MULTIQUIP Power WhisperWatt DCA45SSIU4, Operations & Parts Manual

Page 1: ...ALL TIMES To find the latest revision of this publication visit our website at www mqpower com Whisperwatt Series MODEL dca45ssiu4 60hz generator isuzu 4JJ1t DIESEL ENGINE PARTS LIST NO M1870301104 Re...

Page 2: ...page 2 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 proposition 65 warning Diesel engine exhaust and some of...

Page 3: ...ay 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 betwee...

Page 4: ...al Panel Connections 28 29 Inspection Setup 30 33 Generator Start Up Procedure 34 35 Generator Shut Down Procedures 36 Maintenance 37 39 Trailer Maintenance 40 43 Trailer WirIng Diagram 44 Generator W...

Page 5: ...ite View Parts Diagrams Order Parts Print Specification Information Note Discounts Are Subject To Change Goto www multiquip com and click on Order Parts to log in and save Use the internet and qualify...

Page 6: ...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...

Page 7: ...not recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result alWaYS know the location of the nearest fire extinguisher alWaYS know the location of the neares...

Page 8: ...ion never tamper with the factory settings of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable Wet stacking is a comm...

Page 9: ...perating condition alWaYS shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating alWaYS i...

Page 10: ...enerator Inspect for cuts in the insulation never grab or touch a live power cord or cable with wet hands The possibility exists of electrical shock electrocution or death Make sure power cables are s...

Page 11: ...e of this equipment is over remove battery and bring to appropriate facility for lead reclamation Use safety precautions when handling batteries that contain sulfuric acid When the life cycle of this...

Page 12: ...uency 60 Hz Speed 1800 rpm Aux AC Power Single Phase 60 Hz Aux Voltage Output 4 8 Kw 2 4 kW x 2 Table 2 Engine Specifications Model ISUZU 4JJ1T Type 4 cycle water cooled direct injection turbo charged...

Page 13: ...age 13 Dimensions Figure 1 Dimensions Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 30 31 in 770 mm F 76 38 in 1 940 mm B 25 00 in 635 mm G 49 21 in 1 250 mm C...

Page 14: ...page 14 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 Installation Figure 2 Typical Generator Grounding Application...

Page 15: ...ration 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 o...

Page 16: ...nections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section When a heavy load such a...

Page 17: ...ERSPEED ENGINE RUNNING MOOOOO 20001Q Denyo 2 4 1 5 6 7 8 3 45 45 Table 4 Generator Major Components ITEM NO DESCRIPTION 1 Output Terminal Panel Assembly 2 Output Receptacles Assembly 3 Air Filter Asse...

Page 18: ...ws the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off 5 ACVoltmeter Indicates the output voltage present at the U V and W Output T...

Page 19: ...DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 page 19 Notes...

Page 20: ...10 24 13 ENGINE OPERATING PANEL Figure 5 Engine Operating Panel 1000 2000 3000 0 R P M OFF W U V OFF W U V W U V DECREASE INCREASE AUTO MANUAL OFF RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERC...

Page 21: ...pt to crank the engine for 10 seconds before disengaging If the engine does not engage start by the third attempt the engine will be shutdown by the engine controller s Over Crank Protection mode If t...

Page 22: ...Panel Figure 6 is provided with the following Three 120 240V output receptacles 50 amp Three Circuit Breakers 50 amps Two 120V GFCI receptacles 20 amp Two GFCI Circuit Breakers 20 amps Five Output Ter...

Page 23: ...69 receptacles Figure 8 provided on the output terminal panel These receptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position Figure 8 120 240V T...

Page 24: ...ut terminals from overload a 3 pole 110A main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine Figure 11 Connecting Loads Over Curr...

Page 25: ...ctor By Load Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equipment...

Page 26: ...Voltages Available Three Phase Switchable 208V 220V 240V 416V 440V 480V Single Phase Switchable 120V 1127V 139V 240V 254V 277V Generator Amperage Table 8 shows the maximum amps the generator can provi...

Page 27: ...15 to activate the AC Voltmeter Gauge Figure 16 and read the available voltage between the two lugs For example to measure the voltage between theW and U terminal lugs set the ACVoltmeter Change Over...

Page 28: ...lector Switch 3 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 20 Figure 20 UVWO Terminal Lugs 3 240 139V Connections 3 Turn the voltage regulator knob Figure 21 c...

Page 29: ...e regulator adjustment knob whenever fine tuning of the output voltage is required 1 240 120V UVWOTerminal Output Voltages 1 Place the voltage selector switch in the 1 240 120 position as shown in Fig...

Page 30: ...ith the specified amount of oil as outlined in the ISUZU Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements A...

Page 31: ...AYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank NOTICE ONLY use 2 diesel fuel when refueling 2 Open cabinet...

Page 32: ...ause severe burns Table 12 Coolant Capacity Engine and Radiator 2 88 gal 10 9 liters Reserve Tank 2 quarts 1 9 liters Table 13 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point C F 50 3...

Page 33: ...T and reconnect negative terminal LAST When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL positio...

Page 34: ...ON The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel WARNING NEVERmanuallystarttheenginewiththemain GFCIor auxil...

Page 35: ...ecrease the desired voltage Figure 44 Voltmeter Figure 45 Voltage Adjust Control Knob 7 The ammeter Figure 46 will indicate zero amps with no load applied When a load is applied the ammeter will indic...

Page 36: ...tion Emergency Shutdown Procedure 1 Place the MPEC Control Switch Figure 54 in the OFF RESET position 11 Place the main GFCI and aux circuit breakers in the ON position Figure 50 Figure 50 Main Aux an...

Page 37: ...Check all Hoses and Clamps 4 X Clean Inside of Fuel Tank X Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X Maintenance General Inspection Prior to each use th...

Page 38: ...osits or debris that have accumulated inside the fuel tank Figure 56 Fuel Tank Cleaning FuelTank Inspection In addition to cleaning the fuel tank the following components should be inspected for wear...

Page 39: ...ufacturer 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 screw...

Page 40: ...rt device with maximum pound requirement from the tongue of the trailer 7 Coupler Type of hitch used on the trailer for towing 8 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and...

Page 41: ...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 kink...

Page 42: ...th great force and cause serious eye or bodily injury Table 16 Tire WearTroubleshooting Wear Pattern Cause Solution Center Wear Over inflation Adjust pressure to particular load per tire manufacturer...

Page 43: ...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...

Page 44: ...page 44 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 Trailer Wiring Diagram Figure 61 Trailer Towing Vehicle Wiring Diagram...

Page 45: ...DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 page 45 Generator Wiring Diagram Figure 62 Generator Wiring Diagram...

Page 46: ...page 46 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 Engine Wiring Diagram Figure 63 Engine Wiring Diagram...

Page 47: ...DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 page 47 controller Wiring Diagram Figure 64 Controller Wiring Diagram...

Page 48: ...ter Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Defective Exciter Field Check for approximately 17 3 ohms ac...

Page 49: ...ly lit when the MPEC Control Switch is placed in the MANUAL position 2 If engine trouble occurs the diagnostic lamp will be brightly lit as long as the control switch is left in the manual position 3...

Page 50: ...s not guarantee the availability of the parts listed NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order QtY...

Page 51: ...NIT WATER TEMPERATURE 1 8121468300 SEnsor WATER temp ENGINE SIDE 1 8980274560 Sensor OIL pressure ENGINE SIDE 1 1096300850 gasket sensor oil pressure engine side 1 m1310501403 radiator hose upper 1 m1...

Page 52: ...page 52 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 GENERATOR ASSY...

Page 53: ...WASHER FLAT 6 1 13 0071906309 BEARING 1 2 0010310020 HEX HEAD BOLT 8 3 0042510000 WASHER LOCK 8 4 B3130000903 STATOR ASSY 1 4 1 0845041904 GROMMET 2 5 B3137000803 FIELD ASSY EXCITER 1 6 0016008060 HE...

Page 54: ...page 54 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 control box ASSY...

Page 55: ...60500104 SET PANEL ELECTRIC PARTS 1 14 0016906016 HEX HEAD BOLT 4 15 0601802218 HOLDER FUSE 1 15A 0601806671 FUSE 15A 3 16 0027103020 MACHINE SCREW 1 17 LY 2D DC12V RELAY 2 REPLACES P N 0601827656 17A...

Page 56: ...page 56 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 control box ASSY...

Page 57: ...CHINE SCREW 4 45A 0207004000 HEX NUT 4 46 0016906016 HEX HEAD BOLT 4 47 M1213602604 SWITCH COVER 1 48 0016906016 HEX HEAD BOLT 8 49 M1213602704 SWITCH COVER 1 49 1 0317700180 SEAL RUBBER 1 50 00169060...

Page 58: ...page 58 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 control box ASSY...

Page 59: ...7105010 MACHINE SCREW 2 74 0027105010 MACHINE SCREW 4 75 M9220100004 SET SCREW 2 76 0080200007 SNAP RING 2 77 0602122272 UNIT OIL PRESSURE 1 78 M9200100004 ADAPTER 1 79 0130000000 ELBOW 1 8 1 80 03043...

Page 60: ...page 60 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 ENGINE AND RADIATOR ASSY...

Page 61: ...TOR HOSE 1 13 0165515147 HOSE BAND 4 14 M1310300903 FAN GUARD 1 15 0016908020 HEX HEAD BOLT 4 16 M1310300504 FAN GUARD 1 17 M1310300604 FAN GUARD 1 18 0016908020 HEX HEAD BOLT 6 19 0602046585 AIR CLEA...

Page 62: ...page 62 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 ENGINE AND RADIATOR ASSY continued...

Page 63: ...15106 HOSE BAND 2 45 M9300000003 RESERVE TANK 1 46 M9300100003 CAP RESERVE TANK 1 47 0199100215 HOSE 1 48 M1317100004 BRACKET RESERVE TANK 1 49 0016908020 HEXHEAD BOLT 1 50 0199100800 HOSE 1 51 019360...

Page 64: ...1 10 24 13 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 3 SPECTRUM GREY 7...

Page 65: ...00 WASHER LOCK 2 13B 0041206000 WASHER FLAT 2 13C 0080200005 RETAINING RING 2 14 0016906016 HEX HEAD BOLT 4 15 M1236400004 CABLE OUTLET COVER 1 16 M1236300004 SUPPORTER CABLE OUTLET COVER 1 17 0016906...

Page 66: ...page 66 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 BATTERY ASSY...

Page 67: ...BATTERY 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 WASHER LOCK 2 6 M1346400804 BATTERY CABLE 1 7 M1346400704 BATTERY CABLE 1 8 CABLE 1 M...

Page 68: ...page 68 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 Muffler Assy...

Page 69: ...0100902 MUFFLER 1 1 M1330100703 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M1333002703 EXHAUST PIPE 1 4 8943690210 GASKET 1 REPLACES P N 0602320101 5 M1333200114 GASKET 1 6 0039308000 HEX HEAD NUT 6 7 0...

Page 70: ...page 70 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 FUEL TANK ASSY...

Page 71: ...0016908025 HEX HEAD BOLT 2 19 8980139861 FUEL FILTER MAIN 1 REPLACES P N 0602042426 19A 8980088400 ELEMENT FUEL FILTER 1 REPLACES P N 0602042515 20 8980758550 FUEL FILTER PRE 1 REPLACES P N 060204240...

Page 72: ...ev 1 10 24 13 ENCLOSURE 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 3 SPECTRUM GREY 7 CA...

Page 73: ...4000 WASHER FLAT 8 13 0010114030 HEX HEAD BOLT 8 13A 0040014000 WASHER LOCK 8 13B 0041214000 WASHER FLAT 8 14 M1443001802 REAR FRAME 1 14A M1493300504 ACOUSTIC SHEET 1 15 0016908020 HEX HEAD BOLT 4 16...

Page 74: ...10 24 13 ENCLOSURE ASSY continued ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY...

Page 75: ...M1453302004 DUCT 1 40A M1493411404 ACOUSTIC SHEET 1 41 M1453301804 DUCT 1 41A M1493411704 ACOUSTIC SHEET 1 42 M1453301503 DUCT 1 42A M1493409204 ACOUSTIC SHEET 1 43 M1453301904 DUCT 1 43A M1493412504...

Page 76: ...page 76 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 RUBBER SEALS ASSY...

Page 77: ...L RUBBER 1 4 0229400970 SEAL RUBBER 3 5 M1490300104 SEAL RUBBER 1 6 0228800515 SEAL RUBBER 1 7 0229400485 SEAL RUBBER 1 8 0228900910 SEAL RUBBER 1 9 0228900790 SEAL RUBBER 1 10 0229200540 SEAL RUBBER...

Page 78: ...page 78 DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 NAMEPLATE AND DECALS ASSY...

Page 79: ...0000 18 M9503200104 DECAL DANGER 1 M90320010 19 M9510000104 DECAL DOCUMENT BOX LOCATED 1 M91000010 20 M9510100004 DECAL CAUTION 1 M91010000 21 M9510100403 DECAL CAUTION 1 M91010040 22 M9510200002 DECA...

Page 80: ...er products h Items purchased in kits 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 instruc...

Page 81: ...DCA45SSIU4 60 hz Generator operation and parts manual rev 1 10 24 13 page 81 notes...

Page 82: ...act sales multiquip co uk Tel 0161 339 2223 Fax 0161 339 3226 COPYRIGHT 2013 MULTIQUIP INC Multiquip Inc the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc and may not be use...