MULTIQUIP DCA125USI3CAN, Operation And Parts Manual

Page 1: ...NT AT ALL TIMES To find the latest revision of this publication visit our website at www multiquip com MODEL DCA125USI3CAN 60 hz generator isuzu 4hk1x DIESEL ENGINE PARTS LIST NO M3874400004 Revision...

Page 2: ...5USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 fuel and chemical warnings Diesel engine exhaust and some of its constituents are know to cause cancer birth defects and other reprod...

Page 3: ...may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems betwe...

Page 4: ...ons 28 29 Inspection Setup 30 33 Generator Start Up Procedure 34 35 Generator Shut Down Procedures 36 Maintenance 37 40 Trailer Maintenance 41 44 Trailer Wiring Diagram 45 Generator Wiring Diagram 46...

Page 5: ...bsite View Parts Diagrams Order Parts Print Specification Information Note Discounts Are Subject To Change Goto www multiquip com and click on Order Parts to log in and save Use the internet and quali...

Page 6: ...e safety messages specifically address the level of exposure to the operator and are preceded by one of four words DANGER WARNiNG CAuTiON or NotICe SaFetY SYmBolS DANGER Indicates a hazardous situatio...

Page 7: ...not recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result alWaYS know the location of the nearest fire extinguisher alWaYS know the location of the neare...

Page 8: ...ction Never tamper with the factory settings of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable Wet stacking is a co...

Page 9: ...operating condition alWaYS shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating alWaYS...

Page 10: ...applicable laws and electrical codes Failure to do so could result in electrical shock or burn causing serious injury or even death power Cord Cable Safety DANGER Never let power cords or cables lay i...

Page 11: ...ttery in a well ventilated environmenttoavoidtheriskofadangerousconcentration of combustible gasses If the battery liquid dilute sulfuric acid comes into contact with clothing or skin rinse skin or cl...

Page 12: ...eed 1800 rpm Aux AC Power Single Phase 60 Hz Aux Voltage Output 120V 4 8 Kw 2 4 kW x 2 Sound Level dB A Full Load at 23 ft 7 0 Meters 65 Dry Weight 5 689 lbs 2 580 kg Wet Weight 7 012 lbs 3 180 kg Tab...

Page 13: ...age 13 Dimensions Figure 1 Dimensions Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 38 20 in 970 mm F 120 10 in 3 050 mm B 37 00 in 940 mm G 73 00 in 1 855 mm...

Page 14: ...page 14 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 Installation Figure 2 Typical Generator Grounding Application...

Page 15: ...isolate vibration of the generator when it is running The generator must set at least 6 inches above the floor or grade level in accordance to NFPA 110 Chapter 5 4 1 DO NOT remove the metal skids on t...

Page 16: ...ower from the voltage regulator is supplied from the parallel connections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then rectified and are the ex...

Page 17: ...Table 4 Generator Major Components ITEM NO DESCRIPTION 1 Muffler Assembly 2 Engine Assembly 3 Enclosure Assembly 4 Generator Assembly 5 Output Terminal Assembly 6 Fuel Tank Assembly 7 Battery Assembl...

Page 18: ...r to be switched off 5 Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 6 AC Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by...

Page 19: ...DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 page 19 Notes...

Page 20: ...page 20 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 ENGINE OPERATING PANEL Figure 5 Engine Operating Panel...

Page 21: ...will shutdown the generator During cranking cycle the ECU will attempt to crank the engine for 10 seconds before disengaging If the engine does not engage start by the third attempt the engine will be...

Page 22: ...generator Lift up on the cover to gain access to receptacles and terminal lugs NOTICE Terminal legs O and Ground are considered bonded grounds OutputTerminal Familiarization The Output Terminal Panel...

Page 23: ...69 receptacles Figure 8 provided on the output terminal panel These receptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position Figure 8 120 240V T...

Page 24: ...ut terminals from overload a 3 pole 350 amp main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine Figure 11 Connecting Loads Over C...

Page 25: ...wer Factor By Load Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equ...

Page 26: ...osition Voltage Selector Switch 3 Phase 480 270V Position 3 Line Line 208V 220V 240V 416V 440V 480V 1 Line Neutral 120V 127V 139V 240V 254V 277V Voltage Selector Switch Single Phase 240 120V Position...

Page 27: ...itch Figure 14 Voltage Selector Switch 240 139V 3 Position AC Voltmeter Gauge Reading Place the ACVoltmeter Change Over Switch Figure 15 in theW U position and observe the phase to phase voltage readi...

Page 28: ...tage Selector Switch 3 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 20 Figure 20 UVWO Terminal Lugs 3 240 139V Connections 3 Turn the voltage regulator knob Figu...

Page 29: ...age regulator adjustment knob whenever fine tuning of the output voltage is required 1 240 120V UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 1 240 120 position as shown in...

Page 30: ...pecified amount of oil as outlined in the ISUZU Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements API Servic...

Page 31: ...nd or inhaling fumes CAUTION ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank NOTICE ONLY use 2 diesel fu...

Page 32: ...hich can cause severe burns Table 12 Coolant Capacity Engine and Radiator 5 2 gal 19 7 liters Reserve Tank TBD Table 13 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point C F 50 37 34 NO...

Page 33: ...ST and reconnect negative terminal LAST When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL positi...

Page 34: ...ine enclosure doors Figure 37 Figure 37 Engine Enclosure Doors CAUTION The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby p...

Page 35: ...ED on the MPEC unit Figure 44 in ON lit after the engine has been started Figure 44 Engine Running LED ON 7 The generator s frequency meter Figure 45 should be displaying the 60 cycle output frequency...

Page 36: ...ring operation Emergency Shutdown Procedure 1 Place the MPEC Control Switch Figure 56 in the OFF RESET position WARNING NEVER stop the engine suddenly except in an emergency 12 The coolant temperature...

Page 37: ...Check all Hoses and Clamps 4 X Clean Inside of Fuel Tank X Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X Maintenance General Inspection Prior to each use t...

Page 38: ...deposits or debris that have accumulated inside the fuel tank Figure 58 Fuel Tank Cleaning FuelTank Inspection In addition to cleaning the fuel tank the following components should be inspected for we...

Page 39: ...anufacturer Close radiator cap tightly Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed DO NOT clean radiator core with any objects such as a scr...

Page 40: ...When using the generator in hot climates there is no reason to apply power to jacket water heater However if the generator will be used in cold climates it is always a good idea to apply power to the...

Page 41: ...port device with maximum pound requirement from the tongue of the trailer 7 Coupler Type of hitch used on the trailer for towing 8 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc a...

Page 42: ...ge brakes Figure 61 should not require any special attention with the exception of routine maintenance such as shoe and lining replacement Brake lines should be periodically checked for cracks kinks o...

Page 43: ...with great force and cause serious eye or bodily injury Table 16 Tire WearTroubleshooting Wear Pattern Cause Solution Center Wear Over inflation Adjust pressure to particular load per tire manufacture...

Page 44: ...nuts by hand 2 Torque all lug nuts in sequence Figure 63 DO NOT torquethewheellugnutsallthewaydown Tighteneach lug nut in 3 separate passes as defined by Table 18 3 After first road use retorque all...

Page 45: ...DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 page 45 Trailer Wiring Diagram Figure 64 Trailer Towing Vehicle Wiring Diagram...

Page 46: ...page 46 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 Generator Wiring Diagram Figure 65 Generator Wiring Diagram...

Page 47: ...DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 page 47 Engine Wiring Diagram Figure 66 Engine Wiring Diagram...

Page 48: ...page 48 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 controller Wiring Diagram Figure 67 Controller Wiring Diagram...

Page 49: ...meter Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Defective Exciter Field Check for approximately 17 3 ohms...

Page 50: ...imly lit when the MPEC Control Switch is placed in the MANUAL position 2 If engine trouble occurs the diagnostic lamp will be brightly lit as long as the control switch is left in the manual position...

Page 51: ...DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 page 51 Notes...

Page 52: ...es not guarantee the availability of the parts listed NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order Qt...

Page 53: ...fuel element main 3 8980742880 filter fuel element pre 1 0602122272 UNIT OIL PRESSURE 1 0602123260 UNIT WATER TEMPERATURE 1 9095720140 PACKING WATER TEMPERATURE 1 8121468300 SEnsor water temperature...

Page 54: ...page 54 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 GENERATOR ASSY...

Page 55: ...ARING 1 2 C0130000503 STARTER ASSY 1 3 0845041804 GROMMET 2 4 8131315202 END BRACKET 1 5 8101350013 FIELD ASSY EXCITER 1 6 0012110060 HEX HEAD BOLT 4 7 0042610000 WASHER LOCK 4 8 031110160 WASHER FLAT...

Page 56: ...page 56 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 control box ASSY...

Page 57: ...OR INLET AIR TEMP 1 REPLACES P N 0603210240 18 M3260500503 SET PANEL ELECTRIC PARTS 1 19 0016906016 HEX HEAD BOLT 4 20 8980710280 CONTROLLER 1 REPLACES P N 0602202686 21 M3260500604 BRACKET 1 22 00169...

Page 58: ...page 58 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 control box ASSY continued...

Page 59: ...HANGE OVER SWITCH VOLTMETER 1 56 0601840073 RHEOSTAT VR 2W 1K OHM 1 57 0601840100 KNOB 1 REPLACES P N 0601840121 58 0602202641 CONTROLLER ECU CAN77 1 59 0027104040 MACHINE SCREW 2 59A OEMAA8 HEX NUT 2...

Page 60: ...page 60 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 control box ASSY continued...

Page 61: ...arts manual rev 2 09 24 13 page 61 control box ASSY continued NO PART NO PART NAME QTY REMARKS 84 0601830762 SWITCH FUEL PUMP 1 85 M3246703004 WIRE HARNESS GENERATOR 1 86 M3357202002 WIRE HARNESS ENGI...

Page 62: ...page 62 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 ENGINE AND RADIATOR ASSY...

Page 63: ...HEAD BOLT 2 REPLACES P N 0019208020 18 M3310502603 RADIATOR HOSE UPPER 1 19 M3310502703 RADIATOR HOSE LOWER 1 20 0605515148 HOSE BAND 1 21 M3310600303 HOSE SUPPORT 1 22 0016906016 HEX HEAD BOLT 4 23 M...

Page 64: ...page 64 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 ENGINE AND RADIATOR ASSY continued...

Page 65: ...9 0602021070 CAP 1 60 0269200800 DRAIN HOSE 1 61 M3323500004 BRACKET OIL FILTER 1 62 0016910025 HEX HEAD BOLT 2 63 8973243861 OIL FILTER 1 REPLACES P N 0602041007 63A 1132402322 CARTRIDGE OIL FILTER 1...

Page 66: ...page 66 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 ENGINE AND RADIATOR ASSY continued...

Page 67: ...ACKET 1 88A 0228900320 RUBBER SEAL 1 89 011206020 HEX HEAD BOLT 1 REPLACES P N 0016906020 90 M3310303803 FAN SHROUD 1 91 M3310303903 FAN SHROUD 1 92 011206020 HEX HEAD BOLT 8 REPLACES P N 0016906020 9...

Page 68: ...page 68 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 OUTPUT TERMINAL ASSY...

Page 69: ...004 CABLE OUTLET COVER 1 16 M3236300004 SUPPORTER CABLE OUTLET COVER 1 17 011206020 HEX HEAD BOLT 6 REPLACES P N 0016906020 18 0601815194 TERMINAL BLOCK 1 19 7538070 MACHINE SCREW 2 REPLACES P N 00271...

Page 70: ...page 70 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 BATTERY ASSY...

Page 71: ...KS 1 0602220198 BATTERY 1 2 M9310500404 BATTERY SHEET 1 3 M9103000504 BATTERY BAND 1 4 0602220921 BATTERY BOLT SET 2 5 M3346901604 BATTERY CABLE 1 6 M3346901504 BATTERY CABLE 1 7 CABLE 1 MAKE LOCALLY...

Page 72: ...page 72 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 Muffler Assy...

Page 73: ...MUFFLER 1 2 012212030 HEX HEAD BOLT 4 REPLACES P N 0017112030 3 M3333001603 EXHAUST PIPE 1 4 1141451840 GASKET 1 REPLACES P N 0602320108 5 M3333200304 GASKET 1 6 0039308000 HEX NUT 8 7 0017110050 HEX...

Page 74: ...page 74 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 FUEL TANK ASSY...

Page 75: ...S P N 8980758550 16A 8980742880 ELEMENT FUEL FILTER 1 REPLACES P N 8980758540 17 8973834270 JOINT PIPE 4 REPLACES P N 0602042661 18 1096750951 JOINT BOLT 4 REPLACES P N 0602042621 19 1096300860 PACKIN...

Page 76: ...page 76 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 ENCLOSURE ASSY PART 1...

Page 77: ...EX HEAD BOLT 2 REPLACES P N 0019208020 18 M3423200704 DUCT COVER 2 19 011206020 HEX HEAD BOLT 14 REPLACES P N 0016906020 20 M3310302704 SHROUD BRACKET 1 21 0016906016 HEX HEAD BOLT 6 22 M3423300304 DI...

Page 78: ...page 78 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 ENCLOSURE ASSY PART 1 continued...

Page 79: ...EX HEAD BOLT 8 REPLACES P N 0019208020 38 M3423202704 OVER COVER FRONT FRAME 1 38A M3493108004 ACOUSTIC SHEET 1 39 011008020 HEX HEAD BOLT 51 REPLACES P N 0019208020 40 0017110025 HEX HEAD BOLT 8 REPL...

Page 80: ...page 80 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 ENCLOSURE ASSY PART 2...

Page 81: ...8704 ACOUSTIC SHEET 2 12 011008020 HEX HEAD BOLT 4 REPLACES P N 0019208020 13 011008020 HEX HEAD BOLT 4 REPLACES P N 0019208020 14 M3443200803 DOOR REAR FRAME 1 15 M3443600304 WINDOW PLATE 1 16 020730...

Page 82: ...page 82 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 ENCLOSURE ASSY PART 2 continued...

Page 83: ...6 REPLACES P N M9110100804 32 0845047004 HINGE 5 REPLACES P N M9110100904 33 M9116100004 WASHER 11 34 011008020 HEX HEAD BOLT 26 REPLACES P N 0019208020 35 0601850097 STOPPER 8 36 0027208025 MACHINE...

Page 84: ...page 84 DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 RUBBER SEALS ASSY...

Page 85: ...901105 RUBBER SEAL 3 10 0228900565 RUBBER SEAL 1 11 0228900945 RUBBER SEAL 4 12 0228900505 RUBBER SEAL 1 13 0229201090 RUBBER SEAL 1 14 0229201335 RUBBER SEAL 2 15 0228901335 RUBBER SEAL 1 16 02289006...

Page 86: ...3 NAMEPLATE AND DECALS ASSY 3 6A 8 11A 3 4A 9 2A 9 2 4 1A 4 8A 4 7A 6 1A A A 1 3 4 3A 9 6A 9 6 9 2A 9 2 4 6 2 9A 3 7A 3 4A 5 3A 1 1A 8 9A 1 2A 2 8A 8 9 9 7 12 9 7A 8 12A 8 1 4 6A 9 6A 9 2A 9 6 9 2 4 6...

Page 87: ...TER 1 M90010000 3 3 M9500100304 DECAL INTER COOLER DRAIN 1 M90010030 3 4 M9503000004 DECAL WARNING MOVING PARTS ENGLISH 2 M90300000 3 4A DECAL WARNING MOVING PARTS FRENCH 2 M90300000CE 3 5 M9503000103...

Page 88: ...EPLATE AND DECALS ASSY continued 3 6A 8 11A 3 4A 9 2A 9 2 4 1A 4 8A 4 7A 6 1A A A 1 3 4 3A 9 6A 9 6 9 2A 9 2 4 6 2 9A 3 7A 3 4A 5 3A 1 1A 8 9A 1 2A 2 8A 8 9 9 7 12 9 7A 8 12A 8 1 4 6A 9 6A 9 2A 9 6 9...

Page 89: ...11 M3550002204 DECAL CAUTION BAIL MAX CAPACITY ENGLISH 1 M35000220 8 11A DECAL CAUTION BAIL MAX CAPACITY FRENCH 1 8 12 M9503200104 DECAL DANGER EXHAUST GAS ENGLISH 1 M90320010 8 12A DECAL DANGER EXHA...

Page 90: ...per products h Items purchased in kits 7 The sender will be notified of any material received that is not acceptable 8 Such material will be held for five working days from notification pending instru...

Page 91: ...DCA125USI3CAN 60 hz Generator operation and parts manual rev 2 09 24 13 page 91 notes...

Page 92: ...3 Fax 0161 339 3226 Canada Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin multiquip com Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 COPYRIGHT 2013 MULTIQUIP INC Mult...