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Multiquip DCA-25SSIU2 User's Manual

1. 5 han NO DESCRIPTION 27 24 9 Panel sey 2 2 5 Output Receptacies Assembly Ar Fiter Muflar Assembly Tank Assembly Engine Assembly Battery Assembly Generator Assembly Engine Operating Panel Assembly 10 Generator Corral Panel Assembly Figure 5 Major Components DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 19 A 25SSIU2 60 HZ GENERATOR CONTROL PANEL Oo Figure 6 Generator Control Panel The definitions below describe the controls and functions ofthe DCA 25SSIU2 HZ Generator Control Panel Figure 6 1 Main Circuit Breaker This three pole 60A main breaker is provided to protect the U V and W Output Terminal Lugs from overload 2 Voltage Regulator Control Allows 15 manual adjustment of the generators output voltage 3 Frequency Meter Indicates the output frequency in hertz Hz Normally 60 He 4 AC Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch 5 Indicates the output voltage present at the U V and W Output Terminal Lugs 6 Change Over Switch This switch allows the AC ammeter to indicate the current flowing to the l
2. SW T Ecion son RI RENTON Ret Ter DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAI Eum 231 CURRENT TRANSFORMER H s e uem omy at EN Ep 88 Gb M ME T E CIRCUIT BREAKER one TE 5 ag Figure 61 Generator Wiring Diagram 55102 60 ENGINE WIRING DIAGRAM COLOR CODE WREGOLOR WIRE COLOR STOP RUN B R RED 1 START BR Y vELLOw of G GREEN s Fei GRAY LG LIGHT GREEN GRAY 19 WARNING CONNECTOR For t P PINK Figure 62 Engine Wiring Diagram PAGE 46 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 A 25SSIU2 60 HZ TROUBLESHOOTING GENERATOR Practically breakdowns can be prevented by proper handling and maintenance inspections but in the event of breakdown use Table 20 shown below for diagnosis of Generator f the problem cannot be remedied consult our company s business office or service plant TABLE 20 GENERATOR TROUBL
3. REV 80 01 27 06 PAGE 5 CA 25SSIU2 60 2 SPECIFICATIONS Model DCA 25SSIU2 Type Revolving field self verd can prot type synchronous Armature Connection Star with Neutral Zig Zag Phase Single Standby Output 275 22KW 158 KW Prime Output 25 KVA 20 KW 144 KW Voltage 240 or 480V Frequency Speed 1 800 rpm Power Factor 08 1 Aux AC Power Single Phase 60 Hz Voltage 120 VAC Output 48 KW 2 4 KW x 2 Model ISUZU AA 4LE2 Type 4 Cycle water cooled direct injection No of Cylinders 4 cylinders Bore x Stroke 3 35 in x 3 78 in 85 mm x 96 mm Displacement 132 cu in 2 179 cc Starting Electric Coolant Capacity 17 gal 64 liters Lube Oil Capacity 2 24 gal 85 liters Fuel Tank Capacity 172 gal 65 Fuel Consumption 144 gal 547 Lyhr at full load Battery 27 0 5254 X1 Fuel 2 Diesel Fuel PAGE DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 555102 60 HZ DIMENSIONS TOP SIDE AND FRONT VIEW T Fatt Dimension nm vew B 25 00 in 835 mm G 3937 in 1 000 mm Figure 1 Dimensions DCA 25SSIU
4. REV 0 01 27 06 CA 25SSIU2 60 2 MAINTENANCE Jacket Water Heater and Internal Battery Charger 120 Input Receptacles OPTIONAL This generator can be optionally equipped with two 120 VAC 20 amp input receptacles located on the output terminal panel The purpose of these receptacles to provide power via commercial power tothe jacket water heater and internal battery charger These receptacles will ONLY function when commercial power has been supplied to them Figure 56 To apply commercial power to these receptacles a power cord of adequate size will be required See Table 6 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 its always good idea to apply power to the jacket water heater at imes To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size Ifthe generator willbe used daily the battery should normally not require charging If the generator wil be idle used for long periods of ime apply power to the battery charger receptacle via commercial power using an power cord of adequate size To ensure adequate starting capability always have power applied to the generator s internal battery charger 12111717 OUTPUT TERMINAL BATTERY CHARGER T20VAG INPUT RECEP
5. 1 DOT Requirements include the folowing Connect and test electric brake operation Secure portable power cables in cable tray with tie wraps 2555102 60 HZ RULES FOR SAFE OPERATION The maximum speed for highway towing is 55 MPH unless posted otherwise Recommended off road towing is not to exceed 15 MPH or less depending on type terrain Wi Place chock blocks underneath wheel to prevent rolling while parked Wi Use the trailers swivel jack to adjust the trailer height to level positon while parked WI Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops improve towing W Avoid sharp turns M Trailer should be adjusted a level positon at all imes when towing 1 Raise and lock trailer wheel stand in up position when transporting The maximum speed for highway towing is 55 MPH unless posted otherwise Recommended ofi road towing is not to exceed 15 MPH or less depending on type terrain Wi Place support blocks underneath the trailers bumper to prevent tipping while parked W Avoid sharp turns to prevent roling DO NOT transport generator with fuel in tank Km nearest phone or Keep a phone on the job site in case of emergencies M ALWAYS have easy access to the phone numbers ofthe nearest Ambulance Doctor and Fire Department This information will be invaluable in the case of an emergency AGE 13 Emergenci
6. OPERATION AND PARTS MANUAL REV 0 01 27 06 A 25SSIU2 60 HZ OUTPUT TERMINAL PANEL CONNECTIONS 30 480 277 Output Terminal Lug Voltages 1 Place the voltage selector switch in the 30 480 277 position as shown in Figure 27 ree po soo Figure 27 Voltage Selector Switch 480 277V Three Phase Position 2 Connect the load wires to the Output Terminal Lugs as shown in Figure 28 10 240V 120V Output Terminal Lug Voltages 1 Place the voltage selector switch in the 10 240 120 position as shown in Figure 29 Figure 29 Voltage Selector Switch 240 120V Single Phase Position 2 Connect the load wires tothe Output Terminal Lugs as shown in Figure 30 Figure 28 Output Terminal Lugs 30 480 277V Three Phase Connections 3 Tumthe voltage regulator knob Figure 24 clockwise to increase voltage output turn counterclockwise to decrease voltage output OPERATION AND PARTS MANUAL REV 0 01 27 06 Figure 30 Output Terminal Lugs 10 240 120V Connections 3 Tum the voltage regulator knob Figure 24 clockwise to increase voltage output turn counterclockwise to decrease voltage output Circuit Breakers To protect the generator from an overload a 3 pole 60 amp main circuit breaker is provided to protect the UV and W Output Terminals rom overload In addition two single pole 20 amp GFCI circuit breakers are provided t
7. 1t 0027104016 MACHINE SCREW 4 12 0601820671 AUTOMATIC VOLTAGE REGULATOR NTA 5A 2DB 1 13 0027105016 MACHINE SCREW 4 14 0601806115 CURRENT TRANSFORMER 812 943 50 5A 3 15 0027106016 MACHINE SCREW 6 16 0601820847 OVER CURRENT RELAY TA25DU 4 0 1 17 0601820848 OVER CURRENT RELAY DB25 25A 1 18 0027104016 MACHINE SCREW 2 18A 0207004000 HEX NUT 2 19 M1213500203 CONTROLBOX COVER 1 20 0016906016 HEX HEAD BOLT 4 21 M1923100004 SELECTOR SWITCH VY 40 1 21A 47130106 KNOB SELECTOR SWITCH 1 22 M1213600114 SWITCH BRACKET 1 23 0330000160 EDGING 2 24 0027103010 MACHINE SCREW 4 25 0016906016 HEX HEAD BOLT 4 26 M1213600014 SWITCH COVER 1 27 0016906016 HEX HEAD BOLT 3 28 001696016 HEX HEAD BOLT 8 28A 0040506000 TOOTHEDWASHER 1 29 M1223000403 CONTROL PANEL 1 30 0601807641 FREQUENCY METER FCF 6 45 65Hz 240V 1 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 55 DCA 25SSIU2 60 HZ CONTROL BOX ASSY CONTROL BOX ASSY CONT PAGE 56 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 255 12 60 HZ CONTROL BOX ASSY CONTROL BOX ASSY CONT NO PARTNO PART NAME QTY REMARKS 31 0601808985 AC AMMETER ACF 6 0 50A 100A 5A 1 32 0601801040 CHANGE OVER SWITCH AMMETER SL 2 AS 1 38 0601806859 AC VOLTMETER SCF 6 0 600V 1 34 0601801041 SWITCH VOLTMETER 51 215 1 35 0801840073 RHEOSTAT VOLT REGULAT RAZOA2SE102B 2W1KQ 1 36 0601840
8. Open Delta Excitation System The DCA 25SSIU 60 HZ generator is equipped with the state of the art Open Delta excitation system The open delta system consist an electrically independent winding wound among stationary windings ofthe AC output section There are four connections of the open delta C and D During steady state loads the power from the voltage regulator is supplied from the parallel connections of A to B 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 section When heavy load such as a motor starting or a short circuit occurs the automatic voltage regulator AVR switches the configuration of the open delta to the series connection of B oC This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads The connections of the AVR to the AC output windings are for sensing only No power is required from these windings The open delta design provides virtually unlimited excitation current offering maximum motor starting capabilities The excitation does not have fixed ceiling and responds according the demands of the required load REV 0 01 27 06 2555102 60 2 MAJOR COMPONENTS
9. WARNING kar 0010000 uy oniy in open v PIN M9503100004 vent exhaust ouside PIN 9520100204 PIN 9520100404 Do not operate with oars open Siop engine before icing use 50 amp receptacles adjust the voltage selector switch to the single phase position and the main line circuit breaker to the on a position PIN 1550000204 CAUTION ELECTRIC SHOCK HAZARD HOT PARTS burn skin Do not touch output terminals while this machine is operating Tum power off before servicing Do not touch until sufficiently cooled PIN M9510100004 PIN 9520100503 WARFNNG ELECTRIC SHOCK HAZARD Do not touch internal wiring or connections while this machine is operating Turn power off before servicing PIN M9520100004 Figure 3 Generator Decals Continued DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAI GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING GROUND GROUND CABLE MINIMUM REFERENCE 250 83 C Figure 4 Typical Grounding Application PAGE 16 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL 01 27106 Outdoor Installation Install the generator in a area that is free of debris bystanders and overhead obstructions Make sure the generatoris on secure level ground so that i cannot slide shift around Also install t
10. 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 77 DCA 25SSIU2 60 HZ NAMEPLATE AND DECALS NAMEPLATE AND DECALS ASSY PAGE 78 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 2555102 60 HZ NAMEPLATE AND DECA NAMEPLATE AND DECALS ASSY NO PARTNO PART NAME ary REMARKS 1 M1550000104 DECAL NOTE 15000010 2 M1550000204 DECAL NOTE M15000020 M1550001603 DECAL GENERATOR CONTROL 15000160 4 M1550017003 DECAL ENGINE OPERATING 15000170 5 1550001803 DECAL AUXILLARY OUTPUT M15000180 6 1550001904 DECAL CAUTION M15000190 M9500000004 DECAL OILDRAIN PLUG M90000000 8 M9500100004 DECAL WATER M90010000 9 9500100104 DECAL WATER M90010010 10 M9500300004 H 9500300104 DECAL 12 9500500004 DECAL DIESEL FUEL 13 9500500104 DECAL FUEL DRAIN PLUG 14 9503000004 DECAL WARNING 15 9509000103 DECAL WATER Ol 16 M9503100004 DECAL WARNING 17 9503100004 DECAL WARNING 18 9510100004 19 9510200002 20 M9520000004 21 M9520000104 M91010000 M91020000 M92000000 M92000010 DECAL CAUTION DECAL AMMETER CHANGE OVER SN 22 Mi9520000204 DECAL VOLTMETER CHANGE OVER SW M92000020
11. 60 HZ TRAILER MAINTENANCE Brakes Trailer brakes should be inspected the first 200 miles of operation This wil allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes every 3 000 miles lf driving over rough terrain inspect the brakes more frequently Figure 57 displays the major hydraulic surge brake components that will require inspection and maintenance Please inspect these components as required using steps 1 through 8 and Table 15 as shown below Brake Adjustment 1 Place the trailer on jack stands Make sure the jack stands are placed on secure level ground 2 Check the wheel and drum for free rotation 3 Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate 4 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes 5 Adjstthe brake shoes outward until he pressure of the lining against the wheel drum makes the wheel dificult to turn 6 Adjust rotate the star wheel in the opposite direction unti the wheel rotates freely with sight ining drag 7 Replace the adjusting hole cover and ower the trailer to the ground 8 Repeat steps 1 through 7 on the remaining brakes Hydraulic Surge Brakes Hydraulic surge brakes Figure 56 should not require any special attention with the exception of routine maintenance such as shoe and lining replacement Brake lines should
12. 96 20 amps per receptacle Table 10 Receptacle Load Capability KVA in Us Available Load the voltages as listed in Table 7 see below will require UVWO Terminals Curent amps fine adjustment using the voltage regulator VA control FCI Duplex NENA knob located on the control panel 50 200 5208 120V 5 7 208 amps per receptacle Eel uin 125 15 amps per receptacle Swap W 220 240 nw w 84 20 amps per receptacle single Phase Sra Phase aay zr uw so PAGE 26 DCA 25SSIU2 60 2 OPERATION AND PARTS MANUAL REV 0 01 27 06 GAUGE READING How to Read the Output Terminal Gau The gauges and selector switches on the control panel DO NOT effect the generator output They are provided to help observe how much power is being supplied at the Output terminals lugs Before taking a reading off either gauge set the Volta Selector Switch Figure 17 to the position which produces the required voltage For example for 30 240V choose the center 30 240 139V position on the volt age selector switch PHASE 2467139 80277 Figure 17 Voltage Selector Switch 240 139V Three Phase Position For 30 208 10 120 place NOTE the Voltage Selector Switch in the 3 Phase 240 139 position ading Voltage To determine the voltage between two terminal lugs set the AC V
13. Fuel overflow pipe clogged Clean este ene of fedus 10 1e speted in Btw or bue bast gas SEATO compressor Aus tp sama mm son ka mm pom dre omy Cien or change dog pum Deter Pepa eae econ ing Ea moving parts par eae Defer ouput Ursin rein pum Rapal or Topla the noi Replace head gasket tighten cylinder head glow plug and Compression leak DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL 0 01 27 06 PAGE 49 EXPLANATION OF CODE IN REMARKS COLUMN Howto read the marks and remarks used in ths parts book Items Found In the Remarks Column Serial Numbers Where indicated this indicates a serial number range inclusive where a particular part is used Model Number Where indicated this shows that the corresponding part is utlized only with this specific model number or model number variant Items Found In the Items Number Column All parts with same symbol in the number column or lt belong to the same assembly or kit E 9 t more than one of the same NOTE reference number is listed last one listed indicates newest or latest available wort conte
14. conditions the pressure between 28 71 psi 198 490 kPa Figure 44 Frequency Meter Hz Figure 48 Pressure Gauge 10 The generators voltage meter Figure 45 displays the 14 The coolant temperature gauge Figure 49 will indicate 120 in VOLTS Ifthe voltage isnotwithin the specified the coolant temperature Under normal operating frequency tolerance conditions the coolant temperature is between 165 and 203 degrees Fahrenheit 74 95 degrees Celsius a pve Figure 45 AC Voltmeter 11 Use the voltage adjustment control knob Figure 46 to Figure 49 Coolant Temperature Gauge increase or decrease the desired voltage 15 The tachometer Figure 50 will indicate the speed of the engine when the generatoris operating Under normal operating conditions this speed is approximately 1800 DECREASE INCREASE ms Figure 46 Voltage Adjusted Control Knob lt 12 The ammeter Figure 47 willindicate zero amps with no load applied When a load is applied this meter will indicate the amount of current that the load is drawing fom the generator Figure 50 Engine Tachometer Figure 47 Ammeter No Load DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU2 60 HZ START UP PROCEDURE SHUTDOWN 16 Tum the main GFCI and aux circuit breakers to the MAIN AUXILIARY ON position Figure 51 CIRCUIT C
15. level ground before refueling Figure 24 Fueling the Generator to prevent spiling and maximize the amount of fuel that can be pumped into the tank 3 NEVER overfill fuel tank Iis important to read the fuel gauge when filing trailer fuel tank DO NOT waitfor fuel to rise in filer neck Figure 35 FUEL GAUGE LOCATED CONTROL PANEL 2 Le NOTE ONLY use 2 diesel fuel when Figure 35 Full Fuel Tank refueling DO NOT fill on unlevel ground CAUTION REFUELINGTHE GENERATOR DO NOT OVERFILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 36 Fuel EXPANDS When Heated ve m Figure 36 Fuel Expansion DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 Coolant Isuzu Antifreeze Summer Coolant Water Isuzu recommends Isuzu Antifreeze Summer Coolant for use in their engines which can be purchased in concentrate and mixed with 50 demineralized water or pre diuted See the Isuzu Engine Owner s Manual for further details WARNING BURN HAZARDS f adding cooanlanifreeze mix to the 3 radiator DO remove the radiator cap until the unit has completely cooled The possibilty of hot coolant exists which 4 can cause severe burns Day to day addition of coolant is done from the recovery tank When adding coolant to the radiator DO NOT remove the radiator cap until the un
16. of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob p Use this position for Remember the voltage selector switch determines the range 0 77 30 208 or 18120 of the output voltage The voltage regulator allows the A user to increase or decrease the selected voltage 5 30 240 139 Output Terminal Lug Voltages Figure 25 Voltage Selector Switch 240 139V Place the voltage selector switch in the 30 240 139 position as shown in Figure 22 Three Phase Position 2 Connect the load wires to the Output Terminal Lugs as hee ime shown in Figure 26 Figure 22 Voltage Selector Switch 240 139 Three Phase Position 2 Connect the load wires to the Output Terminal Lugs as shown in Figure 23 o Figure 26 Output Terminal Lugs 30 208 120V Connections 3 Tum the voltage regulator knob Figure 25 clockwise to increase voltage output turn counterclockwise to decrease voltage output Figure 23 Output Terminal Lugs 30 240 139 Three Phase Connections 3 Tum the voltage regulator knob Figure 24 clockwise to increase voltage output turn counterclockwise to decrease voltage output DECREASE INCREASE N To achieve 30 208V output the voltage selector switch must be in the 30 240 139 position and the voltage regulator must be adjusted to 208V Figure 24 Voltage Regulator Knob 139V 240V PAGE 28 DCA 25SSIU2 60 2
17. spill the fuel during disassembly Vent any air PAGE 38 DCA 25SSIU2 60 2 OPERATION AND PARTS MANUAL 595102 60 2 MAINTENANCE Flushing Out Radiator and Replacing Coolant Open both cocks located at the crankcase side and at the lower part ofthe radiator and drain coolant Open the radiator cap while draining Remove the overflow tank and drain Check hoses for softening and kinks Check clamps for signs of leakage 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 screwdriver Tighten both cocks and replace the overflow tank Replace with coolant Table 13 for correct mixture Close radiator cap tightly Allow engine to coolwhen ushingout L 7 radiator Flushing the radiator while hot could cause serious bums from water 5 steam k Generator Storage For longe term storage of the generator the following is recommended the tuel tank completely Treat with a stabilizer if necessary Completely drain the from the crankcase and refi it necessary with fresh Clean the entire generator internal and external Cover the generating set and store in a clean dry place Disconnect the battery Make sure engine coolant is at proper level If generator is mounted on a trailer jack trailer up and place on block so tires do touch the ground or remove tires
18. 0097 DOOR STOPPER 8 46 0027208025 MACHINE SCREW 8 47 M9310000004 BLIND PLUG 8 48 0600500090 EMBLEM 1 49 0021106016 MACHINE SCREW 2 50 0016910020 HEX HEAD BOLT 1 50A 0040510000 TOOTHEDWASHER 1 51 0016908020 HEX HEAD BOLT 1 51A 0040508000 TOOTHED WASHER 1 52 0016906020 HEX HEAD BOLT 1 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 75 DCA 25SSIU2 60 2 RUBBER SEALS ASSY ENCLOSURE ASSY n 2 esed 6 5 1 PAGE 76 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 25551 2 60 HZ RUBBER SEALS ASSY ENCLOSURE ASSY NO PARTNO PART NAME QTY REMARKS 1 0228901170 SEAL RUBBER 2 2 0228000695 SEALRUBBER 3 3 0228000725 SEALRUBBER 1 4 1490300004 SEAL RUBBER 1 5 022880035 SEAL RUBBER 1 6 0228900370 SEAL RUBBER 1 7 0228900550 SEAL RUBBER 1 8 0228900560 SEAL RUBBER 1 9 0229200595 SEAL RUBBER 1 10 0228900620 SEAL RUBBER 1 1i 0229200750 SEAL RUBBER 2 12 0229200740 SEAL RUBBER 1 13 0228800670 SEAL RUBBER 2 14 0228800445 SEAL RUBBER 1 15 0228800485 SEAL RUBBER 1 16 0228100458 SEAL RUBBER 1 17 0228100171 SEAL RUBBER 1 18 0228100351 SEAL RUBBER 1 19 0228100285 SEAL RUBBER 1 20 0228100153 SEAL RUBBER 1 21 0228100180 SEAL RUBBER 1 DCA 25SSIU2
19. 0400204 COVER 2 9 0016906016 HEX HEAD BOLT 4 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 69 DCA 25SSIU2 60 HZ FUEL TANK ASSY FUEL TANK ASSY PAGE 70 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 CA 25SSIU2 60 HZ FUEL TANK ASSY FUEL TANK ASSY NO PARTNO PART NAME ry REMARKS 1 M1363000212 FUELTANK 1 2 0605505070 FUEL TANK 1 1363200004 2 4 M9310500104 SUPPORTER SHEET 4 5 0016908020 HEX HEAD BOLT 2 6 0207308000 HEXNUT 2 7 0222100080 RUBBER SHEET 4 8 9200000003 DRAIN JOINT 1 9 M8200200004 DRAIN BOLT 1 10 0150000018 ORING 1 17 0016906020 HEX HEAD BOLT 2 12 M1363400104 DRAIN HOSE 1 13 0605515198 HOSE BAND 2 14 8943672922 FILTER FUEL e INCLUDES ITEM Wi i REPLACES PIN 0602042202 14A 8943692993 CARTRIDGE FUEL FILTER REPLACES P N 0602042700 45 M1366700104 BRACKET FUEL FILTER 1 16 0016908020 HEX HEAD BOLT 6 17 8970398340 FUEL PUMP ids n REPLACES P N 0602023177 17A 8944370220 FILTER FUEL PUMP 18 0016906025 HEX HEAD BOLT H 19 0191200900 SUCTION HOSE 1 20 0191200300 SUCTION HOSE 1 21 0191200650 SUCTION HOSE 1 22 0191201100 RETURN HOSE 1 23 0605515108 HOSE BAND 5 24 0605515198 HOSE BAND 3 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 71 ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PA
20. 121 KNOB 25N 1 37 M1223100004 STOPPER 1 38 0027105010 MACHINE SCREW 2 38 0027105010 MACHINE SCREW 4 40 M8220100004 SET SCREW 1 41 0080200007 SNAP RING 1 42 8079259120 ENGINE CONTROLLER 1 43 0016906016 HEX HEAD BOLT 2 4 0207006000 NUT 2 44 8944299470 RELAY 2 45 8944001061 GLOW RELAY 1 46 0027105016 MACHINE SCREW 4 471246702304 WIRE HARNESS GENERATOR 1 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 57 DCA 25SSIU2 60 HZ ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANNEL ASSY PAGE 58 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 25551 2 60 2 ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY NO PARTNO PART NAME QTY REMARKS 1 8970444180 IGNITION SWITCH nn d os INCLUDES ITEM Wi 8944024980 KEYS IGNITION SWITCH 1 2 0602103092 PREHEAT LAMP 1 INCLUDES ITEM W 2A 0601810245 BULB E 10T 10 DC1 1 3 0602120095 TACHOMETER 1 4 0602122093 OIL PRESSURE GAUGE 1 5 0602123090 WATERTEMPERATURE GAUGE 1 6 0602121080 CHARGING AMMETER 1 0602125090 FUELGAUGE 1 8 0602103092 ALARM INCLUDES ITEM Wie 0601810245 BULB E 107 10DC1aV 3 9 0601810141 PANEL LIGHT 1 10 0601831330 SWITCH PANEL LIGHT 1 1i 1357201212 WIRE HARNESS ENGINE 1 12 983101570 UNIT OIL PRESSURE 1 18 804032410 SENDER OVERHEAT SWITCH 1 DCA 25SSIU2 60 HZ OPERAT
21. 2 60 HZ MAINTENANCE TABLE 14 INSPECTION MAINTENANCE Check Engine Fuid Levels 10 Hrs DAILY x 250 500Hrs 1000 Hrs Check Air Cleaner Check Battery Acid Level Check Fan Condon Check for Lenis Check for Loosening of Pars x x x x x Replace Engine Oi and ENGINE Ar Far Can Inside and Outside Change Fuel Fiter Can Radiator and Check Coolant Protoction Laer x Replace Air Fiter 2 Check al Hoses and Clean inside of Fuel Tark Measure insulation Rosstance Over ohms GENERATOR Check olor Rear Support Bearing 1 Replace engine ol and flor at 100 hours frst ime 72 Add Supplemental Coolant dives SCA S to recharge tho engine coolant Replace primary air element when esticton indicator shows a vaccum of 625 mm 25 in 4 Taowby needs to be replaced ensure that the sape of tha blowby hose at 1 2 inch par fot wih sags or dips that coud colec andor oi General Inspection Prior to each use the generator should be cleaned and inspected for deficiencies Check for loose missing or damaged nuts bolts or other fasteners Also check for fuel oil and coolant leaks Use Table 14 a general maintenance guidelineEngine Side Refer to the Engine Instruction Manual Air Cleaner Every 250 hour
22. 2 60 HZ OPERATION AND PARTS MANUAL A 25SSIU2 60 HZ Safety precautions should be followed at all times when operating this equipment Failure to read and understand the Safety Messages and Operating Instructions could result injury to yourself and others This Operation and Parts Manual 7 has been developed to provide complete instructions for the safe and efficient operation of Power Model DCA 25SSIU2 60Hz Whisperwatt Generator Before using this generator ensure that the operating individual has read and understands all instructions in SAFETY MESSAGE ALERT SYMBO HAZARD SYMBOLS Potential hazards associated with the operation of this equipment willbe referenced with Hazard Symbols which appear throughout this manual and will be referenced in conjunction with Safety Message Alert Symbols WARNING LETHAL EXHAUST GASES ae Diesel engine exhaust gases contain gt poisonous carbon monoxide This gas is colorless and odorless and can cause DEATH if inhaled NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air this manu SAFETY MESSAGE ALERT SYMBOLS The three 3 Safety Messages shown below willinform you about potential hazards that could injure you or others The Safety Messages specifically address the level of exposure to the operator and are precede
23. 209 BALANCING WEIGHT KIT 1 iii 0071906308 BEARING 6308000 1 2 0010308035 HEX HEAD BOLT 6 2 0040008000 SPRINGWASHER 6 28 0041208000 PLAIN WASHER 6 3 0070506803 BEARING 680377 1 4 B1130201103 STATOR ASSY 1 0845041904 GROMMET 1 5 1138000003 FIELD ASSY EXCITER 1 6 0016008045 SOCKET HEAD CAP SCREW 8 22 3 7 0042508000 SPRINGWASHER 3 8 8351315003 END BRACKET 1 9 0017108035 HEX HEAD BOLT 6 10 8351312004 PACKING 1 8951331004 COVER SUCTION 1 2 0017106016 HEX HEAD BOLT 3 13 0010310030 HEX HEAD BOLT 6 13A 0040010000 SPRINGWASHER 6 138 0041210000 PLAINWASHER 6 80155400204 COVER 1 15 0010106030 HEX HEAD BOLT 1 16 0041206000 PLAIN WASHER 1 17 0600815000 NUT USN 6001 1 18 M9312600004 RUBBER SUSPENSION 2 19 0207010000 2 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 53 DCA 25SSIU2 60 HZ CONTROL BOX ASSY CONTROL BOX ASSY PAGE 54 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 255 12 60 HZ CONTROL BOX ASSY CONTROL BOX ASSY NO PARTNO PART NAME QTY REMARKS 1 M1213000902 CONTROL BOX 1 2 0601870430 CIRCUIT BREAKER 603060033 3 60ATC 12VDC 1 3 0021004075 MACHINE SCREW 4 4 0601842384 RESISTOR GG20W 50 OHM 1 5 0021004010 MACHINE SCREW 2 6 0601823240 RECTIFIER DE45 2 7 0027104030 MACHINE SCREW 1 8 0601815759 TERMINAL BOARD KT 20 6P 1 9 0027104020 MACHINE SCREW 2 10 0601823863 RELAY UNIT MSA9013A 2
24. 23 9520100004 DECAL WARNING 92010000 24 M9520100503 DECAL WARNING 92010050 25 M9520100204 DECAL CAUTION 92010020 26 9520100804 DECAL SAFETY IN M92010030 27 9520100404 DECAL DANGER 92010040 28 M9520200003 DECAL CONNECTION OF OUTPUT CABLE MS2020000 28 9520200404 DECAL OVER CURRENT RELAY M92020040 30 M1560100403 STRIPE WHISPERWATT 3 M1560100504 STRIPE 25 32 M1560101604 DECAL MQ POWER 33 MI560101704 STRIPE 34 M1560101804 STRIPE 35 9521000004 DECAL TERMINAL OPERATION AND PARTS MANUAL REV 0 01 27 06 Effective PAYMENTTERMS Termsofpaymentforparts are net 10 days FREIGHTPOLICY Al parts orders will shipped collect or repaid with thecharges added othe invoice Al shipments are FOB point of origin Muliqupisresponsibiltyceaseswhena signed manilesthasbeen obtained from the carier andanyclaimforshortageordamage mustbe setledbetweentheconsignee andthe carrier MINIMUM ORDER TheminimumchargeforordersfromMultiquip is 15 00 net Customers wil be asked for instructions regarding handling of ordersnot meeting thisrequirement RETURNED GOODS POLICY Retum shipmentswillbeacceptedandcredit willbeallowed subjecttothefolowing provi sions 1 ARetumed Material Authorization must be approved by Muliquip prior to shi met 2 TooblainaRetum Material Authorization alistmustbeprovidedto MuliquipParts Salesthatdefinesitemnumbers quanti ties and descriptions o
25. 4452 POWER WHISPERWATT SERIES MODEL DCA 25SSIU2 60 Hz GENERATOR PARTS LIST NO 1870300804 Revision 0 01 27 06 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES CALIFORNIA Propos Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 HERE S HOW GET HELP PLEASE HAVETHE MODEL AND SERIAL NUMBER ON HANDWHEN CALLING POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Carson 90746 FAX 310 632 2656 Email mqpower multiquip com Internet www mqpower com PARTS DEPARTMENT 800 427 1244 FAX 800 672 7877 310 537 3700 FAX 310 637 3284 SERVICE DEPARTMENT 800 835 2551 FAX 310 638 8046 310 537 3700 TECHNICAL ASSISTANCE 800 835 2551 FAX 310 638 8046 WARRANTY DEPARTMENT 800 835 2551 EXT 279 FAX 310 638 8046 310 537 3700 EXT 279 COPYRIGHT 2005 MULTIQUIP INC Power Inc Ultra Silent series and the Power logo are registered trademarks of Multiqui 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 This manual MUST accompany the equipment at all imes This manual is considered a permanent part of the equipment and should remain with the unt if resold
26. 601812598 RECEPTACLE GF 53 125V 20AX2 2 28 0601812538 RECEPTACLE 056369 250V 50A 2 24 0027104016 MACHINE SCREW 8 24A 0207004000 HEX NUT 4 25 M1236100503 TERMINAL COVER 1 25 0010112045 HEX HEAD BOLT 2 27 0041212000 PLAIN WASHER 2 28 9310200004 STAY RUBBER 2 0030012000 HEX NUT 2 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 65 255 12 60 HZ BATTERY ASSY BATTERY ASSY 66 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 A 25SSIU2 60 HZ BATTERY ASSY BATTERY ASSY NO PARTNO PART NAME ary REMARKS 1 0602220185 BATTERY 1 2 M9310500014 BATTERY SHEET 1 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 5 0040006000 SPRINGWASHER 2 6 M1348400204 BATTERY CABLE 1 M2346400104 BATTERY CABLE 1 8 0016910020 HEX HEAD BOLT 1 9 0040510000 TOOTHEDWASHER 1 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 67 DCA 25SSIU2 60 HZ MUFFLER ASSY MUFFLER ASSY PAGE 68 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 CA 25SSIU2 60 HZ MUFFLER ASSY MUFFLER ASSY NO PARTNO QTY REMARKS 1 0802300390 MUFFLER 1 2 0016908020 HEX HEAD BOLT 4 3 M1333201703 EXHAUST 1 4 8070420280 GASKET sa 1 REPLACES P N 0602320100 5 1333200014 GASKET 1 6 0207008000 HEX NUT 4 7 0016908035 HEX HEAD BOLT 4 8 133
27. Current Relay Over Current Relay over current relay Figure 14 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over cur rent relay must be pressed The over current relay is lo cated in the control box PAGE 24 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL to draw outside air into the cabinet to cool the engine The fan has 10 amp AC fuse located beneath the Voltage Selector Switch Figure 15 VOLTAGE SELECTOR SWITCH FUSE FUSE HOLDER Figure 15 Blower Fan Fuse DANGER ELECTROCUTION HAZARDS This fuse has current running through time the engine is running This fuse is NOT connected to the main circuit breaker of the generator Attempting to replace the fuse withthe engine and or generator operating could result electrocution and severe bodily harm ALWAYS turn the unit completely oft before attempting replace or handle this fuse REV 0 01 27 06 Single Phase Load Always be sure to check the nameplate on the generator and equipment o insure the wattage amperage frequency and voltage requirements are satisfactorily supplied by the generator for operating the equipment Generally the wattage listed on the nameplate of the equipments its rated output Equipment may require 130 150 more wattage than th
28. EANER 27 1373100803 HOSE AIR CLEANER i 28 0605515147 HOSE BAND 3 29 0602022560 ADAPTER 10 M20X1 5 F80X S 1 30 M1320300304 PACKING 4 31 0602011430 FAN BELT ISUZU 897224 9990 1 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 61 DCA 25SSIU2 60 HZ ENGINE amp RADIATOR ASSY CONT ENGINE amp RADIATOR ASSY CONT PAGE 62 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 555102 60 HZ ENGINE amp RADIATOR ASSY ENGINE 8 RADIATOR ASSY CONT NO PARTNO PART NAME ary REMARKS 31 0602022561 90 DEGREE ELBOW 33982 10 10 1 32 0603306590 CONNECTOR 10WFTX S 1 38 0603300285 LOCKNUT 10WLN 1 34 0605511395 VALVE XV500P 8 1 35 0603306395 HOSE JOINT 30182 8 10 1 36 0602021070 10FNTX S 1 37 0269200280 DRAIN HOSE 836 10 1 38 02000003 DRAIN JOINT 1 38 9200200004 PLUG 1 40 0150000018 ORING 1 4i 0016906020 HEX HEAD BOLT 2 42 0199900600 DRAIN HOSE 1 43 0199900500 DRAIN HOSE 1 44 0605515106 HOSE BAND RS 8006 4 45 M9300000003 RESERVE TANK 1 46 M9300100003 CAP RESERVE TANK 1 47 0199100215 1 48 M1317100004 BRACKET RESERVE TANK 1 49 0199100350 1 50 0193600850 1 51 0605515106 HOSE BAND 85 8006 2 52 0602120481 PICK UP TACHOMETER 71255 00 1 53 9827200690 SENDER OIL SWITCH 1 5 9200100004 ADAPTER 1 55 8970785920 UNIT
29. ESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION No Votage Output JG Votar detective heck output votage using a wing connection loose Check wiring and repa is AVR place necessary Detective Rotatng Rector Check and replace Ector Chock for 17 3 ohms across K on CN Low Votage Ouput 1s engine speed conect Tum engine lever to s wing connections loca Check wiring and Delect AVAT place necessary Votage 1s wiring connections loose heck wiring and repa Detective AVAT place necessary Breaker Tepod Shot i kas Check ad and repair Over curent Con load requirements and reduce breaker heck and replace Over curent Relay actuated Confirm load roqurement and replace DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAI A 25SSIU2 60 HZ TROUBLESHOOTING ENGINE Practically breakdowns can be prevented by proper handing and maintenance inspections but in the event of a breakdown use Table 21 Engine Troubleshooting as basic guideline for troubleshooting the Engine Ifthe problem cannot be remedied consult our company s business office or service plant TABLE 21 ENGINE TROUBLESHOOTING Engine does not start SYMPTOM POSSIBLE PROBLEM SOLUTION No Replenish fuel Airin the fuel system Bleed system Water in the fuel
30. G PARTS NEVER operate equipment with covers cor guards removed Keep fingers hands hair and clothing away from all moving parts to prevent injury CAUTION RESPIRATORY HAZARDS ALWAYS wear approved respiratory protection AX CAUTION ACCIDENTAL STARTING OFF ALWAYS place the Engine ON OFF switch in the OFF position and remove 2 t key when the pump is not in Z AX CAUTION SIGHT AND HEARING HAZARDS ALWAYS wear approved eye and hearing protection CAUTION OVER SPEED CONDITIONS equipment can result operating in CAUTION EQUIPMENT DAMAGE MESSAGES NEVER tamper with the factory settings Other important messages are provided throughout this of the engine governor or settings manual to help prevent damage to your generator other Personal injury and damage tothe engine property or the surrounding environment speed ranges above maximum allowable IFFFEF EET ni 9 This generator other property the surrounding environment could be damaged if you do not follow instructions DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL DCA 25SSIU2 60 HZ RULES SAFE OPERATION DANGER READTHIS MANUAL Failure to follow instructions in this manual may lead to serious injury or even DEATH This equipment is to be operated by trained and qualified personnel only This equipment s for industrial use on
31. HINE SCREW HEX NUT HINGE WASHER MACHINE SCREW BLIND PLUG ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT BONNET CAP CHAIN ASSY HEX HEAD BOLT SPLASHER PANEL 25551 2 60 HZ ENCLOSURE ASSY QTY REMARKS 1 2 4 8 8 8 4 u 7 8 8 4 4 2 2 3 2 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 DCA 25SSIU2 60 HZ ENCLOSURE ASSY CONT ENCLOSURE ASSY CONT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ORANGE WHITE YELLOW SPECTRUM GREY 7 0ATO GOLD GREEN RED THE SERIAL NUMBER MAY REQUIRED PAGE 74 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU2 60 HZ ENCLOSURE ASSY ENCLOSURE 1 ASSY CONT NO PARTNO PART NAME QTY REMARKS 31 0016908055 HEX HEAD BOLT 2 32 0016908020 HEX HEAD BOLT 2 33 1453003803 SIDE DOOR 1 M1493405604 ACOUSTIC SHEET 1 34 M1453003903 SIDE DOOR 1 34 1493405704 ACOUSTIC SHEET 1 35 1453004003 SIDE DOOR 1 M1493405804 ACOUSTIC SHEET 1 36 1453004103 SIDE DOOR 1 1493405904 ACOUSTIC SHEET 1 S7 M1453301203 DUCT 1 38 0207006000 HEX NUT 4 39 M9113000002 DOOR HANDLE ASSY 3 40 0021806016 MACHINE SCREW 12 40A 0030006000 HEX NUT 12 4i M9110100204 HINGE 4 42 M9110100304 HINGE 4 43 M9116100004 WASHER 8 44 0021808020 MACHINE SCREW 9 45 060185
32. ION AND PARTS MANUAL REV 0 01 27 06 PAGE 59 DCA 25SSIU2 60 HZ ENGINE amp RADIATOR ASSY ENGINE amp RADIATOR ASSY 4 PAGE 60 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 555102 60 HZ ENGINE 8 RADIATOR ASSY ENGINE amp RADIATOR ASSY NO PARTNO PART NAME QTY REMARKS 1 1923200044 ENGINE ISUZU AA 4LE2 DA 05 14 0802041210 CARTRIDGE OIL FILTER ISUZU 894456 7411 1 2 M1305200304 ENGINEFOOT 1 M1305200204 ENGINEFOOT 1 4 0010310025 HEAD BOLT 8 5 0040010000 SPRING WASHER 8 6 0041210000 PLAINWASHER 8 7 0605000065 RUBBER SUSPENSION 50 2 8 0207010000 HEX NUT 2 9 0602012776 RADIATOR 2951 292 0000 1 94 0602011079 RADIATOR 6713 092 0901 1 10 9312200104 MOUNT RUBBER 2 11 0016908040 HEX HEAD BOLT 2 12 0207008000 HEX NUT 2 13 1310500803 RADIATOR HOSE 1 14 M1310500903 RADIATOR HOSE 1 15 0605515149 HOSE BAND 4 16 1310200003 FAN SHROUD 1 17 1310200103 FAN SHROUD 1 17A M1493105004 ACOUSTIC SHEET 1 18 0016908020 HEX HEAD BOLT 8 19 M1310300703 FAN GUARD i 20 1310300803 FAN GUARD 1 21 0016908020 HEAD BOLT 8 22 0602048580 AIR CLEANER FPG05 7513 1 20A 0602046321 ELEMENT AIR CLEANER P82 1575 1 23 0602040651 INDICATOR AIR CLEANER X00 2352 1 24 0602040552 BRACKET AIR CLEANER 77 7730 1 25 0016908030 HEX HEAD BOLT 2 28 M1373100303 HOSE AIR CL
33. IRCUIT CIRCUIT BREAKER BREAKERS BREAKERS MAIN GFCI_ AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER WEN e Circuit Breakers OFF Figure 51 Main AUX and GFCI 2 Let the engine cool by running it for 3 5 minutes with no Circuit Breakers ON load applied circuit breakers in the off postion 3 Place the ignition switch Figure 54 inthe STOP poston 17 Observe the generators ammeter Figure 52 andveriy remove the key and store in a sale place it reads the anticipated amount of curent with respect to the load The ammeter will only display current reading if the load is in use START Figure 54 Ignition Switch Stop Position 4 Remove all loads from the generator Figure 52 Ammeter Load 18 The generator will run until manually stopped or an EMERGENCY SHUT DOWN abnormal condition occurs 1 To shut down the engine in the event of an emergency switch the MAIN GFCI and LOAD Figure 55 circuit breakers to position 2 Tum the ignition switch key to the STOP position NORMAL SHUEDO NN STOP OPERATION To shutdown the generator use the following procedure PREHEAT 1 Switch the MAIN AUX and GFCI circuit breakers START Figure 53 to the OFF positon no load Figure 55 Ignition Switch Position PAGE 36 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU
34. Inc ty co JAPAN 4 son caooo Your Local Dealeris 310 537 9700 800 421 1244 FAX 310 632 2656 POWE E mail mqpower multiquip com Intemetwiicmapowercom
35. ND PARTS MANUAL COMPONENT DRAWINGS Generator Assembly 52 53 54 57 58 59 60 63 64 65 66 67 68 69 70 71 72 75 72 73 74 76 76 77 78 79 Engine amp Radiator Assembly Output Terminal Assy Battery Assembly Muffler Assembly Fuel Tank Assembly Enclosure Assembly Rubber Seal Assembly Name Plate And Decals Rubber Seal Assembly Nameplate and Decals Terms and Condition of Sale Parts 80 Specification and part number are subject to change without n NOTE 11111111 REV 0 01 27 06 PARTS ORDERING PROCEDURES When ordering parts please supply the following information Dealeraccountnumber Dealername and address Shipping address different than billing address 3 Returnfaxnumber Applicable mode number Quantity part number and description of each part Specify preferred method of shipment Femex orbs Grand Note Unless otherwise indicated by customer al FedEx or UPS Second Day orThird Day are teated as Standard Orders and wil FedEx or UPS Next Day ship win 24 hours We wil ake every efti Federal Express Priority One ship Air Shipments he same hat the orderis y Ut received 2PM west coast tine Stock Orders must be so noted on fax or web forms 7 Tuk Here s how to get help Place lon Perte m or Fax Please have the model and serial numbe
36. NEL TO INDICATE COLOR OF UNIT ORANGE SLACK WHITE SCHTERPLLLAR YELLOW SPECTRUM GREY 7 CATO GOLD GREEN THE SERIAL NUMBER MAY BE REQUIRED DCA 25SSIU2 60 HZ ENCLOSURE ASSY PAGE 72 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 ENCLOSURE ASSY NO PARTNO 1 1419002802 2 M1413400004 3 0016908020 4 M1423001802 4 M1493104903 5 0016908020 6 M1423200304 6A M1493100604 7 0016908020 8 M1433000203 9 M1433000303 10 0010114030 10A 0040014000 108 0041214000 Ti Mi443001402 12 0016908020 13 M1443300513 13A M1493300304 14 M1443301503 14A M1493300404 15 0207006000 16 0016908020 17 1443200613 18 M1443600114 19 0037906000 18A 0041206000 20 M9113000002 21 0021806016 21A 0030006000 22 M9110100204 23 9116100004 24 0016908020 25 9310000004 26 Mi463001702 26A 1493502903 27 0016908020 28 9310000103 29 1483600204 291 0016908020 30 1453200702 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 73 PART NAME BASE UNDER COVER HEX HEAD BOLT FRONT FRAME ACOUSTIC SHEET HEX HEAD BOLT COVER FRONT FRAME ACOUSTIC SHEET HEX HEAD BOLT CENTER FRAME CENTER FRAME HEX HEAD BOLT SPRING WASHER PLAIN WASHER REAR FRAME HEX HEAD BOLT REAR COVER ACOUSTIC SHEET DUCT REAR COVER ACOUSTIC SHEET HEX NUT HEX HEAD BOLT REAR DOOR WINDOW PLATE HEX NUT PLAINWASHER DOOR HANDLE ASSY MAC
37. ON EYESIGHT HAZARD ALWAYS wear safety glasses when Palio comply may rosin sereus 22 injury a DO NOT attempt to repair or modiy wheel DO NOT install in nner tube to correct a leak through the Ifthe tube may cause pieces of the rim to explode break off with great force and properly matched removing installing force fitted parts AX CAUTION REPAIRING TRAILER WHEELS rimis cracked the air pressure inthe inner 2 cause serious eye or bodily injury Tire WearlInflation Tire inflation pressure is the most important factor in tire lle Pressure should be checked cold before operation DO NOT Suspension The leaf suspension springs and associated components Figure 58 should be visually inspected every 6 000 miles for signs of excessive wear elongation of holes and loosening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 17 SHACKLE SUPPORT TO FRAME HANGER SUPPORT TO FRAME BOLTS SUSPENSION FRONT front MANGER BOLT LOGKING TIE PLATE NUT Figure 58 Major Suspension Components Table 17 Suspension Torque Requirements bleed air from tires when they are Check inflation tem Torque Ft Lbs pressure weekly during use to insure the maximum tire andiread wear 38 U BOLT MIN 30 35 Table 16 Tire Wear Troubleshoo
38. TACLE V 120 VAC POWER SOURCE FOR PROP EXTENSION CORD OPERATION AND PARTS MANUAL REV 0 01 27 06 JACKET WATER HEATER 120VAC INPUT RECEPTACLE SE Figure 56 DCA 25SSIU2 Battery Charger amp Jacket Water Heater Power Connections A 25SSIU2 60 HZ TRAILER MAINTENANCE Trailer Maintenance This section is intended to provide the user with generic trailer service and maintenance information The service and maintenance guidelines referenced in this section referto a wide range of trailers Remember periodic inspection of the trailer wil ensure safe towing of the generator and will prevent personal injury and damage to the equipment The definitions below describe some ofthe major components ofa typical trailer that would be used with the DCA 25SSIU2 Whisperwatt Generator 1 Fuel Cell Provides an adequate amount of fuel forthe equipmentin use Fuel cells must be empty when trans porting equipment 2 Braking System System employed in stopping the trailer Typical braking systems are electric surge hy hydraulic surge and air 3 GVWR Gross Vehicle Weight Rating GVWR is the maximum number of pounds the trailer can in cluding the fuel cell empty 4 Frame Length Measurement is from the hitch to the rear bumper reflector Frame Width Measurement is from fender to fender Jack Stand Trailer support device with maximum pound require
39. TOR ONLY properly trained personnel who have read and understand this section should refil the fuel tank system Located at he bottom ront of the cabinet Figure 32 is the internal fuel tank Some generators may be equipped with a trailer mounted fuel tank option ALWAYS fil the either fuel tank with clean and fresh 2 diesel fuel DO NOT fill the fuel tanks beyond their capacities Pay attention to the fuel tank capacity when replenishing fuel The fuel tank cap must be closed tightly after filing Handle fuel in a safety container If the container does not have spout use funnel Wipe up any spilled fuel immediately Figure 32 Internal Fuel Tank System PAGE 30 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 CA 25SSIU2 60 HZ PRE SETUP Refueling Procedure 2 Remove fuel cap and fil fuel tank as shown in Figure 34 WARNING RESPIRATORY HAZARDS Diesel fuel and its vapors are dangerous xn to your health and the surrounding environment Avoid skin contact and or WHISPERWATT inhaling fumes FUEL TANK FILLER PORT Level Tanks Make sure fuel cells are level with the ground Failure to do so wil cause fuel to spill from the tank before reaching full capacity Figure 33 CAUTION REFUELING THE GENERATOR ALWAYS place trailer on firm
40. The information and specifications included in this publication were in effect at the time of approval for printing Ilustrations are based on the DCA 25SSIU2 60 HZ Whisperwatt Generator Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any ime without notice and without incurring any obligations To find the latest revision of this publication visit our website at www mqpower com DCA 25S8U2 60 HZ OPERATION AND PARTS MANUAL TABLE OF CONTENTS MQ POWER DCA 25SSIU2 60 HZ WHISPERWATT GENERATOR California Proposition 65 Warning Here s HowTo Get Help Table Of Contents Paris Ordering Procedures Specification Dimensions Side Front Safety Message Alert Symbols Rules for Safe Operation Generator Decals Installation General Information Major Components Generator Control Pane Engine Operating Panel Output Terminal Panel Famiarization Load Application Generator Outputs Gauge Reading Output Terminal Panel Connection Pre Setup Generator Start up Procedur Generator Shut Down Procedure Maintenance Trailer Maintenan Trailer Wiring Diagram Generator Wiring Diagram Engine Wiring Diagram Generator Troubleshooting Engine Troubleshooting Explanation of Code in Remarks Column Suggested Spare Parts PAGE DCA 25SSIU2 60 2 OPERATION A
41. WATER TEMPERATURE 1 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 63 555102 60 HZ OUTPUT TERMINAL ASS OUTPUT TERMINAL ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ORANGE WHITE CATERPILLAR YELLOW SPECTRUM GREY 7 CATO GOLD ASUNBEITGREEN THE SERIAL NUMBER MAY BE REQUIRED PAGE 64 2555102 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 C 5SSIU2 60 HZ OUTPUT TERMINAL ASSY OUTPUT TERMINAL ASSY NO PARTNO PART NAME QTY REMARKS O M1230700003 TERMINAL PANEL 1 2 M9220000004 OUTPUT TERMINAL BOLT 5 8 M9220000104 BOLT 5 4 0039308000 HEX NUT 10 5 0040008000 SPRING WASHER 5 6 0041408000 PLAINWASHER 2 7 0016906020 HEX HEAD BOLT 4 8 Mt236100813 TERMINAL COVER t 9 M1236100404 OUTPUT WINDOW 1 10 0605010040 HINGE TH TM122 2 di 0027103010 MACHINE SCREW 4 A 0030003000 HEX NUT 4 11B 0041203000 PLAINWASHER 4 12 0027103010 MACHINESCREW 4 128 0030003000 HEX NUT 4 18 0016906020 HEX HEAD BOLT 2 14 0016908016 HEX HEAD BOLT 4 15 M1236400004 CABLE OUTLET COVER 1 16 129600004 SUPPORTER CABLE OUTLET COVER 1 17 0016906020 HEX HEAD BOLT 6 18 0601870441 CIRCUIT BREAKER QCF 2050 2P 50A 2 18 0601870440 CIRCUIT BREAKER 1020 1P 20A 2 20 M1260700404 BREAKER FITTING COVER 1 201 0222100080 CUSHION RUBBER 1 21 0016906020 HEX HEAD BOLT 2 22 0
42. are to resist damage to the bottom ofthe generator and to maintain alignment OPERATION AND PARTS MANUAL REV 0 01 27 06 555102 60 HZ INSTALLATION Generator Grounding guard against electrical shock and possible damage to the equipment itis important to provide good EARTH ground See Figure 4 for a typical grounding configuration Artide 250 Grounding ofthe National Electrical Code NEC provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical NEC articles 250 64 b and 250 66 set the following grounding requirements 1 Use one of the following wire types to connect the generator to earth ground Copper 10 AWG 6 3 mm or larger b Aluminum 8 AWG 8 4 or larger 2 When grounding the generator Figure 5 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect the other end of the ground cable to earth ground 3 article 250 52 c specifies that the earth ground Tod should be buried aminimum of 8ft into the ground 9 When connecting the generator NOTE Z to any buildings electrical system ALWAYS consult with a licensed electrician 1111111 DC DCA 25SSIU2 60 Series Familiarization Generator The MQ Power Model DCA 25SSIU2 60 Hz is a 20 KW generator Fi
43. be periodically checked for cracks kinks or blockage Anchor Post Retractor Hydraulic Wheel Springs Backing Plate Actuating Pin Hold Down Secondary Spring Shoe Shoe Adjuster Assembly Figure 57 Hydraulic Brake Components Actuator Hydraulic surge braking requires the installation of an actuator atthe tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder supplying hydraulic pressure to the trailer brakes Periodically check and test the surge actuator to make sure that it is functioning correctly Never use an undersize actuator Table 15 Hydraulic Brake Troubleshooting Symptom Possible Cause Solon Te Bales IST UTI LI I Vask ies Bae Pal sed one EIL TIT Bact C Te oroa EIE Son ae ta dw ei 777287 ru OPERATION AND PARTS MANUAL REV 0 01 27 06 CA 25SSIU2 60 HZ TRAILER MAINTENANCE Tires Wheels Lug Nuts Tires and wheels are very important and critical components of the trailer When specifying or replacing the trailer wheels itis important the wheels res and axle are CAUTI
44. cannot the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable See Table 6 11111111 When connecting a resistance load such as an incandescent lamp or electric heater a capacity of up to the generating sets rated output KW can be used When connecting a fluorescent or mercury lamp capacity up to the generating sets rated output KW muliplied by 0 6 can be used When connecting an electric dril or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools capacity of up to the generating sets rated output KW multiplied by 0 8 can be used DANGER ELECTRICAL SYSTEM HAZARDS Before connecting this generator to any buildings electrical system a licensed electrician must install an isolation transfer switch Serious damage to the building s electrical system may occur without his transfer switch DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 25 Voltage Selector Switch The voltage selector switch Figure 16 is located above the output terminal panel s Hard Wire Hook up Panel It has been provided for ease of voltage selection Figure 16 Voltage Selector Switch Voltage Selector Switch Locking Button The voltage selector switch has a locking button to protect the generator and load from being switched w
45. ctrocution electrical shock or burn which can cause severe bodily harm or even DEATH To avoid these hazards NEVER use damaged or worn cables when connecting equipment to the generator Make sure power connecting cables are securely connected to the generators output terminal nsficienttightering ofthe terminal connecons may cause damage to the generator and electrical shock NEVER grab or touch a live power cord with wet hands NEVER touch output terminals during operation This is extremely dangerous ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required Backfeed to a utility system can cause electrocution andor property damage DO NOT connect to any building s electrical system except through an approved device o after building main switch is opened ALWAYS have licensed electrician perform the installation OPERATION AND PARTS MANUAL REV 0 01 27 06 25551 2 60 HZ RULES SAFE OPERATION Maintenance Safety The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits Turn all circuit breakers before performing maintenance on the generator NEVER lubricate components or attempt service on a running machine WI ALWAYS disconnect NEGATIVE battery terminal before performing service on the generator Follow all Bat
46. d by one of three words DANGER WARNING or CAUTION DaNGER You WILL be KILLED or SERIOUSLY injured if you do not follow directions WARNING EXPLOSIVE FUEL Diesel fuelis extremely flammable and its vapors can cause an explosion if ignited DO NOT start the engine near spilled fuel or combustible fluids DO NOT il the fue tank while the engine is running or hot DO NOT overil tank since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system Store fuel in approved containers in well ventilated areas and away from sparks and flames NEVER use fuel as a cleaning agent WARNING You COULD be KILLED or SERIOUSLY injured if you do not follow directions caution You be injured if you do follow directions WARNING BURN HAZARDS Engine components can generate extreme heat To prevent bums DO NOT touch these areas while the engine is running or immediately after operations NEVER operate the engine with heat shields or heat guards removed DANGER ELECTROCUTION HAZARDS PAGE DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL During operation of this generator there n exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even DEATH REV 0 01 27 06 DCA 25SSIU2 60 HZ SAFETY MESSAGE ALERT SYMBO WARNING ROTATIN
47. e rating on the nameplate as the wattage 5 influenced by the efficiency power factor and starting system of the equipment wattage is not given the equipment s name plate iz NOTE approximate wattage may determined by multiplying D nameplate voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 5 below when connecting loads Table 5 Power Factor By Load Type Of Load Power Factor Single phase induction motors 04 075 Electric heaters incandescent 10 lamps Fluorescent lamps mercury lamps 04 09 Electronic devices communication 10 equipment Common power tools 08 6 Cale Selection 0 Hs Single Phase Operation mI Warum Movie Cae ang Amp eto wat owe nme ton orte 25551 2 60 HZ LOAD APPLICATION Three Phase Load When calculating the power requirements for 3 phase power use the following equation VOLTAGE X AMPERAGE X 1 732 1000 Ks 130 load KVA is not given on the equipment nameplate approximate 30 load output maybe determined by muttiplying voltage by amperage by 1 732 NOTE s 1111111 Motors and motor driven equipment draw much greater current for starting than during operation An inadequate size connecting cable which
48. er if the fan belt bends 10 to 15 mm Figure 37 when depressed with the thumb as shown below 10 15 DEY LECTION We Bary va bd Figure 37 Fan Belt Tension pants NEVER place hands near the belts fan while the generator set is running Ver REV 0 01 27 06 Battery This unit is of negative ground DO NOT connect in reverse Always maintain battery fluid level between the specified marks Battery wil be shortened if the fluid level are not properly maintained Add only distilled water when Teplenishment is necessary DO NOT over fil Check to see whether the battery cables are loose Poor contact may result in poor starting or malfunctions Always keep the terminals firmly tightened Coating the terminals with an approved battery terminal treatment compound Replace battery with only recommended type battery The battery type used in this generator is BCI Group 27 The battery is sufficiently charged if the specific gravity of the battery fluid is 1 28 at 68 If the specific gravity should fll to 1 245 or lower indicates that the battery is dead and needs to be recharged or replaced Before charging the battery with an extemal electric source be sure to disconnect the battery cables Battery Cable installation ALWAYS be sure the battery cables Figure 38 are properly connected tothe battery terminals as shown below The Red Cable is c
49. es W ALWAYS know the location of the nearest fire extinguisher ALWAYS know the location of the nearest and first aid kit I ALWAYS know the location of the DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 2555102 60 2 GENERATOR DECA The DCA 25SSIU2 60 Hz Whisperwatt Generatoris equipped with number of safety decals Figures 2 amp 3 These decals are provided for operator safety and maintenance information The ilustration below and on the preceding page show the decals as they appear on the machine Should any of these decals become unreadable replacements can be obtained from your dealer SAFETY INSTRUCTIONS npg pean tt rachina ean couse pe hin vnl used bett nda ne ose pars ana hot we sita temi PIN M3552000103 i En 9 PIN M9520100304 OIL DRAIN PLUGY PIN M950000004 PIN M9520000104 PIN M9520000204 OVER CURRENT RELAY PIN 9520200104 PN Hm FUEL DRAIN PLUGY PIN 9510200002 DIESEL FUEL PIN M9500300004 PIN M9500500104 IL CHECK AND FILL DAILY PIN M9500500004 WATER PIN M9503000103 Figure 2 Generator Decals PAGE 14 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAI REV 0 01 27 06 A 25SSIU2 60 HZ GENERATOR DEC WARNING JT COOLANT can cause w
50. fthe items to be Thepartsrumbersand descriptions must match the current parts price The list must be typed or computer generated Thelist muststate the reason s for theretum d The list must reference the sales order s orinvoices under which the items were originally purchased Thelist must include the name and phone number ofthepersonrequest RMA 3 Acopyotthe Return Material Authoriza tionmustacoompanytheretum shipment 4 Freight is at the sender s expense All partsmustbe returnedtreigh prepaidto designated receiving point PAGE 80 DC 2 TERMS AND CONDITIONS OF SALE PAR 8 Partsmustbe innewandresalablecon dition inthe origina Muitiquip package i and with Multiquip part numbers clearly marked 6 Thefolowingitemsarenotretumable Obsolete parts f an item is in the price book and shows as being replaced by another item it is obsolete h Any parts with limited shelf such as gaskets seals rings andotherrubberparts that werepur chasedmorethansixmonthsprorto theretumdate Anylineitemwithan extendeddealer netpriceoflessthan 5 0 Special orderitems Electrical components Paint chemicals andlubricants Decalsandpaper product thems purchasedin 7 The sender will be notified of any materialreceivedthatisnotacceptable amp Such material will be held for five Working days from notif
51. g and specifies that the cable ground shall be connected to the grounding system of the building as close to the point cable entry as practical The following safety recommendations should also be followed 18 ALWAYS make sure generator is properly grounded NEVER use gas piping as an electrical ground 18 ALWAYS make sure that electrical circuits are properly grounded the National Electrical Code NEC and local codes before operating generator Severe injury or DEATH by electrocution can result from operating an ungrounded generator 1 ALWAYS be sure to use the ground terminal green vire when connecting load to the UV and W output terminal lugs Electrical Safety 18 ALWAYS have qualified electrician perform the generator wiring installation 18 ALWAYS make sure generator installation is accordance with the National Electrical Code NEC and local codes before operating generator NEVER use defective or frayed power cable Check the cable for cuts in the insulation NEVER use a extension cord thats frayed or damaged where the insulation has been cut WI ALWAYS make certain that proper extension cord has been selected for job See Table 1 NEVER power cables or cords lay in water 1 NEVER stand in water while AC power from the generator is being transfer to a load DANGER ELECTROCUTION HAZARDS During operation of this generator there exists the possibilty of ele
52. gure 5 thatis designed as a high quality portable requires a trailer for transport power source for telecom sites lghting facilities power tools submersible pumps and other industrial and construction machinery Engine Operating Panel The Engine Operating Pane is provided with the following Tachometer Water Temperature Gauge Water Temperature Alarm Lamp Oil Pressure Gauge Oil Pressure Alarm Lamp Charging Ammeter Gauge Fuel Level Gauge Pre heat Lamp Panel Light Panel Light Switch Ignition Switch Fuel Filter Water Level Alarm Lamp Generator Control Panel The Generator Control Pane is provided with the following Frequency Meler Hz AC Ammeter Amps AC Voltmeter Volts Ammeter Change Over Switch Voltmeter Change Over Switch Voltage Regulator 3 Pole 60 amp Main Circuit Breaker Control Box located behind the Gen Control Panel Automatic Voltage Regulator Current Transformer Over Current Relay Voltage Rectifier Starter Relay Voltage Selector Switch Output Terminal Panel The Output Terminal Pane is provided with the folowing Two 120 240V output receptacles CS 6369 50A Two auxiliary circuit breakers 50 Two 120V output receptacles 20 Two GFCI circuit breakers 20A Five output terminal lugs 30 power Battery Charger Optional Water Heater Optional PAGE 18 585102 60 HZ DCA 25SSIU2 60 2 OPERATION AND PARTS MANUAL GENERAL INFORMATION
53. he generator in a manner so that the exhaust will not be discharged in the direction of nearby homes The installation site must be relatively free from moisture and dust All electrical equipment should be protected excessive moisture Failure to do wil result deterioration oftheinsulation and wil resultin short circuits and grounding Foreign materials such as dust sand lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts CAUTION EXHAUSTHAZARD Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area Indoor Installation Exhaust gases from diesel engines are extremely poisonous Whenever an engine is installed indoors the exhaust fumes mustbe vented to the outside The engine should be installed at least two feet from any outside wall Using an exhaust pipe which is too long or too small can cause excessive back pressure which wil cause the engine to heat excessively and possibly bum the valves Mounting The generator must be mounted on a solid foundation such as concrete and set firmly on the foundation to isolate vibration of the generator when itis 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 bottom of the generator They
54. hile the engine is running To lock the voltage selector switch press and hold the red button located at the bottom of the switch CAUTION CHANGING VOLTAGES NEVER change the position ofthe voltage selector switch while the engine is running ALWAYS place circuit breaker in the open position before selecting voltage Generator OutputVoltages A wide range of voltages are available to supply voltage for many different applications Voltages are selected by using the voltage selector switch Figure 16 To obtain some of 555102 60 HZ GENERATOR OUTPUT Generator Amperage Table 8 describes the generator current output capability for both 1 phase and 30 phase applications Lr 3er aw E7177 Tht Pie NEN GFCI Receptacle Load Capability The load capability of the receptacles is directly re lated to the voltage being supplied at either the output termi nals or the 2 twist lock auxiliary receptacles Tables 9 and 10 show what amount of currentis available at the GFCI receptacles when the output terminals and twist lock receptacles are in use Be careful that your load does not to exceed the available current capability at the recep tacles Table 9 GFCI Receptacle Load Capability KW in Use Available Load Tuist Lock 056369 Current Amps 10 240120 TIO 144 0 132 5 amps per receptacle 120 10 amps per receptacle 108 15 amps per receptacle
55. ication pending instructions If is not received within five days the material wil be re tumedtothesenderathisexpense 8 Creditonretumedpartswilbeissuedat dealer net price at time ofthe original purchase lessa 15 restocking charge 10 Incases where an item is accepted for which the original purchase document can notbe determined the price will be basedonthelistpricethatwas effective twelve months priortothe RMA date 11 Credit issued wil be applied to future purchasesonly PRICING ANDREBATES Prices are subject to change without prior notice Price changes are effectve ona spe cficdate andallordersrecelvedonoratterthat dotewilbebiledattherevised price Rebates 55102 60 HZ OPERATION AND PARTS MANUAL forpricedecinesandaddedchargesforprice increaseswil notbemadeforstockonhandat thetime ofany price change Muliquip reserves the rightto quote and sell directto Govemmentagencies andto Original Equipment Manufacturer accounts who use products as integral parts of ther own products SPECIAL EXPEDITING SERVICE AS35 00surchargewilbeaddedtotheinvoice forspecialhandiingincludingbus shipments insuredparcel postorincases where mustpersonally deliverhepartstothecarrer LIMITATIONS OF SELLER S LIABILITY Muliquip shall not be fable here under for damagesinexcessofthe purchase price ofthe itemwihrespectio which damagesare claimed andinnoeventshall Muliquipbe iabefor
56. it has completely cooled See Table 12 for engine radiator and recovery tank coolant capacities Make sure the coolant level in the recovery tank is always between the H and the L markings Table 12 Coolant Capacity Engine and Radiator 174 Gal 68 2 Quarts 1 9 liters Reserve Tank Operation Freezing Weather When operating in freezing weather be certain the proper amount of antifreeze Table 13 has been added Table 13 Anti Freeze Operating Temperatures Vol Freezing Point Anti Freeze 50 3 34 i2 NOTES When the antireezeis mixed with water the antifreeze mixing ratio must be less than 50 PAGE 32 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL CA 25SSIU2 60 HZ PRE SETUP Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radiator fins with compressed air Cleaning inside the machine is dangerous so clean only with the engine tumed off and the negative battery terminal disconnected Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the Isuzu Engine Owner s Manual Fan Belt Tension slack fan belt may contribute to overheating or to insufficient charging of the battery Inspect the fan for damage and wear and adjustitin accordance with the Isuzu Engine Owner s Manual The fan belt tension is prop
57. ition Each receptacle is protected by a 20 amp circuit breaker These breakers are located directly above the receptacles Remember the load output current of both receptacles is dependent on the load requirements of the U V and W output terminal lugs Pressing the reset button resets the GFCI receptacle after being ripped Pressing the Test Button See Figure 8 in the center of the receptacle will check the GFCI function Both receptacles should be tested at least once a month CS 6369 TWST LOCK RECEPTACLES S 105 SINGLE PHASE 120240 VAC S0AMP OUTPUT Figure 10 120 240V Twist Lock Auxiliary Receptacles Twist Lock Dual Voltage 120 240 VAC Receptacles There are two 120 240V 50 amp auxiliary twist lock CS 6369 receptacles Figure 10 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 DCA 25SSIU2 60 H OPERATION AND PARTS MANUAL REV 0 01 27 06 555102 60 HZ OUTPUT TERMINAL PANEL FAMILIARIZATION DECREASE INCREASE N Figure 11 Voltage Regulator Control Knob Each auxiliary receptacle is protected by a 50 amp circuit breaker These breakers located directly above the GFCI receptacles Remember the load output current three receptacles is dependent on the load requirements of the Output Terminal Lugs Tum the voltage regulator control kn
58. loss of profit or good wil or for any other special consequential orincidental damages LIMITATION OF WARRANTIES express orimplied aremadein connection with the sale of parts or trade accessories norastoany enginenotmanutac tured by Muliquip Such warranties made in connectionwththesaleofne completeunits are made exclusively bya statement of war rantypackaged with such units and Mutquip neitherassumesnotauthorzesany personto assume tor other obligation o ability whatever in connection with the sale of its products Apartiromsuchwritenstatementof warranty there are no warranties express impliedorstatutory which extendbeyondthe descriptonoftheproductsontheface hereof REV 0 01 27 06 NOTE PAGE DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAI OPERATION AND PARTS MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HANDWHEN CALLING POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Carson CA 90746 FAX 310 632 2656 Email mqpower multiquip com Internet www mqpower com PARTS DEPARTMENT 800 427 1244 310 537 3700 SERVICE DEPARTMENT 800 835 2551 FAX 310 638 8046 310 537 3700 TECHNICAL ASSISTANCE 800 835 2551 FAX 310 638 8046 WARRANTY DEPARTMENT 800 835 2551 EXT 279 FAX 310 638 8046 310 537 3700 EXT 279 actured for Multiqulp
59. ly The following safety guidelines should always be used when operating the DCA 25SSIU2 60 HZ Generator 1 DO NOT operate or service this equipment before reading this entire The operator MUST BE familiar with proper safety precautions and operations techniques before using This equipment should not be operated by persons under 18 years of age clothing shatterproof glasses steetoed boots and other protective devices required the job NEVER operate this equipment when not medicine NEVER operate this equipment under the influence or General Safety or generator NEVER operate this equipment without proper protective 00000 feeling well due to fatigue illness or taking drugs or alcohol NEVER use accessories or attachments which are not recommended by Power for this equipment Damage to the equipment and or injury to user may result WI Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties Whenever necessary replace nameplate operation and safely decals when they become difficult read PAGE 10 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL ALWAYS check the machine for loosened threads or bolts before starting NEVER operate the generatorin an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or e
60. ment from the tongue of the trailer 7 Coupler Type of hitch used on the trailer for towing PAGE 40 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL 8 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and the width in millimeters 175 185 205 etc The tire diameter must match the diameter of the tire rim 9 Tire Ply The tire ply layers number is rated in letters 2 ply4 ply6 ply etc 10 Wheel Hub The wheel hub is connected to the trailers axe 11 Tire Rim Tires mounted on a rim The ire rim must match the size of the tire 12 Lug Nuts Used to secure the wheel to the wheel hub Always use a torque wrench to tighten down the lug nuts See Table 18 and Figure 58 for lug nut tightening and sequence 13 Axle Indicates the maximum weight the axle can sup port in pounds and the diameter of the axle expressed in inches Please note that some trailers have a double axle This wil be shown as 2 6000 Ibs meaning two axles with total weight capacity of 6000 pounds 14 Suspension Protects the trailer chassis from shocks transmitted through the wheels Types of suspension used are leaf and air ride 15 Electrical Electrical connectors looms are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle 16 Application Indicates which units can be employed ona particular trailer REV 0 01 27 06 DCA 25SSIU2
61. n to tighten wheel lug nuts PNEUMATIC AIR GUN TORQUE WRENCH Figure 59 Wheel Lug Nuts Tightening Sequence DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU2 60 HZ TRAILER WIRING DIAGRAM vouete FILAMENT SINGLE FILAMENT DOUBLE FILAMENT BULB DOUBLE FILAMENT swate FILAMENT E vouete FILAMENT TRAILER SIDE REL ames RIGHT TAILLIGHT TOWING VEHICLE 1 were common zouo iow an sucess y oaee eroe LENT FLAT PIN MOLDED MATING CONNECTOR LICENSE TALUGHT years coon orcun aenean A GREEN 169 LEFT TAILLIGHT FLAT ROUND CONNECTOR FLArSPINROUND CONNECTOR Figure 60 Trailer Towing Vehicle Wiring Diagram 55102 60 2 OPERATION AND PARTS MANUAL REV 0 01 27 06 v os A 25SSIU2 60 HZ GENERATOR WIRING DIAGRAM VR Janana OC T OR
62. nts of this catalog are subject to change without notice PAGE 50 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 GESTED SPARE PAR DCA 25SSIU2 60 HZ ULTRA SILENT GENRATOR W ISUZU AA 4LE2 ENGINE 1TO 3 UNITS Description 5 2944566410 FILTER OIL 5 8943692993 FILTER FUEL 3 0602046321 ELEMENT AIR 1 8972606490 BELT FAN 1 0605505070 CAP FUEL TANK 1 9831401570 UNIT OIL PRESSURE 1 8970785920 UNIT WATER TEMPERATURE 1 8944032410 SENDER WATER SWITCH ENGINE SIDE 1 9827200690 SENDER SWITCH ENGINE SIDE f Part number on this Suggested Spare Parts list NOTE may supercedelreplace the PIN shown in the text 1111111 pages ofthis book DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 51 DCA 25SSIU2 60 HZ GENERATOR ASSY GENERATOR ASSY PAGE 52 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 CA 25SSIU2 60 2 GENERATOR ASSY GENERATOR ASSY PARTNO QTY REMARKS 1 B1110200602 ROTORASSY INCLUDES ITEMS Wir tt FIELD ASSY 1 7961025004 RECTIFIER 1 14 0601822630 SURGE ABSORBER TNR23G471K 1 i4 8001070003 FAN 1 15 8351611004 COUPLING DISK 2 18 8351612004 WASHER COUPLING HUB 1 1 78 B1112300003 BALANCING PLATE PURCHASE SET OF 1 10 18 0010310025 HEX HEAD BOLT 4 19 0042510000 SPRINGWASHER 4 1 10 0601000
63. o protect the receptacles from overload Two 50 amp 2 pole circuit breakers have also been provided to protect the auxiliary receptacles from overload Make sure to switch ALL circuit breakers to the OFF position prior to staring the engine Lubrication Oil Fillthe engine crankcase with lubricating through the filer hole but DO NOT overil Make sure the generator is level and verify that the level is maintained between the two notches Figure 31 on the dipstick See Table 11 for proper selection of engine OIL FULL LIMIT Figure 31 Engine Dipstick When checking the engine be sure to check if the oil is clean If the 0115 not clean drain the ol by removing the oil drain plug and refil with the specified amount of oil outined 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 Service Classification CC SC API Service Classification CC SD Service Classification CC SE 8 API Service Classification CC SF Table 11 Recommended Motor Oil OIL SAE 555102 60 HZ PRE SETUP Fuel Check DANGER EXPLOSIONIFIRE HAZARDS Fuelspilage on a hotengine can cause a fire or explosion It fuel spillage occurs wipe up the spilled fuel completely to prevent hazards NEVER smoke around or near the Su CAUTION REFUELINGTHE GENERA
64. oad connected to any phase of the output terminals or to be switched off This switch does not effect the generator output in any fashion itis for current reading only 7 Voltmeter Change Over Switch This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched PAGE 20 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL Located behind the generator control panel is Generator Contro Box This box contains some of the necessary electronic components required to make the generator function The Control Box is equipped with the following major components m OverCurrent Relay Voltage Rectifier AVR m Starter Relay Current Transformer Voltage Selector Switch Remember the overcurrent relay monitors the current flowing from the and W Output Terminal Lugs to the load In the event of a short circuit or over current condition it will automatically trip the 60 amp main breaker To restore power to the Output Terminal Panel press the reset button on the overcurrent relay and place the main circuit breaker in the closed position ON REV 0 01 27 06 25551 2 60 HZ ENGINE OPERATING PANEL Figure 7 Engine Operating Panel The definitions below describe the controls and functions of the DCA 25SSIU2 60 HZ Engine Operating Panel Figure 7 1 Panel Light Normally used in dark places orat night When activa
65. oads always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound The following list of safety precautions should be followed when towing your generator CAUTION FOLLOWTOWING REGULATIONS Check with your local county or state safety towing regulations in addition to meeting Department of Transportation DOT Safety Towing Regulations before towing your generator 1 ALWAYS shutdown engine before transporting I Tighten both fuel tank caps securely B if generator is mounted on a trailer make sure trailer complies with local and state safety transportation laws Follow the listed Towing amp Transporting Safety guidelines for basic towing techniques Make sure the hitch and coupling of the towing vehicle are rated equal o or greater than the trailer gross vehicle weight rating 18 ALWAYS inspect the hitch and coupling for wear NEVER towatrailer with defective hitches couplings chains etc 18 Check the tire air pressure on both towing vehicle and trailer Trailer tires should be inflated to 50 psi cold Also check the tire tread wear on both vehicles 1 ALWAYS make sure the trailer is equipped with a Safety Chain 18 ALWAYS attach trailers safety chains to towing vehicle properly 1 ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly
66. ob Figure 11 on the control panel to obtain the desired voltage Turning the knob Clockwise increase the voltage tuming the knob counter clockwise will decrease the voltage Removing the Plastic Face Plate Hard Wire Hookup Panel The Output Terminal Lugs are protected by a plastic face plate cover Figure 12 Un screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure After the load wires have been securely attached to the terminal lugs reinstall the plastic face plate S HOOKUP PANEL COVER Figure 12 Plastic Face Plate Output Terminal Lugs DCA 25SSIU2 60 2 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Blower Fan Loads can be connected to the generator by the Output This unit has an intake fan located atthe rear of the machine Terminal Lugs or the convenience receptacles Figure 13 Make sure to read the operation manual before attempting to connect a load to the generator To protect the output terminals from overload a 3 pole 60A main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to staring the engine TWISTLOCK RECEPTACLES HARD WIRE a HOOKUP PANEL gt Logo RECEPTACLE tome 2 Jecrouno D E wu T SR Figure 13 Connecting Loads Ld d 2 5 e uy Figure 14 Over
67. oltmeter Change Over Switch to the appropriate setting Figure 18 to activate the AC Voltmeter Gauge Figure 19 and read the available voltage between the two lugs For example to measure the voltage between the W and U terminal lugs set the AC Voltmeter Change Over Switch toW U and read the AC Voltmeter Gauge Figure 18 AC Voltmeter Figure 19 AC Voltmeter Gauge Change Over Switch A 25SSIU2 60 HZ Reading Amperage To determine the amperage at a terminal lug set the AC Ammeter Change Over Switch to the appropriate setting Figure 20 to activate the AC Ammeter Gauge Figure 21 and read the available amperage at the terminal lug For example to measure the amperage at the U terminal lug set the AC Ammeter Change Over Switch to Uand read the AC Ammeter Gauge OFF Figure 20 AC Ammeter Change Over Switch y Figure 21 Ammeter The ammeter gauge will only show a reading when the Output Terminal Lugs are connected toa load andin use 1111111 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 CA 25SSIU2 60 HZ OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages 30 208V 10120V Output Terminal Lug Voltages Various output voltages can be obtained using the Output 1 Place the voltage selector switch in the 30 240 139 Terminal Lugs The voltages at the terminals are depen position as shown in Figure 25 denton the position
68. onnected to the positive terminal of the battery and the Black Cable is connected to the negative terminal of the battery CAUTION BATTERY SERVICING SAFETY ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE BATTERY Figure 38 Battery Connections 25551 2 60 HZ When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the ignition is in the operate or start position 2 Place a small amount of battery terminal treatment compound around both battery terminals This wil ensure a good connection and wil help prevent corrosion around the battery terminals It the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polarity of the battery when connecting the battery 9 1111111 CAUTION BATTERY SERVICING SAFETY Inadequate battery connections may cause poor starting of the generator and create other malfunctions Alternator The polarity ofthe altemator is negative grounding type When an inverted circuit connection takes place the circuit will be in shor circuitinstantaneously resuling the alternator failure DO NOT put water directly on the alternator Entry of water into the alternator can cause corrosion and damage the alternator Wiring Inspect the entire generator bad or wom electrical wi
69. r UNL TOTALS oh hand when calling Domestic USA Dealers Only POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Extra Discounts Carson CA 90746 FAX 3106322056 Al parts orders which include complete part numbers and Email mqpower multiquip com are received by our automated web parts order system Internet www mqpower com by fax qualify for the following extra discounts PARTS DEPARTMENT Ordered Standard Stock orders 800 427 1244 FAX 800 672 7877 via orders S750 istand above 310 537 3700 FAX 310 637 3284 Fax 10 SERVICE DEPARTMENT Web 5 10 pied FAX 310 638 8046 Special freight allowances TECHNICAL Assistance When you order 10 or 800 835 2551 Fax 310 638 8046 line items via Web or Fax WARRANTY DEPARTMENT FedEx Ground Service at no charge for freight 800 835 2551 EXT 279 FAX 310 638 8046 other allowances on freight shipped by any other carrier Common nuts bolts and washers all items under 1 00 list price do not count towards the line items 310 537 3700 EXT 279 MOPONER A Division ofMutiguip Inc Direct TOLL FREE access 7 POSTOFFICEBOX6254 2 4 4 Ganson casas to our Parts Department ea Toll free nationwide 800 427 1244 FAX 310 632 2656 E MAlL mgpower muttiquip com POWI INTERNET maponer oom DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAI
70. ring or connections If any wiring or connections are exposed insulation missing replace wiring immediately Piping and Hose Connection Inspect all piping hose and fuel hose connections for wear and tightness Tighten all hose clamps and check hoses for leaks f any hose fuel or lines are defective replace them immediately DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 33 2555102 60 HZ GENERATOR START UP PROCEDURE Before Starting CAUTION LETHAL EXHAUST HAZARD The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel WARNING STARTINGTHE GENERATOR NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position 1 Place the main G F C L and aux circuit breakers Figure 39 in the OFF positon prior to starting the engine MAIN AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKERS BREAKERS Figure 39 Main Aux and GFCI Circuit Breakers OFF 2 Connect the load to the receptacles or the Output Terminal Lugs as shown in Figure 13 These load connection points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel 3 The output terminal lugs are protected by a plastic cover Remove this cover to gain access to the terminals Tighten terminal nut
71. s Remove air cleaner element and clean the heavy duty paper element with light spray of compressed air Replace the air cleaner as needed Air Cleaner with Dust indicator This indicator is attached to the air cleaner When the air cleaner element is clogged air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service After changing the air element press the dust indicator button to reset the indicator DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAI Service Daily If the engine is operating in very dusty or dry gra conditions a clogged air cleaner will result This can lead to loss of power excessive carbon buildup in the combustion chamber and high fuel consumption Change air cleaner more frequently if these conditions exists Fuel Addition Add diesel fuel he grade may vary according to season and locations Removing Water from the Fuel Tank Afterprolonged use water and other impurities accumulate in the bottom of the tank Occasionally inspect the fuel tank for water contamination and drain the contents if required During cold weather the more empty volume inside the tank the easier it is for water to condense This can be reduced by keeping the tank full with diesel fue DC Air Removal If air enters the fuel injection system of a diesel engine starting becomes impossible After running out of fuel after disassembling the fuel sy
72. s securely to prevent load wires from slipping out 4 Close engine enclosure doors Figure 40 WS INCORRECT Figure 40 Engine Enclosure Doors PAGE 34 DCA 25SSIU2 60 2 OPERATION AND PARTS MANUAL 5 Place the voltage selector switchin the desired voltage position Figure 41 Figure 41 Voltage Selector Switch 6 Preheat the engine glow plugs by tuming the ignition key Figure 42 to the OPERATION position STOP OPERATION PRE HEAT START Figure 42 Ignition Switch Operation Pre Heat Position 7 When the preheat lamp iluminates Figure 43 tum the ignition key to the START position Once the engine starts release the ignition key and allow it to return to the OPERATION positon Figure 42 Figure 43 Pre Heat Indicator Lamp 8 Let the engine run for 3 5 minutes isten and check for any abnormal sounds or smells Check for fuel leaks and noises that would associate with a loose cover hardware If any of the above mentioned conditions exists shut down the engine and correct the problem REV 0 01 27 06 CA 25SSIU2 60 HZ GENERATOR START UP PROCEDURE 9 The generators frequency meter Figure 44 displays 13 The engine oil pressure gauge Figure 48 will indicate the 60 cycle output frequency in HERTZ the pressure of the engine Under normal operating
73. should read between 165 to 203 F Oil Pressure Gauge Normal operation should be between 28 71 psi 193 490 kPa When starting the generator the oil pressure may read a bit higher but afierthe engine warms up the oil pressure should retum to normal 9 555102 60 HZ Output Terminal Panel The OutputTerminai Panel Figure 8 shown belowis located onthe right hand side from control panel ofthe generator Liftup on the coverto gain access to receptacles and terminal lugs 2 Terminal legs O and Ground are considered bonded grounds OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Familiarization The Output Terminal Panel Figure 9 is provided with the following 120 240 output receptacles 2 8 50 amp Circuit Breakers 2 50 amps 2 pole 120V receptacles 2 20 amp GFCI Circuit Breaker 2 20 amps 1 pole W Five 5 Output Terminal Lugs U V W O Ground WIRE Access DOR Figure 8 Output Terminal Panel PAGE 22 DCA 25SSIU2 60 2 OPERATION AND PARTS MANUAL 01 27 06 120 GFC RECEPTACLE M RESET BUTTON TEST 0 5 Figure 9 G F C L Receptacle 120VAC GFCI Receptacles There are two 120 VAC 20 amp GFCI Duplex 5 208 receptacles provided on the output terminal panel These receptacles can be accessed in any voltage selector switch pos
74. stem bleed the system according tothe following procedure To restart after running out of fuel tum the switch to the ON position for 15 30 seconds Try again needed This unitis equipped with an automatic air bleeding system Cleaning the Fuel Strainer Clean the fuel strainer if it contains dust or water Remove dust or water in the strainer cap and wash it gasoline Securely fasten the fuel strainer cap so that fuel wil not leak Check the fuel strainer every 200 hours of operation or once a month Check Oil Level Check the crankcase level prior to each use or when the fuel tank is filed Insufficient may cause severe damage to the engine Make sure the generator is level The oil level must be between the two notches on the dipstick shown in Figure 31 Replacing Oil Filter To remove the fiter grip the filer body and turn counter clockwise Apply a fim of oil to the rubber seal gasket Place the fiter body onto the oi fiter spindle by turing clockwise DO NOT over tighten After the oil fiter has been replaced the engine oil wil drop slightly Run the engine for a while and check for leaks before adding more oil if needed Clean excessive oil from engine Replacing Fuel Filter Replace the tuel filter cartridge with new one every 500 hours or so Loosen the drain plug at the lower top of the fuel filter Drain the fuel in the fuel body together with the mixed water DO NOT
75. system Remove water from fuel tank Fuel pipe clogged Clean fuel pipe Fuel fiter clogged Clean or change tuel fiter Excessively high viscosity of fuel or engine at low temperature Use the specified fuel or engine ol Fuel with low cetane number Use the specified fue Fuel leak due to loose injection pipe retaining nut Tighten nut Injection nozzle clogged Clean injection nozzie Injection pump malfunctioning Repair or replace Seizure of crankshaft camshaf Piston cylinder liner bearing Repair or replace Compression leak trom Replace head gasket tighten cylinder head glow plug and yinder nozzle holder Piston ring and iner wom Replace Excessive valve clearance Starter malfunctioning Repair or replace Starter does not run Wiring disconnected Connect wiring PAGE 48 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 2555102 60 HZ TROUBLESHOOTING ENGINE SYMPTOM POSSIBLE PROBLEM SOLUTION Fuel fiter logged or dirty Clean or change Ar cleaner clogged Clean change Fuel leak due to loose injection pipe retaining nut Tighten nut Injection pump malfunctioning Repair or replace Engine revolution is not smooth Incorrect nozzle opening m pressure Injection nozzle stuck or or replace
76. ted pane wil iluminate When the generator is not in use turn the panel light switch to the position 2 Panel Light Switch When activated wiltum on control panel ight 3 Oil Pressure Alarm Lamp Indicates that the oil pressures too low orhigh and wil shut down the engine 4 Water Temperature Alarm Lamp Indicates that the water temperature is outside of normal range and will shut down the engine 5 Fuel Filter Water Lever Alarm Lamp Indicates that water level in the fuel level has risen Drain the water in the fuel fiter strainer when this condition occurs 6 Ignition Switch Three position switch stop operation and start Insert ignition key to start and stop engine DCA 25SSIU2 60 H 10 n 12 OPERATION AND PARTS MANUAL REV 0 01 27 06 Pre heat Lamp This indicates when the engine is ready for starting during cold weather operating conditions Tachometer indicates engine speed in RPM s for 50 Hz operation This meter should indicate 1500 RPM s when the rated load is applied In addition a builtin hour meter will record the number of operational hours that the generator has been in use Fuel Gauge Indicates amount of diesel fuel available Charging Ammeter Gauge Indicates the current being supplied by the engine s alternator which provides current for generators control circuits and battery charging system Water Temperature Gauge During normal operation this gauge be
77. tery Safety Guidelines listed in this manual when handing or servicing the generator WI ALWAYS allow the machine a proper amount of time to cool before servicing 18 Keep the machinery in proper running condition Fix damage to the machine immediately and always replace broken parts WI ALWAYS service air cleaner frequently to prevent engine malfunction WARNING BURN HAZARDS To prevent burns DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations Always allow sufficient time for the engine and generator to cool before performing maintenance Wi Radiator Cap Removing the radiator cap while the engine shot will resltin high pressurized boiing water to gush out of the radiator causing severe scalding to any persons in the general area of the generator 18 Coolant Drain Plug Removing the coolant drain plug while the engine is hot wil resultin hot coolant gushing out of the coolant drain plug therefore causing severe scalding to any persons in the general area of the generator I Engine Oil Drain Plug Removing the engine oil drain plug while the engine s hot wil resultin hot oil gushing out of the oil drain plug therefore causing severe scalding to any persons in the general area of the generator PAGE 12 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL Battery Safety Use the following guidelines when handing the battery WI The ba
78. ting will help pinpointthe 776 U BOLT MINAS causes and solutions of tire wear problems PARTS MUST ROTATE FREELY Suone Loona on corren ens ane m 255 RETAN ASSEMBLY Center Wear Over Intation wean MIN 30 50 OWE t Under taton Side Wear Allg wheels pma gm cepe oaa Opening tine messi stp wn gt posted PAGE 42 555102 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 CA 25SSIU2 60 HZ TRAILER MAINTENANCE Lug Nut Torque Requirements Itis extremely important to apply and maintain proper wheel mounting torque on the trailer Be sure to use only the fasteners matched to the cone angle of the wheel Proper procedure for attachment of the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque all lug nutsin sequence see Figure 59 DO NOT torque the wheel lug nuts al way down Tighten each lug nutin 3 separate passes as defined by Table 18 3 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically 18 Tire Torque Requirements Wheel Size First Pass Second Pass Third Pass FTLBS FFLBS FHES E 2025 3540 5065 E 2025 3540 5065 51UG NUTS 81UG NUTS m 2025 5040 90 120 15 2025 5040 90 120 LUG NUTS 16 2025 5040 90 120 2 NEVER use an pneumatic air gu
79. ttery contains acids that can avoid eye irritation always wear safety 2 glasses cause injury to the eyes and skin To Use well insulated gloves when picking up the battery DANGER EXPLOSION HAZARDS The risk of an explosion exists when performing service on the battery To avoid severe injury or DEATH DO NOT drop the battery There is the possibilty of risk that the battery may explode DO NOT expose the battery to open flames sparks cigarettes elc The battery contains combustible gases and liquids If these gases and liquids come in contact with a fame or spark an explosion could occur 1 ALWAYS keep the battery charged If the battery is not charged a buildup of combustible gas will occur ALWAYS keep battery charging and cables in good working condition Repair or replace all worn cables Wi ALWAYS recharge the battery in an vented air environment to avoid risk of a dangerous concentration of combustible gases In case the battery liquid dilute sulfuric acid comes in contact with clothing or skin rinse skin or clothing immediately with plenty of water B In case the battery liquid dilute sulfuric acid comes in contact with your EYES rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention REV 0 01 27 06 Towing amp Transporting Safety To reduce the possibilty of an accident while transporting the generator on public r
80. ven death W NEVER touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or generator M HighTemperatures Allow the engine Ue to cool before performing service and Sys al maintenance functions Contact wih SE hot components can cause serious 7 bums The engine of this generator requires an adequate free flow of cooling air NEVER operate the generator in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricteditwill cause serious damage to the generator or engine and may cause injury to people The generator engine gives off DEADLY carbon monoxide gas DO NOT place hands or fingers inside generator engine compartment when engine is running NEVER run engine without air Severe engine damage may occur DO NOT leave the generator unningin the manual mode unattended Wi Refer to the Isuzu Engine Owner s Manual for engine technical questions or information W ALWAYS store equipment properly when itis not being used Equipment should be stored in clean dry location out of the reach of children REV 0 01 27 06 DCA 25SSIU2 60 2 RULES FOR SAFE OPERATION Generator Grounding To guard against electrical shock and possible damage to the equipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC provides uide ines for proper groundin

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