Multiquip DCA400SSI Portable Generator Operation And Parts Manual

OPERATION AND PARTS MANUAL

WHISPERWATT™ SERIES

MODEL DCA400SSI

60HZ GENERATOR

(ISUZU 6WG1X DIESEL ENGINE)

PARTS LIST NO. C3871301004

Revision #2 (11/03/08)

To fi nd 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

Diesel engine exhaust and some of

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

Traffi c 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 fi nds 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 information about motor vehicle safety from http://www.safecar.gov.

DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 3

DCA400SSI GENERATOR

Proposition 65 Warning ........................................... 2

Reporting Safety Defects ......................................... 3

Table Of Contents .................................................... 4

Parts Ordering Procedures ...................................... 5

Safety Information .............................................. 6-11

Specifi cations ........................................................ 12

Dimensions ............................................................ 13

Installation ........................................................ 14-15

General Information ............................................... 16

Major Components ................................................ 17

Generator Control Panel ................................... 18-19

Engine Operating Panel ......................................... 20

Output Terminal Panel Familiarization .............. 22-24

Load Application .................................................... 25

Generator Outputs ............................................ 26-27

Gauge Reading ..................................................... 27

Output Terminal Panel Connections ................. 28-29

Inspection/Setup ............................................... 30-33

Generator Start-Up Procedure (Manual) .......... 34-35

Generator Start-Up Procedure (Auto Mode) .......... 36

Generator Shut-Down Procedures ........................ 37

Maintenance ..................................................... 38-41

Trailer Maintenance .......................................... 42-45

Trailer Wiring Diagram ........................................... 46

Generator Wiring Diagram ..................................... 47

Engine Wiring Diagram .......................................... 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 Assembly ......................................... 56-59

Engine Operating Panel Assembly ................... 60-61

Control Box Assembly ..................................... 62-67

Engine And Radiator Assembly ........................ 68-71

Output Terminal Assembly ................................ 72-73

Battery Assembly.............................................. 74-77

Fuel Tank Assembly (S/N 3813334 & Below) ... 78-79

Fuel Tank Assembly (S/N 3813335 & Above) ... 80-81

Enclosure #1 Assembly .................................. 82-83



Rubber Seals Assembly ................................... 90-91

Nameplate And Decals Assembly .................... 92-95

Terms And Conditions Of Sale — Parts ................ 96

NOTICE

Specifi cations and part numbers are subject to change without notice.


Best Deal!

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

Order via Internet

(Dealers Only)

:

Order parts on-line using Multiquip’s SmartEquip website!

■ View Parts Diagrams

■ Order Parts

■ Print Specification Information

Effective:

January 1 st

, 2006

If you have an MQ Account, to obtain a

Username and Password, E-mail us at:

[email protected].

To obtain an MQ Account, contact your

District Sales Manager for more information.

Goto www.multiquip.com and click on

Order Parts

to log in and save!

Use the internet and qualify for a 5% Discount on

Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Order via Fax

(Dealers Only)

:

All customers are welcome to order parts via Fax.

Domestic (US) Customers dial:

1-800-6-PARTS-7 (800-672-7877)

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Order via Phone:

Domestic (US) Dealers Call:

1-800-427-1244

❒

❒

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

International Customers should contact their local Multiquip Representatives for

Parts Ordering information.

When ordering parts, please supply:

✓ UPS/Fed Ex

■ Priority One

■ Ground

■ Next Day

■ Second/Third Day

✓ DHL

✓ Truck

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!


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 specifi cally address the level of exposure to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION or NOTICE.

SAFETY SYMBOLS

SAFETY INFORMATION

Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

WARNING


COULD result in DEATH or SERIOUS INJURY.

CAUTION


COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.


GENERAL SAFETY

CAUTION



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 infl uence of drugs or alcohol.

NOTICE



This equipment should only be operated by trained and qualifi ed personnel 18 years of age and older.



Whenever necessary, replace nameplate, operation and safety decals when they become diffi cult read.



Manufacturer does not assume responsibility for any accident due to equipment modifi cations. Unauthorized equipment modifi cation 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.



ALWAYS

know the location of the nearest

fi re extinguisher.



ALWAYS

know the location of the nearest

fi rst aid kit.



ALWAYS

know the location of the nearest phone or

keep a phone on the job site. Also, know the phone numbers of the nearest ambulance, doctor and fi re

department. This information will be invaluable in the case of an emergency.


GENERATOR SAFETY

DANGER



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 fl ow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free flow of the air is restricted. If the air fl ow 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. An explosion or fi re could result causing severe

bodily harm or even death.

WARNING



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.

CAUTION



NEVER

lubricate components or attempt service on a running machine.

NOTICE



ALWAYS

ensure generator is on level ground before use.



ALWAYS

keep the machine in proper running condition.



Fix damage to machine and replace any broken parts immediately.



ALWAYS

store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel.


ENGINE SAFETY

WARNING



DO NOT

place hands or fingers inside engine compartment when engine is running.



NEVER

operate the engine with heat shields or guards removed.



Keep fi ngers, hands hair and clothing away from all moving parts to prevent injury.



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 gush out of the coolant tank and severely scald any persons in the general area of the generator.



DO NOT

remove the engine oil drain plug while the engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator.

CAUTION



NEVER

touch the hot exhaust manifold, muffl er or cylinder. Allow these parts to cool before servicing equipment.

NOTICE



NEVER

run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter 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 maximum allowable.




Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied. When a diesel engine operates without suffi cient 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 effi ciency, it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel.

Wet stacking does not usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition. It can reduce the system performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several hours to burn off the accumulated unburned fuel.



State Health Safety Codes and Public Resources

Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or fl ames from the engine exhaust. Spark arresters are qualifi ed 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.


FUEL SAFETY

DANGER



DO NOT

start the engine near spilled fuel or combustible fl uids. Diesel fuel is extremely fl ammable and its vapors can cause an explosion if ignited.



ALWAYS

refuel in a well-ventilated area, away from sparks and open fl ames.



ALWAYS

use extreme caution when working with

fl ammable liquids.



DO NOT

fi ll the fuel tank while the engine is running or hot.



DO NOT

overfi ll 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 fl ames.



NEVER

use fuel as a cleaning agent.



DO NOT

smoke around or near the equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

TOWING SAFETY

CAUTION



Check with your local county or state safety towing regulations, in addition to meeting

Department of Transportation (DOT)

Safety Towing Regulations, before towing your generator.



Refer to MQ Power trailer manual for additional safety information.



In 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 infl ated to 50 psi cold.

Also check the tire tread wear on both vehicles.



ALWAYS

make sure the trailer is equipped with a safety

chain.



ALWAYS

properly attach trailer’s safety chains to towing vehicle.



ALWAYS

make sure the vehicle and trailer directional, backup, brake and trailer lights are connected and working properly.



DOT Requirements 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.



Avoid sudden stops and starts. This can cause skidding, or jack-knifi ng. Smooth, gradual starts and stops will improve towing.



Avoid sharp turns to prevent rolling.



Trailer should be adjusted to a level position at all times when towing.



Raise and lock trailer wheel stand in up position when towing.



Place chock blocks underneath wheel to prevent rolling while parked.



Place support blocks underneath the trailer’s bumper to prevent tipping while parked.



Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.


ELECTRICAL SAFETY

DANGER



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 any objects into the output receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution

or death.



Backfeed to a utility system can cause

electrocution and/or property damage.

NEVER connect the generator to a building’s electrical system without a transfer switch or other approved device. All installations should be performed by a

licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious injury or

even death.

Power Cord/Cable Safety

DANGER



NEVER

let power cords or cables lay in water.



NEVER stand in water

while AC power from the generator is being transferred to a load.



NEVER

use damaged or worn cables or cords when connecting equipment to generator. Inspect for cuts in the insulation.



NEVER

grab or touch a live power cord or cable with wet hands. The possibility exists of electrical shock,

electrocution or death.




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

DANGER



ALWAYS

make sure that electrical circuits are properly grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator. Severe injury or death by

electrocution can result from operating an ungrounded generator.



NEVER

use gas piping as an electrical ground.


BATTERY SAFETY

DANGER



DO NOT

drop the battery. There is a possibility that the battery will explode.



DO NOT

expose the battery to open fl ames, sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a fl ame or spark, an explosion could occur.

WARNING



ALWAYS

wear safety glasses when handling the battery to avoid eye irritation.

The battery contains acids that can cause injury to the eyes and skin.



Use well-insulated gloves when picking up the battery.



ALWAYS

keep the battery charged. If the battery is not charged, combustible gas will build up.



ALWAYS

recharge the battery in a well-ventilated environment to avoid the risk of a dangerous concentration of combustible gasses.



If the battery liquid (dilute sulfuric acid) comes into contact with clothing or skin, rinse skin or clothing immediately with plenty of water.



If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

CAUTION



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



Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, fuel and fuel fi lters.



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.


SPECIFICATIONS

Model

Type

Armature Connection

Phase

Standby Output

Prime Output

Voltage — 1Ø

Voltage — 3Ø

Frequency

Speed

Power Factor

Aux. AC Power

Table 1. Generator Specifi cations

DCA400SSI

Revolving fi eld, self ventilated, open protected type synchronous generator

Star with Neutral

3

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

0.8

Single Phase, 60 Hz

Aux. Voltage/Output

Dry Weight

Wet Weight

Model

4.8 Kw (2.4 kW x 2)

11,640 lbs. (5,280 kg.)

12,875 lbs. (5,840 kg.)

Table 2. Engine Specifi cations

ISUZU 6WG1X

Type

No. of Cylinders

Bore x Stroke

4 cycle, water-cooled, direct injection, turbo-charged with air to air after cooler

6 cylinders

5.79 in. x 6.06 in. (147 mm x 154 mm)

Displacement

Rated Output

Starting

Coolant Capacity

Lube Oil Capacity

Fuel Type

Fuel Tank Capacity

Fuel Consumption

Battery

957 cu. 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)

23.0 gal. (87.3 L)/hr at full load

12V-200 Ah x 2


DIMENSIONS

Figure 1. Dimensions

Reference

Letter

A

D

E

B

C

F

G

Table 3. Dimensions

Dimension in. (mm) Reference Letter Dimension in. (mm)

17.72 in. (450 mm)

35.83 in. (910 mm)

23.23 in. (590 mm.)

31.89 in. (810 mm)

18.11 in. (685 mm)

22.24 in. (565 mm)

31.89 in. (810 mm)

K

L

M

H

J

I

23.23 in. (590 mm)

35.83 in. (910 mm)

17.72 in. (450 mm)

181.10 in. (4,600 mm)

82.68 in. (2,100 mm)

55.12 in. (1,400 mm)


INSTALLATION

Figure 2. Typical Generator Grounding Application


OUTDOOR INSTALLATION

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

INDOOR INSTALLATION

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall.

Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

MOUNTING

The generator must be mounted on a solid foundation (such as concrete) and set fi rmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the fl oor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

INSTALLATION

GENERATOR GROUNDING

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the National Electrical Code

(NEC) provides guide lines for proper grounding and specifi es that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.

b. Aluminum - 8 AWG (8.4 mm2) 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. NEC article 250-52(c) specifi es 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.


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 with the following:



Tachometer



Emergency Stop Switch



Water Temperature Gauge



Oil Pressure Gauge



Charging Ammeter Gauge



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 Box” (located behind the Gen. Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Voltage Rectifi er

• 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, 50A



Two 120V output receptacles (GFCI), 20A



Two GFCI circuit breakers, 20A



Eight output terminal lugs (3Ø power)



Battery Charger (Optional)



Water Heater (Optional)

GENERAL INFORMATION

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 the open delta A, B, C and

D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to

B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectifi ed 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 confi guration 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 “fi xed ceiling” and responds according the demands of the required load.

ENGINE

The DCA400SSI is powered by a 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 specifi cations.

In keeping with MQ Power’s policy of constantly improving its products, the specifi cations quoted herein are subject to change without prior notice.

ELECTRIC GOVERNOR SYSTEM

The electric governor system controls the RPMs of the engine.

When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

EXTENSION CABLES

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size.


MAJOR COMPONENTS

Table 4. Generator Major Components

ITEM NO.

1

2

3

DESCRIPTION

Output Receptacles Assembly

Output Terminal Panel Assembly

Muffl er Assembly

6

7

4

5

Air Filter Assembly

Fuel Tank Assembly

Engine and Radiator Assembly

Generator Assembly

10

11

8

9

Battery Assembly

Generator Control Panel Assembly

Circuit Breaker Assembly

Engine Operating Panel Assembly

Figure 3. Major Components



Figure 4. Generator Control Panel

The defi nitions below describe the controls and functions of the DCA400SSI Generator Control Panel (Figure 4).

1.

Pilot Lamp

— Indicates the system is running.

2.

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.

3.

AC Voltmeter

— Indicates the output voltage present at the U,V, and W Output Terminal Lugs.

4.

Frequency Meter

— Indicates the output frequency in hertz (Hz). Normally 60 Hz.

5.

AC Ammeter

— Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

6.

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.

7.

Ammeter Change-Over Switch

— This switch allows the AC ammeter to indicate the current fl owing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

8.

Panel Light Switch

— When activated will turn on control panel light.

9.

Voltage Regulator Control

— Allows ±15% manual adjustment of the generator’s output voltage.

10.

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.

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 and all major faults will shutdown the generator. During cranking

cycle, The MPEC will attempt to crank the engine for 10 seconds before disengaging.

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s 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.


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 building’s 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 autostart 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 the 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.



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:



Over-Current Relay



Voltage Rectifi er (AVR)



Starter Relay



Current Transformer



Voltage Change-Over Board



Three Phase Circuit Breaker

NOTICE

Remember the overcurrent relay monitors the current fl owing from the U,V, and W Output Terminal Lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the 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).


1 2

3 4 5

ENGINE OPERATING PANEL

6

7

8 9

10

WATER TEMP.

OIL PRESS.

FUEL LEVEL

AIR FILTER COOLANT LEVEL

ON

OFF

Figure 5. Engine Operating Panel

The defi nitions 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.

4.

Water Temperature Gauge

— During normal operation this gauge be should read between 167° and 203°F

(75°~95°C).

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.

6.

Fuel Gauge

— Indicates amount of diesel fuel available.

Engine Warning Lamps

— There are three engine warning lamps, they are defi ned as follows: a.

Overheat Lamp

— This lamp goes ON when the cooling water temperature rises abnormally. If the lamp goes ON during normal operation of the generator, the emergency shutdown device will stop the engine automatically.

normal operation of the generator this lamp should remain OFF. When the

Auto-OFF/Reset-Manual switch is set c. d. 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.

Air Filter Alarm

— When the air fi lter element is clogged, this lamp goes ON indicating the element should be immediately cleaned or replaced.

7.

8.

9. goes ON when the coolant level is low. If this lamp goes ON 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 will 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.

10.

Battery Switch

— This switch should be set 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.


NOTES


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 “O” 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 @ 50 amps



Two (2) 120V GFCI receptacles @ 20 amp



Two (2) GFCI Circuit Breakers @ 20 amps



Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)

Figure 6. Output Terminal Panel



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.

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.

Figure 9. Voltage Regulator Control Knob

Figure 7. G.F.C.I. 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 receptacles can only be accessed when the voltage selector switch is placed in the single-

phase 240/120 position.

Figure 8. 120/240V Twist-Lock Auxiliary

Receptacles



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.

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

Figure 10. Connecting Loads


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 infl uenced by the effi ciency, 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 Power Factor

Single-phase induction motors

Electric heaters, incandescent lamps

Fluorescent lamps, mercury lamps

Electronic devices, communication equipment

Common power tools

0.4-0.75

1.0

0.4-0.9

1.0

0.8

Table 6. Cable Selection (60 Hz, Single Phase Operation)

2.5

5

7.5

10

15

20

Current in

Amperes

Load in Watts

At 100

Volts

At 200

Volts

300

600

600

1200

Maximum Allowable Cable Length

#10 Wire

1000 ft.

500 ft.

#12 Wire

600 ft.

300 ft.

#14 Wire

375 ft.

200 ft.

900

1200

1800

1800

2400

3600

350 ft.

250 ft.

150 ft.

200 ft.

150 ft.

100 ft.

125 ft.

100 ft.

65 ft.

2400 4800 125 ft.

75 ft.

50 ft.

CAUTION: Equipment damage can result from low voltage

#16 Wire

250 ft.

125 ft.

100 ft.

LOAD APPLICATION

THREE PHASE LOAD

When calculating the power requirements for 3-phase power use the following equation:

NOTICE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø 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.



When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.



When connecting a fl uorescent or mercury lamp, a capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.



When connecting an electric drill or other power tools, pay close attention to the required starting current capacity.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.


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 fi ne 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.

Figure 12. Voltage Change-Over Board

CAUTION

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 bodily harm or even death!

Three Phase

(Switchable)

Single Phase

(Switchable)

Table 7. Voltages Available

208V

120V

220V

127V

240V

139V

416V

240V

440V

254V

480V

277V

GENERATOR OUTPUTS

Generator Amperage

Tables 8 and 9 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

Table 8. Generator Ampere Ratings — 1Ø kW

80

120V

222

139V

191

240V

111

277V

96

480V

55

110

140

170

200

305

388

472

555

263

335

407

480

152

194

236

277

131

167

203

240

76

97

118

138

230

260

638 551 319 275 160

722 623 361 311 180

290 805 695 402 347 201

320 (Max) 889 767 444 383 222

These calculations refl ect 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 — 3Ø

KVA

100

240V

240

480V

120

130

160

190

220

250

280

310

312

384

457

529

601

674

746

156

192

228

264

300

337

373

340

370

400

818

890

962

409

445

481


GENERATOR OUTPUTS/GAUGE READING

Maximum Amps

Table 10 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed.

Table 10. Generator Maximum Amps

Model

Rated Voltage

DCA400SSI

Maximum Amps

Single Phase 120 Volt 888.9 amps (4 wire)

Single Phase 240 Volt 444.4 amps (4 wire)

Three Phase 240 Volt

Three Phase 480 Volt

962.3 amps

481.1 amps

Figure 14. AC Voltmeter

Change-Over Switch

Figure 16. AC Ammeter

Change-Over Switch

HOW TO READ THE OUTPUT TERMINAL GAUGE

The AC ammeter and AC voltmeter change-over switches on the control panel DO NOT effect the generator output.

They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

When the voltage change-over board is jumpered for 3Ø,

240V operation (See Figures 14 and15), place the AC

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.

Figure 15. AC Voltmeter

Gauge (Volt reading on

W-U Lug)

Figure 17. AC Ammeter

(Amp reading on U lug)

NOTICE

The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use.

Figure 13. Voltage Change-Over Board 240V

Confi guration


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 confi gured 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 confi guration. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 18.

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 fi ne tuning of the output voltage is required

Figure 20. Voltage Regulator Knob


1.

2.

Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 18.

Connect the load wires to the UVWO terminals as shown in Figure 21.


Confi guration

2. Connect the load wires to the UVWO terminals as shown in Figure 19.

Figure 21. UVWO Terminal Lugs 1Ø-240V

Connections


1.

2.

3.

Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 18.

Adjust voltage regulator knob (Figure 20) for an output of 208V to obtain 120V at the UVWO terminals.

Connect the load wires to the UVWO terminals as shown in Figure 22.

Figure 19. UVWO Terminal Lugs

Figure 22. UVWO Terminal Lugs

1Ø-120V

Connections


OUTPUT TERMINAL PANEL CONNECTIONS


1. Jumper the voltage change-over board for 480V operation as shown in Figure 23. This confi guration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate must be used.


1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 23.



Confi guration



Connections


1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 23.



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 fi re.


Connections


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 fi ller hole, but DO NOT overfi ll. 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. If the oil is not clean, drain the oil by removing the oil drain plug, and refi ll with the specifi ed amount of oil as outlined in the ISUZU Engine Owner’s Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements:



API Service Classifi cation CC/SC





API Service Classifi cation CC/SD



API Service Classifi cation CC/SE

API Service Classifi cation CC/SF

Table 11. Recommended Motor Oil

INSPECTION/SETUP

FUEL CHECK

DANGER

Fuel spillage on a hot engine can cause a fi re or explosion. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

Refi lling the Fuel System

CAUTION

ONLY properly trained personnel who have read and understand this section should refi ll 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 fi ll the fuel tanks with clean fresh #2 diesel fuel. DO NOT fi ll 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 fi lling.

Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

Figure 28. Internal Fuel Tank System


Refueling Procedure:

WARNING

Diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.


2. Open cabinet doors on the “right side” of the generator

(from generator control panel position). Remove fuel cap and fi ll tank (Figure 30).

1.

Level Tanks

— Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 29).

CAUTION

ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

Figure 30. Fueling the Generator

3.

NEVER overfi ll fuel tank

— It is important to read the fuel gauge when fi lling trailer fuel tank. DO NOT wait for fuel to rise in fi ller neck (Figure 31).

Figure 29. Only Fill on Level Ground

NOTICE

ONLY use #2 diesel fuel when refueling.

Figure 31. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel expansion. Fuel expands when heated (Figure 32).

Figure 32. Fuel Expansion


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 50% demineralized water) or pre-diluted. See the ISUZU Engine Owner’s Manual for further details.

WARNING

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See

Table 12 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the “H” and the “L” markings.

Table 12. Coolant Capacity

Engine and Radiator

Reserve Tank

15.8 Gal (60 liters)

TBD

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

Freezing Point

Vol %

Anti-Freeze

°C °F

50 -37 -34


Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fi ns 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 insuffi cient 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.

Figure 33. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan while the generator set is running.

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.


BATTERY

This unit is of negative ground DO NOT connect in reverse.

Always maintain battery fl uid level between the specifi ed marks. Battery life will be shortened, if the fl uid 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 type used in this generator is BCI Group 27.

The battery is suffi ciently charged if the specifi c gravity of the battery fl uid is 1.28 (at 68° F). If the specifi c 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.

CAUTION

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

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 the battery when connecting the battery.

CAUTION

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.


GENERATOR START-UP PROCEDURE (MANUAL)

BEFORE STARTING

CAUTION

The engine’s exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating.

Direct exhaust away from nearby personnel.

STARTING (MANUAL)

1. Place the engine speed switch (Figure 37) in the LOW

(down) position.

WARNING

NEVER manually start the engine with the main, GFCI or

auxiliary circuit breakers in the ON (closed) position.

1. Place the main, G.F.C.I., and aux. circuit breakers (Figure

35) in the OFF position prior to starting the engine.

2.

Figure 37. Engine Speed Switch (Low)

Place the MPEC control switch in the MANUAL position to start the engine (Figure 38).

3.

Figure 38. MPEC Control Switch

(Manual Position)

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 35. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been confi gured 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).

4.

Figure 39. Pre-Heat Button

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 smoothly, place the engine speed switch (Figure 40) in the HIGH (up) position.

5.

Figure 40. Engine Speed Switch (High)

Verify that the engine running status LED on the MPEC unit

(Figure 41) is ON (lit) after the engine has been started.

Figure 36. Engine Enclosure Doors

Figure 41. Engine Running LED (ON)


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

7. 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.

10. 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

11. 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.

Figure 48. Engine Tachometer Gauge

12. Place the main, GFCI, and aux. circuit breakers in the

ON position (Figure 49).

Figure 43. Voltmeter

Figure 44. Voltage Adjust Control Knob

8. 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 49. Main, Aux. and GFCI

Circuit Breakers (ON)

13. Observe the generator’s 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 45. Ammeter (No Load)

9. The engine 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 50. Ammeter (Load)

14. The generator will run until manually stopped or an abnormal condition occurs.

Figure 46. Oil Pressure Gauge


GENERATOR START-UP PROCEDURE (AUTO MODE)

STARTING (AUTO MODE)

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.

When starting generator in AUTO mode use the “Manual

Start-up” procedure except where noted (see below).

1. Perform steps 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

CAUTION

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.

Figure 51. Engine Speed Switch (High)

3. Place the MPEC Control Switch (Figure 52) in the

AUTO position.

Figure 52. MPEC Control Switch (AUTO)

4. Continue operating the generator as outlined in the

Manual Start-up procedure (start at step 5).

WARNING

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.

CAUTION

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.


GENERATOR SHUT-DOWN PROCEDURES

WARNING

NEVER stop the engine suddenly except in an emergency.

EMERGENCY SHUTDOWN PROCEDURE

1. To 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.

NORMAL SHUTDOWN PROCEDURE

To shutdown the generator, use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 35 to the OFF position.

2. Place the engine speed switch (Figure 53) in the “LOW”

(down) position.

Figure 55. Emergency Stop Button

Figure 53. Engine Speed Switch (Low)

3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

4. Place the MPEC Control Switch (Figure 54) to the

OFF/RESET position.

Figure 54. MPEC Control Switch (Off/Reset)

5. Verify that all the status LEDs on the MPEC display are OFF (not lit).

6. Remove all loads from the generator.

7. Inspect entire generator for any damage or loosening of components that may have occurred during operation.


MAINTENANCE

Table 14. Inspection/Maintenance

Check Engine Fluid Levels

Check Air Cleaner

Check Battery Acid Level

Check Fan Belt Condition

10 Hrs

DAILY

X

X

X

X

X

X

250 Hrs 500 Hrs

1000

Hrs

Engine

Check for Leaks

Check for Loosening of Parts

Replace Engine Oil and Filter *

1

Clean Air Filter

Check Fuel Filter/Water Separator Bowl

Clean Unit, Inside and Outside

X

X

X

X

Change Fuel Filter

Clean Radiator and Check Coolant Protection Level* 2

Replace Air Filter Element * 3

Check all Hoses and Clamps * 4

X

X

X

Clean Inside of Fuel Tank

Measure Insulation Resistance Over 3M ohms

Generator

Check Rotor Rear Support Bearing

* 1 Replace engine oil and fi lter at 100 hours, fi rst time only.

X

X

X

X

* 2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.

*

3

Replace primary air fi lter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).

*

4

If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot, with no sags or dips that could collect moisture and/or oil.

GENERAL INSPECTION

Prior to each use, the generator should be cleaned and inspected for defi ciencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine

Instruction Manual)

AIR CLEANER

Every 250 hours: Remove air cleaner element (Figure 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

This indicator (Figure 56) is attached to the air cleaner.

When the air cleaner element is clogged, air intake 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.

Figure 56. Air Cleaner/Indicator

NOTICE

The air fi lter should not be changed until the indicator reads “RED”. Dispose of old air fi lter. It may not be cleaned or reused.


If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exists.

FUEL ADDITION

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

Cleaning Inside the Fuel Tank

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.

MAINTENANCE

FUEL TANK INSPECTION

In addition to cleaning the fuel tank, the following components should be inspected for wear:



Rubber Suspension

— look for signs of wear or deformity due to contact with oil. Replace the rubber suspension if necessary.



Fuel Hoses

— inspect nylon and rubber hoses for signs of wear, deterioration and hardening.



Fuel Tank Lining

— inspect the fuel tank lining for signs of excessive amounts of oil or other foreign matter.

Replacing Fuel Filter



Replace the fuel fi lter cartridge with new one every 500 hours or so.



Loosen the drain plug at the lower top of the fuel fi lter.

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 for details.

Figure 57. Fuel Tank Cleaning


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 fi lled. Insuffi cient 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 fi lter.



Apply a fi lm of oil to the gasket on the new oil fi lter.



Install the new oil fi lter.



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 overfl ow tank and drain.



Check hoses for softening and kinks. Check clamps for signs of leakage.



Tighten both cocks and replace the overfl ow 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 signs of rust and dirt are removed. DO

NOT clean radiator core with any objects, such as a screwdriver.

WARNING

Allow engine to cool when fl ushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.

MAINTENANCE

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 fi ns 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 fi ns 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.



Completely drain the oil from the crankcase and refi ll 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.



If 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.

JACKET WATER 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.


The purpose of these receptacles is to provide power via 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.

MAINTENANCE

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 battery charger receptacle via commercial power using a power applied to the generator's internal battery charger.


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 Cell

— Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2.

Braking System

— System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3.

GVWR

— Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4.

Frame Length

— Measurement is from the ball hitch to the rear bumper (refl ector).

5.

Frame Width

— Measurement is from fender to fender

6.

Jack Stand

— Trailer support device with maximum pound requirement from the tongue of the trailer.

7.

Coupler

— Type of hitch used on the trailer for towing.


8.

Tire Size

— Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters

(175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9.

Tire Ply

— The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10.

Wheel Hub

— The wheel hub is connected to the trailer’s axle.

11.

Tire Rim

— Tires mounted on a tire rim. The tire rim must match the size of the tire.

12.

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.

13.

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 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14.

Suspension

— Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-fl ex, and air ride.

15.

Electrical

— Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16.

Application

— Indicates which units can be employed on a particular trailer.


BRAKES

Trailer brakes should be inspected the fi rst 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the fi rst 200 mile interval, inspect the brakes

every 3,000 miles. If driving over rough terrain, inspect the brakes 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.

2.

3.

4.

5.

6.

7.

8.

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.

Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel diffi cult to turn.

Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

Replace the adjusting hole cover and lower the trailer to the ground.

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.

Figure 60. Hydraulic Brake Components

Actuator

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the surge

or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes.

As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying hydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator” to make sure that it is functioning correctly. Never use an undersize actuator.

Symptom

No Brakes

Table 15. Hydraulic Brake Troubleshooting

Possible Cause

Weak Brakes or Brakes Pull to

One Side

Brake line broken or kinked?

Brake lining glazed?

Trailer overloaded?

Brake drums scored or grooved?

Tire pressure correct?

Solution

Repair or replace.

Reburnish or replace.

Correct weight.

Machine or replace.

Infl ate all tires equally.

Match tires.

Locking Brakes

Tires unmatched on the same axle?

Brake components loose, bent or broken?

Brake drums out-of-round?

System lubricated?

Replace components.

Noisy Brakes

Replace.

Lubricate.

Dragging Brakes

Brake components correct?

Brake lining thickness incorrect or not adjusted correctly?

Enough brake fl uid or correct fl uid?

Replace and correct.

Install new shoes and linings.

Replace rubber parts fi ll with dot 4 fl uid.


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.

CAUTION

ALWAYS wear safety glasses when removing or installing force fi tted parts.

Failure to comply may result in serious injury.

CAUTION

DO NOT attempt to repair or modify a 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/Infl ation

Tire infl ation 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 infl ation 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.

Wear Pattern

Table 16. Tire Wear Troubleshooting

Center Wear

Cause

Over infl ation.

Solution

Adjust pressure to particular load per tire manufacturer.

Edge Wear

Side Wear

Under infl ation.

Loss of camber or overloading.

Adjust pressure to particular load per tire manufacturer.

Make sure load does not exceed axle rating.

Align wheels.

Toe Wear Incorrect toe-in.

Align wheels.

Cupping

Flat Spots

Out-of-balance.

Check bearing adjustment and balance tires.

Wheel lockup and tire skidding.

Avoid sudden stops when 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 components as detailed in Table 17.

Figure 61. Major Suspension Components

Table 17. Suspension Torque Requirements

Item Torque (Ft.-Lbs.)

3/8" U-Bolt

7/16" U-Bolt

1/2" U-Bolt

Min-30 Max-35

Min-45 Max-60

Shackle Bolt

Spring Eye Bolt

Min-45 Max-60

Snug fi t only. Parts must rotate freely.

Locking nuts or cotter pins are provided to retain nut-bolt assembly.

Shoulder Type

Min-30 Max-50

Shackle Bolt


Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 62).

DO

NOT torque the wheel lug nuts all the way down.

Tighten each lug nut in 3 separate passes as defi ned by Table 18.

3. After fi rst road use, retorque all lug nuts in sequence.

Check all wheel lug nuts periodically.

Wheel Size

12"

Table 18. Tire Torque Requirements

First Pass

FT-LBS

20-25

Second Pass

FT-LBS

35-40

Third Pass

FT-LBS

50-65

13" 20-25 35-40 50-65

14"

15"

16"

20-25

20-25

20-25

50-60

50-60

50-60

90-120

90-120

90-120


Figure 62. Wheel Lug Nuts

Tightening Sequence

NOTICE

NEVER use an pneumatic air gun to tighten wheel lug nuts.


TRAILER WIRING DIAGRAM

Figure 63. Trailer/Towing Vehicle Wiring Diagram


GENERATOR WIRING DIAGRAM

Figure 64. Generator Wiring Diagram


ENGINE WIRING DIAGRAM

Figure 65. Engine Wiring Diagram


CONTROLLER WIRING DIAGRAM

Figure 66. Controller Wiring Diagram


TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business offi ce or service plant.

Symptom

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Table 19. Generator Troubleshooting

Possible Problem

AC Voltmeter defective?

Solution

Check output voltage using a voltmeter.

Is wiring connection loose?

Check wiring and repair.

Is AVR defective?

Replace if necessary.

Defective Rotating Rectifi er?

Check and replace.

Defective Exciter Field?

Check for approximately 19 ohms across J & K on CN1

Is engine speed correct?

Turn engine throttle lever to “High”.

Is wiring connections loose?


Defective AVR?


Is wiring connections loose?


Defective AVR?

Short Circuit in load?

Over current?

Defective circuit breaker?


Check load and repair.

Confi rm load requirements and reduce.

Check and replace.

Over current Relay actuated?

Confi rm load requirement and replace.


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 offi ce or service plant.

High coolant temperature light is on.

Symptom

Low oil pressure light is on.

Low coolant level light is on.

(Optionally installed)

Overcrank light is on.

Overspeed light is on.

Loss of MPU light(s) or on.

Table 20. Engine Controller Troubleshooting (MPEC)

Low oil level?

Possible Problem

Fill oil level.

Solution

Replace oil pressure sending unit.

Oil pressure sending unit failure?

Time delay malfunction in controller?

Wire shorted?

Refer to dealer.

Inspect/repair wire.

Low coolant level?

Sending unit failure?

Low battery voltage?

Fan belt tension incorrect?

Fill coolant level.

Replace sending unit.

Replace/charge battery.

Tighten/replace fan belt.

Air fl ow is not circulating through radiator?

Clean/repair radiator grill.

Doors open?

Close doors.

Exhaust leaking?

Generator being overloaded?

Replace/repair gaskets or faulty part.

Check/reduce load.

Thermostat failure?

Air intake blocked?

Temperature switch failure

No or low fuel?

Replace thermostat.

Clean all air intakes.

Replace temperature switch.

Fill fuel level.

Controller needs to be calibrated?

RPM engine speed too high?

Refer to dealer.

Adjust RPM.

Governor actuator needs to be adjusted?

Adjust governor actuator.

Governor controller needs to be adjusted?

Adjust governor controller.

Engine controller needs to be calibrated?

Refer to dealer.

Magnetic pick up out of adjustment?

Adjust magnetic pick up.

Magnetic pick up dirty?

Clean magnetic pick up.


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.

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. If 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.


NOTES


EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed.

Sample Parts List:

NO. PART NO. PART NAME QTY.

REMARKS

1 12345 BOLT ...................... 1 ...... INCLUDES ITEMS W/

WASHER, 1/4 IN. ............. NOT SOLD SEPARATELY

*

2

*

2

*

12347

3 12348

WASHER, 3/8 IN. ... 1 ...... MQ-45T ONLY

HOSE ................... A/R .... MAKE LOCALLY

4 12349 BEARING ............... 1 ...... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same unique symbol

(

*

, #,

+

, %, 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 part that 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 - Item quantity can be indicated by a number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold separately. Other entries will be clarified in the “Remarks”

Column.

REMARKS Column

Some of the most common notes found in the “Remarks”

Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit - All items on the parts list with the same unique symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break - Used to list an effective serial number range 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:

“XXXXX ONLY”

“NOT USED ON XXXX”

“Make/Obtain Locally” - Indicates that the part can be purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately” - Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.


DCA400SSI WHISPERWATT GENERATOR WITH

ISUZU 6WG1X DIESEL ENGINE

1 to 3 units

QTY. P/N DESCRIPTION

1............C3310500003 ....... HOSE, RADIATOR UPPER

1............C3310500103 ....... HOSE, RADIATOR LOWER

1............0602011059 .......... RADIATOR CAP

1............0845500104 .......... FUEL CAP

3............0602015252 .......... V-BELT SET

1............8972177780 ......... OIL PRESSURE SENSOR, ENGINE

1............0602122272 .......... OIL PRESSURE UNIT

1............0602123267 .......... WATER TEMPERATURE UNIT

1............8973639360 .......... WATER TEMP. SENSOR, ENGINE

1............1802200140 .......... BOOST SENSOR

1............0602123290 .......... SWITCH, COOLANT LEVEL

6............0810105400 .......... FILTER, FUEL TANK

6............0602042405 .......... FILTER, FUEL PRIMARY

6............0602042516 .......... ELEMENT PRIMARY FUEL FILTER

6............0602042515 .......... ELEMENT, MAIN FUEL FILTER

6............0602041219 .......... FILTER, OIL CARTRIDGE, MAIN

6............0602041220 .......... FILTER, OIL CARTRIDGE, BYPASS

3............0602046628 .......... ELEMENT AIR CLEANER OUTER

3............0602046629 .......... ELEMENT AIR CLEANER INNER

1............0601808803 .......... CIRCUIT BREAKER 1P 20A

1............0601808804 .......... CIRCUIT BREAKER 2P 50A

2............LY2DUS24VDC ..... RELAY

NOTICE

Part number on this Suggested Spare Parts list may supersede/replace the P/N shown in the text pages of this book.

SUGGESTED SPARE PARTS


GENERATOR ASSY.

5

5A

1-4A

1-4B

1-4

6-6

6-6A

18

18A

9B

9A

9

18B

16

16A

11

13

13A

13B


GENERATOR ASSY.

NO. PART NO.

1 C3110000502

1-1

1-2* 0601842401

1-3* 0601823282

PART NAME QTY.

REMARKS

ROTOR ASSY. ..........................................1 ............. INCLUDES ITEMS W/*

1

RESISTOR, 80W 300 K OHM

RECTIFIER

2

1

1-4* 0018205020

1-4A 0040005000

1-4B 0041205000

1-5* 8201070002

HEX SOCKET HEAD CAP SCREW 2

2

FAN

2

1

1-6* 8201611004

1-7* C3164200004

1-8*

1-9*

8201015003

0012116045

COUPLING WASHER

12

1

BALANCING PLATE .................................1 ............. PURCHASE ITEMS 1-11 AS A SET

HEX HEAD BOLT 10

1-10* 0042618000

1-11* 0601000209

1-12 C3112500004 BEARING

1-13 007906315 BEARING

3 0010312050

5-A 0042512000

HEX HEAD BOLT

4 0042512000 WASHER,

5 0010312040 HEX HEAD BOLT

1

8

8

12

10

1

1

1

6-1 0226200495

6-2 8211323004

6-3 0223300172

6-4 8211323103

6-5 0221200440

6-6 0010110035

CLAMPER

CLAMPER

HEX HEAD BOLT

6-6A 0041210000

6-7 C3132200003 COVER

6-8 0226000290

6-9 0225000590

6-10 0017106020

6-11 0601850144

HEX HEAD BOLT

GROMMET

1

2

1

1

12

1

1

1

2

1

2

1

1

1

6

1

8 C3138000003 FIELD ASSY. EXCITER


9A 0042610000 WASHER,

9B 0041210000 WASHER,


11 C3154300104 BEARING

12 C3154300004 BEARING

4

4

4

4

1

1


GENERATOR ASSY. (CONTINUED)


GENERATOR ASSY. (CONTINUED)

REMARKS

NO. PART NO. PART NAME

13 0010106060

13A 0040006000

HEX HEAD BOLT

13B 0041206000

14 C3154400003 SUCTION

15 0017106016

17 0010312030

17A 0042512000

HEX HEAD BOLT

16 C3163600003 COUPLING

HEX HEAD BOLT

18 0070506206 BEARING


19A 0042512000

20 C3132300014 FAN

21 0010106030

21A 0041206000

HEX HEAD BOLT

21B 0601815000 NUT

22 0605000061 RUBBER

23 0030016000 HEX

23A 0040016000

QTY.

4

1

4

4

8

1

12

12

1

16

16

1

8

8

1

1

1

4


ENGINE OPERATING PANEL ASSY.


ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY.

REMARKS


1

8

3 0207006000

4 1823200010

HEX 4

BATTERY SWITCH .....................................1 ................REPLACES P/N 0602101001

5 0021008080 MACHINE

5A 0030008000 HEX

5B 0040008000 WASHER,

5C 0041608000 WASHER,

6 0601830710 ENGINE SPEED SWITCH

7 0602103090 PREHEAT

7A 0601810244

8 0601831589

BULB, DC 28V

EMERGINCY STOP BUTTON

9 0602103090

9A 0601810244

11 0602122093

ALARM

BULB, DC 28V

10 0602120095 TACHOMETER

OIL PRESSURE GAUGE

2

2

2

2

1

1

1

1

5

5

1

1

12 0601842450 VOLTAGE 1

13 0602123092 WATER GAUGE 1

14 0602121081 CHARGING

15 0602125091 FUEL

1

1

16 C3483003303

17

18

0017110030

17A 0207010000

0017110030

SET

HEX HEAD BOLT

HEX HEAD BOLT

19 0602123267 WATER UNIT

19A 0602021702

20 0602122272

20A M9200100004

PACKING

OIL PRESSURE UNIT

ADAPTER OIL PRESSURE UNIT

20B 0130200000

20C 8943998582

20D 1096301410

2

3

1

2

1

1

1

1

1

ADAPTER ....................................................1 ................REPLACES P/N 0602020220

PACKING .....................................................1 ................REPLACES P/N 0602021701


CONTROL BOX ASSY.


CONTROL BOX ASSY.


1

2 0601801170 CURRENT 750/5A 3

3 0027106016 MACHINE

4 0601807514 CIRCUIT BREAKER, 1000A

6

1

5 0601820625 AUTOMATIC REGULATOR 1

6 0027105016

7 0601842468

8 0027103010

MACHINE

RESISTOR, 5W 150 OHM

MACHINE

4

1

2

9

11

C3274000003

10 8221852104

0017108030

12 C2277200004

VOLTAGE CHANGE- OVER BOARD

CHANGE

HEX HEAD BOLT

TERMINAL

1

10

20

3

13 8221853104

14

17

18

0801830804

15 0040016000

16 0041416000

0801830704

8201852504

19 0040012000

20 0041412000

CHANGE

HEX HEAD BOLT

WASHER,

WASHER,

HEX HEAD BOLT

HEX HEAD BOLT

WASHER,

WASHER,

13

3

16

16

6

10

10

10

REMARKS

21

22

23

24

0017110030

C3260503003

0017108020

8980956110

25 C3260503104

26 0016906012

HEX HEAD BOLT

ELECTRIC PARTS SET PANEL

4

1

HEX HEAD BOLT 4

CONTROLLER ................................................ 1 ............... REPLACES P/N 0602202684

27 0602103090 DIAGNOSTIC

27A 0601810244

BRACKET

HEX HEAD BOLT

1

4

1

1

28 0601831205

29 0601830710

30

31

0601830746

0016906016

DIAGNOSTIC

DIAGNOSTIC

HIGH IDLE SPEED SWITCH

HEX HEAD BOLT

1

1

1

4

32 0601823240

33 0027105020

34

34A

LY2DUS24VDC

PTF08A

RECTIFIER

MACHINE

1

1

RELAY ............................................................. 4 ............... REPLACES P/N 0601827655

SOCKET .......................................................... 4 ............... REPLACES P/N 0601823109

34B PYCA1

35 0027104020

HOLDER ......................................................... 4 ............... REPLACES P/N 0601824400

MACHINE 8

36 8972177780

37 0027104010

BAROMETRIC PRESSURE SENSOR ........... 1 ............... REPLACES P/N 0602130220

MACHINE 2

38 8980056310

39 0016906016

STARTER RELAY ............................................ 1 ............... REPLACES P/N 0602201401

HEX HEAD BOLT 2

40 8980137900

41 0027105010

RELAY ............................................................. 2 ............... REPLACES P/N 0602202682

MACHINE 2


CONTROL BOX ASSY. (CONTINUED)




REMARKS

42 8944607060

43 0027105010

GLOW PLUG RELAY .......................................1 ............. REPLACES P/N 0602202683

MACHINE 2

44 0601815154

45 0027104016

TERMINAL

MACHINE

1

2

46 8121468300

48-1 0228800115

INLET AIR TEMPERATURE SENSOR ...........1 ............. REPLACES P/N 0603210240

1

RUBBER

1

2

48-2 0228800190 RUBBER

49 0605011211 PIN

50 0601807622 FREQUENCY METER, 45~65Hz 200V

51 0601806987 AC AMMETER, 0~750A 0~1500A

2

2

1

1

52 0601801040

53 0601806887

AMMETER CHANGE- OVER SWITCH

AC 0~600V

1

1

54 0601801041

55 0601810072

VOLTMETER CHANGE- OVER SWITCH 1

PILOT 1

55A 0601810261 BULB,

56 0601840073 RHEOSTAT, VOLT. REG, 2W 1K OHM

57 0601840121 KNOB

1

1

1

58 ECU9988N220V ENGINE CONTROLLER, ................................1 ............. REPLACES P/N 0602202545

59 0601830765

60 0601810161

60A 0601810214

61 0207004000

62 0601830710

63 C9221100004

SWITCH

PANEL

BULB

HEX

PANEL LIGHT SWITCH

HEX HEAD BOLT

63A 0040008000 WASHER,

63B 0041208000 WASHER,

2

2

1

2

1

2

1

1

63C 0080200007 SNAP

64 0017108040

65 3871824004

HEX HEAD BOLT

CONTROL PANEL STOPPER

66 0041206000 WASHER,

67 0605010502 SNAP

68 0601820847

69 0601820848

OVER CURRENT RELAY

OVER CURRENT RELAY

70 0027104016 MACHINE

71 0601802204 FUSE

72 0601806671 FUSE,

73 0601802149 FUSE,

74 0027103020 MACHINE

75 C3358201704

75A 0601806644

75B 0601802410

76 0017106016

FUSE HOLDER ASSY.

FUSE, 30A

FUSE HOLDER BRACKET

HEX HEAD BOLT

77 0601815153 TERMINAL

1

1

1

1

1

2

2

2

1

1

1

2

4

1

1

1

2






78 0027104020 MACHINE

79 8221814804

80 0017108020

81 8224117004

CONTROL BOX COVER

HEX HEAD BOLT

CONTROL BOX SIDE PANEL

82 0017108020

83 C3213400604

84 0017108020

85 0017110035

HEX HEAD BOLT

CONTROL BOX PANEL

HEX HEAD BOLT

HEX HEAD BOLT

85A 0207010000 HEX

86 0601806640 FUSE,

QTY.

8

1

2

1

8

4

4

1

4

1

REMARKS


ENGINE AND RADIATOR ASSY.


ENGINE AND RADIATOR ASSY.


REMARKS

1 C3923200194 ENGINE, ISUZU 6WG1X

1-1 1132402330

1

MAIN OIL FILTER CARTRIDGE ..........................1 ...........REPLACES P/N 0602041219

1-2 1132402410

1-3 8980088400

BYPASS OIL FILTER CARTRIDGE .....................1 ...........REPLACES P/N 0602041220

MAIN FUEL FILTER ELEMENT ...........................2 ...........REPLACES P/N 0602042515

3

8

0010314040

0010316040

HEX HEAD BOLT

HEX HEAD BOLT 8

8

1

1

8

8

2

8

15 C3923200174

15-1 0602011059

17

23

24

0010116065

0017112025

0017112025

RADIATOR & INTER COOLER ASSY.

CAP

HEX HEAD BOLT

HEX HEAD BOLT

HEX HEAD BOLT

4

2

1

1

6

6

6

12

8

8

8

4

8

1

2

1

27

33

34

37

40A

40B

0016910025

0602123290

C3310500203

C3310500303

0602046628

0602046629

HEX HEAD BOLT

COOLANT LEVEL SWITCH

INTER COOLER HOSE

INTER COOLER HOSE

AIR CLEANER OUTER ELEMENT

AIR CLEANER INNER ELEMENT

1

1

16

1

1

1

2

14

1

1

1

1

1

1

1

1

1

1


ENGINE AND RADIATOR ASSY. (CONTINUED)


ENGINE AND RADIATOR ASSY. (CONTINUED)


41 0602040779

42 0602040582

45 0016910025

PART NAME

AIR CLEANER CAP

AIR CLEANER BAND

43 C3373200004 AIR CLEANER BRACKET


44A 0207010000 HEX

HEX HEAD BOLT

46 C3373000003 AIR CLEANER PIPE

47 0602040393 90 DEGREE ELBOW

49 0602040666 AIR CLEANER INDICATOR

50 C3373200104 AIR CLEANER PIPE BRACKET


1

4

4

1

4

4

1

2

QTY.

1

4

1

2

REMARKS

53 0602022560 ADAPTER

54 M1320300304 PACKING

55 0602022561 90 DEGREE ELBOW

56 0603306590 CONNECTOR

57 0603300285 ROCKNUT

58 0605511395 VALVE

60 0602021070 CAP

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1


66 0602022929 JOINT

67 0199900800 HOSE

68 0199900300 HOSE

69 0199901600 HOSE

70 0193602000 HOSE

72 0193601300 HOSE

73 0193600550 HOSE

74 0269502100 HOSE

77

79

81

8972177780

8980305320

1136714740

1

1

1

6

1

1

1

2

TEMPERATURE 1

OIL PRESSURE SENSOR 1

1

BLOWBY FILTER ELEMENT .........................1 ..................REPLACES P/N 0602044210

1

FAN BELT .......................................................3 ..................REPLACES P/N 0602015252

1


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.



1 C2231700403

PART NAME

OUTPUT TERMINAL SET BOARD



9 0601808803

10 0601808804

CIRCUIT BREAKER, 20A

CIRCUIT BREAKER, 50A

11 C3261600704 CIRCUIT BREAKER BREAKER

11-1 0221200150 RUBBER


14 0601812565 RECEPTACLE, CS-6369

15A 0207004000 HEX

16 C2234500104 COVER


20 0601850275 GROMMET

21 0601851780 GROMMET


27 0845043704 SPRING

28 C2237101204 COVER



32 0845054204 COLLAR

34 C2237101504 COVER

35 C2237400104 BRACKET


OUTPUT TERMINAL ASSY.

2

1

7

1

2

1

2

2

1

2

1

1

3

10

10

1

1

1

2

2

2

4

2

1

8

1

2

1

5

5

2

3

24

32

3

5

QTY.

REMARKS

1

8

8

16


BATTERY ASSY.



1 0165721052 BATTERY

2 C9109100704 BATTERY

3 0805007804 BATTERY

4 0805006504 BATTERY

5 0037808000 WING

6 0040008000 WASHER,

7 0041608000 WASHER,

8 C3346601804 BATTERY

9 C3346601904 BATTERY

10 C3346602004 BATTERY

11 C3346602104 BATTERY

12 C3346200004 EARTH

HEX HEAD BOLT 13 0347010030

14 0208110000

15 0845040114

16 0845041004

17 0017114025

18 0040514000

19 0017110025

20 0040510000

21 0017112025

22 0040512000

TERMINAL CAP (+)

TERMINAL CAP (-)

HEX HEAD BOLT

HEX HEAD BOLT

HEX HEAD BOLT

1

1

1

1

4

1

4

4

QTY.

2

4

2

2

1

1

1

1

1

1

2

2

4

4

BATTERY ASSY.

REMARKS


MUFFLER ASSY.



1 C3330100402 MUFFLER


2A 0042310000

2B 0047010030

3 C3333001903 EXHAUST

4 C9304000304 GASKET

5 C3334200804 GASKET


6A 0030316000

6B 0042516000

6C 0041616000


7A 0030016000

7B 0042516000

7C 0041616000

8 C3333302104 BRACKET

9 0017108020

10 0602326065

HEX HEAD BOLT

11 C3331300404 COVER


8

8

16

4

1

8

1

1

QTY.

4

4

1

4

8

1

4

4

2

4

4

1

MUFFLER ASSY.

REMARKS


FUEL TANK ASSY. (S/N 3813334 AND BELOW)


FUEL TANK ASSY. (S/N 3813334 AND BELOW)


1 C3363002503 FUEL

1-1 0845500104

1-2 0810105400

1-3 0264100525 FUEL GAUGE HOSE

2

1

1

1

2

4

1

5

QTY.

REMARKS

1

1

1

1

1-4 0605515079

2 0605503020 FUEL

3 0802120604 PACKING

4 0605501089 FUEL

5 0605516090 PACKING

6 0022905015 MACHINE

7 8225523104 TANK

8 0805003414 TANK BAND PAD

9 0016908020

10 0207308000

11 0222100300

12 0130206000

HEX HEAD BOLT

SUPER LOCK NUT

STREET ELBOW, 1/2”

13 0134306170

14 0603325026 VALVE

15 0132006000

16 C1367700304 LOCK

2

2

6

1

1

1

1

1

17 0019208020

18 0845039604

HEX HEAD BOLT

19 C3366704704 BRACKET


21 8980758550

21A 8980758540

22 8980955010

23 1096750951

2

1

1

3

PRIMARY FUEL FILTER ASSY. .................2...........REPLACES P/N 0602042405

PRIMARY FUEL FILTER ELEMENT ..........2...........REPLACES P/N 0602042516

JOINT PIPE ................................................4...........REPLACES P/N 0602042662

JOINT BOLT ...............................................4...........REPLACES P/N 0602042621

24 1096301110

25 0017110040

26 0010110075

26A 0040010000

26B 0041210000

27 0130406000

28 0130206000

29 0602022209

30 0191402500

31 0191400600

32 0191400500

33 0191402800

34 0191405300

35 0605515132

PACKING ....................................................8...........REPLACES P/N 0602021702

HEX HEAD BOLT 4

HEX HEAD BOLT


2

2

2

1

1

2

2

2

4

6

1

14


FUEL TANK ASSY. (S/N 3813335 AND ABOVE)


FUEL TANK ASSY. (S/N 3813335 AND ABOVE)


1 C3363002503 FUEL

1-1 0845500104

1-2 0810105400

1-3 0264100525 FUEL GAUGE HOSE

2

1

1

1

2

4

1

5

QTY.

REMARKS

1

1

1

1

1-4 0605515079

2 0605503020 FUEL

3 0802120604 PACKING

4 0605501089 FUEL

5 0605516090 PACKING

6 0022905015 MACHINE

7 8225523104 TANK

8 0805003414 TANK BAND PAD

9 0016908020

10 0207308000

11 0222100300

12 0130206000

HEX HEAD BOLT

SUPER LOCK NUT


13 0134306170

14 0603325026 VALVE

15 0132006000

16 C1367700304 LOCK

2

2

6

1

1

1

1

1

17 0019208020

18 0845039604

HEX HEAD BOLT

19 C3366704704 BRACKET


21 8980758550

21A 8980758540

22 8980955010

23 1096750951

2

1

1

3

PRIMARY FUEL FILTER ASSY. .................2...........REPLACES P/N 0602042405

PRIMARY FUEL FILTER ELEMENT ..........2...........REPLACES P/N 0602042516

JOINT PIPE ................................................4...........REPLACES P/N 0602042662

JOINT BOLT ...............................................4...........REPLACES P/N 0602042621

24 1096301110

25 0017110040

26 0010110075

26A 0040010000

26B 0041210000

27 0130406000

28 0130206000

29 0602022209

30 0191402500

31 0191400600

32 0191400500

33 0191402800

34 0191405300

35 0605515132

36 C3366704804

37 0019208020

38 0131506000

39 0130206000

PAACKING .................................................8...........REPLACES P/N 0602021702

HEX HEAD BOLT 4

HEX HEAD BOLT


2

2

2

1

1

2

2

2

4

6

1

14

BRACKET ..................................................1...........S/N 3813335 AND ABOVE

HEX HEAD BOLT .......................................2...........S/N 3813335 AND ABOVE

NIPPLE 1/2” ...............................................2...........S/N 3813335 AND ABOVE

STREET ELBOW 1/2” ................................2...........S/N 3813335 AND ABOVE


ENCLOSURE #1 ASSY.



MQW-WHITE




1 C3413003502 BASE

2 C3414100104 FLOOR

3 C3413100304 FLOOR

4 C3414100804 FLOOR


6 C3413600004 BASE

6A 0228901070


8 C2367700404 COVER


10 C3424001204

10A C3493100703 LINING

11 C3423001003

11A C3493100703

12 C3423001102

12A C3493100703

LINING

LINING

13 C3423001202

13A C3493100703

14

15

0019208020

C3423300003

15A C3492100703

16 C3424301103

16A C3493100703

17 0019208020

18

19

0019210025

C3424201403

20 C3424203104

20A C3494102604

21 0845042703

22 0019208020

23

24

0019208020

C3423201103

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

HEX HEAD BOLT

HEX HEAD BOLT

FRONT FRAME COVER


26 C3433000202

27 0010120060

27A 0030020000

27B 0040020000

27C 0041620000

28 0010120050

28A 0030020000

28C 0041620000

29 C3463101402

29A C3493500203

30 M3310600004

31 0019204020

32 0019208020

33 C3463500204

34

35

0019208020

0019210025

36 0019116025

36A 0042416000

HEX HEAD BOLT

HEX HEAD BOLT

LINING

COVER

HEX HEAD BOLT

HEX HEAD BOLT

GUTTER

HEX HEAD BOLT

HEX HEAD BOLT

HEX HEAD BOLT


QTY.

1

1

4

28

1

8

1

1

1

1

1

1

24

1

1

20

1

1

1

1

1

1

2

1

1

38

1

1

4

1

1

2

4

8

8

8

16

14

1

4

4

20

2

2

4

1

1

1

1

1

4


REMARKS




MQW-WHITE




1 C3443000403 REAR

1A 0228901290

2 C3443000502 REAR

2A 8225940104

3 0017108020

4

5

0019210025

C3443302103

LINING

HEX HEAD BOLT

HEX HEAD BOLT

REAR FRAME COVER

5A C3493300004 LINING

6 C3444302504 DUCT

6A C3491400004

7

8

9

0017108020

0019208020

C3443201303

10 C3443201403

11 8225147004

12 0207306000

13 0600800320

LINING

HEX HEAD BOLT

HEX HEAD BOLT

REAR DOOR FRAME

REAR DOOR FRAME

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

STAY

HINGE

WASHER

HINGE

WASHER

HEX HEAD BOLT

STOPPER 27 0601850097

28 0025408025

29 0845031504

30 C3463201202

30A C3493500304

31 C3464501704

31A C3494502204

32 0017108020

33 0019208020

34 C3463500304

35

36

0092108020

0019210025

CAP

LINING

ROOF PANEL COVER

LINING

HEX HEAD BOLT

HEX HEAD BOLT

GUTTER

HEX HEAD BOLT

HEX HEAD BOLT

1

1

1

15

4

1

2

2

20

2

2

4

2

6

2

2

4

2

1

1

4

8

1

1

4

4

4

1

QTY.

1

1

2

12

1

12

15

1

1

1

4

1

1

1

1

11


REMARKS





MQW-WHITE




1 C3453200702 SPLASHER

1A C3493402104

2 0019108065

2A 0042308000

2B 0042408000

LINING

HEX HEAD BOLT

3 C3453100503 SIDE

3A C3493401004 LINING

4 C3453100603 SIDE

4A C3493401104 LINING

5 0019108065

5A 0042308000

HEX HEAD BOLT

5B 0042408000

6 C3453100703 SIDE

6A C3493401204 LINING

7 C3453100803 SIDE

7A C3493401304 LINING

8 C3453300504 DUCT

8A C3493401803 LINING

9 C3453300604 DUCT

9A C3493401903

10 C3453300704

10A C3493402003

11 0207006000

LINING

DUCT

LINING

12 C3453000903

12A C3493400604

13 C3453001003

13A C3493400704

14 C3453001103

14A C3493400804

15 C3453005203

15A C3493400904

16 C3453300304

16A C3493401603

17 C3453300804

17A C3493402203

18 C3453300404

18A C3493401704

19 C3453500004

19A C3493401704

20 0019208016

21 0207006000

22 B9114000002

23 0825007362

24 0021806015

24A 0030006000

LINING

LINING

LINING

LINING

DUCT

LINING

DUCT

LINING

DUCT

LINING

PANEL

LINING

HEX HEAD BOLT

QTY.

1

1

1

1

1

1

1

1

1

1

21

1

1

1

1

1

1

1

1

1

1

10

10

10

1

1

1

1

1

6

6

1

6

1

1

4

10

1

1

1

1

4

3

28

28


REMARKS


ENCLOSURE #3 ASSY. (CONTINUED)



MQW-WHITE




25 0845046904

25A 0845045004

26 0845047005

26A 0845045004

27 0019208020

28 0601850097

29 0025408025

30 0845031504

31 0019108065

31A 042308000

31B 0042408000

ENCLOSURE #3 ASSY. (CONTINUED)

REMARKS

PART NAME

HINGE

WASHER

HINGE

WASHER

HEX HEAD BOLT

STOPPER

CAP

HEX HEAD BOLT

QTY.

8

11

11

16

4

8

8

8

37

4

4


RUBBER SEALS ASSY.



1 0229201400

2 0228901320

3 0228901450

4 0228900850

5 0228901350

6 0228801390

7 0228901390

8 0228900790

9 0229201340

10 0221200795

11 0228801250

12 0229200560

13 0229201230

14 0228100120

15 0228100510


4

2

1

2

2

4

4

1

1

2

3

2

4

4

4

RUBBER SEALS ASSY.

REMARKS


NAMEPLATE AND DECALS ASSY.



1-1 C3550000703

1-2 C9522100003

NAMEPLATE AND DECALS ASSY.


REMARKS

DECAL : HANDLING PROCEDURES ......................... 1 ................. C35000070

DECAL : CAUTION ...................................................... 2 ................. C92210000

2-1 0800520100

2-2 0800520904

2-3 0800520814

2-4 0840624504

2-5 0840624604

2-6 0840624704

2-7 0840624804

2-8 B9531100604

2-9 C0551000903

2-10 C2551000004

2-11 C3551001004

2-12 C3560100003

2-13 C9500402104

2-14 C9520027704

2-15 C9521007504

CONTROL BOX GROUP

PLATE : ON - OFF ........................................................ 1 ................. AT- 202

PLATE : AMMETER CHANGE- OVER SWITCH .......... 1 ................. N-2438

PLATE : VOLTMETER CHANGE- OVER SWITCH ....... 1 ................. N-2439

DECAL : CIRCUIT BREAKER ...................................... 1 ................. S-3031

DECAL : PANEL LIGHT SWITCH ................................ 1 ................. S-3032

DECAL : PILOT LAMP ................................................. 1 ................. S-3033

DECAL : VOLTAGE REGULATOR ................................ 1 ................. S-3034

DECAL : WARNING ELECTRIC SHOCK HAZARD ..... 2 ................. B93110060

DECAL : SETTING FOR OUTPUT VOLTAGE .............. 1 ................. C05100090

DECAL : SAFETY INSTRUCTIONS............................. 1 ................. C25100000

DECAL : DIAGNOSTIC LAMP ..................................... 1 ................. C35100100

DECAL : WHISPERWATT 400 ..................................... 1 ................. C36010000

DECAL : HIGH IDLE SPEED ....................................... 1 ................. C90040210

DECAL : DIAGNOSTIC BUTTON ................................ 1 ................. C92002770

DECAL : DIAGNOSTIC SWITCH ................................. 1 ................. C92100750

3-1 1320610603

ENGINE & RADIATOR GROUP

DECAL : WATER- OIL .................................................. 1 ................. S-1760

3-2 6360610304 WATER

3-3 6360620204 DECAL : OIL DRAIN PLUG.......................................... 1 ................. S-1885

3-4 B9504000304

3-5 B9504000404

3-6 B9504100104

3-7 C3550000603

DECAL : CAUTION HOT PARTS .................................. 1 ................. B90400030

DECAL : WARNING MOVING PARTS .......................... 2 ................. B90400040

DECAL : WARNING HOT COOLANT........................... 1 ................. B90410010

DECAL : AIR BLEEDING PROCEDURE ..................... 1 ................. C35000060

4-1 C0551000504

4-2 C3550000404

4-3 C3550000503

5-1 0840614104

5-2 0840619904

5-3 9039209064

5-4 B9511100304

5-5 B9511100404

5-6 B9531100504

5-7 C0551000404

5-8 C1551000803

ENGINE OPERATING PANEL GROUP

DECAL : BATTERY SWITCH ....................................... 1 ................. C05100050

DECAL : ALARM LAMP ............................................... 1 ................. C35000040

DECAL : OPERATING PANEL ..................................... 1 ................. C35000050

OUTPUT TERMINAL GROUP

DECAL : GROUND ...................................................... 1 ................. S-2635

DECAL : DANGER HIGH VOLTAGE ............................. 1 ................. S-2731

DECAL : START CONTACT ......................................... 1 ................. S-4468

DECAL : WARNING .................................................... 1 ................. B91110030



DECAL : 3- PHASE OUTPUT TERMINAL ................... 1 ................. C05100040

DECAL : RECEPTACLE & CIRCUIT BREAKER .......... 1 ................. C15100080


NAMEPLATE AND DECALS ASSY. (CONTINUED)



6-1 0800689404

6-2 0800689504

6-3 C9505300004

NAMEPLATE AND DECALS ASSY. (CONTINUED)


REMARKS

DECAL : + ............................................................... 1 ...................... S-2090

DECAL : - ................................................................ 1 ...................... S-2091

DECAL : CAUTION ................................................. 1 ...................... C90530000

7-1 A9504000014

7-2 B9504200004

DECAL : DANGER .................................................. 1 ...................... A90400001

DECAL : WARNING ENGINE EXHAUST ................ 1 ...................... B90420000

8-1 1320620904

8-2 6360620004

8-3 B9504500004

DECAL : DIESEL FUEL .......................................... 1 ...................... S-1756

DECAL : FUEL DRAIN PLUG ................................. 1 ...................... S-1883

DECAL : WARNING DIESEL FUEL ........................ 1 ...................... B9045 000

9-1

9-2

1320621504

0840625902

DECAL : SUPPORT HOOK .................................... 1 ...................... S-2257

DECAL : MQ............................................................ 1 ...................... S-3057

9-3 0600500090 EMBLEM

9-3A 0021106016 MACHINE SCREW

2

4

9-4 C2561101204 STRIPE

9-5 C3561100203 STRIPE

9-6 C4561102204 STRIPE

9-7 C3561101603 STRIPE

2

1

2

1

9-8 C3561100803 STRIPE

9-9 C3561101703 STRIPE

9-10 C3561101003 STRIPE

9-11 C5561100204 STRIPE

9-12 C9504000304

1

1

1

2

DECAL : CAUTION ................................................. 1 ...................... C90400030


TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 30 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice.

All shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1.

A Returned Material Authorization must be approved by Multiquip prior to shipment.

2.

To obtain a Return Material Authorization, a list must be provided to Multiquip Parts

Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions must match the current parts price list.

b. The list must be typed or computer generated.

c. The list must state the reason(s) for the return.

d. The list must reference the sales order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and phone number of the person requesting the RMA.

3.

A copy of the Return Material Authorization must accompany the return shipment.

4.

Freight is at the sender’s expense. All parts must be returned freight prepaid to

Multiquip’s designated receiving point.

5.

Parts must be in new and resalable condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

6.

The following items are not returnable: a. Obsolete parts. (If an item is in the price book and shows as being replaced by another item, it is obsolete.) b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer net price of less than $5.00.

d. Special order items.

e. Electrical components.

f.

Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7.

The sender will be notified of any material received that is not acceptable.

8.

Such material will be held for five working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

9.

Credit on returned parts will be issued at dealer net price at time of the original purchase, less a 15% restocking charge.

10. In cases where an item is accepted, for which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

11. Credit issued will be applied to future purchases only.

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

Multiquip reserves the right to quote and sell direct to Government agencies, and to Original

Equipment Manufacturer accounts who use our products as integral parts of their own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of profit or good will or for any other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. Apart from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof.

Effective: February 22, 2006


NOTES


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

Lewisville, TX 75057

Fax (972) 315-1847

Contact: [email protected]

Web: www.mqpower.com

MQ Parts Department

Service/Tech Support/Warranty

© 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 specifi cations 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 specifi cations, design or the information published in this publication at any time without notice and without incurring any obligations.

Your Local Dealer is:

Manufactured for

Multiquip Inc.

by

DENYO CO., LTD, JAPAN

Multiquip DCA400SSI Portable Generator Operation And Parts Manual

OPERATION AND PARTS MANUAL

WHISPERWATT™ SERIES

60HZ GENERATOR

(ISUZU 6WG1X DIESEL ENGINE)

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

REPORTING SAFETY DEFECTS

TABLE OF CONTENTS

Component Drawings

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

Order Parts

When ordering parts, please supply:

SAFETY MESSAGES

SAFETY INFORMATION

GENERAL SAFETY

SAFETY INFORMATION

GENERATOR SAFETY

ENGINE SAFETY

SAFETY INFORMATION

FUEL SAFETY

TOWING SAFETY

SAFETY INFORMATION

ELECTRICAL SAFETY

Power Cord/Cable Safety

SAFETY INFORMATION

Grounding Safety

BATTERY SAFETY

SAFETY INFORMATION

ENVIRONMENTAL SAFETY

SPECIFICATIONS

DIMENSIONS

INSTALLATION

OUTDOOR INSTALLATION

INDOOR INSTALLATION

MOUNTING

INSTALLATION

GENERATOR GROUNDING

GENERATOR

ENGINE OPERATING PANEL

GENERATOR CONTROL PANEL

OUTPUT TERMINAL PANEL

GENERAL INFORMATION

OPEN DELTA EXCITATION SYSTEM

ENGINE

ELECTRIC GOVERNOR SYSTEM

EXTENSION CABLES

MAJOR COMPONENTS

GENERATOR CONTROL PANEL

GENERATOR CONTROL PANEL

ENGINE OPERATING PANEL

NOTES

OUTPUT TERMINAL PANEL FAMILIARIZATION

OUTPUT TERMINAL PANEL

OUTPUT TERMINAL FAMILIARIZATION

OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

Twist Lock Dual Voltage 120/240 VAC Receptacles

OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Over Current Relay

SINGLE PHASE LOAD

LOAD APPLICATION

THREE PHASE LOAD

GENERATOR OUTPUT VOLTAGES

Voltage Change-Over Board

GENERATOR OUTPUTS

Generator Amperage

GENERATOR OUTPUTS/GAUGE READING

Maximum Amps

HOW TO READ THE OUTPUT TERMINAL GAUGE

OUTPUT TERMINAL PANEL CONNECTIONS

UVWO TERMINAL OUTPUT VOLTAGES

3Ø-240V UVWO Terminal Output Voltages

1Ø-240V UVWO Terminal Output Voltages

1Ø-120V UVWO Terminal Output Voltages

OUTPUT TERMINAL PANEL CONNECTIONS