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Multiquip DCA40SSKU User's Manual

1. 28 a CH CH15 CNIS CHU Figure 63 Engine Wiring Diagram DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 45 TROUBLESHOOTING GENERATOR Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 19 shown below for diagnosis of the Generator If the problem cannot be remedied consult our company s business office or service plant Table 19 Generator Troubleshooting Sympom PossblePrbem O No Voltage Output Low Voltage Output azia When the Emergency Malfunction shutdown system has been activated the engine will be stopped and the pre heat lamp will indicate the malfunction by a series of flashing patterns The flashing patterns and corrective action are shown below in Table 20 The flashing patterns consist of combinations of one or more long flashes and one or more short flashes Table 20 Engine Generator Troubleshooting Pre heat Lamp Type of Fault Possible Fault Pre meal amp Indication Engine Overspeed 115 or more rated RPM speed Long 1 Short 1 Check electronic governor Low Oil Pressure Long 1 Short2 Check oil level greater Insufficient Charge No Voltage of Charging Genset Long 1 Short3 Check wiring and repair Engine Overheat 230 F 110 C Long 1 Short4 Check cooling system High Water Temperature 3 Emergency Stop Emer
2. These units will ONLY function when commercial power has been supplied to them Figure 57 When using extension cords refer to Table 6 for the correct size and length The battery charger should always be connected to a commercial power source to ensure that the battery does not get discharged When using the generator in hot climates there is no need to apply power to jacket water heater However if the generator will be used in cold climates it is best to apply power to the jacket water heater at all times JACKET WATER HEATER CONNECT TO EXTERNAL 120 VAC POWER SOURCE Figure 57 Battery Charger and Jacket Water Heater option MAINTENANCE the generator will be used daily the battery should normally not require charging If the generator will be idle not used for long periods of time apply power to the battery charger receptacle via commercial power using a power cord of adequate size NOTICE To ensure adequate starting capability always have power applied to the generator s internal battery charger PAGE 38 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 TRAILER MAINTENANCE This section is intended to provide the user with generic trailer service and maintenance information The service and maintenance guidelines referenced in this section refer to a wide range of trailers Remember periodic inspection of the trailer will ensure safe towing of the genera
3. WIRING VIEW Re RECTFER 123 CB2 3 CB4 5 CONT 2 CONS 4 Figure 62 Generator Wiring Diagram PAGE 44 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 ENGINE WIRING DIAGRAM CONNECTORS VIEW FROM WIRING SIDE CONTROL UNIT OG pP 5522 2828 ctr 06 m 3 mrt 8185 cem 4 PSI 1 i P 95 E Mr F E i LE quic 281222 15 Fm i CM ee OLL LI 8 m T LS IC on LL TT l li CHARGE s Mg a n 1250 Ls i PRSESAT WARMING ks 1812 3 FUSE B T n xis Tn n il 29 ps KE INL CONNECTOR ARRANGEMENT VIEW FROM VARING SIDE COLOR CODE BLACK R RED LVIOLET O J ORANGE LI PINK Lo jJ KEY CONNECTION DIAGRAM _ _ F er 4123 2 18 7 8 5 QAH CNS CHa CHT START OHOH H HH 0 Che cng CHM 413 CHH
4. Ammeter Change Over Switch This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals or to be switched off This switch does not effect the generator output in any fashion it is for current reading only Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage 6 Main Circuit Breaker This three pole 100A main breaker is provided to protect the the U V and W Output Terminal Lugs from overload NOTICE Remember the overcurrent relay monitors the current flowing from the U V and W output terminal lugs to the load In the event of a short circuit or over current condition it will automatically trip the 100 amp main breaker To restore power to the output terminal panel press the reset button on the overcurrent relay and place the main circuit breaker in the closed position ON DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 19 OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL The Output Terminal Panel Figure 6 shown below is located on the right hand side left from control panel of the generator Lift up on the cover to gain access to receptacles and terminal lugs NOTICE Terminal legs and Ground are considered bonded grounds 16 AND 30 480 120 VAC OUTPUT TERMINALS NEUTRAL TERMINAL BLACK RED BLUE WHITE GREEN CIR
5. Tire inflation pressure is the most important factor in tire life Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot Check inflation pressure weekly during use to insure the maximum tire life and tread wear Table 16 Tire Wear Troubleshooting will help pinpoint the causes and solutions of tire wear problems Table 16 Tire Wear Troubleshooting Center Wear Over inflation Adjust pe load per tire manufacturer Edge Wear Under inflation es dod load per tire manufacturer Make sure load does not Loss of camber Side Wear exceed axle rating or overloading Align wheels Check bearing adjustment Flat Spots Wheellockup and Avoid sudden stops when QM tire skidding possible and adjust brakes Suspension The leaf suspension springs and associated components Figure 59 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 Torqued suspension components as detailed in Table 17 SHACKLE SUPPORT BRACKET IS WELDED TO FRAME 6 SHACKLE BOLTS SUSPENSION SHACKLE HANGER SUPPORT BRACKET IS WELDED TO FRAME HANGER BOLT LOCKING TIE PLATE NUT Figure 59 Major Suspension Components Table 17 Suspension Torque Requirements Torgue Ft Lbs Shackle Bolt snug fit only Part
6. 0017106016 0105091025 030210250 B5131300004 0340406040 Y0500815000 0401450050 B3131300804 0029205012 0401450050 0605000455 0030012000 0040012000 031112230 PART NAME ROTOR ASSY FIELD ASSY RECTIFIER ZNR HOLDER ZNR INSULATOR WASHER INSULATOR WASHER FAN COUPLING DISK o lt GENERATOR ASSY REMARKS ITEMS 1 9 1 9 amp 1 98 MUST ORDERED WHEN REPLACING COUPLING DISK HEX HEAD BOLT BALANCING WEIGHT KIT U NUT COUPLING WASHER HEX SOCKET HEAD CAP SCREW WASHER FLAT BEARING HEX HEAD BOLT WASHER LOCK STATOR ASSY GROMMET FIELD ASSY EXCITER HEX SOCKET HEAD CAP SCREW WASHER LOCK END BRACKET HEX HEAD BOLT PACKING COVER BEARING HEX HEAD BOLT HEX HEAD BOLT WASHER LOCK COVER END BRACKET HEX HEAD BOLT NUT WASHER FLAT COVER END BRACKET MACHINE SCREW WASHER FLAT RUBBER SUSPENSION HEX NUT WASHER LOCK WASHER FLAT Z A gt gt DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 51 CONTROL BOX ASSY PAGE 52 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 ope M1213002012 Y0330000555 Y0330000255 Y0330000190 0016906016 Y0601307526 060182386
7. HEAD NUT 8 48 9110100204 HINGE MALE L PARENT 4 49 M9110100304 HINGE MALE R PARENT 4 50 M9116100004 WASHER HINGE 8 0019208020 HEX HEAD BOLT 9 52 0601350097 DOOR STOPPER 8 53 0027208025 MACHINE SCREW 8 54 0845031504 CAP 8 55 Y0600300320 MANUAL PAK 1 56 0021806016 MACHINE SCREW 4 57 0600500090 EMBLEM 1 58 0021106016 MACHINE SCREW 2 59 0016910025 HEX HEAD BOLT 1 59A 0040510000 TOOTHED WASHER 1 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 71 RUBBER SEALS ASSY IAD E m nAD ene ee 3 A lt lt 12 1 cnm a 4 i n 3 4 B E PAGE 72 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 ap gt DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 73 PART NO Y0228901240 Y0228900625 Y0228900595 0229400970 0229400485 Y0229400910 Y0229400425 0228800515 Y0228800820 0228800510 0228800470 0228100420 0228100325 0229200950 Y0229200890 PART NAME SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER RUBBER SEALS ASSY QTY 3 1 1 3 1 1 1 1 2 1 1 2 2 2 11
8. The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area INDOOR INSTALLATION Exhaust gases from diesel engines are extremely poisonous Whenever an engine is installed indoors the exhaust fumes must be vented to the outside The engine should be installed at least two feet from any outside wall Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves MOUNTING The generator must be mounted on a solid foundation such as concrete and set firmly on the foundation to isolate vibration of the generator when it is running The generator must set at least 6 inches above the floor or grade level in accordance to NFPA 110 Chapter 5 4 1 DO NOT remove the metal skids on the bottom of the generator They are to resist damage to the bottom of the generator and to maintain alignment 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 guide lines 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 wi
9. 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 KUBOTA Engine Owner s Manual FAN BELT TENSION A slack fan belt may contribute to overheating or to insufficient charging of the battery Inspect the fan belt for damage and wear and adjust it in accordance with the KUBOTA Engine Owner s Manual The fan belt tension is proper if the fan belt bends 10 to 15 mm Figure 34 when depressed with the thumb as shown below 10 15 MM DEFLECTION Figure 34 Fan Belt Tension NEVER place hands near the belts or fan while the generator set is running PAGE 30 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 BATTERY This unit is of negative ground DO NOT connect in reverse Always maintain battery fluid level between the specified marks Battery life will be shortened if the fluid level are not properly maintained Add only distilled water when replenishment is necessary DO NOT over fill Check to see whether the battery cables are loose Poor contact may result in poor starting or mal
10. 11 13 PAGE 53 CONTROL BOX ASSY PAGE 54 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 NO PART NO 40 0601806859 41 0601808986 42 0601807641 43 0601801040 44 0601840073 45 0601840100 46 0601810523 46A 0601810830 47 0601800682 48 0021004016 49 OEMAA8 50 0602125090 51 0601830710 52 0602100057 52 1742263720 53 0601851754 54 Y0601851725 55 0016906016 55A 0040506000 96 M1246705904 57 M1357202502 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 55 PART NAME AC VOLTMETER 0 600V AC AMMETER 0 75 150A 5A FREQUENCY METER 45 65HZ 240V CHANGE OVER SWITCH AMMETER VOLT REG RHEOSTAT 2W 1K OHM KNOB INDICATOR WARNING BULB HOUR METER MACHINE SCREW SELF LOCKING NUT FUEL GAUGE TOGGLE SWITCH STARTER SWITCH KEY STARTER SWITCH GROMMET GROMMET HEX HEAD BOLT TOOTHED WASHER WIRE HARNESS GENERATOR WIRE HARNESS ENGINE 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 CONTROL BOX ASSY QTY ENGINE AND RADIATOR ASSY 74 ay 5 PAGE 56 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 gt PART NO M1923200164 1654197010 1663143560 HH1C032430 0605000451 020310080 0040010000 031110160 B3924200324 0602011079 Y0220300550 M1310302204 M1310302304 011008020 M1310302404 M1310302504 0110080
11. 3 5 minutes with no load applied 4 Place the ignition switch Figure 52 in the STOP position remove the key and store in a safe place STOP RUN START Figure 52 Ignition Switch Stop Position 5 Remove all loads from the generator 6 Inspect entire generator for any damage or loosening of components that may have occurred during operation EMERGENCY SHUTDOWN PROCEDURE 1 Turn ignition switch key to the STOP position 2 Toshut down the engine in the event of an emergency switch the MAIN GFCI and LOAD Figure 50 circuit breakers to OFF position AUTOMATIC SHUT DOWN SYSTEM This unit is equipped with safety devices to automatically stop the engine in the event of low oil pressure approximately 7 psi 49 kPa or high water temperature approximately 230 F 110 C The alarm lamps on the Engine Control Panel illuminate to signify the reason for the shutdown NOTICE Before inspecting turn the ignition switch to the STOP position place all circuit breakers in the OFF position and allow sufficient time for adequate cooling When ready to restart complete all steps in the Generator Startup Procedure section of this manual PAGE 34 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 Table 14 Inspection Maintenance Check Engine Fluid Levels Check Air Cleaner MAINTENANCE 10 Hrs DAILY 250 Hrs 500 Hrs Replace Engine Oil and Filter Clean Air Filter Chan
12. 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED OUTPUT TERMINAL ASSY PAGE 60 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 OUTPUT TERMINAL ASSY NO PART NO PART NAME QTY REMARKS 1 8111860303 TERMINAL PANEL 1 2 0801831704A OUTPUT TERMINAL BOLT 3 012210020 TIE SCREW 5 4 0039310000 HEX NUT 10 0040010000 WASHER LOCK 15 6 0041410000 WASHER PLAIN 20 7 011208025 HEX HEAD BOLT 8 M1236102023 TERMINAL COVER 1 9 0016906016 HEX HEAD BOLT 4 10 M1236102124 OUTPUT WINDOW 1 11 Y0605012028 HINGE 1 12 0027103010 MACHINE SCREW 4 12A 0207003000 HEX NUT 4 12B 0041203000 WASHER PLAIN 4 13 011206020 HEX HEAD BOLT 2 14 M1236101814 COVER 1 19 0016906016 HEX HEAD BOLT 7 16 0601870440 CIRCUIT BREAKER 1P 20A 2 17 0601870441 CIRCUIT BREAKER 2P 50A 2 18 M1260700404 BREAKER FITTING COVER 1 18 1 0222100080 CUSHION RUBBER 2 19 011206020 HEX HEAD BOLT 2 20 Y0601814014 RECEPTACLE CS6369LM2 250V 50A 2 21 0601814013 RECEPTACLE GF20LA 125V 20A 2 22 7538070 MACHINE SCREW 8 23 SELF LOCKING NUT 8 24 Y0317700480 CUSHION RUBBER 1 20 M1236400104 COVER 1 26 0016906016 HEX HEAD BOLT 4 27 1236101904 TERMINAL COVER 1 28 012212045 HEX HEAD BOLT 2 29 031112230 WASHER PLAIN 4 30 0805009804 STAY RUBBER 2 31 0030012000 HEX NUT 2 32 0019208020 HEX HEAD BOLT 1 33 0019208020 HEX HEAD BOLT 1 33A 0040508000 TOOTHED WASHER 1 34 0605010040 HINGE PARENT 1 35 Y027103010 MAC
13. 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 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 GENERAL SAFETY m NEVER operate this equipment without proper protective clothing shatterproof glasses respiratory protection hearing protection steel toed boots and other protective devices required by the job or city and state regulations NEVER operate this equipment when not feeling well due to fatigue illness or when under medication 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
14. 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 based 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 3 Q gt 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 includ
15. 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 0 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 E NEVER operate the equipment in an explosive atmosphere or near combustible materials 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 Equi
16. from nearby personnel 240 139 NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position 1 Place the main G F C l and aux circuit breakers U i SS TO LOC Figure 36 in the OFF position prior to starting the engine Figure 38 Voltage Selector Switch CIRCUIT CIRCUIT CIRCUIT STARTING 1 Place the engine speed control switch Figure 39 the Start Idle position down Figure 36 Main Aux and GFCI i Circuit Breakers OFF START IDLE 2 Make sure the voltage change over board has been Figure 39 Engine Speed Control Switch configured for the desired output voltage Start Idle Position 3 Connect the load to the receptacles or the output 1 In warm weather conditions skip to step In cold terminal lugs as shown in Figure 11 These load weather conditions preheat the engine glow plugs by connection points can be found on the output terminal turning the ignition key Figure 40 to the RUN position panel and the output terminal panel s hard wire hookup STOP RUN panel START 4 Tighten terminal nuts securely to prevent load wires from slipping out 5 Close all engine enclosure doors Figure 37 Figure 40 Ignition Switch Pre Heat Run Position CORRECT INCORRECT Figure 37 Engine Enclosure Doors PAGE 32 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 GENERATOR START UP PROCEDURE 2 Depen
17. 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 of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the We maximum allowable Wet stacking is 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 operate 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
18. 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 is MULTIQUIP
19. the oil level is maintained between the two notches Figure 28 on the dipstick See Table 11 for proper selection of engine oil ADD FULL OIL LIMIT Figure 28 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 KUBOTA Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements API Service Classification CC SC API Service Classification CC SD API Service Classification CC SE API Service Classification CC SF Table 11 Recommended Motor Oil INSPECTION SETUP FUEL CHECK 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 understand this section should refill the fuel tank system This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank Figure 29 ALWAYS fill the fuel tanks with clean fresh 2 diesel fuel DO NOT fill the fuel tanks beyond their capacities Pay attention to the fuel tank capacity when replenishing fuel The fuel tank cap m
20. the system according to the following procedure See the KUBOTA Engine Manual for details To restart after running out of fuel turn the switch to the position for 15 30 seconds Try again if needed CHECK OIL LEVEL Check the crankcase oil level prior to each use or when the fuel tank is filled Insufficient oil may cause severe damage to the engine Make sure the generator is level The oil level must be between the two notches on the dipstick as shown in Figure 28 Replacing Oil Filter Remove the old oil filter Apply a film of oil to the gasket on the new oil filter E Install the new oil filter B After the oil cartridge 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 FLUSHING OUT RADIATOR AND REPLACING COOLANT Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant Open the radiator cap while draining Remove the overflow tank and drain Check hoses for softening and kinks Check clamps for signs of leakage B Tighten both cocks and replace the overflow tank Replace with coolant as recommended by the engine manufacturer Close radiator cap tightly B Flush the radiator by 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 screwdr
21. voltage for many different applications Voltages are selected by using the voltage selector switch Figure 13 To obtain some of the voltages as listed in Table 7 see below will require a fine adjustment using the voltage regulator VR control knob located on the control panel Voltage Selector Switch The voltage selector switch Figure 13 is located above the output terminal panel s Hard Wire Hook up Panel It has been provided for ease of voltage selection 3 PHASE 240 139 PRESS TO LOCK Figure 13 Voltage Selector Switch Voltage Selector Switch Locking Button To lock the voltage selector switch press and hold the red button located at the bottom of the switch While holding the red button down insert a pad lock into the hole next to the button to retain it in the inward locked position When the lock is removed the red button is spring loaded and will return to its normal outward unlocked position NEVER change the position of the voltage selector switch while the engine is running ALWAYS place circuit breaker in the OFF position before selecting voltage Table 7 Voltages Available Voltage Selector Switch 3 Phase 480 270V 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 UVWO Output Terminal Lugs Voltage Selector Switch 3 Phase 240 139V Position GENERATOR OUTPUTS
22. 20 B3311501503 B3311501603 0605515147 0602046585 0602046366 0602040651 0602040557 011208030 M1373200704 011008020 M1373102103 M1373100603 9500202080 0605515146 Y0602022588 Y0602022579 Y0379500700 Y0603306399 Y0605511399 Y0603306597 Y0603300286 Y0602021071 0802081403D 0802081104 0199100215 M1317100004 011008020 Y0199101000 ENGINE AND RADIATOR ASSY PART NAME ENGINE KUBOTA V3300 E3BG FAN BELT ELEMENT FUEL FIITER CARTRIDGE OIL FILTER RUBBER SUSPENSION HEX HEAD NUT WASHER LOCK WASHER FLAT RADIATOR CAP RADIATOR RUBBER SEAT FAN SHROUD FAN SHROUD HEX HEAD BOLT FAN GUARD FAN GUARD HEX HEAD BOLT RADIATOR HOSE RADIATOR HOSE HOSE BAND AIR CLEANER ELEMENT AIR CLEANER AIR CLEANER INDICATOR BRACKET AIR CLEANER HEX HEAD BOLT BRACKET AIR CLEANER HEX HEAD BOLT HOSE AIR CLEANER HOSE AIR CLEANER HOSE BAND HOSE BAND ADAPTER 90 DEG ELBOW DRAIN HOSE HOSE JOINT VALVE CONNECTOR ROCKNUT CAP RESERVE TANK CAP RESERVE TANK HOSE BRACKET RESERVE TANK HEX HEAD BOLT HOSE QTY CC Ce 3 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 57 ENGINE AND RADIATOR ASSY CONTINUED 74 19 G ES il par 11 E S 21 T 18 1 7 67 5 7 68 69 lt 53 VIEW Y 30 29 PAGE 58 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MA
23. 3 7538070 0601820602 0027105016 0601801123 0027106020 0601820847 0601820848 0027104020 M1270100604 M1213602814 0027105020 0030005000 0016906016 Y0602202647 0021005050 0032005000 0401450050 Y0602202635 0602202566 0027105016 M0261200004 0601806642 0601806645 0027105016 0601806640 M1213501004 0016906016 M1213400014 0016906016 M1223001523 0027105010 M9220100004 Y0080200007 M1224100104 0027105010 PART NAME CONTROL BOX EDGING EDGING EDGING HEX HEAD BOLT CIRCUIT BREAKER 100 INSULATING PLATE RELAY UNIT MACHINE SCREW AUTOMATIC VOLTAGE REGULATOR MACHINE SCREW CURRENT TRANSFORMER 150 5A MACHINE SCREW OVER CURRENT RELAY OVER CURRENT RELAY DB25 25A MACHINE SCREW HEX NUT SELECTOR SWITCH SWITCH BRACKET MACHINE SCREW HEX NUT HEX HEAD BOLT ENGINE CONTROL UNIT MACHINE SCREW SPRING WASHER LOCK WASHER FLAT RELAY GLOW RELAY STARTER MACHINE SCREW FUSE BOX FUSE 5A F1 3 FUSE 10A F4 6 MACHINE SCREW FUSE 65A CONTROL BOX COVER HEX HEAD BOLT CONTROL BOX COVER HEX HEAD BOLT CONTROL PANEL MACHINE SCREW SET SCREW SNAP RING STOPPER MACHINE SCREW QTY 1 1 1 1 10 1 1 1 1 4 3 6 1 1 1 1 4 4 1 1 1 1 5 4 1 1 4 1 4 1 4 1 CONTROL BOX ASSY REMARKS INCLUDES ITEM W DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03
24. 3 11 13 DIMENSIONS TOP VIEW Figure 1 Dimensions Table 3 Dimensions Reference Letter 2519 640mm 4921 in 1 250 mm 8228m B0mm 1 3740 950mm 24 60 in 625 mm DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 13 INSTALLATION GENERATOR GROUND LUG ZW GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING GROUND GROUND CABLE x 8 FT MINIMUM REFERENCE NEC 250 846 Figure 2 Typical Generator Grounding Application PAGE 14 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 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 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
25. 68 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 gt PART NO M1413004202 M1413400004 011008020 M1423003102 M1493110203 011008020 M1423200604 M1493100804 0019208020 M1423203303 0016908020 M1423203214 011008020 M3310600004 0019208020 M1433001703 M1433001803 0013616040 0040016000 0041216000 M1443002412 M1493300504 011008020 M1443302613 M1443302713 M1493307114 0176060030 0019208020 M1443201303 M1444600004 020106050 952404470 B9114000002 0021806016 020106050 M9110100204 M9116100004 0019208020 0845031504 M1463002712 M1493506113 0019208020 0013616040 0040016000 0041216000 M1453201422 PART NAME BASE PANEL BASE U C PARENT HEX HEAD BOLT FRONT FRAME ACOUSTIC SHEET HEX HEAD BOLT COVER FRONT FRAME PARENT ACOUSTIC SHEET HEX HEAD BOLT INNER COVER FRONT FRAME HEX HEAD BOLT OVER COVER FRONT FRAME HEX HEAD BOLT COVER RADIATOR CAP PARENT HEX HEAD BOLT CENTER FRAME CENTER FRAME HEX HEAD BOLT WASHER LOCK WASHER PLAIN REAR FRAME Kit A S Rear Frame HEX HEAD BOLT REAR COVER DUCT REAR COVER ACOUSTIC SHEET SELF LOCKING NUT HEX HEAD BOLT REAR DOOR WINDOW PLATE SELF LOCKING NUT WASHER PLAIN DOOR HANDLE ASSY MACHINE SCREW HEX HEAD NUT HINGE MALE PARENT WASHER HINGE HEX HEAD BOLT CAP ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLT WASHER LOCK WASHER FLAT SPLASHER P
26. 8 20605 AUTOMATIC VOLTAGE REGULATOR rs 0601840073 RHEOSTAT VOLTAGE REGULATOR PE 0601840100 KNOB RHEOSTAT 0601810830 BULB INDICATOR WARNING 0601870440 CIRCUIT BREAKER 1 20 0601870441 CIRCUIT BREAKER 2P 50A 0601806640 FUSE 65 a 1106365660 SENSOR WATER TEMP ENGINE SIDE eer 5160137670 SWITCH WARNING OVERHEAT ENGINE SIDE 1584139010 SWITCH OIL PRESSURE ENGINE SIDE 3824032830 SWITCH THERMOMETER 5671342930 ELEC MAG TIC PICKUP NOTICE Part number on this Suggested Spare Parts list may supersede replace the P N shown in the text pages of this book DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 49 GENERATOR ASSY PAGE 50 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 lt w gt B3110001302 0601820083 0601822664 B3120100804 B3120100604 B3120100704 B3111100603 B2163100004 0010304016 B2163700004 0204004000 B3163200104 0342612030 0046512000 0071906309 012210020 030210250 B3130000903 0845041904 B3137000803 0016008060 0042508000 B3153000513 0017108035 B3153400504 B3153400404
27. ANEL QTY 1 1 1 1 4 1 1 0000 5 5 5 ENCLOSURE ASSY REMARKS DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 69 ENCLOSURE ASSY CONTINUED 6 CATERPILLAR YELLOW 7 GOLD 5 BLACK 8 RED NUMBER WHEN ORDERING ANY PAINTED PANEL TO THE SERIAL NUMBER MAY BE REQUIRED INDICATE COLOR OF UNIT ADD THE FOLLOWING DIGITS AFTER THE PART 1 ORANGE 2 WHITE 3 SPECTRUM GREY 4 SUNBELT GREEN Se 70 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 ENCLOSURE ASSY CONTINUED NO PARTNO PART NAME QTY REMARKS 36 0019108055 HEAD BOLT 2 36A 0042308000 WASHER LOCK 2 36B 031108160 WASHER FLAT 2 37 011008020 HEX HEAD BOLT 2 38 0019208020 HEX HEAD BOLT 2 39 11453006213 SIDE DOOR 1 39A 1493414814 ACOUSTIC SHEET 1 40 M1453006313 SIDE DOOR 1 40A M1493414914 ACOUSTIC SHEET 1 M1453006403 SIDE DOOR 1 M1493415004 ACOUSTIC SHEET 1 42 M1453006523 SIDE DOOR 1 42A 1493415114 ACOUSTIC SHEET 1 43 M1453302904 DUCT 2 1493415204 ACOUSTIC SHEET 2 44 M1453303104 0 1 44A 1493415404 ACOUSTIC SHEET 1 45 0176060030 SELF LOCKING NUT 14 46 89114000002 DOOR HANDLE ASSY 2 47 0021806016 MACHINE SCREW 8 47A 020106050 HEX
28. ANK ASSY PAGE 66 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 gt PART NO M1363002602 0605505070 0605501072 0605516090 M1363200104 M9310500104 011008020 0207308000 0222100600 0222100085 M9200000003 M9200200004 0150000018 011206020 M1363400104 0605515198 M1366701204 011206020 0016908065 Y0602042255 RB10151280 R140151350 0191201500 Y0191200500 Y0191200500 Y0191202500 0605515109 PART NAME FUEL TANK CAP FUEL TANK FUEL SENDER UNIT GASKET TANK BAND SUPPORTER SHEET HEX HEAD BOLT HEX NUT RUBBER SHEET RUBBER SHEET DRAIN JOINT DRAIN BOLT O RING HEX HEAD BOLT DRAIN HOSE HOSE BAND FUEL FILTER BRACKET HEX HEAD BOLT HEX HEAD BOLT FUEL FILTER ELEMENT FUEL FILTER FUEL PUMP SUCTION HOSE SUCTION HOSE SUCTION HOSE RETURN HOSE HOSE BAND QTY 1 1 1 1 4 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 8 FUEL TANK ASSY REMARKS DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 67 ENCLOSURE ASSY 6 CATERPILLAR YELLOW 5 BLACK 7 GOLD 8 RED THE SERIAL NUMBER MAY BE REQUIRED 1 ORANGE NUMBER WHEN ORDERING ANY PAINTED PANEL TO 2 WHITE ADD THE FOLLOWING DIGITS AFTER THE PART INDICATE COLOR OF UNIT 3 SPECTRUM GREY 4 SUNBELT GREEN px p a a Fie U s PAGE
29. 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 nameplate voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 5 below when connecting loads Table 5 Power Factor By Load Type of Load Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps Fluorescent lamps mercury lamps 0409 4 0 9 Electronic devices communication 10 equipment Common power tools Table 6 Cable Selection 60 Hz Single Phase Operation Ls ew own sew 25 sane ne ome c ost 75 w sos aen en 698 95 toon oon 2 5 0 em ast ma son L CAUTION Equipment damage can result from low voltage LOAD APPLICATION THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation VOLTAG
30. CT RIGHT TO CHASSIS TAIL LIGHT FREUND WHITE SINGLE BLACK m YELLOW BROWN EL GREEN STOP amp TURN LEFT LICENSE TAIL LIGHT i DOUBLE FILAMENT BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT I TAIL LIGHT 1 1 1 I DOUBLE FILAMENT BULB CONNECT RIGHT TO CHASSIS TAIL LIGHT PENR 1 ETE WHITE COMMON GROUND SINGLE BK BLUE TURN RIGHT FILAMENT GREEN TAIL amp LICENSE BULB 1 YELLOW STOP RED TURN LEFT LICENSE TAIL LIGHT I I DOUBLE i FILAMENT BULB FLAT 5 PIN ROUND FLAT 5 PIN ROUND CONNECTOR i CONNECTOR i LEFT TAIL LIGHT i I I Figure 61 Trailer Towing Vehicle Wiring Diagram DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 43 GENERATOR WIRING DIAGRAM eye RUD S S RUD TU enr een d C GD ONION NUN SE l mm T p 11 CNI Qe spa Lag lt TO CHI 1 D 1 A _ E CN10 i 98 dor o0 o lt ci SUN CT LB SS LB 9 9 d CN5 iere 0811 CNI tl E gt CN CN 11 CN 17 GE GR BRUSHLESS AC GENERATOR SYMBO DESIGNATION MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING MAIN GENERATOR FIELD WINDING CONNECTOR ARRANGEMENT
31. CUIT BREAKERS FOR CS 6369 TWIST LOCK RECEPTACLES 120 VAC 20 AMP GFCI RECEPTACLES RECEPTACLE CIRCUIT BREAKER PANEL AUX POWER RECEPTACLES 240 139V 50 AMPS CIRCUIT BREAKERS FOR GFCI RECEPTACLES OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel Figure 6 is provided with the following Two 120 240V output receptacles 50 amp Two Circuit Breakers 50 amps Two 120V GFCI receptacles 20 amp Two GFCI Circuit Breakers 20 amps Five Output Terminal Lugs V W Ground GROUND TERMINAL HARD WIRE HOOKUP PANEL Co 2 052505255 52 lt 2 lt 52525 Co 506252520 Se ACCESS DOOR LIFT TO OPEN CS 6369 TWIST LOCK Figure 6 Output Terminal Panel PAGE 20 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles There are two 120 VAC 20 amp GFCI Duplex Nema 5 20R receptacles provided on the output terminal panel These receptacles can be accessed in any voltage selector switch position Each receptacle is protected by a 20 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current of both GFCI receptacles is dependent on the load requirements of the U V and W output terminal lugs Pressing the reset button resets the GFCI receptacle after being tripped Pressing the test button See F
32. E 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 See Table 6 B When connecting a resistance load such as incandescent lamp or electric heater a capacity of up to the generating set s rated output KW can be used When connecting a fluorescent or mercury lamp a capacity of up to the generating set 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 generating set s rated output KW multiplied by 0 8 can be used DANGER Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer switch Serious damage to the building s electrical system may occur without this transfer switch DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 23 GENERATOR OUTPUT VOLTAGES A wide range of voltages are available to supply
33. Generator Amperage Table 8 shows the maximum amps the generator can provide DO NOT exceed the maximum amps as listed Table 8 Generator Maximum Amps Rated Voltage 10 120 Volt 82 amps 4 wire 89A x 2 Zigzag 41 amps 4 wire 89A Zigzag 10 240 Volt GFCI Receptacle Load Capability The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles Table 9 and Table 10 show what amount of current is available at the GFCI receptacles when the output terminals and twist lock receptacles are in use Be careful that your load does not to exceed the available current capability at the receptacles Table 9 10 GFCI Receptacle Load Capacity KW in Use Available Load Twist Lock C6369 Current Amps GFCI Duplex 10 240 120V 5 208 120V 5 amps receptacle 10 amps receptacle 15 amps recoptack 20 amps receptacle Table 10 30 Generator Maximum Amps KVA in Use Available Load UVWO Terminals Current Amps GFCI Duplex 30 240 480V 5 20R 120V 0 amps receptacle 5 amps receptacle 10 amps receptacle 15 amps receptacle 20 amps receptacle PAGE 24 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 GENERATOR OUTPUTS GAUGE READING HOW TO READ THE AC AMMETER AND AC VOLTAGE GAUGES The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change o
34. HINE SCREW 4 35A 0207003000 HEX NUT 4 35B 0041203000 WASHER PLAIN 4 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 61 BATTERY ASSY PAGE 62 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PART NO 0602220199 M9310500014 M9103000304 0602220920 M1346400104 0348200104 Y0013512025 8A 0040012000 8B 031112230 8C 0040512000 0016910020 9A 0040510000 10 020108060 PART NAME BATTERY 727MF BATTERY SHEET BATTERY BAND BATTERY BOLT SET BATTERY CABLE BATTERY CABLE CABLE oko adiit idus HEX HEAD BOLT WASHER LOCK WASHER PLAIN TOOTHED WASHER HEX HEAD BOLT TOOTHED WASHER HEX NUT BATTERY ASSY QTY REMARKS 1 1 1 2 1 1 E 1 1 1 1 1 1 1 1 MAKE LOCALLY DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 63 MUFFLER ASSY PAGE 64 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PART NO M1330101403 011008020 M1333003503 Y0602320157 0030410000 0602325097 M1333300504 011008020 Y0602326066 i dp MUFFLER HEX HEAD BOLT EXHAUST PIPE GASKET HEX NUT SEAL CLAMP BRACKET EXHAUST PIPE HEX HEAD BOLT U BOLT QTY 1 4 1 1 8 1 1 1 MUFFLER ASSY REMARKS DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 65 FUEL T
35. INTENANCE FUEL TANK INSPECTION In addition to cleaning the fuel tank the following components should be inspected for wear B 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 or other foreign matter Replacing Fuel Filter Replace the fuel filter cartridge with new one every 500 hours or so 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 E Vent any air FUEL FILTER WATER SEPARATOR Inspect the fuel filter water separator daily If the fuel filter water separator Figure 55 has collected a significant amount of water and sediment at the bottom of the cup it should be drained off Refer to your engine manual for specific details to perform this operation lt FUEL COCK RETAINING RING CUP SEDIMENT Figure 55 Fuel Filter Water Separator PAGE 36 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 AIR REMOVAL If 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
36. NUAL REV 1 03 11 13 PART NO 0193601300 0605515170 M1310200904 M1310201004 M1310201104 011008020 M9312200104 1502025103C 011206020 0802011104 0150000018 Y0379501000 0605515198 0193601000 0602220911 011008020 0601850239 M1303200604 M1303200704 Y0013512025 0040012000 031112230 M1357301004 M1357300804 Y0013512025 0040012000 031112230 M1357300904 0010510020 0040010000 031110160 1J41905810 1584139010 5160137670 1106365660 3824032830 5671342930 HOSE HOSE BAND BRACKET RADIATOR BRACKET RADIATOR BRACKET RADIATOR HEX HEAD BOLT MOUNT RUBBER DRAIN JOINT HEX HEAD BOLT DRAIN BOLT O RING BRACKET RADIATOR HOSE BAND DRAIN HOSE CLAMP HEX HEAD BOLT GROMMET ENGINE FOOT ENGINE FOOT HEX HEAD BOLT WASHER LOCK WASHER PLAIN HARNESS CLAMP HARNESS CLAMP HEX HEAD BOLT WASHER LOCK WASHER PLAIN HARNESS CLAMP HEX HEAD BOLT WASHER LOCK WASHER PLAIN KIT ELEMENT SWITCH OIL PRESSURE SWITCH WARNING OVERHEAT SENSOR WATER TEMP SWITCH THERMOMETER ELECT MAG TIC PICKUP QTY Vict Cb cii kk i ie fit i i ee to i a et ENGINE AND RADIATOR ASSY CONTINUED REMARKS DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 59 ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD
37. OPERATION AND PARTS MANUAL Vt MULTIQUIP 2 POWER MODEL DCA40SSKU MODEL 4055 041 60Hz Whisperwatt Generator KUBOTA V3300 E3BG DIESEL ENGINE PARTS LIST NO M1870301604 Revision 1 03 11 13 To find the latest revision of this publication visit our website at www mqpower com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT 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 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 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 TTY 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator NHTSA 1200 New Jersey Avenu
38. R DECAL WARNING DECAL CAUTION DECAL DOCUMENT BOX LOCATED DECAL MQ I cl cl JN PO PO PO i o o o o c REMARKS M92200050 M92000010 M92200060 M90040020 M90140000 M15000350 92010030 92020040 M92010020A M90150000 M90050010 M90000000 M90010000 M90300010 90030010 90030000 91020000 92000000 15000180 15000450 15000020 92010050 92020000 92010000 92010070 92010040 91010000 90300000 90310000 90320000 90320010 90420000 15000230 91000010 91120000 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 75 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 a 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 su
39. REMARKS NAMEPLATE AND DECALS ASSY 36 Te 20 221 ia PAGE 74 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 i M EL 9522000504 9520000104 9522000604 9500400204 9501400014 9521000204 M1550003503 M9520100304 M9520200404 M9520100204 M9501500004 M9500500104 M9500000004 M9500100004 M9503000103 M9500300104 M9500300004 M9510200002 M1560100603 M1560102804 M1560102903 M1560103104 M1560103004 M9520000004 M1550001803 M1550004504 M1550000204 M9520100503 M9520200003 M9520100004 M9520100704 M9520100404 M9510100004 M9503000004 M9503100004 M9503200004 M9503200104 920214100 M1550002304 M9510000104 M951 1200004 NAMEPLATE AND DECALS ASSY PART NAME QTY DECAL CIRCUIT BREAKER DECAL AMMETER CHANGE OVER SW DECAL VOLTAGE REGULATOR DECAL STARTER SWITCH DECAL SPEED CONTROL DECAL FUSE BOX DECAL OPERATING PROCEDURES DECAL GENERAL CAUTIONS DECAL O C R RESET DECAL CAUTION DECAL DIESEL FUEL DECAL FUEL DRAIN PLUG DECAL OIL DRAIN PLUG DECAL WATER DECAL WATER OIL CHECK DECAL DECAL DECAL MQ STRIPE WHISPERWATT STRIPE STRIPE MQ POWER STRIPE 40 STRIPE DECAL GROUNDING DECAL AUXILLARY OUTPUT DECAL NOTE DECAL NOTE DECAL WARNING DECAL CONNECTION OUTPUT CABLE DECAL WARNING DECAL WARNING DECAL DANGER DECAL CAUTION DECAL WARNING DECAL WARNING DECAL WARNING DECAL DANGE
40. anuary 13 2006 Order via Internet Dealers Only If you have an MQ Account to obtain a Username Order parts on line using Multiquip s SmartEquip website and Password E mail us at parts multiquip View Parts Diagrams com Order Parts To obtain an MQ Account contact your lll Print Specification Information District Sales Manager for more information Goto www multiquip com and click on Use the internet and qualify for a 5 Discount Parts to log in and save on Standard orders for all orders which include complete part numbers L 4 r 4 Order via Fax Dealers Only Fax your order in and qualify for a 2 Discount All customers are welcome to order parts via Fax on Standard orders for all orders which include Domestic US Customers dial part numbers 1 800 6 PARTS 7 800 672 7877 Note Discounts Are Subject Change Order Phone Domestic US Dealers Call 1 800 427 1244 Non Dealer Customers Contact your local Multiquip Dealer for ied iine 2 i 2 parts or call 800 427 1244 for help in locating a dealer near you Parts Ordering information CM ME J ee s When ordering parts please supply Dealer Account Number Spec
41. bject to the following provisions 1 Returned Material Authorization must be approved by Multiquip prior to shipment 2 Toobtain a 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 Thelist 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 person requesting the RMA 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
42. ct multiquip 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 310 537 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 9 cipsa com mx Tel 52 222 225 9900 Fax 52 222 285 0420 Tel 0161 339 2223 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 9 multiquip com Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 COPYRIGHT 2013 MULTIQUIP INC Multiquip Inc the MQ 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
43. ding on the temperature of the coolant cold weather conditions the pre heat lamp Figure 41 will light ON and remain on until the pre heating cycle has been completed After completion of the pre heating cycle the light will go OFF and the engine can be started 0 Figure 41 Pre Heat Lamp Turn the ignition key to the start position Figure 42 Once the engine starts release the ignition key and allow it to return to the RUN position Figure 40 the engine fails to start after 10 seconds wait approximately 30 seconds and repeat steps 3 4 STOP RUN START Figure 42 Ignition Switch Start Position Let the engine run for 1 2 minutes Listen for any abnormal noises any abnormalities exist shut down the engine and correct the problem Place the engine speed control switch Figure 43 in the RUN position up Ut Figure 43 Engine Speed Control Switch Run Position 6 The generators frequency meter Figure 44 should be displaying the 60 cycle output frequency in HERTZ Figure 44 Frequency Meter The generators AC voltmeter Figure 45 will display the generator s output in VOLTS Figure 45 Voltmeter Meter If the voltage is not within the specified tolerance use the voltage adjustment control knob Figure 46 to increase or decrease the desired voltage DECREASE INCREASE Figure 46 Voltage Adjust Control Knob 9 Theammeter Figure 47 will indicate zero amps with no l
44. e S E Washington DC 20590 You can also obtain information about motor vehicle safety from http www safecar gov DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 3 DCA45SSKU SSKU4i 60 Hz Generator Proposition 65 Warning 2 Reporting Safety 3 Table COMENTS 4 Parts Ordering Procedures 5 Safety Information 6 11 unu 12 DIMEN ONS 13 14 15 General Information 16 Major 17 Generator Control 18 Engine Operating 19 Output Terminal Panel Familiarization 20 22 OAC ADDIIGAQU um 23 Generator 24 Generator Outputs Gauge Reading 25 Output Terminal Panel Connections 26 27 Inspection Setup 28 31 Generator Start Up Procedure 32 33 Generator Shut Down Procedures 34 Mai
45. e 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 B 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 while parked Use the trailers swivel jack to adjust the trailer height to a level position while parked DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 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 he 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 in
46. election chart Table 6 as a guide for selecting proper extension cable size PAGE 16 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 MAJOR COMPONENTS Table 4 Generator Major Components ITEM NO DESCRIPTION Output Terminal Panel Assembly 3 5 v 3 E NE 58 UNE DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 17 ENGINE CONTROL PANEL Figure 4 Engine Control Panel The definitions below describe the controls and functions d Pre Heat Lamp The pre heat lamp will be ON of the Engine Control Panel Figure 4 during the pre heating cycle cold weather conditions When the pre heat cycle is completed the lamp will turn OFF and the engine can be started 1 Engine Warning Lamps There are four engine warning lamps they are defined as follows a Low Oil Pressure Alarm Lamp During normal In addition this T operation of the generator this lamp iba dq qs s will remain OFF When the ignition engine trouble shooting faults via a switch is placed in the RUN position flashes blinking See engine to start the engine the lamp will be trouble codes in the maintenance ON When the oil pressure rises section of this manual after start up the lamp will go OFF 2 Fuel Gauge Indicates amount of diesel fuel available lf this lamp is ever li
47. ess to the output terminal lugs After the load wires have been securely attached to the Output terminal lugs lower the plastic face plate and reinstall the retaining bolts TERMINAL ay K PLASTIC TERMINAL COVER RETAINING BOLT Figure 10 Plastic Face Plate Output Terminal Lugs DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 21 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles Figure 11 Make sure to read the operation manual before attempting to connect a load to the generator To protect the output terminals from overload a 3 pole 100A main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine CS 6369 TWIST LOCK RECEPTACLES AC OUTPUT TERMINALS NEUTRAL Figure 11 Connecting Loads Over Current Relay An over current relay Figure 12 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over current relay must be pressed The over current relay is located in the control box Figure 12 Over Current Relay PAGE 22 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 SINGLE PHASE LOAD
48. functions Always keep the terminals firmly tightened Coating 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 it indicates that the battery 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 be sure the battery cables Figure 35 are properly connected to the battery terminals as shown below The red cable is connected to the positive terminal of the battery and the black cable is connected to the negative terminal of the battery ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE ma Ass M BATTERY Figure 35 Battery Connections INSPECTION SETUP When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position ALWAYS make sure that the MPEC Control Switch is in the OFF RESET position when connecting the battery 2 Place a small amount of battery terminal treatment compound around both battery terminals This will ensure a good connection and will help prevent co
49. ge Fuel Filter Clean Unit Inside and Outside Check Fuel Filter Water Separator Bowl re Clean Radiator and Check Coolant Protection Level Replace Air Filter Element 3 Check all Hoses and Clamps 4 Clean Inside of Fuel Tank Measure Insulation Resistance Over 3M ohms Generator Check Rotor Rear Support Bearing Replace engine oil and filter at 100 hours first time only Supplemental Coolant Additives SCA S to recharge the engine coolant 3 Replace primary air filter element when restriction indicator shows a vacuum of 625 mm 25 in H20 4 If blowby hose needs to be replaced ensure that the slope of the blowby hose is at least a 1 2 inch per foot with no sags or dips that could collect moisture and or oil GENERAL INSPECTION Prior to each use the generator should be cleaned and inspected for deficiencies Check for loose missing or damaged nuts bolts or other fasteners Also check for fuel oil and coolant leaks Use Table 14 as a general maintenance guideline Engine Side Refer to the Engine Instruction Manual AIR CLEANER Every 250 hours Remove air cleaner element Figure 53 and clean the heavy duty paper element with light spray of compressed air Replace the air cleaner as needed Air Cleaner with Dust Indicator This indicator Figure 53 is attached to the air cleaner When the air cleaner element is clogged air intake restriction becomes greater and the dust indicator signal s
50. gency Stop signal detected Long 1 Short5 Check and repair fault Starter Motor Protection 7 Long 1 7 Check wiring and repair F Engine Overheat 248 120 Long1Short6 Check cooling system Sensor PAGE 46 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 NOTES DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 47 EXPLANATION OF CODE 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 INCLUDES ITEMS W 2 WASHER 1 4 IN NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 12348 AR MAKE LOCALLY 4 12349 BEARING 1 S N 2345B AND ABOVE NO Column Unique Symbols All items with same unique symbol 8 96 or gt in the number column belong 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 whic
51. h 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 be included when this item is purchased Indicated by INCLUDES ITEMS W unique symbol Serial Number Break Used to list an effective serial number range
52. hows RED meaning the element needs changing or service After changing the air element press the dust indicator button to reset the indicator AIR CLEANER INDICATOR AIR CLEANER ELEMENT Figure 53 Air Cleaner Indicator NOTICE The air filter should not be changed until the indicator reads RED Dispose of old air filter It may not be cleaned or reused DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 35 the engine is operating in very dusty or dry grass conditions a clogged air cleaner will result This can lead to aloss of power excessive carbon buildup in the combustion chamber and high fuel consumption Change air cleaner more frequently if these conditions exists 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 required 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 If necessary drain the fuel inside the fuel tank completely Using a spray washer Figure 54 wash out any deposits or debris that have accumulated inside the fuel tank Figure 54 Fuel Tank Cleaning MA
53. ify Preferred Method of Shipment Dealer Name and Address V UPS Fed DHL Shipping Address if different than billing address Priority One v Truck Return Fax Number Ground B 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 WV WV TA 2 S19 d WE ACCEPT ALL MAJOR CREDIT CARDS gt gt 2d DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 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 read 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 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
54. igure 7 in the center of the receptacle will check the GFCI function Both receptacles should be tested at least once a month 120 VAC 1 RECEPTACLE RESET BUTTON TEST BUTTON Figure 7 G F C I Receptacle Twist Lock Dual Voltage 120 240 VAC Receptacles There are two 120 240V 50 amp auxiliary twist lock CS 6369 receptacles Figure 8 provided on the output terminal panel These receptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position 5 6369 TWIST LOCK RECEPTACLES ES 97 02 Lo SINGLE PHASE 120 240 VAC 50 AMP OUTPUT Figure 8 120 240V Twist Lock Auxiliary Receptacles Each auxiliary receptacle is protected by a 50 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current on both auxiliary receptacles is dependent on the load requirements of the Output Terminal Lugs Turn the voltage regulator control knob Figure 9 on the control panel to obtain the desired voltage Turning the knob clockwise will increase the voltage turning the knob counter clockwise will decrease the voltage DECREASE INCREASE Figure 9 Voltage Regulator Control Knob Removing the Plastic Face Plate Hard Wire Hookup Panel The Output Terminal Lugs are protected by a plastic face plate cover Figure 10 Un screw the securing bolts 2 and raise the plastic face plate to gain acc
55. inal Lugs are connected to a load and in use DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 25 OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES Various output voltages can be obtained using the UVWO output terminal lugs The voltages at the terminals are dependent on the position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob Remember the voltage selector switch determines the range of the output voltage The voltage regulator VR allows the user to increase or decrease the selected voltage 90 240 199 UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 30 240 139 position as shown in Figure 19 3 PHASE 240 139 3 PHASE 1 PHASE 480 277 240 120 PRESS TO LOCK Figure 19 Voltage Selector Switch 30 240 139 Position 2 Connect the load wires to the UVWO terminals as shown in Figure 20 BLUE WHITE GREEN GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 20 UVWO Terminal Lugs 30 240 139 Connections 3 Turn the voltage regulator knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required DECREASE INCREASE Figure 21 Voltage Regulator Knob 30 208V 10 120V UVWO Terminal Output Voltages 1 Place the voltage selector s
56. inder supplying hydraulic pressure to the trailer brakes Periodically check and test the surge actuator to make sure that it is functioning correctly Never use an undersize actuator PAGE 40 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 Table 15 Hydraulic Brake Troubleshooting Possible Cause Weak Brakes or Brakes Pull to One Side Locking Brakes Noisy Brakes Dragging Brakes Soon Brake components loose bent or Replace components broken System lubricated Brake components correct Replace and correct Brake lining thickness incorrect or Install new shoes and not adjusted correctly linings Replace rubber parts 9 Enough brake fluid or correct fluid fill with dot 4 fluid Brake drums out of round TRAILER MAINTENANCE TIRES WHEELS LUG NUTS Tires and wheels are a very important and critical components of the trailer When specifying or replacing the trailer wheels it is important the wheels tires and axle are properly matched ALWAYS wear safety glasses when ET removing or installing force fitted parts Failure to comply may result in serious injury DO NOT attempt to repair or modify a ET wheel DO NOT install in inner tube to correct a leak 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 Tire Wear Inflation
57. ing agent B DO 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 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 B ALWAYS shutdown engine before transporting SAFETY INFORMATION Make sure the hitch and coupling 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 on both towing vehicle and trailer Trailer tires should be inflated to 50 psi cold Also check the tire tread wear on both vehicles ALWAYS make sure the trailer is equipped with a safety chain 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 includ
58. ing 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 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 76 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 NOTES DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 77 OPERATION AND PARTS MANUAL UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave Carson CA 90746 Conta
59. iver MAINTENANCE Allow engine to cool when flushing out radiator Flushing the radiator while hot could cause serious burns from water or steam RADIATOR CLEANING The radiator Figure 56 should be sprayed cleaned with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling fins or tube When using a high pressure washer stand at least 5 feet 1 5 meters away from the radiator to prevent damage to the fins and tube Figure 56 Radiator Cleaning GENERATOR STORAGE For long term storage of the generator the following is recommended B Drain the fuel tank completely Treat with a fuel stabilizer if necessary Completely drain the oil from the crankcase and refill if necessary with fresh oil Clean the entire generator internal and external Cover the generating set and store in a clean dry place Disconnect the battery sure engine coolant is at proper level generator is mounted on a trailer jack trailer up and place on blocks so tires do not touch the ground or block and completely remove the tires DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 37 JACKET WATER HEATER AND INTERNAL BATTERY OPTIONAL This generator can be equipped as an option with a jacket water heater and an internal battery charger They are provided with electric cords to connect to a commercial power source
60. mmeter Change Over Switch Voltage Regulator 3 100 amp Main Circuit Breaker Control located behind the Gen Control Panel Automatic Voltage Regulator Current Transformer Over Current Relay e Starter Relay Voltage Selector Switch OUTPUT TERMINAL PANEL The Output Terminal Panel is provided with the following Two 250 VAC output receptacles CS 6369 50 amps Two auxiliary circuit breakers 250V 250 amps Two 125 VAC output receptacles GFCI 20 amps Two GFCI circuit breakers 125V 20 amps Five output terminal lugs 30 power OPTIONS Battery Charger Water Heater Low Coolant Level Switch Indicator Camlock Connectors GENERAL INFORMATION OPEN DELTA EXCITATION SYSTEM This generator is equipped with the state of the art Open Delta excitation system The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section There are four connections of the open delta A B C and D During steady state loads the power from the voltage regulator is supplied from the parallel connections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section When a heavy load such as a motor starting or a short circuit occurs the automatic voltage regulator AVR switches the configuration of the
61. ntenance 35 38 Trailer Maintenance 39 42 Trailer Wiring Diagram 43 Generator Wiring 44 Engine Wiring Diagram 45 Troubleshooting Generator 46 Explanation Of Code In Remarks Column 48 Suggested Spare 49 TABLE OF CONTENTS Component Drawings Generator Assembly 50 51 Control Box Assembly 52 55 Engine and Radiator Assembly 56 59 Output Terminal Assembly 60 61 Battery 5 62 63 Muffler Assembly 64 65 Fuel Tank Assembly 66 67 Enclosure Assembly 68 71 Rubber Seals Assembly 72 73 Nameplate and Decals Assembly 74 75 Terms And Conditions Of Sale Parts 76 PAGE 4 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options Effective J
62. oad applied When a load is applied the ammeter will indicate the amount of current that the load is drawing from the generator Figure 47 Ammeter No Load DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 33 GENERATOR SHUT DOWN PROCEDURES 10 Place the main GFCI and aux circuit breakers in the ON position Figure 48 MAIN 5 6369 CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKERS BREAKERS a Figure 48 Main Aux and GFCI Circuit Breakers ON 11 Observe the generators ammeter Figure 49 and verify it reads the anticipated amount of current with respect to the load The ammeter will only display a current reading if a load is in use Figure 49 Ammeter Load 12 The generator will run until manually stopped or an abnormal condition occurs NORMAL SHUTDOWN PROCEDURE NEVER stop the engine suddenly except in an emergency To shutdown the generator use the following procedure 1 Place both the MAIN GFCI and LOAD circuit breakers as shown in Figure 50 to the OFF position MAIN C S 6369 GFCI CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKERS BREAKERS T T TI TI Figure 50 GFCI and Load Circuit Breakers Off 2 Place the engine speed control switch Figure 51 in the Start Idle position down START IDLE Figure 51 Engine Speed Control Switch Start Idle Position Let the engine cool by running it at low speed for
63. 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 B 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 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 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 ALWAYS refuel in a well ventilated area away from sparks and open flames 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 clean
64. ontact 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 GO 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 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 11 SPECIFICATIONS Table 1 Generator Specifications Model DCA 40SSKU KU4i Revolving field self ventilated ynchronous generator Armature Connection Star with Neutral 3 Voltage Selector Switch at 30 240 139 240Y 139 Voltage Selector Switch at 30 480 277 480Y 277 10 Voltage L L L N PowerFactor 9 08 10 WetWeight 2 282 lbs 1 035 kg Table 2 Engine Specifications 202 in 3 3 liters Starting 20 3 49 gal 13 2 liters 26 4 gal 100 liters 1 9 gal 7 3 L hr at 3 4 load 1 0 gal 3 8 Ly hr at 1 4 load 27 CCA 0 800A x 1 PAGE 12 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 0
65. open delta to the series connection of B to C This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads The connections of the AVR to the AC output windings are for sensing only No power is required from these windings The open delta design provides virtually unlimited excitation current offering maximum motor starting capabilities The excitation does not have a fixed ceiling and responds according the demands of the required load ENGINE This generator unit incorporates an Kubota V3800 DI I E3B diesel engine This engine is designed to meet every performance requirement for the generator Reference Table 2 for engine specifications In keeping with MQ Power s policy of constantly improving its products the specifications quoted herein are subject to change without prior notice ELECTRIC GOVERNOR SYSTEM OPTION The electric governor system controls the RPMs of the engine When the engine demand increases or decreases the governor system regulates the frequency variation to 25 EXTENSION CABLES When electric power is to be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to a minimum Use the cable s
66. own in Figure 26 24039 3 PHASE 480 277 PRESS TO LOCK Figure 26 Voltage Selector Switch 10 240 120 Position 2 Connect the load wires to the UVWO terminals as shown in Figure 27 BLUE GREEN WHITE GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 27 UVWO Terminal Lugs 10 200 100 Connections Turn the voltage regulator knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required NOTICE ALWAYS make sure that the connections to the UVWO terminals are secure and tight The possibility of arcing exists that could cause a fire DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 27 CIRCUIT BREAKERS To protect the generator from an overload a 3 pole 100 amp main circuit breaker is provided to protect the U V and W output terminals from overload In addition two single pole 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload Two 50 amp circuit breakers have also been provided to protect the auxiliary receptacles from overload Make sure to switch ALL circuit breakers to 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
67. pment should be stored in a clean dry location out of the reach of children and unauthorized personnel DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 7 ENGINE SAFETY B 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 NEVER operate the engine with heat shields or guards removed i Keep fingers hands hair and clothing away from all moving parts to prevent injury lt DO NOT remove the radiator cap while the engine is hot High pressure boiling water 50722 will gush out of the radiator and severely W scald any persons in the general area of 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
68. re types to connect the generator to earth ground a Copper 8 AWG 5 3 mm b Aluminum 6 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 5 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 This generator has a permanent bonding conductor between the generator stator windings and the frame DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 15 GENERATOR This MQ Power generator Figure 3 is a high quality portable requires a trailer for transport power source for telecom sites lighting facilities power tools submersible pumps and other industrial and construction machinery ENGINE CONTROL PANEL The Engine Operating Panel is provided with the following Engine Warning Lamp Module Oil Pressure Alarm Lamp e Water Temperature Lamp Charging Alarm Lamp Pre Heat Lamp Fuel Gauge Hour Meter Speed Control Switch Ignition Switch GENERATOR CONTROL PANEL The Generator Control Panel is provided with the following Frequency Meter Hz AC Ammeter Amps AC Voltmeter Volts A
69. rly 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 NEVER use gas piping as an electrical ground PAGE 10 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 BATTERY SAFETY DANGER DO NOT drop the battery There is 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 irritation The battery gt contains acids that can cause injury to the eyes and skin Use well insulated gloves when picking up the battery ALWAYS keep the battery charged If the battery is not charged combustible gas will build up ALWAYS recharge the battery in a well ventilated environmentto 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 c
70. rrosion around the battery terminals NOTICE If the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polarity of the battery when connecting the battery 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 be in short circuit instantaneously resulting the alternator failure DO NOT put water directly on the alternator Entry of water into the alternator can cause corrosion and damage the alternator WIRING Inspect the entire generator for bad or worn electrical wiring or connections If any wiring or connections are exposed insulation missing replace wiring immediately PIPING AND HOSE CONNECTION Inspect all piping oil hose and fuel hose connections for wear and tightness Tighten all hose clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 31 GENERATOR START UP PROCEDURE BEFORE STARTING STARTING 1 Place the voltage selector switch in the desired voltage position Figure 38 The engine s exhaust contains harmful emissions 3 PHASE ALWAYS have adequate ventilation when operating Direct exhaust away
71. s must rotate freely Locking nuts or cotter pins are Spring Eye Bolt provided to retain nut bolt assembly Shoulder Type Min 30 Max 50 Shackle Bolt DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 41 TRAILER MAINTENANCE 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 60 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 18 3 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically Table 18 Tire Torque Requirements First Pass Second Pass Third Pass FT LBS FT LBS FT LBS 20 25 35 40 50 65 5 LUG NUTS 8 LUG NUTS 20 25 35 40 50 65 20 25 50 60 90 120 LUG NUTS 15 20 25 50 60 90 120 6 1 20 25 20 60 90 120 PNEUMATIC AIR GUN TORQUE WRENCH Figure 60 Wheel Lug Nuts Tightening Sequence NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts PAGE 42 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 TRAILER WIRING DIAGRAM TRAILER SIDE TOWING VEHICLE SIDE DOUBLE FILAMENT BULB CONNE
72. t ON during normal operation 3 Hour Meter Indicates amount of time generator has of the generator the emergency shutdown system been in use will stop the engine automatically b Water Temperature Alarm Lamp This lamp goes ON when the cooling water temperature rises abnormally If the lamp goes ON during normal operation of the generator the emergency shutdown system will NK stop the engine automatically c Battery Charge Alarm Lamp This lamp is ON when the output voltage of the alternator drops below a set value If this lamp is ON during normal operation the emergency shutdown system will immediately stop the engine 4 Engine Speed Switch This switch controls the speed of the engine low high 5 Ignition Switch Three position switch stop run and Start Insert ignition key to start and stop engine PAGE 18 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 1 GENERATOR CONTROL PANEL Figure 5 Generator Control Panel The definitions below describe the controls and functions of the Generator Control Panel Figure 5 1 Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz AC Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch AC Voltmeter Indicates the output voltage present at the U V and W output terminal lugs
73. ted Figure 33 ONLY use low sulfur or ultra low sulfur diesel fuel when refueling Fuel EXPANDS When Heated Figure 33 Fuel Expansion DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 29 COOLANT ANTIFREEZE SUMMER COOLANT WATER KUBOTA 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 KUBOTA Engine Owner s Manual for further details lf adding coolant antifreeze mix to the wem 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 Engine and Radiator 2 91 gal 11 liters quart 0 9 liters 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
74. to the output receptacles during operation This is 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 worn cables or cords when connecting equipment to generator Inspect for cuts in the insulation NEVER grab or touch a live power cord or cable with wet hands The 2 075 possibility exists of electrical shock SRE electrocution or death POWER POWER ON SAFETY INFORMATION Make sure power cables are securely connected to the generator s 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 prope
75. tor and will prevent personal injury and damage to the equipment The definitions below describe some of the major components of a typical trailer that would be used with generator ls Fuel Cell Provides an adequate amount of fuel for the equipment in use Fuel cells must be empty when transporting equipment Braking System System employed in stopping the trailer Typical braking systems are electric surge hydraulic hydraulic surge and air GVWR Gross Vehicle Weight Rating GVWR is the maximum number of pounds the trailer can carry including the fuel cell empty Frame Length Measurement is from the ball hitch to the rear bumper reflector Frame Width Measurement is from fender to fender Jack Stand Trailer support device with maximum pound requirement from the tongue of the trailer Coupler Type of hitch used on the trailer for towing TRAILER MAINTENANCE Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and the width in millimeters 175 185 205 etc The tire diameter must match the diameter of the tire rim Tire Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc Wheel Hub The wheel hub is connected to the trailers axle Tire Rim Tires mounted on a tire rim The tire rim must match the size of the tire Lug Nuts Used to secure the wheel to the wheel hub Always use a torque wrench to tighten do
76. ust be closed tightly after filling Handle fuel in a safety container If the container does not have a spout use a funnel Wipe up any spilled fuel immediately OPTION Figure 29 Internal Fuel Tank System PAGE 28 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 INSPECTION SETUP Refueling Procedure 2 Remove fuel cap and fill tank as shown in Figure 31 Diesel fuel and its vapors are dangerous WHISPERWATT to your health and the surrounding environment Avoid skin contact and or inhaling fumes FUEL TANK FILLER PORT DIESEL FUEL 1 Level Tanks Make sure fuel cells are level with the ground Failure to do so will cause fuel to spill from the tank before reaching full capacity Figure 30 Figure 31 Fueling the Generator ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount NEVER overfill fuel tank It is important to read the of fuel that can be pumped into the tank fuel gauge when filling trailer fuel tank DO NOT wait for fuel to rise in filler neck Figure 32 FUEL GAUGE LOCATED ON CONTROL PANEL DO NOT fill on unlevel ground 25257 Of OD Of OL OF Of Of OL Of OL otl Figure 32 Full Fuel Tank Figure 30 Only Fill on Level Ground NOTICE DO NOT OVERFILL fuel system Leave room for fuel expansion Fuel expands when hea
77. ver switches Both of these switches are located on the control panel and DO NOT effect the generator output They are provided to help observe how much power is being supplied produced at the UVWO terminals lugs Before taking a reading from either gauge set the Voltage Selector Switch Figure 14 to the position which produces the required voltage For example for 30 240V choose the center 30 240 139V position on the voltage selector switch 3 PHASE 240 139 3 PHASE 1 PHASE 480 277 QU PRESS TO LOCK Figure 14 Voltage Selector Switch 240 139V 30 Position NOTICE For 30 208V 10 120V place the Voltage Selector owitch in the 3 Phase 240 139 position AC Voltmeter Gauge Reading Place the AC Voltmeter Change Over Switch Figure 15 in the W U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge Figure 16 V W U V W U OFF Figure 15 AC Voltmeter Figure 16 AC Voltmeter Change Over Switch Gauge AC Ammeter Gauge Reading Place the AC Ammeter Change Over Switch Figure 17 in the U position and observe the current reading load drain on the U terminal as indicated on the AC Ammeter Gauge Figure 18 This process can be repeated for terminals V and W V OFF Figure 17 AC Ammeter Change Over Switch Figure 18 AC Ammeter Amp Reading on U Lug NOTICE The ammeter gauge will only show a reading when the Output Term
78. wheel and drum for free rotation 3 Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate 4 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes 5 Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn 6 Adjust rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag 7 Replace the adjusting hole cover and lower the trailer to the ground 8 Repeat steps 1 through 7 on the remaining brakes TRAILER MAINTENANCE Hydraulic Surge Brakes Hydraulic surge brakes Figure 58 should not require any special attention with the exception of routine maintenance such as shoe and lining replacement Brake lines should be periodically checked for cracks kinks or blockage Anchor Post Springs Cylinder Backing tuating Plate Actuating Pin Hold Down Spring Primary Shoe Adjuster Spring Adjuster Assembly Figure 58 Hydraulic Brake Components Actuator Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cyl
79. 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 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 48 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 SUGGESTED SPARE PARTS DCA40SSKU KU4i WHISPERWATT GENERATOR WITH KUBOTA V3300 E3BG DIESEL ENGINE 1 to 3 units QTY DESCRIPTION Duos 1663143560 ELEMENT FUEL FILTER HH1C032430 CARTRIDGE OIL FILTER 10151280 ELEMENT FUEL FILTER FUEL TANK 0602046366 ELEMENT AIR CLEANER ER 1654197010 FAN BELT jm B3311501503 RADIATOR HOSE UPPER m B3311501603 RADIATOR HOSE LOWER Y0602100057 STARTER SWITCH 1 42263 0 KEY STARTER SWITCH 06001
80. witch in the 30 240 139 position as shown in Figure 22 3 PHASE 240 139 PRESS TO LOCK Figure 22 Voltage Selector Switch 30 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 23 BLUE GREEN WHITE GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 23 UVWO Terminal Lugs 30 208 10 120 Connections Connections NOTICE To achieve a 30 208V output the voltage selector switch must be in the 30 240 139 position and the voltage regulator must be adjusted to 208V PAGE 26 DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 OUTPUT TERMINAL PANEL CONNECTIONS 30 480 277 UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 30 480 277 position as shown in Figure 24 3 PHASE 240 139 1 PHASE 240 120 Figure 24 Voltage Selector Switch 30 480 277 Position 2 Connect the load wires to the UVWO terminals as shown in Figure 25 BLUE GREEN WHITE GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 25 UVWO Terminal Lugs 30 440 254V Connections Turn the voltage regulator knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required 10 240 120V UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 10 240 120 position as sh
81. wn the lug nuts See Table 18 and Figure 60 for lug nut tightening and sequence Axle Indicates the maximum weight the axle can support in pounds and the diameter of the axle expressed in inches Please note that some trailers have a double axle This will be shown as 2 6000 Ibs meaning two axles with a total weight capacity of 6000 pounds Suspension Protects the trailer chassis from shocks transmitted through the wheels Types of suspension used are leaf Q flex and air ride Electrical Electrical connectors looms are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle Application Indicates which units can be employed on a particular trailer DCA40SSKU KU4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 1 03 11 13 PAGE 39 BRAKES Trailer 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 Figure 58 displays the major hydraulic surge brake components that will require inspection and maintenance Please inspect these components as required using steps 1 through 8 and Table 15 as listed below Brake Adjustment 1 Place the trailer on jack stands Make sure the jack stands are placed on secure level ground 2 Check the

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