Multiquip Portable Generator Dca70Us13Can Users Manual
DCA70US13CAN to the manual c5ae46cc-b653-43fa-9d3d-fdac2216b3f7
2015-02-09
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OperatiOn and parts Manual
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
®
WHISPERWATT™ SERIES
MODEL DCA70USI3CAN
60HZ GENERATOR
(ISUZU BJ4JJ1-XYGD-02 DIESEL ENGINE)
PARTS LIST NO. M2870400304C
M2874400004
Revision #1 (09/24/13)
FUEL AND CHEMICAL WARNING
Diesel engine exhaust and some of
its constituents are know to cause
cancer, birth defects and other
reproductive harm.
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
TABLE OF CONTENTS
DCA70USI3CAN Generator
Fuel and Chemical Warnings ................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information .............................................. 6-11
Specifications ........................................................ 12
Dimensions ............................................................ 13
Installation ............................................................. 14
Installation ............................................................. 15
General Information ............................................... 16
Major Components ................................................ 17
Generator Control Panel ........................................ 18
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization .............. 22-24
Load Application .................................................... 25
Generator Outputs ................................................. 26
How To Read AC Ammeter/AC Voltmeter Gauges 27
Output Terminal Panel Connections ................. 28-29
Inspection/Setup ............................................... 30-33
Generator Start-Up Procedure ........................ 34-35
Generator Shut-Down Procedures ........................ 36
Maintenance ..................................................... 37-39
Trailer Maintenance .......................................... 40-43
Trailer Wiring Diagram ........................................... 44
Generator Wiring Diagram ..................................... 45
Engine Wiring Diagram .......................................... 46
Troubleshooting (Generator) .................................. 47
Troubleshooting (Diagnostic Lamp) ....................... 48
Explanation Of Code In Remarks Column............. 50
Suggested Spare Parts ......................................... 51
Component Drawings
Generator Assy. ................................................ 52-53
Control Box Assy. .............................................. 54-59
Engine And Radiator Assy. ............................... 60-63
Output Terminal Assy. ....................................... 64-65
Battery Assy. ..................................................... 66-67
Muffler Assy. ..................................................... 68-69
Fuel Tank Assy. ................................................ 70-71
Enclosure Assy. ................................................ 72-77
Rubber Seals Assy. ........................................... 78-79
Nameplate And Decals Assy. ........................... 80-83
Terms And Conditions Of Sale — Parts ................ 84
PARTS ORDERING PROCEDURES
www.multiquip.com
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 ck
■ Ground
■ Next Day
■ Second/Third Day
If you have an MQ Account, to obtain a Username
and Password, E-mail us at:
parts@multiquip.
com.
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
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)
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Order via Phone: Domestic (US) Dealers Call:
1-800-427-1244
Best Deal!
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
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
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.
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION
or
DANGER
Indicates a hazardous situation which, if not avoided,
result in DEATH or
WARNING
Indicates a hazardous situation which, if not avoided,
result in DEATH or
CAUTION
Indicates a hazardous situation which, if not avoided,
result in or
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.
SAFETY INFORMATION
CAUTION
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.
operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
operate this equipment under the infl uence of
drugs or alcohol.
check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
know the location of the nearest
know the location of the nearest
know the location of the nearest
phone or
Also, know the
phone numbers of the nearest ambulance, doctor
and
This information will be invaluable in
the case of an emergency.
GENERATOR SAFETY
DANGER
operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fi re could result causing severe
WARNING
disconnect any
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
lubricate components or attempt service on a
running machine.
NOTICE
ensure generator is on level ground before use.
keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
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
SAFETY INFORMATION
ENGINE 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
fl ow of cooling air.
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
operate the engine with heat shields or
guards removed.
Keep fi ngers, 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
touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
frequently to prevent engine malfunction.
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
suffi cient 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 effi ciency,
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 fl ames
from the engine exhaust. Spark arresters are qualifi ed
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.
SAFETY INFORMATION
DANGER
DO NOT start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.
refuel in a well-ventilated area, away from
sparks and open fl ames.
use extreme caution when working with
fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DO NOT overfi ll 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 fl ames.
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)
Safety Towing 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,
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
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.”
inspect the hitch and coupling for wear.
tow a trailer with defective hitches, couplings, chains, etc.
Check the tire air pressure on both towing vehicle and
trailer.
Trailer tires should be infl ated to 50 psi cold.
Also check the tire tread wear on both vehicles.
make sure the trailer is equipped with a
safety
properly
attach trailer’s safety chains to towing
vehicle.
make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
DOT Requirements include the following:
•Connectandtestelectricbrakeoperation.
•Secure portablepowercables incabletraywith tie
wraps.
The maximum speed for highway towing is
unless
posted otherwise. Recommended off-road towing is not to
exceed or less depending on type of terrain.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifi ng. 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.
SAFETY INFORMATION
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
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.
insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
Backfeed to a utility system can cause
electrocution and/or property damage.
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
DANGER
let power cords or cables
while AC power from the
generator is being transferred to a load.
use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
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
make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
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.
use gas piping as an electrical ground.
DANGER
DO NOT
drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
WARNING
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.
keep the battery charged. If the battery is not
charged, combustible gas will build up.
recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
SAFETY INFORMATION
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
disconnect the
before performing service on the generator.
keep battery cables in good working condition.
Repair or replace all worn cables.
NOTICE
Decommissioning is a controlled process used to safely
retire a piece of equipment that is no longer serviceable.
If the equipment poses an unacceptable and unrepairable
safety risk due to wear or damage or is no longer cost
effective to maintain (beyond life-cycle reliability) and is to
be decommissioned (demolition and dismantlement),be
sure to follow rules below.
DO NOT pour waste or oil directly onto the ground, down
a drain or into any water source.
Contact your country's Department of
Public Works or recycling agency in your
area and arrange for proper disposal of
any electrical components, waste or oil
associated with this equipment.
When the life cycle of this equipment is over, remove
battery and bring to appropriate facility for lead
reclamation. Use safety precautions when handling
batteries that contain sulfuric acid.
When the life cycle of this equipment is over, it is
recommended that the trowel frame and all other metal
parts be sent to a recycling center.
Metal recycling involves the collection of metal from
discarded products and its transformation into raw
materials to use in manufacturing a new product.
Recyclers and manufacturers alike promote the process
of recycling metal. Using a metal recycling center
promotes energy cost savings.
NOTICE
The gasoline engine used in this equipment has been
designed to reduce harmful levels of carbon monoxide
(CO), hydrocarbons (HC) and nitrogen oxides (NOx)
contained in diesel exhaust emissions.
This engine has been certifi ed to meet US EPA Evaporative
emissions requirements in the installed confi guration.
Attempting to modify or make adjustments to the engine
emission system by unauthorized personnel without proper
training could damage the equipment or create an unsafe
condition.
Additionally, modifying the fuel system may adversely affect
evaporative emissions, resulting in fi nes or other penalties.
The emission control label is an integral part of the emission
system and is strictly controlled by regulations.
The label must remain with the engine for its entire life.
If a replacement emission label is needed, please contact
your authorized engine distributor.
Generator Specifications
DCA-70USI3CAN
Type Revolving field, self ventilated,
open protected type synchronous generator
Armature Connection Star with Neutral Zigzag
Phase 3 Single
Standby Output 77 kVA (62 kW) 44 KW
Prime Output 70 kVA (56 KW) 40 KW
240 or 480V 240 or 120V
Frequency 60 Hz
Speed 1800 rpm
Power Factor 0.8 1.0
Single Phase, 60 Hz
120V
Output 4.8 Kw (2.4 kW x 2)
3,771 lbs. (1,710 kg)
4,553 lbs. (2,065 kg)
14,050 lbs. (6,370 kg)
Engine Specifications
ISUZU BJ-4JJ1XYGD-02 Tier 3
Type 4 cycle, water-cooled, direct injection, turbo-charged
air to air intercooled
4 cylinders
3.76 in. x 4.13 in. (95.4 mm x 105 mm)
Displacement 183 cu. in. (3,000 cc)
Rated Output 87.4 HP/1800 RPM
Starting Electric
Coolant Capacity 3.57 gal. (13.5 liters)
3.96 gal. (15.0 liters)
Fuel Type #2 Diesel Fuel
Fuel Tank Capacity 103 gal. (390 liters)
Fuel Consumption 4.1 gal. (15.4 L)/hr at full load 3.1 gal. (11.9 L)/hr at
2.1 gal. (8.10 L)/hr at 1.3 gal. (4.80 L)/hr at
12V 72Ah x 1
SPECIFICATIONS
DIMENSIONS
Figure 1. Dimensions
Dimensions
Reference
A 30.10 in. (790 mm.) F 105.1 in. (2,670 mm.)
B 30.20 in. (766 mm.) G 68.30 in. (1,735 mm.)
C 30.20 in. (766 mm.) H 37.40 in. (950 mm.)
D 30.20 in. (766 mm.)
E 30.20 in. (766 mm.)
INSTALLATION
Figure 2. Typical Generator Grounding Application
INSTALLATION
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.
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.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
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.
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.
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.
GENERATOR GROUNDING
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.
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.
a. Copper - 8 AWG (5.3 mm2)
b. Aluminum - 6 AWG (8.4 mm2)
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.
NOTICE
When connecting the generator to any buildings
electrical system consult with a licensed
electrician.
GENERATOR
This generator (Figure 3) is 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 “Engine Operating Panel” is provided with the following:
Tachometer
Water Temperature Gauge
Warning Lamp
Fuel Leak Detected Alarm Lamp
Pre-Heat Lamp
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Panel Light/Panel Light Switch
ECU Controller
Engine Speed Switch
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
3-Pole, 175 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
•Automatic Voltage Regulator
•Current Transformer
•Over-Current Relay
•Starter Relay
•Voltage Selector Switch
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
Five output terminal lugs (3Ø power)
This 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.
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.
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.
ENGINE
This generator unit incorporates an ISUZU BJ-4JJ1X 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.
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%.
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.
GENERAL INFORMATION
MAJOR COMPONENTS
Figure 3. Major Components
DESCRIPTION
1 Muffler Assembly
2 Engine Assembly
3 Enclosure Assembly
4 Generator Assembly
5Output Terminal Assembly
6 Battery Assembly
7Fuel Tank Assembly
8 Generator Control Panel Assembly
9 Engine Operating Panel Assembly
GENERATOR CONTROL PANEL
Figure 4. Generator Control Panel
1000 2000
3000
0
RPM
OFF
W
U
V
OFF
W-U
V-W
U-V
DECREASE
INCREASE
AUTO MANUAL
OFF/RESET
LOWOIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
OVERSPEED
ENGINE RUNNING
MOOOOO-20001Q
1
2
4
3
6
7
5
The definitions below describe the controls and functions
of the Generator Control Panel (Figure 4).
1. — Allows ±15% manual
adjustment of the generator’s output voltage.
2. —This three-pole, 175A main
breaker is provided to protect the U,V, and W Output
Terminal Lugs from overload.
3. 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.
4. — 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.
5. — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
6. AC Ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
7. — Indicates the output frequency
in hertz (Hz). Normally 60 Hz.
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.
The Control Box is equipped with the following major
components:
Over-Current Relay
Automatic Voltage Regulator (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
NOTICE
Remember the overcurrent relay monitors the current
flowing from the
to the load.
In the event of a short circuit or over current condition,
it will automatically trip the 175 amp main breaker.
To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
NOTES
ENGINE OPERATING PANEL
Figure 5. Engine Operating Panel
OFF
W
U
V
OFF
W-U
V-W
U-V
DECREASE
INCREASE
1000 2000
3000
0
RPM
AUTO MANUAL
OFF/RESET
LOWOIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
OVERSPEED
ENGINE RUNNING
MOOOOO-20001Q
3
4
5
6
7
11
9
8
12
2
1
10
The definitions below describe the controls and functions
of the Engine Operating Panel (Figure 5).
1. — 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.
2. — When activated will turn on control
panel light.
3. Oil Pressure Gauge — During normal operation this
gauge should read between 42 ~71 psi. (290~490 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.
4. Water Temperature Gauge — During normal operation this
gauge be should read between 167°~203°F (75° ~95°C
5. 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.
6. Fuel Gauge — Indicates amount of diesel fuel available.
7. 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.
8. — As the engine cranks, this lamp will
illuminate to indicate automatic preheating of the engine
glow plugs. When the lamp turns off, this indicates that
the preheat cycle is complete and the engine will start
automatically.
9. — This lamp will illuminate when a critical
engine fault has occurred.
10. — This lamp will
illuminate when fuel level is low (25.5 gal/98 liters)
11. Engine Speed Switch — This switch controls the speed
of the engine (low/high).
12. — 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 ECU will attempt to
crank the engine for 10 seconds
before disengaging.
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.
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.
A. — 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.
If the generator is to be connected to a building’s
AC power source via an automatic 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 connected 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
generator to the ATS.
B. — Indicates the engine pressure
has fallen below 15 psi (103 kPa). The oil pressure
is detected using variable resistive values from the
oil pressure sending unit. This is considered a major
fault.
C. High Coolant Temperature — Indicates the engine
temperature has exceeded 230°F (110°C). The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
D. Overcrank Shutdown — Indicates the unit has
attempted to start a pre- programmed number of
times, and 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.
E. Overspeed Shutdown — Indicates the engine is
running at an unsafe speed. This is considered a
major fault.
F. Engine Running — Indicates that engine is running
at a safe operating speed.
ENGINE OPERATING PANEL
OUTPUT TERMINAL PANEL 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.
NOTICE
Terminal legs “O” and “Ground” are considered bonded
grounds.
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
Three 120/240V output receptacles @ 50 amp
Three Circuit Breakers @ 50 amps
Two 120V GFCI receptacles @ 20 amp
Two GFCI Circuit Breakers @ 20 amps
Five Output Terminal Lugs ( U, V, W, O, Ground)
Figure 6. Output Terminal Panel
OUTPUT TERMINAL PANEL FAMILIARIZATION
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.
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 7. G.F.C.I. Receptacle
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-
Figure 8. 120/240V Twist-Lock Auxiliary
Receptacles
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
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.
Figure 9. Voltage Regulator Control Knob
The Output Terminal Lugs are protected by a plastic
face plate cover (Figure 10). Unscrew the securing bolts
and lift the plastic terminal cover to gain access to the
terminal enclosure.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 10. Plastic Face Plate
(Output Terminal Lugs)
OUTPUT TERMINAL PANEL FAMILIARIZATION
Loads can be connected to the generator by the Output
or the convenience receptacles (Figure 11).
Make sure to read the operation manual before attempting
to connect a load to the generator.
To protect the output terminals from overload, a 3-pole,
175A main circuit breaker is provided. Make sure to switch
circuit breakers to the OFF position prior to starting
the engine.
Figure 11. Connecting Loads
Over Current Relay
An over current relay (Figure 12) 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.
Figure 12. Over Current Relay
LOAD APPLICATION
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.
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.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
Current
in
Amperes
At 200
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
CAUTION: Equipment damage can result from low voltage
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.
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
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 cause a voltage drop which can burn out
the appliance or tool and overheat the cable. SeeTable 6.
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.
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.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
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.
DANGER
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an . Serious damage to
the building’s electrical system may occur without this
transfer switch.
GENERATOR OUTPUTS
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 13). 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.
The voltage selector switch (Figure 13) is located above
the output terminal panel’s Hard Wire Hook-up Panel. It
has been provided for ease of voltage selection.
Figure 13. Voltage Selector Switch
The voltage selector switch has a locking button to protect
the generator and load from being switched while the
engine is running. To lock the voltage selector switch, press
and hold the red button located at the bottom of the switch.
CAUTION
change the position of the voltage selector
switch while the engine is running. place
circuit breaker in the OFF position before selecting
voltage
3Ø 208V 220V 240V 416V 440V 480V
1Ø 120V 127V 139V 240V 254V 277V
1Ø
120V
Line-Neutral N/A N/A 240V
Line-Line N/A N/A
Generator Amperage
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed..
The load capability of the GFCI receptacles is directly
related to the voltage being supplied at either the output
terminals or the three twist lock auxiliary receptacles.
Table 9 and Table 10 show what amount of current is
available at the GFCI receptacles when the output terminals
and twist lock receptacles are in use. Be careful that your
load does not to exceed the available current capability at
the receptacles.
1Ø 120 Volt 155.5 X 2 amps (4 wire)
168 amps X 2 (Zigzag)
1Ø 240 Volt 78.8 amps (4 wire)
168 amps (Zigzag)
3Ø 240 Volt 168 amps
3Ø 480 Volt 84 amps
KW in Use
1Ø 240/120V GFCI Duplex
5-20R 120V
40.4 0
39.2 5 amps/receptacle
38.0 10 amps/receptacle
38.6 15 amps/receptacle
35.6 20 amps/receptacle
3Ø 240/480V GFCI Duplex
5-20R 120V
70 0 amps/receptacle
65.8 5 amps/receptacle
61.7 10 amps/receptacle
57.5 15 amps/receptacle
53.4 20 amps/receptacle
GENERATOR OUTPUTS/GAUGE READING
The AC ammeter and AC voltmeter gauges are controlled
by the AC ammeter and AC voltmeter change-over
switches.
Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.
Before taking a reading from either gauge, set the Voltage
Selector Switch (Figure 14) to the position which produces
the required voltage (For example, for 3Ø 240V, choose
the center 3Ø 240/139V position on the voltage selector
switch).
Figure 14. Voltage Selector Switch
240/139V 3Ø Position
Place the AC Voltmeter Change-Over Switch (Figure 15)
in the W-U position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 16)
NOTICE
For 3Ø 208V/1Ø,120V, place the Voltage Selector
Switch in the 3 Phase 240/139 position.
Change-Over Switch
Gauge
AC Ammeter Gauge Reading
Place the AC Ammeter Change-Over Switch (Figure 17)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 18). This process can be repeated for
terminals V and W.
AC Ammeter
Change-Over Switch
AC Ammeter
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
OUTPUT TERMINAL PANEL CONNECTIONS
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the position of the
and the adjustment of the
Knob.
Remember the voltage selector switch determines the
range of the output voltage. The voltage regulator (VR)
allows the user to increase or decrease the selected
voltage.
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 19..
Figure 19. Voltage Selector Switch
3Ø-240/139V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 20.
Figure 20. UVWO Terminal Lugs
3Ø-240/139V Connections
3. Turn the voltage regulator knob (Figure 21) 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.
Figure 21. Voltage Regulator Knob
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 22.
Figure 22. Voltage Selector Switch
3Ø-240/139V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 23.
Figure 23. UVWO Terminal Lugs
3Ø-208/1Ø-120V Connections
NOTICE
To achieve a 3Ø 208V output the voltage selector switch
must be in the 3Ø-240/139 position and the voltage
regulator must be adjusted to 208V..
OUTPUT TERMINAL PANEL CONNECTIONS
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 24.
Figure 24. Voltage Selector Switch
3Ø-480/277V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 25.
Figure 25. UVWO Terminal Lugs
3Ø-440/254V Connections
3. Turn the voltage regulator knob (Figure 21) 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.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 26.
Figure 26. Voltage Selector Switch
1Ø-240/120V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 27.
Figure 27. UVWO Terminal Lugs
1Ø-240/120V Connections
3. Turn the voltage regulator knob (Figure 27) 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.
NOTICE
make sure that the connections to the UVWO
terminals are secure and tight. The possibility of arcing
exists, that could cause a fire.
INSPECTION/SETUP
To protect the generator from an overload, a 3-pole, 175
amp, main circuit breaker is provided to protect the
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
circuit breakers to the OFF position prior to starting
the engine.
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 28) on the dipstick. See Table 11 for
proper selection of engine oil.
Figure 28. Engine Oil Dipstick
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 . 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
Refilling the Fuel System
This generator has an internal fuel tank located inside
the trailer frame and may also be equipped with an
environmental fuel tank (Figure 29). fill the fuel
tanks with clean fresh fill the fuel
tanks beyond their capacities.
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.
Figure 29. Internal Fuel Tank System
DANGER
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. smoke
around or near the generator.
CAUTION
who have read
and understand this section should refill the fuel tank
system.
INSPECTION/SETUP
Refueling Procedure:
1. — 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 30).
Figure 30. Only Fill on Level Ground
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
CAUTION
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
use when refueling.
2. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel
cap and fill tank (Figure 31).
Figure 31. Fueling the Generator
3. — It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait
for fuel to rise in filler neck (Figure 32).
Figure 32. Full Fuel Tank
Figure 33. Fuel Expansion
CAUTION
fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 33).
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
thefor further details.
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.
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
WARNING
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.
Coolant Capacity
Engine and Radiator 3.57 gal (13.5 liters)
Reserve Tank 2 quarts (1.9 liters)
Anti-Freeze Operating Temperatures
Vol %
Anti-
Freeze
Freezing Point Boiling Point
°C °F °C °F
50 -37 -34 108 226
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
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.
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the .
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
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 34) when depressed with the thumb as shown
below.
Figure 34. Fan Belt Tension
CAUTION
NEVER place hands near the belts or fan
while the generator set is running.
INSPECTION/SETUP
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.
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 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.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
ALWAYS be sure the battery cables (Figure 35) 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.
Figure 35. Battery Connections
CAUTION
disconnect the negative terminal FIRST and
reconnect negative terminal .
When connecting battery do the following:
1. connect the battery cables to the battery
terminals when the is in either
the position. make sure that the
is in the position
when connecting the battery.
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.
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.
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.
If any hose (fuel or oil) lines are defective replace them
immediately.
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.
CAUTION
Inadequate battery connections may cause poor
starting of the generator, and create other malfunctions.
INSPECTION/SETUP
GENERATOR START-UP PROCEDURE
1. Place the circuit breakers (Figure
36) in the OFF position prior to starting the engine.
Figure 36. 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 inFigure 11. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
4. Tighten terminal nuts securely to prevent load wires
from slipping out.
5. Close all engine enclosure doors (Figure 37).
Figure 37. Engine Enclosure Doors
CAUTION
The engine’s exhaust contains harmful emissions.
Direct exhaust away from nearby personnel.
WARNING
manually start the engine with the main, GFCI or
auxiliary circuit breakers in the ON (closed) position.
INCORRECT
CORRECT
STARTING
1. Place the voltage selector switch in the desired
voltage position (Figure 38).
Figure 38. Voltage Selector Switch
1. Place the engine speed switch (Figure 39) in the LOW
(down) position.
Figure 39. Engine Speed Switch (Low)
2. Place the in the
position to start the engine (Figure 40).
Figure 40. MPEC Control Switch
(Manual Position)
3. Depending on the temperature of the coolant (cold
weather conditions), the pre-heat lamp (Figure 41) 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 41. Pre-Heat Lamp
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
GENERATOR START-UP PROCEDURE
the problem. If the engine is running smoothly, place
the engine speed switch (Figure 42) in the HIGH (up)
position.
Figure 42. Engine Speed Switch (High)
5. Verify that the engine running status LED on the
MPEC module (Figure 43) is lit (ON) after the engine
has started.
Figure 43. Engine Running (LED ON)
6. The generator’s frequency meter (Figure 44) should be
displaying the 50 cycle output frequency in
Figure 44. Frequency Meter
7. The generator’s AC-voltmeter (Figure 45) will display
the generator’s output in ..
Figure 45. Voltmeter Meter
8. If the voltage is not within the specified tolerance use
the voltage adjustment control knob (Figure 46) to
increase or decrease the desired voltage.
Figure 46. Voltage Adjust Control Knob
9. The ammeter (Figure 47) 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 47. Ammeter (No Load)
10. The engine oil pressure gauge (Figure 48) will indicate
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 42 to 71
psi. (290~490 kPa).
Figure 48. Oil Pressure Gauge
11. The coolant temperature gauge (Figure 49) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 167°~203°F (75°~95°C) (Green Zone).
Figure 49. Coolant Temperature Gauge
12. The tachometer gauge (Figure 50 will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Figure 50. Engine Tachometer Gauge
GENERATOR SHUT-DOWN PROCEDURES
2. Place the engine speed switch (Figure 54) in the “”
(down) position..
Figure 54. 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 (Figure 55) to the
position.
Figure 55. MPEC Control Switch (Off/Reset)
5. Verify that all 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.
1. Place the (Figure 55) in the
position.
This unit is equipped with safety devices to automatically
stop the engine in the event of low oil pressure, approximately
14 psi (97 kPa), or high water temperature, approximately
230° F (110° C), overspeed approximately +15%. The alarm
lamps on the ECU illuminate to signify the reason for the
shutdown.
NOTICE
Before inspecting generator, check that the Auto/
Manual switch is in the position, and place
all circuit breakers in the OFF position. Allow sufficient
time for adequate cooling. When ready to restart,
complete all steps in the Generator Startup Procedure
section of this manual.
13. Place the circuit breakers in the
ON position (Figure 51).
Figure 51. Main, Aux. and GFCI
Circuit Breakers (ON)
14. Observe the generator’s ammeter (Figure 52) 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 52. Ammeter (Load)
15. The generator will run until manually stopped or an
abnormal condition occurs.
To shutdown the generator, use the following procedure:
1. Place both the circuit breakers
as shown in Figure 53 to the OFF position.
Figure 53. Main, GFCI and Load
Circuit Breakers (OFF
WARNING
stop the engine suddenly except in an
emergency.
*1 Replace engine oil and filter at 100 hours, first time only.
*2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
*3 Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
with no sags or dips that could collect moisture and/or oil.
Hrs
Engine
Check Engine Fluid Levels X
Check Air Cleaner X
Check Battery Acid Level X
Check Fan Belt Condition X
Check for Leaks X
Check for Loosening of Parts X
Replace Engine Oil and Filter * 1X
Clean Air Filter X
Check Fuel Filter/Water Separator Bowl X
Clean Unit, Inside and Outside X
Change Fuel Filter X
Clean Radiator and Check Coolant Protection Level*2X
Replace Air Filter Element * 3X
Check all Hoses and Clamps * 4X
Clean Inside of Fuel Tank X
Generator Measure Insulation Resistance Over 3M ohms X
Check Rotor Rear Support Bearing X
MAINTENANCE
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)
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.
Air Cleaner with Dust Indicator
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.
Figure 56. Air Cleaner/Indicator
NOTICE
The air filter should not be changed until the indicator
reads “RED”. Dispose of old air filter. It may not be
cleaned or reused.
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.
Add diesel fuel (the grade may vary according to season
and locations).
Removing Water from the Fuel Tank
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.
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.
Cleaning Inside the Fuel Tank
If necessary, 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.
Figure 57. Fuel Tank Cleaning
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 rubber hoses for signs
of wear, deterioration and hardening.
— inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 500
hours or so.
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.
Vent any air
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
for details.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed.
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 28.
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.
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.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Tighten both cocks and replace the overflow tank.
Replace with coolant as recommended by the engine
manufacturer.
Close radiator 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.
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.
Figure 58. Radiator Cleaning
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
Drain the fuel tank completely. Treat with a fuel stabilizer
if necessary.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Make sure engine coolant is at proper level.
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.
MAINTENANCE
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.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
The definitions below describe some of the major
components of a typical trailer that would be used with
generator.
1. Fuel Cell — Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
2. — System employed in stopping
the trailer. Typical braking systems are electric, surge,
hydraulic, hydraulic-surge and air.
3. — Gross Vehicle Weight Rating (GVWR) is
the maximum number of pounds the trailer can carry,
including the fuel cell (empty).
4. — Measurement is from the ball hitch
to the rear bumper (reflector).
5. Frame Width — Measurement is from fender to
fender
6. Jack Stand — Trailer support device with maximum
pound requirement from the tongue of the trailer.
7. Coupler — Type of hitch used on the trailer for
towing.
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.
9. Tire Ply — The tire ply (layers) number is rated in
letters; 2-ply, 4-ply, 6-ply, etc.
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.
12. — 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 61 for lug nut
tightening and sequence.
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.
14. Suspension — Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical — Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application — Indicates which units can be employed
on a particular trailer.
TRAILER MAINTENANCE
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
If driving over rough terrain, inspect the
brakes more frequently.
Figure 59 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:
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.
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
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.
8. Repeat steps 1 through 7 on the remaining brakes.
Hydraulic surge brakes (Figure 59) 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 59. Hydraulic Brake Components
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.
Periodically check and test the surge “actuator” to make sure
that it is functioning correctly. Never use an undersized actuator.
Symptom Possible Cause Solution
No Brakes Brake line broken or kinked? Repair or replace.
Weak Brakes or Brakes Pull to
One Side
Brake lining glazed? Reburnish or replace.
Trailer overloaded? Correct weight.
Brake drums scored or grooved? Machine or replace.
Tire pressure correct? Inflate all tires equally.
Tires unmatched on the same axle? Match tires.
Locking Brakes
Brake components loose, bent or
broken? Replace components.
Brake drums out-of-round? Replace.
Noisy Brakes System lubricated? Lubricate.
Brake components correct? Replace and correct.
Dragging Brakes
Brake lining thickness incorrect or
not adjusted correctly?
Install new shoes and
linings.
Enough brake fluid or correct fluid? Replace rubber parts
fill with dot 4 fluid.
TRAILER MAINTENANCE
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.
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 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
CAUTION
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.
Tire Wear Troubleshooting
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-in. Align wheels.
Cupping Out-of-balance. Check bearing adjustment
and balance tires.
Flat Spots Wheel lockup and
tire skidding.
Avoid sudden stops when
possible and adjust brakes.
Suspension
The leaf suspension springs and associated components
(Figure 60) 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.
Figure 60. Major Suspension Components
Suspension Torque Requirements
Item
3/8" U-Bolt Min-30 Max-35
7/16" U-Bolt Min-45 Max-60
1/2" U-Bolt Min-45 Max-60
Shackle Bolt
Spring Eye Bolt
Snug fit only. Parts must rotate freely.
Locking nuts or cotter pins are
provided to retain nut-bolt assembly.
Shoulder Type
Shackle Bolt
Min-30 Max-50
TRAILER MAINTENANCE
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 61). 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.
Tire Torque Requirements
Wheel Size First Pass
Second Pass
Third Pass
12" 20-25 35-40 50-65
13" 20-25 35-40 50-65
14" 20-25 50-60 90-120
15" 20-25 50-60 90-120
16" 20-25 50-60 90-120
Figure 61. Wheel Lug Nuts
Tightening Sequence
NOTICE
use an pneumatic air gun to tighten wheel
lug nuts.
TRAILER WIRING DIAGRAM
Figure 62. Trailer/Towing Vehicle Wiring Diagram
GENERATOR WIRING DIAGRAM
Figure 63. Generator Wiring Diagram
ENGINE WIRING DIAGRAM
Figure 64. Engine Wiring Diagram
CONTROLLER WIRING DIAGRAM
Figure 65. Engine Controller
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.
Generator Troubleshooting
Symptom Possible Problem Solution
No Voltage Output
AC Voltmeter defective? Check output voltage using a voltmeter.
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 17.3 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 wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Circuit Breaker Tripped
Short Circuit in load? Check load and repair.
Over current? Confirm load requirements and reduce.
Defective circuit breaker? Check and replace.
Over current Relay actuated? Confirm load requirement and replace.
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 66) on the
diagnostic panel to determine if an engine malfunction has
occurred.
Figure 66. Diagnostic Panel
1. Normally, the diagnostic lamp will be dimly lit when
the is placed in the
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.
EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
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.
SAMPLE
PARTS LIST
NO.
PA R T NO. PA R T NAME QTY. REMARKS
1
12345 BOLT ......................1 .....INCLUDES ITEMS W/%
2%
WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY
2%
12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY
3
12348 HOSE ..................A/R ...MAKE LOCALLY
4
12349 BEARING ..............1 .....S/N 2345B AND ABOVE
NO. Column
Unique Symbols — All items with same unique
symbol
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which 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.
PA RT
NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the 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.
NOTICE
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.
NOTICE
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.
QTY. Column
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.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
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.
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)”
Serial Number Break
— Used to list an effective serial
number range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
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.
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.
“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.
SUGGESTED SPARE PARTS
DCA70USI3CAN WHISPERWATT GENERATOR
5............8980188580 ..........CARTRIDGE , OIL FILTER
5............8981430410 ..........FILTER, FUEL, ELEMENT, MAIN
5............8980758551 ..........FILTER, FUEL, ELEMENT, PRE
5............8980742880 ..........FILTER, FUEL, ELEMENT
5............8980714010 ..........FILTER, FUEL, FEED PUMP
3............0602046365 ..........ELEMENT, AIR
1............8980388560 ..........BELT, FAN
1............M2310502203 .......RADIATOR HOSE, UPPER
1............M2310502404 .......RADIATOR HOSE, UPPER, SHORT
1............M2310502303 .......RADIATOR HOSE, LOWER
1............8121468300 ..........SENSOR, WATER TEMP. (ENGINE SIDE)
1............8971256001 ..........SWITCH, WARNING, OVERHEAT (ENGINE SIDE)
1............8980274560 ..........SENSOR, OIL PRESSURE (ENGINE SIDE)
1............1096300850 ..........GASKET, SENSOR OIL PRESSURE (ENGINE SIDE)
1............0601870440 ..........CIRCUIT BREAKER, 1P, 20 AMP
1............0601870441 ..........CIRCUIT BREAKER, 2P, 50 AMP
1............0601806644 ..........FUSE, 30 AMP
1............0601806640 ..........FUSE, 65 AMP
3............0601806671 ..........FUSE, 15 AMP
1............0601820602 ..........AUTOMATIC VOLTAGE REGULATOR
1............0602122272 ..........UNIT, OIL PRESSURE
2............0601810245 ..........BULB, ALARM LAMP
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
GENERATOR ASSY.
3
21-12
1-11
12
9
6
7
1-10
14
13
16
17
18
21
20
21
23B
23A
23
1 - 9B
1 - 9A
1 - 9
GENERATOR ASSY.
1 B5110000402 ROTOR ASSY 1
1-1 FIELD ASSY 1
1-2 0601820083 RECTIFIER 3
1-3 0601822664 ZNR 1
1-4 B3120100804 HOLDER, ZNR 1
1-5 B3120100604 INSULATOR WASHER 3
1-6 B3120100604 INSULATOR WASHER 5
1-7 B3111100603 FAN 1
1-8 B2163100004 COUPLING DISK ......................... 3 .....PURCHASE ITEMS 1-9 THRU 1-9B AS A SET W/ 1-8
1-9 0010304016 HEX HEAD BOLT 1
1-9A B2163700004 BALANCING WEIGHT 1
1-9B 0204004000 U-NUT 1
1-10 B3163200104 COUPLING WASHER 2
1-11 0342612030 HEX HEAD CAP SCREW 6
1-12 0046512000 WASHER, FLAT 6
1-13 0071906309 BEARING 1
2 0010310020 HEX HEAD BOLT 8
3 0042510000 WASHER, LOCK 8
4 B5130000303 STATOR ASSY 1
4-1 0845041904 GROMMET 2
5 B3137000803 FIELD ASSY EXCITER 1
6 0016008060 HEX HEAD CAP SCREW 4
7 0042508000 WASHER, LOCK 4
8 B3153000513 END BRACKET 1
9 0017108035 HEX HEAD BOLT 6
10 B3153400504 PACKING 1
11 B3153400404 COVER, BEARING 1
12 0017106016 HEX HEAD BOLT 3
13 0010310025 HEX HEAD BOLT 12
14 0042510000 WASHER, LOCK 12
15 B5131300004 COVER, END BRACKET 1
16 0340406040 HEX HEAD BOLT 1
17 0600815000 NUT 1
18 0041206000 WASHER, FLAT 1
19 B3131300804 COVER, END BRACKET 1
20 0029205012 MACHINE SCREW 4
21 0041205000 WASHER, FLAT 4
22 0605000413 RUBBER SUSPENSION 2
23 0030012000 HEX NUT 2
23A 0040012000 WASHER, LOCK 2
23B 0041212000 WASHER, FLAT 2
CONTROL BOX ASSY.
1 M2214000302 CONTROL BOX 1
1-1 0330000180 EDGING 2
1-2 0330000610 EDGING 1
1-3 0330000045 EDGING 2
1-4 0330000120 EDGING 2
1-5 0330000230 EDGING 1
2 0601870432 CIRCUIT BREAKER, 175A 1
2-1 0601870490 COVER, CIRCUIT BREAKER 2
3 0021004040 MACHINE SCREW 4
4 0601823863 RELAY UNIT 2
5 0027104016 MACHINE SCREW 4
6 0601820602 AUTOMATIC VOLTAGE REGULATOR 1
7 0027105016 MACHINE SCREW 4
8 0601801123 CURRENT TRANSFORMER 3
9 0027106020 MACHINE SCREW 6
10 0601820847 OVER CURRENT RELAY 1
11 0601820848 OVER CURRENT RELAY 1
12 0027104016 MACHINE SCREW 2
12A 0207004000 HEX NUT 2
13 M2260500204 SET PANEL, ELECTRIC PARTS 1
14 0016906016 HEX HEAD BOLT 4
15 0601802218 HOLDER, FUSE 1
15A 0601806671 FUSE, 15A 3
16 0027103016 MACHINE SCREW 1
17 LY2DUS12VDC RELAY .........................................................2 ................REPLACES P/N 0601827656
17A PTF08A BASE ...........................................................2 ................REPLACES P/N 0601823109
17B PYCA1 CLIP ............................................................4 ................REPLACES P/N 0601824400
18 0027104020 MACHINE SCREW 4
19 0601815153 TERMINAL 1
20 0027104016 MACHINE SCREW 2
21 8121468300 SENSOR, INLET AIR TEMP. .......................1 ................REPLACES P/N 0603210240
22 8980980660 CONTROLLER ............................................1 ................REPLACES P/N 0602202689
23 M3260500604 BRACKET 1
24 0016906016 HEX HEAD BOLT 4
25 0601831205 PUSH BUTTON SWITCH 1
26 0601831330 DIAGNOSTIC SWITCH 1
27 0016916016 HEX HEAD BOLT 4
28 0601823240 RECTIFIER 1
29 0027105020 MACHINE SCREW 1
30 8972177780 SENSOR, BAROMETRIC PRESSURE ......1 ................REPLACES P/N 0602130220
31 M2260600104 BRACKET, SENSOR 1
32 0027105016 MACHINE SCREW 2
33 0027105016 MACHINE SCREW 2
34 8944001061 RELAY, STARTER .......................................1 ................REPLACES P/N 0602202502
CONTROL BOX ASSY.
CONTROL BOX ASSY.
CONTROL BOX ASSY.
35 8970119490 RELAY, GLOW PLUG ..................................1 ................REPLACES P/N 0602202685
36 0027105016 MACHINE SCREW 4
37 5825500290 RELAY .........................................................3 ................REPLACES P/N 0602201400
38 0027105016 MACHINE SCREW 3
39 M2213500604 CONTROL BOX COVER 1
40 0016906016 HEX HEAD BOLT 4
41 M2270100204 SELECTOR SWITCH 1
41A M2550001404 DECAL : SELECTOR SWITCH NO. 1
41B M2550001504 DECAL : SELECTOR SWITCH NO. 1
42 M2213602303 SWITCH BRACKET 1
42-1 0330000150 EDGING 2
43 M2213602404 SWITCH BRACKET 1
44 0027104035 MACHINE SCREW 4
44A 0207004000 HEX NUT 4
45 0027104016 MACHINE SCREW 4
45A 0207004000 HEX NUT 4
46 0016906016 HEX HEAD BOLT 4
47 M2213602504 SWITCH COVER 1
48 0016906016 HEX HEAD BOLT 6
49 M2213602604 SWITCH COVER 1
49-1 0228800175 SEAL RUBBER 1
49-2 0228800150 SEAL RUBBER 1
49-3 0317700180 SEAL RUBBER 1
50 0016906016 HEX HEAD BOLT 4
51 0016906016 HEX HEAD BOLT 12
51A 0040506000 TOOTHED WASHER 1
52 M2223001003 CONTROL PANEL 1
53 0601807641 FREQUENCY METER, 45~ 65Hz 240V 1
54 0601808987 AC AMMETER, 0~ 150A/300A : 5A 1
55 0601801040 CHANGE- OVER SWITCH, AMMETER 1
56 0601806859 AC VOLTMETER, 0~ 600V 1
57 0601801041 CHANGE-OVER SWITCH, VOLTMETER 1
58 0601840073 RHEOSTAT (VR), 2W 1K OHM 1
59 0601840121 KNOB 1
60 0602202641 CONTROLLER 1
61 0021004040 MACHINE SCREW 2
61A 0207004000 HEX NUT 2
62 0601831340 SWITCH 1
63 0602103092 ALARM LAMP 2
63A 0601810245 BULB, DC18V 2
64 0602120095 TACHOMETER 1
65 0602122093 OIL PRESSURE GAUGE 1
66 0602123090 WATER TEMPERATURE GAUGE 1
67 0602121081 CHARGING AMMETER 1
CONTROL BOX ASSY.
CONTROL BOX ASSY.
68 0602125090 FUEL GAUGE 1
69 0601810141 PANEL LIGHT 1
70 0601831330 SWITCH, PANEL LIGHT 1
71 0601831395 SWITCH, ENGINE SPEED 1
72 M1224100104 STOPPER 1
73 0027105010 MACHINE SCREW 2
74 0027105010 MACHINE SCREW 4
75 M9220100004 SET SCREW 2
76 0080200007 SNAP RING 2
77 0602122272 UNIT, OIL PRESSURE 1
78 M9200100004 ADAPTER 1
79 0602120465 PICK UP, TACHOMETER 1
80 M2357202104 FUSE HOLDER UNIT 1
80A 0601806644 FUSE, 30A 1
81 0601806640 FUSE, 65A 1
82 0601830762 SWITCH, FUEL PUMP 1
83 M2246702304 WIRE HARNESS, GENERATOR 1
84 M2357201712 WIRE HARNESS, ENGINE 1
85 M2357201802 WIRE HARNESS, CONTROLLER 1
ENGINE AND RADIATOR ASSY.
1A
4
5
6
46
47
71
70
69
68
30A
17A
17B
ENGINE AND RADIATOR ASSY.
1 M2923200134 ENGINE, ISUZU BJ-4JJ1X 1
1A 8980388560 FAN BELT ....................................................1 ................REPLACES P/N 0602015254
1-1 8980188580 CARTRIDGE, OIL FILTER ..........................1 ................REPLACES P/N 0602041222
2 0605000451 RUBBER SUSPENSION 2
3 M2413800104 COLLAR 2
4 0030010000 HEX NUT 2
5 0040010000 WASHER, LOCK 2
6 0042810000 WASHER, FLAT 2
7 0602012773 RADIATOR 1
7-1 0602011079 CAP, RADIATOR 1
8 M9312200104 RUBBER MOUNT 2
9 0016906025 HEX HEAD BOLT 2
10 M2310502203 RADIATOR HOSE, UPPER 1
11 M2310502404 RADIATOR HOSE, UPPER, SHORT 1
12 M2310400104 RADIATOR PIPE 1
13 M2310502303 RADIATOR HOSE, LOWER 1
14 0605515147 HOSE BAND 4
15 M2923200124 INTER COOLER 1
16 0132004000 PLUG, 3/8" 1
17 0010510020 HEX HEAD BOLT 8
17A 0040010000 WASHER, LOCK 8
17B 0041210000 WASHER, FLAT 8
18 M2310502103 INTER COOLER HOSE 1
19 M2310503203 INTER COOLER HOSE 1
20 M2310400203 INTER COOLER PIPE 1
21 M2310501703 INTER COOLER HOSE 1
22 0605515208 HOSE BAND 3
23 0605515205 HOSE BAND 1
24 0605515207 HOSE BAND 3
25 0605515237 HOSE BAND 1
26 M2313300404 FAN BRACKET 1
27 0017110030 HEX HEAD BOLT 4
28 0601822798 FAN MOTOR 1
29 0017110030 HEX HEAD BOLT 4
30 0602046582 AIR CLEANER 1
30A 0602046365 ELEMENT, AIR CLEANER 1
31 0602040651 INDICATOR, AIR CLEANER 1
32 0602040554 AIR CLEANER BAND 1
33 0016908030 HEX HEAD BOLT 2
34 M2373101304 HOSE, AIR CLEANER 1
35 M2326100204 BLOWBY PIPE 1
36 M2373101204 HOSE, AIR CLEANER 1
37 M2373100603 HOSE, AIR CLEANER 1
38 0605515230 HOSE BAND 1
39 0605515230 HOSE BAND 2
40 0605515197 HOSE BAND 2
ENGINE AND RADIATOR ASSY. (CONTINUED)
1A
4
5
6
46
47
71
70
69
68
30A
17A
17B
ENGINE AND RADIATOR ASSY. (CONTINUED)
41 0191500680 BLOWBY HOSE 1
42 0605515149 HOSE BAND 2
43 M3326200204 BLOWBY HOSE BRACKET 1
44 001698020 HEX HEAD BOLT 1
45 M9602000003 DRAIN JOINT 1
46 M9200200004 PLUG 1
47 0150000018 O-RING 1
48 0016906020 HEX HEAD BOLT 2
49 0199901700 DRAIN HOSE 1
50 0199901400 DRAIN HOSE 1
51 0605515106 HOSE BAND 4
52 0602022581 ADAPTER 1
53 0602022561 90° ELBOW 1
54 0603306590 CONNECTOR 1
55 0603300285 LOCKNUT 1
56 0605511395 VALVE 1
57 0603306395 HOSE JOINT 1
58 0602021070 CAP 1
59 0269200400 DRAIN HOSE 1
60 M9300000203 RESERVE TANK 1
61 0602010900 CAP, RESERVE TANK 1
62 M3316100303 BRACKET, RESERVE TANK 1
63 0016908020 HEX HEAD BOLT 2
64 0199101800 HOSE 1
65 0193600700 HOSE 1
66 0605515106 HOSE BAND 3
67 0603306798 PLUG 1/4" 1
68 8121468300 SENSOR, WATER TEMPERATURE 1
69 8971256001 SWITCH, WARNING OVERHEAT 1
70 8980274560 SENSOR, OIL PRESSURE 1
71 1096300850 GASKET, SENSOR OIL PRESSURE 1
OUTPUT TERMINAL ASSY.
28A
28A
28
4
5
6
4
6
5
11
11A
11B
12
12A
28
39
39A
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE 5-BLACK
2-WHITE 6-CATERPILLAR YELLOW
3-SPECTRUM GREY 7-CATO GOLD
4-SUNBELT GREEN 8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
OUTPUT TERMINAL ASSY.
1 M3230700003 TERMINAL PANEL 1
2 M9220100304 OUTPUT TERMINAL BOLT 5
3 M9220100404 TIE BOLT 5
4 0039316000 HEX NUT 10
5 0040016000 WASHER, LOCK 15
6 0041416000 WASHER, FLAT 20
7 0016908035 HEX HEAD BOLT 5
8 M3236100803 TERMINAL COVER 1
9 M3236100404 OUTPUT WINDOW 1
10 0605010040 HINGE 2
11 0027103010 MACHINE SCREW 4
11A 0030003000 HEX NUT 4
11B 0041203000 WASHER, FLAT 4
12 0027103010 MACHINE SCREW 4
12A 0030003000 HEX NUT 4
13 0016906020 HEX HEAD BOLT 2
14 0016906016 HEX HEAD BOLT 4
15 M3236400004 CABLE OUTLET COVER 1
16 M3236300004 SUPPORTER, CABLE OUTLET COVER 1
17 0016906020 HEX HEAD BOLT 6
18 0601815194 TERMINAL 1
19 0027104016 MACHINE SCREW 2
20 0603306775 BLIND PLUG 2
21 0027104016 MACHINE SCREW 4
22 0601870440 CIRCUIT BREAKER, 1P 20A 2
23 0601870441 CIRCUIT BREAKER, 2P 50A 3
24 M1260700504 BREAKER FITTING COVER 1
24-1 0222100100 CUSHION RUBBER 2
25 0016906020 HEX HEAD BOLT 2
26 0601812598 RECEPTACLE, GF530EM 125V 20Ax2 2
27 0601812538 RECEPTACLE, CS6369 250V 50A 3
28 0027104016 MACHINE SCREW 10
28A 0207004000 HEX NUT 10
29 M2453400004 COVER 1
30 0016906016 HEX HEAD BOLT 6
31 M2236100603 TERMINAL COVER 1
32 0010112045 HEX HEAD BOLT 2
33 0041212000 WASHER, FLAT 2
34 M9310200004 STAY RUBBER 2
35 0030012000 HEX NUT 2
36 M4236100604 COVER 1
37 M4236400304 BRACKET 1
38 0019206015 HEX HEAD BOLT 2
39 0019208020 HEX HEAD BOLT 1
39A 0040508000 TOOTHED WASHER 1
BATTERY ASSY.
BATTERY ASSY.
1 0602220199 BATTERY 1
2 M9310500014 BATTERY SHEET 1
3 M9103000304 BATTERY BAND 1
4 0602220920 BATTERY BOLT SET 2
5 M2346900504 BATTERY CABLE 1
6 M2346900604 BATTERY CABLE 1
7 CABLE .........................................................1 ................MAKE LOCALLY
8 0017112025 HEX HEAD BOLT 1
8A 0040512000 TOOTHED WASHER 1
9 0016908025 HEX HEAD BOLT 1
9A 0040508000 TOOTHED WASHER 1
MUFFLER ASSY.
MUFFLER ASSY.
1 M2330101103 MUFFLER 1
2 0017112030 HEX HEAD BOLT 4
3 M2333001403 EXHAUST PIPE 1
4 M2333200404 GASKET 1
5 0017110040 HEX HEAD BOLT 4
6 M2333200304 GASKET 1
7 0017110035 HEX HEAD BOLT 4
8 M2333001303 EXHAUST PIPE 1
9 0017110050 HEX HEAD BOLT 4
10 8943690210 GASKET ......................................................1 ................REPLACES P/N 0602320101
11 0039308000 U-BOLT 6
FUEL TANK ASSY.
FUEL TANK ASSY.
1 M2363001202 FUEL TANK 1
1-1 0605501079 FUEL SENDER UNIT 1
1-1A 0605516090 GASKET 1
2 M2363200704 TANK BAND 3
3 M2363200804 TANK BAND 3
4 M9310500104 SUPPORTER SHEET 6
5 0016908020 HEX HEAD BOLT 6
6 020108060 HEX NUT .....................................................3 ................REPLACES P/N 0207008000
7 0222100710 TANK SHEET 5
8 0191302200 VENT HOSE 1
9 0605515109 HOSE BAND 2
10 M2323400103 FUEL FILTER BRACKET 1
11 011008020 HEX HEAD BOLT 3
12 M2366700104 FUEL PUMP BRACKET 1
13 011208030 HEX HEAD BOLT 2
14 8980139861 FUEL FILTER (MAIN) ..................................1 ................REPLACES P/N 0602042426
14A 8981430410 ELEMENT, FUEL FILTER, (MAIN) ..............1 ................REPLACES P/N 0602042515
15 8980758551 FUEL FILTER (PRE) ...................................1 ................REPLACES P/N 0602042405
15A 8980742880 ELEMENT, FUEL FILTER ............................ 1 ................REPLACES P/N 0602042516
16 8973834270 JOINT PIPE ................................................. 1 ................REPLACES P/N 0602042661
17 1096750951 JOINT BOLT ................................................4 ................REPLACES P/N 0602042621
18 1096300860 PACKING ..................................................... 8 ................REPLACES P/N 0602042641
19 0017108040 HEX HEAD BOLT 4
20 0010108080 HEX HEAD BOLT 2
20A 0040008000 WASHER, LOCK 2
20B 0041208000 WASHER, FLAT 2
21 8980682750 FUEL FEED PUMP .....................................1 ................REPLACES P/N 0602023240
21A 8980714010 FUEL FILTER ..............................................1 ................REPLACES P/N 0602042517
22 0016906025 HEX HEAD BOLT 2
23 0191300950 SUCTION HOSE 1
24 0191300740 SUCTION HOSE 1
25 0191300370 SUCTION HOSE 1
26 0191301580 SUCTION HOSE 1
27 0191300400 RETURN HOSE 1
28 0605515109 HOSE BAND 10
29 M2367700003 FUEL FILTER HOSE 1
30 0605515225 HOSE BAND 2
31 0605505072 FUEL TANK CAP 1
32 M2484600003 FUEL FILLER BRACKET 1
32A M2494600004 ACOUSTIC SHEET 1
33 0019208020 HEX HEAD BOLT 4
ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
1 M2413002002 BASE 1
2 M2363300603 ENVIRONMENTAL TANK 1
3 0016908030 HEX HEAD BOLT 12
4 0603306797 PLUG 1
5 M2423001702 FRONT FRAME 1
5A M2493108503 ACOUSTIC SHEET 1
6 M2423002002 FRONT FRAME 1
6A M2493108503 ACOUSTIC SHEET 1
7 0601850265 GROMMET 1
8 0601850263 GROMMET 1
9 0601851777 GROMMET 1
10 0016908020 HEX HEAD BOLT 22
11 0016910025 HEX HEAD BOLT 6
12 M2310601003 HOSE COVER 1
13 M2310601104 HOSE COVER 1
14 0016906020 HEX HEAD BOLT 10
15 0016906020 HEX HEAD BOLT 2
16 M2423203604 DUCT COVER 2
17 0016906020 HEX HEAD BOLT 14
18 M2310200402 INTER-COOLER BRACKET 1
18A M2493600104 ACOUSTIC SHEET 1
19 0601851777 GROMMET 1
20 0016906020 HEX HEAD BOLT 14
21 M2310303204 FAN SHROUD 1
22 M2310303304 FAN SHROUD 1
23 M2310303404 FAN SHROUD 1
24 0016908020 HEX HEAD BOLT 9
25 0016906016 HEX HEAD BOLT 4
26 M2310302104 FAN GUARD 1
27 M2310302204 FAN GUARD 1
28 0016906016 HEX HEAD BOLT 6
29 M2423202803 COVER, FRONT FRAME 1
29A M2493108604 ACOUSTIC SHEET 1
30 M2423202903 FRONT LOUVER 1
31 0019206016 HEX HEAD BOLT 6
32 0019208020 HEX HEAD BOLT 4
33 0019208020 HEX HEAD BOLT 4
34 M2433001003 CENTER FRAME 1
ENCLOSURE ASSY. #1 (CONTINUED)
ENCLOSURE ASSY. #1 (CONTINUED)
35 0010114040 HEX HEAD BOLT 4
35A 0030014000 HEX NUT 4
35B 0040014000 WASHER, LOCK 4
35C 0041214000 WASHER, FLAT 8
36 0010120050 HEX HEAD BOLT 4
36A 0030020000 HEX NUT 4
36B 0040020000 WASHER, LOCK 4
36C 0041220000 WASHER, FLAT 8
37 M2463100402 ROOF PANEL 1
37A M2493505004 ACOUSTIC SHEET 1
38 M2463200702 ROOF PANEL 1
38A M2493502403 ACOUSTIC SHEET 1
39 M3463200704 BACK PLATE 2
40 0016906016 HEX HEAD BOLT 12
41 M2463200503 DUCT 1
41A M2493502704 ACOUSTIC SHEET 1
42 0016908020 HEX HEAD BOLT 10
43 M2463400103 DUCT COVER 1
44 0016908020 HEX HEAD BOLT 6
45 M2423203004 OVER-COVER, FRONT FRAME 1
45A M2493104404 ACOUSTIC SHEET 1
46 0019208020 HEX HEAD BOLT 38
47 0019210025 HEX HEAD BOLT 8
48 M3310600004 COVER, RADIATOR CAP 1
49 0019208020 HEX HEAD BOLT 4
50 M2483100404 COVER, EXHAUST PIPE 1
51 0016908020 HEX HEAD BOLT 2
52 0016908020 HEX HEAD BOLT 1
52A 0040508000 TOOTHED WASHER 1
53 0605503062 FUEL LEAK DETECTED SWITCH 1
54 M1414800104 BRACKET 1
55 0016908020 HEX HEAD BOLT 2
56 M2357300004 HARNESS CLAMP 1
57 0016908020 HEX HEAD BOLT 2
58 M2310304604 FAN GUARD 1
59 0016906016 HEX HEAD BOLT 3
60 0603306793 PLUG 1
ENCLOSURE 2 ASSY.
ENCLOSURE 2 ASSY.
1 M2443001202 REAR FRAME 1
1A M2493305103 ACOUSTIC SHEET 1
2 M2443301803 DUCT 2
2A M2493305904 ACOUSTIC SHEET 1
3 0016908020 HEX HEAD BOLT 12
4 0016910025 HEX HEAD BOLT 4
5 M2444300103 COVER, REAR FRAME 1
5A M2443305204 ACOUSTIC SHEET 1
6 0016908020 HEX HEAD BOLT 3
7 0016908020 HEX HEAD BOLT 3
8 M2443200503 DOOR, REAR FRAME 1
9 M1444600004 WINDOW PLATE 1
10 0037906000 U-NUT 8
10A 0041206000 WASHER, PLAIN 8
11 M9113000002 DOOR HANDLE ASSY. 1
12 0021806018 MACHINE SCREW 4
12A 0030006000 HEX. NUT 4
13 M9110100204 HINGE 2
14 M9116100004 WASHER 2
15 0019208020 HEX HEAD BOLT 3
16 M2453201802 SPLASHER PANEL 1
16A M2493405204 ACOUSTIC SHEET 1
17 0019108065 HEX HEAD BOLT 4
17A 0042308000 WASHER, LOCK 4
17B 0042408000 WASHER, FLAT 4
18 0016910025 HEX HEAD BOLT 2
19 M2453002703 SIDE DOOR 1
19A M2493409104 ACOUSTIC SHEET 1
20 M2453002603 SIDE DOOR 1
20A M2493409304 ACOUSTIC SHEET 1
21 M2453001903 SIDE DOOR 1
21A M2493405304 ACOUSTIC SHEET 1
22 M2453002403 SIDE DOOR 1
22A M2494403604 ACOUSTIC SHEET 1
23 M9113000002 DOOR HANDLE ASSY. 4
23A C9312500004 RUBBER SEAL 4
24 0021806016 MACHINE SCREW 16
24A 0030006000 HEX. NUT 16
25 M9110100804 HINGE 6
26 M9110100904 HINGE 5
27 M9116100004 WASHER 11
28 0019208020 HEX HEAD BOLT 26
29 0601850097 STOPPER 8
30 0027208025 MACHINE SCREW 8
31 M9310000004 CAP 13
32 0600800320 MANUAL PACK 1
33 0021806016 MACHINE SCREW 4
34 M2454100003 SIDE PANEL 1
34A M2494403604 ACOUSTIC SHEET 1
RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
1 0229200840 SEAL RUBBER 1
2 0314502200 SEAL RUBBER 1
3 0229200950 SEAL RUBBER 3
4 0229200125 SEAL RUBBER 4
5 0228901165 SEAL RUBBER 2
6 0228900770 SEAL RUBBER 8
7 0228901105 SEAL RUBBER 2
8 0228900535 SEAL RUBBER 1
9 0228900475 SEAL RUBBER 1
10 0228100530 SEAL RUBBER 1
11 0228100870 SEAL RUBBER 1
12 0228101240 SEAL RUBBER 3
13 0228100800 SEAL RUBBER 1
14 0228100635 SEAL RUBBER 2
15 0228800525 SEAL RUBBER 1
16 0228800790 SEAL RUBBER 1
17 0228800475 SEAL RUBBER 1
18 0228100325 SEAL RUBBER 2
19 0228100420 SEAL RUBBER 2
20 0228900700 SEAL RUBBER 1
21 0228900640 SEAL RUBBER 1
22 0229200295 SEAL RUBBER 2
23 0229200220 SEAL RUBBER 2
NAMEPLATE AND DECALS ASSY.
53A
53
53A
54
54A
6A
6
53
36
30
24
30A
3A
55A
51A
55
51
NAMEPLATE AND DECALS ASSY.
1 EE57066 DECAL : NOTICE, 50 AMP RECEPTACLES (ENGLISH) 1
1A EE57067 DECAL : NOTICE, 50 AMP RECEPTACLES (FRENCH) 1
2 M1550002203 DECAL : AUXILIARY OUTPUT ................................................. 1 ........... M15000220
3 EE57082 DECAL : NOTICE, LOAD SHARING (ENGLISH) 1
3A EE57083 DECAL : NOTICE, LOAD SHARING (FRENCH) 1
4 M2550002103 DECAL : GENERATOR CONTROL .......................................... 1 ........... M25000210
5 M2550002203 DECAL : ENGINE OPERATING ............................................... 1 ........... M25000220
6 M2550002303 DECAL : OPERATING PROCEDURES (ENGLISH) ................. 1 ........... M25000230
6A EE57088 DECAL : OPERATING PROCEDURES (FRENCH) 1
7 M3550002204 DECAL : CAUTION, BAIL MAX CAPACITY (ENGLISH) ........... 1 ........... M35000220
7A# DECAL : CAUTION, BAIL MAX CAPACITY (FRENCH) 1
8 M9500000004 DECAL : OIL DRAIN PLUG ...................................................... 1 ........... M90000000
9 M9500100004 DECAL : WATER ....................................................................... 1 ........... M90010000
10 M9500100304 DECAL : INTER- COOLER DRAIN PLUG ................................ 1 ........... M90010030
11 M9500300004 DECAL : - .................................................................................. 1 ........... M90030000
12 M9500300104 DECAL : + ................................................................................. 1 ........... M90030010
13 M9500500004 DECAL : DIESEL FUEL ............................................................ 1 ........... M90050000
14 M9503000004 DECAL : WARNING, MOVING PARTS (ENGLISH) .................. 2 ........... M90300000
14A# DECAL : WARNING, MOVING PARTS (FRENCH) ................... 2 ........... M90300000CE
15 M9503000103 DECAL : WATER - OIL CHECK ................................................ 1 ........... M90300010
16 M9503100004 DECAL : WARNING, HOT COOLANT (ENGLISH) ................... 2 ........... M90310000
16A# DECAL : WARNING, HOT COOLANT (FRENCH) .................... 2 ........... M9031000CE
17 M9503200004 DECAL : WARNING, ENGINE EXHAUST (ENGLISH) ............. 1 ........... M90320000
17A# DECAL : WARNING, ENGINE EXHAUST (FRENCH) .............. 1 ........... MQB90420000CE
18 M9503200104 DECAL : DANGER EXHAUST GAS (ENGLISH) ...................... 1 ........... M90320010
18A# DECAL : DANGER EXHAUST GAS (FRENCH) ....................... 1 ........... M90320010CE
19 M9510000004 DECAL : FUEL DRAIN .............................................................. 1 ........... M91000000
20 M9510000104 DECAL : DOCUMENT BOX ...................................................... 1 ........... M91000010
21 M9510100004 DECAL : CAUTION HOT PARTS (ENGLISH) ........................... 1 ........... M91010000
21A# DECAL : CAUTION HOT PARTS (FRENCH) ............................ 1 ........... MQB90400030CE
22 EE57068 DECAL: NOTICE, ENVIRONMENTAL WARNING (ENGLISH) 1
22A EE57069 DECAL: NOTICE, ENVIRONMENTAL WARNING (FRENCH) 1
23 M9510100403A DECAL : CAUTION, OFF/RESET SW (ENGLISH) ................... 1 ........... M91010040
23A# DECAL : CAUTION, OFF/RESET SW (FRENCH) .................... 1 ........... MQC90530000CE
24 M9520000004 DECAL : GROUND ................................................................... 1 ........... M92000000
25 M9520000104 DECAL : AMMETER CHANGE - OVER SWITCH .................... 1 ........... M92000010
26 M9520000204 DECAL : VOLTMETER CHANGE - OVER SWITCH ................. 1 ........... M92000020
27 M9520000504 DECAL : START CONTACT ...................................................... 1 ........... M92000050
28 M9520000904 DECAL : DIAGNOSTIC SWITCH.............................................. 1 ........... M92000090
29 M9520001104 DECAL : DIAGNOSTIC BUTTON ............................................. 1 ........... M92000110
30 M9520100004 DECAL : WARNING ELECTRICAL SHOCK HAZ.(ENGLISH) .. 2 ........... M92010000
30A# DECAL : WARNING ELECTRICAL SHOCK HAZ.(FRENCH) .. 2 ........... MQB9310050CE
31 M9520100204A DECAL : CAUTION, STOP ENGINE (ENGLISH) ..................... 1 ........... M92010020A
31A# DECAL : CAUTION, STOP ENGINE (FRENCH) ...................... 1 ........... M92010020CE
32 M9520100304 DECAL : SAFETY INSTRUCTIONS (ENGLISH) ...................... 1 ........... M92010030
32A# DECAL : SAFETY INSTRUCTIONS (FRENCH) ....................... 1 ........... B92110040CE
NAMEPLATE AND DECALS ASSY.
53A
53
53A
54
54A
6A
6
53
36
30
24
30A
3A
55A
51A
55
51
NAMEPLATE AND DECALS ASSY.
33 M9520100404 DECAL : DANGER, HIGH VOLTAGE (ENGLISH) ..................... 1 ........... M92010040
33A# DECAL : DANGER, HIGH VOLTAGE (FRENCH) ...................... 1 ........... MQS-2731CE
34 M9520100503 DECAL : WARNING, ELECTRICAL (ENGLISH)....................... 1 ........... M92010050
34A# DECAL : WARNING, ELECTRICAL (FRENCH) ....................... 1 ........... M92010050CE
35 M9520100603 DECAL : CAUTION,START/STOP (ENGLISH) ......................... 2 ........... M92010060
35A# DECAL : CAUTION,START/STOP (FRENCH) .......................... 1 ........... MQC92210000CE
36 M9520200003 DECAL : CONNECTION OF OUTPUT CABLE ........................ 1 ........... M92020000
37 M9520200404 DECAL : OVER CURRENT RELAY .......................................... 1 ........... M92020040
38 M9512200004 DECAL : MQ ............................................................................. 1 ........... M91220000
39 M9510200304 DECAL : MQ POWER 1
40 M2560101104 STRIPE 2
41 M2560100603 STRIPE : WHISPERWATT 2
40 M3560102204 STRIPE 2
43 M2560101303 STRIPE : 70 1
44 M2560101403 STRIPE : 70 1
45 M3560102504 STRIPE 2
46 0600500092 PLATE : MQ POWER 2
47 0021106016 MACHINE SCREW 4
48 M9520000804 DECAL : AC 1
49 920214100 DECAL: WARNING, SPARKS (ENGLISH) 1
49A# DECAL: WARNING, SPARKS (FRENCH) ................................ 1 ........... M9042000CE
50 49002 DECAL: WARNING, TRAILER (ENGLISH) 1
50A# DECAL: WARNING, TRAILER (FRENCH)................................ 1 ........... 490002CE
51$ EE57072 DECAL: NOTICE, BONDED TO FRAME (ENGLISH) 2
51A$ EE57073 DECAL: NOTICE, BONDED TO FRAME (FRENCH) 2
53 EE57077 DECAL: NOTICE, CLASS H (ENGLISH) 1
53A EE57078 DECAL: NOTICE, CLASS H (FRENCH) 1
54$ EE57070 DECAL: NOTICE, OVERLOAD (ENGLISH) 1
54A$ EE57071 DECAL: NOTICE, OVERLOAD (FRENCH) 1
55$ EE57079 DECAL: NOTICE, SUPPLY WIRES (ENGLISH) 1
55A$ EE57080 DECAL: NOTICE, SUPPLY WIRES(FRENCH) 1
56 EE52657 DECAL KIT (FRENCH) ............................................................. 1 ........... INCLUDES ITEMS W/ #
57 EE57074 DECAL KIT (ENGLISH & FRENCH) ......................................... 1 ........... INCLUDES ITEMS W/ $
58 EE57089 NAME PLATE, EMISSION CONTROL (ENGLISH & FRENCH) 1
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
Terms of payment for parts are net 30 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
MINIMUM ORDER
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
RETURNED GOODS POLICY
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
A Returned Material Authorization
1.
must be approved by Multiquip prior to
shipment.
To obtain a Return Material Authorization,
2.
a list must be provided to Multiquip
Parts Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
The parts numbers and descriptions a.
must match the current parts price
list.
The list must be typed or computer b.
generated.
The list must state the reason(s) c.
for the return.
The list must reference the sales d.
order(s) or invoice(s) under
which the items were originally
purchased.
The list must include the name e.
and phone number of the person
requesting the RMA.
A copy of the Return Material Authorization
3.
must accompany the return shipment.
Freight is at the sender’s expense. All
4.
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
Parts must be in new and resalable 5.
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
The following items are not returnable:6.
Obsolete parts. (If an item is in the a.
price book and shows as being
replaced by another item, it is
obsolete.)
Any parts with a limited shelf life b.
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
Any line item with an extended c.
dealer net price of less than
$5.00.
Special order items.d.
Electrical components.e.
Paint, chemicals, and lubricants.f.
Decals and paper products.g.
Items purchased in kits.h.
The sender will be notified of any material 7.
received that is not acceptable.
Such material will be held for five 8.
working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.
Credit on returned parts will be issued 9.
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
In cases where an item is accepted, for 10.
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
Credit issued will be applied to future 11.
purchases only.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a
specific date and all orders received on or
after that date will be billed at the revised price.
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
Multiquip reserves the right to quote and
sell direct to Government agencies, and to
Original Equipment Manufacturer accounts
who use our products as integral parts of their
own products.
SPECIAL EXPEDITING SERVICE
A $35.00 surcharge will be added to the
invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
LIMITATIONS OF SELLER’S LIABILITY
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of
the item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
LIMITATION OF WARRANTIES
No warranties, express or implied, are
made in connection with the sale of parts or
trade accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes nor
authorizes any person to assume for it
any other obligation or liability whatever in
connection with the sale of its products. Apart
from such written statement of warranty,
there are no warranties, express, implied or
statutory, which extend beyond the description
of the products on the face hereof.
Effective: February 22, 2006
NOTES
OperatiOn and parts Manual
Your Local Dealer is:
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
United StateS
Multiquip Corporate Office MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: mq@multiquip.com
Tel. (800) 421-1244
Fax (310) 537-3927
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department Warranty Department
800-421-1244
310-537-3700
Fax: 310-537-4259 800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244 Fax: 310-943-2238
mexico United Kingdom
MQ Cipsa Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: pmastretta@cipsa.com.mx
Tel: (52) 222-225-9900
Fax: (52) 222-285-0420
Unit 2, Northpoint Industrial Estate,
Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: sales@multiquip.co.uk
Tel: 0161 339 2223
Fax: 0161 339 3226
Canada
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: jmartin@multiquip.com
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2013, MULTIQUIP INC.
Multiquip Inc
, the MQ logo 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.
