MULTIQUIP Power WHISPERWATT DCA150SSIU Operation And Parts Manual Download

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THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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WHISPErWATT™ SErIES

MODEL DCA150SSI

MODEL DCA150SSIU

60Hz gENErATOr

(ISUzU 6HkIx DIESEL ENgINE)

PARTS LIST NO. cO870301504 (SSI)

PARTS LIST NO. m3870301304 (SSIU)

Revision #0 (11/23/09)

OPErATION AND PArTS MANUAL

Summary of Contents for Power WHISPERWATT DCA150SSIU

Page 1: ...st revision of this publication visit our website at www mqpower com Whisperwatt Series MODEL dca150SSI MODEL dca150SSiU 60hz generator isuzu 6hkix DIESEL ENGINE PARTS LIST NO co870301504 SSI parts li...

Page 2: ...page 2 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 proposition 65 warning Diesel engine exhaust and some of...

Page 3: ...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 betw...

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

Page 5: ...site 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 qualif...

Page 6: ...e 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 situatio...

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 neare...

Page 8: ...ction 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 co...

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

Page 10: ...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 i...

Page 11: ...attery 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 c...

Page 12: ...eight No Fuel 5 711 lbs 2 590 kg Weight Fuel 6 417 lbs 2 910 kg Engine Specifications Table 2 Model ISUZU 6HK1X Tier 3 Type 4 cycle water cooled direct injection turbocharged air to air intercooled No...

Page 13: ...age 13 Dimensions Dimensions Figure 1 Dimensions Table 3 Reference Letter Dimension in mm Reference Letter Dimension in mm A 42 13 in 1070 mm F 133 86 in 3400 mm B 37 00 in 940 mm G 59 06 in 1500 mm C...

Page 14: ...page 14 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 Installation Typical Generator Grounding Application Figure 2...

Page 15: ...ibration 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...

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

Page 17: ...omponents Table 4 ITEM NO DESCRIPTION 1 Muffler Assembly 2 Air Filter Assembly 3 Output Terminal Panel Assembly 4 Generator Assembly 5 Output Receptacle Assembly 6 Engine Assembly 7 Battery Assembly 8...

Page 18: ...the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off Frequency Meter 5 Indicates the output frequency in hertz Hz Normally 60 Hz AC...

Page 19: ...DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 page 19 Notes...

Page 20: ...0 11 23 09 ENGINE OPERATING PANEL Engine Operating Panel Figure 5 AUTO MANUAL OFF RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING MOOOOO 20001Q 1 1000 2000 3000 0 R...

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

Page 22: ...generator 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...

Page 23: ...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 120 240V Twist L...

Page 24: ...ut terminals from overload a 3 pole 400 amp main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine Connecting Loads Figure 11 Over C...

Page 25: ...y Load Table 5 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 equipme...

Page 26: ...s Available Table 7 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 prov...

Page 27: ...witch Voltage Selector Switch Figure 14 240 139V 3 Positio AC Voltmeter Gauge Reading Place the ACVoltmeter Change Over Switch Figure 15 in theW U position and observe the phase to phase voltage readi...

Page 28: ...witch Figure 19 3 240 139V Position Connect the load wires to the UVWO terminals as 2 shown in Figure 20 UVWO Terminal Lugs Figure 20 3 240 139V Connections Turn the voltage regulator knob Figure 21 c...

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

Page 30: ...with 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...

Page 31: ...LWAYS 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 Open cabinet...

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

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

Page 34: ...UTION The engine s exhaust contains harmful emissions ALWAYS have adequate ventilationwhen operating Direct exhaust away from nearby personnel WARNING NEVERmanuallystarttheenginewiththemain GFCIor aux...

Page 35: ...lerance Voltmeter Figure 45 Use the voltage adjustment control knob Figure 46 8 to increase or decrease the desired voltage Voltage Adjust Control Knob Figure 46 The ammeter Figure 47 will indicate 9...

Page 36: ...ration Emergency Shutdown Procedure Place the 1 MPEC Control Switch Figure 55 in the OFF RESET position Place the 13 main GFCI and aux circuit breakers in the ON position Figure 51 Main Aux and GFCI F...

Page 37: ...X 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...

Page 38: ...deposits or debris that have accumulated inside the fuel tank Fuel Tank Cleaning Figure 57 FuelTank Inspection In addition to cleaning the fuel tank the following components should be inspected for we...

Page 39: ...anufacturer 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 scr...

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

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

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

Page 43: ...hand 1 Torque all lug nuts in sequence see Figure 61 2 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 18 After first road use retorque...

Page 44: ...page 44 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 Trailer Wiring Diagram Trailer Towing Vehicle Wiring Diagram Figure 62...

Page 45: ...DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 page 45 Generator Wiring Diagram Generator Wiring Diagram Figure 63...

Page 46: ...page 46 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 Engine Wiring Diagram Engine Wiring Diagram Figure 64...

Page 47: ...DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 page 47 controller Wiring Diagram Controller Wiring Diagram Figure 65...

Page 48: ...meter 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...

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

Page 50: ...oes 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 Q...

Page 51: ...nk 3 8900714010 fuel filter feed pump 3 8980088400 filter fuel element main 3 8980758540 filter fuel element pre 1 0602122272 UNIT OIL PRESSURE 1 0602123260 UNIT WATER TEMPERATURE 1 8971703270 SEnsor...

Page 52: ...page 52 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 GENERATOR ASSY...

Page 53: ...GHT KIT 1 1 15 0071906312 BEARING 1 2 C0130000603 STARTOR ASSY 1 3 0845041804 GROMMET 2 4 8131315202 END BRACKET 1 5 8101350013 FIELD ASSY EXCITER 1 6 0012110060 HEX HEAD BOLT 4 7 0042610000 WASHER LO...

Page 54: ...page 54 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 control box ASSY...

Page 55: ...T HEAD CAP SCREW 6 DCA150SSI 2 1 0342604120 HEX SOCKET HEAD CAP SCREW 6 DCA150SSIU 3 0021006080 MACHINE SCREW 4 4 0601823860 RELAY UNIT 2 5 0027104016 MACHINE SCREW 4 6 0601820602 AUTOMATIC VOLTAGE RE...

Page 56: ...page 56 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 control box ASSY continued...

Page 57: ...30220 33 0027104016 MACHINE SCREW 2 34 8980056310 RELAY STARTER 1 REPLACES P N 0602201401 35 0027106016 MACHINE SCREW 2 36 8980137900 RELAY 2 REPLACES P N 0602202682 37 0027105016 MACHINE SCREW 2 38 5...

Page 58: ...page 58 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 control box ASSY continued...

Page 59: ...0 PANEL LIGHT 1 70 0601831330 SWITCH PANEL LIGHT 1 71 0601830740 SWITCH ENGINE SPEED 1 DCA150SSI 71 0601831395 SWITCH ENGINE SPEED 1 DCA150SSIU 72 M1223100004 STOPPER 1 73 M3223100004 STOPPER 1 74 002...

Page 60: ...page 60 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 ENGINE AND RADIATOR ASSY...

Page 61: ...150SSU 16 0605515117 HOSE BAND 1 DCA150SSI 16 0605515146 HOSE BAND 1 DCA150SSIU 17 M3923200124 INNER COOLER 1 18 0132004000 PLUG 3 8 1 19 M3310503403 INNER COOLER HOSE 1 20 M3310400803 INNER COOLER PI...

Page 62: ...page 62 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 ENGINE AND RADIATOR ASSY continued...

Page 63: ...10110150 HEX HEAD BOLT 2 53A 0040010000 WASHER LOCK 2 53B 0041210000 WASHER FLAT 2 54 0602022535 ADAPTER 4 55 C0324300504 ENGINE OIL HOSE 1 DCA150SSI 55 0379001500 ENGINE OIL HOSE 1 DCA150SSIU 56 C032...

Page 64: ...page 64 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 OUTPUT TERMINAL ASSY...

Page 65: ...EW 4 12A 0030003000 HEX NUT 4 13 M9220100804 SET SCREW 2 13A 0040006000 WASHER LOCK 2 13B 0041206000 WASHER FLAT 2 13C 0080200005 RETAINING RING 2 14 0016906015 HEX HEAD BOLT 4 DCA150SSI 14 0016906016...

Page 66: ...page 66 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 OUTPUT TERMINAL ASSY CONTINUED...

Page 67: ...28A 0207004000 HEX NUT 10 29 M3236400204 COVER 1 30 0016906020 HEX HEAD BOLT 8 30 0016906016 HEX HEAD BOLT 8 31 M3236100213 TERMINAL COVER 1 32 0010112045 HEX HEAD BOLT 2 33 0041212000 WASHER FLAT 2 3...

Page 68: ...page 68 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 BATTERY ASSY dca150ssi...

Page 69: ...TERY BOLT SET 4 5 C0346400504 BATTERY CABLE 1 6 C0346400604 BATTERY CABLE 1 7 C0346400704 BATTERY CABLE 1 8 EARTH CABLE 1 MAKE LOCALLY 9 0602220310 TERMINAL ASSY 2 10 0602220311 TERMINAL ASSY 2 11 084...

Page 70: ...page 70 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 BATTERY ASSY dca150ssiu...

Page 71: ...BATTERY SHEET 2 3 M9103000304 BATTERY BAND 2 4 0602220920 BATTERY BOLT SET 4 5 M3346901904 BATTERY CABLE 1 6 M3346901804 BATTERY CABLE 1 7 M3346901704 BATTERY CABLE 1 8 EARTH CABLE 1 MAKE LOCALLY 9 00...

Page 72: ...page 72 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 Muffler Assy...

Page 73: ...TY REMARKS 1 M3330101102 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M3333001703 EXHAUST PIPE 1 4 1141451920 GASKET 1 REPLACES P N 0602320109 5 M3333200104 GASKET 1 6 0030710000 HEX NUT 8 7 0017110050 HE...

Page 74: ...page 74 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 FUEL TANK ASSY dca150ssi...

Page 75: ...FUEL FILTER 1 REPLACES P N 0602042515 19 8980758551 FUEL FILTER PRE 1 REPLACES P N 0602042405 19A 8980758540 ELEMENT FUEL FILTER 1 REPLACES P N 0602042516 20 8973834270 JOINT PIPE 4 REPLACES P N 06020...

Page 76: ...page 76 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 FUEL TANK ASSY dca150ssiU...

Page 77: ...26 18A 8980088400 ELEMENT FUEL FILTER 1 REPLACES P N 0602042515 19 8980758551 FUEL FILTER PRE 1 REPLACES P N 0602042405 19A 8980758540 ELEMENT FUEL FILTER 1 REPLACES P N 0602042516 20 8973834270 JOINT...

Page 78: ...page 78 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 ENCLOSURE ASSY...

Page 79: ...EET 1 10 M4310600304 RUBBER SHEET 2 11 0017112055 HEX HEAD BOLT 4 12 M3310202504 BRACKET RADIATOR 2 13 0016910025 HEX HEAD BOLT 4 14 0016910025 HEX HEAD BOLT 2 15 M3310202403 BRACKET INNER COOLER 2 16...

Page 80: ...page 80 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 ENCLOSURE ASSY continued...

Page 81: ...W 4 39A 0030006000 HEX NUT 4 40 0845047104 HINGE 2 DCA150SSI 40 M9110100204 HINGE 2 DCA150SSIU 40A 0845045004 WASHER 2 DCA150SSI 40A M9116100004 WASHER 2 DCA150SSIU 41 0019208020 HEX HEAD BOLT 3 42 08...

Page 82: ...page 82 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 ENCLOSURE ASSY continued...

Page 83: ...EX NUT 16 63 0600800320 MANUAL PAK 1 64 0021806015 MACHINE SCREW 4 DCA150SSI 64 0021806016 MACHINE SCREW 4 DCA150SSIU 65 M2453700204 GUTTER 2 66 M4453600004 GUTTER 1 67 M3453700004 GUTTER 2 68 0019206...

Page 84: ...page 84 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 RUBBER SEALS ASSY...

Page 85: ...SEAL RUBBER 3 4 0228901150 SEAL RUBBER 3 5 0228900935 SEAL RUBBER 4 6 0228900520 SEAL RUBBER 1 7 0228900580 SEAL RUBBER 1 8 0229201140 SEAL RUBBER 1 9 0228801070 SEAL RUBBER 2 10 0228800640 SEAL RUBBE...

Page 86: ...page 86 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 NAMEPLATE AND DECALS ASSY dca150ssi...

Page 87: ...L DRAIN PLUG 1 S 1885 3 2 6360610304 DECAL WATER 1 S 1880 3 3 B9504000404 DECAL WARNING MOVING PARTS 1 B9040 0040 3 4 1320610603 DECAL WATER OIL CHECK 1 S 1760 3 5 B9504100104 DECAL WARNING HOT COOLAN...

Page 88: ...page 88 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 NAMEPLATE AND DECALS ASSY dca150ssi continued...

Page 89: ...RE GROUP 8 1 0840625902 DECAL MQ 1 S 3057 8 2 0600500090 EMBLEM 1 8 2 A 0021106016 MACHINE SCREW 2 8 3 C0560100503 STRIPE 1 8 4 C0560100603 STRIPE 2 8 5 C0560100704 STRIPE 2 8 6 C0560100803 STRIPE 1 8...

Page 90: ...page 90 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 NAMEPLATE AND DECALS ASSY dca150ssiu...

Page 91: ...OUP 3 1 M9500000004 DECAL OIL DRAIN PLUG 1 M90000000 3 2 M9500100004 DECAL WATER 1 M90010000 3 3 M9500000304 DECAL WARNING MOVING PARTS 1 M90010000 3 4 M9503000004 DECAL WATER OIL CHECK 1 M90100030 3...

Page 92: ...page 92 DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 NAMEPLATE AND DECALS ASSY dca150ssiu continued...

Page 93: ...2 DECAL MQ 1 M91020000 8 2 0600500090 EMBLEM 1 8 2 A 0021106016 MACHINE SCREW 2 8 3 M3560100903 STRIPE 1 8 4 M3560101003 STRIPE 2 8 5 M3560101304 STRIPE 2 8 6 M3560101403 STRIPE 1 8 7 M3560101504 STRI...

Page 94: ...er products g Items purchased in kits h The sender will be notified of any material 7 received that is not acceptable Such material will be held for five 8 working days from notification pending instr...

Page 95: ...DCA150SSI dca150ssiu 60 hz Gen operation and parts manual rev 0 11 23 09 page 95 notes...

Page 96: ...chnical 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 publ...

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