PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
®
MODEL DCA25USIXF
MODEL DCA25USI2XF
60 Hz GENERATOR
PARTS LIST NO. M1873400004A (DCA-25USI)
PARTS LIST NO. M1873400204A (DCA-25USI2)
Revision #2 (07/26/11)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
TABLE OF CONTENTS
DCA25USIXF/DCA25USI2XFDCA25USIXF/DCA25USI2XF
DCA25USIXF/DCA25USI2XF
DCA25USIXF/DCA25USI2XFDCA25USIXF/DCA25USI2XF
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
NOTICE
Specification and part number are subject to
change without notice.
WINGSWINGS
WINGS
WINGSWINGS
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 3
1
PARTS ORDERING PROCEDURES
r
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
Goto www.multiquip.com and click on
Order Parts
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
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 you
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
When ordering parts, please supply:
❒ Dealer Account Number
❒ Dealer Name and Address
❒ Shipping Address (if different than billing address)
❒ Return Fax Number
❒ Applicable Model Number
❒ Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL
■ Priority One ✓ Tr uck
■ Ground
■ Next Day
■ Second/Third Day
www.multiquip.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
PAGE 4 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
DCA-25USIXF/DCA-25USI2XF— SAFETY MESSAGE ALERT SYMBOLS
SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifically address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 5
1
DCA-25USIXF/DCA-25USI2XF— SAFETY MESSAGE ALERT SYMBOLS
.
SAFETY INFORMATION
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the influence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
NEVER use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fire extinguisher.
ALWAYS know the location of the nearest
first aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fire department. This information will be invaluable in
the case of an emergency.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fire could result causing severe
bodily harm or even death.
WARNING
NOTICE
This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
ALWAYS store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel
PAGE 6 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION
r
SAFETY INFORMATION
ENGINE SAFETY
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
flow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air filter or with a dirty air
filter. Severe engine damage may occur. Service air filte
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 7
1
DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION
SAFETY INFORMATION
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.
ALWAYS use extreme caution when working with
flammable liquids.
DO NOT fill the fuel tank while the engine is running
or hot.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety
information.
In order to reduce the possibility of an accident while
transporting the generator on public roads, ALWAYS
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
ALWAYS shutdown engine before transporting
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains, etc.
Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a safety
chain.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
DOT Requirements include the following:
s#ONNECTANDTESTELECTRICBRAKEOPERATION
s3ECUREPORTAB
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.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent rolling
while parked.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
LEPOWERCABLES INCABLE TRAYWITH TIE
PAGE 8 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION
SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
The electrical voltage required to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 9
1
DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION
SAFETY INFORMATION
BATTERY SAFETY
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open flames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ENVIRONMENTAL SAFETY
NOTICE
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.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
PAGE 10 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION
SPECIFICATIONS
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DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 11
DCA-25USIXF/DCA-25USI2XF— DIMENSIONS (TOP, SIDE AND FRONT)
DIMENSIONS
Figure 1. Dimensions
PAGE 12 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
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DECALS
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 13
Figure 2. Generator Decals
1
DECALS
PAGE 14 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
Figure 3. Generator Decals (Continued)
INSTALLATION
Figure 4. Typical Generator Grounding Application
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 15
1
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
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.
engine and alternator parts.
a. Copper - 10 AWG (5.3 mm2) or larger.
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.
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 a minimum of 8 ft. into the ground.Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. 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
NOTICE
When connecting the generator to any buildings electrical
system, ALWAYS consult with a licensed electrician.
back pressure which will cause the engine to heat excessively
and possibly burn the valves.
Mounting
NOTICE
This generator has a permanent bonding conductor between
the generator stator windings and the frame.
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.
PAGE 16 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
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
1
"
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 17
COMPONENTS
Figure 5. Major Components
PAGE 18 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
Table 4. Generator Major Components
ITEM NO. DESCRIPTION
1 Muffler Assembly
2 Engine Assembly
3 Generator Assembly
4 Output Terminal Assembly
5 Fuel Tank Assembly
6Battery Assembly
7 Generator Control Panel Assembly
8 Engine Operating Panel Assembly
Figure 6. Generator Control Panel
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
NOTICE
Remember the
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.
Generator
. This box contains some of the necessary
overcurrent relay
monitors the current
7. AC Ammeter – Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 19
To restore power to the UWVO output terminals, press the
reset
button on the overcurrent relay and place the
circuit breaker in the
closed
position (ON).
main
1
Figure 7. Engine Operating Panel
ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the "
Engine Operating Panel
" (Figure 7).
1. Panel Light - Normally used in dark places or at night.
When activated, panel 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.
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.
6. Water Temperature Gaug e – During normal operation this
gauge should read between 165°~203° F. (74°~95° C).
PAGE 20 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
OUTPUT TERMINAL PANEL
Output Terminal Panel
Output Terminal Panel
The
(Figure 8) shown below is located
on the right-hand side (left from control panel) of the generator.
Lift up on the cover to gain access to receptacles and terminal
Output Terminal Familiarization
Output Terminal Panel
The “
following:
■■
■
Two (2) 120/240V output receptacles @ 50 amp
■■
lugs.
■■
■
Two (2) Circuit Breakers @ 50 amps
■■
NOTICE
Terminal legs “O” and “Ground” are considered
grounds
.
bonded
■■
■
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
■■
” (Figure 6) is provided with the
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 21
Figure 8. Output Terminal Panel
1
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
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.
phase 240/120 position.
.
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 10. 120/240V Twist-Lock
Auxiliary Receptacles
PAGE 22 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
Figure 12. Plastic Face Plate (UVWO Terminals)
OUTPUT TERMINAL PANEL
Connecting Loads
Loads can be connected to the generator by the UVWO terminal
lugs or the convienience receptacles. (See Figure 13). Make
sure to read the operation manual before attempting to connect
a load to the generator.
To protect the UVWO output terminals from overload, a 3-pole,
main
60 amp,
ALL
circuit breakers to the "OFF" position prior to starting the
engine.
circuit breaker is provided. Make sure to switch
Over Current Relay
An
over current relay
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the
rent relay must be pressed. The over current relay is located in the control box.
(Figure 14) is connected to the main
reset button
Figure 14. Over Current Relay
on the over cur-
Figure 13. Connecting Loads
DANGER
This fuse has current running through it
any time the engine is running. This fuse
is NOT connected to the main circuit
breaker of the generator. Attempting to
replace the fuse with the engine and/or
generator operating could result in
severe bodily harm
off before attempting to replace or handle this fuse.
. ALWAYS turn the unit completely
electrocution
and
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 23
1
LOAD APPLICATION
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
starting system of the equipment.
NOTICE
If 3Ø load (kVA) is not given on the equipment nameplate,
approximate 3Ø load output maybe determined by
NOTICE
multiplying voltage by amperage by 1.732.
If wattage is not given on the equipment's name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
WATTS = VOLTAGE x AMPERAGE
An inadequate size connecting cable which cannot carry the
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.
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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
Before connecting this generator to any building’s
electrical system, a
an
isolation (transfer) switch
licensed electrician
must install
. Serious damage to the
building’s electrical system may occur without this
transfer switch.
PAGE 24 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
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GAUGE READING/TERMINAL PANEL CONNECTIONS
Voltage Selector Switch
The
voltage selector
the output terminal panel’s
switch (Figure 15) is located above
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
NEVER change the position of the
switch
while the engine is running. ALWAYS place
voltage selector
not to exceed the available current capability at the receptacles.
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.
voltage regulator
(VR)
control
maximum
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DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 25
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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
.
Voltage
(Figure 16) to the position which produces
NOTICE
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
NOTICE
to the appropriate
AC Ammeter Gauge
AC Ammeter Change-Over Switch
Figure 20. AC Ammeter
(Amp reading on U lug)
The
ammeter
Output Terminal Lugs
Reading Voltage
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
use.
gauge will only show a reading when the
are connected to a load and in
PAGE 26 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
OUTPUT TERMINAL PANEL CONNECTIONS
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.
Use this position for
3Ø-240 or 1Ø120V.
Figure 24. Voltage Selector
Switch 240/139V
Three-Phase Position
Output Terminal Lugs
as
Figure 21. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the
shown in Figure 22.
Figure 22. Output Terminal Lugs
3Ø-240/139V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Output Terminal Lugs
as
Figure 25. Output Terminal Lugs
3Ø-208/120V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
NOTICE
To achieve a 3Ø 208V output the voltage selector switch
must be in the 3Ø-240/139 position and the voltage
regulator must be adjusted to 208V.
Figure 23. Voltage Regulator Knob (139V/240V)
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 27
1
OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 Output Terminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 26.
Figure 26. Voltage Selector Switch 480/277V
Three-Phase Position
2. Connect the load wires to the
shown in Figure 27.
Output Terminal Lugs
1Ø 240V/120V Output Terminal Lug Voltages
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 28.
Figure 28. Voltage Selector Switch 240/120V
2. Connect the load wires to the
as
shown in Figure 29.
Single-Phase Position
Output Terminal Lugs
as
Figure 27. Output Terminal Lugs
3Ø-480/277V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
PAGE 28 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
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
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
load
receptacles from overload. Two 50 amp
circuit breakers
have also been provided to protect the auxiliary receptacles
from overload. Make sure to switch
ALL
circuit breakers to
DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.
the "OFF" position prior to starting the engine.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two
notches (Figure 30) on the dipstick. See Table 11 for proper
selection of engine oil.
Refilling the Fuel System
CAUTION - REFUELING THE GENERATOR
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
Figure 30. Engine Oil Dipstick
This generator has an internal fuel tank located inside the
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the Isuzu Engine Owner's Manual. Oil should be warm
before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classification CH-4
API Service Classification CG-4
API Service Classification CF-4
ACEA Specification E3
ACEA Specification E2
Table 11. Recommended Motor Oil
30
OIL: SAE
5W30
ARCTIC OIL
10W/40
15W30
20W40
10W
10W30
122
104
86
68
50
-14
-22
-40
F
C
50
40
30
20
10
10W40
032
-10
-4
-20
-30
-40
trailer frame and may also be equipped with an environmental
fuel tank (Figure 31).
fresh
#2 diesel fuel.
capacities.
Pay attention to the fuel tank capacity when replenishing
fuel.The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
hot
engine can cause a
ALWAYS
fill the fuel tanks with clean
fire
or
explosion
DO NOT fill the fuel tanks beyond their
Figure 31. Internal Fuel Tank System
1
.
DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11) — PAGE 29
DCA-25USIXF/DCA-25USI2XF— SETUP
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
NOTICE
ONLY! use
#2 diesel fuel
when refueling.
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
PAGE 30 — DCA25USIXF/DCA25USI2XF — OPERATION AND PARTS MANUAL — REV. #2 (07/26/11)
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