THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES
PARTS LIST NO. M1870400004
OPERATION AND PARTS MANUAL
MODEL DCA45USI2
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
REPORTING SAFETY DEFECTS
Inspection/Setup
TABLE OF CONTENTS
How To Read AC Ammeter/AC Voltmeter Gauges
Generator Assembly
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PARTS ORDERING PROCEDURES
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Choose from three easy options
SAFETY SYMBOLS
SAFETY INFORMATION
SAFETY MESSAGES
DANGER
fire extinguisher
GENERAL SAFETY
GENERATOR SAFETY
first aid kit
DANGER
ENGINE SAFETY
SAFETY INFORMATION
NEVER operate the engine with heat shields or guards removed
SAFETY INFORMATION
FUEL SAFETY
TOWING SAFETY
DANGER
Power Cord/Cable Safety
ELECTRICAL SAFETY
Grounding Safety
SAFETY INFORMATION
SAFETY INFORMATION
BATTERY SAFETY
ENVIRONMENTAL SAFETY
DANGER
Model
SPECIFICATIONS
Table 1. Generator Specifications
Phase
Figure 1. Dimensions
DIMENSIONS
Table 3. Dimensions
Dimension in. mm
INSTALLATION
Figure 2. Typical Generator Grounding Application
MOUNTING
OUTDOOR INSTALLATION
INDOOR INSTALLATION
GENERATOR GROUNDING
ENGINE OPERATING PANEL
GENERAL INFORMATION
GENERATOR
GENERATOR CONTROL PANEL
Table 4. Generator Major Components
MAJOR COMPONENTS
DESCRIPTION
Figure 3. Major Components
Figure 4. Generator Control Panel
GENERATOR CONTROL PANEL
fl owing from the U,V, and W Output Terminal Lugs to the load
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HIGH COOLANT TEMPERATURE
ENGINE OPERATING PANEL
OFF/RESET
Figure 5. Engine Operating Panel
ENGINE OPERATING PANEL
6. Fuel Gauge - Indicates amount of diesel fuel available
OUTPUT TERMINAL PANEL
OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL FAMILIARIZATION
OUTPUT TERMINAL PANEL FAMILIARIZATION
Removing the Plastic Face Plate Hard Wire Hookup Panel
120 VAC GFCI Receptacles
Figure 7. G.F.C.I. Receptacle
Figure 11. Connecting Loads
Connecting Loads
Over Current Relay
OUTPUT TERMINAL PANEL FAMILIARIZATION
Table 5. Power Factor By Load
SINGLE PHASE LOAD
THREE PHASE LOAD
LOAD APPLICATION
GENERATOR OUTPUTS
Voltage Selector Switch
Voltage Selector Switch Locking Button
GENERATOR OUTPUT VOLTAGES
AC Voltmeter Gauge Reading
HOW TO READ THE AC AMMETER AND AC VOLTAGE GAUGES
GENERATOR OUTPUTS/GAUGE READING
AC Ammeter Gauge Reading
3Ø-240/139 UVWO Terminal Output Voltages
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO TERMINAL OUTPUT VOLTAGES
3Ø-208V/1Ø-120V UVWO Terminal Output Voltages
Figure 24. Voltage Selector Switch 3Ø-480/277V Position
3Ø-480/277V UVWO Terminal Output Voltages
1Ø-240/120V UVWO Terminal Output Voltages
Figure 26. Voltage Selector Switch 1Ø-240/120V Position
LUBRICATION OIL
INSPECTION/SETUP
CIRCUIT BREAKERS
FUEL CHECK
INSPECTION/SETUP
Refueling Procedure
ONLY use #2 diesel fuel when refueling
Figure 30. Only Fill on Level Ground
COOLANT ANTIFREEZE/SUMMER COOLANT/ WATER
CLEANING THE RADIATOR
AIR CLEANER
Operation in
WIRING
BATTERY
Battery Cable Installation
ALTERNATOR
STARTING
GENERATOR START-UP PROCEDURE
BEFORE STARTING
STARTING MANUAL
GENERATOR START-UP PROCEDURE
the problem. If the engine is running smoothly, place the engine speed switch Figure 42 in the HIGH up position
EMERGENCY SHUTDOWN PROCEDURE
GENERATOR SHUT-DOWN PROCEDURES
NORMAL SHUTDOWN PROCEDURE
AUTOMATIC SHUT-DOWN SYSTEM
GENERAL INSPECTION
MAINTENANCE
Air Cleaner with Dust Indicator
AIR CLEANER
Removing Water from the Fuel Tank
Cleaning Inside the Fuel Tank
FUEL ADDITION
FUEL TANK INSPECTION
Replacing Oil Filter
RADIATOR CLEANING
CHECK OIL LEVEL
FLUSHING OUT RADIATOR AND REPLACING COOLANT
TRAILER MAINTENANCE
TRAILER MAINTENANCE
Hydraulic Surge Brakes
Brake Adjustment
BRAKES
Actuator
Suspension
TIRES/WHEELS/LUG NUTS
Tire Wear/Inflation
TRAILER MAINTENANCE
Figure 61. Wheel Lug Nuts Tightening Sequence
Lug Nut Torque Requirements
TRAILER MAINTENANCE
Table 18. Tire Torque Requirements
TRAILER WIRING DIAGRAM
Figure 62. Trailer/Towing Vehicle Wiring Diagram
GENERATOR WIRING DIAGRAM
Figure 63. Generator Wiring Diagram
ENGINE WIRING DIAGRAM
Figure 64. Engine Wiring Diagram
CONTROLLER WIRING DIAGRAM
Figure 65. Engine Controller
Symptom
TROUBLESHOOTING GENERATOR
Table 19. Generator Troubleshooting
Possible Problem
TROUBLESHOOTING DIAGNOSTIC LAMP
METHOD OF OPERATION
NO. Column
SAMPLE PARTS LIST
EXPLANATION OF CODE IN REMARKS COLUMN
PART NO. Column
1 to 3 units
SUGGESTED SPARE PARTS
DCA45USI2 WHISPERWATT GENERATOR WITH ISUZU BU-4JJ1T DIESEL ENGINE
GENERATOR ASSY
GENERATOR ASSY
PART NAME
QTY. REMARKS
CONTROL BOX ASSY
PART NAME
REMARKS
CONTROL BOX ASSY
CURRENT TRANSFORMER,150/5A
CONTROL BOX ASSY
REMARKS
CONTROL BOX ASSY
PART NAME
CHANGE-OVER SW, VOLTMETER
CONTROL BOX ASSY
CONTROL BOX ASSY
WIRE HARNESS, GENERATOR
WIRE HARNESS, CONTROLLER
PART NAME
ENGINE AND RADIATOR ASSY
REMARKS
ENGINE AND RADIATOR ASSY
PART NAME
FAN BELT....................................................1 ................REPLACES P/N
ENGINE AND RADIATOR ASSY. CONTINUED
ENGINE AND RADIATOR ASSY. CONTINUED
SWITCH, WARNING, OVERHEAT
SENSOR, WATER TEMPERATURE
PART NAME
OUTPUT TERMINAL ASSY
RECEPTACLE CS6369, 250V, 50A
OUTPUT TERMINAL ASSY
PART NAME
RECEPTACLE GF-530EM, 125V 20A
BATTERY ASSY
PART NAME
BATTERY ASSY
BATTERY CABLE
REMARKS
MUFFLER ASSY
REMARKS
MUFFLER ASSY
PART NAME
REPLACES P/N
FUEL TANK ASSY
REMARKS
FUEL TANK ASSY
PART NAME
ENCLOSURE ASSY
REMARKS
ENCLOSURE ASSY
PART NAME
ENCLOSURE ASSY. CONTINUED
PART NAME
FUEL LEAK DETECTED SWITCH
ENCLOSURE ASSY. CONTINUED
RUBBER SEALS ASSY
REMARKS
RUBBER SEALS ASSY
PART NAME
NAMEPLATE AND DECALS ASSY
M92010020A
NAMEPLATE AND DECALS ASSY
PART NAME
PAYMENT TERMS
TERMS AND CONDITIONS OF SALE - PARTS
SPECIAL EXPEDITING SERVICE
FREIGHT POLICY
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Service Department
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