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Multiquip manual Table of Contents, Component Drawings, DCA25USI 60 Hz Generator, 6-11

Models: DCA25USI

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Table of Contents

Table of Contents

DCA25USI 60 Hz Generator

Proposition 65 Warning	2
Reporting Safety Defects	3
Table Of Contents	4
Parts Ordering Procedures	5
Safety Information	6-11
Specifications	12
Dimensions	13
Installation	14-15
General Information	16
Major Components	17
Generator Control Panel	18
Engine Operating Panel	19
Output Terminal Panel Familiarization	20-22
Load Application	23
Generator Outputs	24
Generator Outputs/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	38-41
Trailer Wiring Diagram	42
Generator Wiring Diagram	43
Engine Wiring Diagram	44-45
Troubleshooting (Generator)	46
Explanation Of Code In Remarks Column	48
Suggested Spare Parts	50

COMPONENT DRAWINGS

Generator Assembly	50-51
Control Box Assembly	52-55
Engine and Radiator Assembly	56-59
Output Terminal Assembly	60-61
Battery Assembly	62-63
Muffler Assembly	64-65
Fuel Tank Assembly	65-67
Enclosure Assembly	68-73
Rubber Seals Assembly	74-75
Nameplate and Decals Assembly	76-77
Terms And Conditions Of Sale — Parts	78

page 4 — DCA25Usi 60 hz Generator • operation and parts manual — rev. #3 (07/19/11)

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Multiquip manual Table of Contents, Component Drawings, DCA25USI 60 Hz Generator, 6-11

Contents

PARTS LIST NO. M1871400104 parts list no. m1871400114c Operation and Parts ManualTHIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES MODEL dca25USIproposition 65 warning Diesel engine exhaust and some ofReporting Safety Defects Table of Contents COMPONENT DRAWINGSDCA25USI 60 Hz Generator 6-11Parts Ordering Procedures Ordering parts has never been easier Choose from three easy optionsWhen ordering parts, please supply Best Deal! Order via Internet Dealers OnlySafety Information saFeTY messagessaFeTY sYmBols Dangergeneral saFeTY generaTor saFeTYSafety Information „ never lubricate components or attempt service on a running machineSafety Information engine saFeTYDanger FUel saFeTY ToWing saFeTYSafety Information DangereleCTriCal saFeTY grounding safetypower Cord/Cable safety deathBaTTerY saFeTY environmenTal saFeTYSafety Information „ Use well-insulated gloves when picking up the batterySpecifications Table 1. Generator SpecificationsModel DCA25USIDimensions Table 3. DimensionsFigure 1. Dimensions TOP VIEWInstallation Figure 2. Typical Generator Grounding ApplicationOutdoor Installation Indoor InstallationMounting Generator GroundingGeneral Information GeneratorEngine Operating Panel Generator Control PanelMajor Components Table 4. Generator Major ComponentsITEM NO Figure 3. Major ComponentsGenerator Control Panel „„Starter Relay „„Current Transformer „„Voltage Selector SwitchThe Control Box is equipped with the following major components „„Over-Current Relay „„Automatic Voltage Regulator AVRENGINE OPERATING PANEL Figure 5. Engine Operating PanelOUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal FamiliarizationOutput Terminal Panel Terminal legs “O” and “Ground” are considered bonded groundsRemoving the Plastic Face Plate Hard Wire Hookup Panel 120 VAC GFCI ReceptaclesOUTPUT TERMINAL PANEL FAMILIARIZATION Figure 7. G.F.C.I. ReceptacleConnecting Loads Over Current RelayFigure 12. Over Current Relay Figure 11. Connecting Loads OUTPUT TERMINAL PANEL FAMILIARIZATIONSingle Phase Load Three Phase LoadTable 5. Power Factor By Load Load ApplicationVoltage Selector Switch Voltage Selector Switch Locking ButtonGENERATOR OUTPUTS Generator Output VoltagesHow to Read the ac ammeter and ac voltage gauges GENERATOR OUTPUTS/gauge readingAC Voltmeter Gauge Reading AC Ammeter Gauge ReadingOUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages3Ø-240/139 UVWO Terminal Output Voltages 3Ø-208V/1Ø-120V UVWO Terminal Output Voltages3Ø-480/277V UVWO Terminal Output Voltages 1Ø-240/120V UVWO Terminal Output VoltagesFigure 24. Voltage Selector Switch 3Ø-480/277V Position Figure 26. Voltage Selector Switch 1Ø-240/120V Positioninspection/SETUP Circuit BreakersLubrication Oil Fuel CheckRefueling Procedure ONLY use #2 diesel fuel when refuelinginspection/SETUP Figure 30. Only Fill on Level GroundCleaning the Radiator Air CleanerCoolant Antifreeze/Summer Coolant/ Water Operation in Freezing WeatherBattery Battery Cable InstallationWiring AlternatorGENERATOR START-UP PROCEDURE Before StartingStarting Figure 38. Voltage Selector SwitchGENERATOR START-UP PROCEDURE Figure 43. Voltage Adjust Control KnobFigure 42. Frequency Meter Figure 46. Coolant Temperature GaugeNormal Shutdown Procedure GENERATOR SHUT-DOWN PROCEDURESEmergency Shutdown Procedure Maintenance Air Cleaner with Dust IndicatorGeneral Inspection Air CleanerCleaning Inside the Fuel Tank Fuel AdditionRemoving Water from the Fuel Tank Fuel Tank InspectionRadiator Cleaning Check Oil LevelReplacing Oil Filter Flushing Out Radiator and Replacing CoolantTrailer Maintenance Trailer MaintenanceBrake Adjustment BrakesHydraulic Surge Brakes ActuatorTires/Wheels/Lug Nuts Tire Wear/InflationSuspension Trailer MaintenanceLug Nut Torque Requirements Trailer MaintenanceFigure 58. Wheel Lug Nuts Tightening Sequence Table 18. Tire Torque RequirementsTrailer Wiring Diagram Figure 59. Trailer/Towing Vehicle Wiring DiagramGenerator Wiring Diagram Figure 60. Generator Wiring DiagramEngine Wiring Diagram Figure 61. Engine Wiring DiagramEngine Wiring Diagram Troubleshooting Generator Table 19. Generator TroubleshootingSymptom Possible ProblemPage Sample partS liSt Explanation of Code in Remarks ColumnNO. Column part NO. ColumnSuggested Spare Parts dcA25usi WHISPERWATT GENERATOR with ISUZU AA-4LE2 DIESEL engine1 to 3 units DescriptionGENERATOR ASSY PART NAME QTY. REMARKSGENERATOR ASSY HEX SOCKET HD CAP SCREWcontrol box ASSY REMARKS control box ASSYPART NAME AUTOMATIC VOLTAGE REGULATORcontrol box ASSY PART NAME control box ASSYREMARKS ENGINE AND RADIATOR ASSY PART NAME ENGINE AND RADIATOR ASSYREMARKS ENGINE AND RADIATOR ASSY. continued SENDER, OIL PRESSURE SWITCH ENGINE AND RADIATOR ASSY. continuedPART NAME REMARKSOUTPUT TERMINAL ASSY OUTPUT TERMINAL ASSY PART NAMERECEPTACLE,CS6369 250V 50A REMARKSBATTERY ASSY PART NAME BATTERY ASSYREMARKS Muffler Assy PART NAME Muffler AssyREMARKS FUEL TANK ASSY PART NAME FUEL TANK ASSYREMARKS ENCLOSURE ASSY PART NAME ENCLOSURE ASSYREMARKS ENCLOSURE ASSY. continued PART NAME ENCLOSURE ASSY. continuedREMARKS ENCLOSURE ASSY. continued PART NAME ENCLOSURE ASSY. continuedREMARKS RUBBER SEALS ASSY RUBBER SEALS ASSY REMArksPART NAME NAMEPLATE AND DECALS ASSY PART NAME NAMEPLATE AND DECALS ASSYREMARKS Terms and Conditions of Sale - Parts SPECIAL EXPEDITING SERVICEPAYMENT TERMS FREIGHT POLICYPage HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLINGService Department Warranty Department