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MULTIQUIP WhisperWatt DCA45SSKU, Operation And Parts Manual

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MULTIQUIP WhisperWatt DCA45SSKU Operation And Parts Manual Download Page 1

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

To find the latest revision of this 

publication, visit our website at: 

www.mqpower.com

Revision #0 (12/15/11)

OperatiOn and parts Manual

®

MOdel dca45ssKu

MOdel dca45ssKu3

60hz WhisperWatt™ generatOr

(KuBOta V3800-di-t diesel engine)

parts list nO. M1870301504

Summary of Contents for WhisperWatt DCA45SSKU

Page 1: ...S To find the latest revision of this publication visit our website at www mqpower com Revision 0 12 15 11 Operation and Parts Manual MODEL dca45SSKU MODEL dca45SSKU3 60hz Whisperwatt generator KUBOTA...

Page 2: ...page 2 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 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 betwe...

Page 4: ...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...

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: ...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 neare...

Page 8: ...tion 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 com...

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: ...pplicable 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: ...tery 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 clo...

Page 12: ...A 240 120 Power Factor 0 8 1 0 Frequency 60 Hz Speed 1800 rpm Aux AC Power Single Phase 60 Hz Aux Voltage Output 4 8 Kw 2 4 kW x 2 Dry Weight 2 072 lbs 940 kg Wet Weight 2 314 lbs 1 050 kg Table 2 Eng...

Page 13: ...D B TOP VIEW SIDE VIEW C 45 M91020000 H Figure 1 Dimensions Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 25 19 in 640 mm F 76 37 in 1 940 mm B 25 19 in 640 mm...

Page 14: ...page 14 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 Installation Figure 2 Typical Generator Grounding Application...

Page 15: ...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 t...

Page 16: ...r 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 excit...

Page 17: ...DECREASE INCREASE 13 Figure 3 Major Components Table 4 Generator Major Components ITEM NO DESCRIPTION 1 Output Terminal Panel Assembly 2 Terminal Panel Assembly 3 Voltage Selector Switch Assembly 4 Co...

Page 18: ...water temperature rises abnormally If the lamp goes ON during normal operation of the generator the emergency shutdown system will stop the engine automatically c Battery Charge Alarm Lamp This lamp...

Page 19: ...h 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...

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

Page 21: ...minal 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 Twist Lock Auxiliary Receptacles Each auxiliary rec...

Page 22: ...put terminals from overload a 3 pole 125A 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 23: ...er 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 equi...

Page 24: ...se 240 139V 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 1...

Page 25: ...itch 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 readi...

Page 26: ...elector 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...

Page 27: ...ge 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 Fi...

Page 28: ...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 API Service Classification...

Page 29: ...firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank Level Ground Unlevel Ground Level Ground Unlevel Ground DO NOT fill on unlevel...

Page 30: ...burns Table 12 Coolant Capacity Engine and Radiator 2 91 gal 11 liters Reserve Tank 1 quart 0 9 liters Table 13 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point Boiling Point C F C F...

Page 31: ...ST 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 positi...

Page 32: ...ping out 5 Close all engine enclosure doors Figure 37 Figure 37 Engine Enclosure Doors CAUTION The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct ex...

Page 33: ...e run for 1 2 minutes Listen for any abnormal noises If any abnormalities exist shut down the engine and correct the problem 5 Place the engine speed control switch Figure 43 in the RUN position up Fi...

Page 34: ...pproximately 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 START IDLE NOTICE Before ins...

Page 35: ...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 t...

Page 36: ...ts or debris that have accumulated inside the fuel tank Figure 54 Fuel Tank Cleaning FuelTank Inspection In addition to cleaning the fuel tank the following components should be inspected for wear Rub...

Page 37: ...ank and drain Check hoses for softening and kinks Check clamps for signs of leakage Tighten both cocks and replace the overflow tank Replace with coolant as recommended by the engine manufacturer Clos...

Page 38: ...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 be...

Page 39: ...ort 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 an...

Page 40: ...rakes 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 bl...

Page 41: ...ith 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 42: ...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 43: ...DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 page 43 Trailer Wiring Diagram Figure 61 Trailer Towing Vehicle Wiring Diagram...

Page 44: ...page 44 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 Generator Wiring Diagram Figure 62 Generator Wiring Diagram...

Page 45: ...DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 page 45 Engine Wiring Diagram Figure 63 Engine Wiring Diagram...

Page 46: ...nections loose Check wiring and repair Defective AVR Replace if necessary Circuit Breaker Tripped Short Circuit in load Check load and repair Over current Confirm load requirements and reduce Defectiv...

Page 47: ...DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 page 47 notes...

Page 48: ...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 49: ...3 RADIATOR HOSE UPPER 1 B3311501603 RADIATOR HOSE LOWER 1 T106365660 SENSOR WATER TEMP ENGINE SIDE 1 5160137670 SWITCH WARNING OVERHEAT ENGINE SIDE 1 1584139010 SWITCH OIL PRESSURE ENGINE SIDE 1 38240...

Page 50: ...page 50 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 GENERATOR ASSY...

Page 51: ...AD CAP SCREW 6 1 12 0046512000 WASHER FLAT 6 1 13 0071906309 BEARING 1 2 0010310020 HEX HEAD BOLT 8 3 0042510000 WASHER LOCK 8 4 B3130000903 STATOR ASSY 1 4 1 0845041904 GROMMET 2 5 B3137000803 FIELD...

Page 52: ...page 52 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 control box ASSY...

Page 53: ...SELECTOR SWITCH 1 14 1213602814 SWITCH BRACKET 1 15 0027105020 MACHINE SCREW 4 15A 0030005000 HEX NUT 4 REPLACES P N 0207005000 16 0016906016 HEX HEAD BOLT 2 17 1E31560601 ENGINE CONTROL UNIT 1 18 Y0...

Page 54: ...page 54 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 control box ASSY...

Page 55: ...6 45 65HZ 240V 1 43 0601801040 CHANGE OVER SWITCH 1 44 0601840073 VOITAGE REGUIATOR 2W 1K OHM 1 45 0601840121 KNOB 1 46 0601810523 INDICATOR WARNING 1 46A 0601810830 BULB 4 47 0601800682 HOUR METER 1...

Page 56: ...page 56 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 ENGINE AND RADIATOR ASSY...

Page 57: ...BOLT 6 14 B3311501503 RADIATOR HOSE 1 15 B3311501603 RADIATOR HOSE 1 16 0605515147 HOSE BAND 4 17 0602046585 AIR CLEANER 1 17A 0602046366 ELEMENT AIR CLEANER 1 18 0602040651 AIR CLEANER INDICATOR 1 1...

Page 58: ...page 58 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 ENGINE AND RADIATOR ASSY continued...

Page 59: ...Y0379501000 DRAIN HOSE 1 55 0605515198 HOSE BAND 2 56 0193601000 DRAIN HOSE 1 57 Y0602220910 CLAMP 2 58 011008020 HEX HEAD BOLT 1 59 0601850239 GROMMET 1 60 M1303200604 ENGINE FOOT 1 61 M1303200704 EN...

Page 60: ...0 12 15 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...

Page 61: ...EX HEAD BOLT 2 14 M1236101814 COVER 1 15 0016906016 HEX HEAD BOLT 7 16 0601870440 CIRCUIT BREAKER 1P 20A 2 17 0601870441 CIRCUIT BREAKER 2P 50A 2 18 M1260700404 BREAKER FITTING COVER 1 18 1 0222100080...

Page 62: ...page 62 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 BATTERY ASSY...

Page 63: ...BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 M1346400104 BATTERY CABLE 1 6 M0348200104 BATTERY CABLE 1 7 CABLE GROUND 1 MAKE LOCALLY 8 Y0013512025 HEX HEAD BOLT 1 8A...

Page 64: ...page 64 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 Muffler Assy...

Page 65: ...fler Assy NO PART NO PART NAME QTY REMARKS 1 B3331102203 MUFFLER 1 2 011008020 HEX HEAD BOLT 4 3 B3334001403 EXHAUST PIPE 1 4 1925812231 GASKET 1 5 0030410000 HEX NUT 8 6 0602325097 SEAL CLAMP 1 7 M13...

Page 66: ...page 66 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 FUEL TANK ASSY...

Page 67: ...EET 1 7 0222100085 RUBBER SHEET 2 8 1502025103C DRAIN JOINT 1 REPLACES P N M9200000003 9 0802011104 DRAIN BOLT 1 REPLACES P N M9200200004 10 0150000018 O RING 1 11 011206020 HEX HEAD BOLT 2 12 M136340...

Page 68: ...page 68 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 ENCLOSURE ASSY...

Page 69: ...HEAD BOLT 4 16A 0040016000 WASHER LOCK 4 16B 0041216000 WASHER FLAT 4 17 M1443002412 REAR FRAME 1 17A M1493300504 ACOUSTIC SHEET 1 18 011008020 HEX HEAD BOLT 4 19 M1443302613 REAR COVER 1 20 M14433027...

Page 70: ...page 70 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 ENCLOSURE ASSY continued...

Page 71: ...IDE DOOR 1 42A M1493415114 ACOUSTIC SHEET 1 43 M1453302904 DUCT 2 43A M1493415204 ACOUSTIC SHEET 2 44 M1453303104 DUCT 1 44A M1493415404 ACOUSTIC SHEET 1 45 0176060030 SELF LOCKING NUT 14 46 B91140000...

Page 72: ...page 72 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 RUBBER SEALS ASSY...

Page 73: ...AL RUBBER 1 3 Y0228900595 SEAL RUBBER 1 4 0229400970 SEAL RUBBER 3 5 0229400485 SEAL RUBBER 1 6 Y0229400910 SEAL RUBBER 1 7 Y0229400425 SEAL RUBBER 1 8 0228800515 SEAL RUBBER 1 9 Y0228800820 SEAL RUBB...

Page 74: ...page 74 DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 NAMEPLATE AND DECALS ASSY...

Page 75: ...CHECK 1 M90300010 16 M9500300104 DECAL 1 M90030010 17 M9500300004 DECAL 1 M90030000 18 M9510200002 DECAL MQ 1 M91020000 19 M1560100603 STRIPE WHISPERWATT 1 20 M1560102804 STRIPE 2 21 M1560102903 STRIP...

Page 76: ...r 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 instru...

Page 77: ...DCA45ssk ku3 60 hz Generator operation and parts manual rev 0 12 15 11 page 77 notes...

Page 78: ...3 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 Mult...

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