Multiquip DCA-25USIXF, DCA-25USI2XF User Manual

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

ULTRA-SILENT

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.

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

Standard orders

Fax

your order in and qualify for a 2% Discount

Standard orders

Domestic (US) Dealers Call:

for all orders which include

International Customers

their local Multiquip Representatives for

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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A).mm596(.ni03.72F ).mm091,2(.ni02.68

B).mm05

C).mm575(.ni46.22H ).mm097(.ni01.13

D).mm036(.ni08.42

E).mm035(.ni09.02

PAGE 6 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

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).mm(.ninoisnemiDretteLecnerefeR).mm(.ninoisnemiD

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!

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"

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

■

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

■

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

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

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

120

20A

120V

OFF

GA-2.9R

ACCIRCUIT BREAKER

OFF

120

20A

120V

OFF

GA-2.9R

ACCIRCUIT BREAKER

22A

120

20A

120V

OFF

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

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

ACCIRCUIT

2900

ACCIRCUIT BREAKER

NEVER use inside a home or garage, even if doors and windows are open

Avoid other generator hazards.

2900

120V

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.

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

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.

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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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.

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 21

DCA-25USIXF/DCA-25USI2XF— OUTPUT TERMINAL PANEL

Output Terminal Panel

The

(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

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

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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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.

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

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

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

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

shown in Figure 29.

CONNECTIONS

Single-Phase Position

Output Terminal Lugs

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.

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

OIL: SAE

5W30

ARCTIC OIL

10W/40

15W30

20W40

10W

10W30

122

104

-14

-22

-40

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

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)

DCA-25USIXF/DCA-25USI2XF— SETUP

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 32).

CAUTION - REFUELING THE GENERATOR

ALWAYS

to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

place trailer on firm level ground before refueling

3. Open cabinet doors on the “right side” of the generator

3. NEVER overfill fuel tank – It is important to read the

(from generator control panel position). Remove fuel cap and fill tank (Figure 33).

Figure 33. Fueling the Generator

fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 34).

Figure 32. Only Fill on Level Ground

NOTE

ONLY! use

refueling.

#2 diesel fuel

when

Figure 34. Full Fuel Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVER-FILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 35).

Figure 35. Fuel Expansion

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 31

DCA-25USIXF/DCA-25USI2XF— SETUP

Coolant (ISUZU Antifreeze/Summer Coolant/Water)

ISUZU recommends ISUZU Antifreeze/Summer Coolant for use in thier engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the ISUZU Engine Owner's Manual for further details.

Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the

negative

WARNING - BURN HAZARDS

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in

If adding coolant/antifreeze mix to the

accordance with the ISUZU Engine Owner's Manual.

radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of

hot!

coolant exists which

can cause severe burns.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the ISUZU

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 12 for engine, radiator, and recovery tank coolant

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 36) when depressed with the thumb as shown below.

capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

battery terminal disconnected.

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Operation Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

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When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

less than 50%.

Figure 36. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

PAGE 32 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— SETUP

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation ALWAYS be sure the battery cables (Figure 37) are properly

connected to the battery terminals as shown below. The Red Cable is connected to the positive terminal of the battery,

and the Black Cable is connected to the negative terminal of the battery.

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the Heat, RUN, or START position. ALWAYS make sure that the ignition switch is in the STOP position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTE

CAUTION - BATTERY SERVICING SAFETY

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

Alternator

ignition

switch is in either the Pre-

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION - BATTERY SERVICING SAFETY

ALWAYS

reconnect negative terminal LAST.

disconnect the negative terminal FIRST and

Figure 37. Battery Connections

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrision and damage the alternator.

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose ( immediately.

fuel

oil

) lines are defective replace them

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 33

DCA-25USIXF/DCA-25USI2XF— GENERATOR START-UP PROCEDURE

Before Starting

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER!

1. Place the

manually start the engine with the

auxiliary

(Figure 38) in the OFF position prior to starting the engine.

circuit breakers in the ON (closed) position.

main, G.F.C.I.,

and

aux.

main, GFCI

circuit breakers

Start-up Procedure

1. Place the position (Figure 40).

2. In warm weather conditions, skip to step 3. Preheat the

engine (Figure 41) to the RUN position. When the preheat lamp (Figure 42) illuminates, proceed to step 3.

voltage selector switch

Figure 40. Voltage

Selector Switch

glow plugs

by turning the ignition key

in the desired voltage

Figure 38. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Connect the load to the

Terminal Lugs

connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

3. The output terminal lugs are protected by a plastic cover. Remove this cover to gain access to the terminals. Tighten terminal nuts securely to prevent load wires from slipping out.

4. Close all engine enclosure doors (Figure 39).

as shown in (Figure 11). These load

receptacles or

the

Output

INCORRECTCORRECT

Figure 41. Ignition Switch Pre-Heat

(Run Position)

Figure 42. Pre-Heat Indicator Lamp

Figure 39. Engine Enclosure Doors

PAGE 34 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— GENERATOR START-UP PROCEDURE

3. Turn the ignition key to the START position (Figure 43). Once the engine starts, release the ignition key and allow it to return to the RUN position (Figure 41).

If the engine fails to start after 10 seconds, wait approximately 30 seconds and repeat steps 2-3.

Figure 43. Ignition Switch (Start Position)

4. Let the engine idle for 3-5 minutes, listen and check for any abnormal sounds or smells. Check for fuel leaks, and noises that would associate with a loose cover or hardware.

Check the electric motor fan cooling the radiator for abnormal speed, sound or vibration conditions.

If any of the above mentioned conditions exists, shutdown the engine and correct the problem before operating the generator.

5. The generator's frequency meter (Figure 44) displays the 60 cycle output frequency in HERTZ.

6. The generator's AC-voltmeter (Figure 45) displays the output voltage in VOLTS. If the voltage is not within the specified frequency tolerance, use the voltage adjustment control knob (Figure 46) to increase or decrease the desired voltage.

7. The ammeter (Figure 47) will indicate zero amps with no load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator.

Figure 45. AC Voltmeter

Figure 46. Voltage Adjust Control Knob

Figure 44. Frequency Meter (Hz)

Figure 47. Ammeter (No Load)

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 35

DCA-25USIXF/DCA-25USI2XF— GENERATOR START-UP PROCEDURE

8. The engine oil pressure gauge (Figure 48) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 28~71 psi (193~490 kPa).

Figure 48. Oil Pressure Gauge

9. The coolant temperature gauge (Figure 49) will indicate the coolant temperature. Under normal operating conditions the coolant temperature is between 165°~203° F. (74°~95° C).

11. Turn the ON position (Figure 51).

12. Observe the generator's ammeter (Figure 52) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if the load is in use.

main, GFCI

Figure 51. Main, AUX. and GFCI

Circuit Breakers (ON)

, and

aux

. circuit breakers to the

Figure 49. Coolant Temperature Gauge

10. The tachometer (Figure 50) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 50. Engine Tachometer

13. The generator will run until manually stopped or an abnormal condition occurs.

Figure 52. Ammeter (Load)

PAGE 36 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— GENERATOR SHUT-DOWN PROCEDURE

Normal Shut-down Procedure

To shutdown the generator, use the following procedure:

1. Switch the MAIN, AUX and GFCI circuit breakers (Figure 53) to the OFF position (no load).

Figure 53. Main, AUX. and GFCI

Circuit Breakers (OFF)

3. Let the engine cool by running it for 3-5 minutes with no load applied (circuit breakers in the OFF position).

4. Place the ignition switch (Figure 54) in the “STOP” position, remove the key and store in a safe place.

Emergency Shut-down Procedure

1. To shut-down the engine in the event of an emergency, switch the breakers to OFF position.

2. Turn the ignition switch key to the STOP position (Figure 54).

Automatic Shut-down System

This unit is equipped with safety devices to automatically stop the engine in the event of low oil pressure, approximately 14 psi (97 kPa), or high water temperature, approximately 230° F (110° C). The alarm lamps on the Engine Control Panel illuminate to signify the reason for the shutdown.

After automatic shut-down, eliminate any problems before attempting to restart. Failure to do so can damage the unit.

Before inspecting, turn the position, place all position and allow sufficient time for adequate cooling. When ready to restart, complete all steps in the Generator Startup Procedure section of this manual.

MAIN, GFCI

CAUTION - AUTOMATIC SHUT-DOWN

Generator Circuit Breakers

and

LOAD

ALWAYS

starter switch

(Figure 53) circuit

inspect the unit and

to the STOP

in the OFF

Figure 54. Ignition Switch (Off Position)

5. Remove

6. Allow for sufficient time for cooling and then inspect the complete unit for any damage or loosening that may have occured during operation.

7. Check the engine oil, coolant and fuel levels. Replenish as necessary.

all

loads from the generator.

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 37

NOTE

Regularly maintain the unit as specified in the Maintenance section of this manual to prevent damage.

Engine protection is furnished during operation, but cannot replace normal preventive maintenance.

DCA-25USIXF/DCA-25USI2XF— MAINTENANCE

ECNANETNIAM/NOITCEPSNI.41ELBAT

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General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use

Table 14 as a general maintenance guideline.

Engine Side,

refer to the Engine Instruction Manual

Air Cleaner

Every 50 hours: Remove air cleaner element and clean the heavy duty paper element with kerosene, or foam element with liquid

Service Daily

If the engine is operating in very clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more conditions exists.

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations). Always pour through the mesh filter.

detergent and hot water. Wrap foam element in a cloth and squeeze dry. For heavy duty paper element, wipe excess kerosene with towel.

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows “RED” meaning the element

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally remove the drain cock and drain the contents. During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

needs changing. After changing the air element, press the dust indicator button to reset the indicator.

PAGE 38 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

dusty

dry grass

conditions, a

frequently

if these

DCA-25USIXF/DCA-25USI2XF— MAINTENANCE

Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure.

To restart after running out of fuel, turn the switch to the ON position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 30.

Replacing Oil Filter



Detach the oil filter by loosening center bolt and remove the element together with the filter body.



Apply a film of oil to the gasket for the cartridge.



Install the filter body together with the element and fix them by tightening the center bolt.



After the oil cartridge has been replaced, the engine oil will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

Flushing Out Radiator and Replacing Coolant



Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.



Check hoses for softening and kinks. Check clamps for signs of leakage.



Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.



Tighten both cocks and replace the overflow tank.



Replace with coolant (Table 12 for correct mixture).



Close radiator cap tightly.

WARNING - BURN HAZARDS

Allow engine to radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Generator Storage

For longe term storage of the generator the following is recommended:



Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.



Completely drain the oil from the crankcase and refill if necessary with fresh oil.

cool

when flushing out



Replacing Fuel Filter



Replace the fuel filter cartridge with new one every 400 hours or so.



Loosen the drain plug at the lower top of the fuel filter. Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.



Vent any air.

Feed Pump Strainer Cleaning

The strainer is incorporated in the feed pump inlet side joint bolt. Clean the strainer with compressed air and rinse it in the fuel oil.

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 39

Clean the entire generator, internal and external.



Cover the generating set and store in a clean, dry place.



Disconnect the battery.



Make sure engine coolant is at proper level.



If generator is mounted on a trailer, jack trailer up and place on block so tires do touch the ground or remove tires.

DCA-25USIXF/DCA-25USI2XF— TRAILER MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles

. If driving over rough terrain, inspect the

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 53) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

brakes more frequently. Figure 55 displays the major hydraulic surge brake

components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 15 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the

Figure 55. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake shoes.

Actuator

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying

7. Replace the adjusting hole cover and lower the trailer to

hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “

8. Repeat steps 1 through 7 on the remaining brakes.

sure that it is functioning correctly. Never use an undersize actuator.

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PAGE 40 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— TRAILER MAINTENANCE

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

Suspension

The (Figure 56) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components

CAUTION - EYESIGHT HAZARD

ALWAYS

wear safety glasses when

as detailed in Table 17.

removing or installing force fitted parts. Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

DO NOT attempt to repair or modify a wheel. DO NOT

install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

leaf suspension

springs and associated components

Figure 56. Major Suspension Components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are

hot!

. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 16 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

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LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

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05-XAM03-NIM

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 41

DCA-25USIXF/DCA-25USI2XF— TRAILER MAINTENANCE

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 57). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 18.

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

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Figure 57. Wheel Lug Nuts

Tightening Sequence

NOTE

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

PAGE 42 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— TRAILER WIRING DIAGRAM

Figure 58. Trailer/Towing Vehicle Wiring Diagram

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 43

DCA-25USIXF/DCA-25USI2XF— ENGINE WIRING DIAGRAM

Figure 59A. Engine Wiring Diagram

PAGE 44 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— ENGINE WIRING DIAGRAM

Figure 59B. Engine Wiring Diagram(Continued)

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 45

DCA-25USIXF/DCA-25USI2XF— GENERATOR WIRING DIAGRAM

Figure 60. Generator Wiring Diagram

PAGE 46 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the engine. If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTENIGNE.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

foytisocsivhgihylevissecxE

?erutarepmet

woltalioenigneroleuf

.lioenigneroleufdeificepsehtesU

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

?tungniniaterepip

.tratstonseodenignE

?nrowtfahsmacleuF .ecalpeR

morfkaelnoisserpmoC

?rednilyc

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

noitcejniesooloteudkaelleuF

?gnimitnoitcejnitcerrocnI .tsujdA

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?gninoitcnuflamretratS .ecalperroriapeR

.tunnethgiT

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

.nurtonseodretratS

?detcennocsidgniriW .gniriwtcennoC

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 47

DCA-25USIXF/DCA-25USI2XF— TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?tungniniaterepip

.htoomstonsinoituloverenignE

?erusserp

?deggolc

?lioenigneevissecxE .leveldeificepsehtotecudeR

.devresbosi

sagtsuahxeeulbroetihwrehtiE

?kcuts

?noisserpmoctneicifeD .ecnaraelcpottsujdA

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

.tunnethgiT

.tsujdA

.ecalperroriapeR

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?gnizieseb

?kaelnoisserpmoC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

PAGE 48 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 20 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 49

DCA-25USIXF/DCA-25USI2XF— EXPLANATION OF CODE IN REMARKS

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ...................... 1 ...... INCLUDES ITEMS W/

2*12347 WASHER, 3/8 IN. ... 1 ......

3 12348 HOSE ................... A/R .... MAKE LOCALLY

4 12349 BEARING ............... 1 ...... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same unique symbol

(

, #, +, %, or >) in the number column belong to the same

assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers - Duplicate numbers indicate multiple part numbers are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

without notice

WASHER, 1/4 IN. .............

. Multiquip does not

NOT SOLD SEPARATELY MQ-45T ONLY

QTY. Column

Numbers Used - Item quantity can be indicated by a

number, a blank entry, or A/R. A/R (As Required) is generally used for hoses or other parts

that are sold in bulk and cut to length. A blank entry generally indicates that the item is not sold

separately. Other entries will be clarified in the “Remarks” Column.

REMARKS Column

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit

unique symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Specific Model Number Use

used only with the specific model number or model number variant listed. It can also be used to show a part is NOT used on a specific model or model number variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

COLUMN

- All items on the parts list with the same

- Used to list an effective serial

- Indicates that the part is

PART NO. Column

Numbers Used - Part numbers can be indicated by a

number, a blank entry, or TBD. TBD (To Be Determined) is generally used to show a part

that has not been assigned a formal part number at time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clarified in the “Remarks” Column.

PAGE 50 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

“Make/Obtain Locally”

purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately”

purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.

- Indicates that the part can be

- Indicates that an item cannot be

DCA-25USIXF/DCA-25USI2XF— SUGGESTED SPARE PARTS

DCA-25USIXF/DCA-25USI2XF (Big Tank) W/ISUZU AA-4LE2/BV-4LE2 DIESEL ENGINES 1 TO 3 UNITS

Qty. P/N Description Remarks

3 ......... 8944567411 .............. OIL FILTER, DCA-25USI

3 ......... 8944567412 .............. ELEMENT OIL FILTER, DCA-25USI2

3 ......... 0602046611 .............. AIR ELEMENT

3 ......... 8943692993 .............. CARTRIDGE, FUEL FILTER

1 ......... 0602122272 .............. UNIT, OIL PRESSURE

1 ......... 0602123266 .............. UNIT WATER TEMPERATURE, DCA-25USI

1 ......... 0602123275 .............. UNIT WATER TEMPERATURE, DCA-25USI2

1 ......... 0605505072 .............. FUEL CAP

1 ......... 8972309390 .............. FAN BELT

1 ......... M1312500203 ........... HOSE, RADIATOR UPPER

1 ......... M1312500303 ........... HOSE, RADIATOR LOWER

1 ......... 0601808803 .............. CIRCUIT BREAKER, 20A

1 ......... 0601808804 .............. CIRCUIT BREAKER, 50A

1 ......... 0602103092 .............. ALARM LAMP

1 ......... 0601810245 .............. BULB, ALARM LAMP/PRE-HEAT LAMP

1 ......... 8944024980 .............. KEY, IGNITION SWITCH

1 ......... 0601840073 .............. RHEOSTAT, VOLTAGE REGULATOR

1 ......... 0601840121 .............. KNOB RHEOSTAT

1 ......... 0601820671 .............. AUTOMATIC VOLTAGE REGULATOR, DCA25USI

1 ......... 0601820602 .............. AUTOMATIC VOLTAGE REGULATOR, DCA25USI2

2 ......... 0601802160 .............. FUSE, 5A, DCA-25USI

3 ......... 8944370220 .............. FUEL FILTER KIT

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 51

GENERATOR ASSY.

DCA-25USIXF/DCA-25USI2XF— GENERATOR ASSY.

PAGE 52 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B1110200602 ROTOR ASSY. ............................................... 1 ............. INCLUDES ITEMS W/

1-1

1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 2 0010308035 HEX, HEAD BOLT 6 2A 0040008000 WASHER, LOCK 6 2B 0041208000 WASHER, FLAT 6 3 0070506803 BEARING 1 4 B1130201103 STATOR ASSY. 1 4-1 0845041904 GROMMET 1 5 B1138000003 FIELD ASSY. EXCITER 1 6 0016008045 HEX, SOCKET HEAD CAP SCREW 2 7 0042508000 WASHER, LOCK 3 8 8351315003 END BRACKET 1 9 0017108035 HEX, HEAD BOLT 6 10 8351312004 PACKING 1 11 8351331004 COVER, SUCTION 1 12 0017106016 HEX, HEAD BOLT 3 13 0010310030 HEX, HEAD BOLT 6 13A 0040010000 WASHER, LOCK 6 13B 0041210000 WASHER, FLAT 6 14 B0155400204 COVER, FAN 1 15 0010106030 HEX, HEAD BOLT 1 16 0041206000 WASHER, FLAT 1 17 0600815000 NUT 1 18 M9312600004 RUBBER SUSPENSION 2 19 0207010000 HEX, NUT 2

7961025004 RECTIFIER 1

0601822630 SURGE ABSORBER 1

8001070003 FAN 1

8351611004 COUPLING DISK 2

8351612004 WASHER, COUPLING HUB 1

B1112300003 BALANCING PLATE ...................................... 1 ............. PURCHASE ITEMS 1-10 AS A SET

0010310025 HEX. HEAD BOLT 4

0042510000 WASHER, LOCK 4

0601000209 BALANCING WEIGHT KIT 1

0071906308 BEARING 1

FIELD ASSY. 1

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 53

CONTROL BOX ASSY. (DCAUSIXF ONLY)

DCA-25USIXF— CONTROL BOX ASSY.

PAGE 54 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF— CONTROL BOX ASSY.

CONTROL BOX ASSY. (DCAUSIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

1 M1215000612 CONTROL BOX 1 2 0601808820 CIRCUIT BREAKER, 3P 60A 1 3 0021005080 MACHINE SCREW 4 4 0601823240 RECTIFIER 2 5 0021004040 MACHINE SCREW 1 5A 0040004000 WASHER, LOCK 1 5B 0041204000 WASHER, FLAT 1 6 0601842384 RESISTOR, 20W 50 OHM 1 7 0027104010 MACHINE SCREW 2 8 0601815759 TERMINAL BOARD 1 8A M9521000004 DECAL; TERMINAL SYMBOL 1 9 0027104020 MACHINE SCREW 4 10 0601823863 RELAY UNIT 2 11 0027104016 MACHINE SCREW 4 12 0601820671 AUTOMATIC VOLTAGE REGULATOR 1 13 0027105016 MACHINE SCREW 4 14 0601806115 CURRENT TRANSFORMER, 50/5A 3 15 0027106016 MACHINE SCREW 6

16 0601820845 OVER CURRENT RELAY ....................................1 ............. S/N 8100001~8100586

16 0601820847 OVER CURRENT RELAY ....................................1 ............. S/N 8100587 AND ABOVE

17 0601820846 OVER CURRENT RELAY ....................................1 ............. S/N 8100001~8100586

17 0601820848 OVER CURRENT RELAY ....................................1 ............. S/N 8100587 AND ABOVE

18 0027104016 MACHINE SCREW 2 18A 0207004000 HEX, NUT 2 19 M1213500203 CONTROL BOX COVER 1 20 0016906016 HEX, HEAD BOLT 4

21 SELECTOR SWITCH .......................................... 1............. S/N 8100001~8101735

............................................................................................ ORDER ITEMS W/#

21# M1270100104 SELECTOR SWITCH .......................................... 1 ............. S/N 8101736 AND ABOVE

21A M1550002504 DECAL; SELECTOR SWITCH NUMBER ............................ S/N 8100001~8101735

21A# M1550002604 DECAL; SELECTOR SWITCH NUMBER ............................ S/N 8101736 AND ABOVE

22 M1215601204 SWITCH BRACKET ............................................ 1 ............. S/N 8100001~8101735

22# M1215600204 SWITCH BRACKET ............................................ 1 ............. S/N 8101736 AND ABOVE

23 0027103010 MACHINE SCREW ..............................................4 ............. S/N 8100001~8101735

23# 0027104030 MACHINE SCREW ..............................................4 ............. S/N 8101736 AND ABOVE

23A# 0207004000 HEX, NUT ............................................................ 4 ............. S/N 8101736 AND ABOVE

24 0016906016 HEX, HEAD BOLT 4

25 0330000160 EDGING ..............................................................1 ............. S/N 8100001~8101735

25# 0330000150 EDGING .............................................................. 1 ............. S/N 8101736 AND ABOVE

26 M1215601104 SWITCH COVER .................................................1 ............. S/N 8100001~8101735

26# M1213600404 SWITCH COVER .................................................1 ............. S/N 8101736 AND ABOVE

26-1# 0228800060 RUBBER SEAL ...................................................1 ............. S/N 8101736 AND ABOVE

26-2# 0228800108 RUBBER SEAL ...................................................1 ............. S/N 8101736 AND ABOVE

26-3# 0317700180 RUBBER SEAL ...................................................1 ............. S/N 8101736 AND ABOVE

27 0016906016 HEX, HEAD BOLT ............................................... 3 ............. S/N 8100001~8101735

27# 0016906016 HEX, HEAD BOLT ...............................................6 ............. S/N 8101736 ~AND ABOVE

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 55

DCA-25USIXF— CONTROL BOX ASSY. (CONTINUED)

CONTROL BOX ASSY. (DCAUSIXF ONLY)

PAGE 56 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF— CONTROL BOX ASSY. (CONTINUED)

CONTROL BOX ASSY. (DCAUSIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

28 0016906016 HEX, HEAD BOLT 9 28A 0040506000 TOOTHED WASHER 1

29 M1225000323 CONTROL PANEL ............................................... 1 ............. S/N 8100001~8100586

29 M1225000333 CONTROL PANEL ............................................... 1 ............. S/N 8100587 AND ABOVE

30 0601808985 FREQUENCY METER, 45~65Hz 240V 1 31 0601808985 AC AMMETER, 0~50A/100A:5A 1 32 0601801040 CHANGE-OVER SWITCH, AMMETER 1 33 0601806859 AC VOLTMETER, 0~600V 1 34 0601801041 CHANGE-OVER SWITCH, AMMETER 1 35 0601840073 RHEOSTAT(VR), 2W 1K OHM 1 36 0601840121 KNOB 1

37 8970444180 STARTER SWITCH ............................................. 1 ............. REPLACES P/N 0602100009

37A 8944024980 KEY, IGNITION SWITCH 1 38 0602103092 PREHEAT LAMP 1 38A 0601810245 BULB, DC18V 1 39 0602120095 TACHOMETER 1 40 0602122093 OIL PRESSURE GAUGE 1 41 0602123090 WATER TEMPERATURE GAUGE 1 42 0602121080 CHARGING AMMETER 1 43 0602125090 FUEL GAUGE 1 44 0602103092 ALARM LAMP 3 44A 0601810245 BULB, DC18V 3

45 9826800370 PANEL LIGHT ......................................................1 ............. REPLACES P/N 0601810141

46 0601831330 SWITCH, PANEL LIGHT 1 47 M1225100004 STOPPER 1 48 0027105010 MACHINE SCREW 2 49 0027105010 MACHINE SCREW 4 50 M9220100004 SET SCREW 2 51 0080200007 SNAP RING 2

52 8973259120 ENGINE CONTROLLER ......................................1 ............. REPLACES P/N 0602202523

53 0016906016 HEX, HEAD BOLT 2 53A 0207006000 HEX, NUT 2

54 5825500290 RELAY .................................................................2 ............. REPLACES P/N 0602201400

55 8942481610 GLOW RELAY .....................................................1 ............. REPLACES P/N 0602202502

56 0027105016 MACHINE SCREW 4

57 0602103092 ALARM LAMP ..................................................... 1 ............. S/N 8100231~ AND ABOVE

57A 0601810245 BULB, DC18V......................................................1 ............. S/N 8100231~ AND ABOVE

58 M1213600305 SWITCH BRACKET ............................................ 1 ............. S/N 8101736 ~AND ABOVE

59 0027104016 MACHINE SCREW ..............................................4 ............. S/N 8101736 ~AND ABOVE

59A 0207004000 HEX, NUT............................................................4 ............. S/N 8101736 ~AND ABOVE

60 M1248700004 WIRE HARNESS, GENERATOR .........................1 ............. S/N 8100001~8101735

60 M1248700024 WIRE HARNESS, GENERATOR .........................1 ............. S/N 8101736 ~AND ABOVE

61 M1359200602 WIRE HARNESS, ENGINE ................................. 1 ............. S/N 8100001 ~8101465

61 M1359200612 WIRE HARNESS, ENGINE ................................. 1 ............. S/N 8101466 ~ AND ABOVE

62 0601802160 FUSE, 5A 2

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 57

CONTROL BOX ASSY. (DCAUSI2XF ONLY)

DCA-25USI2XF— CONTROL BOX ASSY.

PAGE 58 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USI2XF— CONTROL BOX ASSY.

CONTROL BOX ASSY. (DCAUSIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

1 M1213001002 CONTROL BOX 1 2 0601808820 CIRCUIT BREAKER, 3P 60A 1 3 0021005080 MACHINE SCREW 4 4 0601842384 RESISTOR, 20W 50 OHM 1 5 0027104010 MACHINE SCREW 2 6 0601823240 RECTIFIER 2 7 0027104030 MACHINE SCREW 1 8 0601815759 TERMINAL BOARD 1 9 0027104020 MACHINE SCREW 4 10 0601823863 RELAY UNIT 2 11 0027104016 MACHINE SCREW 4 12 0601820602 AUTOMATIC VOLTAGE REGULATOR 1 13 0027105016 MACHINE SCREW 4 14 0601801122 CURRENT TRANSFORMER, 100/5A 3 15 0027106020 MACHINE SCREW 6 16 0601820847 OVER CURRENT RELAY 1 17 0601820848 OVER CURRENT RELAY 1 18 0027104016 MACHINE SCREW 2 18A 0207004000 NUT, SELF-LOCKING 2 19 M1213500203 ENGINE CONTROLLER 1 20 0602202523 HEX, HEAD BOLT 4

21 5825500290 RELAY .................................................................2 ............. REPLACES P/N 0602201400

22 8942481610 GLOW RELAY .....................................................1 ............. REPLACES P/N 0602202502

23 0027105016 MACHINE SCREW 4 24 M1213500403 CONTROL BOX COVER 1 25 0016906016 HEX, HEAD BOLT 4 26 M1270100504 SELECTOR SWITCH 1 26A M1550002504 DECAL; SELECTOR SWITCH NUMBER 1 26B M1550002604 DECAL; SELECTOR SWITCH NUMBER 1 27 M1215601204 SWITCH BRACKET 1 28 M1215600204 SWITCH BRACKET 1 29 0021104035 MACHINE SCREW 4 29A 0207004000 NUT, SELF-LOCKING 4 30 0027104016 MACHINE SCREW 4 30A 0207004000 NUT, SELF-LOCKING 4 31 0016906016 HEX, HEAD BOLT 4 32 M1213601704 SWITCH COVER 1 32-1 0317700180 RUBBER SEAL 1 33 0016906016 HEX, HEAD BOLT 4 34 M1213601604 SWITCH COVER 1 34-1 0330000070 RUBBER SEAL 1 35 0016906016 HEX, HEAD BOLT 6 36 0016906016 HEX, HEAD BOLT 10 36A 0040506000 TOOTHED WASHER 1

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 59

DCA-25USI2XF— CONTROL BOX ASSY. (CONTINUED

CONTROL BOX ASSY. (DCAUSI2XF ONLY)

PAGE 60 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USI2XF— CONTROL BOX ASSY. (CONTINUED)

CONTROL BOX ASSY. (DCAUSI2XF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

37 M1223000603 CONTROL PANEL ............................................... 1 .............

38 0601807641 FREQUENCY METER, 45~65Hz 240V 1 39 0601808985 AC AMMETER, 0~50A/100A:5A 1 40 0601801040 CHANGE-OVER SWITCH, AMMETER 1 41 0601806859 AC VOLTMETER, 0~600V 1 42 0601801041 CHANGE-OVER SWITCH, AMMETER 1 43 0601840073 RHEOSTAT(VR), 2W 1K OHM 1 44 0601840121 KNOB 1 45 0602103092 ALARM LAMP 3 45A 0601810245 BULB, DC18V 3

46 8970444180 STARTER SWITCH ............................................. 1 ............. REPLACES P/N 0602100009

46A 8944024980 KEY, IGNITION SWITCH 1 47 0602103092 PREHEAT LAMP 1 47A 0601810245 BULB, DC18V 1 48 0602120095 TACHOMETER 1 49 0602122093 OIL PRESSURE GAUGE 1 50 0602123090 WATER TEMPERATURE GAUGE 1 51 0602121080 CHARGING AMMETER 1 52 0602125090 FUEL GAUGE 1

53 9826800370 PANEL LIGHT ......................................................1 ............. REPLACES P/N 0601810141

54 0601831330 SWITCH, PANEL LIGHT 1 55 0602103092 ALARM LAMP 1 55A 0601810245 BULB, DC18V 1 56 M1225100004 STOPPER 1 57 0027105010 MACHINE SCREW 2 58 0027105010 MACHINE SCREW 4 59 M9220100004 SET SCREW 2 60 0080200007 SNAP RING 2 61 0601851727 GROMMET 1 62 M1246703604 WIRE HARNESS, GENERATOR 1

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 61

DCA-25USIXF— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY. (DCAUSIXF ONLY)

PAGE 62 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY. (DCAUSIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

1 B1925200254 ENGINE, ISUZU AA-4LE2 1

1-1 8944567411 CARTRIDGE, OIL FILTER ............................. 1 ...........REPLACES P/N 0602041210

2 M1305200304 ENGINE FOOT 1 3 M1305200204 ENGINE FOOT 1 4 0010310025 HEX, HEAD BOLT 8 5 0040010000 WASHER, LOCK 8 6 0041210000 WASHER, FLAT 8 7 060500066 RUBBER SUSPENSION 2 8 0207010000 HEX, NUT 2 9 M1923200074 RADIATOR 1 9A 0602011079 CAP, RADIATOR 1 10 M9312200104 MOUNT RUBBER 2 11 0016908040 HEX, HEAD BOLT 2 12 0207008000 HEX, NUT 2 13 M1312500203 RADIATOR HOSE 1 14 M1312500303 RADIATOR HOSE 1 15 0605515149 HOSE BAND 4 16 M1312300103 FAN COVER 1 17 0016906020 HEX, HEAD BOLT 4 18 0602046531 AIR CLEANER 1 18A 0602046611 ELEMENT, AIR CLEANER 1 19 0602040650 INDICATOR, AIR CLEANER 1 20 0602040552 BRACKET, AIR CLEANER 1 21 0016908030 HEX, HEAD BOLT 2 22 M1375100303 HOSE, AIR CLEANER 1 23 M1375100203 HOSE, AIR CLEANER 1 24 0605515147 HOSE BAND 3 25 0602022560 ADAPTER 1 26 M1320300304 PACKING 1 27 0602022561 90 DEG. ELBOW 1 28 0603306590 CONNECTOR 1 29 0603300285 LOCKNUT 1 30 0605511395 VALVE 1 31 0603306395 HOSE JOINT 1 32 0602021070 CAP 1 33 0269200380 DRAIN HOSE 1

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 63

DCA-25USIXF— ENGINE AND RADIATOR ASSY. (CONTINUED)

ENGINE AND RADIATOR ASSY. (DCAUSIXF ONLY)

PAGE 64 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF— ENGINE AND RADIATOR ASSY. (CONTINUED)

ENGINE AND RADIATOR ASSY. (DCAUSIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

34 M9602000003 DRAIN JOINT 1 35 M9200200004 PLUG 1 36 0150000018 O RING 1 38 0199901600 DRAIN HOSE 1 39 0199900800 DRAIN HOSE 1 40 0605515106 HOSE BAND 4 41 M9300000003 RESERVE TANK 1 42 M9300100003 CAP, RESERVE TANK 1 43 0199100215 HOSE 1 44 M1318100103 BRACKET, RESERVE TANK 1 45 0016906025 HEX, HEAD BOLT 1 46 0016906020 HEX, HEAD BOLT 2 47 0199100700 HOSE 1 48 0193600850 HOSE 1 49 0605515106 HOSE BAND 3 50 0602120481 PICK UP, TACHOMETER 1 51 0602122272 UNIT, OIL PRESSURE 1 52 M9200100004 ADAPTER 1 53 0602123266 UNIT, WATER TEMPERATURE 1 54 M1353800004 CLAMPER ROD 1 55 0016908020 HEX, HEAD BOLT 2 56 0220300425 SEAL RUBBER 2 57 0601822794 MOTOR FAN 1 58 0016908025 HEX, HEAD BOLT 4 59 0207008000 HEX, NUT 4

60 8972309390 FAN BELT........................................................ 1 ..........REPLACES P/N 0602011431

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 65

DCA-25USI2XF— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY. (DCAUSI2XF ONLY)

PAGE 66 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USI2XF— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY. (DCAUSI2XF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

1 M1923200124 ENGINE, ISUZU BV-4LE2 1

1-1 8944567412 CARTRIDGE, OIL FILTER ............................. 1 ...........REPLACES P/N 0602041210

2 M1305200304 ENGINE FOOT 1 3 M1305200204 ENGINE FOOT 1 4 0010310025 HEX, HEAD BOLT 8 5 0040010000 WASHER, LOCK 8 6 0041210000 WASHER, FLAT 8 7 060500066 RUBBER SUSPENSION 2 8 0207010000 HEX, NUT 2 9 M1923200074 RADIATOR 1 9-1 0602011079 CAP, RADIATOR 1 10 M9200100904 PLUG 1 11 0150000016 O-RING 1 12 M9312200104 MOUNT RUBBER 2 13 0016908035 HEX, HEAD BOLT 2 14 0207008000 HEX, NUT 2 15 M1312500203 RADIATOR HOSE 1 16 M1312500303 RADIATOR HOSE 1 17 0605515149 HOSE BAND 4 18 M1312300103 FAN COVER 1 19 0016906020 HEX, HEAD BOLT 4 20 0220300425 SEAL RUBBER 2 21 0601822794 MOTOR FAN 1 22 0016908025 HEX, HEAD BOLT 4 23 0602046531 AIR CLEANER 1 23A 0602046611 ELEMENT, AIR CLEANER 1 24 0602040650 INDICATOR, AIR CLEANER 1 25 0602040552 BRACKET, AIR CLEANER 1 26 0016908030 HEX, HEAD BOLT 2 27 0207008000 HEX, NUT 2 28 M1375100303 HOSE, AIR CLEANER 1 29 M1373101403 HOSE, AIR CLEANER 1 30 0605515147 HOSE BAND 3 31 0602022560 ADAPTER 1 32 M1320300304 PACKING 1 33 0602022561 90 DEG. ELBOW 1 34 0603306590 CONNECTOR 1 35 0603300285 LOCKNUT 1 36 0605511395 VALVE 1 37 0603306395 HOSE JOINT 1 38 0602021070 CAP 1 39 0269200350 DRAIN HOSE 1

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 67

DCA-25USI2XF— ENGINE AND RADIATOR ASSY. (CONTINUED)

ENGINE AND RADIATOR ASSY. (DCAUSI2XF ONLY)

PAGE 68 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USI2XF— ENGINE AND RADIATOR ASSY. (CONTINUED)

ENGINE AND RADIATOR ASSY. (DCAUSI2XF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

40 M9602000003 DRAIN JOINT 1 41 M9200200004 PLUG 1 42 0150000018 O-RING 1 43 0016906020 HEX, HEAD BOLT 2 44 0199901600 DRAIN HOSE 1 45 0199900800 DRAIN HOSE 1 46 0605515106 HOSE BAND 4 47 M9300000003 RESERVE TANK 1 48 M9300100003 CAP, RESERVE TANK 1 49 0199100215 HOSE 1 50 M1316100603 BRACKET, RESERVE TANK 1 51 0016906025 HEX, HEAD BOLT 1 52 0016906020 HEX, HEAD BOLT 2 53 0199100700 HOSE 1 54 0193600850 HOSE 1 55 0605515106 HOSE BAND 3 56 0602120481 PICK UP, TACHOMETER 1 57 0602122272 UNIT, OIL PRESSURE 1 58 M9200100004 ADAPTER 1 59 0602123266 UNIT, WATER TEMPERATURE 1 60 M1353800004 CLAMPER ROD 1 61 0016908020 HEX, HEAD BOLT 2

62 8972309390 FAN BELT........................................................ 1 ..........REPLACES P/N 0602011431

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 69

DCA-25USIXF/DCA-25USI2XF— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 70 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1230700003 TERMINAL PANEL 1 2 M9220000004 OUTPUT TERMINAL BOLT 5 3 M9220000104 TIE SCREW 5 4 0039308000 HEX, NUT 10 5 0040008000 WASHER, LOCK 15 6 0041408000 WASHER, FLAT 20 7 0016906025 HEX, HEAD BOLT 4

8 M1238100603 TERMINAL COVER ........................................ 1 ........... DCA25USI

8 M1236101103 TERMINAL COVER ........................................ 1 ........... DCA25USI2

9 M1238100704 OUTPUT WINDOW 1 10 0605010040 HINGE 2 11 0027103010 MACHINE SCREW 8 11A 0030003000 HEX, NUT 8 11B 0041203000 WASHER, FLAT 4 13 0016906020 HEX, HEAD BOLT 2 14 0016906016 HEX, HEAD BOLT 4 15 M1236400004 CABLE OUTLET COVER 1 16 M1236300004 SUPPORTER, CABLE OUTLET COVER 1 17 0016906020 HEX, HEAD BOLT 6 18 0601808803 CIRCUIT BREAKER, 1P@ 20A 2 19 0601808804 CIRCUIT BREAKER, 2P@50A 2 20 M1260700204 BREAKER FITTING COVER 1 20A 0222100115 CUSHION RUBBER 1 21 0016906020 HEX, HEAD BOLT 2 22 0601812598 RECEPTACLE,125V 20A X 2 (GFCI) 2 23 0601812538 RECEPTACLE ,CS6369 250V 50A 2 24 0027104018 MACHINE SCREW 8 24A 0207004000 HEX, NUT 8 25 M1238100503 TERMINAL COVER 1

26 0010112045 HEX, HEAD BOLT .......................................... 2 ........... DCA25USI

26 0010112040 HEX, HEAD BOLT .......................................... 2 ........... DCA25USI2

27 0041212000 WASHER, FLAT 2 28 M9310200004 STAY RUBBER 2 29 0030012000 HEX, NUT 2

30 M1236400104 COVER ........................................................... 1 ...........DCA25USI2

30A M1493408804 ACOUSTIC SHEET ........................................ 1 ........... DCA25USI2

31 0016906016 HEX, HEAD BOLT .......................................... 4 ........... DCA25USI2

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 71

BATTERY ASSY.

DCA-25USIXF/DCA-25USI2XF— BATTERY ASSY.

PAGE 72 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602220185 BATTERY 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 WASHER, LOCK 2 6 M1348400204 BATTERY CABLE 1 7 M1348400314 BATTERY CABLE 1 8 0016910020 HEX, HEAD BOLT 1 8A 0040510000 TOOTHED WASHER 1

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 73

MUFFLER ASSY. (DCA-25USIXF ONLY)

DCA-25USIXF— MUFFLER ASSY.

PAGE 74 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF — MUFFLER ASSY.

MUFFLER ASSY. (DCA-25USIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

1 M1332000002 MUFFLER ....................................................... 1 ........... S/N 810000 ~8101465

1 M1332000012 MUFFLER ....................................................... 1 ...........S/N 8101466 AND ABOVE

2 0016908020 HEX, HEAD BOLT 7

3 M1335000103 EXHAUST PIPE ............................................. 1 ........... S/N 810000 ~8101465

3 M1335000113 EXHAUST PIPE ............................................. 1 ........... S/N 8101466 AND ABOVE

4 8970420280 GASKET ........................................................ 1 ...........REPLACES S/N 0602320100

5 M0335200004 GASKET ........................................................ 1 ........... S/N 810000 ~8101465

5 8970420280 GASKET ........................................................ 1 ...........S/N 8101466 AND ABOVE

......................................................................................REPLACES S/N 0602320100

6 0207008000 HEX NUT 4

7 0016908030 HEX HEAD BOLT ........................................... 2 ...........S/N 810000 ~8101465

7 0016908030 HEX HEAD BOLT ........................................... 4 ........... S/N 8101466 AND ABOVE

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 75

MUFFLER ASSY. (DCA-25USI2XF ONLY)

DCA-25USI2XF— MUFFLER ASSY.

PAGE 76 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USI2XF— MUFFLER ASSY.

MUFFLER ASSY. (DCA-25USI2XF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

1 M1332000512 MUFFLER 1 2 M1333200304 GASKET 1 3 0016908035 HEX, HEAD BOLT 6 4 M1333300204 STAY 1 5 0016908020 HEX, HEAD BOLT 6 6 M1333003013 EXHAUST PIPE 1 6-1 M1490003604 HEAT INSULATOR1

7 8970420280 GASKET ........................................................ 1 ...........REPLACES P/N 0602320100

8 M1333200214 GASKET 1 9 0207008000 HEX NUT 4 10 0016908035 HEX HEAD BOLT 4

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 77

FUEL TANK ASSY.

DCA-25USIXF/DCA-25USI2XF— FUEL TANK ASSY.

PAGE 78 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1363001302 FUEL TANK 1 2 0605505072 FUEL TANK CAP 1 3 0605501098 FUEL SENDER UNIT 1 4 0605516090 GASKET 1 5 0027104016 MACHINE SCREW 5 6 M1363300314 TANK SUPPORT 2 7 0016908035 HEX, HEAD BOLT 8 8 0602022791 HOSE JOINT 2 9 0191301200 VENT HOSE 1 10 0605515109 HOSE BAND 7

11 8943672922 FUEL FILTER ASSY. ...................................... 1 ........... REPLACES P/N 0602042202

11A 8943692993 CARTRIDGE, FUEL FILTER .......................... 1 ...........REPLACES P/N 0602042700

12 M1368700004 BRACKET, FUEL FILTER 1 13 0016908020 HEX, HEAD BOLT 4

14 8970398340 FUEL PUMP ................................................... 1 ...........REPLACES P/N 0602023177

14A 8944370220 FUEL FILTER, KIT 1 15 0016906025 HEX, HEAD BOLT 2 16 M1363400404 PICKUP TUBE 2 17 0603306863 BUSHING 2 18 0602022971 HOSE JOINT 2 19 0191200330 SUCTION HOSE 1 20 0191200200 SUCTION HOSE 1 21 0191201300 SUCTION HOSE 1 22 0191200800 RETURN HOSE 1 23 0605515198 HOSE BAND 3 24 0603306797 PLUG, 1-1/2 1 25 0222100550 TANK SHEET 4

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 79

ENCLOSURE ASSY. (DCA25USIXF ONLY)

DCA-25USIXF— ENCLOSURE ASSY.

PAGE 80 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF— ENCLOSURE ASSY.

ENCLOSURE ASSY. (DCA25USIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

1 M1413002502 BASE 1 1A M1493000004 ACOUSTIC SHEET 1 2 M1413100003 ENVIRONMENTAL TANK 1 3 0603306797 PLUG, 1-1/2 1 4 0016910030 HEX, HEAD BOLT 6 5 M1424000502 FRONT FRAME 1 5A M1495100403 ACOUSTIC SHEET 1 6 0601850151 GROMMET 1 7 M1424200702 FRONT DUCT 1 7A M1495100503 ACOUSTIC SHEET 1 8 0601851740 GROMMET 1 9 0601850239 GROMMET 1 10 0601850097 STOPPER 5 11 0027208025 MACHINE SCREW 5 12 0016908020 HEX, HEAD BOLT 9 13 0016906020 HEX, HEAD BOLT 4 14 0016908020 HEX, HEAD BOLT 6 15 M1425201204 DUCT COVER 2 16 0016906020 HEX, HEAD BOLT 10 17 M1424200803 HOSE COVER 1 18 0016906020 HEX, HEAD BOLT 4

19 M1425200903 COVER, FROM FRAME ................................. 1 ........... S/N 8100001~8101465

19 M1423202003 COVER, FROM FRAME ................................. 1 ........... S/N 8101466 AND ABOVE

20 0019208020 HEX, HEAD BOLT 5 21 M1435300503 CENTER FRAME 1 22 M1435300603 CENTER FRAME 1 23 0013612030 HEX, HEAD BOLT 4 23A 0040012000 WASHER, LOCK 4 24B 0041212000 WASHER, FLAT 4 24 0013612030 HEX, HEAD BOLT 4 24A 0040012000 WASHER, LOCK 4 24B 0041212000 WASHER, FLAT 4 25 M1445000802 REAR FRAME 1 25A M1495300304 ACOUSTIC SHEET 1 26 0016908020 HEX, HEAD BOLT 4

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 81

DCA-25USIXF— ENCLOSURE ASSY. (CONTINUED)

ENCLOSURE ASSY. (DCA25USIXF ONLY)

PAGE 82 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF— ENCLOSURE ASSY. (CONTINUED)

ENCLOSURE ASSY. (DCA25USIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

27 M1445300103 REAR COVER 1 27A M1495300504 ACOUSTIC SHEET 1 27B M1495300604 ACOUSTIC SHEET 1 28 M1445400103 DUCT 1 28A M1495300604 ACOUSTIC SHEET 2 29 0207006000 HEX, NUT 7 30 0019208020 HEX, HEAD BOLT 6 31 M1445200303 REAR DOOR 1 32 M1445600204 WINDOW PLATE 1 33 0207306000 HEX, NUT 10 33A 0041206000 WASHER, FLAT 10 34 M9113000002 DOOR HANDLE ASSY. 1 35 0021806016 MACHINE SCREW 4 35A 0030006000 HEX, NUT 4 36 M9112100404 HINGE 2 37 M9112100604 HINGE 2 38 0016908020 HEX, HEAD BOLT 8 39 M1463001402 ROOF PANEL 1 39A M1495500213 ACOUSTIC SHEET 1 40 0019208020 HEX, HEAD BOLT 23 41 M1465400104 COVER 1 42 0019208020 HEX, HEAD BOLT 2 43 M1455200702 SPLASHER PANEL 1 43A M1495401004 ACOUSTIC SHEET 1 44 0016908020 HEX, HEAD BOLT 4 45 M1455100003 SIDE PANEL 1 45A M1495400904 ACOUSTIC SHEET 1 46 M1455000903 SIDE DOOR 1 46A M1495500904 ACOUSTIC SHEET 1 46B M1495501004 ACOUSTIC SHEET 1 47 M1455000803 SIDE DOOR 1 47A M1495501204 ACOUSTIC SHEET 1 47B M1495501304 ACOUSTIC SHEET 1 46C M1495401304 ACOUSTIC SHEET 1 48 M1455000703 SIDE DOOR 1 48A M1495501104 ACOUSTIC SHEET 1 49 M1455300403 DUCT 1 49A M1495401204 ACOUSTIC SHEET 3 49B M1495401304 ACOUSTIC SHEET 1 49C M1495401404 ACOUSTIC SHEET 1 50 0207006000 HEX, NUT 6

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 83

DCA-25USIXF— ENCLOSURE ASSY. (CONTINUED)

ENCLOSURE ASSY. (DCA25USIXF ONLY)

PAGE 84 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF— ENCLOSURE ASSY. (CONTINUED)

ENCLOSURE ASSY. (DCA25USIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

51 M9113000002 DOOR HANDLE ASSY. 2 51A C9312500004 SEAL RUBBER 2 52 0021806016 MACHINE SCREW 8 52A 0030006000 HEX, NUT 8 53 M9112100404 HINGE 4 54 M9112100504 HINGE 4 55 M9112100604 HINGE 8 56 0016908020 HEX, HEAD BOLT 32 57 0016908020 HEX, HEAD BOLT 2 60 M1435000903 BRACKET STAY 1 61 M1435000803 BRACKET STAY 1 62 0016908020 HEX, HEAD BOLT 4 63 M1435000703 SUPPORT LEG 1 63A M1498200004 ACOUSTIC SHEET 1 64 0016908020 HEX, HEAD BOLT 4 67 0016908020 HEX, HEAD BOLT 1 67A 0040508000 TOOTHED WASHER 1 68 0605503066 FUEL LEAK DETECTED SWITCH 1 69 M1414800204 BRACKET 1 70 0017108020 HEX, HEAD BOLT 2

71 M1423202103 FRONT LOUVER ............................................ 1 ...........S/N 8101466 AND ABOVE

72 0016906016 HEX, HEAD BOLT .......................................... 8 ........... S/N 8101466 AND ABOVE

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 85

ENCLOSURE ASSY. (DCA25USI2XF ONLY)

DCA-25USI2XF— ENCLOSURE ASSY.

PAGE 86 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USI2XF— ENCLOSURE ASSY.

ENCLOSURE ASSY. (DCA25USIXF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

1 M1413003902 BASE 1 1A M1493000704 ACOUSTIC SHEET 1 2 M1413100003 ENVIRONMENTAL TANK 1 3 0603306797 PLUG, 1-1/2 1 4 0016910030 HEX, HEAD BOLT 6 5 M1424000502 FRONT FRAME 1 5 M1413600004 DUCT 1 6 0016908020 HEX, HEAD BOLT 6 7 M1423002402 FRONT FRAME 1 7A M1493108303 ACOUSTIC SHEET 1 8 0601850151 GROMMET 1 9 M1423202602 FRONT DUCT 1 9A M1493108003 ACOUSTIC SHEET 1 10 0601851740 GROMMET 1 11 0601850239 GROMMET 1 12 0016908020 HEX, HEAD BOLT 10 13 0016906020 HEX, HEAD BOLT 1 14 0016908020 HEX, HEAD BOLT 6 15 M1423202704 DUCT COVER 2 16 0016906020 HEX, HEAD BOLT 10 17 M1423202704 DUCT COVER 1 18 0016906020 HEX, HEAD BOLT 5 19 M1424200803 HOSE COVER 1 20 0016906020 HEX, HEAD BOLT 5 21 M1423202003 COVER, FROM FRAME 1 22 M1423202103 FRONT LOUVER 1 23 0016906016 HEX, HEAD BOLT 8 24 0019208020 HEX, HEAD BOLT 5 25 M1433001403 CENTER FRAME 1 26 M1433400003 CENTER FRAME 1 27 0013612030 HEX, HEAD BOLT 4 27A 0040012000 WASHER, LOCK 4 27B 0041212000 WASHER, FLAT 4 28 0013612030 HEX, HEAD BOLT 4 28A 0040012000 WASHER, LOCK 4 28B 0041212000 WASHER, FLAT 4 29 M1443001502 REAR FRAME 1 29A M1493304004 ACOUSTIC SHEET 1 29B M1493305304 ACOUSTIC SHEET 1 30 M1453301703 DUCT COVER 1 30A M1493305304 ACOUSTIC SHEET 1 30B M1493305404 ACOUSTIC SHEET 1 30C M1493305504 ACOUSTIC SHEET 1

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 87

DCA-25USI2XF— ENCLOSURE ASSY. (CONTINUED)

ENCLOSURE ASSY. (DCA25USI2XF ONLY)

PAGE 88 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USI2XF— ENCLOSURE ASSY. (CONTINUED)

ENCLOSURE ASSY. (DCA25USI2XF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

31 0016906016 HEX, HEAD BOLT 1 32 0207006000 HEX, NUT 2 33 0019208020 HEX, HEAD BOLT 4 34 M1443302203 REAR COVER 1 34A M1493305104 ACOUSTIC SHEET 1 35 M1443400103 DUCT 1 35A M1493305204 ACOUSTIC SHEET 1 36 0207006000 HEX, NUT 7 37 0019208020 HEX, HEAD BOLT 6 38 M1445200303 REAR DOOR 1 39 M1445600204 WINDOW PLATE 1 40 0207306000 HEX, NUT 10 40A 0041206000 WASHER, FLAT 10 41 M9113000002 DOOR HANDLE ASSY. 1 42 0021806016 MACHINE SCREW 4 42A 0030006000 HEX, NUT 4 43 M9112100404 HINGE 2 44 M9112100604 HINGE 2 45 0016908020 HEX, HEAD BOLT 8 46 M1463001902 ROOF PANEL 1 46A M1493505603 ACOUSTIC SHEET 1 47 0019208020 HEX, HEAD BOLT 23 48 M3310600004 COVER 1 49 0019208020 HEX, HEAD BOLT 4 50 M1453200802 SPLASHER PANEL 1 51 0016908020 HEX, HEAD BOLT 4 52 M1455100003 SIDE PANEL 1 52A M1493410104 ACOUSTIC SHEET 1 53 M1453004903 SIDE DOOR 1 53A M1493409904 ACOUSTIC SHEET 1 53B M1495501004 ACOUSTIC SHEET 1 54 M1455000803 SIDE DOOR 1 54A M1495501204 ACOUSTIC SHEET 1 54B M1495501304 ACOUSTIC SHEET 1 54C M1495401404 ACOUSTIC SHEET 1 55 M1453005003 SIDE DOOR 1 55A M1493410004 ACOUSTIC SHEET 1 56 M1455300403 DUCT 1 56A M1495401204 ACOUSTIC SHEET 3 56B M1495401404 ACOUSTIC SHEET 1 57 0207006000 HEX, NUT 6

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 89

DCA-25USI2XF— ENCLOSURE ASSY. (CONTINUED)

ENCLOSURE ASSY. (DCA25USI2XF ONLY)

PAGE 90 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USI2XF— ENCLOSURE ASSY. (CONTINUED)

ENCLOSURE ASSY. (DCA25USI2XF ONLY)

NO. PART NO. PART NAME QTY. REMARKS

58 M9113000002 DOOR HANDLE ASSY. 2 58A C9312500004 SEAL RUBBER 2 59 0021806016 MACHINE SCREW 8 59A 0030006000 HEX, NUT 8 60 M9112100404 HINGE 4 61 M9112100504 HINGE 4 62 M9112100604 HINGE 8 63 0016908020 HEX, HEAD BOLT 32 64 0016908020 HEX, HEAD BOLT 2 65 0601850097 STOPPER 5 66 0027208025 MACHINE SCREW 5 67 M1433300003 BRACKET STAY 1 68 M1435000803 BRACKET STAY 1 69 0016908020 HEX, HEAD BOLT 4 70 M1433001103 SUPPORT LEG 1 70A M1493200004 ACOUSTIC SHEET 1 71 0016908020 HEX, HEAD BOLT 4 72 0016908020 HEX, HEAD BOLT 1 72A 0040508000 TOOTHED WASHER 1 73 0600800321 MANUAL HOLDER 1 74 0605503066 CLAMP, MANUAL HOLDER 2 75 0016906016 HEX, HEAD BOLT 4 76 0605503066 FUEL LEAK DETECTED SWITCH 1 77 M1414800204 BRACKET 1 78 0017108020 HEX, HEAD BOLT 2

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 91

RUBBER SEALS ASSY.

DCA-25USIXF/DCA-25USI2XF— RUBBER SEALS ASSY.

PAGE 92 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0229200790 SEAL RUBBER 3 2 0314500560 SEAL RUBBER 2 3 0229200630 SEAL RUBBER 1 4 0228901220 SEAL RUBBER 3 5 0228900690 SEAL RUBBER 3 6 0228800690 SEAL RUBBER 1 7 0228900655 SEAL RUBBER 1 8 0228900325 SEAL RUBBER 1 9 0229200325 SEAL RUBBER 1

10 0228800595 SEAL RUBBER .............................................. 1 ........... DCA25USI

10 0228800590 SEAL RUBBER .............................................. 1 ........... DCA25USI2

11 0228800375 SEAL RUBBER 1 12 0228900375 SEAL RUBBER 1 13 0229200650 SEAL RUBBER 2 14 0229200320 SEAL RUBBER 2 15 0228800650 SEAL RUBBER 2 16 0228900520 SEAL RUBBER 1 16 0228900510 SEAL RUBBER 1

17 0228800520 SEAL RUBBER .............................................. 1 ........... DCA25USU

17 0228800510 SEAL RUBBER .............................................. 1 ........... DCA25USI2

18 0228100390 SEAL RUBBER 2 19 0228100320 SEAL RUBBER 2

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 93

DCA-25USIXF/DCA-25USI2XF— NAMEPLATE AND DECALS ASSY.

NAME PLATE ASSY.

PAGE 94 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

DCA-25USIXF/DCA-25USI2XF— NAMEPLATE AND DECALS ASSY.

NAME PLATE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1512400002 DECAL; GENERATOR CONTROL, DCAUSIXF ...... 1 ............ M11240000A

1 M1510300902 DECAL; GENERATOR CONTROL, DCAUSI2XF .... 1 ............ M11030090

2 M1512400122 DECAL; ENGINE OPERATING, DCAUSIXF .......... 1 ............ M11240012

2 M1510301002 DECAL; ENGINE OPERATING, DCAUSI2XF......... 1 ............ M15000010

3 M1550000104 DECAL; NOTE ........................................................ 1 ............ M15000010

4 M1550000204 DECAL; NOTE ........................................................ 1 ............ M15000020

5 M1552000603 DECAL; AUXILLARY OUTPUT ............................... 1 ............ M15200060

6 M9500000004 DECAL; OIL DRAIN PLUG ..................................... 1 ............ M90000000

7 M9500100004 DECAL; WATER ...................................................... 1 ............M90010000

8 M9500300004 DECAL; - ................................................................ 1 ............ M90030000

9 M9500300104 DECAL; + ............................................................... 1 ............ M90030010

10 M9500500004 DECAL; DIESEL FUEL, DCA25USIXF ................... 1 ............ M90050000

10 M9500500304 DECAL; DIESEL FUEL, DCA25USI2XF ................. 1 ............ M90050030

11 M9503000004 DECAL; WARNING MOVING PARTS ..................... 2 ............ M90300000

12 M9503000103 DECAL; WATER - OIL CHECK ............................... 1 ............M90300010

13 M9503100004 DECAL; WARNING HOT COOLANT ....................... 1 ............ M90310000

14 M9503200004 DECAL; WARNING ENGINE EXHAUST ................. 1 ............ M90320000

15 M9510000004 DECAL; FLUID DRAIN ........................................... 1 ............ M91000000

16 M9510100004 DECAL; CAUTION HOT PARTS ............................. 1 ............ M91010000

17 M9512200004 DECAL; MQ ............................................................ 1 ............M91220000

18 M9520000004 DECAL; GROUND .................................................. 1 ............ M92000000

19 M9520000104 DECAL; AMMETER CHANGE-OVER SW. ............. 1 ............ M92000010

20 M9520000204 DECAL; VOLTMETER CHANGE-OVER SW. .......... 1 ............ M92000020

21 M9520100004 DECAL; WARNING ELECTRIC SHOCK HAZARD . 2 ............ M92010000

22 M9520100204 DECAL; CAUTION .................................................. 1 ............M92010020A

23 M9520100304 DECAL; SAFETY INSTRUCTION........................... 1 ............ M92010030

24 M9520100404 DECAL; DANGER HIGH VOLTAGE ........................ 1 ............ M92010040

25 M9520100503

26 M9520200003 DECAL; CONNECTION OF OUTPUT CABLE ........ 1 ............ M92020000

27 M9520200104 DECAL; OVER CURRENT RELAY ......................... 1 ............ M92020010

28 M1561000004 DECAL; MQ POWER, DCA25USI .......................... 3 ............ S/N 8011111 TO 8100219

28 M1561000004 DECAL; MQ POWER, DCA25USI .......................... 2 ............ S/N 8100220~

28 M1561000004 DECAL; MQ POWER, DCA25USI2 2 29 M1562100004 STRIPE 2 30 M1562100103 STRIPE; WHISPERWATT 2 31 M1562100204 STRIPE; 25 1 32 M1562100304 STRIPE; 25 1 33 M1562100404 STRIPE 2

34 M9510100304 DECAL; ENVIR. WARNING .................................... 1 ............ M91010030

35 0600500092 PLATE; MQ POWER 1 36 0021106016 MACHINE SCREW 4 37 M1550001404 DECAL; CAUTION 1

38 M9520000804 DECAL; AC, DCA25USIXF ..................................... 1 ............M92000080 S/N 8101596~

38 M9520000804 DECAL; AC, DCA25USI2XF 1

39 M9510000104 DECAL; DOCUMENT BOX, DCA25USI2XF ........... 1 ............ M91000010

40 M1550001404 DECAL; CAUTION, DCA25USI2XF ........................ 1 ............ M15000120

41 M9521000004 DECAL; TERMINAL, DCA25USI2XF 1

42 M9504200004 DECAL; WARNING START FIRES, DCA25USI2XF 1 ............ M90420000 S/N 8103260~

DECAL; WARNING ................................................. 1 ............ M92010050

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 95

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1. A Returned Material Authorization must be approved by Multiquip prior to shipment.

2. To obtain a Return Mater ial Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions

must match the current parts price list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and

phone number of the person requesting the RMA.

3. A copy of the Return Material Authorization must accompany the return shipment.

4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point.

5. Parts must be in new and resalable con-

6. The following items are not returnable:

7. The sender will be notified of any

8. Such material will be held for five

9. Credit on returned parts will be issued at

10. In cases where an item is accepted, for

11. Credit issued will be applied to future

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates

for price declines and added charges for price dition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

a. Obsolete parts. (If an item is in the

price book and shows as being replaced by another item, it is obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items. e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

material received that is not acceptable.

working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

dealer net price at time of the original purchase, less a 15% restocking charge.

which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

purchases only.

increases will not be made for stock on hand at

the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade acces-

sories nor as to any engine not manufactured

by Multiquip. Such warranties made in connec-

tion with the sale of new, complete units are

made exclusively by a statement of warranty

packaged with such units, and Multiquip nei-

ther assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such written statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

PAGE 96 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)

NOTE PAGE

DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #1 (05/08/09) — PAGE 97

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

ON-HAND

WHEN CALLING

MQ Power

1800 Water Ridge Rd. Tel. (800) 883-2551 Suite 500/600 Fax (972) 315-1847 Lewisville, TX 75057 Contact: mqpower@multiquip.com Web: www.mqpower.com

MQ Parts Department

800-427-1244 Fax: 800-672-7877 310-537-3700 Fax: 310-637-3284

Service/Tech Support/Warranty

800-835-2551 Fax: 310-638-8046

MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time without notice and without incurring any obligations.

Manufactured for

Multiquip Inc.

Your Local Dealer is:

DENYO CO., LTD, JAPAN

Multiquip DCA-25USIXF, DCA-25USI2XF User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual