Multiquip Portable Generator DCA 25USI2XF User Manual

PARTS AND OPERATION MANUAL  
OPERATION AND PARTS MANUAL  
ULTRA-SILENTTM 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:  
THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.  
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DCA-25USIXF/DCA-25USI2XF— PROPOSITION 65WARNING  
Diesel engine exhaust and some of  
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DCA-25USIXF/DCA-25USI2XFTABLE OF CONTENTS  
COMPONENT DRAWIMGS  
MQ POWER DCA-25USIXF/25USI2XF  
60 HZ ULTRA-SILENT GENERATORS  
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  
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  
Terms and Condition of Sale — Parts ............................ 80  
Specifications are subject to  
NOTE  
change without notice.  
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DCA-25USIXF/DCA-25USI2XF— PARTS ORDERING PROCEDURES  
Ordering parts has never been easier!  
Choose from three easy options:  
Effective:  
Order via Internet (Dealers Only)  
Orderpartson-lineusingMultiquip’sSmartEquipwebsite!  
:
If you have an MQ Account, to obtain a  
Username and Password, E-mail us at:  
View Parts Diagrams  
Order Parts  
To obtain an MQ Account, contact your  
Use the internet and qualify for a 5% Discount  
on Standard orders for all orders which include  
Gotowww.multiquip.comandclickon  
to log in and save!  
Order Parts  
Note: Discounts Are Subject To Change  
Fax your order in and qualify for a 2% Discount  
on Standard orders for all orders which include  
Order via Fax (Dealers Only)  
:
All customers are welcome to order parts via Fax.  
Domestic (US) Customers dial:  
Note: Discounts Are Subject To Change  
Domestic (US) Dealers Call:  
Order via Phone:  
Non-Dealer Customers:  
Contact your local Multiquip Dealer for  
parts or call 800-427-1244 for help in  
International Customers should contact  
their local Multiquip Representatives for  
When ordering parts, please supply:  
Specify Preferred Method of Shipment:  
Dealer Account Number  
UPS/Fed Ex  
DHL  
Dealer Name and Address  
Priority One  
Ground  
Truck  
Shipping Address (if different than billing address)  
Return Fax Number  
Applicable Model Number  
Next Day  
AllordersaretreatedasStandardOrders  
andwillshipthesamedayifreceivedprior  
WE ACCEPT ALL MAJOR CREDIT CARDS!  
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DCA-25USIXF/DCA-25USI2XF— SPECIFICATIONS  
Table 1. Generator Specifications  
Model  
Type  
DCA-25USIXF/DCA-25USI2XF  
Revolving field, self ventilated, open protected type synchronous generator  
Armature Connection  
Phase  
Star with Neutral  
3
Zig Zag  
Single  
Standby Output  
Prime Output  
Voltage  
26.5 KVA (21.2 KW)  
25 KVA (20 KW)  
240V or 480V  
15.3 KW  
14.4 KW  
240/120V  
Frequency  
Speed  
60 Hz  
1,800 rpm  
Power Factor  
Aux. AC Power  
Voltage  
0.8  
1
Single Phase, 60 Hz  
120 VAC  
Output  
4.8 KW (2.4 KW x 2)  
Table 2. Engine Specifications  
ISUZU AA-4LE21 Tier 2  
Model  
Type  
ISUZU BV-4LE22 Tier4  
4 Cycle, water-cooled, direct injection  
4 cylinders  
No. of Cylinders  
Bore x Stroke  
Rated Output  
Displacement  
Starting  
3.35 in. x 3.78 in. (85 mm x 96 mm)  
34.3 HP/1,800 rpm  
133 cu. in. (2,179 cc)  
Electric  
Coolant Capacity  
Lube Oil Capacity  
Fuel Tank Capacity  
1.7 gal. (6.4 liters)  
2.25 gal. (8.5 liters)  
106 gal. (400 liters)  
1.44 gal. (5.47 L)/hr at full load1  
1.64 gal. (6.23 L)/hr at full load2  
0.86 gal. (3.28 L)/hr at 1/2 load2  
1.20 gal. (4.57 L)/hr at 3/4 load2  
0.57 gal. (2.17 L)/hr at 1/4 load2  
1.05 gal. (3.99 L)/hr at 3/4 load1  
0.74 gal. (2.81 L)/hr at 1/2 load1  
0.45 gal. (1.70 L)/hr at 1/4 load1  
Fuel Consumption  
Fuel  
#2 Diesel Fuel  
Battery  
12V 53Ah X 1  
2,200 lbs. (1,000 kg.)1 Dry  
2,973 lbs. (1,349 kg.)1 Wet  
2,249 lbs. (1,020 kg.)2 Dry  
3,021 lbs. (1,370 kg.)2 Wet  
Weight  
DCA25USIXF1  
DCA25USI2XF2  
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DCA-25USIXF/DCA-25USI2XF— DIMENSIONS (TOP, SIDE AND FRONT)  
TABLE 3. DIMENSIONS  
Reference  
Dimension in. (mm.) Reference Letter Dimension in. (mm.)  
Letter  
A
B
C
D
E
27.30 in. (695 mm.)  
25.59 in. (650 mm.)  
22.64 in. (575 mm.)  
24.80 in. (630 mm.)  
20.90 in. (530 mm.)  
F
G
H
86.20 in. (2,190 mm.)  
56.90 in. (1,445 mm.)  
31.10 in. (790 mm.)  
PAGE 6 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)  
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DCA-25USIXF/DCA-25USI2XF— SAFETY MESSAGE ALERT SYMBOLS  
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!  
HAZARD SYMBOLS  
Potential hazards associated with the operation of this  
equipment will be referenced with "Hazard Symbols" which  
appear throughout this manual, and will be referenced in  
conjunction with Safety "Message Alert Symbols".  
Safety precautions should be followed at all times when  
operating this equipment.Failure to read and understand the  
Safety Messages and Operating Instructions could result in  
injury to yourself and others.  
This Operation Manual has  
been developed to provide  
WARNING - LETHAL EXHAUST GASES  
NOTE  
complete instructions for the  
safe and efficient operation of  
the generator.  
Diesel engine exhaust gases contain  
poisonous carbon monoxide. This gas is  
colorless and odorless, and can cause  
DEATH if inhaled. NEVER operate this  
equipment in a confined area or enclosed structure that  
does not provide ample free flow air.  
Before using this generator, ensure that the operating  
individual has read and understands all instructions in  
this manual.  
WARNING - EXPLOSIVE FUEL  
SAFETY MESSAGE ALERT SYMBOLS  
Diesel fuel is extremely flammable, and  
its vapors can cause an explosion if  
ignited. DO NOT start the engine near  
spilled fuel or combustible fluids.  
DO NOT fill the fuel tank while the engine  
is running or hot.  
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.  
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.  
DANGER  
You WILL be KILLED or SERIOUSLY injured if you  
do not follow directions.  
WARNING  
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.  
You COULD be KILLED or SERIOUSLY injured if  
you do not follow directions.  
CAUTION  
You CAN be injured if you do not follow directions  
DANGER - ELECTROCUTION HAZARDS  
During operation of this generator, there  
exists the possibility of electrocution,  
electrical shock or burn, which can cause  
severe bodily harm or even DEATH!  
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DCA-25USIXF/DCA-25USI2XF— SAFETY MESSAGE ALERT SYMBOLS  
WARNING - ROTATING PARTS  
CAUTION - RESPIRATORY HAZARDS  
NEVER operate equipment with covers,  
ALWAYS wear approved respiratory  
protection.  
or guards removed. Keep fingers, hands,  
hair and clothing away from all moving  
parts to prevent injury.  
CAUTION - ACCIDENTAL STARTING  
CAUTION - SIGHT AND HEARING HAZARDS  
ALWAYS place the Engine ON/OFF  
switch in the OFF position and remove  
the ignition key when the pump is not in  
use.  
ALWAYS wear approved eye and  
hearing protection.  
CAUTION - OVER-SPEED CONDITIONS  
CAUTION - EQUIPMENT DAMAGE MESSAGES  
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.  
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)  
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 turbocharges, and reduce the operating  
performance.  
This generator, other property, or  
the surrounding environment  
could be damaged if you do not  
follow instructions.  
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.  
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DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION  
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.  
DANGER - READTHIS 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.  
NEVER touch the hot exhaust  
manifold, muffler or cylinder.Allow  
these parts to cool before  
servicing engine or generators.  
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 engine section of this generators requires an adequate  
free flow of cooling air. NEVER operate the generators in  
any enclosed or narrow area where free flow of the air is  
restricted. If the air flow is restricted it will cause serious  
damage to the generators  
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.  
or engine and may cause  
injury  
to  
people.  
NEVER operate this equipment without proper protective  
clothing, shatterproof glasses, steel-toed boots and other  
protective devices required by the job.  
Remember the generator's  
engine gives off DEADLY  
carbon monoxide gas.  
Denyo  
DANGEROUS  
GAS FUMES  
ALWAYS refuel in a well-ventilated area, away from sparks  
and open flames.  
NEVER operate this equipment when not  
feeling well due to fatigue, illness or taking  
medicine.  
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 this equipment under the influence or  
drugs or alcohol.  
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.  
ALWAYS wear proper respiratory (mask),  
hearing and eye protection equipment when  
operating the generator.  
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.  
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.  
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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.  
Maintenance Safety  
NEVER lubricate components or attempt service on a running  
machine.  
NEVER leave the generator unattended, turn off engine when  
unattended.  
HighTemperatures – Always stop engine and  
allow the engine to cool before adding fuel, oil  
or performing service and maintenance  
functions. Contact with hot! components can  
cause serious burns.  
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.  
Keep the machinery in proper running condition.  
Fix damage to the machine immediately and replace any  
broken parts immediately.  
NEVER run engine without air cleaner.Severe engine damage  
may occur.  
ALWAYS replace any worn or damaged warning decals.  
NEVER change or adjust the engine speed which has been  
set at the factory prior to shipping.  
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.  
Power Cord Safety  
The electrical voltage required to operate the generator can  
cause severe injury or even death through physical contact  
with live circuits. Turn all circuit breakers OFF before  
performing maintenance on the generator.  
NEVER let power cables or cords lay in water.  
NEVER stand in water while AC power from the generators  
is being transfer to a load.  
Dispose of hazardous waste properly. Examples of potentially  
hazardous waste are used motor oil, fuel and fuel filters.  
NEVER use a defective or frayed power cable. Check the  
cable for cuts in the insulation.  
DO NOT use food or plastic containers to dispose of  
hazardous waste.  
NEVER use a extension cord that is frayed or damaged where  
the insulation has been cut.  
DO NOT pour waste, oil or fuel directly onto the ground,  
down a drain or into any water source.  
ALWAYS make certain that proper power or extension cord  
has been selected for the job See Table 6.  
ALWAYS allow the machine a proper amount of time to  
cool before servicing.  
Grounding Safety  
ALWAYS service air cleaner frequently to prevent engine  
malfunction.  
ALWAYS make sure that electrical circuits are properly  
grounded per the National Electrical Code (NEC) and  
local codes before operating generator. Severe injury or  
death! by electrocution can result from operating an  
ungrounded generator.  
ALWAYS 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.  
ALWAYS make sure the generators are properly grounded to  
a suitable earth ground (GROUND ROD). See installation in  
this manual.  
NEVER use gas piping as an electrical ground.  
PAGE 10 — DCA-25USIXF/DCA-25USI2XF — OPERATION AND PARTS MANUAL — REV. #8 (05/08/09)  
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DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION  
Battery Safety  
WARNING - BURN HAZARDS  
Use the following guidelines when handling the battery:  
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.  
The battery contains acids that can  
cause injury to the eyes and skin. To  
avoid eye irritation, always wear safety  
glasses.  
Use well insulated gloves when picking up the battery.  
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.  
DANGER - EXPLOSION HAZARDS  
The risk of an explosion exists when performing service  
on the battery. To avoid severe injury or DEATH:  
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.  
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.  
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.  
ALWAYS keep the battery charged. If the battery is not  
charged a buildup of combustible gas will occur.  
ALWAYS keep battery charging and cables in good  
working condition. Repair or replace all worn cables.  
ALWAYS recharge the battery 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 clothing or skin, rinse skin or clothing  
immediately with plenty of water.  
In case the battery liquid (dilute sulfuric acid) comes in  
contact with your EYES, rinse eyes immediately with  
plenty of water and contact the nearest doctor or hospital  
to seek medical attention.  
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DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION  
DANGER-Electrocution Hazards  
DANGER-Lethal Exhaust Gas Hazards  
During operation of this generation, there  
exists the possibility of electrocution,  
electrical shock or burn, which can  
cause severe bodily harm or even  
DEATH!  
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.  
To avoid these hazards:  
NEVER use damaged or worn cables when connecting  
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.  
DANGER  
Using a generator indoors CAN KILL YOU IN MINUTES.  
Generator exhaust contains carbon monoxide. This is  
a posion you cannot see or smell  
20A  
120  
2900  
V
GA-9
120V  
A
B
 C
C
I
R
K
E
U
R
I
T
NEVER grab or touch a live  
power cord with wet hands, the  
possibility exist of electrical  
shock, electrocution, and even  
death!  
20A  
20A  
120  
120  
2900  
900  
V
V
ON  
GA-
GA-2
120V  
A
BR  
E
I
I
R
K
C
E
U
 R
I
T
120V  
A
BR  
  E
E
I
R
K
E
U
OFF  
ON  
ON  
OFF  
OFF  
Only use OUTSIDE and  
far away from windows,  
doors, and vents.  
NEVER use inside a home  
or garage, even if doors  
and windows are open  
Avoid other generator hazards.  
READ MANUAL BEFORE USE.  
Emergencies  
NEVER insert any objects into  
the output receptacles during  
operation. This is extremely  
ALWAYS know the location of the  
nearest fire extinguisher.  
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,  
electrical shock or burn, which can cause severe  
bodily harm or even death!  
ALWAYS know the location of the nearest  
first aid kit.  
In emergencies 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.  
Backfeed to a utility system can cause  
electrocution and or property damage.  
NEVER connect the generators 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!  
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DCA-25USIXF/DCA-25USI2XF— RULES FOR SAFE OPERATION  
DOT Requirements include the following:  
If your generator is trailer mounted, please  
read the towing and safety requirements  
listed below.  
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.  
Towing andTransporting 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.  
Place chock blocks underneath wheel to prevent rolling,  
while parked.  
Use the trailer’s swivel jack to adjust the trailer height to  
a level position while parked.  
The following list of safety precautions should be followed  
when towing your generator:  
Avoid sudden stops and starts.This can cause skidding,  
or jack-knifing. Smooth, gradual starts and stops will  
improve towing.  
CAUTION - FOLLOWTOWING REGULATIONS  
Avoid sharp turns.  
Check with your local county or state safety towing  
regulations, in addition to meeting Department of  
Transportation (DOT) SafetyTowing Regulations, before  
towing your generator.  
Trailer should be adjusted to a level position at all times  
when towing.  
Raise and lock trailer wheel stand in up position when  
transporting.  
ALWAYS shutdown engine before 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.  
Drain fuel from generator fuel tank before towing.  
If generator is mounted on a trailer, make sure trailer