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Multiquip DCA-25USI2XF Portable Generator User Manual

1. 21 Output Terminal Panel Familiarization 22 24 Load Applicatiof RE 25 Gauge Reading Terminal Panel Connections 26 27 Output Terminal Panel Connections 28 29 ei RE EE Generator Start up Procedure Generator Shut down Procedure Maintenance 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 COMPONENT DRAWIMGS Generator Assembly 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 250512 66 69 Output Terminal Assembly 70 71 Battery Assembly 72 73 Muffler Assembly DC
2. ef GROUND NG BUILDING gt GROUND GROUND CABLE 1 8 FT MINIMUM REFERENCE 250 83 0 77 Figure 4 Generator Grounding Application PAGE 16 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF INSTALLATION Outdoor Installation Install the generator in a area that is free of debris bystanders and overhead obstructions Make sure the generator is on secure level ground so that it cannot slide or shift 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 Exhaust gases from diesel engines are extremely poisonous Whenever an engine is installed indoors the exhaust fumes must be vented to the outside
3. T m m Figure 53 Main AUX GFCI Circuit Breakers OFF 3 Letthe engine cool by running it for 3 5 minutes with no load applied circuit breakers in the OFF position 4 Placethe ignition switch Figure 54 in the STOP position remove the 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 Checkthe engine oil coolant and fuel levels Replenish as necessary 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 AX CAUTION AUTOMATIC SHUT DOWN 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
4. DCA 25USIXF DCA 25USI2XF EXPLANATION OF CODE IN REMARKS The following section explains the different symbols and remarks used in the Parts section of this manual Use the help numbers found on the back page of the manual if there are any questions The contents and part numbers listed in the parts section are subject to change without notice Multiquip does not guarantee the availibility of the parts listed Sample Parts List NO PART NO PART NAME QTY REMARKS 1 12345 BOLT dicentes INCLUDES ITEMS W 2 WASHER 14 IN NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 3 12348 BOSE AR MAKE LOCALLY 4 12349 BEARING S N2345B 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 inthe Remarks column Duplicate Numbers Duplicate numbers indicate multiple part numbers 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 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 ge
5. JE M92020010 28 M1561000004 DECAL MQ POWER DCA25USI S N 8011111 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 91010030 35 0600500092 PLATE MQ POWER 1 36 0021106016 MACHINE SCREW 4 37 M1550001404 DECAL CAUTION 1 38 M9520000804 DECAL AC DCA25USIXF a M92000080 S N 8101596 38 M9520000804 DECAL AC DCA25USI2XF 1 39 M9510000104 DECAL DOCUMENT BOX DCA25USI2XF p M91000010 40 M1550001404 DECAL CAUTION DCA25USI2XF EEE M15000120 41 M9521000004 DECAL TERMINAL DCA25USI2XF 1 42 M9504200004 DECAL WARNING START FIRES DCA25USI2XF 1 M90420000 S N 8103260 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 95 Effective October 1 2002 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 addedto the invoice All shipments are F O B point of origin Multiquip s responsibility ceases when asigned manifest has been ob
6. pem S N 8101736 AND ABOVE 26 14 0228800060 RUBBER etes desees S N 8101736 AND ABOVE 26 24 0228800108 RUBBER SEAL aq S N 8101736 AND ABOVE 26 38 0317700180 RUBBER SEAL aaah S N 8101736 AND ABOVE 27 0016906016 HEX HEAD BOLT O asas S N 8100001 8101735 27 0016906016 HEX HEAD BOLT D S N 8101736 AND ABOVE DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 55 DCA 25USIXF CONTROL BOX ASSY CONTINUED CONTROL BOX ASSY DCAUSIXF ONLY S N 810000 8101735 S N 8101736 AND ABOVE PAGE 56 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF CONTROL BOX ASSY CONTINUED CONTROL BOX ASSY DCAUSIXF ONLY NO 28 28A 29 29 30 31 32 33 34 35 36 37 37 38 38A PART NO 0016906016 0040506000 M1225000323 M1225000333 0601808985 0601808985 0601801040 0601806859 0601801041 0601840073 0601840121 8970444180 8944024980 0602103092 0601810245 0602120095 0602122093 0602123090 0602121080 0602125090 0602103092 0601810245 9826800370 0601831330 M1225100004 0027105010 0027105010 M9220100004 0080200007 8973259120 0016906016 0207006000 5825500290 8942481610 0027105016 0602103092 0601810245 M1213600305 0027104016 0207004000 M1248700004 M1248700024 M1359200602 M1359200612 0601802160 PART NAME HEX HEAD
7. Obsolete parts If an item is in the price book 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 andother rubber parts that were pur chased morethan six months priorto thereturn date c Anylineitemwith an extended dealer netprice of less than 5 00 d Special order items Electrical components f Paint chemicals and lubricants 9 Decalsandpaper products h Items purchasedin 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 turnedto the sender at his expense 9 Creditonreturned parts will be issuedat dealer net price at time of the original purchase lessa 15 restocking charge 10 In cases where an item is accepted for which the original purchase document can not be determined the price will be based onthe list price that was effective twelve months prior to 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 all orders received on or afterthat date willbe billed atthe revised price Rebates forprice declines and added charges for price increases willnotbe made for
8. Possible Cause Solution Repair or replace Reburnish or replace Correct weight Weak Brakes or Brakes Pull to One Side Brake drums scored or grooved Tire pressure correct Tires unmatched on the same axle Brake components loose bent or broken Machine or replace Inflate all tires equally Match tires Replace components Locking Brakes Noisy Brakes Brake drums out of round System lubricated Brake components correct Brake lining thickness incorrect or not adjusted correctly Replace Lubricate Replace and correct Install new shoes and linings Dragging Brakes Enough brake fluid or correct fluid Replace rubber parts fill with dot 4 fluid PAGE 40 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF 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 CAUTION EYESIGHT HAZARD ALWAYS wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious 27 Injury 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 tu
9. 90030010 10 M9500500004 DECAL DIESEL FUEL DCA25USIXF I M90050000 10 M9500500304 DECAL DIESEL FUEL DCA25USI2XF M90050030 11 M9503000004 DECAL WARNING MOVING PARTS M90300000 12 M9503000103 DECAL WATER OIL NES M90300010 13 M9503100004 DECAL WARNING HOT COOLANT M90310000 14 M9503200004 DECAL WARNING ENGINE EXHAUST Jioc M90320000 15 M9510000004 DECAL FLUID DRAIN assu M91000000 16 M9510100004 DECAL CAUTION HOT peer M91010000 17 M9512200004 DECAL 91220000 18 M9520000004 DECAL GROUND Luise pes M92000000 19 M9520000104 DECAL AMMETER CHANGE OVER SW d seins M92000010 20 M9520000204 DECAL VOLTMETER CHANGE OVER SW 92000020 21 9520100004 DECAL WARNING ELECTRIC SHOCK HAZARD 2 M92010000 22 M9520100204 DECAL CAUTION U 92010020 23 9520100304 DECAL SAFETY prre M92010030 24 M9520100404 DECAL DANGER HIGH VOLTAGE 92010040 25 9520100503 DECAL WARININU 92010050 26 9520200003 DECAL CONNECTION OF OUTPUT 92020000 27 M9520200104 DECAL OVER CURRENT RELAY
10. 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 dustyor dry grass conditions a clogged air cleaner will result This can lead to a loss of power excessive carbon buildup in the combustion chamber and high fuel 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 tank full with diesel fuel PAGE 38 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA
11. 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 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 Engine does not start pipe retaining nut Tighten nut Incorrect injection timing Adjust Fuel cam shaft worn Replace Injection nozzle clogged Clean injection nozzle Injection pump malfunctioning Seizure of crankshaft camshaft piston cylinder liner or bearing Repair or replace 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 malfunctioning Repair or replace Starter does not run Wiring disconnected Connect wiring DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 47 DCA 25USIXF DCA 25USI2XF TROUBLESHOOTING ENGINE TABLE 19 ENGINE TROUBLESHOOTING CONTINUED SYMPTOM POSSIBLE PROBLEM SOLUTION Engine revolution is n
12. S N 8101736 AND ABOVE T S N 8101736 AND ABOVE S N 8101736 AND ABOVE S N 8100001 8101735 S N 8101736 AND ABOVE S N 8100001 8101465 S N 8101466 AND ABOVE DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 57 DCA 25USI2XF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSI2XF ONLY 24 Z PAGE 58 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USI2XF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSIXF ONLY NO PART NO M1213001002 0601808820 0021005080 0601842384 0027104010 0601823240 0027104030 0601815759 0027104020 0601823863 0027104016 0601820602 0027105016 0601801122 0027106020 0601820847 0601820848 0027104016 0207004000 M1213500203 0602202523 5825500290 8942481610 0027105016 M1213500403 0016906016 M1270100504 M1550002504 M1550002604 M1215601204 M1215600204 0021104035 0207004000 0027104016 0207004000 0016906016 M1213601704 0317700180 0016906016 M1213601604 0330000070 0016906016 0016906016 0040506000 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 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 MACHI
13. CHANGE OVER SWITCH AMMETER AC VOLTMETER 0 600V CHANGE OVER SWITCH AMMETER RHEOSTAT VR 2W 1K OHM KNOB ALARM LAMP BULB DC18V STARTER SWITCH gumman KEY IGNITION SWITCH PREHEAT LAMP BULB DC18V TACHOMETER OIL PRESSURE GAUGE WATER TEMPERATURE GAUGE CHARGING AMMETER FUEL GAUGE PANEL LIGHT SWITCH PANEL LIGHT ALARM LAMP BULB DC18V STOPPER MACHINE SCREW MACHINE SCREW SET SCREW SNAP RING GROMMET WIRE HARNESS GENERATOR TY REMARKS 1 REPLACES P N 0602100009 REPLACES P N 0601810141 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 61 DCA 25USIXF ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY DCAUSIXF ONLY 5 O 35 PAGE 62 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY DCAUSIXF ONLY PART NO B1925200254 8944567411 M1305200304 M1305200204 0010310025 0040010000 0041210000 060500066 0207010000 M1923200074 0602011079 M9312200104 0016908040 0207008000 M1312500203 M1312500303 0605515149 M1312300103 0016906020 0602046531 0602046611 0602040650 0602040552 0016908030 M1375100303 M1375100203 0605515147 0602022560 M1320300304 0602022561 0603306590 0603300285 0605511395 0603306395 0602021070 0269200380 PART NAME ENGINE ISUZU AA
14. 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 WASHER FLAT COVER FAN HEX HEAD BOLT WASHER FLAT NUT RUBBER SUSPENSION HEX NUT QTY T 1 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 REMARKS INCLUDES ITEMS W PURCHASE ITEMS 1 10 AS A SET DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 53 DCA 25USIXF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSIXF ONLY S N 810000 8101735 S N 8101736 AND ABOVE PAGE 54 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF CONTROL BOX ASSY CONTROL BOX ASSY DCAUSIXF ONLY NO PART 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 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 5 3 15 0027106016 M
15. 1 2 load 120 at 3 4 load L hr at 1 4 load 0 57 ga J hr at 1 4 load 2 200 Ibs 1 000 kg Dry 2 249 lbs 1 020 kg Dry 2 973 Ibs 1 349 kg Wet 3 021 Ibs 1 370 Wet DCA25USIXF DCA25USI2XF PROD Po 4 510900 r rrr DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 5 DCA 25USIXF DCA 25USI2XF DIMENSIONS TOP SIDE AND FRONT TOP VIEW Figure 1 Dimensions WHISPERWATT SIDE VIEW TABLE 3 DIMENSIONS cuase Reference Letter 77 mane 75 71773 gt sn PAGE 6 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF SAFETY MESSAGE ALERT SYMBOLS FOR YOUR SAFETY AND THE SAFETY OF OTHERS Safety precautions should 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 This Operation Manual has been developed to provide complete instructions for the safe and efficient operation of the generator Before using this generator ensure that the operatin individual has read and understands all instructions in this manual SAFETY MESSAGE ALERT SYMBOLS The three 3 Safety Messages shown below will inform you about potential hazards that could injure you or others The
16. 25USIXF DCA 25USI2XF MAINTENANCE 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 Detachthe 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 e 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 while and check for leaks before adding more oil if needed Clean excessive oil
17. All funcitons fo the Automatic shutdown person with sufficient knowledge and skill Manual ne As soon as the engine starts Close the cover and control panel before 11 Adjust the Voltage Regulator to the E voltage Close all doors and lock them before P N M3552000103 operating M92010030 P N M9520100304 OIL U UW DRAIN PLUGY Qu P N M950000004 OFF OFF P N M9520000104 P N M9520000204 OVER CURRENT RELAY If itis Impossible to reset the CIRCUIT BREAKER open the control panel and push the RESET BUTTON as below Ua 08 TE 6 OID 9 POWER 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 PAGE 14 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF DECALS ELECTRIC SHOCK HAZARD ELECTRIC SHOCK HAZARD Before connecting this generator to any building s lectrical system a licensed electrician must install Do not touch output e Always complete the grounding EI 5 terminals when this path from the ground terminal an enden sien chine is op on this genset t exti 3 5 machine Serious death may result without this e Turn power off before manual for details transfer switch servicing M9520100503 P
18. CX TO v aan CN7 FUSE SA M Das O CIM fou EE 1 l MLECZ Kovevi 4 WIRING VIEW 12 3 12 3 Notice J A 1 No designation lead size 1 25 NIS lara d ES SYMBOL DESIGNATION CON12 CON3 4 SW RY1 2 FUSE RECEPTACLE 250V 50 RECEPTACLE 125V 20AX2 OVER CURRENT RELAY SELECTOR SWITCH RELAY UNIT RELAY RECTIFIER FAN MOTOR S AMPS TERMINAL BLACK R TRED Y GRAY VIOLET PINK LT D 2 1 1234 CN2 10 513 E 13 3 Re RECFER SCS 1 2 AR CN3 CN11 TG og CHANGE OVER SWITCH AMMETER 12 CN4 CN8 CN12 Mp CIRCUIT BREAKER 1 20A CONS oc su RY12 FUSE Figure 60 Generator Wiring Diagram PAGE 46 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF TROUBLESHOOTING ENGINE 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 be remedied consult our company s business office or service plant TABLE 19 ENGINE TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION
19. DO NOT touch these areas while the engine is running or immediately after operations NEVER operate the engine with heat shields or heat guards removed AX DANGER ELECTROCUTION HAZARDS During operation of this generator there exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even DEATH DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 7 DCA 25USIXF DCA 25USI2XF SAFETY MESSAGE SYMBOLS WARNING ROTATING PARTS WM NEVER operate equipment with covers A or guards removed Keep fingers hands hair and clothing away from all moving parts to prevent injury AX CAUTION ACCIDENTAL STARTING OFF ALWAYS place the Engine ON OFF switch in the OFF position and remove the ignition key when the pump is not in use AX CAUTION OVER SPEED CONDITIONS NEVER tamper with the factory settings of the engine governor or settings Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable This generator other property or the surrounding environment could be damaged if you do not follow instructions AX CAUTION RESPIRATORY HAZARDS ALWAYS wear approved respiratory protection AX CAUTION SIGHT AND HEARING HAZARDS ALWAYS wear approved eye and 2 hearing protection AX CAUTION EQUIPMENT DAMAGE MESSAGES Other important me
20. 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 Engine protection is furnished during operation but cannot replace normal preventive maintenance Regularly maintain the unit as specified in the Maintenance section of this manual to prevent damage DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 37 DCA 25USIXF DCA 25USI2XF MAINTENANCE 10 Hrs TABLE 14 INSPECTION MAINTENANCE Drain Bottom of Fuel Tank 250 Hrs 500 Hrs 1000 Hrs ENGINE Check Fuel Filter Water Seperator Bowl Clean Unit Inside and Outside Check Blowby Hose 21 11 17 1 Replace engine oil anf filter at 100 hours first time only GENERATOR 2 If blowby hose needs to be replaced ensure that the slope of the blowby hose is at least a 1 2 inch per foot with no sags or dips that could collect moisture and or oil 8 Replace primary air filter element when restriction indicator shows a 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 oil and coolant leaks Use Table 14 as a general maintenance guideline Engine Side referto the Engine Instruction Manual
21. SAFE OPERATION ALWAYS be sure the operator is familiar with proper safety precautions and operation techniques before using generators NEVER leave the generator unattended turn off engine when unattended Unauthorized equipment modifications will void all warranties ALWAYS ensure generator 15 on level ground before use Mi DO NOT place hands or fingers inside generators engine compartment when engine is running NEVER run engine without air cleaner Severe engine damage may occur NEVER change or adjust the engine speed which has been setat the factory prior to shipping Power Cord Safety E NEVER let power cables or cords lay in water NEVER stand in water while AC power from the generators is being transfer to a load NEVER use a defective or frayed power cable Check the cable for cuts in the insulation NEVER use extension cord that is frayed or damaged where the insulation has been cut ALWAYS make certain that proper power or extension cord has been selected for the job See Table 6 Grounding Safety ALWAYS make sure that electrical circuits are properly grounded 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 ALWAYS make sure the generators are properly grounded to asuitable earth ground GROUND ROD See installation in this manual NEVER us
22. al Generator cr gt ente Improper operation of this machine can cause te present at Dus e Severe injury or death Opp Read the instruction manual carefully SAFETY INSTRUCTIONS ek for abnormal noise prol D DD ee FER Gre TR Sepals to ensure safe operation sit don rot or heat 1 Place the Generator Circuit Breakers in the OFF position High voltage circuits are located inside the QUE operating Ue Moving parts and hot surfaces are contained 6 Turn the Auto OffiReset Manuel switch to the Manuel 1 pe the Auto 5 S PS eeo Closure of the remote start contacts will begin engine cranking before operating or servicing and the Auto OffiReset Manual switch must be returned to When the contacts are opened cranking stop or IF running This machine should only ba operated by a Fulton for spproximetely 19 seconds CADO Is warm If the engine stil does not start please operate as In using the Auto OfiReset Manual switch to the Manual Starting mor heater supplleda 2 Turn the Auto OffiReset Manual switch to the Off Reset tput terminal d confrol ow SER output terminal cover and control panel reac ati 10 Check the NO Load speed as shown table below within the enclosure 60Hz operation Approx 60 0Hz 1800rpm position before precoding the engine will stop
23. charging the battery 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 CAUTION BATTERY SERVICING SAFETY ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE BATTERY Figure 37 Battery Connections 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 If the battery cable is connected incorrecily electrical damage to the generator will occur Pay close attention to the polarity of the battery when connecting the battery CAUTION BATTERY SERVICING SAFETY 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 inv
24. 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 39 DCA 25USIXF DCA 25USI2XF TRAILER MAINTENANCE Brakes Trailer brakes should be inspected the first 200 miles of operation This will allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes 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 Check the wheel and drum for free rotation Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate 4 Witha 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 lining agains
25. 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 B 2 2 a Figure 51 Main AUX and GFCI 9 Thecoolanttemperature gauge Figure 49 will indicate the Circuit Breakers ON coolant temperature Under normal operating conditions the coolant temperature is between 165 203 F 74 95 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 will run until manually stopped or an RPM s abnormal condition occurs TACH HOURS T Figure 50 Engine Tachometer PAGE 36 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF GENERATOR SHUT DOWN PROCEDURE 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
26. stock on handat the time of any price change Multiquip reserves the right to quote and sell directto Government agencies and Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 35 00 surcharge willbe addedto theinvoice for special handling including bus shipments insured parcel post orincases where Multiquip mustpersonally deliverthe parts tothe carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable here under for damagesin excess of the purchase price ofthe itemwith respectto whichdamages claimed andinno event shall Multiquip be liable forloss of profit or good will or for any other special consequential orincidental damages LIMITATION OFWARRANTIES No warranties express orimplied are made in connection withthe sale of parts ortrade acces sories nor asto any engine not manufactured byMultiquip Such warranties madeinconnec tion with the sale of new complete units are made exclusively by a statementof 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 DCA 25USIXF DCA 25USI2XF
27. 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 68 20 50 10 32 0 14 10 4 20 22 30 40 40 10W40 20W40 10W 5W30 ARCTIC OIL 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 in a safety container If the container does not have a spout use a funnel Wipe up any spilled fuel immediately y Generator Internal Fuel Tank Figure 31 Internal Fuel Tank System PAGE 30 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF SETUP Refueling Procedure 3 Open cabin
28. the location of the nearest position when contact with the output receptacles is uk l FIRSTAID ded first aid kit KIT required There exist the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even death emergencies always know the location of the nearest phone or keep a phone on the job site Backfeed to a utility system can cause Also know the phone numbers of the nearest electrocution and or property damage ambulance doctor and fire department This NEVER connect the generators to a 15 information will be invaluable the case of building s electrical system without a emergency transfer switch or other approved device Allinstallations should be performed by P lt a licensed electrician in accordance with all applicable laws and electrical codes Failure to do so could result in Ed m ee electrical shock or burn causing serious 00 injury or even death PAGE 12 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF RULES FOR SAFE OPERATION If your generator is trailer mounted please 277 read the towing and safety requirements listed below Towing and Transporting Safety 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 towi
29. 0 139 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 19 AC Ammeter Change Over Switch Figure 20 AC Ammeter Amp reading on U lug The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 27 DCA 25USIXF DCA 25USI2XF OUTPUT TERMINAL PANEL UVWO Terminal Output Voltages 30 208V 10120V Output Terminal Lug Voltages Various output voltages can be obtained using the Output 1 Place the voltage selector switch in the
30. 0016908020 M1463001402 M1495500213 0019208020 M1465400104 0019208020 M1455200702 M1495401004 0016908020 M1455100003 M1495400904 M1455000903 M1495500904 M1495501004 M1455000803 M1495501204 M1495501304 M1495401304 M1455000703 M1495501104 M1455300403 M1495401204 M1495401304 M1495401404 0207006000 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 83 DCA 25USIXF ENCLOSURE ASSY CONTINUED ENCLOSURE ASSY DCA25USIXF ONLY 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 REMARKS Gyda ee ee OS Be DCA 25USIXF ENCLOSURE ASSY CONTINUED ENCLOSURE ASSY DCA25USIXF ONLY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE K 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE S
31. 0020 HEX HEAD BOLT 1 8A 0040510000 TOOTHED WASHER 1 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 73 DCA 25USIXF MUFFLER ASSY MUFFLER ASSY DCA 25USIXF ONLY PAGE 74 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF MUFFLER ASSY MUFFLER ASSY DCA 25USIXF ONLY NO PART PART NAME QTY REMARKS 1 M1332000002 a u M pP T S N 810000 8101465 1 M1332000012 MUFFLER Lua j cm S N 8101466 AND ABOVE 2 0016908020 HEX HEAD BOLT 7 3 M1335000103 EXHAUST PIPE aus su aus S N 810000 8101465 3 M1335000113 EXHAUST PIPE S N 8101466 AND ABOVE 4 8970420280 GASKET EE EE REPLACES S N 0602320100 5 M0335200004 GASKET su SIN 810000 8101465 5 8970420280 GASKET odit waaka aaa S N 8101466 AND ABOVE EEE REPLACES S N 0602320100 6 0207008000 HEX NUT 4 4 0016908030 HEX HEAD S N 810000 8101465 F 0016908030 HEX HEAD BOLT EE SIN 8101466 AND ABOVE DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 75 DCA 25USI2XF MUFFLER ASSY MUFFLER ASSY DCA 25USI2XF ONLY PAGE 76 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USI2XF MUFFLER ASSY MUFFLER ASSY DCA 25USI2XF ON
32. 05 08 09 DCA 25USIXF DCA 25USI2XF TROUBLESHOOTING GENERATOR 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 be remedied consult our company s business office or service plant TABLE 20 GENERATOR TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION No Voltage Output AC 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 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 49
33. 0700 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 ems REPLACES P N 0602011431 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 69 DCA 25USIXF DCA 25USI2XF 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 OUTPUT TERMINAL ASSY NO PART 1 M1230700003 2 M9220000004 3 M9220000104 4 0039308000 5 0040008000 6 0041408000 7 0016906025 8 M1238100603 8 M1236101103 9 M1238100704 10 0605010040 11 0027103010 0030003000 11B 0041203000 13 0016906020 14 0016906016 15 M1236400004 16 M1236300004 17 0016906020 18 0601808803 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 1493408804 31 0016906016 DCA 25USI
34. 17 0603306863 BUSHING 2 18 0602022971 HOSE JOINT 2 19 0191200330 SUCTION HOSE 1 20 0191200200 SUCTION HOSE 1 21 0191201300 SUCTION HOSE 1 22 0191200800 RETURN HOSE 1 23 0605515198 HOSE BAND 3 24 0603306797 PLUG 1 1 2 1 25 0222100550 TANK SHEET 4 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 79 DCA 25USIXF ENCLOSURE 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 80 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF ENCLOSURE ASSY ENCLOSURE ASSY DCA25USIXF ONLY NO PART NO M1413002502 M1493000004 M1413100003 0603306797 0016910030 M1424000502 M1495100403 0601850151 M1424200702 M1495100503 0601851740 0601850239 0601850097 0027208025 0016908020 0016906020 0016908020 M1425201204 0016906020 M1424200803 0016906020 M1425200903 M1423202003 0019208020 M1435300503 M1435300603 0013612030 0040012000 0041212000 0013612030 0040012000 0041212000 M1445000802 M1495300304 0016908020 PART NAME 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 H
35. 2 Connect the load to the receptacles or the Output Terminal Lugs as shown in Figure 11 These load connection 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 INCORRECT Figure 39 Engine Enclosure Doors Start up Procedure 1 Place the voltage selector switch in the desired voltage position Figure 40 3 PHASE 240 139 PRESS 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 PAGE 34 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF GENERATOR START UP PROCEDURE the ignition key to the START position Figure 43 6 generator s AC voltmeter Figure 45 displays the 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
36. 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 puri Use this position for Remember the voltage selector switch determines the range 30 240 or 1 120V of the output voltage The voltage regulator VR allows the user to increase or decrease the selected voltage 3 240 139 Output Terminal Lug Voltages 1 Place the voltage selector switch in the 30 240 139 position as shown in Figure 21 Figure 24 Voltage Selector Switch 240 139V Three Phase Position 3 PHASE 240158 2 Connectthe load wires to the Output Terminal Lugs as shown in Figure 25 BLUE GREEN WHITE PRESS TO LOCK Figure 21 Voltage Selector Switch 240 139V Three Phase Position 2 Connectthe load wires to the OutputTerminal Lugs as shown in Figure 22 GROUND CONNECTION MUST BE USED ATALL TIMES BLUE WHITE GREEN Figure 25 Output Terminal Lugs 3 208 120V Connections 3 the voltage regulator knob Figure 23 clockwise to increase voltage output turn counterclockwise to GROUND CONNECTION decrease voltage output MUST BE USED AT ALL TIMES To achieve a 3 208V output the voltage selector switch must be in the 3 240 139 position and the voltage regulator must be adjusted to 208V Figure 22 Output Terminal Lugs 3 240 139V Connections Tu
37. 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 C Ny RP 4 1 REMARKS REPLACES P N 0602041210 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 63 DCA 25USIXF ENGINE AND RADIATOR ASSY CONTINUED ENGINE AND RADIATOR ASSY DCAUSIXF ONLY PAGE 64 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF ENGINE AND RADIATOR ASSY CONTINUED ENGINE AND RADIATOR ASSY DCAUSIXF ONLY NO 34 3 36 38 39 40 41 42 PART NO M9602000003 M9200200004 0150000018 0199901600 0199900800 0605515106 M9300000003 M9300100003 0199100215 M1318100103 0016906025 0016906020 0199100700 0193600850 0605515106 0602120481 0602122272 M9200100004 0602123266 M1353800004 0016908020 0220300425 0601822794 0016908025 0207008000 89
38. 5USI2XF ENCLOSURE ASSY CONTINUED ENCLOSURE ASSY DCA25USI2XF ONLY 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 QD N q amp q amp cq 0 REMARKS DCA 25USIXF DCA 25USI2XF RUBBER SEALS ASSY RUBBER SEALS ASSY 3 Xa TM ps Var SE Za arta Le m i us in rif T r aa E LLLI IM B 1 VIEW Z PAGE 92 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 RUBBER SEALS ASSY NO PART 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 93 PART NAME
39. 72309390 PART NAME DRAIN JOINT PLUG ORING 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 OlL PRESSURE ADAPTER UNIT WATER TEMPERATURE CLAMPER ROD HEX HEAD BOLT SEAL RUBBER MOTOR FAN HEX HEAD BOLT HEX NUT REMARKS REPLACES P N 0602011431 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 65 DCA 25USI2XF ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY DCAUSI2XF ONLY PAGE 66 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 PART NO M1923200124 8944567412 M1305200304 M1305200204 0010310025 0040010000 0041210000 060500066 0207010000 M1923200074 0602011079 M9200100904 0150000016 M9312200104 0016908035 0207008000 M1312500203 M1312500303 0605515149 M1312300103 0016906020 0220300425 0601822794 0016908025 0602046531 0602046611 0602040650 0602040552 0016908030 0207008000 M1375100303 M1373101403 0605515147 0602022560 M1320300304 0602022561 0603306590 0603300285 0605511395 0603306395 0602021070 0269200350 DCA 25USI2XF ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY DCAUSI2XF ONLY PART NAME ENGINE ISUZU BV 4LE2 CARTRIDGE OIL FILTER ENGINE FOOT ENGINE FOOT HEX HEAD BOLT WASHER LOCK WASHER FLAT RUBBER SUSPENSION HEX N
40. A 25USI 74 75 Muffler Assembly DCA 25USI2 76 77 Fuel Tank Assembly 78 79 Enclosure Assembly 25051 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 Sos are subject to change without notice DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 3 DCA 25USIXF DCA 25USI2XF PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options Effective Order via Internet Dealers Only If you have Account to obtain Orderparts on line using Multiquip s SmartEquip website Username and Password E mail us at View Parts Diagrams parts multiquip com Order Parts To obtain an MQ Account contact your PS mE nana TE Goto www multiquip com and click on Use the internetand qualify for 5 Discount Parts tologin save on Standard orders for all orders which include 1 Order via Fax Dealers Only Faxyour order in and qualify for a 2 Discount All customers are welcome to order parts via Fax on Standard orders for all orders which include Domestic US Cus
41. ACHINE SCREW 6 16 0601820845 OVER CURRENT RELAY aaa S N8100001 8100586 16 0601820847 OVER CURRENT RELAY ix titer tates S N 8100587 AND ABOVE 17 0601820846 OVER CURRENT RELAY S N8100001 8100586 17 0601820848 OVER CURRENT RELAY rime S N 8100587 AND ABOVE 18 0027104016 MACHINE SCREW 2 18A 0207004000 HEX NUT 2 19 M1213500203 CONTROL BOX COVER 1 20 0016906016 HEX HEAD BOLT 4 21 SELECTOR SWITCH u a e S N 8100001 8101735 ORDER ITEMS W 214 1270100104 SELECTOR SWITCH u a au a usa S N 8101736 AND ABOVE 21A 1550002504 DECAL SELECTOR SWITCH NUMBER S N 8100001 8101735 21 1550002604 DECAL SELECTOR SWITCH NUMBER S N 8101736 AND ABOVE 22 M1215601204 SWITCH BRACKET ticus tiki ti iios S N 8100001 8101735 228 215600204 SWITCH BRACKET S N 8101736 AND ABOVE 23 0027103010 MACHINE SCREW niisiis SIN 8100001 8101735 23 0027104030 MACHINE SCREW Fe SIN 8101736 AND ABOVE 23A 0207004000 ME Massen RE SIN 8101736 AND ABOVE 24 0016906016 HEX HEAD BOLT 4 25 0330000160 EDGING qaqa akaqa a S N8100001 8101735 25 0330000150 EDGING IER S N 8101736 AND ABOVE 26 M1215601104 SWITCHCOVER SIN 8100001 8101735 268 1213600404 SWITCH COVER ua ana
42. BOLT TOOTHED WASHER CONTROL PANEL CONTROL PANEL oiis FREQUENCY METER 45 65Hz 240V AC AMMETER 0 50A 100A 5A CHANGE OVER SWITCH AMMETER AC VOLTMETER 0 600V CHANGE OVER SWITCH AMMETER RHEOSTAT VR 2W 1K OHM KNOB STARTER SWITCH KEY IGNITION SWITCH PREHEAT LAMP BULB DC18V TACHOMETER OIL PRESSURE GAUGE WATER TEMPERATURE GAUGE CHARGING AMMETER FUEL GAUGE ALARM LAMP BULB DC18V u sun a SWITCH PANEL LIGHT STOPPER MACHINE SCREW MACHINE SCREW SET SCREW SNAP RING ENGINE CONTROLLER HEX HEAD BOLT HEX NUT RELAY EE GLOW RELAY J a MACHINE SCREW ALARM LAMP aaa sauna sn BULB DG IBV SWITCH BRACKET MACHINE SCREW HEX EE EEE WIRE HARNESS GENERATOR WIRE HARNESS GENERATOR WIRE HARNESS ENGINE WIRE HARNESS ENGINE FUSE 5A QTY REMARKS 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 1 1 1 2 4 2 2 1 2 2 2 1 4 1 1 1 4 4 1 1 1 1 2 EE SIN 8100001 8100586 EE SIN 8100587 AND ABOVE REPLACES P N 0602100009 Miss REPLACES P N 0601810141 REPLAGES P N 0602202523 REPLACES P N 0602201400 REPLACES P N 0602202502 S N 8100231 AND ABOVE S N 8100231 AND ABOVE
43. 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 aminimum of 8 ft into the ground When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 17 DCA 25USIXF DCA 25USI2XF GENERAL INFORMATION FAMILIARIZATION Generator The MQ Power DCA 25USIXF DCA 25USI2XF Ultra Silent generators Figure 5 are 56 kW generators that are designed 5 high quality portable requires 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 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
44. EAD BOLT HEX HEAD BOLT DUCT COVER HEX HEAD BOLT HOSE COVER HEX HEAD BOLT COVER FROM FRAME 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 Boa qoa CO Gy ROS A RRR RRO TY REMARKS S N 8100001 8101465 S N 8101466 AND ABOVE DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 81 DCA 25USIXF ENCLOSURE ASSY CONTINUED ENCLOSURE ASSY DCA25USIXF ONLY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERINGANY PAINTED PANEL TO 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 82 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 NO 27 27A 27B 28 28A 29 30 31 32 33 34 35 35A 36 37 38 39 39 40 41 42 43 43A 44 45 45A 46 46A 46B 47 47A 47B 46 48 48 49 49 49 49 50 1445300103 1495300504 1495300604 M1445400103 M1495300604 0207006000 0019208020 M1445200303 M1445600204 0207306000 0041206000 M9113000002 0021806016 0030006000 M9112100404 M9112100604
45. EPTACLES 120 240V 50 AMPS Figure 8 Output Terminal Panel PAGE 22 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF OUTPUT TERMINAL PANEL 120 VAC GFCI Receptacles There are two 120 VAG 20 amp GFCI Duplex Nema 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 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 GF C I RECEPTACLE RESET BUTTON Figure 9 G F C l 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 5 6369 TWIST LOCK RECEPTACLES 59 SINGLE PHASE 120 240 VAC 50 AMP OUTPUT Figure 10 120 240V Twist Lock Auxiliary Receptacles Each auxi
46. ERIAL NUMBER MAY BE REQUIRED PAGE 84 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 NO 51 51 52 52 53 54 55 56 57 60 61 62 63 6 64 67 67 68 69 70 71 72 9113000002 9312500004 0021806016 0030006000 9112100404 9112100504 9112100604 0016908020 0016908020 1435000903 1435000803 0016908020 1435000703 1498200004 0016908020 0016908020 0040508000 0605503066 1414800204 0017108020 1423202103 0016906016 DCA 25USIXF ENCLOSURE ASSY CONTINUED ENCLOSURE ASSY DCA25USIXF ONLY 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 usa HEX HEAD BOLT u u u u s BR HS 00 REMARKS S N 8101466 AND ABOVE S N 8101466 AND ABOVE DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 85 DCA 25USI2XF ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE x K 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL
47. LOSURE ASSY Q gt c 4 12 4 4 4 IDI gt TY DCA 25USI2XF ENCLOSURE ASSY CONTINUED ENCLOSURE ASSY DCA25USI2XF ONLY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE S BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 88 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 NO 31 32 33 34 4 35 5 36 56 568 57 0016906016 0207006000 0019208020 1443302203 1493305104 1443400103 1493305204 0207006000 0019208020 1445200303 1445600204 0207306000 0041206000 9113000002 0021806016 0030006000 9112100404 9112100604 0016908020 1463001902 1493505603 0019208020 M3310600004 0019208020 M1453200802 0016908020 M1455100003 M1493410104 M1453004903 M1493409904 M1495501004 M1455000803 M1495501204 M1495501304 M1495401404 M1453005003 M1493410004 M1455300403 M1495401204 M1495401404 0207006000 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 89 DCA 25USI2XF ENCLOSURE ASSY CONTINUED ENCLOSURE ASSY DCA25USI2XF ONLY PART NAME HEX HEAD BOLT HEX NUT HEX HEAD BOLT
48. LY NO PART NO 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 Tasa REPLACES P N 0602320100 8 M1333200214 GASKET 1 9 0207008000 HEX NUT 4 10 0016908035 HEX HEAD BOLT 4 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 77 DCA 25USIXF DCA 25USI2XF FUEL TANK ASSY FUEL TANK ASSY PAGE 78 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF FUELTANK ASSY FUEL TANK ASSY NO PART PART NAME QTY J REMARKS 1 M1363001302 FUELTANK 1 2 0605505072 FUEL TANK CAP 1 3 0605501098 FUEL SENDER UNIT 1 4 0605516090 GASKET 1 5 0027104016 MACHINE SCREW 5 6 1363300314 SUPPORT 2 F 0016908035 HEX HEAD BOLT 8 8 0602022791 HOSE JOINT 2 9 0191301200 VENT HOSE 1 10 0605515109 HOSE BAND 7 11 8943672922 FUEL FILTER ASSY u uu uuu us p REPLACES P N 0602042202 11A 8943692993 CARTRIDGE FUEL FILTER REPLACES P N 0602042700 12 M1368700004 BRACKET FUEL FILTER 1 13 0016908020 HEX HEAD BOLT 4 14 8970398340 FUEL PUMP REPLACES P N 0602023177 14A 8944370220 FUEL FILTER KIT 1 15 0016906025 HEX HEAD BOLT 2 16 M1363400404 PICKUP TUBE 2
49. N M9520100503 WARNING HOT u s can cause A WARNING 1 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 M9503200004 CAUTION CAUTION MOVING PARTS can cause severe injury M90310000 M90320000 M9520100204 Do not operate with doors open Stop engine before servicing M90300000 To use 50 amp receptacles adjust the voltage 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 WARNING A CAUTION ELECTRIC SHOCK HAZARD HOT PARTS can burn skin e Do not touch output terminals while this Do not touch until machine is operating the machine has e Turn power off before sufficiently cooled 91010000 servicing P N M9510100004 P N M9520100503 L WARNING _ ELECTRIC SHOCK HAZARD e Do not touch internal wiring or connections while this machine is operating e Turn power off before servicing N CAUTION This machine stops and starts Automatically and without notice P N B15200010 M92010000 15200010 PIN M9520100004 Figure 3 Generator Decals Continued DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 15 DCA 25USIXF DCA 25USI2XF INSTALLATION GENERATOR GROUND LUG 522 GROUND ROD
50. NE SCREW OVER CURRENT RELAY OVER CURRENT RELAY MACHINE SCREW NUT SELF LOCKING ENGINE CONTROLLER HEX HEAD BOLT RELAY Sua aa aaa assays phi GLOW RELAY METTI MACHINE SCREW CONTROL BOX COVER HEX HEAD BOLT SELECTOR SWITCH 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 REMARKS REPLACES P N 0602201400 de REPLACES P N 0602202502 DCA 25USI2XF CONTROL BOX ASSY CONTINUED CONTROL BOX ASSY DCAUSI2XF ONLY 22 22 2 PAGE 60 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 NO 37 38 39 40 41 42 43 44 45 45A 46 46 47 47 48 PART NO M1223000603 0601807641 0601808985 0601801040 0601806859 0601801041 0601840073 0601840121 0602103092 0601810245 8970444180 8944024980 0602103092 0601810245 0602120095 0602122093 0602123090 0602121080 0602125090 9826800370 0601831330 0602103092 0601810245 M1225100004 0027105010 0027105010 M9220100004 0080200007 0601851727 M1246703604 DCA 25USI2XF CONTROL BOX ASSY CONTINUED CONTROL BOX ASSY DCAUSI2XF ONLY PART NAME CONTROLPANEL a FREQUENCY METER 45 65Hz 240V AC AMMETER 0 50A 100A 5A
51. NUMBER MAY BE REQUIRED PAGE 86 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 ENCLOSURE ASSY DCA25USIXF ONLY NO 1 gt ee PART NO M1413003902 M1493000704 M1413100003 0603306797 0016910030 M1424000502 M1413600004 0016908020 M1423002402 M1493108303 0601850151 M1423202602 M1493108003 0601851740 0601850239 0016908020 0016906020 0016908020 M1423202704 0016906020 M1423202704 0016906020 M1424200803 0016906020 M1423202003 M1423202103 0016906016 0019208020 M1433001403 M1433400003 0013612030 0040012000 0041212000 0013612030 0040012000 0041212000 M1443001502 M1493304004 M1493305304 M1453301703 M1493305304 M1493305404 M1493305504 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 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 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 DCA 25USI2XF ENC
52. ODE B BLACK BR BROWN Y YELLOW VIOLET O ORANGE CP PINK CONNECTOR VIEW FROM INSERTING WIRE SIDE KEY CONNECTION DIAGRAM 5 RUN L Figure 59 Engine Wiring Diagram PAGE 44 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF ENGINE WIRING DIAGRAM PREHEAT LAMP f TERMINAL BOARD TO CONTROL BUX CONNECTER IL PRESSALARM ESN JS ALARM TACHO I 3 METER G s G G TO PICKUP 8S4 on 5 A FUEL PUMP L OS FUES FUSEGSA UNII 7 f TERMINAL BOARD 8 151 2 CHARGING AMMETER PANEL LIGHT oO Go PANEL LIGHT SWITCH WIRE SIZE CONTINUED FROM EREVIOUS PAGE CONNECTOR COLOR CODE VIEW FROM INSERTING WIRE SIDE OFF KEY CONNECTION DIAGRAM UN eu IB B 1 R2 S28 START RUN FO 5 VIOLET O ORANGE P PINK l jJ Figure 59B Engine Wiring Diagram Continued DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 45 DCA 25USIXF DCA 25USI2XF GENERATOR WIRING DIAGRAM n Q 655 MLFC
53. OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF TRAILER WIRING DIAGRAM DOUBLE FILAMENT BULB SINGLE FILAMENT BULB DOUBLE FILAMENT BULB DOUBLE FILAMENT BULB SINGLE FILAMENT BULB DOUBLE FILAMENT BULB TOWING VEHICLE SIDE TRAILER SIDE CONNECT TO CHASSIS GROUND RIGHT 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 TO CHASSIS GROUND RIGHT TAIL LIGHT 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 FLAT 5 PIN ROUND FLAT 5 PIN ROUND 1 1 1 1 I I 1 1 1 Figure 58 Trailer Towing Vehicle Wiring Diagram DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 43 DCA 25USIXF DCA 25USI2XF ENGINE WIRING DIAGRAM IST 2319 FSR POPI PPPI PA VATER TEMP SWITCH 3 ENGINE SPEED PICKUP SOLENOID CTHE TYPE NORMALLY ELECTRIFYING irt FUEL CUT RELAY N16 GLOW RELAY E SIZE COLOR C
54. OPERATION AND PARTS MANUAL REV 8 05 08 09 NOTE PAGE DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 97 OPERATION AND PARTS MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING MQ Power 1800 Water Ridge Rd Tel 800 883 2551 Suite 500 600 Fax 972 315 1847 Lewisville TX 75057 Contact mqpower multiquip com Web www mqpower com MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537 3700 Fax 310 637 3284 Service Tech Support Warranty 800 835 2551 Fax 310 638 8046 COPYRIGHT 2009 MULTIQUIP INC MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc and may not be used reproduced 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 pu
55. OPERATION AND PARTS MANUAL 4 4 POWER ULTRA SILENT SERIES MODEL DCA 25USIXF MODEL DCA 25USI2XF 60 Hz GENERATOR PARTS LIST M1873400004A 25 51 PARTS LIST NO M1873400204A DCA 25USI2 Revision 1 05 08 09 To find the latest revision of this publication visit our website at www multiquip com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES DCA 25USIXF DCA 25USI2XF 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF TABLE OF CONTENTS MQ POWER DCA 25USIXF 25USI2XF 60 HZ ULTRA SILENT GENERATORS Proposition 65 u u 2 Table Of GOMES ai tee Ip eue 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 16 17 General 18 Major Components 19 Generator Control 20 Engine Operating
56. RAME SHACKLE HANGER SUPPORT BRACKET IS WELDED TO FRAME iuc SUSPENSION FRONT HANGER NUT FRONT U BOLT 1 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 41 DCA 25USIXF DCA 25USI2XF TRAILER MAINTENANCE Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer Be sure to use only the fasteners matched to the cone angle of the wheel Proper procedure for attachment of the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque alllug 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 Za Ii RE FT LBS FT LBS FT 3 9 AIR GUN TORQUE WRENCH Figure 57 Wheel Lug Nuts Tightening Sequence NEVER use an pneumatic air gun to tighten wheel lug nuts PAGE 42 DCA 25USIXF DCA 25USI2XF
57. 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 TY ye GS Te Lage SN RS S Gp SJ JG PS REMARKS DCA 25USI2XF ENCLOSURE ASSY CONTINUED 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 90 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 NO 58 58 59 59 60 61 62 PART NO M9113000002 C9312500004 0021806016 0030006000 M9112100404 M9112100504 M9112100604 0016908020 0016908020 0601850097 0027208025 M1433300003 M1435000803 0016908020 M1433001103 M1493200004 0016908020 0016908020 0040508000 0600800321 0605503066 0016906016 0605503066 M1414800204 0017108020 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 91 DCA 2
58. 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 SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER DCA 25USIXF DCA 25USI2XF RUBBER SEALS ASSY REMARKS DCA25USI DCA25USI2 DCA25USU DCA25USI2 DCA 25USIXF DCA 25USI2XF NAMEPLATE AND DECALS ASSY NAME PLATE ASSY PAGE 94 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF NAMEPLATE AND DECALS ASSY NAME PLATE ASSY NO PART PART NAME QTY REMARKS 1 M1512400002 DECAL GENERATOR CONTROL DCAUSIXF 11240000 1 1510300902 DECAL GENERATOR CONTROL DCAUSI2XF 1 11030090 2 1512400122 DECAL ENGINE OPERATING DCAUSIXF M11240012 2 M1510301002 DECAL ENGINE OPERATING DCAUSI2XF 15000010 3 M1550000104 DECALS NOTE em 15000010 4 M1550000204 DECAL NOTE 15000020 5 M1552000603 DECAL AUXILLARY OUTPUT Lassie M15200060 6 M9500000004 DECAL OIL DRAINPLUG driias pm M90000000 7 M9500100004 HE EN M90010000 8 M9500300004 DECALS Y M90030000 9 M9500300104 ee W
59. Safety Messages specifically address the level of exposure to the operator and are preceded by one of three words DANGER WARNING or CAUTION You WILL be KILLED or SERIOUSLY injured if you do not follow directions You COULD be KILLED or SERIOUSLY injured if you do not follow directions You CAN be injured if you do not follow directions HAZARD SYMBOLS Potential hazards associated with the operation of this equipment will be referenced with Hazard Symbols which appear throughout this manual and will be referenced in conjunction with Safety Message Alert Symbols WARNING LETHAL EXHAUST GASES Diesel engine exhaust gases contain poisonous carbon monoxide This gas is colorless and odorless and can cause DEATH if inhaled NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited DO NOT start the engine near spilled fuel or combustible fluids DO NOT fill the fuel tank while the engine is running or hot 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 approved containers in well ventilated areas and away from sparks and flames NEVER use fuel as a cleaning agent WARNING BURN HAZARDS Engine components can generate extreme heat To prevent burns
60. T VOLTAGE REGULATOR Lanes 0601840121 KNOB RHEOSTAT 0601820671 AUTOMATIC VOLTAGE REGULATOR DCA25USI Issa 0601820602 AUTOMATIC VOLTAGE REGULATOR DCA25USI2 0601802160 FUSE 5A DCA 25USI es 8944370220 FUEL FILTER KIT DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 51 DCA 25USIXF DCA 25USI2XF GENERATOR ASSY GENERATOR ASSY PAGE 52 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 GENERATORASSY NO PART 1 B1110200602 1 1 1 2 7961025004 1 3 0601822630 1 4 8001070003 1 5 8351611004 1 6 8351612004 1 7 1112300003 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 5 1138000003 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 DCA 25USIXF DCA 25USI2XF GENERATOR ASSY PART NAME ROTOR ASSY FIELD ASSY RECTIFIER SURGE ABSORBER FAN COUPLING DISK WASHER COUPLING HUB BALANCING PLATE nns HEX HEAD BOLT WASHER LOCK BALANCING WEIGHT KIT BEARING HEX HEAD BOLT WASHER LOCK WASHER FLAT BEARING STATOR ASSY GROMMET
61. 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 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 larger 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
62. UT 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 RPE REMARKS REPLACES P N 0602041210 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 67 DCA 25USI2XF ENGINE AND RADIATOR ASSY CONTINUED ENGINE AND RADIATOR ASSY DCAUSI2XF ONLY PAGE 68 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USI2XF ENGINE AND RADIATOR ASSY CONTINUED ENGINE AND RADIATOR ASSY DCAUSI2XF ONLY NO PART PART NAME QTY REMARKS 40 M9602000003 DRAIN JOINT 1 41 M9200200004 PLUG 1 42 0150000018 O RING 1 43 0016906020 HEX HEAD BOLT 2 4 0199901600 DRAIN HOSE 1 4 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 019910
63. XF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 71 PART NAME TERMINAL PANEL OUTPUT TERMINAL BOLT TIE SCREW HEX NUT WASHER LOCK WASHER FLAT HEX HEAD BOLT TERMINAL COVER TERMINAL COVER 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 950A BREAKER FITTING COVER CUSHION RUBBER HEX HEAD BOLT RECEPTACLE 125V 20A X 2 RECEPTACLE CS6369 250V 50A MACHINE SCREW HEX NUT TERMINAL COVER HEX HEAD BOLT HEAD BOLT WASHER FLAT STAY RUBBER HEX NUT ACOUSTIC SHEE T HEX HEAD BOLT aaa qataqa DCA 25USIXF DCA 25USI2XF OUTPUTTERMINAL ASSY QTY REMARKS DCA25USI pe DCA25USI2 DCA25USI DCA25USI2 DCA25USI2 DCA25USI2 DCA25USI2 DCA 25USIXF DCA 25USI2XF BATTERY ASSY BATTERY ASSY PAGE 72 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF BATTERY ASSY BATTERY ASSY NO PART PART NAME QTY REMARKS 1 0602220185 BATTERY 1 2 M9310500014 BATTERY 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 001691
64. ad 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 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 ELECTROCUTION HAZARDS 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 PAGE 24 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF LOAD APPLICATION MAXIMUM Single Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage amperage frequency and vo
65. age output turn counterclockwise to decrease voltage output decrease voltage output DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 29 DCA 25USIXF DCA 25USI2XF SETUP 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 GFCI 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 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 generator Refilling the Fuel System A CAUTION REFUELING THE GENERATOR ONLY properly trained personel who have read and understand this section should refill the fuel tank system Figure 30 Engine Oil Dipstick When checking
66. and test electric brake operation Secure portable power cables in cable tray with tie wraps 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 Place chock blocks underneath wheel to prevent rolling while parked Use the trailers swivel jack to adjust the trailer height to a level position while parked Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing Avoid sharp turns Trailer should be adjusted to a level position at all times when towing Raise and lock trailer wheel stand in up position when transporting 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 Place support blocks underneath the trailer s bumper to prevent tipping while parked Avoid sharp turns to prevent rolling DO NOT transport generator with fuel in tank For more saftey tips see the trailer saftey guidelines section in this manual DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 13 CA 25USI2XF DECALS OPERATING PROCEDURES Manual Startin Manual Stopping 1 Check the engine oil coolant and fuel levels 1 Place me Circuit OFF peter 2 Place
67. be may cause pieces of the rim to explode break off with great force and 47 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 WEAR PATTERN Center Wear Over Inflation Adjust pressure to particular load per tire manufacturer Edge Wear Under Inflation Adjust pressure to particular load per tire manufacturer Side Wear Loss of camber or overloading Make sure load does not exceed axle rating Align wheels Toe Wear Cupping Incorrect toe in Out of balance Align wheels Check bearing adjustment and balance tires Flat Spots Wheel lockup amp tire skidding Avoid sudden stops when possible and adjust brakes 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 F
68. blished in this publication at any time without notice and without incurring any obligations Manufactured for Multiquip Inc by Your Local Dealer is DENYO CO LTD JAPAN VRL POWER
69. e 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 CAUTION CHANGING VOLTAGES NEVER change the position ofthe 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 208V 220V 240V 416V 440V 480V Single Phase Switchable 254V 277V 120V 127V 139V PAGE 26 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 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 Single Phase 120 Volt 55 5 amps 4 wire Single Phase 240 Volt 27 8 amps 4 wire Three Phase Three Phase 40 Amos 480 Volt p GFCI Receptacle Load Capability The load capabilit
70. e gas piping as an electrical ground Maintenance Safety NEVER lubricate components or attempt service on a running machine High Temperatures Always stop engine and allow the engine to cool before adding fuel oil or performing service and maintenance functions Contact with hot components can 4000 0 cause serious burns Keep the machinery in proper running condition Fix damage to the machine immediately and replace any broken parts immediately ALWAYS replace any worn or damaged warning decals 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 un authorized personnel The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits Turn all circuit breakers OFF before performing maintenance on the generator Dispose of hazardous waste properly Examples of potentially hazardous waste are used motor oil fuel and fuel filters DO NOT use food 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 ALWAYS allow the machine a proper amount of time to cool before servicing ALWAYS service air cleaner frequently to prevent engine malfunction ALWAYS disconnect the NEGATIVE battery terminal before performing service
71. e to follow instructions in this manual may lead to serious injury or even DEATH This equipment is to be operated by trained and qualified personnel only This equipment is for industrial use only The following safety guidelines should always be used when operating the generator General Safety DO NOT operate or service this equipment before reading this entire manual The operator MUST BE familiar with proper safety precautions and operations techniques before using generator This equipment should not be operated by persons under 18 years of age NEVER operate this equipment without proper protective clothing shatterproof glasses steel toed boots and other protective devices required by the job NEVER operate this equipment when not Ae feeling well due to fatigue illness or taking V medicine NEVER operate this equipment under the influence or drugs or alcohol hearing and eye protection equipment when operating the generator E Whenever necessary replace nameplate operation and safety decals when they become difficult read Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties ALWAYS wear proper respiratory mask 5 i eA E NEVER use accessories or attachments which are not recommended by Multiquip for this equipment Damage to the equipment and or inju
72. ed at any hardware shop or made out of available items Examples include battery cables shims 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF SUGGESTED SPARE PARTS DCA 25USIXF DCA 25USI2XF Big Tank W ISUZU AA 4LE2 BV 4LE2 DIESEL ENGINES 1TO 3 UNITS Qty PIN Description Remarks sende 8944567411 OIL FILTER DCA 25USI c 8944567412 ELEMENT OIL FILTER DCA 25USI2 ER 0602046611 ELEMENT c 8943692993 CARTRIDGE FUEL FILTER ENT 0602122272 UNIT OIL PRESSURE pem 0602123266 UNIT WATER TEMPERATURE DCA 25USI 1 aes 0602123275 UNIT WATER TEMPERATURE DCA 25USI2 0005505072 FUEL CAP prom 8972309390 FAN BELT ems 1312500203 HOSE RADIATOR UPPER lasso M1312500303 HOSE RADIATOR LOWER 0601808803 CIRCUIT BREAKER 20 0601808804 CIRCUIT BREAKER 50A 0602103092 ALARM LAMP sju 0601810245 BULB ALARM LAMP PRE HEAT LAMP Toston 8944024980 KEY IGNITION SWITCH 0601840073 RHEOSTA
73. erted circuit connection takes place the circuit 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 33 DCA 25USIXF DCA 25USI2XF GENERATOR START UP PROCEDURE 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 WARNING STARTING THE 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 prior to starting the engine MAIN 5 6369 GFCI CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKERS BREAKERS m m m m Figure 38 Main Aux GFCI Circuit Breakers OFF
74. et doors on the right side of the generator from generator control panel position Remove fuel cap WARNING RESPIRATORY HAZARDS and fill tank Figure 33 Diesel fuel and its vapors are dangerous to your health and the surrounding 4 2 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 CAUTION REFUELINGTHE GENERATOR 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 Figure 33 Fueling the Generator DO NOT fill on unlevel ground _ 3 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 Figure 32 Only Fill on Level Ground ON CONTROL PANEL ONLY use 2 diesel fuel when refueling DO NOT OVER FILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 35 Fuel EXPANDS eg 2 When Heated Figure 35 Fuel Expansion DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 31 DCA 25USIXF DCA 25USI2XF SETUP Coolant ISUZU Antifreeze Summer Coolant Water ISUZU recommends ISUZU Antifreeze Summe
75. following Two 250 VAC output receptacles CS 6369 50 amps Two auxilliary circuit breakers 250V 050 amps Two 125 VAC output receptacles GFCI 20 amps Two GFCI circuit breakers 125 20amps Five output terminal lugs 3 power Control Box The Control is provided with the following Automatic Voltage Regulator Current Transformer Emergency Relay Open Delta Excitation System This generator is equipped with the state of the art Open Delta 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 ofthe open delta A B C and D During steady state loads the power from the voltage regulator is supplied from the parallel connections of Ato 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 heavy 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 Bto C This has the effect of adding the voltages of each phase ot provide 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 de
76. from engine Replacing Fuel Filter e Replace 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 e Ventany 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 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 Replace with coolant Table 12 for correct mixture Close radiator cap tightly WARNING BURN HAZARDS Allow engine to cool when flushing out radiator Flushing the radiator while hot could cause serious burns from water or KA steam ca x Generator Storage For longe term storage of the generator the following is recommended Fil the fuel tank completely Treat with a fuel stabilizer if necessary Completely
77. g conditions Fuel Leak Detected Alarm Lamp This lamp will illuminate when leak in the fuel containment enclosure is detected PanelLight Switch When activated will turn on control panel light DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 21 DCA 25USIXF DCA 25USI2XF OUTPUT TERMINAL PANEL Output Terminal Panel The OutputTerminal Panel Figure 8 shown below is located onthe right hand side left from control panel of the generator Lift up on the cover to gain access to receptacles and terminal lugs Terminal legs O and Ground are considered bonded grounds 10 AND 39 480 120 VAC OUTPUT TERMINALS BLACK CIRCUIT BREAKERS FOR 5 6369 TWIST LOCK RECEPTACLES 120 VAC 20 AMP GFCI RECEPTACLES RECEPTACLE AND CIRCUIT BREAKER gt PANEL NEUTRAL TERMINAL RED BLUE WHITE GREEN CIRCUIT BREAKERS FOR RECEPTACLES Output Terminal Familiarization The Output Terminal Panel Figure 6 is provided with the following Two Two 2 120 240V output receptacles 50 amp 2 Circuit Breakers 50 amps 2 120V GFCI receptacles amp 20 amp Two 2 Circuit Breakers 20 amps Five 5 Output Terminal Lugs V W O Ground One Main Circuit Breaker 060 amps Two GROUND TERMINAL HARD WIRE HOOKUP PANEL ACCESS DOOR LIFT TO OPEN CS 6369 TWIST LOCK AUX POWER REC
78. lliary receptacle is piotecteu 30 amp 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 2 TERMINAL Figure 12 Plastic Face Plate UVWO Terminals DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 23 DCA 25USIXF DCA 25USI2XF OUTPUT TERMINAL PANEL Connecting Loads Loads can be connected to the generator by the UVWO terminal lugs or the convienience receptacles See Figure 13 Make sure to re
79. lta 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 to 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 i
80. ltage 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 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 Power Factor Single phase induction motors Electric heaters incandescent lamps Fluorescent mercury 2 Common power tools Table 6 Cable Selection 60 Hz Single Phase Operation At120 At240 Volts Volts 10 Wire 12 Wire 14 Wire 1000 ft 375 ft 250 ft Current in Amperes 125 ft CAUTION Equipment damage can result from low voltage Three Phase Load When calculating the power requirements for 3 power use the following equation VOLTAGE X AMPERAGE X 1 732 1000 KVA 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 Motors and motor driven equipment draw much g
81. n 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 WaterTemperature Gauge During normal operation this gauge should read between 1659 2039 F 74 95 C Charging Ammeter 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 use lgnition 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 operatin
82. nerally used to show a part that has not been assigned a formal part number at time of publication A 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 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 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 Make Obtain Locally Indicates that the part can be purchas
83. ng vehicle are in good operating condition and both units are mechanically sound The following list of safety precautions should be followed when towing your generator CAUTION FOLLOWTOWING REGULATIONS Check with your local county or state safety towing regulations in addition to meeting Department of Transportation DOT Safety Towing Regulations before towing your generator ALWAYS shutdown engine before transporting Drain fuel from generator fuel tank before towing f generator is mounted on a trailer make sure trailer complies with all local and state safety transportation laws Follow the listed Towing amp Transporting Safety guidelines for basic towing techniques Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the 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 ALWAYS make sure the trailer is equipped with a Safety Chain ALWAYS attach trailer s safety chains to towing vehicle properly ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly DOT Requirements include the following Connect
84. on of this generation there Engine exhaust gases contain exists the possibility of electrocution poisonous carbon monoxide This gas electrical shock or burn which can is colorless and odorless and can cause severe bodily harm or even cause death if inhaled NEVER operate DEATH this equipment in a confined area or To avoid these hazards enclosed structure that does not provide NEVER use damaged or worn cables when connecting ample free flow air equipment to the generator Make sure power connecting DANGER cables are securely connected to the generator s output receptacles incorrect connections may cause damage NER to the generators and electrical shock Generator exhaust contains carbon monoxide This is a posion you cannot see or smell NEVER grab or touch a live power cord with wet hands the possibility exist of electrical NEVER use inside a home vae from or garage even if doors far away from windows shock electrocution and even and windows are open 90075 and vents death Avoid other generator hazards 7 READ MANUAL BEFORE USE Emergencies NEVER insert any objects into E ALWAYS know the location of the lt ER the output receptacles during nearest fire extinguisher operation This is extremely dangerous ALWAYS turn off the generators and place all circuit breakers in the OFF B ALWAYS know
85. on the generator Follow all battery safety guidelines listed in this manual when handleing or servicing the generator PAGE 10 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF RULES FOR SAFE OPERATION WARNING BURN HAZARDS To prevent burns DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations Always allow sufficient time for the engine and generator to cool before performing E maintenance Radiator Cap Removing the radiator cap while the engine is hot will result in high pressurized boiling water to gush out of the radiator causing severe scalding to any persons in the general area of the generator Coolant Drain Plug Removing the 7 4 coolant drain plug while the engine 5 N 122 hot will result in hot coolant gushing 2 out of the plug therefore CA causing severe scalding to any persons in the general area of the generator Engine Oil Drain Plug Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug therefore causing severe scalding to any persons in the general area of the generator Battery Safety Use the following guidelines when handling the battery M The battery contains acids that can Cause injury to the eyes and skin To gt avoid eye irritation always wear
86. ot 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 Incorrect nozzle opening pressure Injection nozzle stuck or clogged Adjust Repair or replace Fuel over flow pipe clogged Governor malfunctioning Clean 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 Air cleaner clogged Clean or change Clean or change Deficient nozzle injection 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 PAGE 48 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8
87. r Coolant for use in thier engines which can be purchased in concentrate and mixed with 50 demineralized water or pre diluted See the ISUZU Engine Owner s Manual for further details WARNING BURN HAZARDS If adding coolant antifreeze mix to the radiator DO NOT remove the radiator cap until the unit has completely cooled The 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 H 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 Whenthe antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 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
88. reater 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 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 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 ELECTRICAL SYSTEM HAZARDS 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 25 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 DCA 25USI GAUGE READING TERMINAL PANEL CONNECTIONS Voltage Selector Switch The voltage 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 1 PHASE 240 120 Figure 15 Voltag
89. replacement is necessary 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 adjustitin 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 NEVER place hands near the belts or fan while the generator set is running PAGE 32 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF SETUP 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
90. rn 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 PAGE 28 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF OUTPUT TERMINAL PANEL 3 480 277 Output Terminal Lug Voltages 10 240V 120V Output Terminal Lug Vohayes 1 Place the voltage selector switch in the 30 480 277 place the voltage selector switch in the 10 240 120 position as shown in Figure 26 position as shown in Figure 28 3 PHASE 240 139 3 PHASE 1 PHASE 240 139 240 120 PRESS TO LOCK PRESS TO LOCK Figure 26 Voltage Selector Switch 480 277V Three Phase Position Figure 28 Voltage Selector Switch 240 120V Single Phase Position 2 Connectthe load wires to the Output Terminal Lugsas 2 Connect the load wires to the Output Terminal Lugs as shown in Figure 27 shown in Figure 29 BLUE RED GREEN WHITE BLUE WHITE GREEN GROUND CONNECTION MUST BE USED ATALL TIMES GROUND CONNECTION MUST BE USED ATALL TIMES Figure 27 Output Terminal Lugs Figure 29 Output Terminal Lugs 3 480 277V Connections 10 240 120 Connections 3 Turnthe voltage regulator knob Figure 23 clockwise to 3 Turn the voltage regulator knob Figure 23 clockwise to increase voltage output turn counterclockwise to increase volt
91. ry to user may result E NEVER touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or generators The engine section of this generators requires an adequate free flow of cooling air NEVER operate the generators in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it M cause serious damage to the generators or engine and may cause injury to people Remember the generator s engine gives off DEADLY carbon monoxide gas DANGEROUS GAS FUMES ALWAYS refuel in a well ventilated area away from sparks and open flames M ALWAYS use extreme caution when working with flammable liquids When refueling stop the engine and allow it to cool DO NOT smoke around or near the machine Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine E NEVER operate the generator in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 9 DCA 25USIXF DCA 25USI2XF RULES FOR
92. s held to a minimum Use the cable selection chart Table 6 as a guide for selecting proper extension cable size PAGE 18 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF MAJOR COMPONENTS Table 4 Generator Major Components Figure 5 Major Components Engine Operating Panel Assembly DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 19 DCA 25USIXF DCA 25USI2XF GENERATOR CONTROL PANEL 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 2 Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage 3 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 4 Main Circuit Breaker This three pole 60 amp main breaker is provided to protect the UVWO output terminals from overload 5 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 6 AC Voltmeter Indicates the o
93. safety 2 glasses 7 Use well insulated gloves when picking up the battery DANGER EXPLOSION HAZARDS The risk of an explosion exists when performing service on the battery To avoid severe injury or DEATH DO NOT drop the battery There is the possibility of risk that the battery may 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 in contact with a flame or spark an explosion could occur ALWAYS keep the battery charged If the battery is not charged a buildup of combustible gas will occur ALWAYS keep battery charging and cables in good working condition Repair or replace all worn cables ALWAYS recharge the battery an vented air environment to avoid risk of a dangerous concentration of combustible gases n case the battery liquid dilute sulfuric acid comes in contact with clothing or skin rinse skin or clothing immediately with plenty of water In case the battery liquid dilute sulfuric acid comes in contact with your EYES rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 11 DCA 25USIXF DCA 25USI2XF RULES FOR SAFE OPERATION y DANGER Electrocution Hazards y DANGER Lethal Exhaust Gas Hazards During operati
94. 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 noises 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 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 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 1 05 08 09 PAGE 35 DCA 25USIXF DCA 25USI2XF GENERATOR START UP PROCEDURE 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
95. ssages are provided throughout this manual to help prevent damage to your generator other property or the surrounding environment CAUTION ENGINE LOAD WET STACKING 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 operates 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 the exhaust system which can foul the fuel injectors engine valves and exhaust system including turbocharges 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 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 PAGE 8 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF RULES FOR SAFE OPERATION DANGER READTHIS MANUAL Failur
96. t 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 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 RE Actuating Pin VT Hold Down Secondary 47 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 Brake line broken or kinked Brake lining glazed Trailer overloaded
97. tained from the carrier and any claim for shortage or damage mustbe settled betweenthe consignee and the carrier MINIMUM ORDER Theminimum charge for 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 willbe 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 ToobtainaReturn Material Authorization alistmustbe providedto Multiquip Parts Salesthat defines item numbers quanti ties and descriptions of the items to be returned a 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 whichthe items were originally purchased e Thelist must include the name and phone number ofthe person request ingthe RMA 3 Acopyofthe Return Material Authoriza tion mustaccompanythe return shipment 4 Freight is at the sender s expense All parts must be returned freight prepaidto Multiquip s designated receiving point 5 Parts must bein newandresalable con dition inthe original Multiquip package if any and with Multiquip part numbers clearly marked 6 Thefollowingitems are not returnable
98. tomers dial Note Discounts Are Subject To Change OVVETr COITN Order via Phone Domestic US Dealers Call 2 Non Dealer Customers International Cust m9 Contact your local Multiquip Dealer for CONIAC parts or call 800 427 1244 for help their local Multiquip Representatives for ee ee E 4 EET EE 1 4 When ordering parts please supply Dealer Account Number Specify Preferred Method of Shipment Dealer Name and Address UPS Fed Ex DHL Shipping Address if different than billing address 2 7 v Truck Return Fax Number Next Day Applicable Model Number Allorders are treated as Standard Orders and will shipthe same day if received prior vvvvvv mqal l WE ACCEPT ALL MAJOR CREDIT CARDS PAGE 4 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 DCA 25USIXF DCA 25USI2XF SPECIFICATIONS Table 1 Generator Specifications ma me a 09 Prime Output 14 4 KW Voltage 240 120V Frequency 60 Hz Speed 1 800 rpm Power Factor Aux AC Power Single Phase 60 Hz Voltage 120 VAC Table 2 Engine Specifications meterne _ Type 4 Cycle water cooled direct injection sm 1 Ly hr at full load 1 64 hr at full load L hr 3 4 load 0 86 ga hr at 1 2 load Fuel Consumption at
99. utput voltage present at the UVWO terminals 7 AC Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch 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 Rememberthe 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 PAGE 20 DCA 25USIXF DCA 25USI2XF OPERATION AND PARTS MANUAL REV 8 05 08 09 Figure 7 Engine Operating Panel DCA 25USIXF DCA 25USI2XF ENGINE OPERATING PANEL D 30 The definitions below describe the controls and functions of the Engine Operating Panel Figure 7 1 Panel Light Normally used in dark places or at night When activated panel willluminate When the generator is not in use turn the panel light switch to the OFF positio
100. y of the GFCI receptacles is directly re latedto the voltage being supplied at either the output termi 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 Table 9 GFCI Receptacle Load Capability 1 KW in Use Available Load Twist Lock 56369 Current Amps Duplex NEMA 1 240 120V 5 208 120V 96 20 amps per receptacle Table 10 GFCI Receptacle Load Capability 3 Available Load KVA in Use UVWO Terminals Current Amps Duplex NEMA 30 240 480V 5 20R 120V po DCA 25USI 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 32 240V choose the center 3 240 139V position on the voltage selector switch 3 PHASE 240 139 3 480 277 Figure 16 Voltage Selector Switch 240 139V Three Phase Position PRESS TO LOCK For 3 208V 1 120V place the Voltage Selector Switch in the 3 Phase 24

Multiquip DCA-25USI2XF Portable Generator User Manual

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