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MQ Power WHISPERWATT DCA70SSIU4FC8B Operation Manual

60 hz generator (isuzu br-4jj1x diesel engine)
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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL
DCA70SSIU4FC8B
60 Hz GENERATOR
(ISUZU BR-4JJ1X DIESEL ENGINE)
INSTRUCTION MANUAL NO. M2844000104
Revision #0 (06/27/23)
To find the latest revision of this publication or
associated parts manual, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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Summary of Contents for MQ Power WHISPERWATT DCA70SSIU4FC8B

  • Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA70SSIU4FC8B 60 Hz GENERATOR (ISUZU BR-4JJ1X DIESEL ENGINE) INSTRUCTION MANUAL NO. M2844000104 Revision #0 (06/27/23) To find the latest revision of this publication or associated parts manual, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING PAGE 2 — DCA70SSIU4FC8B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/27/23)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA70SSIU4FC8B NOTICE 60 Hz Generator Specifications are subject to change without notice. Proposition 65 Warning ........... 2 Table of Contents ............. 3 Safety Decals ............4 Safety Information ..........5–10 Specifications ............11 Dimensions ............12 Installation ............13–14 General Information ..........

  • Page 4: Safety Decals

    SAFETY DECALS SAFETY DECALS NOTICE Safety decals are attached to the generator as shown in For safety decal part numbers, refer to the associated Figure 1. Keep these safety decals clean at all times. When parts manual. the safety decals become worn or damaged, contact your nearest dealer or the Multiquip Parts Department.

  • Page 5: Safety Information

    SAFETY INFORMATION Do not operate or service the generator before reading the Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all generator will be referenced with hazard symbols which times when operating this generator. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
  • Page 6 „ NEVER use accessories or attachments that are not being used. The generator should be stored in a clean, recommended by MQ Power for this generator. Damage dry location out of the reach of children and unauthorized to the generator and/or injury to the user may result.
  • Page 7 SAFETY INFORMATION ENGINE SAFETY „ Operation of the generator may create sparks that can start fi res around dry vegetation. A spark arrestor DANGER may be required. The operator should contact local fi re agencies for laws or regulations relating to fi re prevention „...
  • Page 8 „ The trailer should be adjusted to a level position at all times when towing. „ Refer to the MQ Power trailer manual for additional safety information. „ Raise and lock the trailer wheel stand in the upright position when towing.
  • Page 9 SAFETY INFORMATION ELECTRICAL SAFETY „ Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections DANGER may cause electrical shock and damage to the generator. „ NEVER touch the output terminals NOTICE during operation. Contact with the „...
  • Page 10 SAFETY INFORMATION EMISSIONS INFORMATION „ If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty NOTICE of water and contact the nearest doctor or hospital to seek medical attention. The diesel engine used in this equipment has been designed to reduce harmful levels of carbon monoxide CAUTION (CO), hydrocarbons (HC), and nitrogen oxides (NOx)

  • Page 11: Specifications

    SPECIFICATIONS Table 1. Generator Specifications Model DCA70SSIU4FC8B Type Revolving field, self-ventilated, open protected type synchronous generator Armature Connection Star with Neutral Zigzag Phase Single Standby Output 61 kW (77 kVA) 44 kW Prime Output 56 kW (70 kVA) 40 kW 3Ø...

  • Page 12: Dimensions

    DIMENSIONS 6,960 lb. (3,157 kg) Figure 2. Dimensions Table 3. Dimensions Reference Dimension Reference Dimension Letter in. (mm) Letter in. (mm) 33.95 (862) 33.86 (860) 29.52 (750) 105.12 (2,670) 38.27 (972) 71.79 (1,823) 32.36 (822) 37.40 (950) PAGE 12 — DCA70SSIU4FC8B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/27/23)

  • Page 13: Installation

    GENERATOR GROUND LUG GROUND ROD GROUND CABLE REFERENCE NEC 250 Figure 3. Typical Generator Grounding Application NOTICE Trailer-mounted generators are the sole responsibility of MQ Power. DCA70SSIU4FC8B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/27/23) — PAGE 13...
  • Page 14 INSTALLATION OUTDOOR INSTALLATION MOUNTING Install the generator in an area that is free of debris, The generator must be mounted on a solid foundation bystanders, and overhead obstructions. Make sure the (such as concrete) and set firmly on the foundation to generator is on secure, level ground so that it cannot slide isolate vibration of the generator when it is running.

  • Page 15: General Information

    Refer to • Automatic Voltage Regulator Table 2 for engine specifications. • Current Transformer In keeping with MQ Power’s policy of constantly improving its products, the specifications quoted herein are subject • Overcurrent Relay to change without prior notice.

  • Page 16: Major Components

    MAJOR COMPONENTS Table 4. Major Components Item No. Description Muffler Assembly Voltage Selector Switch Emergency Stop Switch Generator Assembly Output Terminal Panel Assembly Engine Assembly DOC/SCR Assembly DEF Tank Assembly Coolant Drain Oil Drain with Valve Fuel Tank Assembly Battery Assembly Digital Genset Controller Assembly Control Panel Assembly Main Circuit Breaker...

  • Page 17: Control Panel

    CONTROL PANEL Figure 5. Control Panel The definitions below describe the controls and functions of the control panel (Figure 5). 1. Basler DGC-2020 Digital Genset Controller — 5. Panel Light Switch — When activated, will turn on the Displays parameters (AC voltage, AC current, phase, control panel light.

  • Page 18: Basler Digital Genset Controller

    BASLER DIGITAL GENSET CONTROLLER LCD DISPLAY VOLT 60.0 HR : 3:58 DEF : 33 % 60 % 28.2 FUEL TEMP BATT Figure 6. Basler DGC-2020 The definitions below describe the controls and functions of the Basler DGC-2020 digital genset controller (Figure 6). Refer to the digital controller’s instruction manual for more information.
  • Page 19 BASLER DIGITAL GENSET CONTROLLER 2. Not In Auto Indicator — This red LED lights whenever 11. Arrow Pushbuttons — These four buttons are used the DGC-2020 is not operating in Auto mode. to navigate through the front panel display menus and to modify settings.

  • Page 20: Output Terminal Panel Familiarization

    OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The output terminal panel (Figure 8) shown below is The output terminal panel (Figure 8) is provided with the provided for the connection of electrical loads. Lift up on following: the cover to gain access to receptacles and terminal lugs.
  • Page 21 OUTPUT TERMINAL PANEL FAMILIARIZATION 120-Volt AC GFCI Receptacles CS-6369 TWIST-LOCK NOTICE RECEPTACLES It is recommended that the GFCI receptacles be tested when the generator is initially uncrated. The receptacles should then be tested daily at startup. There are two 120-volt, 20-amp GFCI (duplex NEMA 5-20R) receptacles provided on the output terminal panel.
  • Page 22 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads OVERCURRENT RELAY An overcurrent relay (Figure 12) is connected to the Loads can be connected to the generator via the output terminal panel, convenience receptacles, or optional main circuit breaker. In the event of an overload, both the cam-loks (Figure 11).

  • Page 23: Load Application

    LOAD APPLICATION SINGLE-PHASE LOAD THREE-PHASE LOAD Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase and equipment to ensure the wattage, amperage, power, use the following equation: frequency, and voltage requirements are satisfactorily VOLTAGE ×...

  • Page 24: Powerbalance

    POWERBALANCE ® PowerBalance (Figure 13) is an optional load management ® solution that helps protect the engine generator from problems resulting from sustained low-load operations (defined as less than 30% of the generator full-load rating). POWERBALANCE ® ASSEMBLY Figure 13. PowerBalance ®...

  • Page 25: Generator Outputs

    GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES MAXIMUM AMPS Table 8 shows the maximum amps the generator can A wide range of voltages (Table 7) is available for many different applications. provide. DO NOT exceed the maximum amps as listed. Table 7. Voltages Available Table 8.

  • Page 26: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES 3. Turn the voltage regulator (Figure 18) clockwise to increase voltage output, counterclockwise to Various output voltages can be obtained using the UVWO decrease voltage output. Use the voltage regulator output terminal lugs. The voltages at the terminals are whenever fine tuning of the output voltage is required.
  • Page 27 OUTPUT TERMINAL PANEL CONNECTIONS 3-Phase 480/277-Volt Single-Phase 240/120-Volt UVWO Terminal Output Voltages UVWO Terminal Output Voltages 1. Place the Voltage Selector switch in the 3-phase 1. Place the Voltage Selector switch in the 1-phase 480/277-volt position as shown in Figure 20. 240/120-volt position as shown in Figure 22.

  • Page 28: Inspection/Setup

    INSPECTION/SETUP ENGINE OIL CHECK NOTICE 1. To check the engine oil level, place the generator on When adding engine oil, DO NOT overfill (Figure 25B). secure, level ground with the engine stopped. 2. Remove the dipstick from its holder (Figure 24) and wipe it clean.
  • Page 29 INSPECTION/SETUP FUEL CHECK Refueling Procedure DANGER WARNING Fuel spillage on a hot engine can cause a Diesel fuel and its vapors are dangerous fire or explosion. If fuel spillage occurs, to your health and the surrounding wipe up the spilled fuel completely to prevent environment.
  • Page 30 INSPECTION/SETUP DEF Refilling (Continuous Operation) 3. NEVER overfill the fuel tank. When refueling, DO NOT wait for fuel to rise inside the filler neck It is recommended to shut down the engine prior to (Figure 30). Leave room for fuel expansion. Fuel refilling the DEF tank.
  • Page 31 INSPECTION/SETUP Cleaning The Radiator 2. Verify that the coolant level in the coolant reserve tank is between the FULL and LOW markings as The engine may overheat if the radiator cooling fins shown in Figure 33. (Figure 34) become overloaded with dust or debris. Periodically clean the radiator fins with compressed air.
  • Page 32 INSPECTION/SETUP FAN BELT TENSION The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68°F). If the specific gravity A slack fan belt may contribute to overheating, or to should fall to 1.245 or lower, it indicates that the battery is insufficient charging of the battery.
  • Page 33 INSPECTION/SETUP NOTICE Inadequate battery connections may cause poor starting of the generator or other malfunctions. ALTERNATOR The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting in alternator failure.

  • Page 34: Generator Start-Up Procedure (Manual)

    GENERATOR START - UP PROCEDURE ( MANUAL ) BEFORE STARTING 6. Close all engine enclosure doors (Figure 40). CAUTION The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel. WARNING CORRECT INCORRECT Figure 40.
  • Page 35 GENERATOR START - UP PROCEDURE ( MANUAL ) 8. The controller display will indicate the coolant NOTICE temperature (Figure 42D). Under normal operating Once the engine has warmed up, engine speed will conditions the coolant temperature should be automatically increase to 1,800 rpm. 167°–194°F (75°–90°C).

  • Page 36: Generator Start-Up Procedure (Auto Mode)

    GENERATOR START - UP PROCEDURE ( AUTO MODE ) STARTING (AUTO MODE) When starting the generator in Auto mode use the manual start-up procedure except where noted (see below). DANGER 1. Perform steps 1 through 6 in Before Starting found in Before connecting this generator to any the Generator Start-Up Procedure (Manual) section.

  • Page 37: Generator Shutdown Procedures

    GENERATOR SHUTDOWN PROCEDURES NORMAL SHUTDOWN PROCEDURE (MANUAL) EMERGENCY SHUTDOWN PROCEDURE 1. Place the load’s ON/OFF switch in the OFF position. 1. To stop the engine in the event of an emergency, push the Emergency Stop switch (Figure 47). This switch is 2.

  • Page 38: Maintenance

    MAINTENANCE Every Every 250 Every 500 Table 13. Inspection/Maintenance Daily 1,000 Other Hours Hours Hours Check Engine Oil and Coolant Levels Check Fuel Filter/Water Separator Bowl Check Battery Fluid Level Check Air Cleaner Check for Leaks Visual Walk Around Inspection Clean Air Cleaner Element Replace Engine Oil and Oil Filter* Replace Fuel Filter Elements...
  • Page 39 MAINTENANCE GENERAL INSPECTION Primary And Secondary Air Cleaner Elements Prior to each use, the generator should be cleaned and Every 250 hours: Remove the air cleaner elements and inspected for deficiencies. Check for loose, missing, or clean them with a light spray of compressed air. damaged nuts, bolts, or other fasteners.
  • Page 40 MAINTENANCE Air Cleaner Restriction Indicator Draining The Fuel Filter The air cleaner is equipped with a restriction indicator 1. Loosen the air bleeder plug (Figure 50) on the fuel (Figure 49). As the air cleaner element becomes clogged, filter body. air intake restriction increases and the indicator signal shows RED, indicating that the element needs to be 2.
  • Page 41 MAINTENANCE Fuel Filter Element Replacement ELECTROMAGNETIC FUEL PUMP (500 HOURS) 1. Using a filter wrench, remove the element case from The filter inside the electromagnetic fuel pump (Figure 52) the fuel filter body (Figure 51). is either a paper type or steel mesh type depending on the fuel pump type.
  • Page 42 MAINTENANCE DRAINING THE CONTAINMENT TANK 1. This generator is equipped with an environmental containment tank. Inspect this tank regularly. 2. If the containment tank becomes full with fluids, remove the containment tank drain plug (Figure 53) and allow the fluids to drain into a suitable container. FUEL TANK DRAIN PLUG Figure 54.
  • Page 43 MAINTENANCE FUEL TANK INSPECTION ENGINE OIL FILTER REPLACEMENT In addition to cleaning the fuel tank, the following NOTICE components should be inspected for wear: Filter head appearance may vary. „ Rubber Suspension — Look for signs of wear or deformity due to contact with oil. Replace the rubber 1.
  • Page 44 MAINTENANCE 5. Fill the engine crankcase with high-quality detergent 2. Open the cabinet door and remove the coolant drain oil classified “For Service CI-4.” Fill to the upper limit bolt and O-ring (Figure 59), then allow the coolant to of the dipstick. DO NOT overfill. Refer to Table 2 for drain into a suitable container.
  • Page 45 MAINTENANCE RADIATOR CLEANING The radiator (Figure 60) should be sprayed (cleaned) with DRIVE BELT a high-pressure washer when excessive amounts of dirt and debris have accumulated on the cooling fins or tube. When using a high-pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the fins and tube.
  • Page 46 MAINTENANCE TESTING THE GFCI RECEPTACLE 5. Press the RESET button (Figure 65) to restore power to the GFCI receptacle and verify that the status LED NOTICE is ON (GREEN). The GFCI receptacle is designed to interrupt power when a ground fault exists to prevent injuries and shock hazards.
  • Page 47 MAINTENANCE ENGINE BLOCK HEATER AND When using the generator in hot climates there is no reason to apply power to the engine block heater. However, if the OPTIONAL INTERNAL BATTERY CHARGER generator will be used in cold climates it is always a good 120 VAC INPUT RECEPTACLES idea to apply power to the heater at all times.
  • Page 48 MAINTENANCE EMISSION CONTROL PREVENTIVE MAINTENANCE PROGRAMS The emission control system employed with this diesel Most challenging to a rental organization is the fact that a engine consists of a diesel oxidation catalyst (DOC) customer’s power assumptions may not meet the minimum and a selective catalytic reduction (SCR) catalyst load requirements of the power equipment selected.
  • Page 49 MAINTENANCE SELECTIVE CATALYTIC REDUCTION (SCR) Refer to Table 14 for digital controller messages displayed during SCR Purge operation. Diesel engines can be run with a lean burn air-to-fuel Table 14. SCR Purge Controller Messages ratio, to ensure the full combustion of soot and to prevent the exhaust of unburnt fuel.
  • Page 50 MAINTENANCE Automatic Purge Operation While a Forced Purge operation is in progress, the Alarm lamp will begin flashing (red) and the message “SCR The purging operation is automatically performed every Forced Purge” will appear on the controller screen 30 hours. The Alarm lamp will begin flashing (red) and the (Figure 71).
  • Page 51 MAINTENANCE DIESEL EXHAUST FLUID (DEF) The amount of fluid in the DEF tank will be displayed on the digital controller during operation (Figure 73). The Diesel Exhaust Fluid (DEF) indicator (Figure 72) will be displayed on the digital controller during either of the following operating conditions: „...
  • Page 52 MAINTENANCE INDUCEMENT NOTICE When the system senses improper usage such as no Replace the DEF filter (located in the urea SCR system supply of DEF, use of poor quality DEF, problems with supply module) every 1,000 hours of operation. Refer DEF dosing, or disconnection of sensors, a warning will be to the Replacement of DEF Filter section in the Isuzu issued before the situation becomes critical.
  • Page 53 MAINTENANCE ESCAPE MODE 6. When Escape mode is enabled, the Alarm lamp will flash and the message “Escape Mode PA” will appear When emergency shutdown occurs, inspection and repair on the Pre-Alarm screen. should generally be performed promptly. However, if 7.
  • Page 54 MAINTENANCE Escape Mode Deactivation 1. Press the Off button on the digital controller (Figure 76) to stop the engine. The engine will stop after a 1-minute cool-down process. Figure 76. Digital Controller (OFF Button) 2. After the engine has stopped completely, place the Control Power switch in the OFF position (Figure 77).

  • Page 55: Troubleshooting (Diagnostics)

    TROUBLESHOOTING ( DIAGNOSTICS ) DIAGNOSTIC MODE The digital controller can be placed in Diagnostic mode which will keep the key switch on for service tool purposes. To place the unit in Diagnostic mode, the engine must be turned OFF. 1. Press and hold the Alarm Silence button and the Lamp Test button (Figure 78) simultaneously for 5 seconds.
  • Page 56 Allow a sufficient cooling period, then inspect the unit and repair the problem before restarting operation. If necessary, contact your nearest MQ Power dealer for additional technical support. When the unit is ready to restart, press the Off button on the digital controller.
  • Page 57 TROUBLESHOOTING ( DIAGNOSTICS ) Table 17. Automatic Engine Shutdown System Operating Circuit Breaker Engine Digital Controller Operating Condition/ Parameter OFF LED Shutdown LED Display Message Set Point Under Voltage — — 27-1 UndVolt Prealarm When under voltage occurs Under Voltage 27-2 UndVolt Alarm When under voltage occurs Over Voltage...

  • Page 58: Troubleshooting (Generator)

    TROUBLESHOOTING ( GENERATOR ) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 shown below for diagnosis of the generator. If the problem cannot be remedied, consult our company’s business office or service plant.

  • Page 59: Generator Wiring Diagram (M2814000603)

    GENERATOR WIRING DIAGRAM ( M2814000603 ) DCA70SSIU4FC8B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/27/23) — PAGE 59...

  • Page 60: Engine Wiring Diagram (M2814100903)

    ENGINE WIRING DIAGRAM ( M2814100903 ) PAGE 60 — DCA70SSIU4FC8B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/27/23)

  • Page 61: Controller Wiring Diagram (A) (M2814101003)

    CONTROLLER WIRING DIAGRAM ( A ) ( M2814101003 ) DCA70SSIU4FC8B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/27/23) — PAGE 61...

  • Page 62: Controller Wiring Diagram (B) (M2814101103)

    CONTROLLER WIRING DIAGRAM ( B ) ( M2814101103 ) PAGE 62 — DCA70SSIU4FC8B 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/27/23)

  • Page 63: Battery Charger Wiring Diagram (Option)

    BATTERY CHARGER WIRING DIAGRAM ( OPTION ) BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG. GROUND (G) TO CHASSIS GROUND BATTERY CHARGER GREEN 16 AWG. TO STARTER “B” TERMINAL RED 16 AWG. 120 VAC INPUT, INSERT EXTERNAL POWER CORD HERE.
  • Page 64 Multiquip Inc. reserves the right to discontinue or change specifi cations, design or the information published in this publication at any time without notice and without incurring any obligations. Manufactured for MQ Power Inc. DENYO MANUFACTURING CORP.

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