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