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