Whisperwatt series 60hz generator (isuzu 6wg1x diesel engine) (98 pages)
Summary of Contents for MULTIQUIP Power WHISPERWATT DCA25SSIU
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OPERATION AND PARTS MANUAL ® MODEL DCA25SSIU WHISPERWATT™ GENERATOR (Standard) Revision #7 (04/18/12) To find the latest revision of this publication, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
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PAGE 2 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)
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PAGE 3 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)
, 2006 Order via Internet (Dealers Only) Best Deal! If you have an MQ Account, to obtain a Username Order parts on-line using Multiquip’s SmartEquip website! and Password, E-mail us at: parts@multiquip. ■ View Parts Diagrams com. ■ Order Parts To obtain an MQ Account, contact your ■...
RULES FOR SAFE OPERATION CAUTION: CAUTION: CAUTION: CAUTION: CAUTION: ■ NEVER touch the hot exhaust manifold, muffler or cylinder. Allow Failure to follow instructions in this manual these parts to cool before servicing may lead to serious injury or even death! engine or generator.
RULES FOR SAFE OPERATION CAUTION CAUTION CAUTION: CAUTION CAUTION CAUTION CAUTION: CAUTION CAUTION CAUTION DO NOT touch or open any of the below mentioned components while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance. ■...
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RULES FOR SAFE OPERATION ■ NEVER Run engine without air filter. Severe engine Battery damage may occur. CAUTION CAUTION CAUTION CAUTION CAUTION: ■ Always service air cleaner frequently to prevent carburetor Never over fill the battery with water above malfunction. the upper limit.
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RULES FOR SAFE OPERATION Transporting Maintenance Safety ■ Always shutdown engine before transporting. ■ NEVER lubricate components or attempt service on a running machine. ■ Tighten fuel tank cap securely. ■ Always allow the machine a proper amount of time to ■...
DCA-25SSIU — TOWING RULES FOR SAFE OPERATION ■ ALWAYS attach trailer's safety chain to bumper of towing Towing Safety Precautions vehicle. CAUTION : CAUTION : CAUTION : CAUTION : CAUTION : ■ ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and Check with your county or state safety working properly.
DCA-25SSIU — TRAILER-SAFETY GUIDELINES CAUTION: CAUTION: CAUTION: CAUTION: CAUTION: Frame Width - This measurement is from fender to fender. ALWAYS make sure the trailer is in good Jack Stand - Trailer support device with maximum operating condition. Check the tires for pound requirement from the tongue of the trailer.
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DCA-25SSIU — TRAILER-SPECIFICATIONS i f i o i t ) t ' " 2 X " " 0 B " X " " 5 . B " X " " 5 . B " " 5 . B " " 5 . "...
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DCA-25SSIU — TRAILER SAFETY GUIDELINES Tires/Wheels/Lug Nuts Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched. CAUTION: DO NOT attempt to repair or modify a wheel.
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DCA-25SSIU — TRAILER SAFETY GUIDELINES e r i e t I - . t ) . s " 8 / " 6 " 2 / SHACKLE BOLT SNUG FIT ONLY PARTS MUST ROTATE FREELY SPRING EYE BOLT LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT BOLT ASSEMBLY SHOULDER TYPE...
DCA-25SSIU — TRAILER-WIRING DIAGRAM NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT PAGE 16 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)
DCA-25SSIU — GENERATOR DECALS The DCA-25SSIU generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the machine.
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DCA-25SSIU — GENERATOR DECALS PAGE 18 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)
DCA-25SSIU — GENERAL INFORMATION DCA-25SSIU FAMILIARIZATION Open Delta Excitation System Generator The DCA-25SSIU generator is equipped with the state of the art " Open-Delta " excitation system. The open delta The MQ Power Model DCA-25SSIU is a 20 kW generator system consist of an electrically independent winding wound that is designed as a high quality portable (requires a trailer among stationary windings of the AC output section.
DCA-25SSIU — CONTROL PANEL Figure 6. Control Panel PAGE 24 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)
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DCA-25SSIU — CONTROL PANEL The definitions below describe the controls and functions of the DCA-25SSIU " Control Panel " (Figure 6). Main Circuit Breaker – This three-pole, 60 Amp main breaker is provided to protect the UNV voltage output terminals from overload. Frequency Meter –...
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DCA-25SSIU — ENGINE OPERATING PANEL The definitions below describe the controls and functions of the DCA-25SSIU " Engine Operating Panel " (Figure 7). 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’...
DCA-25SSIU — OUTPUT TERMINAL PANEL Output Terminal Panel Connecting Load Loads can be connected to the generator by the UVW Lugs or The output control panel is located on the rear (control panel) the duplex receptacle. (See Figure 9). Make sure to read the end of the generator.
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DCA-25SSIU — OUTPUT TERMINAL PANEL NOTE Legs “O” and Ground are considered Bonded Grounds. Figure 10. Output Terminal Description PAGE 29 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)
DCA-25SSIU — OUTPUT AMPERAGE SETUP Over Current Relay Output Terminal Panel Available Voltages An over current relay is connected to the circuit breaker. A wide range of voltages are available to supply load to During an over current situation, both the circuit breaker many different applications.
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DCA-25SSIU — OUTPUT AMPERAGE SETUP Receptacle Use When the UVWO terminals are providing power, the receptacle power available decrease. Do not exceed receptacle power available listed on Table 8. l i a Figure 11. Voltage Selector Switch 240/120V Single Phase Position t s i x e l Figure 12.
DCA-25SSIU — OUTPUT VOLTAGE SETUP 240/12 0V Hard Wire Hookup 480/240V Hard Wire Hookup With the voltage selector set and locked at ‘3 phase 480/ With the voltage selector set and locked at ‘single phase 277’ (Figure 17) and using the 3-phase 240 volt hookup, it 240/120’...
DCA-25SSIU — OUTPUT VOLTAGE SETUP Voltage Selector Switch- 3 Phase 480/277V Position Single Phase: 480V, 440V, or 416 Volt The following are additional voltages available when the This setting can provide single phase power at 480, 440, voltage selector switch is in the 3 phase 480/277V or 416 volts.
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DCA-25SSIU — OUTPUT VOLTAGE SETUP Single Phase: 240V, 220V, or 208 Volt Voltage Selector Switch- 3 Phase 240/139V Position This setting can provide single phase power at 240, 220, The following are additional voltages available when the voltage selector switch is in the 3 phase 240/139V or 208 volts.
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DCA-25SSIU — OUTPUT VOLTAGE SETUP Single Phase: 120 Volt Voltage Selector Switch- Single Phase 240/120V This setting can provide single phase power at 120 volts. Position After hooking up the hard wires to the lugs as shown in The following are additional voltages available when the Figure 29, 120 volts can be obtained by using the voltage 240/120V position.
DCA-25SSIU — INSTALLATION Outdoor Installation CAUTION CAUTION : CAUTION CAUTION CAUTION Install the generator in a location where it will not be exposed An electric shock may happen when to rain or sunshine. Make sure the generator is on secure vibrators are used.
DCA-25SSIU — PRE-SETUP General Inspection Prior to Operation Circuit Breakers The DCA-25SSIU generator has been thoroughly inspected To protect the generator from an overload, a 3-pole, 60 amp, and accepted prior to shipment from the factory. However, main circuit breaker is provided to protect the UVW output be sure to check for damaged parts or components, or loose terminals from overload.
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DCA-25SSIU — PRE-SETUP Lubrication Oil Fuel Fill the fuel tank with clean and fresh diesel fuel . DO NOT Fill the engine crankcase with lubricating oil through the filler fill the tank beyond capacity. hole, but do not overfill. Make sure the generator is level. With the dipstick inserted all the way, verify that the oil level Pay attention to the fuel tank capacity when replenishing is maintained between the two notches (Figure 31) on the...
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DCA-25SSIU — PRE-SETUP CAUTION : CAUTION : CAUTION : CAUTION : CAUTION : Cleaning the Outer Radiator The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator When adding coolant or antifreeze to the fins with compressed air.
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DCA-25SSIU — PRE-SETUP CAUTION : CAUTION : CAUTION : Battery CAUTION : CAUTION : This unit is of negative ground. DO NOT connect in reverse. If the battery cable is connected Always maintain battery fluid level between the specified incorrectly, damage to the generator will marks.
DCA-25SSIU — LOAD APPLICATION Single Phase Load CAUTION CAUTION CAUTION CAUTION: CAUTION Motors and motor-driven equipment draw Always be sure to check the nameplate on the generator much greater current for starting than and equipment to insure the wattage, amperage and during operation.
DCA-25SSIU — GENERATOR START-UP PROCEDURE WARNING: WARNING: WARNING: WARNING: WARNING: 2. Connect the load to the UVW terminals as shown in The engine's exhaust contains harmful Figure 35. These terminals can be found on the output emissions. ALWAYS ventilate the terminal panel, (see page 29 Figure10).
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DCA-25SSIU — GENERATOR START-UP PROCEDURE 4. Close all engine enclosure doors (Figure 37). 8. Once the preheat indicator lights, turn the ignition key to ‘START’ until the engine starts (Figure 41). Then release the key to ‘RUN’. Figure 41. Ignition Switch ‘START’ Figure 37.
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DCA-25SSIU — GENERATOR START-UP PROCEDURE 15. The charging ammeter will dindicate if the battery is being properly charged or if the any current is being charged properly. Figure 45. Voltage Adjust Control Knob 12. The ammeter (Figure 46) will indicate zero amps with no Figure 49.
DCA-25SSIU — GENERATOR SHUTDOWN PROCEDURE 18. Observe the generator's ammeter (Figure 52) and verify ENGINE SHUTDOWN it reads the anticipated amount of current with respect To shutdown the generator, use the following procedure: to the load. The ammeter will only display a current reading if the load is in use.
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NOTE PAGE PAGE 47 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)
DCA-25SSIU — MAINTENANCE General Inspection Check Oil Level Prior to each use, the generator should be cleaned and Check the crankcase oil level prior to each use, or when inspected for deficiencies. Check for loose, missing or the fuel tank is filled. Insufficient oil may cause severe damaged nuts, bolts or other fasteners.
DCA-25SSIU — MAINTENANCE Generator Storage For storage of the generator for over 30 days, the following is required: Drain the fuel tank completely. Completely drain the oil from the crankcase and refill with fresh oil. Clean all external parts of the generator with a cloth. ...
DCA-25SSIU — TROUBLESHOOTING (ENGINE) Practically all breakdowns can be prevented by proper diagnosis based on the Engine Troubleshooting (Table 14). If handling and maintenance inspections, but in the event of a the problem cannot be remedied, consult our company's breakdown, use the tables shown for business office or service plant.
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DCA-25SSIU — TROUBLESHOOTING (ENGINE) l i f r e t o l c t r i r i A e l c i t c . t u i n i i t c f l a i t c c a l i t u l .
DCA-25SSIU — TROUBLESHOOTING (GENERATOR/ENGINE) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table15). If the problem cannot be remedied, consult our company's business office or service plant. t l o i t c a t l...
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NOTE PAGE PAGE 55 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)
A blank entry generally indicates that the item is not sold assembly/kit that can be purchased, or is not available separately or is not sold by Multiquip. Other entries will for sale through Multiquip. be clarified in the “Remarks” Column.
DCA-25SSIU --- OUTPUT TERMINAL ASSY. OUTPUT TERMINAL ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 5 -BLACK 1-ORANGE 6 -CATERPILLAR YELLOW 2-WHITE 7 -CATO GOLD 3 -SPECTRUM GRAY 8 -RED 4 -SUNBELT GREEN THE SERIAL NUMBER MAY BE REQUIRED.
DCA-25SSIU --- FUEL TANK ASSY. FUEL TANK ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 5 -BLACK 1-ORANGE 6 -CATERPILLAR YELLOW 2-WHITE 7 -CATO GOLD 3 -SPECTRUM GRAY 8 -RED 4 -SUNBELT GREEN THE SERIAL NUMBER MAY BE REQUIRED.
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DCA-25SSIU --- FUEL TANK ASSY. FUEL TANK ASSY. PART NO. ITEM QTY. REMARKS M1363000202 FUEL TANK 0605505070 CAP, FUEL TANK M1363200004 TANK BAND M9310500104 SUPPORTER SHEET 011008020 HEX. HEAD BOLT ......2 ... REPLACES 0016908020 00379080000 HEX. NUT ........2 ... S/N7100001 TO S/N7101449; REPLACES 0037908000 0207308000 HEX.
DCA-25SSIU --- ENCLOSURE ASSY. ENCLOSURE ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 5 -BLACK 1-ORANGE 6 -CATERPILLAR YELLOW 2-WHITE 7 -CATO GOLD 3 -SPECTRUM GRAY 8 -RED 4 -SUNBELT GREEN THE SERIAL NUMBER MAY BE REQUIRED.
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DCA-25SSIU --- ENCLOSURE ASSY. ENCLOSURE ASSY. PART NO. ITEM QTY. REMARKS M1413000212 BASE ........... 1 .....S/N7100291 TO S/N7104749 REPLACES M1413000202 M1413000222 BASE ........... 1 .....S/N7104750~ M1413400004 UNDER COVER 011008020 HEX. HEAD BOLT ....... 2 .....REPLACES 0016908020 M1423000302 FRONT FRAME ........1 .....S/N7100001 TO 7105049 M1493100503 ACOUSTIC SHEET ......
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DCA-25SSIU --- ENCLOSURE ASSY. ENCLOSURE ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 5 -BLACK 1-ORANGE 6 -CATERPILLAR YELLOW 2-WHITE 7 -CATO GOLD 3 -SPECTRUM GRAY 8 -RED 4 -SUNBELT GREEN THE SERIAL NUMBER MAY BE REQUIRED.
DCA-25SSIU --- RUBBER SEAL ASSY. RUBBER SEAL ASSY. S/N7100001 TO 7101589 S/N7101590~ PAGE 82 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)
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DCA-25SSIU --- RUBBER SEAL ASSY. RUBBER SEAL ASSY. PART NO. ITEM QTY. REMARKS 0228910300 RUBBER SEAL 0228900725 RUBBER SEAL M1490300004 RUBBER SEAL 0228800360 RUBBER SEAL 0228900370 RUBBER SEAL 0228800605 RUBBER SEAL 0229200595 RUBBER SEAL 0228900645 RUBBER SEAL 0229200750 RUBBER SEAL ....... 3 ... S/N7100001 TO S/N7101589 0229200750 RUBBER SEAL .......
ISUZU C240 --- CYLINDER HEAD AND COVER ASSY. CYLINDER HEAD AND COVER ASSY. PAGE 86 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)
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ISUZU C240 --- CYLINDER HEAD AND COVER ASSY. CYLINDER HEAD AND COVER ASSY. PART NO. ITEM QTY. REMARKS 5111102070 CYLINDER HEAD ASSY. 1096000051 SEALING CUP, RR FACE D=44 5111290060 SEALING CUP, LOWER D=16 5112190080 SEALING CUP, UPPER D=18 5096000130 SEALING CUP, DRILLED D=12 9098605220 PLUG;...
ISUZU C240 --- WATER PUMP AND FAN ASSY. WATER PUMP AND FAN ASSY. PAGE 104 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)
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ISUZU C240 --- WATER PUMP AND FAN ASSY. WATER PUMP AND FAN ASSY. PART NO. ITEM QTY. REMARKS 5136101673 WATER PUMP ASSY....1 .... INCL. ITEMS W/ 5878101391 WATER PUMP REPAIR KIT ..1 .... INCL. ITEMS W.# 5136310080 BEARING UNIT 9136210760 IMPELLER...
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ISUZU C240 --- ENGINE FOOT ASSY. ENGINE FOOT ASSY. PART NO. ITEM QTY. REMARKS 9117712070 ENGINE FOOT, RIGHT SIDE 5117710501 ENGINE FOOT, LEFT SIDE 9029510250 FOOT BOLT, RIGHT SIDE 9029510250 BOLT FOOT, LEFT SIDE 9029560400 BOLT FOOT, LEFT SIDE 9098518660 PLAIN WASHER 5197110010 ALTERNATOR BRACKET...