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PARTS MANUAL MODEL SERIES: P1204 12 kW Stationary Standby Electric Generator Product style and configuration may vary. Thoroughly read the OPERATOR’S MANUAL before operating the generator. Safe operation and top performance can be obtained only when equipment is operated and maintained properly. Deadly exhaust fumes! This generator is designed to be installed outside only! 200-2666 - Revision A - 10/07 TA B L E O F C O N T E N T S BATTERY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 3 GENHEAD INLET PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 4 CONTROL PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 5 MUFFLER BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 6 ENGINE GENHEAD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 7 ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 8 GENERATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 9 NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 10-11 CUSTOMER SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 12 2 200-2666 PA R T S D R AW I N G - B AT T E RY A S S E M B LY PA R T S L I S T - B AT T E RY A S S E M B LY Item No. 1 2 3 Part Number 026-0481 026-0480 N/A Qty 1 1 1 Description CABLE BATTERY, NEGATIVE CABLE BATTERY, POSITIVE BATTERY, BCI GROUP 26 or 26R VENTED *N/A - Must be purchased separately. 200-2666 3 PA R T S D R AW I N G - G E N H E A D I N L E T PA N E L A S S E M B LY NOTE: Seal all connections with gas tape. Use 2½ wraps minimum. Check all connections under pressure using a soap and water solution. PA R T S L I S T - G E N H E A D I N L E T PA N E L A S S E M B LY - 2 2 K W Item Part No. Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 068-0076 026-0741 N/A N/A N/A 012-0142 103-0160 093-0074 058-0177 058-0176 061-0220 N/A 115-0397 N/A 114-0652 019-0252 064-0056 068-0088 N/A 115-0364 Qty Description 2 2 1 1 2 2 5 4 4 4 4 4 1 2 2 1 1 1 1 1 FITTING 3/4NPT X 1/2BARB SOLENOID FUEL SHUT OFF NIPPLE 3/4" NPT BLACK PIPE CLOSE ELBOW, 3/4” STEEL NPT BOLT HH 1/4-20 X 1.00 CLAMP-CONDUIT, 1" CLIP-WIRE LOCKING PUSH MOUNT LINER-PLASTIC, EXTRUSION NUT-TEE, ZINC 5/16-18 NUT-TEE, 1/4"-20, SLF LCK SCREW, 1/4-20 UNC CUP POINT SET BOLT, 5/16" X 1/2 HEX HEAD INLET BOX SIDE, 12KW CLAMP HOSE 1" ID EXTRUSION CORNER UPRIGHT REGULATOR-PRESSURE ELBOW 90 DEGREE BRASS CONNECTOR 1/8" NPTF x 3/8" TB HOSE, FUEL 1/2” PANEL-ENGINE INLET Item Part No. Number 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 0057079 026-0776 N/A 026-0798 0037762.01 N/A N/A 0057183 N/A 094-0158 012-0147 114-0664 N/A N/A 115-0378 N/A N/A 093-0053 145-0562 Qty Description 1 1 1 2 1 2 26 3 2 1 1 1 4 12 1 1 2 1 1 OIL COOLER TERMINAL BLOCK SCREW #8-32 X 1 1/4" LG SCKT HD RELAY DC 12V COIL RECPT 5-20R BLK BOLT HH 1/4-20 X 1.50 SCREW, #10 TRILOBE 1/2" PANHEAD GROMMET .88ID X 1.50OD SCREW, #08-32 X.25 INSULATION, ENGINE INLET PANEL HOSE-FUEL, LP .50" ID BAFFLE-AIR INLET BOLT HH 1/4-20 X .63 ZP NUT 1/4-20 NYLON STOP CONTROL BOX BACK NUT HEX #8-32 KEPS WSHR-FLAT .344D X 1.125 GROMMET 1" I.D. x 1 3/4" O.D. FUEL INLET ASSEMBLY *N/A - These are standard parts available at your local hardware store. 4 200-2666 PA R T S D R AW I N G - C O N T R O L PA N E L A S S E M B LY PA R T S L I S T - C O N T R O L PA N E L A S S E M B LY Item No. Part Number Qty Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 002-0060 0058069 N/A 026-0780 061-0221 026-0309 026-0518 026-0548 N/A 115-0405 N/A 115-0398 N/A 103-0160 N/A N/A N/A N/A 0057217 N/A N/A 098-3949 098-3976 098-3974 1 1 4 1 4 2 1 1 4 1 8 2 8 1 4 4 2 2 1 8 4 1 1 1 BREAKER CIRCUIT 50 AMP BREAKER MOUNT CIR BREAKER NUT #6-32 NYLON INSERT STOP CONTROLLER DYNAGEN, GSC200 STANDOFF #6-32 UNC X .438 FUSE HLDR FUSE 3AG TYPE 25 AMP 32V FUSE 3AG TYPE 5AMP 250 VOLT NUT 1/4-20 NYLON STOP CONTROLLER BOX DYNAGEN, GSC200 WASHER LOCK 1/4 ZP SHROUD STAND-OFF BRACKET BOLT HH 1/4-20 X .75 CLIP-WIRE LOCKING PUSH MOUNT WASHER, LOCK #06 SCREW, CRPH#06-32 X .38 SCREW, CRPH #08-32 X.25 SCREW, BUTTON HEAD #10-32 X 3/4" LG BATTERY CHARGER HX NUT 1/4 BOLT HH 1/4-20 X .63 LABEL, BREAKER ON/OFF LABEL, OVERLAY DYNAGEN GSC200 LABEL, FUSE 25 026-0781 1 (NOT SHOWN)WIRE HARNESS, ENGINE/CONTROLLER *N/A - These are standard parts available at your local hardware store. 200-2666 5 PA R T S D R AW I N G - M U F F L E R B O X A S S E M B LY PA R T S L I S T - M U F F L E R B O X A S S E M B LY Item No. 1 2 3 4 5 6 7 Part Number 094-0144 115-0391 094-0146 094-0147 094-0150 115-0392 N/A Qty 2 1 1 1 1 1 12 Description INSULATION, SIDES MUFFLER BOX BASE INSULATION, BOTTOM INSULATION, TOP INSULATION, FRONT SIDE MUFFLER BOX TOP SCREW, #10 TRILOBE 1/2" PANHEAD TORX *N/A - These are standard parts available at your local hardware store. 6 200-2666 PA R T S D R AW I N G - E N G I N E G E N H E A D A S S E M B LY PA R T S L I S T - E N G I N E G E N H E A D A S S E M B LY Item Part No. Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 025-0076 160-0309 115-0390 N/A N/A 115-0389 N/A 093-0074 114-0652 N/A N/A 115-0399 N/A 115-0366 N/A 058-0176 061-0220 058-0177 094-0153 N/A Qty Description 1 1 2 8 4 2 4 4 2 4 4 2 8 1 4 8 4 8 1 4 ENGINE, SUBARU, EH72 GEN ASSY "UL" 1446 MECCALTE 12KW GENHEAD AIR SCOOP SCREW, #10 TRILOBE 1/2" PANHEAD SCREW #8-18 X .375" LG GENHEAD AIR SCOOP COVER BOLT HH 1/4-20 X .75 LINER-PLASTIC, EXTRUSION EXTRUSION CORNER UPRIGHT WASHER LOCK 1/4 ZP HEX NUT 1/4 NC SHROUD MOUNTING BRACKET BOLT, 1/4"X 3/8"-20 PANEL-GENHEAD INLET BOLT, 5/16" X 1/2 HEX HEAD NUT-TEE, 1/4"-20, SLF LCK, DUAL TAP SCREW, 1/4-20 UNC CUP POINT SET NUT-TEE, ZINC 5/16-18 INSULATION-GENHEAD INLET SCREW LAG 5/16" x 2" Item Part No. Number 21 22 23 24 25 26 27 28 29 30 108-0185 109-0124 N/A N/A N/A 801-0007 N/A N/A 094-0068 103-0115 Qty Description 1 1 12 2 3 1 1 4 3 1 ASSEMBLY-FRAME PALLET-PLASTIC SCREW, 5/16"-18 X 3/4" LG BOLT, 5/16NC HHCS X1 1/2 G5 WASHER LOCK 1/4 ZP MUFFLER, EH72, SUBARU BOLT, 5/16NC HHCS X1 1/4 G5ZP BOLT WHZ 3/8-16 X .75 ISOLATOR, VIBRATION CLIP, WIRE HARNESS *N/A - These are standard parts available at your local hardware store. 200-2666 7 PA R T S D R AW I N G - E N C L O S U R E PA R T S L I S T - E N C L O S U R E Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number Qty Description 115-0367 115-0431 1 1 STEEL LID ASSEMBLY (INCLUDES INSULATION) ALUMINUM LID ASSEMBLY (INCLUDES INSULATION) 094-0152 115-0369 115-0432 094-0151 094-0149 094-0160 115-0373 115-0433 094-0148 112-0151 115-0375 115-0434 094-0159 146-0029 058-0177 N/A N/A 1 2 2 2 2 1 1 1 2 4 1 1 1 1 4 4 4 INSULATION-LID STEEL ASSEMBLY-DOOR SIDE (INCLUDES INSULATION & 1/4 TURN LATCHES) ALUMINUM ASSEMBLY-DOOR SIDE (INCLUDES INSULATION & 1/4 TURN LATCHES) INSULATION-DOOR PANEL WEATHER SEAL, 1/8 X 1/4 X 39.50 INSULATION, AIR INLET DOOR PNL STEEL ASSEMBLY-DOOR AIR INLET (INCLUDES INSULATION) ALUMINUM ASSEMBLY-DOOR AIR INLET (INCLUDES INSULATION) WEATHER SEAL, 1/8 X 1/4 X 21.50 1/4 TURN LATCH ASSEMBLY, 32MM FINGER PULL STEEL ASSEMBLY-DOOR EXHAUST OUTLET (INCLUDES INSULATION) ALUMINUM ASSEMBLY-DOOR EXHAUST OUTLET (INCLUDES INSULATION) INSULATION, EXHAUST OUTLET DOOR 12KW KEY-1/4 TURN LATCH NUT-TEE, ZINC 5/16-18 WIDE SPOT WELD BOLT, 5/16NC HHCS X1 1/4 G5ZP WASHER, STAR 5/16 EXT *N/A - These are standard parts available at your local hardware store. 8 200-2666 PA R T S D R AW I N G - G E N E R AT O R Torque to 15 lbs-ft ITEM 10 PA R T S L I S T - G E N E R AT O R Item No. 1 2 3 4 5 6 7 8 9 10 -- 200-2666 Part Number 0056629 0056623 160-0311 100-0003 059-0348 160-0312 166-0133 077-0168 098-2827 026-0774 160-0309 Qty 1 1 1 2 1 1 2 1 1 1 1 Description DISCHARGE LOUVERED COVER ENGINE ADAPTER ROTOR ASSEMBLY DIODE/VARISTOR ASSEMBLY ROTOR BOLT STATOR ASSEMBLY CAPACITOR, 40F, 500V TERMINAL BOX COVER WARNING LABEL WIRE HARNESS, GENHEAD COMPLETE GENERATOR ASSEMBLY 9 NOTES 10 200-2666 NOTES 200-2666 11 CONTACT THE POWERMATE PRODUCT SERVICE DEPARTMENT AT 1-800-445-1805 to obtain warranty service information or to order replacement parts or accessories. HOW TO ORDER REPLACEMENT PARTS Even quality built equipment such as the Powermate standby generator you have purchased, might need occasional replacement parts to maintain it in good condition over the years. To order replacement parts, please give the following information: 1. Model No. and Serial No. and all specifications shown on the Model No./Serial No. plate. 2. A brief description of the trouble with the generator. Powermate Corporation 4970 Airport Road P. O. Box 6001 Kearney, NE 68848 1-800-445-1805 1-308-237-2181 Fax 1-308-234-4187 Made in USA with domestic and foreign components Powermate Corporation, Aurora, IL 60504 ©2007 Powermate Corporation All Rights Reserved. Tous droits réservés. Reservados todos los derechos. Powermate® is a registered trademark of Powermate Corporation. Powermate® est une marque déposée de Powermate Corporation. Powermate® es una marca comercial registrada de Powermate Corporation. PowerStation® is a registered trademark of Powermate Corporation. PowerStation® est une marque déposée de Powermate Corporation. PowerStation® es una marca comercial registrada de Powermate Corporation.