Page 2 - prOpOSItIOn 65 WarnIng; Diesel engine exhaust and some of
page 2 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) prOpOSItIOn 65 WarnIng Diesel engine exhaust and some of
Page 3 - rEpOrtIng SafEty DEfEctS; You can also obtain information about motor vehicle safety from
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 3 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 Traffi c Safety Administration (NHTS...
Page 4 - taBLE Of cOntEntS; cOMpOnEnt DraWIngS
page 4 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) taBLE Of cOntEntS Dca25USI2 60 hz generator Proposition 65 Warning ........................................... 2 Reporting Safety Defects ......................................... 3 Table 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
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — 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 ❒ Dea...
Page 6 - SafEty InfOrMatIOn; saFetY messages; saFetY sYmBols
page 6 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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 safet...
Page 7 - general saFetY; CAUTION; GENERATOR SAFETY; DANGER
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — 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 protective de...
Page 8 - ENGINE SAFETY; never
page 8 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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 requires ...
Page 9 - FUel saFetY; TOWING SAFETY; Safety Towing Regulations,
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — 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 a we...
Page 10 - eleCtriCal saFetY; power Cord/Cable safety; Grounding Safety; BatterY saFetY
page 10 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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. The electr ical volt...
Page 11 - clothing or skin; environmental saFetY/DeCommissioning; DO NOT; emissions inFormation; emission Control label
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 11 SafEty InfOrMatIOn If the battery liquid (dilute sulfuric acid) comes into contact with clothing or skin , rinse skin or clothing immediately with plenty of water. If the battery liquid (dilute sulfuric acid) c...
Page 12 - SpEcIfIcatIOnS; Generator Specifications; Single; Engine Specifications; cylinders
page 12 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) SpEcIfIcatIOnS table 1. Generator Specifications model DCA25USI2 Type Revolving field, self ventilated, drip-proof, single-bearing generator Armature Connection Star with Neutral Zigzag Phase 3 Single Standby Outpu...
Page 13 - DIMEnSIOnS; TOP VIEW; Dimensions
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 13 DIMEnSIOnS D B C A E F 25 H G TOP VIEW SIDE VIEW FRONT VIEW Figure 1. Dimensions table 3. Dimensions Reference letter Dimension in. (mm) reference letter Dimension in. (mm) A 22.64 in. (575 mm.) F 70.47 in. (1,790 ...
Page 14 - InStaLLatIOn; Figure 2. Typical Generator Grounding Application
page 14 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) InStaLLatIOn Figure 2. Typical Generator Grounding Application
Page 15 - oUtDoor installation; GENERATOR GROUNDING; EARTH; alWaYs
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — 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 shift ar...
Page 16 - GENERATOR; Delta”; ENGINE; gEnEraL InfOrMatIOn
page 16 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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 an...
Page 17 - MajOr cOMpOnEntS; Figure 3. Major Components; table 4. generator major Components
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 17 MajOr cOMpOnEntS 2 4 3 6 AMP 1000 2000 3000 0 R P M 7 U V W O 1 8 5 Figure 3. Major Components table 4. generator major Components item no. DESCRIPTION 1 Muffler Assembly 2 Engine Assembly 3 Enclosure Assembly 4 Ge...
Page 18 - gEnEratOr cOntrOL panEL; Figure 4. Generator Control Panel; voltage regulator Control
page 18 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) gEnEratOr cOntrOL panEL Figure 4. Generator Control Panel 1000 2000 3000 0 R P M OFF W U V OFF W-U V-W U-V DECREASE INCREASE 1 2 4 3 6 7 5 STOP OPERATION (PRE-HEAT) START The definitions below describe the controls...
Page 19 - EngInE OpEratIng panEL; Figure 5. Engine Operating Panel; The definitions below describe the controls and functions
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 19 EngInE OpEratIng panEL Figure 5. Engine Operating Panel 1000 2000 3000 0 R P M OFF W U V OFF W-U V-W U-V DECREASE INCREASE STOP OPERATION (PRE-HEAT) START 3 1 2 4 5 6 7 8 9 10 11 12 13 The definitions below describ...
Page 20 - OUtpUt tErMInaL panEL faMILIarIzatIOn; oUtpUt terminal panel; oUtpUt terminal Familiarization; Figure 6. Output Terminal Panel
page 20 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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 to gai...
Page 21 - 20 vaC gFCi receptacles; Receptacles; Figure 9. Voltage Regulator Control Knob; removing the plastic Face plate (hard Wire; output terminal lugs; Figure 10. Plastic Face Plate
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 21 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 volt...
Page 22 - Connecting loads; output; main; Figure 11. Connecting Loads; Over Current Relay; over current relay; Figure 12. Over Current Relay
page 22 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) OUtpUt tErMInaL panEL faMILIarIzatIOn 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 a...
Page 23 - LOaD appLIcatIOn; single phase loaD; table 5. power Factor By load; three phase loaD
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 23 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 genera...
Page 24 - gEnEratOr OUtpUtS; generator oUtpUt voltages; press and hold the; table 7. voltages available; Generator Amperage; table 8. generator maximum amps
page 24 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) gEnEratOr OUtpUtS generator oUtpUt voltages A 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 obtai...
Page 25 - gEnEratOr OUtpUtS/gaUgE rEaDIng; hoW to reaD the aC ammeter anD aC; Figure 14. Voltage Selector Switch; aC voltmeter gauge reading; Figure 15. aC voltmeter; AC Ammeter Gauge Reading; AC Ammeter
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 25 gEnEratOr OUtpUtS/gaUgE rEaDIng hoW to reaD the aC 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...
Page 26 - OUtpUt tErMInaL panEL cOnnEctIOnS; UvWo terminal oUtpUt voltages; voltage selector switch; Figure 19. Voltage Selector Switch
page 26 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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 position of the voltag...
Page 27 - Figure 24. Voltage Selector Switch
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 27 OUtpUt tErMInaL panEL cOnnEctIOnS 3Ø-480/277v UvWo terminal output voltages 1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 24. Figure 24. Voltage Selector Switch 3Ø-480/277V Posi...
Page 28 - CirCUit BreaKers; all; lUBriCation oil; Figure 28. Engine Oil Dipstick; isUzU engine owner’s manual; FUel CheCK; Figure 29. Internal Fuel Tank System
page 28 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) InSpEctIOn/SEtUp CirCUit BreaKers To protect the generator from an overload, a 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,...
Page 29 - level tanks; Figure 30. Only Fill on Level Ground; WARNING; onlY; Figure 31. Fueling the Generator; never overfill fuel tank; Figure 32. Full Fuel Tank
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — 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. O...
Page 30 - Operation in Freezing Weather; Coolant Capacity; Cleaning the raDiator; Fan Belt tension; isUzU engine owner’s manual.; Figure 34. Fan Belt Tension
page 30 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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. S...
Page 31 - Figure 35. Battery Connections; alternator
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 31 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. Ad...
Page 32 - gEnEratOr Start-Up prOcEDUrE; BeFore starting; Figure 37. Engine Enclosure Doors; alWaYs have adequate ventilation; INCORRECT; STARTING; Figure 38. Voltage Selector Switch
page 32 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) gEnEratOr Start-Up prOcEDUrE BeFore starting 1. Place the main, g.F.C.i., and aux. circuit breakers ( Figure 36 ) in the OFF position prior to starting the engine. Figure 36. Main, Aux. and GFCI Circuit Breakers (O...
Page 33 - volts; Figure 42. Frequency Meter; zero amps; Figure 45. Oil Pressure Gauge; coolant temperature gauge; Figure 46. Coolant Temperature Gauge; tachometer gauge; Figure 47. Engine Tachometer Gauge; ON
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 33 gEnEratOr Start-Up prOcEDUrE 6. The generator’s AC-voltmeter (Figure 42) will display the generator’s output in volts .. Figure 42. Frequency Meter 7. If the voltage is not within the specified tolerance use the vo...
Page 34 - gEnEratOr ShUt-DOWn prOcEDUrES; emergenCY shUtDoWn proCeDUre; Circuit Breakers Off
page 34 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) gEnEratOr ShUt-DOWn prOcEDUrES emergenCY shUtDoWn proCeDUre 1. Place the main, g.F.C.i., and aux. circuit breakers ( Figure 50 ) in the OFF position. 2. Turn the ignition key (Figure 52) to the STOP position. Figur...
Page 35 - DailY; MaIntEnancE; general inspeCtion; Engine Side; air Cleaner; RED; “RED”
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 35 * 1 Replace engine oil and filter at 100 hours, first time only. * 2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant. * 3 Replace primary air filter element when restriction indicator sh...
Page 36 - FUel aDDition; Figure 54. Fuel Tank Cleaning; FUel tanK inspeCtion; Fuel tank lining; Replacing Fuel Filter; engine manual
page 36 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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 fuel co...
Page 37 - DO; raDiator Cleaning; Figure 55. Radiator Cleaning; GENERATOR STORAGE
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 37 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 betw...
Page 38 - traILEr MaIntEnancE; trailer maintenanCe; Braking system
page 38 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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 refer...
Page 39 - BraKes; Figure 56. Hydraulic Brake Components; Actuator; surge
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 39 traILEr MaIntEnancE 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 ever...
Page 40 - Suspension; Figure 57. Major Suspension Components
page 40 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) traILEr MaIntEnancE tires/Wheels/lUg nUts Tires and wheels are a ver y impor tant and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle ...
Page 41 - lug nut torque requirements; Figure 58. Wheel Lug Nuts
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 41 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....
Page 42 - traILEr WIrIng DIagraM; Figure 59. Trailer/Towing Vehicle Wiring Diagram
page 42 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) traILEr WIrIng DIagraM Figure 59. Trailer/Towing Vehicle Wiring Diagram
Page 43 - gEnEratOr WIrIng DIagraM; Figure 60. Generator Wiring Diagram
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 43 gEnEratOr WIrIng DIagraM Figure 60. Generator Wiring Diagram
Page 44 - EngInE WIrIng DIagraM; Figure 61. Engine Wiring Diagram
page 44 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) EngInE WIrIng DIagraM Figure 61. Engine Wiring Diagram
Page 46 - ExpLanatIOn Of cODE In rEMarkS cOLUMn; Sample partS liSt; remarKS Column
page 46 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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 there ar...
Page 47 - SUggEStED SparE partS; DCA25USI2 WHISPERWATT GENERATOR WITH; DesCription
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 47 SUggEStED SparE partS DCA25USI2 WHISPERWATT GENERATOR WITH isUzU Bv-4le2-nYgD02 Diesel engine 1 to 3 units QtY. p/n DesCription 5............2944566410 .......... ELEMENT, OIL FILTER 5............8980374810 ..........
Page 54 - EngInE anD raDIatOr aSSy.
page 54 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) EngInE anD raDIatOr aSSy. 1A 23A 62 63 64
Page 55 - part name
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 55 EngInE anD raDIatOr aSSy. no. part no. part name QtY. remarKs 1 M1923200124 ENGINE, ISUZU BV4LE2 1 1A 8972309390 FAN BELT ....................................................1 ................REPLACES P/N 060201143...
Page 58 - OUtpUt tErMInaL aSSy.
page 58 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) OUtpUt tErMInaL aSSy. 11 11B 11A 12A 10 12 24A 24 25A 13 13B 13A 13C 24A 24 ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT. 1-ORANGE 2-WHITE 6-CATERPILLAR Y...
Page 63 - HEX HEAD BOLT
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 63 MUffLEr aSSy. no. part no. part name QtY. remarKs 1 M1330000512 MUFFLER 1 2 M1333200304 GASKET 1 3 0016908035 HEX HEAD BOLT 6 4 M1333300204 STAY 1 5 0016908020 HEX. HEAD BOLT 2 6 M1333003013 EXHAUST PIPE 1 6-1 M149...
Page 74 - naMEpLatE anD DEcaLS aSSy.
page 74 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) naMEpLatE anD DEcaLS aSSy. 42
Page 76 - tErMS anD cOnDItIOnS Of SaLE — partS
page 76 — DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/14/14) 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 shipments...
Page 77 - nOtES
DCa25Usi2 60 hz generator • operation anD parts manUal — rev. #0 (02/04/14) — page 77 nOtES
Page 78 - OperatiOn and parts Manual; Your Local Dealer is:; HERE’S HOW TO GET HELP; PLEASE HAVE THE MODEL AND SERIAL; UNITED STATES; CANADA; UNITED KINGDOM
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 © 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 pe...
