Home

Multiquip DCA400SSI Portable Generator User Manual

1. 46 Generator Wiring 47 Engine Wiring 48 Controller Wiring Diagram 49 Troubleshooting Generator 50 Troubleshooting Engine Controller 51 Troubleshooting Diagnostic Lamp 52 Explanation Of Code In Remarks Column 54 Suggested Spare Parts 55 TABLE OF CONTENTS Component Drawings Generator 56 59 Engine Operating Panel Assembly 60 61 Control Box 62 67 Engine And Radiator Assembly 68 71 Output Terminal 0 72 73 Battery 74 77 Fuel Tank Assembly S N 3813334 8 Below 78 79 Fuel Tank Assembly S N 3813335 amp Above 80 81 Enclosure 1 Assembly ttes 82 83 Enclosure 2 84 85 Enclosure 3 48500101 86 89 Rubber Seals Assembly 90 91 Nameplate And Decals Assembly 92 95 Terms And Conditions Of Sale Parts 96 NOTICE Specifications and par
2. 5 1883 DECAL WARNING DIESEL FUEL 89045 000 6 0 DECAL SUPPORT I00 5 2257 95 3057 2 MACHINE SCREW 4 STRIPE 2 STRIPE 1 STRIPE 2 STRIPE 1 STRIPE 1 STRIPE 1 STRIPE 1 STRIPE 2 90400030 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 95 TERMS AND CONDITIONS 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 addedito the invoice All shipments are point of origin Multiquip s responsibility ceases when a signed manifest has been obtained from the carrier andany claim for shortage or damage mustbe settled between the consignee andthe carrier MINIMUM ORDER The minimum charge for orders from Multiquip is 15 00 net Customers will be asked for instructions regarding handling of orders not meeting this requirement RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed subjectto the following sions 1 AReturned Material Authorization must be approved by Multiquip prior to ship ment 2 ToobtainaReturn Material Authorization alistmustbe providedto Multiquip Parts Salesthatdefinesitem numbers quanti ties and des
3. C35100100 DECAL WHISPERWATT 400 0 DECAL SPEED rts _ C90040210 DECAL DIAGNOSTIC BUT ICII pem C92002770 DECAL DIAGNOSTIC 92100750 ENGINE 8 RADIATOR GROUP DECAL WATER OIL js iccssissesinvstnsstisaisavareieediecasatatennes 1760 DECAL WATER __ 1880 DECALS OIL DRAIN LV 5 1885 DECAL CAUTION HOT 5 eee B90400030 DECAL WARNING MOVING _ 890400040 DECAL WARNING HOT 890410010 DECAL AIR BLEEDING PROCEDURE gt C35000060 ENGINE OPERATING PANEL GROUP DECAL BATTERY SWITCH 05100050 DECAL ALARM LAMP 35000040 DECAL OPERATING PANEL C35000050 OUTPUT TERMINAL GROUP DECAL GROUND fm RR 2635 DECAL DANGER HIGH V0LI C 2731 DECAL START CONTACT dedic eet 5 4468 DECALS WARNING iene 91110030 DECAL WARNING ELECTRIC SHOCK 1 B91110040 DECAL WARNING ELECTRIC SHOCK HAZARD 1 B93110050 DECAL 3 PHASE OUTPUT TERMINAL C05100040 DECAL
4. HEX HEAD BOLT RELAY MACHINE SCREW CONTROL BOX ASSY QTY b P po po 45 BR BSH BR Ro Ro KR REMARKS TT REPLACES P N 0602202684 REPLACES P N 0601827655 T REPLACES P N 0601823109 T REPLACES P N 0601824400 T REPLACES P N 0602130220 gt REPLACES P N 0602201401 id REPLACES P N 0602202682 CONTROL BOX ASSY CONTINUED PAGE 64 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NO PART 42 8944607060 43 0027105010 44 0601815154 45 0027104016 46 8121468300 47 C3224001303 48 C3224002403 48 1 0228800115 48 2 0228800190 49 0605011211 50 0601807622 51 0601806987 52 0601801040 53 0601806887 54 0601801041 55 0601810072 55A 0601810261 56 0601840073 57 0601840121 58 ECU9988N220V b8 0601830765 60 0601810161 60A 0601810214 61 0207004000 62 0601830710 63 9221100004 63A 0040008000 63B 0041208000 63 0080200007 64 0017108040 65 3871824004 66 0041206000 67 0605010502 68 0601820847 69 0601820848 70 0027104016 71 0601802204 72 0601806671 73 0601802149 74 0027103020 75 3358201704 75 0601806644 758 0601802410 76 0017106016 0601815153 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 65 CONTROL BOX ASSY CONTINUED PART
5. 5 3813335 HEX HEAD 5 3813335 NIPPLE 5 3813335 STREET ELBOW 07 5 3813335 REPLACES P N 0602042405 REPLACES P N 0602042516 REPLACES P N 0602042662 PEN REPLACES P N 0602042621 REPLACES P N 0602021702 4 gt 00 HAMA a 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 81 ENCLOSURE 1 ASSY THE PART NUMBER INDICATED IS ORANGE PLEASE ADD THE FOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT MQW WHITE THE SERIAL NUMBER MAY BE REQUIRED PAGE 82 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NO 1 C3413003502 2 C3414100104 3 C3413100304 4 C3414100804 D 0019208020 6 C3413600004 6A 0228901070 7 0019208020 8 C2367700404 9 0019208025 10 C3424001204 10A 3493100703 11 C3423001003 11 3493100703 12 3423001102 12 3493100703 13 3423001202 13 3493100703 14 0019208020 15 3423300003 15 3492100703 16 3424301103 16 3493100703 17 0019208020 18 0019210025 19 3424201403 20 3424203104 20 3494102604 21 0845042703 22 0019208020 23 0019208020 24 3423201103 25 0019208020 26 3433000202 27 0010120060 27A 0030020000 278 0040020000 27C
6. NO PART NO 1 3363002503 1 1 0845500104 1 2 0810105400 1 3 0264100525 1 4 0605515079 2 0605503020 0802120604 4 0605501089 5 0605516090 6 0022905015 7 8225523104 8 0805003414 9 0016908020 10 0207308000 11 0222100300 12 0130206000 13 0134306170 14 0603325026 15 0132006000 16 C1367700304 17 0019208020 18 0845039604 19 C3366704704 20 0016910025 21 8980758550 21 8980758540 22 8980955010 23 1096750951 24 1096301110 25 0017110040 26 0010110075 26 0040010000 26 0041210000 27 0130406000 28 0130206000 29 0602022209 30 0191402500 31 0191400600 32 0191400500 33 0191402800 34 0191405300 35 0605515132 36 3366704804 37 0019208020 38 0131506000 39 0130206000 FUEL TANK ASSY S N 3813335 AND ABOVE PART NAME QTY REMARKS FUEL TANK FUEL TANK CAP FUEL FILTER FUEL GAUGE HOSE HOSE BAND FUEL SENSOR PACKING FUEL UNIT PACKING MACHINE SCREW TANK BAND TANK BAND PAD HEX HEAD BOLT SUPER LOCK NUT TANK SHEET STREET ELBOW 1 2 DRAIN PIPE VALVE PLUG 1 2 LOCK PLATE HEX HEAD BOLT RUBBER SEAL BRACKET HEX HEAD BOLT PRIMARY FUEL FILTER PRIMARY FUEL FILTER ELEMENT JOINT JOINT BOLT PAACKING HEX HEAD BOLT HEX HEAD BOLT WASHER LOCK WASHER FLAT T JOINT 1 2 STREET ELBOW 1 2 HOSE JOINT SUCTION HOSE SUCTION HOSE SUCTION HOSE SUCTION HOSE RETURN HOSE HOSE BAND 14 BNC ED
7. x ca a caca 0 5 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 87 ENCLOSURE 3 ASSY CONTINUED THE PART NUMBER INDICATED IS ORANGE PLEASE ADD THE FOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT MQW WHITE THE SERIAL NUMBER MAY BE REQUIRED PAGE 88 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 ENCLOSURE 3 ASSY CONTINUED NO NO PART NAME QTY REMARKS 25 0845046904 HINGE 8 25A 0845045004 WASHER 8 26 0845047005 HINGE 8 26A 0845045004 WASHER 8 27 0019208020 HEX HEAD BOLT 37 28 0601850097 STOPPER 11 29 0025408025 MACHINE SCREW 11 30 0845031504 CAP 16 31 0019108065 HEX HEAD BOLT 4 042308000 WASHER LOCK 4 31B 0042408000 WASHER FLAT 4 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 89 RUBBER SEALS ASSY PAGE 90 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 0 1 gt la la la gt 0229201400 0228901320 0228901450 0228900850 0228901350 0228801390 0228901390 0228900790 0229201340 0221200795 0228801250 0229200560 0229201230 0228100120 0228100510
8. DIAGNOSTIC DIAGNOSTIC CV SWITCH LAMP BUTTON DIAGNOSTIC 4 0 SWITCH Figure 67 Diagnostic Panel METHOD OF OPERATION 1 Normally the diagnostic lamp will be dimly lit when the MPEC Control Switch is placed in the MANUAL position 2 f engine trouble occurs the diagnostic lamp will be brightly lit as long as the control switch is left in the manual position 3 The diagnostic lamp will indicate that an engine malfunction has occurred NOTICE For a complete understanding of error codes and troubleshooting procedures refer to the enclosed engine instruction manual NOTICE If the engine is cranked while the diagnostic switch is in the ON position the engine will not be stopped even if the starter switch is turned to the OFF position In such case turn the diagnostic switch to the OFF position PAGE 52 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 53 EXPLANATION OF CODE 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 Th Su e contents and part n
9. 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 Voltmeter Change Over Switch This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off 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 orto be switched off This switch does not effect the generator output in any fashion it is for current reading only 8 Panel Light Switch When activated will turn on control panel light Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage Main Circuit Breaker This three pole 1 000 amp main breaker is provided to protect the U V and W Output Terminal Lugs from overload Auto On Off Engine Controller MPEC This controller has a vertical row of status LED s inset that when lit indicate that an engine malfunction fault has been detected When a fault has been detected the engine controller will evaluate the fault Ea and all major faults will shutdown the generator During cranking cycle The MPEC will attempt to crank the engine for 10 seconds before disengaging 0 LOWOI
10. OPERATION AND PARTS MANUAL POWER WHISPERWATT SERIES MODEL DCA4OOSSI 60HZ GENERATOR ISUZU 6WG1X DIESEL ENGINE PARTS LIST NO C3871301004 Revision 2 11 03 08 To find the latest revision of this publication visit our website at www mqpower com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 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 Avenue S E Washington DC 20590 You can also obtain info
11. RECEPTACLE 8 CIRCUIT BREAKER 0 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 93 NAMEPLATE AND DECALS ASSY CONTINUED 19 2 1 2 7 9 5 5 3 eee ae oo 0600 99 8 PAGE 94 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NAMEPLATE AND DECALS ASSY CONTINUED NO 6 1 0800689404 6 2 0800689504 6 3 C9505300004 7 1 9504000014 7 2 9504200004 8 1 1320620904 8 2 6360620004 8 3 89504500004 9 1 1320621504 9 2 0840625902 9 3 0600500090 9 3A 0021106016 9 4 2561101204 9 5 C3561100203 9 6 C4561102204 9 7 C3561101603 9 8 C3561100803 9 9 C3561101703 9 10 3561101003 9 11 4 9 12 09504000304 PART NAME QTY REMARKS BATTERY GROUP DECALS T 2090 jr m 5 2091 CAUTION C90530000 MUFFLER GROUP 90400001 DECAL WARNING ENGINE 05 B90420000 FUEL TANK GROUP DECAL 1756 DECAL FUEL DRAIN
12. 71 1904 305M95 EAVTSY 2 9 9ILV0II0VL 14 13481 IN 3 110 18 1009 IN SA N88 66 94 I Ja 51 98504 T 01 aa wash ua Q3128NNO2 ad Ol gt X98 21 1 2280918 AIA 018185 Mavas VUS ANTONA on o CE 8 S 2 3 M0LL09 4015 EG Ba A 5 gt BU BU 09V TYONYR OlDV E 3 gt 4 gt lt w 1 093 HOLIAS MA xc Di 44845 39 X9 lt gt 5 E lo a 09 2 x 3 2 a w gt 40 5 gt 2 s LC me V 0i pep m a 80151584 dT WOM d8 TTOWLNOO 12051 402 C9V09 TVNIWUZL 01515349 Figure 65 Engine Wiring Diagram PAGE 48 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 CONTROLLER WIRING DIAGRAM Ls o eoa e vee 4072 ANVON JO NOILISOdSIG Eau n 5 89
13. 800 835 2551 Fax 310 638 8046 COPYRIGHT 2008 MULTIQUIP INC MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc and may not be used reproduced or altered without written permission All other trademarks are the property of their respective owners and used with permission This manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Manufactured for Multiquip Inc by Your Local Dealer is DENYO CO LTD JAPAN VRL POWER
14. AIR GUN TORQUE WRENCH Figure 62 Wheel Lug Nuts Tightening Sequence NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 45 TRAILER WIRING DIAGRAM TOWING TRAILER SIDE VEHICLE SIDE CONNECTOR CONNECTOR LEFT TAIL LIGHT I 1 LI 1 1 i 1 1 1 1 1 1 LI DOUBLE FILAMENT BULB TO CHASSIS TAIL LIGHT ENS 1 1 SINGLE FILAMENT 1 BULB GREEN STOP 8 TURN LEFT 1 LICENSE TAIL LIGHT 1 DOUBLE FILAMENT BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT TAIL LIGHT 1 1 1 1 LI DOUBLE i FILAMENT i BULB Eus HASSIS RIGHT GROUND TAIL LIGHT 125 WHITE 1 SINGLE FILAMENT Ed BULB RED TURN LEFT LICENSE TAIL LIGHT 1 1 DOUBLE FILAMENT i BULB FLAT 5 PIN ROUND FLAT 5 ROUND 1 1 1 1 1 Figure 63 Trailer Towing Vehicle Wiring Diagram PAGE 46 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 GENERATOR WIRING DIAGRAM CONTROL BOX CONTROL PANEL BRUSHLESS AC GENERATOR Voltage Change Over Voltage Change Over Figure 64 Generator Wiring Diagram Board 240V Set Board 480V Set 1 A J C CM ARMATURE WINDING ACAMMETERO 750 1 500A MAIN GENERATOR
15. DO NOT attempt to repair or modify a E 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 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 lo particular load per tire manufacturer Edge Wear Under inflation Adjust pressure to particular load per tire manufacturer Make sure load does not Loss of camber Side Wear exceed axle rating or overloading Align wheels Cupping Out of balance Check bearing adjustment and balance tires Flat Spots Wheel lockup and Avoid sudden stops when tire skidding possible and adjust brakes Suspension The leaf suspension springs and associated components Figure 61 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 compon
16. Engine Warning Lamps There are three engine warning lamps they are defined as follows a Overheat Lamp This lamp goes ON when the cooling water temperature rises 1 abnormally If the lamp goes ON during normal operation of the generator the emergency shutdown device will stop the engine automatically b Low Oil Pressure Lamp During normal operation of the generator this lamp should remain OFF When the Auto OFF Reset Manual switch is set ores 8 10 to the MANUAL position to start the engine the lamp will be lit When the oil pressure rises after start up the lamp will go OFF If this lamp is ever lit ON during normal operation of the generator the emergency shutdown device will stop the engine automatically Low Fuel Level Lamp When this lamp is ON it is time to stop the engine and add fuel Remember to let the engine cool before adding fuel d Air Filter Alarm When the air filter element is clogged this lamp goes ON indicating the element should be immediately cleaned or replaced AIR FILTER e Coolant Level Alarm This lamp goes ON when the coolant level is low If this lamp goes while the engine is in operation the emergency shutdown device will automatically stop the engine Engine Speed Switch This switch controls the speed of the engine low high Pre Heat Lamp When ECU is placed in AUX position pre heat lamp wil
17. Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication 10 equipment Common power tools Table 6 Cable Selection 60 Hz Single Phase Operation A ene ome ms 25 e wo coon 5 me soon xot aon 76 soon wer vo ume or o oe ison 6 vox oon CAUTION Equipment damage can result from low voltage THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation VOLTAGE X AMPERAGE X 1 732 1000 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 capacity of up to the generating set s rated output KW multiplied by 0 6 can be used When connecting an electric dr
18. 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 91 PART NAME 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 SEAL lt aa A RUBBER SEALS ASSY REMARKS NAMEPLATE AND DECALS ASSY 19 2 3 2 8 2 3 7 d 3 1 a 1 6 3 uu ii 6 2 6 Bo 1 T3 9 5 9 1 9 6 1 dot 3 ET IHR ZEE 5 3 9 1 4 3 4 3 5 1 9696999 6 iJ 5 2 1 n 5 5 8 gt I reg 219 9 3 5 7 5 6 5 5 ie 2 13 7 123 24 Er CL 2 6 7 m 2 5 y ps 7 2 1 E 9 10 1 A 3 22 12 728 2 9 gt Y feme em 7 I 7 2 1 1 4 2 4 3 4 4 4 9 2 PAGE 92 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NAMEPLATE AND DECALS
19. 0017108020 8 0019208020 9 C3443201303 10 C3443201403 11 8225147004 12 0207306000 13 0600800320 14 0207006000 15 B9114000102 16 0021806015 16A 0030006000 17 8225146204 18 8225146304 19 0845050704 20 0207006000 21 0805011304 22 0805011204 23 0207006000 24 0845047104 24A 0845045004 25 0845047204 25A 0845045004 26 0019208020 27 0601850097 28 0025408025 29 0845031504 30 3463201202 30A C3493500304 31 C3464501704 3494502204 32 0017108020 33 0019208020 34 C3463500304 35 0092108020 36 0019210025 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 85 PART NAME REAR FRAME RUBBER SEAL REAR FRAME LINING HEX HEAD BOLT HEX HEAD BOLT REAR FRAME COVER LINING DUCT COVER LINING HEX HEAD BOLT HEX HEAD BOLT REAR DOOR FRAME REAR DOOR FRAME WINDOW PLATE HEX NUT A ENCLOSURE 2 ASSY REMARKS MANUAL 9000 07 DOOR HANDLE MACHINE SCREW HEX NUT DOOR ROD DOOR ROD STAY HEX NUT DOOR STOPPER DOOR STOPPER HEX NUT HINGE WASHER HINGE WASHER HEX HEAD BOLT STOPPER MACHINE SCREW CAP ROOF PANEL LINING ROOF PANEL COVER LINING HEX HEAD BOLT HEX HEAD BOLT GUTTER HEX HEAD BOLT HEX HEAD BOLT 1 4 1 4 4 1 1 4 8 1 1 4 2 2 2 2 6 2 2 4 1 1 1 1 5 ENCLOSURE 3 ASSY THE PART NUMBER INDICATED IS ORANGE PLEASE ADD THE FOL
20. 0041620000 28 0010120050 28 0030020000 28 0041620000 29 3463101402 29 3493500203 30 3310600004 31 0019204020 32 0019208020 33 3463500204 34 0019208020 35 0019210025 36 0019116025 36A 0 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 83 PART NAME BASE FLOOR PANEL FLOOR PANEL FLOOR PANEL HEX HEAD BOLT BASE DUCT RUBBER SEAL HEX HEAD BOLT COVER HEX HEAD BOLT FRONT FRAME LINING FRONT FRAME LINING FRONT FRAME LINING FRONT FRAME LINING HEX HEAD BOLT AIR GUIDE PANEL LINING AIR GUIDE PANEL LINING HEX HEAD BOLT HEX HEAD BOLT FRONT FRAME COVER FRONT FRAME COVER LINING FILLER BASKET HEX HEAD BOLT HEX HEAD BOLT FRONT FRAME COVER HEX HEAD BOLT CENTER FRAME HEX HEAD BOLT HEX NUT WASHER LOCK WASHER FLAT HEX HEAD BOLT HEX NUT WASHER FLAT ROOF PANEL LINING COVER HEX HEAD BOLT HEX HEAD BOLT GUTTER HEX HEAD BOLT HEX HEAD BOLT HEX HEAD BOLT HEX NUT o lt n2 ENCLOSURE 1 ASSY REMARKS ENCLOSURE 2 ASSY THE PART NUMBER INDICATED IS ORANGE PLEASE ADD THE FOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT MQW WHITE THE SERIAL NUMBER MAY BE REQUIRED PAGE 84 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NO 1 C3443000403 1A 0228901290 2 C3443000502 2A 8225940104 3 0017108020 4 0019210025 5 C3443302103 5A C3493300004 6 C3444302504 6A C3491400004 7
21. 1244 for help in their local Multiquip Representatives for locating a dealer near you Parts Ordering information ______ _ ___ _ _ gt When ordering parts please supply Dealer Account Number C Specify Preferred Method of Shipment C Dealer Name and Address UPS Fed Ex 4 DHL Shipping Address if different than billing address Truck Return Fax Number Next Day C Applicable Model Number Second Third Day C Quantity Part Number and Description of Each Part All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST WE ACCEPT ALL MAJOR CREDIT CARDS AMERICAN EXPRESS DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 5 SAFETY INFORMATION 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 DANGER Indicates hazardous si
22. Figure 28 Internal Fuel Tank System PAGE 30 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 INSPECTION SETUP Refueling Procedure 2 Opencabinet doors on the right side of the generator from generator control panel position Remove fuel cap and fill tank Figure 30 Diesel fuel and its vapors are dangerous to your health and the surrounding environment Avoid skin contact and or inhaling fumes FUEL TANK DIESEL FILLER PORT 1 LevelTanks 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 29 ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount Figure 30 Fueling the Generator of fuel that can be pumped into the tank 3 NEVER overfill fuel tank It is important to read the fuel gauge when filling trailer fuel tank DO NOT wait DO NOT fill on for fuel to rise in filler neck Figure 31 unlevel ground FUEL GAUGE LOCATED ON CONTROL PANEL ENI _ 2 Figure 29 Only Fill on Level Ground MAM LAM ALAM HL Figure 31 Fuel Tank ONLY use 2 diesel fuel when refueling DO NOT OVERFILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 32 Fuel EXPANDS we 2 When Heated WELT Figure 32 Fuel Expansion DCA400SSI GENERATOR OPERATION AND
23. NAME GLOW PLUG RELAY ttis MACHINE SCREW TERMINAL BLOCK MACHINE SCREW INLET AIR TEMPERATURE SENSOR CONTROL PANEL CONTROL PANEL RUBBER SEAL RUBBER SEAL PIN FREQUENCY METER 45 65Hz 200V AC AMMETER 0 750A 0 1500A AMMETER CHANGE OVER SWITCH AC VOLTMETER 0 600V VOLTMETER CHANGE OVER SWITCH PILOT LAMP BULB 13W RHEOSTAT VOLT REG 2W 1K OHM KNOB ENGINE CONTROLLER SWITCH PANEL LIGHT BULB HEX NUT PANEL LIGHT SWITCH HEX HEAD BOLT WASHER LOCK WASHER FLAT SNAP RING HEX HEAD BOLT CONTROL PANEL STOPPER WASHER FLAT SNAP PIN OVER CURRENT RELAY OVER CURRENT RELAY MACHINE SCREW FUSE HOLDER FUSE 15A FUSE 10A MACHINE SCREW FUSE HOLDER ASSY FUSE 30A FUSE HOLDER BRACKET HEX HEAD BOLT TERMINAL BLOCK QTY REMARKS t eee BDO i REPLACES P N 0602202683 REPLACES P N 0603210240 0 REPLACES P N 0602202545 CONTROL BOX ASSY CONTINUED PAGE 66 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 CONTROL BOX ASSY CONTINUED NO PART NO PART NAME QTY REMARKS 78 0027104020 MACHINE SCREW 2 79 8221814804 CONTROL BOX COVER 1 80 0017108020 HEX HEAD BOLT 8 81 8224117004 CONTROL BOX SIDE PANEL 1
24. SEAL CLAMPER RUBBER SEAL HEX HEAD BOLT WASHER FLAT COVER RUBBER SEAL RUBBER SEAL HEX HEAD BOLT GROMMET END BRACKET FIELD ASSY EXCITER HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX HEAD BOLT BEARING COVER BEARING GASKET DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 57 GENERATOR ASSY CONTINUED PAGE 58 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NO PART NO 13 0010106060 13A 0040006000 138 0041206000 14 C3154400003 15 0017106016 16 C3163600003 17 0010312030 17A 0042512000 18 0070506206 19 0010312040 19A 0042512000 20 C3132300014 21 0010106030 21A 0041206000 218 0601815000 22 0605000061 23 0030016000 23 0040016000 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 59 GENERATOR ASSY CONTINUED PART NAME HEX HEAD BOLT WASHER LOCK WASHER FLAT SUCTION COVER HEX HEAD BOLT COUPLING ADAPTER HEX HEAD BOLT WASHER LOCK BEARING HEX HEAD BOLT WASHER LOCK FAN COVER HEX HEAD BOLT WASHER FLAT NUT RUBBER SUSPENSION HEX NUT WASHER LOCK QTY REMARKS 00 gt gt gt 16 ENGINE OPERATING PANEL ASSY PAGE 60 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PART NO 1 C3351100603 2 0017106020 3 0207006000 4 1823200010 5 0021008080 5A 0030008000 5B 0040008000 5C 0041608000 6 06018307
25. __ _ gt ___ _ _ _ 5 REPLACES P N 0602044210 T REPLACES P N 0602015252 OUTPUT TERMINAL ASSY THE PART NUMBER INDICATED IS ORANGE PLEASE ADD THE FOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT MQW WHITE THE SERIAL NUMBER MAY BE REQUIRED PAGE 72 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PART NO 1 2231700403 2 0277500004 3 0801830904 4 0039320000 5 0040020000 6 0041420000 7 3501860604 8 0019110050 8 0042310000 88 0042410000 9 0601808803 10 0601808804 11 C3261600704 11 1 0221200150 12 0019206016 13 0601812598 14 0601812565 15 0025304016 15A 0207004000 16 2234500104 17 0019206016 18 0601815194 19 0025304016 20 0601850275 21 0601851780 22 2237102303 23 0019112045 24 0042412000 25 0805015604 26 0205012000 27 0845043704 28 2237101204 29 0019208020 30 2237102403 31 0019210030 32 0845054204 33 0805015604 34 2237101504 35 2237400104 36 0019206020 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 73 PART NAME OUTPUT TERMINAL SET BOARD OUTPUT TERMINAL HEX HEAD BOLT HEX NUT WASHER LOCK WASHER FLAT TERMINAL PLATE HEX HEAD BOLT WASHER LOCK WASHER FLAT CIRCUIT BREAKER 20A CIRCUIT BREAKER 50A CIRCUIT BREAKER BREAKER RUBBER CUSHION HEX HEAD BOLT RECEPTACLE GF 530EM RECEPTACLE 5 6369 MACHINE SCREW HEX
26. and contact the nearest doctor or hospital to seek medical attention ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator ALWAYS keep battery cables in good working condition Repair or replace all worn cables ENVIRONMENTAL SAFETY NOTICE M Dispose of hazardous waste properly Examples of potentially hazardous waste are used motor oil fuel and fuel filters DO NOT use food or plastic containers to dispose of hazardous waste DO NOT pour waste oil or fuel directly onto the ground down a drain or into any water source DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 11 SPECIFICATIONS Table 1 Generator Specifications Type Armature Connection Standby Output Prime Output Voltage 10 Voltage 30 Frequency Speed Power Factor Aux AC Power Aux Voltage Output Dry Weight Type No of Cylinders Bore x Stroke Displacement Rated Output Coolant Capacity Lube Oil Capacity Fuel Type 0 400 1 Revolving field self ventilated open protected type synchronous generator Star with Neutral 440 KVA 352 KW 400 KVA 320 KW 120 127 139 240 254 and 277V 208 220 240 416 440 and 480V 60 Hz 1800 rpm Single Phase 60 Hz 4 8 Kw 2 4 kW x 2 11 640 Ibs 5 280 kg 12 875 Ibs 5 840 kg Table 2 Engine Specifications ISUZU 6WG1X 4 cycle water cooled direct injection turbo charged with a
27. are properly grounded to a suitable earth ground ground rod per the National Electrical Code NEC and local codes before operating generator Severe injury or death by electrocution can result from operating an ungrounded generator NEVER use gas piping as an electrical ground PAGE 10 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 SAFETY INFORMATION BATTERY SAFETY DANGER DO NOT drop the battery There is a possibility that the battery will explode DO NOT expose the battery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come into contact with a flame or spark an explosion could occur B ALWAYS wear safety glasses when handling the battery to avoid eye irritation gt The battery contains acids can cause injury to the eyes and skin M 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 environment to avoid the risk of a dangerous concentration of combustible gasses f the battery liquid dilute sulfuric acid comes into contact with clothing or skin rinse skin or clothing immediately with plenty of water W f the battery liquid dilute sulfuric acid comes into contact with eyes rinse eyes immediately with plenty of water
28. be liable for loss of profit or good will or for any otherspecial consequential orincidental dam ages LIMITATION OFWARRANTIES No warranties express orimplied are made in connection with the sale of parts or trade accessories norasto any engine not manufac tured by Multiquip Such warranties made in connection withthe sale of new completeunits are made exclusively by a statement of war ranty packaged with such units and Multiquip neitherassumes norauthorizes any personto assume for it any other obligation or liability whatever in connection with the sale of its products Apartfrom such written statement of warranty there are no warranties express implied or statutory which extend beyondthe description ofthe products on the face hereof Effective February 22 2006 PAGE 96 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 97 OPERATION AND PARTS MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING MQ Power 1800 Water Ridge Rd Tel 800 883 2551 Suite 500 600 Fax 972 315 1847 Lewisville TX 75057 Contact mqpower multiquip com Web www mqpower com MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537 3700 Fax 310 637 3284 Service Tech Support Warranty
29. 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 wire types to connect the generator to earth ground Copper 10 AWG 5 3 mm2 or larger b Aluminum 8 AWG 8 4 2 or larger 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 NECarticle 250 52 c specifies that the earth ground rod should be buried a minimum of 8 ft into the ground NOTICE When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 15 GENERAL INFORMATION GENERATOR The MQ Power Model DCA400SSI is a 320 kW generator Figure 3 that is designed as 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 OPERATING PANEL The Engine Operating Panel is provided
30. for details DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 39 MAINTENANCE To restart after running out of fuel turn the switch to the ON position for 15 30 seconds Try again if needed This unit is equipped with an automatic air bleeding system 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 27 Replacing Oil Filter Remove the old oil filter Apply a film of oil to the gasket on the new oil filter Install the new oil filter 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 Tighten both cocks and replace the overflow tank Replace with coolant as recommended by the engine manufacturer Close radiator cap tightly Flush the radiator by running clean tap water through radiator until sign
31. 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 Symptom Possible Problem No Voltage Output Low Voltage Output eee Check load and repair Circuit Breaker Tripped Check and replace PAGE 50 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 TROUBLESHOOTING ENGINE CONTROLLER Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 20 Engine Controller Troubleshooting as a basic guideline for troubleshooting the Microprocessor Engine Controller unit MPEC If the problem cannot be remedied consult our company s business office or service plant Table 20 Engine Controller Troubleshooting Low oil pressure light is Ne m High coolant temperature light is on Overspeed light is Loss of MPU light s or DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 51 TROUBLESHOOTING DIAGNOSTIC LAMP The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself Press the diagnostic button Figure 67 on the diagnostic panel to determine if an engine malfunction has occurred
32. period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition This can take several hours to burn off the accumulated unburned fuel State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters must be used on internal combustion engines that use hydrocarbon fuels A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator PAGE 8 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 SAFETY INFORMATION 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
33. 01820625 6 0027105016 7 0601842468 8 0027103010 9 C3274000003 10 8221852104 11 0017108030 12 C2277200004 13 8221853104 14 0801830804 15 0040016000 16 0041416000 17 0801830704 18 8201852504 19 0040012000 20 0041412000 21 0017110030 22 C3260503003 23 0017108020 24 8980956110 25 C3260503104 26 0016906012 27 0602103090 27 0601810244 28 0601831205 29 0601830710 30 0601830746 31 0016906016 32 0601823240 33 0027105020 34 LY2DUS24VDC 34A 348 35 0027104020 36 8972177780 37 0027104010 38 8980056310 39 0016906016 40 8980137900 41 0027105010 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 63 PART NAME CONTROL BOX CURRENT TRANSFORMER 750 5A MACHINE SCREW CIRCUIT BREAKER 1000A AUTOMATIC VOLTAGE REGULATOR MACHINE SCREW RESISTOR 5W 150 OHM MACHINE SCREW VOLTAGE CHANGE OVER BOARD CHANGE TERMINAL HEX HEAD BOLT TERMINAL PLATE CHANGE PLATE HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX HEAD BOLT HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX HEAD BOLT ELECTRIC PARTS SET PANEL HEX HEAD BOLT CONTROLLER reo BRACKET HEX HEAD BOLT DIAGNOSTIC LAMP BULB DC28V DIAGNOSTIC BUTTON DIAGNOSTIC SWITCH HIGH IDLE SPEED SWITCH HEX HEAD BOLT RECTIFIER MACHINE SCREW 8 MACHINE SCREW BAROMETRIC PRESSURE SENSOR MACHINE SCREW STARTER
34. 10 7 0602103090 7 0601810244 8 0601831589 9 0602103090 9 0601810244 10 0602120095 11 0602122093 12 0601842450 13 0602123092 14 0602121081 15 0602125091 16 C3483003303 17 0017110030 17A 0207010000 18 0017110030 19 0602123267 19A 0602021702 20 0602122272 20A 9200100004 20 0130200000 20C 8943998582 20D 1096301410 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 61 ENGINE OPERATING PANEL ASSY PART NAME OPERATING PANEL HEX HEAD BOLT HEX NUT BATTERY SWITCH MACHINE SCREW HEX NUT WASHER LOCK WASHER FLAT ENGINE SPEED SWITCH PREHEAT LAMP BULB DC 28V EMERGINCY STOP BUTTON ALARM LAMP BULB DC 28V TACHOMETER OIL PRESSURE GAUGE VOLTAGE DIVIDER WATER TEMPERATURE GAUGE CHARGING AMMETER FUEL GAUGE SET FRAME HEX HEAD BOLT HEX NUT HEX HEAD BOLT WATER TEMPERATURE UNIT PACKING OIL PRESSURE UNIT ADAPTER OIL PRESSURE UNIT STREET ELBOW PAGS is coire niet add pde QTY 1 8 4 1 2 2 2 2 1 1 1 1 5 5 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 T REPLACES P N 0602101001 REPLACES 0602020220 REPLACES P N 0602021701 CONTROL BOX ASSY PAGE 62 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PART NO 1 213002802 2 0601801170 0027106016 4 0601807514 5 06
35. 40V UVWO Terminal Output Voltages 1 Jumper the voltage change over board for 240V operation as shown in Figure 18 JUMPER 6 PLACES Figure 18 Voltage Change Over Board 240V Configuration 2 Connect the load wires to the UVWO terminals as shown in Figure 19 GROUND CONNECTION MUST BE USED ATALL TIMES THREE PHASE 240 VAC LOAD CONNECTIONS Figure 19 UVWO Terminal Lugs 3 Turn the voltage regulator knob Figure 20 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 N Figure 20 Voltage Regulator Knob 10 240 UVWO Terminal Output Voltages 1 sure the voltage change over board 15 jumpered for 240V operation as shown in Figure 18 2 Connect the load wires to the UVWO terminals as shown in Figure 21 CONNECTION MUST BE USED AT ALL TIMES SINGLE PHASE 240 VAC LOAD CONNECTIONS Figure 21 UVWO Terminal Lugs 10 240V Connections 10 120 UVWO Terminal Output Voltages 1 sure the voltage change over board 15 jumpered for 240V operation as shown in Figure 18 2 Adjust voltage regulator knob Figure 20 for an output of 208V to obtain 120V at the UVWO terminals 3 Connect the load wires to the UVWO terminals as shown in Figure 22 BLUE WHITE GREEN GROUND CONNECTION MUST BE USED AT ALL TIMES SIN
36. 6 0040010000 26 0041210000 27 0130406000 28 0130206000 29 0602022209 30 0191402500 31 0191400600 32 0191400500 33 0191402800 34 0191405300 35 0605515132 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 79 PART NAME FUEL TANK FUEL TANK CAP FUEL FILTER FUEL GAUGE HOSE HOSE BAND FUEL SENSOR PACKING FUEL UNIT PACKING MACHINE SCREW TANK BAND TANK BAND PAD HEX HEAD BOLT SUPER LOCK NUT TANK SHEET STREET ELBOW 1 2 DRAIN PIPE VALVE PLUG 1 2 LOCK PLATE HEX HEAD BOLT RUBBER SEAL BRACKET HEX HEAD BOLT PRIMARY FUEL FILTER PRIMARY FUEL FILTER ELEMENT JOINT PIPE JOINT 80LI DM HEX HEAD BOLT HEX HEAD BOLT WASHER LOCK WASHER FLAT T JOINT 1 2 STREET ELBOW 1 2 HOSE JOINT SUCTION HOSE SUCTION HOSE SUCTION HOSE SUCTION HOSE RETURN HOSE HOSE BAND QTY FUEL TANK ASSY S N 3813334 AND BELOW REMARKS gt gt 00 HAMA 4 gt P N 0602042405 REPLACES P N 0602042516 REPLACES P N 0602042662 REPLACES P N 0602042621 REPLACES P N 0602021702 FUEL TANK ASSY S N 3813335 AND ABOVE 6 35 6 35 80 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08
37. 6 Oil Pressure Gauge 10 17 12 13 14 The coolant temperature gauge Figure 47 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 167 203 F 75 95 C Green Zone Figure 47 Coolant Temperature Gauge The tachometer gauge Figure 48 will indicate the speed of the engine when the generator is operating Under normal operating conditions this speed is approximately 1800 RPM s 20 x100 5 TACH 0 Figure 48 Engine Tachometer Gauge Place the main GFCI and aux circuit breakers in the ON position Figure 49 MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER 49 Circuit Breakers Observe the generators ammeter Figure 50 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 50 Ammeter Load The generator will run until manually stopped or an abnormal condition occurs DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 35 GENERATOR START UP PROCEDURE AUTO MODE STARTING AUTO MODE DANGER Before connecting this generator to any 9 buildings electrical system a licensed electrician must install an isolation transfer switch Serious damage to the bu
38. 82 0017108020 HEX HEAD BOLT 4 83 3213400604 CONTROL BOX PANEL 1 84 0017108020 HEX HEAD BOLT 8 85 0017110035 HEX HEAD BOLT 4 85A 0207010000 HEX NUT 4 86 0601806640 FUSE 65A 1 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 67 ENGINE RADIATOR ASSY 5550 56 57 60 58 7 PAGE 68 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NO PART NO 1 C3923200194 1 1 1132402330 1 2 1132402410 1 3 8980088400 2 63303200504 3 0010314040 4 0040014000 5 0041614000 6 3303200604 7 3303200704 8 0010316040 9 0040016000 10 0041616000 11 0605000061 12 0030016000 13 0040016000 14 0041616000 15 C3923200174 15 1 0602011059 16 C3493600004 17 0010116065 18 0030016000 19 0040016000 20 0041216000 21 C3311100504 22 C3311100604 23 0017112025 24 0017112025 25 C33110200403 26 C3310200503 27 0016910025 28 C3310500003 29 3310500103 30 3310400004 31 63310500404 32 0605515290 33 0602123290 34 63310500203 35 0605515214 36 0605515213 37 3310500303 38 0605515238 39 0605515239 40 0602046539 40A 0602046628 40 0602046629 ENGINE RADIATOR ASSY QTY PART NAME ENGINE ISUZU 6WG1X MAIN OIL FILTER CARTRIDGE BYP
39. AGE 37 MAINTENANCE 10 Hrs 1000 Table 14 Inspection Maintenance DAILY 250 Hrs 500 Hrs Hrs Check Engine Fid Leves X 12 Check AirCleaner Check Battery AcidLevel X Check Fan Belt Condition Checkforleaks EX Checkforloosening of Pars X f Replace Engine Oil and Fiter ooo X Clean airFiter Check Fuel FilterWaterSeparatorBowl x J Clean Unit Inside and Outside Change Fuel Fiter Clean Radiator and Check Coolant Protection Leve X Replace AirFilterElement Check all Hoses andClamps Clean inside ofFuelTank o X Measure Insulation Resistance Over3M ohms X Measure Insulation Resistance Over 3M ohms Generator Check Rotor Rear Support Bearing o PX O Replace engine oil and filter at 100 hours first time only 2 Add Supplemental Coolant Additives SCA S to recharge the engine coolant 5 Replace primary air filter element when restriction indicator shows a vacuum of 625 mm 25 in H20 If blowby hose needs to be replaced ensure that the slope of the blowby hose is at least 1 2 inch per foot with no sags or dips that could collect moisture and or oil GENERAL INSPECTION AIR CLEANER INDICATOR 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 coola
40. ASS OIL FILTER CARTRIDGE MAIN FUEL FILTER ELEMENT ENGINE FOOT HEX HEAD BOLT WASHER LOCK WASHER FLAT ENGINE FOOT ENGINE FOOT HEX HEAD BOLT WASHER LOCK WASHER FLAT RUBBER SUSPENSION HEX NUT WASHER LOCK WASHER FLAT RADIATOR amp INTER COOLER ASSY CAP ACOUSTIC SHEET HEX HEAD BOLT HEX NUT WASHER LOCK WASHER FLAT RADIATOR BRACKET RADIATOR BRACKET HEX HEAD BOLT HEX HEAD BOLT FAN GUARD FAN GUARD HEX HEAD BOLT RADIATOR HOSE RADIATOR HOSE RADIATOR PIPE RADIATOR HOSE HOSE BAND COOLANT LEVEL SWITCH INTER COOLER HOSE HOSE BAND HOSE BAND INTER COOLER HOSE HOSE BAND HOSE BAND AIR CLEANER AIR CLEANER OUTER ELEMENT AIR CLEANER INNER ELEMENT REMARKS 1 1 1 2 2 8 8 8 1 1 8 8 8 4 8 8 8 1 2 1 6 6 6 2 1 1 4 2 1 1 16 REPLACES P N 0602041219 REPLACES P N 0602041220 REPLACES 0602042515 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 69 ENGINE RADIATOR ASSY CONTINUED 5550 56 57 60 58 7 PAGE 70 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NO
41. ASSY NO 1 1 C3550000703 1 2 C9522100003 2 1 0800520100 2 2 0800520904 2 3 0800520814 2 4 0840624504 2 5 0840624604 2 6 0840624704 27 0840624804 2 8 89531100604 2 9 C0551000903 2 10 2551000004 2 11 4 2 12 63560100003 2 13 C9500402104 2 14 09520027704 2 15 4 3 1 1320610603 3 2 6360610304 3 3 6360620204 3 4 89504000304 3 5 89504000404 3 6 89504100104 3 7 C3550000603 4 1 C0551000504 4 2 C3550000404 4 3 C3550000503 5 1 0840614104 5 2 0840619904 5 3 9039209064 5 4 9511100304 5 5 9511100404 5 6 9531100504 5 7 0551000404 5 8 1551000803 DECAL HANDLING PROCEDURES prt C35000070 C92210000 CONTROL BOX GROUP PLATE ON OFF _ 202 PLATE CHANGE OVER SWITCH M 2438 PLATE VOLTMETER CHANGE OVER SWITCH 1 N 2439 DECAL CIRCUIT ss Pr 5 3031 DECAL PANEL LIGHT SWITCH 5 3032 DECALS PILOT LAMP 5 3033 DECAL VOLTAGE REGULATOR 5 3034 DECAL WARNING ELECTRIC SHOCK HAZARD 2 B93110060 DECAL SETTING FOR OUTPUT VOLTAGE peer C05100090 DECAL SAFETY INSTRUCTIONS _ _ _ _ C25100000 DECAL DIAGNOSTIC
42. D PARTS MANUAL REV 2 11 03 08 NO PART NO 1 C3330100402 2 0019110025 2 0042310000 2 0047010030 C3333001903 4 C9304000304 5 C3334200804 6 0010316060 0030316000 68 0042516000 6C 0041616000 7 0010316060 7 0030016000 7 0042516000 7 0041616000 8 C3333302104 9 0017108020 10 0602326065 11 C3331300404 12 0019208020 MUFFLER HEX HEAD BOLT WASHER LOCK WASHER FLAT EXHAUST PIPE GASKET GASKET HEX HEAD BOLT HEX NUT WASHER LOCK WASHER FLAT HEX HEAD BOLT HEX NUT WASHER LOCK WASHER FLAT BRACKET HEX HEAD BOLT U BOLT COVER HEX HEAD BOLT QTY 4 8 8 8 1 4 4 1 1 1 6 4 4 4 8 1 4 1 2 4 MUFFLER ASSY REMARKS DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 77 FUEL TANK ASSY S N 3813334 AND BELOW Z au m 2829 35 lt A PAGE 78 400551 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NO PART NO 1 3363002503 1 1 0845500104 1 2 0810105400 1 3 0264100525 1 4 0605515079 2 0605503020 0802120604 4 0605501089 5 0605516090 6 0022905015 7 8225523104 8 0805003414 9 0016908020 10 0207308000 11 0222100300 12 0130206000 13 0134306170 14 0603325026 15 0132006000 16 C1367700304 17 0019208020 18 0845039604 19 C3366704704 20 0016910025 21 8980758550 21 8980758540 22 8980955010 23 1096750951 24 1096301110 25 0017110040 26 0010110075 2
43. FIELD WINDING VOLTMETER CHANGE OVER SWITCH 1 2 2 ona PU 122 12 VIEW FROM INSERTING VIEW FROM INSERTING 01153 CON2 3 GFO 20A 125V WIRE SIDE WIRE SIDE Te OVER CURRENT RELAY ica TOR CODE OC OVERCURRENTRELAY ROE am 018 ORCUT Ri BREAKER 2201 siue ware SIDE Y YELLOW 6 GREEN LB LIGHTBLUE CB1 CONNECTOR GR GRAY LG LIGHTGREEN VIEW FROM INSERTING je fvoueT_ O ORANGE WIRE SIDE P PINK DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 47 ENGINE WIRING DIAGRAM 019 g 9 0 0L 004 00 001 CC 1 0 p 9014 A019 H N2 ZINO y 74 OL L 53 21185 Waluvls us I HHSISNOHOVL OL LVHHWNd OL H NOLVNESITV OL 4 JETI 4019 181 B EAVTSN OL 58504 OL NOILOSNNO2 89 86 300 OL 1 4 05425 13441 INY1002 5 1 1 WwolvNuziTv 0182 V199 110 4844 1 5 TUIA 61 5 9 5 HSLSNOHOVIL 01 2 1009 quvosS 40 _ jews qivOH TIVNINSSL O 805845
44. GLE PHASE 120 VAC LOAD CONNECTIONS Figure 22 UVWO Terminal Lugs 10 120 Connections PAGE 28 400551 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 OUTPUT TERMINAL PANEL CONNECTIONS 10 480V UVWO Terminal Output Voltages 30 480V UVWO Terminal Output Voltages 1 Jumper the voltage change over board for 480V operation as shown in Figure 23 This configuration uses 6 jumper plates in 3 different positions Remember there are 2 jumper plates at every position Every jumper plate must be used USE 2 JUMPER PLATES EACH POSITION N Figure 23 Voltage Change Over Board 480V Configuration 2 Connect the load wires to the UVWO terminals as shown in Figure 24 GROUND CONNECTION MUST BE USED AT ALL TIMES THREE PHASE 480 VAC LOAD CONNECTIONS Figure 24 Terminal Lugs 30 480V Connections 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 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 23 Connect the load wires to the UVWO terminals as shown in Figure 25 GROUND CONNECTION MUST BE USED AT ALL TIMES EE PHASE 480 VAC LOAD CONNECTIONS Figure 25 UVWO Terminal Lugs 10 480 Connections 10 277V UVWO Terminal Output Voltages 1 Make sure the voltage change over board is jumpered for 480V operat
45. L PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING If the engine does not engage start by the third attempt the engine will be shutdown by the engine controllers Over Crank Protection mode If the engine engages at a speed RPM s that is not safe the controller will shutdown the engine by initializing the Over Speed Protection mode PAGE 18 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 GENERATOR CONTROL PANEL Also the engine controller will shut down the engine in the event of low oil pressure high coolant temperature low coolant level and loss of magnetic pickup These conditions can be observed by monitoring the LED status indicators on the front of the controller module MPEC Control Switch This switch controls the running of the unit If this switch is set to the OFF RESET position the unit will not run When this switch is set to the manual position the generator will start immediately If the generator is to be connected to a buildings AC power source via a transfer switch isolation place the switch in the AUTO position In this position should an outage occur the automatic transfer switch ATS will start the generator automatically via the generator s auto start contacts conn ected to the ATS s start contacts Please refer to your ATS installation manual for further instructions for the correct installation of the auto start contacts of t
46. LOWING LETTERS WHEN ORDERING COLOR OF UNIT MQW WHITE THE SERIAL NUMBER MAY BE REQUIRED PAGE 86 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 ENCLOSURE ASSY NO NO 1 C3453200702 1A C3493402104 2 0019108065 2A 0042308000 2B 0042408000 3 C3453100503 3A C3493401004 4 C3453100603 4A C3493401104 5 0019108065 5A 0042308000 5B 0042408000 6 C3453100703 6A C3493401204 7 C3453100803 7 C3493401304 8 C3453300504 8A C3493401803 9 C3453300604 9A C3493401903 10 C3453300704 10A 63493402003 11 0207006000 12 C3453000903 12A 63493400604 13 C3453001003 13 63493400704 14 C3453001103 14 3493400804 15 3453005203 15 3493400904 16 3453300304 16 3493401603 17 3453300804 3493402203 18 3453300404 18 3493401704 19 3453500004 19 3493401704 20 0019208016 21 0207006000 22 9114000002 23 0825007362 24 0021806015 24 0030006000 SPLASHER PANEL LINING HEX HEAD BOLT WASHER LOCK WASHER FLAT SIDE PANEL LINING SIDE PANEL LINING HEX HEAD BOLT WASHER LOCK WASHER FLAT SIDE PANEL LINING SIDE PANEL LINING DUCT LINING DUCT LINING DUCT LINING HEX NUT SIDE PANEL LINING SIDE PANEL LINING SIDE PANEL LINING SIDE PANEL LINING DUCT LINING DUCT LINING DUCT LINING PANEL LINING HEX HEAD BOLT HEX NUT DOOR HANDLE DOOR HANDLE MACHINE SCREW HEX NUT c4
47. ND PARTS MANUAL REV 2 11 03 08 The purpose of these receptacles is to provide power commercial power to the jacket water heater and internal battery charger These receptacles will ONLY function when commercial power has been supplied to them Figure 59 To apply commercial power to these receptacles a power cord of adequate size will be required See Table 6 When using the generator in hot climates there is no reason to apply power to jacket water heater However if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size OUTPUT TERMINAL PANEL 120 INPUT RECEPTACLE JACKET WATER HEATER 120 VAC INPUT RECEPTACLE REFERENCE TABLE 6 FOR PROPER SIZE EXTENSION CORD CONNECT TO EXTERNAL 120 VAC POWER SOURCE Figure 59 Battery Charger and Jacket Water Heater Power Connections If the generator will be used daily the battery should normally not require charging If the generator will be idle NOTICE boWeensudeo amp ddqqatdessar ing capability always have power applied to the generator s internal battery charger DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 41 TRAILER MAIN
48. NEVER fuel as a cleaning agent B DO NOT smoke around or near 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 4 your generator Refer to MQ Power trailer manual for additional safety information n order to reduce the possibility of an accident while transporting the generator on public roads ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition ALWAYS shutdown engine before transporting 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 M 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 Require
49. 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 running machine NOTICE ALWAYS ensure generator is on level ground before use ALWAYS keep the machine in proper running condition Fix damage to machine and replace any broken parts immediately ALWAYS store equipment properly when it is not being used Equipment should be stored in a clean dry location out of the reach of children and unauthorized personnel PAGE 7 SAFETY INFORMATION ENGINE SAFETY 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 A DO NOT remove the radiator cap while the engine is hot High pressure boiling water will gush out of the radiator and severely 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 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 a
50. NUT COVER HEX HEAD BOLT TERMINAL BLOCK MACHINE SCREW GROMMET GROMMET OUTPUT TERMINAL COVER HEX HEAD BOLT WASHER FLAT STAY RUBBER HEX NUT SPRING COVER HEX HEAD BOLT OUTPUT TERMINAL COVER HEX HEAD BOLT COLLAR STAY RUBBER COVER BRACKET HEX HEAD BOLT OUTPUT TERMINAL ASSY REMARKS QTY 1 8 8 16 24 0 BATTERY ASSY PAGE 74 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PART NO 1 0165721052 2 C9109100704 0805007804 4 0805006504 5 0037808000 6 0040008000 T 0041608000 8 3346601804 9 3346601904 10 C3346602004 11 C3346602104 12 C3346200004 13 0347010030 14 0208110000 15 0845040114 16 0845041004 17 0017114025 18 0040514000 19 0017110025 20 0040510000 21 0017112025 22 0040512000 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 75 PART NAME BATTERY BATTERY SHEET BATTERY BAND BATTERY BOLT WING NUT WASHER LOCK WASHER FLAT BATTERY CABLE BATTERY CABLE BATTERY CABLE BATTERY CABLE EARTH CABLE HEX HEAD BOLT HEX NUT TERMINAL CAP 4 TERMINAL CAP HEX HEAD BOLT TOOTHED WASHER HEX HEAD BOLT TOOTHED WASHER HEX HEAD BOLT TOOTHED WASHER lt S BATTERY ASSY REMARKS MUFFLER ASSY PAGE 76 DCA400SSI GENERATOR OPERATION AN
51. PART NO 41 0602040779 42 0602040582 43 C3373200004 44 0016910025 44A 0207010000 45 0016910025 46 C3373000003 47 0602040393 48 0605515260 49 0602040666 50 C3373200104 51 0016908020 52 0602326064 53 0602022560 54 M1320300304 55 0602022561 56 0603306590 57 0603300285 58 0605511395 59 0603306395 60 0602021070 61 0269200500 62 0802081003 63 0602010900 64 1317100103 65 0016910025 66 0602022929 67 0199900800 68 0199900300 69 0199901600 70 0193602000 71 0605515106 72 0193601300 73 0193600550 74 0269502100 75 0605515067 76 8973639360 7 8972177780 78 0602120465 79 8980305320 80 C3357200002 81 1136714740 82 1802200140 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 71 ENGINE AND RADIATOR ASSY CONTINUED PART NAME AIR CLEANER CAP AIR CLEANER BAND AIR CLEANER BRACKET HEX HEAD BOLT HEX NUT HEX HEAD BOLT AIR CLEANER PIPE 90 DEGREE ELBOW HOSE BAND AIR CLEANER INDICATOR AIR CLEANER PIPE BRACKET HEX HEAD BOLT U BOLT ADAPTER PACKING 90 DEGREE ELBOW CONNECTOR ROCKNUT VALVE HOSE JOINT CAP DRAIN HOSE RESERVE TANK RESERVE TANK CAP RESERVE TANK BRACKET HEX HEAD BOLT JOINT HOSE HOSE HOSE HOSE HOSE BAND HOSE HOSE HOSE HOSE BAND WATER TEMPERATURE SENSOR OIL PRESSURE SENSOR PICK UP TACHOMETER BLOWBY FILTER ENGINE WIRE HARNESS FAN BOOST SENSOR ___ _
52. PARTS MANUAL REV 2 11 03 08 PAGE 31 INSPECTION SETUP COOLANT ANTIFREEZE SUMMER COOLANT WATER ISUZU recommends ISUZU antifreeze summer coolant for use in their engines which can be purchased in concentrate and mixed with 5096 demineralized water or pre diluted See the ISUZU Engine Owner s Manual for further details adding coolant antifreeze mix to the radiator DO NOT remove the radiator cap until the unit has completely cooled The vA 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 and the L markings Table 12 Coolant Capacity Engine and Radiator 15 8 Gal 60 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 Anti Freeze When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radi
53. T CIRCUIT BREAKER BREAKER BREAKER Figure 35 Main Aux and GFCI Circuit Breakers OFF 2 Make sure the voltage change over board has been configured for the desired output voltage 3 Connect the load to the receptacles or the output terminal lugs as shown in Figure 10 These load connection points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel 4 Tighten terminal nuts securely to prevent load wires from slipping out 5 Close all engine enclosure doors Figure 36 CORRECT INCORRECT Figure 36 Engine Enclosure Doors STARTING MANUAL 1 Place the engine speed switch Figure 37 in the LOW down position Q LOW DOWN Figure 37 Engine Speed Switch Low 2 Place the MPEC control switch in the MANUAL position to start the engine Figure 38 gt lt gt MANUAL OFF RESET Figure 38 MPEC Control Switch Manual Position 3 Depending on the temperature of the coolant cold weather conditions the pre heat lamp Figure 39 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 will start up automatically Figure 39 Pre Heat Button 4 Once the engine starts let the engine run for 1 2 minutes Listen for any abnormal noises If any abnormalities exist shut down the engine and correct the problem If the engine is running smoo
54. TENANCE 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 generator 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 the DCA400SSI Whisperwatt Generator 1 Fuel 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 10 11 12 13 14 15 16 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 dia
55. TO position AUTO ce MANUAL OFF RESET Figure 52 MPEC Control Switch AUTO 4 Continue operating the generator as outlined in the Manual Start up procedure start at step 5 PAGE 36 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 GENERATOR SHUT DOWN PROCEDURES EMERGENCY SHUTDOWN PROCEDURE NEVER stop the engine suddenly except in an emergency NORMAL SHUTDOWN PROCEDURE To shutdown the generator use the following procedure 1 Place both the GFCI and LOAD circuit breakers as shown in Figure 35 to the OFF position Place the engine speed switch Figure 53 in the LOW down position Q LOW DOWN Figure 53 Engine Speed Switch Low Let the engine cool by running it at low speed for 3 5 minutes with no load applied Place the MPEC Control Switch Figure 54 to the OFF RESET position AUTO MANUAL OFF RESET Figure 54 MPEC Control Switch Off Reset Verify that all the status LEDs on the MPEC display are OFF not lit Remove all loads from the generator Inspect entire generator for any damage or loosening of components that may have occurred during operation 1 stop the engine in the event of an emergency PUSH the emergency stop button Figure 55 inward This button is located on the engine operating panel see Figure 5 Figure 55 Emergency Stop Button DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 P
56. UTRAL J GROUND LOAD s Figure 10 Connecting Loads Over Current Relay An over current relay Figure 11 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 11 Over Current Relay PAGE 24 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 LOAD APPLICATION SINGLE PHASE LOAD Always be sure to check the nameplate on the generator and equipment to insure the wattage amperage frequency and voltage requirements are satisfactorily supplied by the generator for operating the equipment Generally the wattage listed on the nameplate of the equipment is its rated output Equipment may require 130 150 more wattage than the rating on the nameplate as the wattage is influenced by the efficiency power factor and starting system of the equipment NOTICE If wattage is not given on the equipment s name plate approximate wattage may be determined by multiplying 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
57. a t 8a 012 arem II Sta ta a VII _ 066 20109 apis 0V 1105 mata 08 aprs LNSASDNVHHV HOLOSNNOO ERI Eea 5 9 NO 4 M 85 OL OL SRIONS Ol OL u N3 9 Q NO 222333 dans 5885 5 235253 9999 996 f BAR g S 5 5 405845 RIL HOSNSS 440553 4 18181 OL OINLISMONVS Ol 1 2 JJILSONDVIG SHIELD WIRE 50 HOLIMS 21150 9 14 T TeTeTeT ToTeToTo a a eo NOW 12061 216 616 4 51815 4 21818 j iagram D iring Controller W Figure 66 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 49 TROUBLESHOOTING GENERATOR Practically all breakdowns can be prevented by proper handling and
58. akes more frequently Figure 60 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 Check the 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 Hydraulic Surge Brakes Hydraulic surge brakes Figure 60 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 Plate Actuating Pin Hold Down Secondary S Spring Primary Shoe Adjuster Spring Adiuster Assembly Figure 60 Hydraulic Brake Components Actuator Hydraulic surge braking requires the i
59. antity can be indicated by a number a blank entry or 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 where a particular part is used Indicated by S N XXXXX AND BELOW S N XXXX AND ABOVE S N 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 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 availabl
60. any objects into the output e receptacles during operation This is A extremely dangerous The possibility exists of electrical shock electrocution or death 6 building s electrical system without a transfer switch or other approved device 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 DANGER NEVER let power cords or cables lay in water M Backfeed to a utility system can cause electrocution and or property damage NEVER connect the generator to a 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 possibility exists of electrical shock RM electrocution or death rower CORD POWER ON 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
61. ator 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 ISUZU 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 ISUZU Engine Owner s Manual The fan belt tension is proper if the fan belt bends 10 to 15 mm Figure 33 when depressed with the thumb as shown below 10 15 MM DEFLECTION Figure 33 Fan Belt Tension NEVER place hands near the belts or fan while the generator set is running PAGE 32 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 INSPECTION SETUP 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 malfunctions 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
62. criptions of the items to be returned Theparts numbers and descriptions must match the current parts price list b The list must be typed or computer generated c The list must state the reason s for the return d The list must reference the sales order s orinvoice s under whichthe items were originally purchased e The list must include the name and phone number of the person request ing the RMA 3 Acopy ofthe Return Material Authoriza tionmustaccompanythe return shipment 4 Freight is at the sender s expense All parts mustbe returned freight prepaid to Multiquip s designated receiving point 5 Partsmustbeinnewandresalable con dition inthe original Multiquip package if any and with Multiquip part numbers clearly marked 6 Thefollowingitems are not returnable 8 Obsolete parts If an item is in the price book and shows as being re placedby another item itis obsolete b Any parts with a limited shelf life such as gaskets seals O rings andother rubber parts thatwere pur chased more than six months priorto thereturn date c Anylineitemwith anextendeddealer netprice of less than 5 00 d Specialorder items 0 Electrical components f Paint chemicals and lubricants 9 Decalsandpaper products h Items purchasedin kits 7 Thesenderwillbe notified of any material receivedthatis not acceptable 8 Suchmaterial willbe heldforfive working days from notification pe
63. e for sale through Multiquip PAGE 54 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 SUGGESTED SPARE PARTS DCA400SSI WHISPERWATT GENERATOR WITH ISUZU 6WG1X DIESEL ENGINE 1 to 3 units QTY __ DESCRIPTION C3310500003 HOSE RADIATOR UPPER C3310500108 HOSE RADIATOR LOWER 0602011059 RADIATOR 0845500104 FUEL 0602015252 V BELT SET 8972177780 OIL PRESSURE SENSOR ENGINE men 0602122272 OIL PRESSURE UNIT 0602123267 WATER TEMPERATURE UNIT 8973639360 WATER TEMP SENSOR ENGINE 1802200140 BOOST SENSOR jer 0602123290 SWITCH COOLANT LEVEL 0810105400 FILTER FUEL TANK Bonos 0602042405 FILTER FUEL PRIMARY 0602042516 ELEMENT PRIMARY FUEL FILTER _ 0602042515 ELEMENT MAIN FUEL FILTER 0602041219 FILTER OIL CARTRIDGE MAIN 0602041220 FILTER OIL CARTRIDGE BYPASS 0602046628 ELEMENT AIR CLEANER OUTER 0602046629 ELEMENT AIR CLEANER INNER _ _ 0601808803 CIRCUIT BREAKER 20A 0601808804 CIRCUIT BREAKER 2P 50A _ LY2DUS24VDC RELAY NOTICE Part number on this Suggested Spare Parts list may supersede replace the P N shown in the text pages o
64. eceptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position 5 6369 TWIST LOCK RECEPTACLES 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 all three 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 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 23 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles Figure 10 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 1000A main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine 5 6369 TWIST LOCK RECEPTACLES HARD WIRE HOOKUP PANEL LOAD 4 NE
65. el 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 Drain the fuel inside the fuel tank completely Using a spray washer Figure 57 wash out any deposits or debris that have accumulated inside the fuel tank Figure 57 Fuel Tank Cleaning 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 B 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 Vent any air 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 the system according to the following procedure See the ISUZU Engine Manual
66. ents as detailed in Table 17 SHACKLE SUPPORT BRACKET IS WELDED TO FRAM SHACKLE NUTS AXLE HANGER SUPPORT BRACKET IS WELDED TO FRAM SHACKLE BOLTS LEAF FRONT U BOLT HANGER BOLT LOCKING TIE PLATE NUT Figure 61 Major Suspension Components Table 17 Suspension Torque Requirements Torque Fitts Shackle Bolt Snug fit only Parts must 996 freely Locking nuts cotter pins are Spring Eye Bolt provided to retain nut bolt assembly Shoulder Type Min 30 Max 50 Shackle Bolt PAGE 44 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 TRAILER MAINTENANCE Lug Nut Torque Requirements It is extremely important 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 62 DO 4 LUG NUTS 6 LUG NUTS 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 PE aly 20 25 50 60 90 120 20 25 50 60 90 120 PNEUMATIC
67. er and AC voltmeter change over switches W U Lug on the control panel DO NOT effect the generator output They are provided to help observe how much power is being supplies ammeter gauge will only show a reading when When the voltage change over board is jumpered for 30 the Output Terminal Lugs are connected to a load 240V operation See Figures 14 and15 place the AC and in use Voltmeter Change Over Switch See Figures 16 and 17 to the W U position and the AC Ammeter Change Over Switch Figure 16 to the U or W position to read the output on the selected leg JUMPER 6 PLACES Figure 13 Voltage Change Over Board 240V Configuration DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 27 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 placement of the jumpers plates 6 on the Voltage Change Over Board and the adjustment of the Voltage Regulator Control Knob Remember the voltage change over board determines the range of the output voltage and can be configured in two different positions that provide 6 different output voltages at the UVWO output terminals The generator is shipped from the factory in the 240V configuration The voltage regulator VR allows the user to increase or decrease the selected voltage 30 2
68. ety decals when they become difficult read Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties NEVER use accessories or attachments that are not recommended by Multiquip for this equipment Damage to the equipment and or injury to user may result M ALWAYS know the location of the nearest ps fire extinguisher ALWAYS know the location of the nearest first aid kit ALWAYS know the location of the nearest phone 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 e DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 GENERATOR SAFETY E 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 NEVER operate the equipment in an explosive atmosphere or near combustible materials explosion or fire could result causing severe bodily harm or even death
69. f this book DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 55 GENERATOR ASSY 18B PAGE 56 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NO PART NO 1 C3110000502 1 1 12 0601842401 1 3 0601823282 1 0018205020 1 4A 0040005000 1 48 0041205000 1 5 8201070002 1 6 8201611004 1 7 3164200004 1 8 8201015003 1 9 0012116045 1 10 0042618000 1 11 0601000209 1 12 63112500004 1 13 007906315 2 63164400103 3 0010312050 4 0042512000 5 0010312040 5 0042512000 6 63130100003 6 1 0226200495 6 2 8211323004 63 0223300172 6 4 8211323103 6 5 0221200440 6 6 0010110035 6 6A 0041210000 6 7 3132200003 6 8 0226000290 6 9 0225000590 6 10 0017106020 6 11 0601850144 f C3154000002 8 C3138000003 9 0012110080 9A 0042610000 9B 0041210000 10 0017112045 11 C3154300104 12 C3154300004 PART NAME QTY GENERATOR ASSY REMARKS ROTOR AS Y iden Met INCLUDES ITEMS W FIELD ASSY RESISTOR 80W 300 K OHM RECTIFIER HEX SOCKET HEAD CAP SCREW WASHER LOCK WASHER FLAT FAN COUPLING DISK COUPLING HUB WASHER 1 2 1 2 2 2 1 12 1 BALANCING I PURCHASE ITEMS 1 11 AS HEX HEAD BOLT WASHER LOCK BALANCING WEIGHT KIT BEARING FLANGE BEARING COUPLING RING HEX HEAD BOLT WASHER LOCK HEX HEAD BOLT WASHER LOCK STATOR ASSY RUBBER SEAL CLAMPER RUBBER
70. from moisture and dust All electrical equipment should be protected from excessive moisture Failure to do will result in deterioration of the insulation and will result in short circuits and grounding Foreign materials such as dust sand lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area INDOOR INSTALLATION Exhaust gases from diesel engines are extremely poisonous Whenever an engine is installed indoors the exhaust fumes must be vented to the outside The engine should be installed at least two feet from any outside wall Using an exhaust pipe 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 GENERATOR GROUNDING To guard against electrical shock and possible damage to the
71. he 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 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 33 GENERATOR START UP PROCEDURE MANUAL BEFORE STARTING The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position 1 Placethe main and aux circuit breakers Figure 35 in the OFF position prior to starting the engine MAIN GFCI AUXILIARY CIRCUIT CIRCUI
72. he geerator to the ATS Low Oil Pressure Indicates the engine pressure has fallen below a safe operating level The oil pressure is detected using variable resistive values from the oil pressure sending unit This is considered a major fault B High Coolant Temperature Indicates the engine temperature has exceeded a safe operating level The engine temperature is detected using variable resistive values from the temperature sending unit This is considered a major fault Overcrank Shutdown Indicates the unit has attempted to start a pre programmed number of timesand has failed to start The number of cycles and duration are programmable It is pre set at 3 cycles with a 10 second duration This is considered a major fault Overspeed Shutdown Indicates the engine is running at an unsafe speed This is considered a major fault Engine Running Indicates that engine is running at a safe operating speed Located behind the generator control panel is the Generator Control Box This box contains some of the necessary electronic components required to make the generator function The Control Box is equipped with the following major components B Over Current Relay Bi Voltage Rectifier AVR Starter Relay Current Transformer Voltage Change Over Board Three Phase Circuit Breaker NOTICE Remember the overcurrent relay monitors the current flowing from the U V and W Output Ter
73. he 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 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 The DCA400SSI is powered by 6 cylinder water cooled direct injection turbocharged air to air ISUZU 6WG1X 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 The electric g
74. ildings electrical system may occur without this transfer switch When connecting the generator to a isolation transfer switch ALWAYS have power applied to the generator s internal battery charger This will ensure that the engine will not fail due to a dead battery NOTICE When the generator is set in the AUTO mode the generator will automatically start in the event of commercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch When running the generator in the AUTO mode remember the generator can start up at any time without warning NEVER attempt to perform any maintenance when the generator is in the auto mode The engine speed switch must be set to the High position when running in the auto start mode Failing to set the switch in the proper position can result in damage to your generator when it turns on NOTICE When the MPEC control switch is placed in the AUTO position the engine glow plugs will be warmed and the engine will start automatically When starting generator in AUTO mode use the Manual Start up procedure except where noted see below 1 Performsteps 1 through 5 in the Before Starting section as outlined in the Manual Starting Procedure 2 Place the engine speed switch Figure 51 in the HIGH position HIGH UP 15 Figure 51 Engine Speed Switch High 3 Place the MPEC Control Switch Figure 52 in the AU
75. ill 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 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 25 GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES A wide range of voltages are available to supply voltage for many different applications Voltages are selected by applying jumpers 6 to the voltage change over board Figure 12 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 Change Over Board The voltage change over board Figure 12 is located on the control box behind the generator control panel This board has been provided for ease of voltage selection JUMPER 6 PLACES Figure 12 Voltage Change Over Board NEVER attempt to place jumper plates on the voltage change over board while the generator is in operation There exist the possibility of electrocution electrical shock or burn which can cause severe bodi
76. ion as shown in Figure 23 Connect the load wires to the UVWO terminals as shown in Figure 26 GROUND CONNECTION MUST BE USED ATALL TIMES SINGLE PHASE 277 VAC LOAD CONNECTIONS Figure 26 UVWO Terminal Lugs 10 277 Connections DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 29 INSPECTION SETUP CIRCUIT BREAKERS To protect the generator from an overload a 3 pole 600 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 Three 50 amp load 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 the oil level is maintained between the two notches Figure 27 on the dipstick See Table 11 for proper selection of engine oil Figure 27 Engine Oil Dipstick When checking the engine oil be sure to check if the oil is clean II the oil is not clean drain the oil by removing the oil drain plug and refill with the specified amount of oil as outlined in the ISUZU Engine Owner s Manual Oil should be warm before draining Other types of mot
77. ir to air after cooler 6 cylinders 5 79 in x 6 06 in 147 mm x 154 mm 957 in 15 681 cc 464 HP at 1800 rpm Electric 24 VDC 15 8 gal 60 0 liters 14 4 gal 55 0 liters 2 Diesel Fuel 129 gal 490 liters Fuel Tank Capacity 23 0 gal 87 3 L hr at full load Fuel Consumption Battery 12V 200 Ah x 2 PAGE 12 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 VIEW SIDE VIEW 255 PESE 2 DIMENSIONS Figure 1 Dimensions Table 3 Dimensions semgom sanoo DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 13 INSTALLATION E GENERATOR GROUND LUG ZW GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING GROUND GROUND CABLE 8 FT MINIMUM REFERENCE NEC250 83C Figure 2 Typical Generator Grounding Application PAGE 14 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 INSTALLATION OUTDOOR INSTALLATION Install the generator in a area that is free of debris bystanders and overhead obstructions Make sure the generator is on secure level ground so that it cannot slide or shift around Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes The installation site must be relatively free
78. l be ON When pre heat cycle is completed lamp will turn OFF Emergency Stop Button Push this button inward to stop the engine in the event of an emergency DO NOT use this button as a means of stopping the engine Battery Switch This switch should be to the ON position during normal operation When the engine has been stop place this switch in the OFF position DO NOT turn this switch during normal operation it could cause damage to the electrical equipment COOLANT LEVEL PAGE 20 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 0 400 1 GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 21 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 OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel Figure 6 is provided with the following Three 3 120 240V output receptacles 50 amp Three 3 Circuit Breakers 6 50 amps MI Two 2 120V receptacles 6 20 amp Two 2 GFCI Circuit Breakers 6 20 amps Eight 8 Output Terminal Lugs U V W G
79. ly harm or even death Table 7 Voltages Available Three Phase Single Phase om Tables 8 and 9 describe the generator s current output capability for both 10 and 30 phase applications Table 8 Generator Ampere Ratings 10 120V 139V 240v 277V 480V 80 222 191 III 55 These calculations reflect the maximum amount of current the generator can provide at each output terminal pair To obtain the total generator amperage multiply by 3 Example 1 488 6 amps 120V per output terminal pair X 3 1 486 amps Example 2 244 3 amps 240V per out put terminal pair X 3 733 amps Table 9 Generator Ampere Ratings 30 PAGE 26 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 GENERATOR OUTPUTS GAUGE READING Maximum Amps VW V Table 10 shows the maximum amps the generator can provide DO NOT exceed the maximum amps as listed U VV U V W U Table 10 Generator Maximum Amps OFF OFF 0 400 1 Figure 14 Voltmeter Figure 16 Ammeter Rated Voltage Change Over Switch Change Over Switch Single Phase 120 Volt 888 9 amps 4 wire Single Phase 240 Volt 444 4 amps 4 wire Three Phase 240 Volt 962 3 amps Three Phase 480 Volt 481 1 amps HOW TO READTHE OUTPUT TERMINAL GAUGE Figure 15 AC Voltmeter Figure 17 AC Ammeter Gauge Volt reading Amp reading on U lug The AC ammet
80. ments include the following Connect and test electric brake operation Secure portable power cables in cable tray with tie wraps The 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 M Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing M Avoid sharp turns to prevent rolling Trailer should be adjusted to a level position at all times when towing Raise and lock trailer wheel stand in up position when towing B Place chock blocks underneath wheel to prevent rolling while parked B Place support blocks underneath the trailers bumper to prevent tipping while parked Use the trailer s swivel jack to adjust the trailer height to a level position while parked DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 9 SAFETY INFORMATION ELECTRICAL SAFETY DO NOT touch output terminals during operation Contact with output terminals during operation can cause electrocution electrical shock or burn The 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
81. meter of the tire rim Tire Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc Wheel Hub The wheel hub is connected to the trailer s axle 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 down the lug nuts See Table 18 and Figure 62 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 108 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 PAGE 42 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 TRAILER MAINTENANCE 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 br
82. minal Lugs to the load In the event of a short circuit or over current condition it will automatically trip the 1000 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 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 19 ENGINE OPERATING PANEL Figure 5 Engine Operating Panel The definitions below describe the controls and functions of the DCA400SSI Engine Operating Panel Figure 5 1 Tachometer Indicates engine speed in RPM s for 60 Hz operation This meter should indicate 1800 RPM s when the rated load is applied In addition a built in hour meter will record the number of operational hours that the generator has been in use 2 Oil Pressure Gauge During normal operation this gauge be should read between 28 to 85 psi 193 586 kPa When starting the generator the oil pressure may read a little higher but after the engine warms up the oil pressure should return to the correct pressure range 3 WaterTemperature Gauge During normal operation this gauge be should read between 167 and 203 F 75 95 C 4 Charging Ammeter Gauge Indicates the current being supplied by the engine s alternator which provides current for generator s control circuits and battery charging system 5 Fuel Gauge Indicates amount of diesel fuel available 6
83. nding instruc tions Ifa reply is not received within five days the material will be returnedtothe sender athis expense 9 Crediton 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 spe cific date andall orders received on orafterthat date will bebilled atthe 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 Multiquip reserves the right to quote and sell directto Governmentagencies andto Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 35 00 surcharge willbe addedtothe invoice for special handling including bus shipments insured parcel postor in cases where Multiquip mustpersonally deliverthe parts to the carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable hereunder for damages in excess of the purchase price ofthe item with respect to which damages are claimed and in no event shall Multiquip
84. nstallation 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 cylinder supplying hydraulic pressure to the trailer brakes Periodically check and test the surge actuator to make sure that itis functioning correctly Never use an undersize actuator Table 15 Hydraulic Brake Troubleshooting Poseble Cause Brake components 10088 bent or Replace components Locking Brakes broken Brake drums out of round System lubricated Noisy Brakes Brake components correct Replace and correct Brake lining thickness incorrect or Install new shoes and not adjusted correctly linings Replace rubber parts E h brake fluid or correct fluid fill with dot 4 fluid Dragging Brakes DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 43 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 removing or installing force fitted parts Failure to comply may result in serious injury
85. nt 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 56 and clean the heavy duty paper element with light spray of compressed air Replace the air cleaner as needed Air Cleaner with Dust Indicator The air filter should not be changed until the indicator This indicator Figure 56 is attached to the air cleaner reads RED Dispose of old air filter It may not be When the air cleaner element is clogged air intake Cleaned or reused restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service After changing the air element press the dust indicator button to reset the indicator AIR CLEANER ELEMENT Figure 56 Air Cleaner Indicator PAGE 38 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 MAINTENANCE If 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 fu
86. ny persons in the general area of the generator NEVER touch the hot exhaust manifold 2y muffler or cylinder Allow these parts to cool before servicing equipment 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 Y 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
87. or oils may be substituted if they meet the following requirements API Service Classification CC SC API Service Classification CC SD Service Classification CC SE Service Classification CC SF Table 11 Recommended Motor lec 0IL SAE 122 50 104 40 g 86 30 lt 68 20 Fo 10 8 5 32 0 ONT MT S is gt 20 T 22 30 5 40 4 FUEL CHECK DANGER Fuel spillage on hot engine can cause fire or explosion If fuel spillage occurs wipe up the spilled fuel completely to prevent fire hazards NEVER smoke around or near the generator wW 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 28 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 must 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 TRAILER MOUNTED FUEL TANK OPTION ENVIRONMENTAL OPTION
88. overnor system controls the RPMs of the engine When the engine demand increases or decreases the governor system regulates the frequency variation to 2590 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 selection chart Table 6 as a guide for selecting proper extension cable size PAGE 16 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 5 ce NE NS EE EN 9 0 7 10 Figure 3 Major Components DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 17 10 6 Figure 4 Generator Control Panel The definitions below describe the controls and functions of the DCA400SSI Generator Control Panel Figure 4 1 2 Pilot Lamp Indicates the system is running Panel Light Normally used in dark areas or at night time When activated panel lights will illuminate When the generator is not in use be sure to turn the panel light switch to the OFF position AC Voltmeter Indicates the output voltage present at the U V and W Output Terminal Lugs
89. rmation about motor vehicle safety from http www safecar gov DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 3 0 400 1 GENERATOR Proposition 65 Warning 2 Reporting Safety 3 Table Of Contents 4 Parts Ordering 5 Safety Information 6 11 12 DIMENSIONS 13 14 15 General 1 16 Major 17 Generator Control 18 19 Engine Operating 20 Output Terminal Panel Familiarization 22 24 Load 25 Generator 26 27 Gauge Reading 27 Output Terminal Panel Connections 28 29 Inspection Setup sene 30 33 Generator Start Up Procedure Manual 34 35 Generator Start Up Procedure Auto 36 Generator Shut Down Procedures 37 NENNT ep UNS 38 41 Trailer Maintenance 42 45 Trailer Wiring Diagram
90. round 10 AND 30 NEUTRAL OUTPUT TERMINALS TERMINAL TERMINAL HARD WIRE HOOKUP PANEL AUX POWER RECEPTACLES 120 240V 50 AMPS CS 6369 TWIST LOCK CIRCUIT BREAKERS FOR CS 6369 TWIST LOCK RECEPTACLES CIRCUIT BREAKERS FOR GFCI RECEPTACLES 120 VAC 20 AMP GFCI RECEPTACLES Figure 6 Output Terminal Panel PAGE 22 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 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 Figure 7 in the center of the receptacle will check the GFCI function Both receptacles should be tested at least once a month 120 VAC RECEPTACLE RESET TEST BUTTON Figure 7 G F C l Receptacle Twist Lock Dual Voltage 120 240 VAC Receptacles There are three 120 240V 50 amp auxiliary twist lock CS 6369 receptacles Figure 8 provided on the output terminal panel These r
91. s of rust and dirt are removed DO NOT clean radiator core with any objects such as a screwdriver 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 58 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 58 Radiator Cleaning GENERATOR STORAGE For long term storage of the generator the following is recommended Drain the fuel tank completely Treat with a fuel stabilizer if necessary M 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 Make 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 JACKETWATER HEATER AND INTERNAL BATTERY CHARGER 120 VAC INPUT RECEPTACLES OPTIONAL This generator can be optionally equipped with two 120 VAC 20 amp input receptacles located on the output terminal panel PAGE 40 DCA400SSI GENERATOR OPERATION A
92. t numbers are subject to change without notice PAGE 4 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options Effective January 1 2006 Order via Internet Dealers Only If you have an MQ Account to obtain a Best Deal Order parts on line using Multiquip s SmartEquip website Username and Password E mail us at View Parts Diagrams parts 6 multiquip com Order Parts To obtain an MQ Account contact your lli Print Specification Information District Sales Manager for more information Goto www multiquip com and click on Use the internet and qualify for 5 Discount Parts lto log in and save on Standard orders for all orders which include complete part numbers I gt ee Order Fax Dealers Only Fax your order in and qualify for a 296 Discount All customers are welcome to order parts via Fax on Standard orders for all orders which include Domestic US Customers dial complete part numbers 1 800 6 PARTS 7 800 672 7877 Note Discounts Are Subject To Change Order via Phone Domestic US Dealers Call 858 1 800 427 1244 te Non Dealer Customers Contact your local Multiquip Dealer for International Customers should contact parts or call 800 427
93. thly place the engine speed switch Figure 40 in the HIGH up position Figure 40 Engine Speed Switch High 5 Verify that the engine running status LED on the MPEC unit Figure 41 is ON lit after the engine has been started AUTO 6 MANUAL OFF RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK ENGINE RUNNING D Figure 41 Engine Running LED ON PAGE 34 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 GENERATOR START UP PROCEDURE MANUAL 6 The generator s frequency meter Figure 42 should be displaying the 60 cycle output frequency in HERTZ Figure 42 Frequency Meter The generator s AC voltmeter Figure 43 will display the generator s output in VOLTS If the voltage is not within the specified tolerance use the voltage adjustment control knob Figure 44 to increase or decrease the desired voltage Figure 43 Voltmeter DECREASE INCREASE N Figure 44 Voltage Adjust Control Knob The ammeter Figure 45 will indicate zero amps with no load applied When a load is applied the ammeter will indicate the amount of current that the load is drawing from the generator Figure 45 Ammeter No Load Theengine oil pressure gauge Figure 46 will indicate the oil pressure of the engine Under normal operating conditions the oil pressure is approximately 28 to 85 psi 193 586 kPa Figure 4
94. tuation which if not avoided WILL result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in MINOR or MODERATE INJURY NOTICE Addresses practices not related to personal injury 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 W Explosive fuel hazards aS E Burn hazards Overspeed hazards Rotating parts hazards Pressurized fluid hazards Electric shock hazards PAGE 6 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 SAFETY INFORMATION GENERAL SAFETY 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 NOTICE This equipment should only be operated by trained and qualified personnel 18 years of age and older Whenever necessary replace nameplate operation and saf
95. type used in this generator is BCI Group 27 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 34 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 584 Figure 34 Battery Connections 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 corrosion 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 t
96. umbers listed in the parts section are bject to change without notice Multiquip does not guarantee the availability of the parts listed Sample Parts List NO PART NO PARTNAME QTY REMARKS 1 12345 BOIT 1 INCLUDES ITEMS W 2 WASHER 1 4 IN NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 3 12348 AR MAKE LOCALLY 4 12349 BEARING 1 S N 23458 AND ABOVE NO Column Unique Symbols All items with same unique symbol 96 or 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 are in effect for the same general item such as different size saw blade guards in use or a partthat has been updated on newer versions of the same machine 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 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 ltem qu
97. with the following M Tachometer Emergency Stop Switch Water Temperature Gauge B Oil Pressure Gauge Charging Ammeter Gauge B Fuel Level Gauge Pre Heat Lamp Engine Speed Switch Battery Switch Engine Alarm Lamps 5 GENERATOR CONTROL PANEL The Generator Control Panel is provided with the following Frequency Meter Hz AC Ammeter Amps AC Voltmeter Volts Ammeter Change Over Switch Voltmeter Change Over Switch Voltage Regulator Panel Light Panel Light Switch 3 Pole 1 000 amp Main Circuit Breaker Control located behind the Gen Control Panel Automatic Voltage Regulator Current Transformer Over Current Relay Voltage Rectifier Starter Relay Engine Controller Computer Controlled Voltage Change Over Board OUTPUT TERMINAL PANEL The Output Terminal Panel is provided with the following Three 120 240V output receptacles CS 6369 50A Three auxiliary circuit breakers Two 120V output receptacles GFCI 20A Two circuit breakers 20A Eight output terminal lugs 30 power Battery Charger Optional Water Heater Optional OPEN DELTA EXCITATION SYSTEM The DCA400SSI 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 t

Multiquip DCA400SSI Portable Generator User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents