Multiquip DCA25USI User Manual
OPERATION AND PARTS MANUAL
®
MODEL DCA25USI
60HZ WHISPERWATT™ GENERATOR
(ISUZU AA-4LE2 DIESEL ENGINE)
PARTS LIST NO. M1871400104
PARTS LIST NO. M1871400114C
Revision #3 (07/19/11)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at
1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or
write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safecar.gov.
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 3
TABLE OF CONTENTS
DCA25USI 60 Hz Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information ..............................................6-11
Specifications ........................................................ 12
Dimensions ............................................................ 13
Installation ........................................................14-15
General Information ............................................... 16
Major Components ................................................ 17
Generator Control Panel ........................................ 18
Engine Operating Panel......................................... 19
Output Terminal Panel Familiarization .............. 20-22
Load Application .................................................... 23
Generator Outputs ................................................. 24
Generator Outputs/Gauge Reading ....................... 25
Output Terminal Panel Connections ................. 26-27
Inspection/Setup ............................................... 28-31
Generator Start-Up Procedure ........................ 32-33
Generator Shut-Down Procedures ........................ 34
Maintenance ..................................................... 35-37
Trailer Maintenance .......................................... 38-41
Trailer Wiring Diagram ........................................... 42
Generator Wiring Diagram ..................................... 43
Engine Wiring Diagram ..................................... 44-45
Troubleshooting (Generator) .................................. 46
Explanation Of Code In Remarks Column............. 48
Suggested Spare Parts ......................................... 50
COMPONENT DRAWINGS
Generator Assembly ......................................... 50-51
Control Box Assembly ...................................... 52-55
Engine and Radiator Assembly ........................ 56-59
Output Terminal Assembly ................................ 60-61
Battery Assembly. ............................................. 62-63
Muffler Assembly .............................................. 64-65
Fuel Tank Assembly ......................................... 65-67
Enclosure Assembly ......................................... 68-73
Rubber Seals Assembly ................................... 74-75
Nameplate and Decals Assembly .................... 76-77
Terms And Conditions Of Sale — Parts ................ 78
PAGE 4 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
If you have an MQ Account, to obtain a Username
Effective:
Choose from three easy options:
January 1st, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
Goto www.multiquip.com and click on
Order Parts
to log in and save!
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Order via Phone:
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
and Password, E-mail us at: parts@multiquip.
com.
To ob ta i n an MQ Acc oun t, con ta ct yo ur
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
When ordering parts, please supply:
❒ Dealer Account Number
❒ Dealer Name and Address
❒ Shipping Address (if different than billing address)
❒ Return Fax Number
❒ Applicable Model Number
❒ Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL
■ Priority One ✓ Truck
■ Ground
■ Next Day
■ Second/Third Day
www.multiquip.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 5
SAFETY INFORMATION
Do not operate or service the equipment before reading the
Potential hazards associated with the operation of this
entire manual. 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.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
SAFETY INFORMATION
GENERAL SAFETY
NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
Also, know the
and
This information will be invaluable in
emergency or safety devices.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
ensure generator is on level ground before use.
keep the machine in proper running condition.
store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site.
phone numbers of the nearest ambulance, doctor
fi re department.
the case of an emergency.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fi re could result causing severe
bodily harm or even death.
WARNING
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
NEVER disconnect any
These devices are intended for operator safety.
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS
ALWAYS
Fix damage to machine and replace any broken parts
immediately.
ALWAYS
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 7
ENGINE SAFETY
NOTICE
run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
Wet stacking is a common problem with diesel engines
no load applied. When a diesel engine operates without
suffi cient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
In order for a diesel engine to operate at peak effi ciency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
applied to relieve the condition. It can reduce the system
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
from the engine exhaust. Spark arresters are qualifi ed
SAFETY INFORMATION
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
DO NOT place han d s or fingers inside en g ine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fi ngers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
NEVER
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
which are operated for extended periods with light or
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
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.
State Health Safety Codes and Public Resources
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
PAGE 8 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
to prevent accidental discharge of sparks or fl ames
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
FUEL SAFETY
DANGER
Make sure the hitch and coupling of the towing vehicle
NEVER
tow a trailer with defective hitches, couplings, chains, etc.
Trailer tires should be infl ated to 50 psi cold.
safety
attach trailer’s safety chains to towing
make sure the vehicle and trailer directional,
unless
posted otherwise. Recommended off-road towing is not to
Avoid sudden stops and starts. This can cause skidding,
Trailer should be adjusted to a level position at all times
rolling
underneath the trailer’s bumper
Use the trailer’s swivel jack to adjust the trailer height to
SAFETY INFORMATION
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
DO NOT start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open fl ames.
ALWAYS use extreme caution when working with
fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DO NOT overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and fl ames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or ne a r the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
Check with your local county or state safety
towing regulations, in addition to meeting
Depar tment of Transpor tation (DOT)
Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety
information.
In order to reduce the possibility of an accident while
transporting the generator on public roads, ALWAYS
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
ALWAYS shutdown engine before transporting
CAUTION
ALWAYS inspect the hitch and coupling for wear.
Check the tire air pressure on both towing vehicle and
trailer.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a
chain.
ALWAYS properly
vehicle.
ALWAYS
backup, brake and trailer lights are connected and
working properly.
DOT Requirements include the following:
• Connect and test electric brake operation.
• Secure portable power cables in cable tray with tie
wraps.
The maximum speed for highway towing is 55 MPH
exceed 15 MPH or less depending on type of terrain.
or jack-knifi ng. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent
while parked.
Place support blocks
to prevent tipping while parked.
a level position while parked.
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 9
ELECTRICAL SAFETY
DANGER
Make sure power cables are securely connected to the
make certain that proper power or extension
cord has been selected for the job. See Cable Selection
make sure that electrical circuits are properly
Severe injury or death by
can result from operating an ungrounded
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
SAFETY INFORMATION
generator’s output receptacles. Incorrect connections
may cause electri cal sh ock and damage to the
generator.
NOTICE
ALWAYS
The electr ical vol tage require d to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
NEVER insert any objects into the output
receptacles during op era tion. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Chart in this manual.
Grounding Safety
DANGER
ALWAYS
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator.
electrocution
generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 10 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
SAFETY INFORMATION
BATTERY SAFETY
ENVIRONMENTAL SAFETY
pour waste, oil or fuel directly onto the ground,
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
NOTICE
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel fi lters.
DO NOT use food or plastic containers to
dispose of hazardous waste.
DO NOT
down a drain or into any water source.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 11
SPECIFICATIONS
Table 1. Generator Specifications
Model
Type
Armature Connection Star with Neutral Zigzag
Phase
Standby Output
Prime Output
Power Factor
Voltage
Frequency
Speed
Aux. AC Power
Aux. Voltage/Output
Dry Weight
Wet Weight
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
Coolant Capacity
Lube Oil Capacity
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
27.5 kVA (22.0 KW) 15.8 KW
25kVA (20 KW) 14.4 KW
240 or 480V 240V/120V
Table 2. Engine Specifications
1.44 gal. (5.47 L)/hr at full load 1.05 gal. (3.99 L)/hr at 3/4 load
0.74 gal. (2.81 L)/hr at 1/2 load 0.45 gal. (1.70 L)/hr at 1/4 load
Revolving field, self ventilated,
drip-proof, single-bearing generator
3 Single
0.8 1.0
ISUZU AA-4LE2 Tier 2 Certified
4 cycle, water-cooled, direct injection
3.35 in. x3.78 in. (85 mm x 96 mm)
DCA25USI
60 Hz
1800 rpm
Single Phase, 60 Hz
4.8 Kw (2.4 kW x 2)
1,808 lbs. (820 kg.)
2,138 lbs. (970 kg.)
4 cylinders
132 cu. in. (2,179 cc)
30.6 HP at 1800 rpm
Electric
1.7 gal. (6.4 liters)
2.25 gal. (8.5 liters)
#2 Diesel Fuel
41.7 gal. (158 Liters)
12V-53 Ah x 1
PAGE 12 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
DIMENSIONS
TOP VIEW
B
D
A
C
E
25
SIDE VIEW
FRONT VIEW
F
Figure 1. Dimensions
Table 3. Dimensions
G
Reference
Letter
A 22.64 in. (575 mm.) F 70.47 in. (1,790 mm.)
B 20.87 in. (530 mm.) G 49.61 in. (1,260 mm.)
C 27.36 in. (695 mm.) H 31.1 in. (790 mm.)
D 24.41 in. (620 mm.)
Dimension in. (mm) Reference Letter Dimension in. (mm)
E 25.59 in. (650 mm.)
H
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 13
INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
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.
CAUTION
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.
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 - 8 AWG (5.3 mm2)
b. Aluminum - 6 AWG (8.4 mm2)
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
INDOOR INSTALLATION
Exhaust gases from diesel engines are extremel y
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
MOUNTING
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are
to resist damage to the bottom of the generator and to
maintain alignment.
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 15
GENERAL INFORMATION
GENERATOR
This MQ Power generator (Figure 3) is a high quality
portable (requires a trailer for transport) power source for
telecom sites, lighting facilities, power tools, submersible
pumps and other industrial and construction machinery.
ENGINE OPERATING PANEL
The “Engine Operating Panel” is provided with the following:
Tachometer
Water Temperature Gauge
Warning Lamp
Pre-Heat Lamp
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Panel Light/Panel Light Switch
Oil Pressure Alarm Lamp
Water Temperature Alarm Lamp
Fuel Filter Water Level 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, 6 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
• Automatic Voltage Regulator
• Current Transformer
• Over-Current Relay
• Starter Relay
• Voltage Selector Switch
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
Two 120/240V output receptacles (CS-6369), 50A
Two auxiliary circuit breakers, 50A
Two 120V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Five output terminal lugs (3Ø power)
OPEN DELTA EXCITATION SYSTEM
This generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist
of an electrically independent winding wound among
stationary windings of the AC output section.
There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to 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 a 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 B to C. This has the effect of adding the
voltages of each phase to 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-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a “fixed ceiling” and responds
according the demands of the required load.
ENGINE
This generator unit incorporates an ISUZU AA-4LE2 diesel
engine. This engine is designed to meet every performance
requirement for the generator. Reference Table 2 for engine
specifications.
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
ELECTRIC GOVERNOR SYSTEM
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.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) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
MAJOR COMPONENTS
2
6
UVWO
3
1
4
5
AMP
1000
2000
0
3000
RPM
7
Table 4. Generator Major Components
8
ITEM NO. DESCRIPTION
1 Muffler Assembly
2 Engine Assembly
3 Enclosure Assembly
4 Generator Assembly
5 Output Terminal Assembly
6 Battery Assembly
7 Fuel Tank Assembly
8 Generator Control Panel Assembly
9 Engine Operating Panel Assembly
Figure 3. Major Components
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 17
GENERATOR CONTROL PANEL
1000
2000
3000
0
R P M
OFF
W
U
V
OFF
W-U
V-W
U-V
DECREASE
INCREASE
1
2
4
3
6
7
5
STOP
OPERATION
(PRE-HEAT)
START
Figure 4. Generator Control Panel
The definitions below describe the controls and functions
of the Generator Control Panel (Figure 4).
1. Voltage Regulator Control — Allows ±15% manual
adjustment of the generator’s output voltage.
2. Main Circuit Breaker—This three-pole, 60A main
breaker is provided to protect the the U,V, and W
Output Terminal Lugs from overload.
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. 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.
5. AC Voltmeter — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
6. AC Ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
7. Frequency Meter — Indicates the output frequency
in hertz (Hz). Normally 60 Hz.
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the generator
function.
The Control Box is equipped with the following major
components:
Over-Current Relay
Automatic Voltage Regulator (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
NOTICE
Remember the overcurrent relay monitors the current
flowing from the U,V, and W Output Terminal Lugs
to the load.
In the event of a short circuit or over current condition,
it will automatically trip the 60 amp main breaker.
To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
PAGE 18 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
ENGINE OPERATING PANEL
1000
2000
3000
0
R P M
OFF
W
U
V
OFF
W-U
V-W
U-V
DECREASE
INCREASE
STOP
OPERATION
(PRE-HEAT)
START
3
1
2
4
5
6
7
8
9
10
11
12
Figure 5. Engine Operating Panel
The definitions below describe the controls and functions
of the Engine Operating Panel (Figure 5).
1.
Panel Light Switch — When activated will turn on control
panel light.
2. Panel Light — Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel light
switch to the OFF position.
3. Oil Pressure Alarm Lamp — Indicates that the oil
pressure is too low or high and will shut down the engine.
4. Oil Pressure Alarm Lamp — Indicates that the water
temperature is outside of normal range and will shut
down the engine.
5. Fuel Filter Water Lever Alarm Lamp — Indicates that
water level in the fuel level has risen. Drain the water in
the fuel filter strainer when this condition occurs.
6. Preheat Lamp — When the ignition key is placed in
the preheat position, this lamp will illuminate to indicate
preheating of the engine glow plugs. When the lamp turns
off, this indicates that the preheat cycle is complete and
the engine can be started.
7. Ignition Switch — Three position switch, stop, operation
and start. Insert ignition key to start and stop engine.
8. Oil Pressure Gauge — Normal operation should be
between 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.
9. Water Temperature Gauge — During normal operation
this gauge be should read between 165° F to 203° F.
10. Charging Ammeter Gauge — Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
11. Fuel Gauge — Indicates amount of diesel fuel available
12. Tachometer — Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 19
OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
The Output Terminal Panel (Figure 6) shown below is
located on the right-hand side (left from control panel) of
the generator. Lift up on the cover to gain access to
receptacles and terminal lugs.
NOTICE
Terminal legs “O” and “Ground” are considered bonded
grounds.
OUTPUT TERMINAL FAMILIARIZATION
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
Two 120/240V output receptacles @ 50 amp
Two Circuit Breakers @ 50 amps
Two 120V GFCI receptacles @ 20 amp
Two GFCI Circuit Breakers @ 20 amps
Five Output Terminal Lugs ( U, V, W, O, Ground)
Figure 6. Output Terminal Panel
PAGE 20 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles provided on the output terminal panel.
These receptacles can be accessed in any voltage
selector switch position. Each receptacle is protected by a
20 amp circuit breaker. These breakers are located directly
above the GFCI receptacles. Remember the load output
(current) of both GFCI receptacles is dependent on the load
requirements of the U, V, and W output terminal lugs.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 7) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
GFCI receptacles. Remember the load output (current) on
each receptacle is dependent on the load requirements of
the output terminal lugs.
Turn the voltage regulator control knob (Figure 9) 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.
Figure 9. Voltage Regulator Control Knob
Removing the Plastic Face Plate (Hard Wire
Hookup Panel)
The output terminal lugs are protected by a plastic face
plate cover (Figure 10). Un-screw the securing bolts and
lift the plastic terminal cover to gain access to the terminal
enclosure.
Figure 7. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are two 120/240V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 8) 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.
Figure 8. 120/240V Twist-Lock Auxiliary
Receptacles
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 10. Plastic Face Plate
(Output Terminal Lugs)
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 21
OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the output
terminal lugs or the convenience receptacles (Figure 11).
Make sure to read the operation manual before attempting
to connect a load to the generator.
To protect the 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.
Over Current Relay
An over current relay (Figure 12) 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
current relay must be pressed. The over current relay is
located in the control box.
Figure 12. Over Current Relay
Figure 11. Connecting Loads
PAGE 22 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
LOAD APPLICATION
SINGLE PHASE LOAD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require
130—150% more wattage than the rating on the nameplate,
as the wattage is influenced by the efficiency, power factor
and starting system of the equipment.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
THREE PHASE LOAD
When calculating the power requirements for 3-phase
power use the following equation:
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. SeeTable 6.
Table 5. Power Factor By Load
Type of Load Power Factor
Single-phase induction motors 0.4-0.75
Electric heaters, incandescent lamps 1.0
Fluorescent lamps, mercury lamps 0.4-0.9
Electronic devices, communication
equipment
1.0
Common power tools 0.8
Table 6. Cable Selection (60 Hz, Single Phase Operation)
Current
in
Amperes
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
Load in Watts Maximum Allowable Cable Length
At 100
Volts
CAUTION: Equipment damage can result from low voltage
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
When connecti ng a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
DANGER
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11) — PAGE 23
GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 13). To 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.
Voltage Selector Switch
The voltage selector switch (Figure 13) is located above
the output terminal panel’s Hard Wire Hook-up Panel. It
has been provided for ease of voltage selection.
Figure 13. Voltage Selector Switch
Voltage Selector Switch Locking Button
To lock the voltage selector switch, press and hold the
red button located at the bottom of the switch. While
holding the red button down, insert a pad lock into the hole
next to the button to retain it in the inward locked position.
When the lock is removed, the red button is spring loaded
and will return to its normal outward unlocked position .
CAUTION
NEVER change the position of the voltage selector
switch while the engine is running. ALWAYS place
circuit breaker in the OFF position before selecting
voltage.
Table 7. Voltages Available
UVWO Output
Terminal Lugs
Line-Line
3Ø
1Ø Line-Neutral 120V 127V 139V 240V 254V 277V
1Ø Line-Neutral/
Line-Line
Voltage Selector Switch
3-Phase 240/139V Position
208V 220V 240V 416V 440V 480V
Voltage Selector Switch Single-Phase 240/120V Position
120V
Line-Neutral
N/A N/A
Voltage Selector Switch
3-Phase 480/270V Position
240V
Line-Line
N/A N/A
Generator Amperage
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed..
Table 8. Generator Maximum Amps
Rated Voltage Maximum Amps
1Ø 120 Volt
1Ø 240 Volt
3Ø 240 Volt 60 amps
3Ø 480 Volt 30 amps
55.6 amps (4 wire)
60A x 2 (Zigzag)
27.8 amps (4 wire)
60A (Zigzag)
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly
related to the voltage being supplied at either the output
terminals or the two twist lock auxiliary receptacles.
Table 9 and Table 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 receptacles.
Table 9. 1Ø GFCI Receptacle Load Capacity
KW in Use
Twist Lock (C6369)
1Ø 240/120V
14.4 0 amps/receptacle
13.2 5 amps/receptacle
12.0 10 amps/receptacle
10.8 15 amps/receptacle
9.6 20 amps/receptacle
Table 10. 3Ø Generator Maximum Amps
KVA in Use
(UVWO Terminals)
3Ø 240/480V
25
20.8
16.7
12.5
8.4
Available Load
Current (Amps)
GFCI Duplex
5-20R 120V
Available Load
Current (Amps)
GFCI Duplex
5-20R 120V
0 amps/receptacle
5 amps/receptacle
10 amps/receptacle
15 amps/receptacle
20 amps/receptacle
PAGE 24 — DCA25USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #3 (07/19/11)
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