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Multiquip TLG-12SPX Portable Generator User Manual

Contents

1. 11 15 Trailer Wiring Diagram 16 Operation and Safety Decals 17 18 TLG 12SPX Specifications 19 POWER TLG 12SPX AC GENERATOR General Information 20 Major Components 21 Dimensions EE 22 Control Panel Descriptions 24 25 Engine Operating Output Terminal Panel Descriptions 26 27 Output Terminal Information 28 29 STANTON 30 31 Pre M 32 35 Load 36 Generator Start up Procedure 37 Generator Shutdown Procedure 38 acest dost psec REUS 40 41 Engine Wiring Diagram 42 Generator Wiring Diagram 43 Engine Troubleshooting 44 45 Generator Engine Troubleshooting 46 Explanation of Codes in Remarks Column 48 Suggested Spare Parts 49 Generator Assembly 50 51 Control Panel Assembly 52 55 Engine amp Radiator Assembly 56 57 Battery
2. 32 0192200435 DRAIN HOSE 33 0605515009 5 34 0802081403 RESERVE TANK 35 0802081104 CAP RESERVE TANK 36 8702082004 BRACKET RESERVE TANK 37 011606025 HEX HEAD 38 0017106016 HEX HEAD BOLT 39 0199900320 HOSE 40 7222016304 HOSE 41 060551594 HOSE BAND 42 060551526 HOSE BAND TLG 12SPX ENGINE AND RADIATOR ASSY QTY REMARKS SUZU 3LB1 inis 1 REPLACES 0602041210 1 ISUZU 8970687980 2 REPLACES 7605419004 aid 1 0B89010000 1 R912010 00 pn 2 6659210381 1 REPLACES 8941521130 aba 2 REPLACES 0602040501 6 REPLACES 0017108020 vs 1 255 EN 2 OOO 1 1 REPLACES 1502025103 2 2 18 4 1 1 uen 4 12 1 1 2 SW22 1 ve 007 2 1 1 T 3 212 T 1 2 244 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 57 TLG 12SPX BATTERY ASSY BATTERY ASSY PAGE 58 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 BATTERY ASSY 1 0167306531 2 7612251004 BATTERY SHEET 3 8522250004 BATTERY BAND 4 7612252004 BATTERY BO
3. jg 5 5107226 8525960003 ACOUSTIC SHEET 1 37 8525162004 ROOF COVER 1 38 011008020 HEX HEAD 1 im REPLACES 0017108020 39 1625165103 FILLER COVER 1 40 8525172003 SIDE PANEL 1 8525971004 ACOUSTIC SHEET 1 41 8525172103 DUCT 1 8525971004 ACOUSTIC SHEET 1 49 0207006000 NUT 5 43 0017108040 HEAD BOLT 6 44 8525171203 SIDE DOOR 1 8525970103 ACOUSTIC SHEET 1 8525171103 SIDE DOOR 1 8525970003 ACOUSTIC SHEET 1 46 8525173004 WINDOW PLATE 1 47 0027103010 SCREW 4 0207003000 NUT 4 48 0825007362 DOOR HANDLE 1 49 0021805016 MACHINE SCREW 4 50 M9110100304 HINGE Lr REPLACES 0845047204 0845045004 WASHER 2 51 43110100204 REPLACES 0845047104 0845045004 SET WASHER 2 52 011008020 HEAD BOLT REPLACES 0017108020 53 0845031304 4 54 9511200003 EMBLEM 1 55 0021106020 MACHINE SCREW 2 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 67 TLG 12SPX RUBBER SEAL ASSY RUBBER SEAL ASSY PAGE 68 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 RUBBER SEAL ASSY NO 56 0227600590 57 0227600835 58 0229400560 59 0229400550 60 0229400840 61 0229400220 62 0229400590 63 0229200210 64 0229200615 65 0226900570 66 0229200680 TLG 12SPX PARTS AND OPERATION MANUAL STD
4. 58 59 Muffler Assembly inizia bu 60 61 Fuel Tank Assembly i is 62 63 Enclosure Assembly 64 67 Rubber Seal Assembly 68 69 Name Plate And Decals 70 71 ISUZU 3LB1 ENGINE Cylinder Head Cover Assembly 72 73 Cylinder Head Assembly 74 75 Cylinder Block Assembly 76 77 Oil amp Level Gauge Assembly 78 79 Camshaft amp Valve Assembly 80 81 Crankshaft Piston amp Flywheel Assembly 82 83 Timing Gear amp Flywheel Housing Assembly 84 85 Inlet Manifold Assembly 86 87 Exhaust Manifold Assembly 88 89 Ventilation 90 91 Water Pump amp Corrosion Resistor Assembly 92 93 Thermostat and Housing Assembly 94 95 Fan amp Fan Belt Assembly 96 97 Fuel Injection Assembly 98 99 Fuel Filter amp Bracket Assembly 100 101 Fuel Pump amp Pipe Assembly 102 103 Oil Cooler amp Oil Filter Assembly 104 105 Pump amp
5. REV 4 03 08 05 TLG 12SPX CONTROL PANEL The definitions below describe the controls and functions of the TLG 12SPX Control Panel Figure 6 1 Circuit Breaker This three pole 65 amp breaker is provided to protect the UNV voltage output terminals from overload 2 Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 1 Hz 3 AC Voltmeter Indicates the single phase output voltage present at the UNV terminals 4 AC Ammeter Indicates the amount of current the load is drawing from the generator 5 Indicator Lamp This engine waring indicator will notify possible damage before it occurs A Pressure the light will go on during initial start but will go out once the engine is warm If the oil pressure light comes on during operation this may indicate critical low oil level B Charge Light This light indicates the battery is not charging Water Temperature Light This light indicates the coolant temperature is abnormally high D Engine Protection This will shut down the engine if there is an abnormal event that may have occurred This prevents damage to the engine 6 Starter Switch This is to turn on and off the engine with a key 7 Hour Meter This indicates the amount of time the generator has been running 8 Voltage Regulator Control Allows manual adjustment of the generator output voltage TLG 12SPX PARTS AND OPERATION MANUAL STD
6. REV 44 03 08 05 PAGE 25 TLG 12SPX ENGINE OPERATING OUTPUT TERMINAL PANEL THROTTLE HANDLE GFCI RECEPTACLE 5 NEMA 5 6369 RECEPTACLE Figure 7 Engine Control Output Terminal Panel PAGE 26 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX ENGINE OPERATING OUTPUTTERMINAL PANEL definitions below describe the controls and functions of the TLG 12SPX Engine Operating Output Terminal Panel Figure 7 1 Control Switch This switch is used to change the idle of the engine from low to high on some models 2 Throttle Handle This handle is used for initial start up of the engine 3 Receptacle This is 20 120V parallel slot with a U ground Pedo 4 NEMA receptacle These output receptacles are locking type Both are 30 amps one is 120V the other 240V Y rms 5 NEMA 5 6369 receptacle This locking AX type output receptacle is 50 amp 120 240 5 6369 RECEPTACLE TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 27 TLG 12SPX OUTPUT TERMINAL PANEL TLG 12SPX FAMILIARIZATION The Output Terminal panel is provided with the following One GFCI 120 Volt Receptacle 20 Amp single phase Ground Terminal for GFCI receptacle Main Circuit Breaker 50 amps GFCI Circuit Breaker 20 amps NEMA L530R Output Receptacle NEMA L630R Output Receptacle NEMA 56369 Output Recep
7. See Engine NSS Electrical Assy See Cylinder Head Cover PAGE 92 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 WATER PUMP AND CORROSION RESISTOR ASSY WATER PUMP AND CORROSION RESISTOR ASSY QTY REMARKS 2 8971632590 WATER PUMP ASSY REPLACES 8970698821 24 0280808450 BOLT 8 45 FLANGE 1 36 0280908600 BOLT M8X60 FLANGE 2 0280808400 BOLT M8X40 FLANGE 2 40 0911502080 NUT 2 42 9041108400 STUD 1 58 5096050050 HEATER PLUG 1 144 1096050500 THERMOSTAT PLUG 1 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 44 03 08 05 PAGE 93 ISUZU 3LB1 THERMOSTAT AND HOUSING ASSY THERMOSTAT AND HOUSING ASSY 0 9 64 PAGE 94 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 O See Water Pump 55 ISUZU 31 1 THERMOSTAT AND HOUSING ASSY THERMOSTAT AND HOUSING ASSY NO 1 49 50 64 PART NO PART NAME QTY REMARKS 8943255131 THERMOSTAT 1992 1996 8971606540 THERMOSTAT 1997 8970958411 WATER OUTLET PIPE 1 0280808200 BOLT 2 8943259561 GASKET 1 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 44 03 08 05 PAGE 95 15020 3LB1 AND BELT 557 FAN AND FAN BELT ASSY 96
8. The basic controls and indicators for the TLG 12SPX generator are addressed on the following pages Mechanical Governor System The mechanical governor system control the RPM of the engine When the engine demands increase or decrease the mechanical governor system regulates the frequency variation to 1 5 The electronic governor option in creases frequency variation to 25 PAGE 20 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX MAJOR COMPONENTS DESCRIPTION GENERATOR ASSY FUEL TANK ASSY ENGINE AND RADIATOR ASSY ENCLOSURE ASSY MUFFLER ASSY BATTERY ASSY CONTROL PANEL ASSY joo Po gt Figure 4 Major Components TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 21 TLG 12SPX DIMENSIONS SIDE AND FRONT Top View 430 mm 16 92 in 850 mm 33 46 in 690 27 16 in Figure 5 Dimensions PAGE 22 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 23 TLG 12SPX CONTROL PANEL no 1 6 STARTER SMITCH 8 VOLTAGE REGULATOR Figure 6 Control Panel PAGE 24 TLG 12SPX PARTS AND OPERATION MANUAL STD
9. 150 150 180 200 GAL HYDRAULIC SURGE 11160LBS 5000 LB FLAT PAD TRLR 220XF DCA 220 250 GAL HYDRAULIC SURGE 14000LBS 222 83 5000 LB FLAT PAD TRLR 300XF DCA 300 250 GAL HYDRAULIC SURGE 18000LBS 238 83 5000 LB FLAT PAD TRLR 400XF DCA 400 350 GAL ELECTRIC 18000LBS 238 83 5000 LB FLAT PAD TRLR 600XF DCA 600 800 550 GAL AIR 30000LBS 384 96 5000 LB FLAT PAD TRLR 800SX DCA 600 800 550 GAL AIR 30000LBS 384 5000 LB FLAT PAD PAGE 12 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX TRAILER SPECIFICATIONS Table 1 Specifications Con t MODEL COUPLER TIRES WHEELS AXLE HUBS SUSPENSION ELECTRICAL TRLR 10W 2 BALL CLASS 175 13 13 4 50 2200 2 2 5 LUG 3 LEAF 4 WIRE LOOM W 2 ADJUSTABLE 4 POLE FLAT TRLR 10 2 BALL CLASS 175 13 13 X4 5 2200 2 2 5 LUG 3 LEAF 4 POLE FLAT 2 ADJUSTABLE TRLR 10XF 2 BALL CLASS 175 13 13 4 5 2200 2 2 5 LUG 3 LEAF 2 ADJUSTABLE TRLR 225W 2 BALL CLASS 175 13B 13 4 5 2200 2 2 5 LUG 2 ADJUSTABLE TRLR BLW 2 BALL CLASS 175 13 13 4 5 2200 2 2 5 LUG 3 LEAF 400 2 ADJUSTABLE TRLR 50X 2 BALL CLASS B78 13LRC 13 4 50 3500 5 LUG 4 LEAF 2 3 8 TRLR 50XF 2 BALL CLASS B78 13LRC 13 X4 50 3500 5 LUG 4 LEAF 2 3 8 TRLR 70W 2 BALL CLASS 205 14C 14 X5 3500 5 LUG 5 LEAF 3 ADJUSTABLE BIAS 4 3 TRLR 70X 2 BALL CLASS 205 14C 14 X5 3500lbs 5 LUG 5 LEAF 3 ADJUSTABLE BIAS 4 3 TRLR 70XF 2 BALL CLASS 205 14C
10. COPYRIGHT 2001 MU PARTS AND OPERATION MANUAL MQ POWER TLG 12SPX WHISPER WATT AG GENERATOR Standard Revision 4 03 08 05 S N 5107226 MULTIQUIP INC PARTS DEPARTMENT 18910 WILMINGTON AVE 800 427 1244 4 oe 90746 FAX VICE 672 7 4 4 2 SERVICE DEPARTMENT 800 835 2551 e 3927 FAX 310 638 8046 POWER E mail mq multiquip com www multiquip com AWARNING CALIFORNIA Proposition 65 Warnin Engine exhaust and some of its constituents are know to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 TLG 128PX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 5 HOW GET HELP PLEASE HAVE THE MODEL SERIAL NUMBER ON HAND WHEN CALLING PARTS DEPARTMENT 800 427 1244 or 310 537 3700 FAX 800 672 7877 or 310 637 3284 SERVICE DEPARTMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 WARRANTY DEPARTMENT 800 835 2551 or 310 537 3700 310 638 8046 MAIN 800 421 1244 or 310 537 3700 FAX 310 537 3927 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 3 TABLE OF CONTENTS Here s How To Get 3 Table Of Contents 4 Parts Ordering Procedures 5 Rules for Safe Operation 6 9 TOWING and Transportation 10 Trailer Safety
11. 8971263620 8971263630 8971263640 TLG 12SPX PARTS AND OPERATION PART NAME QTY REMARKS INJECTION PUMP ASSY 3 BOLT 6 CLIP 2 RUBBER HOSE 1 NOZZLE ASSY JE INCL ITEMS HOLDER ASSY B INCL ITEMS W NOZZLE 3 NUT 3 GASKET 3 SEAT 3 SPRING 3 SPACER 3 WASHER 3 GASKET 3 SHIELD 3 PIPE 1 FUEL PIPE 1 STM ecce dort por T 0 1 SHIM u pero T20 2 SHIM pa T 0 3 poro 0 4 0 5 SE pes 0 52 SAIM y apasha 0 54 SE 0 56 SHIM aaa asua hasa m 0 58 SHIM Len 0 6 NUT 3 NUT 6 NJ SAM 0 2 5 8970346152 IJ SHIM T 0 3 REPLACES 8970346162 pes 0 4 REPLACES 8970346172 INJ SEIM Th T 0 5 REPLACES 8970346182 NJ SHIM u aaa aaa pem T 0 6 REPLACES 8970346192 INJ SHIM 0 7 REPLACES 8970346202 INJ T 0 8 5 8970346212 INJ SHIM pm 1 0 REPLACES 897034622 SHIM Pete 1 2 REPLACES 8970346232 MANUAL STD REV 4 03 08 05 PAGE 99 ISUZU 3LB1 FUEL FILTER AND BRACKET ASSY FUEL FILTER ASSY PAGE 100 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 FUEL FILTER AND
12. REV 4 03 08 05 PAGE 69 ITE RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL TLG 12SPX RUBBER SEAL ASSY QTY PO PYM REMARKS TLG 12SPX DECALS DECAL ASSY 4 10 gen UB 4 ATT PAGE 70 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX DECALS DECAL ASSY NO PART NO ITEM QTY REMARKS 1 1 7440611013 DECAL OPERATING PROCEDURE 1 517428 2 1 7670623004 DECAL VOLTAGE REGULATOR 53737 2 2 0840624504 DECAL CIRCUIT BREAKER 5 3031 2 3 8520621104 DECAL STARTER SWITCH eer 94753 2 4 17670622004 DECAL SPEED CONTROL HANDLE 53822 2 5 8520620203 DECAL POWER OUTPUT 1 94754 2 6 7670624004 DECAL GROUND irit indere trii 53821 27 8700611904 DECAL DANGER 54985 3 1 1630610404 DECALS CAUTION a 1406 3 2 1920620904 DECAL DIESEL IE 51756 33 7810680104 DECAL FUEL DRAIN ssis 53060 3 4 8520635004 a aa 55068 3 5 8700615204 DECAL FUEL GAUGE 1 4 1 0800628504 DECAL pm 91123 4 2 1630645004 enn 514
13. generator is mounted on a trailer make sure trailer complies with all local and state safety transportation laws See page 10 for basic towing procedures Emergencies Always know the location of the nearest fire extinguisher and first aid kit Know the location of the nearest telephone Also know the phone numbers of the nearest ambulance doctor and fire department Maintenance Safety NEVER lubricate components or attempt service on a running machine Always allow the machine a proper amount of time to cool before servicing Keep the machinery in proper running condition Fix damage to the machine immediately and always replace broken parts Dispose of hazardous waste properly Examples of potentially hazardous waste are used motor oil coolant fuel and fuel filters DO NOT use plastic containers to dispose of hazardous waste DO NOT pour waste oil coolant or fuel directly onto the ground down a drain or into any water source TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 9 TLG 12SPX TOWING RULES FOR SAFE OPERATION Towing Safety Precautions CAUTION Check with your county or state safety towing regulations department before towing your generator To reduce the possibility of an accident while transporting the generator on public roads always make sure the trailer Figure 1 that supports the generator and the towing vehicle are in good ope
14. nuts and bolts which could have occurred in transit Circuit Breaker To protect the generator from an overload a 3 pole 65 amp circuit breaker is provided to protect the output terminals from overload Make sure to switch circuit breaker to the OFF position prior to starting the engine Extension Cable When electric power is to be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to minimum Use the Cable Selection Guide Table 6 as guide for selecting proper cable size NOTE ALWAYS consult with a licensed electrician for correct extension cord wire size Table 6 Cable Selection 60 Hz Single Phase Operation Load In Watts Load In Watts Watts Maximum Allowable Cable Length Current in Amperes At 120 At 240 AR 3 amp s oe oe CAUTION Equipment damage can result from low voltage ft ft 150 ft 100 ft PAGE 32 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX PRE SETUP Lubrication Oil Fill the engine with lubricating oil through the filler hole but do not overfill Make sure the generator
15. where a particular part is used Model Number Where indicated this shows that the corresponding partis utilized only with this specific model number or model number variant Items Found In the Items Number Column All parts with same symbol in the number column 07 belong to the same assembly or kit Note If more than one of the same reference number is listed the last one listed indicates newest or latest part available PAGE 48 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX SUGGESTED SPARE PARTS TLG 12SPX W ISUZU 3LB1 DIESEL ENGINE 1 TO 3 UNITS Qty PIN Description ferme 0601806537 CIRCUIT BREAKER 0601820663 AUTOMATIC VOLTAGE REGULATOR m 0601840073 RHEOSTAT VOLTAGE REGULATOR pm 0601840121 KNOB RHEOSTAT Tarana 8522015503 RADIATOR HOSE UPPER pem 8971076820 RADIATOR HOSE LOWER 8944567411 OIL FILTER 8970488490 FUEL FILTER m 0602046202 AIR ELEMENT 1824100990 UNIT OIL PRESSURE jp 8941268220 UNIT WATER PRESSURE 0208006120 FAN BELT Part number this Suggested Spare Parts list may supercede replace the P N shown in the text pages of this book TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 49 TLG 12SPX GENERATOR ASSY GENERATOR ASSY PAGE 50 TLG 12SPX PARTS AND OPERATION
16. 03 08 05 PAGE 37 TLG 12SPX SHUTDOWN PROCEDURE 5 The generator s frequency meter Figure 23 displays 8 Setthe circuit breaker to ON Observe the generator s the 60 cycle output frequency in HERTZ ammeter Figure 27 and verify it reads the anticipated amount of current with respect to the load The ammeter will only display a current reading if the load is in use Figure 23 Frequency Meter Hz Figure 27 Ammeter Load 6 The generator s voltage meter Figure 24 displays the 9 generator will run until manually stopped or an 120 VAC in VOLTS If the voltage is not within the abnormal condition occurs specified frequency tolerance use the voltage adjustment control knob Figure 25 to increase ENGINE SHUTDOWN decrease the desired voltage To shutdown the generator use the following procedure 1 Turn off all equipment attached to generator Switch the Circuit Breaker to OFF 2 Turn the throttle handle to the left and push in Figure 24 Voltage Meter Volts 3 i ius cool by running it for 3 5 minutes with no oad applied 4 Turn the key to STOP position and remove the key INCREASE DECREASE Figure 25 Voltage Adjust Control Knob 7 Theammeter Figure 26 will indicate zero amps with no load applied When a load is applied this meter will indicate the amount of current that the load is drawing from the generator s alternator Figure 26 Ammeter No Load PAGE 38 T
17. 4 03 08 05 TLG 12SPX MAINTENANCE INSPECTION MAINTENANCE 10 Hrs DAILY 250 Hrs 500 Hrs 1000 Hrs Check Engine Fluid Levels Check Air Cleaner Check Battery Acid Level Check Fan Belt Condition Check for Leaks Check for Loosening of Parts Check Water Separator Replace Engine Oil and Filter ENGINE Clean Air Filter Drain Bottom of Fuel Tank Clean Unit Inside and Outside X P EE EE 1 1060 X 1 Replace engine oil anf filter at 100 hours first time only Replace fuel filter at 250 Hours first time only TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 41 TLG 12SPX ENGINE WIRING DIAGRAM SOLENOID SOLENOID RELAY ECS ENGINE CONTROLLER CHARGING GENERATOR PICK UP GR WATER TEMP SENSOR d BR OIL PRESS SMTCH ost WATER TEMP SWITCH d oc MLFC38 TUE n15 Cn14 TW amp PUMP aot 214 2 YT 5 AA AA 6 MLEC38 LAMP UNIT BATTERY CONNECTOR View from inserting wire side GLOW PLUG Cn Cn10 Cnll Cn12 Cn13 14 Ens Cn16 WIRING COLOR CODE BR ACC R2 69 TERMINAL BOARD Tsymeorl coon OFF sack RED eR ON ue START KEY SWITCH DIAGRAM PAGE 42 SPX PARTS AN TLG 12SPX GENERATOR WI
18. Oil Strainer Assembly 106 107 Electrical Control Assembly 108 109 Starter Comp Assembly 110 111 Injection Pump Comp Assembly 112 115 Timing Chain X Case Assembly 116 119 Air Cleaner 120 121 Switch and Relay Assembly 122 123 Terms and Condition of Sale Parts 124 NOTE Specification and part number are subject to change without notice PAGE 4 TLG 128PX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PARTS ORDERING PROCEDURES Dealer account number Dealer name and address Shipping address if different than billing address Return fax number Applicable model number Quantity part number and description of each part Specify preferred method of shipment e UPS Ground UPS Second Day or Third UPS Next Day Federal Express Priority One please provide us with your Federal Express account number Airborne Express Truck or parcel post Normally shipped the same day the order is received if prior to 2 west coast time Earn Extra Discounts when you order by FAX All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts Number of line items ordered Additional Discount 1 9 item
19. a aaa REPLACES 8970718062 53 1097470020 GUIDE LEVER PIN 1 54 8971059100 TENSION LEVER 1 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 117 ISUZU 3LB1 TIMING CHAIN CASE 55 TIMING CHAIN CASE ASSY 24 8 25 22 0 21 21 e 4943 3108 29 7 Look BE 74 pa 66 63 s 6 C 63 R 28 i A Nn AN gt A See Camshaft 55 ar See Timing Gear Case Assy See Timing Gear Case Assy 46 0 71 PAGE 118 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 TIMING CHAIN CASE 55 TIMING CHAIN CASE ASSY NO PART NO PART NAME QTY REMARKS 55 8970346383 SHIFTER 56 9082136250 SHAFT 57 9091854040 58 8970624222 SNAP RING FLOATING LEVER a APR 1992 TO JUN 1996 1 1 1 1 8971485480 FLOATING LEVER JUL 1996 59 1096050500 PLUG 1 60 8971062050 lanse DEC 1993 TO APR 1995 8971062051 neset 1995 61 8970395841 SCREW 1 62 8970164410 SCREW 1 6 9091605040 IDLE WASHER 1 63B 9091607040 IDLE WASHER 1 64 9091854030 SNAP RING 1 65 8943176381 SCREW 2 66 9091505080 LOCK WASHER 1 67 9081604360 PIN 1 69 8970837140 SET SPRING 1 70 8970392644 COVER 1 71 5111290060 SEALING 1 72 9095612530 COVER 1 73 8970395461 SPRING 1 74 9091105080 NUT 1 75 8970388021 BUSHING 1 76 8944546150 CUP 1 78 897105
20. be sure to check the nameplate on the generator and equipment to insure the wattage amperage and frequency requirements are satisfactorily supplied by the generator for operating the equipment Generally the wattage listed on the nameplate of the equipment is its rated output Equipment may require 130 150 more wattage than the rating on the nameplate as the wattage is influenced by the efficiency power factor and starting system of the equipment NOTE If wattage is not given on the equipments name plate approximate wattage may be determined by voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE TLG 12SPX PARTS AND OPERATION MANUAL STD REV 44 03 08 05 PAGE 35 TLG 12SPX LOAD APPLICATION The power factor of this generator is 1 0 See Table 10 Before Starting below when connecting loads Generator and Control Panel 1 sure to disconnect the electrical load and switch Table 10 Power Factor By Load the circuit breaker to the OFF position prior to Type Of Load Power Factor starting the engine Single phase induction motors 0 4 0 75 2 Connect the negative battery cable BLACK to the heaters incandescent 1 0 negative post on the battery Figure 17 Fluorescent lamps mercury lamps Electronic devices communication equipment Common power tools NOTE If output KVA is not given on the equipment nameplate approxima
21. is level With the dipstick inserted all the way but without being screw into the filler hole verify that the oil level is maintained between the two notches Figure 14 on the dipstick See Table 7 for proper selection of engine oil UPPER LIMIT LOWER LIMIT Figure 14 Engine Dipstick When checking the engine be sure to check if the oil is clean and viscous If the oil is not clean drain the oil by removing the oil drain plug and refill with the specified amount of oil as outlined in the Isuzu Engine Owner s Manual Fuel Fill the fuel tank with clean and fresh diesel fuel DO NOT fill the tank beyond capacity Pay attention to the fuel tank capacity when replenishing fuel Refer to the fuel tank capacity listed on page 19 Specification Table 5 The fuel tank cap must be closed tightly after filling Handle fuel in a safety container If the container does not have spout use funnel Wipe up any spilled fuel immediately CAUTION Never fill the fuel tank while the engine is running or in the dark Diesel spillage on a hot engine can cause a fire or explosion If diesel spillage occurs wipe up the spilled diesel completely to prevent fire hazards Coolant Use only drinkable tap water If hard water or water with many impurities is used the inside of the engine and radiator may become coated with deposits and cooling efficiency will be reduced An anticorrosion additive added to th
22. office or service plant TABLE 17 GENERATOR TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION No Voltage Output AC Voltmeter defective Check output voltage using a voltmeter Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Low Voltage Output Is engine speed correct Turn engine throttle lever to High Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary High Voltage Output Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary Circuit Breaker Tripped Short Circuit in load Check load and repair Over current Confirm load requirements and reduce Defective circuit breaker Check and replace Over current Relay actuated Confirm load requirement and replace PAGE 46 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 NOTE PAGE TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 47 EXPLANATION OF CODE IN REMARKS COLUMN How to read the marks and remarks used in this parts book Items Found In the Remarks Column Serial Numbers Where indicated this indicates a serial number range inclusive
23. operation manual before attempting to connect a load to the generator Maximum Output The entire load connected to the UNV Lugs and both slots in the duplex receptacle must not exceed 13 kW in standby or 12 kW in prime output Maximum Amps The generator unit provides 50 amps of power Do not exceed the maximum amps Output Terminal Panel Available Voltages The TLG12SPX is a single phase generator only It is able to supply both 120 volt and 240 volt NOTE When using plural single phase voltages make sure to balance the load on each of the single phase legs PAGE 28 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX OUTPUTTERMINAL PANEL RECEPTACLE 15 308 L6 30R 5 6369 120V 20 120V 30A 240V 30A 120 240V 50A SERFIGURE B SEE FIGURE C Figure 10 TLG12SPX Output Terminal Panel 120 VAC 20 AMP GFCI 5 20R RECEPTACLES U1 G U2 N Figure 11 5 20R Receptacles Details 5 6369 V2 U1 V1 U2 G Figure 12 NEMA Receptacles Details TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 29 TLG 12SPX INSTALLATION Outdoor Installation Install the generator in a location where it will not be exposed to rain or sunshine Make sure the generator is on secure level ground so it cannot slide or shift around Also install the generator so the exhaust will not be discharged in the direction of nearby h
24. temperature Use the specified fuel or engine oil Fuel with low cetane number Use the specified fuel Fuel leak due to loose injection pipe retaining nut Tighten nut Incorrect injection timing Adjust Fuel cam shaft worn Replace Injection nozzle clogged Clean injection nozzle Injection pump malfunctioning Repair or replace Seizure of crankshaft camshaft piston cylinder liner or bearing Repair or replace Compression leak from cylinder Replace head gasket tighten cylinder head bolt glow plug and nozzle holder Improper valve timing Correct or replace timing gear Piston ring and liner worn Replace Excessive valve clearance Adjust Starter does not run Starter malfunctioning Repair or replace Wiring disconnected Connect wiring PAGE 44 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX TROUBLESHOOTING ENGINE TABLE 11 ENGINE TROUBLESHOOTING CONTINUED SYMPTOM POSSIBLE PROBLEM SOLUTION Engine revolution is not smooth Fuel filter clogged or dirty Clean or change Air cleaner clogged Clean or change Fuel leak due to loose injection pipe retaining nut Tighten nut Injection pump malfunctioning Repair or replace Incorrect nozzle opening pressure Adjust Injection nozzle stuck clogged Repair or repl
25. will improve gas milage Avoid sharp turns to prevent rolling Remove wheel stand when transporting DO NOT transport generator with fuel in tank CHOCKED BLOCKS PREVENT ROLLING SUPPORT BLOCKS PAGE 10 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX TRAILER SAFETY GUIDELINES CAUTION ALWAYS make sure the trailer is in good operating condition Check the tires for proper inflation and wear Also check the wheel lug nuts for proper tightness Explanation of Chart This section is intended to provide the user with trailer ser vice and maintenance information The service and mainte nance guidelines referenced in this section apply a wide range of trailers Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent dam age to the equipment and personal injury It is the purpose of this section to cover the major mainte nance components of the trailer The following trailer com ponents will be discussed in this section Brakes Tires m LugNutTorquing Suspension m Electrical Brake Troubleshooting Tables Use the following definitions with reading Table 1 1 Fuel Cell Provides adequate amount of fuel for the equipment in use Fuel cells must be empty when trans porting equipment Braking System System employed in stopping the trailer Typical braking systems are electric surge hy draul
26. 0000 REPLACES 7605419004 6803ZZ gt o lt Em lt cc H lt O gt lt a 0 2 lt gt cc e E lt 5 lt z lt gt lt e lt gt lt a o lt l N lt CONTROL PANEL ASSY TLG 12SPX CONTROL PANEL ASSY CONTROL PANEL ASSY NO ITEM QTY REMARKS 1 8521827203 CONTROL PANEL 1 2 0605010060 u mp B1075L 3 0027103010 5 B esu REPLACES 0021103010 4 0021806030 MACHINE SCREW 2 5 0601800408 5 220V 45 65Hz 6 0601805745 AC 50 75 7 0601800281 L ne SCF5A 0 150V 0 300V 8 0601840073 RHEOSTAT VOLTAGE REGULATOR RA20A2SE102BJ 2W 1K OHM 9 0601840121 1 10 0601806537 CIRCUIT BREAKER Ten SC50NS 50 11 0021004060 MACHINE SCREW 2 0040004000 LOCK WASHER 2 031104080 PLAIN WASHER REPLACES 0041204000 12 8970444180 STARTER 5 REPLACES 0602100009 8944024980 STARTER KEY REPLACES 060
27. 025 REPLACES 1552143160 REPLACES 0602023175 gt o 42 lt cc o lt LLI gt lt QO 0 ME lt gt ES lt gt 2 lt 2 lt a am 2 lt 72 gt lt a 72 T a ENCLOSURE ASSY ENCLOSURE ASSY PARTNO 1 8525110012 8525910003 2 8525110604 3 0017106016 4 85251 18003 8525911004 5 0017106016 6 8525114003 8525912004 7 8525115003 8525913004 8 0017106016 9 8525181103 8525980004 10 8525181203 8525980004 11 0017106016 12 8525120003 8525920003 13 0601850239 14 0601850253 15 8525125003 8525922003 16 0017106016 17 011008020 18 8525121102 8525921004 19 011008020 20 8522030003 21 0017106016 22 8525132113 8525132223 23 8525132013 8525132023 24 0012312030 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 65 ITEM BASE ACOUSTIC SHEET FLOOR PANEL HEX HEAD BOLT PANEL ACOUSTIC SHEET HEX HEAD BOLT DUCT ACOUSTIC SHEET BATTERY FRAME ACOUSTIC SHEET HEX HEAD BOLT SPLASHER PANEL ACOUSTIC SHEET SPLASHER PANEL ACOUSTIC SHEET HEX HEAD BOLT FRONT FRAME ACOUSTIC SHEET GROMMET GROMMET DUCT COVER ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLL FRONT FRAME ACOUSTIC SHEET HEX HEAD BOLT FAN
28. 03 4 3 1630647004 DECAL COOLANT DRAIN AER 51404 4 4 1630610504 DECAL CAUTION tears 51409 4 5 6360610304 DECAL WATER c 1880 4 6 1920621504 DECAL SUPPORT DR 52257 47 6390671104 DECAL IMPORTANT sidan bd LEA S2377 4 8 0840625902 DECAL n dades d acies 53057 4 59 8700611514 DECAL WARNING ssis S4926A 4 10 8700611804 DECAL WARNING 94984 4 11 8520632003 STRIPE 4 12 8520632604 STRIPE 4 13 8520632504 STRIPE 4 14 8520632704 STRIPE 4 15 8520632104 STRIPE 4 16 8520632304 STRIPE 4 17 8520632404 STRIPE 4 18 8520632204 STRIPE 4 19 0600501103 DECAL WARNING 4 20 0820650604 DECAL DANGER h h h TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 71 ISUZU 3LB1 CYLINDER HEAD COVER 55 CYLINDER HEAD COVER ASSY See Inlet Manifold Assy Camshaft and Valve Assy PAGE 72 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 CYLINDER HEAD COVER 55 CYLINDER HEAD COVER ASSY NO PART NAME QTY REMARKS 1 8970655484 CYLINDER HEAD COVER 1 4 8941332075 OIL FILLER INCL ITEMS W 5 8941236231 FILLER GASKET 1 28 0280806200 9 69 8970655472 GASKET 1 TLG 12SPX PARTS AN
29. 06642 0601806645 0601806644 0027105020 0601815759 0027105020 0602202501 8944299470 8944001061 0027105016 0601801123 0017106016 0601820663 0027105016 0601806640 TLG 12SPX CONTROL PANEL ASSY ITEM QTY REMARKS MACHINE SCREW 8 LT B REPLACES 0207004000 GROUNDTERMINAL 1 381 RESISTOR 1 FF20W30 OHM MACHINE SCREW 2 RECTIFIER RE EEE l nen S5VB60 MACHINE SCREW 1 RECTIFIER sansaq a naa Leisner S15VB60 MACHINE SCREW 1 FUSE BOX sasa FB6PS FUSE au aaa e d ruinis 5A dal grand 10 FUSE 3 MACHINE SCREW 2 TERMINAL BOARD dics KT206P MACHINE SCREW 2 CONTROLLER u L u u u u vs ISUZU 8970912900 RELAY ua aa 2 REPLACES 0602201206 RELAY GLOW PLUG REPLACES 0602201206 MACHINE SCREW 6 CURRENT TRANSFORMER 1 150 5 HEX HEAD BOLT 2 AUTOMATIC VOLTAGE REGULATOR 5201 MACHINE SCREW 4 eb MT erm 65A TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 55 TLG 12SPX ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY Fr Y P Y EE wal ses PAGE 56 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 E
30. 1 SE 1 SE 1 SHIM EG 1 Sj 1 SHIM 1 SN 1 SHIM 1 SE 1 SER 1 SEE 1 SE 1 SER 1 SENER 1 SEE 1 SHIM EE 1 QTY REMARKS APR 1992 TO FEB 1995 MAR 1995 ISUZU 3LB1 INJ PUMP COMP ASSY INJ PUMP COMP ASSY G 109 181 Co proppar Co PAGE 114 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 INJ PUMP COMP ASSY NJ PUMP COMP ASSY QTY REMARKS 8941289550 SHIM Mm 3 80 8941289560 3 85 8941289570 SHIM ees p 3 90 8941289580 uu ass asa Y ER 3 95 8941289590 SHIM asua sasatan pror 4 00 8941289600 SIM 4 05 8941289610 SHIM a asas T 4 10 193 8970833500 SNAP RING 3 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 115 ISUZU 3LB1 TIMING CHAIN CASE ASSY TIMING CHAIN CASE ASSY 24 8 25 gt e 21 4943 31 8 8129 7 22 21 m N 9 ae 40 39 Q xs 67 N 28 1 See Camshaft Assy 8 NS 48 SN 47 See Timing Gear Case Assy See Timing Gear Case ASSy 46 A PAGE 116 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 TIMING CHAIN CASE 55 TIMING CH
31. 14 5 3500 5 LUG 5 LEAF 3 ADJUSTABLE BIAS 4 3 TRLR 100XF ADJUSTABLE 2 5 6 205 15 14 5 5 3500 5 LUG 5 LEAF OPT 3 EYE BIAS 4 3 TRLR 85 125 ADJUSTABLE 2 5 6 ST225 75R15D 14 x6 2 60001 5 6 LUG 7 LEAF OPT 3 EYE RADIAL 4 TRLR 150XF 3 BALL EYE 750 16 E 16 7 2 60001 5 8 LUG 7 LEAF BIAS 4 2 bs bs 4 POLE FLAT 4 POLE FLAT 4 POLE FLAT 4 POLE RUBBER FLAT 4 POLE RUBBER FLAT 4 POLE RUBBER FLAT 4 POLE RUBBER FLAT 4 POLE RUBBER FLAT 4 WIRE LOOM 4 WIRE LOOM 4 WIRE LOOM 4 WIRE LOOM TRLR 220XF 3 EYE ST235 85R16E 16 X7 2 7000 8 LUG Q FLEX ADJUSTABLE RADIAL 4 TRLR 300XF 3 EYE ST235 85R16E 16 X7 2 6000 8 LUG Q FLEX ADJUSTABLE RADIAL 6 TRLR 400XF 3 EYE ST235 85R16E 16 X7 3 7000Ibs 8 LUG Q FLEX ADJUSTABLE RADIAL 6 TRLR 600XF 5TH WHEEL ST215 75R17 5H 16 X7 3 1000065 8 LUG 7 LEAF RADIAL 8 TRLR 800AR 5TH WHEEL ST215 75R17 5H 16 X7 3 1000065 8 LUG AIR RIDE RADIAL 8 4 WIRE LOOM 4 WIRE LOOM 6 WIRE LOOM 6 WIRE LOOM TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 13 TLG 12SPX TRAILER SAFETY GUIDELINES Tires Wheels Lug Nuts Tires and wheels are a very important and critical TABLE 2 TIRE WEAR TROUBLESHOOTING components of the trailer When specifying or replacing the __wearparrern CAUSE SOLUTION iler w it is i i X Adjust pressure to trailer wheels it is important the
32. 2 Coolant Drain Plug Removing the coolant drain plug device or after building main switch is opened while the engine is hot will result in hot coolant to gush out of the coolant drain plug therefore causing severe scalding to any persons in the general area of the generator 3 Engine Oil Drain Plug Removing the engine oil drain plug while the engine is hot will result in hot oil to gush out of the oil drain plug therefore causing severe scalding to any persons in the general area of the generator CAUTION Never use damaged or worn cables when connecting power tools or equipment to the generator Make sure power connecting cables are securely connected to the generator s output terminals insufficient tightening of the terminal connections may cause damage to the generator and electrical shock TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 7 RULES FOR SAFE OPERATION Battery CAUTION Never over fill the battery with water above the upper limit The battery contains acids that can cause injury to the eyes and skin To avoid eye irritation always wear safety glasses Use well insulated gloves when picking up the battery Use the following guidelines when handling the battery BATTERY 1 DO NOT drop the battery There is the possibility of risk that the battery may explode 2 DO NOT expose the battery to open flames sparks cigarettes etc The battery contains combusti
33. 2100200 13 0601810523 1 1 1280 0601810207 BULB 4 14 0601800680 acis 15113 15 0027103512 MACHINE SCREW 2 0030003500 NUT 2 0040403500 WASHER 2 16 7672142008 SLIDE LEVER 1 17 0501840190 KNOB issiima REPLACES 0805012904 18 8522144103 THROTTLE CABLE 1 19 30321430044 SPRING 1 20 8522141004 BRACKET 1 21 011006010 HEX HEAD a REPLACES 0017106010 22 0601812597 _RECEPTACLE u ua m 520R 125V 20A 23 0601811031 EE vasca L530R 125V 30A 24 06018110383 RECEPTACLE J L630R 250V 30 25 0601811034 CA6369125 250V 50 REPLACES 0601812565 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 53 gt c o t lt EM je cc H lt O gt lt 0 E lt gt ES lt gt 2 lt 2 lt a am 2 lt 72 gt a 72 E 12 a CONTROL PANEL ASSY CONTROL PANEL ASSY NO 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45 46 PART NO 0027104012 003000400 0601815109 0601842347 0027104012 0601823204 0027103016 0601820038 0027104025 6781899004 06018
34. 25 50 60 90 120 AIR GUN 20 25 50 60 90 120 TORQUE WRENCH Figure 3 Wheel Lug Nuts Tightening Sequence NOTE NEVER use an pneumatic air gun to tighten wheel lug nuts TLG 12SPX PARTS AND OPERATION MANUAL STD REV 44 03 08 05 PAGE 15 TLG 12SPX TRAILER WIRING DIAGRAM TRAILER SIDE DOUBLE FILAMENT BULB CONNECT TO CHASSIS TAIL LIGHT SINGLE FILAMENT YELLOWIBROWN BULB LICENSE TAIL LIGHT DOUBLE FILAMENT BULB FLAT 4 PIN MOLDED CONNECTOR LEFT TAIL LIGHT DOUBLE FILAMENT BULB CONNECT RIGHT TO CHASSIS TAIL LIGHT WHITE SINGLE BLACK FILAMENT BULE um ELLOW LICENSE TAIL LIGHT DOUBLE FILAMENT BULB FLAT 5 PIN ROUND CONNECTOR LEFT TAIL LIGHT NOTE LIGHTS ARE ORIENTED FROM THE DRIVER S SEAT TOWING VEHICLE SIDE STOP amp TURN LEFT FLAT 4 PIN MOLDED MATING CONNECTOR WHITE COMMON GROUND BLUE TURN RIGHT GREEN TAIL amp LICENSE YELLOW STOP RED TURN LEFT iN FLAT 5 PIN ROUND CONNECTOR PAGE 16 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 6 125 GENERATOR DECALS The TLG 12SPX generator is equipped with a number of safety decals These decals are provided for operator safety and maintenance information The illustration below and on the preceding pages show the decals as they appear on the machine Should any of these decals become unreadable replacemen
35. 35 TLG 12SPX FUELTANK ASSY FUEL TANK ASSY PAGE 62 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 FUEL TANK ASSY NO PARTNO 1 8525500003 14 0810105900 1 2 0810105900 1 3 0267700200 1 4 0605515005 2 8525525003 3 011008020 4 8525523004 5 0805003404 6 011008020 7 020108060 8 1555527004 9 7812014003 10 0802011104 11 0150000018 12 0017106016 13 0199900830 14 0605515094 15 8525546014 16 011208025 17 8971041891 8970713480 18 0017108065 19 0602023175 20 0199900350 21 0199900300 22 0199900400 23 0199700500 24 0199700270 25 0605515094 26 0605515096 27 1615511204 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 63 ITE FUEL TANK CAP FUEL TANK FUEL FILTER HOSE FUEL GAUGE HOSE BAND BRACKET FUEL TANK HEX HEAD TANK BAND PAD TANK BAND HEX HEAD BOLLI TANK SHEET DRAIN JOINT PLUG O RING ssi a azas HEX HEAD BOLT DRAIN HOSE BAND HEX HEAD BOLLI FUELFITER u u ua una ELEMENT FUEL FILTER HEX HEAD BOLT FUELPUMP iai ime SUCTION HOSE SUCTION HOSE SUCTION HOSE RETURN HOSE RETURN HOSE HOSE BAND HOSE RUBBER SEAL TLG 12SPX FUEL TANK ASSY REMARKS REPLACES 0810105800 REPLACES 0017108020 REPLACES 0017108020 REPLACES 0207008000 REPLACES 0017108
36. 9090 ADJUSTER 1 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 119 ISUZU 3LB1 AIR CLEANER ASSY AIR CLEANER ASSY PAGE 120 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 AIR CLEANER ASSY AIR CLEANER ASSY PARTNO QTY REMARKS 1 8941251130 CLEANER ASSY ERE INCL ITEMS W 2 9142170620 WING NUT 1 6 5142150140 AIR CLEANER FILTER 1 89 9142191410 INDICATOR 1 90 8941591510 CUP 1 91 5142170040 CLAMP 1 139 8970497220 AIR CLEANER BAND 2 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 121 ISUZU 3LB1 SWITCH AND RELAY ASSY SWITCH AND RELAY ASSY 58 288 424 434 PAGE 122 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 SWITCH RELAY ASSY SWITCH AND RELAY ASSY REMARKS 58 8970444180 IGNITION SWITCH INCL ITEMS W 288 5825500290 SAFETY RELAY 1 424 5825500290 RELAY 2 4347 1823160070 STARTER SWITCH KEY 1 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 123 Effective July 1 2000 TERMS AND CONDITIONS OF SALE PARTS PAYMENT TERMS Terms of payment for parts are net 10 days FREIGHT POLICY All parts orders will be shipped collect or withthe charges ad
37. AIN CASE ASSY NO PART 0 REMARKS 1 8970456175 FLYWEIGHT 1 5 8970849771 SLEEVE uuu a 1992 1996 8971474890 SLEEVE 1996 9081608500 LEVER 5 1 6B 9081605450 LEVER SHAFT 1 6C 8970164460 LEVER SHAFT 1 7 8971176720 COVER Susa Tasa ass saus APR 1992 TO JUN 1996 8971062740 COVER JUL 1996 JAN 1997 8971617450 COVER gemene h r FEB 1997 16 1079470020 LEVER PIN 1 18 8970346393 PLATE panne 1992 JUN 1996 8971485500 PLATE u as a nasua qsqa Luse JUL 1996 21 5095031320 GASKET SCREW 2 22A 9091114060 NUT 3 228 9091104060 NUT 1 24 5094000480 NUT 1 25 5156690021 CAP 1 27 8970493280 LEVER 1 28 8971059061 EET APR 1992 JUN 1996 8971605721 LEVER NN JUL 1996 29 1096230550 GASKET 2 30 8970169400 SPRING 1 31 5095031350 WASHER 2 32 9091105080 NUT 1 34 5157292391 EYE 1 35 987109759 MAIN SPRING 1 36 8970843250 START SPRING 1 37 8970169361 IDLE SPRING 1 39 8971097751 ANGLEICH KIT 1 40 8941304380 NUT 1 43 8970164492 LEVER 1 44 8970646881 COVER GASKET 1 45 8943695450 GEAR CASE BUSHING 1 46A 0280806200 BOLT 4 46 0280806140 BOLT 1 46C 8970728300 BOLT 1 47 1157390020 LEAD SEAL 2 48 8913254460 LEAD SEAL WIRE 2 49 1096050190 COVER PLUG 1 50 8970345945 GUIDE LEVER 1 52 8971122650 GUIDE PIEG E Jes
38. ANGER NUT FRONT HANGER BOLT LOCKING TIE PLATE NUT ALWAYS wear safety glasses when removing Figure 2 Major Suspension Components or installing force fitted parts Failure to comply may result in serious injury PAGE 14 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX TRAILER SAFETY GUIDELINES Table 3 Suspension Torque Requirements 3 8 U BOLT MIN 30 MAX 35 7 16 U BOLT MIN 45 MAX 60 1 2 U BOLT MIN 45 MAX 60 SHACKLE BOLT SNUG FIT ONLY PARTS MUST ROTATE FREELY SPRING EYE BOLT LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT BOLT ASSEMBLY SHOULDER TYPE MIN 30 MAX 50 SHACKLE BOLT Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer Be sure to use only the fasteners matched to the cone angle of the wheel Proper procedure for attachment of the wheels is as follows 1 Startall wheel lug nuts by hand 5 LUG NUTS 8 LUG NUTS 2 Torque all lug nuts in sequence See Figure 3 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 4 3 After first road use retorque all lug nuts in sequence LUG NUTS Check all wheel lug nuts periodically a Table 4 Requirements Qu Wheel Size First Pass Second Pass Third Pass FT LBS FT LBS FT LBS 20 25 35 40 50 65 20 25 35 40 50 65 20 25 50 60 90 120 PNEUMATIC 20
39. ASSY FUEL FILTER AND BRACKET ASSY 1 8971041891 2 8970713480 26 8941551830 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 101 PART NAME QTY FUEL FILTER ASSY EEE FUEL FILTER ELEMENT KIT 1 GASKET 1 REMARKS INCL ITEMS W ISUZU 3LB1 FUEL PUMP AND PIPE ASSY FUEL PUMP AND PIPE ASSY PAGE 102 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 FUEL PUMP AND PIPE ASSY FUEL PUMP AND PIPE ASSY NO PART NAME QTY REMARKS 1 8942411792 FUEL PUMP ASSY s INCL ITEMS W 9 9019106280 BOLT 2 34 8942336550 RUBBER 2 57 8942336570 WASHER 2 215 8942389070 COLLAR 2 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 103 ISUZU 3LB1 OIL FILTER ASSY OIL FILTER ASSY PAGE 104 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 OIL FILTER ASSY OIL FILTER ASSY NO PART NO PART NAME QTY REMARKS 2 8943142633 OIL FILTER ELEMENT 1 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 105 ISUZU 3LB1 PUMP AND OIL STRAINER ASSY OIL PUMP AND OIL STRAINER ASSY 132 See Cylinder Block Assy PAGE 106 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 OIL PUMP AND OIL STRAINER ASSY O
40. CAMSHAFT RING 273A 9000906100 CAMSHAFT BEARING 273B 9000906570 CAMSHAFT BEARING TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 81 ISUZU 3LB1 CRANKSHAFT PISTON AND FLYWHEEL ASSY CRANKSHAFT PISTON AND FLYWHEEL ASSY PAGE 82 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 CRANKSHAFT PISTON AND FLYWHEEL ASSY CRANKSHAFT PISTON AND FLYWHEEL ASSY NO PART NAME QTY REMARKS 1 8970405203 CRANKSHAFT 1 7 8970395820 METAL KIT 1 12 8971078930 biis INCL ITEM W 18 8971093721 PULLEY 1 28 8970345920 GEAR 1 35 8944196021 RING GEAR 1 38 8970232680 WASHER 6 40 8941333281 BOLT 6 42 5115990023 WASHER 2 43 8943860790 BOLT 1 48 8942016410 WOODRUFF KEY 1 59 8941347920 WASHER 1 63 8971768880 PISTON 3 67 8970871050 PISTON O S 0 25 3 68 8970346090 RING SET reset APR 1992 TO SEP 1995 8971137620 RING SET OCT 1995 71 8971412040 RING SET 0 25 3 73 5122710141 METAL SET 3 83 8944017510 PISTON PIN 3 84 8970200670 CONNECTOR ROD ASSY O S INCL ITEMS W 85 8941375220 BUSHING 3 86 8941075501 BOLT 6 884 8942409020 NUT 6 126 8944017501 SNAP RING 6 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 44 03 08 05 PAGE 83 ISUZU 3LB1 TIMING GEAR AND FLYWHEEL HOUSING ASSY TIMING GEAR AND FLYWHEEL HOUSING ASSY See Cylinder Blo
41. D OPERATION MANUAL STD REV 4 03 08 05 PAGE 73 ISUZU 3LB1 CYLINDER HEAD ASSY CYLINDER HEAD ASSY PAGE 74 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 CYLINDER HEAD 55 CYLINDER HEAD ASSY NO PARTNO 1 8971056750 8971633991 2 8970439332 3A 8944637840 3 8970369591 4 8970317490 8970317101 5B 8970317110 1096000112 7B 1096000051 10 8971065490 11 8970346333 12 8970853900 14 5093000650 15 028088160 25 511190090 2 7 8970446351 36 8941105591 4 0280808160 50 8970946410 103 5096050050 168 8970853890 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 75 PART NAME CYLINDER HEAD ASSY CYLINDER HEAD ASSY GASKET BOLT BOLT VALVE GUIDE VALVE INSERT SEAT VALVE INSERT SEAT SEALING CUP SEALING CUP GLOW PLUG CONNECTOR HANGER EXHAUST MANIFOLD STUD BOLT CYLINDER HEAD PLUG HOT PLUG OIL SEAL BOLT ROCKER ARM STUD PLUG FRONT HANGER QTY REMARKS EN 1 ne 1 gt MH 1993 OCT 1996 INCL ITEMS W 1996 ISUZU 3LB1 CYLINDER BLOCK ASSY CYLINDER BLOCK ASSY Front See Oil Pump Assy See Timing Gear Case Assy DEN 4 gt m N 443 29 41 1 4 See Cooler 7 144 141 PAGE 76 TLG 12S
42. EVEL GAUGE ASSY OIL AND LEVEL GAUGE ASSY See Cylinder Block Assy PAGE 78 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 31 1 OIL PAN AND LEVEL GAUGE ASSY OIL LEVEL GAUGE ASSY QTY REMARKS 1 8971322101 OIL PAN AS SM REPLACES 8970439362 INCL ITEMS W 2 8970439421 OIL LEVER GAUGE 1 3 1096230570 GASKET 1 4 9096620120 OIL DRAIN PLUG 1 23 8971351410 BOLT sere 15546 REPLACES 0280806140 24 8971378360 DIL PAN NUT I L erbe Bosne REPLACES 0911502060 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 44 03 08 05 PAGE 79 ISUZU 31 1 CAMSHAFT AND VALVE ASSY CAMSHAFT AND VALVE ASSY gt 91 SR 228 78 Cylinder Assy Cylinder Head Assy lt 89 6 80 TLG 12SPX PARTS OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 CAMSHAFT AND VALVE 55 CAMSHAFT AND VALVE ASSY NO PARTNO PART NAME QTY REMARKS 1 8970621401 CAMSHAFT ausis INCL ITEMS W 4 8971021240 VALVE 3 5 8970346283 EXHAUST VALVE 3 6 5094000530 NUT 1 34 9098786260 1 53 8970668721 5 1 55 9992023140 PLUG 1 57 0280806250 BOLT 6 25 FLANGE 4 0286806160 BOLT M6X16 4 65 8942395010 SPLIT COLLAR 12 68 8970346291 VALVE S
43. EXHAUST MANIFOLD ASSY NO PARTNO 1 8970345881 2 8970376822 15 0280808400 0280808700 16 9041108200 18 0911502080 84 8970420280 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 89 ISUZU 3LB1 EXHAUST MANIFOLD ASSY PART NAME EXHAUST MANIFOLD GASKET BOLT M8X40 FLANGE BOLT M8X70 FLANGE STUD NUT GASKET EXHAUST PIPE QTY 1 1 1 1 4 2 1 REMARKS ISUZU 3LB1 VENTILATION ASSY VENTILATION ASSY See Cylinder Head Cover Assy PAGE 90 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 VENTILATION ASSY VENTILATION ASSY NO PART NO 13 9039104100 32 5097070051 43A 8971056801 438 8971025191 43C 8971056811 8971025191 59 8941271440 62 8942493171 73 8942386100 1097070870 8970833300 5111790520 8943295490 130 130 135 SCREW CLIP PCV HOSE PCV HOSE POV HOSE HOSE HOSE CLIP CHECK VALVE CHECK VALVE CLIP CHECK VALVE CLIP PCV PIPE PCV PIPE VENTILATOR ASSY QTY REMARKS 4 4 1 1 CU 1 OCT 1993 TO OCT 1997 1 NOV 1997 1 1 Em 1 OCT 1993 TO OCT 1997 NOV 1997 Q TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 91 ISUZU 3LB1 WATER PUMP AND CORROSION RESISTOR ASSY WATER PUMP AND CORROSION RESISTOR ASSY
44. GUARD HEX HEAD BOLT HEX HEAD BOLT TLG 12SPX ENCLOSURE ASSY REMARKS REPLACES 0017108020 REPLACES 0017108020 S N5107198 5107225 S N5107226 S N5107198 5107225 S N5107226 THE PART NUMBER DEFAULT IS SCARLET COLOR INDICATE THE LETTERS BELOW TO INDICATE DIFFERENT COLOR OF UNIT MQW WHITE THE SERIAL NUMBER MAY BE REQUIRED TLG 12SPX ENCLOSURE ASSY ENCLOSURE ASSY THE PART NUMBER DEFAULT IS SCARLET COLOR INDICATE THE LETTERS BELOW TO INDICATE DIFFERENT COLOR OF UNIT MQW WHITE THE SERIAL NUMBER MAY BE REQUIRED PAGE 66 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX ENCLOSURE 55 ENCLOSURE ASSY NO ITEM QTY REMARKS 25 8525141102 REAR FRAME 5 5107188 05107225 85251411112 REAR 5 5107226 26 011008020 HEX HEAD BOLT ctio iiia REPLACES 0017108020 27 8525144104 COVER REAR FRAME 1 8525940104 ACOUSTIC SHEET 1 28 011008020 HEX HEAD BOLT B anus REPLACES 0017108020 29 8525145103 DOOR REAR FRAME 1 30 8525146104 WINDOW PLATE 1 31 0207006000 6 32 0605010230 DOOR HANDLE 1 33 0021505012 MACHINE SCREW 4 34 0810015204 HINGE 2 0810015504 WASHER 2 35 0017106016 HEAD BOLT 4 36 8525161002 Teens S N7107198 TO 7107225 8525161012
45. IL PUMP AND OIL STRAINER ASSY NO PART NAME QTY REMARKS 1 8970488094 OIL PUMP ASSY INCL ITEMS W 13 0280808300 BOLT 4 23 9081606160 2 26 8970448430 OIL PUMP PIPE 1 29 0280806300 BOLT M6X30 FLANGE 2 0280806500 BOLT M6X50 FLANGE 1 51 8970439410 STRAINER AND PIPE ASSY 1 61 0280808160 BOLT 1 85 8971096790 GASKET 1 102 1096234960 STRAINER 1 119 8942446550 RELIEF VALVE PLUG APR 1992 TO NOV 1994 8941046150 RELIEF VALVE PLUG DEC 1994 120 8941145120 RELIEF VALVE SPRING snen APR 1992 TO NOV 1994 8971133320 RELIEF VALVE SPRING DEC 1994 121 8942355671 VALVE 1 132 5824100361 OIL PRESSURE SWITCH 1 151 8970448133 OIL PUMP SUB ASSY 1 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 107 ISUZU 3LB1 ELECTRICAL CONTROL ASSY ELECTRICAL CONTROL ASSY See Fan Assy 5 N See Thermostat and Housing Assy See Thermostat and Housing Assy 89 See Water Pump Assy See Cylinder JR Block Assy P See Cylinder Block Assy PAGE 108 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ELECTRICAL CONTROL ASSY PARTNO 1 8970489652 STARTER ASSY 2 8970489701 GENERATOR ASSY 4 0281812300 BOLT 7 9091114080 NUT 16 0280810700 BOLT 23 0911502100
46. LG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 39 TLG 12SPX MAINTENANCE General Inspection Prior to each use the generating set should be cleaned and inspected for deficiencies Check for loose missing or damaged nuts bolts or other fasteners Also check for fuel or oil leaks Engine Side Fuel Oil and Coolant Refer to the Engine Instruction Manual Air Cleaner Every 50 hours Remove air cleaner element and clean heavy duty paper element with kerosene or foam element with liquid detergent and hot water Wrap foam element in a cloth and squeeze dry For heavy duty paper element wipe excess kerosene with towel Fuel Addition Add diesel fuel the grade may vary according to season and locations Always pour through the mesh filter Removing Water from the Tank After prolonged use water and other impurities accumulate in the bottom of the tank Occasionally remove the drain cock and drain the contents During cold weather the greater the empty volume inside the tank the easier it is for water to condense This can be reduced by always keeping the tank as full as possible Air Removal If air enters the fuel injection system of a diesel engine starting becomes impossible After running out of fuel or afte
47. LT 5 0037808000 WING NUT 6 0040008000 LOCKWASHER 7 031108160 PLAIN WASHER BATTERY CABLE BATTERY CABLE 10 0602220310 TERMINAL ASSY 11 0602220311 TERMINAL ASSY 12 0602220600 TERMINAL TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 59 TLG 12SPX BATTERY ASSY QTY REMARKS 1 65D31R NNN 1 NOSP EN 1 dandus 1 TC7R TLG 12SPX MUFFLER ASSY MUFFLER ASSY PAGE 60 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 MUFFLER ASSY NO 1 8522310102 2 011008020 3 8522330003 4 8522332004 5 8522331004 6 011008020 7 0017106016 8 3312320004 9 011208035 10 897042080 11 1502336004 12 020108060 13 011208035 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 61 ITEM MUFFLER HEX HEAD BOLT EXHAUST PIPE EXHAUST PIPE EXHAUST PIPE HEX HEAD BOLT HEX HEAD BOLT PIPE BAND HEX HEAD BOLT GASKET GASKET HEX NUT HEX HEAD BOLT TLG 12SPX MUFFLER ASSY QTY REMARKS 1 4 REPLACES 0017108020 1 1 1 2 REPLACES 0017108020 1 2 2 REPLACES 0017108035 1 REPLACES 0602320110 1 4 REPLACES 0207208000 T 2 REPLACES 00171080
48. MANUAL STD REV 4 03 08 05 GENERATOR ASSY 1 0110000403 1 1 0601820037 1 2 0601822638 1 3 0071206307 1 4 0080000035 2 1711027003 3 7611611003 4 3311612004 5 0012808025 6 0012308030 7 04153100102 8 8521384003 9 04153000202 10 80137000003 11 0017105035 12 04153400403 13 04131200004 14 0040012000 15 031112230 16 0030012000 17 80131300104 18 0017108030 19 012010030 20 030210250 21 031112230 22 0207210000 23 05131300003 24 0017105025 25 8521320104 26 8521320004 27 0017110025 28 7605419004 29 0207010000 30 0070506803 TLG 12SPX PARTS OPERATION MANUAL STD REV 4 03 08 05 PAGE 51 ITEM ROTOR ASSY SNAP RING FAN COUPLING DISK WASHER COUPLING HUB HEX HEAD BOLT HEX HEAD BOLT END BRACKET ARMATURE ASSY END BRACKET FIELD ASSY EXCITER HEX HEAD BOLT GROMMET SET BOLT LOCKWASHER PLAIN WASHER HEX HEAD BOLT COVER HEX HEAD BOLT HEX HEAD BOLLI LOCKWASHER PLAIN WASHER HEX NUT COVER HEX HEAD BOLT GENERATOR FOOT GENERATOR FOOT HEX HEAD BOLT RUBBER SUSPENSION HEX NUT BEARING TLG 12SPX GENERATOR ASSY de 4 FS HH O REMARKS S10VB60 TNR15G431K 6307DDU REPLACES 0012808025 REPLACES 0041212000 REPLACES 0010310030 REPLACES 0042510000 REPLACES 004121
49. NGINE AND RADIATOR ASSY NO ITEM 1 8520150004 1 1 8943142633 CARTRIDGE OIL FILTER 060201140 FAN BEE 2 8525112104 ENGINE FOOT 3 0012810020 HEAD BOLT 4 7605419004A RUBBER SUSPENSION 5 0207010000 NUT 6 0602011956 6 1 06020110888 RADIATOR 7 8702014004 RUBBER MOUNT 8 605000460 RUBBER MOUNT 9 8522015503 RADIATOR HOSE 10 8522015602 RADIATOR HOSE 11 0605515112 5 12 0605515114 5 13 5142150140 AIR FILTER ELEMENT 13 1 0602040690 INDICATOR DUST 14 8970497220 BAND AIR CLEANER 15 8522031004 BRACKET AIR CLEANER 16 011008020 HEX HEAD 17 8522032003 HOSE AIR CLEANER 18 6602032103 HOSE AIR CLEANER 19 0605515020 5 20 0605515001 5 21 1622014103 DRAIN JOINT WATER 22 1502025103C DRAIN JOINT OIL 23 08020111044 PLUG 24 015000018 25 0017106016 HEAD BOLT 26 0199900900 DRAIN HOSE 27 0199900450 DRAIN HOSE 28 0605515094 5 29 0805010004 DRAIN JOINT 30 3362054104 JOINT BOLT 31 0602021190
50. NUT 46 8942481610 GLOW PLUG RELAY 89 8941679410 SWITCH 177 8970701303 SOLENOID ASSY 8971830140 SOLENOID ASSY 238 9095720140 GASKET 292 9091505080 LOCK WASHER 603 8941268220 SENSOR ASSY 613 8970912901 CONTROL UNIT 8971163140 CONTROL UNIT 8971461050 CONTROL UNIT 729 8970633010 SENSOR TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 109 ISUZU 3LB1 ELECTRICAL CONTROL ASSY o lt gt N REMARKS uten APR 1992 TO JUL 1998 si AUG 1998 APR 1992 TO JUN 1992 Menu JUL 1992 TO MAY 1996 JUN 1996 ISUZU 31 1 STARTER COMP ASSY STARTER COMP ASSY PAGE 110 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 STARTER COMP ASSY STARTER COMP ASSY PARTNO 2 8970786480 13 581110110 16 5811210310 17A 5098000790 178 5098000400 21 5811170070 22 5811180220 23 581150340 27 5811291820 27B 5811291830 31 8970786470 32 5811190290 41 5811291810 43 5811291000 44 5811290990 46 5811230110 47 5811290960 48 5811290920 54 5811240031 114 5094000420 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 111 CASE YOKE ARMATURE BEARING BEARING SPRING HOLDER COVER BOLT BOLT SWITCH COVER SCREW RETAINER ROLLER GEA
51. PRING 6 7 8942510311 SPRING SEAT 6 78A 8970668761 ROCKER ARM INLET aa SE APR 1992 TO SEP 1992 8972125180 ROCKER ARM INLET EO OCT 1992 REPLACES 8971164480 788 8970668781 ROCKER ARM EXHAUST c TM APR 1992 TO SEP 1992 78 8972125200 ROCKER ARM EXHAUST assu OCT 1992 REPLACES 8971164500 81 8970104850 SCREW 83 9091115060 NUT 88 8970668692 PUSH ROD 89 8971243690 VALVE TAPPET a REPLACES 8970346301 91 0911502060 92A 8971056791 ROCKER ARM BRACKET T nes 1993 1995 8971312450 ROCKER ARM BRACKET 1 JUN 1995 1995 928 8971634112 95 8970698871 5 SPRING 98 9081605160 SHAFT REPLACES 9096785100 107 8971297800 IDLE GEAR Hansen REPLACES 8970728290 111 5125350051 COLLAR 112 8970375940 DUER GEAR Nc 1992 5 1995 8971297820 DUER GEAR OCT 1995 196 9091801620 SNAP RING 228A 9111290830 SEALING CUP 228 8970395260 SEALING DDD t HH gt O 263 9095714140 GASKET 270 8971022880 INJECTION PUMP GEAR 271 0280908600 BOLT ec 1992 SEPT 1995 0280908450 BOLT ct 1995 272 8970620480
52. PX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 31 1 CYLINDER BLOCK ASSY CYLINDER BLOCK ASSY NO QTY REMARKS 1 8971061943 CYLINDER BLOCK Tarus DEC 1993 TO MAR 1995 INCL ITEMS W 8971290721 CYLINDER BLOCK ASSY tnn 1995 1997 8971691440 CYLINDER BLOCK ASSY 1997 6A 8942298530 SEALING CUP 4 6B 1096000112 SEALING 1 8 8941674711 BOLT 8 15A 1096050500 OIL GALLERY PLUG PT 1 8 1 158 1096050040 OIL GALLERY PLUG PT 1 8 50 HEAD 1 15C 1096050190 OIL GALLERY PLUG 1 4 1 54 9041106160 OIL PAN STUD 2 61 9081606160 STRAIGHT 2 61B 9098785320 STRAIGHT PIN SER REPLACES 9081606160 83 9081608160 FLYWHEEL PIN 2 89 5096000130 OIL GALLERY CUP 9 114 5137210281 WATER DRAIN NIPPLE 1 141 0280806140 BOLT 6 16 FLANGE 4 144 0911502060 NUT 2 205 1093050050 STUD 6 232 9041108400 WATER PUMP STUD 1 297 8971062031 COVER 1 300 9041106160 COVER STUD 6 16 L 25 3 8943438960 COVER STUD M6X19 L 27 1 416 8943255950 OIL FILTER STUD 1 439 8970470560 BEARING 1 440 8970394953 PIN 2 441 9112290581 DOWEL 0 11 4 441 8942008190 DOWEL D 15 2 442 8970471421 THRUST PLUG 1 443A 5096000130 SEALING CAP 1 443B 1096000121 SEALING CAP 1 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 77 ISUZU 3LB1 OIL PAN AND L
53. R SPRING BALL CLUTCH NUT QTY 1 1 1 1 1 4 1 1 2 2 1 1 2 1 5 1 1 1 1 1 ISUZU 3LB1 INJ PUMP COMP ASSY INJ PUMP COMP ASSY Ck G Co PAGE 112 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 INJ PUMP COMP ASSY INJ PUMP COMP ASSY 6 8941327461 7 8941289150 9 8941289110 8941289120 8970833460 8970833450 8971386490 8970833480 8943796920 8941289230 8941289200 8941289190 8941289210 8941289160 8970833490 8970833470 8970833551 8941445880 8943796880 8943796910 8941289310 8941289320 8941289330 8941289340 8941289350 8941289360 8941589370 8941289380 8941289390 8941289400 8941289410 8941289420 8941289430 8941289440 8941289450 8941289460 8941289470 8941289480 8941289490 8941289500 8941289510 8941289520 8941289530 8941289540 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 113 PART NAME HOLDER 3 GASKET 3 SPRING 3 GASKET 3 VALVE 3 PLUNGER ASSY niiin 3 PLUNGER ASSY 3 FLANGE 3 GASKET 6 SLEEVE 3 SEAT 3 SPRING 3 SEAT 3 TAPPET 3 TAPPET GUIDE 3 HOUSING PLUG 3 RACK 3 GASKET 6 BOLT 3 BOLT 6 en 1 SE 1 Sj 1 SHIM 1 SHIM 1 gii aan 1 SHIM u a aus 1 1 SE
54. RING DIAGRAM G B 2 0 N m To Starter Switch AC Connector PARTS View at Wiring Side WIRING COLOR CODE AMT Coil 1 SYMBOL COLOR SYMBOL COLOR Armature Exciter x lt B Back R Fe Field Exciter Bue f W White Brown Yellow CN 1 IG Green 1B Light Blue Light Green AC Ammeter Violet O Orange LP pk Current Transformer Ammeter CN2 Circuit Breaker Output Receptacle mE J K jAc 50 19 30 Automatic Voltage Regulator 2 Combination Terminal Voltage Regulator Combination Terminal Ground Terminal LJ CN 4 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 43 TLG 12SPX TROUBLESHOOTING ENGINE Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event breakdown use the tables shown for diagnosis based on the Engine Troubleshooting Table 11 If the problem cannot be remedied consult our company s business office or service plant TABLE 11 ENGINE TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION Engine does not start No fuel Replenish fuel Air in the fuel system Bleed system Water in the fuel system Remove water from fuel tank Fuel pipe clogged Clean fuel pipe Fuel filter clogged Clean or change fuel filter Excessively high viscosity of fuel or engine oil at low
55. See Engine Electrical Assy PAGE 96 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 FAN AND FAN BELT ASSY FAN AND FAN BELT ASSY NO PART NAME QTY REMARKS 1 8970967090 COOLING FAN D 330 6 BLOW 24A 0208006120 BOLT 6 12 2 248 0280808220 BOLT M8X22 FLANGE 4 36 8970407640 BELT LS826 1992 AUG 1996 8971604370 sauen in Tocas SEPT 1996 38 8970634001 FAN SPACER 1 80 5136741040 ADJUSTMENT PLATE 1 96 0280808200 BOLT 1 112 8970384030 PULLEY 1 GROOVE 1 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 97 ISUZU 3LB1 FUEL INJECTION ASSY FUEL INJECTION ASSY See Cylinder Block Assy See Cylinder Block PAGE 98 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 FUEL INJECTION ASSY FUEL INJECTION ASSY PARTNO 1 8970345915 2 0280808200 29 5097070051 30 8970408090 31 8970799760 32 8970908420 33 8941305320 35 8970846170 36 8941049930 43 8941289630 47 8941289640 47 8970833580 49 8941060403 50 8942575920 51 8941060551 63 8970346261 121 8970964020 140 8941769620 8941769630 8941769640 8941769650 8941769660 8941769670 8941769680 8941769690 8941769700 8941769710 147 8941290060 158 0911502080 159 8971263560 8971263570 8971263580 8971263590 8971263600 8971263610
56. ace Fuel over flow pipe clogged Clean Governor malfunctioning Repair Either white or blue exhaust gas is observed Excessive engine oil Reduce to the specified level Piston ring and liner worn or stuck Repair or replace Incorrect injection timing Adjust Deficient compression Adjust top clearance Either black or dark gray exhaust gas is observed Overload Lessen the load Low grade fuel used Use the specified fuel Fuel filter clogged Clean or change Air cleaner clogged Clean or change Deficient nozzle injection Repair or replace the nozzle Deficient output Incorrect injection timing Adjust Engine s moving parts seem to be seizing Repair or replace Uneven luel injection Repair or replace the injection pump Deficient nozzle injection Repair or replace the nozzle Compression leak Replace head gasket tighten cylinder head bolt glow plug and nozzle holder TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 45 Gs TLG 12SPX TROUBLESHOOTING GENERATOR Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use the tables shown for diagnosis based on the Engine and Generator Troubleshooting Table 12 If the problem cannot be remedied consult our company s business
57. ad understand and follow procedures in Operator s Manual before attempting to operate equipment Refer to the Isuzu Engine Operator s Manual for engine technical questions or information Loading and Unloading Crane Before lifting make sure the generator s lifting hook is secure and that there is no apparent damage to the generator itself loose screws nuts and bolts If any part is loose or damaged please take corrective action before lifting Always drain fuel prior to lifting Always make sure crane or lifting device has been properly secured to the hook of guard frame on generator NEVER lift the machine while the engine is running Use adequate lifting cable wire or rope of sufficient strength When lifting the generator always use the balanced center point suspension hook and lift straight upwards NEVER allow any person or animal to stand underneath the machine while lifting When loading the generator on a truck be sure to use the front and back frame bars as a means to secure the generator during transport PAGE 8 TLG 128PX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 RULES FOR SAFE OPERATION Transporting Always shutdown engine before transporting Tighten fuel tank cap securely II Drain fuel when transporting generator over long distances or bad roads Always tie down the generator during transportation by securing the generator
58. ble gases and liquids If these gases and liquids come in contact with a flame or spark an explosion could occur 3 Always keep the battery charged If the battery is not charged buildup of combustible gas will occur 4 Always keep battery charging and booster cables in good working condition Repair or replace all worn cables 5 Always recharge the battery in an open air environment to avoid risk of a dangerous concentration of combustible gases 6 In case the battery liquid dilute sulfuric acid comes in contact with clothing or skin rinse skin or clothing immediately with plenty of water 7 In case the battery liquid dilute sulfuric acid comes in contact with your eyes rinse eyes immediately with plenty of water then contact the nearest doctor or hospital and seek medical attention MNEVER Run engine without air filter Severe engine damage may Always service air cleaner frequently to prevent carburetor malfunction E Always disconnect the battery before performing service on the generator E Always be sure the operator is familiar with proper safety precaution s and operations techniques before using generator E Always store equipment properly when not in use Equipment should be stored in a clean dry location out of the reach of children I DO NOT leave the generator running in the manual mode unattended NOT allow unauthorized people to operate this equipment Il Always re
59. ck Assy See Cylinder Block Assy PAGE 84 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TIMING GEAR AND FLYWHEEL HOUSING ASSY ISUZU 3LB1 TIMING GEAR AND FLYWHEEL HOUSING ASSY NO PART NAME 1 8970851331 TIMING GEAR CASE 2 8970470233 FLYWHEEL HOUSING 40 0911502080 103 5096250790 SEAL 134 9041108600 STUD M8X60 L 72 9041108500 STUD M8X50 L 62 172 8970447862 RETAINER 175 5096250940 OIL SEAL 185 0280806200 BOLT 211 0281810250 226 8941277030 STUD 367 0280808800 BOLT 8 80 FLANGE 0280908600 BOLT 8 60 FLANGE 531 8944256852 OIL FILLER 532 8941236231 GASKET TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 85 REMARKS INCL W ISUZU 3LB1 INLET MANIFOLD ASSY INLET MANIFOLD ASSY See Cylinder Head Cover Assy 303 A PAGE 86 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 ISUZU 3LB1 INLET MANIFOLD ASSY INLET MANIFOLD ASSY NO PART NAME QTY REMARKS 303 8970346140 AIR PIPE 1 62 9041106160 DUCTSTUD 2 653 0911502060 NUT 2 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 87 ISUZU 3LB1 EXHAUST MANIFOLD ASSY EXHAUST MANIFOLD ASSY See Cylinder Head Assy PAGE 88 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05
60. dedtothe invoice All shipments are F O B point of origin Multiquip s responsibility ceases when a signed manifest has been obtained from carrier and any claim for shortage or damage must be settled between the consignee andthe carrier MINIMUM ORDER The minimum charge for orders from Multiquip is 15 00 net Customers will be asked for instructions regarding handling of orders not meeting this requirement RETURNED GOODS POLICY Return shipments willbe accepted and credit will be allowed subject to the following provisions 1 AReturned Material Authorization must be approved by Multiquip priorto shipment 2 Toobtaina Return Material Authorization alist mustbe provided to Multiquip Parts Sales that defines item numbers quantities and descriptions of the items tobe returned Thepartsnumbersand descriptions must match the current parts price list b The list must be typed or computer generated Thelistmuststate the reason s for the return d Thelistmust reference the sales order s or invoice s under which theitems were originally purchased Thelistmustincludethe name and phone number ofthe person requestingthe RMA 3 copy of the Return Material Authorization must accompanythe return shipment Freight is at the sender s expense All parts must be returned freight prepaid to Multiquip s designatedreceiving point Parts must be in new and resalable condition inthe original Mul
61. dor statutory which extend beyond the description of the products onthe face hereof PAGE 124 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 NOTE PAGE TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 125 COPYRIGHT 2001 MULTIQUIP INC PARTS AND OPERATION MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING PARTS DEPARTMENT 800 427 1244 or 310 537 3700 FAX 800 672 7877 or 310 637 3284 SERVICE DEPARTMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 WARRANTY DEPARTMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 MAIN 800 421 1244 or 310 537 3700 FAX 310 537 3927 MULTIQUIP INC PARTS DEPARTMENT 18910 WILMINGTON AVE 800 427 1244 CARSON CALIFORNIA 90746 FAX 800 672 7877 310 537 3700 SERVICE DEPARTMENT 800 421 1244 800 835 2551 FAX 310 537 3927 FAX 310 638 8046 POWER E mail mq multiquip com www multiquip com
62. e water will help prevent deposits and corrosion in the cooling system See the engine manual for further details Table 7 Recommended Motor Oil Temperature Range Type Oil 104 23 40 C 5 C 5 F 15 SAE 20 20W 30 40 Below 5 15 SAE 10W SAE 5W 20 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 33 TLG 12SPX PRE SETUP GAUTION When adding coolant or antifreeze to the radiator do not remove the radiator cap until the unit has completely cooled Day to day addition of coolant is done from the reserve tank When adding coolant to the radiator See Table 8 for engine radiator and reserve tank coolant capacities Make sure the coolant level in the reserve tank is always between the H and the L markings Table 8 Coolant Capacity Engine and Radiator 0 92 Gal 3 5L Reserve Tank 0 26 Gal 1L Operation in Freezing Weather When operating in freezing weather be certain the proper amount of antifreeze Table 9 has been added Table 9 Anti Freeze Operating Temperatures Freezing Point Boiling Point Vol Anti Freeze s When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radiator fins with co
63. e wheels Types of suspension used are leaf Q flex and air ride Electrical Electrical connectors looms are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle Application Indicates which units can be employed on a particular trailer TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 11 TLG 12SPX TRAILER SPECIFICATIONS Table 1 Specifications MODEL APPLICATION FUEL BRAKE GVWR FRAME FRAME JACK CELL SYSTEM LENGTH WIDTH STAND TRLR 10W SDW225 NO NO 1900LBS 50 800LB SGW250 TLW300 FULL TILT WHEEL TRLR 10 DCA10 TLG12 NO NO 1900LBS 50 800LB DCA 15 FULL TILT WHEEL TRLR 10XF DCA10 TLG 12 52 GAL NO 1900LBS 50 800LB DCA15 TLW 300 FULL TILT WHEEL O NO 2200LBS 85 42 800LB FULL TILT WHEEL TRLR BLW400 BLW 400 o ELECTRIC 2700LBS W MAST 154 55 800LB W O 124 78 TALL FULL TILT WHEEL TRLR 50X DCA 25 NO NO 2700LBS 124 55 800LB FULL TILT WHEEL 1 TRLR 225W WELDERS DA7000SS N N TRLR 50XF DCA 25 NO 2700LBS 124 55 8001 FULL WHEEL TRLR 70W DCA 45 60 70 NO SURGE 7000LBS 86 77 2000LB FLAT PAD TRLR 70X DCA 45 60 70 OPT SURGE 7000LBS 138 2000LB FLAT PAD TRLR 70XF 45 60 70 53 GAL SURGE 7000LBS 138 2000LB FLAT PAD TRLR 100XF DCA 100 125 150 GAL HYDRAULIC SURGE 7000LBS 190 76 2000LB FLAT PAD TRLR 85 125 DCA 85 100 145 GAL HYDRAULIC 10000LBS 186 77 200018 125 FLAT PAD
64. ead Always check the machine for loosened threads or bolts before starting Be sure the generator is on secure level ground so that it cannot slide or shift around endangering workers Also keep the immediate area free of all bystanders result from fuel vapors or if fuel is spilled on a hot engine M NEVER operate the generator in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death Topping off to filler port is dangerous as it tends to spill fuel PAGE 6 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 RULES FOR SAFE OPERATION CAUTION CAUTION DO NOT touch or open any of the below mentioned components while the generator is running Always allow sufficient time for the engine and generator to cool before performing maintenance II NEVER touch output terminals during operation This Radiator extremely dangerous Always stop the machine when contact with the output terminals is required 1 Radiator Cap Removing the radiator cap while the engine is hot will result in high pressurized boiling water to gush out of the radiator causing severe scalding to AUTION persons the general area of the generator Backfeed to a utility system can cause electrocution and or property damage Do not connect to any building s electrical system except through an approved
65. ic hydraulic surge and air GVWR Gross Vehicle Weight Rating GVWR is the maximum number of pounds the trailer can carry in cluding the fuel cell empty 9 10 Frame Length This measurement is from the ball hitch to the rear bumper reflector Frame Width This measurement is from fender to fender Jack Stand Trailer support device with maximum pound requirement from the tongue of the trailer Coupler Type of hitch used on the trailer for towing Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and the width in millimeters 175 185 205 etc The tire diameter must match the diameter of the tire rim Tire Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc Wheel Hub The wheel hub is connected to the trailer s axle 11 Tire Rim Tires mounted on tire rim The tire rim must 12 match the size of the tire Lug Nuts Used to secure the wheel to the wheel hub Always use a torque wrench to tighten down the lug nuts See Table 4 and Figure 5 or lug nut tightening and sequence Axle Indicates the maximum weight the axle can sup port in pounds and the diameter of the axle expressed in inches see Table 3 Please not that some trailers have a double axle This will be shown as 2 6000 Ibs meaning two axles with a total weight capacity of 6000 pounds 14 Suspension Protects the trailer chassis from shocks 15 transmitted through th
66. mp Two 120V input receptacles 20 amp and 30 One 240V input receptacle 30amp Open Delta Excitation System The TLG 12SPX generator is equipped with the state of the art excitation system The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section There are four leads A B C and D During light loads the power to the Automatic Voltage Regulator AVR is supplied from the leads parallel connections of B amp C When loads increase the AVR switches and accepts power from leads A amp D The output of leads A amp D increase proportionally with load This of adding the voltages to each phase provides better voltage response during heavy loads The connections of the AVR to the AC output windings are for sensing only No power is required from these windings The open delta design provides virtually unlimited excitation current offering maximum motor starting capabilities The excitation does not have a fixed ceiling and responds according the demands of the required load Engine The TLG 12SPX is powered by a 4 cycle water cooled Isuzu 3LB1 diesel engine This engine is designed to meet every performance requirement for the generator Reference Table 5 page 19 for engine specifications In keeping with Multiquip s policy of constantly improving its products the specifications quoted herein are subject to change without prior notice
67. mpressed air Cleaning inside the machine is dangerous so clean only with the engine turned off and the battery disconnected Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the Isuzu Engine Owner s Manual Fan Tension A slack fan belt may contribute to overheating or to insufficient charging of the battery Inspect the fan belt damage and wear and adjust it in accordance with the Isuzu Engine Owner s Manual The fan belt tension is proper if the fan belt bends 7 to 10 mm Figure 15 when depressed with the thumb as shown below 7 10 MM DEFLECTION FAN c2 Figure 15 Fan Belt Tension CAUTION Never place hands near the belts or fan while the generator set is running PAGE 34 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX PRE SETUP LOAD APPLICATION Battery This unit is of negative ground DO NOT connect in reverse Always maintain battery fluid level between the specified marks Battery life will be shortened if the fluid level 1 not properly maintained Add only distilled water when replenishment is necessary The battery is sufficiently charged if the specific gravity of the battery fluid is 1 28 at 68 If the specific gravity should fall to 1 245 or lower it indicates that the battery is dead and needs to be recharged or replaced Check to see whether the battery cables are loose Poor contact may
68. nding and specifies the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical NEC articles 250 64 b and 250 66 set the following grounding requirements 1 Use one of the following wire types to connect the generator to earth ground 10 AWG 5 3 mm or larger b Aluminum 8 AWG 8 4 mm or larger 2 When grounding the generator Figure 13 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect the other end of the ground cable to earth ground 3 NEC article 250 52 c specifies that the earth ground rod should be buried a minimum of 8 ft into the ground NOTE When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician PAGE 30 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX INSTALLATION WZ GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING GROUND GROUND CABLE 8 FT MINIMUM REFERENCE NEC 250 52 C Figure 13 Typical Generator Grounding Application TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 31 TLG 12SPX PRE SETUP General Inspection Prior to Operation TLG 12SPX generator has been thoroughly inspected and accepted prior to shipment from the factory However be sure to check for damaged parts or components or loose
69. o starting the engine START IDLE Make sure the generator is level The oil level must be maintained between two notches on the dipstick 2 When there is not enough lubricating oil fill the PULL TO RUN crankcase with high grade motor oil Use a high quality detergent oil classified CC or higher See Table Figure 19 Throttle Handle Idle 7 on page 31 3 Check the coolant level in the radiator and subtank gt Turn switch key to start Once it is cranked and Replenish with antifreeze as necessary Always maintain starts to run release the key Figure 20 the coolant level between the FULL and LOW markings on the coolant container Be sure that the radiator cap is 5 RUN fastened securely 9 4 Check the fuel level the fuel gauge If fuel is low fill the fueltank with clean fresh unleaded automotive diesel If diesel spillage occurs completely up the spilled fuel immediately Figure 20 Key switch WARNING 3 Pull the throttle handle and turn to right until the notch The engine s exhaust contains harmful sets the handle out Figure 21 emissions ALWAYS ventilate the exhaust when operating inside tunnels excavations or buildings Direct exhaust away from nearby personnel START IDLE B PULL TO RUN Figure 21 Throttle Handle Run 4 the main circuit breaker to ON Figure 22 Figure 22 Main Circuit Breaker TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4
70. omes The installation site must be relatively free from moisture and dust All electrical equipment should be protected from excessive moisture Failure to do will result in deterioration of the insulation and will result in short circuits and grounding Foreign materials such as dust sand lint and abrasive materials have a tendency to cause excessive wear to the engine parts and alternator CAUTION Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area Indoor Installation Exhaust gases from diesel engines are extremely poisonous Whenever an engine is installed indoors the exhaust fumes must be vented to the outside The engine should be installed at least two feet from any outside wall Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves CAUTION An electric shock may happen when vibrators are used Pay close attention to handling when operating vibrators and always use rubber boots and gloves to insulate the body from electrical shock Generator Grounding To guard against electrical shock and possible damage to the equipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC provides guide lines for proper grou
71. r disassembling the fuel system bleed the system according to the following procedure To restart after running out of fuel turn the key switch to the 5 position for 15 30 seconds Try again if needed This unit is equipped with an automatic air bleeding system Service Daily If engine is operating in very dusty and dry grass conditions a clogged air cleaner will result in high fuel consumption loss of power and excessive carbon buildup in the combustion chamber Cleaning the Fuel Strainer Clean the fuel strainer if it contains dust or water Remove dust or water in the strainer cap and wash it in diesel Securely fasten the fuel strainer cap so that fuel will not leak Check the fuel strainer every 200 hours of operation or once month Check Oil Level Check the crankcase oil level prior to each use or when the fuel tank is filled Insufficient oil may cause severe damage to the engine Make sure the generator is level The oil level must be between the two notches on the dipstick as shown on page 31 Figure 9 Generator Storage For storage of the generator for over 30 days the following is required Drain the fuel tank completely Completely drain the oil from the crankcase and refill with fresh oil Clean all external parts of the generator with cloth generating set and store in clean dry place PAGE 40 TLG 12SPX PARTS AND OPERATION MANUAL STD REV
72. rating condition and both units are mechanically sound The following list of suggestions should be used when towing your generator Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating GVWR ALWAYS inspectthe hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure on both towing vehicle and trailer Also check the tire tread wear on both vehicles ALWAYS make sure the trailer is equipped with a Safety Chain COUPLER TRAILER 264 X HAND WINCH ADJUSTS TRAILER HEIGHT Figure 1 Generator with Trailer ALWAYS attach trailer s safety chain to bumper of towing vehicle ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly The maximum speed for highway towing is 45 MPH unless posted otherwise Recommended off road towing is not to exceed 10 MPH or less depending on type of terrain Place chocked blocks underneath wheel to prevent rolling while parked Place support blocks underneath the trailers bumper to prevent tipping while parked Use the trailers hand winch to adjust the height of the trailer then insert locking pin to lock wheel stand in place while parked Avoid sudden stops and starts This can cause skidding or jackknifing Smooth gradual starts and stops
73. result in poor starting or malfunctions Always keep the terminals firmly tightened Coating the terminals with a thin film of grease will help to inhibit corrosion Battery Cable Installation ALWAYS be sure the battery cables Figure 16 are properly connected to the battery terminals as shown below The RED cable is connected positive terminal ofthe battery and the BLACK cable is connected to the negative terminal of the battery POSITIVE NEGATIVE Figure 16 Battery Connections CAUTION If the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polarity of the battery when connecting the battery When connecting battery do the following 1 Place a small amount of grease around both battery terminals This will ensure a good connection and will help prevent corrosion around the battery terminals CAUTION Inadequate battery connections may cause poor starting of the generator and create other malfunctions Wiring Inspect the entire generator for bad or worn electrical wiring or connections If any wiring or connections are exposed insulation missing replace wiring immediately Piping and Hose Connection Inspect all piping oil hose and fuel hose connections for wear and tightness Tighten all hose clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately Single Phase Load Always
74. s 3 10 items 5 Get special freight allowances when you order 10 or more H H line items via FAX Now Direct TOLL FREE access UPS Ground Service at no charge for freight to our Parts Department PS Third Day Service at one half of actual freight cost MM Toll free nationwide No other allowances on freight shipped by any other carrier Common nuts bolts and washers all items under 1 00 list price 800 421 1244 do not count towards the 10 line items Toll free FAX DISCOUNTS ARE SUBJECT TO CHANGE 800 6 5 7 800 672 7877 Fax order discount and UPS special programs revised June 1 1995 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 5 RULES FOR SAFE OPERATION CAUTION NEVER touch the hot exhaust Failure to follow instructions in this manual manifold muffler or cylinder Allow may lead to serious injury or even death these parts to cool before servicing This equipment is to be operated by trained engine or generator and qualified personnel only This equipment is for industrial use only The following safety guidelines should always be used when operating the TLG 12SPX portable generator DO NOT E High Temperatures Allow the engine to cool before adding fuel or performing service and maintenance GENERAL SAFETY functions Contact with hot components can cause serious E DO NOT operate or service this equipment before b
75. servicing WARNING HOT PARTS can burn skin eDo nottouch until the machine has sufficiently cooled M92010000 We ull Lu P N M9520100004 P N M9510100004 PAGE 18 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX SPECIFICATIONS Table 5 Specifications Generator Specifications Model TLG 12SPX Sound level dB A 67 Full load 23 feet Type Revolving field self ventilated drip proof single bearing generator Engine Specifications 1 4 gal 5 3L hr at full load 1 2 gal 4 5L hr at 3 4 load Fuel Consumption 1 0 gal 3 7L hr at 1 2 load 0 8 gal 3 0L hr at 1 4 load Battery 12V 70Ah x 1 Fuel 2 Diesel Fuel TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 19 TLG 12SPX GENERAL INFORMATION TLG 12SPX FAMILIARIZATION Generator The Power Model TLG 12SPX is a 9 6 kW generator that is designed as a high quality portable power source for telecom sites lighting facilities power tools submersible pumps and other industrial and construction machinery Control Panel The Control Panel is provided with the following Engine Speed Switch Indicator panel Output Voltage Adjustment Knob Frequency Meter Hz AC Ammeter Amps AC Voltmeter Volts Main Circuit Breaker 50 amps Output Terminal Panel The Output Terminal Panel is provided with the following 120 240V output receptacle 50 a
76. tacle Output Terminal Panel The Output Control Panel See Figure 6 is located on the rear Control Panel end of the generator The UNV lugs are protected by a face plate cover that can be secured in the close position by a 6mm bolt See Figure 7 UNV LUG COVER Figure 8 Retaining Bolt 120 Volt Receptacle One GFCI Duplex Nema 5 20R 120V 20 Amp receptacle is provided on the output terminal This receptacle can be used anytime the generator is in operation The receptacle is controlled by the circuit breaker located on the control panel Pressing the reset button will reset the receptacle if it is tripped Pressing the Test Button See Figure 2 in the center of this receptacle will check the GFCI function The receptacle should be tested at least once a month esee Figure 9 GFCI Test GFCI TEST BUTTON Button NEMA L5 30R Output Receptacle The L5 30R receptacle supplies 30 amps at 120 volts A 30 amp circuit breaker helps protect any load being used NEMA L6 30R Output Receptacle The L6 30R is receptacle that supplies 30 amps at 240 volts The 30 amp circuit breaker helps protect any load being used NEMA CS 6369 Output Receptacle The CS 6369 is a receptacle that supplies 50 amps at 120 240 volts A 50 amp circuit breaker helps protect any load being used See Figure 12 for details Connecting Load Loads are to be connected to the generator by the receptacles supplied Make sure to read the
77. te output may be determined by multiplying voltage by amperage by Figure 17 Battery Connections Motors and motor driven equipment draw much greater current for starting than during operation CI engine enclosur rs Figure 18 An inadequate size connecting cable which cannot carry the required load cause voltage drop which burn out the appliance or tool and overheat the cable When connecting resistance load such as an incandescent lamp or electric heater a capacity of up to the generating set s rated output KW can be used amp lt il Be Sy adi 1 ne When connecting a fluorescent or mercury lamp a CORRECT INCORRECT capacity of up to the generating set s rated output KW multiplied by 0 6 can be used Figure 18 Engine Enclosure Doors When connecting an electric drill or other power tools pay close attention to the required starting current 4 Ground any equipment necessary using the ground capacity lug on the generator and the GFCI ground plug located on the output terminal panel next to the throttle lever See Figure 8 page 29 for proper grounding techniques PAGE 36 TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 TLG 12SPX START UP PROCEDURE Before Starting Starting the Generator Engine 1 Set Throttle switch to Start ldle Figure 19 1 Checkthe lubricating oil level prior t
78. tiquip package ifany and with Muiltiquip partnumbers clearly marked The following items are not returnable Obsolete parts If an item is listed inthe parts price book as being replaced by another item itis obsolete b Any parts with a limited shelf life such as gaskets seals O rings andother rubber parts that were purchased more than six months priorto the return date c Anylineitemwithan extended dealer net priceoflessthan 5 00 Special order items Electrical components Paint chemicals and lubricants Decals and paper products Items purchased in kits The sender will be notified of any material receivedthatis notacceptable Such material will be held for 5 working days from notification pending instructions If a reply is not received within 5 days the material will be returned tothe sender at his expense Credit on returned parts will be issued at dealer net price at time of the original purchase less 15 restocking charge In cases where an item is accepted for which the original purchase document can not be determined the price will be based on the list price that was effective twelve months the date Credit issued will be applied to future purchases only PRICING AND REBATES Prices are subject to change without prior notice Price changes are effective on a specific date andallorders receivedonorafterthatdate will be billed a
79. ts be obtained from your dealer IMPORTANT CHECK DAILY SAFETY INSTRUCTIONS 1 Radiator water level Improper operat on of this machine can cause severe injury or death Read the nstruction manual ly before operating or servicing Th ne should on be operated by a person with sufficient know edge and sk to ensure safe operation 2 Reserve tank water level Important Not more than 50 50 Anti FreezeNvater H gh voltage c rcuits are located ns the output terminal cover and control panel Close the cover and contro pane before operat ng Mixture is recomended Engine Level Moving parts and hot surfaces are contained wthin the enc osure P N 63906 71 1 04 Close al doors and lock them before operat ng GROUND For G F C I 5 3821 76706 24004 OFF WATER 5 1880 63606 10304 5 4753 CIRCUIT BREAKER SUPPORT Never use it for lifting the unit Use the LIFT HOOK on the roof for lifting 5 2257 DIESEL FUEL TLG 12SPX PARTS AND OPERATION MANUAL STD REV 4 03 08 05 PAGE 17 VOLTAGE REGULATOR 13206 21504 TLG 12SPX GENERATOR DECALS WARNING ____ Before connect ng th s generator to ding s R electr cal system a licensed electr c an must nsta isolation transfer sw tch ed death may res
80. tthe revised price Rebates for price declines and added charges for price increases will not be made for stock on hand atthe time of any price change Multiquip reserves the right to quote and sell directto Government agencies and Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 20 00 to 50 00 surcharge will be addedto the invoice for special handling including bus shipments insured parcel post or in cases where Multiquip must personally deliver the parts tothe carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable here under for damagesin excess of the purchase price of the item with respect to which damages are claimed and in no event shall Multiquip be liable for loss of profit or good will or for any other special consequential or incidental damages LIMITATION OF WARRANTIES Nowarranties express or implied are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip Such warranties made in connection with the sale of new complete units are made exclusively by statement of warranty packaged with such units and Multiquip neither assumes not authorizes any person to assume for it any other obligation or liability whatever in connection withthe sale ofits products from such written statement of warranty there arenowarranties express implie
81. ult w thout th 5 H IG H VO LTAG 5 4985 9520100004 08040619904 DANGER EXPLOSIVE GASES Cigarettes flames sparks could cause batter to explode Always shield eyes and face from battery Do not charge or use dooster cables adjust post connections without proper instruction and training KEEP VENT CAPS TIGHT AND LEVEL POISON causes SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing In event of accident flush with water and call a physician immediately path from the ground termina KEEP OUT OF REAGH CHILDREN on this genset to an external grounding source See instruction P N 08206 50604 manua for detais P N B93110050 WARNING ELECTRIC SHOCK HAZARD Always comp ete the grounding WARNING ENGINE EXHAUST can cause severe death HOT COOLANT can cause severe burns Use only in open well ventilated areas or vent exhaust outside P N B950420004 MOVING PARTS can cause severe injury Do not operate with doors open Stop engine before Do not remove if radiator is hot P N B9504100104 SUPPORT HOOK Never use it for lifting the unit Use the LIFT HOOK on the roof for lifting S 2257 P N 1320621504 servicing P N M9503000004 WARNING ___ ELECTRIC 5 HAZARD e Do not touch internal wiring or connections while this machine is operating e Turn power off before
82. urns reading this entire manual The engine of this generator requires adequate free flow of cooling air Never operate the generator in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people The generator engine gives off DEADLY carbon monoxide gas This equipment should not be operated by persons under 18 years of age NEVER operate this equipment without proper protective clothing shatterproof glasses steel toed boots and other protective devices required by the job NEVER operate this equipment when not feeling well due to fatigue illness or taking medicine CAUTION NEVER operate this equipment under the Always refuel in a well ventilated area influence or drugs or alcohol away from sparks and open flames NEVER use accessories or attachments which are not recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result Manufacturer does not assume responsibility for any accident due to equipment modifications Always use extreme caution when working with flammable liquids When refueling stop the engine and allow it to cool DO NOT smoke around or near the machine Fire or explosion could E Whenever necessary replace nameplate operation and safety decals when they become difficult r
83. wheels tires and axle are properly matched Center Wear Over Inflation particular load per tire manufacturer Adjust pressure to manufacturer Make sure load does DO NOT attempt to repair or modify 9 Align wheels correct a leak through the rim If the ri Check bearing adjustment is cracked the Wheel lockup amp Avoid sudden stops when tire skidding possible and adjust brakes air pressure in the inner tube may cause pieces of the rim to explode break off with great force and cause serious eye or bodily injury Suspension The leaf suspension springs and associated components Figure 2 should be visually inspected every 6 000 miles for Tire Wear Inflation signs of excessive wear elongation of bolt holes and Tire inflation pressure is the most important factor in tire life loosening of fasteners Replace all damaged parts Pressure should be checked cold before operation DO NOT suspension immediately Torqued suspension components bleed air from tires when they are hot Check inflation as detailed in Table 3 pressure weekly during use to insure the maximum tire life andtread wear Table 2 Tire Wear Troubleshooting will help pinpoint the causes and solutions of tire wear problems CAUTION SHACKLE NUTS AXLE CAUTION SHACKLE SUPPORT BRACKET IS WELDED Ma VNA U BOLT 9 HANGER SUPPORT BRACKET IS WELDED SHACKLE TO FRAME BOLTS LEAF SUSPENSION FRONT H

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