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Multiquip SG1400C3-55748 User's Manual

1. PAGE 84 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PART NO 54732 54733 EE16449 EE24234 EE11315 EE32580 EE18071 EE18072 16428 EE16434 48477 RADIATOR PIPING PART NAME TY UPPER WATER LINE LOWER WATER LINE ELBOW 2 1 2 X 90 RUBBER FILTER COOLANT SPIN ON MNTG HEAD KIT COOLANT FILTER BRACKET FUEL SEP COOLANT FILTER VALVE LOCKING BALL BRASS 3 8 FNPT 2 VALVE LOCKING BALL BRASS 1 2 FNPT HOSE STR RAD BLUE 1 3 4 X 3 7 1 1 1 HOSE STR RAD BLUE 2 1 2 X 7 uo nas 1PC 1FT CLAMP SILICONE HEATER HOSE 2 1 16 TO 3 12 OBTAIN LOCALLY HOSE 3 8 GOODYEAR HIGH MILER REMARKS JZOR ADS EO oa 90 OBTAIN LOCALLY HOSE 3 8 GOODYEAR HIGH MILER 2 UT OBTAIN LOCALLY HOSE 5 8 GOODYEAR FLAME RESISTANT INST GRIP USMSHA 2G IC 14C 33 OBTAIN LOCALLY HOSE 1 4 SAE 7 uuu uuu uu u p m OBTAIN LOCALLY BOLT HXHD 3 8 X 1 2 OBTAIN LOCALLY WASHER LOCK 9 8 5i oisi dites me LE OBTAIN LOCALLY WASHER FEAT GR 2 n OBTAIN LOCALLY HOSE 3 8 GOODYEAR HIGH MILER J20R3 HI D3 EC unu u d u u usu OBTAIN LOCALLY HOSEI4 WATER uuu u uyu u un usa OBTAIN LOCALLY CLAMP
2. mE AN x X gt lt gt lt gt gt Ck x CoolantLevel chex x 0 DriveBets Chek X j Engine Coolant Antifreeze Chek X _ Fuel Fiter Spin On Type Replace Lubricating Oil Change X Radiator PressureCap Check X Cooling Fan Bet Tensioner Chek Fan Hub BetDwen ff og Cooling System _ Vibration Damper Rubber Check Vibration Damper Viscous Chek X m The lubricating oil and lubricating oil filter interval can be adjusted based on application fuel consumption gross vehicle weight and idle time gt gt gt gt lt gt lt gt lt gt lt 2 Antifreeze check interval is every oil change or 500 hours or 6 months whichever occurs first The operator must use heavy duty year round antifreeze that meets the chemical composition of ASTM D6210 The antifreeze change interval is 2 years or 2000 hours whichever occurs first Antifreeze is essential for freeze overheat and corrosion protection 3 Follow the manufacturer s recommended maintenance procedures for the starter alternator generator batteries electrical components exhaust brake charge air cooler radiator air compressor air cleaner refrigerant compressor
3. 37 VIGNE MANIC ecc 38 43 Troubleshooting Generator 44 Troubleshooting Engine 45 Troubleshooting Controller 46 Trailer Guidelines 47 61 Hydraulic Hoses Schematic 62 Maintenance Parts Locator 6 Generator Wiring 64 65 Explanation Of Codes In Remarks Column 66 Suggested Spare 67 TABLE OF CONTENTS Component Drawings Housing Base 68 69 Housing Interior ASSY 70 71 Camlok 4 72 73 Control Box Assy Panel 74 75 Control Box Assy Interior 76 77 Engine Generator Mounting Assy 78 79 Radiator Muffler Support 90 81 Radiator Fan 5 82 83 uisum emp da E CO 84 85 Air Filter Hosing Piping 06 87 mA 88 89 Saddle 90 91 Engine Starter Relay And Battery Assy 92 93 Fuel System 5
4. RELAY STARTER SOLENOID 24V 45026 SENSOR COOLANT LEVEL 4954905 SENSOR WATER TEMPERATURE doin 4921517 SENSOR OIL PRESSURE ang RELAY BOSCH 24V L 3973834 THERMOSTAT RE 3954829 SEAL THERMOSTAT 1 2881804 KIT WATER PUMP W SEAL EE5804 FUSE 10 AMP B EE5810 FUSE 30 50 AMP rm EE5788 FUSE BUSS AGC 10 AMP NOTICE Part numbers on this Suggested Spare Parts list may supersede replace the part numbers shown in the following parts lists G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 67 HOUSING BASE ASSY PAGE 68 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 HOUSING BASE ASSY PART PART NAME QTY REMARKS 1 55742 HOUSING 1400 STUDIO SINGLE BUS DOOR 1 2 EE40474 BASE 1400A STUDIO 48 X 100 1 3 ia SEE NOTICE BELOW 4 6 6 SEE NOTICE BELOW 5 IO D RF FA SEE NOTICE BELOW 6 EE6653 BRACKET STEP BAFFLE MTG TO HSG 2 7 WASHER COMM 3 a OE OBTAIN LOCALLY 8 WASHER 61 6 1 e OBTAIN LOCALLY 9 c NWFN YCW HRN A FAR ANF Boon OBTAIN LOCALLY
5. AEHICCFEC YTLLOFEOSIT E2 CYMYDN EM Y T DYLE DE ex EY CS OU ED 309 HEA V IEHICTE COMEOBWNG LO WT CIVWDYDDO bEEGCBIBED JHE AEHICTE CVEELA ELEECL OTI EHE DUE CE AEHICOFE E LL 1 LO WIT YbbrICYBTE N H ELEECL OV LAE DWALE VRAC MET 2 V EEA DE COMET 4 EVGH YXTE CHYGNE E22IER eR AWN BBA NEYCANHED BA fo DM Figure A Vehicle VIN Tag G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 49 VIN TAG Figure B VIN Tag Location The trailer VIN Tag contains the following critical safety information for the use of your trailer GAWR The maximum gross weight that an axle It is the lowest of axle wheel or tire rating Usually the tire or wheel rating is lower than the axle rating and determines GAWR GVWR The maximum allowable gross weight of the trailer and its contents The gross weight of the trailer includes the weight of the trailer and all of the items within it GVWR is sometimes referred to as GTWR Gross Trailer Weight Rating or MGTW Maximum Gross Trailer Weight GVWR GTWR and MGTW are all the same rating The sum total of the GAWR for all trailer axles may
6. 24VDC 106 cee EXTERIOR 306 WORK LIGHTS 107 ace OPTIONAL 307 108 308 109 CONTROL POWER WORK LIGHT TIMER 309 GRN RED CB9 BLU RED YELLOW 24 VDC 110 INTERIOR 310 WORK LIGHTS 111 K10 IVDR 311 BLU RED 30 86 INTAKE VENT DOOR 112 SOLENOID 12 113 313 BLU RED 30 BLK WHT EXHAUST VENT DOOR 114 SOLENOID 314 ns in 0 5 as 24 po STARTER SOANE 116 RED 4 0 AWG 7 RED 10AWG BLK ae CHARGING ALTERNATOR Ha STARTER 318 119 SOLENOID 4 PIN POWER CONNECTOR 319 LOCATED 120 EN 320 ii POWER CONNECTOR 33 122 322 Es ar PRIMING 2 optional 10 AMP FUEL PUMP 124 BATTERY DISCONNECT 324 SWITCH 125 325 126 326 24 VDC SYSTEM 127 ENGINE BATTERIES 327 SERIES CONNECTION 128 328 ALLD CGROUNDS 129 INTELLIVISION 5 DISPLAY MODULE NE AT 329 ENGINE BLOCK 130 GROUND POINT 330 131 331 132 332 133 IG NTC BB 333 INTELLIGEN GEN SET CONTROLLER OPTIONAL 134 OTHER CONNECTIONS AT 334 GROUND FAULT CT LINES 419 420 524 535 622 623 ES 135 ORG YEL 335 136 336 137 337 138 338 139 339 140 GRY RED War GRY RED GRY RED GRY RED WHITE GREEN WHT 500 SH6 RED 2 it ECM 50 PIN INTERFACE CONG SH1 RED s MEM v 202 5 402 LOW COOLANT SH1 WHT 0 pu LEVEL SENSOR Lus SH1 SHD pec IG NTC BB 5 5 OPTIONAL INTELLIGEN GEN SET CONTROLLER 205 OTHER CONNECTIONS AT ANALOG CONVERTSI OAGSH
7. REV 1 02 15 12 PAGE 43 TROUBLESHOOTING GENERATOR Troubleshooting Generator Sympom Possible Problem 0005 Low Voltage Output High Voltage Output Short Circuit in load Check load and repair 0 ver current Confirm load requirements and reduce Defective circuit breaker Check and replace Over current Relay actuated Confirm load requirement and replace PAGE 44 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 TROUBLESHOOTING ENGINE Troubleshooting Engine Symptom Possible Problem No Fuel reaching injection pump Add fuel Check entire fuel system Defective fuel pump Replace fuel pump Fuel filter clogged Replace fuel filter and clean tank Faulty fuel supply line Replace or repair fuel line Check piston cylinder and valves Adjust or Compression too low repair per engine repair manual Engine will not start or start is delayed 9 although engine can be turned over Fuel pump not working correctly Repair or replace fuel pump Oil pressure too low Check engine oil pressure Comply with cold starting instructions and Low starting temperature limit exceeded proper oil viscosity Defective battery Charge or replace battery Check carefully for loosened fuel line Air or water mixed in fuel system coupling loose cap nut etc Refill engine crankcase with correct type of Eng
8. The proper tightness torque for lug nuts is listed in the lug nut tightening section of this manual Use a torque wrench to tighten the lug nuts If you do not have a torque wrench use a lug wrench from your tow vehicle and tighten the nuts as much as you can Then have a service garage or trailer dealer tighten the lug nuts to the proper torque Metal creep between the wheel rim and lug nuts will cause rim to loosen and could result in a wheel coming off leading to death or serious injury Tighten lug nuts before each tow TRAILER GUIDELINES Lug nuts are also prone to loosen after first being assembled When driving a new trailer or after wheels have been remounted check to make sure they are tight after the first 10 25 and 50 miles of driving and before each tow thereafter Failure to perform this check can result in a wheel parting from the trailer and a crash leading to death or serious injury Lug nuts are prone to loosen after initial installation which can lead to death or serious injury Check lug nuts for tightness on a new trailer or when wheel s have been remounted after the first 10 25 and 50 miles of driving Improper lug nut torque can cause a wheel parting from the trailer leading to death or serious injury Be sure lug nuts are tight before each tow Improper tire pressure can result in a blowout and loss of control which can lead to death or serious injury Be sure tires are inflate
9. 94 97 Hyd Vent Actuator Hosing Assy 98 99 Engine Component Assy 100 101 Hyd Manifold Valve And Hose Assy 102 103 Hyd Tank Filter And Hose Assy 104 107 Hyd Pump Cooler Fan Motor And Hose Assy 108 109 Crankcase Ventilation Assy 110 111 Trailer 0 2 112 113 Terms And Conditions Of Sale Parts 114 NOTICE opecifications are subject to change without notice PAGE 4 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options Effective January 15 2006 Order via Internet Dealers Only you have MQ Account to obtain a Username Order parts on line using Multiquip s SmartEquip website and Password E mail us at partsmultiguip View Parts Diagrams com Order Parts To obtain an MQ Account contact your District Sales Manager for more information Print Specification Information p ee 1 Goto www multiquip com and click on Use the internet and qualify for a 5 Discount Parts lto log in and save on Standard orders for all orders which include complete part numbers L Order Fax Dealers Only Fax your order in and qualify for a 2 Discount All customers are welcome to ord
10. HYD VENT ACTUATOR HOSING ASSY PART NAME QTY REMARKS 1 2 5 HOSE 3 8 X35 MANIFOLD to CYLINDER 6802 08 06 NWO ELBOW 45 1 2 MJ to 3 8 MAORB 2501 06 04 EE41337 EE46266 41837 KTM110210 30 250 10 287 28 248 10 289 10 258 6400 06 06 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 99 ANGLE BRACKET SOLENOID VALVE 3WAY 24V 3 8 PORTS 2 1 ELBOW 90 3 8 to 1 4 NPT 2 1 1 CONN DIN PROPORTIONAL SOLENOID 1 BOLT HEX HD 1 4 20 X 2 OBTAIN LOCALLY WASHER FLAT iia i qus t vecta bsa OBTAIN LOCALLY WASHER LOCK 1 4 OBTAIN LOCALLY NUT 1 4 20 59 nA YH HR RR nny OBTAIN LOCALLY O gt VINYL TUBING CLEAR 1 4X3 8X18 LONG 3 HOSE BARB STEEL 1 4 30882 4 4B 4 ELBOW MALE 90 SAE 45 FLARE 1 4X1 4 149F 4 4 2 TEE BRASS STREET 1 2 2225P 8 1 ELBOW MALE 90 SAE 45 FLARE 1 4X1 2 149F 4 8 1 FITTING BRASS MALE 1 4X1 2 48F 4 8 1 FITTING STRAIGHT 3 8MJX3 8MAORB 1 ENGINE COMPONENT ASSY 6 7 A lt PAGE 100 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 1
11. WASHER FEAT 8 NUT NY LOG 9 0 erinin tiation BOLT HXHD 3 6 16 X 1 WASHER LOCK 3 8 NUT GIS akay TRANSFORMER CURRENT 1000 5 SADDLE BOX ASSY QTY REMARKS OBTAIN LOCALLY ous OBTAIN LOCALLY AR OBTAIN LOCALLY 4 OBTAIN LOCALLY nae 8 OBTAIN LOCALLY gs 8 OBTAIN LOCALLY 3 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 91 ENGINE STARTER RELAY AND BATTERY ASSY PAGE 92 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PART NO 55818 2923 2917 10881 10878 EE9983 EE9954 EE9985 EE55839 EE55840 EE11875 EE7752 EE7791 EE34486 EE40908 EE22005 EE22005 EE22005 EE23247 EE23248 EE5758 EE5788 EE43186 PART NAME PANEL STARTER RELAY RELAY BOSCH 24V RELAY STARTER SOLENOID 24V BREAKER CIRCUIT PUSHBUTTON 30A BREAKER CIRCUIT PUSHBUTTON 15A TRACK FLEXIBLOCK TERMINAL STRIP BLOCK BLUE FLEXI TERMINAL 6 STOP BLUE FLEXI BLOCK TERMINAL SPACER 1 2 IDXI ALUM STANDOFF 1 4 20 1 BATTERY AUTO GROUP 27 CENTENNIAL TRAY BATTERY 27 60 SS BRACKET HOLD DOWN ANGLE J BOLT BATTERY 10 38 LONG NUT ACORN 5 16 18 SS NUT NYLOCK 55 5 16 18 SS WASHER SNUBBING 2 0 OD 45 I
12. otop 0 Figure 31 STOP Button 4 Press the STOP button again to shut down the engine NOTICE STOP button is not pressed again the engine will remain in idle mode for about an hour then will shut down 5 Place the Control Power switch Figure 32 on the control panel to the OFF position DOWN Figure 32 Control Power Switch OFF EMERGENCY SHUTDOWN PROCEDURE 1 Press the STOP button twice Figure 31 on the controller to shut down the engine 2 Place the main circuit breaker Figure 30 in the OFF position PAGE 36 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PROTECTIVE DEVICES Protection devices and emergency stop devices are designed as standard components for protection of the generator against trouble during operation The LCD on the Digital Controller will inform the user when a fault has occurred When a major fault is detected such as low oil pressure high water temperature and overspeed the engine automatically shuts down Check the display for the fault and correct the problem For minor faults the engine will continue working Stop the engine and remedy the cause of the problem The Digital Controller will display the cause of the fault Before inspecting or troubleshooting the generator press the OFF button on the Digital Controller Place the main circuit breaker in the OFF position and allow sufficient time for adequate cooling PRO
13. 10 EE33397 ASSY STEP BAFFLE WITH INSULATION 1 NOTICE For repair of the base unit needs to be returned to the MQ Service Department in Carson CA Contact Telephone No 800 421 1244 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 69 HOUSING INTERIOR ASSY gt cc lt LLI ac PAGE 70 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PART NO 55742 844402 9 279 1 PH110ZN EE55742 1 2101 L LEFT 87403 ASSY 107084 2 107084 1 10 EE55742 18 11 EE55742 18 2 11A 2 12 EE55742 18 1 13 EE55742 18 3 14 EE55742 18 4 15 R241542 KEYIL101 16 84402 11 ASSY oe SI I 17 PH108ZN 18 84402 8 ASSY 19 84402 25 20 9416K1720 21 EE26562 22 9416K74 23 EE7745 24 EE26552 25 26313 26 23297 27 55742 18 5 28 EE7379 29 7490 30 21973 31 10244 32 EE10644 33 97440 1 ASSY 34 87440 2 ASSY 35 EE39267 36 EE39269 37 26975 38 EE7663 39 EE22204 40 EE16554 41 42 43 EE55766 44 EE55790 HOUSING INTERIOR ASSY PART NAME HOUSING 1400 A STUDIO SINGLE BUS DOOR DOOR ASSY LEFT SIDE HANDLE DOOR ASSY LATCH DOOR HANDLE 2 POINT DOOR ASSY CAMLOK HANDLE DOOR ASSY DOOR ASSY RAIN DOOR EXHAUST VENT DOOR ASSY INTAKE VENT DOOR ASSY DOOR ASSY CONTROL PANEL PLEXIGLASS WINDOW GASKET PLEXIGLASS WINDOW DOOR CONTROL PANEL BRACKET DOOR PROP
14. By rotating the jack handle clockwise the jack will extend and raise the tongue of the trailer The load rating of the coupler and the necessary pintle hitch size are listed on the trailer tongue You must provide a pintle hitch and pintle coupler for your tow vehicle where the load rating of the pintle hitch and pintle coupler is equal to or greater than that of your trailer Also the pintle hitch size must be the same as the pintle coupler size If the hitch is too small too large underrated loose or worn the trailer can come loose from the tow vehicle and may cause death or serious injury Pintle Coupler and Pintle Hook Before each tow check the locking device that secures the coupler to the pintle hook assembly The pintle hook lever must be able to operate freely and automatically snap into place into the latched position Lightly oil the pivot points and sliding surfaces with SAE30W motor oil to prevent rust and help ensure proper operation of the latching mechanism If you see or feel evidence of wear such as flat spots deformations pitting or corrosion on the pintle hook or coupler immediately have your dealer inspect them to determine the proper action to prevent possible failure of PAGE 54 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 the ball andcoupler system All bent or broken coupler parts must be replaced before towing the trailer THE TOW VEHICLE PINTLE HITCH AND
15. GROUND ROD uz FOR EARTH GROUND 4 NOTE GROUND LUG MUST CONNECT TO BE INSTALLED BY USER RARE Wy GROUND Figure 2 Typical Generator Grounding Application PAGE 14 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 OUTDOOR INSTALLATION Install the generator in a area that is free of debris bystanders and overhead obstructions Make sure the generator is on secure level ground so that it cannot slide or shift around Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes 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 engine and alternator parts 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 whic
16. JU OBTAIN LOCALLY NUT FINISHED HEX HD 1 2 13 BRASS OU OBTAIN LOCALLY WIRE WITH TERMINAL 5 CONN FEMALE SOCKET MIL SPEC 20 PIN 1 SCREW PHIL TRUSS 6 32X1 2 SS 4 CAP PROTECTIVE MS RECEPTACLE 1 CABLE ETHERNET CAT5E SHIELDED 50 1 CONVERTER COMAP NT TO LEGACY PAR L 1 SCREW PHIL TRUSS HD 6 32X5 8 SS 2 2 RAIL DIN ALUM 413 1 37 1 END STOP DIN RAIL SDCIA 2 LEXAN COVER OUTPUT BUS 2 STICKER DANGER HIGH VOLTAGE 2 STANDOFF HEX STYLE ALUM 3 2 PLACARD VINYL ADHESIVE ARC FLASH 7 BOLT HEX HD 1 4 20 X 3 4 5 6 WASHER LOCK 1 4 SS 6 WASHER FLAT 1 4 6 MAKE LOCALLY OBTAIN LOCALLY pu OBTAIN LOCALLY RUNE OBTAIN LOCALLY sacas OBTAIN LOCALLY dms OBTAIN LOCALLY T OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 73 CONTROL BOX ASSY PANEL PAGE 74 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 gt 4 O 3 EE55750 EE6523 EE55753 EE55754 10387 10390 EE10391 EE6585 EE2668 EE55761 EE5663 EE2619 EE2595 EE2591 43775 44320 51131 CONTROL BOX ASSY PANEL PART NAME
17. ADD FULL OIL LIMIT Figure 11 Engine Oil Dipstick When checking the engine oil be sure to check if the oil is clean 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 Cummins Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements B API Service Classification CC SC B API Service Classification CC SD Service Classification CC SE Service Classification CC SF Table 11 Recommended Motor Oil OIL SAE INSPECTION SETUP FUEL CHECK 4 DANGER Fuel spillage on a hot engine can cause gt a fire or explosion If fuel spillage occurs wipe up the spilled fuel completely to prevent fire hazards NEVER smoke around or near the generator Refilling the Fuel System ONLY properly trained personnel who have read and understood this section should refill the fuel tank system This generator has a fuel tank located in the sub base assembly frame ALWAYS fill the fuel tank with clean fresh 2 diesel fuel DO NOT fill the fuel tank beyond its capacity Pay attention to the fuel tank capacity when replenishing fuel The fuel tank cap must be closed tightly after filling Handle fuel in a safe container If the container does not have a spout use a funnel Wipe up any spilled fuel immediately Refueling Procedure Diesel fue
18. MANIFOLD VALVE AND HOSE ASSY PART PART NAME QTY REMARKS 1 4 7423 MANIFOLD HYD ACTUATORS 150 PSI 1 2 41126 TEST FITTING PRESSURE GAUGE 1 3 41837 CONN DIN PROPORTIONAL SOLENOID 1 4 47425 BRACKET HYD ACTUATOR MANIFOLD 1 5 SCREW PAN HD 102922 u k uuu omi piden OBTAIN LOCALLY 6 WASHER PEAR OBTAIN LOCALLY 7 NUT INY LOCK a OBTAIN LOCALLY 8 BOLT HX HD 1 4 X 1 1 2 u uuu usss 2 OBTAIN LOCALLY 9 WASHER FLAT usus OBTAIN LOCALLY 10 NUT NYEOON uu 1 l luu 2 OBTAIN LOCALLY 11 6802 08 06 NWO ELBOW 45 1 2 MJ x 3 8 MAORB 1 12 30 255 BARB 45 SAE FLARE FEMALE SWIVEL 1 2 1 2 3 13 10 300 ELBOW 90 1 2 1 2 MALE FLARE MALE NPTF 2 15 EE18072 VALVE LOCKING BALL BRASS 1 2 FNPT 1 16 28 214 FITTING HX NIPPLE 1 2 NPTF 1 17 28 027 TEE UNION 1 2 NPTF 1 18 28 225 FITTING REDUCING HX NIPPLE 3 4 x 1 2 NPTF 1 19 28 249 TEE STREET 3 4 1 20 37982 8 8 BARB SAE 90 SWIVEL HB 1 21 HOSE INSTAGRIP 1 2 300SIWP FLAME OBTAIN LOCALLY RESISTANT USMSHA 20 16 140 33 GOODYEAR 22 6801 08 06 NWO ELBOW 90 1 2 MJ x 3 8 MAORB 1 23 6801 06 06 NWO ELBOW 90 3 8 MJ x 3 8 MAORB 2 24 G8SAE100R2 AT160 HOSE HYD 3 8 x 160 MANIFOLD to 3 WAY VALVE 1 G1400C3 STUDIO GENERATO
19. PANEL INSTR INTELIVISION 5 HINGE CONTROL PNL MTG INTELIVISION 5 7 DISPLAY INTELLIGEN NT BASE BOX W ETHERNET METER DIGITAL RED LED FREQUENCY METER DIGITAL RED LED AC VOLTMETER METER DIGITAL RED LED AC AMMETER COVER DIGITAL METER SWITCH ROTARY VOLTAGE SELECTOR LIGHT PANEL LED LED RED 24 V SNAP IN MTG SWITCH TOGGLE MOM ON OFF MOM ON SWITCH TOGGLE DPDT ON OFF ON SWITCH TOGGLE SINGLE POLE SPST RUBBER BUMPER MALE 5 16 18 WASHER 3 16 SPACER ALUM SCREW PHIL TRUSS M S 10 32X3 8 SS DONGLE LOADSHARING AND POWER MGMT QTY cb REMARKS OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 75 CONTROL BOX ASSY INTERIOR PAGE 76 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 55789 EE41835 EE45116 EE26112 EE26107 EE26106 EE10618 EE10071 EE26385 23861 26135 2998 4 7964 EE3015 EE55870 EE55810 EE55811 55793 55794 40238 2940 41836 42034 EE37735 EE37935 EE32611 EE36833 EE55812 EE41693 55813 EE55788 CONTROL BOX ASSY INTERIOR PART NAME QTY REMARKS BOX INTELLIGEN CONTROL 1 SX MICRO CONTROL CAN BUS HYD CTRL 1 CONN DEUTCH 9 PIN ROUND 1 BLOCK TERMINAL SAK 4 WEIDMULLER END PLATE TERM SAK 4 WEIDMULLER PARTITION WEIDMULLER SWITCH 15 MIN TIMER W SCREWS
20. RAILDIN ALUM 413 1 37 X36 BASE RELAY SNAP SURFACE MTG 8 BLADE RELAY MINIATURE 8 BLADE RETAINER HLD DOWN WIRE FOR RLY 8 BLADE BASE DIN RAIL SNAP MTG 5H SERIES 5 BLADE RELAY MINIATURE 5 BLADE RETAINER RELAY HOLDDOWN IDEC MIDGET TRANSFORMER 120V COMAP 16 AVRI TRANS 100 RECEPTACLE DEUTCH 24 PIN GASKET DEUTCH RECEPTACLE 24 PIN RECEPTACLE DEUTCH 40 PIN GASKET DEUTCH RECEPTACLE 40 PIN MODULE VOLT REG CTRL INTELLIGEN A C SCREW TRUSS HD 6 92 1 2 99 nu O OBTAIN LOCALLY NUT NYLOG 6 927 59 Pb un uS OBTAIN LOCALLY SCREW TRUSS HD 8 82 X5 8 SS 8 OBTAIN LOCALLY NUT NY LOG 00 OBTAIN LOCALLY SCREW PN HD 1 4 20 X 2 1 4 SS 2 OBTAIN LOCALLY END STOP DIN RAIL SO W SCREW CONN KIT SX MICRO CONTROL 18 CONTACT CONN KIT SX MICRO CONTROL 3 CONTACT FAN CONTROL PROGRAMMING CONNECTOR 4 PIN SOLID GOLD PLATED 16 51 PLUG SEAL DEUTCH 12 16 SOCKETS 27 JUMPER 3 POLE SAK 4 WEIDMULLER 9 SOCKET SOLID GOLD CONTACT 51 PLUG DEUTCH 24 SOCKET 1 CONN RECTANG 40 SOCKET 5216 1 BOOT DEUTCH DRC26 24 BT 1 BOOT DEUTCH DRC26 40 BT 1 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 77 ENGINE GENERATOR MOUNTING ASSY WATER DRAIN OIL DRAIN FUEL IN PAGE 78 SG1400C3 STUDIO GENERATOR OPERATION A
21. WASHER FLAT 3 8 SAE FLASHING ALUM RAD SPACER BOLT HX HD 3 8 16 X 1 1 4 NUT 3 8106 2 ipi HERR BOLT HX HD 1 4 20 X 1 WASHER FLAT WA 0AE sons du dus NY LOK 4 201222 uuu RE EE LAMP RUBBER HSG 24 VDC W MTG HDWR BOLT 3 8 16 X2 9 4 WASHER FLAT 9 8 tco aaa asas a NUT NYLOCK 3 8 T6 sciant tite RO NO OO OBTAIN LOCALLY AR OBTAIN LOCALLY AR OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY BHO OBTAIN LOCALLY EM INCLUDES ITEMS W nin OBTAIN LOCALLY OBTAIN LOCALLY m OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 81 RADIATOR FAN ASSY PAGE 82 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PART NO EE41227 EE38918 EE43735 EE41285 EE40443 42213 42208 46381 46373 7079 41809 41081 42215 42568 42988 45521 45520 45518 45026 45519 26294 RADIATOR FAN ASSY PART NAME QTY RADIATOR ALUM 1 OVERFLOW BOTTLE RAD COOLANT 1 BRACKET OVERFLOW BOTTLE 1 MNTG PLATE CHARGE AIR COOLER 2 CHARGE
22. and fan clutch PAGE 38 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 GENERAL INSPECTION Prior to each use the generator should be cleaned and inspected for deficiencies Check for loose missing or damaged nuts bolts and other fasteners Also check for fuel oil and coolant leaks Use Table 14 as a general maintenance guideline For engine maintenance refer to the engine maintenance manual AIR FILTER Every 250 hours Remove air filter element Figure 33 and clean the filter element with low pressure compressed air Air pressure must not exceed 30 psi 207 kPa The filter can be cleaned and reused for up to six times if properly cleaned Replace air filter if rips or tears are detected while cleaning Air Filter Dust Indicator The air filter indicator Figure 33 is attached to the air filter When the air filter element is clogged air intake restriction becomes greater and the air filter indicator signal shows RED When indicator is red replace filter immediately After changing the air filter press the air filter indicator button to reset Air Filter Indicator Air Filter Element Figure 33 Air Filter Indicator MAINTENANCE NOTICE The air filter should be changed more frequently in dusty operating conditions the engine is operating in very dusty or dry grass conditions a clogged air cleaner will result This can lead to a loss of power excessive
23. lighting system operates from the 24 VDC battery system The light fixtures are sealed incandescent bulbs which are activated by a 0 15 minute timer switch located on the side control panel box The DC lighting system can be used to perform off line maintenance or assist in setup prior to AC power connection Trailer Optional If equipped the generator set can be mounted on a tandem axle trailer Standard trailer is available with 8 lug chrome wheels and electric or hydraulic brakes Options may include electric jack stands adjustable hitch ground rod holder and rear stabilizing jacks OPTIONS Battery Charger 24 VDC 3 AMP 120 V Input Battery Disconnect Switch 400 Amps Optima Red Top Batteries Replaces standard batteries Block Heater 120 V 1500 Watt CSA Package Includes 400 Amp and 200 Amp Circuit Breakers Exterior Lights Fire Extinguisher and Box Mounted on Door Forklift Base GPS and Remote Monitoring Module Lift off Doors Low Oil Murphy Swichgage Oil Level Sight Glass 30 Micron Racor 1000 Fuel Water Separator Replaces Racor 900 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 17 InteliVision 5 Digital Controller The InteliVision 5 Digital Controller provides monitoring and fault detection capability of all engine and generator operating parameters A list of operating parameters is sh
24. AIR COOLER 1 HEAT EXCHANGER OIL AIR COIL 1 BRACKET OIL COOLER 1 SCREW CAP SOCKET HD 8 32 X 1 2 HAT SECTION EXHAUST VENT HYD ACT 1 NUT 14 20 2 HYDRAULIC CYLINDER 1 1 2 10 STROKE 2 SPRING EXT 072 DIA X 16 LG SS 4 SHIM 063 BRACKET HYD MOTOR 4 BRACKET HYD MOTOR 1 MOTOR HYD 1 FAN 30 9 BLADE 40 1 WASHER SAFETY HYDRAULIC FAN 1 SEAL PACKARD CONN 3 TERMINAL FEMALE PACKARD CONN 3 CONN BODY 3 TERMINAL PACKARD 1 SENSOR COOLANT LEVEL 3 PIN 1 TPA LOCK 3 TERMINAL PACKARD CONN 1 BOLT HEX HD 3 8 16 X 4 WASHER PEAR 3 8 uu u NUT NYLOC THIN 3 8 16 sss SCREW FLAT SOCKET HD 3 8 16 X 1 NUT NYLOC 3 05 1D d sos BOLT HX HD 3 8 16 X 1 sss SN WASHER LOCK sitet DC Mert EE t BOLT HX HD 1 4 20 X 4 UU a WASHER LOCK 1 4 M conn WASHER FLAT 1 4 5 REMARKS OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 83 RADIATOR PIPING
25. BLUE HEATER AR OBTAIN LOCALLY SAEJ20R3 HT D3 EC GOODYEAR 30 266 BARB FEMALE 37 JIC FLARE SWIVEL 3 8 x 3 8 1 6801 06 06 NWO ELBOW 90 3 8 MJ x 3 6 MAORB 1 6801 08 10 NWO ELBOW 90 5 8 MAORB 1 2 MJ 1 1 2SAE100R2 AT 124 HOSE HYD 1 2 124 MOTOR TO COOLER 1 1 2SAE100R2 AT 04 HOSE HYD 1 2 x 94 90 STR BYPASS TO COOLER 1 6602 08 08 08 RUN TEE 1 2 FJS 1 2 MJ x 1 2 MJ 1 6801 08 12 NWO ELBOW 90 1 2 MJ 3 4 MAORB 1 1 2SAE100R2 AT 170 HOSE HYD 1 2 x 170 COOLER TO TANK 1 6801 08 12 NWO ELBOW 90 3 4 MAORB 1 2 MJ 1 1 2SAE100R2 Al 94 HOSE HYD 1 2 X 94 FILTER TO MOTOR 1 S BSAE100R2 Al 48 HOSE HYD 3 8 48 MOTOR MANIFOLD 1 6801 08 08 NWO ELBOW 90 1 2 MJ x 1 2 MAORB 1 6801 06 08 NWO ELBOW 90 3 8 x 1 2 MORB 1 6835 08 08 08 NWO_ TEE RUN 1 2 FORM x 1 2 FORM x 1 2 FORB 1 2 MAORB1 EE41126 TEST FITTING PRESSURE GUAGE 1 6410 08 04 0 FITTING STRAIGHT 1 2 MORB x 1 4 FORB 1 6835 08 08 08 NWO TEE RUN 1 2 FORB 1 2 FORB x 1 2 FORB x 1 2 MAORB 1 6410 10 08 O FITTING STRAIGHT 1 2 FORB x 5 8 MORB 1 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 109 CRANKCASE VENTILATION ASSY TO ENGINE BLOCK PAGE 110 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 CRANKCASE VENTILATION ASSY PART PART NAME QTY REMARKS 56220 ASSY CRANK
26. DOOR PROP LATCH LOCKING DOOR ASSY FRONT LATCH DOOR HANDLE 3 POINT DOOR ASSY RIGHT SIDE DOOR ASSY RIGHT SIDE FRONT GAS SPRING 20 LB BALL STUD GAS SPRING 10 MM STEEL BALL SOCKET 10 MM STEEL BRACKET EXTERIOR LIGHTS LIGHT OVAL 24 V GROMMET EXTERIOR LIGHTS MANUAL HOLDER BRACKET DOOR LATCH BRACKET RETAINER DOOR STOP ASSY STRAP ANCHOR DOOR RESTRAINT GUIDE 7 16 SS STOP DOOR CHAIN 30 SWITCH OMRON ENCLOSED LIMIT SWINGING SKIRT ASSY RT SWINGING SKIRT ASSY LT ASSY FLANGE AND NIPPLE 6 LOW PRO RAIN CAP ASSY HOOK OPEN END TYPE 30455 SPOILER VENT DOOR PROTECTOR RAIN GUTTER J STRIP BLY FIN LAMP RUBBER HSG 24VDC W MTG HDWR BOLT 3 8 16 X 2 3 4 SS NUT HEAT SHIELD 6 RAINCAP 16 GA SS HAT SECTION VENT DOORS QTY REMARKS I cl I c cl c a Aa BPO MO RO N Y INCLUDES ITEMS W AR 1 PC 1 FT T INCLUDES ITEM W OBTAIN LOCALLY OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 71 CAMLOK ASSY PAGE 72 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 55746 6378 6381 6380 6379 6382 EE6387 55776
27. ENGINE OFF MANIFOLD 3 8 ID PAGE 62 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 MAINTENANCE PARTS LOCATOR 252 5 P 2 5 7 A Z 233 my 5109 yC Wy R Q 1 WY Y Xa ANN ays w 1 e 2 Drie Z A NW x 65 ji y y V Je d HU f N PA AA Ner Ab 577 cms GL 7 S 2 N h gt d 2 S 4 N LJ gt hy S OA N SY 2 999 y 3 SIS Z DNA ASL N Z NES 6 0 Devs KS N 0 AAMAS y D A 2 amp AN X ho 5 q v KY ANNES NAIA ALE V N O SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 63 GENERATOR WIRING DIAGRAM GRY RED WHT GRY RED GRY RED 13 14 100 2 STARTER SOLENOID 300 225 65 RELAY 101 ac 301 102 PANELLIGHTS 1 24V0C 302 0 WHT YEL PANEL LIGHTS a ONA L DROOP CT X E VDC 104 CB8 82 155 BUS PANEL LIGHT 304 RED YEL 305 EXTERIOR LIGHTS 606
28. HOSE FOR 1 4 DIA HOSE OBTAIN LOCALLY VALVE BALL BV SS 3 8 NPT 1 BOLT 9 8 X 1 61 OBTAIN LOCALLY WASHER FLAT 3 0 U uu sunan Peter OBTAIN LOCALLY NUT NYLOC THIN 3 8 16 OBTAIN LOCALLY CLAMP SILICON HEATER HOSE 1 3 16 TO 2 3 4 4 OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 85 FRONT VIEW 99 DNI ey 795 Lge gt IRA Wi lt REAR VIEW 2 4 0 gt 7 D NW 0 S Y Sw W ce 4 xj PAGE 86 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PART EE41139 P537876 EE24247 EE32335 EE16789 EE16792 EE24057 EE55031 EE36505 EE16667 EE48340 EE48341 EE54758 EE48686 16745 40452 41646 42343 55855 16666 10851 26294 55854 54757 54759 23216 55838 16786 10858 16787 AIR FILTER HOSING PIPING PART NAME AIR FILTER 13 DONALDSON ELEMENT AIR CLEANER BAND METAL A C MNTG 13 HUMP HOSE STR RUBBER 5 ID CIA TURBO STYLE 4 1 2 CIA TURBO STYLE 6 UNISTRUT NUT SPRING LOADED AIR INTAKE TUBE HUMP HOSE STR RUBBER 6 TO 5 CIA TURBO STYLE 5 ASSY FLANGE amp NIPPLE 5 DIA PERFORATED TUBING 5 AIR INTAKE
29. PARTS MANUAL REV 1 02 15 12 PAGE 95 FUEL SYSTEM ASSY WATER FUEL SEPARATOR A Cy PAGE 96 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PART NO 49411 5502 8 55857 5404 8 8 9602 8 2903 10 98 5404 8 6 2501 6 6 29180 2501 6 8 5404 4 4 2404 6 4 46690 37982 8 8 2404 8 4 28 194 NIPPLE 1 2NPT X 4 STEEL BLACK ELBOW 90 VALVE CHECK BALL 1 2NPT FEM SS NIPPLE PIPE HX 1 2 X 1 2 STREET TEE 1 2 THREAD ELBOW 45 7 8 14 X 1 2 20 NIPPLE PIPE HX 1 2 X 3 8 ELBOW 90 3 8 X 3 8 CLAMP HOSE 3 8 ELBOW 90 3 8 X 1 2 NIPPLE PIPE HX 1 4 X 1 4 ADAPTER MALE JIC 9 16 18 X 1 4 HOSE FUEL 1 4 X 15 SAEJ30R7 BARB 90 FOR 1 2 HOSE ADAPTER JIC MALE 3 4 16 X 1 4 ADAPTER EXTENDED 3 8 X 3 8 FUEL SYSTEM ASSY TY REMARKS 1 1 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 97 HYD VENT ACTUATOR HOSING ASSY REAR ACTUATOR YY GY Ah 1 J J 7 ID M 7 Y 6 3 eu 7 N 50 PAGE 98 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 cR ME PART
30. PINTLE COUPLER MUST HAVE A RATED TOWING CAPACITY EQUAL TO OR GREATER THAN THE TRAILER Gross Vehicle Weight Rating GVWR ITIS ESSENTIAL THAT THE PINTLE HITCH BE OF THE SAME SIZE AS THE PINTLE COUPLER The coupler size and load rating capacity are marked on the coupler Hitch capacity is marked on the hitch Coupler to hitch mismatch can result in uncoupling leading to death or serious injury Be sure the LOAD RATING of the pintle hitch hook is equal or greater than the load rating of the pintle eye coupler Be sure the SIZE of the pintle hitch hook matches the size of the pintle eye coupler A worn cracked or corroded pintle hitch hook can fail while towing and may result in death or serious injury Before coupling trailer inspect the pintle hitch hook for wear corrosion and cracks Replace worn or damaged pintle hitch hook Rock the pintle eye coupler to make sure it is secured tightly to the hitch E Wipe the inside and outside of the pintle coupler Clean and inspect it visually for cracks and deformations Feel the inside of the coupler for worn spots and pits Be sure the coupler is secured tightly to the tongue of the trailer All coupler fasteners must be visibly solid against the trailer frame Raise the bottom surface of the coupler to be above the top of the pintle hitch hook Use the tongue jackstand to support the trailer tongue Wood or concrete blocks may also be used TRAILE
31. RED AUXILIARY W I LEFT 6 PIN MOLDED I 6 PIN MOLDED TAIL LIGHT AUXILIARY CONNECTOR CONNECTOR CLEARANCE LIGHTS RIGHT TURN TAIL LIGHT TO CHASSIS I RIGHT GROUND TAIL L TAIL CLEARANCE LICENSE PLATE BROWN GROUND TO TOW VEHICLE WHITE AB BLACK LICENSE BLUE 6 7 e TAIL LIG YELLOW 5 LEFT TURN SIGNAL HAZZARD YELLOW 0 STOP LAMP RED 00000000 GREEN GE GREEN i 7 PIN ROUND 7 PIN ROUND CONNECTOR CONNECTOR LEFT STOP TAIL LIGHT TRAILER SIDE TOWING VEHICLE SIDE LEFT TURN Figure M Trailer to Tow Vehicle Wiring Diagram G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 61 HYDRAULIC HOSES SCHEMATIC 1 2 ID BYPASS lt OIL COOLER 3 8 ID 1 2 ID 3 8 ID CASE DRAIN 3000 PSI GAUGE CHECK VALVE 1 2 ID FILTER 3 4 1 2 10 O RING INTAKE VENT BALL VALVE 09 3 4 1 _ DRAIN VALVE 1 271 7 GALLON TANK PROPORTIONAL BER 3 4 NPT RELIEF VALVE A 3 8 ID 150 PSI 3 1 271 REDUCING VALVE 2 HOSES 600 PSI INTAKE VENT CLEAR CLEAR EXHAUST GAUGE CYLINDER p 1 4 ID CYLINDER gt 1 4 DRAIN 1 4 NPT 1 4 NPT DRAIN ENGINE ON Yi
32. REV 1 02 15 12 FUEL SAFETY DO NOT start the engine near spilled fuel or combustible fluids Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited m ALWAYS refuel in a well ventilated area away from Sparks and open flames m ALWAYS use extreme caution when working with flammable liquids DO NOT fill the fuel tank while the engine is running or hot DO NOT overfill tank since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system Store fuel in appropriate containers in well ventilated areas and away from sparks and flames NEVER use fuel as a cleaning agent 0 NOT smoke around or near the equipment Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine TOWING SAFETY Check with your local county or state safety towing regulations in addition to meeting Department of Transportation DOT Safety Towing Regulations before towing your generator 22 Refer to MQ Power trailer manual for additional safety information order to reduce the possibility of an accident while transporting the generator on public roads ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition ALWAYS shutdown engine before transporting SAFETY INFORMATION Make sure the hitch and coupli
33. TENSION A slack drive belt may contribute to overheating or to insufficient charging of the battery adjust drive belt in accordance with the Cummins Engine Owner s Manual DRIVE BELT INSPECTION Inspect the drive belt for damage and wear Horizontal across the belt cracks are acceptable See Figure 16 below Vertical direction of belt ribs cracks that intersect with horizontal cracks are not acceptable If the drive belt is frayed punctured or material is missing do not use drive belt Figure 16 Drive Belt Inspection yw NEVER place hands near the belts or fan while the generator is running PAGE 32 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 BATTERY This unit is of negative ground DO NOT connect in reverse Always maintain battery fluid level between the specified marks DO NOT over fill Battery life will be shortened if the fluid level is not properly maintained Add only distilled water when replenishment is necessary Check to see whether the battery cables are loose Poor contact may result in poor starting or malfunction Always keep the terminals firmly tightened Coat the terminals with an approved battery terminal treatment compound Replace battery with only recommended type battery The battery is sufficiently charged if the specific gravity of the battery fluid is 1 28 at 68 F If the specific gravity should fall to 1 245 or lower the batter
34. TUBING CAC TO AIR INTAKE HOSE CHARGE AIR COOLER 3 DIA X 6 NUT CORN DOME 3 8 16 CIA U STYLE ZINC HVY DUTY 3 BRACKET 3 U CLAMP CAC TUBING MODIFIED ELBOW CAC 3 DIA HUMP HOSE HIGH TEMP 3 DIA ELBOW 4 DIA X 90 SS CIA TURBO STYLE 4 ELBOW 90 RUBBER 4 INDIDICATOR RESTRICTED AIR FLOW CLAMP TURBO SPRING LOADED SS HOSE CAC 3 RING 3 5 X 6 5HO2NG CAC TO TURBO CIA TURBO STYLE 2 3 4 BLANKET CAC TUBING 45 3 CLAMP TURBO STYLE SS 3 HUMP HOSE REDUCER 5 TO 4 BOLT HX HD 1 4 20 X 1 WASHER FLAT 1 4 WASHER LOCK TA u uu its NUT 1 42 nb unupas CLAMP TURBO STYLE SS 3 1 2 QTY REMARKS dch o gt T 15 00 00 NK OBTAIN LOCALLY M OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 87 EXHAUST ASSY 7 1 PAGE 88 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PART EE55763 55747 16728 EE55764 EE55765 55758 45708 3903652 EXHAUST ASSY PART NAME QTY REMARKS MOUNTING BAND 16 ROUND SILENCER 16 CYLINDRICAL U CLAMP FLAT 5 X 3 8 TAILPIPE 5 EXPANDED U BOLT 4 FLAT ASSY FLEX TUBING BLANKET
35. a capacity of up to the generator s rated output KW can be used When connecting a fluorescent or mercury lamp a capacity of up to the generator s rated output kW multiplied by 0 6 can be used When connecting an electric drill or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generator s rated output KW multiplied by 0 8 can be used A DANGER Before connecting this generator to any building s electrical system a licensed electrician must install a transfer switch Serious damage to the building s electrical system may occur without this transfer switch PAGE 28 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES Generator Amperage wide range of voltages are available to supply voltage for Table 10 shows the maximum amps the generator can many different applications Voltages are selected by using provide DO NOT exceed the maximum amps as listed the voltage selector switch Figure 10 To obtain some of the voltages as listed in Table 9 see below will require Table 10 Generator Maximum Amps a fine adjustment using the voltage adjust toggle switch located the digital control panel Rated Voltage Total Amps Voltage Selector Switch casi ape 30 208 Vol e voltage selector switch Figure 10 is located on the 20286
36. and spindle washer remove the hub to inspect the bearings for wear and damage Replace bearings that have flat spots on rollers broken roller cages rust or pitting Always replace bearings and cups in sets The inner and outer bearings are to be replaced at the same time Replace seals that have nicks tears or wear Lubricate the bearings with a high quality EP 2 automotive wheel bearing grease WHEEL HUB ADJUSTMENT Every time the wheel hub is removed and the bearings are reassembled follow the steps below to check the wheel bearings for free running and adjust the hub slowly by hand while tightening the spindle nut until you can no longer turn the hub by hand ii Loosen the spindle nut just until you are able to turn it the spindle nut by hand Do not turn the hub while the spindle nut is loose ii Install a new cotter pin through the spindle nut and axle Check the adjustments Both the hub and the spindle nut should be able to move freely the spindle nut motion will be limited by the cotter pin ymw ci NEVER crawl under the trailer unless it is on firm and level ground and resting on properly placed and secured jackstands The possibility exists of the trailer falling thus causing equipment damage and severe bodily harm even death 4 DANGER When performing trailer inspection and maintenance activities you must jack up the trailer using jacks and jackstands When jack
37. be required to sufficiently tow the trailer and pump BRAKE CONTROLLER For trailers equipped with electric brakes the electric brake controller is part of the tow vehicle and is essential in the operation of the electric brakes on the trailer The brake controller is not the same as the safety breakaway brake system that may be equipped on the trailer SIDE VIEW MIRRORS The size of the trailer that is being towed and your state law regulations determine the size of the mirrors However some states prohibit extended mirrors on a tow vehicle except while a trailer is actually being towed In this situation detachable extended mirrors are necessary Check with your dealer or the appropriate state agency for mirror requirements HEAVY DUTY FLASHER A Heavy Duty Flasher is an electrical component that may be required when your trailer turn signal lights are attached to the tow vehicle flasher circuit ELECTRICAL CONNECTOR An Electrical Connector connects the light and brake systems on the trailer to the light and brake controls on the towing vehicle PAGE 50 56140063 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 EMERGENCY FLARES ANDTRIANGLE REFLECTORS It is wise to carry these warning devices even if you are not towing a trailer It is particularly important to have these when towing a trailer because the hazard flashers of your towing vehicle will not operate for as long a period of time when the
38. information about motor vehicle safety from http www satecar gov G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 3 560140063 Studio Generator Proposition 65 Warning 2 Reporting Safety 3 Table Of Contents 4 Parts Ordering Procedures 5 Safety Information 6 11 Specifications 12 DIMENSIONS EEF 13 Installation seen 14 15 General Information 16 18 Generator Major Components 20 21 Basic Engine Components 22 Basic Trailer 23 CODO Panel lll rR 24 Camlok Voltage Output 25 Circuit Breaker 26 Digital Controller 27 Load Application Generator Output 28 Generator Outputs a a 29 5 1 30 33 nc 34 36 Protective Devices
39. non OBTAIN LOCALLY OBTAIN LOCALLY anes OBTAIN LOCALLY m OBTAIN LOCALLY OBTAIN LOCALLY cm OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY N G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 93 FUEL SYSTEM ASSY WATER FUEL SEPARATOR PAGE 94 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 E d ee PART NO EE36703 2580 EE50144 EE11227 EE40458 EE37090 EE2609 EE10938 EE37503 EE10619 48478 4 8479 48480 4 8475 48477 48788 2501 6 4 6801 10 10 6801 8 10 28 212 944 116 10 256 30 250 10 257 28 247 FUEL WATER SEPARATOR RACOR BRACKET FULL SEPARATOR COOLANT FILTER PUMP FUEL STEWART WARNER 24V FILTER FUEL PUMP BRACKET WATERLINE amp PRIMING PUMP PLATE MTG FUEL PUMP SWITCH TOGGLE SPST OFF MOM ON BREAKER CIRCUIT AUTO RESET 24V 10A FITTING ADAPTOR ALUM RACOR DRAIN BOLT HEX HD 3 8 16 X 1 1 4 WASHER FLAT 38 NUT NYLOCK 3 8 16 BOLT HEX HD 1 4 20 X 1 1 4 WASHER FERT s S NUT NYLOCK 1 4 20 FILTER VOLUME CHAMBER 2 00 AMERICAN HOSE BARB
40. position the locking mechanism securely holds the coupler to the hitch ball Insert a pin or lock through the hole the locking mechanism Be sure the coupler is all the way on the hitch ball and the locking mechanism is engaged A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle Using the trailer jackstand verify that you can raise the rear of the tow vehicle by 1 inch after the coupler is locked to the hitch B Lower the trailer so that its entire tongue weight is held by the hitch Raise the jackstand to a height where it will not interfere with the road PAGE 52 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 NOTICE Overloading can damage the tongue jack DO NOT use the tongue jack to raise the tow vehicle more than one inch the coupler cannot be secured to the hitch ball do tow the trailer Call your dealer for assistance Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retracted position Attaching Safety Chain Visually inspect the safety chains and hooks for wear or damage Replace worn or damaged safety chains and hooks before towing Attach the safety chains so that they Cross underneath the coupler See Figure TOW VEHICLE TRAILER NZ TONGUE Q gt 0 0 4 2 Se Sx o
41. that is located on or under the rear bumper of tow vehicle This system of coupling a trailer to a tow vehicle is sometimes referred to as bumper pull A ball hitch trailer may be fitted with a tongue jack that can raise and lower the coupler The tongue jack is mounted to the A frame front or tongue part of the trailer By rotating the jack handle clockwise the jack will extend and raise the tongue of the trailer Figure C Ball Hitch Coupler Before each tow coat the ball with a thin layer of automotive bearing grease to reduce wear and ensure proper operation Check the locking device that secures the coupler to the ball for proper operation you see or feel evidence of wear such as flat spots deformations pitting or corrosion on the ball or coupler immediately have your dealer inspect them to determine the proper action to prevent possible failure of the ball and coupler system All bent or broken coupler parts must be replaced before towing the trailer The coupler handle lever must be able to rotate freely and automatically snap into the latched position Oil the pivot points sliding surfaces and spring ends with SAE 30W motor oil Keep the ball socket and latch mechanism clean Dirt or contamination can prevent proper operation of the latching mechanism The load rating of the coupler and the necessary ball size are listed on the trailer tongue You must provide a hitch and ball for your
42. the tow vehicle is equal to or greater than that of the trailer The trailer VIN tag contains the critical safetyinformation TRAILER GUIDELINES for the use of your trailer Again be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer Proper selection and condition of the coupler and hitch are essential to safely towing your trailer A loss of coupling may result in death or serious injury Be sure the hitch load rating is equal to or greater than the load rating of the coupler Be sure the hitch size matches the coupler size Observe the hitch for wear corrosion and cracks before coupling Replace worn corroded or cracked hitch components before coupling the trailer to the tow vehicle Be sure the hitch components are tight before coupling the trailer to the tow vehicle An improperly coupled trailer can result in death or serious injury DO NOT move the trailer until The coupler is secured and locked to hitch The safety chains are secured to the tow vehicle The trailer jack s are fully retracted DO NOT tow the trailer on the road until Tires and wheels are checked The trailer brakes are checked The breakaway switch is connected to the tow vehicle The load is secured to the trailer The trailer lights are connected and checked Use of a hitch with a load rating less than the load rating of the trailer can result in lo
43. tow vehicle where the load rating of the hitch and ball is equal to or greater than that of your trailer Also the ball size must be the same as the coupler size If the hitch ball is too small too large is underrated is loose G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 51 or is worn the trailer can come loose from the tow vehicle and may cause death or serious injury THE TOW VEHICLE HITCH AND BALL MUST HAVE A RATED TOWING CAPACITY EQUAL TO OR GREATER THAN THE TRAILER Gross Vehicle Weight Rating GVWR IT IS ESSENTIAL THAT THE HITCH BALL BE OF THE SAME SIZE AS THE COUPLER The ball size and load rating capacity are marked on the ball Hitch capacity is marked on the hitch Coupler to hitch mismatch can result in uncoupling leading to death or serious injury Be sure the LOAD RATING of the hitch ball is equal or greater than the load rating of the coupler Be sure the SIZE of the hitch ball matches the size of the ball coupler A worn cracked or corroded hitch ball can fail while towing and may result in death or serious injury Before coupling trailer inspect the hitch ball for wear corrosion and cracks Replace worn or damaged hitch ball A loose hitchball nut can result in uncoupling leading to death or serious injury Be sure the hitch ball is tight to the hitch before coupling the trailer Rock the ball to make sure it is tightened to the hitch and
44. 1 518 KRAUS amp NAIMER M RECONNECT SWITCH 2 CROMPTON M X400308 FREQUENCY METER in 35 99 99 H 235 AUX CONTACTS AT C DGHU BSAU AU 28 220 LINES 206 208 210 438 521 721 TEST POINTS 0 AT BUS PANEL IG NTC BB a INTELLIGEN CONTROLLER 722 0 9 9 9 OTHER CONNECTIONS AT 523 LINES 200 239 419 420 622 623 723 524 GREY 724 525 RED 725 526 BLU 2 726 ERA AUXILLIARY CONTACTS 528 AT LINE 219 YEL PUR AC8 6 6 728 529 gt YEL GRN amal 729 530 BLU PUR 6 PES Essi 730 J 531 ICER 2 BLU GRN ac ledio 731 1 a ll j 5 534 734 535 735 536 736 537 737 538 738 L1 AMMETER L2 AMMETER L3 AMMETER 539 0 1000 AAC 0 1000 AAC 0 1000 AAC 739 CROMPTON CROMPTON CROMPTON 262 DDBUL SSSC 6PO 262 DDBUL SSSC 6PQ 262 DDBUL SSSC 6PO BLU GRY BLU GRY 600 800 601 801 CUTLER AUXILLIARY CONTACTS m O O O HAMMER AT LINE 217 802 600 AMP D C G BREAKER 603 803 604 804 SKUR TRANS ABB AL16 22 00 81 CONTACTOR K9 106 WHT 606 120 VAC 806 1 2 ATM10 BLU GRY AC17 807 607 r 12AWG PURPLE 608 808 12 AWG PURPLE 609 809 610 810 en 12 AWG PURPLE an 120VAC n aa 12 AWG GREY 12 AWG PURPLE 213 12 AWG GREEN 15 AMP 614 814 615 69 815 CCRK3 ACI8 ORG GRY W2 BLU GRY 616 816 A3 lt 617 JOSLYN CLARK VACUUME CONTACTOR 817 AUXILIARY CONTACT AT LINE 212 618 818 619 Eee INTELLIGEN NT CONTROLLER 819 K5 BHSR BUS HOT
45. 1 08 12 NWO ELBOW 90 1 2 MJ x 3 4 MORB 1 42217 FILTER MEDIUM PRESSURE 4000PSI 1 E3041B1C05 ELEMENT HYD FILTER 1 2 4 2 BOLT HX HD TEX 1 sta uu OBTAIN LOCALLY WASHER FLAT 14 un trates etis OBTAIN LOCALLY NUT NYLOGCK 145 sss OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 105 HYD TANK FILTER AND HOSE ASSY ENGINE HYDRAULIC OIL PAN FILTER HYDRAULIC TANK NOTE Hose Ends C D E F and G are shown on HYD PUMP COOLER FAN MOTOR and HOSE ASSY PAGE 106 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 HYD TANK FILTER AND HOSE ASSY NO PARTNO PART NAME QTY REMARKS 26 42719 SPACER 1 2 OD x 1 4 ID x 3 4 LG ZINC PLT 27 EE55034 Z BRACKET HYD FILTER W QSB7 28 WASHER COMES WITH ENGINE 29 NUT COMES WITH ENGINE 30 12SAE100R2 AF94 HOSE HYD 1 2 x 94 FILTER TO MOTOR 31 6801 08 08 NWO ELBOW 90060 1 2 MAORB x 1 2 MJ 32 3832 08 08 08NWO BRANCH 1 2MAORB x 1 2FORB x 1 2FORB 33 6410 12 08 O FITTING STRAIGHT 3 4MORB x 1 2FORB 34 3474 08 08 NWO FITTING STRAIGHT 1 2MAORB x 1 2MORB 35 42147 PROPORTIONAL RELIEF VALVE W BODY 3000PS 36 6802 08 08 NWO ELBOW 45 1 2MAORB x 1 2MJ 37 1 2SAE100R2 AT 04 HOSE HYD 1 2 x 94 BYPASS TO COOLER p ideni clt y eh 39 7045 08 22 METRI
46. 2 STOP Button Press button to cool the generator for about 5 minutes then the generator will stop A second press will bypass cool down and will stop the generator immediately NOTICE START and STOP buttons work in MAN manual or SEM semi manual mode only 13 FAULT RESET Button Press button to acknowledge faults and alarms active only in Alarm screen 14 HORN RESET Button Press button to deactivate the horn audible alarm 15 DISPLAY Shows menu measurements setpoints alarm list history and help others screens NOTICE For more detailed operating and programming information on the digital controller refer to the InteliVision 5 Controller User s Guide G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 27 LOAD APPLICATION GENERATOR OUTPUT SINGLE PHASE LOAD Always be sure to check the nameplate on the generator and equipment to insure the wattage amperage frequency and voltage 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 NOTICE If wattage is not given on the equipment s name plate approximate wattage may be determined by multiplying namepl
47. 223 Fax 0161 339 3226 Unit 2 Northpoint Industrial Estate Globe Lane Dukinfield Cheshire SK16 4UJ Contact sales multiquip co uk CANADA Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin multiquip com Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 COPYRIGHT 2012 MULTIQUIP INC Multiquip Inc the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc and may not be used reproduced or altered without written permission All other trademarks are the property of their respective owners and used with permission This manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Your Local Dealer 15 MULTIQUIP
48. 3 AC Amps Display Indicates the amount of current the load is drawing from line 3 of the generator Voltage Status LEDs During operation these status LED s will indicate the phase voltage of the generator 30 277 480 30 120 208 or 10 120 240 Frequency Display Indicates the frequency of the generator in Hertz AC Voltmeter Display Indicates the output voltage present at the camlok terminals This display is used in conjunction with the voltmeter select switch item 8 Voltmeter Selector Switch Place switch in desired position to read line line or line neutral voltage Switch 5 used in conjunction with AC voltmeter display item 7 Digital Controller Starts and stops the generator and monitors various engine operating parameters 10 11 Controller Power Switch Provides power to engine controller Light Switch In the up position turns on exterior lights In the down position turns on panel lighting In the center position turns off all lights Panel Lights Located on each side of the digital control panel is a panel light Lights are activated by light switch Light Timer Control The interior lights are controlled by an electronic turn dial timer that allows the operator to turn on the lights inside the generator for up to 15 minutes The lights will automatically shut off when the timer reaches zero AC Output Connector Provides AC power to various electronic a
49. 5 back side of the Saddle Box Assembly It has been provided 606 amps for ease of voltage selection 120 208 32 Figure 10 Voltage Selector Switch NEVER change the position of the voltage selector switch while the engine is running ALWAYS place main circuit breaker in the OFF position before selecting voltage and activate voltage change mode switch Table 9 Voltages Available L1 L2 L3 Output Voltage Selector Switch Voltage Selector Switch Terminal Lugs 3 Phase 120 208V Position 3 Phase 480 277V Position 30 Line Line 208V 220V 240V 416V 440V 480V 10 Line Neutral 120V 127V 139V 240V 254V 277V Voltage Selector Switch Single Phase 240 120V Position 10 Line Neutral 120V 240 NOTICE Controller has over under voltage protection based on 208 V nominal 480 V nominal 240 V nominal voltage G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 29 MAIN CIRCUIT BREAKER The generator is equipped with a 3 pole 600 amp circuit breaker to protect the camlok receptacles from overload Make sure that the main circuit breaker is in the OFF position prior to starting the engine LUBRICATION OIL Fill the engine crankcase with lubricating oil through the filler hole but DO NOT overfill Make sure the generator is level and verify that the oil level is maintained between the two notches Figure 11 on the dipstick See Table 11 for proper selection of engine oil
50. 5 12 PAGE 101 PART NO 4989106 3974823 3954829 2874863 5256608 5256607 5257595 3947269 3947270 4932790 2830977 3937736 4921776 4921517 4010519 2872277 4928599 4921322 4903482 4954905 5263314 5260246 3974093 3957592 3979344 2881804 3906698 ENGINE COMPONENT ASSY QTY PART NAME FILTER FUEL THERMOSTAT W SEAL SEAL THERMOSTAT ALTERNATOR PUMP FUELASS Y PUMP FUEL ACTUATOR ETR FUEL CONTROL SEAL O RING SEAL O RING SCREW SOCKET HD CAP SEAL O RING CARTRIDGE LUBRICATOR OIL FILTER MODULE ELECTRONIC CONTROL SENSOR PRESSURE OIL SEAL O RING SENSOR POSITION SEAL O RING SENSOR PRESSURE TEMPERATURE SEAL O RING SENSOR TEMPERATURE INJECTOR W SEALS SENSOR PRESSURE FUEL VALVE PRESSURE RELIEF MOTOR STARTING BELT V RIBBED KIT WATER PUMP SEAL RECTANGULAR RING REMARKS LI lI INCLUDES ITEM W INCLUDES ITEM W 1 INCLUDES ITEM W INCLUDES ITEM W INCLUDES ITEM W 9 a INCLUDES ITEM W INCLUDES ITEM W HYD MANIFOLD VALVE AND HOSE ASSY 3 WAY VALVE PAGE 102 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 HYD
51. ARE 14951 cw 566 LINES 419 420 524 535 622 623 COM PORT TO SH3 RED DC18 SH3 RED FOR LEGACY CONTROLS 1406 A OPTIONAL 7 207 407 UL C ctn 21 K2 RSR 277748030 l 408 2 RED BLU_DC8 1 2 7 209 480 VAC LIGHT 409 s 590 1 ME 25 120 2401 211 MODE 5794 411 212 120 208 30 208 VAC LIGHT 412 120 208 au pio 5 60 HZ JUMPER 213 MODE 9 4 XZ T X X 413 L 5i3 214 CONTACTOR AUX CONTACTS 414 GCB YEL BLK 11 13 414 215 FEEDBACK 415 CONNECTOR 216 GCB AUX SWITCH e 416 2 0 GRN BLK 12 blue black MOUNT ON CONTROL BOX 217 GCB OPEN 417 602 218 GEN SENSING CB AUX 418 219 SENSING BREAKER BUS SENSING CB AUX 419 ST DC20 SH4 WHT UE io 1 42 COMMUNICATIONS WHT BLK 71 221 VOLTAGE UP 2 421 O sHesHD WW INPUT Ye ADJUST es 222 422 BRN BLK 223 VOLTTAGE DOWN 423 INPUT T 224 424 STARTER X STARTER OUTPUT 225 OUTPUT BLU BRN 13 14 RELAY 425 SX FAN CONTROL NO 100 PROGRAMMING 226 426 CONNECTOR FUEL BLK BRN ao as RUN SIGNAL 227 OUTPUT RAAH 427 CONTACT NO 408 HYDRAULIC FAN VALVE 28 DC22 SH7 WHT CLOSE CONTACTOR PROGRAMMED FOR BEA 229 429 CLOSE BREAKER 230 inte 430 PROGRAMMED FOR GRN BRN RELAY 231 IDLE NC 501 503 431 K5 BSHR DOi 232 432 12 8 BRN WHT CONVENIENCE CONTACTOR PROGRAMMED FOR WHT BRN BUS HOT SOURCE RELAY RA
52. C ADAPTER 1 2 FP x 22MM x 1 5 39 9900 8 ELBOW 90 MALE PIPE 40 18072 VALVE LOCKING BALL BRASS 1 2 FNPT 41 10 273 FITTING MALE ADAPTER SAE 45 FLARE 58x 1 2 42 30 258 BARB 45 SAE FLARE FEMALE SWIVEL 58 x5 8 43 HOSE 5 8 INSTAGRIP 300PSI WP OBTAIN LOCALLY FLAME RESISTANT USMSHA2G 1C 14C 33 GOODYEAR 44 10 303 ELBOW 90 MALE 5 8 x1 2 2 45 28 027 TEE UNION 1 2 NPTR 1 46 207ACBH 8 COUPLING BULKHEAD W STAR WSH amp NUT 1 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 107 HYD PUMP COOLER FAN MOTOR AND HOSE ASSY FAN MOTOR 49 9 HYDRAULIC NOTE Hose Ends A B C D E F and G are also shown on HYD TANK FILTER and HOSE ASSY PAGE 108 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 o HYD PUMP COOLER FAN MOTOR AND HOSE ASSY PART NO PART NAME QTY REMARKS 3 4SAE100R4 46 HOSE HYD 3 4 46 TANK TO PUMP 1 6801 12 12 NWO ELBOW 90 3 4 MJ x 3 4 MAORB 1 6801 08 10 NWO ELBOW 90 5 8 MAORB 1 2 MJ 1 1 2SAE100R2 AT 1 HOSE HYD 1 2 17 PUMP TO FILTER 1 55927 PUMP HYD 0 88CU IN REV CCW A FLANGE 1 SCREW SOCKET HD CAP 10MM 30MM OBTAIN LOCALLY WASHER FLAT 10MM OBTAIN LOCALLY WASHER FENDER 3 8 CUT FLAT on ONE SIDE 2 OBTAIN LOCALLY HOSE HIMILER
53. C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 111 TRAILER ASSY PAGE 112 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 6264 42617 EE35394 EE42618 EE55941 EE16523 EE23172 23173 23276 42512 7210 23182 43001 47139 43535 47063 2926 47138 47137 23183 47141 55450 16547 16549 EE36960 EE38731 EE38730 EE48199 EE38732 EE43005 PART NAME PINTLE EYE RING 3 CAP SCREW HX HD GRD 8 WASHER FLAT ZINC PLT 5 8 NUT HX NYLOCK INSERT GRD 8 ACTUATOR HYDR SURGE BRK 20K JACK BULLDOG SQ TUBE HOOK CHAIN CHAIN TRANSPORT TRLR 3 8 CARRIER SPARE TIRE TOOL BOX COVER TANDEM AXLE TANK FUEL 150 GAL SGL WALL FENDER 12 STUDIO TANDEM AXLE PLATE TREAD BRITE FENDER TOP CHROME BEZEL 2 1 2 W O VISOR LIGHT AMBER 2 1 2 CLEARANCE SIDE KIT LIGHT MARKER RED LIGHT UTILITY MULTI PURPOSE LIGHT GUARD STAINLESS STEEL LIGHT CLEARANCE MARKER RED BUMPER RUBBER CROME BEZEL 4 W O VISOR KIT LIGHT STOP TURN TAIL 4 RED LIGHT RED RUNNING WARNING LIGHT AMBER RUNNING WARNING AXLE TANDEM ELEC BRK TIRE 16 GOODYEAR W STEMS WHEEL RIM 16 CHROME LUG NUT 1 2 20 CHROME WHEEL amp TIRE 16 CHROME PLATE TREAD BRITE FENDER STEP 1PC 10FT G1400C3 STUDIO GENERAT
54. CASE VENT FILTER CV6001 1 1 CCV552393 CANISTER CRANKCASE ASSY 1 2 CCV55274 08 FILTER HIGH DENSITY 1 3 CCV55274 10 FILTER ULTRA DENSITY 1 EE56219 ADAPTER 1 5 8 O RING TO 3 4 FPT BRASS 1 4 55252 HEAD CRANKCASE ASSY 1 5 ELBOW 90 MALE 3 4 x 3 4 2 10 306 6 BARB 45 SAE FLARE FEMALE SWIVEL 3 4 x 3 4 2 30 259 7 HOSE 3 4 1BD LISTED STYLE GAS AR OBTAIN LOCALLY 8 GOODYEAR 559N 9 CLAMP HOSE TET OBTAIN LOCALLY 10 ADAPTER COMES W CRANKCASE VENT FILTER 1 12 HOSE 3 8 INSTAGRIP 300PSI WP FLAME RESISTANT USMSHA 2G 1C 14C 33 GOODYEAR AR OBTAIN LOCALLY 13 33782 6 6 BARB 45 STEEL HOSE FITTING 2 14 CCV55279 DRAIN CHECK VALVE KIT 1 15 28 106 FITTING HX BUSHING SAE130140 1 2 1 4 1 16 28 232 ELBOW 45 STREET SAE130339 3 8 NPTF 1 17 7045 08 22 METRIC ADAPTER 1 2 FP x 22MM 1 5MM 1 18 BOLT HX HD 5 16 1 3 4 d onse OBTAIN LOCALLY 19 WASHER FLAT O TO susciter OBTAIN LOCALLY 20 WASHERS LOCK 5 105 S OBTAIN LOCALLY 21 OBTAIN LOCALLY 22 56218 BRACKET CRANKCASE VENT FILTER 1 23 BOLT HX HD 1 4 20 x 8 OBTAIN LOCALLY 24 WASHER LOCK u u t OBTAIN LOCALLY 25 WASHER FLAT 1 4 OBTAIN LOCALLY 26 1 1 81 OBTAIN LOCALLY G1400
55. D BOLT HEX HD 3 8 16 X 1 1 4 WASHER LOCK 3 6 WASHER FEAL SS SA SPRING NUT 3 8 16 U CHANNEL CABLE WELDING 5225 84 STRAND 9 CABLE WELDING 5225 34 STRAND 298 CABLE WELDING 5225 34 STRAND 34 BOOT COVER TERMINAL POSITIVE RED BOOT COVER TERMINAL NEGATIVE BLACK HOLDER FUSE IN LINE FUSE BUSS AGC 10A NU M BOLT HEX HD 12MM 1075 X 50 MM WASHER LOCK 12MM WASHER FLAT 12MM SCREW PHIL PAN HD 10 32 X 1 2 WASHER FEAT 4 10 SCREW TRUSS PHIL HD 6 32 X 3 8 HEAT SHIELD BOLT HEX HD 1 4 0 X 5 8 122812 9 61 6 1 WASHER FLAT 114 5 BOLT HEX HD 10 MM X 1 1 4 WASHER LOCK 10 WASHER FLAT 10 ENGINE STARTER RELAY AND BATTERY ASSY QTY REMARKS 1 2 1 1 2 1 18 2 2 2 2 1 1 2 OBTAIN LOCALLY Uu E OBTAIN LOCALLY 2 OBTAIN LOCALLY OBTAIN LOCALLY O S OBTAIN LOCALLY D aa OBTAIN LOCALLY vm 1PC 1FT 2 OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY s OBTAIN LOCALLY
56. EE34475 EE6129 EE40182 EE22728 EE55760 EE55791 EE55869 EE25626 EE25628 EE25627 EE25625 EE55777 EE2889 EE2880 EE55780 EE55871 EE10071 EE2940 55859 6449 15770 51414 PART PANEL OUTPUT BUS CAMLOK 1 RECEPTACLE PNL MTG FEMALE BLACK 6 RECEPTACLE PNL MTG FEMALE BLUE 6 RECEPTACLE PNL MTG FEMALE RED 6 RECEPTACLE PNL MTG FEMALE WHITE 6 RECEPTACLE PNL MTG FEMALE GREEN 5 RECEPTACLE PNL MTG MALE GREEN 1 BUS BAR 6 SET CAMLOK 3 SPACING 5 BUS BAR GROUND TO NEUTRAL 1 RECEPTACLE FLANGED PHILLIP SLOT SCREW 2 SCREW PHILLIPS 8 32 3 4 SS 4 BATES CONN 100A 125V FEMALE 2 SCREW PHILLIPS FH COUNTERSUNK 1 4 20X1 SS 4 LED PILOT LIGHT RED 270V LEDTRONIC 1 JACK FEEDTHROUGH RJ45 5 5HD 2 CB HEIN 15A 1 POLE UL489 240V 2 SCREW PHILLIPS TRUSS HD 5 32 X 5 8 SS 8 HEIN 100A 1 P UL489 240V W 24V SHUNT 2 JACK BANANA PLUG 4 MM IEC1010 BLACK 1 JACK BANANA PLUG 4 IEC1010 BLUE 1 JACK BANANA PLUG 4 MM IEC1010 RED 1 JACK BANANA PLUG 4 IEC1010 WHITE 2 COVER RECEPTACLE EXPANSION W MQ LOGO 1 QTY CAMLOK ASSY REMARKS OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY SCREW PHIL PAN HD 10 3 4 SS 111 699 OBTAIN LOCALLY WASHER FLAT 1 2 BRASS OBTAIN LOCALLY WASHER SPLIT LOCK 1 2 5
57. EXHAUST FLEX 1 INS CLAMP V BAND BOLT HEX HD 3 8 16 X 1 1 4 sser WASHER FEAT 0 9 SAE aai niet ek etus WASHER LOCK 3 8 NUT m OBTAIN LOCALLY OBTAIN LOCALLY annie OBTAIN LOCALLY OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 89 SADDLE BOX ASSY PAGE 90 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 528258 A 66377 45 EE7330 EE55779 EE2767 EE7392 EE2996 5816 5804 5810 9954 9985 9983 24222 B 525528F 24369 55785 55784 4 38 EE30075 EE55787 EE10479 PART NAME REGULATOR VOLTAGE DVR2000E CAPACITOR 7 5 MFD DECAL CAUTION DO NOT SWITCH TRANSFORMER 3 KVA SWITCH K N VOLTAGE SELECT 3 POS BRACKET MTG SWITCH TO SADDLE BOX CONTACTOR 24 VDC 4P 600V 30A BUSS FUSE BLOCK HOLDER FUSE GOULD SHAWMUT MIDGET 10A FUSE GOULD SHAWMUT MIDGET 30 50A BLOCK BLUE FLEXI TERMINAL 6 STOP BLUE FLEXI BLOCK TERMINAL TRACK FLEXI BLOCK TERMINAL STRIP CONTACTOR VACCUM 120 VAC RECTIFIER ASSY CIRCUIT BREAKER 600A 3P W SHUNT AUX SW SWITCH AUX ABB CIRCUIT BREAKER ABB 3P 10A UL 480V SPACER BRASS CIRCUIT BREAKER SPACER CIRCUIT BREAKER PANEL CIRCUITBREAKER 2 SENSING BOLT HXHD 3 8 16 X 1 1 4
58. Generator The MQ Power Model SG1400C3 is a 200kVA studio generator that is designed as a high quality power source for entertainment and studio applications In keeping with Multiquip s policy of constantly improving its products the specifications quoted herein are subject to change without prior notice Permanent Magnet Generator Excitation System The SG1400C3 generator is equipped with a PMG Permanent Magnet Generator generator end The excitation system provides a minimum short circuit support current of 300 of the standby rating for 10 seconds at 60 Hz and approximately 275 at 50 Hz Both the PMG and the exciter are mounted outboard of the bearing for ease of maintenance The rotating brushless exciter features hermetically sealed diodes for three phase full wave rectification The three phase bridge is protected against abnormal transient conditions by a multiplate selenium surge protector Engine This generator is powered by a six cylinder 4 cycle direct injection turbocharged air cooled Cummins QSB7 G5 diesel engine Engine speed is set at the factory at 1800 RPM This engine is designed to meet every performance requirement for the generator Refer to Table 2 for engine specifications Principle Of Operation This generator is a brushless self excited externally voltage regulated synchronous AC generator The generator is made up of six major components main stator armature main rotor field exciter sta
59. Generator Voltage Test Points To determine if the generator s output voltage is present and correct connect a test meter to these test points during troubleshooting and maintenance Paralleling Cable In This Ethernet input connection point is used when multiple generators are going to be connected Paralleling Cable Out This Ethernet output connection point is used when multiple generators are going to be connected BUS Hot Indicator Lamp When lit this indicator lamp informs that the voltage bus is active high voltage NEVER connect or disconnect cables from the camlok or auxiliary receptacles when this indicator is ON The possibility exists of electrocution shock or even death if cables are connected or unplugged when this indicator is lamp lit 120 VAC Output Receptacles These 15 amp receptacles provide 120 VAC output The maximum allowable combined amps both receptacles is 25 amps when the voltage selector switch in the 30 277 480 position Bates 120VAC Output Receptacles These receptacles provide AC voltage output Each receptacle is protect by a 100 amp breaker These receptacles cannot be used when the voltage selector switch is in the 30 277 480 VAC position Camlok Receptacles These output voltage connection points 6 pairs are used for load connection ALWAYS pay close attention when connecting and disconnecting power cables from these camlok receptacles The possibility exists of
60. IN DOOR SWITCH NO 607 608 233 LOW VOLTAGE NO 621 433 SHOWN WITH NC 606 609 234 434 OREN INTAKE VENT DOOR PROGRAMMED FOR YEL BRN SINGLE PHASE RELAY 235 SINGLE PHASE RELAY 435 NO 112 523 DC25 346 NC 526 623 436 RED WITT EXHAUST VENT DOOR PROGRAMMED FOR PNK BRN ECM POWER RELAY 237 ECM OUTPUT 337 SELECTOR SW AUX sss 6 ORG BLU TOLINE 511 PROGRAMMED FOR GRY BRN CONTROL POWER 521 TT FUEL SOLENOID LATCH RELAY 439 BINARY OUTPUTS MAXIMUM 500MA EA CPLR NO 112 GRY R WT GRY RED RED WHT WHT PAGE 64 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 GENERATOR WIRING DIAGRAM 500 700 d 0 BLK PNK WHT PNK N 201 502 702 DROOP ORG PNK 503 3005 ee 703 OPTIONAL DVR 2000 AC2 233 4 504 ME 2 VOLTAGE 1 704 REGULATOR 505 705 EXCITER FIELD 506 706 100A BATES e 9 507 F2 707 508 ET MODULE 18 120 BLU GRY 708 SH5RED DC ORG GRY 509 S our l 709 100 AMP I SH5 BLK DC28 I 0 2 PUR GRY 510 Q1 2 710 511 ORG BLU AVRI TRANSFORMER 711 24V SHUNT PRIMARY 120 VAC FROM LINE 438 SECONDARY 18 VAC 512 712 513 713 T 100A BATES 514 gt L 714 100 AMP VOLTMETER SWITCH 515 SF CA11USJ189 Jis 516 716 CROMPTON 517 0 600 VOLTMETER 717 262 DDVU ETCM PQ 6
61. ND PARTS MANUAL REV 1 02 15 12 ENGINE GENERATOR MOUNTING ASSY PART PART NAME QTY REMARKS 1 EE15831 ALTERNATOR MARATHON 431RSL4007 1 2 9518500 DRIVE DISC ASSY SAE 11 5 1 3 55740 ENGINE CUMMINS QSB7 G5NRS 1 4 41016 MOTOR MOUNT FAIL SAFE 840 LBS 6 5 40474 BASE 1400 AMP STUDIO 48 X 100 1 6 EE54726 MOUNTING LEG CUMMINS QSB7 LEFT 1 6A 54727 MOUNTING LEG CUMMINS QSB7 RIGHT 1 7 BOLT SOCKET HD 3 8 16 X1 GRD 8 OBTAIN LOCALLY 7A WASHER LOCK 10 MM SS 2 OBTAIN LOCALLY 8 BOLT 3 4 10 X 5 O OBTAIN LOCALLY 9 WASHER 3 4 SS D scans OBTAIN LOCALLY 10 EE41017 WASHER SNUBBING 3 4 I D MOTOR MT 6 11 NUT 34 10 NY LOC d eite uir n dud B uana OBTAIN LOCALLY 12 BOLT 1 2 13 X 1 3 4 GRD 5 SS OBTAIN LOCALLY 13 WASHER LOCK 1 2 SS scis OBTAIN LOCALLY 14 WASHER 1 2 1 1 0 TA vasis OBTAIN LOCALLY 15 6780 NUT PLATE BASE ASSY 4 16 55924 PLACARD WATER 8 OIL DRAINS FUEL IN 8 OUT 1 17 SCREW MACH PHIL FLAT HD 1 4 20 X 3 4 Dod OBTAIN LOCALLY 18 BOLT HEX HD 3 4 10 X 2 SS GRD 8 OBTAIN LOCALLY 19 WASHER FLAT 3 4 So D seen OBTAIN LOCALLY 20 EE17201 FITTING BULKHEAD BRASS 1 4 NPT 1 21 EE17203 FITTING BULKHEAD B
62. ODE BUTTON Figure 25 Mode Button Manual STARTING MANUAL 1 Press the START button Figure 26 on the controller to start the engine Start Figure 26 START Button The engine will go to idle mode Listen for any abnormal noises If any abnormalities exist shut down the engine and correct the problem STARTUP 4 To bypass idle mode press the START button again The generator should go to full speed NOTICE If START button is not pressed again the engine will remain in idle mode for about an hour then will go to full speed 5 Verify that the no load frequency reading on the control panel frequency display is approximately 60 Hz 1800 rpm 6 Verify that the voltage reading on the control panel AC voltmeter display matches the voltage selector switch position that was selected prior to startup 7 Press the GCB control button on the controller Figure 27 to close circuit breaker InteliVision 5 PRESS GCB CONTROL BUTTON Figure 27 Generator Circuit Breaker Closed 8 Verify that the BUS HOT light on the Camlok Voltage Output Panel is on Voltage is now available at the receptacles BUS HOT LIGHT Figure 28 Bus Hot Light G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 35 9 f paralleling to another unit and the bus was already energized from another unit BUS HOT light already on pressing to close GCB button once would initia
63. ON position prior to starting the engine LIGHTS IF HASE SELECTED 0 208 VAC 3 PHASE MAIN CIRCUIT BREAKER 120 240 vac PHAS E Figure 20 Voltage Status LEDs verry ciRCUIT 3 If itis necessary to prime engine before starting such as after changing fuel filter or running out of fuel place the fuel valves in the prime position Figure 21 Place the fuel priming switch Figure 22 in the up position Figure 24 Circuit Breakers ON PAGE 34 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 6 unit is to be used in parallel with another unit interconnect the units Interconnect the output buses with suitable power cables to carry full load capacity special male to male Camlok cables will be needed For 480 V mode it is recommended that one 4 0 cable per phase neutral and ground be used For 208V mode use two 4 0 cables per phase and neutral and one 4 0 cable for ground Also connect the parallel communication cables Connect the load to the receptacles on the Camlok Voltage Output Panel When the camloks are inserted into the outlet connector rotate clockwise until they are locked in place Make sure the camloks are connected securely Press the MODE button Figure 25 on the Digital Controller Display and select manual mode MAN with the arrow keys Press Enter key when MAN is highlighted on the screen InteliVision 5 PRESS M
64. OPERATION AND PARTS MANUAL MULTIQUIP POWER MODEL SG1400C3 55748 3 POSITION SWITCH PARALLELING 1400 AMP STUDIO GENERATOR CUMMINS GSB7 G5 DIESEL ENGINE Revision 1 02 15 12 To find the latest revision of this publication visit our website at www mgpower com THIS MANUAL MUST ACCOMPANY THE EGUIPMENT AT ALL TIMES PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect that could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Multiquip at 1 800 421 1244 If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Multiquip To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator NHTSA 1200 New Jersey Avenue S E Washington DC 20590 You can also obtain
65. OR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 113 TRAILER ASSY TERMS AND CONDITIONS OF SALE PARTS PAYMENT TERMS Terms of payment for parts are net 30 days FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice All shipments are F O B point of origin Multiquip s responsibility ceases when signed manifest has been obtained from the carrier and any claim for shortage or damage must be settled between the consignee and the 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 will be accepted and credit will be allowed subject to the following provisions 1 Returned Material Authorization must be approved by Multiquip prior to shipment 2 Toobtaina Return Material Authorization a list must be provided to Multiquip Parts Sales that defines item numbers quantities and descriptions of the items to be returned a The parts numbers and descriptions must match the current parts price list b The list must be typed or computer generated c The list must state the reason s for the return d The list must reference the sales order s or invoice s under which the items were originally purchased e The list must include the name and phone number of the
66. OTHER CONNECTIONS AT o ACI9 L YEL ORG BLU ORG bus a li 208 277V 622 PNK RED RED ORG 822 Im um mig 5 624 IE BLK ORG C22 824 625 AUXLUARYCONTACIS 825 AT LINE 220 TAAWGMINIMUM 627 827 028 SADDLE BOX eons STUD CONTROL es 629 630 EX 632 a pu KD NOTE NEUTRAL BONDED IK DU 638 CO 11 IMPORTANT NOTE SINGLE PHASE OUTPUT 5 oq L1 A PHASE L2 C PHASE 506140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 65 EXPLANATION OF CODES IN REMARKS COLUMN The following section explains the different symbols and remarks used in the Parts section of this manual Use the help numbers found on the back page of the manual if there are any questions NOTICE The contents and part numbers listed in the parts section are subject to change without notice Multiquip does not guarantee the availability of the parts listed SAMPLE PARTS LIST NO PARTNO PARTNAME QTY REMARKS 1 12345 1 lNCLUDES ITEMS W 2 WASHER 1 4 N NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 1248 AR MAKE LOCALLY 4 12349 BEARING 1 S N 23458 AND ABOVE NO Column Unique Symbols All items with same unique symbol O ff 96 or gt in the number column belon
67. R OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 103 HYD TANK FILTER AND HOSE ASSY ENGINE OIL PAN HYDRAULIC TANK NOTE Hose Ends C D E F and G are shown on HYD PUMP COOLER FAN MOTOR and HOSE ASSY PAGE 104 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 CO O HYD TANK FILTER AND HOSE ASSY PART NO PART NAME QTY REMARKS 41070 TANK ASSY 7 GAL HYD RESIVOIR 1 41067 FILLER ASSY W 4 STRAINER 8 40 MICR 1 42758 SIGHT LEVEL GAUGE 5 LEXAN TUBE 1 2501 12 12 ELBOW 90 3 4 MP x 3 4 MJ 1 3 4SAE100R4 46 HOSE HYD 3 4 46 TANK TO PUMP 1 40 069 NIPPLE BRASS 1 2 X 5 1 2 2 28 248 TEE STREET 1 2 NPTF 2 10 265 FITTING MALE ADPT SAE 45 FLARE 38 x 1 2 1 30 252 BARB 45 SAE FLARE FEMALE SWIVEL 3838 4 10 296 ELBOW 90 3 8 x 3 8 1 HOSE 3 8 HIMILER BLUE HEATER FLAME AR OBTAIN LOCALLY RESISTANT SAEJ20R3 HT D3 EC GOODYEAR 28 111 FITTING BRASS PIPE HEX BUSH 3 4 x 1 2 6400 08 06 FITTING STRAIGHT 1 2 x 3 8 MAORB EE42220 CHECK VALVE SAE 6 HYDRAC RV 10 01 1 1 1 6410 08 04 O FITTING STRAIGHT 1 2 MORB x FORB 1 1 2SAE100R2 Al 170 HOSE HYD 1 2 170 COOLER TO TANK 1 6801 06 06 NWO ELBOW 90 3 8 MJ x 3 8 MAORB 2 3 8SAE100R2 Al 48 HOSE HYD 3 8 x 48 MOTOR TO MANIFOLD 1 1 2SAE100R2 AT 17 HOSE HYD 1 2 x 17 PUMP TO FILTER 1 680
68. R GUIDELINES A defective pintle hitch not properly fastened can result in uncoupling leading to death or serious injury Be sure the pintle hook is securly tighten to the tow vehicle before coupling the trailer Coupling Trailer to Tow Vehicle Pintle Coupler Slowly back up the tow vehicle so that the pintle hitch hook is near or aligned under the pintle eye ring coupler Using the jackstand at the front of trailer tongue turn the jackstand crank handle to raise the trailer If the pintle eye coupler does not line up with the pintle hitch hook adjust the position of the tow vehicle OPEN the pintle hook locking mechanism Figure Place the hook inside the eye coupler CLOSE the pintle hook mechanism TRAILER PINTLE a 4 N 2 8 WS B S df rfl 22 42 PINTLE 2 5 mH RING EYE SAFETY CROSS BOTH Figure H Attaching Safety Chain Pintle Hitch B Insert a pin or lock through the hole in the locking mechanism Be sure the pintle hook is inserted completely through the eye ring and the locking mechanism is engaged A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle Using the trailer jack test to see that you can raise the rear of the tow vehicle by1 inch after the coupler is locked to the hitch B Lower the trailer so that its entire tongue weight is held by t
69. RASS 1 2 NPT 1 22 EE48788 FITTING ASSY BULKHEAD 1 2 NPT SS 2 23 SCREW HEX HD CAP 10 MM X 1 1 2 GRD 8 17 OBTAIN LOCALLY 24 WASHER LOCK 10 MM SS M OBTAIN LOCALLY 25 WASHER FLAT 10 5 ee OBTAIN LOCALLY 26 6487 BRACKET LIFTING EYE TRAILER MTG 4 2 WASHER LOCK 3 4 SS OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 79 RADIATOR MUFFLER SUPPORT 5 yao PAGE 80 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PART NO 41013 25484 41023 4 1698 EE32785 EE42003 EE46381 EE55759 EE7363 EE42004 EE42005 EE43047 EE55771 EE42987 EE16554 RADIATOR MUFFLER SUPPORT QTY PART NAME SUPPORT RADIATOR COVER FAN STEEL ASSY ARC BAFFEL W INSULATION VENTURI RING 30 REVERSE CONSTR UNISTRUT CHANNEL MFL SUPPORT SUPPORT MUFFLER HAT SECTION EXH VENT HYD ACTUATOR MOUNTING PLATE 16 CYL SILENCER MOUNTING BRACKET MUFFLER SUPPORT DIAGONAL SUPPORT 45 RIGHT DIAGONAL SUPPORT 45 LEFT MOUNTING PLATE BAFFLE BAFFLE 28 X 21 5 X 2 THICK ALUM BOLT HXHD 3 8 16 X 1 3 4 REMARKS 3 O gt gt gt OBTAIN LOCALLY LOCK WASHER 38 OBTAIN LOCALLY
70. STEEL 3 8 HOSE GOODYEAR INSTAGRIP USMSHA 2G 1C 14C 23 FLAME RESISTANT 300 PSI WP 3 8 X 40 HOSE BARB STEEL 1 2 HOSE GOODYEAR INSTAGRIP USMSHA 2G 1C 14C 33 FLAME RESISTANT 300 PSI WP 1 2 X 56 HOSE GOODYEAR INSTAGRIP USMSHA 2G 1C 14C 33 FLAME RESISTANT 300 PSI WP 5 8 X 24 HOSE BARB STEEL 5 8 SCREW PHIL TRUSS HD 8 82 X 1 2 WASHER FEAT 8 92 u u sa NUT 0 32 uu VALVE 3 WAY BV SS 1 2 NPT VALVE BALL BV SS 3 8 NPT BOLT HX HD 9 8 16 BULKHEAD FITTING ASSY 1 2NPT SS ELBOW 90 JIC MALE 9 16 18 X 1 4 ELBOW 90 JIC 7 8 16 X 7 8 ELBOW 90 JIC 1 2 20 X 7 8 NIPPLE PIPE HX 1 4 NPTF VALVE BRASS 1 4 X 1 4 ADAPTER MALE HX 1 4 X 1 4 BARB 45 SAE FLARE SWIVEL 1 4 X 1 4 ADAPTER MALE HX 1 4 X 3 8 STREET TEE 3 8 NPTF 207ACBH 4LONG COUPLING BULKHEAD QTY O O yh FUEL SYSTEM ASSY REMARKS OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY AR OBTAIN LOCALLY AB OBTAIN LOCALLY OBTAIN LOCALLY 1 4 OBTAIN LOCALLY DO nies OBTAIN LOCALLY OBTAIN LOCALLY NO ND UN OBTAIN LOCALLY m OBTAIN LOCALLY OBTAIN LOCALLY OBTAIN LOCALLY G1400C3 STUDIO GENERATOR OPERATION AND
71. TECTIVE DEVICES After automatic shutdown always inspect the generator and eliminate any problems that might have caused the shutdown before attempting to restart the generator When ready to restart check and make sure that no alarms are shown in the Alarm List on the Digital Controller Restart the generator as outlined in the Startup section of this manual Refer to the InteliVision 5 Controller User s Guide for detailed information of faults and display information To prevent damage to the equipment and severe bodily harm even death please follow all lock out safety procedures when performing maintenance G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 37 MAINTENANCE Use Table 14 as a general maintenance guideline when servicing your engine For more detail engine maintenance information refer to the engine owner s manual supplied with your engine Table 14 Engine Maintenance Schedule INTERVAL DESCRIPTION OPERATION 250 HOURS 500 HOURS 1000HOURS 2000HOURS 5000 HOURS DAILY OR OR OR 3 MONTHS 6 MONTHS 2 T o X T Dm X T L 06 T 18 cwn 4 T wm
72. X pounds Step 4 The resulting figure equals the available amount of cargo and luggage capacity For example if the XXX amount equals 1400 Ibs and there will be five 150 Ib passengers in your vehicle the amount of available cargo and luggage capacity is 650 Ibs 1400 750 5 x 150 650 Ibs Step 5 Determine the combined weight of luggage and cargo being loaded on the vehicle That weight may not safely exceed the available cargo and luggage capacity calculated in Step 4 If your vehicle will be towing a trailer load from your trailer Will be transferred to your vehicle Consult the tow vehicle s manual to determine how this weight transfer reduces the available cargo and luggage capacity of your vehicle otudies of tire safety show that maintaining proper tire pressure observing tire and vehicle load limits not carrying more weight in your vehicle than your tires or vehicle can safely handle avoiding road hazards and inspecting tires for cuts slashes and other irregularities are the most important things you can do to avoid tire failure such as tread separation or blowout and flat tires These actions along with other care and maintenance activities can also Improve vehicle handling Help protect you and others from avoidable breakdowns and accidents Improve fuel economy Increase the tire life G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 57 Us
73. ad and understand the safety messages and operating instructions could result in injury to yourself and others SAFETY MESSAGES The four safety messages shown below will inform you about potential hazards that could injure you or others The Safety messages specifically address the level of exposure to the operator and are preceded by one of four words DANGER WARNING CAUTION or NOTICE SAFETY SYMBOLS AX DANGER Indicates a hazardous situation which if not avoided WILL result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in MINOR or MODERATE INJURY NOTICE Addresses practices not related to personal injury SAFETY INFORMATION Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages Safety Hazard Lethal exhaust gas hazards Explosive fuel hazards Burn hazards Overspeed hazards Rotating parts hazards Pressurized fluid hazards Electric shock hazards PAGE 6 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 GENERAL SAFETY m NEVER operate this equipment without proper protective clothing shatterproof glasses respiratory protection hearing protection steel toed boots and other protective devices re
74. alidate configuration table Error Unsupported controller Error Unsupported cfg table format Error Correct firmware has to be programmed Controller configuration has to be reprogrammed or upgraded Controller upgrade necessary Configuration table is invalid Controller is not supported Controller configuration table is not supported InteliVision 5 firmware upgrade 15 necessary Mismatch parameters length Error Controller parameters mismatch Controller configuration upgrade is necessary Mismatch const values length Controller constants mismatch Error Controller configuration upgrade is necessary Mismatch values length Error Controller values mismatch Controller configuration upgrade is necessary Mismatch val states length Error Controller values states mismatch Controller configuration upgrade is necessary Controller is not connected or communication via RS485 is Communication is lost or RS485 line A and B are Controller was not detected EDO interrupted swapped Controller is detected RS485 5 A Sae rW IM RS485 line is not terminated properly environment Communication Error dir a level is not defined disturbance is present or RS485 line is too long Unsupported controller firmware Screen template missing Error missing InteliVision 5 support Upgrade controller firmware screen template version Error Unsupported controller screen Corrupted display font Font
75. ate voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE The power factor of this generator is 1 0 See Table 7 below when connecting loads Table 7 Power Factor By Load Type of Load Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication 10 equipment Common power tools Table 8 Cable Selection 60 Hz Single Phase Operation in 25 20 60 os 668 558 son 5 we o soon aon coon 99 awn mo 626 90 o 2 ison toon in o sm oon 2 eo aw ast CAUTION Equipment damage can result from low voltage THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation VOLTAGE X AMPERAGE X 1 732 1000 KVA NOTICE If 30 load kVA is not given on the equipment nameplate approximate 30 load may be determined by multiplying voltage by amperage by 1 732 NOTICE Motors and motor driven equipment draw much greater current for starting than during operation An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable Refer to Table 8 to select the correct cable size When connecting a resistance load such as incandescent lamp or electric heater
76. battery is running both the trailer lights and tow vehicle lights SAFETY CHAINS the coupler connection comes loose the safety chains can keep the trailer attached to the tow vehicle With properly rigged safety chains it is possible to keep the tongue of the trailer from digging into the road pavement even if the coupler to hitch connection comes apart TRAILER LIGHTING AND BRAKING CONNECTOR A device that connects electrical power from the tow vehicle to the trailer Electricity is used to turn on brake lights running lights and turn signals as required In addition if your trailer has a separate braking system the electrical connector will also supply power to the brakes from the tow vehicle BREAKAWAY SYSTEM the trailer coupler connection comes loose the breakaway system can actuate emergency hydraulic brakes depending on the type of actuator on the trailer The breakaway cable must be rigged to the tow vehicle with appropriate slack that will activate the system if the coupler connection comes loose JACKSTAND A device on the trailer that is used to raise and lower the coupler The jack is sometimes called the landing gear or the tongue jack COUPLER TYPES Two types of coupler used wit the trailer are discussed below Ball Hitch Coupler Pintel Eye Coupler TRAILER GUIDELINES BALL HITCH COUPLER A ball hitch coupler Figure C connects to a ball
77. be less than the GVWR for the trailer because some of the trailer load is to be carried by the tow vehicle rather than by the trailer axle s The total weight of the cargo and trailer must not exceed the GVWR and the load on an axle must not exceed its GAWR PSIC The tire pressure psi measured when cold VIN The Vehicle Identification Number EMPTY WEIGHT Some information that comes with the trailer such as the Manufacturer s Statement of Origin is not a reliable source for empty or net weight The shipping documents list average or standard weights and your trailer may be equipped with options TRAILER GUIDELINES To determine the empty or net weight of your trailer weigh it on an axle scale To find the weight of the trailer using an axle scale you must know the axle weights of your tow vehicle without the trailer coupled Some of the trailer weight will be transferred from the trailer to the tow vehicle axles and an axle scale weighs all axles including the tow vehicle axles TOW VEHICLE The towing hitch attached to your tow vehicle must have a capacity equal to or greater than the load rating of the trailer you intend to tow The hitch capacity must also be matched to the tow vehicle capacity Your vehicle dealer can provide and install the proper hitch on your tow vehicle SUSPENSION SYSTEM Sway bars shock absorbers heavy duty springs heavy duty tires and other suspension components may
78. brakes they function the same way the surge brakes do on your tow vehicle The hydraulic braking system must be inspected at least as often as the brakes on the tow vehicle but no less than once per year This inspection includes an assessment of the condition and proper operation of the wheel cylinders brake shoes brake drums and hubs MANUALLY ADJUSTING THE BRAKES Most axles are fitted with a brake mechanism that will adjust the brakes during a hard stop However some braking systems are not automatically adjusted by hard stopping These brakes require manual adjustment The following Steps apply to adjust most manually adjustable brakes 1 Jack up the trailer and secure it on adequate capacity jackstands 2 the wheel and brake drum rotate freely 3 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 4 With a screwdriver or standard adjusting tool rotate the starwheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note Your trailer maybe equipped with drop spindle axles See axle manual for your axle type You will need a modified adjusting tool for adjusting the brakes in these axles With drop spindle axles a modified adjusting tool with about an 80 degree angle should be used 5 Rotate the starwheel in the oppos
79. cap When refueling it is recommended to use ASTM D975 No 2 diesel fuel A drain port is provided on the end of the tank Fuel Priming Pump The generator set is equipped with an electric 24 VDC fuel priming pump to assist in priming the system for maintenance purposes The priming pump bypass valves and priming switch are located on the side of the diesel engine in the engine compartment Fuel Water Separator A 30 micron Racor 900 fuel water separator is part of the fuel system assembly and is located on the side of the engine in within the enclosure compartment The supply line between the engine fuel pump and tank passes through an in line fuel water separator filter The filter element is rated to filter elements down to 10 microns Intake Ventilation Door The intake air ventilation door is located on the roof of the generator set enclosure near the control panel The door is hydraulically actuated Upon startup of the diesel engine pressure fills the cylinder and opens the door Intake air passes through the opening and across the engine s radiator to cool the engine During rainy conditions the roof ventilation door will close when the front ventilation door is opened GENERAL INFORMATION Interior Lighting The interior lighting system is distributed throughout the interior There are three separate lighting fixtures Two lights are in the engine compartment and one light is in the generator compartment
80. carbon buildup in the combustion chamber and high fuel consumption Change air cleaner more frequently if these conditions exist FUEL ADDITION Add diesel fuel the grade may vary according to season and locations Removing Water from the Fuel Tank After prolonged use water and other impurities accumulate in the bottom of the tank Occasionally inspect the fuel tank for water contamination and drain the contents if necessary During cold weather the more empty volume inside the tank the easier it is for water to condense This can be reduced by keeping the tank full with diesel fuel Cleaning Inside the Fuel Tank necessary drain the fuel inside the fuel tank completely Using a spray washer Figure 34 wash out any deposits or debris that have accumulated inside the fuel tank Figure 34 Fuel Tank Cleaning G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 39 FUEL TANK INSPECTION In addition to cleaning the fuel tank the following components should be inspected for wear m Rubber Suspension look for signs of wear or deformity due to contact with oil Replace the rubber suspension if necessary Fuel Hoses inspect nylon and rubber hoses for signs of wear deterioration and hardening Fuel Tank Lining inspect the fuel tank lining for signs of excessive amounts of oil and other foreign matter Replacing Fuel Filter Replace the
81. complete units are made exclusively by a statement of warranty packaged with such units and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products Apart from such written statement of warranty there are no warranties express implied or statutory which extend beyond the description of the products on the face hereof Effective February 22 2006 PAGE 114 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 NOTES G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 115 OPERATION AND PARTS MANUAL UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave Carson CA 90746 Contact mg multiguip com Service Department 800 421 1244 310 537 3700 Technical Assistance 800 478 1244 MEXICO MQ Cipsa HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING Tel 800 421 1244 Fax 800 537 3927 Fax 310 537 4259 Fax 310 943 2238 MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537 3700 Fax 310 637 3284 Warranty Department 800 421 1244 Fax 310 943 2249 310 537 3700 UNITED KINGDOM Multiquip UK Limited Head Office Carr Fed Mexico Puebla KM 126 5 Momoxpan Cholula Puebla 72760 Mexico Contact pmastretta cipsa com mx Tel 52 222 225 9900 Fax 52 222 285 0420 Tel 0161 339 2
82. d the last four numbers represent the week and year the tire was built For example the numbers 3197 means the 31st week of 1997 The other numbers are marketing codes used at the manufacturer s discretion This information is used to contact consumers if a tire defect requires a recall Tire Ply Composition and Materials Used The number of plies indicates the number of layers of rubber coated fabric in the tire In general the greater the number of plies the more weight a tire can support Tire manufacturers also must indicate the materials in the tire which include steel nylon polyester and others Maximum Load Rating This number indicates the maximum load in kilograms and pounds that can be carried by the tire Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions PAGE 58 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 Uniform Tire Quality Grading Standards UTQGS Treadwear Number This number indicates the tire s wear rate The higher the treadwear number is the longer it should take for the tread to wear down For example a tire graded 400 should last twice as long as a tire graded 200 Traction Letter This letter indicates a tire s ability to stop on wet pavement A higher graded tire should allow you to stop your car on wet roads in a shorter distance than a tire with a lo
83. d to pressure indicated on side wall before towing trailer Determining Load Limit of Trailer Determining the load limits of a trailer includes more than understanding the load limits of the tires alone On all trailers there is a Federal certification VIN label that is located on the forward half of the left road side of the unit This certification VIN label will indicate the trailers Gross Vehicle Weight Rating GVWR This is the most weight the fully loaded trailer can weigh It will also provide the Gross Axle Weight Rating GAWR This is the most a the axle can weigh PAGE 56 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 There is a vehicle placard Figure located in the same location as the certification label described above This placard provides tire and loading information In addition this placard will show a statement regarding maximum Cargo capacity The weight of cargo should never exceed XXX kg Or XXX lbs COLD TIRE PRESSURE Figure I Trailer Tire Placard additional work items hoses tools clamps etc are going to be added to the trailer be sure they are distributed evenly to prevent overloading front to back and side to side Heavy items should be placed low and as close to the axle positions as reasonable Too many items on one side may overload a tire Excessive loads and or underinflation cause tire overloading and as a result abnor
84. dard Symptom No Brakes hardware Pay close attention to bolt length and grade ALWAYS use manufacturer s recommended parts when replacing channel mounting hardware MAINTENANCE ADJUSTABLE P CHANNEL 41 5 8 X 11 X 5 BOLT 5 8 NYLOG 2 or 2 5 16 BALL WASHER COUPLER Figure 37 Adjustable Channel WHEEL BEARINGS Wheel bearings Figure 38 must be inspected and lubricated once a year or 12 000 miles to insure safe operation of your trailer trailer wheel bearings are immersed in water they must be replaced DANGER If trailer wheels are under water for a long period of time wheel bearings may fail If this is the case service wheel bearings immediately The possibility exists of the wheels falling off causing equipment damage and severe bodily harm even death If the trailer has not been used for an extended amount of time have the bearings inspected and packed more frequently at least every six months and prior to use Follow the steps below to disassemble the wheel hub and service the wheel bearings See Figure 38 BEARING 0 WHEEL Z HUB OIL SEAL BEARING COTTER PIN BEARING ae CUP BEARING DUST LUG CAP NUT gt SPINDLE WASHER SPINDLE NUT Figure 38 Wheel Hub Components PAGE 42 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 After removing the dust cap cotter pin spindle nut
85. down if you have to go over a pothole or other object in the road DO NOT run over curbs or other foreign objects in the roadway and try not to strike the curb when parking Check tire inflation pressure weekly during use to insure the maximum tire life and tread wear DO NOT bleed air from tires when they are hot Inspect tires for uneven wear patterns on the tread cracks foreign objects or other signs of wear or trauma Remove bits of glass and foreign objects wedged in the tread Make sure your tire valves have valve caps ALWAYS check tire pressure on tow vehicle and trailer before towing Check tire pressure at least once a month DO NOT overload tow vehicle Check the tire information and loading placard for safe allowable tire loading conditions Tire Repair The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that surrounds the puncture hole Punctures through the tread can be repaired if they are not too large but punctures to the sidewall should not be repaired Tires must be removed from the rim to be properly inspected before being plugged and patched Replacing Worn or Damaged Tires Replace the tire before towing the trailer if the tire treads have less than 1 16 inch depth or the telltale bands are visible Check inflation pressure weekly during use to insure the maximum tire life and tread wear A bubble cut or bulge
86. e included when this item is purchased Indicated by INCLUDES ITEMS W unique symbol Serial Number Break Used to list an effective serial number range where a particular part is used Indicated by SIN XXXXX AND BELOW SIN XXXX AND ABOVE SIN XXXX TO S N XXX Specific Model Number Use Indicates that the part is used only with the specific model number or model number variant listed It can also be used to show a part is NOT used on a specific model or model number variant Indicated by XXXXX ONLY NOT USED ON XXXX Make Obtain Locally Indicates that the part can be purchased at any hardware shop or made out of available items Examples include battery cables shims and certain washers and nuts Not Sold Separately Indicates that an item cannot be purchased as a separate item and is either part of an assembly kit that can be purchased or is not available for sale through Multiquip PAGE 66 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 SUGGESTED SPARE PARTS SG1400C3 WITH CUMMINS QSB7 G5 DIESEL ENGINE 1 to 3 units Qty P N Description 3937736 CARTRIDGE LUB OIL FILTER U 4989106 FUEL FILTER ENGINE P537876 ELEMENT AIR CLEANER NE 3979344 BELT V RIBBED a EE11227 FILTER FUEL PUMP 24234 FILTER COOLANT SPIN ON EE2917
87. e parked Use the trailers swivel jack to adjust the trailer height to a level position while parked G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 9 ELECTRICAL SAFETY DO NOT touch output terminals during operation Contact with output terminals during operation can cause electrocution electrical shock or burn B electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals NEVER insert any objects into the output receptacles during operation This is N extremely dangerous The possibility exists of electrical shock electrocution or death Backfeed to a utility system can cause electrocution and or property damage NEVER connect the generator to a building s electrical system without a transfer switch or other approved device All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes Failure to do so could result in electrical shock or burn causing serious injury or even death Power Cord Cable Safety NEVER let power cords or cables lay in water NEVER stand in water while AC power from the generator is being transferred to a load NEVER use damaged or wo
88. e the information contained in this section to make tire Safety a regular part of your vehicle maintenance routine Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure TIRE FUNDAMENTALS Federal law requires tire manufacturers to place standardized information on the sidewall of all tires Figure J This information identifies and describes the fundamental characteristics of the tire and also provides a tire identification number for safety standard certification and in case of a recall Rad Ratio of height to code width aspect ratio Load index amp speed symbol Nominal width of tire in millimeters U S DOT tire identification number Severe snow conditions Tire ply composition and materials use Treadwear traction and temperature grades Figure J Standard Tire Sidewall Information P The P indicates the tire is for passenger vehicles Next number This three digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge In general the larger the number the wider the tire Next number This two digit number known as the aspect ratio gives the tire s ratio of height to width Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement P The R stands for radial Radial ply constructio
89. ed on the list price that was effective twelve months prior to the RMA date 11 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 and all orders received on or after that date will be billed at the revised price Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change 2 Q gt o Multiquip reserves the right to quote and sell direct to Government agencies and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 35 00 surcharge will be added to the invoice for special handling including bus shipments insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable hereunder for damages in 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 No warranties 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
90. efore each tow thereafter 4 LUG NUTS 6 LUG NUTS 8 LUG NUTS 5 00 NUTS PNEUMATIC AIR GUN Figure L Wheel Lug Nuts Sequence PAGE 60 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 TRAILER GUIDELINES Table C Tire Torque Requirements Replace any broken or burned out lamps as necessary Check the wire harness for cuts fraying or other damage Wheel Size uc qj eee If it needs replacing contact your dealer 20 25 35 40 50 65 Improper operating taillights stoplights and turn signals can cause collisions Check all lights before each tow Lights and Signals Before each tow check the trailer taillights stoplights turn signals and any clearance lights for proper operation CONNECT L TO CHASSIS GROUND WHITE eal GREEN TAIL LIGHT KAMA BLACK GREEN BROWN YELLOW BROWN LICENSE TAIL LIGHT FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED WHITE COMMON GROUND RIGHT TURN SIGNAL HAZZARD GREEN LEET CONNECTOR MATING CONNECTOR I TAIL LIGHT ELECTRIC CONNECT TO CHASSIS i GROUND A WHITE WHITE COMMON GROUND BLUE ELECTRIC BRAKE RIGHT GREEN RIGHT STOP amp TURN BROWN 172 gt BROWN TAIL amp LICENSE ED YELLOW LEFT STOP amp TURN TAILLIGHT
91. electrocution shock or even death if cables are connected or unplugged when the bus hot indicator lamp is lit G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 25 CIRCUIT BREAKER PANEL CB2 GENERATOR METERING 1 MAIN CIRCUIT BREAKER DO NOT USE AS A SWITCH Electronic Trip Unit Instantaneous Trip Setting Amps Push to Trip A 500 E 1250 B 600 F 1500 CB3 190 C 800 2000 BUS LONG INST D 1000 H 2500 METERING Figure 8 Main Breaker Panel The definitions below describe the controls and functions of the Main Breaker Panel Figure 8 1 CB2 Circuit Breaker This breaker monitors senses the generator voltage bus If breaker trips signal is sent to controller CB3 Circuit Breaker This breaker monitors senses the voltage bus If breaker trips signal is sent to controller Main Circuit Breaker This 600 amp breaker protects the camlok receptacles load from overload Electronic Trip Unit This unit protects the generator from in rush current load spikes NOTICE When setting the trip point on the electric trip unit be careful not to set the trip point too high Setting the trip point too high may cause the main breaker not to trip This condition could cause serious damage to the equipment and serious bodily harm even death to operating personnel Always be conservative when setting
92. er fluid level in the actuator may result in loss of braking action which could cause severe property damage injury or death Periodically check the actuator mounting fasteners for damage or loosening Inspect the actuator for worn or damaged parts As you are towing your trailer be aware of any changes in braking quality This could be an early warning of brake or actuator malfunction and requires immediate attention Consult a certified brake specialist to make necessary adjustment or repairs Table 15 Hydraulic Brake Troubleshooting Possible Cause Solution Brake d d Weak Brakes or Machine or replace Brakes Pull to grooved One Side Inflate all tires equally Tires unmatched on the Match tires same axle Brake components loose Replace components Locking Brakes bent or broken Brake drums out of round System lubricated Noisy Brakes Brake components correct Replace and correct Brake lining thickness incall new shoes incorrect or not adjusted e Dragging correctly linings a Enough brake fluid or correct Replace rubber parts fluid fill with dot 4 fluid ADJUSTABLE CHANNEL Your trailer may be equipped with an adjustable channel Figure 3 that allows the coupler to be raised or lowered to a desired height Periodically check the channel bolts for damage or loosening NOTICE When replacing channel mounting hardware nuts bolts and washers NEVER substitute substan
93. er parts via Fax on Standard orders for all orders which include Domestic US Customers dial complete part numbers 1 800 6 PARTS 7 800 672 7877 Note Discounts Are Subject To Change XJ Order via Phone Domestic US Dealers Call aa 1 800 427 1244 p eec o lt lt 7 Non Dealer Customers Y A a International Customers should contact parts or call 800 427 1244 for help in their local Multiquip Representatives for locating dealer near you Parts Ordering information E AE aes 4 75 1 When ordering parts please supply Dealer Account Number C Specify Preferred Method of Shipment Dealer Name and Address V UPS Fed Ex DHL Shipping Address if different than billing address Priority One v Truck Return Fax Number Ground Next Day Applicable Model Number Second Third Day Quantity Part Number and Description of Each Part NOTICE All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST MAYA ATA AY m WE ACCEPT ALL MAJOR CREDIT CARDS AAG VS MAUI Ud G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 5 Do not operate or service the equipment before reading the entire manual Safety precautions should be followed at all times when operating this equipment Failure to re
94. erator s output voltage against an internal reference set point and provides the necessary DC output voltage to the exciter field required to maintain constant generator terminal voltage The generator s terminal voltage is changed by adjusting the regulator s reference set point Electronic Governor System The electronic governor system controls the RPMs of the engine When the engine demand increases or decreases the governor system regulates the frequency variation to 0 2596 Battery The battery system is located in the engine compartment on the sub base The battery s primary purpose is to provide starting power for the diesel engine starter motor The battery system is comprised of two 12 VDC sealed lead acid batteries wired in series to provide 24 VDC to the starting motor The battery is charged by the charging alternator while the engine is engaged Exhaust System The exhaust system is located above the diesel engine The exhaust system is comprised of rigid and flexible tubing a silencer and a roof mounted exhaust riser with a rain cap PAGE 16 56140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 Fuel Tank This generator can be equipped with a 150 gallon 567 liters fuel tank located beneath the trailer deck The tank is made of steel baffled The tank can be filled from an external fill port located on the side of the trailer The fill port has a 2 inch 51 mm fill neck with vented
95. fuel filter cartridge with a new one every 500 hours Loosen the drain plug at the lower top of the fuel filter Drain the fuel in the fuel body together with the mixed water DO NOT spill the fuel during disassembly Vent any air AIR REMOVAL air enters the fuel injection system of a diesel engine starting becomes impossible After running out of fuel or after disassembling the fuel system bleed the system Refer to the Cummins engine manual for details 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 The oil level must be between the two notches on the dipstick Replacing Oil Filter 1 Remove the old oil filter Apply a film of oil to the gasket on the new oil filter Install the new oil filter amp N After the oil filter has been replaced the engine oil will drop slightly Run the engine for a while and check for leaks before adding more oil if needed Clean excessive oil from engine MAINTENANCE FLUSHING OUT RADIATOR AND REPLACING COOLANT Allow engine to cool before flushing out wolf radiator Flushing the radiator while hot Ww 9 could cause serious burns from water or CANA GN 22 SY steam 1 Remove radiator cap Remove coolant drain plug located on side of generator Place coolant drain lever in the open position to drain coolant 2 Flush the radiator by
96. further details lf adding coolant antifreeze mix to the wife radiator do not remove the radiator cap until the unit has completely cooled The possibility of hot coolant exists which can Cause severe burns Day to day addition of coolant is done from the recovery tank When adding coolant to the radiator DO NOT remove the radiator cap until the unit has completely cooled See Table 12 for engine radiator and recovery tank coolant capacities Make sure the coolant level in the recovery tank is always between the H and the L markings Table 12 Coolant Capacity 7 8 gal 29 5 liters 6 quarts 6 6 liters Engine and Radiator Reserve Tank OPERATION IN FREEZING WEATHER When operating in freezing weather be certain the proper amount of antifreeze Table 13 has been added Table 13 Anti Freeze Operating Temperatures Vol Freezing Point Boiling Point Anti NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 INSPECTION SETUP CLEANING THE RADIATOR The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radiator fins with compressed air Cleaning inside the machine is dangerous so clean only with the engine turned off and the negative battery terminal disconnected AIR CLEANER Periodic cleaning replacement is necessary Inspect it in accordance with the Cummins Engine Owner s Manual FAN BELT
97. g to the same assembly or kit which is indicated by a note in the Remarks column Duplicate Item Numbers Duplicate numbers indicate multiple part numbers which are in effect for the same general item such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order PART NO Column Numbers Used Part numbers can be indicated by a number a blank entry or TBD TBD To Be Determined is generally used to show a part that has not been assigned a formal part number at the time of publication A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip Other entries will be clarified in the Remarks Column QTY Column Numbers Used Item quantity can be indicated by a number a blank entry or A R A R As Required is generally used for hoses or other parts that are sold in bulk and cut to length A blank entry generally indicates that the item is not sold separately Other entries will be clarified in the Remarks Column REMARKS Column Some of the most common notes found in the Remarks Column are listed below Other additional notes needed to describe the item can also be shown Assembly Kit All items on the parts list with the same unique symbol will b
98. gnal Emergency Stop Diagnostic LED Indicators Run Output Energized Crank Output Energized Remote Start Signal Initiated Common Fail Output Energized Watchdog CPU Running Programmable Output Contacts PAGE 18 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 NOTES G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 19 GENERATOR MAJOR COMPONENTS NS d 46D e Figure 3 Major Components A Neb eg AN TES 0 K N A 2 AN AN TIE N A Yeas Y ynas 68 EN 0 9 T Q PAGE 20 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 GENERATOR MAJOR COMPONENTS Figure 3 Major Components Table 5 Generator Major Components 6 Charge Air Cooler 18 interior Lights 30 Waerpan 8 SkVATansome 20 9 Generator 21 Hydraulic Oil Tank 33 FulOt GPS Module Option 12 Hydraulic Oil Filter G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 21 BASIC ENGINE COMPONENTS gt 2 2 lt ER 2 7056 5 yy NN ANN NO WE S en 0 gt N NS con Dis nc YES Figure 4 Basic Engine Compo
99. h is too long or too small can Cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves INSTALLATION 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 guidelines for proper grounding and specifies that 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 a Copper 10 AWG 5 3 mm b Aluminum 8 AWG 8 4 mm 2 When grounding the generator Figure 2 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 NOTICE When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician NOTICE If connection of the ground rod is not feasible please check city local or state electrical requirements on generator grounding requirements G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 15
100. he hitch Raise the jackstand to a height where it will not interfere with the road G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 55 TIRE SAFETY Unsafe Tires Lug Nuts or Wheels Trailer tires and wheels are more likely to fail than car tires and wheels because they carry a heavier load Therefore it is essential to inspect the trailer tires before each tow a tire has a bald spot bulge cuts is showing any cords or is cracked replace the tire before towing If a tire has uneven tread wear take the trailer to a dealer service center for diagnosis Uneven tread wear can be caused by tire imbalance axle misalignment or incorrect inflation Tires with too little tread will not provide adequate tracking on wet roadways and can result in loss of control leading to death or serious injury Improper tire pressure causes an unstable trailer and can result in a tire blowout and loss of control Therefore before each tow you must also check the tire pressure Tire pressure must be checked when tires are cold Allow 3 hours cool down after driving as much as 1 mile at 40 mph before checking tire pressure Trailer tires will be inflated to higher pressures than passenger vehicle tires Since trailer wheels and lug nuts or bolts are subjected to greater side loads than automobile wheels they are more prone to loosen Before each tow check to make sure they are tight
101. impact has occurred Wheels Bearings and Lug Nuts A loose worn or damaged wheel bearing is the most common cause of brakes that grab To check wheel bearings jack trailer and check wheels for side to side looseness If the wheels are loose or spin with a wobble the bearings must be serviced or replaced Check inflation pressure weekly during use to insure the maximum tire life and tread wear Most trailer axles are built with sealed bearings that are not serviceable Sealed bearings must be replaced as complete units TRAILER GUIDELINES NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts Over tightening lug nuts will result in breaking the studs or permanently deforming the mounting stud holes in the wheels Lug nuts are prone to loosen after initial installation which can lead to death or serious injury Check all wheel lug nuts periodically 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 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence See Figure L DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table C 3 Check to see if the lug nuts are tight after the first 10 25 and 50 miles of driving and b
102. in a side wall can result in a tire blowout Inspect both side walls of each tire for any bubble cut or bulge and replace a damaged tire before towing the trailer G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 59 Table B below will help pinpoint the causes and solutions of tire wear problems B Tire Wear Troubleshooting Center Wear Over inflation IE pe load per tire manufacturer Edge Wear Under inflation pale pee ID PAREM load per tire manufacturer Make sure load does not Loss of camber Side Wear i exceed axle rating or overloading i Align wheels Cupping Out of balance Check bearing adjustment and balance tires Flat Spots Wheel lockup and Avoid sudden stops when 4 tire skidding possible and adjust brakes ALWAYS wear safety glasses when removing or installing force fitted parts DO NOT attempt to repair or modify a wheel DO NOT install an inner tube to correct a leak through through the rim If the rim is cracked the 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 Wheel Rims the trailer has been struck or impacted on or near the wheels or if the trailer has struck a curb inspect the rims for damage i e being out of round and replace any damaged wheel Inspect the wheels for damage every year even if no obvious
103. ine oil too thick oil for winter environment At low temperatures engine will not start Defective battery Fuel filter blocked Fuel supply blocked Replace battery Replace fuel filter Engine fires but stops soon as starter is switched off Check the entire fuel system Defective fuel pump Replace fuel pump Add fuel Replace fuel filter Fuel tank empty Fuel filter blocked Defective fuel pump Engine stops by itself during normal operation Replace fuel pump Mechanical oil pressure shutdown sensor 51005 the engine due to low oil Add oil Replace low oil shutdown sensor if necessary Fuel tank empty Replace fuel filter Fuel filter clogged Replace fuel filter Fuel tank venting is inadequate Ensure that tank is adequately vented Check threaded pipe unions tape and tighten Rea unions a required Low engine power output and speed Speed control lever does not remain in selected position see engine manual for corrective action Use No 2 D diesel fuel only Check the fuel Engine oil level too full Correct engine oil level Injection pump wear injection pump element and delivery valve assembly and replace as necessary G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 45 TROUBLESHOOTING CONTROLLER Troubleshooting Intelivision 5 Controller Possible Problem SW and HW mismatch Symptom Wrong Display HW Inv
104. ing and using jackstands place them so as to clear wiring brake lines and suspension parts i e springs torsion bars Place jacks and jackstands inside of the perimeter strip on the supporting structure to which the axles are attached MAINTENANCE DANGER Improper weld repair will lead to early failure of the trailer structure and can cause serious injury or death DO NOT repair cracked or broken welds unless you have a certified welder perform the repair If not have the welds repaired by your dealer the trailer is involved in an accident have it inspected immediately by qualified personnel In addition the trailer should be inspected annually for signs of wear or deformations LEAF SUSPENSION The leaf suspension springs and associated components Figure 39 should be visually inspected every 6 000 miles for signs of excessive wear elongation of bolt holes and loosening of fasteners Replace all damaged parts Suspension immediately SHACKLE SUPPORT BRACKET IS WELDED TO FRAME SHACKLE NUTS AXLE HANGER SUPPORT BRACKET IS WELDED TO FRAME LEAF FRONT HANGER NUT FRONT U BOLT HANGER BOLT LOCKING TIE PLATE NUT Figure 39 Leaf Suspension Components 4 DANGER Worn or broken suspension parts can cause loss of control damage to equipment and severe bodily injury even death Check suspension regularly G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL
105. ional signal lever Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes and can lead to collision Before each tow Check that the taillights brake lights and turn signals work Check that the electric brakes work by operating the brake controller inside the tow vehicle Uncoupling the Ball Hitch Follow these steps to uncouple ball hitch from tow vehicle Block trailer tires to prevent the trailer from rolling before jacking the trailer up Disconnect the electrical connector Disconnect the breakaway brake switch cable Promptly replace the pullpin in the switchbox Before extending jackstand make certain the ground surface below the jackstand foot will support the tongue load Rotate the jackstand handle or crank clockwise This will slowly extend the jack and transfer the weight of the trailer tongue to the jack TRAILER GUIDELINES PINTLE HITCH COUPLER A pintle eye coupler Figure G connects to a pintle hook hitch that is located on or under the rear bumper of the tow vehicle This system of coupling a trailer to a tow vehicle is sometimes referred to as a lunette eye tow ring or G I hitch Figure G Pintle Hitch Coupler A pintle hitch trailer may be fitted with a tongue jackstand that can raise and lower the coupler The tongue jack is mounted to the A frame front or tongue part of the trailer
106. itation The battery 49 contains acids that can cause injury to the eyes and skin Use well insulated gloves when picking up the battery m ALWAYS keep the battery charged If the battery is not charged combustible gas will build up m ALWAYS recharge the battery in a well ventilated environment to avoid the risk of a dangerous concentration of combustible gasses the battery liquid dilute sulfuric acid comes into contact with clothing or skin rinse skin or clothing immediately with plenty of water the battery liquid dilute sulfuric acid comes into contact with eyes rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator ALWAYS keep battery cables in good working condition Repair or replace all worn cables SAFETY INFORMATION ENVIRONMENTAL SAFETY NOTICE Dispose of hazardous waste properly Examples of potentially hazardous waste are used motor oil fuel and fuel filters DO NOT use food or plastic containers to dispose of hazardous waste DO NOT pour waste oil or fuel directly onto the ground down a drain or into any water source G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 11 SPECIFICATIONS Table 1 Generator Specifications open protected type synchronou
107. ite direction until the wheel turns freely with a slight drag MAINTENANCE 6 Replace the adjusting hole cover 7 Repeat the above procedure on all brakes 8 Lower the trailer to the ground Check the fluid level in the master cylinder reservoir at least every three months If you tow your trailer an average of 1 000 miles per month in a hot and dry environment you must check the brake fluid level once a month The brake fluid reservoir is located on the tongue of the trailer Always fill with clean uncontaminated DOT 4 brake fluid Figure 35 below displays the major hydraulic brake components that will require inspection and maintenance Please inspect these components as required using steps 1 through 6 as referenced in the Manually Adjusting The Brakes section on this page See Hydraulic Brake Troubleshooting table in maintenance section Anchor Post Plate Primary Shoe Adjuster Spring Adjuster Assembly Figure 35 Hydraulic Brake Components HYDRAULIC BRAKE ACTUATOR The hydraulic brake actuator Figure 36 is the mechanism that activates the trailers brake system This actuator changes fluid power into mechanical power Therefore the fluid level must be checked frequently to assure that the brakes function properly HYDRAULIC BRAKE FLUID RESERVOIR Figure 36 Hydraulic Brake Actuator G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 41 Failure to maintain prop
108. l and its vapors are dangerous to your health and the surrounding environment Avoid skin contact and or inhaling fumes ALWAYS make sure generator is on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank PAGE 30 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 INSPECTION SETUP 1 Place the generator level with the ground Failure to do 50 will cause fuel to spill from the tank before reaching full capacity Figure 12 DO NOT fill on unlevel ground a Figure 14 Full Fuel Tank Figure 12 Only Fill on Level Ground DO NOT OVERFILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 15 NOTICE ONLY use 2 diesel fuel when refueling 2 Remove fuel cap and fill tank Figure 13 Fuel EXPANDS when heated DIESEL FUEL Figure 13 Fueling the Generator 3 Monitor the fuel gauge while filling fuel tank Stop filling when the fuel gauge indicates full Figure 14 DO NOT wait for fuel to rise in filler neck Figure 15 Fuel Expansion G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 31 COOLANT ANTIFREEZE SUMMER COOLANT Cummins recommends antifreeze summer coolant for use in their engines which can be purchased in concentrate and mixed with 50 demineralized water or pre diluted See the Cummins Engine Owner s Manual for
109. le Gross Axle Weight Rating GAWR 6 000 Ibs 2 722 kg Gross Vehicle Weight Rating is 10 000 105 4 536 kg Rear Bumper Reflectors Provides high visibility when towing in dark areas Safety Chains Connectto towing vehicle Reference towing section in this manual Tool Box Tongue mounted tool box lift spare tire to gain access to this compartment Fuel Tank Holds 150 gallons 568 liters of No 2 diesel fuel Fuel Tank Filler Port Fuel filler port 2 inch 51 mm neck Side Running Lamps Provides high visibility when towing in dark areas Tool Box Locking Latch Release this latch to gain access to tool box Pull spare tire upward and back Plug Holder Holds trailer harness lights cable plug G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 23 CONTROL PANEL Figure 6 Control Panel The definitions below describe the controls and functions of the Control Panel Figure 6 1 Voltage Adjust Switch To increase the output voltage pull upward and hold the switch until the desired voltage is achieved by monitoring the AC voltage display item 8 To decrease the voltage pull downward Line 1 AC Amps Display Indicates the amount of current the load is drawing from line 1 of the generator Line 2 AC Amps Display Indicates the amount of current the load is drawing from line 2 of the generator Line
110. ler brake and tow vehicle brake Note the effect that the trailer brakes have when they are the only brakes used When properly adjusted the trailer brakes will come on just before the tow vehicle brakes It will take practice to learn how to back up a tow vehicle with a trailer attached Take it slow Before backing up get out of the tow vehicle and look behind the trailer to make sure that there are no obstacles some drivers place their hands at the bottom of the steering wheel and while the tow vehicle is in reverse think of the hands as being on the top of the wheel When the hands move to the right counterclockwise as you would do to turn the tow vehicle to the left when moving forward the rear of the trailer moves to the right Conversely rotating the steering wheel clockwise with your hands at the bottom of the wheel will move the rear of the trailer to the left while backing up you are towing a bumper hitch rig be careful not to allow the trailer to turn too much because it will hit the rear of the tow vehicle To straighten the rig either pull forward or turn the steering wheel in the opposite direction TRAILER VIN TAG Figure A below is a sample of the Vehicle Identification Number VIN Tag which is typically located on the left front of the trailer See Figure B for location LAbE LEY OBWE OL FYN GOWL vir umo AEBLN
111. ls An explosion or fire could result causing severe bodily harm or even death NEVER disconnect any emergency or safety devices These devices are intended for operator safety Disconnection of these devices can cause severe injury bodily harm or even death Disconnection of any of these devices will void all warranties NEVER lubricate components or attempt service on a running machine NOTICE ALWAYS ensure generator is on level ground before use ALWAYS keep the machine in proper running condition Fix damage to machine and replace any broken parts immediately ALWAYS store equipment properly when it is not being used Equipment should be stored in a clean dry location out of the reach of children and unauthorized personnel G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 7 ENGINE SAFETY The engine fuel exhaust gases contain poisonous carbon monoxide This gas is colorless and odorless and can cause death if inhaled The engine of this equipment requires an adequate free flow of cooling air NEVER operate this equipment in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine B DO NOT place hands or fingers inside engine compartment when engine is running B NEVER operate the engi
112. mal tire flexing occurs This situation can generate an excessive amount of heat within the tire Excessive heat may lead to tire failure It is the air pressure that enables a tire to support the load so proper inflation is critical The proper air pressure may be found on the certification VIN label and or on the Tire and Loading Information placard This value should never exceed the maximum cold inflation pressure stamped on the tire Perform the following steps to determine the load limit of your trailer Step 1 Locate the statement The weight of cargo should never exceed XXX kg Ibs on your vehicle s Tire and Loading Information placard Figure l This value equals the available amount of equipment load capacity Step 2 Determine the weight of the equipment being loaded on the tow vehicle That weight may not safely exceed the available equipment load capacity The trailers Tire Information Placard is attached adjacent to or near the trailers VIN Certification label at the left front of the trailer See Figure TRAILER GUIDELINES Determining Load Limit of Tow Vehicle Step 1 Locate the statement The combined weight of occupants and cargo should never exceed XXX Ibs on your vehicle s placard Step 2 Determine the combined weight of the driver and passengers who will be riding in your vehicle Step 3 subtract the combined weight of the driver and passengers from XXX kilograms or XX
113. n of tires has been the industry standard for the past 20 years Next number This two digit number is the wheel or rim diameter in inches If you change your wheel size you will have to purchase new tires to match the new wheel diameter Next number This two or three digit number is the tire s load index It is a measurement of how much weight each tire can support You may find this information in your owner s manual If not contact a local tire dealer Note You may not find this information on all tires because it is not required by law TRAILER GUIDELINES M amp S The 5 or M S indicates that the tire has some mud and snow capability Most radial tires have these markings hence they have some mud and snow capability Speed Rating The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time The ratings range from 99 miles per hour mph to 186 mph These ratings are listed in Table A Note You may not find this information on all tires because it is not required by law Table A Speed Rating x R mph U TMmh H mm Lo 2 Mmh W _ m x Y U S DOT Tire Identification Number This begins with the letters DOT and indicates that the tire meets all federal standards The next two numbers or letters are the plant code where was manufactured an
114. nd damage WIRING Inspect the generator for bad 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 fatigue wear and tightness Tighten all hose clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 33 STARTUP BEFORE STARTING FUEL VALVES IN PRIME MODE The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating 1 Place the Control Power switch Figure 18 on the digital control panel in the up position ON 4 ON UP Figure 21 Fuel Valves Prime Mode ON UP Figure 18 Control Power Switch ON 4 2 2 Place the voltage selector switch Figure 19 in the desired voltage setting position The corresponding Voltage Status LED on the control panel will light to Figure 22 Fuel Priming Switch ON indicate the selected voltage Figure 20 4 After priming is complete release the fuel priming 1201208 switch Place the fuel valves in the run mode Figure 23 FUEL VALVES IN 1 RUN MODE 16 Figure 19 Voltage Selector Switch 120 208 Position Figure 23 Fuel Valves Run Mode 5 Verify that all three circuit breakers Figure 24 are in the
115. ne with heat shields or i guards removed Keep fingers hands hair and clothing away from all moving parts to prevent injury DO NOT remove the radiator cap whilethe engine is hot High pressure boiling water will gush out of the radiator and severely e scald any persons in the general area of 4 the generator DO NOT remove the coolant drain plug while the engine is hot Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator DO NOT remove the engine oil drain plug while the engine is hot Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator NEVER touch the hot exhaust manifold 2 muffler or cylinder Allow these parts to cool before servicing equipment SAFETY INFORMATION NOTICE NEVER run engine without an air filter or with a dirty air filter Severe engine damage may occur Service air filter frequently to prevent engine malfunction NEVER tamper with the factory settings N of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the W maximum allowable Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied When a diesel engine operates without sufficient load less than 40 of the rated output it will not ope
116. nents 0 o o o o o 9 o cO 9 r DESCRIPTION Oil Filler Cap Alternator Oil Filter Oil Drain Plug Water Pump Oil Dipstick Fuel Filter Fuel Rail 10 Turbocharger PAGE 22 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 BASIC TRAILER COMPONENTS Figure 5 Basic Trailer Components 10 The definitions below describe the controls and functions of the Trailer Figure 6 1 Pintle Eye Coupler Adjustable 3 inch eye coupler rated at 20 000 Ibs 9 072 kg Hydraulic Brake Actuator Replaceable bolt on actuator assists in the stopping of the trailer Rated at 12 000 Ibs 5 443 kg Spare Tire Tongue mounted spare tire with anti theft wheel lock and locking mount Jackstand Tongue mounted swivel jack with flat disc foot rated 5000 Ibs 2 268 kg lift Reflectors Side mounted reflectors are mounted on both sides of the trailer to provide high visibility when towing in dark areas Tires Recommended tire size is LT235 85R16 LR E Tire load rating is 3 500 Ibs tire Reflective Tape Provides high visibility when towing in dark areas Brake Turn Lights DOT approved tail stop and turn signal lamps Bumper Guard Protects trailer frame when coming in contact with stationary objects 11 License Plate Lights Illuminates license plate Axle Tandemum ax
117. ng of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure both towing vehicle and trailer Trailer tires should be inflated to 50 psi cold Also check the tire tread wear on both vehicles m ALWAYS make sure the trailer is equipped with a safety chain m ALWAYS properly attach trailer s safety chains to towing vehicle ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly DOT Requirements include the following Connect and test electric brake operation Secure portable power cables in cable tray with tie wraps he maximum speed for highway towing is 55 MPH unless posted otherwise Recommended off road towing is not to exceed 15 MPH or less depending on type of terrain Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing Avoid sharp turns to prevent rolling Trailer should be adjusted to a level position at all times when towing Raise and lock trailer wheel stand in up position when towing Place chock blocks underneath wheel to prevent rolling while parked Place support blocks underneath the trailers bumper to prevent tipping whil
118. nished with a trailer in tow It takes longer to get up to speed you need more room to turn and pass and more distance to stop when towing a trailer You will need to spend time adjusting to the different feel and maneuverability of the tow vehicle with a loaded trailer Because of the significant differences in all aspects of maneuverability when towing a trailer the hazards and risks of injury are also much greater than when driving without a trailer You are responsible for keeping your vehicle and trailer in control and for all the damage that is caused if you lose control of your vehicle and trailer As you did when learning to drive an automobile find an open area with little or no traffic for your first practice trailering Of course before you start towing the trailer you must follow all of the instructions for inspection testing loading and coupling Also before you start towing adjust the mirrors so you can see the trailer as well as the area to the rear of it TRAILER GUIDELINES Drive slowly at first 5 mph or so and turn the wheel to get the feel of how the tow vehicle and trailer combination responds Next make some right and left hand turns Watch in your side mirrors to see how the trailer follows the tow vehicle Turning with a trailer attached requires more room Stop the rig a few times from speeds no greater than 10 mph If your trailer is equipped with brakes try using different combinations of trai
119. orner In addition you will need a longer distance to pass due to slower acceleration and increased length Be alert for slippery conditions You are more likely to be affected by slippery road surfaces when driving a tow vehicle with a trailer than driving a tow vehicle without a trailer Check rearview mirrors frequently to observe the trailer and traffic NEVER drive faster than what 15 safe Driving too fast for severe road conditions can result in loss of control and cause death or serious injury Decrease your speed as road weather and lighting conditions deteriorate Always check for local trailer tow speed limits in your area Do not transport people on the trailer The transport of people puts their lives at risk and may be illegal COUPLING TO THE TOW VEHICLE Follow all of the safety precautions and instructions in this manual to ensure safety of persons equipment and satisfactory life of the trailer Always use an adequate tow vehicle and hitch If the vehicle or hitch is not properly selected and matched to the Gross Vehicle Weight Rating GVWR of your trailer you can cause an accident that could lead to death or serious injury you already have a tow vehicle know your vehicle tow rating and make certain the trailers rated capacity is less than or equal to the tow vehicle s rated towing capacity If you already have or plan to buy a trailer make certain that the tow rating of
120. own below AC Metering Display Voltage Amperage Frequency Generator Phase Voltage Current Generator Frequency Engine Information Display Engine Temperature Oil Pressure psi Battery Voltage DC Tachometer Hourmeter Minor Fault Warning Display Switch Not In Auto Low Fuel Level Low Oil Pressure Alarm Low Engine Temperature High Engine Temperature Alarm Low Battery Voltage e High Battery Voltage Weak Battery Condition Battery Charger Input Fail Undervoltage Over Underfrequency Overcurrent Major Fault Shutdown Display Overvoltage Emergency Stop Loss Of Speed Overcrank Overspeed Low Oil Pressure High Engine Temperature Low Coolant Level Spare Programmable Digital Faults GENERAL INFORMATION Switches And Operating Controls Run Off Auto Load Test Buttons Decrement Increment Previous Exit Next Enter Program Buttons Emergency Stop Button Audible Alarm Horn Alarm Horn Silence Button Lamp Test Button Fault Reset Function e RS 485 Remote Communications External Expansion Module Ports Timer Countdown Display Engine Start Delay Oil Bypass Overcrank Cycle Crank e Starter Re engage Delay Bypass Delay Control LED Indicators Switch Position Run Off Auto Test Common Alarm Minor Fault Common Shutdown Major Fault Generator Ready When in Auto Speed Si
121. person requesting the RMA 3 Acopy ofthe Return Material Authorization must accompany the return shipment 4 Freight is at the sender s expense All parts must be returned freight prepaid to Multiquip s designated receiving point 5 Parts must be in new and resalable condition in the original Multiquip package if any and with Multiquip part numbers clearly marked 6 Thefollowing items are not returnable a Obsolete parts If an item is in the price book and shows as being replaced by another item it is obsolete b Any parts with a limited shelf life such as gaskets seals O rings and other rubber parts that were purchased more than six months prior to the return date c Any line item with an extended dealer net price of less than 5 00 Special order items Electrical components Paint chemicals and lubricants Decals and paper products Items purchased in kits 7 _ The sender will be notified of any material received that is not acceptable 8 Such material will be held for five working days from notification pending instructions If a reply is not received within five days the material will be returned to the sender at his expense 9 Credit on returned parts will be issued at dealer net price at time of the original purchase less a 15 restocking charge 10 In cases where an item is accepted for which the original purchase document can not be determined the price will be bas
122. programming was not done properly Unsupported font Unsupported format InteliVision 5 firmware has to be updated Display firmware font programming is necessary Font not valid Error Display firmware font programming is necessary Font format not supported Error InteliVision 5 font or firmware is necessary Bitmaps not valid Error Bitmaps format not supported Error Firmware upgrade is necessary Unsupported bitmaps format Firmware upgrade is necessary Default lang not supported Error Default Defined language error not supported Language change or code page change is necessary PAGE 46 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 The following guidelines are intended to assist the operator in the operation and handling of a trailer Safety precautions should be followed at all times when operating a trailer Failure to read understand and follow the safety guidelines could result in injury to yourself and others Loss of control of the trailer or tow vehicle can result in death or serious injury COMMON CAUSES FOR LOSS OF TRAILER Driving too fast for the conditions maximum speed when towing a trailer is 55 mph Overloading the trailer or loading the trailer unevenly Trailer improperly coupled to the hitch No braking on trailer Not maintaining proper tire pressure Not keeping lug nuts tight Not properly maintaining the trailer st
123. quired by the job or city and state regulations m NEVER operate this equipment when not feeling well due to fatigue illness or when under medication m NEVER operate this equipment under the influence of drugs or alcohol ALWAYS check the equipment for loosened threads or bolts before starting DO NOT use the equipment for any purpose other than its intended purposes or applications NOTICE This equipment should only be operated by trained and qualified personnel 18 years of age and older Whenever necessary replace nameplate operation and safety decals when they become difficult read Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties SAFETY INFORMATION NEVER use accessories or attachments that are not recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result ALWAYS know the location of the nearest fire extinguisher ALWAYS know the location of the nearest first aid kit ALWAYS know the location of the nearest phone or keep a phone on the job site Also Know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency GENERATOR SAFETY DANGER NEVER operate the equipment in an explosive atmosphere or near combustible materia
124. rate at its optimum temperature This will allow unburned fuel to accumulate in the exhaust system which can foul the fuel injectors engine valves and exhaust system including turbochargers and reduce the operating performance In order for a diesel engine to operate at peak efficiency it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel Wet stacking does not usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition It can reduce the system performance and increase maintenance Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition This can take several hours to burn off the accumulated unburned fuel State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters must be used on internal combustion engines that use hydrocarbon fuels A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator PAGE 8 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL
125. re you enter the curve and power through the curve This way the towing vehicle remains in charge DO NOT apply the brakes to correct extreme trailer swaying Continued pulling of the trailer and even slight acceleration will provide a stabilizing force Anticipate the trailer swaying Swaying is the trailer reaction to the air pressure wave caused by passing trucks and buses Continued pulling of the trailer provides a stabilizing force to correct swaying DO NOT apply the brakes to correct trailer swaying Use lower gear when driving down steep or long grades Use the engine and transmission as a brake Do not ride the brakes as they can overheat and become ineffective B aware of your trailer height especially when approaching roofed areas and around trees Make regular stops about once each hour Confirm that Coupler is secure to the hitch and is locked e Electrical connectors are secure There is appropriate slack in the safety chains here is appropriate slack in the breakaway switch pullpin cable ires are not visibly low on pressure G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 47 DRIVING CONDITIONS When towing a trailer you will have decreased acceleration increased stopping distance and increased turning radius which means you must make wider turns to keep from hitting curbs vehicles and anything else that is on the inside c
126. rn cables or cords when connecting equipment to generator Inspect for cuts in the insulation NEVER grab or touch a live power 47 cord or cable with wet hands The a 5 possibility exists of electrical shock SRE electrocution or death Power POWER ON SAFETY INFORMATION Make sure power cables are securely connected to the generators output receptacles Incorrect connections may cause electrical shock and damage to the generator NOTICE ALWAYS make certain that proper power or extension cord has been selected for the job See Cable Selection Chart in this manual Grounding Safety ALWAYS make sure that electrical circuits are properly grounded to a suitable earth ground ground rod per the National Electrical Code NEC and local codes before operating generator Severe injury or death by electrocution can result from operating an ungrounded generator m NEVER use gas piping as an electrical ground PAGE 10 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 BATTERY SAFETY DANGER DO NOT drop the battery There is a possibility that the battery will explode DO NOT expose the battery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come into contact with a flame or spark an explosion could occur ALWAYS wear safety glasses when handling the battery to avoid eye irr
127. ructure Ensure machine is towed level to tow vehicle TRAILER TOWING GUIDELINES Recheck the load tiedowns to make sure the load will not shift during towing Before towing check coupling safety chain safety brake tires wheels and lights Check the lug nuts or bolts for tightness Check coupler tightness after towing 50 miles Use your mirrors to verify that you have room to change lanes or pull into traffic Use your turn signals well in advance Allow plenty of stopping space for your trailer and tow vehicle Allow plenty of stopping space for your trailer and tow vehicle DO NOT drive so fast that the trailer begins to sway due to speed Allow plenty of room for passing A rule of thumb is that the passing distance with a trailer is 4 times the passing distance without the trailer TRAILER GUIDELINES Shift your automatic transmission into a lower gear for city driving ALWAYS use lower gears for climbing and descending grades DO NOT ride the brakes while descending grades they may get so hot that they stop working Then you will potentially have a runaway tow vehicle and trailer conserve fuel don t use full throttle to climb a hill Instead build speed on the approach Slow down for bumps in the road Take your foot off the brake when crossing the bump DO NOT brake while in a curve unless absolutely necessary Instead slow down befo
128. running clean tap water through radiator until signs of rust and dirt are removed Do not clean radiator core with any objects such as a screwdriver 3 Check hoses for softening and kinks Check clamps for signs of leakage 4 Move lever to the closed position and reinstall coolant drain plug 5 Replace with coolant as recommended by the engine manufacturer 6 Close radiator cap tightly GENERATOR STORAGE For long term storage of the generator the following is recommended 1 Drain the fuel tank completely Treat with a fuel stabilizer if necessary 2 Completely drain the oil from the crankcase and refill if necessary with fresh oil Clean the entire generator inside and outside Disconnect the battery Make sure engine coolant is at proper level oS pi c Cover the generator and store in a clean and dry place PAGE 40 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 The following trailer maintenance guidelines are intended to assist the operator in preventive maintenance TRAILER BRAKES Properly functioning brake shoes and drums are essential to ensure safety The brakes should be inspected the first 200 miles of operation This will allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes every 3 000 miles If driving over rough terrain inspect the brakes more frequently HYDRAULIC BRAKES your trailer has hydraulic
129. s generator Armature Connection No of Poles Prime Output 10 Voltage 30 Voltages Frequency no load to full load Frequency Regulation ody tag Speed Power Factor 8 Aux AC Voltage Weight Generator Only Weight Trailer Only Dimensions LxWxH 100 x 48 x 110 in 254 x 122 x 279 cm Table 2 Engine Specifications Cummins QSB7 G5 Tier 3 4 cycle direct injection turbocharged Type charge air cooled No of Cylinders 6 cylinders Bore x Stroke in mm 4 21 x 4 88 107 x 124 Displacement 408 cu in 6 690 cc Rated Output Coolant Capacity Lube Oil Capacity 5 0 gal 19 0 liters Fuel Type Fuel Tank Capacity 150 gal 567 liters 13 3 gal 64 L hr at full load 10 6 gal 40 L hr at 3 4 load 7 8 gal 30 L hr at 1 2 load 4 0 gal 15 L hr at 1 4 load Table 3 Battery Specifications Fuel Consumption Battery Top Post 12V 750 CCA x 2 24 VDC System Group 27 Dimensions HxWxL in cm 8 x 12x 6 6 20 3 x 30 5 x 16 8 PAGE 12 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 DIMENSIONS Figure 1 Dimensions SIDE VIEW Table 4 Dimensions Reference Dimensions Reference Letter in mm Letter 900280 H 115 2921 23 0 0 96 2 438 Chrome Wheels 24 610 Aluminum Wheels 180 4 572 O A EN me 62 506140003 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 13 INSTALLATION
130. ss of control and may lead to death or serious injury Use of a tow vehicle with a towing capacity less than the load rating of the trailer can result in loss of control and may lead to death or serious injury Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer PAGE 48 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 INOPERABLE BRAKES LIGHTS OR MIRRORS Be sure that the brakes and all of the lights on your trailer are functioning properly before towing your trailer Check the trailer taillights by turning on your tow vehicle headlights Check the trailer brake lights by having someone step on the tow vehicle brake pedal while you look at trailer lights Do the same thing to check the turn signal lights See Trailer Wiring Diagram section in this manual Standard mirrors usually do not provide adequate visibility for viewing traffic to the sides and rear of a towed trailer You must provide mirrors that allow you to safely observe approaching traffic Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and can lead to collision Before each tow check that the tail lights brake lights and turn signals work TRAILER TOWING TIPS Driving a vehicle with a trailer in tow is vastly different from driving the same vehicle without a trailer in tow Acceleration maneuverability and braking are all dimi
131. ssemblies DC Output Connector Provides DC power to engine interface Fan Control Module Provides necessary control electronics to operate fan Engine Com Connector 9 pin connector for communication to engine via a PC with engine software PAGE 24 G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 CAMLOK VOLTAGE OUTPUT PANEL 9 mo m 6 G 2 mo z 9 A m 0 UJ r 00 gt A gt Figure 7 Camlok Voltage Output Panel The definitions below describe the controls and functions of the Camlok Voltage Output Panel Figure 7 1 CB4 CB5 Circuit Breakers These circuit breakers protect the 120 VAC auxiliary output receptacles from overload CB6 CB7 Circuit Breakers These circuit breakers protect the bates output receptacles from overload
132. stem The breakaway brake system includes a brake cable connected to the tow vehicle on one end and to the emergency brake lever located on the hydraulic actuator on the other end An ineffective breakaway brake system can result in a runaway trailer leading to death or serious injury if the coupler or ball hitch fails Connect the breakaway cable to the tow vehicle and NOT to the hitch ball or support Before towing the trailer test the function of the breakaway brake system If the breakaway brake system is not working DO NOT tow the trailer Have it serviced or repaired NOTICE DO NOT tow the trailer with the breakaway brake system ON because the brakes will overheat which can result in permanent brake failure NOTICE Replace the breakaway brake battery if equipped at intervals specified by manufacturer G1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 PAGE 53 Connecting Trailer Lights Connect the trailer lights to the tow vehicle s electrical system using the electric connectors at the front of the trailer tongue Refer to the wiring diagram shown in the trailer wiring diagram section of this manual Before towing the trailer check for the following Running lights turn on tow vehicle headlights Brake Lights step on tow vehicle brake pedal Backup Lights place tow vehicle gear shift in reverse B Turn Signals activate tow vehicle direct
133. te a synchronizing mode The light above the button will begin flashing bring the generator into phase and automatically close the breaker Once the breaker closes the light above the button would then become solid and the generators would now be in parallel As load is applied units will share the load proportionally CLOSING THE ENCLOSURE DOORS 1 Close the enclosure doors once the generator has started Figure 29 Top vents stay open for proper ventilation RAIN DOOR INTAKE VENT Figure 29 Engine Enclosure Doors 2 f access to the controls or other components is necessary while the engine is running make sure the doors are not left open for an extended period of time 3 protect the unit from rain the top intake vent be closed by opening the upper front vent door on the generator enclosure The front vent will automatically close the upper roof intake vent The upper exhaust vent will remain open NORMAL SHUTDOWN PROCEDURE To shutdown the generator use the following procedure NEVER stop the engine suddenly except in an emergency STARTUP 1 Press the GCB control button on the controller Figure 30 to open circuit breaker InteliVision 5 PRESS BUTTON Figure 30 Generator Circuit Breaker Open 2 Let the engine cool by running it at full speed for 3 5 minutes with no load applied 3 Press the STOP button Figure 31 on the controller The engine will go to idle mode
134. the trip point The trip setting for this generator is position B 600 amps DO NOT adjust the trip point setting when the equipment is in operation PAGE 26 SG1400C3 STUDIO GENERATOR OPERATION AND PARTS MANUAL REV 1 02 15 12 DIGITAL CONTROLLER Figure 9 Digital Controller Refer to Figure 9 for location of controls and indicators 1 STATUS LED Indicates status of the controller Lights green when the controller is running NAVIGATIONS BUTTONS 2 ARROW UP Button Press button to scroll up through the status menus or programming prompts 3 ARROW DOWN Button Press button to scroll down through the status menus or programming prompts 4 MENU Button Press button to jump to menu sub menu page or escape from any dialog window 5 ENTER Button Press button to confirm a value or open a value adjustment within setting dialogs CONTEXT BUTTONS 6 MODE Button Press button to jump to the controller mode window 7 HISTORY Button Press button to jump to history screen 8 ALARM Button Press button to jump to alarm list 9 GCB Generator Circuit Breaker CONTROL Button Press button to close open GCB 10 MCB CONTROL Button Not functional in this application CONTROL BUTTONS 11 START Button Press button to go idle mode about an hour then generator starts A second press will bypass idle mode and generator goes to full speed immediately 1
135. tor field exciter rotor armature rectifier assembly and voltage regulator The generator s exciter consists of a stationary field and a rotating armature The stationary field exciter stator is designed to be the primary source of the generator s residual magnetism This residual magnetism allows the exciter rotor armature to produce AC voltage even when the exciter stator field is not powered This AC voltage is rectified to DC by the rotating rectifier assembly and fed directly to the main rotor field As the generator GENERAL INFORMATION shaft continues to rotate the main rotor field induces a voltage into the generator s main stator armature At rated speed the main stator s voltage produced by the residual magnetism of the exciter allows the automatic voltage regulator to function The regulator provides voltage to the exciter resulting in a build up of generator terminal voltage This system of using residual magnetism eliminates the need for a special field flashing circuit in the regulator After the generator has established the initial residual voltage the regulator provides a controlled DC field voltage to the exciter stator resulting in a controlled generator terminal voltage Voltage Regulation In the standard configuration shunt excited the automatic voltage regulator receives both its input power and voltage sensing from the generator s output terminals The regulator automatically monitors the gen
136. visually check that the hitch ball nut is solid against the lock washer and hitch frame Wipe the inside and outside of the coupler Clean and visually inspect it for cracks and deformations Feel the inside of the coupler for worn spots and pits Be sure the coupler is secured tightly to the tongue of the trailer All coupler fasteners must be visibly solid against the trailer frame The bottom surface of the coupler must be above the top of the hitch ball Use the tongue jackstand to support TRAILER GUIDELINES the trailer tongue Wood or concrete blocks may also be used Coupling the Trailer to the Tow Vehicle Ball Coupler Lubricate the hitch ball and the inside of the coupler with a thin layer of automotive bearing grease Slowly back up the tow vehicle so that the hitch ball is near or aligned under the coupler Using the jackstand at the front of trailer tongue turn the jackstand crank handle to raise the trailer If the ball coupler does not line up with the hitch ball adjust the position of the tow vehicle Open the coupler locking mechanism Ball couplers have a locking mechanism with an internal moving piece and an outside handle In the open position the coupler is able to drop fully onto the hitch ball B Lower the trailer Figure D until the coupler fully engages the hitch ball Figure D Ball Hitch Coupling Mechanism Engage the coupler locking mechanism In the engaged
137. wer grade Traction is graded from highest to lowest as and Temperature Letter This letter indicates a tire s resistance to heat The temperature grade is for a tire that is inflated properly and not overloaded Excessive speed underinflation or excessive loading either separately or in combination can cause heat build up and possible tire failure From highest to lowest a tire s resistance to heat is graded as A or Refer to Figure K for additional tire information for light trucks usd 5 Lie 68 8 dual 1661 mia Figure K UTQGS Tire Information Tires for light trucks have other markings besides those found on the sidewalls of passenger tires LT The LT indicates the tire is for light trucks or trailers ST An ST is an indication the tire is for trailer use only Max Load Dual kg Ibs at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is used as a dual that is when four tires are put on each rear axle a total of six or more tires on the vehicle Max Load Single kg Ibs at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is used as a single TRAILER GUIDELINES Load Range This information identifies the tire s load carrying capabilities and its inflation limits Tire Safety Tips Slow
138. y 2 Be sS V 2 SH SAFETY CHAIN CROSS BOTH SAFETY CHAINS MASTER LINK Figure E Attaching Safety Chain Ball Hitch Loop around a frame member of the tow vehicle or holes provided in the hitch system DO NOT attach them to an interchangeable part of the hitch assembly Have enough slack to permit tight turns but not be close to the road surface so if the trailer uncouples the safety chains can hold the tongue up above the road Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle leading to death or serious injury if the trailer uncouples from the tow vehicle Fasten chains to frame of tow vehicle DO NOT fasten chains to any part of the hitch unless the hitch has holes or loops specifically for that purpose Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up if the trailer comes loose TRAILER GUIDELINES Breakaway Brake System the coupler or hitch fails a properly connected and working breakaway brake system Figure F will apply the hydraulic brakes on the trailer The safety chains will keep the tow vehicle attached and as the brakes are applied at the trailers axles the trailer tow vehicle combination will come to a controlled stop Breakaway Lever Connect Cable to Tow Vehicle Hydraulic Actuator Figure F Breakaway Brake System Breakaway Cable Surge Brake Sy
139. y is dead and needs to be recharged or replaced Before charging the battery with an external electric source be sure to disconnect the battery cables Battery Cable Installation ALWAYS make sure that the battery cables Figure 17 are properly connected to the battery terminals as shown below ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE bee 8444 tpt HL Mt Figure 17 Battery Connections INSPECTION SETUP When connecting the battery do the following 1 Place a small amount of battery terminal treatment compound around both battery terminals This will ensure a good connection and will help prevent corrosion around the battery terminals 2 Connectthe red cable to the positive terminal of the battery and the black cable to the negative terminal of the battery NOTICE If the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polarity when connecting the battery Inadequate battery connections may cause poor starting of the generator and create other malfunctions ALTERNATOR The polarity of the alternator is negative grounding type When an inverted circuit connection takes place the circuit will short instantaneously resulting in alternator failure DO NOT put water directly on the alternator Water in the alternator can cause corrosion a

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