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Multiquip DCA400SSI manual Operation And Parts Manual, PARTS LIST NO. C3871301004, 60HZ GENERATOR

Models: DCA400SSI

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OPERATION AND PARTS MANUAL

WHISPERWATT™ SERIES

MODEL DCA400SSI

60HZ GENERATOR

(ISUZU 6WG1X DIESEL ENGINE)

PARTS LIST NO. C3871301004

Revision #2 (11/03/08)

To ﬁnd the latest revision of this publication, visit our website at: www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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Multiquip manual Operation And Parts Manual, PARTS LIST NO. C3871301004, MODEL DCA400SSI, Whisperwatt Series

Contents

OPERATION AND PARTS MANUAL PARTS LIST NO. C3871301004MODEL DCA400SSI WHISPERWATT SERIESDiesel engine exhaust and some of PROPOSITION 65 WARNINGREPORTING SAFETY DEFECTS DCA400SSI GENERATOR TABLE OF CONTENTSComponent Drawings 6-11When ordering parts, please supply PARTS ORDERING PROCEDURESView Parts Diagrams Order Parts Print Specification InformationSAFETY MESSAGES SAFETY INFORMATIONSAFETY SYMBOLS DANGERGENERATOR SAFETY GENERAL SAFETYﬁre extinguisher ﬁrst aid kitSAFETY INFORMATION ENGINE SAFETYNOTICE TOWING SAFETY FUEL SAFETYSAFETY INFORMATION DANGERGrounding Safety ELECTRICAL SAFETYPower Cord/Cable Safety SAFETY INFORMATIONENVIRONMENTAL SAFETY BATTERY SAFETYSAFETY INFORMATION DANGERTable 1. Generator Speciﬁcations SPECIFICATIONSModel DCA400SSITable 3. Dimensions DIMENSIONSFigure 1. Dimensions ReferenceFigure 2. Typical Generator Grounding Application INSTALLATIONINDOOR INSTALLATION OUTDOOR INSTALLATIONMOUNTING GENERATOR GROUNDINGGENERATOR GENERAL INFORMATIONENGINE OPERATING PANEL GENERATOR CONTROL PANELTable 4. Generator Major Components MAJOR COMPONENTSITEM NO 11.Auto On/Off Engine Controller MPEC — GENERATOR CONTROL PANELOver-CurrentRelay Voltage Rectiﬁ er AVR GENERATOR CONTROL PANELNOTICE ENGINE OPERATING PANEL e.Coolant Level Alarm — This lampNOTES OUTPUT TERMINAL FAMILIARIZATION OUTPUT TERMINAL PANEL FAMILIARIZATIONOUTPUT TERMINAL PANEL NOTICEOUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI ReceptaclesFigure 7. G.F.C.I. Receptacle Twist Lock Dual Voltage 120/240 VAC ReceptaclesOver Current Relay Connecting LoadsFigure 10. Connecting Loads OUTPUT TERMINAL PANEL FAMILIARIZATIONTHREE PHASE LOAD SINGLE PHASE LOADTable 5. Power Factor By Load LOAD APPLICATIONGENERATOR OUTPUT VOLTAGES GENERATOR OUTPUTSVoltage Change-OverBoard Generator AmperageMaximum Amps GENERATOR OUTPUTS/GAUGE READINGTable 10. Generator Maximum Amps HOW TO READ THE OUTPUT TERMINAL GAUGEUVWO TERMINAL OUTPUT VOLTAGES OUTPUT TERMINAL PANEL CONNECTIONS3Ø-240VUVWO Terminal Output Voltages 1Ø-240VUVWO Terminal Output Voltages1Ø-480VUVWO Terminal Output Voltages 3Ø-480VUVWO Terminal Output Voltages1Ø-277VUVWO Terminal Output Voltages OUTPUT TERMINAL PANEL CONNECTIONSCIRCUIT BREAKERS INSPECTION/SETUPLUBRICATION OIL FUEL CHECKONLY use #2 diesel fuel when refueling Refueling ProcedureINSPECTION/SETUP NOTICEAIR CLEANER Cleaning the RadiatorCOOLANT ANTIFREEZE/SUMMER COOLANT/ WATER Operation in Freezing WeatherBattery Cable Installation BATTERYWIRING ALTERNATORBEFORE STARTING GENERATOR START-UPPROCEDURE MANUALSTARTING MANUAL Figure 42. Frequency Meter GENERATOR START-UPPROCEDURE MANUALSTARTING AUTO MODE GENERATOR START-UPPROCEDURE AUTO MODEDANGER NOTICENORMAL SHUTDOWN PROCEDURE GENERATOR SHUT-DOWNPROCEDURESEMERGENCY SHUTDOWN PROCEDURE Air Cleaner with Dust Indicator MAINTENANCEGENERAL INSPECTION AIR CLEANERFUEL ADDITION Cleaning Inside the Fuel TankRemoving Water from the Fuel Tank FUEL TANK INSPECTIONCHECK OIL LEVEL RADIATOR CLEANINGReplacing Oil Filter FLUSHING OUT RADIATOR AND REPLACING COOLANTNOTICE MAINTENANCEcharger TRAILER MAINTENANCE TRAILER MAINTENANCEBRAKES Brake AdjustmentHydraulic Surge Brakes ActuatorTire Wear/Inﬂation TIRES/WHEELS/LUG NUTSSuspension TRAILER MAINTENANCETRAILER MAINTENANCE Lug Nut Torque RequirementsNOTICE Figure 63. Trailer/Towing Vehicle Wiring Diagram TRAILER WIRING DIAGRAMFigure 64. Generator Wiring Diagram GENERATOR WIRING DIAGRAMFigure 65. Engine Wiring Diagram ENGINE WIRING DIAGRAMFigure 66. Controller Wiring Diagram CONTROLLER WIRING DIAGRAMTable 19. Generator Troubleshooting TROUBLESHOOTING GENERATORSymptom Possible ProblemTable 20. Engine Controller Troubleshooting MPEC TROUBLESHOOTING ENGINE CONTROLLERMETHOD OF OPERATION TROUBLESHOOTING DIAGNOSTIC LAMPNOTICE NOTICENOTES NO. Column EXPLANATION OF CODE IN REMARKS COLUMNPART NO. Column QTY. ColumnDCA400SSI WHISPERWATT GENERATOR WITH SUGGESTED SPARE PARTSISUZU 6WG1X DIESEL ENGINE 1 to 3 units NOTICE5A 5 1-4B 1-4A GENERATOR ASSY6-6 6-6A 9B 9A 9PART NAME PART NOREMARKS GENERATOR ASSYGENERATOR ASSY. CONTINUED PART NAME GENERATOR ASSY. CONTINUED0010106060 ENGINE OPERATING PANEL ASSY PART NO ENGINE OPERATING PANEL ASSYPART NAME REMARKSCONTROL BOX ASSY PART NO CONTROL BOX ASSYPART NAME REMARKSCONTROL BOX ASSY. CONTINUED PART NO CONTROL BOX ASSY. CONTINUEDPART NAME REMARKSCONTROL BOX ASSY. CONTINUED PART NO CONTROL BOX ASSY. CONTINUEDPART NAME 0027104020ENGINE AND RADIATOR ASSY PART NO ENGINE AND RADIATOR ASSYPART NAME REMARKSENGINE AND RADIATOR ASSY. CONTINUED PART NO ENGINE AND RADIATOR ASSY. CONTINUEDPART NAME REMARKSFOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT OUTPUT TERMINAL ASSYMQW-WHITE THE SERIAL NUMBER MAY BE REQUIRED PART NO OUTPUT TERMINAL ASSYPART NAME C2231700403BATTERY ASSY PART NO BATTERY ASSYPART NAME REMARKSMUFFLER ASSY PART NO MUFFLER ASSYPART NAME REMARKSFUEL TANK ASSY. S/N 3813334 AND BELOW PART NO FUEL TANK ASSY. S/N 3813334 AND BELOWPART NAME REMARKSFUEL TANK ASSY. S/N 3813335 AND ABOVE PART NO FUEL TANK ASSY. S/N 3813335 AND ABOVEPART NAME REMARKSENCLOSURE #1 ASSY PART NO ENCLOSURE #1 ASSYPART NAME REMARKSENCLOSURE #2 ASSY PART NO ENCLOSURE #2 ASSYPART NAME REMARKSENCLOSURE #3 ASSY PART NO ENCLOSURE #3 ASSYPART NAME REMARKSENCLOSURE #3 ASSY. CONTINUED PART NO ENCLOSURE #3 ASSY. CONTINUEDPART NAME 0845046904RUBBER SEALS ASSY PART NO RUBBER SEALS ASSYPART NAME REMARKSNAMEPLATE AND DECALS ASSY ENGINE & RADIATOR GROUP CONTROL BOX GROUPENGINE OPERATING PANEL GROUP OUTPUT TERMINAL GROUPNAMEPLATE AND DECALS ASSY. CONTINUED NAMEPLATE AND DECALS ASSY. CONTINUED BATTERY GROUPPART NO PART NAMESPECIAL EXPEDITING SERVICE TERMS AND CONDITIONS OF SALE — PARTSPAYMENT TERMS FREIGHT POLICYNOTES NUMBER ON-HANDWHEN CALLING HERE’S HOW TO GET HELPMQ Power Contact: mqpower@multiquip.com