MULTIQUIP Power WHISPERWATT DCA400SSI Bedienungsanleitung

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT 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 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 3

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

1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or

write to:

Administrator

NHTSA

1200 New Jersey Avenue S.E.

Washington, DC 20590

You can also obtain information about motor vehicle safety from

http://www.safecar.gov.

REPORTING SAFETY DEFECTS

PAGE 4 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)

TABLE OF CONTENTS

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

Component Drawings

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.

DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 5

PARTS ORDERING PROCEDURES

www.mqpower.com

Best Deal!

Ordering parts has never been easier!

Choose from three easy options:

WE ACCEPT ALL MAJOR CREDIT CARDS!

When ordering parts, please supply:

❒❒

❒

Dealer Account Number

❒❒

❒

Dealer Name and Address

❒❒

❒

Shipping Address (if different than billing address)

❒❒

❒

Return Fax Number

❒❒

❒

Applicable Model Number

❒❒

❒

Quantity, Part Number and Description of Each Part

❒❒

❒

Specify Preferred Method of Shipment:

✓

UPS/Fed Ex

✓DHL

■

Priority One

✓

Tr u c k

■

Ground

■Next Day

■

Second/Third Day

All orders are treated as

Standard Orders

and will ship the same day if received prior

to 3PM PST.

If you have an MQ Account, to obtain a

Username and Password, E-mail us at:

[email protected].

To obtain an MQ Account, contact your

District Sales Manager for more information.

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■

View Parts Diagrams

■

Order Parts

■

Print Specification Information

Note: Discounts Are Subject To Change

Goto www.multiquip.com and click on

Order Parts to log in and save!

Use the

internet

and qualify for a 5% Discount

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)

Fax

your order in and qualify for a 2% Discount

Standard orders

for all orders which include

complete part numbers.*

Order via Phone: Domestic (US) Dealers Call:

1-800-427-1244

International Customers

should contact

their local Multiquip Representatives for

Parts Ordering information.

Non-Dealer Customers:

Contact your local Multiquip Dealer for

parts or call 800-427-1244 for help in

locating a dealer near you.

Note: Discounts Are Subject To Change

Effective:

January 1st, 2006

PAGE 6 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)

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.

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.

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.

DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 7

SAFETY INFORMATION

GENERAL SAFETY

CAUTION

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.

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.

NOTICE

This equipment should only be operated by trained and

qualiﬁed personnel 18 years of age and older.

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.

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.

ALWAYSknow the location of the nearest

ﬁre extinguisher.

ALWAYSknow the location of the nearest

ﬁrst aid kit.

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.

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 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 the equipment in an explosive

atmosphere or near combustible materials.An

explosion or ﬁre could result causing severe

bodily harm or even death.

WARNING

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.

CAUTION

NEVERlubricate components or attempt service on a

running machine.

NOTICE

ALWAYSensure generator is on level ground before use.

ALWAYSkeep the machine in proper running condition.

Fix damage to machine and replace any broken parts

immediately.

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.

PAGE 8 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)

SAFETY INFORMATION

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.

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.

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.

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.

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.

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.

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.

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.

DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08) — PAGE 9

SAFETY INFORMATION

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refuel in a well-ventilated area, away from

sparks and open ﬂames.

ALWAYSuse extreme caution when working with

ﬂammable liquids.

DO NOTﬁll the fuel tank while the engine is running

or hot.

DO NOToverﬁll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from

the ignition system.

Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and ﬂames.

NEVERuse fuel as a cleaning agent.

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.

TOWING SAFETY

CAUTION

Check with your local county or state safety towing

regulations, in addition to meeting

Department of Transportation (DOT)

SafetyTowing Regulations, before towing

your generator.

Refer to MQ Power trailer manual for additional safety

information.

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.

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 50 psi cold.

Also check the tire tread wear on both vehicles.

ALWAYSmake sure the trailer is equipped with a safety

chain.

ALWAYSproperly attach trailer’s safety chains to towing

vehicle.

ALWAYSmake sure the vehicle and trailer directional,

backup, brake and trailer lights are connected and

working properly.

DOT Requirements include the following:

• Connect and test electric brake operation.

• Secure portable power cables in cable tray with tie

wraps.

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.

Avoid sudden stops and starts.This can cause skidding,

or jack-kniﬁng. Smooth, gradual starts and stops will

improve towing.

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.

Placechock blocks underneath wheel to prevent rolling

while parked.

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.

PAGE 10 — DCA400SSI GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (11/03/08)

SAFETY INFORMATION

ELECTRICAL SAFETY

DANGER

DO NOTtouch output terminals during

operation. Contact with output terminals

during operation can cause electrocution,

electrical shock or burn.

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.

NEVERinsert any objects into the output

receptacles during operation. This is

extremely dangerous. The possibility

exists of electrical shock, electrocution

or death.

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.

Make sure power cables are securely connected to the

generator’s output receptacles. Incorrect connections

may cause electrical shock and damage to the

generator.

NOTICE

ALWAYSmake certain that proper power or extension

cord has been selected for the job. See Cable Selection

Chart in this manual.

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use gas piping as an electrical ground.

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