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THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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publication, visit our website at:

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WHISPERWATT™ SERIES

MODEL DCA400SSI

60HZ GENERATOR

(ISUZU 6WG1X DIESEL ENGINE)

PARTS LIST NO. C3871301004

Revision #2 (11/03/08)

OPERATION AND PARTS MANUAL

Summary of Contents for Power WHISPERWATT DCA400SSI

Page 1: ... ALL TIMES To find the latest revision of this publication visit our website at www mqpower com WHISPERWATT SERIES MODEL DCA400SSI 60HZ GENERATOR ISUZU 6WG1X DIESEL ENGINE PARTS LIST NO C3871301004 Revision 2 11 03 08 OPERATION AND PARTS MANUAL ...

Page 2: ...PAGE 2 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PROPOSITION 65 WARNING Diesel engine exhaust and some of ...

Page 3: ...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 1 888 327 4236 TTY 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator NHTSA ...

Page 4: ... 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 Component Drawings Generator Assembly 56 59 Engine Operating Panel Assembly 6...

Page 5: ... for more information Order via Internet Dealers Only Orderpartson lineusingMultiquip sSmartEquipwebsite View Parts Diagrams Order Parts PrintSpecificationInformation Note Discounts Are Subject To Change Gotowww multiquip comandclickon Order Parts to log in and save Use the internet and qualify for a 5 Discount on Standard orders for all orders which include completepartnumbers Order via Fax Deale...

Page 6: ...fety 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 w...

Page 7: ...o know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency GENERATOR SAFETY DANGER The engine fuel exhaust gases contain poisonous carbon monoxide This gas is colorless and odorless and can cause death if inhaled The engine of this equipment requires an adequate free flow of cooling air NEVER operate this equipment i...

Page 8: ...sel 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 pe...

Page 9: ...ating condition ALWAYS shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure on both towing vehicle and trailer Trailer tires should be inflated to 5...

Page 10: ...icable 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 insul...

Page 11: ...attery in a well ventilated environmenttoavoidtheriskofadangerousconcentration 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 ...

Page 12: ...er Single Phase 60 Hz Aux Voltage Output 4 8 Kw 2 4 kW x 2 DryWeight 11 640 lbs 5 280 kg WetWeight 12 875 lbs 5 840 kg Engine Specifications Table 2 Model ISUZU 6WG1X Type 4 cycle water cooled direct injection turbo charged with air to air after cooler No of Cylinders 6 cylinders Bore x Stroke 5 79 in x 6 06 in 147 mm x 154 mm Displacement 957 cu in 15 681 cc Rated Output 464 HP at 1800 rpm Starti...

Page 13: ...Table 3 Reference Letter Dimension in mm Reference Letter Dimension in mm A 17 72 in 450 mm H 23 23 in 590 mm B 35 83 in 910 mm I 35 83 in 910 mm C 23 23 in 590 mm J 17 72 in 450 mm D 31 89 in 810 mm K 181 10 in 4 600 mm E 18 11 in 685 mm L 82 68 in 2 100 mm F 22 24 in 565 mm M 55 12 in 1 400 mm G 31 89 in 810 mm ...

Page 14: ...PAGE 14 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 INSTALLATION Typical Generator Grounding Application Figure 2 ...

Page 15: ...ion 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 CAUTION Pay close attention to ventilation when operating the generator inside tunnels and caves The eng...

Page 16: ...oads 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 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...

Page 17: ...DESCRIPTION 1 Output Receptacles Assembly 2 Output Terminal Panel Assembly 3 Muffler Assembly 4 Air Filter Assembly 5 Fuel Tank Assembly 6 Engine and Radiator Assembly 7 Generator Assembly 8 Battery Assembly 9 Generator Control Panel Assembly 10 Circuit Breaker Assembly 11 Engine Operating Panel Assembly Major Components Figure 3 ...

Page 18: ... allows theACammetertoindicatethecurrentflowingtotheload 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 Panel Light Switch 8 When activated will turn on control panel light Voltage Regulator Control 9 Allows 15 manual adjustment of the generator s output voltage Main Circuit Breaker...

Page 19: ... unit This is considered a major fault High Coolant Temperature Indicates the engine temperature has exceeded a safe operating level The engine temperature is detected using variable resistive values from the temperature sending unit This is considered a major fault Overcrank Shutdown Indicates the unit has attempted to start a pre programmed number of timesand has failed to start The number of cy...

Page 20: ... b During normal operation of the generator this lamp should remain OFF When the Auto OFF Reset Manual switch is set 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 shutdowndevicewillstoptheengine automatically LowFuelLevelLamp c Whenthi...

Page 21: ...DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 21 NOTES ...

Page 22: ... Lift up on the cover to gain access to receptacles and terminal lugs NOTICE Terminal legs O and Ground are considered bonded grounds OUTPUTTERMINAL FAMILIARIZATION The Output Terminal Panel Figure 6 is provided with the following Three 3 120 240V output receptacles 50 amp Three 3 Circuit Breakers 50 amps Two 2 120V GFCI receptacles 20 amp Two 2 GFCI Circuit Breakers 20 amps Eight 8 Output Termina...

Page 23: ...tion Both receptacles should be tested at least once a month G F C I Receptacle Figure 7 Twist Lock DualVoltage 120 240VAC 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 120 240V Twist Lock Auxili...

Page 24: ...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 Connecting Loads Figure 10 Over Current Relay An over current relay Figure 11 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can not...

Page 25: ...able 5 Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equipment 1 0 Common power tools 0 8 THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation An inadequate size connecting cable which cannot carry the required load can...

Page 26: ...hich can cause severe bodily harm or even death Voltages Available Table 7 Three Phase Switchable 208V 220V 240V 416V 440V 480V Single Phase Switchable 120V 127V 139V 240V 254V 277V Generator Amperage Tables 8 and 9 describe the generator s current output capability for both 1Ø phase and 3Ø phase applications These calculations reflect the maximum amount of current the generator can provide at eac...

Page 27: ...ace 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 Voltage Change Over Board 240V Figure 13 Configuration Generator Maximum Amps Table 10 Model DCA400SSI RatedVoltage Maximum Amps Single Phase 120 Volt 888 9 amps 4 wire Single Phase 240 Volt 444 4 amps 4 wire ...

Page 28: ...n as shown in Figure 18 Voltage Change Over Board 240V Figure 18 Configuration Connect the load wires to the UVWO terminals as 2 shown in Figure 19 UVWO Terminal Lugs Figure 19 Turn the voltage regulator knob Figure 20 clockwise 3 to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required ...

Page 29: ...4 UVWO Terminal Lugs 3Ø 480V Figure 24 Connections NOTICE ALWAYS make sure that the connections to the UVWO terminals are secure and tight The possibility of arcing exists that could cause a fire 1Ø 480V UVWOTerminal OutputVoltages Make sure the voltage change over board is jumpered 1 for 480V operation as shown in Figure 23 Connect the load wires to the UVWO terminals as 2 shown in Figure 25 UVWO...

Page 30: ... 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 Recommended Motor Oil Table 11 FUEL CHECK Refilling the Fuel System This...

Page 31: ...S place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank NOTICE ONLY use 2 diesel fuel when refueling Open cabinet doors on the right side of the generator 2 from generator control panel position Remove fuel cap and fill tank Figure 30 Fueling the Generator Figure 30 NEVER overfill fuel tank 3 It is important to read...

Page 32: ... can cause severe burns Coolant Capacity Table 12 Engine and Radiator 15 8 Gal 60 liters Reserve Tank TBD Anti Freeze Table 13 OperatingTemperatures Vol Anti Freeze Freezing Point C F 50 37 34 NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Period...

Page 33: ...nnect the negative terminal FIRST and reconnect negative terminal LAST When connecting battery do the following NEVER 1 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 Place a small amount of battery terminal treatment 2 compound a...

Page 34: ...VERmanuallystarttheenginewiththemain GFCIor auxiliary circuit breakers in the ON closed position STARTING MANUAL Place the engine speed switch Figure 37 in the LOW 1 down position Engine Speed Switch Low Figure 37 Place the 2 MPEC control switch in the MANUAL position to start the engine Figure 38 MPEC Control Switch Figure 38 Manual Position Depending on the temperature of the coolant cold 3 weat...

Page 35: ...l pressure of the engine Under normal operating conditions the oil pressure is approximately 28 to 85 psi 193 586 kPa Oil Pressure Gauge Figure 46 The 10 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 Coolant Temperature Gauge Figure 47 The 11 tachometer gauge Figure ...

Page 36: ...running the generator in the AUTO mode rememberthegeneratorcanstartupatanytimewithout 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...

Page 37: ...nutes with no load applied Place the 4 MPEC Control Switch Figure 54 to the OFF RESET position MPEC Control Switch Off Reset Figure 54 Verify that 5 all the status LEDs on the MPEC display are OFF not lit Remove all loads from the generator 6 Inspect entire generator for any damage or loosening 7 of components that may have occurred during operation WARNING NEVER stop the engine suddenly except in...

Page 38: ...ck all Hoses and Clamps 4 X Clean Inside of Fuel Tank X Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X MAINTENANCE 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 maintenan...

Page 39: ...sing a spray washer Figure 57 wash out any deposits or debris that have accumulated inside the fuel tank Fuel Tank Cleaning Figure 57 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 Hoses inspect nylon and rubb...

Page 40: ...adiator cap tightly Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed DO NOT clean radiator core with any objects such as a screwdriver WARNING Allow engine to cool when flushing out radiator Flushing the radiator while hot could cause serious burns from water or steam RADIATOR CLEANING The radiator Figure 58 should be sprayed cleaned with a hi...

Page 41: ... 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 Battery Charger and Jacket Water Figure 59 Heater Power Connections If the generator will be used daily the battery...

Page 42: ...ailer support device with maximum pound requirement from the tongue of the trailer Coupler 7 Type of hitch used on the trailer for towing Tire Size 8 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 Tire Ply 9 The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc Wheel Hub...

Page 43: ...ge 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 Hydraulic Brake Components Figure 60 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 ...

Page 44: ... great force and cause serious eye or bodily injury TireWearTroubleshooting Table 16 Wear Pattern Cause Solution Center Wear Over inflation Adjust pressure to particular load per tire manufacturer Edge Wear Under inflation Adjust pressure to particular load per tire manufacturer Side Wear Loss of camber or overloading Make sure load does not exceed axle rating Align wheels Toe Wear Incorrect toe i...

Page 45: ... 1 Torque all lug nuts in sequence see Figure 62 2 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 18 After first road use retorque all lug nuts in sequence 3 Check all wheel lug nuts periodically TireTorque Requirements Table 18 Wheel Size First Pass FT LBS Second Pass FT LBS Third Pass FT LBS 12 20 25 35 40 50 65 13 20 25 35 40 50 6...

Page 46: ...PAGE 46 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 TRAILER WIRING DIAGRAM Trailer Towing Vehicle Wiring Diagram Figure 63 ...

Page 47: ...DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 47 GENERATOR WIRING DIAGRAM Generator Wiring Diagram Figure 64 ...

Page 48: ...PAGE 48 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 ENGINE WIRING DIAGRAM Engine Wiring Diagram Figure 65 ...

Page 49: ...DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 49 CONTROLLER WIRING DIAGRAM Controller Wiring Diagram Figure 66 ...

Page 50: ...er Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Defective Exciter Field Check for approximately 19 ohms across J K on CN1 Low Voltage Output Is engine speed correct Turn engine throttle lever to High Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary High Voltage Output Is...

Page 51: ...Fill coolant level Sending unit failure Replace sending unit Low battery voltage Replace charge battery High coolant temperature light is on Fan belt tension incorrect Tighten replace fan belt Air flow is not circulating through radiator Clean repair radiator grill Doors open Close doors Exhaust leaking Replace repair gaskets or faulty part Generator being overloaded Check reduce load Thermostat f...

Page 52: ... lit when the MPEC Control Switch is placed in the MANUAL position If engine trouble occurs the diagnostic lamp will be 2 brightly lit as long as the control switch is left in the manual position The diagnostic lamp will indicate that an engine 3 malfunction has occurred NOTICE For a complete understanding of error codes and troubleshooting procedures refer to the enclosed engine instruction manua...

Page 53: ...DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 53 NOTES ...

Page 54: ...t number at time of publication A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip Other entries will be clarified in the Remarks Column QTY Column Numbers Used Item quantity can be indicated by a number a blank entry or A R A R AsRequired isgenerallyusedforhosesorotherparts that are sold in bulk and cut to length A blank entry generally indicates th...

Page 55: ...ERATURE 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 CLE...

Page 56: ...PAGE 56 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 GENERATOR ASSY 1 4 1 4A 1 4B 5 5A 6 6 6 6A 9A 9B 9 13 13A 13B 16 16A 18 18A 18B 11 ...

Page 57: ...EARING FLANGE 1 1 13 007906315 BEARING 1 2 C3164400103 COUPLING RING 1 3 0010312050 HEX HEAD BOLT 8 4 0042512000 WASHER LOCK 8 5 0010312040 HEX HEAD BOLT 12 5 A 0042512000 WASHER LOCK 12 6 C3130100003 STATOR ASSY 1 6 1 0226200495 RUBBER SEAL 1 6 2 8211323004 CLAMPER 1 6 3 0223300172 RUBBER SEAL 1 6 4 8211323103 CLAMPER 1 6 5 0221200440 RUBBER SEAL 1 6 6 0010110035 HEX HEAD BOLT 2 6 6A 0041210000 W...

Page 58: ...PAGE 58 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 GENERATOR ASSY CONTINUED ...

Page 59: ...400003 SUCTION COVER 1 15 0017106016 HEX HEAD BOLT 8 16 C3163600003 COUPLING ADAPTER 1 17 0010312030 HEX HEAD BOLT 12 17A 0042512000 WASHER LOCK 12 18 0070506206 BEARING 1 19 0010312040 HEX HEAD BOLT 16 19A 0042512000 WASHER LOCK 16 20 C3132300014 FAN COVER 1 21 0010106030 HEX HEAD BOLT 1 21A 0041206000 WASHER FLAT 1 21B 0601815000 NUT 1 22 0605000061 RUBBER SUSPENSION 4 23 0030016000 HEX NUT 8 23...

Page 60: ...PAGE 60 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 ENGINE OPERATING PANEL ASSY ...

Page 61: ...P BUTTON 1 9 0602103090 ALARM LAMP 5 9A 0601810244 BULB DC 28V 5 10 0602120095 TACHOMETER 1 11 0602122093 OIL PRESSURE GAUGE 1 12 0601842450 VOLTAGE DIVIDER 1 13 0602123092 WATER TEMPERATURE GAUGE 1 14 0602121081 CHARGING AMMETER 1 15 0602125091 FUEL GAUGE 1 16 C3483003303 SET FRAME 1 17 0017110030 HEX HEAD BOLT 2 17A 0207010000 HEX NUT 2 18 0017110030 HEX HEAD BOLT 3 19 0602123267 WATER TEMPERATU...

Page 62: ...PAGE 62 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 CONTROL BOX ASSY ...

Page 63: ...WASHER LOCK 16 20 0041412000 WASHER FLAT 16 21 0017110030 HEX HEAD BOLT 4 22 C3260503003 ELECTRIC PARTS SET PANEL 1 23 0017108020 HEX HEAD BOLT 4 24 8980956110 CONTROLLER 1 REPLACES P N 0602202684 25 C3260503104 BRACKET 1 26 0016906012 HEX HEAD BOLT 4 27 0602103090 DIAGNOSTIC LAMP 1 27A 0601810244 BULB DC28V 1 28 0601831205 DIAGNOSTIC BUTTON 1 29 0601830710 DIAGNOSTIC SWITCH 1 30 0601830746 HIGH I...

Page 64: ...PAGE 64 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 CONTROL BOX ASSY CONTINUED ...

Page 65: ...1810072 PILOT LAMP 1 55A 0601810261 BULB 13W 1 56 0601840073 RHEOSTAT VOLT REG 2W 1K OHM 1 57 0601840121 KNOB 1 58 ECU9988N220V ENGINE CONTROLLER 1 REPLACES P N 0602202545 59 0601830765 SWITCH 1 60 0601810161 PANEL LIGHT 1 60A 0601810214 BULB 1 61 0207004000 HEX NUT 2 62 0601830710 PANEL LIGHT SWITCH 1 63 C9221100004 HEX HEAD BOLT 2 63A 0040008000 WASHER LOCK 2 63B 0041208000 WASHER FLAT 2 63C 008...

Page 66: ...PAGE 66 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 CONTROL BOX ASSY CONTINUED ...

Page 67: ...QTY REMARKS 78 0027104020 MACHINE SCREW 2 79 8221814804 CONTROL BOX COVER 1 80 0017108020 HEX HEAD BOLT 8 81 8224117004 CONTROL BOX SIDE PANEL 1 82 0017108020 HEX HEAD BOLT 4 83 C3213400604 CONTROL BOX PANEL 1 84 0017108020 HEX HEAD BOLT 8 85 0017110035 HEX HEAD BOLT 4 85A 0207010000 HEX NUT 4 86 0601806640 FUSE 65A 1 ...

Page 68: ...PAGE 68 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 ENGINE AND RADIATOR ASSY ...

Page 69: ...00 WASHER FLAT 8 15 C3923200174 RADIATOR INTER COOLER ASSY 1 15 1 0602011059 CAP 2 16 C3493600004 ACOUSTIC SHEET 1 17 0010116065 HEX HEAD BOLT 6 18 0030016000 HEX NUT 6 19 0040016000 WASHER LOCK 6 20 0041216000 WASHER FLAT 12 21 C3311100504 RADIATOR BRACKET 1 22 C3311100604 RADIATOR BRACKET 1 23 0017112025 HEX HEAD BOLT 4 24 0017112025 HEX HEAD BOLT 2 25 C33110200403 FAN GUARD 1 26 C3310200503 FAN...

Page 70: ...PAGE 70 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 ENGINE AND RADIATOR ASSY CONTINUED ...

Page 71: ...22561 90 DEGREE ELBOW 1 56 0603306590 CONNECTOR 1 57 0603300285 ROCKNUT 1 58 0605511395 VALVE 1 59 0603306395 HOSE JOINT 1 60 0602021070 CAP 1 61 0269200500 DRAIN HOSE 1 62 0802081003 RESERVE TANK 1 63 0602010900 RESERVE TANK CAP 1 64 C1317100103 RESERVE TANK BRACKET 1 65 0016910025 HEX HEAD BOLT 2 66 0602022929 JOINT 1 67 0199900800 HOSE 1 68 0199900300 HOSE 1 69 0199901600 HOSE 1 70 0193602000 H...

Page 72: ...SI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 OUTPUT TERMINAL ASSY THE PART NUMBER INDICATED IS ORANGE PLEASE ADD THE FOLLOWING LETTERS WHEN ORDERING COLOR OF UNIT MQW WHITE THE SERIAL NUMBER MAY BE REQUIRED ...

Page 73: ...ER CUSHION 1 12 0019206016 HEX HEAD BOLT 2 13 0601812598 RECEPTACLE GF 530EM 2 14 0601812565 RECEPTACLE CS 6369 3 15 0025304016 MACHINE SCREW 10 15A 0207004000 HEX NUT 10 16 C2234500104 COVER 1 17 0019206016 HEX HEAD BOLT 8 18 0601815194 TERMINAL BLOCK 1 19 0025304016 MACHINE SCREW 2 20 0601850275 GROMMET 1 21 0601851780 GROMMET 2 22 C2237102303 OUTPUT TERMINAL COVER 1 23 0019112045 HEX HEAD BOLT ...

Page 74: ...PAGE 74 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 BATTERY ASSY ...

Page 75: ... 4 7 0041608000 WASHER FLAT 4 8 C3346601804 BATTERY CABLE 1 9 C3346601904 BATTERY CABLE 1 10 C3346602004 BATTERY CABLE 1 11 C3346602104 BATTERY CABLE 1 12 C3346200004 EARTH CABLE 1 13 0347010030 HEX HEAD BOLT 4 14 0208110000 HEX NUT 4 15 0845040114 TERMINAL CAP 2 16 0845041004 TERMINAL CAP 2 17 0017114025 HEX HEAD BOLT 1 18 0040514000 TOOTHED WASHER 1 19 0017110025 HEX HEAD BOLT 1 20 0040510000 TO...

Page 76: ...PAGE 76 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 MUFFLER ASSY ...

Page 77: ...4 3 C3333001903 EXHAUST PIPE 1 4 C9304000304 GASKET 1 5 C3334200804 GASKET 1 6 0010316060 HEX HEAD BOLT 8 6A 0030316000 HEX NUT 8 6B 0042516000 WASHER LOCK 8 6C 0041616000 WASHER FLAT 16 7 0010316060 HEX HEAD BOLT 4 7A 0030016000 HEX NUT 4 7B 0042516000 WASHER LOCK 4 7C 0041616000 WASHER FLAT 8 8 C3333302104 BRACKET 1 9 0017108020 HEX HEAD BOLT 4 10 0602326065 U BOLT 1 11 C3331300404 COVER 2 12 00...

Page 78: ...PAGE 78 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 FUEL TANK ASSY S N 3813334 AND BELOW ...

Page 79: ...LVE 1 15 0132006000 PLUG 1 2 1 16 C1367700304 LOCK PLATE 1 17 0019208020 HEX HEAD BOLT 2 18 0845039604 RUBBER SEAL 1 19 C3366704704 BRACKET 1 20 0016910025 HEX HEAD BOLT 3 21 8980758550 PRIMARY FUEL FILTER ASSY 2 REPLACES P N 0602042405 21A 8980758540 PRIMARY FUEL FILTER ELEMENT 2 REPLACES P N 0602042516 22 8980955010 JOINT PIPE 4 REPLACES P N 0602042662 23 1096750951 JOINT BOLT 4 REPLACES P N 060...

Page 80: ...PAGE 80 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 FUEL TANK ASSY S N 3813335 AND ABOVE ...

Page 81: ... RUBBER SEAL 1 19 C3366704704 BRACKET 1 20 0016910025 HEX HEAD BOLT 3 21 8980758550 PRIMARY FUEL FILTER ASSY 2 REPLACES P N 0602042405 21A 8980758540 PRIMARY FUEL FILTER ELEMENT 2 REPLACES P N 0602042516 22 8980955010 JOINT PIPE 4 REPLACES P N 0602042662 23 1096750951 JOINT BOLT 4 REPLACES P N 0602042621 24 1096301110 PAACKING 8 REPLACES P N 0602021702 25 0017110040 HEX HEAD BOLT 4 26 0010110075 H...

Page 82: ...0SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 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 83: ...3 LINING 1 16 C3424301103 AIR GUIDE PANEL 1 16A C3493100703 LINING 1 17 0019208020 HEX HEAD BOLT 24 18 0019210025 HEX HEAD BOLT 8 19 C3424201403 FRONT FRAME COVER 1 20 C3424203104 FRONT FRAME COVER 1 20A C3494102604 LINING 1 21 0845042703 FILLER BASKET 1 22 0019208020 HEX HEAD BOLT 4 23 0019208020 HEX HEAD BOLT 28 24 C3423201103 FRONT FRAME COVER 1 25 0019208020 HEX HEAD BOLT 14 26 C3433000202 CEN...

Page 84: ...0SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 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 85: ...13 0600800320 MANUAL PAK 1 9000 07 14 0207006000 HEX NUT 4 15 B9114000102 DOOR HANDLE 1 16 0021806015 MACHINE SCREW 4 16A 0030006000 HEX NUT 4 17 8225146204 DOOR ROD 1 18 8225146304 DOOR ROD 1 19 0845050704 STAY 4 20 0207006000 HEX NUT 8 21 0805011304 DOOR STOPPER 1 22 0805011204 DOOR STOPPER 1 23 0207006000 HEX NUT 4 24 0845047104 HINGE 2 24A 0845045004 WASHER 2 25 0845047204 HINGE 2 25A 08450450...

Page 86: ...0SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 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 87: ...4 LINING 1 8 C3453300504 DUCT 1 8A C3493401803 LINING 1 9 C3453300604 DUCT 1 9A C3493401903 LINING 1 10 C3453300704 DUCT 1 10A C3493402003 LINING 1 11 0207006000 HEX NUT 21 12 C3453000903 SIDE PANEL 1 12A C3493400604 LINING 1 13 C3453001003 SIDE PANEL 1 13A C3493400704 LINING 1 14 C3453001103 SIDE PANEL 1 14A C3493400804 LINING 1 15 C3453005203 SIDE PANEL 1 15A C3493400904 LINING 1 16 C3453300304 ...

Page 88: ...GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 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 89: ... PART NAME QTY REMARKS 25 0845046904 HINGE 8 25A 0845045004 WASHER 8 26 0845047005 HINGE 8 26A 0845045004 WASHER 8 27 0019208020 HEX HEAD BOLT 37 28 0601850097 STOPPER 11 29 0025408025 MACHINE SCREW 11 30 0845031504 CAP 16 31 0019108065 HEX HEAD BOLT 4 31A 042308000 WASHER LOCK 4 31B 0042408000 WASHER FLAT 4 ...

Page 90: ...PAGE 90 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 RUBBER SEALS ASSY ...

Page 91: ...ER SEAL 4 3 0228901450 RUBBER SEAL 4 4 0228900850 RUBBER SEAL 2 5 0228901350 RUBBER SEAL 4 6 0228801390 RUBBER SEAL 2 7 0228901390 RUBBER SEAL 3 8 0228900790 RUBBER SEAL 1 9 0229201340 RUBBER SEAL 1 10 0221200795 RUBBER SEAL 2 11 0228801250 RUBBER SEAL 2 12 0229200560 RUBBER SEAL 2 13 0229201230 RUBBER SEAL 1 14 0228100120 RUBBER SEAL 4 15 0228100510 RUBBER SEAL 4 ...

Page 92: ...PAGE 92 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NAMEPLATE AND DECALS ASSY ...

Page 93: ...PEED 1 C90040210 2 14 C9520027704 DECAL DIAGNOSTIC BUTTON 1 C92002770 2 15 C9521007504 DECAL DIAGNOSTIC SWITCH 1 C92100750 ENGINE RADIATOR GROUP 3 1 1320610603 DECAL WATER OIL 1 S 1760 3 2 6360610304 DECAL WATER 1 S 1880 3 3 6360620204 DECAL OIL DRAIN PLUG 1 S 1885 3 4 B9504000304 DECAL CAUTION HOT PARTS 1 B90400030 3 5 B9504000404 DECAL WARNING MOVING PARTS 2 B90400040 3 6 B9504100104 DECAL WARNI...

Page 94: ...PAGE 94 DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 NAMEPLATE AND DECALS ASSY CONTINUED ...

Page 95: ... B90420000 FUEL TANK GROUP 8 1 1320620904 DECAL DIESEL FUEL 1 S 1756 8 2 6360620004 DECAL FUEL DRAIN PLUG 1 S 1883 8 3 B9504500004 DECAL WARNING DIESEL FUEL 1 B9045 000 BONNET GROUP 9 1 1320621504 DECAL SUPPORT HOOK 1 S 2257 9 2 0840625902 DECAL MQ 1 S 3057 9 3 0600500090 EMBLEM 2 9 3A 0021106016 MACHINE SCREW 4 9 4 C2561101204 STRIPE 2 9 5 C3561100203 STRIPE 1 9 6 C4561102204 STRIPE 2 9 7 C356110...

Page 96: ...dlubricants g Decalsandpaperproducts h Itemspurchasedinkits 7 Thesenderwillbenotifiedofanymaterial receivedthatisnotacceptable 8 Suchmaterialwillbeheldforfiveworking days from notification pending instruc tions Ifareplyisnotreceivedwithinfive days thematerialwillbereturnedtothe senderathisexpense 9 Creditonreturnedpartswillbeissuedat dealer net price at time of the original purchase lessa15 restoc...

Page 97: ...DCA400SSI GENERATOR OPERATION AND PARTS MANUAL REV 2 11 03 08 PAGE 97 NOTES ...

Page 98: ... 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 obligat...

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