OperatiOn and parts Manual
®
MOdel dCa40ssKu
MOdel dCa40ssKu4i
60Hz Whisperwatt™ Generator
(KuBOta V3300-e3BG diesel enGine)
parts list nO. M1870301604
Revision #1 (03/11/13)
To find the latest revision of this
publication, visit our website at:
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
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repOrtinG safety defeCts
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at
write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 3
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Table of ConTenTs
Component Drawings
DCa45ssKU/ssKU4i 60 Hz
Generator Assembly......................................... 50-51
Control Box Assembly ...................................... 52-55
Engine and Radiator Assembly ........................ 56-59
Output Terminal Assembly................................ 60-61
Battery Assembly.............................................. 62-63
Muffler Assembly.............................................. 64-65
Fuel Tank Assembly.......................................... 66-67
Enclosure Assembly......................................... 68-71
Rubber Seals Assembly ................................... 72-73
Nameplate and Decals Assembly..................... 74-75
Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects......................................... 3
Table Of Contents.................................................... 4
Parts Ordering Procedures...................................... 5
Safety Information .............................................. 6-11
Specifications ........................................................ 12
Dimensions............................................................ 13
Installation ........................................................ 14-15
General Information............................................... 16
Major Components ................................................ 17
Generator Control Panel........................................ 18
Engine Operating Panel......................................... 19
Output Terminal Panel Familiarization.............. 20-22
Load Application.................................................... 23
Generator Outputs................................................. 24
Generator Outputs/Gauge Reading....................... 25
Output Terminal Panel Connections ................. 26-27
Inspection/Setup............................................... 28-31
Generator Start-Up Procedure ........................ 32-33
Generator Shut-Down Procedures ........................ 34
Maintenance..................................................... 35-38
Trailer Maintenance .......................................... 39-42
Trailer Wiring Diagram ........................................... 43
Generator Wiring Diagram..................................... 44
Engine Wiring Diagram.......................................... 45
Troubleshooting (Generator).................................. 46
Explanation Of Code In Remarks Column............. 48
Suggested Spare Parts ......................................... 49
Terms And Conditions Of Sale — Parts ................ 76
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parts OrderinG prOCedures
Ordering parts has never been easier!
Choose from three easy options:
Effective:
January 1st, 2006
Best Deal!
order via internet (Dealers only):
Order parts on-line using Multiquip’s SmartEquip website!
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
I View Parts Diagrams
I Order Parts
I Print Specification Information
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
to log in and save!
Order Parts
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
order via Fax (Dealers only):
All customers are welcome to order parts via Fax.
Domestic (Us) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Note: Discounts Are Subject To Change
Domestic (Us) Dealers Call:
order via phone:
1-800-427-1244
non-Dealer Customers:
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
Ì
Dealer account number
Ì
specify preferred method of shipment:
Ì
Ì
Ì
Ì
Ì
Dealer name and address
ꢀ UPS/Fed Ex
ꢀ DHL
ꢀ Truck
I
I
Priority One
Ground
shipping address (if different than billing address)
return Fax number
I Next Day
Second/Third Day
applicable model number
I
Quantity, part number and Description of each part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
We aCCepT all maJor CreDiT CarDs!
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safety infOrMatiOn
Do not operate or service the equipment before reading the
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
saFeTY messages
The four safety messages shown below will inform you
about potential hazards that could injure you or others.The
safety messages specifically address the level of exposure
to the operator and are preceded by one of four words:
Danger, Warning, CaUTion or noTiCe.
saFeTY sYmBols
Danger
Indicates a hazardous situation which, if not avoided,
Will result in DeaTh or serioUs inJUrY.
Warning
Indicates a hazardous situation which, if not avoided,
CoUlD result in DeaTh or serioUs inJUrY.
CaUTion
Indicates a hazardous situation which, if not avoided,
CoUlD result in minor or moDeraTe inJUrY.
NOTICE
Addresses practices not related to personal injury.
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safety infOrMatiOn
„ never 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.
general saFeTY
CaUTion
„ never operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
„ alWaYs know the location of the nearest
fire extinguisher.
„ alWaYs know the location of the nearest
first aid kit.
„ alWaYs know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fire department. This information will be invaluable in
the case of an emergency.
„ never operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
„ never operate this equipment under the influence of
drugs or alcohol.
generaTor saFeTY
Danger
„ neveroperatetheequipmentinanexplosive
atmosphereornearcombustiblematerials.An
explosion or fire could result causing severe
bodily harm or even death.
„ alWaYs 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.
Warning
„ never disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death.Disconnection of any of these
devices will void all warranties.
NOTICE
„ This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
„ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
CaUTion
„ Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
„ never lubricate components or attempt service on a
running machine.
NOTICE
„ alWaYs ensure generator is on level ground before use.
„ alWaYs keep the machine in proper running condition.
„ Fix damage to machine and replace any broken parts
immediately.
„ alWaYs store equipment properly when it is not being
used.Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel
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safety infOrMatiOn
engine saFeTY
NOTICE
Danger
„ never run engine without an air filter or with a dirty air
filter.Severe engine damage may occur.Service air filter
frequently to prevent engine malfunction.
„ The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
„ never tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
„ The engine of this equipment
requires an adequate free
flow of cooling air. never
operate this equipment in
any enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
„ Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied.When a diesel engine operates without
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
Warning
„ Do noT place hands or fingers inside engine
compartment when engine is running.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
„ never operate the engine with heat shields or
guards removed.
„ Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition.It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
„ Do noT remove the 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.
„ State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels.A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
„ Do noT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CaUTion
„ never touch the hot exhaust manifold,
muffler or cylinder.Allow these parts to cool
before servicing equipment.
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safety infOrMatiOn
„ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
FUel saFeTY
Danger
„ Do noT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
„ alWaYs inspect the hitch and coupling for wear. never
tow a trailer with defective hitches, couplings, chains, etc.
„ Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
„ alWaYs refuel in a well-ventilated area, away from
sparks and open flames.
„ alWaYs use extreme caution when working with
flammable liquids.
„ alWaYs make sure the trailer is equipped with a safety
chain.
„ Do noT fill the fuel tank while the engine is running
or hot.
„ alWaYs properly attach trailer’s safety chains to towing
vehicle.
„ Do noT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
„ alWaYs make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
„ Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.
„ DOT Requirements include the following:
• Connect and test electric brake operation.
„ never use fuel as a cleaning agent.
• Secure portable power cables in cable tray with tie
wraps.
„ Do noT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
„ The maximum speed for highway towing is55 mphunless
posted otherwise.Recommended off-road towing is not to
exceed 15 mph or less depending on type of terrain.
ToWing saFeTY
„ Avoid sudden stops and starts.This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
CaUTion
„ Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
SafetyTowing Regulations, before towing
your generator.
„ Avoid sharp turns to prevent rolling.
„ Trailer should be adjusted to a level position at all times
when towing.
„ Raise and lock trailer wheel stand in up position when
towing.
„ Refer to MQ Power trailer manual for additional safety
information.
„ Place chock blocks underneath wheel to prevent rolling
while parked.
„ In order to reduce the possibility of an accident while
transporting the generator on public roads, alWaYs
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
„ Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
„ Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
„ alWaYs shutdown engine before transporting
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safety infOrMatiOn
„ Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
eleCTriCal saFeTY
Danger
„ Do noT touch output terminals during
operation. Contact with output terminals
duringoperationcancauseelectrocution,
electrical shock or burn.
NOTICE
„ alWaYs make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
„ The electrical voltage required to
operate the generator can cause severe
grounding safety
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.
Danger
„ alWaYs make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. severe injury or death by
electrocution can result from operating an ungrounded
generator.
„ never insert any objects into the output
receptacles during operation. This is
extremely dangerous.The possibility exists
of electrical shock, electrocution or
death.
„ never use gas piping as an electrical ground.
„ Backfeed to a utility system can cause
electrocution and/or property damage.
never connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
power Cord/Cable safety
Danger
„ never let power cords or cables lay in water.
„ never stand in water while AC power from the
generator is being transferred to a load.
„ never use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
„ never grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
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safety infOrMatiOn
BaTTerY saFeTY
Danger
environmenTal saFeTY
NOTICE
„ Do noT drop the battery. There is a possibility that the
battery will explode.
„ Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel filters.
„ Do noT expose the battery to open flames,
sparks, cigarettes, etc.The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
„ Do noT use food or plastic containers to
dispose of hazardous waste.
„ Do noT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
Warning
„ alWaYswearsafetyglasseswhenhandling
the battery to avoid eye irritation.The battery
contains acids that can cause injury to the
eyes and skin.
„ Use well-insulated gloves when picking up the battery.
„ alWaYs keep the battery charged. If the battery is not
charged, combustible gas will build up.
„ alWaYs recharge the battery in a well-ventilated
environmenttoavoidtheriskofadangerousconcentration
of combustible gasses.
„ If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
„ If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CaUTion
„ alWaYs disconnect the negaTive battery terminal
before performing service on the generator.
„ alWaYs keep battery cables in good working condition.
Repair or replace all worn cables.
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speCifiCatiOns
Table 1. generator specifications
DCA-40SSKU/KU4i
model
Revolving field, self ventilated,
open protected type synchronous generator
Type
armature Connection
phase
star with neutral
3
zigzag
Single
standby output
prime output
31.2 KW (39.0 kVA)
30.0 KW (37 kVA)
22.5 KW
21 KW
3Ø voltage (l-l/l-n)
voltage selector switch at 3Ø 240/139
208Y/120, 220Y/127,
240Y/139
N/A
N/A
3Ø voltage (l-l/l-n)
voltage selector switch at 3Ø 480/277
416Y/240, 440Y/254,
480Y/277
1Ø voltage (l-l/l-n)
voltage selector switch at 1Ø 240/120
N/A
0.8
240/120
1.0
power Factor
Frequency
60 Hz
speed
1800 rpm
aux. aC power
aux. voltage/output
Dry Weight
Single Phase, 60 Hz
4.8 Kw (2.4 kW x 2)
2,039 lbs. (925 kg)
2,282 lbs. (1,035 kg)
Wet Weight
Table 2. engine specifications
model
Type
Kubota V3300-E3BG EPA Interim Tier 4 Certified
4-cycle, water cooled, swirl chamber
4 cylinders
no. of Cylinders
Bore x stroke
Displacement
rated output
starting
3.86 x 4.33 in. (98 x 110 mm)
202. in3 (3.3 liters)
41.2 HP at 1800 rpm
Electric
Coolant Capacity
lube oil Capacity
FuelType
2.91 gal. (11.0 liters)
3.49 gal. (13.2 liters)
Ultra Low Sulfer No. 2 Diesel Fuel
26.4 gal. (100 liters)
FuelTank Capacity
2.6 gal. (9.8 L)/hr at full load
1.4 gal. (5.4 L)/hr at 1/2 load
1.9 gal. (7.3 L)/hr at 3/4 load
Fuel Consumption
1.0 gal. (3.8 L)/hr at 1/4 load
Battery
27 (CCA 0° 800A) x 1
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diMensiOns
40
Figure 1. Dimensions
Table 3. Dimensions
reference
letter
Dimension in. (mm)
reference letter
Dimension in. (mm)
A
B
C
D
E
25.19 in. (640 mm.)
25.19 in. (640 mm.)
24.60 in. (625mm.)
32.28 in. (820 mm.)
24.60 in. (625 mm.)
F
G
H
I
76.37 in. (1,940 mm.)
49.21 in. (1,250 mm.)
52.91 in. (1,344 mm.)
37.40 in. (950 mm.)
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installatiOn
Figure 2. Typical Generator Grounding Application
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installatiOn
oUTDoor insTallaTion
generaTor groUnDing
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide
or shift around. Also install the generator in a manner so
that the exhaust will not be discharged in the direction of
nearby homes.
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good earTh
ground.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifies that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
The installation site must be relatively free from moisture
and dust.All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
a. Copper - 8 AWG (5.3 mm2)
b. Aluminum - 6 AWG (8.4 mm2)
CaUTion
Pay close attention to ventilation when operating the
generator inside tunnels and caves.The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.
2. When grounding the generator ( Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
3. NECarticle250-52(5)specifiesthattheearthgroundrod
should be buried a minimum of 8 ft. into the ground.
inDoor insTallaTion
Exhaust gases from diesel engines are extremely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
NOTICE
When connecting the generator to any buildings
electrical system alWaYs consult with a licensed
electrician.
NOTICE
This generator has a permanent bonding conductor
between the generator stator windings and the frame.
moUnTing
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running.The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1).Do noT remove
the metal skids on the bottom of the generator. They are
to resist damage to the bottom of the generator and to
maintain alignment.
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 15
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General infOrMatiOn
generaTor
open DelTa exCiTaTion sYsTem
This MQ Power 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.
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.
engine ConTrol panel
The “Engine Operating Panel” is provided with the following:
„ Engine Warning Lamp Module
• Oil Pressure Alarm Lamp
• Water Temperature Lamp
• Charging Alarm Lamp
• Pre-Heat Lamp
„ Fuel Gauge
„ Hour Meter
„ Speed Control Switch
„ Ignition Switch
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.
generaTor ConTrol panel
The “Generator Control Panel” is provided with the following:
„ Frequency Meter (Hz)
„ AC Ammeter (Amps)
„ AC Voltmeter (Volts)
„ Ammeter Change-Over Switch
„ Voltage Regulator
„ 3-Pole, 100 amp Main Circuit Breaker
„ “Control Box” (located behind the Gen. Control Panel)
• Automatic Voltage Regulator
• Current Transformer
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 Kubota V3800-DI-T-E3B
diesel engine. This engine is designed to meet every
performance requirement for the generator. Reference
Table 2 for engine specifications.
• Over-Current Relay
• Starter Relay
• Voltage Selector Switch
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
oUTpUT Terminal panel
eleCTriC governor sYsTem (opTion)
The “Output Terminal Panel” is provided with the following:
„ Two 250 VAC output receptacles (CS-6369), 50 amps
„ Two auxiliary circuit breakers, 250V @50 amps
„ Two 125 VAC output receptacles, (GFCI), 20 amps
„ Two GFCI circuit breakers, 125V@ 20 amps
„ Five output terminal lugs (3Ø power)
TheelectricgovernorsystemcontrolstheRPMsoftheengine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to .25%.
exTension CaBles
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
opTions
„ Battery Charger
„ Water Heater
„ Low Coolant Level Switch/Indicator
„ Camlock Connectors
page 16 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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MajOr COMpOnents
40
3
PHASE
240/139
3
PHASE
1
PHASE
480/277
240/120
2
1
3
PRESS TO LOCK
U
V
W
O
5
4
6
Figure 3. Major Components
8
7
40
9
12
10
11
Table 4. generator major Components
13
14
iTem no.
DesCripTion
Output Terminal Panel Assembly
Terminal Panel Assembly
Voltage Selector Switch Assembly
Coolant Drain Plug
1
2
3
V-W
U-V
W-U
4
INCREASE
DECREASE
OFF
STOP
RUN
START
5
Fuel Drain Plug
6
Air Cleaner Assembly
Lifting Hook
7
8
Muffler Assembly
M91020000
9
Generator Assembly
10
11
12
13
14
Engine/Radiator Assembly
Battery
Fuel Tank Assembly
Engine Control Panel Assembly
Generator Control Panel Assembly
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 17
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enGine COntrOl panel
1
2
3
V-W
W-U
U-V
INCREASE
DECREASE
OFF
STOP
RUN
START
4
5
Figure 4. Engine Control Panel
The definitions below describe the controls and functions
of the Engine Control Panel (Figure 4).
d. pre-heat lamp — The pre-heat lamp will be ON
during the pre-heating cycle (cold weather
conditions).When the pre-heat cycle is completed
the lamp will turn OFF and the engine can be
started.
1. engine Warning lamps — There are four engine
warning lamps, they are defined as follows:
a. low oil pressure alarm lamp — During normal
operation of the generator this lamp
will remain OFF. When the ignition
In addition this lamp displays
engine trouble shooting faults via
flashes (blinking). See engine
trouble codes in the maintenance
section of this manual.
switch is placed in the RUN position
to start the engine, the lamp will be
ON. When the oil pressure rises
after start-up the lamp will go OFF.
2. Fuel gauge – Indicates amount of diesel fuel available
If this lamp is ever lit (on) during normal operation
of the generator, the emergency shutdownsystem
will stop the engine automatically.
3. hour meter – Indicates amount of time generator has
been in use.
4. engine speed switch –This switch controls the speed
of the engine (low/high).
b. Water Temperature alarm lamp — This lamp
goes ON when the cooling water
temperature rises abnormally. If
the lamp goes ON during normal
operation of the generator, the
emergency shutdown system will
stop the engine automatically.
5. ignition switch – Three position switch, stop, run and
start. Insert ignition key to start and stop engine.
c. Battery Charge alarm lamp — This lamp is
ON when the output voltage of
the alternator drops below a set
value. If this lamp is ON during
normal operation, the emergency
shutdown system will immediately
stop the engine.
page 18 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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GeneratOr COntrOl panel
1
4
2
3
V-W
OFF
W-U
U-V
INCREASE
DECREASE
5
6
STOP
RUN
START
Figure 5. Generator Control Panel
The definitions below describe the controls and functions
of the Generator Control Panel (Figure 5).
6. main Circuit Breaker—This three-pole, 100A main
breaker is provided to protect the the U,V, andW Output
Terminal Lugs from overload.
1. Frequency meter — Indicates the output frequency
in hertz (Hz). Normally 60 Hz.
NOTICE
2. aC ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
Remember the overcurrent relay monitors the current
flowing from the U,v, and W output terminal lugs to
the load.
3. aC voltmeter — Indicates the output voltage present
at the U,V, and W output terminal lugs.
In the event of a short circuit or over current condition,
it will automatically trip the 100 amp main breaker.
4. 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.
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).
5. voltage regulator Control — Allows 15% manual
adjustment of the generator’s output voltage.
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 19
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Output terMinal panel faMiliariZatiOn
oUTpUT Terminal panel
oUTpUT Terminal FamiliarizaTion
The Output Terminal Panel (Figure 6) shown below is
located on the right-hand side (left from control panel) of
the generator. Lift up on the cover to gain access to
receptacles and terminal lugs.
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
„ Two 120/240V output receptacles @ 50 amp
„ Two Circuit Breakers @ 50 amps
NOTICE
„ Two 120V GFCI receptacles @ 20 amp
„ Two GFCI Circuit Breakers @ 20 amps
„ Five Output Terminal Lugs ( U, V, W, O, Ground)
Terminal legs “O”and “Ground”are considered bonded
grounds.
1Ø AND 3Ø,
NEUTRAL
480 -120 VAC
TERMINAL
OUTPUT TERMINALS
GROUND
TERMINAL
HARD WIRE
HOOKUP PANEL
V
U
W
O
BLACK
RED BLUE WHITE GREEN
M
Q
P
O
W
E
R
CIRCUIT BREAKERS
FOR CS-6369 TWIST
LOCK RECEPTACLES
CIRCUIT BREAKERS
FOR GFCI RECEPTACLES
120 VAC, 20 AMP
GFCI RECEPTACLES
ACCESS DOOR
LIFT TO OPEN
RECEPTACLE
AND
CIRCUIT BREAKER
PANEL
Y
W
X
CS-6369
TWIST-LOCK
AUX. POWER RECEPTACLES
240/139V, 50 AMPS
Figure 6. Output Terminal Panel
page 20 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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Output terMinal panel faMiliariZatiOn
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
GFCI receptacles. Remember the load output (current)
on both auxiliary receptacles is dependent on the load
requirements of the output Terminal lugs.
120 vaC gFCi receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles provided on the output terminal panel.
These receptacles can be accessed in any voltage
selector switch position.Each receptacle is protected by a
20 amp circuit breaker.These breakers are located directly
above the GFCI receptacles. Remember the load output
(current) of both GFCI receptacles is dependent on the load
requirements of the U, V, and W output terminal lugs.
Turn the voltage regulator control knob (Figure 9) on the
control panel to obtain the desired voltage.Turning the knob
clockwise will increase the voltage, turning the knob
counter-clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 7) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 9. Voltage Regulator Control Knob
removing the plastic Face plate (hard Wire
hookup panel)
The Output Terminal Lugs are protected by a
plastic face plate cover (Figure 10). Un-screw the securing
bolts (2) and raise the plastic face plate to gain access to
the output terminal lugs.
After the load wires have been securely attached to the
output terminal lugs, lower the plastic face plate, and
reinstall the retaining bolts.
Figure 7. G.F.C.I. Receptacle
Twist lock Dualvoltage 120/240 vaC receptacles
There are two 120/240V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 8) provided on the output
terminal panel. These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.
TERMINAL
ENCLOSURE
RETAINING
BOLT
PLASTIC
TERMINAL
COVER
Figure 10. Plastic Face Plate
(Output Terminal Lugs)
Figure 8. 120/240V Twist-Lock Auxiliary
Receptacles
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 21
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Output terMinal panel faMiliariZatiOn
Connecting loads
over Current relay
Loads can be connected to the generator by the output
Terminal lugs or the convenience receptacles (Figure 11).
Make sure to read the operation manual before attempting
to connect a load to the generator.
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.
To protect the output terminals from overload, a 3-pole,
100A main circuit breaker is provided.Make sure to switch
all circuit breakers to the oFF position prior to starting
the engine.
Figure 12. Over Current Relay
Figure 11. Connecting Loads
page 22 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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lOad appliCatiOn
single phase loaD
Three phase loaD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
When calculating the power requirements for 3-phase
power use the following equation:
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require
130—150% more wattage than the rating on the nameplate,
as the wattage is influenced by the efficiency, power factor
and starting system of the equipment.
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
WATTS = VOLTAGE x AMPERAGE
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.
The power factor of this generator is 0.8.SeeTable 5 below
when connecting loads.
„ 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.
Table 5. power Factor By load
Type of load
power Factor
Single-phase induction motors
0.4-0.75
„ 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.
Electric heaters, incandescent lamps
Fluorescent lamps, mercury lamps
1.0
0.4-0.9
Electronic devices, communication
equipment
„ When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
1.0
0.8
Common power tools
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Table 6. Cable selection (60 hz, single phase operation)
load in Watts
maximum allowable Cable length
Current
in
amperes
at 100
volts
at 200
volts
#10 Wire #12 Wire #14 Wire #16 Wire
Danger
2.5
5
300
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
600
1200
1800
2400
3600
4800
7.5
10
15
20
900
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 23
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GeneratOr Outputs
generaTor oUTpUT volTages
generator amperage
A wide range of voltages are available to supply voltage for
many different applications.Voltages are selected by 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.
Table 8 shows the maximum amps the generator can
provide. Do noT exceed the maximum amps as listed..
Table 8. generator maximum amps
rated voltage
maximum amps
82 amps (4 wire)
89A x 2 (Zigzag)
1Ø 120 Volt
voltage selector switch
41 amps (4 wire)
89A (Zigzag)
1Ø 240 Volt
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.
3Ø 240 Volt
3Ø 480 Volt
89 amps
44 amps
gFCi receptacle load Capability
The load capability of the GFCI receptacles is directly
related to the voltage being supplied at either the output
terminals or the 2 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.
Figure 13. Voltage Selector Switch
voltage selector switch locking Button
Table 9. 1Ø gFCi receptacle load Capacity
kW in Use
Twist lock (C6369)
available load
Current (amps)
To lock the voltage selector switch, press and hold the
red button located at the bottom of the switch. While
holding the red button down, insert a pad lock into the hole
next to the button to retain it in the inward locked position.
When the lock is removed, the red button is spring loaded
and will return to its normal outward unlocked position.
GFCI Duplex
5-20R 120V
1Ø 240/120V
21.0
19.8
0
5 amps/receptacle
18.6
17.4
16.2
10 amps/receptacle
15 amps/receptacle
20 amps/receptacle
CaUTion
never change the position of the voltage selector
switch while the engine is running. alWaYs place
circuit breaker in the oFF position before selecting
voltage.
Table 10. 3Ø generator maximum amps
kva in Use
(UvWo Terminals)
available load
Current (amps)
GFCI Duplex
5-20R 120V
3Ø 240/480V
Table 7. voltages available
UvWo output
Terminal lugs
voltage selector switch
3-phase 240/139v position
voltage selector switch
3-phase 480/270v position
0 amps/receptacle
5 amps/receptacle
37
32.8
208V
120V
220V
127V
240V
139V
416V
240V
440V
254V
480V
277V
3Ø line-line
10 amps/receptacle
15 amps/receptacle
20 amps/receptacle
28.7
24.5
20.4
1Ø line-neutral
voltage selector switch single-phase 240/120v position
1Ø line-neutral/
line-line
120V
Line-Neutral
240V
Line-Line
N/A
N/A
N/A
N/A
page 24 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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GeneratOr Outputs/GauGe readinG
hoW To reaD The aC ammeTer anD aC
volTage gaUges
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.
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 17. aC ammeter
Change-over switch
Figure 18. aC ammeter
(amp reading on U lug)
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
Figure 14. Voltage Selector Switch
240/139V 3Ø Position
NOTICE
For 3Ø 208V/1Ø,120V, place the Voltage Selector
Switch in the 3 Phase 240/139 position.
aC voltmeter gauge reading
Place the ACVoltmeter Change-Over Switch (Figure 15)
in theW-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)
Figure 15. aC voltmeter
Change-over switch
Figure 16. aC voltmeter
gauge
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 25
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Output terMinal panel 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.
UvWo Terminal oUTpUT volTages
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the position of the voltage selector switch
and the adjustment of the voltage regulator Control
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.
Figure 21. Voltage Regulator Knob
3Ø-208v/1Ø-120v UvWoTerminal output voltages
3Ø-240/139 UvWo Terminal output voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 22.
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 19..
Figure 22. Voltage Selector Switch
3Ø-240/139V Position
Figure 19. Voltage Selector Switch
3Ø-240/139V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 23.
2. Connect the load wires to the UVWO terminals as
shown in Figure 20.
Figure 23. UVWO Terminal Lugs
3Ø-208/1Ø-120V Connections 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..
Figure 20. UVWO Terminal Lugs
3Ø-240/139V Connections
page 26 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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Output terMinal panel COnneCtiOns
3Ø-480/277v UvWo Terminal output voltages
1Ø-240/120v UvWo Terminal output voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 24.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 26.
Figure 24. Voltage Selector Switch
3Ø-480/277V Position
Figure 26. Voltage Selector Switch
1Ø-240/120V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 25.
2. Connect the load wires to the UVWO terminals as
shown in Figure 27.
Figure 25. UVWO Terminal Lugs
3Ø-440/254V Connections
Figure 27. UVWO Terminal Lugs
1Ø-200/100V 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.
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.
NOTICE
alWaYs make sure that the connections to the UVWO
terminals are secure and tight.The possibility of arcing
exists, that could cause a fire.
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 27
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inspeCtiOn/setup
CirCUiT Breakers
FUel CheCk
Danger
To protect the generator from an overload, a 3-pole, 100
amp, main circuit breaker is provided to protect the U,v,and
W output terminals from overload. In addition two single-
pole, 20 amp gFCi circuit breakers are provided to protect
the GFCI receptacles from overload. Two 50 amp circuit
breakers have also been provided to protect the auxiliary
receptacles from overload.Make sure to switch all circuit
breakers to the oFF position prior to starting the engine.
Fuel spillage on a hot engine can cause
a fire or explosion.If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. never smoke
around or near the generator.
refilling the Fuel system
lUBriCaTion oil
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.
CaUTion
onlY properly trained personnel who have read
and understand this section should refill the fuel tank
system.
This generator has an internal fuel tank located inside
the trailer frame and may also be equipped with an
environmental fuel tank (Figure 29). alWaYs fill the fuel
tanks with clean fresh #2 diesel fuel. Do noT fill the fuel
tanks beyond their capacities.
Figure 28. Engine Oil Dipstick
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
When checking the engine oil, be sure to check if the oil
is clean. If the oil is not clean, drain the oil by removing
the oil drain plug, and refill with the specified amount of oil
as outlined in the kUBoTa engine owner’s manual. Oil
should be warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
45
„ API Service Classification CC/SC
„ API Service Classification CC/SD
„ API Service Classification CC/SE
„ API Service Classification CC/SF
INTERNAL
FUEL
TANK
Table 11. recommended motor oil
TRAILER
FUEL TANK
(OPTION)
Figure 29. Internal Fuel Tank System
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inspeCtiOn/setup
2. Remove fuel cap and fill tank as shown in Figure 31.
refueling procedure:
Warning
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. levelTanks — Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 30).
CaUTion
Figure 31. Fueling the Generator
alWaYs place trailer on firm level ground before
refueling to prevent spilling and maximize the amount
of fuel that can be pumped into the tank.
3. never overfill fuel tank — It is important to read the
fuel gauge when filling trailer fuel tank. Do noT wait
for fuel to rise in filler neck (Figure 32).
45
DO NOT fill on
150
unlevel ground
!
!
=
Level Ground
Level Ground
Figure 32. Full Fuel Tank
Figure 30. Only Fill on Level Ground
CaUTion
NOTICE
Do noT overFill fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 33).
onlY use low sulfur or ultra low sulfur diesel
fuel when refueling.
Figure 33. Fuel Expansion
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 29
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inspeCtiOn/setup
CoolanT (anTiFreeze/sUmmer CoolanT/
WaTer)
Cleaning The raDiaTor
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the
radiator fins with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
kUBoTa recommends antifreeze/summer coolant for use in
their engines, which can be purchased in concentrate (and
mixed with 50% demineralized water) or pre-diluted. See the
kUBoTa engine owner’s manual for further details.
air Cleaner
Warning
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the kUBoTa engine owner’s manual.
If adding coolant/antifreeze mix to the
radiator, Do noT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which can
cause severe burns.
Fan BelT Tension
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
kUBoTa engine owner’s manual.
Day-to-day addition of coolant is done from the recovery
tank.When adding coolant to the radiator, Do noT remove
the radiator cap until the unit has completely cooled. See
Table 12 for engine, radiator, and recovery tank coolant
capacities.Make sure the coolant level in the recovery tank
is always between the “H” and the “L” markings.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 34) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
Reserve Tank
2.91 gal (11 liters)
1 quart (0.9 liters)
operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Figure 34. Fan Belt Tension
CaUTion
Table 13. anti-Freeze operatingTemperatures
never place hands near the belts or fan
while the generator set is running.
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%.
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inspeCtiOn/setup
When connecting battery do the following:
BaTTerY
1. never connect the battery cables to the battery
terminals when the mpeC Control switch is in either
the manUal position. alWaYs make sure that the
mpeC Control switch is in the oFF/reseT position
when connecting the battery.
This unit is of negative ground Do noT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are
not properly maintained. Add only distilled water when
replenishment is necessary.
2. Place a small amount of battery terminal treatment
compound around both battery terminals. This will
ensure a good connection and will help prevent
corrosion around the battery terminals.
Do noT over fill. Check to see whether the battery
cables are loose. Poor contact may result in poor starting
or malfunctions. always keep the terminals firmly
tightened. Coating the terminals with an approved battery
terminal treatment compound. Replace battery with only
recommended type battery.
NOTICE
If the battery cable is connected incorrectly, electrical
damage to the generator will occur.Pay close attention to
the polarity of the battery when connecting the battery.
The battery is sufficiently charged if the specific gravity
of the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
CaUTion
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Inadequate battery connections may cause poor
starting of the generator, and create other malfunctions.
Battery Cable installation
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.
alTernaTor
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.
CaUTion
Do noT put water directly on the alternator. Entry of water
into the alternator can cause corrosion and damage the
alternator.
alWaYs disconnect the negative terminal FirsT and
reconnect negative terminal lasT.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
piping anD hose ConneCTion
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check
hoses for leaks.
Figure 35. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
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GeneratOr start-up prOCedure
BeFore sTarTing
sTarTing
1. Place the voltage selector switch in the desired
voltage position (Figure 38)..
CaUTion
The engine’s exhaust contains harmful emissions.
alWaYs have adequate ventilationwhen operating.
Direct exhaust away from nearby personnel.
Warning
never manually start the engine with the main, gFCi
or auxiliary circuit breakers in the on (closed) position.
1. Place the main, g.F.C.i., and aux. circuit breakers
(Figure 36) in the oFF position prior to starting the
engine.
Figure 38. Voltage Selector Switch
sTarTing
1. Place the engine speed control switch (Figure 39) in
the Start/Idle position (down)..
Figure 36. Main, Aux. and GFCI
Circuit Breakers (OFF)
START/IDLE
2. Make sure the voltage change-over board has been
configured for the desired output voltage.
Figure 39. Engine Speed Control Switch
Start Idle Position
1. In warm weather conditions, skip to step 3. In cold
weather conditions, preheat the engine glow plugs by
turning the ignition key (Figure 40) to the rUn position
3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 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 40. Ignition Switch Pre-Heat
(Run Position)
CORRECT
INCORRECT
Figure 37. Engine Enclosure Doors
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GeneratOr start-up prOCedure
2. Depending on the temperature of the coolant (cold
6. The generator’s frequency meter (Figure 44) should
be displaying the 60 cycle output frequency in herTz.
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 can be started
Figure 44. Frequency Meter
7. The generator’s aC-voltmeter (Figure 45) will display
the generator’s output in volTs..
Figure 41. Pre-Heat Lamp
3. Turn the ignition key to the start position (Figure 42).
Oncetheenginestarts, releasetheignitionkeyandallow
it to return to the rUn position (Figure 40).
If the engine fails to start after 10 seconds, wait
approximately 30 seconds and repeat steps 3-4.
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 42. Ignition Switch (Start Position)
4. Let the engine run for 1-2 minutes. Listen for any
abnormal noises.If any abnormalities exist, shut down
the engine and correct the problem.
Figure 46. Voltage Adjust Control Knob
5. Place the engine speed control switch (Figure 43) in
the RUN position (up).
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.
RUN
Figure 43. Engine Speed Control Switch
Run Position
Figure 47. Ammeter (No Load)
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GeneratOr sHut-dOWn prOCedures
10. Place the main, gFCi, and aux. circuit breakers in the
on position (Figure 48).
2. Place the engine speed control switch (Figure 51) in
the Start/Idle position (down).
START/IDLE
Figure 51. Engine Speed Control Switch
Start Idle Position
Figure 48. Main, Aux. and GFCI
Circuit Breakers (ON)
3. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
11. Observe the generator’s ammeter (Figure 49) 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.
4. Place the ignition switch (Figure 52) in the “sTop”
position, remove the key and store in a safe place.
Figure 52. Ignition Switch (Stop Position)
Figure 49. Ammeter (Load)
5. Remove all loads from the generator.
12. The generator will run until manually stopped or an
abnormal condition occurs.
6. Inspect entire generator for any damage or loosening of
components that may have occurred during operation.
normal shUTDoWn proCeDUre
emergenCY shUTDoWn proCeDUre
Warning
1. Turn ignition switch key to the sTop position.
never stop the engine suddenly except in an
emergency.
2. To shut-down the engine in the event of an emergency,
switch the main, gFCi and loaD (Figure 50) circuit
breakers to oFF position.
To shutdown the generator, use the following procedure:
aUTomaTiC shUT-DoWn sYsTem
1. Place both the main, gFCi and loaD circuit breakers
as shown in Figure 50 to the oFF position..
This unit is equipped with safety devices to automatically
stoptheengineintheeventoflowoilpressure,approximately
7 psi (49 kPa), or high water temperature, approximately
230° F (110° C). The alarm lamps on the Engine Control
Panel illuminate to signify the reason for the shutdown.
NOTICE
Before inspecting, turn the ignition switch to the sTop
position, place all circuit breakers in the oFF position
and allow sufficient time for adequate cooling. When
ready to restart, complete all steps in the Generator
Startup Procedure section of this manual.
Figure 50. Main, GFCI and Load
Circuit Breakers Off
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MaintenanCe
10 hrs
DailY
1000
hrs
Table 14. inspection/maintenance
250 hrs 500 hrs
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Replace Engine Oil and Filter * 1
Clean Air Filter
X
X
engine
Check Fuel Filter/Water Separator Bowl
Clean Unit, Inside and Outside
Change Fuel Filter
Clean Radiator and Check Coolant Protection Level*2
Replace Air Filter Element * 3
Check all Hoses and Clamps * 4
Clean Inside of Fuel Tank
X
X
X
X
X
X
X
Measure Insulation Resistance Over 3M ohms
X
generator
Check Rotor Rear Support Bearing
Replace engine oil and filter at 100 hours, first time only.
X
1
*
2
*
Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
3
*
4
*
with no sags or dips that could collect moisture and/or oil.
general inspeCTion
Prior to each use, the generator should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for
fuel, oil, and coolant leaks. Use Table 14 as a general
maintenance guideline engine side (Refer to the Engine
Instruction Manual)
air Cleaner
Every 250 hours: Remove air cleaner element (Figure 53)
and clean the heavy duty paper element with light spray of
compressed air. Replace the air cleaner as needed.
Figure 53. Air Cleaner/Indicator
NOTICE
air Cleaner with Dust indicator
The air filter should not be changed until the indicator
reads “reD”. Dispose of old air filter. It may not be
cleaned or reused.
This indicator (Figure 53) is attached to the air cleaner.
When the air cleaner element is clogged, air intake
restriction becomes greater and the dust indicator signal
shows reD meaning the element needs changing or
service. After changing the air element, press the dust
indicator button to reset the indicator.
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MaintenanCe
If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result.This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber and high fuel consumption. Change air cleaner
more frequently if these conditions exists.
FUel Tank inspeCTion
In addition to cleaning the fuel tank, the following
components should be inspected for wear:
„ rubber suspension — look for signs of wear or
deformity due to contact with oil. Replace the rubber
suspension if necessary.
FUel aDDiTion
Add diesel fuel (the grade may vary according to season
and locations).
„ Fuel hoses — inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
removing Water from the FuelTank
„ FuelTank lining — inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally inspect the fuel
tank for water contamination and drain the contents if
required.
replacing Fuel Filter
„ Replace the fuel filter cartridge with new one every 500
hours or so.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
„ Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. Do noT spill the fuel during disassembly.
Cleaning inside the FuelTank
„ Vent any air
If necessary, drain the fuel inside the fuel tank completely.
Using a spray washer (Figure 54) wash out any deposits
or debris that have accumulated inside the fuel tank.
FUel FilTer/WaTer separaTor
Inspect the fuel filter water separator daily. If the fuel filter/
water separator (Figure 55) has collected a significant
amount of water and sediment at the bottom of the cup, it
should be drained off. Refer to your engine manual for
specific details to perform this operation.
FUEL
COCK
RETAINING
RING
CUP
SEDIMENT
Figure 55. Fuel Filter/Water Separator
Figure 54. Fuel Tank Cleaning
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MaintenanCe
air removal
Warning
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 kUBoTa
engine manual for details.
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed.
raDiaTor Cleaning
The radiator (Figure 56) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fins or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fins and tube.
CheCk oil level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled.Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil
level must be between the two notches on the dipstick as
shown in Figure 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.
FlUshing oUT raDiaTor anD replaCing
CoolanT
Figure 56. Radiator Cleaning
generaTor sTorage
„ 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.
For long term storage of the generator the following is
recommended:
„ Drain the fuel tank completely.Treat with a fuel stabilizer
if necessary.
„ Check hoses for softening and kinks. Check clamps for
signs of leakage.
„ Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
„ Tighten both cocks and replace the overflow tank.
„ Clean the entire generator, internal and external.
„ Cover the generating set and store in a clean, dry place.
„ Disconnect the battery.
„ Replace with coolant as recommended by the engine
manufacturer.
„ Close radiator cap tightly.
„ 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.
„ 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.
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MaintenanCe
If the generator will be used daily, the battery should
normally not require charging. If the generator will be idle
(not used) for long periods of time, apply power to the
battery charger receptacle via commercial power using a
power cord of adequate size.
JaCkeTWaTerheaTeranDinTernalBaTTerY
(opTional)
This generator can be equipped as an option with a jacket
water heater and an internal battery charger. They are
provided with electric cords to connect to a commercial
power source.
NOTICE
To ensure adequate starting capability, always have
power applied to the generator's internal battery
charger.
These units will onlY function when commercial power has
been supplied to them (Figure 57). When using extension
cords, refer to Table 6 for the correct size and length.
The battery charger should always be connected to a
commercial power source to ensure that the battery does
not get discharged.
When using the generator in hot climates there is no need
to apply power to jacket water heater. However, if the
generator will be used in cold climates, it is best to apply
power to the jacket water heater at all times.
JACKET
WATER
HEATER
CONNECT TO EXTERNAL
120 VAC POWER SOURCE
Figure 57. Battery Charger and Jacket Water
Heater (option)
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trailer MaintenanCe
8. Tire size — Indicates the diameter of the tire in
inches (10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
Trailer mainTenanCe
This section is intended to provide the user with generic
trailer service and maintenance information. The service
and maintenance guidelines referenced in this section refer
to a wide range of trailers.
9. Tire ply — The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
10. Wheel hub — The wheel hub is connected to the
trailer’s axle.
11. Tire rim — Tires mounted on a tire rim. The tire rim
must match the size of the tire.
The definitions below describe some of the major
components of a typical trailer that would be used with
generator.
12. lug nuts — Used to secure the wheel to the wheel
hub. Always use a torque wrench to tighten down
the lug nuts. See Table 18 and Figure 60 for lug nut
tightening and sequence.
1. Fuel Cell — Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
13. axle — Indicates the maximum weight the axle can
support in pounds, and the diameter of the axle
expressed in inches. Please note that some trailers
have a double axle.This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
2. Braking system — System employed in stopping
the trailer.Typical braking systems are electric, surge,
hydraulic, hydraulic-surge and air.
3. gvWr — Gross Vehicle Weight Rating (GVWR) is
the maximum number of pounds the trailer can carry,
including the fuel cell (empty).
14. suspension— Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
4. Frame length — Measurement is from the ball hitch
to the rear bumper (reflector).
5. FrameWidth — Measurement is from fender to fender
15. electrical— Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
6. Jack stand — Trailer support device with maximum
pound requirement from the tongue of the trailer.
16. application — Indicates which units can be employed
on a particular trailer.
7. Coupler — Type of hitch used on the trailer for
towing.
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trailer MaintenanCe
Brakes
hydraulic surge Brakes
Trailer brakes should be inspected the first 200 miles of
operation.This will allow the brake shoes and drums to seat
properly.After the first 200 mile interval, inspect the brakes
every 3,000 miles. If driving over rough terrain, inspect the
brakes more frequently.
Hydraulic surge brakes (Figure 58) 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 58 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 and Table 15 as listed below:
Brake adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting
slot at the bottom brake backing plate.
Figure 58. Hydraulic Brake Components
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
actuator
Hydraulic surge braking requires the installation of an
actuator at the tongue of the trailer. Remember the surge
or push of the trailer toward the tow vehicle automatically
synchronizes the trailer brakes with the tow vehicle brakes.
As the trailer pushes against the tow vehicle the actuator
telescopes together and applies force to the master
cylinder, supplying hydraulic pressure to the trailer brakes.
5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer
to the ground.
Periodically check and test the surge “actuator” to make sure
that it is functioning correctly.Never use an undersize actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 15. hydraulic BrakeTroubleshooting
symptom
possible Cause
solution
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Repair or replace.
Reburnish or replace.
Correct weight.
Trailer overloaded?
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or
broken?
Replace components.
Locking Brakes
Noisy Brakes
Brake drums out-of-round?
System lubricated?
Replace.
Lubricate.
Brake components correct?
Replace and correct.
Install new shoes and
linings.
Brake lining thickness incorrect or
not adjusted correctly?
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
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trailer MaintenanCe
Tires/Wheels/lUg nUTs
suspension
Tires and wheels are a very important and critical
components of the trailer.When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
The leaf suspension springs and associated components
(Figure 59) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately.Torqued suspension components
as detailed in Table 17.
CaUTion
alWaYs wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CaUTion
Do noT attempt to repair or modify a
wheel. Do noT install in inner tube to
correct a leak through the rim. If the rim
is cracked, the air pressure in the inner
tube may cause pieces of the rim to explode (break off)
with great force and cause serious eye or bodily injury.
Tire Wear/inflation
Figure 59. Major Suspension Components
Table 17. suspensionTorque requirements
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.
item
Torque (Ft.-lbs.)
Min-30 Max-35
Min-45 Max-60
Min-45 Max-60
3/8" U-Bolt
7/16" U-Bolt
1/2" U-Bolt
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Snug fit only. Parts must rotate freely.
Locking nuts or cotter pins are
Shackle Bolt
Table 16. Tire WearTroubleshooting
Spring Eye Bolt
provided to retain nut-bolt assembly.
Wear pattern
Cause
solution
Shoulder Type
Shackle Bolt
Adjust pressure to particular
load per tire manufacturer.
Center Wear Over inflation.
Edge Wear Under inflation.
Min-30 Max-50
Adjust pressure to particular
load per tire manufacturer.
Make sure load does not
exceed axle rating.
Align wheels.
Loss of camber
Side Wear
or overloading.
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
Check bearing adjustment
and balance tires.
Wheel lockup and Avoid sudden stops when
tire skidding. possible and adjust brakes.
Flat Spots
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trailer MaintenanCe
lug nut Torque requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (see Figure 60). Do
noT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defined
by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. TireTorque requirements
First pass
FT-lBs
second pass
FT-lBs
Third pass
FT-lBs
Wheel size
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 60. Wheel Lug Nuts
Tightening Sequence
NOTICE
never use an pneumatic air gun to tighten wheel
lug nuts.
page 42 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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trailer WirinG diaGraM
Figure 61. Trailer/Towing Vehicle Wiring Diagram
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 43
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GeneratOr WirinG diaGraM
Figure 62. Generator Wiring Diagram
page 44 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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enGine WirinG diaGraM
Figure 63. Engine Wiring Diagram
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 45
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trOuBlesHOOtinG (GeneratOr)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business office or service plant.
Table 19. generatorTroubleshooting
symptom
possible problem
AC Voltmeter defective?
Is wiring connection loose?
Is AVR defective?
solution
Check output voltage using a voltmeter.
Check wiring and repair.
No Voltage Output
Replace if necessary.
Defective Rotating Rectifier? Check and replace.
Defective Exciter Field?
Is engine speed correct?
Check and replace.
Turn engine throttle lever to “High”.
Low Voltage Output
High Voltage Output
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
Defective AVR?
Replace if necessary.
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Circuit Breaker Tripped
Defective circuit breaker?
Over current Relay actuated? Confirm load requirement and replace.
When the Emergency/Malfunction shutdown system has been activated, the engine will be stopped and the pre-heat lamp
will indicate the malfunction by a series of flashing patterns. The flashing patterns and corrective action are shown below
in Table 20. The flashing patterns consist of combinations of one or more long flashes and one or more short flashes.
Table 20. engine/generatorTroubleshooting (pre-heat lamp)
pre-heat lamp
indication
Type of Fault
Engine Overspeed
Low Oil Pressure
Insufficient Charge
possible Fault
solution
Check electronic governor
Check oil level.
115% or more rated RPM speed?
Long 1 Short 1
Oil pressure 7 psi (49 kPa) or
greater?
Long 1 Short 2
No Voltage of Charging Genset?
Engine Overheat, 230° F (110° C)?
Engine Overheat, 248° F (120° C)?
Emergency Stop signal detected?
Long 1 Short 3
Long 1 Short 4
Long 1 Short 6
Long 1 Short 5
Check wiring and repair.
Check cooling system.
Check cooling system.
Check and repair fault
High Water Temperature
Emergency Stop
Starter motor run for 12 seconds
or more?
Starter Motor Protection
Long 1 Short 7
Check wiring and repair.
Rotation Sensor
Solenoid
Defective sensor, short circuit?
Defective solenoid, short circuit?
Disconnection
Long 2 Short 1
Long 2 Short 2
Long 2 Short 4
Long 2 Short 5
Long 2 Short 6
Long 3 Short 1
Check wiring and repair.
Check wiring and repair.
Check connection.
Water Temperature
Sensor
Short Circuit
Check sensor. Replace.
Check connections.
Charging Gen. Terminal Disconnection
Over Voltage VCC 18 volts or greater
Check overcurrent relay.
page 46 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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nOtes
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 47
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explanatiOn Of COde in reMarKs COluMn
The following section explains the different symbols and
QTY. Column
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
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.
A blank entry generally indicates that the item is not sold
separately.Other entries will be clarified in the“Remarks”
Column.
sample parTs lisT
remarks Column
no. parT no. parT name
QTY. remarks
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.
1
2%
12345
BOLT .....................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY
WASHER, 3/8 IN. ..1 .....MQ-45T ONLY
2% 12347
3
4
12348
12349
HOSE ..................A/R ...MAKE LOCALLY
BEARING ..............1 .....S/N 2345B AND ABOVE
assembly/kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
no. Column
Indicated by:
Unique symbols — All items with same unique
symbol
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
serial number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
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.
“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.
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.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
parT no. Column
numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
“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.
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.
“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.
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.
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suGGested spare parts
DCa40sskU/kU4i WhisperWaTT generaTor
WiTh kUBoTa v3300-e3Bg Diesel engine
1 to 3 units
QTY. p/n
DesCripTion
6............1663143560..........ELEMENT, FUEL FILTER
3............HH1C032430........CARTRIDGE, OIL FILTER
6............RB10151280.........ELEMENT, FUEL FILTER, FUEL TANK
3............0602046366..........ELEMENT, AIR CLEANER
1............1G54197010.........FAN BELT
1............B3311501503 .......RADIATOR HOSE, UPPER
1............B3311501603 .......RADIATOR HOSE, LOWER
1............Y0602100057 .......STARTER SWITCH
3............1742263720..........KEY, STARTER SWITCH
1............0601820602..........AUTOMATIC VOLTAGE REGULATOR
1............0601840073..........RHEOSTAT VOLTAGE REGULATOR
1............0601840100..........KNOB, RHEOSTAT
2............0601810830..........BULB, INDICATOR WARNING
1............0601870440..........CIRCUIT BREAKER 1P 20A
1............0601870441..........CIRCUIT BREAKER 2P 50A
5............0601806642 .........FUSE 5A
4............0601806645..........FUSE 10A
1............0601806640..........FUSE 65A
1............T106365660 .........SENSOR, WATER TEMP. (ENGINE SIDE)
1............5160137670..........SWITCH, WARNING, OVERHEAT (ENGINE SIDE)
1............1584139010..........SWITCH, OIL PRESSURE (ENGINE SIDE)
1............3824032830..........SWITCH, THERMOMETER
1............5671342930..........ELEC/MAG/TIC., PICKUP
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 49
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GeneratOr assy.
page 50 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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GeneratOr assy.
no.
1
parT no.
B3110001302
parT name
ROTOR ASSY.
FIELD ASSY.
RECTIFIER
QTY.
remarks
1
1
3
1
1
3
5
1
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
0601820083
0601822664
B3120100804
B3120100604
B3120100704
B3111100603
B2163100004
ZNR
HOLDER, ZNR
INSULATOR WASHER
INSULATOR WASHER
FAN
COUPLING DISK ........................................3 ................ITEMS 1-9, 1-9A & 1-9B MUST
.......................................................................................BE ORDERED WHEN
.......................................................................................REPLACING COUPLING DISK
1-9
0010304016
HEX. HEAD BOLT
BALANCING WEIGHT KIT
U-NUT
COUPLING WASHER
HEX. SOCKET HEAD CAP SCREW
WASHER, FLAT
12
1
12
2
6
6
1
8
8
1
2
1
4
4
1
6
1
1
3
6
6
1
1
1
1
1
4
4
2
2
2
2
1-9A B2163700004
1-9B 0204004000
1-10 B3163200104
1-11 0342612030
1-12 0046512000
1-13 0071906309
2
3
4
4-1
5
BEARING
012210020
030210250
HEX. HEAD BOLT
WASHER, LOCK
STATOR ASSY.
B3130000903
0845041904
B3137000803
0016008060
0042508000
B3153000513
0017108035
B3153400504
B3153400404
0017106016
0105091025
030210250
B5131300004
0340406040
Y0500815000
0401450050
B3131300804
0029205012
0401450050
0605000455
0030012000
0040012000
031112230
GROMMET
FIELD ASSY. EXCITER
HEX. SOCKET HEAD CAP SCREW
WASHER, LOCK
END BRACKET
HEX. HEAD BOLT
PACKING
COVER BEARING
HEX. HEAD BOLT
HEX. HEAD BOLT
WASHER, LOCK
COVER, END BRACKET
HEX. HEAD BOLT
NUT
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
23A
23B
WASHER, FLAT
COVER, END BRACKET
MACHINE SCREW
WASHER, FLAT
RUBBER SUSPENSION
HEX. NUT
WASHER, LOCK
WASHER, FLAT
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 51
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COntrOl BOx assy.
page 52 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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COntrOl BOx assy.
no.
1
1-1
1-2
1-3
2
parT no.
parT name
CONTROL BOX
EDGING
EDGING
EDGING
HEX. HEAD BOLT
QTY.
1
1
1
1
10
remarks
M1213002012
Y0330000555
Y0330000255
Y0330000190
0016906016
Y0601307526
3
CIRCUIT BREAKER, 3P 100A....................1 ................INCLUDES ITEM W/$
3A$
4
5
6
7
INSULATING PLATE
RELAY UNIT
1
1
2
1
4
3
6
1
1
2
2
1
1
4
4
2
1
2
2
2
1
1
2
1
5
4
2
1
1
4
1
4
1
4
2
2
1
2
0601823863
7538070
MACHINE SCREW
AUTOMATIC VOLTAGE REGULATOR
MACHINE SCREW
CURRENT TRANSFORMER, 150/5A
MACHINE SCREW
OVER CURRENT RELAY
OVER CURRENT RELAY, DB25/25A
MACHINE SCREW
HEX. NUT
SELECTOR SWITCH
SWITCH BRACKET
MACHINE SCREW
HEX. NUT
0601820602
0027105016
0601801123
0027106020
0601820847
0601820848
0027104020
OEMAA8
8
9
10
11
12
12A
13
14
15
15A
16
17
18
18A
18B
19
20
21
27
27A
27B
28
29
30
31
32
33
34
35
36
37
38
39
M1270100604
M1213602814
0027105020
0030005000
0016906016
Y0602202647
0021005050
0032005000
0401450050
Y0602202635
0602202566
0027105016
M0261200004
0601806642
0601806645
0027105016
0601806640
M1213501004
0016906016
M1213400014
0016906016
M1223001523
0027105010
M9220100004
Y0080200007
M1224100104
0027105010
HEX. HEAD BOLT
ENGINE CONTROL UNIT
MACHINE SCREW
SPRING WASHER, LOCK
WASHER, FLAT
RELAY GLOW
RELAY STARTER
MACHINE SCREW
FUSE BOX
FUSE, 5A (F1~3)
FUSE, 10A (F4~6)
MACHINE SCREW
FUSE, 65A
CONTROL BOX COVER
HEX. HEAD BOLT
CONTROL BOX COVER
HEX. HEAD BOLT
CONTROL PANEL
MACHINE SCREW
SET SCREW
SNAP RING
STOPPER
MACHINE SCREW
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 53
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COntrOl BOx assy.
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COntrOl BOx assy.
no.
40
41
42
43
44
45
46
46A
47
48
49
50
51
52
52A
53
54
55
55A
56
57
parT no.
parT name
QTY.
remarks
0601806859
0601808986
0601807641
0601801040
0601840073
0601840100
0601810523
0601810830
0601800682
0021004016
OEMAA8
0602125090
0601830710
Y0602100057
1742263720
Y0601851754
Y0601851725
0016906016
0040506000
M1246705904
M1357202502
AC VOLTMETER, 0~600V
AC AMMETER, 0~75/150A:5A
FREQUENCY METER, 45~65HZ 240V
CHANGE-OVER SWITCH, AMMETER
VOLT. REG., RHEOSTAT, 2W 1K OHM
KNOB
INDICATOR WARNING
BULB
HOUR METER
1
1
1
1
1
1
1
4
1
2
2
1
1
1
1
1
2
1
1
1
1
MACHINE SCREW
SELF-LOCKING NUT
FUEL GAUGE
TOGGLE SWITCH
STARTER SWITCH
KEY, STARTER SWITCH
GROMMET
GROMMET
HEX. HEAD BOLT
TOOTHED WASHER
WIRE HARNESS, GENERATOR
WIRE HARNESS, ENGINE
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 55
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enGine and radiatOr assy.
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enGine and radiatOr assy.
no.
1
1A
1-1
1-2
2
3
4
5
6
parT no.
parT name
ENGINE, KUBOTA V3300-E3BG
FAN BELT
ELEMENT, FUEL FIITER
CARTRIDGE, OIL FILTER
RUBBER SUSPENSION
HEX. HEAD NUT
WASHER, LOCK
WASHER, FLAT
RADIATOR
QTY.
1
1
1
1
2
2
2
2
1
1
2
1
1
6
1
1
6
1
1
4
1
1
1
1
2
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
remarks
M1923200164
1G54197010
1663143560
HH1C032430
0605000451
020310080
0040010000
031110160
B3924200324
0602011079
Y0220300550
M1310302204
M1310302304
011008020
M1310302404
M1310302504
011008020
B3311501503
B3311501603
0605515147
0602046585
0602046366
0602040651
0602040557
011208030
6-1
7
8
CAP, RADIATOR
RUBBER SEAT
FAN SHROUD
9
FAN SHROUD
10
11
12
13
14
15
16
17
17A
18
19
20
21
22
23
24
25
26
29
30
31
32
33
34
35
36
37
38
39
40
41
42
HEX. HEAD BOLT
FAN GUARD
FAN GUARD
HEX. HEAD BOLT
RADIATOR HOSE
RADIATOR HOSE
HOSE BAND
AIR CLEANER
ELEMENT, AIR CLEANER
AIR CLEANER INDICATOR
BRACKET, AIR CLEANER
HEX. HEAD BOLT
BRACKET, AIR CLEANER
HEX. HEAD BOLT
HOSE, AIR CLEANER
HOSE, AIR CLEANER
HOSE BAND
HOSE BAND
ADAPTER
90 DEG. ELBOW
DRAIN HOSE
HOSE JOINT
VALVE
CONNECTOR
ROCKNUT
CAP
RESERVE TANK
CAP, RESERVE TANK
HOSE
BRACKET, RESERVE TANK
HEX. HEAD BOLT
HOSE
M1373200704
011008020
M1373102103
M1373100603
9500202080
0605515146
Y0602022588
Y0602022579
Y0379500700
Y0603306399
Y0605511399
Y0603306597
Y0603300286
Y0602021071
0802081403D
0802081104
0199100215
M1317100004
011008020
Y0199101000
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 57
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enGine and radiatOr assy. (COntinued)
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enGine and radiatOr assy. (COntinued)
no.
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
parT no.
parT name
HOSE
HOSE BAND
BRACKET, RADIATOR
BRACKET, RADIATOR
BRACKET, RADIATOR
HEX. HEAD BOLT
MOUNT RUBBER
DRAIN JOINT
HEX. HEAD BOLT
DRAIN BOLT
O-RING
BRACKET, RADIATOR
HOSE BAND
DRAIN HOSE
QTY.
1
2
1
1
2
8
4
1
2
1
1
1
2
1
2
1
1
1
1
8
8
8
1
1
3
3
3
1
2
2
2
1
1
1
1
1
1
remarks
0193601300
0605515170
M1310200904
M1310201004
M1310201104
011008020
M9312200104
1502025103C
011206020
0802011104
0150000018
Y0379501000
0605515198
0193601000
0602220911
011008020
0601850239
M1303200604
M1303200704
Y0013512025
0040012000
031112230
M1357301004
M1357300804
Y0013512025
0040012000
031112230
M1357300904
0010510020
0040010000
031110160
1J41905810
1584139010
5160137670
T106365660
3824032830
5671342930
CLAMP
HEX. HEAD BOLT
GROMMET
ENGINE FOOT
ENGINE FOOT
HEX. HEAD BOLT
WASHER, LOCK
WASHER, PLAIN
HARNESS CLAMP
HARNESS CLAMP
HEX. HEAD BOLT
WASHER, LOCK
WASHER, PLAIN
HARNESS CLAMP
HEX. HEAD BOLT
WASHER, LOCK
WASHER, PLAIN
KIT, ELEMENT
SWITCH, OIL PRESSURE
SWITCH, WARNING, OVERHEAT
SENSOR, WATER TEMP
SWITCH, THERMOMETER
ELECT/MAG/TIC. PICKUP
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 59
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Output terMinal assy.
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
7-CATO GOLD
8-RED
3-SPECTRUM GREY
4-SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
page 60 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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Output terMinal assy.
no.
1
2
parT no.
parT name
QTY.
1
5
remarks
8111860303
0801831704A
012210020
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE SCREW
3
5
4
5
6
7
8
9
10
11
12
12A
12B
13
14
15
16
17
18
0039310000
0040010000
0041410000
011208025
M1236102023
0016906016
M1236102124
Y0605012028
0027103010
0207003000
0041203000
011206020
M1236101814
0016906016
0601870440
0601870441
M1260700404
HEX NUT
10
15
20
5
1
4
1
1
4
4
4
2
1
7
2
2
1
2
2
2
2
8
8
1
1
4
1
2
4
2
2
1
1
1
WASHER, LOCK
WASHER, PLAIN
HEX. HEAD BOLT
TERMINAL COVER
HEX. HEAD BOLT
OUTPUT WINDOW
HINGE
MACHINE SCREW
HEX. NUT
WASHER, PLAIN
HEX. HEAD BOLT
COVER
HEX. HEAD BOLT
CIRCUIT BREAKER, 1P 20A
CIRCUIT BREAKER, 2P 50A
BREAKER FITTING COVER
CUSHION RUBBER
HEX. HEAD BOLT
RECEPTACLE, CS6369LM2, 250V 50A
RECEPTACLE, GF20LA, (125V 20A)
MACHINE SCREW
SELF-LOCKING NUT
CUSHION RUBBER
COVER
HEX. HEAD BOLT
TERMINAL COVER
HEX. HEAD BOLT
WASHER, PLAIN
STAY RUBBER
18-1 0222100080
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
33A
34
35
35A
35B
011206020
Y0601814014
0601814013
7538070
OEMAA8
Y0317700480
M1236400104
0016906016
M1236101904
012212045
031112230
0805009804
0030012000
0019208020
0019208020
0040508000
0605010040
Y027103010
0207003000
0041203000
HEX. NUT
HEX. HEAD BOLT
HEX. HEAD BOLT
TOOTHED WASHER
HINGE (PARENT #)
MACHINE SCREW
HEX. NUT
1
4
4
4
WASHER, PLAIN
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 61
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Battery assy.
page 62 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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Battery assy.
no.
1
2
3
4
parT no.
parT name
QTY.
remarks
0602220199
M9310500014
M9103000304
0602220920
M1346400104
M0348200104
BATTERY, 727MF
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET
BATTERY CABLE
BATTERY CABLE
1
1
1
2
1
1
5
6
7
CABLE.........................................................1 ................MAKE LOCALLY
8
Y0013512025
0040012000
031112230
0040512000
0016910020
0040510000
020108060
HEX. HEAD BOLT
WASHER, LOCK
WASHER, PLAIN
TOOTHED WASHER
HEX. HEAD BOLT
TOOTHED WASHER
HEX. NUT
1
1
1
1
1
1
1
8A
8B
8C
9
9A
10
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 63
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Muffler assy.
page 64 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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Muffler assy.
no.
1
2
3
4
5
6
7
8
parT no.
M1330101403
011008020
M1333003503
Y0602320157
0030410000
0602325097
M1333300504
011008020
parT name
MUFFLER
HEX. HEAD BOLT
EXHAUST PIPE
GASKET
QTY.
remarks
1
4
1
1
8
1
1
2
1
HEX. NUT
SEAL CLAMP
BRACKET, EXHAUST PIPE
HEX. HEAD BOLT
U-BOLT
9
Y0602326066
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 65
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fuel tanK assy.
page 66 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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fuel tanK assy.
no.
1
1-1
1-2
parT no.
parT name
FUEL TANK
CAP FUEL TANK
FUEL SENDER UNIT
GASKET
QTY.
1
1
1
1
remarks
M1363002602
0605505070
0605501072
1-2A 0605516090
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17A
18
19
20
21
22
23
M1363200104
M9310500104
011008020
0207308000
0222100600
0222100085
M9200000003
M9200200004
0150000018
011206020
M1363400104
0605515198
M1366701204
011206020
0016908065
Y0602042255
RB10151280
R140151350
0191201500
Y0191200500
Y0191200500
Y0191202500
0605515109
TANK BAND
2
4
2
2
1
2
1
1
1
2
1
2
1
4
1
1
1
1
1
1
1
1
8
SUPPORTER SHEET
HEX. HEAD BOLT
HEX. NUT
RUBBER SHEET
RUBBER SHEET
DRAIN JOINT
DRAIN BOLT
O-RING
HEX. HEAD BOLT
DRAIN HOSE
HOSE BAND
FUEL FILTER BRACKET
HEX. HEAD BOLT
HEX. HEAD BOLT
FUEL FILTER
ELEMENT, FUEL FILTER
FUEL PUMP
SUCTION HOSE
SUCTION HOSE
SUCTION HOSE
RETURN HOSE
HOSE BAND
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 67
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enClOsure assy.
page 68 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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enClOsure assy.
no.
1
2
3
4
4A
5
6
6A
7
8
parT no.
parT name
BASE
PANEL BASE (U.C.) (PARENT#)
HEX. HEAD BOLT
FRONT FRAME
QTY.
1
1
2
1
1
4
1
1
12
1
4
1
10
1
4
1
1
4
4
4
1
1
4
1
1
1
14
10
1
1
8
8
1
4
4
remarks
M1413004202
M1413400004
011008020
M1423003102
M1493110203
011008020
ACOUSTIC SHEET
HEX. HEAD BOLT
COVER, FRONT FRAME (PARENT#)
ACOUSTIC SHEET
HEX. HEAD BOLT
INNER COVER, FRONT FRAME
HEX. HEAD BOLT
OVER COVER. FRONT FRAME
HEX. HEAD BOLT
COVER, RADIATOR CAP (PARENT#)
HEX. HEAD BOLT
CENTER FRAME
CENTER FRAME
HEX. HEAD BOLT
WASHER, LOCK
WASHER, PLAIN
REAR FRAME
Kit A.S.Rear Frame
HEX. HEAD BOLT
REAR COVER
DUCT, REAR COVER
ACOUSTIC SHEET
SELF-LOCKING NUT
HEX. HEAD BOLT
REAR DOOR
WINDOW PLATE
SELF-LOCKING NUT
WASHER, PLAIN
DOOR HANDLE ASSY.
MACHINE SCREW
HEX. HEAD NUT
HINGE MALE (PARENT#)
WASHER HINGE
HEX. HEAD BOLT
CAP
ROOF PANEL
ACOUSTIC SHEET
HEX HEAD BOLT
HEX. HEAD BOLT
WASHER, LOCK
M1423200604
M1493100804
0019208020
M1423203303
0016908020
M1423203214
011008020
M3310600004
0019208020
M1433001703
M1433001803
0013616040
0040016000
0041216000
M1443002412
M1493300504
011008020
M1443302613
M1443302713
M1493307114
0176060030
0019208020
M1443201303
M1444600004
020106050
9
10
11
12
13
14
15
16
16A
16B
17
17A
18
19
20
20A
21
22
23
24
25
25A
26
27
27A
28
29
30
31
32
32A
33
34
34A
34B
35
952404470
B9114000002
0021806016
020106050
M9110100204
M9116100004
0019208020
0845031504
M1463002712
M1493506113
0019208020
0013616040
0040016000
0041216000
M1453201422
2
2
3
2
1
1
10
4
4
WASHER, FLAT
SPLASHER PANEL
4
1
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 69
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enClOsure assy. (COntinued)
page 70 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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enClOsure assy. (COntinued)
no.
36
36A
36B
37
38
39
39A
40
40A
41
41A
42
42A
43
43A
44
44A
45
46
47
47A
48
49
50
51
52
53
54
55
56
57
58
parT no.
parT name
QTY.
2
2
2
2
2
1
1
1
1
1
1
1
1
2
2
1
1
14
2
8
8
4
4
8
9
8
8
8
1
4
1
2
1
remarks
0019108055
0042308000
031108160
HEX. HEAD BOLT
WASHER, LOCK
WASHER, FLAT
HEX. HEAD BOLT
HEX. HEAD BOLT
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
SELF-LOCKING NUT
DOOR HANDLE ASSY.
MACHINE SCREW
HEX. HEAD NUT
HINGE, MALE (L) (PARENT#)
HINGE MALE (R) (PARENT#)
WASHER HINGE
HEX. HEAD BOLT
DOOR STOPPER
MACHINE SCREW
CAP
MANUAL PAK
MACHINE SCREW
EMBLEM
MACHINE SCREW
HEX. HEAD BOLT
TOOTHED WASHER
011008020
0019208020
M1453006213
M1493414814
M1453006313
M1493414914
M1453006403
M1493415004
M1453006523
M1493415114
M1453302904
M1493415204
M1453303104
M1493415404
0176060030
B9114000002
0021806016
020106050
M9110100204
M9110100304
M9116100004
0019208020
Y0601350097
0027208025
0845031504
Y0600300320
0021806016
0600500090
Y0021106016
0016910025
0040510000
59
59A
1
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 71
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ruBBer seals assy.
page 72 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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ruBBer seals assy.
no.
1
2
3
4
5
6
7
8
parT no.
parT name
QTY.
3
1
1
3
1
1
1
1
2
1
1
2
2
2
1 1
remarks
Y0228901240
Y0228900625
Y0228900595
0229400970
0229400485
Y0229400910
Y0229400425
0228800515
Y0228800820
0228800510
0228800470
0228100420
0228100325
0229200950
Y0229200890
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
9
10
11
12
13
14
15
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 73
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naMeplate and deCals assy.
page 74 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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naMeplate and deCals assy.
no.
1
2
3
4
5
6
7
8
parT no.
parT name
DECAL: CIRCUIT BREAKER
QTY.
remarks
M92200050
M92000010
M92200060
M90040020
M90140000
M9522000504
M9520000104
M9522000604
M9500400204
M9501400014
M9521000204
M1550003503
M9520100304
M9520200404
M9520100204
M9501500004
M9500500104
M9500000004
M9500100004
M9503000103
M9500300104
M9500300004
M9510200002
M1560100603
M1560102804
M1560102903
M1560103104
M1560103004
M9520000004
M1550001803
M1550004504
M1550000204
M9520100503
M9520200003
M9520100004
M9520100704
M9520100404
M9510100004
M9503000004
M9503100004
M9503200004
M9503200104
920214100
1
DECAL: AMMETER CHANGE-OVER SW. 1
DECAL: VOLTAGE REGULATOR
DECAL: STARTER SWITCH
DECAL: SPEED CONTROL
DECAL: FUSE BOX
DECAL: OPERATING PROCEDURES
DECAL: GENERAL CAUTIONS
DECAL: O. C. R. RESET
DECAL: CAUTION
DECAL: DIESEL FUEL
DECAL: FUEL DRAIN PLUG
DECAL: OIL DRAIN PLUG
DECAL: WATER
DECAL: WATER 0IL CHECK
DECAL: +
DECAL: -
DECAL: MQ
STRIPE: WHISPERWATT
STRIPE
STRIPE: MQ POWER
STRIPE: 40
STRIPE
DECAL: GROUNDING
DECAL: AUXILLARY OUTPUT
DECAL: NOTE
DECAL: NOTE
DECAL: WARNING
DECAL: CONNECTION OUTPUT CABLE 1
DECAL: WARNING
DECAL: WARNING
DECAL: DANGER
DECAL: CAUTION
DECAL: WARNING
DECAL: WARNING
DECAL: WARNING
DECAL: DANGER
DECAL: WARNING
DECAL: CAUTION
DECAL: DOCUMENT BOX LOCATED
DECAL: MQ
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
1
1
1
1
M15000350
M92010030
M92020040
M92010020A
M90150000
M90050010
M90000000
M90010000
M90300010
M90030010
M90030000
M91020000
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
M92000000
M15000180
M15000450
M15000020
M92010050
M92020000
M92010000
M92010070
M92010040
M91010000
M90300000
M90310000
M90320000
M90320010
M90420000
M15000230
M91000010
M91120000
1
1
1
1
2
1
1
1
1
1
1
1
M1550002304
M9510000104
M9511200004
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 75
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terMs and COnditiOns Of sale — parts
5. Parts must be in new and resalable
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
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.
paYmenT Terms
Terms of payment for parts are net 30 days.
FreighT poliCY
6. The following items are not returnable:
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.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
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.
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
limiTaTions oF seller’s liaBiliTY
minimUm orDer
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.
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.
c. Any line item with an extended
dealer net price of less than
$5.00.
d. Special order items.
reTUrneD gooDs poliCY
e. Electrical components.
f. Paint, chemicals, and lubricants.
g. Decals and paper products.
h. Items purchased in kits.
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
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.
1. A Returned Material Authorization
must be approved by Multiquip prior to
shipment.
7. The sender will be notified of any material
received that is not acceptable.
8. Such material will be held for five
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.
2. To obtain a Return Material Authorization,
a list must be provided to Multiquip
Parts Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
9. Credit on returned parts will be issued
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
a. The parts numbers and descriptions
must match the current parts price
list.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
c. The list must state the reason(s)
for the return.
Effective: February 22, 2006
d. The list must reference the sales
order(s) or invoice(s) under
which the items were originally
purchased.
11. Credit issued will be applied to future
purchases only.
priCing anD reBaTes
e. The list must include the name
and phone number of the person
requesting the RMA.
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.
3. AcopyoftheReturnMaterialAuthorization
must accompany the return shipment.
4. Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
page 76 — DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13)
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nOtes
DCa40sskU/kU4i 60 hz generaTor • operaTion anD parTs manUal — rev. #1 (03/11/13) — page 77
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OperatiOn and parts Manual
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
United StateS
Multiquip Corporate Office
MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: [email protected]
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
Fax: 310-943-2238
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
mexico
United Kingdom
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [email protected]
Tel: (52) 222-225-9900
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223
Fax: (52) 222-285-0420 Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: [email protected]
Fax: 0161 339 3226
Canada
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [email protected]
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2013, MULTIQUIP INC.
Multiquip Inc, the MQ 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.
Your Local Dealer is:
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