MULTIQUIP WHISPERWATT DCA70SSIU2 Operation And Parts Manual Download

Page: 67 / 84

DCA70SSIU2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (05/29/09) — PAGE 67

BATTERY ASSY.

NO.

PART NO.

PART NAME

QTY.

REMARKS

1 0602220199

BATTERY

2 M9310500014 BATTERY

SHEET

3 M9103000304 BATTERY

BAND

0602220920

BATTERY BOLT SET

5 0040006000

WASHER,

LOCK

6 M2346900704 BATTERY

CABLE

7 M2346900604 BATTERY

CABLE

.........................................................1

................MAKE

LOCALLY

0017112025

HEX HEAD BOLT

9A 0040512000

TOOTHED

WASHER

0016910025

HEX HEAD BOLT

10A 0040510000

TOOTHED

WASHER

Summary of Contents for WHISPERWATT DCA70SSIU2

Page 1: ...L TIMES To find the latest revision of this publication visit our website at www mqpower com Revision 0 05 29 09 OPERATION AND PARTS MANUAL WHISPERWATT SERIES MODEL DCA70SSIU2 60HZ GENERATOR ISUZU BJ...

Page 2: ...PAGE 2 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 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: ...ter AC Voltmeter Gauges 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...

Page 5: ...uip website N View Parts Diagrams N Order Parts N 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 interne...

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: ...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: ...put 4 8 Kw 2 4 kW x 2 Weight No Fuel 2 701 lbs 1 225 kg Weight Fuel 3 035 lbs 1 376 kg Engine Specifications Table 2 Model ISUZU BJ4JJ1X Tier 3 Type 4 cycle water cooled direct injection turbo charged...

Page 13: ...AGE 13 DIMENSIONS Dimensions Figure 1 Dimensions Table 3 Reference Letter Dimension in mm Reference Letter Dimension in mm A 30 31 in 770 mm F 94 49 in 2 400 mm B 30 50 in 775 mm G 55 12 in 1 400 mm C...

Page 14: ...PAGE 14 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 INSTALLATION Typical Generator Grounding Application Figure 2...

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: ...m 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 a...

Page 17: ...ajor Components Figure 3 Generator Major Components Table 4 ITEM NO DESCRIPTION 1 Muffler Assembly 2 Engine Assembly 3 Enclosure Assembly 4 Generator Assembly 5 Output Terminal Assembly 6 Battery Asse...

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

Page 19: ...DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 PAGE 19 NOTES...

Page 20: ...05 29 09 ENGINE OPERATING PANEL Engine Operating Panel Figure 5 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 OVERC...

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: ...enerator 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 F...

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 120 240V Twist Lock...

Page 24: ...ut terminals from overload a 3 pole 175A 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 Curr...

Page 25: ...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 equipment...

Page 26: ...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 provi...

Page 27: ...tch 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 reading...

Page 28: ...tch 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 clo...

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

Page 32: ...urns Coolant Capacity Table 12 Engine and Radiator 3 09 gal 11 7 liters Reserve Tank 2 quarts 1 9 liters Anti Freeze OperatingTemperatures Table 13 Vol Anti Freeze Freezing Point Boiling Point C F C F...

Page 33: ...al 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...

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

Page 35: ...ure 45 will display 7 the generator s output in VOLTS Frequency Meter Figure 45 If the voltage is not within the specified tolerance use 8 the voltage adjustment control knob Figure 46 to increase or...

Page 36: ...the generator 6 Inspect entire generator for any damage or loosening 7 of components that may have occurred during operation EMERGENCY SHUTDOWN PROCEDURE Place the 1 MPEC Control Switch Figure 55 in t...

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 Fuel Tank Cleaning Figure 57 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 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 and...

Page 41: ...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 kink...

Page 42: ...th 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 manufacturer...

Page 43: ...nd 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 al...

Page 44: ...PAGE 44 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 TRAILER WIRING DIAGRAM Trailer Towing Vehicle Wiring Diagram Figure 62...

Page 45: ...DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 PAGE 45 GENERATOR WIRING DIAGRAM Generator Wiring Diagram Figure 63...

Page 46: ...PAGE 46 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 ENGINE WIRING DIAGRAM Engine Wiring Diagram Figure 64...

Page 47: ...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 48: ...ly 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 Th...

Page 49: ...DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 PAGE 49 NOTES...

Page 50: ...es 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 QT...

Page 51: ...TOR HOSE LOWER 1 8121468300 SENSOR WATER TEMP ENGINE SIDE 1 8971256001 SWITCH WARNING OVERHEAT ENGINE SIDE 1 8980274560 SENSOR OIL PRESSURE ENGINE SIDE 1 1096300850 GASKET SENSOR OIL PRESSURE ENGINE S...

Page 52: ...PAGE 52 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 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 B5130000303 STATOR ASSY 1 4 1 0845041904 GROMMET 2 5 B3137000803 FIELD ASSY EXCITER 1 6 0016008060...

Page 54: ...PAGE 54 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 CONTROL BOX ASSY...

Page 55: ...016906016 HEX HEAD BOLT 4 15 0601802218 HOLDER FUSE 1 15A 0601806671 FUSE 15A 3 16 0027103020 MACHINE SCREW 1 17 LY20DC12V RELAY 2 REPLACES P N 0601827656 17A PTF08A BASE 2 REPLACES P N 0601823109 17B...

Page 56: ...PAGE 56 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 CONTROL BOX ASSY...

Page 57: ...T 4 46 0016906016 HEX HEAD BOLT 4 47 M2213602804 SWITCH COVER 1 48 0016906016 HEX HEAD BOLT 6 49 M2213602904 SWITCH COVER 1 49 1 0228800165 SEAL RUBBER 1 49 2 0228800115 SEAL RUBBER 1 49 3 0317700180...

Page 58: ...PAGE 58 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 CONTROL BOX ASSY...

Page 59: ...SPEED 1 72 M1224100104 STOPPER 1 73 0027105010 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 ADAP...

Page 60: ...PAGE 60 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 ENGINE AND RADIATOR ASSY...

Page 61: ...0124 INTER COOLER 1 15 0132004000 PLUG 3 8 1 16 0010510020 HEX HEAD BOLT 8 16A 0040010000 WASHER LOCK 8 16B 0041210000 WASHER FLAT 8 17 M2310501903 INTER COOLER HOSE 1 18 M2310501803 INTER COOLER HOSE...

Page 62: ...PAGE 62 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 ENGINE AND RADIATOR ASSY CONTINUED...

Page 63: ...285 LOCKNUT 1 46 0605511395 VALVE 1 47 0603306395 HOSE JOINT 1 48 0602021050 CAP 1 49 0269200500 DRAIN HOSE 1 50 M9300000103 RESERVE TANK 1 51 M9300100003 CAP RESERVE TANK 1 52 0199100500 HOSE 1 53 01...

Page 64: ...0 05 29 09 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: ...G RING 2 14 0016906016 HEX HEAD BOLT 4 15 M3236400004 CABLE OUTLET COVER 1 16 M3236300004 SUPPORTER CABLE OUTLET COVER 1 17 0016906020 HEX HEAD BOLT 6 18 0601815194 TERMINAL 1 19 0027104016 MACHINE SC...

Page 66: ...PAGE 66 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 BATTERY ASSY...

Page 67: ...9 BATTERY 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 WASHER LOCK 2 6 M2346900704 BATTERY CABLE 1 7 M2346900604 BATTERY CABLE 1 8 CABLE 1...

Page 68: ...PAGE 68 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 MUFFLER ASSY...

Page 69: ...M2330101203 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M2333001503 EXHAUST PIPE 1 4 8943690210 GASKET 1 REPLACES P N 0602320101 5 M2333200504 GASKET 1 6 0039308000 HEX NUT 6 7 0016908040 HEX HEAD BOLT...

Page 70: ...PAGE 70 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 FUEL TANK ASSY...

Page 71: ...80139861 FUEL FILTER MAIN 1 REPLACES P N 0602042426 18A 8980088400 ELEMENT FUEL FILTER MAIN 1 REPLACES P N 0602042515 19 8980758550 FUEL FILTER PRE 1 REPLACES P N 0602042405 19A 8980758540 ELEMENT FUE...

Page 72: ...PAGE 72 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 ENCLOSURE ASSY...

Page 73: ...INTER COOLER 1 13 0017110020 HEX HEAD BOLT 4 14 M2310200504 BRACKET INNER COOLER 2 15 0016908020 HEX HEAD BOLT 8 16 M2310302803 FAN SHROUD 1 17 M2310302903 FAN SHROUD 1 18 0016908020 HEX HEAD BOLT 6...

Page 74: ...PAGE 74 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 ENCLOSURE ASSY CONTINUED...

Page 75: ...0042308000 WASHER LOCK 4 48B 0042408000 WASHER FLAT 4 49 0016908020 HEX HEAD BOLT 2 50 M2453003003 SIDE DOOR 1 50A M2493409404 ACOUSTIC SHEET 1 51 M2453003103 SIDE DOOR 1 51A M2493409604 ACOUSTIC SHEE...

Page 76: ...PAGE 76 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 ENCLOSURE ASSY CONTINUED...

Page 77: ...PPER 8 67 0027208025 MACHINE SCREW 8 68 M2453700204 DOOR BRACKET 1 69 M2453700304 DOOR BRACKET 2 70 M2453700404 DOOR BRACKET 1 71 M2453700504 DOOR BRACKET 1 72 0019206015 HEX HEAD BOLT 13 73 M93100000...

Page 78: ...PAGE 78 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 RUBBER SEALS ASSY...

Page 79: ...0229401120 SEAL RUBBER 3 5 0229400375 SEAL RUBBER 1 6 0228800680 SEAL RUBBER 1 7 0229400440 SEAL RUBBER 1 8 0228901060 SEAL RUBBER 1 9 0229200900 SEAL RUBBER 2 10 0229200840 SEAL RUBBER 1 11 022880077...

Page 80: ...PAGE 80 DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 NAMEPLATE AND DECALS ASSY...

Page 81: ...03200004 DECAL WARNING 1 M90320000 19 M9503200104 DECAL DANGER 1 M90320010 20 M9510000104 DECAL DOCUMENT BOX 1 M91000010 21 M9510100004 DECAL CAUTION 1 M91010000 22 M9510100403 DECAL CAUTION 1 M910100...

Page 82: ...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 83: ...DCA70SSIU2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 05 29 09 PAGE 83 NOTES...

Page 84: ...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 a...

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