Page 2 - PROPOSITION 65 WARNING; Diesel engine exhaust and some of
PAGE 2 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) PROPOSITION 65 WARNING Diesel engine exhaust and some of
Page 3 - REPORTING SAFETY DEFECTS
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 3 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 Traffi c Safety Administration (NHTSA) in addition to no...
Page 4 - TABLE OF CONTENTS; Component Drawings; NOTICE
PAGE 4 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) TABLE OF CONTENTS DCA250SSI/DCA250SSIU 60HZ GENERATORS Proposition 65 Warning ........................................... 2Reporting Safety Defects ......................................... 3Table Of Contents ....
Page 5 - PARTS ORDERING PROCEDURES; Ordering parts has never been easier!; Choose from three easy options:; Order via Internet; Order; Order via Fax
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 5 PARTS ORDERING PROCEDURES www .multiquip .com Ordering parts has never been easier! Choose from three easy options: WE ACCEPT ALL MAJOR CREDIT CARDS! When ordering parts, please supply: ❒ Dealer Account Number ...
Page 6 - SAFETY INFORMATION; SAFETY MESSAGES; DANGER
PAGE 6 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) SAFETY INFORMATION 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 ...
Page 7 - GENERAL SAFETY; GENERATOR SAFETY
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 7 SAFETY INFORMATION GENERAL SAFETY CAUTION NEVER operate this equipment without proper protective clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protecti...
Page 8 - ENGINE SAFETY
PAGE 8 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) SAFETY INFORMATION ENGINE SAFETY DANGER 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 requ...
Page 9 - FUEL SAFETY; TOWING SAFETY; Trailer tires should be infl ated to 50 psi cold
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 9 SAFETY INFORMATION FUEL SAFETY DANGER DO NOT start the engine near spilled fuel or combustible fl uids. Diesel fuel is extremely fl ammable and its vapors can cause an explosion if ignited. ALWAYS refuel in...
Page 10 - ELECTRICAL SAFETY; Power Cord/Cable Safety; Grounding Safety
PAGE 10 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) SAFETY INFORMATION ELECTRICAL SAFETY DANGER DO NOT touch output terminals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or burn. T h e e l e c t...
Page 11 - BATTERY SAFETY; ENVIRONMENTAL SAFETY
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 11 SAFETY INFORMATION BATTERY SAFETY DANGER DO NOT drop the battery. There is a possibility that the battery will explode. DO NOT expose the battery to open fl ames, sparks, cigarettes, etc. The battery conta...
Page 12 - Table 1. Generator Specifi cations; open protected type synchronous generator; Table 2. Engine Specifi cations; ISUZU BH6UZ1X EPA Tier 3 Certifi ed; SPECIFICATIONS
PAGE 12 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) Table 1. Generator Specifi cations Model DCA250SSI/DCA250SSIU Type Revolving fi eld, self ventilated, open protected type synchronous generator Armature Connection Star with Neutral Phase 3 Standby Output 220 ...
Page 13 - DIMENSIONS
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 13 DIMENSIONS Figure 1. Dimensions Table 3. Dimensions Reference Letter Dimension in. (mm.) Reference Letter Dimension in. (mm) A 39.40 in. (1,010 mm.) F 44.07 in. (1,130 mm.) B 39.40 in. (1,010 mm.) G 147.6 in. ...
Page 14 - INSTALLATION; Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) INSTALLATION Figure 2. Typical Generator Grounding Application
Page 15 - OUTDOOR INSTALLATION; DO NOT; remove; CAUTION; GENERATOR GROUNDING; EARTH; Use one of the following wire types to connect the; ALWAYS; consult with a licensed
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 15 INSTALLATION 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 shi...
Page 16 - “fi xed ceiling”; GENERAL INFORMATION
PAGE 16 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) GENERATOR The MQ Power Model DCA250SSI/DCA250SSIU are 220 kW generators (Figure 3) that are designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facil...
Page 17 - MAJOR COMPONENTS; Table 4. Generator Major Components; Figure 3. Major Components
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 17 MAJOR COMPONENTS Table 4. Generator Major Components ITEM NO. DESCRIPTION 1 Air Filter Assembly 2 Muffl er Assembly 3 Fuel Tank Assembly 4 Engine and Radiator Assembly 5 Generator Assembly 6 Output Receptacles...
Page 18 - GENERATOR CONTROL PANEL; Figure 4. Generator Control Panel
PAGE 18 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) GENERATOR CONTROL PANEL Figure 4. Generator Control Panel The defi nitions below describe the controls and functions of the Generator Control Panel (Figure 4). 1. Pilot Lamp — Indicates the system is running. ...
Page 20 - ENGINE OPERATING PANEL; Figure 5. Engine Operating Panel
PAGE 20 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) ENGINE OPERATING PANEL The defi nitions below describe the controls and functions of the Engine Operating Panel (Figure 5). 1. Tachometer — Indicates engine speed in RPM’s for 60 Hz operation. This meter shoul...
Page 21 - NOTES
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 21 NOTES
Page 22 - OUTPUT TERMINAL PANEL FAMILIARIZATION; OUTPUT TERMINAL PANEL; OUTPUT TERMINAL FAMILIARIZATION; Figure 6. Output Terminal Panel
PAGE 22 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) OUTPUT TERMINAL PANEL FAMILIARIZATION 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 t...
Page 23 - 20 VAC GFCI Receptacles; Receptacles
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 23 OUTPUT TERMINAL PANEL FAMILIARIZATION 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...
Page 24 - Connecting Loads; Figure 10. Connecting Loads; Over Current Relay; Figure 11. Over Current Relay
PAGE 24 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Loads can be connected to the generator by the Output BusbarTerminal Lugs or the convenience receptacles (Figure 10). Make sure to read the operation manu...
Page 25 - LOAD APPLICATION; SINGLE PHASE LOAD; Table 5. Power Factor By Load; THREE PHASE LOAD
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 25 LOAD APPLICATION 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 g...
Page 26 - GENERATOR OUTPUTS; GENERATOR OUTPUT VOLTAGES; Generator Amperage; Table 8. Generator Maximum Amps
PAGE 26 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by applying jumpers (6) to the voltage change-over bo...
Page 27 - GENERATOR OUTPUTS/GAUGE READING; AC Voltmeter Gauge Reading; AC Ammeter Change-Over Switch; ammeter
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 27 GENERATOR OUTPUTS/GAUGE READING H OW TO R E A D T H E AC A M M E T E R A N D AC VOLTAGE GAUGES The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches. Bot...
Page 28 - OUTPUT TERMINAL PANEL CONNECTIONS; UVWO TERMINAL OUTPUT VOLTAGES; Voltage Change-Over Board; Ø-240V UVWO Terminal Output Voltages; Connections
PAGE 28 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) OUTPUT TERMINAL PANEL CONNECTIONS 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 placement of the ...
Page 29 - must; Figure 23. Voltage Change-Over Board 480V; Ø-480V UVWO Terminal Output Voltages; Ø-277V UVWO Terminal Output Voltages
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 29 OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480V UVWO Terminal Output Voltages 1. Jumper the voltage change-over board for 480V operation as shown in Figure 23. This confi guration uses 6 jumper plates in 3 different...
Page 30 - Figure 27. Engine Oil Dipstick; Table 9. Recommended Motor Oil; FUEL CHECK; Figure 28. Internal Fuel Tank System
PAGE 30 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) INSPECTION/SETUP CIRCUIT BREAKERS To protect the generator from an overload, a 3-pole, 800 amp, main circuit breaker is provided to protect the U,V, and W Output Terminals from overload. In addition two single...
Page 31 - Figure 29. Only Fill on Level Ground; Figure 30. Fueling the Generator
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 31 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 29). Figure ...
Page 32 - Operation in Freezing Weather; Table 10. Coolant Capacity; Cleaning the Radiator; Figure 33. Fan Belt Tension
PAGE 32 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) 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-dilute...
Page 33 - Figure 34. Battery Connections; ALTERNATOR
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 33 BATTERY This unit is of negative ground DO NOT connect in reverse. Always maintain battery fl uid level between the specifi ed marks. Battery life will be shortened, if the fl uid level are not properly mainta...
Page 34 - BEFORE STARTING; Figure 36. Engine Enclosure Doors
PAGE 34 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) GENERATOR START-UP PROCEDURE (MANUAL) BEFORE STARTING 1. Place the main, G.F.C.I., and aux. circuit breakers (Figure 35) in the OFF position prior to starting the engine. Figure 35. Main, Aux. and GFCI Circuit...
Page 37 - GENERATOR SHUT-DOWN PROCEDURES; NORMAL SHUTDOWN PROCEDURE; Figure 57. Emergency Stop Button
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 37 GENERATOR SHUT-DOWN PROCEDURES 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 35 to the OFF position...
Page 38 - DAILY; MAINTENANCE; GENERAL INSPECTION; Engine Side; (Refer to the Engine; AIR CLEANER; RED; meaning the element needs changing or; “RED”; . Dispose of old air fi lter. It may not be
PAGE 38 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) * 1 Replace engine oil and fi lter at 100 hours, fi rst time only. * 2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant. * 3 Replace primary air fi lter element when restriction indi...
Page 39 - Figure 59. Fuel Tank Cleaning
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 39 MAINTENANCE 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 fu...
Page 40 - DO; RADIATOR CLEANING; Figure 60. Radiator Cleaning; GENERATOR STORAGE
PAGE 40 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) To restart after running out of fuel, turn the switch to the “ON” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system. CHECK OIL LEVEL Check the crankc...
Page 41 - jacket water heater; Figure 61. Battery Charger and Jacket Water
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 41 MAINTENANCE The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal battery charger. These receptacles will ONLY function when commercial power has bee...
Page 42 - TRAILER MAINTENANCE
PAGE 42 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) TRAILER MAINTENANCE 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 ...
Page 43 - BRAKES; Figure 62. Hydraulic Brake Components; Actuator; surge
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 43 TRAILER MAINTENANCE BRAKES Trailer brakes should be inspected the fi rst 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the fi rst 200 mile interval, inspect the brak...
Page 44 - Suspension; Figure 63. Major Suspension Components
PAGE 44 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) TRAILER MAINTENANCE TIRES/WHEELS/LUG NUTS Tires and wheels are a ver y impor tant and cr itical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and...
Page 45 - Lug Nut Torque Requirements; torque the wheel lug nuts all the way down.; Figure 64. Wheel Lug Nuts; NEVER; use an pneumatic air gun to tighten wheel
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 45 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 w...
Page 46 - TRAILER WIRING DIAGRAM; Figure 65. Trailer/Towing Vehicle Wiring Diagram
PAGE 46 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) TRAILER WIRING DIAGRAM Figure 65. Trailer/Towing Vehicle Wiring Diagram
Page 47 - GENERATOR WIRING DIAGRAM; Figure 66. Generator Wiring Diagram
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 47 GENERATOR WIRING DIAGRAM Figure 66. Generator Wiring Diagram
Page 48 - ENGINE WIRING DIAGRAM; Figure 67. Engine Wiring Diagram
PAGE 48 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) ENGINE WIRING DIAGRAM Figure 67. Engine Wiring Diagram
Page 49 - CONTROLLER WIRING DIAGRAM; Figure 68. Controller Wiring Diagram
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 49 CONTROLLER WIRING DIAGRAM Figure 68. Controller Wiring Diagram
Page 52 - Figure 69. Diagnostic Panel; METHOD OF OPERATION; dimly
PAGE 52 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) TROUBLESHOOTING (DIAGNOSTIC LAMP) The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself. Press the diagnostic button (Figure 69) on the diag...
Page 54 - EXPLANATION OF CODE IN REMARKS COLUMN; SAMPLE PARTS LIST; REMARKS Column
PAGE 54 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) EXPLANATION OF CODE IN REMARKS COLUMN 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 the...
Page 55 - SUGGESTED SPARE PARTS; DESCRIPTION
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 55 SUGGESTED SPARE PARTS DCA250SSI/DCA250SSIU WHISPERWATT GENERATORS WITH ISUZU BH6UZ1X DIESEL ENGINE 1 to 3 units QTY. P/N DESCRIPTION 1............M5311500003 ....... HOSE, RADIATOR UPPER1............M531150010...
Page 60 - ENGINE OPERATING PANEL ASSY.
PAGE 60 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) ENGINE OPERATING PANEL ASSY.
Page 68 - ENGINE AND RADIATOR ASSY.
PAGE 68 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) ENGINE AND RADIATOR ASSY.
Page 69 - PART NAME
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 69 ENGINE AND RADIATOR ASSY. NO. PART NO. PART NAME QTY. REMARKS 1 M5924200004 ENGINE, ISUZU BH6UZ1X 1 1A 1136714730 FAN BELT ....................................................1 ................REPLACES P/N 060...
Page 72 - OUTPUT TERMINAL ASSY.
PAGE 72 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) OUTPUT TERMINAL ASSY.
Page 91 - HEX HEAD BOLT
DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 91 NO. PART NO. PART NAME QTY. REMARKS 51 0019108065 HEX HEAD BOLT 6 51A 0042308000 WASHER, LOCK 6 51B 0401450080 WASHER, FLAT ..........................................6 ................REPLACES P/N 031108160 52...
Page 102 - TERMS AND CONDITIONS OF SALE — PARTS
PAGE 102 — DCA250SSI/DCA250SSIU GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) TERMS AND CONDITIONS OF SALE — PARTS 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 shi...
Page 104 - OPERATION AND PARTS MANUAL; Your Local Dealer is:; HERE’S HOW TO GET HELP; PLEASE HAVE THE MODEL AND SERIAL; CANADA
OPERATION AND PARTS MANUAL Your Local Dealer is: HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING UNITED STATES Multiquip Corporate Offi ce MQ Parts Department 18910 Wilmington Ave.Carson, CA 90746 Contact: [email protected] Tel. (800) 421-1244Fax (800) 537-3927 800...