Operation and parts Manual
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES
EE55916
3-Position Switch/Paralleling 1400 amp Studio Generator
proposition 65 warning
Diesel engine exhaust and some of
Reporting Safety Defects
Administrator NHTSA 1200 New Jersey Avenue S.E Washington, DC
You can also obtain information about motor vehicle safety from
Table of Contents
Component Drawings
SG1400C3 Studio Generator
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Safety Information
SaFeTY meSSageS
SaFeTY SYmBolS
danger
general SaFeTY
generaTor SaFeTY
Safety Information
never lubricate components or attempt service on a running machine
engine SaFeTY
Safety Information
danger
Fuel SaFeTY
ToWing SaFeTY
Safety Information
danger
eleCTriCal SaFeTY
grounding Safety
power Cord/Cable Safety
death
BaTTerY SaFeTY
environmenTal SaFeTY
Safety Information
Use well-insulated gloves when picking up the battery
Specifications
Model
Cummins QSB7-G5
Table 3. Battery Specifications
dimensions
Table 4. Dimensions
L K M
E F G H I J
installation
BE INSTALLED BY USER
Figure 2. Typical Generator Grounding Application
GENERATOR GROUND LUG
Outdoor Installation
Indoor Installation
Generator Grounding
installation
Battery
general information
Generator
Engine
Fuel Tank
Fuel Priming Pump
Fuel Water Separator
Intake Ventilation Door
InteliVision 5 Digital Controller
general information
Page
Generator MAJOR COMPONENTS
Figure 3. Major Components
generator MAJOR COMPONENTS
Figure 3. Major Components
Table 5. Generator Major Components
DESCRIPTION
BASIC ENGINE COMPONENTS
Table 6. Basic Engine Components
DESCRIPTION
BASIC TRAILER COMPONENTS
control panel
camlok/voltage output panel
Figure 7. Camlok/Voltage Output Panel
circuit Breaker panel
Figure 8. Main Breaker Panel
digital controller
NAVIGATIONS BUTTONS
CONTEXT BUTTONS
CONTROL BUTTONS
Single Phase Load
Three Phase Load
Table 7. Power Factor By Load
load application/generator output
Voltage Selector Switch
GENERATOR OUTPUTS
Generator Output Voltages
Generator Amperage
inspection/setup
Refueling Procedure
MAIN CIRCUIT BREAKER
Lubrication Oil
when heated
ONLY use #2 diesel fuel when refueling
Source Heat
inspection/setup
Cleaning the Radiator
Air Cleaner
Coolant Antifreeze/summer coolant
Operation in Freezing Weather
Battery Cable Installation
Wiring
Alternator
Piping and Hose Connection
ALWAYS have adequate ventilation when operating
Before Starting
ON UP
LIGHTS IF SELECTED
startup
Starting Manual
Normal Shutdown Procedure
emergency Shutdown Procedure
CLOSING THE ENCLOSURE DOORs
startup
protective devices
protective devices
maintenance
Table 14. Engine Maintenance Schedule
Air Filter Dust Indicator
Cleaning Inside the Fuel Tank
General Inspection
Air FILTER
Fuel Tank Inspection
Replacing Fuel Filter
Air Removal
Check Oil Level
Manually Adjusting the Brakes
Trailer Brakes
hydraulic Brakes
Hydraulic Brake Actuator
Adjustable Channel
Wheel Bearings
maintenance
Figure 37. Adjustable Channel
Wheel Hub Adjustment
Leaf Suspension
maintenance
DANGER
troubleshooting generator
Troubleshooting Generator
Symptom
Possible Problem
troubleshooting engine
Troubleshooting Engine
troubleshooting controller
Troubleshooting Intelivision 5 Controller
Symptom
Possible Problem
trailer guidelines
Common CauSeS For loSS oF Trailer
Trailer ToWing guidelineS
driving CondiTionS
Coupling To THe ToW veHiCle
trailer guidelines
inoperaBle BraKeS, ligHTS or mirrorS
Trailer ToWing TipS
Trailer vin Tag
trailer guidelines
eleCTriCal ConneCTor
ToW veHiCle
SuSpenSion SYSTem
BraKe ConTroller
SaFeTY CHainS
Trailer ligHTing and BraKing ConneCTor
emergenCY FlareS andTriangle reFleCTorS
BreaKaWaY SYSTem
Coupling the Trailer to the Tow vehicle Ball Coupler
trailer guidelines
attaching Safety Chain
Breakaway Brake System
Breakaway Cable Surge Brake System
Hydraulic Actuator
Connecting Trailer lights
uncoupling the Ball Hitch
pinTle HiTCH Coupler
pintle Coupler and pintle Hook
Coupling Trailer to Tow vehicle pintle Coupler
Figure H. Attaching Safety Chain Pintle Hitch
trailer guidelines
Tire SaFeTY unsafe Tires, lug nuts or Wheels
determining load limit of Trailer
trailer guidelines
Step
determining load limit of Tow vehicle Step
trailer guidelines
Step
Tire FundamenTalS
Table a. Speed rating
letter rating
Speed rating
Tire Safety Tips
Tire repair
replacing Worn or damaged Tires
uniform Tire Quality grading Standards uTQgS
Table B. Tire Wear Troubleshooting
Wheel rims
Wheels, Bearings and lug nuts
lug nut Torque requirements
lights and Signals
Table C. Tire Torque requirements
Figure M. Trailer to Tow Vehicle Wiring Diagram
trailer guidelines
HYDRAULIC HOSES SCHEMATIC
MAINTENANCE PARTS LOCATOR
GENERATOR WIRING DIAGRAM
Q1 B
GENERATOR WIRING DIAGRAM
V2 CB6
Sample parTS liST
explanation of codes in remarks column
no. Column
parT no. Column
suggested spare parts
SG1400C3 with CUMMINS QSB7-G5 DIESEL ENGINE 1 to 3 units
description
HOUSING BASE assy
PART NAME
REMARKS
HOUSING BASE assy
HOUSING, 1400 STUDIO, SINGLE BUS DOOR
HOUSING interior assy
REAR VIEW
FRONT VIEW
HOUSING interior assy
PART NAME
REMARKS
BALL STUD, GAS SPRING, 10 MM STEEL
cAMLOK assy
FRONT
REAR
cAMLOK assy
PART NAME
REMARKS
RECEPTACLE, PNL MTG, FEMALE BLACK
control box assy. panel
SWITCH, TOGGLE SINGLE POLE SPST
SWITCH, ROTARY, VOLTAGE SELECTOR
control box assy. panel
PART NAME
CONTROL BOX assy. INTERIOR
CONTROL BOX assy. INTERIOR
PART NAME
REMARKS
BLOCK, TERMINAL, SAK, 4-WEIDMULLER
ENGINE/GENERATOR MOUNTING assy
WATER DRAIN
OIL DRAIN
FUEL IN
ENGINE/GENERATOR MOUNTING assy
PART NAME
REMARKS
ALTERNATOR, MARATHON, 431RSL4007
RADIATOR/MUFFLER SUPPORT
RADIATOR/MUFFLER SUPPORT
PART NAME
REMARKS
VENTURI RING, 30 REVERSE CONSTR
RADIATOR/FAN ASSY
RADIATOR/FAN ASSY
PART NAME
REMARKS
HAT SECTION, EXHAUST VENT HYD ACT
RADIATOR piping
RADIATOR piping
PART NAME
REMARKS
BRACKET, FUEL SEP./COOLANT FILTER
AIR FILTER HOSING/PIPING
AIR FILTER HOSING/PIPING
PART NAME
REMARKS
HOSE, CHARGE AIR COOLER, 3 DIA
EXHAUST assy
EXHAUST assy
PART NAME
REMARKS
SADDLE BOX ASSY
SADDLE BOX ASSY
PART NAME
REMARKS
B-528258
engine starter, relay AND batterY ASSY
engine starter, relay AND batterY ASSY
BATTERY, AUTO, GROUP-27 CENTENNIAL
BOOT COVER, TERMINAL, POSITIVE RED
PART NAME
FUEL SYSTEM ASSY
FUEL
PRIMING
PUMP
BREAKER, CIRCUIT, AUTO RESET, 24V 10A
FILTER, VOLUME CHAMBER, 2.00 AMERICAN
FUEL SYSTEM ASSY
PART NAME
FUEL SYSTEM ASSY
FUEL
PRIMING
PUMP
FUEL SYSTEM ASSY
PART NAME
EE49411
HYD. vent actuator hosing ASSY
REAR
ACTUATOR
FRONT ACTUATOR
HYD. vent actuator hosing ASSY
PART NAME
REMARKS
HOSE, 3/8X35 MANIFOLD to CYLINDER
engine component ASSY
2215A
SENSOR, PRESSURE TEMPERATURE
SENSOR, TEMPERATURE
engine component ASSY
PART NAME
hyd. MANIFOLD, VALVE AND HOSE ASSY
MANIFOLD
INTAKE BALL VALVE
3-WAY VALVE
hyd. MANIFOLD, VALVE AND HOSE ASSY
PART NAME
REMARKS
FITTING, REDUCING HX NIPPLE, 3/4 x 1/2NPTF
hyd. TANK, FILTER AND HOSE ASSY
hyd. TANK, FILTER AND HOSE ASSY
PART NAME
REMARKS
SIGHT LEVEL GAUGE, 5, LEXAN TUBE
hyd. TANK, FILTER AND HOSE ASSY
hyd. TANK, FILTER AND HOSE ASSY
PART NAME
REMARKS
FITTING, STRAIGHT, 3/4MORB x 1/2FORB
hyd. PUMP, COOLER, FAN MOTOR AND HOSE ASSY
OIL COOLER
FAN MOTOR
HYDRAULIC
hyd. PUMP, COOLER, FAN MOTOR AND HOSE ASSY
PART NAME
REMARKS
crankcase ventilation ASSY
TO DRAIN
CRANKCASE
TO ENGINE BLOCK
crankcase ventilation ASSY
PART NAME
REMARKS
ASSY. CRANKCASE VENT FILTER, CV6001
trailer ASSY
trailer ASSY
PART NAME
REMARKS
EE36264
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paYmenT TermS
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HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
Service Department
Warranty Department