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DCA25SSIU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/20/10) — PAGE 29

INSPECTION/SETUP

Refueling Procedure:

1. 

Level Tanks

 — 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).

Figure 30.  Only Fill on Level Ground 

  WARNING

Diesel fuel

 and its vapors are dangerous 

to your health and the surrounding 
environment. Avoid skin contact and/or 
inhaling fumes.

  CAUTION

ALWAYS

 place trailer on fi rm level ground before 

refueling to prevent spilling and maximize the amount 
of fuel that can be pumped into the tank.

NOTICE

ONLY

 use

 #2 diesel fuel

 when refueling.

2.  Open cabinet doors on the “right side” of the generator 

(from generator control panel position). Remove fuel 
cap and fi ll tank (Figure 31).

Figure 31.  Fueling the Generator

3. 

NEVER overfi ll fuel tank

 — It is important to read the 

fuel gauge when fi lling trailer fuel tank. 

DO NOT

 wait 

for fuel to rise in fi ller neck (Figure 32). 

Figure 32.  Full Fuel Tank

Figure 33.  Fuel Expansion

  CAUTION

DO NOT OVERFILL

 fuel system. Leave room for fuel 

expansion. Fuel expands when heated (Figure 33).

Summary of Contents for Whisperwatt DCA25SSIU3

Page 1: ...LL TIMES To find the latest revision of this publication visit our website at www mqpower com Revision 0 12 20 10 OPERATION AND PARTS MANUAL WHISPERWATT SERIES MODEL DCA25SSIU3 60HZ GENERATOR ISUZU BV...

Page 2: ...PAGE 2 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 PROPOSITION 65 WARNING Diesel engine exhaust and some of...

Page 3: ...ay 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 betwee...

Page 4: ...utputs Gauge Reading 25 Output Terminal Panel Connections 26 27 Inspection Setup 28 31 Generator Start Up Procedure 32 33 Generator Shut Down Procedures 34 Maintenance 35 37 Trailer Maintenance 38 42...

Page 5: ...site View Parts Diagrams Order Parts Print Speci cation Information Note Discounts Are Subject To Change Goto www multiquip com and click on Order Parts to log in and save Use the internet and qualify...

Page 6: ...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 DANGER Indicates a hazardous situation...

Page 7: ...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 fire extinguisher ALWAYS know the location of the neares...

Page 8: ...ion NEVER tamper with the factory settings of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable Wet stacking is a comm...

Page 9: ...perating condition ALWAYS shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS i...

Page 10: ...plicable 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 DANGER NEVER let power cords or cables lay in...

Page 11: ...ery in a well ventilated environmenttoavoidtheriskofadangerousconcentration of combustible gasses If the battery liquid dilute sulfuric acid comes into contact with clothing or skin rinse skin or clot...

Page 12: ...tput 4 8 Kw 2 4 kW x 2 Weight No Fuel 1 411 lbs 640 kg Maximum Lifting Capacity 3 240 lbs 1 470 kg Table 2 Engine Specifications Model ISUZU BV 4LE2 Tier 4 Type 4 cycle water cooled direct injection t...

Page 13: ...AGE 13 DIMENSIONS Figure 1 Dimensions Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 21 06 in 535 mm F 94 49 in 1 850 mm B 21 06 in 535 mm G 39 37 in 1 000 mm C...

Page 14: ...PAGE 14 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 INSTALLATION Figure 2 Typical Generator Grounding Application...

Page 15: ...solate 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 th...

Page 16: ...regulator is supplied from the parallel connections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for t...

Page 17: ...Components Table 4 Generator Major Components ITEM NO DESCRIPTION 1 Terminal Panel Assembly 2 Output Terminal Assembly 3 Air Cleaner Assembly 4 Muffler Assembly 5 Fuel Tank Assembly 6 Engine Assembly...

Page 18: ...current reading only 6 Voltmeter Change Over Switch This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off 7 Main...

Page 19: ...er strainer when this condition occurs 6 Pre heat Lamp Indicates ON when the engine is ready for starting during cold weather operating conditiions 7 Ignition Switch Three position switch stop run and...

Page 20: ...generator Lift up on the cover to gain access to receptacles and terminal lugs NOTICE Terminal legs O and Ground are considered bonded grounds OUTPUTTERMINAL FAMILIARIZATION The Output Terminal Panel...

Page 21: ...e 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 Figure 8 120 240V Twist Lock Auxiliary...

Page 22: ...utput terminals from overload a 3 pole 60A main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine Figure 11 Connecting Loads Over Cu...

Page 23: ...r Factor By Load Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equip...

Page 24: ...e 240 139V Position Voltage Selector Switch 3 Phase 480 270V Position 3 Line Line 208V 220V 240V 416V 440V 480V 1 Line Neutral 120V 127V 139V 240V 254V 277V Voltage Selector Switch Single Phase 240 12...

Page 25: ...tch Figure 14 Voltage Selector Switch 240 139V 3 Position AC Voltmeter Gauge Reading Place the ACVoltmeter Change Over Switch Figure 15 in theW U position and observe the phase to phase voltage readin...

Page 26: ...lector Switch 3 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 20 Figure 20 UVWO Terminal Lugs 3 240 139V Connections 3 Turn the voltage regulator knob Figure 21 c...

Page 27: ...e regulator adjustment knob whenever fine tuning of the output voltage is required 1 240 120V UVWOTerminal Output Voltages 1 Place the voltage selector switch in the 1 240 120 position as shown in Fig...

Page 28: ...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 API S...

Page 29: ...AYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank NOTICE ONLY use 2 diesel fuel when refueling 2 Open cabinet...

Page 30: ...burns Table 12 Coolant Capacity Engine and Radiator 1 74 gal 6 6 liters Reserve Tank 1 quart 0 9 liters Table 13 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point Boiling Point C F C F...

Page 31: ...T and reconnect negative terminal LAST When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL positio...

Page 32: ...e Doors CAUTION The engine s exhaust contains harmful emissions ALWAYS have adequate ventilationwhen operating Direct exhaust away from nearby personnel WARNING NEVER manually start the engine with th...

Page 33: ...he specified tolerance use the voltage adjustment control knob Figure 44 to increase or decrease the desired voltage Figure 44 Voltage Adjust Control Knob 8 The ammeter Figure 45 will indicate zero am...

Page 34: ...230 F 110 C The alarm lamps on the Engine Control Panel illuminate to signify the reason for the shutdown NOTICE Before inspecting turn the ignition switch to the STOP position place all circuit brea...

Page 35: ...Check all Hoses and Clamps 4 X Clean Inside of Fuel Tank X Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X MAINTENANCE GENERAL INSPECTION Prior to each use th...

Page 36: ...osits or debris that have accumulated inside the fuel tank Figure 54 Fuel Tank Cleaning FUELTANK INSPECTION In addition to cleaning the fuel tank the following components should be inspected for wear...

Page 37: ...ufacturer Close radiator cap tightly 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 screw...

Page 38: ...rt device with maximum pound requirement from the tongue of the trailer 7 Coupler Type of hitch used on the trailer for towing 8 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and...

Page 39: ...akes 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 blo...

Page 40: ...th great force and cause serious eye or bodily injury Table 16 Tire WearTroubleshooting Wear Pattern Cause Solution Center Wear Over inflation Adjust pressure to particular load per tire manufacturer...

Page 41: ...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...

Page 42: ...PAGE 42 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 TRAILER WIRING DIAGRAM Figure 59 Trailer Towing Vehicle Wiring Diagram...

Page 43: ...DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 PAGE 43 GENERATOR WIRING DIAGRAM Figure 60 Generator Wiring Diagram...

Page 44: ...PAGE 44 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 ENGINE WIRING DIAGRAM Figure 61 Engine Wiring Diagram...

Page 45: ...ter Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Defective Exciter Field Check for approximately 17 3 ohms ac...

Page 46: ...es not guarantee the availability of the parts listed 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 QT...

Page 47: ...EMENT 5 8944370220 FILTER FUEL FEED PUMP 3 0602046611 ELEMENT AIR 1 8972606490 BELT FAN 1 B1312500403 RADIATOR HOSE UPPER 1 B1312500530 RADIATOR HOSE LOWER 1 0601820602 AUTOMATIC VOLTAGE REGULATOR 1 0...

Page 48: ...PAGE 48 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 GENERATOR ASSY...

Page 49: ...308 BEARING 6308DDU 1 2 0010308035 HEX HEAD BOLT 6 2A 0040008000 WASHER LOCK 6 2B 0041208000 WASHER FLAT 6 3 0070506803 BEARING 6803ZZ 1 4 B1130201103 STATOR ASSY 1 4 1 0845041904 GROMMET 1 5 B1138000...

Page 50: ...PAGE 50 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 CONTROL BOX ASSY...

Page 51: ...LOCKING NUT 2 19 8973259120 ENGINE CONTROLLER 1 REPLACES P N 0602202523 20 0016906016 HEX HEAD BOLT 2 21 5825500290 RELAY 2 REPLACES P N 0602201400 22 I8942481610 GLOW RELAY 1 REPLACES P N 0602202502...

Page 52: ...PAGE 52 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 CONTROL BOX ASSY...

Page 53: ...1 45 0602103092 ALARM LAMP 3 45A 0601810245 BULB DC18V 3 46 8970444180 STARTER SWITCH 1 REPLACES P N 0602100009 47 0602103092 PREHEAT LAMP 1 47A 0601810245 BULB DC18V 1 48 0602120095 TACHOMETER 1 49 0...

Page 54: ...PAGE 54 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 ENGINE AND RADIATOR ASSY...

Page 55: ...00403 RADIATOR HOSE UPPER 1 REPLACES P N M1310500803 14 B1312500503 RADIATOR HOSE LOWER 1 REPLACES P N M1310500903 15 0605515149 HOSE BAND 4 16 M1310200003 FAN SHROUD 1 17 M1310200103 FAN SHROUD 1 17A...

Page 56: ...PAGE 56 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 ENGINE AND RADIATOR ASSY CONTINUED...

Page 57: ...3 RESERVE TANK 1 46 M9300100003 CAP RESERVE TANK 1 47 0199100215 HOSE 1 48 M1317100004 BRACKET RESERVE TANK 1 49 0199100350 HOSE 1 50 0193600850 HOSE 1 51 0605515106 HOSE BAND 2 52 0602120481 PICK UP...

Page 58: ...0 12 20 10 OUTPUT TERMINAL ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7...

Page 59: ...4 12A 0030003000 HEX HEAD NUT 4 13 0016906020 HEX HEAD BOLT 2 14 0016906016 HEX HEAD BOLT 4 15 M1236400004 CABLE OUTLET COVER 1 16 M1236300004 SUPPORTER CABLE OUTLET COVER 1 17 0016906020 HEX HEAD BOL...

Page 60: ...PAGE 60 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 BATTERY ASSY...

Page 61: ...PART NO PART NAME QTY REMARKS 1 0602220185 BATTERY 1 2 B9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 WASHER LOCK 2 6 M1348400204 BATTERY CABLE...

Page 62: ...PAGE 62 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 MUFFLER ASSY...

Page 63: ...PART NO PART NAME QTY REMARKS 1 M1330100803 MUFFLER 1 2 0016908020 HEX HEAD BOLT 4 3 M1333002803 EXHAUST PIPE 1 4 8970420280 GASKET 1 REPLACES P N 0602320100 5 M1333200014 GASKET 1 6 0207004000 SELF L...

Page 64: ...PAGE 64 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 FUEL TANK ASSY...

Page 65: ...150000018 O RING 1 11 0016906020 HEX HEAD BOLT 2 12 M1363400104 DRAIN HOSE 1 13 0605515198 HOSE BAND 2 14 8943672922 FUEL FILTER 1 REPLACES P N 0602042202 14A 8943692993 CARTRIDGE FUEL FILTER 1 REPLAC...

Page 66: ...PAGE 66 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 ENCLOSURE ASSY...

Page 67: ...COVER 1 14A M1493303604 ACOUSTIC SHEET 1 15 0207006000 SELF LOCKING NUT 7 16 0019208020 HEX HEAD BOLT 7 17 M1443201103 REAR DOOR 1 18 M1443600114 WINDOW PLATE 1 19 0037906000 SELF LOCKING U NUT 8 19A...

Page 68: ...PAGE 68 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 ENCLOSURE ASSY CONTINUED...

Page 69: ...ACHINE SCREW 12 40A 0030006000 HEX HEAD NUT 12 41 M9110100204 HINGE 4 42 M9110100304 HINGE 4 43 M9116100004 WASHER 8 44 0019208020 HEX HEAD BOLT 9 45 0601850097 DOOR STOPPER 8 46 0027208025 MACHINE SC...

Page 70: ...PAGE 70 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 RUBBER SEALS ASSY...

Page 71: ...RUBBER 1 6 0229400430 SEAL RUBBER 1 7 0228900540 SEAL RUBBER 1 8 0228900550 SEAL RUBBER 1 9 0229200595 SEAL RUBBER 1 10 0228900610 SEAL RUBBER 1 11 0229200750 SEAL RUBBER 2 12 0229200740 SEAL RUBBER...

Page 72: ...PAGE 72 DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 NAMEPLATE AND DECALS ASSY...

Page 73: ...300010 15 M9503100004 DECAL WARNING 1 M90310000 16 M9503200004 DECAL WARNING 1 M90320000 17 M9510100004 DECAL CAUTION 2 M91010000 18 M9510200002 DECAL MQ 1 M91020000 19 M9520000004 DECAL GROUND 1 M920...

Page 74: ...r products g Items purchased in kits h The sender will be noti ed of any material 7 received that is not acceptable Such material will be held for five 8 working days from noti cation pending instruct...

Page 75: ...DCA25SSIU3 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 20 10 PAGE 75 NOTES...

Page 76: ...right to discontinue or change speci cations design or the information published in this publication at any time without notice and without incurring any obligations UNITED STATES Multiquip Corporate...

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