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Multiquip dca25USI2 User's Manual

1. CONTROL BOX ASSY PAGE 50 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 CONTROL BOX ASSY TY REMARKS S N 8103349 AND BELOW ke S N 8103350 AND ABOVE He S N 8103349 AND BELOW S N 8103350 AND ABOVE et S N 8103350 AND ABOVE S N 8103350 AND ABOVE q ys REPLACES P N 0602202523 REPLACES P N 0602201400 MEE REPLACES P N 0602202502 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 51 10 1 1 1 1 1 2 4 1 2 2 1 1 2 2 4 1 4 3 6 1 1 2 2 1 2 2 1 4 1 4 1 1 1 1 1 4 4 4 4 4 1 1 4 1 1 6 PART NAME CONTROL BOX paan CONTROL BOX uuu het dos CIRCUIT BREAKER 3P CIRCUIT BREAKER 6OA T C 12V DC EF TERMINAL 12 3 MACHINE SCREW RESISTOR MACHINE SCREW RECTIFIER MACHINE SCREW TERMINAL BOARD 20 6P MACHINE SCREW RELAY UNIT MACHINE SCREW AUTOMATIC VOLTAGE REGULATOR MACHINE SCREW CURRENT TRANSFORMER MACHINE SCREW OVER CURRENT RELAY OVER CURRENT RELAY MACHINE SCREW SELF LOCKING NUT ENGINE CONTROLLER HEX HEAD BOLT GLOW RELAY uu u au MACHINE SCREW CONTROL BOX COVER HEX HEAD BOLT SELECTOR SWITCH DECAL SELECTOR SWITCH NUMBER DECAL SELECTOR SWITCH NUMBER SWITCH BRACKET SWITCH BRACKET MACHINE SCRE
2. Two 120V GFCI receptacles 20 amp Two GFCI Circuit Breakers 20 5 Five Output Terminal Lugs W O Ground GROUND TERMINAL HARD WIRE HOOKUP PANEL ACCESS DOOR LIFT TO OPEN 5 9 TWIST LOCK CIRCUIT BREAKERS FOR RECEPTACLES OUTPUT TERMINAL PANEL 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 NOTICE Terminal legs O and Ground are considered bonded grounds 10 AND 30 480 120 VAC OUTPUT TERMINALS NEUTRAL TERMINAL BLACK RED BLUE WHITE GREEN CIRCUIT BREAKERS FOR 5 6369 TWIST LOCK RECEPTACLES 120 VAC 20 AMP GFCI RECEPTACLES RECEPTACLE CIRCUIT BREAKER gt PANEL AUX POWER RECEPTACLES 120 240V 50 AMPS Figure 6 Output Terminal Panel PAGE 20 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 OUTPUT TERMINAL PANEL FAMILIARIZATION Each auxiliary receptacle is protected by 2 50 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current on all three receptacles is dependent on the load requirements of the output terminal lugs Turn the voltage regulator control knob Figure 9 on the control panel to obtain the desired voltage Turning the knob clockwise will increase the voltage turning t
3. 4110 Industriel Boul Tel 450 625 2244 Unit 2 Northpoint Industrial Estate Tel 0161 339 2223 Laval Quebec Canada H7L 6V3 Tel 877 963 4411 Globe Lane Fax 0161 339 3226 Contact jmartin multiquip com Fax 450 625 8664 Dukinfield Cheshire SK16 4UJ Contact sales multiquip co uk COPYRIGHT 2014 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 This manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Your Local Dealer is MULTIQUIP
4. DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 GENERATOR OUTPUTS Generator Amperage Table 8 shows the maximum amps the generator can provide DO NOT exceed the maximum amps as listed Table 8 Generator Maximum Amps 1 120 Volt 55 5 amps 4 wire 1 240 Volt 27 8 amps 4 wire GFCI Receptacle Load Capability The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles Tables 9 and 10 show what amount of current is 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 receptacles Table 9 10 GFCI Receptacle Load Capacity KW in Use Available Load Twist Lock C6369 Current Amps GFCI Duplex 10 240 120V 5 20R 120V 144 0 5 amps receptacle 10 amps receptacle 15 20 amps receptacle Table 10 3 Generator Maximum Amps KVA in Use Available Load UVWO Terminals Current Amps GFCI Duplex 30 5 20R 120V GENERATOR OUTPUT VOLTAGES 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 fine adjustment using the voltage regul
5. 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 and the L markings Table 12 Coolant Capacity Engine and Radiator 1 70 gal 6 4 liters 2 quarts 1 9 liters Operation in 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 Yo Freezing Point Boiling Point Anti NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 PAGE 30 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 INSPECTION SETUP When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the ignition switch is in the START position ALWAYS make sure that the ignition switch is in the OFF position when connecting the battery 2 Place small amount of battery terminal treatment compound around both battery terminals This will ensure 2 good connection and will help prevent corrosion around the battery terminals NOTICE If the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention t
6. QTY Column Numbers Used Item quantity can be indicated by a number 2 blank entry or A R As Required is generally used for hoses or other parts that are sold in bulk and cut to length blank entry generally indicates that the item is not sold separately Other entries will be clarified in the Remarks Column REMARKS Column Some of the most common notes found in the Remarks Column are listed below Other additional notes needed to describe the item can also be shown Assembly Kit All items on the parts list with the same unique symbol will be included when this item is purchased Indicated by INCLUDES ITEMS W unique symbol Serial Number Break Used to list an effective serial number range where a particular part is used Indicated by SIN XXXXX AND BELOW SIN XXXX AND ABOVE SIN XXXX TO SIN XXX Specific Model Number Use Indicates that the part is used only with the specific model number or model number variant listed It can also be used to show a part is NOT used on a specific model or model number variant Indicated by XXXXX ONLY NOT USED ON XXXX Make Obtain Locally Indicates that the part can be purchased at any hardware shop or made out of available items Examples include battery cables shims and certain washers and nuts Not Sold Separately Indicates that an item cannot be purchased as a separate item and is eithe
7. quantities and descriptions of the items to be returned a The parts numbers and descriptions must match the current parts price list b Thelist must be typed or computer generated c The list must state the reason s for the return d The list must reference the sales order s or invoice s under which the items were originally purchased e The list must include the name and phone number of the person requesting the RMA 3 Acopyofthe Return Material Authorization must accompany the return shipment 4 Freight is at the sender s expense All parts must be returned freight prepaid to Multiquip s designated receiving point PAGE 76 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 NOTES DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 77 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 MQ Parts Department 18910 Wilmington Ave Tel 800 421 1244 800 427 1244 Fax 800 672 7877 Carson CA 90746 Fax 310 537 3927 310 537 3700 Fax 310 637 3284 Contact mq multiquip com Service Department Warranty Department 800 421 1244 Fax 310 537 4259 800 421 1244 Fax 310 943 2249 310 537 3700 310 537 3700 Technical Assistance 800 478 1244 Fax 310 943 2238 CANADA UNITED KINGDOM Multiquip Multiquip UK Limited Head Office
8. 53 0199100700 HOSE 1 54 0193600850 HOSE 1 99 0605515106 HOSE BAND 2 56 0602120481 PICK UP TACHOMETER 1 57 0602122272 UNIT OIL PRESSURE 1 58 M9200100004 ADAPTER 1 59 0602123275 UNIT WATER TEMPERATURE 1 60 M1353800004 CLAMPER ROD 1 61 0016908020 HEX HEAD BOLT 2 62 8970633010 SENSOR WATER TEMP 1 63 8973022030 SWITCH WARNING OVERHEAT 1 64 1824100990 SENSOR OIL PRESSURE Lasser REPLACES 5824100362 OUTPUT TERMINAL ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED 5 BLACK 9 DESERT TAN THE SERIAL NUMBER MAY BE REQUIRED PAGE 58 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 OUTPUT TERMINAL ASSY PART NO PART NAME QTY REMARKS M1230700003 TERMINAL PANEL 1 M9220000004 OUTPUT TERMINAL BOLT 5 M9220000104 TIE BOLT 5 0039308000 HEX NUT 10 0040008000 WASHER LOCK 15 0041408000 WASHER FLAT 20 0016906025 HEX HEAD BOLT 4 M1236101103 TERMANAL COVER 1 M1238100704 OUTPUT WINDOW 1 0605010040 HINGE 2 0027103010 MACHINE SCREW 4 0030003000 HEX NUT 4 0041203000 WASHER FLAT 4 0027103010 MACHINE SCREW 4 0030003000 HEX NUT 4 M9220100804 SET SCREW 2 0040006000 WASHER LOCK 2 0041206000 WASHER FLAT 2 0080200005 RETAINING RING 2 0016906016 HEX HEAD BOLT 4 M1236400004 OUTLET COVER CABLE 1 M1236300004 CABLE OUTLET
9. Adjust rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag 7 Replace the adjusting hole cover and lower the trailer to the ground 8 Repeat steps 1 through 7 on the remaining brakes Table 15 Hydraulic Brake Troubleshooting Possible Cause _ Tires unmatched on the same axle Match tires Brake components loose bent or 2 eplace components Locking Brakes broken Tire pressure correct Inflate all tires equally System lubricated Noisy Brakes Brake components correct Replace and correct Brake drums out of round Brake lining thickness incorrect or Install new shoes and not adjusted correctly linings Replace rubber parts 2 Enough brake fluid or correct fluid fill with dot 4 fluid Dragging Brakes DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 39 TRAILER MAINTENANCE Suspension The leaf suspension springs and associated components Figure 57 should be visually inspected every 6 000 miles for signs of excessive wear elongation of bolt holes and loosening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 17 SHACKLE SUPPORT BRACKET IS WELDED TO FRAME SHACKLE HANGER SUPPORT BRACKET IS WELDED SHACKLE TO FRAME BOLTS LEAF SUSPENSION FRONT HANGER NUT FRONT U BOLT HANGER BOLT LOCKING
10. AC Ammeter Amp Reading on U Lug Figure 17 AC Ammeter Change Over Switch NOTICE The ammeter gauge will only show 2 reading when the Output Terminal Lugs are connected to a load and in use HOW TO READ THE 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 Before taking a reading from either gauge set the Voltage Selector Switch Figure 14 to the position which produces the required voltage For example for 30 240V choose the center 3 240 139V position on the voltage selector switch 3 PHASE 240 139 3 PHASE 1 PHASE 480 277 0 20 PRESS TO LOCK Figure 14 Voltage Selector Switch 240 139 30 Position For 30 208V 1 120V place the Voltage Selector Switch in the 3 Phase 240 139 position AG Voltmeter Gauge Reading Place the AC Voltmeter Change Over Switch Figure 15 in the W U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge Figure 16 V W 0 W U OFF Figure 15 AC Voltmeter Figure 16 AC Voltmeter Change Over Switch Gauge DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 0
11. LEDs on the MPEC display are OFF not lit 5 Remove all loads from the generator 6 Inspect entire generator for any damage or loosening of components that may have occurred during operation PAGE 34 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 10 Hrs DAILY 250 Hrs 500 Hrs Table 14 Inspection Maintenance Check Engine Fluid Levels Check Air Cleaner Replace Engine Oil and Filter Clean Air Filter Change Fuel Filter Clean Unit Inside and Outside Check Fuel Filter Water Separator Bowl Clean Radiator and Check Coolant Protection Level Replace Air Filter Element Check all Hoses and Clamps Clean Inside of Fuel Tank Measure Insulation Resistance Over 3M ohms Generator Check Rotor Rear Support Bearing Replace engine oil and filter at 100 hours first time only Add Supplemental Coolant Additives SCA S to recharge the engine coolant Replace primary air filter element when restriction indicator shows a vacuum of 625 mm 25 H20 4 If blowby hose needs to be replaced ensure that the slope of the blowby hose is at least 1 2 inch per foot with no sags or dips that could collect moisture and or oil AIR CLEANER INDICATOR AIR CLEANER ELEMENT Figure 53 Air Cleaner Indicator NOTICE The air filter should not be changed until the indicator reads RED Dispose of old air filter may not be clean
12. LOAD anag NEUTRAL Figure 11 Connecting Loads PAGE 22 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 LOAD APPLICATION THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation VOLTAGE AMPERAGE X 1 732 1000 NOTICE If 30 load kVA is not given on the equipment nameplate approximate 30 load may be determined by multiplying voltage by amperage by 1 732 NOTICE Motors and motor driven equipment draw much greater current for starting than during operation An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable See Table 6 B When connecting a resistance load such as incandescent lamp or electric heater a capacity of up to the generating set s rated output KW can be used When connecting a fluorescent or mercury lamp capacity of up to the generating set s rated output KW multiplied by 0 6 can be used mi When connecting an electric drill or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generating set s rated output KW multiplied by 0 8 can be used DANGER Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer swi
13. OPERATION AND PARTS MANUAL REV 0 02 14 14 MUFFLER ASSY QTY REMARKS REPLACES P N 0602320100 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 63 PART NAME MUFFLER GASKET HEX HEAD BOLT STAY HEX HEAD BOLT EXHAUST PIPE HEAT INSULATOR GASKET ai GASKET HEX NUT HEX HEAD BOLT PART NO M1330000512 M1333200304 0016908035 M1333300204 0016908020 M1333003013 M1490003604 8970420280 M1333200214 0207008000 0016908035 2 O FUEL TANK ASSY PAGE 64 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 FUEL TANK ASSY QTY REMARKS REPLACES P N 0602042202 ae REPLAGES P N 0602042700 1 1 1 1 2 2 4 4 4 4 1 7 PART FUEL TANK CAP FUEL TANK FUEL SENDER UNIT GASKET TANK BAND TANK BAND SUPPORTER SHEET HEX HEAD BOLT HEX NUT TANK SHEET VENT HOSE HOSE BAND EUELTILTIER auctort CARTRIDGE FUEL FILTER EE AND 8943692993 TE REPLACES P N 0602023177 AERE REPLACES P N 0602042425 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 65 BRACKET FUEL FILTER HEX HEAD BOLT FUEL PUNIP REPAIR KIT FUEL PUMP HEX HEAD BOLT SUCTION HOSE SUCTION HOSE SUCTION HOSE RETURN HOSE HOSE BAND PART NO M1365000302 0605505070
14. TIE PLATE Figure 57 Major Suspension Components Table 17 Suspension Torque Requirements dem Torgue Ft Lbs Shackle Bolt snug fit only Parts must rotate freely Locking nuts or cotter pins are Spring Eye Bolt provided to retain nut bolt assembly Shoulder Type Min 30 Max 50 Shackle Bolt TIRES WHEELS LUG NUTS Tires and wheels 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 ALWAYS wear safety glasses when ET removing or installing force fitted parts Failure to comply may result in serious injury DO NOT attempt to repair or modify a ET wheel DO NOT install in inner tube to correct a leak through the rim If the rim is cracked the air pressure in the inner tube may cause pieces of the rim to explode break off with great force and cause serious eye or bodily injury Tire Wear Inflation Tire inflation pressure is the most important factor in tire life Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot Check inflation pressure weekly during use to insure the maximum tire life and tread wear Table 16 Tire Wear Troubleshooting will help pinpoint the causes and solutions of tire wear problems a 16 Tire Wear Troubleshooting Center Wear Over inflation poe load per tire manufacturer Edge Wear
15. Under inflation 2 load per tire manufacturer Make sure load does not Loss of camber Side Wear exceed axle rating or overloading Align wheels Check bearing adjustment Cupping Out of balance Flat Spots Wheellockup and Avoid sudden stops when QM tire skidding possible and adjust brakes PAGE 40 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 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 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence see Figure 58 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 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 Table 18 Tire Torque Requirements First Pass Second Pass Third Pass FT LBS FT LBS FT LBS 20 25 35 40 50 65 5 LUG NUTS 8 LUG NUTS LUG NUTS PNEUMATIC AIR GUN TORQUE WRENCH Figure 58 Wheel Lug Nuts Tightening Sequence NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 41 TRAILER WIRING DIAGRAM TRAILER SI
16. 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 Hazard Lethal exhaust gas hazards Explosive fuel hazards Burn hazards Overspeed hazards Rotating parts hazards Pressurized fluid hazards Electric shock hazards 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 SAFETY MESSAGES The four safety messages shown below will inform you about potential hazards that could injure you or others The safety messages specifically address the level of exposure to the operator and are preceded by one of four words DANGER WARNING CAUTION or NOTICE SAFETY SYMBOLS 7 DANGER Indicates 2 hazardous situation which if not avoided WILL result in DEATH or SERIOUS INJURY Indicates hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY Indicates hazardous situation which if not avoided COULD result in MINOR or MODERATE INJURY NOTICE Addresses practices not related to personal injury PAGE 6 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 SAFETY INFORMATION m NEVER use accessories or attachm
17. m Replace the fuel filter cartridge with new one every 500 hours or so 98 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 spill the fuel during disassembly E Vent any air AIR REMOVAL If air enters the fuel injection system of a diesel engine starting becomes impossible After running out of fuel or after disassembling the fuel system bleed the system according to the following procedure See the ISUZU Engine Manual for details To restart after running out of fuel turn the switch to the ON position for 15 30 seconds Try again if needed 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 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 fuel Cleaning Inside the Fuel Tank If necessary drain the fuel inside
18. the eyes and skin ii Use well insulated gloves when picking up the battery m ALWAYS keep the battery charged If the battery is not charged combustible gas will build up m ALWAYS recharge the battery in a well ventilated environment to avoid the risk of a dangerous concentration of combustible gasses ELECTRICAL SAFETY DO NOT touch output terminals during operation Contact with output terminals during operation can cause electrocution electrical shock or burn 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 m NEVER insert any objects into the output receptacles during operation This is IN extremely dangerous The possibility exists of electrical shock electrocution or death Backfeed to a utility system can cause electrocution and or property damage NEVER connect the generator to a building s electrical system without a transfer switch or other approved device All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes Failure to do so could result in electrical shock or burn causing serious injury or even death Power Cord Cable Safety m NEVER let power cords or cables lay in water NEVER stand
19. 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 BRAKES Trailer brakes should be inspected the first 200 miles of operation This will allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes every 3 000 miles If driving over rough terrain inspect the brakes more frequently Figure 56 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 listed 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 Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn 6
20. 0 DECAL ENVIRONMENTAL WARNING EE M91010030 EAI saa M91020000 DECALS GROUND sms ETE M92000000 DECAL AMMETER CHANGE OVER SWITCH 1 M92000010 DECAL VOLTMETER CHANGE OVER SWITCH M92000020 DECAL WARNING ELECTRIC SHOCK HAZARD 2 M92010000 DEGAL OA EN M92010020A DECAL SAFETY INSTRUCTIONS Tette M92010030 DECAL DANGER HIGH VOLTAGE M92010040 DECAL WARNING mamamana 92010050 DECAL CONNECTION OF OUTPUT Lue M92020000 DECAL OVER CURRENT RELAY M92020040 MO POWER 2 civ 2 STRIPE WHISPERWATIT 1 ee 1 STRIPE Sa 1 STRIPE ur 2 PLATE POWER acte od oig 1 MAGHINESEREN asi tandis aa 4 DECAL p nana M92000080 DECAL TERMINAL eee 1 DECAL WARNING START FIRES S N 8103260 AND ABOVE ee or REPLAGES M9504200004 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 75 PART NO M1510300902 M1510301002 M1550000104 M1550000204 M1550001404 M1552000603 M9500000004 M9500100004 M9500300004 M9500300104 M9500500304 M9503000004 M9503000103 M9503100004 M9503200004 M9503200104 M9510000004 M9510000104 M9510100004 M9510100304 M951220000
21. 0605501071 0605516090 M1365200204 M1363200304 M9310500104 0016908020 0207008000 0222100550 0191301200 0605515109 8943672922 89803744810 M1368700004 0016908020 8970398340 8944370220 0016906030 0191200330 0191200200 0191201000 0191200600 0605515198 2 O O1 A OO N gt ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER PS WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR a OF UNIT G Fog 153 BD 1 ORANGE 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED 5 BLACK 9 DESERT TAN THE SERIAL NUMBER MAY BE REQUIRED PAGE 66 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 ENCLOSURE ASSY REMARKS DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 67 lt 5 c HB BH za PART NAME BASE ACOUSTIC SHEET ENVIROMENTAL TANK PLUG HEX HEAD BOLT DUCT HEX HEAD BOL FRONT FRAME ACOUSTIC SHEET GROMMET FRONT DUCT ACOUSTIC SHEET GROMMET GROMMET HEX HEAD BOLT HEX HEAD BOLT HEX HEAD BOLT DUCT COVER HEX HEAD BOLT DUCT COVER HEX HEAD BOLT HOSE COVER HEX HEAD BOLT COVER FRONT FRAME FRONT LOVER HEX HEAD BOLT HEX HEAD BOLT CENTER FRAME CENTER FRAME HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX HEAD BOLT WASH
22. 2561 0602022579 0603306590 0603306597 2 O lt gt ENGINE AND RADIATOR ASSY CONTINUED 5 17 9 1 13 14 p zm LAT 7 n 3 Je 12 46 Me i 4 38 36 37 VIEW Y 2 22 gt Q PAGE 56 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 ENGINE AND RADIATOR ASSY CONTINUED DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 57 NO PART PART NAME QTY REMARKS 35 0603300285 sS l S N 8103379 AND BELOW 35 0603300286 ES ee S N 8103380 AND ABOVE 36 0605511395 EN Tes S N 8103379 AND BELOW 36 0605511399 MER S N 8103380 AND ABOVE 37 0603306395 HOSE JOINT Toes S N 8103379 AND BELOW 37 0603306399 HOSE JOINT au Len S N 8103380 AND ABOVE 38 0602021070 AR pe S N 8103379 AND BELOW 38 0602021071 CAP poden raser S N 8103380 AND ABOVE 39 0269200520 DRAIN HOSE u u S N 8103379 AND BELOW 39 0379500520 DRAIN HOSE SN 8103380 AND ABOVE 40 M9602000003 DRAIN JOINT 1 41 M9200200004 PLUG 1 42 0150000018 O RING 1 43 0016906020 HEX HEAD BOLT 2 44 0199901600 DRAIN HOSE 1 45 0605515106 HOSE BAND 4 47 M9300000003 RESERVE TANK 1 48 M9300100003 CAP RESERVE TANK 1 49 0199100215 HOSE 1 50 M1316100603 BRAGKET RESERVE TANK 1 51 0016906025 HEX HEAD BOLT 1 52 0016908020 HEX HEAD BOLT 2
23. 390 0228100320 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 73 k D kas apasi O NAMEPLATE AND DECALS ASSY 7 PAGE 74 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 NAMEPLATE AND DECALS ASSY PART NAME QTY REMARKS DECAL OPERATING PROCEDURES jc M11030090 DECAL GENERATOR CONTROL Jons M11030100 DECAL NOT aa 15000010 DECAL uuu AA nahin 15000020 PECAL CAUTION 15000140 DECAL AUXILIARY OUTPUT 15500060 DECAL OIEDBAINATPEUG Z u uuu e kos 90000000 DECAL WATER Snob abf erm 90010000 DECAL RIE ctm 90030000 DECAL ees 90030010 DECAL DIESEL FUEL 90050000 DECAL WARNING MOVING PARTS 90300000 DECAL WATER OIL Fenians M90300010 DECAL WARNING HOT CQQLAN T Loa ass M90310000 DECAL WARNING ENGINE EXHAUST Larsen M90320000 DECALS DANGER nad 90320010 DECAL FLUID DRAIN u M91000000 DECAL DOCUMENT BOX 91000010 DECAL CAUTION HOT PARTS 9101003
24. 4 M9520000004 M9520000104 M9520000204 M9520100004 M9520100204 M9520100304 M9520100404 M9520100503 M9520200003 M9520200404 M1561000004 M1562100004 M1560100103 M1562100204 M1562100304 M1562100404 0600500092 0021106016 M9520000804 M9521000004 92021400 SATIN SG O TERMS AND CONDITIONS OF SALE PARTS 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 SPECIAL EXPEDITING SERVICE A 535 00 surcharge will be added to the invoice for special handling including bus shipments insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed and in no event shall Multiquip be liable for loss of profit or good will or for any other special consequential or incidental damages LIMITATION OF WARRANTIES No warranties express or implied are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip Such warranties made in connection with the sale of new complete units are made exclusively by a statement of warranty packaged with such units and Multiquip neither assumes nor authorizes any person to assume for it any other o
25. 4 14 PAGE 25 OUTPUT TERMINAL PANEL CONNECTIONS 3 Turn the voltage regulator knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required DECREASE INCREASE N Figure 21 Voltage Regulator Knob 3 208V 1 120V UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 30 240 139 position as shown in Figure 22 3 PHASE USE THIS POSITION FOR 240 139 30 208 or 1 PRESS TO LOCK Figure 22 Voltage Selector Switch 3 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 23 BLUE GREEN WHITE GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 23 UVWO Terminal Lugs 3 208 1 120V Connections Connections NOTICE To achieve a 3 208V output the voltage selector switch must be in the 3 240 139 position and the voltage regulator must be adjusted to 208V 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 3 240 139 UVWO Termi
26. 79 AND BELOW BEES S N 8103380 AND ABOVE 00000 S N 8103379 AND BELOW a S N 8103379 AND BELOW Ke S N 8103380 AND ABOVE e S N 8103379 AND BELOW S N 8103380 AND ABOVE DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 5 PART NAME ENGINE ISUZU BV4LE2 FAN DEDI iiti ELEMENT OIL FILTER ENGINE FOOT ENGINE FOOT HEX HEAD BOLT WASHER LOCK WASHER FLAT RUBBER SUSPENSION HEX NUT RADIATOR CAP RADIATOR PLUG O RING MOUNT RUBBER HEX HEAD BOLT HEX NUT RADIATOR HOSE UPPER RADIATOR HOSE LOWER HOSE BAND FAN COVER HEX HEAD BOLT SEAL RUBBER MOTOR FAN HEX HEAD BOLT AIR CLEANER ELEMENT AIR CLEANER INDICATOR AIR CLEANER BRACKET AIR CLEANER HEX HEAD BOLT HEX NUT HOSE AIR CLEANER HOSE AIR CLEANER HOSE BAND ADAPTER oci optas ADAPTER PAGKING 90 ELBOW snes 0 ELBOW CONNECTOR CONNECTOR M1923200124 8972309390 2944566410 M1305200304 M1305200204 0010310025 0040010000 0041210000 0605000066 0207010000 M1923200074 0602011079 M9200100904 0150000016 M9312200104 0016908035 0207008000 M1312500203 M1312500303 0605515149 M1312300103 0016906020 0220300425 0601822794 0017108025 0602046531 0602046611 0602040650 0602040552 0016908030 0207008000 M1375100303 M1373101403 0605515147 0602022560 0602022587 M1320300304 060202
27. ANCING PLATE 4 4 1 1 6 6 6 1 UN 1 SIN 8103349 AND BELOW iile 1 SIN 8103350 AND ABOVE 1 1 1 3 1 6 1 1 3 6 6 6 1 1 1 1 2 2 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 9 PART NAME ROTOR ASSY FIELD ASSY RECTIFIER SURGE ABSORBER FAN COUPLING DISK WASHER COUPLING HUB BALANCING PLATE HEX HEAD BOLT SPRING WASHER BALANCING WEIGHT KIT BEARING HEX HEAD BOLT SPRING WASHER PLAIN WASHER BEARING STATOR ASS STATOR ASS suuin ust GROMMET FIELD ASSY EXCITER HEX SOCKET HD CAP SCREW SPRING WASHER END HEX HEAD BOLT PAGKING COVER SUCTION HEX HEAD BOLT HEX HEAD BOLT SPRING WASHER PLAIN WASHER COVER FAN HEX HEAD BOLT PLAIN WASHER NUT RUBBER SUSPENSION HEX NUT PART NO B1110200602 7961025004 0601822630 8001070003 8351611004 8351612004 B1112300003 0010310025 0042510000 0601000209 0071906308 0010308035 0040008000 0041208000 0070506803 B1130201103 B1130202103 0845041904 B1138000003 0016008045 0042508000 8351315003 0017108035 8351312004 8351331004 0017106016 0010310030 0040010000 0041210000 B0155400204 0010106030 0041206000 0600815000 M9312600004 0207010000 cb Lo ll WP
28. COVER SUPPORTER 1 0016906020 HEXHEAD BOLT 6 0601808803 CIRCUIT BREAKER 20A 1 0601808804 CIRCUIT BREAKER 50A 2 M1260700204 BREAKER FITTING COVER 1 0222100115 CUSHION RUBBER 1 0016906020 HEX HEAD BOLT 2 0601812598 RECEPTACLE GFCI 125V 2 2 0601812538 RECEPTACLE 56369 250V 50A S N 8103379 AND BELOW 0601814014 RECEPTACLE CS6369L 250 Perser S N 8103380 AND ABOVE 0027104016 SCREW 8 0207004000 HEX NUT 8 M1236400104 COVER 1 M1493408804 ACOUSTIC SHEET 1 0016906016 HEX HEAD BOLT 4 M1238100503 TERMINAL COVER 1 0010112040 HEX HEAD BOLT 2 0041212000 WASHER FLAT 2 M9310200004 RUBBER STAY 2 0030012000 HEX NUT 2 M4236100604 COVER 1 M4236400304 BRACKET 1 0019206015 HEX HEAD BOLT 2 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 59 s C NE O BATTERY ASSY PAGE 60 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 BATTERY ASSY QTY REMARKS 1 1 1 2 2 1 1 1 1 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 61 PART NAME BATTERY BATTERY SHEET BATTERY BAND BATTERY BOLT SET WASHER LOCK BATTERY CABLE BATTERY CABLE HEX HEAD BOLT TOOTHED WASHER PART NO 0602220185 M9310500014 M9103000304 0602220920 0040006000 M1348400204 M1348400314 0016910020 0040510000 2 O INI MUFFLER ASSY PAGE 62 DCA25US12 60 HZ GENERATOR
29. DE TOWING VEHICLE SIDE DOUBLE FILAMENT BULB CONNECT RIGHT TO CHASSIS TAIL LIGHT iL WHITE YELLOW BROWN E P GREEN STOP amp TURN LEFT LICENSE TAIL LIGHT 1 DOUBLE FILAMENT BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT TAIL LIGHT I I I 1 1 DOUBLE FILAMENT BULB CONNECT RIGHT TO CHASSIS TAIL LIGHT 1 MIE qa WHITE COMMON GROUND SINGLE BT BLUE TURN RIGHT FILAMENT CTO s kug GREEN TAIL amp LICENSE BULB YELLOW STOP RED TURN LEFT LICENSE TAIL LIGHT I I DOUBLE FILAMENT BULB FLAT 5 PIN ROUND FLAT 5 ROUND CONNECTOR CONNECTOR i LEFT TAIL LIGHT i Figure 59 Trailer Towing Vehicle Wiring Diagram PAGE 42 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 GENERATOR WIRING DIAGRAM 40 ye 2 kR Y CHINE riv CNT CNB 70 Wee TA YS B gt 05 Mats bog a 94 97 et ae pot lm mg 28 zu eee WAN E E my Paco LB H 18 pA 6 Jenin CN 2 RY2 11 2 BRUSHLESS AC GENERATOR 1 2 3 41 CNT CN8 41198 Notice 3 2 4 1 No designation lead size 1 25 12 3 SYMBOL DESIGNATION CN9 L 64 2 1 MAIN GENERATOR ARMATURE WINDING Re AUTOMATIC VOL
30. ER LOCK WASHER FLAT REAR FRAME ACOUSTIC SHEET ACOUSTIC SHEET DUCT ACOUSTIC SHEET ACOUSTIC SHEET ACOUSTIC SHEET PART NO M1413003402 M1419300504 M1415100202 0603306797 0016910030 M1413600004 0019208020 M1423002402 M1493108303 0601850151 M1423202602 M1493108003 0601851740 0601850239 0016908020 0016906020 0016908020 M1425201204 0016906016 M1423202704 0016906016 M1414200803 0016906020 M1423202003 M1423202103 0016906016 0019208020 M1433001403 M1433400003 0013612030 0040012000 0041212000 0013612030 0040012000 0041212000 M1443001502 M1493304004 M1493305304 M1453301703 M1493305304 M1493305404 M1493305504 2 O gt BAON ENCLOSURE ASSY CONTINUED JEG Eo EU oc Pat ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER Hi am WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR a JULE ji OF UNIT EI 162 1 ORANGE 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED 5 BLACK 9 DESERT TAN THE SERIAL NUMBER MAY BE REQUIRED PAGE 68 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 ENCLOSURE ASSY CONTINUED REMARKS DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 69 QTY PART NAME HEX HEAD BOLT HEX NUT HEX HEAD BOLT REAR COVER ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT H
31. EX HEAD BOLT REAR DOOR WINDOW PLATE HEX NUT WASHER FLAT DOOR HANDLE ASSY MACHINE SCREW HEX NUT HINGE HINGE HEX HEAD BOLT ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT COVER HEX HEAD BOLT SPLASHER PANEL HEX HEAD BOLT SIDE PANEL PART NO 0016906016 0207006000 0016908020 M1443302203 M1493305104 M1443400103 M1493305204 0207006000 0019208020 M1445200303 M1445600204 0207306000 0041206000 M9113000002 0021806016 0030006000 M9112100404 M9112100604 0016908020 M1463001902 M1493505603 0019208020 M3310600004 0019208020 M1453200802 0016908020 M1455100003 ENCLOSURE ASSY CONTINUED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER a WHEN ORDERING PAINTED PANEL INDICATE COLOR P OF UNIT n 163 per 1 ORANGE 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED 5 BLACK 9 DESERT TAN THE SERIAL NUMBER MAY BE REQUIRED PAGE 70 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 ENCLOSURE ASSY CONTINUED REMARKS DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 71 QTY PART NAME ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET ACOUSTIC SHEET ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET DUCT ACOUSTIC SHEET ACOUSTIC SHEET HEX NUT DOOR HANDLE ASSY SEAL RUBBER MACHINE SCREW HEX NUT HINGE HINGE H
32. I2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 3 TABLE OF CONTENTS COMPONENT DRAWINGS Generator ASS 48 49 GOMMI BOX ASS mas 50 53 Engine And Radiator Assy 54 57 Output Terminal Assy 58 59 Battery ASS RO 60 61 MUNSRASS uu 62 63 TANK ASS EN 64 65 05 ASS uuu apanqa qasa 66 71 Rubber Seals 72 73 Nameplate and Decals Assy 74 75 Terms And Conditions Of Sale Parts 76 DCA25USI2 60 Hz Generator Proposition 65 Warning 2 Reporting Safety 3 Table Of Contents 4 Parts Ordering Procedures 5 Safety Information 6 11 OPECINGANONG y u u u pr Sc u 12 u ua eden 13 LE i aaa 14 15 General Information a 16 Major Components 17 Generator Control 18 Engine Operating 19 Output Terminal Panel Familiarization 20 22 load kassene 23 G
33. INGE HEX HEAD BOLT HEX HEAD BOLT STOPPER MACHINE SCREW BRACKET STAY BRACKET STAY HEX HEAD BOLT SUPPORT LEG ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLT TOOTHED WASHER MANUAL PAK BOX CLAMPER HEX HEAD BOLT FUEL LEAK DETECTED SWITCH BRACKET HEX HEAD BOLT PART NO M1493410104 M1453004903 M1493409904 M1495501004 M1455000803 M1495501204 M1495501304 M1495401404 M1453005003 M1493410004 M1455300403 M1495401204 M1495401404 0207006000 M9113000002 C9312500004 0021806016 0030006000 M9112100404 M9112100504 M9112100604 0019208020 0019208020 0601850097 0027208025 M1433300003 M1435000803 0016908020 M1433001103 M1493200004 0016908020 0016908020 0040508000 0600800321 M1483600804 0016906016 0605503066 M1414800204 0017108020 RUBBER SEALS ASSY PAGE 72 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 RUBBER SEALS ASSY REMARKS QTY 3 2 1 3 3 1 1 1 1 1 1 1 2 2 2 1 1 2 2 PART NAME SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER PART NO 0229200790 0314500560 0229900630 0228901220 0228900690 0228800690 0228900655 0228900325 0229200325 0228800590 0228900375 0228900375 0229200650 0229200320 0228800650 0228900510 0228800510 0228100
34. N AND PARTS MANUAL REV 0 02 04 14 PAGE 29 INSPECTION 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 turned 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 A slack fan belt may contribute to overheating or to insufficient charging of the battery Inspect the fan belt for damage and wear and adjust it in accordance with the ISUZU Engine Owner s Manual The fan belt tension is proper if the fan belt bends 10 to 15 mm Figure 34 when depressed with the thumb as shown below 10 15 MM DEFLECTION Figure 34 Fan Belt Tension in NEVER place hands near the belts or fan while the generator set is running COOLANT 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 diluted See the ISUZU Engine Owner s Manual for further details un If adding coolant antifreeze mix to the wa radiator DO NOT remove the radiator until the unit has completely cooled The possibility of hot coolant exists which can cause severe burns
35. OL PANEL FREQUENCY METER 240V AC METER 0 50A 100A 5A1 CHANGE OVER SWITCH AMMETER AC VOLTMETER O 600V CHANGE OVER SWITCH VOLTMETER RHEOSTAT VR 2W 1k OHM KNOB ALARM LAMP BULB STARTER SWITCH KEY IGNITION PREHEAT LAMP BULB TACHOMETER OIL PRESSURE GAUGE WATER TEMPERATURE GAUGE CHARGING AMMETER FUEL GAUGE PANEL LIGHT EE PANEL LIGHT SWITCH ALARM LAMP BULB STOPPER MACHINE SCREW MACHINE SCREW SET SCREW SNAP RING GROMMET HEX HEAD BOLL uuu uuu sa MER NU Trusted etim papi Dd PLAIN WASHER anag tein WIRE HARNESS GENERATOR WIRE HARNESS GENERATOR PART NO M1223000603 M1223000613 0601807641 0601808985 0601801040 0601806859 0601801041 0601840073 0601840121 0602103092 0601810245 8970444180 8944024980 0602103092 0601810245 0602120095 0602122093 0602123090 0602121080 0602125090 9826800370 0601831330 0602103092 0601810245 M1225100004 0027105010 0027105010 M9220100004 0080200007 0601851727 011208030 020108060 0401450080 M1246703604 M1246703614 ENGINE AND RADIATOR ASSY 5 17 9 1 13 14 38 36 37 VIEW Y 21 22 PAGE 54 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 ENGINE AND RADIATOR ASSY QTY REMARKS 1 1 REPLACES P N 0602011431 EEE REPLACES P N 0602041210 AND 8944567412 EMSS S N 81033
36. OPERATION AND PARTS MANUAL MULTIQUIP 44 POWER MODEL DCA25US12 60HZ WHISPERWATT GENERATOR ISUZU BV 4LE2 DIESEL ENGINE PARTS LIST NO M1870400104C Revision 0 02 04 14 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning 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 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 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 Inc 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 However NHTSA cannot become involved in individual problems between you your dealer or Multiquip Inc To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to httip www safecar gov or write to Administrator NHTSA 400 Seventh Street SW Washington DC 20590 You can also obtain information about motor vehicle safety from http www safecar gov DCA25US
37. S MANUAL REV 0 02 14 14 1 GENERATOR START UP PROGEDURE 10 The coolant temperature gauge Figure 46 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 167 203 F 75 95 C Green Zone Figure 46 Coolant Temperature Gauge The tachometer gauge Figure 47 will indicate the speed of the engine when the generator is operating Under normal operating conditions this speed is approximately 1800 RPM s Figure 47 Engine Tachometer Gauge Place the main GFCI and aux circuit breakers in the ON position Figure 48 MAIN AUXILIARY GFCI CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Figure 48 Main Aux and GFCI Circuit Breakers ON Observe the generators ammeter Figure 49 and verify it reads the anticipated amount of current with respect to the load The ammeter will only display current reading if 2 load is in use Figure 49 Ammeter Load 13 14 The generator will run until manually stopped or an abnormal condition occurs PAGE 33 6 The generator s AC voltmeter Figure 42 will display the generator s output in VOLTS Figure 42 Frequency Meter If the voltage is not within the specified tolerance use the voltage adjustment control knob Figure 43 to increase or decrease the desired voltage DECREASE or Figure 43 Voltage Adjust Control Knob The ammeter Figure 44 will i
38. TAGE REGULATOR CHANGE OVER SWITCH AC AMMETER m CHANGE OVER SWITCH VOLTMETER AG VOLTMETER Figure 60 Generator Wiring Diagram DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 43 PAGE 44 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 Figure 61 Engine Wiring Diagram gd 2 i22Y t IVISU bing QL 1 TIA INO OG TIA IND OX y m 1 m 8 ND OL ING gt 1 3 OL AN 2 OL LEI 9 LOVINOD AVIAS TENE OL L AVISER INI ELVIS OL AVISE NIYA D DINDO 050 y DE om 707 159V 28 OL OL ag ONISIA ZNI INO DNISIA SETIQUINOD OL NI 98110120400 OL ENGINE WIRING DIAGRAM TROUBLESHOOTING GENERATOR Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of breakdown use Table 17 shown below for diagnosis of the Generator the problem cannot be remedied consult our company s business office or service plant Table 19 Generator Troubleshooting Symptom Possible Problem Check wiring and repair No Vottage Output Low Voltage rcv DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 45 EXPLANATION OF CODE IN REMARKS COLUMN
39. There are two 120 240V 50 amp auxiliary twist lock CS 6369 receptacles Figure 8 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 CS 6369 TWIST LOCK RECEPTACLES Po ES 09 109 SINGLE PHASE 120 240 VAC 50 AMP OUTPUT Figure 8 120 240 Twist Lock Auxiliary Receptacles DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 21 OUTPUT TERMINAL PANEL FAMILIARIZATION Over Current Relay 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 If the circuit breaker can not be reset the reset button on the over current relay must be pressed The over current relay is located in the control box Figure 12 Over Current Relay Connecting Loads 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 2 load to the generator To protect the output terminals from overload 2 3 pole 60 amp main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine 5 6369 TWIST LOCK RECEPTACLES HARD WIRE _ HOOKUP PANEL LOAD RECEPTACLE LOAD GROUND
40. W SELF LOCKING NUT MACHINE SCREW SELF LOCKING NUT HEX HEAD BOLT SWITCH COVER SEAL RUBBER HEX HEAD BOLT SWITCH COVER SEAL RUBBER HEX HEAD BOLT HEX HEAD BOLT TOOTHED WASHER PART NO M1213001002 M1213001012 0601808820 0601807520 0601827411 0021005080 0601842384 0027104010 0601823240 0027104030 0601815759 0027104020 0601823863 0027104016 0601820602 0027105016 0601801122 0027106020 0601820847 0601820848 0027104016 0207004000 8973259120 0016906016 5825500290 8944001061 0027105016 M1213500403 0016906016 M1270100504 M1550002504 M1550002604 M1213601404 M1213601504 0021104035 0207004000 0027104016 0207004000 0016906016 M1213601704 0317700180 0016906016 M1213601604 0330000070 0016906016 0016906016 0040506000 2 O NN PAGE 52 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 CONTROL BOX ASSY CONTROL BOX ASSY TY REMARKS S N 8103349 AND BELOW enu S N8103350 AND ABOVE nd REPLACES P N 0602100009 S N 8103350 AND ABOVE EE S N 8103350 AND ABOVE S N 8103350 AND ABOVE oss S N 8103349 AND BELOW 1 1 1 1 1 1 1 1 3 3 1 1 1 1 1 1 1 1 1 REPLACES P N 0601810141 1 1 1 1 2 4 2 2 1 6 6 6 1 S N 8103350 AND ABOVE DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 53 PART NAME CONTROL PANE CONTR
41. age to the equipment The definitions below describe some of the major components of a typical trailer that would be used with generator Fuel Cell Provides an adequate amount of fuel for the equipment in use Fuel cells must be empty when transporting equipment Braking System System employed in stopping the trailer Typical braking systems are electric surge hydraulic hydraulic surge and air GVWR Gross Vehicle Weight Rating GVWR is the maximum number of pounds the trailer can carry including the fuel cell empty Frame Length Measurement is from the ball hitch to the rear bumper reflector Frame Width Measurement is from fender to fender Jack Stand Trailer support device with maximum pound requirement from the tongue of the trailer Coupler Type of hitch used on the trailer for towing PAGE 38 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 1 TRAILER MAINTENANCE 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 be periodically checked for cracks kinks or blockage Anchor Post Retractor Hydraulic Wheel Springs Plate Adjuster Spring Adjuster Assembly Figure 56 Hydraulic Brake Components Actuator Hydraulic surge braking requires the installation of an actuator at the tongue of
42. allow it to return to the operation position Figure 39 Figure 40 Pre Heat Lamp 4 Once the engine starts let the engine run for 1 2 minutes Listen for any abnormal noises any abnormalities exist shut down the engine and correct the problem 5 The generator s frequency meter Figure 41 should be displaying the 50 cycle output frequency in HERTZ Figure 41 Frequency Meter BEFORE STARTING The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position Place the main G F C I and aux circuit breakers Figure 36 in the OFF position prior to starting the engine MAIN AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Figure 36 Main Aux and GFCI Circuit Breakers OFF Connect the load to the receptacles or the output terminal lugs as shown in Figure 10 These load connection points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel Tighten terminal nuts securely to prevent load wires from slipping out Close all engine enclosure doors Figure 37 N lt gt a LED 0 IB i J J ES 2 Lo Z NG CORRECT INCORRECT Figure 37 Engine Enclosure Doors PAGE 32 DCA25US12 60 HZ GENERATOR OPERATION AND PART
43. ator VR control knob located on the control panel Voltage Selector Switch The voltage selector switch Figure 13 is located above the output terminal panel s Hard Wire Hook up Panel It has been provided for ease of voltage selection 3 PHASE 240 139 3 PHASE 1 PHASE 480 277 240 120 Figure 13 Voltage Change Over Board Voltage Selector Switch Locking Button To lock the voltage selector switch press and hold the red button located at the bottom of the switch While holding the red button down insert a pad lock into the hole next to the button to retain it in the inward locked position When the lock is removed the red button is spring loaded and will return to its normal outward unlocked position NEVER change the position of the voltage selector switch while the engine is running ALWAYS place circuit breaker in the OFF position before selecting voltage Table 7 Voltages Available Three Phase Switchable 208V 220V 240V sev sov 0 Single Phase Swiehabie O Me 40V 280 EN PAGE 24 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 GENERATOR OUTPUTS GAUGE READING AG Ammeter Gauge Reading Place the Ammeter Change Over Switch Figure 17 in the U position and observe the current reading load drain on the U terminal as indicated on the AC Ammeter Gauge Figure 18 This process can be repeated for terminals V and W OFF Figure 18
44. be the controls and functions of the Engine Operating Panel Figure 5 Panel Light Switch When activated will turn on control panel light Panel Light Normally used in dark areas or at night time When activated panel lights will illuminate When the generator is not in use be sure to turn the panel light switch to the OFF position Oil Pressure Alarm Lamp Indicates that the oil pressure 15 too low or high and will shut down the engine Oil Pressure Alarm Lamp Indicates that the water temperature is outside of normal range and will shut down the engine Fuel Filter Water Lever Alarm Lamp Indicates that water level in the fuel level has risen Drain the water in the fuel filter strainer when this condition occurs Fuel Leak Detected Alarm Lamp This lamp will illuminate when fluids in the containment have reached high levels Preheat Lamp When the ignition key is placed in the preheat position this lamp will illuminate to indicate preheating of the engine glow plugs When the lamp turns off this indicates that the preheat cycle is complete and the engine can be started DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 19 1 2 OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel Figure 6 is provided with the following Three 120 240V output receptacles 50 amp Three Circuit Breakers 50 amps
45. bligation or liability whatever in connection with the sale of its products Apart from such written statement of warranty there are no warranties express implied or statutory which extend beyond the description of the products on the face hereof Effective February 22 2006 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 a Obsolete parts If an item is in the price book and shows as being replaced by another item it is obsolete b Any parts with a limited shelf life such as gaskets seals O rings and other rubber parts that were purchased more than six months prior to the return date Any line item with an extended dealer net price of less than 5 00 d Special order items Electrical components f Paint chemicals and lubricants g Decals and paper products h Items purchased in kits 7 The sender will be notified of any material received that is not acceptable 8 Such material will be held for five working days from notification pending instructions 2 reply is not received within five days the material will be returned to the sender at his expense 9 Credit on returned parts will be issued at dealer net price at time of the original purchase less 15 restocking charge 10 In cases where an item is accepted for which the ori
46. d by a number a blank entry or TBD TBD To Be Determined is generally used to show a part that has not been assigned a formal part number at the time of publication A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip Other entries will be clarified in the Remarks Column PAGE 46 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 SUGGESTED SPARE PARTS DCA25USI2 WHISPERWATT GENERATOR WITH ISUZU BV 4LE2 NYGD02 DIESEL ENGINE DESCRIPTION ELEMENT OIL FILTER ELEMENT FUEL FILTER W O SENSOR REPAIR KIT FUEL PUMP ELEMENT AIR BELT FAN RADIATOR HOSE UPPER RADIATOR HOSE LOWER SENSOR WATER TEMP ENGINE SIDE SWITCH WARNING OVERHEAT ENGINE SIDE SENSOR OIL PRESSURE ENGINE SIDE UNIT WATER TEMP UNIT OIL PRESSURE CIRCUIT BREAKER 1P 20 AMP CIRCUIT BREAKER 2P 50 AMP AUTOMATIC VOLTAGE REGULATOR BULB ALARM LAMP PREHEAT LAMP 1 to 3 units P N QTY NOTICE Part number on this Suggested Spare Parts list may supersede replace the P N shown in the text pages of this bo DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 47 PAGE 48 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 GENERATOR ASSY GENERATOR ASSY QTY REMARKS 1 1 1 1 1 2 1 pt ITEM 1 10 MUST BE ORDERED WHEN REPLACING THE uni BAL
47. e This engine is designed to meet every performance requirement for the generator Reference Table 2 for engine specifications In keeping with MQ Power s policy of constantly improving its products the specifications quoted herein are subject to change without prior notice ELECTRIC GOVERNOR SYSTEM The electric governor system controls the RPMs of the engine When the engine demand increases or decreases the governor system regulates the frequency variation to 4 2596 EXTENSION CABLES When electric power is to be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to a minimum Use the cable selection chart Table 6 as a guide for selecting proper extension cable size GENERATOR 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 ENGINE OPERATING PANEL The Engine Operating Panel is provided with the following E Tachometer m Water Temperature Gauge E Warning Lamp Pre Heat Lamp Oil Pressure Gauge Charging Ammeter Gauge Fuel Level Gauge m Panel Light Panel Light Switch Oil Pressure Alarm Lamp m Water Temperature Alarm Lamp m Fuel Fil
48. e rim Tire Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc Wheel Hub The wheel hub is connected to the trailer s axle Tire Rim Tires mounted on a tire rim The tire rim must match the size of the tire 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 Axle Indicates the maximum weight the axle can support in pounds and the diameter of the axle expressed in inches Please note that some trailers have a double axle This will be shown as 2 6000 Ibs meaning two axles with a total weight capacity of 6000 pounds Suspension Protects the trailer chassis from shocks transmitted through the wheels Types of suspension used are leaf Q flex and air ride Electrical Electrical connectors looms are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle Application Indicates which units can be employed on a particular trailer 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 refer to a wide range of trailers Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and dam
49. e sulfuric acid comes into contact with clothing or skin rinse skin or clothing immediately with plenty of water f the battery liquid dilute sulfuric acid comes into contact with eyes rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention m ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator m ALWAYS keep battery cables in good working condition Repair or replace all worn cables ENVIRONMENTAL SAFETY DECOMMISSIONING NOTICE Decommissioning is 2 controlled process used to safely retire 2 piece of equipment that is no longer serviceable If the equipment poses an unacceptable and unrepairable safety risk due to wear or damage or is no longer cost effective to maintain beyond life cycle reliability and is to be decommissioned demolition and dismantlement be sure to follow rules below DO NOT pour waste or oil directly onto the ground down a drain or into any water source m Contact your country s Department of Public Works or recycling agency in your area and arrange for proper disposal of any electrical components waste or oil associated with this equipment m When the life cycle of this equipment is over remove battery and bring to appropriate facility for lead reclamation Use safety precautions when handling batteries that contain sulfuric acid When the cycle of this equipment is over
50. ed or reused 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 as a general maintenance guideline Engine Side Refer to the Engine Instruction Manual AIR CLEANER Every 250 hours Remove air cleaner element Figure 53 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 Figure 53 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 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 35 MAINTENANCE FUEL TANK INSPECTION In addition to cleaning the fuel tank the following components should be inspected for wear m Rubber Suspension look for signs of wear or deformity due to contact with oil Replace the rubber suspension if necessary Fuel Hoses inspect nylon and rubber hoses for signs of wear deterioration and hardening m Fuel Tank Lining inspect the fuel tank lining for signs of excessive amounts of oil or other foreign matter Replacing Fuel Filter
51. enerator 0 5 24 Generator Outputs Gauge Reading 25 Output Terminal Panel Connections 26 27 6 ua 28 31 Generator Start Up Procedure 32 33 Generator Shut Down Procedures 94 MAME een 35 37 Trailer Maintenance 38 41 Trailer Wiring Diagram 42 Generator Wiring 43 Engine Wiring 44 Troubleshooting Generator 45 Explanation Of Code In Remarks Column 46 Suggested Spare Parts 47 PAGE 4 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options Effective January 15 2006 Order via Internet Dealers Only 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 District Sales Manager for more information li Print Specification Information PETE 1 Goto www multiquip com and click on Use the internet and qualify for a 596 Discou
52. ents that are not recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result ALWAYS know the location of the nearest UN fire extinguisher m ALWAYS know the location of the nearest first aid kit m ALWAYS know the location of the nearest phone or keep a phone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency GENERATOR SAFETY Ay DANGER E NEVER operate the equipment in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death NEVER disconnect any emergency or safety devices These devices are intended for operator safety Disconnection of these devices can cause severe injury bodily harm or even death Disconnection of any of these devices will void all warranties m NEVER lubricate components or attempt service on a running machine NOTICE i ALWAYS ensure generator is on level ground before use m ALWAYS keep the machine in proper running condition E Fix damage to machine and replace any broken parts immediately m 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 GENERAL SAFETY m NEVER operate this equipment without proper protective c
53. erated for extended periods with light or no load applied When a diesel engine operates without sufficient load less than 40 of the rated output it will not operate at its optimum temperature This will allow unburned fuel to accumulate in the exhaust system which can foul the fuel injectors engine valves and exhaust system including turbochargers and reduce the operating performance In order for a diesel engine to operate at peak efficiency it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel Wet stacking does not usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition It can reduce the system performance and increase maintenance Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition This can take several hours to burn off the accumulated unburned fuel 98 State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters must be used on internal combustion engines that use hydrocarbon fuels A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding s
54. ginal purchase document can not be determined the price will be based on the list price that was effective twelve months prior to the RMA date 11 Credit issued will be applied to future purchases only PRICING AND REBATES Prices are subject to change without prior notice Price changes are effective on specific date and all orders received on or after that date will be billed at the revised price Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change PAYMENT TERMS Terms of payment for parts are net 30 days FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice All shipments are point of origin Multiquip s responsibility ceases when signed manifest has been obtained from the carrier and any claim for shortage or damage must be settled between the consignee and the carrier MINIMUM ORDER The minimum charge for orders from Multiquip is 15 00 net Customers will be asked for instructions regarding handling of orders not meeting this requirement RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed subject to the following provisions 1 Returned Material Authorization must be approved by Multiquip prior to shipment 2 To obtain a Return Material Authorization a list must be provided to Multiquip Parts Sales that defines item numbers
55. h only recommended type battery The battery is sufficiently charged if the specific gravity of the battery fluid is 1 28 at 68 If the specific gravity should fall to 1 245 or lower it indicates that the battery is dead and needs to be recharged or replaced Before charging the battery with an external electric source be sure to disconnect the battery cables Battery Cable Installation ALWAYS be sure the battery cables Figure 35 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 ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE EE EEE PO BATTERY Figure 35 Battery Connections DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 31 GENERATOR START UP PROGEDURE STARTING 1 Place the voltage selector switch in the desired voltage position Figure 38 3 PHASE 240 139 3 PHASE 480 277 Figure 38 Voltage Selector Switch 2 Preheatthe engine glow plugs by turning the ignition key Figure 39 to the OPERATION position STOP OPERATION PRE HEAT START Figure 39 ignition Switch 3 When the preheat lamp goes OFF Figure 40 turn the ignition key to the start position Once the engine starts release the ignition key and
56. he knob counter clockwise will decrease the voltage DECREASE INCREASE SG Figure 9 Voltage Regulator Control Knob Removing the Plastic Face Plate Hard Wire Hookup Panel The output terminal lugs are protected by 2 plastic face plate cover Figure 10 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 HARD WIRE HOOKUP PANEL PLASTIC TERMINAL COVER SECURING BOLTS Figure 10 Plastic Face Plate Output Terminal Lugs 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 Pressing the reset button resets the GFCI receptacle after being tripped Pressing the test button See Figure 7 in the center of the receptacle will check the GFCI function Both receptacles should be tested at least once a month 120 VAC RECEPTACLE RESET H BUTTON TEST BUTTON Figure 7 G F C I Receptacle Twist Lock Dual Voltage 120 240 VAC Receptacles
57. ication CC SD API Service Classification CC SE m API Service Classification CC SF Table 11 Recommended Motor Oil PAGE 28 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 INSPECTION SETUP Refueling Procedure 2 Open cabinet doors on the right side of the generator from generator control panel position Remove fuel cap and fill tank Figure 31 Diesel fuel and its vapors are dangerous to your health and the surrounding environment Avoid skin contact and or inhaling fumes 1 LevelTanks Make sure fuel cells are level with the ground Failure to do so will cause fuel to spill from the tank before reaching full capacity Figure 30 ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount Figure 31 Fueling the Generator of fuel that can be pumped into the tank 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 32 DO NOT fill on FUEL GAUGE LOCATED unlevel ground ON CONTROL PANEL 75257 SL Of OL OF Of ZZ ZZ ZZ ff Of OL OF OL 1411 07 NOTICE Figure 32 Full Fuel Tank ONLY use 2 diesel fuel when refueling DO NOT OVERFILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 33 Fuel EXPANDS When Heated Figure 33 Fuel Expansion DCA25USI2 60 HZ GENERATOR OPERATIO
58. in water while AC power from the generator is being transferred to a load NEVER use damaged or worn cables or cords when connecting equipment to generator Inspect for cuts in the insulation m NEVER grab or touch a live power cord or cable with wet hands The al possibility exists of electrical shock SRE electrocution or death Power POWER ON PAGE 10 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 SAFETY INFORMATION EMISSIONS INFORMATION NOTICE The diesel engine used in this equipment has been designed to reduce harmful levels of carbon monoxide CO hydrocarbons and nitrogen oxides NOx contained in diesel exhaust emissions This engine has been certified to meet US EPA Evaporative emissions requirements in the installed configuration Attempting to modify or make adjustments to the engine emission system by unauthorized personnel without proper training could damage the equipment or create an unsafe condition Additionally modifying the fuel system may adversely affect evaporative emissions resulting in fines or other penalties Emission Control Label The emission control label is an integral part of the emission system is strictly controlled by regulations The label must remain with the engine for its entire life If a replacement emission label is needed please contact your authorized engine distributor B the battery liquid dilut
59. ischarged in the direction of nearby homes The installation site must be relatively free from moisture and dust All electrical equipment should be protected from excessive moisture Failure to do will result in deterioration of the insulation and will result in 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 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 must be 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 will cause the engine to heat excessively and possibly burn 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 it is 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 are to resist damage to the bottom of the generator and to maintain alig
60. it is recommended that the trowel frame and all other metal parts be sent to 2 recycling center Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing 2 new product Recyclers and manufacturers alike promote the process of recycling metal Using 2 metal recycling center promotes energy cost savings DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 11 SPECIFICATIONS Table 1 Generator Specifications 0000 DCA25USI2 drip proof single bearing generator Armature Connection Star with Neutral 250 2 Phse _3 Single 14 4 KW Power Factor 0 1 0 240V 120V Table 2 Engine Specifications Starting Elo 202 oem 121 gal 4 6 Ly hr at 3 4 load 0 58 gal 2 2 L hr at 1 4 load PAGE 12 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 DIMENSIONS SIDE VIEW FRONT VIEW EK Figure 1 Dimensions Table 3 Dimensions 7 Reference Letter 2087 630 G 49 64 in 1 260 mm 5 semis DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 13 INSTALLATION GENERATOR GROUND LUG Z GROUND ROD FOR EARTH GROUND BUILDING GROUND GROUND CABLE 8 FT MINIMUM REFERENCE 250 846 Figure 2 Typical Generator Grounding Applicati
61. lothing shatterproof glasses respiratory protection hearing protection steel toed boots and other protective devices required by the job or city and state regulations m NEVER operate this equipment when not feeling well due to fatigue illness or when under medication m NEVER operate this equipment under the influence of drugs or alcohol ALWAYS check the equipment for loosened threads or bolts before starting DO NOT use the equipment for any purpose other than its intended purposes or applications NOTICE This equipment should only be operated by trained and qualified personnel 18 years of age and older Whenever necessary replace nameplate operation and safety decals when they become difficult read Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 7 SAFETY INFORMATION NOTICE NEVER run engine without an air filter or with a dirty air filter Severe engine damage may occur Service air filter frequently to prevent engine malfunction NEVER tamper with the factory settings N of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the AN maximum allowable Wet stacking is a common problem with diesel engines which are op
62. must be closed tightly after filling Handle fuel safety container If the container does not have spout use funnel Wipe up any spilled fuel immediately Figure 29 Internal Fuel Tank System CIRCUIT BREAKERS To protect the generator from an overload 2 3 pole 60 amp main circuit breaker is provided to protect the U V and W Output Terminals from overload In addition two single pole 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload Three 50 amp load 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 LUBRICATION OIL Fill the engine crankcase with lubricating oil through the filler hole but DO NOT overfill Make sure the generator is level and verify that the oil level is maintained between the two notches Figure 28 on the dipstick See Table 11 for proper selection of engine ADD FULL OIL LIMIT Figure 28 Engine Oil Dipstick When checking the engine oil be sure to check if the oil is clean If the oil is not clean drain the oil by removing the oil drain plug and refill with the specified amount of oil as outlined 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 m API Service Classification CC SC API Service Classif
63. n The Control Box is equipped with the following major components Over Current Relay Automatic Voltage Regulator AVR m Starter Relay Current Transformer E Voltage Selector Switch Main Circuit Breaker NOTICE Remember the overcurrent relay monitors the current flowing from the U V and W Output Terminal Lugs to the load In the event of 2 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 The definitions below describe the controls and functions of the Generator Control Panel Figure 4 Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage Main Circuit Breaker This three pole 60A main breaker is provided to protect the the U V W Output Terminal Lugs from overload Ammeter Change Over Switch This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals or to be switched off This switch does not effect the generator output in any fashion it is for current reading only Voltmeter Change Over Switch This switch allows the voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off AG Voltmeter Indicates the output vol
64. nal Output Voltages 1 Place the voltage selector switch in the 3 240 139 position as shown in Figure 19 PHASE 240 139 3 PHASE 1 PHASE 480 277 240 120 PRESS TO LOCK Figure 19 Voltage Selector Switch 3 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 20 BLUE WHITE GREEN GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 20 UVWO Terminal Lugs 3 240 139V Connections PAGE 26 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 OUTPUT TERMINAL PANEL CONNECTIONS 10 240 120 UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 10 240 120 position as shown in Figure 26 3 PHASE 240 139 3 PHASE 480 277 PRESS TO LOCK Figure 26 Voltage Selector Switch 1 240 120V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 27 BLUE GREEN WHITE GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 27 UVWO Terminal Lugs 1 200 100V Connections 3 Turn the voltage regulator knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required NOTICE ALWAYS make sure that the connections to terminals are secure and tight The possibility of arcing exists that could cause a fire 30 480 277 UVWO Terminal Output V
65. ndicate 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 Ammeter No Load The engine oil pressure gauge Figure 45 will indicate the oil pressure of the engine Under normal operating conditions the oil pressure is approximately 42 to 71 psi 290 490 kPa Figure 45 Oil Pressure Gauge DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 GENERATOR SHUT DOWN PROCEDURES EMERGENCY SHUTDOWN PROCEDURE 1 Place the main G F C l and aux circuit breakers Figure 50 in the OFF position 2 Turn the ignition key Figure 52 to the STOP position STOP OPERATION PRE HEAT START Figure 52 Ingition Switch Emergency NEVER stop the engine suddenly except in an emergency NORMAL SHUTDOWN PROCEDURE To shutdown the generator use the following procedure 1 Place both the MAIN GFCI and LOAD circuit breakers as shown in Figure 50 to the OFF position MAIN AUXILIARY GFCI CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Figure 50 Main GFCI and Load Circuit Breakers Off 2 Letthe engine cool by running it at low speed for 3 5 minutes with no load applied 3 Place the ignition switch Figure 51 in the STOP position remove the key and store in a safe place STOP OPERATION PRE HEAT O START Figure 51 Ingition Switch Normal 4 Verify that all status
66. nment DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 15 GENERAL INFORMATION This generator is equipped with the state of the art Open Delta excitation system The open delta system consist of an electrically independent winding wound among stationary windings of the output section There are four connections of the open delta A B C and D During steady state loads the power from the voltage regulator is supplied from the parallel connections of to A to D and 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 2 heavy load such as 2 motor starting or 2 short circuit occurs the automatic voltage regulator AVR switches the configuration of the open delta to the series connection of to 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 2 fixed ceiling and responds according the demands of the required load ENGINE This generator unit incorporates an ISUZU BV 4LE2 diesel engin
67. nt Parts lto log in and save on Standard orders for all orders which include complete part numbers L Order via Fax Dealers Only Fax your order in and qualify for a 296 Discount All customers are welcome to order parts via Fax on Standard orders for all orders which include Domestic US Customers dial complete part numbers 1 800 6 PARTS 7 800 672 7877 L Note Discounts Are Subject To Change Order via Phone Domestic US Dealers Call 1 800 427 1244 LUKO LO PER 7 Se 7 Non Dealer Customers Contact your local Multiquip Dealer for 2 parts or call 800 427 1244 for help in E OC ete locating a dealer near you Parts Ordering information Eae 4 When ordering parts please supply Dealer Account Number CJ Specify Preferred Method of Shipment Dealer Name and Address V UPS Fed Ex DHL Shipping Address if different than billing address B Ala One v Truck Groun etum Fax Number Next Day Applicable Model Number Second Third Day Quantity Part Number and Description of Each Part NOTICE All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST WWW MUl WE ACCEPT ALL MAJOR CREDIT CARDS w 2 DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 5 SAFETY INFORMATION Potential
68. o the polarity of the battery when connecting the battery Inadequate battery connections may cause poor starting of the generator and create other malfunctions ALTERNATOR 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 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 for bad or worn electrical wiring or connections If any wiring or connections are exposed insulation missing replace wiring immediately PIPING AND HOSE CONNECTION Inspect all piping oil hose and fuel hose connections for wear and tightness Tighten all hose clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately BATTERY This unit is of negative ground DO NOT connect in reverse Always maintain battery fluid level between the specified marks Battery life will be shortened if the fluid level are not properly maintained Add only distilled water when replenishment is necessary DO NOT over fill 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 wit
69. o cool before servicing equipment PAGE 8 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 SAFETY INFORMATION Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer 5 vehicle weight rating i ALWAYS inspect the hitch and coupling for wear NEVER tow 2 trailer with defective hitches couplings chains etc 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 m ALWAYS make sure the trailer is equipped with a safety chain m ALWAYS properly attach trailers safety chains to towing vehicle m ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly DOT Requirements include the following e Connect and test electric brake operation e Secure portable power cables in cable tray with tie wraps 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 of terrain Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing Avoid sharp turns to prevent rolling B Trailer should be adjusted to a level position at all times when towing m Raise and lock trailer wheel stand in up po
70. oltages 1 Place the voltage selector switch in the 30 480 277 position as shown in Figure 24 3 PHASE 240 139 1 PHASE 240 120 Figure 24 Voltage Selector Switch 3 480 277V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 25 BLUE GREEN WHITE GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 25 UVWO Terminal Lugs 3 440 254V Connections 3 Turn the voltage regulator knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 27 INSPECTION SETUP FUEL CHECK DANGER Fuel spillage on hot engine can cause a fire or explosion If fuel spillage occurs wipe up the spilled fuel completely to prevent fire hazards NEVER smoke around or near the generator Refilling the Fuel System ONLY properly trained personnel who have read and understand this section should refill the fuel tank system This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank Figure 29 ALWAYS fill the fuel tanks with clean 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
71. on PAGE 14 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 INSTALLATION GENERATOR GROUNDING To guard against electrical shock and possible damage to the equipment it is important to provide good EARTH ground Article 250 Grounding of the National Electrical Code 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 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 8 AWG 5 3 mm2 b Aluminum 6 AWG 8 4 mm2 2 When grounding the generator Figure 2 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 NEC article 250 52 c specifies that the earth ground rod should be buried a minimum of 8 ft into the ground NOTICE When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician OUTDOOR INSTALLATION 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 d
72. on public roads ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition B ALWAYS shutdown engine before transporting DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 9 SAFETY INFORMATION Make sure power cables are securely connected to the generator s output receptacles Incorrect connections may cause electrical shock and damage to the generator NOTICE m ALWAYS make certain that proper power or extension cord has been selected for the job See Cable Selection Chart in this manual Grounding Safety m ALWAYS make sure that electrical circuits are properly grounded to suitable earth ground ground per the National Electrical Code NEC and local codes before operating generator Severe injury or death by electrocution can result from operating an ungrounded generator m NEVER use gas piping as an electrical ground BATTERY SAFETY DANGER 98 DO NOT drop the battery There is 2 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 B ALWAYS wear safety glasses when handling the battery to avoid eye irritation The battery contains acids that can cause injury to
73. park arresters consult the engine distributor or the local Health and Safety Administrator ENGINE SAFETY 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 the air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine B DO NOT place hands or fingers inside engine compartment when engine is running m NEVER operate the engine with heat shields i guards removed Keep fingers hands hair and clothing away from all moving parts to prevent injury m DO NOT remove the radiator cap whilethe engine is hot High pressure boiling water amp i g 4 will gush out of the radiator and severely 0 Wi scald any persons in the general area of WA the generator DO NOT remove the coolant drain plug while the engine is hot Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator DO NOT remove the engine oil drain plug while the engine is hot Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator m NEVER touch the hot exhaust manifold 2 muffler or cylinder Allow these parts t
74. r part of an assembly kit that can be purchased or is not available for sale through Multiquip 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 PART NO PART REMARKS 1 12345 1 INCLUDES ITEMS 6 2 WASHER 1 4 IN NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 3 12348 AR MAKE LOCALLY 4 12349 BEARING 1 S N 2345B AND ABOVE NO Column Unique Symbols All items with same unique symbol 96 Or gt in the number column belong to the same assembly or kit which is indicated by a note in the Remarks column Duplicate Item Numbers Duplicate numbers indicate multiple part numbers which are in effect for the same general item such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order PART NO Column Numbers Used Part numbers can be indicate
75. sition when towing Place chock blocks underneath wheel to prevent rolling while parked Place support blocks underneath the trailers bumper to prevent tipping while parked Use the trailer s swivel jack to adjust the trailer height to a level position while parked FUEL SAFETY 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 m ALWAYS refuel in a well ventilated area away from sparks and open flames m ALWAYS use extreme caution when working with flammable liquids m DO NOT fill the fuel tank while the engine is running or hot m DO NOT overfill tank since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system Store fuel in appropriate containers in well ventilated areas and away from sparks and flames m NEVER use fuel as 2 cleaning agent mDO NOT smoke around or near the equipment Fire or explosion could result from fuel vapors or if fuel is spilled SV hot engine TOWING SAFETY 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 Refer to MQ Power trailer manual for additional safety information order to reduce the possibility of an accident while transporting the generator
76. tage present at the U V and W Output Terminal Lugs Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz PAGE 18 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 ENGINE OPERATING PANEL STOP OPERATION PRE HEAT Figure 5 Engine Operating Panel Ignition Switch Three position switch stop operation and start Insert ignition key to start and stop engine 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 after the engine warms up the oil pressure should return to normal Water Temperature Gauge During normal operation this gauge be should read between 1650 F to 2030 F Charging Ammeter Gauge Indicates the current being supplied by the engine s alternator which provides current for generator s control circuits and battery charging system Fuel Gauge Indicates amount of diesel fuel available 13 TachometerS Indicates engine speed in RPM s for 60 Hz operation This meter should indicate 1800 RPM s when the rated load is applied In addition a built in hour meter will record the number of operational hours that the generator has been in use 8 9 The definitions below descri
77. tch Serious damage to the building s electrical system may occur without this transfer switch PAGE 23 SINGLE 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 Generally the wattage listed on the nameplate of the equipment is its rated output Equipment may require 130 150 more wattage than the rating on the nameplate as the wattage is influenced by the efficiency power factor and starting system of the equipment NOTICE If wattage is not given on the equipment s name plate approximate wattage may be determined by multiplying 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 Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps Fluorescent lamps mercury lamps 0409 4 0 9 Electronic devices communication 10 equipment Common power tools Table 6 Cable Selection 60 Hz Single Phase Operation 25 s om own sew mon ERE SETAE IENE Ls w 900 aen ome 40 Ls mo sm on Lm z ao sa ma son ES CAUTION Equipment damage can result from low voltage
78. ter Water Level Alarm Lamp m Fuel Leak Detected Alarm Lamp GENERATOR CONTROL PANEL The Generator Control Panel is provided with the following Frequency Meter Hz AC Ammeter Amps AC Voltmeter Volts Ammeter Change Over Switch Voltmeter Change Over Switch Voltage Regulator 3 Pole 6 amp Main Circuit Breaker Control located behind the Gen Control Panel Automatic Voltage Regulator e Current Transformer Over Current Relay e Starter Relay e Voltage Selector Switch OUTPUT TERMINAL PANEL The Output Terminal Panel is provided with the following Three 120 240V output receptacles CS 6369 50A B Three auxiliary circuit breakers 50A Two 120V output receptacles GFCI 20 B Two circuit breakers 20 Five output terminal lugs 30 power OPEN DELTA EXCITATION SYSTEM PAGE 16 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 MAJOR COMPONENTS Table 4 Generator Major Components 6 Battery Assembly 8 Generator Control Panel Assembly _ 9 Engine Operating Panel Assembly Figure 3 Major Components DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 17 GENERATOR CONTROL PANEL Figure 4 Generator Control Panel Located behind the generator control panel is the Generator Control Box This box contains some of the necessary electronic components required to make the generator functio
79. the fuel tank completely Using a spray washer Figure 54 wash out any deposits or debris that have accumulated inside the fuel tank Figure 54 Fuel Tank Cleaning PAGE 36 DCA25US12 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 14 14 MAINTENANCE RADIATOR CLEANING The radiator Figure 55 should be sprayed cleaned with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling fins or tube When using a high pressure washer stand at least 5 feet 1 5 meters away from the radiator to prevent damage to the fins and tube Figure 55 Radiator Cleaning GENERATOR STORAGE For long term storage of the generator the following is recommended Drain the fuel tank completely Treat with a fuel stabilizer if necessary Completely drain the oil from the crankcase and refill if necessary with fresh oil Clean the entire generator internal and external Cover the generating set and store a clean dry place Disconnect the battery Make sure engine coolant is at proper level B f generator is mounted on a trailer jack trailer up and place on blocks so tires do not touch the ground or block and completely remove the tires CHECK OIL LEVEL 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
80. two notches on the dipstick as shown in Figure 28 Replacing Oil Filter m Remove the old oil filter m Apply film of oil to the gasket on the new oil filter Install the new oil filter m After the oil cartridge has been replaced the engine oil will drop slightly Run the engine for a while and check for leaks before adding more oil if needed Clean excessive oil from engine FLUSHING OUT RADIATOR AND REPLACING COOLANT Open both cocks located at the crankcase side and at the lower part of the 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 B Tighten both cocks and replace the overflow tank Replace with coolant as recommended by the engine manufacturer Close radiator cap tightly m 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 Allow engine to cool when flushing out M radiator Flushing the radiator while hot could cause serious burns from water or steam DCA25USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 02 04 14 PAGE 37 TRAILER MAINTENANCE 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 tir

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