Operation and Parts Manual Whisperwatt™ Series MODEL dca25ssiu3 60hz generator (isuzu Bv-4le2 DIESEL ENGINE) Used with MLT25 Series light tower only PARTS LIST NO. M1870301004C Revision #1 (01/24/13) To find the latest revision of this publication, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
proposition 65 warning Diesel engine exhaust and some of page 2 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
Table of Contents DCA25SSIU3 Generator Component Drawings (with MLT25 Series Light Tower) Generator Assy.................................................. 44-45 Control Box Assy................................................ 46-49 Engine And Radiator Assy................................. 50-53 Output Terminal Assy........................................... 5-55 Battery Assy....................................................... 56-57 Muffler Assy.......................................................
www.multiquip.com Parts Ordering Procedures Ordering parts has never been easier! Choose from three easy options: Order via Internet (Dealers Only): Best Deal! Effective: January 1st, 2006 If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip. com. Order parts on-line using Multiquip’s SmartEquip website! ■ View Parts Diagrams ■ Order Parts ■ Print Specification Information To obtain an MQ Account, contact your District Sales Manager for more information.
Safety Information Do not operate or service the equipment before reading the entire manual. 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 in injury to yourself and others. Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.
Safety Information generaL SaFeTY CaUTIon never operate this equipment without proper protective clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations. never operate this equipment when not feeling well due to fatigue, illness or when under medication. never operate this equipment under the influence of drugs or alcohol.
Safety Information engIne SaFeTY Danger The engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. The engine of this equipment requires an adequate free flow of cooling air. never operate this equipment in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine.
Safety Information FUeL SaFeTY Danger Do noT start the engine near spilled fuel or combustible fluids. Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited. Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer “gross vehicle weight rating.” aLwaYS inspect the hitch and coupling for wear. never tow a trailer with defective hitches, couplings, chains, etc.
Safety Information eLeCTrICaL SaFeTY Danger Do noT touch output terminals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or burn. The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers oFF before performing maintenance on the generator or making contact with output terminals.
Safety Information BaTTerY SaFeTY Danger Do noT drop the battery. There is a possibility that the battery will explode. Do noT expose the battery to open flames, sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a flame or spark, an explosion could occur. warnIng envIronMenTaL SaFeTY NOTICE Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, fuel and fuel filters.
Specifications Table 1. Generator Specifications Model DCA25SSIU3 Revolving field, self ventilated, Type open protected type synchronous generator Armature Connection Star with Neutral Zigzag Phase 3 Single Standby Output 22.0 KW (27.5 kVA) 15.8 KW Prime Output 20 KW (25.0 kVA) 14.
Dimensions Figure 1. Dimensions Table 3. Dimensions Reference Letter Dimension in. (mm) Reference Letter Dimension in. (mm) A 21.06 in. (535 mm.) F 94.49 in. (1,850 mm.) B 21.06 in. (535 mm.) G 39.37 in. (1,000 mm.) C 24.21 in. (615 mm.) H 29.53 in. (750 mm.) D 26.38 in. (670 mm.) E 25.0 in. (635 mm.) DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Installation GENERATOR GROUND LUG GROUND ROD FOR EARTH GROUND. CONNECT TO BUILDING GROUND IF APPLICABLE GROUND CABLE REFERENCE NEC 250-83 (C) M 8’ ( ) UM M INI Figure 2. Typical Generator Grounding Application page 14 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Installation Outdoor Installation Generator Grounding Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes. To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.
General Information Generator Open Delta Excitation System This MQ Power generator (Figure 3) is a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery. This generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section.
Major Components Figure 3. Major Components Table 4. Generator Major Components ITEM NO. DESCRIPTION 1 Terminal Panel Assembly 2 Output Terminal Assembly 3 Fuse Block Assembly 4 Muffler Assembly 5 Air Cleaner Assembly 6 Engine Assembly 7 Battery Assembly 8 Generator Assembly 9 Generator Control Panel Assembly 10 Engine Operating Panel Assembly DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Generator Control Panel Figure 4. Generator Control Panel The definitions below describe the controls and functions of the Generator Control Panel (Figure 4). 1. Voltage Regulator Control — Allows ±15% manual adjustment of the generator’s output voltage. 2. Frequency Meter — Indicates the output frequency in hertz (Hz). Normally 60 Hz. 3. AC Ammeter — Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch. 4.
ENGINE OPERATING PANEL Figure 5. Engine Operating Panel The definitions below describe the controls and functions of the Engine Operating Panel (Figure 5). 1. Panel Light - Normally used in dark places or at night. When activated, panel will luminate. When the generator is not in use, turn the panel light switch to the OFF position. 2. Panel Light Switch- When activated, will turn on control panel light. 3. Oil Pressure Alarm Lamp - Indicates that the oil pressure is too low or high.
OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Panel Output Terminal Familiarization The Output Terminal Panel (Figure 6) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs. The “Output Terminal Panel ” (Figure 6) is provided with the following: Two 120/240V output receptacles @ 50 amp NOTICE Two Circuit Breakers @ 50 amps Terminal legs “O” and “Ground” are considered bonded grounds.
OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage selector switch position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.
OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Over Current Relay Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 11). Make sure to read the operation manual before attempting to connect a load to the generator. An over current relay (Figure 12) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip.
Load Application Single Phase Load Three Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment. When calculating the power requirements for 3-phase power use the following equation: Generally, the wattage listed on the nameplate of the equipment is its rated output.
GENERATOR OUTPUTS Generator Output Voltages Generator Amperage A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the voltage selector switch (Figure 13). To obtain some of the voltages as listed in Table 7 (see below) will require a fine adjustment using the voltage regulator (VR) control knob located on the control panel. Table 8 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed.. Table 8.
GENERATOR OUTPUTS/gauge reading How to Read the ac ammeter and ac voltage gauges The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches. Both of these switches are located on the control panel and DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.
OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob. Remember the voltage selector switch determines the range of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage. 3Ø-240/139 UVWO Terminal Output Voltages 1.
OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480/277V UVWO Terminal Output Voltages 1Ø-240/120V UVWO Terminal Output Voltages 1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 24. 1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 26. Figure 24. Voltage Selector Switch 3Ø-480/277V Position Figure 26. Voltage Selector Switch 1Ø-240/120V Position 2. Connect the load wires to the UVWO terminals as shown in Figure 25. 2.
inspection/SETUP Circuit Breakers To protect the generator from an overload, a 3-pole, 60 amp, main circuit breaker is provided to protect the U,V, and W Output Terminals from overload. In addition two singlepole, 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Two 50 amp 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 starting the engine.
inspection/SETUP Refueling Procedure: WARNING Diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes. 2. Remove fuel cap from filler neck and fill tank (Figure 29). 3. NEVER overfill fuel tank — It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 31). 1. Level Tanks — Make sure fuel tank is level with the ground.
inspection/SETUP 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 unit 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. damage and wear and adjust it in accordance with the ISUZU Engine Owner’s Manual.
inspection/SETUP Battery Cable Installation Alternator ALWAYS be sure the battery cables (Figure 34) are properly connected to the battery terminals as shown below. The red cable is connected to the positive terminal of the battery, and the black cable is connected to the negative terminal of the battery. The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.
GENERATOR START-UP PROCEDURE Before Starting Starting CAUTION The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel. 1. Place the voltage selector switch in the desired voltage position (Figure 37).. WARNING 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.I., and aux.
GENERATOR START-UP PROCEDURE 3. Turn the ignition key to the start position (Figure 40). Once the engine starts, release the ignition key and allow it to return to the RUN position (Figure 38). If the engine fails to start after 10 seconds, wait approximately 30 seconds and repeat steps 3-4. 8. The ammeter (Figure 44) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator. Figure 44.
GENERATOR SHUT-DOWN PROCEDURES 12. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 48). . Figure 50. Main, GFCI and Load Circuit Breakers Off Figure 48. Main, Aux. and GFCI Circuit Breakers (ON) 13. Observe the generator’s ammeter (Figure 49) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use. Figure 49. Ammeter (Load) 14.
Maintenance 10 Hrs DAILY X X X X X X Table 14.
Maintenance If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a 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 (the grade may vary according to season and locations). Removing Water from the Fuel Tank After prolonged use, water and other impurities accumulate in the bottom of the tank.
Maintenance Check Oil Level Radiator Cleaning Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil 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 as shown in Figure 28. The radiator (Figure 54) should be sprayed (cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling fins or tube.
Generator Wiring Diagram Figure 55. Generator Wiring Diagram page 38 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Engine Wiring Diagram Figure 56. Engine Wiring Diagram DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Troubleshooting (Generator) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 15 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant. Symptom No Voltage Output Low Voltage Output High Voltage Output Circuit Breaker Tripped Table 15.
notes DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Explanation of Code in Remarks Column The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions. NOTICE The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed. Sample partS liSt NO. 1 2% 2% 3 4 part NO. part Name QtY. remarKS 12345 BOLT......................1 .....
Suggested Spare Parts dcA25SSIU3 WHISPERWATT GENERATOR (USED WITH MLT25 LIGHT TOWER) with ISUZU BV-4LE2 DIESEL engine 1 to 3 units Qty. P/N Description 5............2944566410...........CARTRIDGE , OIL FILTER 5............8990374810...........FILTER, FUEL, ELEMENT 5............8944370220...........REPAIR KIT,FUEL PUMP 3............0602046611...........ELEMENT, AIR 1............8972606490...........BELT, FAN 1............B1312500403........RADIATOR HOSE, UPPER 1............B1312500503........
GENERATOR ASSY. page 44 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
GENERATOR ASSY. NO. PART NO.
control box ASSY. page 46 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
control box ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18A 19 20 21 22 23 24 25 26 26A 26B 27 28 29 29A 30 30A 31 32 32A 33 34 34A 35 36 37 PART NO.
control box ASSY. page 48 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
control box ASSY. NO. 38 39 40 41 42 43 44 45 45A 46 46A 47 47A 48 49 50 51 52 53 54 55 56 57 58 59 60 61 PART NO. 0601807641 0601808985 0601801040 0601806859 0601801041 0601840073 0601840121 0602103092 0601810245 8970444180 8944024980 0602103092 0601810245 0602120095 0602122093 0602123090 0602121080 0602125090 0601810141 0601831330 M1223100104 0027105010 0027105010 M9220100004 0080200007 0601851727 M1246702904 PART NAME QTY.
ENGINE AND RADIATOR ASSY. page 50 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
ENGINE AND RADIATOR ASSY. NO. 1 1A 1-1 2 3 4 5 6 7 8 9 9A 9B 9C 10 11 12 13 14 15 16 17 17A 18 19 20 21 22 22A 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PART NO.
ENGINE AND RADIATOR ASSY. (continued) page 52 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
ENGINE AND RADIATOR ASSY. (continued) NO. 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 PART NO.
OUTPUT TERMINAL ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED THE SERIAL NUMBER MAY BE REQUIRED. page 54 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
OUTPUT TERMINAL ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 11A 11B 12 12A 13 13A 13B 13C 13D 14 15 16 17 18 19 20 20-1 21 22 23 24 24A 25 26 27 28 29 30 31 32 32A PART NO.
BATTERY ASSY. page 56 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
BATTERY ASSY. NO. 1 2 3 4 5 6 7 8 8A PART NO. 0602220185 B9310500014 M9103000304 0602220920 0040006000 M1348400204 M2346400104 0016910020 0040510000 PART NAME BATTERY BATTERY SHEET BATTERY BAND BATTERY BOLT SET WASHER, LOCK BATTERY CABLE BATTERY CABLE HEX HEAD BOLT TOOTHED WASHER QTY. 1 1 1 2 2 1 1 1 1 REMARKS DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Muffler Assy. page 58 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Muffler Assy. NO. 1 2 3 4 5 6 7 8 9 10 11 PART NO. M1330100803 0016908020 M1333002803 8970420280 M1333200014 0207008000 0016908035 M1330400804 0016906016 49685 12597 PART NAME QTY. REMARKS MUFFLER 1 HEX HEAD BOLT 4 EXHAUST PIPE 1 GASKET.......................................................1.................
FUEL FILTER ASSY. page 60 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
FUEL FILTER ASSY. NO. 14 14A 15 16 17 17A 18 20 21 24 PART NO. 8943672922 8980374810 M1366700104 0016908020 8970398340 8944370220 0016906025 0191200300 0191200650 0605515198 PART NAME FUEL FILTER CARTRIDGE, FUEL FILTER BRACKET, FUEL FILTER HEX HEAD BOLT FUEL PUMP REPAIR KIT, FUEL PUMP HEX HEAD BOLT SUCTION HOSE SUCTIONHOSE HOSE BAND QTY. 1 1 1 6 1 1 2 1 1 3 REMARKS DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
ENCLOSURE ASSY. page 62 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
ENCLOSURE ASSY. NO. 1 2 3 4 4A 5 6 6A 7 7A 8 9 10 10A 11 12 13 14 14A 15 16 17 18 19 19A 20 21 22 23 24 25 26 26A 27 28 29 30 31 31A 31B 32 33 33A 34 34A PART NO.
ENCLOSURE ASSY. (continued) page 64 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
ENCLOSURE ASSY. (continued) NO. 35 35A 36 36A 37 38 39 40 40A 41 42 43 44 45 46 47 48 49 50 50A 51 51A 52 52A 53 54 55 PART NO.
RUBBER SEALS ASSY. page 66 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
RUBBER SEALS ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART NO.
NAMEPLATE AND DECALS ASSY. page 68 — DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
NAMEPLATE AND DECALS ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PART NO.
Terms and Conditions of Sale — Parts PAYMENT TERMS 5. Parts must be in new and resalable condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked. 6. The following items are not returnable: Multiquip reserves the right to quote and sell direct to Government agencies, and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products. a. SPECIAL EXPEDITING SERVICE Terms of payment for parts are net 30 days.
notes DCA25SSIU3 (with MLT25 series) • operation and parts manual — rev.
Operation and Parts Manual HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING United StateS Multiquip Corporate Office 18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com MQ Parts Department Tel.
