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