MULTIQUIP Whisperwatt dca25ssiu3 Operation And Parts Manual
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MULTIQUIP Whisperwatt dca25ssiu3 Operation And Parts Manual

MULTIQUIP Whisperwatt dca25ssiu3 Operation And Parts Manual

Whisperwatt series 60hz generator
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Download this manual See also: Operation and Parts Manual
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.
pn 49810

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Summary of Contents for MULTIQUIP Whisperwatt dca25ssiu3

  • Page 1 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...

  • Page 2: Proposition 65 Warning

    65 Warning Diesel engine exhaust and some of page 2 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 3: Reporting Safety Defects

    1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to: Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590 You can also obtain information about motor vehicle safety from http://www.safecar.gov. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 3...

  • Page 4: Table Of Contents

    Generator Wiring Diagram ........38 Engine Wiring Diagram .......... 39 Troubleshooting (Generator) ........40 Explanation Of Code In Remarks Column..... 42 Suggested Spare Parts ......... 43 page 4 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 5: Parts Ordering Procedures

    All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST. WE ACCEPT ALL MAJOR CREDIT CARDS! DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 5...

  • Page 6: Safety Information

    CaUTIon Indicates a hazardous situation which, if not avoided, CoULD result in MInor or MoDeraTe InJUrY. NOTICE Addresses practices not related to personal injury. page 6 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 7: General Safety

    „ aLwaYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 7...

  • Page 8: Engine Safety

    „ never touch the hot exhaust manifold, local Health and Safety Administrator. muffl er or cylinder. Allow these parts to cool before servicing equipment. page 8 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 9: Towing Safety

    „ Use the trailer’s swivel jack to adjust the trailer height to „ aLwaYS shutdown engine before transporting a level position while parked. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 9...
  • Page 10 „ never grab or touch a live power cord or cable with wet hands. The possibility exists of electrical shock, electrocution or death. page 10 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 11: Safety Information

    „ aLwaYS disconnect the negaTIve battery terminal before performing service on the generator. „ aLwaYS keep battery cables in good working condition. Repair or replace all worn cables. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 11...

  • Page 12: Specifications

    1.21 gal. (4.6 L)/hr at 3/4 load Fuel Consumption 0.85 gal. (3.2 L)/hr at 1/2 load 0.58 gal. (2.2 L)/hr at 1/4 load Battery 12V 53Ah x 1 page 12 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 13: Dimensions

    21.06 in. (535 mm.) 39.37 in. (1,000 mm.) 24.21 in. (615 mm.) 29.53 in. (750 mm.) 26.38 in. (670 mm.) 25.0 in. (635 mm.) DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 13...

  • Page 14: Installation

    CONNECT TO BUILDING GROUND IF APPLICABLE GROUND CABLE N I M REFERENCE 8 ’ ( NEC 250-83 (C) Figure 2. Typical Generator Grounding Application page 14 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 15 They are to resist damage to the bottom of the generator and to maintain alignment. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 15...

  • Page 16: General Information

    (load) is held to „ 8 Fuses a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size. page 16 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 17: Major Components

    Output Terminal Assembly Fuse Block Assembly Muffler Assembly Air Cleaner Assembly Engine Assembly Battery Assembly Generator Assembly Generator Control Panel Assembly Engine Operating Panel Assembly DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 17...

  • Page 18: Generator Control Panel

    U,V, and W Output main circuit breaker in the closed position (on). Terminal Lugs from overload. page 18 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 19: Engine Operating Panel

    6. pre-heat Lamp - Indicates (ON) when the engine to normal. is ready for starting during cold weather operating conditiions. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 19...

  • Page 20: Output Terminal Panel Familiarization

    „ Two GFCI Circuit Breakers @ 20 amps „ Five Output Terminal Lugs ( U, V, W, O, Ground) „ Eight Fuses Figure 6. Output Terminal Panel page 20 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 21 240/120 position. Figure 10. Plastic Face Plate (Output Terminal Lugs) Figure 8. 120/240V Twist-Lock Auxiliary Receptacles DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 21...

  • Page 22: Output Terminal Panel Familiarization

    60A main circuit breaker is provided. Make sure to switch aLL circuit breakers to the oFF position prior to starting the engine. Figure 12. Over Current Relay Figure 11. Connecting Loads page 22 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 23: Load Application

    1800 3600 150 ft. 100 ft. 65 ft. 2400 4800 125 ft. 75 ft. 50 ft. CAUTION: Equipment damage can result from low voltage DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 23...

  • Page 24: Generator Outputs

    120V 127V 139V 240V 254V 277V 12.5 15 amps/receptacle voltage Selector Switch Single-phase 240/120v position 1Ø Line-neutral/ 20 amps/receptacle 120V 240V Line-Neutral Line-Line Line-Line page 24 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 25: Generator Outputs

    W and U terminals as indicated on the AC Voltmeter Gauge (Figure 16) Figure 15. aC voltmeter Figure 16. aC voltmeter Change-over Switch gauge DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 25...

  • Page 26: Output Terminal Panel Connections

    To achieve a 3Ø 208V output the voltage selector switch Figure 20. UVWO Terminal Lugs must be in the 3Ø-240/139 position and the voltage 3Ø-240/139V Connections regulator must be adjusted to 208V.. page 26 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 27 UVWO terminals are secure and tight. The possibility of arcing exists, that could cause a fire. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 27...

  • Page 28: Inspection/Setup

    „ API Service Classification CC/SD FILLER NECK „ API Service Classification CC/SE „ API Service Classification CC/SF Table 11. recommended Motor oil Figure 29. Trailer Fuel Tank page 28 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 29 Do noT remove the radiator cap until the unit has completely cooled. The possibility of hot coolant exists which can cause severe burns. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 29...

  • Page 30: Air Cleaner

    A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for page 30 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 31 CaUTIon Inadequate battery connections may cause poor starting of the generator, and create other malfunctions. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 31...

  • Page 32: Generator Start-Up Procedure

    5. Close all engine enclosure doors (Figure 36). Figure 39. Pre-Heat Lamp CORRECT INCORRECT Figure 36. Engine Enclosure Doors page 32 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 33 (Figure 43) to approximately 1800 RPM’s. increase or decrease the desired voltage. Figure 43. Voltage Adjust Control Knob Figure 47. Engine Tachometer Gauge DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 33...

  • Page 34: Generator Shut-Down Procedures

    When ready to restart, complete all steps in the Generator Startup Procedure section of this manual. page 34 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 35: Maintenance

    After changing the air element, press the dust indicator button to reset the indicator. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 35...
  • Page 36 To restart after running out of fuel, turn the switch to the “ON” position for 15-30 seconds. Try again, if needed. Figure 53. Fuel Tank Cleaning page 36 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 37 Allow engine to cool when flushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 37...

  • Page 38: Generator Wiring Diagram

    Wiring diagraM Figure 55. Generator Wiring Diagram page 38 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 39: Engine Wiring Diagram

    Wiring diagraM Figure 56. Engine Wiring Diagram DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 39...

  • Page 40: Troubleshooting (Generator)

    Over current? Confirm load requirements and reduce. Circuit Breaker Tripped Defective circuit breaker? Check and replace. Over current Relay actuated? Confirm load requirement and replace. page 40 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 41 DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 41...

  • Page 42: Explanation Of Code In Remarks Column

    Multiquip. Other entries will for sale through Multiquip. be clarified in the “Remarks” Column. page 42 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 43: Suggested Spare Parts

    3....8944024980 ..KEY, IGNITION NOTICE Part numbers on this Suggested Spare Parts list may supersede/replace the P/N shown in the text pages of this book. DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 43...

  • Page 44: Generator Assy

    44 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 45 WASHER, LOCK 0041210000 WASHER, FLAT B0155400204 COVER, FAN 0010106030 HEX HEAD BOLT 0041206000 WASHER, FLAT 0600815000 M9312600004 RUBBER SUSPENSION 0207010000 SELF - LOCKING NUT DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 45...

  • Page 46: Control Box Assy

    BOx assy. page 46 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 47 0317700200 SEAL RUBBER 0016906016 HEX HEAD BOLT M1213602004 SWITCH COVER 0330000070 SEAL RUBBER 0016906016 HEX HEAD BOLT 0016906016 HEX HEAD BOLT M1223000703 CONTROL PANEL DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 47...
  • Page 48 BOx assy. page 48 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 49 0601831330 SWITCH, PANEL LIGHT M1223100104 STOPPER 0027105010 MACHINE SCREW 0027105010 MACHINE SCREW M9220100004 SET SCREW 0080200007 SNAP RING 0601851727 GROMMET M1246702904 WIRE HARNESS, GENERATOR DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 49...

  • Page 50: Engine And Radiator Assy

    50 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 51 0602022587 ADAPTER M1320300304 PACKING 0602022579 90 DEGREE ELBOW 0603306597 CONNECTOR 0603300286 ROCKNUT 0605511399 VALVE 0603306399 HOSE JOINT 0602021071 0379500280 DRAIN HOSE M9602000003 DRAIN JOINT DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 51...
  • Page 52 (cOntinued) page 52 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 53 M1353800004 CLAMPER ROD 0016908020 HEX HEAD BOLT M1357300104 CLAMPER ROD 0016910020 HEX HEAD BOLT 8973022030 WATER TEMP. SWITCH (ENGINE) 1824100990 OIL PRESSURE SWITCH (ENGINE) DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 53...

  • Page 54: Output Terminal Assy

    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. #1 (01/24/13)
  • Page 55 M1236100503 TERMINAL COVER 0010112045 HEX HEAD BOLT 0041212000 WASHER, FLAT M9310200004 STAY RUBBER 0030012000 HEX HEAD NUT 0019208020 HEX HEAD NUT 0040508000 TOOTHED WASHER DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 55...

  • Page 56: Battery Assy

    Battery assy. page 56 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 57: Battery Assy

    BATTERY SHEET M9103000304 BATTERY BAND 0602220920 BATTERY BOLT SET 0040006000 WASHER, LOCK M1348400204 BATTERY CABLE M2346400104 BATTERY CABLE 0016910020 HEX HEAD BOLT 0040510000 TOOTHED WASHER DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 57...

  • Page 58: Muffler Assy

    Muffler assy. page 58 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)

  • Page 59: Muffler Assy

    GASKET 0207008000 SELF- LOCKING NUT 0016908035 HEX HEAD BOLT M1330400804 COVER 0016906016 HEX HEAD BOLT 49685 TUBE, EXHAUST EXTENSION 12597 CLAMP, 2" MUFFLER SADDLE DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 59...

  • Page 60: Fuel Filter Assy

    60 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 61 0016908020 HEX HEAD BOLT 8970398340 FUEL PUMP 8944370220 REPAIR KIT, FUEL PUMP 0016906025 HEX HEAD BOLT 0191200300 SUCTION HOSE 0191200650 SUCTIONHOSE 0605515198 HOSE BAND DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 61...

  • Page 62: Enclosure Assy

    62 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 63 HEX HEAD BOLT 0042308000 WASHER, LOCK 0042408000 WASHER, FLAT 0016908020 HEX HEAD BOLT M1453003803 SIDE DOOR M1493405604 ACOUSTIC SHEET M1453003903 SIDE DOOR M1493405704 ACOUSTIC SHEET DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 63...
  • Page 64 (cOntinued) page 64 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 65 HEX HEAD BOLT 0040508000 TOOTHED WASHER 0016906020 HEX HEAD BOLT 0040506000 TOOTHED WASHER 0600800321 MANUAL - PAK M1483600804 BOX CLAMPER 0016906016 HEX HEAD BOLT DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 65...

  • Page 66: Rubber Seals Assy

    66 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 67 0228800525 SEAL RUBBER 0228800565 SEAL RUBBER 0228100458 SEAL RUBBER 0228100171 SEAL RUBBER 0228100351 SEAL RUBBER 0228100285 SEAL RUBBER 0228100153 SEAL RUBBER 0228100180 SEAL RUBBER DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 67...

  • Page 68: Nameplate And Decals Assy

    68 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 69 DECAL : DANGER ............1 ... M90320010 M9510000104 DECAL : DOCUMENT BOX LOCATED .....1 ... M91000010 M9504200004 DECAL: WARNING START FIRES ......1 ... M90420000 49712 DECAL: VOLTAGE ADJUST DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 69...

  • Page 70: Terms And Conditions Of Sale - Parts

    Multiquip’s designated receiving point. page 70 — DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13)
  • Page 71 DCa25SSIU3 (wITh MLT25 SerIeS) • operaTIon anD parTS ManUaL — rev. #1 (01/24/13) — page 71...
  • Page 72 © COPYRIGHT 2013, MULTIQUIP INC. Multiquip Inc, the MQ logo are registered trademarks of Multiquip 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.

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