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Multiquip DCA25USI2XF User's Manual

1. 74 75 Muffler Assembly DCA 25USI2 76 77 FEE EEE go 78 79 Enclosure Assembly DCA 25USI 80 85 Enclosure Assembly DCA 25USI2 86 91 Rubber Seals Assembly 92 93 Nameplate and Decals 94 95 Terms and Condition of Sale Parts 80 NOTICE Specification and part number are subject to change without notice DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 3 PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options January 1 2006 Order via Internet Dealers Only If you have an MQ Account to obtain a Username Order parts on line using Multiquips SmartEquip website and Password E mail us at parts multiquip View Parts Diagrams com Order Parts To obtain an MQ Account contact your District Sales Manager for more information I Print Specification Information ETT Ge asap Goto www multiquip com and click on Use the internetand qualify for a 5 Discount Parts to log in and save on Standard orders for all orders which include complete part numbers L p com p 4 Order via Fax Dealers Only Fax your order in and qualify for a 2 Discou
2. 22 24 Load Application 25 Gauge Reading Terminal Panel Connections 26 27 Output Terminal Panel Connections 28 29 SEL EEE REE Generator Start up Procedure Generator Shut down Procedure Trailer Maintenance Trailer Wiring Diagram Engine Wiring Diagram Generator Wiring Diagram Engine Troubleshooting Generator Troubleshooting Explanation of Code in Remarks Column 50 Suggested Spare 51 TABLE OF CONTENTS COMPONENT DRAWINGS Generator 52 53 Control Box Assembly DCA 25USI 54 57 Control Box Assembly DCA 25USI 58 61 Engine and Radiator Assembly DCA 25USI 58 61 Engine and Radiator Assembly DCA 25USI2 66 69 Output Terminal Assembly 70 71 Battery 72 73 Muffler Assembly DCA 25USI
3. SINGLE PHASE 120 240 VAC 50 AMP OUTPUT Figure 10 120 240V Twist Lock Auxiliary Receptacles OUTPUT TERMINAL PANEL Each auxilliary receptacle is protected by a 50 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current on all three receptacles is dependent on the load requirements of the Output Terminal Lugs Turn the voltage regulator control knob Figure 11 on the control panel to obtain the desired voltage Turning the knob clockwise will increase the voltage turning the knob counter clockwise will decrease the voltage DECREASE INCREASE Figure 11 Voltage Regulator Control Knob Removing the Plastic Face Plate UVWO Terminals The UVWO terminal lugs are protected by a plastic face plate cover Figure 12 Un lock the locking latch and lift the terminal cover to gain access to the plastic face plate Remove the screws securing the face plate to the terminal enclosure then lift the plastic hinged face plate After the load wires have been securely attached to the UVWO terminals reinstall the plastic face plate Place the terminal cover in the down position and secure the locking latch TERMINAL ENCLOSURE PLASTIC TERMINAL LOCKING LATCH TERMINAL COVER Figure 12 Plastic Face Plate UVWO Terminals PAGE 22 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 Connecting Loads Loads can
4. Incorrect nozzle opening pressure Adjust Injection nozzle stuck or clogged Repair or replace Fuel over flow pipe clogged Clean Governor malfunctioning Repair Either white or blue exhaust gas is observed Excessive engine oil Reduce to the specified level Piston ring and liner worn or stuck Repair or replace Incorrect injection timing Adjust Deficient compression Adjust top clearance Either black or dark gray exhaust gas is observed Overload Lessen the load Low grade fuel used Use the specified fuel Fuel filter clogged Clean or change Air cleaner clogged Deficient nozzle injection Clean or change Repair or replace the nozzle Deficient output Incorrect injection timing Adjust Engine s moving parts seem to be seizing Repair or replace Uneven fuel injection Repair or replace the injection pump Deficient nozzle injection Repair or replace the nozzle Compression leak Replace head gasket tighten cylinder head bolt glow plug and nozzle holder DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 47 TROUBLESHOOTING Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 20 shown below for diagnosis of the Generator If the problem cannot
5. S P 9 PENA soume See instruction e Serious injury or death may result without this e Turn power off before manual for details transfer switch servicing 9520 100503 P N M9520100503 WARNING HOT COOLANT can cause severe burns WARNING ENGINE EXHAUST can cause Do not remove cap if severe injury or death radiator is hot Use only in open well ventilated areas or vent exhaust outside P N M9503100004 190320000 P N M9503200004 CAUTION Stop engine before switching MOVING PARTS can cause severe injury Do not operate with doors open Stop engine before servicing To use 50 receptacles adjust the voltage k 00800 selector switch to the single phase position P N M9503000004 and the main line circuit breaker to the on position P N M1500020 P N M1550000204 CAUTION HOT PARTS can burn skin M90310000 M9520100204 P N M9520100204 WARNING ELECTRIC SHOCK HAZARD e Do not touch output terminals while this machine is operating e Turn power off before servicing Do not touch until the machine has sufficiently cooled 91010000 P N M9510100004 P N M9520100503 _ WARNING N CAUTION ELECTRIC SHOCK HAZARD e Do not touch internal wiring This machine stops and starts Automatically or connections while this and without notice machine is operating e Turn power off before servicing P N B15200010
6. Regularly maintain the unit as specified in the Maintenance section of this manual to prevent damage PAGE 36 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 TABLE 14 INSPECTION MAINTENANCE Check Engine Fluid Levels MAINTENANCE 10 Hrs DAILY 250 Hrs 500 Hrs 1000 Hrs Check Air Cleaner Check Battery Acid Level Check Fan Belt Condition Check for Leaks Check for Loosening of Parts Replace Engine Oil and Filter Drain Bottom of Fuel Tank Check Fuel Filter Water Seperator Bowl Clean Unit Inside and Outside Check Blowby Hose Clean Air Filter Replace Air Filter Element 3 Change Fuel Filter Clean Radiator and Check Coolant Protection Level Check all Hoses and Clamps Clean Inside of Fuel Tank X NEN NEN mer mm Measure Insulation Resistance GENERATOR Check Rotor Rear Support Bearing x 1 Replace engine oil anf filter at 100 hours first time only 2 If blowby hose needs to be replaced ensure that the slope of the blowby hose is at least 1 2 inch per foot with no sags or dips that could collect moisture and or oil 3 Replace primary air filter element when restriction indicator shows vaccumm of 625 mm 25 in H20 General Inspection Prior to each use the generator should be cleaned and inspected for deficiencies Check for loose missing or damaged nuts bolts or other fasteners Also check for fuel oi
7. 1495300604 28 M1445400103 28A M1495300604 29 0207006000 30 0019208020 31 M1445200303 32 M1445600204 33 0207306000 33A 0041206000 34 M9113000002 35 0021806016 35A 0030006000 36 M9112100404 37 M9112100604 38 0016908020 39 M1463001402 39A M1495500213 40 0019208020 41 M1465400104 42 0019208020 43 M1455200702 43A 1495401004 44 0016908020 45 M1455100003 45A M1495400904 46 M1455000903 46A 1495500904 468 1495501004 47 1455000803 47 1495501204 478 1495501304 466 1495401304 48 M1455000703 48A 1495501104 49 M1455300403 49 1495401204 498 1495401304 490 1495401404 50 0207006000 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 83 PART NAME REAR COVER ACOUSTIC SHEET ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT HEX HEAD BOLT REAR DOOR WINDOW PLATE HEX NUT WASHER FLAT DOOR HANDLE ASSY MACHINE SCREW HEX NUT HINGE HINGE HEX HEAD BOLT ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT COVER HEX HEAD BOLT SPLASHER PANEL ACOUSTIC SHEET HEX HEAD BOLT SIDE PANEL ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET ACOUSTIC SHEET ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET DUCT ACOUSTIC SHEET ACOUSTIC SHEET ACOUSTIC SHEET HEX NUT QTY REMARKS Dy eb Ga ee SEN oci SS DCA25USIXF ECLOSURE ASSY ENCLOSURE ASSY DCA25USIXF ONLY ADD THE FOLLOWING DIGITS AF
8. DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 57 DCA25USI2XF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSI2XF ONLY en 2 PAGE 58 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 42 07 26 11 DCA25USI2XF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSIXF ONLY NO PARTNO 1 M1213001002 2 0601808820 3 0021005080 4 0601842384 5 0027104010 6 0601823240 7 0027104030 8 0601815759 9 0027104020 10 0601823863 11 0027104016 12 0601820602 13 0027105016 14 0601801122 15 0027106020 16 0601820847 17 0601820848 18 0027104016 18A 0207004000 19 M1213500203 20 0602202523 21 5825500290 22 8942481610 23 0027105016 24 M1213500403 25 0016906016 26 M1270100504 26A M1550002504 26B M1550002604 27 M1215601204 28 M1215600204 29 0021104035 29 0207004000 30 0027104016 30A 0207004000 31 0016906016 32 M1213601704 321 0317700180 33 0016906016 34 M1213601604 34 1 0330000070 35 0016906016 36 0016906016 36A 0040506000 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 59 PART NAME CONTROL BOX CIRCUIT BREAKER 3P 60A MACHINE SCREW RESISTOR 20W 50 OHM MACHINE SCREW RECTIFIER MACHINE SCREW TERMINAL BOARD MACHINE SCREW RELAY UNIT MACHINE SCREW AUTOMATIC VOLTAGE REGULATOR MACHINE SCREW CURRENT TRANSFORMER 100 5A MACHINE SCREW OVER CURRENT RELAY OVER CURRENT RELAY MACHINE SCREW NUT SELF LOCKING ENGINE C
9. SAFETY DANGER NEVER operate the equipment in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death m NEVER disconnect any emergency or safety devices These devices are intended for operator safety Disconnection of these devices can cause severe injury bodily harm or even death Disconnection of any of these devices will void all warranties m NEVER lubricate components or attempt service on a running machine NOTICE ALWAYS ensure generator is on level ground before use m ALWAYS keep the machine in proper running condition E Fix damage to machine and replace any broken parts immediately m ALWAYS store equipment properly when it is not being used Equipment should be stored in a clean dry location out of the reach of children and unauthorized personnel PAGE 6 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 ENGINE SAFETY E 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 an adequate free flow of cooling air NEVER operate this equipment in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine B DO NOT place hands or finge
10. UVWO Terminal Output Voltages 3 208V 1 120V Output Terminal Lug Voltages Various output voltages can be obtained using the Output 1 Place the voltage selector switch in the 3 240 139 Terminal Lugs The voltages at the terminals are depen position as shown in Figure 24 dent on the position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob pu Use this position for Remember the voltage selector switch determines the range 4 32 240 or 1 120V of the output voltage The voltage regulator VR allows the user to increase or decrease the selected voltage 24 Voltage Selector Switch 240 139V 3 240 139 Output Terminal Lug Voltages Three Phase Position 1 Place the voltage selector switch in the 3 240 139 position as shown in Figure 21 E 2 Connectthe load wiresto the OutputTerminal Lugs as shown in Figure 25 3 PHASE 1 PHASE e BLUE WHITE GREEN PRESS TO LOCK Figure 21 Voltage Selector Switch 240 139V Three Phase Position 2 Connectthe load wiresto the OutputTerminal Lugs as shown in Figure 22 GROUND CONNECTION MUST BE USED AT ALL TIMES b i 9 Figure 25 Output Terminal Lugs 3 208 120V Connections 3 Turn the voltage regulator knob Figure 23 clockwise to le sao increase voltage output turn counterclockwise to n GROUND CONNECTION decrease voltage output TIMES K NOTICE To achie
11. and equipment to insure the wattage amperage frequency and voltage requirements are satisfactorily supplied by the generator for operating the equipment Generally the wattage listed on the nameplate of the equipment is its rated output Equipment may require 130 150 more wattage than the rating on the nameplate as the wattage is influenced by the efficiency power factor and starting system of the equipment NOTICE If wattage is not given on the equipment s name plate approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 5 below when connecting loads Table 5 Power Factor By Load Type Of Load Single phase induction motors Power Factor 0 4 0 75 Electric heaters incandescent lamps Fluorescent lamps mercury lamps Electronic devices communication equipment Common power tools Table 6 Cable Selection 60 Hz Single Phase Operation Load In Watts At 120 At 240 Volts Volts 300 600 Maximum Allowable Cable Length 1000 600 ft 500 ft Amperes 14 Wire 16 Wire 350 ft 100 ft 250 ft CAUTION Equipment damage can result from low voltage LOAD APPLICATION Three Phase Load When calculating the power requirements for 3 phase power use the following equation
12. 0602120481 51 0602122272 52 M9200100004 53 0602123266 54 M1353800004 55 0016908020 56 0220300425 57 0601822794 58 0016908025 59 0207008000 60 8972309390 DRAIN JOINT PLUG O RING DRAIN HOSE DRAIN HOSE HOSE BAND RESERVE TANK CAP RESERVE TANK HOSE BRACKET RESERVE TANK HEX HEAD BOLT HEX HEAD BOLT HOSE HOSE HOSE BAND PICK UP TACHOMETER UNIT OIL PRESSURE ADAPTER UNIT WATER TEMPERATURE CLAMPER ROD HEX HEAD BOLT SEAL RUBBER MOTOR FAN HEX HEAD BOLT HEX NUT FAN DCA25USIXF ENGINE AND RADIATOR ASSY REMARKS REPLACES P N 0602011431 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 65 DCA25USI2XF ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY DCAUSI2XF ONLY PAGE 66 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 ENGINE AND RADIATOR ASSY DCAUSI2XF ONLY NO PARTNO 1 M1923200124 1 1 8944567412 2 M1305200304 3 M1305200204 4 0010310025 5 0040010000 6 0041210000 7 060500066 8 0207010000 9 1923200074 9 1 0602011079 10 M9200100904 11 0150000016 12 M9312200104 13 0016908035 14 0207008000 15 M1312500203 16 M1312500303 17 0605515149 18 M1312300103 19 0016906020 20 0220300425 21 0601822794 22 0016908025 23 0602046531 23A 0602046611 24 0602040650 25 0602040552 26 0016908090 27 0207008000 28 M1375100303 29 M1373101403 30 0605515147 3
13. 61 M9112100504 62 M9112100604 63 0016908020 64 0016908020 65 0601850097 66 0027208025 67 M1433300003 68 M1435000803 69 0016908020 70 M1433001103 70A 1493200004 71 0016908020 72 0016908020 72A 0040508000 73 0600800321 74 0605503066 75 0016906016 76 0605503066 77 M1414800204 78 0017108020 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 91 PART NAME DOOR HANDLE ASSY SEAL RUBBER MACHINE SCREW HEX NUT HINGE HINGE HINGE HEX HEAD BOLT HEX HEAD BOLT STOPPER MACHINE SCREW BRACKET STAY BRACKET STAY HEX HEAD BOLT SUPPORT LEG ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLT TOOTHED WASHER MANUAL HOLDER CLAMP MANUAL HOLDER HEX HEAD BOLT FUEL LEAK DETECTED SWITCH BRACKET HEX HEAD BOLT REMARKS c5 RUBBER SEALS ASSY RUBBER SEALS ASSY Y PAGE 92 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 RUBBER SEALS ASSY NO 1 0229200790 2 0314500560 3 0229200630 4 0228901220 5 0228900690 6 0228800690 7 0228900655 8 0228900325 9 0229200325 10 0228800595 10 0228800590 11 0228800375 12 0228900375 13 0229200650 14 0229200320 15 0228800650 16 0228900520 16 0228900510 17 0228800520 17 0228800510 18 0228100390 19 0228100320 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 93 PART NAME SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBE
14. ABOVE 17 0601820846 OVER CURRENT RELAY jme S N 8100001 8100586 17 0601820848 OVER CURRENT RELAY epe S N 8100587 AND ABOVE 18 0027104016 MACHINE SCREW 2 18A 0207004000 HEX NUT 2 19 M1213500203 CONTROL BOXCOVER 1 20 0016906016 HEX HEAD BOLT 4 21 SELECTOR SIN 8100001 8101735 ORDER ITEMS W 214 M1270100104 SELECTOR SWITCH u i iab Dai SIN 8101736 AND ABOVE 21A 1550002504 DECAL SELECTOR SWITCH NUMBER S N 8100001 8101735 21A M1550002604 DECAL SELECTOR SWITCH NUMBER S N 8101736 AND ABOVE 22 M1215601204 SWITCH BRACKET t S N 8100001 8101735 228 M1215600204 SWITCH BRACKET ssassn SIN 8101736 AND ABOVE 23 0027103010 MACHINE SCREW s is B ease S N 8100001 8101735 23 0027104030 MACHINE SCREW nsise RE SIN 8101736 AND ABOVE 23A 0207004000 pe GNR EE 4 SIN 8101736 AND ABOVE 24 0016906016 HEX HEAD BOLT 4 25 0330000160 EDGING EEE SIN 8100001 8101735 258 0330000150 EE SIN 8101736 AND ABOVE 26 M1215601104 SWITCH COVER aqu aa a auqa T S N 8100001 8101735 26 1213600404 SWITCH COVER ananda Linnea SIN 8101736 AND ABOVE 26 14 0228800060 RUBBER SEAL dk SIN 8101736 AND ABOVE 26 24 0228800108 RUBBER SEAL SIN 8101736 AN
15. Amps AC Voltmeter Volts Ammeter Change Over Switch Voltmeter Change Over Switch Voltage Regulator 3 Pole 60 amp Main Circuit Breaker Output Terminal Panel The Output Terminal Panel is provided with the following Two 250 VAC output receptacles CS 6369 50 amps Two auxilliary circuit breakers 250V 50 amps Two 125 VAC output receptacles GFCI 20 amps Two GFCI circuit breakers 125V amp 20amps Five output terminal lugs 3 power Control Box The Control Box is provided with the following Automatic Voltage Regulator Current Transformer Emergency Relay GENERAL INFORMATION Open Delta Excitation System This generator is equipped with the state of the art excitation system The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section There are four connections of the open delta A B C and D During steady state loads the power from the voltage regulator is supplied from the parallel connections of A to B Ato 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 the exciter section When aheavy load such as a motor starting or a short circuit occurs the automatic voltage regulator AVR switches the configuration of the open delta to the series connection of B to C This has the effect of adding the voltages of each phase ot prov
16. FILTER KIT HEX HEAD BOLT 0 REPLACES P N 0602042700 REPLACES P N 0602023177 O HSH J 16 M1363400404 PICKUP TUBE 17 0603306863 BUSHING 18 0602022971 HOSE JOINT 19 0191200330 SUCTION HOSE 20 0191200200 SUCTION HOSE 21 0191201300 SUCTION HOSE 22 0191200800 RETURN HOSE 23 0605515198 HOSE BAND 24 0603306797 PLUG 1 1 2 25 0222100550 TANK SHEET DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 79 DCA25USIXF ECLOSURE ASSY ENCLOSURE ASSY DCA25USIXF ONLY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL INDICATE COLOR OF UNIT 1 ORANGE K 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO SOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 80 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USIXF ECLOSURE ASSY ENCLOSURE ASSY DCA25USIXF ONLY PART NAME QTY NO PARTNO 1 M1413002502 1A M1493000004 2 M1413100003 3 0603306797 4 0016910030 5 M1424000502 5A M1495100403 6 0601850151 7 M1424200702 M1495100503 8 0601851740 9 0601850239 10 0601850097 11 0027208025 12 0016908020 13 0016906020 14 0016908020 15 M1425201204 16 0016906020 17 M1424200803 18 0016906020 19 M1425200903 19 M1423202003 20 0019208020 21 M1435300503 22 M14353006
17. FRAME Q gt SHACKLE BOLIS c SUSPENSION SHACKLE HANGER SUPPORT BRACKET IS WELDED TO FRAME HANGER BOLT LOCKING TIE PLATE NUT Figure 56 Major Suspension Components Table 17 Suspension Torque Requirements SNUG FIT ONLY PARTS MUST ROTATE FREELY LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT BOLT ASSEMBLY MIN 30 MAX 50 SHACKLE BOLT SPRING EYE BOLT SHOULDER TYPE SHACKLE BOLT PAGE 40 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 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 57 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 all lug nuts in sequence Check all wheel lug nuts periodically Table 18 Tire Torque Requirements First Pass Second Pass Third Pass FT LBS FT LBS FT LBS 20 25 35 40 50 65 TRAILER MAINTENANCE 4 LUG NUTS 6 LUG NUTS 5 LUG NUTS 8 LUG NUTS LUG NUTS PNEUMATIC AIR GUN TORQUE WRENCH Figure 57 Wheel Lug Nuts Tightening Sequence NEVER use an pneumatic air gun to tighten wheel lug nuts DCA25USIXF DCA25USI
18. FRAME FRONT LOUVER HEX HEAD BOLT HEX HEAD BOLT CENTER FRAME CENTER FRAME HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX HEAD BOLT WASHER LOCK WASHER FLAT REAR FRAME ACOUSTIC SHEET ACOUSTIC SHEET DUCT COVER ACOUSTIC SHEET ACOUSTIC SHEET ACOUSTIC SHEET QTY c c P 4 4 4 OO gt DCA25USI2XF ECLOSURE ASSY ENCLOSURE ASSY DCA25USI2XF ONLY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANELTO INDICATE COLOR OF UNIT 1 ORANGE x K 2 WHITE YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 88 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USI2XF ECLOSURE ASSY ENCLOSURE ASSY DCA25USI2XF ONLY NO PARTNO 31 0016906016 32 0207006000 33 0019208020 34 M1443302203 34A 1493305104 35 M1443400103 35A M1493305204 36 0207006000 37 0019208020 38 M1445200303 39 M1445600204 40 0207306000 40A 0041206000 41 M9113000002 42 0021806016 42A 0030006000 43 M9112100404 44 M9112100604 45 0016908020 46 M1463001902 46 1493505603 47 0019208020 48 3310600004 49 0019208020 50 M1453200802 51 0016908020 52 M1455100003 52A M1493410104 53 M1453004903 M1493409904 53B 1495501004 54 M14
19. M92010000 P N B15200010 PIN M9520100004 Figure 3 Generator Decals Continued PAGE 14 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 INSTALLATION GENERATOR GROUND LUG 22 GROUND ROD FOR EARTH GROUND NG CONNECT TO BUILDING GROUND GROUND CABLE H 8 FT MINIMUM REFERENCE H NEC 250 840 Figure 4 Typical Generator Grounding Application DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 15 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 around Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes The installation site must be relatively free from moisture and dust All electrical equipment should be protected from excessive moisture Failure to do will result in deterioration of the insulation and will result in short circuits and grounding Foreign materials such as dust sand lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts AX CAUTION EXHAUST HAZARD Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area Indoor Installation Exhaus
20. VOLTAGE X AMPERAGE X 1 732 1000 KVA NOTICE IF 3 load KVA is not given on the equipment nameplate approximate 3 load output maybe determined by multiplying voltage by amperage by 1 732 NOTICE Motors and motor driven equipment draw much greater current for starting than during operation An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable See Table 6 When connecting a resistance load such as an incandescent lamp or electric heater a capacity of up to the generating set s rated output KW can be used When connecting a fluorescent or mercury lamp a capacity of up to the generating set s rated output KW multiplied by 0 6 can be used When connecting an electric drill or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generating set s rated output KW multiplied by 0 8 can be used DANGER Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer switch Serious damage to the building s electrical system may occur without this transfer switch PAGE 24 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 GAUGE READING TERMINAL PANEL CONNECTIONS Voltage Selector Switch The voltage
21. and GFCI 9 The coolant temperature gauge Figure 49 will indicate the Circuit Breakers ON coolant temperature Under normal operating conditions the coolant temperature is between 165 209 F 74 95 C 12 Observe the generator s ammeter Figure 52 and verify it reads the anticipated amount of current with respect to the load The ammeter will only display a current reading if the load is in use Figure 48 Oil Pressure Gauge Figure 49 Coolant Temperature Gauge 10 The tachometer Figure 50 will indicate the speed of Figure 52 Ammeter Load the engine when the generator is operating Under normal operating conditions this speed is approximately 1800 13 The generator wil run until manually stopped or an RPM s abnormal condition occurs TACH HOURS Figure 50 Engine Tachometer DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 35 Normal Shut down Procedure To shutdown the generator use the following procedure 1 Switch the MAIN AUX and circuit breakers Figure 53 to the OFF position no load MAIN CS 6369 GFCI CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKERS BREAKERS s m m Figure 53 Main AUX and GFCI Circuit Breakers OFF 3 Let the engine cool by running it for 3 5 minutes with no load applied circuit breakers in the OFF position 4 Place the ignition switch Figure 54 in the STOP position remove the
22. and certain washers and nuts Not Sold Separately Indicates that an item cannot be purchased as a separate item and is either part of an assembly kit that can be purchased or is not available for sale through Multiquip PAGE 50 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 SUGGESTED SPARE PARTS DCA 25USIXF DCA 25USI2XF Big Tank W ISUZU AA 4LE2 BV 4LE2 DIESEL ENGINES 170 3 UNITS Qty PIN Description Remarks A 8944567411 OIL FILTER DCA 25USI 8944567412 ELEMENT OIL FILTER DCA 25USI2 s 0602046611 AIR ELEMENT t han 8943692993 CARTRIDGE FUEL FILTER tor 0602122272 UNIT OlL PRESSURE 0602123266 UNIT WATER TEMPERATURE DCA 25USI 0602123275 UNIT WATER TEMPERATURE DCA 25USI2 ng 0605505072 FUEL CAP Tates 8972309390 FAN BELT M1312500203 HOSE RADIATOR UPPER ane M1312500303 HOSE RADIATOR LOWER 0601808803 CIRCUIT BREAKER 20 0601808804 CIRCUIT BREAKER 50 ee 0602103092 ALARM LAMP mem 0601810245 BULB ALARM LAMP PRE HEAT LAMP 8944024960 KEY IGNITION SWITCH 0601840073 RHEOSTAT VOLTAGE REGULATOR as 0601840121 KNOB RHEOSTAT Tasa 0601820671 AUTO
23. and shows as being replaced by another item it is obsolete b Any parts with a limited shelf life such as gaskets seals O rings and other rubber parts that were pur chased more than sixmonths priorto the return date c Anylineitem with anextended dealer netprice ofless than 5 00 d Special order items Electrical components f Paint chemicals and lubricants g Decalsandpaperproducts h Items purchased in kits 7 The sender will be notified of any material receivedthatis not acceptable 8 Such material will be held for five working days from notification pending instructions If a reply is not received within five days the material will be re turnedtothe sender at his expense 9 Crediton returned parts will be issued at dealer net price at time of the original purchase less a 15 restocking charge 10 Incases where an item is accepted for which the original purchase document can not be determined the price will be based on thelist price that was effective twelve months priorto the RMA date 11 Credit issued will be applied to future purchases only PRICING AND REBATES Prices are subject to change without prior notice Price changes are effective on a spe cific date and allorders received on orafter that date willbe billed atthe revised price Rebates for price declines and added charges for price increases willnotbe made for stock on handat the time of any price change Mu
24. be connected to the generator by the UVWO terminal lugs or the convienience receptacles See Figure 13 Make sure to read the operation manual before attempting to connect a load to the generator To protect the UVWO output terminals from overload a 3 pole 60 amp main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine 5 6369 TWIST LOCK RECEPTACLES AC OUTPUT TERMINALS NEUTRAL Figure 13 Connecting Loads OUTPUT TERMINAL PANEL Over Current Relay An over current relay Figure 14 is connected to the main circuit breaker In the event of an overload 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 cur rent relay must be pressed The over current relay is lo cated in the control box Figure 14 Over Current Relay DANGER This fuse has current running through it any time the engine is running This fuse is NOT connected to the main circuit breaker of the generator Attempting to replace the fuse with the engine and or generator operating could result in electrocution and severe bodily harm ALWAYS turn the unit completely off before attempting to replace or handle this fuse DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 23 Single Phase Load Always be sure to check the nameplate on the generator
25. blank entry generally indicates that the item is not sold separately or is not sold by Multiquip Other entries will be clarified in the Remarks Column QTY Column Numbers Used Item quantity can be indicated by a number a blank entry or A R A R As Required is generally used for hoses or other parts that are sold in bulk and cut to length A blank entry generally indicates that the item is not sold separately Other entries will be clarified in the Remarks Column REMARKS Column Some of the most common notes found in the Remarks Column are listed below Other additional notes needed to describe the item can also be shown Assembly Kit All items on the parts list with the same unique symbol will be included when this item is purchased Indicated by INCLUDES ITEMS W unique symbol Serial Number Break Used to list an effective serial number range where a particular part is used Indicated by S N XXXXX AND BELOW S N XXXX AND ABOVE S N XXXX TO S N XXX Specific Model Number Use Indicates that the part is used only with the specific model number or model number variant listed It can also be used to show a part is NOT used on a specific model or model number variant Indicated by XXXXX ONLY NOT USED ON XXXX Make Obtain Locally Indicates that the part can be purchased at any hardware shop or made out of available items Examples include battery cables shims
26. key and store in a safe place STOP RUN START Figure 54 Ignition Switch Off Position 5 Remove all loads from the generator 6 Allow for sufficient time for cooling and then inspect the complete unit for any damage or loosening that may have occured during operation 7 Check the engine oil coolant and fuel levels Replenish as necessary SHUTDOWN Emergency Shut down Procedure 1 To shut down the engine in the event of an emergency switch the MAIN GFCI and LOAD Figure 53 circuit breakers to OFF position 2 Turn the ignition switch key to the STOP position Figure 54 Automatic Shut down System This unit is equipped with safety devices to automatically stop the engine in the event of low oil pressure approximately 14 psi 97 kPa or high water temperature approximately 230 F 110 C The alarm lamps on the Engine Control Panel illuminate to signify the reason for the shutdown After automatic shut down ALWAYS inspect the unit and eliminate any problems before attempting to restart Failure to do so can damage the unit Before inspecting turn the starter switch to the STOP position place all Generator Circuit Breakers in the OFF position and allow sufficient time for adequate cooling When ready to restart complete all steps in the Generator Startup Procedure section of this manual NOTICE Engine protection is furnished during operation but cannot replace normal preventive maintenance
27. pipe Fuel filter clogged Clean or change fuel filter Excessively high viscosity of fuel or engine oil at low temperature Use the specified fuel or engine oil Fuel with low cetane number Use the specified fuel Fuel leak due to loose injection pipe retaining nut Tighten nut Incorrect injection timing Adjust Fuel cam shaft worn Replace Injection nozzle clogged Clean injection nozzle Seizure of crankshaft camshaft piston cylinder liner or bearing Repair or replace Injection pump malfunctioning Repair or replace Compression leak from cylinder Replace head gasket tighten cylinder head bolt glow plug and nozzle holder Improper valve timing Correct or replace timing gear Piston ring and liner worn Replace Excessive valve clearance Adjust Starter does not run Starter malfunctioning Repair or replace Wiring disconnected Connect wiring PAGE 46 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 TROUBLESHOOTING TABLE 19 ENGINE TROUBLESHOOTING CONTINUED SYMPTOM POSSIBLE PROBLEM SOLUTION Engine revolution is not smooth Fuel filter clogged or dirty Clean or change Air cleaner clogged Clean or change Fuel leak due to loose injection pipe retaining nut Tighten nut Injection pump malfunctioning Repair or replace
28. settled between the consignee and the carrier MINIMUM ORDER Theminimum chargefor orders from Multiquip is 15 00 net Customers will be asked for instructions regarding handling of orders not meeting this requirement RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed subjectto the following provi sions 1 A Returned Material Authorization must be approved by Multiquip prior to ship ment 2 Return Material Authorization list must be provided to Multiquip Parts Sales that defines item numbers quanti ties and descriptions of the items to be returned Theparts numbers and descriptions must match the current parts price list b The list must be typed or computer generated The list must state the reason s for thereturn d The list must reference the sales order s orinvoice s under which the items were originally purchased e The list must include the name and phone number ofthe person request ing the RMA 3 Acopyofthe Return Material Authoriza tion mustaccompanythe return shipment 4 Freight is at the sender s expense All parts mustbe returnedfreight prepaidto Multiquip s designated receiving point 5 Partsmustbein newandresalable con dition inthe original Multiquip package if any and with Multiquip part numbers clearly marked 6 Thefollowingitems are not returnable 8 Obsolete parts If an item is in the price book
29. shatterproof glasses respiratory protection hearing protection steel toed boots and other protective devices required by the job or city and state regulations 00000 m NEVER operate this equipment when not feeling well due to fatigue illness or when under medication m NEVER operate this equipment under the influence of m ALWAYS check the equipment for loosened threads or bolts before starting DO NOT use the equipment for any purpose other than its intended purposes or applications NOTICE This equipment should only be operated by trained and qualified personnel 18 years of age and older Whenever necessary replace nameplate operation and safety decals when they become difficult read m Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties SAFETY INFORMATION m NEVER use accessories or attachments that are not recommended by Multiquip for this equipment Damage to the equipment and or injury to user may result m ALWAYS know the location of the nearest fire extinguisher m ALWAYS know the location of the nearest first aid kit m ALWAYS know the location of the nearest phone or keep a phone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency GENERATOR
30. the trailers bumper to prevent tipping while parked m Use the trailers swivel jack to adjust the trailer height to a level position while parked PAGE 8 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 ELECTRICAL SAFETY m DO NOT touch output terminals during operation Contact with output terminals during operation can cause electrocution electrical shock or burn B The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals NEVER insert any objects into the output receptacles during operation This is IN extremely dangerous The possibility exists of electrical shock electrocution or death E Backfeed to a utility system can cause electrocution and or property damage NEVER connect the generator to a building s electrical system without a transfer switch or other approved device All installations should be performed by a licensed electrician in accordance with all applicable 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 m NEVER let power cords or cables lay in water m NEVER stand in water while AC power from the generator is being transferred to a load m NE
31. use Ignition Switch Four position switch pre heat stop run and start Insert ignition key to start and stop engine Pre Heat Lamp Indicates ON when the engine is ready for starting during cold weather operating conditions Fuel Leak Detected Alarm Lamp This lamp will illuminate when a leak in the fuel containment enclosure is detected Panel Light Switch When activated will turn on control panel light PAGE 20 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 OUTPUT TERMINAL PANEL Output Terminal Panel Output Terminal Familiarization The OutputTerminal Panel Figure 8 shown below is located The OutputTerminal Panel Figure 6 is provided with the onthe right hand side left from control panel of the generator following Lift up on the cover to gain access to receptacles andterminal m T o 2 120 240V output receptacles 50 amp lugs 9 Two 2 Circuit Breakers 50 amps NOTICE Two 2 120V GFCI receptacles 20 amp Terminal legs O and Ground are considered bonded Two 2 GFCI Circuit Breakers 20 amps grounds Five 5 Output Terminal Lugs U V W O Ground One Main Circuit Breaker 60 amps 1 AND 3 480 120 VAC OUTPUT TERMINALS NEUTRAL GROUND TERMINAL TERMINAL HARD WIRE HOOKUP PANEL BLACK BLUE WHITE GREEN CIRCUIT BREAKERS FOR 5 6369 TWIST LOCK RECEPTACLES CIRCUIT BREAKERS FOR GFC
32. 0010 10 M9500500004 DECAL DIESEL FUEL DCAZ5USIXF M90050000 10 M9500500304 DECAL DIESEL FUEL DCA25USI2XF a usa M90050030 11 M9503000004 DECAL WARNING MOVING PARTS An M90300000 12 M9503000103 DECAL WATER OIL CHECK preme M90300010 13 M9503100004 DECAL WARNING HOT COOLANT M90310000 14 M9503200004 DECAL WARNING ENGINE EXHAUST EE M90320000 15 M9510000004 DECAL FLUID DRAIN M91000000 16 M9510100004 DECAL CAUTION HOT PARTS 91010000 17 9512200004 DECAL 91220000 18 9520000004 DECAL GROUND 92000000 19 9520000104 DECAL AMMETER CHANGE OVER SW pr M92000010 20 M9520000204 DECAL VOLTMETER CHANGE OVER SW M92000020 21 M9520100004 DECAL WARNING ELECTRIC SHOCK HAZARD 2 M92010000 22 M9520100204 DECAL CAUTION s 92010020 23 M9520100304 DECAL SAFETY INSTRUCGTION 92010030 24 M9520100404 DECAL DANGER HIGH VOLTAGE 92010040 25 M9520100503 DECAL WARNING aaa 92010050 26 9520200003 DECAL CONNECTION OF OUTPUT CABLE M92020000 27 M9520200104 DECAL OVER CURRENT RELAY Tere M92020010 28 M1561000004 DECAL MQ
33. 03 23 0013612030 23A 0040012000 24B 0041212000 24 0013612030 24A 0040012000 24B 0041212000 25 M1445000802 25A 1495300304 26 0016908020 REMARKS BASE ACOUSTIC SHEET ENVIRONMENTAL TANK PLUG 1 1 2 HEX HEAD BOLT FRONT FRAME ACOUSTIC SHEET GROMMET FRONT DUCT ACOUSTIC SHEET GROMMET GROMMET STOPPER MACHINE SCREW HEX HEAD BOLT HEX HEAD BOLT HEX HEAD BOLT DUCT COVER HEX HEAD BOLT HOSE COVER HEX HEAD BOLT COVER FROM COVER FROM FRAME HEX HEAD BOLT CENTER FRAME CENTER FRAME HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX HEAD BOLT WASHER LOCK WASHER FLAT REAR FRAME ACOUSTIC SHEET HEX HEAD BOLT EN EE zi ca Bh Sy EE 01 S N8100001 8101465 S N 8101466 AND ABOVE DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 81 DCA25USIXF ECLOSURE ASSY ENCLOSURE ASSY DCA25USIXF ONLY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING PAINTED PANEL INDICATE COLOR OF UNIT 1 ORANGE x K 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO SOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 82 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USIXF ECLOSURE ASSY ENCLOSURE ASSY DCA25USIXF ONLY NO PARTNO 27 M1445300103 27 1495300504 278
34. 03306590 29 0603300285 30 0605511395 31 0603306395 32 0602021070 33 0269200380 PART NAME ENGINE ISUZU AA 4LE2 CARTRIDGE OIL FILTER ENGINE FOOT ENGINE FOOT HEX HEAD BOLT WASHER LOCK WASHER FLAT RUBBER SUSPENSION HEX NUT RADIATOR CAP RADIATOR MOUNT RUBBER HEX HEAD BOLT HEX NUT RADIATOR HOSE RADIATOR HOSE HOSE BAND FAN COVER HEX HEAD BOLT AIR CLEANER ELEMENT AIR CLEANER INDICATOR AIR CLEANER BRACKET AIR CLEANER HEX HEAD BOLT HOSE AIR CLEANER HOSE AIR CLEANER HOSE BAND ADAPTER PACKING 90 DEG ELBOW CONNECTOR LOCKNUT VALVE HOSE JOINT CAP DRAIN HOSE QTY DCA25USIXF ENGINE AND RADIATOR ASSY REMARKS 4 REPLACES P N 0602041210 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 63 DCA25USIXF ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY DCAUSIXF ONLY PAGE 64 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 ENGINE AND RADIATOR ASSY DCAUSIXF ONLY NO PARTNO 34 M9602000003 35 M9200200004 36 0150000018 38 0199901600 39 0199900800 40 0605515106 41 M9300000003 42 M9300100003 43 0199100215 44 M1318100103 45 0016906025 46 0016906020 47 0199100700 48 0193600850 49 0605515106 50
35. 08803 19 0601808804 20 M1260700204 20A 0222100115 21 0016906020 22 0601812598 23 0601812538 24 0027104018 24A 0207004000 25 M1238100503 26 0010112045 26 0010112040 27 0041212000 28 M9310200004 29 0030012000 30 M1236400104 30A M1493408804 31 0016906016 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 71 OUTPUT TERMINAL ASSY PART NAME TERMINAL PANEL OUTPUT TERMINAL BOLT TIE SCREW HEX NUT WASHER LOCK WASHER FLAT HEX HEAD BOLT TERMINAL TERMINAL COVER sssi OUTPUT WINDOW HINGE MACHINE SCREW HEX NUT WASHER FLAT HEX HEAD BOLT HEX HEAD BOLT CABLE OUTLET COVER SUPPORTER CABLE OUTLET COVER HEX HEAD BOLT CIRCUIT BREAKER 1P 20A CIRCUIT BREAKER 2P 50A BREAKER FITTING COVER CUSHION RUBBER HEX HEAD BOLT RECEPTACLE 125V 20A X 2 GFCI RECEPTACLE CS6369 250V 50A MACHINE SCREW HEX NUT TERMINAL COVER HEX HEAD BOLT HEX HEAD BOLT WASHER FLAT STAY RUBBER HEX NUT QTY REMARKS O FS DCA25USI DCA25USI2 DCA25USI DCA25USI2 DCA25USI2 DCA25USI2 DCA25USI2 BATTERY ASSY BATTERY ASSY PAGE 72 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 BATTERY ASSY BATTERY ASSY NO PART NAME QTY REMARKS 1 0602220185 BATTERY 1 2 M9310500014 BATTE
36. 1 0602022560 32 M1320300304 33 0602022561 34 0603306590 35 0603300285 36 0605511395 37 0603306395 38 0602021070 39 0269200350 PART NAME ENGINE ISUZU BV 4LE2 CARTRIDGE OIL FILTER ENGINE FOOT ENGINE FOOT HEX HEAD BOLT WASHER LOCK WASHER FLAT RUBBER SUSPENSION HEX NUT RADIATOR CAP RADIATOR PLUG O RING MOUNT RUBBER HEX HEAD BOLT HEX NUT RADIATOR HOSE RADIATOR HOSE HOSE BAND FAN COVER HEX HEAD BOLT SEAL RUBBER MOTOR FAN HEX HEAD BOLT AIR CLEANER ELEMENT AIR CLEANER INDICATOR AIR CLEANER BRACKET AIR CLEANER HEX HEAD BOLT HEX NUT HOSE AIR CLEANER HOSE AIR CLEANER HOSE BAND ADAPTER PACKING 90 DEG ELBOW CONNECTOR LOCKNUT VALVE HOSE JOINT CAP DRAIN HOSE QTY DCA25USI2XF ENGINE AND RADIATOR ASSY REMARKS RE REPLACES P N 0602041210 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 67 DCA25USI2XF ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY DCAUSI2XF ONLY PAGE 68 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USI2XF ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY DCAUSI2XF ONLY NO PARTNO PART NAME QTY REMARKS 40 M9602000003 DRAIN JOINT 1 41 M9200200004 P
37. 2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 41 DOUBLE FILAMENT BULB SINGLE FILAMENT BULB DOUBLE FILAMENT BULB DOUBLE FILAMENT BULB SINGLE FILAMENT BULB DOUBLE FILAMENT BULB TRAILER WIRING DIAGRAM TOWING TRAILER SIDE VEHICLE SIDE CONNECT RIGHT TO CHASSIS TAIL LIGHT WHITE WHITE COMMON GROUND GREEN BROWN YELLOW BROWN GREEN STOP amp TURN LEFT LICENSE TAIL LIGHT FLAT 4 PIN MOLDED CONNECTOR FLAT 4 PIN MOLDED MATING CONNECTOR LEFT TAIL LIGHT CONNECT RIGHT TO CHASSIS TAIL LIGHT GROUND BLUE TURN RIGHT GREEN TAIL amp LICENSE YELLOW STOP LICENSE TAIL LIGHT CONNECTOR MATING CONNECTOR LEFT TAIL LIGHT 1 1 1 1 1 1 1 1 1 FLAT 5 PIN ROUND FLAT 5 PIN ROUND 1 1 1 1 I I 1 1 1 1 Figure 58 Trailer Towing Vehicle Wiring Diagram PAGE 42 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 ENGINE WIRING DIAGRAM WATER TEMP SWITCH ENGINE SPEED an PICKUP SOLENOID CTHE TYPE NORMALLY ELECTRIFYING Hay FUEL CUT RELAY Tull EN16 T N15 GLOW RELAY MAE SIZE CONNECTOR VIEW FROM INSERTING WIRE SIDE KEY CONNECTION DIAGRAM OFF COLOR CODE B BR BROWN
38. 55000803 54 1495501204 548 1495501304 1495401404 55 M1453005003 55A M1493410004 56 M1455300403 56 M1495401204 568 1495401404 57 0207006000 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 89 PART NAME HEX HEAD BOLT HEX NUT HEX HEAD BOLT REAR COVER ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT HEX HEAD BOLT REAR DOOR WINDOW PLATE HEX NUT WASHER FLAT DOOR HANDLE ASSY MACHINE SCREW HEX NUT HINGE HINGE HEX HEAD BOLT ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT COVER HEX HEAD BOLT SPLASHER PANEL HEX HEAD BOLT SIDE PANEL ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET ACOUSTIC SHEET ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET DUCT ACOUSTIC SHEET ACOUSTIC SHEET HEX NUT QTY REMARKS H Ga De ee N S DCA25USI2XF ECLOSURE ASSY ENCLOSURE ASSY DCA25USI2XF ONLY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK WHITE CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 90 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USI2XF ECLOSURE ASSY ENCLOSURE ASSY DCA25USI2XF ONLY NO PART NO 58 M9113000002 58A C9312500004 59 0021806016 59A 0030006000 60 M9112100404
39. AND PARTS MANUAL REV 2 07 26 11 PAGE 29 Refueling Procedure AX WARNING RESPIRATORY HAZARDS Diesel fuel and its vapors are dangerous 4 to your health and the surrounding environment Avoid skin contact and or inhaling fumes 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 32 ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank DO NOT fill on Figure 32 Only Fill on Level Ground NOTICE ONLY use 2 diesel fuel when refueling SETUP 3 Open cabinet doors on the right side of the generator from generator control panel position Remove fuel cap and fill tank Figure 33 Figure 33 Fueling the Generator NEVER overfill fuel tank It is important to read the fuel gauge when filling trailer fuel tank DO NOT wait for fuel to rise in filler neck Figure 34 FUEL GAUGE LOCATED ON CONTROL PANEL DO NOT OVER FILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 35 Fuel EXPANDS When Heated Figure 35 Fuel Expansion PAGE 30 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 Coolant ISUZU Antifreeze Summer Coolant Water ISUZU recommends ISUZU Antifreeze Summer Coolant for use in thier engines which ca
40. D ABOVE 26 38 0317700180 RUBBER SEAL ansa as sa SIN 8101736 AND ABOVE 27 0016906016 HEX HEAD BOLT Ru us S N 8100001 8101735 274 0016906016 HEX HEAD SIN 8101736 AND ABOVE DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 55 DCA25USIXF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSIXF ONLY S N 810000 8101735 S N 8101736 AND ABOVE S est ao gt PAGE 56 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USIXF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSIXF ONLY NO PARTNO PART NAME QTY REMARKS 28 0016906016 HEX HEAD BOLT 9 28A 0040506000 TOOTHED WASHER 1 29 M1225000323 CONTROL uuu EEE S N 8100001 8100586 29 M1225000333 CONTROL PANEL acustico tomo SIN 8100587 AND ABOVE 30 0601808985 FREQUENGY METER 45 65Hz 240V 1 31 0601808985 AC AMMETER 0 50A 100A 5A 1 32 0601801040 CHANGE OVER SWITCH AMMETER 1 33 0601806859 AC VOLTMETER 0 600V 1 34 0601801041 CHANGE OVER SWITCH AMMETER 1 35 0601840073 RHEOSTAT VR 2W 1K OHM 1 36 0601840121 KNOB 1 37 8970444180 STARTER SWITCH u a a anaq 1 REPLACES P N 0602100009 37A 8944024980 KEY IGNITION SWITCH 1 38 0602103092 PREHEAT LAMP 1 38A 0601810245 BULB DC18V 39 0602120095 TACHOMETER 1 40 0602122093 OIL PRESSURE GAUGE 1 41 0602123090 WATER TEMPERATURE GAUGE 1 42 0602121080 CHARG
41. E 1 PHASE Figure 16 Voltage Selector Switch 240 139V Three Phase Position PRESS TO LOCK NOTICE For 3 208V 1 120V place the Voltage Selector Switch in the 3 Phase 240 139 position Reading Voltage To determine the voltage between two terminal lugs set the AC Voltmeter Change Over Switch to the appropriate setting Figure 17 to activate the AC Voltmeter Gauge Figure 18 and read the available voltage between the two lugs For example to measure the voltage between the W and U terminal lugs set the AC Voltmeter Change Over Switch to W U and read the AC Voltmeter Gauge V W Figure 17 AC Voltmeter Change Over Switch Figure 18 AC Voltmeter Gauge Volt reading on W U Lug Reading Amperage To determine the amperage at a terminal lug set the AC Ammeter Change Over Switch to the appropriate setting Figure 19 to activate the AC Ammeter Gauge Figure 20 and read the available amperage at the termi nal lug For example to measure the amperage at the U terminal lug set the AC Ammeter Change Over Switch to U and read the AC Ammeter Gauge V OFF Figure 20 AC Ammeter Amp reading on U lug Figure 19 AC Ammeter Change Over Switch NOTICE The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use PAGE 26 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 OUTPUT TERMINAL PANEL CONNECTIONS
42. I RECEPTACLES 120 VAC 20 AMP RECEPTACLES ACCESS DOOR LIFT TO OPEN RECEPTACLE AND CIRCUIT BREAKER gt PANEL CS 6369 TWIST LOCK AUX POWER RECEPTACLES 120 240V 50 AMPS Figure 8 Output Terminal Panel DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 21 120 VAC GFCI Receptacles There are two 120 VAC 20 amp GFCI Duplex 5 20R recepacles provided on the output terminal panel These receptacles can be accessed in any voltage selector switch position Each receptacle is protected by a 20 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current of both GFCI receptacles is dependent on the load requirements of the U V and W output terminal lugs Pressing the reset button resets the GFCI receptacle after being tripped Pressing the Test Button See Figure 9 in the center of the receptacle will check the GFCI function Both receptacles should be tested at least once a month 120 VAC RECEPTACLE RESET BUTTON Figure 9 G F C I Receptacle Twist Lock Dual Voltage 120 240 VAC Receptacles There are three 120 240V 50 amp auxilliary twist lock CS 6369 recepacles Figure 10 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 TEST BUTTON CS 6369 TWIST LOCK RECEPTACLES
43. ING AMMETER 1 43 0602125090 FUEL GAUGE 1 44 0602103092 ALARM LAMP 3 44A 0601810245 BULB DC18V 3 45 9826800370 PANEL LIGHT Qa a sii un pcm REPLACES P N 0601810141 46 0601831330 SWITCH PANEL LIGHT 1 47 M1225100004 STOPPER 1 48 0027105010 MACHINE SCREW 2 49 0027105010 MACHINE SCREW 4 50 M9220100004 SET SCREW 2 51 0080200007 SNAP RING 2 52 8973259120 ENGINE CONTROLLER ii iino i a a REPLAGES P N 0602202523 53 0016906016 HEX HEAD BOLT 2 53A 0207006000 HEX NUT 2 54 5825500290 EN n ns mu aaa aD ER REPLAGES P N 0602201400 55 8942481610 GLOW RELAY REPLACES P N 0602202502 56 0027105016 MACHINE SCREW 4 57 0602103092 EE SIN 8100231 AND ABOVE 57A 0601810245 BULB Mr jp S N 8100231 AND ABOVE 58 M1213600305 SWITCH BRACKET pee S N 8101736 AND ABOVE 59 0027104016 MACHINE SCREW SIN 8101736 AND ABOVE 59 0207004000 HEX NUT akaqa masi T S N 8101736 AND ABOVE 60 M1248700004 WIRE HARNESS GENERATOR d testi S N 8100001 8101735 60 M1248700024 WIRE HARNESS GENERATOR nd SIN 8101736 AND ABOVE 61 M1359200602 WIRE HARNESS ENGINE S N 8100001 8101465 61 M1359200612 WIRE HARNESS ENGINE SIN 8101466 AND ABOVE 62 0601802160 FUSE 5A 2
44. LUG 1 42 0150000018 O RING 1 43 0016906020 HEX HEAD BOLT 2 44 0199901600 DRAIN HOSE 1 45 0199900800 DRAIN HOSE 1 46 0605515106 HOSE BAND 4 47 M9300000003 RESERVE TANK 1 48 M9300100003 CAP RESERVE TANK 1 49 0199100215 HOSE 1 50 M1316100603 BRACKET RESERVE TANK 1 51 0016906025 HEX HEAD BOLT 1 52 0016906020 HEX HEAD BOLT 2 53 0199100700 HOSE 1 54 0193600850 HOSE 1 55 0605515106 HOSE BAND 3 56 0602120481 PICK UP TACHOMETER 1 57 0602122272 UNIT OIL PRESSURE 1 58 M9200100004 ADAPTER 1 59 0602123266 UNIT WATER TEMPERATURE 1 60 M1353800004 CLAMPER ROD 1 61 0016908020 HEX HEAD BOLT 2 62 8972309390 FAN BEL see I RE REPLACES P N 0602011431 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 69 OUTPUT TERMINAL ASSY 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 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 70 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 OUTPUT TERMINAL ASSY NO PARTNO 1 M1230700003 2 M9220000004 3 M9220000104 4 0039308000 5 0040008000 6 0041408000 7 0016906025 8 M1238100603 8 M1236101103 9 M1238100704 10 0605010040 11 0027103010 11A 0030003000 11B 0041203000 13 0016906020 14 0016906016 15 M1236400004 16 M1236300004 17 0016906020 18 06018
45. MATIC VOLTAGE REGULATOR DCA25USI Taqa 0601820602 AUTOMATIC VOLTAGE REGULATOR DCA25USI2 AE 0601802160 FUSE 5A DCA 25USI css 8944370220 FUEL FILTER KIT DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 51 GENERATOR ASSY GENERATOR ASSY PAGE 52 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 GENERATOR ASSY NO PARTNO 1 B1110200602 1 1 1 2 7961025004 1 35 0601822630 1 4 8001070003 1 5 8351611004 1 6 8351612004 1 7 B1112200003 1 8 0010310025 1 9 0042510000 1 10 0601000209 1 11 0071906308 2 0010308035 2A 0040008000 2B 0041208000 3 0070506803 4 B1130201103 4 1 0845041904 B1138000003 6 0016008045 7 0042508000 8 8351315003 9 0017108035 10 8351312004 11 8351331004 12 0017106016 13 0010310030 13A 0040010000 13B 0041210000 14 B0155400204 15 0010106030 16 0041206000 17 0600815000 18 M9312600004 19 0207010000 PART NAME ROTOR ASSY uuu aaa FIELD ASSY RECTIFIER SURGE ABSORBER FAN COUPLING DISK WASHER COUPLING HUB BALANCING PLATE HEX HEAD BOLT WASHER LOCK BALANCING WEIGHT KIT BEARING HEX HEAD BOLT WASHER LOCK WASHER FLAT BEARING STATOR ASSY GROMMET FIELD ASSY EXCITER HEX SOCKET HEAD CAP SCREW WASHER LOCK END BRACKET HEX HEAD BOLT PACKING COVER SUCTION HEX HEAD BOLT HEX HEAD BOLT WASHER LOCK WASHE
46. MMETER AC VOLTMETER 0 600V CHANGE OVER SWITCH AMMETER RHEOSTAT VR 2W 1K OHM KNOB ALARM LAMP BULB DC18V STARTER SWITCH KEY IGNITION SWITCH PREHEAT LAMP BULB DC18V TACHOMETER OIL PRESSURE GAUGE WATER TEMPERATURE GAUGE CHARGING AMMETER FUEL GAUGE PANEL LIGHT sas SWITCH PANEL LIGHT ALARM LAMP BULB DC18V STOPPER MACHINE SCREW MACHINE SCREW SET SCREW SNAP RING GROMMET WIRE HARNESS GENERATOR QTY REMARKS T 1 1 1 1 1 1 1 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 2 2 1 1 REPLACES P N 0602100009 REPLACES P N 0601810141 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 61 DCA25USIXF ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY DCAUSIXF ONLY PAGE 62 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 ENGINE AND RADIATOR ASSY DCAUSIXF ONLY NO PARTNO 1 B1925200254 1 1 8944567411 2 M1305200304 3 M1305200204 4 0010310025 5 0040010000 6 0041210000 060500066 8 0207010000 9 1923200074 9 0602011079 10 9312200104 11 0016908040 12 0207008000 13 M1312500203 14 M1312500303 15 0605515149 16 M1312300103 17 0016906020 18 0602046531 18A 0602046611 19 0602040650 20 0602040552 21 0016908030 22 M1375100303 23 M1375100203 24 0605515147 25 0602022560 26 M1320300304 27 0602022561 28 06
47. OL DESIGNATION Ar MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING 48 LJ CJ ExAr EXCITER ARMATURE WINDING ExFg EXCITER FIELD WINDING RECTIFIER UTOMATIC VOLTAGE REGULATOR OLTAGE REGULATOR RHEOSTAT URRENT TRANSFOR HANGE OVER SWITCH C AM HANGE OVER SWITCH VOLTMETER C VOLTMETER REQUENGY METER RCUIT BREAKER 3P 60A RCUIT BREAKER 2P 50A RCUIT BREAKER 1P 20A RECEPTACLE 250V 50 RECEPTACLE 125V 20AX2 OVER CURRENT RELAY SELECTOR SWITCH RELAY UNIT Re1 RELAY RECTIFIER FM FAN MOTOR FUSE TERMINAL gt CT123 3 2 1 2 nl o o o lt m C82 3 CB4 5 CON1 2 CON3 4 OG SW RY12 gm ls s Asle hi Figure 60 Generator Wiring Diagram DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 45 TROUBLESHOOTING Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 19 shown below for diagnosis of the engine If the problem cannot remedied consult our company s business office or service plant TABLE 19 ENGINE TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION Engine does not start No fuel Replenish fuel Air in the fuel system Bleed system Water in the fuel system Remove water from fuel tank Fuel pipe clogged Clean fuel
48. ONTROLLER HEX HEAD BOLT GLOW EN aaa MACHINE SCREW CONTROL BOX COVER HEX HEAD BOLT SELECTOR SWITCH DECAL SELECTOR SWITCH NUMBER DECAL SELECTOR SWITCH NUMBER SWITCH BRACKET SWITCH BRACKET MACHINE SCREW NUT SELF LOCKING MACHINE SCREW NUT SELF LOCKING HEX HEAD BOLT SWITCH COVER RUBBER SEAL HEX HEAD BOLT SWITCH COVER RUBBER SEAL HEX HEAD BOLT HEX HEAD BOLT TOOTHED WASHER QTY REMARKS 1 1 1 4 1 2 2 1 1 4 2 4 1 4 3 6 1 1 2 2 1 4 2 1 4 1 4 1 1 1 1 1 4 4 4 4 4 1 1 4 1 1 6 0 1 REPLACES P N 0602201400 ER REPLACES P N 0602202502 DCA25USI2XF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSI2XF ONLY r PAGE 60 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USI2XF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSI2XF ONLY NO PARTNO 37 M1223000603 38 0601807641 39 0601808985 40 0601801040 41 0601806859 42 0601801041 43 0601840073 44 0601840121 45 0602103092 45A 0601810245 46 8970444180 46A 8944024980 47 0602103092 47A 0601810245 48 0602120095 49 0602122093 50 0602123090 51 0602121080 52 0602125090 53 9826800370 54 0601831330 55 0602103092 55A 0601810245 56 M1225100004 57 0027105010 58 0027105010 59 M9220100004 60 0080200007 61 0601851727 62 M1246703604 PART NAME CONTROL PANEL incitati FREQUENCY METER 45 65Hz 240V AC AMMETER 0 50A 100A 5A CHANGE OVER SWITCH A
49. OPERATION AND PARTS MANUAL MULTIQUIP ZI POWER MODEL DCA25USIXF MODEL DCA25USI2XF 60 Hz GENERATOR PARTS LIST NO M1873400004A DCA 25USI PARTS LIST NO M1873400204A DCA 25USI2 Revision 2 07 26 11 To find the latest revision of this publication visit our website at www multiquip com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USIXF DCA25USI2XF 60 HZ ULTRA SILENT GENERATORS Proposition 65 Warning 2 Table Of Contents 3 Parts Ordering Procedures 4 Specifications M 5 Dimensions Top Side Front 6 Safety Message Alert Symbols 7 8 Rules for Safe Operation 9 13 Generator Decals 14 15 DSH 16 17 General Information 18 Major Gomponents saa 19 Generator Control 20 Engine Operating 21 Output Terminal Panel Familiarization
50. OTES DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 97 OPERATION AND PARTS MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave Carson CA 90746 Contact multiquip com Service Department 800 421 1244 310 537 3700 Technical Assistance 800 478 1244 MEXICO MQ Cipsa Tel 800 421 1244 Fax 800 537 3927 Fax 310 537 4259 Fax 310 943 2238 MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537 3700 Fax 310 637 3284 Warranty Department 800 421 1244 Fax 310 943 2249 310 537 3700 UNITED KINGDOM Multiquip UK Limited Head Office Carr Fed Mexico Puebla KM 126 5 Momoxpan Cholula Puebla 72760 Mexico Contact pmastretta O cipsa com mx Tel 52 222 225 9900 Fax 52 222 285 0420 Tel 0161 339 2223 Fax 0161 339 3226 Unit 2 Northpoint Industrial Estate Globe Lane Dukinfield Cheshire SK16 4UJ Contact sales multiquip co uk CANADA Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin multiquip com Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 COPYRIGHT 2011 MULTIQUIP INC Multiquip Inc the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc and may not be used reproduced
51. POWER DCA25USI S N 8011111 TO 8100219 28 M1561000004 DECAL MQ POWER DCA25USI S N 8100220 28 M1561000004 DECAL MQ POWER DCA25USI2 2 29 M1562100004 STRIPE 2 30 M1562100103 STRIPE WHISPERWATT 2 31 M1562100204 STRIPE 25 1 32 M1562100304 STRIPE 25 1 33 M1562100404 STRIPE 2 34 M9510100304 DECAL ENVIR WARNING pem M91010030 35 0600500092 PLATE MQ POWER 1 36 0021106016 MACHINE SCREW 4 37 M1550001404 DECAL CAUTION 1 38 M9520000804 DECAL AC DCA25USIXF M92000080 5 8101596 38 M9520000804 DECAL DCA25USI2XF 1 39 M9510000104 DECAL DOCUMENT BOX DCA25USI2XF pm M91000010 40 M1550001404 DECAL CAUTION DCA25USI2XF 15000120 41 M9521000004 DECAL TERMINAL DCA25USI2XF 1 42 M9504200004 DECAL WARNING START FIRES DCA25USI2XF 1 M90420000 S N 8103260 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 95 TERMS AND CONDITIONS OF SALE PARTS PAYMENT TERMS Terms of payment for parts are net 10 days FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added tothe invoice All shipments are F O B point of origin Multiquip s responsibility ceases when a signed manifest has been obtained from the carrier andany claim for shortage or damage must be
52. R FLAT COVER FAN HEX HEAD BOLT WASHER FLAT NUT RUBBER SUSPENSION HEX NUT QTY _ je 1 1 1 1 2 1 1 4 4 1 1 6 6 6 1 1 1 1 2 3 1 6 1 1 3 6 6 6 1 1 1 1 2 2 GENERATOR ASSY REMARKS INCLUDES ITEMS W EE PURCHASE ITEMS 1 10 AS A SET DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 53 DCA25USIXF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSIXF ONLY S N 810000 8101735 S N 8101736 AND ABOVE PAGE 54 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USIXF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSIXF ONLY NO PARTNO PART NAME QTY REMARKS 1 M1215000612 CONTROL BOX 1 2 0601808820 CIRCUIT BREAKER 3P 60A 1 3 0021005080 MACHINE SCREW 4 4 0601823240 RECTIFIER 2 5 0021004040 MACHINE SCREW 1 5A 0040004000 WASHER LOCK 1 5B 0041204000 WASHER FLAT 1 6 0601842384 RESISTOR 20W 50 OHM 1 7 0027104010 MACHINE SCREW 2 8 0601815759 TERMINAL BOARD 1 8A M9521000004 DECAL TERMINAL SYMBOL 1 9 0027104020 MACHINE SCREW 4 10 0601823863 RELAY UNIT 2 11 0027104016 MACHINE SCREW 4 12 0601820671 AUTOMATIC VOLTAGE REGULATOR 1 13 0027105016 MACHINE SCREW 4 14 0601806115 CURRENT TRANSFORMER 50 5A 3 15 0027106016 MACHINE SCREW 6 16 0601820845 OVER CURRENT S N 8100001 8100586 16 0601820847 OVER CURRENT RELAY EEE SIN 8100587 AND
53. R SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER RUBBER SEALS ASSY QTY REMARKS 3 2 1 3 3 1 1 1 1 TE 1 DCA25USI 1 DCA25USI2 1 1 2 2 2 1 1 1 DCA25USU EE 1 DCA25USI2 2 2 NAMEPLATE AND DECALS ASSY NAME PLATE ASSY PAGE 94 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 NAMEPLATE AND DECALS ASSY NAME PLATE ASSY NO PARTNO PART NAME QTY REMARKS 1 M1512400002 DECAL GENERATOR CONTROL DCAUSIXF 1 M11240000A 1 M1510300902 DECAL GENERATOR CONTROL DCAUSI2XF 1 M11030090 2 M1512400122 DECAL ENGINE OPERATING DCAUSIXF 2n M11240012 2 M1510301002 DECAL ENGINE OPERATING DCAUSI2XF rm M15000010 3 M1550000104 DECAL NOTE 6010010102166 jp M15000010 4 M1550000204 a ua usa boo nandi 4 x y M15000020 5 M1552000603 DECAL AUXILLARY QUTPUT M15200060 6 M9500000004 DECAL OIL DRAIN PLUG e M90000000 7 M9500100004 DECAL WATER Ip M90010000 8 M9500300004 DEL AE ip M90030000 9 M9500300104 DECAL 9003
54. RY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 WASHER LOCK 2 6 M1348400204 BATTERY CABLE 1 7 M1348400314 BATTERY CABLE 1 8 0016910020 HEX HEAD BOLT 1 8A 0040510000 TOOTHED WASHER 1 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 73 DCA25USIXF MUFFLER ASSY MUFFLER ASSY DCA 25USIXF ONLY PAGE 74 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USIXF MUFFLER ASSY MUFFLER ASSY DCA 25USIXF ONLY NO PARTNO PART NAME QTY REMARKS 1 M1332000002 MUFFLER S N 810000 8101465 1 M1332000012 MUFFLER E T SIN 8101466 AND ABOVE 2 0016908020 HEX HEAD BOLT 7 3 M1335000103 EXHAUST PIPE Gunnar SIN 810000 8101465 3 M1335000113 EXHAUST PIPE uu unas Nos S N 8101466 AND ABOVE 4 8970420280 GASKET tute pem REPLACES S N 0602320100 5 M0335200004 GASKET asqa Liane S N 810000 8101465 5 8970420280 GASK T SIN 8101466 AND ABOVE EE REPLAGES S N 0602320100 6 0207008000 HEX NUT 4 7 0016908030 HEX HEAD BOL EE S N 810000 8101465 F 0016908030 HEX HEAD BOLT SIN 8101466 AND ABOVE DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 75 DCA25USI2XF MUFFLER ASSY MUFFLER ASSY DCA 25
55. TER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL INDICATE COLOR OF UNIT 1 ORANGE x K 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO SOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 84 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USIXF ECLOSURE ASSY ENCLOSURE ASSY DCA25USIXF ONLY NO PARTNO 51 M9113000002 51A C9312500004 52 0021806016 52A 0030006000 53 M9112100404 54 M9112100504 55 M9112100604 56 0016908020 af 0016908020 60 M1435000903 61 M1435000803 62 0016908020 63 M1435000703 63A 1498200004 64 0016908020 67 0016908020 67A 0040508000 68 0605503066 69 M1414800204 70 0017108020 7i M1423202103 72 0016906016 PART NAME DOOR HANDLE ASSY SEAL RUBBER MACHINE SCREW HEX NUT HINGE HINGE HINGE HEX HEAD BOLT HEX HEAD BOLT BRACKET STAY BRACKET STAY HEX HEAD BOLT SUPPORT LEG ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLT TOOTHED WASHER FUEL LEAK DETECTED SWITCH BRACKET HEX HEAD BOLT FRONTLOUVER u u HEAD BOLT QTY REMARKS 2 2 8 8 4 4 8 32 2 1 1 4 1 1 4 1 1 1 1 2 S N 8101466 AND ABOVE S N 8101466 AND ABOVE DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 85 DCA25USI2XF ECLOSURE ASSY ENCLOSURE ASSY DCA25USI2XF ONLY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
56. USI2XF ONLY PAGE 76 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USI2XF MUFFLER ASSY MUFFLER ASSY DCA 25USI2XF ONLY NO PARTNO PART NAME QTY REMARKS 1 M1332000512 MUFFLER 1 2 M1333200304 GASKET 1 3 0016908035 HEX HEAD BOLT 6 4 M1333300204 STAY 1 5 0016908020 HEX HEAD BOLT 6 6 M1333003013 EXHAUST PIPE 1 6 1 M1490003604 HEAT INSULATOR1 7 8970420280 GASKET T REPLACES P N 0602320100 8 M1333200214 GASKET 1 9 0207008000 HEX NUT 4 10 0016908035 HEX HEAD BOLT 4 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 77 FUEL TANK ASSY FUEL TANK ASSY PAGE 78 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 FUEL TANK ASSY FUEL TANK ASSY NO PART NAME QTY REMARKS 1 M1363001302 FUELTANK 2 0605505072 FUEL TANK CAP 3 0605501098 FUEL SENDER UNIT 4 0605516090 GASKET 5 0027104016 MACHINE SCREW 6 M1363300314 TANK SUPPORT 7 0016908035 HEX HEAD BOLT 8 0602022791 HOSE JOINT 9 0191301200 VENT HOSE 10 0605515109 HOSE BAND 11 8943672922 FUEL FILTER a ua REPLACES P N 0602042202 8943692993 12 M1368700004 13 0016908020 14 8970398340 14A 8944370220 15 0016906025 CARTRIDGE FUEL FILTER BRACKET FUEL FILTER HEX HEAD BOLT PUEL PUMP u aaa aasan sisaqa run FUEL
57. UVWO output terminals from overload 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 AC Voltmeter Indicates the output voltage present at the UVWO terminals AC Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch GENERATOR CONTROL PANEL Located behind the generator control panel is the Generator Control Box This box contains some of the necessary electronic components required to make the genertator function The Control Box is equipped with the following major components Over Current Relay Voltage Rectifer Starter Relay Three Pole Circuit Breaker Current Transformer Voltage Selector Switch NOTICE Remember the overcurrent relay monitors the current flowing from the UWVO output terminals to the load In the event of a short circuit or over current condition it will automatically trip the main 60 amp breaker To restore power to the UWVO output terminals press the reset button on the overcurrent relay and place the main circuit breaker in the closed position ON DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 19 Figure 7 Engine Operating Panel 3 ENGINE OPERATING PANEL C 9 The definitions below describe the controls and
58. VER use damaged or worn cables or cords when connecting equipment to generator Inspect for cuts in the insulation m NEVER grab or touch a live power HANDS ji cord or cable with wet hands The possibility exists of electrical shock SM electrocution or death rower POWER ON SAFETY INFORMATION Make sure power cables are securely connected to the generator s output receptacles Incorrect connections may cause electrical shock and damage to the generator NOTICE ALWAYS make certain that proper power or extension cord has been selected for the job See Cable Selection Chart in this manual Grounding Safety ALWAYS make sure that electrical circuits are properly grounded to a suitable earth ground ground rod per the National Electrical Code NEC and local codes before operating generator Severe injury or death by electrocution can result from operating an ungrounded generator m NEVER use gas piping as an electrical ground DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 9 BATTERY SAFETY DANGER m DO NOT drop the battery There is a possibility that the battery will explode DO NOT expose the battery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come into contact with a flame or spark an explosion could occur m ALWAYS wear safety glasses when handling the batt
59. WHEN ORDERING ANY PAINTED PANEL INDICATE COLOR OF UNIT 1 ORANGE K 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 86 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DCA25USI2XF ECLOSURE ASSY ENCLOSURE ASSY DCA25USIXF ONLY NO PARTNO 1 M1413003902 1A M1493000704 2 M1413100003 3 0603306797 4 0016910030 5 M1424000502 5 M1413600004 6 0016908020 T M1423002402 7A M1493108303 8 0601850151 9 M1423202602 9A M1493108003 10 0601851740 11 0601850239 12 0016908020 13 0016906020 14 0016908020 15 M1423202704 16 0016906020 17 M1423202704 18 0016906020 19 M1424200803 20 0016906020 21 M1423202003 22 M1423202103 23 0016906016 24 0019208020 25 M1433001403 26 M1433400003 27 0013612030 27A 0040012000 278 0041212000 28 0013612030 28A 0040012000 28B 0041212000 29 M1443001502 29A M1493304004 29B 1493305304 30 M1453301703 30A 1493305304 308 1493305404 30C 1493305504 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 87 PART NAME BASE ACOUSTIC SHEET ENVIRONMENTAL TANK PLUG 1 1 2 HEX HEAD BOLT FRONT FRAME DUCT HEX HEAD BOLT FRONT FRAME ACOUSTIC SHEET GROMMET FRONT DUCT ACOUSTIC SHEET GROMMET GROMMET HEX HEAD BOLT HEX HEAD BOLT HEX HEAD BOLT DUCT COVER HEX HEAD BOLT DUCT COVER HEX HEAD BOLT HOSE COVER HEX HEAD BOLT COVER FROM
60. YELLOW v VIOLET 0 ORANGE P PINK RUN JOTO START OTOT T OTOTO Figure 59A Engine Wiring Diagram DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 43 ENGINE WIRING DIAGRAM PREHEAT LAMP f TERMINAL BOARD TO CONTROL CONNECTER JE TACHO I G METER G PRESS GAUGE s G G BIL PRESS UNIT PICKUP c Ale og T FUEL FUEL PUMP pua 2 0 4D FUSECSA 7 69 TERMINAL BOARD G J CHARGING AMMETER PANEL LIGHT oO PANEL LIGHT SWITCH WIRE SIZE fam CONTINUED FROM PREVIOUS PAGE CONNECTOR VIEW FROM INSERTING WIRE SIDE OFF KEY CONNECTION DIAGRAM UN e B Br R1 R2 OFF start ms OFOT Q sTaRT OTOT FO O TO v VIOLET 0 ORANGE PINK l Figure 59B Engine Wiring Diagram Continued PAGE 44 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 GENERATOR WIRING DIAGRAM U 1088 UT Y ATEQ aspa DT L T TE 4 5 l J U TO v CNI3 CN7 BF CNI4 CNIS I GR gt m Y VR v WIRING VIEW Notice 2 4 1 2 es 1 No designation lead size 1 25 CH J mus SYMB
61. ator DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 7 FUEL SAFETY DO NOT start the engine near spilled fuel or combustible fluids Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited m ALWAYS refuel in a well ventilated area away from sparks and open flames m ALWAYS use extreme caution when working with flammable liquids m DO NOT fill the fuel tank while the engine is running or hot m DO NOT overfill tank since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system Store fuel in appropriate containers in well ventilated areas and away from sparks and flames NEVER use fuel as a cleaning agent B DO NOT smoke around or near the equipment Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine TOWING SAFETY m Check with your local county or state safety towing regulations in addition to meeting O Department of Transportation DOT Safety Towing Regulations before towing your generator E Refer to MQ Power trailer manual for additional safety information order to reduce the possibility of an accident while transporting the generator on public roads ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition ALWAYS shutdown engine before transpor
62. attery with an external electric source be sure to disconnect the battery cables Battery Cable Installation ALWAYS be sure the battery cables Figure 37 are properly connected to the battery terminals as shown below The Red Cable is connected to the positive terminal of the battery and the Black Cable is connected to the negative terminal of the battery AX CAUTION BATTERY SERVICING SAFETY ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE BATTERY Figure 37 Battery Connections SETUP When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the ignition switch is in either the Pre Heat RUN or START position ALWAYS make sure that the ignition switch is in the STOP position when connecting the battery 2 Place a small amount of battery terminal treatment compound around both battery terminals This will ensure a good connection and will help prevent corrosion around the battery terminals NOTICE Ifthe battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polarity of the battery when connecting the battery Inadequate battery connections may cause poor starting of the generator and create other malfunctions Alternator The polarity of the alternator is negative grounding type When an inverted circuit connection takes place the circui
63. be remedied consult our company s business office or service plant TABLE 20 GENERATOR TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION No Voltage Output AG Voltmeter defective Check output voltage using a voltmeter 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 17 3 ohms across J amp K on CN1 Low Voltage Output Is engine speed correct Turn engine throttle lever to High Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary High Voltage Output Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary Circuit Breaker Tripped Short Circuit in load Check load and repair Over current Confirm load requirements and reduce Defective circuit breaker Check and replace Over current Relay actuated Confirm load requirement and replace PAGE 48 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 NOTES DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 49 EXPLANATION OF CODE IN REMARKS COLUMN The following section explains the different symbols and rema
64. d personel who have read and understand this section should refill the fuel tank system Figure 30 Engine Oil Dipstick When checking the engine oil be sure to check if the oil is Clean If the oil is not clean drain the oil by removing the oil drain plug and refill with 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 Service Classification CH 4 API Service Classification CG 4 API Service Classification CF 4 ACEA Specification E3 ACEA Specification E2 OIL SAE 122 50 104 40 86 30 gt 68 201 169 s 50 10 5 2 2 og 22 A This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank Figure 31 ALWAYS fill the fuel tanks with clean fresh 2 diesel fuel DO NOT fill the fuel tanks beyond their capacities Pay attention to the fuel tank capacity when replenishing fuel The fuel tank cap must be closed tightly after filling Handle fuel a safety container If the container does not have a spout use a funnel Wipe up any spilled fuel immediately Generator Internal Fuel Tank Figure 31 Internal Fuel Tank System DCA25USIXF DCA25USI2XF OPERATION
65. e may cause pieces of the rim to explode break off with great force and 77 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 16 Tire Wear Troubleshooting will help pinpoint the Causes and solutions of tire wear problems TABLE 16 TIRE WEAR TROUBLESHOOTING SOLUTION Adjust pressure to particular load per tire manufacturer Adjust pressure to particular load per tire manufacturer Make sure load does not exceed axle rating Align wheels WEAR PATTERN CAUSE Center Wear Over Inflation Edge Wear Under Inflation Loss of camber Side Wear or overloading Toe Wear Incorrect toe in Align wheels Check bearing adjustment Out of balance and balance tires Cupping Wheel lockup amp tire skidding Avoid sudden stops when possible and adjust brakes Flat Spots Suspension The leaf suspension springs and associated components Figure 56 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 17 SHACKLE SUPPORT BRACKET IS WELDED TO
66. ery to avoid eye irritation The battery 2 contains acids that can cause injury to the eyes and skin E Use well insulated gloves when picking up the battery m ALWAYS keep the battery charged If the battery is not charged combustible gas will build up m ALWAYS recharge the battery in a well ventilated environment to avoid the risk of a dangerous concentration of combustible gasses W l the battery liquid dilute sulfuric acid comes into contact with clothing or skin rinse skin or clothing immediately with plenty of water W l the battery liquid dilute sulfuric acid comes into contact with eyes rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention m ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator m ALWAYS keep battery cables in good working condition Repair or replace all worn cables SAFETY INFORMATION ENVIRONMENTAL SAFETY NOTICE B Dispose of hazardous waste properly QY Examples of potentially hazardous waste 3 are used motor oil fuel and fuel filters m DO NOT use food or plastic containers to dispose of hazardous waste DO NOT pour waste oil or fuel directly onto the ground down a drain or into any water source PAGE 10 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 SPECIFICATIONS Table 1 Generator Specifications DCA 25USIXF DCA 25USI2XF Type Rev
67. es that would associate with a loose cover or hardware Check the electric motor fan cooling the radiator for abnormal speed sound or vibration conditions If any of the above mentioned conditions exists shut down the engine and correct the problem before operating the generator The generator s frequency meter Figure 44 displays the 60 cycle output frequency in HERTZ Figure 44 Frequency Meter Hz STARTUP The generator s AC voltmeter Figure 45 displays the output voltage in VOLTS If the voltage is not within the specified frequency tolerance use the voltage adjustment control knob Figure 46 to increase or decrease the desired voltage Figure 45 AC Voltmeter DECREASE INCREASE Figure 46 Voltage Adjust Control Knob The ammeter Figure 47 will indicate zero amps with no load applied When a load is applied this meter will indicate the amount of current that the load is drawing from the generator Figure 47 Ammeter No Load PAGE 34 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 STARTUP 8 The engine oil pressure gauge Figure 48 will indicate 11 Turn the main GFCI and aux circuit breakers to the the oil pressure of the engine Under normal operating ON position Figure 51 conditions the oil pressure is approximately 28 71 psi 193 490 kPa MAIN CS 6369 GFCI CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKERS BREAKERS B Figure 51 Main AUX
68. es without sufficient load less than 40 of the rated output it will not operate at its optimum temperature This will allow unburned fuel to accumulate in the exhaust system which can foul the fuel injectors engine valves and exhaust system including turbochargers and reduce the operating performance In order for a diesel engine to operate at peak efficiency it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel Wet stacking does not usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition It can reduce the system performance and increase maintenance Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition This can take several hours to burn off the accumulated unburned fuel m State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters must be used on internal combustion engines that use hydrocarbon fuels A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administr
69. functions of the Engine Operating Panel Figure 7 1 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 Water Temperature Lamp Indicates that the water temperature is outside of normal range and will shut down the engine Oil Pressure Lamp Indicates that the oil pressure is too low or high and will shut down the engine Fuel Filter Water Level Alarm Lamp This lamp turns on when the water level in the fuel filter rises too high Drain the water in the fuel filter strainer to correct the problem Oil Pressure Gauge Normal operation should be approximately 28 71 psi 193 490 kPa 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 Water Temperature Gauge During normal operation this gauge should read between 165 203 F 74 95 C 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 Fuel Gauge Indicates amount of diesel fuel available 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
70. hile and check for leaks before adding more oil if needed Clean excessive oil from engine Replacing Fuel Filter the fuel filter cartridge with new one every 400 hours or so Loosen the drain plug at the lower top of the fuel filter Drain the fuel in the fuel body together with the mixed water DO NOT spill the fuel during disassembly Vent any air Feed Pump Strainer Cleaning The strainer is incorporated in the feed pump inlet side joint bolt Clean the strainer with compressed air and rinse it in the fuel oil MAINTENANCE Flushing Out Radiator and Replacing Coolant Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant Open the radiator cap while draining Remove the overflow tank and drain Check hoses for softening and kinks Check clamps for signs of leakage 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 screwdriver Tighten both cocks and replace the overflow tank with coolant Table 12 for correct mixture Close radiator cap tightly Allow engine to cool when flushing out radiator Flushing the radiator while hot could cause serious burns from water or steam Generator Storage For longe term storage of the generator the following is recommended Fil the fuel tank completely Treat
71. i nals or the 2 twist lock auxiliary receptacles Tables 9 and 10 show what amount of current is available at the GFCI receptacles when the output terminals and twist lock receptacles are in use Be careful that your load does not to exceed the available current capability at the recep tacles Rated Voltage Single Phase 120 Volt Single Phase 240 Volt Three Phase 240 Volt Three Phase 480 Volt Table 9 GFCI Receptacle Load Capability 1 KW in Use Available Load Twist Lock CS6369 Current Amps 108 15 amps per receptacle oe 20 amps per receptacle Table 10 GFCI Receptacle Load Capability 30 KVA in Use UVWO Terminals 3 240 480V Available Load Current Amps GFCI Duplex NEMA 5 20R 120V 5 amps per receptacle 10 amps per receptacle 15 amps per receptacle 20 amps per receptacle DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 25 GAUGE READING TERMINAL PANEL CONNECTIONS The gauges and selector switches on the control panel DO NOT effect the generator output They are provided to help observe how much power is being supplied at the Output terminals lugs Before taking a reading from either gauge set the Voltage Selector Switch Figure 16 to the position which produces the required voltage For example for 3 240V choose the center 3 240 139V position on the voltage selector switch 3 PHASE 240 139 3 PHAS
72. ide higher excitation to the exciter section and thus better voltage response during the application of 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 fixed ceiling and responds according the demands of the required load Engine These generators are powered by two different types of diesel engines depending on the model of the generator Both engines are 4 cycle water cooled direct injection types The DCA25USIXF incorporates an ISUZU AA 4LE2 diesel engine while the DCA25USI2XF incorporates an ISUZU BB 4LE2 diesel engine These engines are designed to meet every performance requirement for the generator Reference Table 2 for engine specifications In keeping with Multiquip s policy of constantly improving its products the specifications quoted herein are subject to change without prior notice The basic controls and indicators for the 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 5 The electronic governor option increases frequency variation to 0 25 Extension Cables When electric power is t
73. l and coolant leaks Use Table 14 as a general maintenance guideline Engine Side refer to the Engine Instruction Manual Air Cleaner Every 50 hours Remove air cleaner element and clean the heavy duty paper element with kerosene or foam element with liquid detergent and hot water Wrap foam element in a cloth and squeeze dry For heavy duty paper element wipe excess kerosene with towel Air Cleaner with Dust Indicator This indicator is attached to the air cleaner When the air cleaner element is clogged air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing After changing the air element press the dust indicator button to reset the indicator Service Daily If the engine is operating in very dusty or dry grass conditions a clogged air cleaner will result This can lead to loss of power excessive carbon buildup in the combustion chamber and high fuel consumption Change air cleaner more frequently if these conditions exists Fuel Addition Add diesel fuel the grade may vary according to season and locations Always pour through the mesh filter Removing Water from the Fuel Tank After prolonged use water and other impurities accumulate in the bottom of the tank Occasionally remove the drain cock and drain the contents During cold weather the more empty volume inside the tank the easier it is for water to condense This can be reduced by keeping the
74. ld be followed at all times when operating this equipment Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others SAFETY MESSAGES The four safety messages shown below will inform you about potential hazards that could injure you or others The 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 which if not avoided WILL result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in MINOR or MODERATE INJURY NOTICE Addresses practices not related to personal injury SAFETY INFORMATION Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages Safety Hazard Lethal exhaust gas hazards W Explosive fuel hazards ann Burn hazards Overspeed hazards Rotating parts hazards Pressurized fluid hazards Electric shock hazards DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 5 GENERAL SAFETY m NEVER operate this equipment without proper protective clothing
75. ltiquip reserves the right to quote and sell directto Governmentagencies andto Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 35 00 surcharge will be added to the invoice for special handling including bus shipments insuredparcel postorincases where Multiquip mustpersonally deliverthe parts tothe carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable here under for damagesin excess ofthe purchase price of the itemwith respectto which damages are claimed andinno event shall Multiquip be liable for loss of profit or good will or for any other special consequential or incidental damages LIMITATION OFWARRANTIES No warranties express orimplied are made in connection with the sale of parts ortrade acces sories nor as o any engine notmanufactured by Multiquip Such warranties made in connec tion with the sale of new complete units are made exclusively by a statement of warranty packaged with such units and Multiquip nei ther assumes not authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products Apartfrom such written statement of warranty there are no warranties express impliedor statutory which extend beyondthe description ofthe products on the face hereof PAGE 96 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 N
76. n be purchased in concentrate and mixed with 50 demineralized water pre diluted See the ISUZU Engine Owner s Manual for further details AX WARNING BURN HAZARDS If adding coolant antifreeze mix to the radiator DO NOT remove the radiator cap until the unit has completely cooled The 6 can cause severe burns Day to day addition of coolant is done from the recovery tank When adding coolant to the radiator DO NOT remove the radiator cap until the unit has completely cooled See Table 12 for engine radiator and recovery tank coolant capacities Make sure the coolant level in the recovery tank is always between the and the L markings Table 12 Coolant Capacity Engine and Radiator 1 70 gal 6 4 liters Operation Freezing Weather When operating in freezing weather be certain the proper amount of antifreeze Table 13 has been added Table 13 Anti Freeze Operating Temperatures Freezing Point Boiling Point Vol Anti Freeze NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 SETUP Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radiator fins with compressed air Cleaning inside the machine is dangerous so clean only with the engine turned off and the negative battery terminal disconnected Air Cleaner Periodic cleaning replacement is nece
77. n points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel 3 The output terminal lugs are protected by a plastic cover Remove this cover to gain access to the terminals Tighten terminal nuts securely to prevent load wires from slipping out 4 Close all engine enclosure doors Figure 39 CORRECT INCORRECT Figure 39 Engine Enclosure Doors STARTUP Start up Procedure 1 Place the voltage selector switch in the desired voltage position Figure 40 3 PHASE 240 139 PRESS TO LOCK Figure 40 Voltage Selector Switch 2 In warm weather conditions skip to step 3 Preheat the engine glow plugs by turning the ignition key Figure 41 to the RUN position When the preheat lamp Figure 42 illuminates proceed to step 3 STOP RUN START Figure 41 Ignition Switch Pre Heat Run Position Figure 42 Pre Heat Indicator Lamp DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 33 3 Turn the ignition key to the START position Figure 43 6 Once the engine starts release the ignition key and allow it to return to the RUN position Figure 41 If the engine fails to start after 10 seconds wait approximately 30 seconds and repeat steps 2 3 STOP RUN START Figure 43 Ignition Switch Start Position Let the engine idle for 3 5 minutes listen and check for any abnormal sounds or smells Check for fuel leaks and nois
78. ng against the wheel drum makes the wheel difficult to turn 6 Adjust rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag 7 Replace the adjusting hole cover and lower the trailer to the ground 8 Repeat steps 1 through 7 on the remaining brakes TRAILER MAINTENANCE Hydraulic Surge Brakes Hydraulic surge brakes Figure 53 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 blockage Anchor Post Hydraulic Wheel Retractor Springs Cylinder Actuating Pin Pl Hold Down Secondary Spring Shoe Primary Shoe Adjuster Spring Adjuster Assembly Figure 55 Hydraulic Brake Components Actuator Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder supplying hydraulic pressure to the trailer brakes Periodically check and test the surge actuator to make sure that it is functioning correctly Never use an undersize actuator Table 15 Hydraulic Brake Troubleshooting Symptom No Brakes Possible Cause Brake line broken o
79. ns 3 Turn the voltage regulator knob Figure 23 clockwise to the voltage regulator knob Figure 23 clockwise to increase voltage output turn counterclockwise to increase voltage output turn counterclockwise to decrease voltage output decrease voltage output PAGE 28 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 Circuit Breakers To protect the generator from an overload a 3 pole 60 amp main circuit breaker is provided to protect the UVW output terminals from overload In addition two single pole 20 amp circuit breakers are provided to protect the GFCI receptacles from overload Two 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine Lubrication Oil Fill the engine crankcase with lubricating oil through the filler hole but DO NOT overfill Make sure the generator is level and verify that the oil level is maintained between the two notches Figure 30 on the dipstick See Table 11 for proper selection of engine oil SETUP Fuel Check DANGER EXPLOSION FIRE HAZARDS Fuel spillage on a hot engine can cause a fire or explosion If fuel spillage occurs wipe up the spilled fuel completely to prevent fire hazards NEVER smoke around or near the Refilling the Fuel System A CAUTION REFUELING THE GENERATOR ONLY properly traine
80. nt All customers are welcome to order parts via Fax on Standard orders for all orders which include Domestic US Customers dial completa part numbers 1 800 6 PARTS 7 800 672 7877 Note Discounts Are Subject To Change Order via Phone Domestic US Dealers Call EBE 1 800 427 1244 p Non Dealer Customers Contact your local Multiquip Dealer for es parts call 800 427 1244 for help in locating dealer near you Parts Ordering information L When ordering parts please supply Dealer Account Number Specify Preferred Method of Shipment Dealer Name and Address UPS Fed v DHL Maas Shipping Address if different than billing address Priority One Truck Return Fax Number Ground i Next Day Applicable Model Number BI Second Third Day an Quantity Part Number and Description of Each Part NOTICE All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST WE ACCEPT ALL MAJOR CREDIT CARDS AVA PAGE 4 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 Do not operate or service the equipment before reading the entire manual Safety precautions shou
81. o be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to a minimum Use the cable selection chart Table as a guide for selecting proper extension cable size DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 17 COMPONENTS Table 4 Generator Major Components Output Terminal Assembly Fuel Tank A Figure 5 Major Components Battery Assembly Generator Control Panel Assembly Engine Operating Panel Assembly PAGE 18 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 Figure 6 Generator Control Panel The definitions below describe the controls and functions of the Generator Control Panel Figure 6 1 Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 1 Hz Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage 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 This switch does not effect the generator output in any fashion it is for current reading only Main Circuit Breaker This three pole 60 amp main breaker is provided to protect the
82. olving field self ventilated open protected type synchronous generator Armature Connection Zig Zag Standby Output Speed 1 800 rpm eme 1 Aux AC Power Single Phase 60 Hz Grus Table 2 Engine Specifications _ 4 Cycle water cooled direct injection 1 2 1 44 gal 5 47 L hr at full load 1 64 gal 6 23 L hr at full load 1 05 gal 3 99 L hr at 3 4 load 0 86 gal 3 28 L hr at 1 2 load Fuel Consumption 0 74 gal 2 81 Lyhr at 1 2 load 1 20 gal 4 57 L hr at 3 4 load 0 45 gal 1 70 L hr at 1 4 load 0 57 gal 2 17 L hr at 1 4 load 23 28 57 17 Battery 12V 53Ah X 1 2 200 Ibs 1 000 kg Dry 2 249 Ibs 1 020 Dry 2 973 Ibs 1 349 Wet 3 021 Ibs 1 370 Wet DCA25USIXF DCA25USI2XF DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 11 TOP VIEW Figure 1 Dimensions WHISPERWATT SIDE VIEW D 2480 in 630 mm 2090 in 530 mm TABLE 3 DIMENSIONS 2130 n 695 mm 8820 2180 mm Te 650 mm 5680 1446 mm 2264 575 mm 3110 190 mm DIMENSIONS Se PAGE 12 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 DECALS OPERATING PROCEDURES SAFETY INSTRUCTIONS vel Starting Manual Stoppin and fuel levels 1 Place the Generator Circuit B
83. or altered without written permission All other trademarks are the property of their respective owners and used with permission This manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Your Local Dealer is 2 MULTIQUIP
84. r 2 When grounding the generator Figure 4 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect the other end of the ground cable to earth ground 3 NEC article 250 52 c specifies that the earth ground rod should be buried a minimum of 8 ft into the ground NOTICE When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician NOTICE This generator has a permanent bonding conductor between the generator stator windings and the frame PAGE 16 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 FAMILIARIZATION Generator The MQ Power DCA 25USIXF DCA 25USI2XF Ultra Silent generators Figure 5 are 56 kW generators that are 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 Tachometer Water Temperature Gauge Alarm Lamp Oil Pressure Gauge Alarm Lamp Charging Ammeter Gauge Pre Heat Lamp Panel Light Panel Light Switch Ignition Preheat Switch Fuel Gauge Fuel Filter Water Level Alarm Lamp Fuel Leak Detected Alarm Lamp Generator Control Panel The Generator Control Panel is provided with the following Frequency Meter Hz AC Ammeter
85. r kinked Brake lining glazed Trailer overloaded Solution Repair or replace Reburnish or replace Correct weight Weak Brakes or Brakes Pull to One Side Locking Brakes Brake drums scored or grooved Tire pressure correct Tires unmatched on the same axle Brake components loose bent or broken Brake drums out of round Machine or replace Inflate all tires equally Match tires Replace components Replace Noisy Brakes Dragging Brakes System lubricated Brake components correct Brake lining thickness incorrect or not adjusted correctly Enough brake fluid or correct fluid Lubricate Replace and correct Install new shoes and linings Replace rubber parts fill with dot 4 fluid DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 39 TRAILER MAINTENANCE 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 AX CAUTION EYESIGHT HAZARD ALWAYS wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury AX CAUTION REPAIRING TRAILER WHEELS 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 tub
86. reakers in the OFF position 2 Sel d switch t W positi allow the position Improper operation of this machine can cause severe injury or death Read the instruction manual carefully before operating or servicing This machine should only be operated by a person with sufficient knowledge and skill to ensure safe operation Voltage change over lt Seine Engine speed stent Pos Auto Starting Stopping 5 Tum the Auto OffReset Manual switch to the Manual With the Auto Manual switch in the position the Auto position to start the engine If the engine fails to start in the ed ED 2 Specified number ot tempts RARE rent ee When the contacts are opened cranking vill stop orif Volet oi the engine will stop All funcitons fo the Automatic shutdown When the engine Is ready for starting during System work as in Manual Starting stopping 2 2 For cold weather conditions utilize the water heater until water butan for approximately 30 seconds Sext angin is warm If the engine still does not start please operate as In using the Auto OfiReset Manual switch to the Starting Manual phum As soon as the engine starts release the but Emergency Stopping angine oes not aba 1 Place the Generator Circuit Breakers In the OFF position 2 Turn the Auto OffiReset Manual switch to the Offi Reset position High
87. rks used in the Parts section of this manual Use the help numbers found on the back page of the manual if there are any questions NOTICE The contents and part numbers listed in the parts section are subject to change without notice Multiquip does not guarantee the availability of the parts listed SAMPLE PARTS LIST NO PARTNAME QTY REMARKS 1 12345 BOL 1 INCLUDES ITEMS W 2 WASHER 1 4 IN NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 3 12348 HOSE AR MAKE LOCALLY 4 12349 BEARING 1 S N 2345B AND ABOVE NO Column Unique Symbols All items with same unique symbol or gt in the number column belong to the same assembly or kit which is indicated by a note in the Remarks column Duplicate Item Numbers Duplicate numbers indicate multiple part numbers which are in effect for the same general item such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine 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 PART NO Column Numbers Used Part numbers can be indicated by a number a blank entry or TBD TBD To Be Determined is generally used to show a part that has not been assigned a formal part number at the time of publication A
88. rs inside engine compartment when engine is running E NEVER operate the engine with heat shields or guards removed i Keep fingers hands hair and clothing away from all moving parts to prevent injury m DO NOT remove the radiator whilethe engine is hot High pressure boiling water e will gush out of the radiator and severely Ay scald any persons in the general area of the generator DO NOT remove the coolant drain plug while the engine is hot Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator m DO NOT remove the engine oil drain plug while the engine is hot Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator m NEVER touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing equipment SAFETY INFORMATION NOTICE NEVER run engine without an air filter or with a dirty air filter Severe engine damage may occur Service air filter frequently to prevent engine malfunction m NEVER tamper with the factory settings QI of the engine or engine governor Damage to the engine or equipment can result 2 if operating in speed ranges above the W maximum allowable E Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied When a diesel engine operat
89. selector switch Figure 15 is located above the output terminal panel s Hard Wire Hook up Panel It has been provided for ease of voltage selection 3 PHASE 240 139 3 PHASE 1 PHASE 480 277 240 120 Figure 15 Voltage Selector Switch Voltage Selector Switch Locking Button The voltage selector switch has a locking button to protect the generator and load from being switched while the engine is running To lock the voltage selector switch press and hold the red button located at the bottom of the switch NEVER change the position of the voltage selector switch while the engine is running ALWAYS place circuit breaker in the open position before selecting voltage 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 15 To obtain some of the voltages as listed in Table 7 see below will require a fine adjustment using the voltage regulator VR control knob located on the control panel Table 7 Voltages Available Three Phase Switchable Single Phase Switchable Maximum Amps Table 8 shows the maximum amps the generator can pro vide DO NOT exceed the maximum amps as listed Table 8 Generator Maximum Amps g GFCI Receptacle Load Capability The load capability of the GFCI receptacles is directly re lated to the voltage being supplied at either the output term
90. ssary Inspect it in accordance with the ISUZU Engine Owner s Manual Fan Belt Tension A slack fan belt may contribute to overheating or to insufficient charging of the battery Inspect the fan belt for damage and wear and adjust it in accordance with the ISUZU Engine Owner s Manual The fan belt tension is proper if the fan belt bends 10 to 15 mm Figure 36 when depressed with the thumb as shown below Figure 36 Fan Belt Tension NEVER place hands near the belts or fan while the generator set is running v DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 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 Add only distilled water when replenishment is necessary DO NOT over fill Check to see whether the battery cables are loose Poor contact may result in poor starting or malfunctions Always keep the terminals firmly tightened Coating the terminals with an approved battery terminal treatment compound Replace battery with only recommended type battery The battery is sufficiently charged if the specific gravity of the battery fluid is 1 28 at 68 F If the specific gravity should fall to 1 245 or lower it indicates that the battery is dead and needs to be recharged or replaced Before charging the b
91. t gases from diesel engines are extremely poisonous Whenever an engine is installed indoors the exhaust fumes must be vented to the outside The engine should be installed at least two feet from any outside wall Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves Mounting The generator must be mounted on a solid foundation such as concrete and set firmly on the foundation to isolate 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 the bottom of the generator They are to resist damage to the bottom of the generator and to maintain alignment INSTALLATION Generator Grounding To guard against electrical shock and possible damage to the equipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical NEC articles 250 64 b and 250 66 set the following grounding requirements 1 Use one of the following wire types to connect the generator to earth ground a Copper 10 AWG 5 3 mm or larger b Aluminum 8 AWG 8 4 mm or large
92. t will be in short circuit instantaneously resulting the alternator failure DO NOT put water directly on the alternator Entry of water into the alternator can cause corrision and damage the alternator Wiring Inspect the entire generator for bad or worn electrical wiring or connections If any wiring or connections are exposed insulation missing replace wiring immediately Piping and Hose Connection Inspect all piping oil hose and fuel hose connections for wear and tightness Tighten all hose clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately PAGE 32 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 Before Starting A CAUTION LETHAL EXHAUST HAZARD The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel AX WARNING STARTINGTHE GENERATOR NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position 1 Place the main G F C I and aux circuit breakers Figure 38 in the OFF position priorto starting the engine MAIN CS 6369 GFCI CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKERS BREAKERS m Figure 38 Main Aux GFCI Circuit Breakers OFF 2 Connect the load to the receptacles or the Output Terminal Lugs as shown in Figure 11 These load connectio
93. tank full with diesel fuel DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 37 Air Removal If air enters the fuel injection system of a diesel engine starting becomes impossible After running out of fuel or after disassembling the fuel system bleed the system according to the following procedure 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 Cleaning the Fuel Strainer Clean the fuel strainer if it contains dust or water Remove dust or water in the strainer cap and wash it in gasoline Securely fasten the fuel strainer cap so that fuel will not leak Check the fuel strainer every 200 hours of operation or once a month 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 between the two notches on the dipstick as shown in Figure 30 Replacing Oil Filter e Detach the oil filter by loosening center bolt and remove the element together with the filter body e Apply a film of oil to the gasket for the cartridge Install the filter body together with the element and fix them by tightening the center bolt e After the oil cartridge has been replaced the engine oil will drop slightly Run the engine for a w
94. ting SAFETY INFORMATION Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating m ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc m Check the tire air pressure on both towing vehicle and trailer Trailer tires should be inflated to 50 psi cold Also check the tire tread wear on both vehicles m ALWAYS make sure the trailer is equipped with a safety chain ALWAYS properly attach trailers safety chains to towing vehicle ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly DOT Requirements include the following Connect and test electric brake operation Secure portable power cables in cable tray with tie wraps E The maximum speed for highway towing is 55 MPH unless posted otherwise Recommended off road towing is not to exceed 15 MPH or less depending on type of terrain Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing Avoid sharp turns to prevent rolling I Trailer should be adjusted to a level position at all times when towing E Raise and lock trailer wheel stand in up position when towing B Place chock blocks underneath wheel to prevent rolling while parked B Place support blocks underneath
95. ve a 3 208V output the voltage selector switch Figure 22 Output Terminal Lugs must be in the 3 240 139 position and the voltage 3 240 139V Connections regulator must be adjusted to 208V 3 the voltage regulator knob Figure 23 clockwise to increase voltage output turn counterclockwise to decrease voltage output DECREASE INCREASE Figure 23 Voltage Regulator Knob 139V 240V DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 27 OUTPUT TERMINAL PANEL CONNECTIONS 3 480 277 Output Terminal Lug Voltages 1 240V 120V Output Terminal Lug Voltages 1 Place the voltage selector switch in the 3 480 277 Place the voltage selector switch in the 1 240 120 position as shown in Figure 26 position as shown in Figure 28 3 PHASE 240 139 3 PHASE 1 PHASE 480 277 QB 3 PHASE 240 139 PRESS TO LOCK Figure 26 Voltage Selector Switch 480 277V Three Phase Position PRESS TO LOCK Figure 28 Voltage Selector Switch 240 120V Single Phase Position 2 Connect the load wires to the Output Terminal Lugsas 2 Connectthe load wires to the OutputTerminal Lugs as shown in Figure 27 shown in Figure 29 BLUE WHITE BLUE GREEN RED WHITE GREEN GROUND CONNECTIOR MUST BE USED AT ALL TIMES GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 27 Output Terminal Lugs Figure 29 Output Terminal Lugs 3 480 277V Connections 1 240 120V Connectio
96. voltage circuits are located inside the output terminal cover and control panel Close the cover and control panel before operating Moving parts and hot surfaces are contained within the enclosure M35200010 Close all doors and lock them before P N M3552000103 operating M9201 0030 P N M9520100304 OIL U W DRAIN PLUGY Qu Ow _ P N M950000004 OFF OFF P N M9520000104 P N M9520000204 OVER CURRENT RELAY If it is Impossible to reset the CIRCUIT BREAKER open the control panel and push the RESET BUTTON as below the ambient conditions warm up 9 After sufficient warm up time has elapsed set the Engine Hi is 10 Check the NO Load speed as shown table below Hz operation Approx 60 0Hz 181 1 Adjust the Voltage Regulator to the GE voltage P N M9500300104 P N M9510200002 DIESEL FUEL P N M9500300004 P N M9500500104 M90050000 PIN M9500500004 WATER OIL CHECK AND FILL DAILY M90300010 P N M9503000103 Figure 2 Generator Decals DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 PAGE 13 DECALS ELECTRIC SHOCK HAZARD ELECTRIC SHOCK HAZARD Before connecting this generator to any building s electrical system a licensed electrician must install Do not touch output Always complete the grounding an isolation transfer switch terminals when this path from the ground terminal machine is operating this genset to an external 2
97. with a fuel stabilizer if necessary Completely drain the oil from the crankcase and refill if necessary with fresh oil Clean the entire generator internal and external Cover the generating set and store in a clean dry place Disconnect the battery Make sure engine coolant is at proper level If generator is mounted on a trailer jack trailer up and place on block so tires do touch the ground or remove tires PAGE 38 DCA25USIXF DCA25USI2XF OPERATION AND PARTS MANUAL REV 2 07 26 11 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 every 3 000 miles driving over rough terrain inspect the brakes more frequently Figure 55 displays the major hydraulic surge brake components that will require inspection and maintenance Please inspect these components as required using steps 1 through 8 and Table 15 as listed below Brake Adjustment 1 Place the trailer on jack stands Make sure the jack stands are placed on secure level ground 2 Check the wheel and drum for free rotation 3 Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate 4 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes 5 Adjust the brake shoes outward until the pressure of the lini

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