

VO

LTS

LTA

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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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