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60hz WhisperWatt™ generatOr (isuzu aa-4le2 diesel engine) parts list nO. M1871400104 parts list nO. M1871400114c Revision #3 (07/19/11) To find the latest revision of this publication, visit our website at: www.multiquip.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
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.
, 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. com. ■ View Parts Diagrams ■ Order Parts 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 Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all equipment will be referenced with hazard symbols which times when operating this equipment. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
safety infOrMatiOn general saFeTY never use accessories or attachments that are not recommended by MQ Power for this equipment. Damage CaUTion to the equipment and/or injury to user may result. never operate this equipment without proper protective alWaYs know the location of the nearest clothing, shatterproof glasses, respiratory protection, fi re extinguisher.
safety infOrMatiOn engine saFeTY NOTICE Danger never run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter The engine fuel exhaust gases contain poisonous carbon frequently to prevent engine malfunction.
safety infOrMatiOn FUel saFeTY Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer “gross Danger vehicle weight rating.” Do noT start the engine near spilled fuel or combustible ...
safety infOrMatiOn eleCTriCal saFeTY Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections Danger may cause electrical shock and damage to the generator. Do noT touch output terminals during operation. Contact with output terminals NOTICE during operation can cause electrocution, ...
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safety infOrMatiOn BaTTerY saFeTY environmenTal saFeTY Danger NOTICE Do noT drop the battery. There is a possibility that the Dispose of hazardous waste properly. battery will explode. Examples of potentially hazardous waste are used motor oil, fuel and fuel fi lters. ...
specificatiOns Table 1. generator specifications model DCA25USI Revolving field, self ventilated, Type drip-proof, single-bearing generator armature Connection star with neutral zigzag phase Single standby output 27.5 kVA (22.0 KW) 15.8 KW prime output 25kVA (20 KW) 14.4 KW power Factor voltage 240 or 480V 240V/120V...
diMensiOns TOP VIEW SIDE VIEW FRONT VIEW Figure 1. Dimensions Table 3. Dimensions reference Dimension in. (mm) reference letter Dimension in. (mm) letter 22.64 in. (575 mm.) 70.47 in. (1,790 mm.) 20.87 in. (530 mm.) 49.61 in. (1,260 mm.) 27.36 in. (695 mm.) 31.1 in.
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installatiOn oUTDoor insTallaTion generaTor groUnDing Install the generator in a area that is free of debris, To guard against electrical shock and possible damage to bystanders, and overhead obstructions. Make sure the the equipment, it is important to provide a good earTh generator is on secure level ground so that it cannot slide ground.
general infOrMatiOn generaTor open DelTa exCiTaTion sYsTem This generator is equipped with the state of the art “open- This MQ Power generator (Figure 3) is a high quality Delta” excitation system. The open delta system consist portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible of an electrically independent winding wound among pumps and other industrial and construction machinery.
generatOr cOntrOl panel INCREASE DECREASE 1000 2000 STOP OPERATION (PRE-HEAT) 3000 START R P M Figure 4. Generator Control Panel The definitions below describe the controls and functions Located behind the generator control panel is the Generator of the Generator Control Panel (Figure 4). Control Box.
engine Operating panel INCREASE DECREASE 1000 2000 STOP OPERATION (PRE-HEAT) 3000 START R P M Figure 5. Engine Operating Panel 7. ignition switch — Three position switch, stop, operation The definitions below describe the controls and functions of the Engine Operating Panel (Figure 5). and start.
Output terMinal panel faMiliarizatiOn oUTpUT Terminal panel oUTpUT Terminal FamiliarizaTion The Output Terminal Panel (Figure 6) shown below is The “Output Terminal Panel ” (Figure 6) is provided with located on the right-hand side (left from control panel) of the following: the generator.
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Output terMinal panel faMiliarizatiOn 120 vaC gFCi receptacles Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the There are two 120 VAC, 20 amp GFCI (Duplex Nema GFCI receptacles. Remember the load output (current) on 5-20R) receptacles provided on the output terminal panel.
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Output terMinal panel faMiliarizatiOn Connecting loads over Current relay Loads can be connected to the generator by the output An over current relay (Figure 12) is connected to the main terminal lugs or the convenience receptacles (Figure 11). circuit breaker. In the event of an overload, both the circuit Make sure to read the operation manual before attempting 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 When calculating the power requirements for 3-phase and equipment to insure the wattage, amperage, frequency, power use the following equation: and voltage requirements are satisfactorily supplied by the generator for operating the equipment.
generatOr Outputs generaTor oUTpUT volTages generator amperage Table 8 shows the maximum amps the generator can A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using provide. Do noT exceed the maximum amps as listed.. the voltage selector switch (Figure 13).
generatOr Outputs/gauge reading hoW To reaD The aC ammeTer anD aC aC ammeter gauge reading volTage gaUges Place the AC Ammeter Change-Over Switch (Figure 17) in the U position and observe the current reading (load The AC ammeter and AC voltmeter gauges are controlled drain) on the U terminal as indicated on the AC Ammeter by the AC ammeter and AC voltmeter change-over Gauge (Figure 18).
Output terMinal panel cOnnectiOns UvWo Terminal oUTpUT volTages 3. Turn the voltage regulator knob (Figure 21) clockwise to increase voltage output, turn counterclockwise to Various output voltages can be obtained using the UVWO decrease voltage output. Use voltage regulator output terminal lugs. The voltages at the terminals are adjustment knob whenever fine tuning of the output dependent on the position of the voltage selector switch voltage is required.
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 1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 24. position as shown in Figure 26.
inspectiOn/setup CirCUiT BreaKers FUel CheCK To protect the generator from an overload, a 3-pole, 60 Danger amp, main circuit breaker is provided to protect the U,v, Fuel spillage on a hot engine can cause and W output Terminals from overload. In addition two a fire or explosion.
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inspectiOn/setup refueling procedure: 2. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel Warning cap and fill tank (Figure 31). Diesel fuel and its vapors are dangerous to your health and the surrounding environment.
inspectiOn/setup CoolanT (anTiFreeze/sUmmer CoolanT/ Cleaning The raDiaTor WaTer) The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the ISUZU recommends ISUZU antifreeze/summer coolant for radiator fins with compressed air. Cleaning inside the use in their engines, which can be purchased in concentrate machine is dangerous, so clean only with the engine turned (and mixed with 50% demineralized water) or pre-diluted.
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inspectiOn/setup BaTTerY When connecting battery do the following: 1. never connect the battery cables to the battery This unit is of negative ground Do noT connect in reverse. terminals when the ignition switch is in the sTarT Always maintain battery fluid level between the specified position.
generatOr start-up prOcedure BeFore sTarTing sTarTing 1. Place the voltage selector switch in the desired CaUTion voltage position (Figure 38).. The engine’s exhaust contains harmful emissions. alWaYs have adequate ventilation when operating. Direct exhaust away from nearby personnel. Warning never manually start the engine with the main, gFCi or auxiliary circuit breakers in the on (closed) position.
generatOr start-up prOcedure 6. The generator’s AC-voltmeter (Figure 42) will display 10. The coolant temperature gauge (Figure 46) will the generator’s output in volTs.. indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 167°~203°F (75°~95°C) (green zone). Figure 42.
generatOr shut-dOWn prOcedures emergenCY shUTDoWn proCeDUre Warning 1. Place the main, g.F.C.i., and aux. circuit breakers (Figure never stop the engine suddenly except in an 52) in the oFF position. emergency. 2. Turn the ignition key (Figure 52) to the sTop position. normal shUTDoWn proCeDUre To shutdown the generator, use the following procedure: 1.
Maintenance 10 hrs 1000 Table 14. inspection/maintenance 250 hrs 500 hrs DailY Check Engine Fluid Levels Check Air Cleaner Check Battery Acid Level Check Fan Belt Condition Check for Leaks Check for Loosening of Parts Replace Engine Oil and Filter * engine Clean Air Filter Check Fuel Filter/Water Separator Bowl...
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Maintenance FUel TanK inspeCTion If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to In addition to cleaning the fuel tank, the following a loss of power, excessive carbon buildup in the combustion components should be inspected for wear: chamber and high fuel consumption.
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Maintenance CheCK oil level raDiaTor Cleaning Check the crankcase oil level prior to each use, or when the The radiator (Figure 55) should be sprayed (cleaned) with fuel tank is filled. Insufficient oil may cause severe damage a high pressure washer when excessive amounts of dirt to the engine.
trailer Maintenance Trailer mainTenanCe 8. Tire size — Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters This section is intended to provide the user with generic (175,185,205, etc.). The tire diameter must match the trailer service and maintenance information.
trailer Maintenance BraKes hydraulic surge Brakes Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 56) should not require any operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance properly.
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trailer Maintenance Tires/Wheels/lUg nUTs suspension The leaf suspension springs and associated components Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the (Figure 57) should be visually inspected every 6,000 miles trailer wheels it is important the wheels, tires, and axle are for signs of excessive wear, elongation of bolt holes, and properly matched.
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trailer Maintenance lug nut Torque requirements It is 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.
trOubleshOOting (generatOr) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 19.
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nOtes DCa25Usi 60 hz generaTor • operaTion anD parTs manUal — rev. #3 (07/19/11) — page 47...
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.
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suggested spare parts DCa25Usi WhisperWaTT generaTor WiTh isUzU aa-4le2 Diesel engine 1 to 3 units QTY. DesCripTion 5....8944567411 ..FILTER, OIL, CARTRIDGE 5....8943672922 ..FILTER, FUEL, 5....8943692993 ..FILTER, FUEL, CARTRIDGE 5....8944370220 ..FILTER, FUEL, FUEL PUMP 3....0602046611 ..ELEMENT, AIR FILTER 1....8972309390 ..BELT, FAN 1....M1312500203 ..RADIATOR HOSE, UPPER 1....M1312500303 ..RADIATOR HOSE, LOWER 1....0601808803 ..CIRCUIT BREAKER, 1P, 20 AMP...
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 60 — DCa25Usi 60 hz generaTor • operaTion anD parTs manUal — rev. #3 (07/19/11)
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Output terMinal assy. parT no. parT name QTY. remarKs M1230700003 TERMINAL PANEL M9220000004 OUTPUT TERMINAL BOLT M9220000104 TIE SCREW 0039308000 HEX, NUT 0040008000 WASHER, LOCK 0041408000 WASHER, FLAT 0016906025 HEX, HEAD BOLT M1238100603 TERMINAL COVER M1238100704 OUTPUT WINDOW 0605010040 HINGE 0027103010 MACHINE SCREW 0030003000...
fuel tank assy. parT no. parT name QTY. remarKs M1365000302 FUEL TANK 0605505070 FUEL TANK CAP 0605501071 FUEL SENDER UNIT 0605516090 GASKET M1365200204 TANK BAND M9310500104 SUPPORTER SHEET 0016908020 HEX, HEAD BOLT 0016908040 HEX, HEAD BOLT 0207008000 HEX, NUT 0191201200 VENT HOSE 0605515108 HOSE BAND...
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enclOsure assy. (cOntinued) parT no. parT name QTY. remarKs M9113000002 DOOR HANDLE ASSY. C9312500004 SEAL RUBBER 0021806016 MACHINE SCREW 0030006000 HEX, NUT M9112100404 HINGE M9112100504 HINGE M9112100604 HINGE 0016908020 HEX, HEAD BOLT 0016908020 HEX, HEAD BOLT 0601850097 STOPPER 0027208025 MACHINE SCREW M1435000903 BRACKET STAY M1435000803...
rubber seals assy. page 74 — DCa25Usi 60 hz generaTor • operaTion anD parTs manUal — rev. #3 (07/19/11)
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rubber seals assy. parT no. parT name QTY. remarKs 0229200790 SEAL RUBBER 0314500560 SEAL RUBBER 0229200630 SEAL RUBBER 0228901220 SEAL RUBBER 0228900690 SEAL RUBBER 0228800690 SEAL RUBBER 0228900655 SEAL RUBBER 0228900325 SEAL RUBBER 0229200325 SEAL RUBBER 0228800595 SEAL RUBBER 0228800375 SEAL RUBBER 0228900375 SEAL RUBBER...
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