Multiquip DCA-25SSAI User Manual

PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
MQ POWER
DCA-25SSAI
TM
WHISPERWATT
GENERATOR
© COPYRIGHT 2001, MULTIQUIP INC.
PARTS LIST NO. 3336000
Final Copy (06/30/01)
MULTIQUIP INC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046
E-mail:mq@multiquip.com www:multiquip.com
SERVICE DEPARTMENT:
PAGE 2 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
PP
ARAR
TS DEPTS DEP
P
AR
TS DEP
PP
ARAR
TS DEPTS DEP 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284
SERSER
VICE DEPVICE DEP
SER
VICE DEP
SERSER
VICE DEPVICE DEP 800/835-2551 or 310/537-3700 FAX: 310/638-8046
WW
ARRANTY DEPARRANTY DEP
W
ARRANTY DEP
WW
ARRANTY DEPARRANTY DEP 800/835-2551 or 310/537-3700 FAX: 310/638-8046
ARAR
TMENTTMENT
AR
TMENT
ARAR
TMENTTMENT
ARAR
AR
ARAR
TMENTTMENT
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TMENTTMENT
ARAR
TMENTTMENT
AR
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MAINMAIN
MAIN
MAINMAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927
PAGE 3 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
TABLE OF CONTENTS
Here's How To Get Help .................................................. 3
Table Of Contents ........................................................... 4
Parts Ordering Procedures ............................................. 5
Rules for Safe Operation .............................................. 6-9
Towing and Transportation ............................................. 10
Trailer Safety Guidelines ............................................ 11-15
Trailer Wiring Diagram .................................................... 16
Operation Decals ....................................................... 17-18
DCA-25SSAI Specifications .......................................... 19
General Information ....................................................... 20
Major Components ........................................................ 21
Dimensions .................................................................... 22
Control Panel Descriptions ........................................ 24-25
Engine Operating Panel Descriptions ........................ 26-27
Output Terminal Panel Descriptions ........................... 28-29
Output Amerage Setup ..............................................30-31
Output Voltage Setup ................................................. 32-35
Installation .................................................................36-37
Pre Setup .................................................................. 38-41
Load Application ............................................................ 42
Generator Start-up Procedure ................................... 43-45
Generator Shutdown Procedure ..................................... 46
Maintenance ..............................................................47-48
Generator Wiring Diagram .............................................. 50
Engine Wiring Diagram .................................................. 51
Engine Troubleshooting .............................................. 52-53
Generator/Engine Troubleshooting ................................. 54
Explanation of Codes in Remarks Column .................... 56
Suggested Spare Parts ................................................. 57
ISUZU C240 ENGINE
Cylinder Head and Cover Assembly ..........................86-87
Cylinder Block Assembly ..........................................88-89
Timing Gear Assembly ..............................................90-91
Flywheel Housing Assembly .....................................92-93
Oil Pan Assembly ...................................................... 94-95
Oil Pump Assembly .................................................. 96-97
Crankshaft, Bridge and Flywheel Assembly ..............98-99
Oil and Fuel Filter Assembly ................................. 100-101
Oil Pipe Assembly ................................................. 102-103
Water Pump and Fan Assembly ............................ 104-105
Intake and Exhaust Manifold Assembly ................ 106-107
Air Cleaner Assembly ............................................ 108-109
Engine Foot Assembly .......................................... 110-111
Injection Pump Assembly ..................................... 112-113
Electrical Parts Assembly ..................................... 114-115
Accessories .......................................................... 116-117
Injection Pump Comp. Assembly .......................... 118-121
Governor Comp. Assembly.................................... 122-127
Feed Pump Comp. Assembly ................................ 128-129
Auto Timer Assembly ............................................ 130-131
Nozzle Holder Comp. Assembly ............................ 132-133
Starter Comp. Assembly ....................................... 134-135
Alternator Comp. Assembly ................................... 136-139
Terms and Conditions of Sales .................................... 140
MQ POWER DCA-25SSAI AC GENERATOR
Generator Assembly .................................................. 58-59
Control Box Assembly ............................................... 60-61
Engine & Radiator Assembly..................................... 62-67
Engine Operating Panel Assembly ............................68-69
Output Terminal Assembly ......................................... 70-71
Battery Assembly ...................................................... 72-73
Muffler Assembly ......................................................74-75
Fuel Tank Assembly .................................................. 76-77
Enclosure Assembly .................................................78-81
Rubber Seal Assembly ..............................................82-83
Name Plate And Decals ............................................ 84-85
PAGE 4 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
NOTE
Specification and part numberSpecification and part number
Specification and part number
Specification and part numberSpecification and part number are subject to change withoutare subject to change without
are subject to change without
are subject to change withoutare subject to change without noticenotice
..
notice
.
..
noticenotice
PARTS ORDERING PROCEDURES
Dealer account number
Dealer name and address
Shipping address (if different than billing address)
Return fax number
Applicable model number
Quantity, part number and description of each part
Specify preferred method of shipment:
UPS Ground
UPS Second Day or Third Day*
UPS Next Day*
Federal Express Priority One (please provide us with your Federal
Express account number)*
Airborne Express*
Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts:
Number of line items ordered Additional Discount
1-9 items 3%
10+ items** 5%
Get special freight allowances when you order 10 or more line items via FAX!**
UPS Ground Service at no charge for freight
PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price) do not count towards the 10+ line items.
Extra Fax Discount
for Domestic USA
Dealers Only
UPS
Special
For faxed orders only
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
*DISCOUNTS ARE SUBJECT TO CHANGE*
Fax order discount and UPS special programs revised June 1, 1995
PAGE 5 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
800/6-PARTS-7 • 800-672-7877
RULES FOR SAFE OPERATION
CAUTION:
Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained
and qualified personnel only! This equipment is for industrial use only.
The following safety guidelines should always be used when operating the DCA-25SSAI portable generator:
GENERAL SAFETY
DO NOT operate or service this equipment before reading this entire manual.
This equipment should not be operated by persons under 18 years of age.
NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel­toed boots and other protective devices required by the job.
NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.
NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.
High Temperatures Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with burns.
generator engine gives off DEADLY carbon monoxide gas.
hot
components can cause serious
The engine of this generator requires an adequate free flow of cooling air. Never operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The
CAUTION
NEVER operate this equipment under the influence or drugs or alcohol.
NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.
Manufacturer does not assume responsibility for any accident due to equipment modifications.
Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.
Always check the machine for loosened threads or bolts before starting.
:
Always refuel in a well-ventilated area, away from sparks and open flames.
Always use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT smoke around or near
the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.
NEVER operate the generator in an
explosive atmosphere or near combustible materials. An explosion or fire could result
causing severe
death.
Topping-off to filler port is
dangerous, as it tends to spill fuel.
bodily harm or even
PAGE 6 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
RULES FOR SAFE OPERATION
CAUTION
NEVER touch output terminals during operation. This is extremely dangerous. contact with the output terminals is required.
CAUTION
:
Always stop the machine when
:
CAUTION
Radiator
1. Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.
:
DO NOT touch or open any of the below
mentioned components while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance.
Backfeed to a utility system can cause electrocution and/or property damage. Do not connect to any building's electrical system except through an approved device or after building main switch is opened.
CAUTION
Never use damaged or worn cables when connecting power tools or equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator and electrical shock.
:
2. Coolant Drain Plug - Removing the coolant drain plug
3. Engine Oil Drain Plug - Removing the engine oil drain
while the engine is hot will result in hot coolant to gush out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.
plug while the engine is hot will result in hot oil to gush out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.
PAGE 7 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
Battery
CAUTION
The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, always wear safety glasses. Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:
1. DO NOT drop the battery. There is the possibility of risk that the battery may explode.
2. DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.
:
Never over fill the battery with water above the upper limit.
NEVER Run engine without air filter. Severe engine damage may occur.
Always service air cleaner frequently to prevent carburetor malfunction.
Always disconnect the battery before performing service on the generator.
Always be sure the operator is familiar with proper safety precaution s and operations techniques before using generator.
Always store equipment properly when not in use. Equipment should be stored in a clean, dry location out of the reach of children.
DO NOT leave the generator running in the manual mode unattended.
DO NOT allow unauthorized people to operate this equipment.
Always read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.
Refer to the technical questions or information.
Loading and Unloading (Crane)
RULES FOR SAFE OPERATION
Isuzu Engine Owner's Manual Isuzu Engine Owner's Manual
Isuzu Engine Owner's Manual
Isuzu Engine Owner's Manual Isuzu Engine Owner's Manual
for engine
3. Always keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.
4. Always keep battery charging and booster cables in good working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment, to avoid risk of a dangerous concentration of combustible gases.
6. In case the battery liquid (dilute sulfuric acid) comes in contact with immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in contact with your eyes, rinse eyes immediately with plenty of water, then contact the nearest doctor or hospital, and seek medical attention.
clothing or skinclothing or skin
clothing or skin
clothing or skinclothing or skin
, rinse skin or clothing
Before lifting, make sure the generator's lifting hook is secure and that there is no apparent damage to the generator itself (loose screws, nuts and bolts). If any part is loose or damaged, please take corrective action before lifting.
Always drain fuel prior to lifting.
Always make sure crane or lifting device has been properly secured to the hook of guard frame on generator.
NEVER lift the machine while the engine is running.
Use adequate lifting cable (wire or rope) of sufficient strength.
When lifting the generator, always use the balanced center-point suspension hook and lift straight upwards.
NEVER allow any person or animal to stand underneath the machine while lifting.
When loading the generator on a truck, be sure to use the front and back frame bars as a means to secure the generator during transport.
PAGE 8 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
RULES FOR SAFE OPERATION
Transporting
Always shutdown engine before transporting.
Tighten fuel tank cap securely.
Drain fuel when transporting generator over long distances or bad roads.
Always tie-down the generator during transportation by securing the generator.
If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. See page 10 for basic towing procedures.
Emergencies
Always know the location of the nearest
first aid kitfirst aid kit
and
first aid kit
first aid kitfirst aid kit
Also know the phone numbers of the nearest
doctordoctor
doctor
and
doctordoctor
. Know the location of the nearest telephone.
fire departmentfire department
fire department
fire departmentfire department
.
fire extinguisherfire extinguisher
fire extinguisher
fire extinguisherfire extinguisher
ambulanceambulance
ambulance
ambulanceambulance
Maintenance Safety
NEVER lubricate components or attempt service on a running machine.
Always allow the machine a proper amount of time to cool before servicing.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace broken parts.
Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, coolant, fuel, and fuel filters.
DO NOT use plastic containers to dispose of hazardous waste.
,
DO NOT pour waste, oil, coolant or fuel directly onto the ground, down a drain or into any water source.
PAGE 9 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
DCA-25SSAI — TOWING RULES FOR SAFE OPERATION
Towing Safety Precautions
CAUTION :
Check with your county or state safety towing regulations department before towing your generator.
To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer (Figure 1) that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.
The following list of suggestions should be used when towing your generator:
Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating" (GVWR).
ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.
Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.
ALWAYS attach trailer’s safety chain to bumper of towing vehicle.
ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.
The maximum speed for highway towing is 45 MPH unless posted otherwise. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain.
Place rolling, while parked.
Place prevent tipping, while parked.
Use the trailer’s hand winch to adjust the height of the trailer, then insert locking pin to lock wheel stand in place, while parked.
Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve gas milage.
Avoid sharp turns to prevent rolling.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
chocked blocks
support blocks
underneath wheel to prevent
underneath the trailers bumper to
ALWAYS make sure the trailer is equipped with a "Safety Chain".
Figure 1. Generator with Trailer
PAGE 10 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
DCA-25SSAI — TRAILER-SAFETY GUIDELINES
CAUTION:
ALWAYS make sure the trailer is in good operating condition. Check the tires for proper inflation and wear. Also check the wheel lug nuts for proper tightness.
Explanation of Chart:
This section is intended to provide the user with trailer ser­vice and maintenance information. The service and mainte­nance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent dam­age to the equipment and personal injury.
It is the purpose of this section to cover the major mainte­nance components of the trailer. The following trailer com­ponents will be discussed in this section:
Tires
Lug Nut Torquing
Suspension
Electrical
Use the following definitions with reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans­porting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy­draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in­cluding the fuel cell (empty).
4. Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
5. Frame Width - This measurement is from fender to fender.
6. Jack Stand - Trailer support 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 the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 4 and Figure 5 or lug nut tightening and sequence.
13. Axle - Indicates the maximum weight the axle can sup­port in pounds, and the diameter of the axle expressed in inches (see Table 3). Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.
14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.
16. Application - Indicates which units can be employed on a particular trailer.
PAGE 11 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
DCA-25SSAI TRAILER-SPECIFICATIONS
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PAGE 12 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
DCA-25SSAI TRAILER-SPECIFICATIONS
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PAGE 13 DCA-25SSAI PARTS AND OPERATION MANUAL FINAL COPY (06/29/01)
DCA-25SSAI TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a 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.
CAUTION:
DO NOT attempt to repair or modify a 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 2 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.
Suspension
The leaf suspension springs and associated components (Figure 2) 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 3.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing or installing force fitted parts. Failure to comply may result in serious injury.
PAGE 14 DCA-25SSAI PARTS AND OPERATION MANUALFINAL COPY (06/30/01)
Figure 2. Major Suspension Components
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DCA-25SSAI TRAILER SAFETY GUIDELINES
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SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
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LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
-
RETAIN NUT
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.
.
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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 3. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 4.
3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.
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"3152-0204-5356-05
"4152-0206-05021-09
"5152-0206-05021-09
"6152-0206-05021-09
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SBL-TF
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SBL-TF
Figure 3. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
PAGE 15 DCA-25SSAI PARTS AND OPERATION MANUAL FINAL COPY (06/29/01)
DCA-25SSAI TRAILER-WIRING DIAGRAM
NOTE: LIGHTS ARE ORIENTED FROM THE DRIVERS SEAT
PAGE 16 DCA-25SSAI PARTS AND OPERATION MANUALFINAL COPY (06/30/01)
DCA-25SSAI GENERATOR DECALS
The DCA-25SSAI generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
PAGE 17 DCA-25SSAI PARTS AND OPERATION MANUAL FINAL COPY (06/29/01)
DCA-25SSAI GENERATOR DECALS
PAGE 18 DCA-25SSAI PARTS AND OPERATION MANUALFINAL COPY (06/30/01)
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DCA-25SSAI SPECIFICATIONS
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PAGE 19 DCA-25SSAI PARTS AND OPERATION MANUAL FINAL COPY (06/29/01)
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DCA-25SSAI GENERAL INFORMATION
DCA-25SSAI FAMILIARIZATION
Generator
genergener
The MQ Power Model DCA-25SSAI is a 20 kW that is designed as 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:
z
Tachometer
z
Water Temperature Gauge
z
Oil Pressure Gauge
z
Charging Ammeter Gauge
z
Fuel level gauge
z
Engine Throttle Lever
z
Pre-Heat Light
z
Alarm Lights
z
Panel Light
z
Panel Light Switch
z
Starter Switch
gener
genergener
atorator
ator
atorator
Open Delta Excitation System
The DCA-25SSAI generator is equipped with the state of the art " system consist of an electrically independent winding wound among stationary windings of the AC output section.
There are four leads: A, B, C and D. During light loads, the power to the from the leads parallel connections of B&C. When loads increase, the AVR switches and accepts power from leads A&D. The output of leads A&D increase proportionally with load. This of adding the voltages to each phase provides better voltage response during 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 a " according the demands of the required load.
Engine
Open-DeltaOpen-Delta
Open-Delta
Open-DeltaOpen-Delta
AA
utomatic utomatic
A
utomatic
AA
utomatic utomatic
" excitation system. The open delta
VV
oltage Regulator oltage Regulator
V
oltage Regulator
VV
oltage Regulator oltage Regulator
fixed ceilingfixed ceiling
fixed ceiling
fixed ceilingfixed ceiling
(AVR) is supplied
" and responds
Generator Control Panel
The “Generator Control Panel” is provided with the following:
z
Output Voltage Adjustment Knob
z
Frequency Meter (Hz)
z
AC Ammeter (Amps)
z
AC Voltmeter (Volts)
z
Ammeter Change-Over Switch
z
Voltmeter Change-Over Switch
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
z
Three 120/240V output receptacles, 50 amp
z
Two 120V input receptacles, 20 amp
z
3 Load Circuit Breakers 240V @50 amps
z
2 Load GFCI Circuit Breakers 120V@ 20amps
Control Box
The Control Box is provided with the following:
z
Main Circuit Breaker 60 amps
z
Over-Current Relay
The DCA-25SSAI is powered by a 4 cycle, water cooled, turbocharged Isuzu QD60(C640) is designed to meet every performance requirement for the generator. Reference Table 5, page 19 for engine specifications.
In keeping with MQ Powers policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.
The basic controls and indicators for the DCA-25SSAI generator are addressed on the following pages.
Mechanical Governor System
The mechanical governor system control the RPM of the engine. When the engine demands increase or decrease, the mechanical governor system regulates the frequency variation to ±1.5%. The electronic governor option in­creases frequency variation to ±.25%.
diesel diesel
diesel
engine. This engine
diesel diesel
PAGE 20 DCA-25SSAI PARTS AND OPERATION MANUALFINAL COPY (06/30/01)
DCA-25SSAI MAJOR COMPONENTS
Figure 4. Major Components
PAGE 21 DCA-25SSAI PARTS AND OPERATION MANUAL FINAL COPY (06/29/01)
DCA-25SSAI DIMENSIONS (TOP, SIDE AND FRONT)
Figure 5. Dimensions
PAGE 22 DCA-25SSAI PARTS AND OPERATION MANUALFINAL COPY (06/30/01)
NOTE PAGE
PAGE 23 DCA-25SSAI PARTS AND OPERATION MANUAL FINAL COPY (06/29/01)
DCA-25SSAI CONTROL PANEL
Figure 6. Control Panel
PAGE 24 DCA-25SSAI PARTS AND OPERATION MANUALFINAL COPY (06/30/01)
DCA-25SSAI CONTROL PANEL
The definitions below describe the controls and functions of the DCA-25SSAI "
1. Main Circuit Breaker This three-pole, 60 amp main
breaker is provided to protect the UVW voltage output terminals from overload.
2. Frequency Meter Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
3. AC Ammeter Indicates the amount of current the
load is drawing from the generator.
4. AC Voltmeter Indicates the single phase output
voltage present at the UVW terminals.
5. Voltage Regulator Control Allows manual
adjustment of the generator’s output voltage.
6. 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.
Control Panel Control Panel
Control Panel
Control Panel Control Panel
" (Figure 6).
7. 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.
8. Pilot Lamp- This will light if the oil pressure or water
temperature is not within normal limits. If the lamp does not illuminate when the lamp switch is turned on, the bulb should be replaced.
PAGE 25 DCA-25SSAI PARTS AND OPERATION MANUAL FINAL COPY (06/29/01)
DCA-25SSAI — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
PAGE 26 DCA-25SSAI PARTS AND OPERATION MANUALFINAL COPY (06/30/01)
DCA-25SSAI — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of the DCA-25SSAI "
1. Oil Pressure Gauge Normal operation should be about
25 psi. 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.
2. Panel light - Normally used in dark places or at night.
When activated, panel will luminate. When the generator is not in use, turn the panel light switch to the ‘OFF’ position.
Engine Operating Panel Engine Operating Panel
Engine Operating Panel
Engine Operating Panel Engine Operating Panel
" (Figure 7).
3. Water Temperature Gauge – During normal operation
o
this gauge be should read between 165
to 215o.
4. 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.
5. Oil Pressure Indicator - This light will luminate if the
oil pressure exceeds 35 psi and will shut off the engine.
6. Water Temperature Indicator - This light will luminate
if the water temperature exceeds 215
0
and will shut off
the engine.
7. Lamp Check Switch (see Control Panel)- Test switch
for the lamp indicator on the control panel that the oil pressure and water temperature warning system is working properly.
8. Panel light switch- When activated, will turn on control
panel light.
9. Speed Control Handle- To change the speed of the
engine from idle to high, pull and turn the handle.
10. Pre-Heat Indicator - This light will luminate once the
engine is warmed to an operating temperature.
11. Ignition Switch - This switch is used with a key to
start, preheat, and stop the engine..
12. Tachometer 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.
PAGE 27 DCA-25SSAI PARTS AND OPERATION MANUAL FINAL COPY (06/29/01)
DCA-25SSAI — OUTPUT TERMINAL PANEL
Output Terminal Panel
The output control panel is located on the rear (control panel) end of the generator. The UVW lugs are protected by a face plate cover that can be secured in the close position by a pad lock.
120 Volt Receptacle
One GFCI Duplex NEMA 5-20R (120V, 20 Amp) receptacle is located on the output terminal. This receptacle can be used anytime the generator is in operation. The receptacle is controlled by the circuit breaker located on the control panel.
The reset button will reset the receptacle after being tripped. Pressing the "Test Button" (See Figure 8) in the center of this receptacle will check the GFCI function. The receptacle should be tested at least once a month.
Connecting Load
Loads can be connected to the generator by the UVW Lugs or the duplex receptacle. (See Figure 9). Make sure to read the operation manual before attempting to connect a load to the generator.
Circuit Breakers
To protect the generator from an overload, a 3-pole, 60 amp,
main main
main
circuit breaker is provided to protect the UVWO output
main main
terminals from overload. In addition two single-pole, 20 amp
GFCIGFCI
GFCI
circuit breakers are provided to protect the GFCI
GFCIGFCI
receptacles from overload. Three 50 amp breakers have also been provided to protect the load side of the generator from overload. Make sure to switch breakers to the "OFF" position prior to starting the engine.
Figure 9. Connecting Loads
loadload
load
loadload
ALLALL
ALL
ALLALL
circuit
circuit
Figure 8. GFCI Test Button
PAGE 28 DCA-25SSAI PARTS AND OPERATION MANUALFINAL COPY (06/30/01)
Maximum Output
The entire load connected to the UVW l ugs and all four slots in the duplex receptacle must not exceed 22 kW in standby or 20 kW in prime output.
120V Receptacles - These receptacles can be used anytime the generator is in operation. They are controlled by the circuit breakers above them.
Twist Lock Dual Voltage Receptacles - To use these receptacles, place the voltage selector switch in the single phase 240/120 voltage position and adjust the output voltage to 240 volts with the voltage regulator on the control panel (see Figure 6, page 24). Place the voltmeter change-over switch to the U-W position and the ammeter change-over switch to the U or W to read the output.
DCA-25SSAI — OUTPUT TERMINAL PANEL
Figure 10. Output Terminal Description
PAGE 29 DCA-25SSAI PARTS AND OPERATION MANUAL FINAL COPY (06/29/01)
NOTE
Legs “O” and Ground are considered Bonded Grounds.
DCA-25SSAI — OUTPUT AMPERAGE SETUP
Output Terminal Panel Available Voltages
A wide range of voltages are available to supply load to many different applications. Voltages may be selected by using the voltage selector switch and depending how you hookup your hard wire connection to the generator. To obtain voltages listed, fine adjustment with the voltage regulator on the control panel is necessary. See the table
Over Current Relay
An over current relay is connected to the circuit breaker. During an over current situation, 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 inside
the control box. below (Table 6) for a list of available voltages the generator is able to supply.
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TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084
TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772
CAUTION :
Maximum Amps
NEVER switch the voltage selector switch
position while the engine is engaged.
The following table show the maximum amps the entire
generator can provide. Do not exceed the maximum amps
listed. (See Table 7)
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Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect the generator and generator load from being switched while the engine is running. To lock the voltage selector switch, press in the red button located on the lower part of the voltage selector switch, and use a pad lock to hold it into this position.
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PAGE 30 DCA-25SSAI PARTS AND OPERATION MANUALFINAL COPY (06/30/01)
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