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:
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
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PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at
write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 3
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TABLE OF CONTENTS
Component Drawings
DCA400SSI GENERATOR
Proposition 65 Warning ........................................... 2
Reporting Safety Defects......................................... 3
Table Of Contents.................................................... 4
Parts Ordering Procedures...................................... 5
Safety Information .............................................. 6-11
Specifications ........................................................ 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
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
Enclosure #2 Assembly.................................. 84-85
Enclosure #3 Assembly.................................. 86-89
Rubber Seals Assembly ................................... 90-91
Nameplate And Decals Assembly .................... 92-95
Terms And Conditions Of Sale — Parts ................ 96
NOTICE
Specifications and part numbers are subject to change
without notice.
PAGE 4 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Effective:
January 1st, 2006
Order via Internet (Dealers Only)
Orderpartson-lineusingMultiquip’sSmartEquipwebsite!
:
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
Best Deal!
■
■
■
View Parts Diagrams
Order Parts
PrintSpecificationInformation
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Gotowww.multiquip.comandclickon
to log in and save!
Order Parts
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
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)
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
1-800-427-1244
Order via Phone:
Non-Dealer Customers:
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
❒
Dealer Account Number
❒
Specify Preferred Method of Shipment:
✓
UPS/Fed Ex
✓ DHL
❒
Dealer Name and Address
■
■
Priority One
Ground
✓
Truck
❒
❒
❒
❒
Shipping Address (if different than billing address)
Return Fax Number
■ Next Day
Applicable Model Number
■
Second/ThirdDay
Quantity, Part Number and Description of Each Part
All orders are treated as Standard Orders
andwillshipthesamedayifreceivedprior
to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 5
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SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others.The
safety messages specifically address the level of exposure
to the operator and are preceded by one of four words:
DANGER,WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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SAFETY INFORMATION
GENERAL SAFETY
CAUTION
GENERATOR SAFETY
DANGER
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.
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment requires an adequate free
flow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air
is restricted. If the air flow
is restricted it will cause
injury to people and property
and serious damage to the
equipment or engine.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the influence of
drugs or alcohol.
NEVER operate the equipment in an explosive
atmosphere or near combustible materials.An
explosion or fire could result causing severe
bodily harm or even death.
NOTICE
WARNING
This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
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.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
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.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
ALWAYS know the location of the nearest
fire extinguisher.
ALWAYS know the location of the nearest
first aid kit.
Fix damage to machine and replace any broken parts
immediately.
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 fire
department. This information will be invaluable in the
case of an emergency.
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.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 7
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SAFETY INFORMATION
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
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
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 fingers, hands hair and clothing away
from all moving parts to prevent injury.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
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.
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.
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.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels.A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
CAUTION
NEVER touch the hot exhaust manifold,
muffler or cylinder.Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air filter or with a dirty air
filter.Severe engine damage may occur.Service air filter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
PAGE 8 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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SAFETY INFORMATION
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains, etc.
Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.
ALWAYS use extreme caution when working with
flammable liquids.
ALWAYS make sure the trailer is equipped with a safety
chain.
DO NOT fill the fuel tank while the engine is running
or hot.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.
DOT Requirements include the following:
• Connect and test electric brake operation.
NEVER use fuel as a cleaning agent.
• Secure portable power cables in cable tray with tie
wraps.
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.
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.
TOWING SAFETY
CAUTION
Avoid sudden stops and starts.This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
Check with your local county or state safety towing
regulations, in addition to meeting
Department of Transportation (DOT)
SafetyTowing Regulations, before towing
your generator.
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.
Refer to MQ Power trailer manual for additional safety
information.
Place chock blocks underneath wheel to prevent rolling
while parked.
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.
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.
ALWAYS shutdown engine before transporting
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 9
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SAFETY INFORMATION
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
duringoperationcancauseelectrocution,
electrical shock or burn.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
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.
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 insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility
exists of electrical shock, electrocution
or death.
NEVER use gas piping as an electrical ground.
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.
PAGE 10 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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SAFETY INFORMATION
BATTERY SAFETY
DANGER
ENVIRONMENTAL SAFETY
NOTICE
DO NOT drop the battery.There is a possibility that the
battery will explode.
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, fuel
and fuel filters.
DO NOT expose the battery to open flames,
sparks, cigarettes, etc.The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
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.
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.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 11
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SPECIFICATIONS
Table 1. Generator Specifications
DCA400SSI
Model
Type
Revolving field, self ventilated,
open protected type synchronous generator
Armature Connection
Phase
Star with Neutral
3
Standby Output
Prime Output
Voltage — 1Ø
Voltage — 3Ø
Frequency
440 KVA (352 KW)
400 KVA (320 KW)
120,127,139, 240, 254 and 277V
208, 220, 240, 416, 440 and 480V
60 Hz
Speed
1800 rpm
Power Factor
Aux. AC Power
Aux.Voltage/Output
Dry Weight
0.8
Single Phase, 60 Hz
4.8 Kw (2.4 kW x 2)
11,640 lbs. (5,280 kg.)
12,875 lbs. (5,840 kg.)
Wet Weight
Table 2. Engine Specifications
Model
Type
ISUZU 6WG1X
4 cycle, water-cooled, direct injection, turbo-charged
with air to air after cooler
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
6 cylinders
5.79 in. x 6.06 in. (147 mm x 154 mm)
957 cu. in. (15,681 cc)
464 HP at 1800 rpm
Electric 24 VDC
Coolant Capacity
Lube Oil Capacity
FuelType
15.8 gal. (60.0 liters)
14.4 gal. (55.0 liters)
#2 Diesel Fuel
FuelTank Capacity
Fuel Consumption
Battery
129 gal. (490 liters)
23.0 gal. (87.3 L)/hr at full load
12V-200 Ah x 2
PAGE 12 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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DIMENSIONS
Figure 1. Dimensions
Table 3. Dimensions
Reference
Letter
Dimension in. (mm)
Reference Letter
Dimension in. (mm)
A
B
C
D
E
F
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)
H
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)
J
K
L
M
G
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 13
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INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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INSTALLATION
OUTDOOR INSTALLATION
GENERATOR GROUNDING
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.
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
specifies that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
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.
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.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
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.
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) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
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.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
MOUNTING
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running.The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1).DO NOT remove
the metal skids on the bottom of the generator. They are
to resist damage to the bottom of the generator and to
maintain alignment.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 15
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GENERAL INFORMATION
GENERATOR
OPEN DELTA EXCITATION SYSTEM
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.
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 rectified and are the
excitation current for the exciter section.
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
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.
Engine Alarm Lamps (5)
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities.The
excitation does not have a “fixed ceiling” and responds
according the demands of the required load.
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
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 specifications.
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
• Over-Current Relay
• Voltage Rectifier
• Starter Relay
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%.
• Engine Controller (Computer Controlled)
• Voltage Change-Over Board
OUTPUTTERMINAL 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)
EXTENSION CABLES
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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MAJOR COMPONENTS
Table 4. Generator Major Components
ITEM NO.
DESCRIPTION
Output Receptacles Assembly
Output Terminal Panel Assembly
Muffler Assembly
1
2
3
4
Air Filter Assembly
5
Fuel Tank Assembly
6
Engine and Radiator Assembly
Generator Assembly
7
8
Battery Assembly
9
Generator Control Panel Assembly
Circuit Breaker Assembly
Engine Operating Panel Assembly
10
11
Figure 3. Major Components
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 17
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GENERATOR CONTROL PANEL
Figure 4. Generator Control Panel
The definitions below describe the controls and functions
of the DCA400SSI Generator Control Panel (Figure 4).
8. Panel Light Switch — When activated will turn on
control panel light.
1. Pilot Lamp — Indicates the system is running.
9. Voltage Regulator Control — Allows 15% manual
adjustment of the generator’s output voltage.
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.
10. Main Circuit Breaker — This three-pole, 1,000 amp
main breaker is provided to protect the U,V, and W
OutputTerminal Lugs from overload.
3. AC Voltmeter — Indicates the output voltage present
at the U,V, and W OutputTerminal Lugs.
11. Auto On/Off Engine Controller (MPEC) —
This controller has a vertical row of status LED’s (inset),
that when lit, indicate that an engine malfunction (fault)
has been detected. When a fault
has been detected the engine
controller will evaluate the fault
and all major faults will shutdown
the generator. During cranking
cycle, The MPEC will attempt to
crank the engine for 10 seconds
before disengaging.
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.
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.
7. Ammeter Change-Over Switch — This switch allows
the AC ammeter to indicate the current flowing to the load
connected to any phase of the output terminals, or to be
switched off. This switch does not effect the generator
output in any fashion, it is for current reading only.
PAGE 18 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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GENERATOR CONTROL PANEL
Also the engine controller will shut down the engine in the
event of low oil pressure, high coolant temperature, low
coolant level, and loss of magnetic pickup.These conditions
can be observed by monitoring the LED status indicators
on the front of the controller module.
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.
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.
The Control Box is equipped with the following major
components:
Over-Current Relay
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 auto-
start contacts conn ected to the ATS’s start contacts.
Please refer to your ATS installation manual for further
instructions for the correct installation of the auto-start
contacts of the geerator to the ATS.
Voltage Rectifier (AVR)
Starter Relay
Current Transformer
Voltage Change-Over Board
Three Phase Circuit Breaker
NOTICE
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.
Remember the overcurrent relay monitors the current
flowing 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.
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.
To restore power to the OutputTerminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
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.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 19
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ENGINE OPERATING PANEL
9
8
10
1
2
7
3
4 5
6
WATER TEMP.
OIL PRESS.
FUEL LEVEL
AIR FILTER
COOLANT LEVEL
ON
OFF
Figure 5. Engine Operating Panel
The definitions below describe the controls and functions
of the DCA400SSI Engine Operating Panel (Figure 5).
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.
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.
c. 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.
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.
d. Air Filter Alarm — When the air filter
element is clogged, this lamp goes ON
indicating the element should be
immediately cleaned or replaced.
3. WaterTemperature Gauge — During normal operation
this gauge be should read between 167° and 203°F
(75°~95°C).
e. Coolant Level Alarm — This lamp
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.
4. Charging Ammeter Gauge — Indicates the current
being supplied by the engine’s alternator which
provides current for generator’s control circuits and
battery charging system.
5. Fuel Gauge — Indicates amount of diesel fuel available.
7. Engine Speed Switch — This switch controls the
speed of the engine (low/high).
6. Engine Warning Lamps — There are three engine
warning lamps, they are defined as follows:
8. 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.
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.
9. 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.
b. Low Oil Pressure Lamp — During
normal operation of the generator this
lamp should remain OFF. When the
Auto-OFF/Reset-Manual switch is set
PAGE 20 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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NOTES
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 21
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OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUTTERMINAL PANEL
OUTPUTTERMINAL FAMILIARIZATION
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.
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
NOTICE
Two (2) 120V GFCI receptacles @ 20 amp
Two (2) GFCI Circuit Breakers @ 20 amps
Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)
Terminal legs “O”and “Ground”are considered bonded
grounds.
Figure 6. Output Terminal Panel
PAGE 22 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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OUTPUT TERMINAL PANEL FAMILIARIZATION
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 OutputTerminal Lugs.
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.
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.
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.
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
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 23
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OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Over Current Relay
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.
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.
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.
Figure 11. Over Current Relay
Figure 10. Connecting Loads
PAGE 24 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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LOAD APPLICATION
SINGLE PHASE LOAD
THREE 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.
When calculating the power requirements for 3-phase
power use the following equation:
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require
130—150% more wattage than the rating on the nameplate,
as the wattage is influenced by the efficiency, power factor
and starting system of the equipment.
NOTICE
If 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
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
WATTS = VOLTAGE x AMPERAGE
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.
The power factor of this generator is 0.8.SeeTable 5 below
when connecting loads.
Table 5. Power Factor By Load
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.
Type of Load
Power Factor
Single-phase induction motors
0.4-0.75
Electric heaters, incandescent lamps
Fluorescent lamps, mercury lamps
1.0
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
0.4-0.9
Electronic devices, communication
equipment
1.0
0.8
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Common power tools
Table 6. Cable Selection (60 Hz, Single Phase Operation)
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Load in Watts
Maximum Allowable Cable Length
Current
in
Amperes
At 100
Volts
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
DANGER
2.5
5
300
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
600
1200
1800
2400
3600
4800
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.
7.5
10
15
20
900
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 25
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GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES
Generator Amperage
A wide range of voltages are available to supply voltage
for many different applications. Voltages are selected by
applying jumpers (6) to the voltage change-over board
(Figure 12). To obtain some of the voltages as listed in
Table 7 (see below) will require a fine adjustment using
the voltage regulator (VR) control knob located on the
control panel.
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 139V 240V 277V 480V
222
305
388
472
555
638
722
805
889
191
263
335
407
480
551
623
695
767
111
152
194
236
277
319
361
402
444
96
55
76
110
131
167
203
240
275
311
347
383
Voltage Change-Over Board
140
97
170
118
138
160
180
201
222
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.
200
230
260
290
320 (Max)
These calculations reflect the maximum amount of current the generator can
provide at each output terminal pair.To obtain the total generator amperage,
multiply by 3.
Example 1: 488.6 amps @ 120V per output terminal pair X 3 = 1,486 amps
Example 2: 244.3 amps @ 240V per out put terminal pair X 3 = 733 amps
Table 9. Generator Ampere Ratings — 3Ø
KVA
100
130
160
190
220
250
280
310
340
370
400
240V
240
312
384
457
529
601
674
746
818
890
962
480V
120
156
192
228
264
300
337
373
409
445
481
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!
Table 7. Voltages Available
Three Phase
(Switchable)
208V
220V
240V
416V
440V
254V
480V
277V
Single Phase
(Switchable)
120V
127V
139V
240V
PAGE 26 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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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
DCA400SSI
Figure 14. AC Voltmeter
Change-Over Switch
Figure 16. AC Ammeter
Change-Over Switch
Rated Voltage
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
HOWTO READTHE OUTPUTTERMINAL GAUGE
Figure 15. AC Voltmeter
Gauge (Volt reading on
W-U Lug)
Figure 17. AC Ammeter
(Amp reading on U lug)
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.
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
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 orW position to read the output
on the selected leg.
Figure 13. Voltage Change-Over Board 240V
Configuration
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 27
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OUTPUT TERMINAL PANEL CONNECTIONS
3. Turn the voltage regulator knob (Figure 20) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required
UVWOTERMINAL OUTPUT VOLTAGES
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the placement of the jumpers plates (6) on
the Voltage Change-Over Board and the adjustment of
the Voltage Regulator Control Knob.
Remember the voltage change-over board determines the
range of the output voltage and can be configured in two
different positions that provide 6 different output voltages
at the UVWO output terminals. The generator is shipped
from the factory in the 240V configuration. The voltage
regulator (VR) allows the user to increase or decrease the
selected voltage.
Figure 20. Voltage Regulator Knob
1Ø-240V UVWOTerminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 18.
2. Connect the load wires to the UVWO terminals as
shown in Figure 21.
3Ø-240V UVWOTerminal Output Voltages
1. Jumper the voltage change-over board for 240V
operation as shown in Figure 18.
Figure 21. UVWO Terminal Lugs 1Ø-240V
Connections
1Ø-120V UVWOTerminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 18.
Figure 18. Voltage Change-Over Board 240V
Configuration
2. Adjust voltage regulator knob (Figure 20) for an output
of 208V to obtain 120V at the UVWO terminals.
2. Connect the load wires to the UVWO terminals as
shown in Figure 19.
3. 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
PAGE 28 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWOTerminal Output Voltages
1Ø-480V UVWOTerminal Output Voltages
1. Jumper the voltage change-over board for 480V
operation as shown in Figure 23. This configuration
uses 6 jumper plates in 3 different positions.Remember
there are 2 jumper plates at every position. Every
jumper plate must be used.
1. Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 23.
2. Connect the load wires to the UVWO terminals as
shown in Figure 25.
Figure 25. UVWO Terminal Lugs 1Ø-480V
Connections
Figure 23. Voltage Change-Over Board 480V
Configuration
1Ø-277V UVWOTerminal Output Voltages
2. Connect the load wires to the UVWO terminals as
shown in Figure 24.
1. Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 23.
2. Connect the load wires to the UVWO terminals as
shown in Figure 26.
Figure 24. UVWO Terminal Lugs 3Ø-480V
Connections
NOTICE
Figure 26. UVWO Terminal Lugs 1Ø-277V
Connections
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight.The possibility of arcing
exists, that could cause a fire.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 29
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INSPECTION/SETUP
CIRCUIT BREAKERS
FUEL CHECK
DANGER
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.
Fuel spillage on a hot engine can cause
a fire or explosion.If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.
Refilling the Fuel System
LUBRICATION OIL
CAUTION
Fill the engine crankcase with lubricating oil through the
filler hole, but DO NOT overfill. Make sure the generator is
level and verify that the oil level is maintained between the
two notches (Figure 27) on the dipstick. See Table 11 for
proper selection of engine oil.
ONLY properly trained personnel who have read
and understand this section should refill the fuel tank
system.
This generator has an internal fuel tank located inside
the trailer frame and may also be equipped with an
environmental fuel tank (Figure 28). ALWAYS fill the fuel
tanks with clean fresh #2 diesel fuel. DO NOT fill the fuel
tanks beyond their capacities.
Figure 27. Engine Oil Dipstick
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
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 refill with the specified amount of oil as
outlined in the ISUZU Engine Owner’s Manual.Oil should
be warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classification CC/SC
API Service Classification CC/SD
API Service Classification CC/SE
API Service Classification CC/SF
Table 11. Recommended Motor Oil
Figure 28. Internal Fuel Tank System
PAGE 30 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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INSPECTION/SETUP
2. Open cabinet doors on the “right side”of the generator
(from generator control panel position). Remove fuel
cap and fill tank (Figure 30).
Refueling Procedure:
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. LevelTanks — Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 29).
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 overfill fuel tank — It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait
for fuel to rise in filler neck (Figure 31).
Figure 29. Only Fill on Level Ground
Figure 31. Full Fuel Tank
NOTICE
CAUTION
ONLY use #2 diesel fuel when refueling.
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 32).
Figure 32. Fuel Expansion
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 31
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INSPECTION/SETUP
COOLANT (ANTIFREEZE/SUMMER COOLANT/
WATER)
Cleaning the Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the
radiator fins with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
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.
AIR CLEANER
WARNING
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the ISUZU Engine Owner’s Manual.
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.
FAN BELTTENSION
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
ISUZU Engine Owner’s Manual.
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.
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.
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.
Figure 33. Fan Belt Tension
CAUTION
Table 13. Anti-Freeze
OperatingTemperatures
NEVER place hands near the belts or fan
while the generator set is running.
Freezing Point
Vol %
Anti-Freeze
°C
°F
50
-37
-34
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
PAGE 32 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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INSPECTION/SETUP
When connecting battery do the following:
BATTERY
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.
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are
not properly maintained. Add only distilled water when
replenishment is necessary.
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.
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.
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.
The battery is sufficiently charged if the specific gravity
of the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
CAUTION
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Battery Cable Installation
ALTERNATOR
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.
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.
CAUTION
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
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.
Figure 34. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 33
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GENERATOR START-UP PROCEDURE (MANUAL)
BEFORE STARTING
CAUTION
STARTING (MANUAL)
1. Place the engine speed switch (Figure 37) in the LOW
(down) position.
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
Figure 37. Engine Speed Switch (Low)
WARNING
2. Place the MPEC control switch in the MANUAL
position to start the engine (Figure 38).
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.
Figure 38. MPEC Control Switch
(Manual Position)
3. Depending on the temperature of the coolant (cold
weather conditions), the pre-heat lamp (Figure 39) will
light (ON) and remain on until the pre-heating cycle has
been completed. After completion of the pre-heating
cycle, the light will go OFF and the engine will start up
automatically.
Figure 35. Main, Aux. and GFCI
Circuit Breakers (OFF)
2. Make sure the voltage change-over board has been
configured for the desired output voltage.
3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 10. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
Figure 39. Pre-Heat Button
4. Once the engine starts, let the engine run for 1-2
minutes. Listen for any abnormal noises. If any
abnormalities exist, shut down the engine and correct
the problem. If the engine is running smoothly, place
the engine speed switch (Figure 40) in the HIGH (up)
position.
4. Tighten terminal nuts securely to prevent load wires
from slipping out.
5. Close all engine enclosure doors (Figure 36).
Figure 40. Engine Speed Switch (High)
5. Verify that the engine running
status LED on the MPEC unit
(Figure 41) is ON (lit) after the
engine has been started.
Figure 36. Engine Enclosure Doors
Figure 41. Engine Running LED (ON)
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GENERATOR START-UP PROCEDURE (MANUAL)
6. The generator’s frequency meter (Figure 42) should be
displaying the 60 cycle output frequency in HERTZ.
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 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.
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
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 35
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GENERATOR START-UP PROCEDURE (AUTO MODE)
When starting generator in AUTO mode use the “Manual
Start-up” procedure except where noted (see below).
STARTING (AUTO MODE)
DANGER
1. Perform steps 1 through 5 in the Before Starting section
as outlined in the Manual Starting Procedure.
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.
2. Place the engine speed switch (Figure 51) in the
HIGH position
CAUTION
Figure 51. Engine Speed Switch (High)
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.
3. Place the MPEC Control Switch (Figure 52) in the
AUTO position.
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 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.
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GENERATOR SHUT-DOWN PROCEDURES
EMERGENCY SHUTDOWN PROCEDURE
WARNING
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.
NEVER stop the engine suddenly except in an
emergency.
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.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 37
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MAINTENANCE
10 Hrs
DAILY
1000
Hrs
Table 14. Inspection/Maintenance
250 Hrs 500 Hrs
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Replace Engine Oil and Filter * 1
Clean Air Filter
X
X
Engine
Check Fuel Filter/Water Separator Bowl
Clean Unit, Inside and Outside
Change Fuel Filter
Clean Radiator and Check Coolant Protection Level*2
Replace Air Filter Element * 3
Check all Hoses and Clamps * 4
Clean Inside of Fuel Tank
X
X
X
X
X
X
X
Measure Insulation Resistance Over 3M ohms
X
Generator
Check Rotor Rear Support Bearing
Replace engine oil and filter at 100 hours, first time only.
X
1
*
2
*
Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
3
*
4
*
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 deficiencies. 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.
Figure 56. Air Cleaner/Indicator
NOTICE
Air Cleaner with Dust Indicator
The air filter should not be changed until the indicator
reads “RED”. Dispose of old air filter. It may not be
cleaned or reused.
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.
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MAINTENANCE
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.
FUELTANK 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 ADDITION
Add diesel fuel (the grade may vary according to season
and locations).
Fuel Hoses — inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
Removing Water from the FuelTank
FuelTank Lining — inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
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.
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 500
hours or so.
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.
Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Cleaning Inside the FuelTank
Vent any air
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.
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
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 39
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MAINTENANCE
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds.Try again, if needed.This
unit is equipped with an automatic air bleeding system.
RADIATOR CLEANING
The radiator (Figure 58) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fins or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fins and tube.
CHECK OIL LEVEL
Check the crankcase oil level prior to each use, or when the
fuel tank is filled.Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil
level must be between the two notches on the dipstick as
shown in Figure 27.
Replacing Oil Filter
Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
After the oil cartridge has been replaced, the engine oil
will drop slightly.Run the engine for a while and check for
leaks before adding more oil if needed.Clean excessive
oil from engine.
Figure 58. Radiator Cleaning
FLUSHING OUT RADIATOR AND REPLACING
COOLANT
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overflow
tank and drain.
Drain the fuel tank completely.Treat with a fuel stabilizer
if necessary.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Tighten both cocks and replace the overflow tank.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Replace with coolant as recommended by the engine
manufacturer.
Close radiator cap tightly.
Make sure engine coolant is at proper level.
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.
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.
JACKETWATER HEATER AND INTERNAL BATTERY
CHARGER 120 VAC INPUT RECEPTACLES
(OPTIONAL)
WARNING
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
This generator can be optionally equipped with two 120
VAC, 20 amp input receptacles located on the output
terminal panel.
PAGE 40 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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MAINTENANCE
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.
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
(not used) for long periods of time, apply power to the
NOTICE
battery charger receptacle via commercial power using a
power cord of adequate size.
To ensure adequate starting capability, always have
power applied to the generator's internal battery
charger.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 41
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TRAILER MAINTENANCE
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.
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.
9. Tire Ply — The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
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.
The definitions below describe some of the major
components of a typical trailer that would be used with the
DCA400SSI Whisperwatt™ Generator.
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.
1. Fuel Cell — Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
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.
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).
14. Suspension — Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
4. Frame Length — Measurement is from the ball hitch
to the rear bumper (reflector).
5. Frame Width — Measurement is from fender to
fender
15. Electrical — Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
6. Jack Stand — Trailer support device with maximum
pound requirement from the tongue of the trailer.
16. Application — Indicates which units can be employed
on a particular trailer.
7. Coupler — Type of hitch used on the trailer for
towing.
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TRAILER MAINTENANCE
BRAKES
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of
operation.This will allow the brake shoes and drums to seat
properly.After the first 200 mile interval, inspect the brakes
every 3,000 miles. If driving over rough terrain, inspect the
brakes more frequently.
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 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 and Table 15 as listed below:
Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting
slot at the bottom brake backing plate.
Figure 60. Hydraulic Brake Components
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
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.
5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer
to the ground.
Periodicallycheckandtestthesurge“actuator”tomakesurethat
it is functioning correctly. Never use an undersize actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 15. Hydraulic BrakeTroubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Repair or replace.
Reburnish or replace.
Correct weight.
Trailer overloaded?
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or
broken?
Replace components.
Locking Brakes
Noisy Brakes
Brake drums out-of-round?
System lubricated?
Replace.
Lubricate.
Brake components correct?
Replace and correct.
Install new shoes and
linings.
Brake lining thickness incorrect or
not adjusted correctly?
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 43
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TRAILER MAINTENANCE
TIRES/WHEELS/LUG NUTS
Suspension
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.
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.
CAUTION
ALWAYS wear safety glasses when
removing or installing force fitted 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.
Figure 61. Major Suspension Components
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire
life.Pressure should be checked cold before operation DO
NOT bleed air from tires when they are hot!.Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 17. SuspensionTorque Requirements
Item
Torque (Ft.-Lbs.)
Min-30 Max-35
Min-45 Max-60
Min-45 Max-60
3/8" U-Bolt
7/16" U-Bolt
1/2" U-Bolt
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Snug fit only. Parts must rotate freely.
Locking nuts or cotter pins are
Shackle Bolt
Spring Eye Bolt
Table 16. Tire WearTroubleshooting
provided to retain nut-bolt assembly.
Wear Pattern
Cause
Solution
Shoulder Type
Shackle Bolt
Min-30 Max-50
Adjust pressure to particular
load per tire manufacturer.
Center Wear Over inflation.
Edge Wear Under inflation.
Adjust pressure to particular
load per tire manufacturer.
Make sure load does not
exceed axle rating.
Align wheels.
Loss of camber
Side Wear
or overloading.
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
Check bearing adjustment
and balance tires.
Wheel lockup and Avoid sudden stops when
tire skidding. possible and adjust brakes.
Flat Spots
PAGE 44 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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TRAILER MAINTENANCE
Lug NutTorque 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 defined
by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. TireTorque Requirements
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
Wheel Size
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
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.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 45
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TRAILER WIRING DIAGRAM
Figure 63. Trailer/Towing Vehicle Wiring Diagram
PAGE 46 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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GENERATOR WIRING DIAGRAM
Figure 64. Generator Wiring Diagram
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 47
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ENGINE WIRING DIAGRAM
Figure 65. Engine Wiring Diagram
PAGE 48 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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CONTROLLER WIRING DIAGRAM
Figure 66. Controller Wiring Diagram
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 49
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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 office or service plant.
Table 19. GeneratorTroubleshooting
Symptom
Possible Problem
AC Voltmeter defective?
Is wiring connection loose?
Is AVR defective?
Solution
Check output voltage using a voltmeter.
Check wiring and repair.
No Voltage Output
Replace if necessary.
Defective Rotating Rectifier? Check and replace.
Defective Exciter Field?
Is engine speed correct?
Check for approximately 19 ohms across J & K on CN1
Turn engine throttle lever to “High”.
Low Voltage Output
High Voltage Output
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
Defective AVR?
Replace if necessary.
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Circuit Breaker Tripped
Defective circuit breaker?
Over current Relay actuated? Confirm load requirement and replace.
PAGE 50 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown,
useTable 20 (Engine ControllerTroubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller
unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.
Table 20. Engine ControllerTroubleshooting (MPEC)
Symptom
Possible Problem
Low oil level?
Solution
Fill oil level.
Oil pressure sending unit failure?
Time delay malfunction in controller?
Wire shorted?
Replace oil pressure sending unit.
Refer to dealer.
Low oil pressure light is on.
Inspect/repair wire.
Low coolant level?
Fill coolant level.
Low coolant level light is on.
(Optionally installed)
Sending unit failure?
Replace sending unit.
Replace/charge battery.
Tighten/replace fan belt.
Low battery voltage?
Fan belt tension incorrect?
Air flow is not circulating through radiator? Clean/repair radiator grill.
Doors open?
Close doors.
Exhaust leaking?
Replace/repair gaskets or faulty part.
Check/reduce load.
Replace thermostat.
Clean all air intakes.
Replace temperature switch.
Fill fuel level.
High coolant temperature
light is on.
Generator being overloaded?
Thermostat failure?
Air intake blocked?
Temperature switch failure
No or low fuel?
Overcrank light is on.
Overspeed light is on.
Loss of MPU light(s) or on.
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?
Magnetic pick up dirty?
Adjust magnetic pick up.
Clean magnetic pick up.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 51
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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.
PAGE 52 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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NOTES
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 53
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EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
QTY. Column
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.
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.
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.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Sample Parts List:
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.
NO. PART NO. PART NAME
QTY. REMARKS
1
2
2
3
4
12345
BOLT ...................... 1 ......INCLUDES ITEMS W/
WASHER, 1/4 IN. .............NOT SOLD SEPARATELY
WASHER, 3/8 IN. ... 1 ......MQ-45T ONLY
HOSE ................... A/R ....MAKE LOCALLY
BEARING ............... 1 ......S/N2345B AND ABOVE
*
*
*
12347
12348
12349
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)”
NO. Column
Unique Symbols - All items with same unique symbol
Serial Number Break - Used to list an effective serial
number range where a particular part is used.
( , #,
+
, %, or >) in the number column belong to the same
*
assembly or kit, which is indicated by a note in the “Remarks”
column.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXXTO S/N XXX”
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.
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.
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.
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.
PART NO. Column
Numbers Used - Part numbers can be indicated by a
number, a blank entry, orTBD.
“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.
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.
PAGE 54 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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SUGGESTED SPARE PARTS
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.
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 55
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GENERATOR ASSY.
5A
5
1-4B
1-4A
1-4
6-6
6-6A
18
18A
9B
9A
18B
9
16A
16
11
13B
13A
PAGE 56 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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GENERATOR ASSY.
NO.
1
PART NO.
C3110000502
PART NAME
ROTOR ASSY...........................................1............. INCLUDES ITEMS W/*
QTY.
REMARKS
1-1
FIELD ASSY
RESISTOR, 80W 300 K OHM
RECTIFIER
HEX SOCKET HEAD CAP SCREW
WASHER, LOCK
WASHER, FLAT
FAN
COUPLING DISK
COUPLING HUB WASHER
1
2
1
2
2
2
1
12
1
1-2* 0601842401
1-3* 0601823282
1-4* 0018205020
1-4A 0040005000
1-4B 0041205000
1-5* 8201070002
1-6* 8201611004
1-7* C3164200004
1-8* 8201015003
1-9* 0012116045
1-10* 0042618000
1-11* 0601000209
1-12 C3112500004
1-13 007906315
BALANCING PLATE.................................1............. PURCHASE ITEMS 1-11 AS A SET
HEX HEAD BOLT
WASHER, LOCK
BALANCING WEIGHT KIT
BEARING FLANGE
BEARING
10
10
1
1
1
2
3
4
5
5-A
6
6-1
6-2
6-3
6-4
6-5
6-6
C3164400103
0010312050
0042512000
0010312040
0042512000
C3130100003
0226200495
8211323004
0223300172
8211323103
0221200440
0010110035
COUPLING RING
HEX HEAD BOLT
WASHER, LOCK
HEX HEAD BOLT
WASHER, LOCK
STATOR ASSY.
RUBBER SEAL
CLAMPER
RUBBER SEAL
CLAMPER
RUBBER SEAL
HEX HEAD BOLT
WASHER, FLAT
COVER
1
8
8
12
12
1
1
1
1
1
1
2
2
1
2
1
6-6A 0041210000
6-7
6-8
6-9
C3132200003
0226000290
0225000590
RUBBER SEAL
RUBBER SEAL
HEX HEAD BOLT
GROMMET
6-10 0017106020
6-11 0601850144
6
1
7
8
9
9A
9B
10
11
12
C3154000002
C3138000003
0012110080
0042610000
0041210000
0017112045
C3154300104
C3154300004
END BRACKET
FIELD ASSY. EXCITER
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
BEARING COVER
BEARING GASKET
1
1
4
4
4
4
1
1
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 57
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GENERATOR ASSY. (CONTINUED)
PAGE 58 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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GENERATOR ASSY. (CONTINUED)
NO.
13
13A
13B
14
15
16
17
17A
18
19
19A
20
21
PART NO.
PART NAME
QTY.
4
4
4
1
REMARKS
0010106060
0040006000
0041206000
C3154400003
0017106016
C3163600003
0010312030
0042512000
0070506206
0010312040
0042512000
C3132300014
0010106030
0041206000
0601815000
0605000061
0030016000
0040016000
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
SUCTION COVER
HEX HEAD BOLT
COUPLING ADAPTER
HEX HEAD BOLT
WASHER, LOCK
BEARING
HEX HEAD BOLT
WASHER, LOCK
FAN COVER
HEX HEAD BOLT
WASHER, FLAT
NUT
8
1
12
12
1
16
16
1
1
1
1
4
21A
21B
22
23
23A
RUBBER SUSPENSION
HEX NUT
WASHER, LOCK
8
8
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 59
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ENGINE OPERATING PANEL ASSY.
PAGE 60 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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ENGINE OPERATING PANEL ASSY.
NO.
1
2
3
4
PART NO.
PART NAME
QTY.
REMARKS
C3351100603
0017106020
0207006000
1823200010
0021008080
0030008000
0040008000
0041608000
0601830710
0602103090
0601810244
0601831589
0602103090
0601810244
0602120095
0602122093
0601842450
0602123092
0602121081
0602125091
C3483003303
0017110030
0207010000
0017110030
0602123267
0602021702
0602122272
M9200100004
0130200000
OPERATING PANEL
HEX HEAD BOLT
HEX NUT
1
8
4
BATTERY SWITCH .....................................1 ................REPLACES P/N 0602101001
5
MACHINE SCREW
HEX NUT
WASHER, LOCK
2
2
2
2
1
1
1
1
5
5
1
1
1
1
1
1
1
2
2
3
1
1
1
1
1
5A
5B
5C
6
7
7A
8
WASHER, FLAT
ENGINE SPEED SWITCH
PREHEAT LAMP
BULB, DC 28V
EMERGINCY STOP BUTTON
ALARM LAMP
BULB, DC 28V
9
9A
10
11
12
13
14
15
16
17
17A
18
19
19A
20
20A
20B
TACHOMETER
OIL PRESSURE GAUGE
VOLTAGE DIVIDER
WATER TEMPERATURE GAUGE
CHARGING AMMETER
FUEL GAUGE
SET FRAME
HEX HEAD BOLT
HEX NUT
HEX HEAD BOLT
WATER TEMPERATURE UNIT
PACKING
OIL PRESSURE UNIT
ADAPTER OIL PRESSURE UNIT
STREET ELBOW
20C 8943998582
20D 1096301410
ADAPTER....................................................1 ................REPLACES P/N 0602020220
PACKING.....................................................1 ................REPLACES P/N 0602021701
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 61
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CONTROL BOX ASSY.
PAGE 62 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
CONTROL BOX
CURRENT TRANSFORMER, 750/5A
MACHINE SCREW
CIRCUIT BREAKER, 1000A
AUTOMATIC VOLTAGE REGULATOR
MACHINE SCREW
RESISTOR, 5W 150 OHM
MACHINE SCREW
VOLTAGE CHANGE- OVER BOARD
CHANGE TERMINAL
HEX HEAD BOLT
TERMINAL PLATE
CHANGE PLATE
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
QTY.
1
3
6
1
1
4
1
2
REMARKS
C3213002802
0601801170
0027106016
0601807514
0601820625
0027105016
0601842468
0027103010
C3274000003
8221852104
0017108030
C2277200004
8221853104
0801830804
0040016000
0041416000
0801830704
8201852504
0040012000
0041412000
0017110030
C3260503003
0017108020
8980956110
C3260503104
0016906012
0602103090
0601810244
0601831205
0601830710
0601830746
0016906016
0601823240
0027105020
LY2DUS24VDC
PTF08A
9
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
27A
28
29
30
31
32
33
34
34A
34B
35
36
37
38
39
40
41
10
20
3
6
10
10
10
13
3
16
16
4
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
ELECTRIC PARTS SET PANEL
HEX HEAD BOLT
CONTROLLER................................................ 1...............REPLACES P/N 0602202684
1
4
BRACKET
1
4
1
1
1
1
1
4
1
1
HEX HEAD BOLT
DIAGNOSTIC LAMP
BULB, DC28V
DIAGNOSTIC BUTTON
DIAGNOSTIC SWITCH
HIGH IDLE SPEED SWITCH
HEX HEAD BOLT
RECTIFIER
MACHINE SCREW
RELAY............................................................. 4...............REPLACES P/N 0601827655
SOCKET.......................................................... 4...............REPLACES P/N 0601823109
HOLDER ......................................................... 4...............REPLACES P/N 0601824400
MACHINE SCREW
BAROMETRIC PRESSURE SENSOR ........... 1...............REPLACES P/N 0602130220
MACHINE SCREW
STARTER RELAY............................................ 1...............REPLACES P/N 0602201401
HEX HEAD BOLT
RELAY............................................................. 2...............REPLACES P/N 0602202682
MACHINE SCREW
PYCA1
0027104020
8972177780
0027104010
8980056310
0016906016
8980137900
0027105010
8
2
2
2
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 63
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CONTROL BOX ASSY. (CONTINUED)
PAGE 64 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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CONTROL BOX ASSY. (CONTINUED)
NO.
42
43
44
45
46
47
48
PART NO.
PART NAME
GLOW PLUG RELAY.......................................1 ............. REPLACES P/N 0602202683
QTY.
REMARKS
8944607060
0027105010
0601815154
0027104016
8121468300
C3224001303
C3224002403
MACHINE SCREW
TERMINAL BLOCK
MACHINE SCREW
2
1
2
INLET AIR TEMPERATURE SENSOR ...........1 ............. REPLACES P/N 0603210240
CONTROL PANEL
CONTROL PANEL
RUBBER SEAL
RUBBER SEAL
PIN
FREQUENCY METER, 45~65Hz 200V
AC AMMETER, 0~750A 0~1500A
AMMETER CHANGE- OVER SWITCH
AC VOLTMETER, 0~600V
VOLTMETER CHANGE- OVER SWITCH
PILOT LAMP
BULB, 13W
RHEOSTAT, VOLT. REG, 2W 1K OHM
KNOB
1
1
2
2
2
1
1
1
1
1
1
1
1
1
48-1 0228800115
48-2 0228800190
49
50
51
52
53
54
55
55A
56
57
58
59
60
0605011211
0601807622
0601806987
0601801040
0601806887
0601801041
0601810072
0601810261
0601840073
0601840121
ECU9988N220V
0601830765
0601810161
0601810214
0207004000
0601830710
C9221100004
0040008000
0041208000
ENGINE CONTROLLER, ................................1 ............. REPLACES P/N 0602202545
SWITCH
PANEL LIGHT
BULB
HEX NUT
PANEL LIGHT SWITCH
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
SNAP RING
HEX HEAD BOLT
CONTROL PANEL STOPPER
WASHER, FLAT
SNAP PIN
1
1
1
2
1
2
2
2
2
4
1
1
1
1
1
2
1
2
2
2
1
1
1
1
1
60A
61
62
63
63A
63B
63C 0080200007
64
65
66
67
68
69
70
71
72
73
74
75
75A
75B
76
77
0017108040
3871824004
0041206000
0605010502
0601820847
0601820848
0027104016
0601802204
0601806671
0601802149
0027103020
C3358201704
0601806644
0601802410
0017106016
0601815153
OVER CURRENT RELAY
OVER CURRENT RELAY
MACHINE SCREW
FUSE HOLDER
FUSE, 15A
FUSE, 10A
MACHINE SCREW
FUSE HOLDER ASSY.
FUSE, 30A
FUSE HOLDER BRACKET
HEX HEAD BOLT
TERMINAL BLOCK
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 65
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CONTROL BOX ASSY. (CONTINUED)
PAGE 66 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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CONTROL BOX ASSY. (CONTINUED)
NO.
78
79
80
81
82
83
84
PART NO.
PART NAME
QTY.
REMARKS
0027104020
8221814804
0017108020
8224117004
0017108020
C3213400604
0017108020
0017110035
0207010000
0601806640
MACHINE SCREW
CONTROL BOX COVER
HEX HEAD BOLT
CONTROL BOX SIDE PANEL
HEX HEAD BOLT
CONTROL BOX PANEL
HEX HEAD BOLT
HEX HEAD BOLT
HEX NUT
2
1
8
1
4
1
8
4
4
1
85
85A
86
FUSE, 65A
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 67
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ENGINE AND RADIATOR ASSY.
PAGE 68 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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ENGINE AND RADIATOR ASSY.
NO.
1
1-1
1-2
1-3
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO.
PART NAME
ENGINE, ISUZU 6WG1X
MAIN OIL FILTER CARTRIDGE ..........................1 ...........REPLACES P/N 0602041219
BYPASS OIL FILTER CARTRIDGE .....................1 ...........REPLACES P/N 0602041220
MAIN FUEL FILTER ELEMENT...........................2 ...........REPLACES P/N 0602042515
QTY.
1
REMARKS
C3923200194
1132402330
1132402410
8980088400
C3303200504
0010314040
0040014000
0041614000
C3303200604
C3303200704
0010316040
0040016000
0041616000
0605000061
0030016000
0040016000
0041616000
C3923200174
ENGINE FOOT
2
8
8
8
1
1
8
8
8
4
8
8
8
1
2
1
6
6
6
12
1
1
4
2
1
1
16
1
1
1
2
14
1
1
1
1
1
1
1
1
1
1
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
ENGINE FOOT
ENGINE FOOT
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
RUBBER SUSPENSION
HEX NUT
WASHER, LOCK
WASHER, FLAT
RADIATOR & INTER COOLER ASSY.
CAP
ACOUSTIC SHEET
HEX HEAD BOLT
HEX NUT
WASHER, LOCK
WASHER, FLAT
15-1 0602011059
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
40A
40B
C3493600004
0010116065
0030016000
0040016000
0041216000
C3311100504
C3311100604
0017112025
0017112025
C33110200403
C3310200503
0016910025
C3310500003
C3310500103
C3310400004
C3310500404
0605515290
0602123290
C3310500203
0605515214
0605515213
C3310500303
0605515238
0605515239
0602046539
0602046628
0602046629
RADIATOR BRACKET
RADIATOR BRACKET
HEX HEAD BOLT
HEX HEAD BOLT
FAN GUARD
FAN GUARD
HEX HEAD BOLT
RADIATOR HOSE
RADIATOR HOSE
RADIATOR PIPE
RADIATOR HOSE
HOSE BAND
COOLANT LEVEL SWITCH
INTER COOLER HOSE
HOSE BAND
HOSE BAND
INTER COOLER HOSE
HOSE BAND
HOSE BAND
AIR CLEANER
AIR CLEANER OUTER ELEMENT
AIR CLEANER INNER ELEMENT
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 69
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ENGINE AND RADIATOR ASSY. (CONTINUED)
PAGE 70 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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ENGINE AND RADIATOR ASSY. (CONTINUED)
NO.
41
42
43
44
44A
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
PART NO.
PART NAME
QTY.
1
2
1
4
4
4
1
2
4
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
6
1
1
1
2
1
1
1
REMARKS
0602040779
0602040582
C3373200004
0016910025
0207010000
0016910025
C3373000003
0602040393
0605515260
0602040666
C3373200104
0016908020
0602326064
0602022560
M1320300304
0602022561
0603306590
0603300285
0605511395
0603306395
0602021070
0269200500
0802081003
0602010900
C1317100103
0016910025
0602022929
0199900800
0199900300
0199901600
0193602000
0605515106
0193601300
0193600550
0269502100
0605515067
8973639360
8972177780
0602120465
8980305320
C3357200002
1136714740
1802200140
AIR CLEANER CAP
AIR CLEANER BAND
AIR CLEANER BRACKET
HEX HEAD BOLT
HEX NUT
HEX HEAD BOLT
AIR CLEANER PIPE
90 DEGREE ELBOW
HOSE BAND
AIR CLEANER INDICATOR
AIR CLEANER PIPE BRACKET
HEX HEAD BOLT
U BOLT
ADAPTER
PACKING
90 DEGREE ELBOW
CONNECTOR
ROCKNUT
VALVE
HOSE JOINT
CAP
DRAIN HOSE
RESERVE TANK
RESERVE TANK CAP
RESERVE TANK BRACKET
HEX HEAD BOLT
JOINT
HOSE
HOSE
HOSE
HOSE
HOSE BAND
HOSE
HOSE
HOSE
HOSE BAND
WATER TEMPERATURE SENSOR
OIL PRESSURE SENSOR
PICK UP TACHOMETER
BLOWBY FILTER ELEMENT.........................1..................REPLACES P/N 0602044210
ENGINE WIRE HARNESS
FAN BELT.......................................................3..................REPLACES P/N 0602015252
BOOST SENSOR
1
1
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 71
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OUTPUT TERMINAL ASSY.
THE PART
FOLLOW
I.
PAGE 72 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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OUTPUT TERMINAL ASSY.
NO.
1
2
3
4
5
6
7
8
8A
8B
9
10
11
PART NO.
PART NAME
QTY.
1
8
REMARKS
C2231700403
C0277500004
0801830904
0039320000
0040020000
0041420000
3501860604
0019110050
0042310000
0042410000
0601808803
0601808804
C3261600704
OUTPUT TERMINAL SET BOARD
OUTPUT TERMINAL
HEX HEAD BOLT
HEX NUT
8
16
24
32
3
5
5
5
2
3
1
1
2
2
3
10
10
1
8
1
2
1
2
1
2
4
2
2
2
1
7
1
2
1
1
1
WASHER, LOCK
WASHER, FLAT
TERMINAL PLATE
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
CIRCUIT BREAKER, 20A
CIRCUIT BREAKER, 50A
CIRCUIT BREAKER BREAKER
RUBBER CUSHION
HEX HEAD BOLT
RECEPTACLE, GF-530EM
RECEPTACLE, CS-6369
MACHINE SCREW
HEX NUT
11-1 0221200150
12
13
14
15
15A
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
0019206016
0601812598
0601812565
0025304016
0207004000
C2234500104
0019206016
0601815194
0025304016
0601850275
0601851780
C2237102303
0019112045
0042412000
0805015604
0205012000
0845043704
C2237101204
0019208020
C2237102403
0019210030
0845054204
0805015604
C2237101504
C2237400104
0019206020
COVER
HEX HEAD BOLT
TERMINAL BLOCK
MACHINE SCREW
GROMMET
GROMMET
OUTPUT TERMINAL COVER
HEX HEAD BOLT
WASHER, FLAT
STAY RUBBER
HEX NUT
SPRING
COVER
HEX HEAD BOLT
OUTPUT TERMINAL COVER
HEX HEAD BOLT
COLLAR
STAY RUBBER
COVER
BRACKET
HEX HEAD BOLT
1
2
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 73
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BATTERY ASSY.
PAGE 74 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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BATTERY ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
BATTERY
BATTERY SHEET
BATTERY BAND
BATTERY BOLT
WING NUT
QTY.
2
2
2
4
4
4
4
1
1
1
1
1
4
4
2
2
REMARKS
0165721052
C9109100704
0805007804
0805006504
0037808000
0040008000
0041608000
C3346601804
C3346601904
C3346602004
C3346602104
C3346200004
0347010030
0208110000
0845040114
0845041004
0017114025
0040514000
0017110025
0040510000
0017112025
0040512000
WASHER, LOCK
WASHER, FLAT
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
EARTH CABLE
HEX HEAD BOLT
HEX NUT
TERMINAL CAP (+)
TERMINAL CAP (-)
HEX HEAD BOLT
TOOTHED WASHER
HEX HEAD BOLT
TOOTHED WASHER
HEX HEAD BOLT
TOOTHED WASHER
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1
1
1
1
1
1
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 75
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MUFFLER ASSY.
PAGE 76 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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MUFFLER ASSY.
NO.
1
2
2A
2B
3
4
5
6
6A
6B
6C
7
7A
7B
7C
8
PART NO.
PART NAME
MUFFLER
QTY.
1
4
4
4
1
1
1
8
8
8
16
4
4
4
8
1
4
REMARKS
C3330100402
0019110025
0042310000
0047010030
C3333001903
C9304000304
C3334200804
0010316060
0030316000
0042516000
0041616000
0010316060
0030016000
0042516000
0041616000
C3333302104
0017108020
0602326065
C3331300404
0019208020
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
EXHAUST PIPE
GASKET
GASKET
HEX HEAD BOLT
HEX NUT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
HEX NUT
WASHER, LOCK
WASHER, FLAT
BRACKET
9
HEX HEAD BOLT
U- BOLT
COVER
10
11
12
1
2
4
HEX HEAD BOLT
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 77
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FUEL TANK ASSY. (S/N 3813334 AND BELOW)
PAGE 78 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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FUEL TANK ASSY. (S/N 3813334 AND BELOW)
NO.
1
PART NO.
PART NAME
FUEL TANK
FUEL TANK CAP
FUEL FILTER
FUEL GAUGE HOSE
HOSE BAND
FUEL SENSOR
PACKING
FUEL UNIT
PACKING
MACHINE SCREW
TANK BAND
TANK BAND PAD
HEX HEAD BOLT
SUPER LOCK NUT
TANK SHEET
STREET ELBOW, 1/2”
DRAIN PIPE
VALVE
PLUG, 1/2”
LOCK PLATE
HEX HEAD BOLT
RUBBER SEAL
BRACKET
QTY.
1
1
1
1
2
1
1
1
1
5
2
4
2
2
6
1
1
1
1
1
2
1
1
3
REMARKS
C3363002503
0845500104
0810105400
0264100525
0605515079
0605503020
0802120604
0605501089
0605516090
0022905015
8225523104
0805003414
0016908020
0207308000
0222100300
0130206000
0134306170
0603325026
0132006000
C1367700304
0019208020
0845039604
C3366704704
0016910025
8980758550
8980758540
8980955010
1096750951
1096301110
0017110040
0010110075
0040010000
0041210000
0130406000
0130206000
0602022209
0191402500
0191400600
0191400500
0191402800
0191405300
0605515132
1-1
1-2
1-3
1-4
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21A
22
23
24
25
26
26A
26B
27
28
29
30
31
32
33
34
35
HEX HEAD BOLT
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
PACKING....................................................8...........REPLACES P/N 0602021702
HEX HEAD BOLT
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
T-JOINT, 1/2”
4
2
2
2
2
4
6
1
2
2
1
1
14
STREET ELBOW, 1/2”
HOSE JOINT
SUCTION HOSE
SUCTION HOSE
SUCTION HOSE
SUCTION HOSE
RETURN HOSE
HOSE BAND
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 79
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FUEL TANK ASSY. (S/N 3813335 AND ABOVE)
PAGE 80 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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FUEL TANK ASSY. (S/N 3813335 AND ABOVE)
NO.
1
PART NO.
PART NAME
FUEL TANK
FUEL TANK CAP
FUEL FILTER
FUEL GAUGE HOSE
HOSE BAND
FUEL SENSOR
PACKING
FUEL UNIT
PACKING
MACHINE SCREW
TANK BAND
TANK BAND PAD
HEX HEAD BOLT
SUPER LOCK NUT
TANK SHEET
STREET ELBOW, 1/2”
DRAIN PIPE
VALVE
PLUG, 1/2”
LOCK PLATE
HEX HEAD BOLT
RUBBER SEAL
BRACKET
QTY.
1
1
1
1
2
1
1
1
1
5
2
4
2
2
6
1
1
1
1
1
2
1
1
3
REMARKS
C3363002503
0845500104
0810105400
0264100525
0605515079
0605503020
0802120604
0605501089
0605516090
0022905015
8225523104
0805003414
0016908020
0207308000
0222100300
0130206000
0134306170
0603325026
0132006000
C1367700304
0019208020
0845039604
C3366704704
0016910025
8980758550
8980758540
8980955010
1096750951
1096301110
0017110040
0010110075
0040010000
0041210000
0130406000
0130206000
0602022209
0191402500
0191400600
0191400500
0191402800
0191405300
0605515132
C3366704804
0019208020
0131506000
0130206000
1-1
1-2
1-3
1-4
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21A
22
23
24
25
26
26A
26B
27
28
29
30
31
32
33
34
35
36
37
38
39
HEX HEAD BOLT
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
PAACKING .................................................8...........REPLACES P/N 0602021702
HEX HEAD BOLT
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
T-JOINT 1/2”
4
2
2
2
2
4
6
1
2
2
1
1
14
STREET ELBOW, 1/2”
HOSE JOINT
SUCTION HOSE
SUCTION HOSE
SUCTION HOSE
SUCTION HOSE
RETURN HOSE
HOSE BAND
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
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 81
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ENCLOSURE #1 ASSY.
THE PART NUMBER INDICATED IS ORANGE. PLEASE ADD THE
FOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT:
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 82 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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ENCLOSURE #1 ASSY.
NO.
1
2
3
4
5
6
6A
7
8
PART NO.
PART NAME
BASE
QTY.
1
1
1
2
38
1
1
4
1
2
1
1
1
1
1
1
1
1
20
1
1
1
1
24
8
1
1
1
1
4
28
1
14
1
4
4
4
REMARKS
C3413003502
C3414100104
C3413100304
C3414100804
0019208020
C3413600004
0228901070
0019208020
C2367700404
0019208025
C3424001204
C3493100703
C3423001003
C3493100703
C3423001102
C3493100703
C3423001202
C3493100703
0019208020
C3423300003
C3492100703
C3424301103
C3493100703
0019208020
0019210025
C3424201403
C3424203104
C3494102604
0845042703
0019208020
0019208020
C3423201103
0019208020
C3433000202
0010120060
0030020000
0040020000
0041620000
0010120050
0030020000
0041620000
C3463101402
C3493500203
M3310600004
0019204020
0019208020
C3463500204
0019208020
0019210025
0019116025
0042416000
FLOOR PANEL
FLOOR PANEL
FLOOR PANEL
HEX HEAD BOLT
BASE DUCT
RUBBER SEAL
HEX HEAD BOLT
COVER
HEX HEAD BOLT
FRONT FRAME
LINING
FRONT FRAME
LINING
FRONT FRAME
LINING
FRONT FRAME
LINING
HEX HEAD BOLT
AIR GUIDE PANEL
LINING
AIR GUIDE PANEL
LINING
HEX HEAD BOLT
HEX HEAD BOLT
FRONT FRAME COVER
FRONT FRAME COVER
LINING
FILLER BASKET
HEX HEAD BOLT
HEX HEAD BOLT
FRONT FRAME COVER
HEX HEAD BOLT
CENTER FRAME
HEX HEAD BOLT
HEX NUT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
HEX NUT
WASHER, FLAT
ROOF PANEL
LINING
9
10
10A
11
11A
12
12A
13
13A
14
15
15A
16
16A
17
18
19
20
20A
21
22
23
24
25
26
27
27A
27B
27C
28
28A
28C
29
29A
30
31
32
33
34
35
36
36A
8
8
8
16
1
1
1
4
20
2
COVER
HEX HEAD BOLT
HEX HEAD BOLT
GUTTER
HEX HEAD BOLT
HEX HEAD BOLT
HEX HEAD BOLT
HEX NUT
2
4
1
1
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 83
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ENCLOSURE #2 ASSY.
THE PART NUMBER INDICATED IS ORANGE. PLEASE ADD THE
FOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT:
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 84 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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ENCLOSURE #2 ASSY.
NO.
1
1A
2
2A
3
4
5
5A
6
6A
7
8
PART NO.
PART NAME
QTY.
1
1
1
1
11
4
1
1
1
REMARKS
C3443000403
0228901290
C3443000502
8225940104
0017108020
0019210025
C3443302103
C3493300004
C3444302504
C3491400004
0017108020
0019208020
C3443201303
C3443201403
8225147004
0207306000
0600800320
0207006000
B9114000102
0021806015
0030006000
8225146204
8225146304
0845050704
0207006000
0805011304
0805011204
0207006000
0845047104
0845045004
0845047204
0845045004
0019208020
0601850097
0025408025
0845031504
C3463201202
C3493500304
C3464501704
C3494502204
0017108020
0019208020
C3463500304
0092108020
0019210025
REAR FRAME
RUBBER SEAL
REAR FRAME
LINING
HEX HEAD BOLT
HEX HEAD BOLT
REAR FRAME COVER
LINING
DUCT COVER
LINING
1
HEX HEAD BOLT
HEX HEAD BOLT
REAR DOOR FRAME
REAR DOOR FRAME
WINDOW PLATE
HEX NUT
12
15
1
1
2
12
9
10
11
12
13
14
15
16
16A
17
18
19
20
21
22
23
24
24A
25
25A
26
27
28
29
30
30A
31
31A
32
33
34
35
36
MANUAL PAK.................................1............. 9000-07
HEX NUT
4
1
4
4
1
1
4
8
1
1
4
2
2
2
2
6
2
2
4
1
1
1
1
15
20
2
2
4
DOOR HANDLE
MACHINE SCREW
HEX NUT
DOOR ROD
DOOR ROD
STAY
HEX NUT
DOOR STOPPER
DOOR STOPPER
HEX NUT
HINGE
WASHER
HINGE
WASHER
HEX HEAD BOLT
STOPPER
MACHINE SCREW
CAP
ROOF PANEL
LINING
ROOF PANEL COVER
LINING
HEX HEAD BOLT
HEX HEAD BOLT
GUTTER
HEX HEAD BOLT
HEX HEAD BOLT
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 85
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ENCLOSURE #3 ASSY.
THE PART NUMBER INDICATED IS ORANGE. PLEASE ADD THE
FOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT:
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 86 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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ENCLOSURE #3 ASSY.
NO.
1
1A
2
2A
2B
3
3A
4
4A
5
5A
5B
6
6A
7
7A
8
PART NO.
PART NAME
SPLASHER PANEL
LINING
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
SIDE PANEL
LINING
QTY.
1
1
6
6
6
1
1
1
REMARKS
C3453200702
C3493402104
0019108065
0042308000
0042408000
C3453100503
C3493401004
C3453100603
C3493401104
0019108065
0042308000
0042408000
C3453100703
C3493401204
C3453100803
C3493401304
C3453300504
C3493401803
C3453300604
C3493401903
C3453300704
C3493402003
0207006000
C3453000903
C3493400604
C3453001003
C3493400704
C3453001103
C3493400804
C3453005203
C3493400904
C3453300304
C3493401603
C3453300804
C3493402203
C3453300404
C3493401704
C3453500004
C3493401704
0019208016
0207006000
B9114000002
0825007362
0021806015
0030006000
SIDE PANEL
LINING
1
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
SIDE PANEL
LINING
SIDE PANEL
LINING
DUCT
LINING
DUCT
LINING
DUCT
LINING
HEX NUT
SIDE PANEL
LINING
SIDE PANEL
LINING
SIDE PANEL
LINING
SIDE PANEL
LINING
DUCT
LINING
DUCT
LINING
DUCT
LINING
PANEL
LINING
HEX HEAD BOLT
HEX NUT
DOOR HANDLE
DOOR HANDLE
MACHINE SCREW
HEX NUT
10
10
10
1
1
1
1
1
1
1
1
1
1
21
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
10
4
3
28
28
8A
9
9A
10
10A
11
12
12A
13
13A
14
14A
15
15A
16
16A
17
17A
18
18A
19
19A
20
21
22
23
24
24A
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 87
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ENCLOSURE #3 ASSY. (CONTINUED)
THE PART NUMBER INDICATED IS ORANGE. PLEASE ADD THE
FOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT:
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 88 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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ENCLOSURE #3 ASSY. (CONTINUED)
NO.
25
25A
26
26A
27
28
29
30
31
31A
31B
PART NO.
PART NAME
HINGE
WASHER
HINGE
WASHER
HEX HEAD BOLT
STOPPER
MACHINE SCREW
CAP
QTY.
8
8
8
8
37
11
11
16
4
REMARKS
0845046904
0845045004
0845047005
0845045004
0019208020
0601850097
0025408025
0845031504
0019108065
042308000
0042408000
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
4
4
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 89
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RUBBER SEALS ASSY.
PAGE 90 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
4
4
4
2
4
2
3
1
1
2
2
2
1
4
4
REMARKS
0229201400
0228901320
0228901450
0228900850
0228901350
0228801390
0228901390
0228900790
0229201340
0221200795
0228801250
0229200560
0229201230
0228100120
0228100510
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
9
10
11
12
13
14
15
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 91
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NAMEPLATE AND DECALS ASSY.
PAGE 92 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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NAMEPLATE AND DECALS ASSY.
NO.
1-1
1-2
PART NO.
C3550000703
C9522100003
PART NAME
QTY.
REMARKS
DECAL : HANDLING PROCEDURES .........................1................. C35000070
DECAL : CAUTION ......................................................2................. C92210000
CONTROL BOX GROUP
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
0800520100
0800520904
0800520814
0840624504
0840624604
0840624704
0840624804
B9531100604
C0551000903
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
2-10 C2551000004
2-11 C3551001004
2-12 C3560100003
2-13 C9500402104
2-14 C9520027704
2-15 C9521007504
ENGINE & RADIATOR GROUP
3-1
3-2
3-3
3-4
3-5
3-6
3-7
1320610603
6360610304
6360620204
B9504000304
B9504000404
B9504100104
C3550000603
DECAL : WATER- OIL ..................................................1................. S-1760
DECAL : WATER ..........................................................1................. S-1880
DECAL : OIL DRAIN PLUG..........................................1................. S-1885
DECAL : CAUTION HOT PARTS..................................1................. B90400030
DECAL : WARNING MOVING PARTS..........................2................. B90400040
DECAL : WARNING HOT COOLANT...........................1................. B90410010
DECAL : AIR BLEEDING PROCEDURE .....................1................. C35000060
ENGINE OPERATING PANEL GROUP
4-1
4-2
4-3
C0551000504
C3550000404
C3550000503
DECAL : BATTERY SWITCH .......................................1................. C05100050
DECAL : ALARM LAMP...............................................1................. C35000040
DECAL : OPERATING PANEL .....................................1................. C35000050
OUTPUTTERMINAL GROUP
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
0840614104
0840619904
9039209064
B9511100304
B9511100404
B9531100504
C0551000404
C1551000803
DECAL : GROUND ......................................................1................. S-2635
DECAL : DANGER HIGH VOLTAGE.............................1................. S-2731
DECAL : START CONTACT .........................................1................. S-4468
DECAL : WARNING ....................................................1................. B91110030
DECAL : WARNING ELECTRIC SHOCK HAZARD.....1................. B91110040
DECAL : WARNING ELECTRIC SHOCK HAZARD.....1................. B93110050
DECAL : 3- PHASE OUTPUT TERMINAL ...................1................. C05100040
DECAL : RECEPTACLE & CIRCUIT BREAKER..........1................. C15100080
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 93
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NAMEPLATE AND DECALS ASSY. (CONTINUED)
PAGE 94 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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NAMEPLATE AND DECALS ASSY. (CONTINUED)
NO.
PART NO.
PART NAME
BATTERY GROUP
QTY.
REMARKS
6-1
6-2
6-3
0800689404
0800689504
C9505300004
DECAL : + ............................................................... 1...................... S-2090
DECAL : -................................................................ 1...................... S-2091
DECAL : CAUTION ................................................. 1...................... C90530000
MUFFLER GROUP
DECAL : DANGER.................................................. 1...................... A90400001
DECAL : WARNING ENGINE EXHAUST................ 1...................... B90420000
7-1
7-2
A9504000014
B9504200004
FUEL TANK GROUP
8-1
8-2
8-3
1320620904
6360620004
B9504500004
DECAL : DIESEL FUEL .......................................... 1...................... S-1756
DECAL : FUEL DRAIN PLUG ................................. 1...................... S-1883
DECAL : WARNING DIESEL FUEL ........................ 1...................... B9045 000
BONNET GROUP
DECAL : SUPPORT HOOK .................................... 1...................... S-2257
DECAL : MQ............................................................ 1...................... S-3057
9-1
9-2
9-3
1320621504
0840625902
0600500090
EMBLEM
MACHINE SCREW
STRIPE
STRIPE
STRIPE
STRIPE
STRIPE
STRIPE
STRIPE
STRIPE
2
4
2
1
2
1
1
1
1
2
9-3A 0021106016
9-4
9-5
9-6
9-7
9-8
9-9
C2561101204
C3561100203
C4561102204
C3561101603
C3561100803
C3561101703
9-10 C3561101003
9-11 C5561100204
9-12 C9504000304
DECAL : CAUTION ................................................. 1...................... C90400030
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 95
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TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
5. Partsmustbeinnewandresalablecon- Multiquipreservestherighttoquoteandsell
dition,intheoriginalMultiquippackage(if directtoGovernmentagencies,andtoOriginal
Terms of payment for parts are net 30 days.
any), and with Multiquip part numbers Equipment Manufacturer accounts who use
FREIGHTPOLICY
clearlymarked.
our products as integral parts of their own
products.
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifesthasbeenobtainedfromthecarrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
SPECIALEXPEDITINGSERVICE
a. Obsolete parts. (If an item is in the
price book and shows as being re- A$35.00surchargewillbeaddedtotheinvoice
placedbyanotheritem,itisobsolete.) forspecialhandlingincludingbusshipments,
insuredparcelpostorincaseswhereMultiquip
mustpersonallydeliverthepartstothecarrier.
(such as gaskets, seals, “O” rings,
b. Any parts with a limited shelf life
andotherrubberparts)thatwerepur- LIMITATIONSOFSELLER’SLIABILITY
MINIMUMORDER
chasedmorethansixmonthspriorto
thereturndate.
Multiquip shall not be liable hereunder for
damagesinexcessofthepurchasepriceofthe
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
c. Anylineitemwithanextendeddealer item with respect to which damages are
netpriceoflessthan$5.00.
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
otherspecial,consequentialorincidentaldam-
ages.
d. Special order items.
RETURNEDGOODSPOLICY
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremade
in connection with the sale of parts or trade
accessoriesnorastoanyenginenotmanufac-
tured by Multiquip. Such warranties made in
connectionwiththesaleofnew,completeunits
are made exclusively by a statement of war-
rantypackagedwithsuchunits,andMultiquip
neitherassumesnorauthorizesanypersonto
assume for it any other obligation or liability
whatever in connection with the sale of its
products.Apartfromsuchwrittenstatementof
warranty, there are no warranties, express,
impliedorstatutory,whichextendbeyondthe
descriptionoftheproductsonthefacehereof.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
7. Thesenderwillbenotifiedofanymaterial
receivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Suchmaterialwillbeheldforfiveworking
days from notification, pending instruc-
tions.Ifareplyisnotreceivedwithinfive
days,thematerialwillbereturnedtothe
senderathisexpense.
a. Thepartsnumbersanddescriptions
must match the current parts price
list.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
Effective: February 22, 2006
d. The list must reference the sales
order(s)orinvoice(s)underwhichthe
itemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. The list must include the name and
phonenumberofthepersonrequest-
ingtheRMA.
PRICINGANDREBATES
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspe-
cificdateandallordersreceivedonorafterthat
datewillbebilledattherevisedprice.Rebates
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All forpricedeclinesandaddedchargesforprice
partsmustbereturnedfreightprepaidto increaseswillnotbemadeforstockonhand
Multiquip’sdesignatedreceivingpoint.
atthetimeofanypricechange.
PAGE 96 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)
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NOTES
DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 97
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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]
MQ Parts Department
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service/Tech Support/Warranty
800-835-2551 Fax: 310-638-8046
© COPYRIGHT 2008, MULTIQUIP INC.
MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the
property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times.This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
Manufactured for
Multiquip Inc.
by
Your Local Dealer is:
DENYO CO., LTD, JAPAN
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