MULTIQUIP DCA5USI, Operation And Parts Manual

Page 1: ...HE EQUIPMENT AT ALL TIMES To find the latest revision of this publication visit our website at www multiquip com Revision 3 07 19 11 MODEL dca25USI 60hz Whisperwatt generator isuzu AA 4LE2 DIESEL ENGI...

Page 2: ...page 2 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 proposition 65 warning Diesel engine exhaust and some of...

Page 3: ...y 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 between...

Page 4: ...eading 25 Output Terminal Panel Connections 26 27 Inspection Setup 28 31 Generator Start Up Procedure 32 33 Generator Shut Down Procedures 34 Maintenance 35 37 Trailer Maintenance 38 41 Trailer Wiring...

Page 5: ...te 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 qualify...

Page 6: ...afety 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 situation w...

Page 7: ...ot 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 nearest...

Page 8: ...on 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 commo...

Page 9: ...perating 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 i...

Page 10: ...licable 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 in w...

Page 11: ...ry 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 cloth...

Page 12: ...Aux Voltage Output 4 8 Kw 2 4 kW x 2 Dry Weight 1 808 lbs 820 kg Wet Weight 2 138 lbs 970 kg Table 2 Engine Specifications Model ISUZU AA 4LE2 Tier 2 Certified Type 4 cycle water cooled direct injecti...

Page 13: ...E F 25 H G TOP VIEW SIDE VIEW FRONT VIEW Figure 1 Dimensions Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 22 64 in 575 mm F 70 47 in 1 790 mm B 20 87 in 530...

Page 14: ...page 14 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 Installation Figure 2 Typical Generator Grounding Application...

Page 15: ...olate 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 the...

Page 16: ...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 excitation current for the exciter...

Page 17: ...0 R P M 7 U V W O 1 8 5 Figure 3 Major Components Table 4 Generator Major Components ITEM NO DESCRIPTION 1 Muffler Assembly 2 Engine Assembly 3 Enclosure Assembly 4 Generator Assembly 5 Output Termina...

Page 18: ...oltage between any two phases of the output terminals or to be switched off 5 ACVoltmeter Indicates the output voltage present at the U V and W Output Terminal Lugs 6 AC Ammeter Indicates the amount o...

Page 19: ...when this condition occurs 6 Preheat Lamp When the ignition key is placed in the preheat position this lamp will illuminate to indicate preheating of the engine glow plugs When the lamp turns off this...

Page 20: ...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 21: ...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 22: ...terminals from overload a 3 pole 60 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 Curr...

Page 23: ...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 equipm...

Page 24: ...Position 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 Positio...

Page 25: ...ch 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 reading...

Page 26: ...ector 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 Figure 21 cl...

Page 27: ...regulator adjustment knob whenever fine tuning of the output voltage is required 1 240 120V UVWOTerminal Output Voltages 1 Place the voltage selector switch in the 1 240 120 position as shown in Figu...

Page 28: ...h the specified 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...

Page 29: ...YS 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 fuel when refueling 2 Open cabinet...

Page 30: ...urns Table 12 Coolant Capacity Engine and Radiator 1 70 gal 6 4 liters Reserve Tank 2 quarts 1 9 liters Table 13 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point Boiling Point C F C F...

Page 31: ...minal FIRST and reconnect negative terminal LAST When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the ignition switch is in the START position...

Page 32: ...rating Direct exhaust away from nearby personnel WARNING NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position INCORRECT CORRECT Starting 1 Place t...

Page 33: ...oil pressure is approximately 42 to 71 psi 290 490 kPa Figure 45 Oil Pressure Gauge 10 The coolant temperature gauge Figure 46 will indicate the coolant temperature Under normal operating conditions t...

Page 34: ...nd LOAD circuit breakers as shown in Figure 50 to the OFF position Figure 50 Main GFCI and Load Circuit Breakers Off 2 Let the engine cool by running it at low speed for 3 5 minutes with no load appli...

Page 35: ...heck 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 the...

Page 36: ...sits or debris that have accumulated inside the fuel tank Figure 54 Fuel Tank Cleaning FuelTank Inspection In addition to cleaning the fuel tank the following components should be inspected for wear R...

Page 37: ...facturer 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 screwd...

Page 38: ...t 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 and...

Page 39: ...kes Figure 56 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 or bloc...

Page 40: ...h 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 manufacturer E...

Page 41: ...and 2 Torque all lug nuts in sequence see Figure 58 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 18 3 After first road use retorque a...

Page 42: ...page 42 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 Trailer Wiring Diagram Figure 59 Trailer Towing Vehicle Wiring Diagram...

Page 43: ...DCA25usi 60 hz Generator operation and parts manual rev 3 07 19 11 page 43 Generator Wiring Diagram Figure 60 Generator Wiring Diagram...

Page 44: ...page 44 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 Engine Wiring Diagram Figure 61 Engine Wiring Diagram...

Page 45: ...DCA25usi 60 hz Generator operation and parts manual rev 3 07 19 11 page 45 Engine Wiring Diagram...

Page 46: ...er 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 acr...

Page 47: ...DCA25usi 60 hz Generator operation and parts manual rev 3 07 19 11 page 47 notes...

Page 48: ...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 QtY C...

Page 49: ...1 M1312500203 RADIATOR HOSE UPPER 1 M1312500303 RADIATOR HOSE LOWER 1 0601808803 CIRCUIT BREAKER 1P 20 AMP 1 0601808804 CIRCUIT BREAKER 2P 50 AMP 3 0601802160 FUSE 5 AMP 1 0601820671 AUTOMATIC VOLTAGE...

Page 50: ...page 50 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 GENERATOR ASSY...

Page 51: ...11 0071906308 BEARING 1 2 0010308035 HEX HEAD BOLT 6 2A 0040008000 WASHER LOCK 6 2B 0041208000 WASHER FLAT 6 3 0070506803 BEARING 1 4 B1130201103 STATOR ASSY 1 4 1 0845041904 GROMMET 1 5 B1138000003 F...

Page 52: ...page 52 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 control box ASSY...

Page 53: ...1806115 CURRENT TRANSFORMER 3 15 0027106016 MACHINE SCREW 6 16 0601820845 OVER CURRENT RELAY 1 S N 8100001 8101586 16 0601820847 OVER CURRENT RELAY 1 S N 8100587 AND ABOVE 17 0601820846 OVER CURRENT R...

Page 54: ...page 54 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 control box ASSY...

Page 55: ...0601810245 BULB 3 45 9826800370 PANEL LIGHT 1 REPLACES P N 0601810141 46 0601831330 SWITCH PANEL LIGHT 1 47 M1225100004 STOPPER 1 48 0027105010 MACHINE SCREW 2 49 0027105010 MACHINE SCREW 4 50 M92201...

Page 56: ...page 56 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 ENGINE AND RADIATOR ASSY...

Page 57: ...0602011079 CAP RADIATOR 1 10 M9312200104 MOUNT RUBBER 2 11 0016908040 HEX HEAD BOLT 2 12 0207008000 HEX NUT 2 13 M1312500203 RADIATOR HOSE 1 14 M1312500303 RADIATOR HOSE 1 15 0605515149 HOSE BAND 4 1...

Page 58: ...page 58 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 ENGINE AND RADIATOR ASSY continued...

Page 59: ...BRACKET RESERVE TANK 1 48 0016906025 HEX HEAD BOLT 1 49 0016906020 HEX HEAD BOLT 2 S N 8100001 8101586 50 0016908020 HEX HEAD BOLT 2 51 0199100700 HOSE 1 52 0193600850 HOSE 1 53 0605515106 HOSE BAND 3...

Page 60: ...07 19 11 OUTPUT TERMINAL ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7...

Page 61: ...7103010 MACHINE SCREW 4 12A 0030003000 HEX NUT 4 13 0016906020 HEX HEAD BOLT 2 14 0016906016 HEX HEAD BOLT 4 15 M1236400004 CABLE OUTLET COVER 1 16 M1236300004 SUPPORTER CABLE OUTLET COVER 1 17 001690...

Page 62: ...page 62 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 BATTERY ASSY...

Page 63: ...PART NO PART NAME QTY REMARKS 1 0602220185 BATTERY 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 WASHER LOCK 2 6 M1348400204 BATTERY CABLE...

Page 64: ...page 64 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 Muffler Assy...

Page 65: ...E 2 0016908020 HEX HEAD BOLT 7 3 M1335000103 EXHAUST PIPE 1 S N 8100001 8101465 3A M1335000113 EXHAUST PIPE 1 S N 8100466 AND ABOVE 4 8970420280 GASKET 1 REPLACES P N 0602320100 5 M0335200004 GASKET 1...

Page 66: ...page 66 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 FUEL TANK ASSY...

Page 67: ...ND 2 7 0605515109 HOSE BAND 7 8 8972112730 FUEL FILTER 1 REPLACES P N 0602042203 8 8943672922 FUEL FILTER 1 REPLACES P N 0602042202 8A 8972134720 CARTRIDGE FUEL FILTER 1 REPLACES P N 0602042701 8A 894...

Page 68: ...page 68 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 ENCLOSURE ASSY...

Page 69: ...COVER 1 S N 8100001 8100230 10A 0228800120 SEAL RUBBER 1 S N 8100001 8100230 10A 0228800040 SEAL RUBBER 2 S N 8100001 8100230 11 0016906016 HEX HEAD BOLT 2 S N 8100001 8100230 12 0016908020 HEX HEAD...

Page 70: ...page 70 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 ENCLOSURE ASSY continued...

Page 71: ...BOLT 8 39 M1465000402 ROOF PANEL 1 39A M1495500213 ACOUSTIC SHEET 1 40 0016908020 HEX HEAD BOLT 23 S N 8100001 8100231 40 0019208020 HEX HEAD BOLT 23 S N 8100232 AND ABOVE 41 M1465400104 COVER 1 42 0...

Page 72: ...page 72 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 ENCLOSURE ASSY continued...

Page 73: ...STOPPER 5 59 0027208025 MACHINE SCREW 5 60 M1435000903 BRACKET STAY 1 61 M1435000803 BRACKET STAY 1 62 0016908020 HEX HEAD BOLT 4 63 M1435000703 SUPPORT LEG 1 63A M1498200004 ACOUSTIC SHEET 1 64 00169...

Page 74: ...page 74 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 RUBBER SEALS ASSY...

Page 75: ...3 6 0228800690 SEAL RUBBER 1 7 0228900655 SEAL RUBBER 1 8 0228900325 SEAL RUBBER 1 9 0229200325 SEAL RUBBER 1 10 0228800595 SEAL RUBBER 1 11 0228800375 SEAL RUBBER 1 12 0228900375 SEAL RUBBER 1 13 022...

Page 76: ...page 76 DCA25Usi 60 hz Generator operation and parts manual rev 3 07 19 11 NAMEPLATE AND DECALS ASSY...

Page 77: ...15 M9510000004 DECAL FLUID DRAIN 1 M91000000 16 M9510100004 DECAL CAUTION HOT PARTS 1 M91010000 17 M9512200004 DECAL MQ 1 M91220000 18 M9520000004 DECAL GROUND 1 M92000000 19 M9520000104 DECAL AMMETER...

Page 78: ...products g Items purchased in kits h The sender will be notified of any material 7 received that is not acceptable Such material will be held for five 8 working days from notification pending instruct...

Page 79: ...DCA25usi 60 hz Generator operation and parts manual rev 3 07 19 11 page 79 notes...

Page 80: ...23 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 2011 MULTIQUIP INC Mul...