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MQ Power WHISPERWATT Series Operation Manual

60hz generator (isuzu br-4jj1x diesel engine)
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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL DCA70SSIU4F
60Hz GENERATOR
(ISUZU BR-4JJ1X DIESEL ENGINE)
Revision #9 (09/19/22)
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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  • Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA70SSIU4F 60Hz GENERATOR (ISUZU BR-4JJ1X DIESEL ENGINE) Revision #9 (09/19/22) 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 — DCA70SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #9 (09/19/22)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA70SSIU4F 60 Hz Generator Proposition 65 Warning ........... 2 Table of Contents ............. 3 Safety Decals ............4 Safety Information ..........5–10 Specifications ............11 Dimensions ............12 Installation ............14–15 General Information ..........16 Major Components ..........17 Engine Control Unit (ECU) ........

  • 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 DCA70SSIU4F 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, dry location out of the reach of children and unauthorized recommended by MQ Power for this generator. Damage to the generator and/or injury to the user may result. personnel.
  • 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 DCA70SSIU4F Type Revolving field, self-ventilated, protected type synchronous generator Armature Connection Star with Neutral Zigzag Phase 3Ø 1Ø Standby Output 62 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 in. (mm) Reference Letter Dimension in. (mm) Letter 33.86 (860) 33.78 (858) 29.45 (748) 105.12 (2,670) 38.19 (970) 68.30 (1,735) 32.28 (820) 37.40 (950) PAGE 12 — DCA70SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #9 (09/19/22)
  • Page 13 NOTES DCA70SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #9 (09/19/22) — PAGE 13...

  • Page 14: Installation

    M I N 2 . 4 T . / REFERENCE NEC 250 Figure 3. Typical Generator Grounding Application NOTICE Trailer-mounted generators are the sole responsibility of MQ Power. PAGE 14 — DCA70SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #9 (09/19/22)
  • Page 15 INSTALLATION OUTDOOR INSTALLATION GENERATOR GROUNDING NOTICE Install the generator in an area that is free of debris, bystanders, and overhead obstructions. Make sure the The Occupational Safety and Health Administration generator is on secure, level ground so that it cannot slide (OSHA) and the National Electrical Code (NEC) or shift around.

  • Page 16: General Information

    „ Frequency Meter (Hz) Reference Table 2 for engine specifications. „ AC Ammeter (Amps) In keeping with MQ Power’s policy of constantly improving „ AC Voltmeter (Volts) its products, the specifications quoted herein are subject to „ Ammeter Change-Over Switch „...

  • Page 17: Major Components

    MAJOR COMPONENTS Table 4. Generator Major Components ITEM NO. DESCRIPTION DOC/SCR Assembly DEF Tank Assembly Coolant Drain Plug Oil Drain With Valve Fuel Tank Assembly Battery Assembly Air Filter Assembly °F VOLTS INCREASE DECREASE OIL PRESS WATER TEMP BATTERY ½ RPMX10 Voltage Selector Switch Assembly FUEL...

  • Page 18: Engine Control Unit (Ecu)

    ENGINE CONTROL UNIT (ECU) Series 800 Controller 5 5 0 0 1 1 8 8 0 0 1 1 8 8 2 2 5 5 7 7 5 5 1 1 4 4 0 0 2 2 2 2 0 0 1 1 2 2 2 2 4 4 Engine Started...

  • Page 19: Engine/Generator Control Panel

    ENGINE/GENERATOR CONTROL PANEL RPMX10 °F INCREASE DECREASE OIL PRESS WATER TEMP SPEED ＥＣＵ RPMX10 VOLTS Integrated Gauge Panel °F Check ½ ½ Check Engine °F °F Purge Refill DEF Exhaust FUEL System Error Fuel OIL PRESS SPEED WATER TEMP ＥＣＵ VOLTS Integrated Gauge Panel Check...

  • 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 located on the right-hand side (left from the control panel) the following: of the generator.
  • Page 21 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles Each auxiliary receptacle is protected by a 50-amp circuit breaker. These breakers are located directly above the NOTICE GFCI receptacles. Remember the load output (current) on It is recommended that the GFCI receptacles be tested both receptacles is dependent on the load requirements of when the generator is initially uncrated.
  • Page 22 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Overcurrent Relay An overcurrent relay (Figure 14) is connected to the main Loads can be connected to the generator by various methods, output terminal lugs, camlocks or the convenience circuit breaker. In the event of an overload, both the circuit receptacles (Figure 13).

  • 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, frequency, power use the following equation: and voltage requirements are satisfactorily supplied by the VOLTAGE ×...

  • Page 24: Powerbalance

    POWERBALANCE™ PowerBalance™ (Figure 15) is an optional load PowerBalance™ continuously monitors engine load by management solution that helps protect the engine generator sensing the engine exhaust temperature. from problems resulting from sustained low-load operations (defined as less than 30% of the generator full-load rating). 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 are available to supply voltage for many different applications. Voltages are selected by using provide. DO NOT exceed the maximum amps as listed. the voltage selector switch (Figure 16).

  • Page 26: Generator Outputs/Gauge Reading

    GENERATOR OUTPUTS/GAUGE READING HOW TO READ THE AC AMMETER AC Ammeter Gauge Reading AND AC VOLTMETER GAUGES Place the AC Ammeter Change-Over Switch (Figure 20) in the U position and observe the current reading (load The AC ammeter and AC voltmeter gauges are controlled drain) on the U terminal as indicated on the AC Ammeter by the AC ammeter and AC voltmeter change-over switches.

  • Page 27: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES 3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to Various output voltages can be obtained using the UVWO decrease voltage output. Use the voltage regulator output terminal lugs.
  • Page 28 OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480/277V UVWO Terminal Output Voltages 1Ø-240/120V UVWO Terminal Output Voltages 1. Place the voltage selector switch in the 3Ø 480/277 1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 26. position as shown in Figure 28.

  • Page 29: Inspection/Setup

    INSPECTION/SETUP ENGINE OIL CHECK 5. If the engine oil level is low (Figure 31C), remove the oil filler cap (Figure 32) and fill to a safe operating level NOTICE (max) as indicated by the dipstick (Figure 31A). This Isuzu engine is equipped with a low oil shutdown NOTICE capability.
  • Page 30 INSPECTION/SETUP FUEL CHECK REFUELING PROCEDURE: WARNING DANGER Diesel fuel and its vapors are dangerous Fuel spillage on a hot engine can cause a to your health and the surrounding fire or explosion. If fuel spillage occurs, environment. Avoid skin contact and/or wipe up the spilled fuel completely to inhaling fumes.
  • Page 31 INSPECTION/SETUP DEF REFUELING 3. NEVER overfill the fuel tank — It is important to read the fuel gauge when filling the trailer fuel tank. DO NOT NOTICE wait for fuel to rise in the filler neck (Figure 36). ONLY fill the DEF tank with diesel exhaust fluid. Any FUEL GAUGE LOCATED other type of fluid may cause severe engine damage.
  • Page 32 INSPECTION/SETUP COOLANT Operation in Freezing Weather (ANTIFREEZE/SUMMER COOLANT/WATER) When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added. Isuzu recommends antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and mixed Table 13.
  • Page 33 INSPECTION/SETUP AIR CLEANER Table 14. Fan Belt Deflection Standard Value Standard Value Periodic cleaning/replacement of the air cleaner is Belt (Amount of Deflection) (Vibration Frequency) necessary. Inspect the air cleaner (Figure 41) in accordance with the maintenance section of this manual or the Isuzu 0.17–0.20 in.
  • Page 34 INSPECTION/SETUP Battery Cable Installation ALTERNATOR ALWAYS be sure the battery cables (Figure 43) are The polarity of the alternator is negative grounding type. properly connected to the battery terminals as shown below. When an inverted circuit connection takes place, the The red cable is connected to the positive terminal of the circuit will be in short circuit instantaneously, resulting in battery, and the black cable is connected to the negative...

  • Page 35: Generator Start-Up Procedure (Manual)

    GENERATOR START-UP PROCEDURE (MANUAL) BEFORE STARTING STARTING (MANUAL) 1. Place the Auto-Off/Reset-Manual Switch in the CAUTION MANUAL position to start the engine (Figure 46). The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. AUTO MANUAL Direct exhaust away from nearby personnel. OFF/RESET WARNING Figure 46.
  • Page 36 GENERATOR START-UP PROCEDURE (MANUAL) 5. If the voltage is not within the specified tolerance, use 9. The tachometer gauge (Figure 53) will indicate the the voltage adjustment control knob (Figure 49) to speed of the engine when the generator is operating. increase or decrease the desired voltage.

  • Page 37: 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 DANGER below). Before connecting this generator to any 1. Perform steps 1 through 5 in the Before Starting section building’s electrical system, a licensed as outlined in the Manual Starting Procedure.

  • Page 38: Generator Shutdown Procedure

    GENERATOR SHUTDOWN PROCEDURE EMERGENCY SHUTDOWN PROCEDURE WARNING NOTICE NEVER stop the engine suddenly except in an emergency. The Emergency Stop Pushbutton Switch should only be used to stop the engine in case of an emergency NORMAL SHUTDOWN PROCEDURE or to lock out operation during service. The emergency stop switch should NEVER be used for routine stopping To shut down the generator, use the following procedure: of the engine.

  • Page 39: Maintenance

    MAINTENANCE 500 Hrs. 3,000 Hrs 10 Hrs. Table 15. Inspection/Maintenance 250 Hrs. or Every or Every OTHER DAILY 12 Months 36 Months Check Engine Oil and Coolant Levels Check Fuel Filter/Water Separator Bowl Check Air Cleaner/Element Clean Air Cleaner/Element Check for Leaks/Hoses/Clamps Check for Loosening of Parts Change Engine Oil and Oil Filter * Clean Unit, Inside and Outside...
  • Page 40 MAINTENANCE GENERAL INSPECTION Primary and Secondary Air Cleaner Elements Prior to each use, the generator should be cleaned and 1. Release the latches (Figure 60) that secure the cover inspected for deficiencies. Check for loose, missing or to the air cleaner body. damaged nuts, bolts or other fasteners.
  • Page 41 MAINTENANCE Air Filter Dust Indicator NOTICE AIR BLEEDER PLUG The air filter should not be changed until the indicator FILTER BODY reads RED. Dispose of the old air filter. It may not be cleaned or reused. FUEL FILTER DRAIN PLUG The air filter indicator (Figure 61) is attached to the air filter.
  • Page 42 MAINTENANCE FUEL FILTER ELEMENT REPLACEMENT ELECTROMAGNETIC FUEL PUMP (500 HOURS) 1. Use a filter wrench to remove the element case The filter inside the fuel pump (Figure 64) is either a paper (Figure 63) from the fuel filter body. type or steel mesh type depending on the fuel pump type. Clean or replace the fuel pump filter as follows: 1.
  • Page 43 MAINTENANCE DRAINING THE CONTAINMENT TANK CLEANING INSIDE THE FUEL TANK 1. This generator is equipped with an environmental If necessary, drain the fuel inside the fuel tank completely. containment tank. Inspect this tank regularly. Using a spray washer (Figure 66) wash out any deposits or debris that have accumulated inside the fuel tank.
  • Page 44 MAINTENANCE DRIVE BELT (DAILY) DRAINING ENGINE OIL Drive Belt Tension 1. Run the engine until the engine coolant reaches a temperature of 140°F (60°C). Turn the engine off. A slack drive belt (Figure 67) may contribute to overheating 2. Remove the oil dipstick from its holder. or insufficient charging of the battery.
  • Page 45 MAINTENANCE ENGINE OIL FILTER REPLACEMENT DRAINING ENGINE COOLANT WARNING 1. Clean the area around the lubricating oil filter head. 2. Using an oil filter wrench (Figure 69), remove the DO NOT remove the pressure cap from the engine oil filter. radiator when the engine is hot! Wait until the coolant temperature is below 120°F (50°C) before removing the pressure cap.
  • Page 46 MAINTENANCE FLUSHING OUT THE RADIATOR TESTING THE GFCI RECEPTACLE AND REPLACING COOLANT NOTICE „ Open both cocks located at the crankcase side and at The GFCI receptacle is designed to interrupt power the lower part of the radiator and drain the coolant. Open when a ground fault exists to prevent injuries and shock the radiator cap while draining.
  • Page 47 MAINTENANCE GENERATOR STORAGE 4. Press the TEST button (Figure 75) on the GFCI receptacle and verify that the status LED turns OFF. For long-term storage of the generator the following is recommended: „ Drain the fuel tank completely. Treat with a fuel stabilizer if necessary.
  • Page 48 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 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 engine block heater at all times.
  • Page 49 MAINTENANCE EMISSION CONTROL EMISSION CARBON CHECK The emission control system employed with the Isuzu Deposition of carbon (soot, unburned fuel) in the exhaust BR-4JJ1X diesel engine consists of a Diesel Oxidation pipe line and muffler could cause not only system derates Catalyst (DOC).
  • Page 50 MAINTENANCE SELECTIVE CATALYTIC REDUCTION (SCR) NOTICE Diesel engines can be run with a lean burn air-to-fuel ratio, During urea SCR system purging, white smoke may to ensure the full combustion of soot and to prevent the be temporarily emitted from the exhaust tailpipe. This exhaust of unburnt fuel.
  • Page 51 MAINTENANCE DIESEL EXHAUST FLUID (DEF) If the diesel exhaust fluid (DEF) symbol (Figure 81) is displayed during ECU controller operation, it indicates the The amount of fluid in the DEF tank will be shown on the following: ECU Controller main screen during operation. The symbol „...
  • Page 52 MAINTENANCE INDUCEMENT When the system senses improper usage such as no supply of DEF, use of poor quality DEF, problems with DEF jets, or disconnection of sensors, a warning will be issued before the situation becomes critical. If the warnings are ignored and the unit enters intermittent operation, the emergency shutdown will activate.
  • Page 53 MAINTENANCE HOW TO ACTIVATE ESCAPE MODE 3. Press the [Program/Exit] button (Figure 84) to enter the Main Menu. If the ECU displays any messages referenced in Table 17, it may be necessary to restart via ESCAPE MODE. SPEED 0000 Starting 1.
  • Page 54 MAINTENANCE 5. Press the [SELECT] button (Figure 86) to enter the 7. Place the Auto Start/Stop Switch (Figure 88) in the “Escape Mode” menu. “Off/Reset” position. FAULT DIAGNOSTICS ABOUT UNIT MANUAL AUTO USER LOGIN ESCAPE MODE OFF/RESET (CENTER) Figure 88. Auto Off/Reset Manual Switch DOWN SELECT (Off/Reset Position) 8.
  • Page 55 MAINTENANCE PROTECTION DEVICES Place the Auto Start/Stop Switch in the “Off/Reset” position. In addition, place all circuit breakers in the OFF position. Automatic Shutdown System Before troubleshooting, allow sufficient time for adequate cooling. Before attempting to restart the generator, perform This unit is equipped with engine protection devices that an overall inspection of the generator and correct the automatically shut down the engine if any of the faults...

  • Page 56: Troubleshooting (Diagnostics)

    TROUBLESHOOTING (DIAGNOSTICS) The engine controller of this generator diagnoses problems 5. Push the Program/Exit Button on the ECU controller and select the Fault Diagnostics mode. This mode (faults/errors) that arise from the engine control system and the engine itself. enables the ability to carry out the fault diagnostics as listed below: 1.

  • Page 57: 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 19 shown below for diagnosis of the generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 19.

  • Page 58: Troubleshooting (Engine)

    TROUBLESHOOTING (ENGINE) Troubleshooting (Engine) Symptom Possible Problem Solution No fuel reaching injection pump? Add fuel. Check entire fuel system. Defective fuel pump? Replace fuel pump. Fuel fi lter clogged? Replace fuel fi lter and clean tank. Faulty fuel supply line? Replace or repair fuel line.
  • Page 59 TROUBLESHOOTING (ENGINE) Troubleshooting (Engine) - continued Symptom Possible Problem Solution Air fi lter blocked? Clean or replace air fi lter. Low engine power output and low speed, Incorrect valve clearances? Adjust valves per engine specifi cation. black exhaust smoke. Malfunction at injector? See engine manual.

  • Page 60: Generator Wiring Diagram (M2814000413)

    GENERATOR WIRING DIAGRAM (M2814000413) PAGE 60 — DCA70SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #9 (09/19/22)

  • Page 61: Engine Wiring Diagram (M2814100643)

    ENGINE WIRING DIAGRAM (M2814100643) DCA70SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #9 (09/19/22) — PAGE 61...

  • Page 62: Controller Wiring Diagram (A)

    CONTROLLER WIRING DIAGRAM (A) PAGE 62 — DCA70SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #9 (09/19/22)

  • Page 63: Controller Wiring Diagram (B) (M2814100813)

    CONTROLLER WIRING DIAGRAM (B) (M2814100813) DCA70SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #9 (09/19/22) — PAGE 63...

  • Page 64: Battery Charger Wiring Diagram

    BATTERY CHARGER WIRING DIAGRAM BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG. GROUND (G) TO CHASSIS GROUND GREEN 16 AWG. TO STARTER “B” TERMINAL RED 16 AWG. 120 VAC INPUT, INSERT EXTERNAL POWER CORD HERE. NOTES: INLET RECEPTACLE &...
  • Page 65 NOTES DCA70SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #9 (09/19/22) — PAGE 65...
  • Page 66 © COPYRIGHT 2022, MULTIQUIP INC. Multiquip Inc , the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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