Multiquip DCA-25USIXF, DCA-25USI2XF User Manual
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
ULTRA-SILENT
TM
SERIES
MODEL DCA-25USIXF
MODEL DCA-25USI2XF
60 Hz GENERATOR
PARTS LIST NO. M1873400004A (DCA-25USI)
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 ALL TIMES.
DCA-25USIXF/DCA-25USI2XF— PROPOSITION 65 WARNING
Diesel engine exhaust and some of
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/25USI2XFMQ POWER DCA-25USIXF/25USI2XF
MQ POWER DCA-25USIXF/25USI2XF
MQ POWER DCA-25USIXF/25USI2XFMQ POWER DCA-25USIXF/25USI2XF
60 HZ UL60 HZ UL
60 HZ UL
60 HZ UL60 HZ UL
Proposition 65 Warning ............................................... 2
Table Of Contents ....................................................... 3
Parts Ordering Procedures ........................................ 4
Specifications .............................................................. 5
Dimensions(Top, Side, Front) ..................................... 6
Safety Message Alert Symbols ............................... 7-8
Rules for Safe Operation ....................................... 9-13
Generator Decals ................................................. 14-15
Installation ............................................................ 16-17
General Information .................................................. 18
Major Components ................................................... 19
Generator Control Panel........................................... 20
Engine Operating Panel............................................ 21
Output Terminal Panel Familiarization................. 22-24
Load Application........................................................ 25
Gauge Reading/Terminal Panel Connections .... 26-27
Output Terminal Panel Connections .................... 28-29
Setup ....................................................................30-33
Generator Start-up Procedure ............................34-36
Generator Shut-down Procedure ............................. 37
Maintenance......................................................... 38-39
Trailer Maintenance .............................................40-42
Trailer Wiring Diagram .............................................. 43
Engine Wiring Diagram ........................................ 44-45
Generator Wiring Diagram ....................................... 46
Engine Troubleshooting .......................................47-48
Generator Troubleshooting....................................... 49
Explanation of Code in Remarks Column ....................... 50
Suggested Spare Parts .................................................. 51
TRA-SILENT GENERATRA-SILENT GENERA
TRA-SILENT GENERA
TRA-SILENT GENERATRA-SILENT GENERA
TORSTORS
TORS
TORSTORS
COMPONENT DRACOMPONENT DRA
COMPONENT DRA
COMPONENT DRACOMPONENT DRA
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, DCA-25USI2 ........... 66-69
Output Terminal Assembly ......................................... 70-71
Battery Assembly ...................................................... 72-73
Muffler Assembly, DCA-25USI .................................. 74-75
Muffler Assembly, DCA-25USI2 ................................ 76-77
Fuel Tank Assembly .................................................. 78-79
Enclosure Assembly, DCA-25USI ............................. 80-85
Enclosure Assembly, DCA-25USI2 ........................... 86-91
Rubber Seals Assembly ............................................ 92-93
Nameplate and Decals .............................................. 94-95
Terms and Condition of Sale — Parts ............................ 80
NOTE
WIMGSWIMGS
WIMGS
WIMGSWIMGS
Specifications are subject to
change without notice.
1
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):
Order parts on-line using Multiquip’s SmartEquip website!
■
View Parts Diagrams
■
Order Parts
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:
Order via Phone:
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
parts@multiquip.com.
To obtain an MQ Account, contact your
Use the
internet
and qualify for a 5% Discount
on
Standard orders
Fax
your order in and qualify for a 2% Discount
on
Standard orders
Domestic (US) Dealers Call:
for all orders which include
for all orders which include
International Customers
their local Multiquip Representatives for
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
should contact
When ordering parts, please supply:
❒❒
❒
Specify Preferred Method of Shipment:
❒❒
❒
Dealer Account Number
❒❒
❒❒
❒
Dealer Name and Address
❒❒
❒❒
❒
Shipping Address (if different than billing address)
❒❒
❒❒
❒
Return Fax Number
❒❒
❒❒
❒
Applicable Model Number
❒❒
All orders are treated as
and will ship the same day if received prior
www.mqpower.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
PAGE 4 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)
❒❒
✓
UPS/Fed Ex
■
■
■ Next Day
Standard Orders
Priority One
Ground
✓ DHL
✓
Tr u ck
DCA-25USIXF/DCA-25USI2XF— SPECIFICATIONS
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DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 5
DCA-25USIXF/DCA-25USI2XF— DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
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PAGE 6 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)
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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
been developed to provide
NOTE
Before using this generator, ensure that the operating
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
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
complete instructions for the
safe and efficient operation of
the generator.
Manual has
HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "
appear throughout this manual, and will be referenced in
conjunction with Safety "
WARNING - LETHAL EXHAUST GASES
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
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.
Hazard Symbols
Message Alert Symbols
Diesel engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH
if inhaled. NEVER operate this
Diesel fuel
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.
is extremely flammable, and
" which
".
WARNING
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
WARNING - BURN HAZARDS
Engine components can generate extreme
heat. To prevent burns, 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.
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there
exists the possibility of
electrical shock or burn,
severe bodily harm
electrocution,
which can cause
or even
DEATH!
1
DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 7
DCA-25USIXF/DCA-25USI2XF— SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
or guards removed. Keep
hair
and clothing away from all moving
parts to prevent injury.
CAUTION - ACCIDENTAL STARTING
ALWAYS place the Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump is not in
use.
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.
fingers, hands
CAUTION - RESPIRATORY HAZARDS
,
CAUTION - SIGHT AND HEARING HAZARDS
CAUTION - EQUIPMENT DAMAGE MESSAGES
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
CAUTION - ENGINE LOAD (WET-STACKING)
ALWAYS wear approved
protection.
ALWAYS wear approved
hearing
protection.
respiratory
eye
and
NOTE
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
This generator, other property, or
the surrounding environment
could be damaged if you do not
follow instructions.
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system, which
can foul the fuel injectors, engine valves and exhaust
system, including 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
DANGEROUS
GAS FUMES
Denyo
■
DANGER - READ THIS MANUAL!
Failure to follow instructions in this manual may lead to
serious injury
or even
DEATH
! This equipment is to be
operated by trained and qualified personnel only! This
equipment is for industrial use only.
The following safety guidelines should always be used when
operating the 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 use accessories or attachments, which are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
■
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.
any enclosed or narrow area where free flow of the air is
restricted. If the air flow is restricted it will cause serious
damage to the generators
or engine and may cause
injury to people.
Remember the generator's
engine gives off
carbon monoxide gas.
NEVER
DEADLY
operate the generators in
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
■
medicine.
■
NEVER operate this equipment under the influence or
drugs or alcohol.
■
■
ALWAYS wear proper respiratory (mask),
hearing and eye protection equipment when
operating the generator.
■
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 refuel in a well-ventilated area, away from sparks
and open flames.
ALWAYS use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool. DO NOT
smoke
around or near the
machine. Fire or explosion could result
from fuel vapors, or if fuel is spilled on a
hot engine.
NEVER operate the generator in an
explosive atmosphere or near
combustible materials. An explosion or
fire could result causing severe
bodily
harm or even death.
NEVER disconnect any
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.
"emergency or safety devices"
.
1
DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 9
DCA-25USIXF/DCA-25USI2XF— RULES FOR 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 is on level ground before use.
■
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
set at the factory prior to shipping.
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
hot!
functions. Contact with
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.
components can
Power Cord Safety
■
NEVER let power cables or cords
■
NEVER
is being transfer to a load.
■
NEVER use a defective or frayed power cable. Check the
cable for cuts in the insulation.
■
NEVER use a 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.
stand in water
while AC power from the generators
lay in wate
r.
■
■
■
■
■
Grounding Safety
■
ALWAYS make sure that electrical circuits are properly
grounded
local codes before operating generator. Severe
death!
ungrounded generator.
■
ALWAYS make sure the generators are properly grounded to
a suitable earth ground (GROUND ROD). See installation in
this manual.
per the
National Electrical Code
(NEC) and
injury
by electrocution can result from operating an
or
■
■
■
The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits.
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 or plastic containers to dispose of
hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
Turn all circuit breakers OFF before
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 on the generator.
Follow all battery safety guidelines listed in this manual
when handleing or servicing the generator.
■
NEVER use
gas piping
PAGE 10 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)
as an electrical ground.
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
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
coolant drain plug while the engine is
hot will result in hot coolant gushing
out of the coolant drain plug, therefore
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:
■
The battery contains acids that can
cause injury to the eyes and skin. To
avoid eye irritation,
glasses.
■
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
■■
■
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
wear safety
severe injury
or
DEATH:
■■
■
ALWAYS keep battery charging and cables in good
■■
working condition. Repair or replace all worn cables.
■■
■
ALWAYS recharge the battery in an vented air
■■
environment, to avoid risk of a dangerous concentration
of combustible gases.
■■
■
In case the battery liquid (dilute sulfuric acid) comes in
■■
contact with
immediately with plenty of water.
■■
■
In case the battery liquid (dilute sulfuric acid) comes in
■■
contact with your
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
clothing or skin
EYES
, rinse skin or clothing
, rinse eyes immediately with
1
DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 11
DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION
ACCIRCUIT
BREAKER
OF
F
2
2
A
120
V
20A
120V
OFF
ON
GA-2.9R
ACCIRCUIT
BREAKER
OFF
2
2A
120
V
20A
120V
OFF
ON
GA-2.9R
ACCIRCUIT
BREAKER
O
FF
22A
120
V
20A
120V
OFF
ON
GA-2.9R
DANGERDANGER
DANGER
DANGERDANGER
During operation of this generation, there
exists the possibility of
electrical shock or burn
cause
severe bodily harm
DEATH!
To avoid these hazards:
NEVER use
Electrocution HazardsElectrocution Hazards
-
Electrocution Hazards
Electrocution HazardsElectrocution Hazards
electrocution
, which can
or even
damaged
or
worn
cables when connecting
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.
equipment to the generator. Make sure power connecting
cables are securely connected to the generator’s output
receptacles, incorrect connections may cause damage
to the generators and electrical shock.
NEVER grab or touch a live
power cord with wet hands, the
possibility exist of electrical
shock, electrocution, and even
death!
DANGERDANGER
DANGER
DANGERDANGER
Lethal Exhaust Gas HazardsLethal Exhaust Gas Hazards
Lethal Exhaust Gas Hazards
-
Lethal Exhaust Gas HazardsLethal Exhaust Gas Hazards
DANGER
Using a generator indoors .CAN KILL YOU IN MINUTES
Generator exhaust contains carbon monoxide. This is
a posion you cannot see or smell
2900
GA-2.9R
F
F
2A
O
2
ACCIRCUIT
2900
F
A
F
2
O
2
ACCIRCUIT
BREAKER
NEVER use inside a home
or garage, even if doors
and windows are open
Avoid other generator hazards.
2900
120V
F
A
F
2
O
2
ACCIRCUIT
BREAKER
Only use OUTSIDE and
far away from windows,
doors, and vents.
BREAKER
.READ MANUAL BEFORE USE
Emergencies
NEVER insert any objects into
the output receptacles during
■
ALWAYS know the location of the
nearest
operation. This is extremely
dangerous. ALWAYS turn-off
the generators and place all circuit breakers in the “OFF”
position when contact with the output receptacles is
required. There exist the possibility of
electrocution,
■
ALWAYS know the location of the nearest
first aid kit
electrical shock or burn, which can cause severe
bodily harm or even death
Backfeed to a utility system can cause
electrocution
NEVER connect the generators to a
building's electrical system without a
transfer switch or other approved device.
All installations should be performed by
licensed electrician
a
with all applicable laws and electrical
codes. Failure to do so could result in
electrical shock or burn causing serious
injury or even death!
and or property damage.
!
in accordance
■
In emergencies
nearest phone or
Also know the phone numbers of the nearest
ambulance, doctor
information will be invaluable in the case of an
emergency.
fire extinguisher
.
.
always
know the location of the
keep a phone on the job site
and
fire department
.
. This
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
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 towing 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 - FOLLOW TOWING REGULATIONS
Check with your local county or state safety towing
regulations, in addition to meeting
Transportation
towing your generator.
■
ALWAYS shutdown engine before transporting.
■
Drain fuel from generator fuel tank before towing.
■
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. Follow the listed
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.”
(DOT)
Safety Towing Regulations
Towing & Transporting Safety
Department of
, before
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
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
Place
while parked.
■
Use the trailer’s 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
prevent tipping, while parked.
■
Avoid sharp turns to prevent rolling.
■
DO NOT transport generator with fuel in tank.
chock blocks
support blocks
underneath wheel to prevent rolling,
underneath the trailer’s bumper to
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
■
Check the tire air pressure on both towing vehicle and
trailer.
Also check the tire tread wear on both vehicles.
■
ALWAYS 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.
Trailer tires should be inflated to 50 psi cold.
DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 13
NOTE
For more saftey tips, see the trailer saftey
guidelines section in this manual.
1
DCA-25USIXF/DCA-25USI2XF— DECALS
Figure 2. Generator Decals
PAGE 14 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)
DCA-25USIXF/DCA-25USI2XF— DECALS
Figure 3. Generator Decals (Continued)
DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 15
1
DCA-25USIXF/DCA-25USI2XF— INSTALLATION
Figure 4. Typical 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.
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
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 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) 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. 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.
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat excessively
and possibly burn the valves.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
NOTE
When connecting the generator
to any buildings electrical
system ALWAYS consult with
a licensed electrician.
1
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
Open Delta Excitation System
This generator is equipped with the state of the art "
excitation system. The open delta system consist of an electrically
independent winding wound among stationary windings of the AC
output section.
as a high quality portable (requires a trailer for transport) power
source for telecom sites, lighting facilities, power tools,
submersible pumps and other industrial and construction
machinery.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
Tachometer
Water Temperature Gauge/ Alarm Lamp
Oil Pressure Gauge/ Alarm Lamp
Charging Ammeter Gauge
Pre-Heat Lamp
Panel Light
Panel Light Switch
Ignition/Preheat Switch
Fuel Gauge
Fuel Filter Water Level Alarm Lamp
Fuel Leak Detected Alarm Lamp
Generator Control Panel
The “Generator Control Panel” is provided with the following:
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
3-Pole, 60 amp Main Circuit Breaker
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
Two 250 VAC output receptacles (CS-6369), 50 amps
Two auxilliary circuit breakers, 250V @50 amps
Two 125 VAC output receptacles, (GFCI), 20 amps
Two GFCI circuit breakers, 125V@ 20amps
Five output terminal lugs (3Ø power)
Control Box
The “Control Box” is provided with the following:
Automatic Voltage Regulator
Current Transformer
Emergency Relay
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 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-delta design provides virtually unlimited excitation current,
offering maximum motor starting capabilities. The excitation does
not have a "
the required load.
Engine
These generator’s 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) is held to a minimum. Use the cable selection chart
(Table 6 ) as a guide for selecting proper extension cable size.
fixed ceiling
" and responds according the demands of
Open-Delta
"
PAGE 18 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)
DCA-25USIXF/DCA-25USI2XF— MAJOR COMPONENTS
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Figure 5. Major Components
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1
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
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 output voltage present
at the UVWO terminals.
" (Figure 6).
Located behind the generator control panel is the
Control Box
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
NOTE
Generator
. This box contains some of the necessary
Remember the
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.
overcurrent relay
7. AC Ammeter – Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
PAGE 20 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)
To restore power to the UWVO output terminals, press the
reset
circuit breaker in the
button on the overcurrent relay and place the
closed
position (ON).
main
DCA-25USIXF/DCA-25USI2XF— ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
The definitions below describe the controls and functions of
the "
Engine Operating Panel
1. Panel Light - Normally used in dark places or at night.
When activated, panel will luminate. When the generator
is not in use, turn the panel light switch to the OFF
position.
2. Water Temperature Lamp - Indicates that the water
temperature is outside of normal range and will shut
down the engine.
3. Oil Pressure Lamp - Indicates that the oil pressure is
too low or high and will shut down the engine.
4. 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.
5. 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.
6. Water Temperature Gauge – During normal operation this
gauge should read between 165°~203° F. (74°~95° C).
" (Figure 7).
7. 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.
8. Fuel Gauge - Indicates amount of diesel fuel available.
9. 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.
10. Ignition Switch – Four position switch, pre-heat, stop,
run and start. Insert ignition key to start and stop engine.
11. Pre-Heat Lamp - Indicates (ON) when the engine is
ready for starting during cold weather operating
conditiions.
12. Fuel Leak Detected Alarm Lamp - This lamp will
illuminate when a leak in the fuel containment enclosure
is detected.
13. Panel Light Switch- When activated, will turn on control
panel light.
1
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
Output Terminal Panel
The
(Figure 8) 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
Output Terminal Familiarization
The “
Output Terminal Panel
following:
■■
■
Two (2) 120/240V output receptacles @ 50 amp
■■
lugs.
■■
■
Two (2) Circuit Breakers @ 50 amps
■■
■■
■
Two (2) 120V GFCI receptacles @ 20 amp
■■
■■
■
Two (2) GFCI Circuit Breakers @ 20 amps
■■
.
■■
■
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
■■
■■
■
One Main Circuit Breaker @60 amps
■■
NOTE
Terminal legs “O” and “Ground”
are considered
bonded grounds
FAMILIARIZATION
” (Figure 6) is provided with the
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 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any
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
being tripped. Pressing the
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
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
when the voltage selector switch is placed in the
phase 240/120 position.
reset
button resets the GFCI receptacle after
Figure 9. G.F.C.I. Receptacle
voltage selector switch
Test Button
(See Figure 9) in
only
be accessed
single-
Each auxilliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
Output Terminal Lugs
Turn the
control panel to obtain the desired voltage. Turning the knob
clockwise will
clockwise will
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.
FAMILIARIZATION
.
voltage regulator control knob
increase
decrease
Figure 11. Voltage Regulator Control Knob
the voltage, turning the knob counter-
the voltage.
(Figure 11) on the
Figure 12. Plastic Face Plate (UVWO Terminals)
Figure 10. 120/240V Twist-Lock
Auxiliary Receptacles
DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 23
1
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 read the operation manual before attempting to connect
a load to the generator.
To protect the UVWO output terminals from overload, a 3-pole,
main
60 amp,
ALL
circuit breakers to the "OFF" position prior to starting the
engine.
circuit breaker is provided. Make sure to switch
Over Current Relay
An
over current relay
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
rent relay must be pressed. The over current relay is located in the control box.
FAMILIARIZATION
(Figure 14) is connected to the main
reset button
Figure 14. Over Current Relay
on the over cur-
Figure 13. Connecting Loads
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
bodily harm
completely off before attempting to replace
or handle this fuse.
electrocution
. ALWAYS turn the unit
and
severe
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
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
,
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
NOTE
starting system of the equipment.
If wattage is not given on the
equipment's name plate,
NOTE
approximate wattage may be
determined by multiplying
nameplate voltage by the
nameplate amperage.
NOTE
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
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the appliance or tool and overheat the cable. See Table 6.
AMPERAGE
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
maybe determined by multiplying
voltage by amperage by 1.732.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
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■■
■
When connecting a resistance load such as an
■■
incandescent lamp or electric heater, a capacity of up to
the generating set’s rated output (kW) can be used.
■■
■
When connecting a fluorescent or mercury lamp, a
■■
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
■■
■
When connecting an electric drill or other power tools,
■■
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
DANGER - ELECTRICAL SYSTEM HAZARDS
Before connecting this generator to any building’s electrical
system, a
(transfer) switch
licensed electrician
must install an
. Serious damage to the building’s
isolation
electrical system may occur without this transfer switch.
1
DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 25
DCA-25USI — GAUGE READING/ TERMINAL PANEL CONNECTIONS
Voltage Selector Switch
voltage selector
The
switch (Figure 15) is located above
the output terminal panel’s
Hard Wire Hook-up Panel
Maximum Amps
Table 8 shows the
vide. DO NOT exceed the maximum amps as listed.
. It
has been provided for ease of voltage selection.
Figure 15. Voltage Selector Switch
GFCI Receptacle Load Capability
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,
hold
the
red button
located at the bottom of the switch.
press
and
The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals 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
CAUTION - CHANGING VOLTAGES
NEVER change the position of the
voltage selector switch
not to exceed the available current capability at the receptacles.
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
knob
located on the control panel.
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PAGE 26 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)
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
Selector Switch
the required voltage (For example, for 3Ø 240V, choose the
center 3Ø 240/139V position on
the voltage selector switch.)
Figure 16. Voltage Selector
Switch 240/139V Three Phase
Position
NOTE
Reading Voltage
.
Voltage
(Figure 16) to the position which produces
For 3Ø 208V/1Ø,120V, place
the Voltage Selector Switch
in the 3 Phase 240/139
position.
Reading Amperage
To determine the amperage at a terminal lug, set the
AC Ammeter Change-Over Switch
setting (Figure 19) to activate the
(Figure 20 and read the available amperage at the terminal lug.
For example, to measure the amperage at the U
terminal lug, set the
to U and read the AC Ammeter Gauge.
Figure 19. AC Ammeter
Change-Over Switch
NOTE
to the appropriate
AC Ammeter Gauge
AC Ammeter Change-Over Switch
Figure 20. AC Ammeter
(Amp reading on U lug)
The
ammeter
show a reading when the
Output Terminal Lugs
connected to a load and in use.
gauge will only
are
To determine the voltage between two terminal lugs, set the
AC Voltmeter Change-Over Switch
setting (Figure 17) to activate the
(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
to W-U and read the
Figure 17. AC Voltmeter
Change-Over Switch
AC Voltmeter Change-Over Switch
AC Voltmeter Gauge
Figure 18. AC Voltmeter
(Volt reading on W-U Lug)
to the appropriate
AC Voltmeter Gauge
.
Gauge
1
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
Various output voltages can be obtained using the
Terminal Lugs
dent on the position of the
adjustment of the
Remember the voltage selector switch determines the
of the output voltage. The voltage regulator (VR) allows the
user to increase or decrease the selected voltage.
3Ø 240/139 Output Terminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 21.
. The voltages at the terminals are depen-
Voltage Selector Switch
Voltage Regulator Control Knob
Output
and the
.
range
3Ø 208V/1Ø120V Output Terminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 24.
2. Connect the load wires to the
shown in Figure 25.
CONNECTIONS
Use this position for
3Ø-240 or 1Ø120V.
Figure 24. Voltage Selector
Switch 240/139V
Three-Phase Position
Output Terminal Lugs
as
Figure 21. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the
shown in Figure 22.
Figure 22. Output Terminal Lugs
3Ø-240/139V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Output Terminal Lugs
as
Figure 25. Output Terminal Lugs
3Ø-208/120V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
To achieve a 3Ø 208V output
the voltage selector switch
NOTE
must be in the 3Ø-240/139
position and the voltage
regulator must be adjusted to
208V.
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
3Ø 480/277 Output Terminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 26.
Figure 26. Voltage Selector Switch 480/277V
Three-Phase Position
2. Connect the load wires to the
shown in Figure 27.
Output Terminal Lugs
1Ø 240V/120V Output Terminal Lug Voltages
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 28.
Figure 28. Voltage Selector Switch 240/120V
2. Connect the load wires to the
as
shown in Figure 29.
CONNECTIONS
Single-Phase Position
Output Terminal Lugs
as
Figure 27. Output Terminal Lugs
3Ø-480/277V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 29
Figure 29. Output Terminal Lugs
1Ø-240/120V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
1
DCA-25USIXF/DCA-25USI2XF— SETUP
Circuit Breakers
Fuel Check
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
DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.
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.
Refilling the Fuel System
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
This generator has an internal fuel tank located inside the
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the Isuzu Engine Owner's Manual. Oil should be warm
before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classification CH-4
API Service Classification CG-4
API Service Classification CF-4
ACEA Specification E3
ACEA Specification E2
Table 11. Recommended Motor Oil
30
OIL: SAE
5W30
ARCTIC OIL
10W/40
15W30
20W40
10W
10W30
122
104
86
68
50
-14
-22
-40
F
C
50
40
30
20
10
10W40
032
-10
-20
-4
-30
-40
trailer frame and may also be equipped with an environmental
fuel tank (Figure 31).
fresh
#2 diesel fuel.
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.
hot
engine can cause a
ALWAYS
fill the fuel tanks with clean
fire
or
explosion
DO NOT fill the fuel tanks beyond their
Figure 31. Internal Fuel Tank System
.
PAGE 30 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)
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