MULTIQUIP Whisperwatt Dca70Usi3caN Operation And Parts Manual Download

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OperatiOn and parts Manual

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

WhisperWatt™ series

MODeL Dca70Usi3caN

60hz geNeratOr

(isUzU BJ4JJ1-XYgD-02 DieseL eNgiNe)

parts List NO. M2870400304c

M2874400004

Revision #1 (09/24/13)

Summary of Contents for Whisperwatt Dca70Usi3caN

Page 1: ...EQUIPMENT AT ALL TIMES To find the latest revision of this publication visit our website at www multiquip com Whisperwatt Series MODEL dca70USI3CAN 60hz generator isuzu BJ4JJ1 XYGD 02 DIESEL ENGINE P...

Page 2: ...0USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 Fuel and chemical warning Diesel engine exhaust and some of its constituents are know to cause cancer birth defects and other reprodu...

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: ...Ammeter 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...

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: ...generator 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...

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: ...3 771 lbs 1 710 kg Weight Fuel 4 553 lbs 2 065 kg Maximum Lifting Capacity 14 050 lbs 6 370 kg Table 2 Engine Specifications Model ISUZU BJ 4JJ1XYGD 02 Tier 3 Type 4 cycle water cooled direct injectio...

Page 13: ...page 13 Dimensions Figure 1 Dimensions Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 30 10 in 790 mm F 105 1 in 2 670 mm B 30 20 in 766 mm G 68 30 in 1 735 mm...

Page 14: ...page 14 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 Installation Figure 2 Typical Generator Grounding Application...

Page 15: ...isolate 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 t...

Page 16: ...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 exciter section Whe...

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

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: ...DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 page 19 Notes...

Page 20: ...09 24 13 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 OVERC...

Page 21: ...enerator 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 the en...

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 Figure 8 120 240V...

Page 24: ...put 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 Figure 11 Connecting Loads Over Cur...

Page 25: ...wer 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 equ...

Page 26: ...tion 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 Position 1 Line Neutral Line Line 120V Line Neutral N A N A 24...

Page 27: ...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 28: ...tage Selector 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 Figu...

Page 29: ...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 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: ...WAYS 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 cabine...

Page 32: ...burns Table 12 Coolant Capacity Engine and Radiator 3 57 gal 13 5 liters Reserve Tank 2 quarts 1 9 liters Table 13 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point Boiling Point C F C...

Page 33: ...FIRST 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 po...

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

Page 35: ...e 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 indi...

Page 36: ...F 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 RESE...

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 t...

Page 38: ...posits 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: ...nufacturer 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 scre...

Page 40: ...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 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: ...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 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 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 Trailer Wiring Diagram Figure 62 Trailer Towing Vehicle Wiring Diagram...

Page 45: ...DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 page 45 Generator Wiring Diagram Figure 63 Generator Wiring Diagram...

Page 46: ...page 46 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 Engine Wiring Diagram Figure 64 Engine Wiring Diagram...

Page 47: ...DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 page 47 controller Wiring Diagram Figure 65 Engine Controller...

Page 48: ...eter 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 a...

Page 49: ...mly 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: ...TOR HOSE UPPER 1 M2310502404 RADIATOR HOSE UPPER SHORT 1 M2310502303 RADIATOR HOSE LOWER 1 8121468300 SENSOR WATER TEMP ENGINE SIDE 1 8971256001 SWITCH WARNING OVERHEAT ENGINE SIDE 1 8980274560 SENSOR...

Page 52: ...page 52 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 GENERATOR ASSY 3 2 1 12 1 11 12 9 6 7 1 10 14 13 16 17 18 21 20 21 23B 23A 23 1 9B 1 9A 1 9...

Page 53: ...0046512000 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 00...

Page 54: ...page 54 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 control box ASSY...

Page 55: ...EL ELECTRIC PARTS 1 14 0016906016 HEX HEAD BOLT 4 15 0601802218 HOLDER FUSE 1 15A 0601806671 FUSE 15A 3 16 0027103016 MACHINE SCREW 1 17 LY2DUS12VDC RELAY 2 REPLACES P N 0601827656 17A PTF08A BASE 2 R...

Page 56: ...page 56 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 control box ASSY...

Page 57: ...6 HEX HEAD BOLT 4 47 M2213602504 SWITCH COVER 1 48 0016906016 HEX HEAD BOLT 6 49 M2213602604 SWITCH COVER 1 49 1 0228800175 SEAL RUBBER 1 49 2 0228800150 SEAL RUBBER 1 49 3 0317700180 SEAL RUBBER 1 50...

Page 58: ...page 58 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 control box ASSY...

Page 59: ...24100104 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 ADAPTER 1 79 060212...

Page 60: ...page 60 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 ENGINE AND RADIATOR ASSY 1A 4 5 6 46 47 71 70 69 68 30A 17A 17B...

Page 61: ...7 HOSE BAND 4 15 M2923200124 INTER COOLER 1 16 0132004000 PLUG 3 8 1 17 0010510020 HEX HEAD BOLT 8 17A 0040010000 WASHER LOCK 8 17B 0041210000 WASHER FLAT 8 18 M2310502103 INTER COOLER HOSE 1 19 M2310...

Page 62: ...page 62 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 ENGINE AND RADIATOR ASSY continued 1A 4 5 6 46 47 71 70 69 68 30A 17A 17B...

Page 63: ...IN HOSE 1 51 0605515106 HOSE BAND 4 52 0602022581 ADAPTER 1 53 0602022561 90 ELBOW 1 54 0603306590 CONNECTOR 1 55 0603300285 LOCKNUT 1 56 0605511395 VALVE 1 57 0603306395 HOSE JOINT 1 58 0602021070 CA...

Page 64: ...L ASSY 28A 28A 28 4 5 6 4 6 5 11 11A 11B 12 12A 28 39 39A 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 CATERPILLA...

Page 65: ...1 16 M3236300004 SUPPORTER CABLE OUTLET COVER 1 17 0016906020 HEX HEAD BOLT 6 18 0601815194 TERMINAL 1 19 0027104016 MACHINE SCREW 2 20 0603306775 BLIND PLUG 2 21 0027104016 MACHINE SCREW 4 22 0601870...

Page 66: ...page 66 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 BATTERY ASSY...

Page 67: ...RKS 1 0602220199 BATTERY 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 M2346900504 BATTERY CABLE 1 6 M2346900604 BATTERY CABLE 1 7 CABLE 1 MAKE LOCALLY...

Page 68: ...page 68 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 Muffler Assy...

Page 69: ...MARKS 1 M2330101103 MUFFLER 1 2 0017112030 HEX HEAD BOLT 4 3 M2333001403 EXHAUST PIPE 1 4 M2333200404 GASKET 1 5 0017110040 HEX HEAD BOLT 4 6 M2333200304 GASKET 1 7 0017110035 HEX HEAD BOLT 4 8 M23330...

Page 70: ...page 70 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 FUEL TANK ASSY...

Page 71: ...2042515 15 8980758551 FUEL FILTER PRE 1 REPLACES P N 0602042405 15A 8980742880 ELEMENT FUEL FILTER 1 REPLACES P N 0602042516 16 8973834270 JOINT PIPE 1 REPLACES P N 0602042661 17 1096750951 JOINT BOLT...

Page 72: ...page 72 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 ENCLOSURE 1 ASSY...

Page 73: ...M2310601104 HOSE COVER 1 14 0016906020 HEX HEAD BOLT 10 15 0016906020 HEX HEAD BOLT 2 16 M2423203604 DUCT COVER 2 17 0016906020 HEX HEAD BOLT 14 18 M2310200402 INTER COOLER BRACKET 1 18A M2493600104 A...

Page 74: ...page 74 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 ENCLOSURE ASSY 1 continued...

Page 75: ...6 HEX HEAD BOLT 12 41 M2463200503 DUCT 1 41A M2493502704 ACOUSTIC SHEET 1 42 0016908020 HEX HEAD BOLT 10 43 M2463400103 DUCT COVER 1 44 0016908020 HEX HEAD BOLT 6 45 M2423203004 OVER COVER FRONT FRAME...

Page 76: ...page 76 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 ENCLOSURE 2 ASSY...

Page 77: ...15 0019208020 HEX HEAD BOLT 3 16 M2453201802 SPLASHER PANEL 1 16A M2493405204 ACOUSTIC SHEET 1 17 0019108065 HEX HEAD BOLT 4 17A 0042308000 WASHER LOCK 4 17B 0042408000 WASHER FLAT 4 18 0016910025 HE...

Page 78: ...page 78 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 RUBBER SEALS ASSY...

Page 79: ...RUBBER 8 7 0228901105 SEAL RUBBER 2 8 0228900535 SEAL RUBBER 1 9 0228900475 SEAL RUBBER 1 10 0228100530 SEAL RUBBER 1 11 0228100870 SEAL RUBBER 1 12 0228101240 SEAL RUBBER 3 13 0228100800 SEAL RUBBER...

Page 80: ...page 80 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 NAMEPLATE AND DECALS ASSY 53A 53 53A 54 54A 6A 6 53 36 30 24 30A 3A 55A 51A 55 51...

Page 81: ...16A DECAL WARNING HOT COOLANT FRENCH 2 M9031000CE 17 M9503200004 DECAL WARNING ENGINE EXHAUST ENGLISH 1 M90320000 17A DECAL WARNING ENGINE EXHAUST FRENCH 1 MQB90420000CE 18 M9503200104 DECAL DANGER EX...

Page 82: ...page 82 DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 NAMEPLATE AND DECALS ASSY 53A 53 53A 54 54A 6A 6 53 36 30 24 30A 3A 55A 51A 55 51...

Page 83: ...WHISPERWATT 2 40 M3560102204 STRIPE 2 43 M2560101303 STRIPE 70 1 44 M2560101403 STRIPE 70 1 45 M3560102504 STRIPE 2 46 0600500092 PLATE MQ POWER 2 47 0021106016 MACHINE SCREW 4 48 M9520000804 DECAL A...

Page 84: ...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 85: ...DCA70USI3can 60 hz Generator operation and parts manual rev 1 09 24 13 page 85 notes...

Page 86: ...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 2013 MULTIQUIP INC Mult...

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