MULTIQUIP M1870400004 Operation Manual Download

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THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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Revision #0 (01/12/11)

OPERATION AND PARTS MANUAL

MODEL DCA45USI2

60HZ WHISPERWATT™ GENERATOR

(ISUZU BU-4JJ1T DIESEL ENGINE)

PARTS LIST NO. M1870400004

Summary of Contents for M1870400004

Page 1: ...ALL TIMES To find the latest revision of this publication visit our website at www multiquip com Revision 0 01 12 11 OPERATION AND PARTS MANUAL MODEL DCA45USI2 60HZ WHISPERWATT GENERATOR ISUZU BU 4JJ...

Page 2: ...PAGE 2 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PROPOSITION 65 WARNING Diesel engine exhaust and some of...

Page 3: ...y 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...

Page 4: ...es 27 Output Terminal Panel Connections 28 29 Inspection Setup 30 33 Generator Start Up Procedure 34 35 Generator Shut Down Procedures 36 Maintenance 37 39 Trailer Maintenance 40 43 Trailer Wiring Dia...

Page 5: ...ite View Parts Diagrams Order Parts Print Speci cation 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: ...ot 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 nearest...

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: ...plicable 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...

Page 11: ...ery 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 clot...

Page 12: ...t 4 8 Kw 2 4 kW x 2 Dry Weight 2 889 lbs 1 310 kg Maximum Lifting Capacity 6 960 lbs 3 157 kg Table 2 Engine Specifications Model ISUZU BU 4JJ1T Tier 4 Type 4 cycle water cooled direct injection turbo...

Page 13: ...FRONT VIEW SIDE VIEW TOP VIEW H A B C D E Figure 1 Dimensions Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 30 55 in 776 mm F 83 07 in 2 130 mm B 24 37 in 619...

Page 14: ...PAGE 14 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 INSTALLATION Figure 2 Typical Generator Grounding Application...

Page 15: ...solate 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 th...

Page 16: ...om the parallel connections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section When...

Page 17: ...URE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING MOOOOO 20001Q 8 7 6 Figure 3 Major Components Table 4 Generator Major Components ITEM NO DESCRIPTION 1 Muffler Assembly 2 Fuel Tank Asse...

Page 18: ...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 Termina...

Page 19: ...DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 19 NOTES...

Page 20: ...12 11 ENGINE OPERATING PANEL Figure 5 Engine Operating Panel OFF W U V OFF W U V W U V DECREASE INCREASE 1000 2000 3000 0 R P M AUTO MANUAL OFF RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRA...

Page 21: ...he generator During cranking cycle the ECU will attempt to crank the engine for 10 seconds before disengaging If the engine does not engage start by the third attempt the engine will be shutdown by th...

Page 22: ...nerator Lift up on the cover to gain access to receptacles and terminal lugs NOTICE Terminal legs O and Ground are considered bonded grounds OUTPUTTERMINAL FAMILIARIZATION The Output Terminal Panel Fi...

Page 23: ...9 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 Tw...

Page 24: ...terminals from overload a 3 pole 110 amp 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 Cur...

Page 25: ...r Factor 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 equip...

Page 26: ...Position Voltage Selector Switch 3 Phase 480 270V Position 3 Line Line 208V 220V 240V 416V 440V 480V 1 Line Neutral 120V 127V 139V 240V 254V 277V Voltage Selector Switch Single Phase 240 120V Positio...

Page 27: ...ch Figure 14 Voltage Selector Switch 240 139V 3 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...

Page 28: ...Switch 3 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 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: ...of oil as outlined in the ISUZU Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements API Service Classification...

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: ...burns Table 12 Coolant Capacity Engine and Radiator 3 15 gal 12 liters Reserve Tank 2 quarts 1 9 liters Table 13 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point Boiling Point C F C F...

Page 33: ...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 position...

Page 34: ...ventilationwhen operating Direct exhaust away from nearby personnel WARNING NEVERmanuallystarttheenginewiththemain GFCIor auxiliary circuit breakers in the ON closed position INCORRECT CORRECT STARTIN...

Page 35: ...46 to increase or decrease the desired voltage Figure 46 Voltage Adjust Control Knob 9 The ammeter Figure 47 will indicate zero amps with no load applied When a load is applied the ammeter will indica...

Page 36: ...110 C overspeed approximately 15 The alarm lamps on the ECU illuminate to signify the reason for the shutdown NOTICE Before inspecting generator check that the Auto Manual switch is in the OFF RESET...

Page 37: ...heck all Hoses and Clamps 4 X Clean Inside of Fuel Tank X Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X MAINTENANCE GENERAL INSPECTION Prior to each use the...

Page 38: ...osits or debris that have accumulated inside the fuel tank Figure 57 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: ...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 th...

Page 41: ...urge brakes Figure 59 should not require any special attention with the exception of routine maintenance such as shoe and lining replacement Brake lines should be periodically checked for cracks kinks...

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 61 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 18 3 After first road use retorque...

Page 44: ...PAGE 44 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 TRAILER WIRING DIAGRAM Figure 62 Trailer Towing Vehicle Wiring Diagram...

Page 45: ...DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 45 GENERATOR WIRING DIAGRAM Figure 63 Generator Wiring Diagram...

Page 46: ...PAGE 46 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 ENGINE WIRING DIAGRAM Figure 64 Engine Wiring Diagram...

Page 47: ...DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 47 CONTROLLER WIRING DIAGRAM Figure 65 Engine Controller...

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: ...501203 RADIATOR HOSE UPPER 1 M1310501303 RADIATOR HOSE LOWER 1 8121468300 SENSOR WATER TEMP ENGINE SIDE 1 8971256001 SWITCH WARNING OVERHEAT ENGINE SIDE 1 8980274560 SENSOR OIL PRESSURE ENGINE SIDE 1...

Page 52: ...PAGE 52 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 GENERATOR ASSY...

Page 53: ...000 WASHER FLAT 6 1 13 0071906309 BEARING 1 2 0010310020 HEX HEAD BOLT 8 3 0042510000 WASHER LOCK 8 4 3130000903 STATOR ASSY 1 4 1 0845041904 GROMMET 2 5 B3137000803 FIELD ASSY EXCITER 1 6 0016008060...

Page 54: ...PAGE 54 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 CONTROL BOX ASSY...

Page 55: ...SCREW 2 12A 0207004000 HEX NUT 2 13 2260500204 SET PANEL ELECTRIC PARTS 1 14 0016906016 HEX HEAD BOLT 4 15 0601802218 HOLDER FUSE 1 15A 0601806671 USE 15A 3 16 0027103020 MACHINE SCREW 1 17 LY 2DDC12...

Page 56: ...PAGE 56 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 CONTROL BOX ASSY...

Page 57: ...50003004 DECAL SELECTOR SWITCH NUMBER 1 42 M1213602204 SWITCH BRACKET 1 43 M1213602304 SWITCH BRACKET 1 44 0021104030 MACHINE SCREW 4 44A 0207004000 HEX NUT 4 45 0027104016 MACHINE SCREW 4 45A 0207004...

Page 58: ...PAGE 58 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 CONTROL BOX ASSY...

Page 59: ...FUEL GAUGE 1 69 0601810141 PANEL LIGHT 1 70 0601831330 SWITCH PANEL LIGHT 1 71 0601831395 SWITCH ENGINE SPEED 1 72 1224100104 STOPPER 1 73 0027105010 MACHINE SCREW 2 74 0027105010 MACHINE SCREW 4 75...

Page 60: ...PAGE 60 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 ENGINE AND RADIATOR ASSY...

Page 61: ...SE BAND 4 15 M1423700004 FAN GUARD 1 16 M1423700114 FAN GUARD 1 17 0016906016 HEX HEAD BOLT 7 18 M1924200004 MOTOR FAN 1 19 0016910025 HEX HEAD BOLT 4 20 0602046582 AIR CLEANER 1 20A 0602046385 ELEMEN...

Page 62: ...PAGE 62 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 ENGINE AND RADIATOR ASSY CONTINUED...

Page 63: ...K 1 51 M9300100003 CAP RESERVE TANK 1 52 0199100215 HOSE 1 53 M1317100004 BRACKET RESERVE TANK 1 54 0016908020 HEX HEAD BOLT 1 55 0199101700 HOSE 1 56 0193601200 HOSE 1 57 0605515106 HOSE BAND 2 58 M1...

Page 64: ...01 12 11 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 1236400004 CABLE OUTLET COVER 1 16 1236300004 SUPPORTER CABLE OUTLET COVER 1 17 001690602...

Page 66: ...PAGE 66 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 BATTERY ASSY...

Page 67: ...O PART NAME QTY REMARKS 1 0602220187 BATTERY 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 06022 20920 BATTERY BOLT SET 2 5 0040006000 WASHER LOCK 2 6 M1347200004 BATTERY CABLE 1 7 M1...

Page 68: ...PAGE 68 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 MUFFLER ASSY...

Page 69: ...UAL REV 0 01 12 11 PAGE 69 MUFFLER ASSY NO PART NO PART NAME QTY REMARKS 1 M1331100102 MUFFLER 1 2 0017112030 HEX HEAD BOLT 4 3 M1333002903 EXHAUST PIPE 1 4 8943690210 GASKET 1 REPLACES P N 0602320101...

Page 70: ...PAGE 70 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 FUEL TANK ASSY...

Page 71: ...0700 TANK SHEET 5 8 0191301300 VENT HOSE 1 9 0605515109 HOSE BAND 2 10 M1366700214 FUEL FILTER BRACKET 1 11 0016910025 HEX HEAD BOLT 4 12 M1366700304 FUEL PUMP BRACKET 1 13 0016908025 HEX HEAD BOLT 2...

Page 72: ...PAGE 72 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 ENCLOSURE ASSY...

Page 73: ...15 0016908020 HEX HEAD BOLT 8 16 0016908020 HEX HEAD BOLT 4 17 1423202404 DUCT COVER 2 18 00169 06016 HEX HEAD BOLT 16 19 1310600103 HOSE COVER 1 20 M1310600004 HOSE COVER 1 21 0016906020 HEX HEAD BO...

Page 74: ...PAGE 74 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 ENCLOSURE ASSY CONTINUED...

Page 75: ...HEX HEAD BOLT 3 50 0019108065 HEX HEAD BOLT 1 50A 0042308000 WASHER LOCK 1 50B 0042408000 WASHER FLAT 1 51 1454000403 SIDE DOOR 1 51A 1493408404 ACOUSTIC SHEET 1 52 M1454000103 SIDE DOOR 1 52A M14934...

Page 76: ...PAGE 76 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 RUBBER SEALS ASSY...

Page 77: ...0630 SEAL RUBBER 1 7 0229400445 SEAL RUBBER 1 8 0228800455 SEAL RUBBER 1 9 0228900445 SEAL RUBBER 1 10 0229200455 SEAL RUBBER 1 11 0228100870 SEAL RUBBER 2 12 0229200840 SEAL RUBBER 1 13 0229200540 SE...

Page 78: ...PAGE 78 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NAMEPLATE AND DECALS ASSY...

Page 79: ...4 DECAL CAUTION HOT PARTS 1 M91010000 20 M9510100304 OECAL ENVIRONMENTAL WARNING 1 M91010030 21 M9510100403 DECAL CAUTION 1 M91010040 22 M9512200004 DECAL MQ 1 M91220000 23 M9520000004 DECAL GROUND 1...

Page 80: ...r products g Items purchased in kits h The sender will be noti ed of any material 7 received that is not acceptable Such material will be held for five 8 working days from noti cation pending instruct...

Page 81: ...DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 81 NOTES...

Page 82: ...Fax 0161 339 3226 CANADA Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin multiquip com Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 COPYRIGHT 2011 MULTIQUIP INC Multi...

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