MQ Power DCA25SSIU4F Operation Manual

OPERATION MANUAL

WHISPERWATT™ SERIES

MODEL DCA25SSIU4F

60Hz GENERATOR

(ISUZU 4LE2T DIESEL ENGINE)

Revision #4 (01/17/18)

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

DCA25SSIU4F 60 Hz
Generator

Proposition 65 Warning ........................................... 2

Safety Information ................................................ 4-9

Specifications ........................................................ 10

Dimensions ............................................................ 11

Installation ........................................................ 12-13

General Information ............................................... 14

Major Components ................................................ 15

Engine/Generator Control Panel.......................16-17

Output Terminal Panel Familiarization .............. 18-20

Load Application .................................................... 21

Generator Outputs ................................................. 22

Generator Outputs/Gauge Reading ....................... 23

Output Terminal Panel Connections ................. 24-25

Inspection/Setup ............................................... 26-29

Generator Start-Up Procedure (Manual) .......... 30-31

Generator Start-Up Procedure (Auto Mode) .......... 32

Generator Shut-Down Procedures ........................ 33

Maintenance ..................................................... 34-38

Troubleshooting Diagnostic Lamp ........................ 39

Troubleshooting Generator .................................. 40

Troubleshooting Engine ................................... 41-42

Generator Wiring Diagram ..................................... 43

Engine Wiring Diagram .......................................... 44

Controller Wiring Wiring Diagram .......................... 45

Battery Charger Wiring Diagram ........................... 46

Jacket Water Heater Wiring Diagram ..................... 47

TABLE OF CONTENTS

NOTICE

Specifications are subject to change without notice.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 3

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 specifi cally address the level of exposure
to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION

SAFETY SYMBOLS

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.

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

WARNING

Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.

or NOTICE.

CAUTION

Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

PAGE 4 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

SAFETY INFORMATION

GENERAL SAFETY







 NEVER use accessories or attachments that are not

recommended by MQ Power for this equipment. Damage

Also, know the

and

This information will be invaluable in

emergency or safety devices.

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

lubricate components or attempt service on a

Fix damage to machine and replace any broken parts

store equipment properly when it is not being

used. Equipment should be stored in a clean, dry location

CAUTION

NEVER operate this equipment without proper protective

clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.

NEVER operate this equipment when not

feeling well due to fatigue, illness or when
under medication.

NEVER operate this equipment under the infl uence of

drugs or alcohol.

ALWAYS check the equipment for loosened threads or
bolts before starting.

DO NOT use the equipment for any purpose other than

its intended purposes or applications.

to the equipment and/or injury to user may result.

 ALWAYS know the location of the nearest

fi re extinguisher.

 ALWAYS know the location of the nearest

fi rst aid kit.

 ALWAYS know the location of the nearest

phone or keep a phone on the job site.
phone numbers of the nearest ambulance, doctor

fi re department.

the case of an emergency.

GENERATOR SAFETY

DANGER

 NEVER operate the equipment in an explosive

atmosphere or near combustible materials. An
explosion or fi re could result causing severe

bodily harm or even death.

WARNING

NOTICE

This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and

safety decals when they become diffi cult read.

Manufacturer does not assume responsibility for any

accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.

 NEVER disconnect any

devices will void all warranties.

CAUTION

 NEVER

running machine.

NOTICE

 ALWAYS ensure generator is on level ground before use.

 ALWAYS keep the machine in proper running condition.



immediately.

 ALWAYS

out of the reach of children and unauthorized personnel

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 5

ENGINE SAFETY



NOTICE

run engine without an air fi lter or with a dirty air

fi lter. Severe engine damage may occur. Service air fi lter

Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
suffi cient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce

it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine

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

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 fl ames
from the engine exhaust. Spark arresters are qualifi ed
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

SAFETY INFORMATION

DANGER

The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.

The engine of this equipment

requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.

WARNING

DO NOT place hands or fingers inside engine

compartment when engine is running.

NEVER operate the engine with heat shields or

guards removed.

Keep fi ngers, hands hair and clothing away

from all moving parts to prevent injury.

 NEVER

frequently to prevent engine malfunction.

 NEVER tamper with the factory settings

of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.



the operating performance.

In order for a diesel engine to operate at peak effi ciency,

to completely burn all of the fuel.

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,

muffl er or cylinder. Allow these parts to cool
before servicing equipment.

hours to burn off the accumulated unburned fuel.



local Health and Safety Administrator.

PAGE 6 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

SAFETY INFORMATION

FUEL SAFETY



TOWING SAFETY

 Make sure the hitch and coupling of the towing vehicle

are rated equal to, or greater than the trailer “gross

NEVER

Check the tire air pressure on both towing vehicle and

Trailer tires should be infl ated to 50 psi cold.

safety

attach trailer’s safety chains to towing

make sure the vehicle and trailer directional,

backup, brake and trailer lights are connected and

• Secure portable power cables in cable tray with tie

unless

posted otherwise. Recommended off-road towing is not to

Avoid sudden stops and starts. This can cause skidding,
or jack-knifi ng. Smooth, gradual starts and stops will

Trailer should be adjusted to a level position at all times

Raise and lock trailer wheel stand in up position when

rolling

underneath the trailer’s bumper

Use the trailer’s swivel jack to adjust the trailer height to

DANGER

DO NOT start the engine near spilled fuel or combustible

fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.

ALWAYS refuel in a well-ventilated area, away from

sparks and open fl ames.

ALWAYS use extreme caution when working with

fl ammable liquids.

DO NOT fi ll the fuel tank while the engine is running

or hot.

DO NOT overfi ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from
the ignition system.

Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and fl ames.

NEVER use fuel as a cleaning agent.

DO NOT smoke around or near the

equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.

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

vehicle weight rating.”

 ALWAYS inspect the hitch and coupling for wear.

tow a trailer with defective hitches, couplings, chains, etc.



trailer.
Also check the tire tread wear on both vehicles.

 ALWAYS make sure the trailer is equipped with a

chain.

 ALWAYS properly

vehicle.

 ALWAYS

working properly.

 DOT Requirements include the following:

• Connect and test electric brake operation.

wraps.

 The maximum speed for highway towing is 55 MPH

exceed 15 MPH or less depending on type of terrain.



improve towing.

 Avoid sharp turns to prevent rolling.



when towing.



towing.

 Place chock blocks underneath wheel to prevent

while parked.

 Place support blocks

to prevent tipping while parked.



a level position while parked.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 7

ELECTRICAL SAFETY

DANGER



Power Cord/Cable Safety

 Make sure power cables are securely connected to the

generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes

Severe injury or death by

can result from operating an ungrounded

drop the battery. There is a possibility that the

keep the battery charged. If the battery is not

recharge the battery in a well-ventilated

environment to avoid the risk of a dangerous concentration

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.

SAFETY INFORMATION

generator.

NOTICE

 ALWAYS

Chart in this manual.

Grounding Safety

DANGER

 ALWAYS

before operating generator.

electrocution

generator.

 NEVER use gas piping as an electrical ground.

BATTERY SAFETY

DANGER

 DO NOT

battery will explode.

 DO NOT expose the battery to open fl ames,

sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.

DANGER

NEVER let power cords or cables lay in water.

NEVER stand in water while AC power from the

generator is being transferred to a load.

NEVER use damaged or worn cables or cords when

connecting equipment to generator. Inspect for cuts in
the insulation.

NEVER grab or touch a live power

cord or cable with wet hands. The
possibility exists of electrical shock,

electrocution or death.

PAGE 8 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

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

charged, combustible gas will build up.

 ALWAYS

of combustible gasses.

 If the battery liquid (dilute sulfuric acid) comes into

contact with clothing or skin, rinse skin or clothing



ENVIRONMENTAL SAFETY/

Decommissioning is a controlled process used to safely
retire a piece of equipment that is no longer serviceable.
If the equipment poses an unacceptable and unrepairable
safety risk due to wear or damage or is no longer cost
effective to maintain (beyond life-cycle reliability) and is to
be decommissioned (demolition and dismantlement),be
sure to follow rules below.

EMISSIONS INFORMATION

The diesel engine used in this equipment has been
designed to reduce harmful levels of carbon monoxide
(CO), hydrocarbons (HC) and nitrogen oxides (NOx)

This engine has been certifi ed to meet US EPA Evaporative

Attempting to modify or make adjustments to the engine
emission system by unauthorized personnel without proper
training could damage the equipment or create an unsafe

Additionally, modifying the fuel system may adversely affect
evaporative emissions, resulting in fi nes or other penalties.

The emission control label is an integral part of the emission

If a replacement emission label is needed, please contact

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.

SAFETY INFORMATION

NOTICE

contained in diesel exhaust emissions.

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.

NOTICE

DECOMMISSIONING

DO NOT pour waste or oil directly onto the ground, down

a drain or into any water source.

Contact your country's Department of

Public Works or recycling agency in your
area and arrange for proper disposal of
any electrical components, waste or oil
associated with this equipment.

emissions requirements in the installed confi guration.

condition.

Emission Control Label

system and is strictly controlled by regulations.

The label must remain with the engine for its entire life.

your authorized engine distributor.

When the life cycle of this equipment is over, remove

battery and bring to appropriate facility for lead
reclamation. Use safety precautions when handling
batteries that contain sulfuric acid.

When the life cycle of this equipment is over, it is

recommended that the trowel frame and all other metal
parts be sent to a recycling center.

Metal recycling involves the collection of metal from
discarded products and its transformation into raw
materials to use in manufacturing a new product.

Recyclers and manufacturers alike promote the process
of recycling metal. Using a metal recycling center
promotes energy cost savings.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 9

Model

Type

Armature Connection Star with Neutral Zigzag

Phase

Standby Output

Prime Output

3Ø Voltage (L-L/L-N)

Voltage Selector Switch at 3Ø 240/139

3Ø Voltage (L-L/L-N)

Voltage Selector Switch at 3Ø 480/277

1Ø Voltage (L-L/L-N)

Voltage Selector Switch at 1Ø 240/120

Power Factor

Frequency

Speed

Aux. AC Power

Aux. Voltage/Output

Dry Weight

Wet Weight

Model

Type

No. of Cylinders

Bore x Stroke

Displacement

Rated Output

Starting

Coolant Capacity

Lube Oil Capacity

Lubricating Type Oil

Fuel Type

Fuel Leak Warning Capacity

Fuel Tank Capacity

Fuel Consumption

Exhaust Gas After-Treatment System

Battery

1

Includes engine and radiator hoses

2

Includes filters

Table 1. Generator Specifications

Revolving field, self ventilated,

open protected type synchronous generator

3Ø 3Ø

22.0 kW (27.5 kVA) 15.8 kW

20 kW (25 kVA) 14.4 kW

208Y/120, 220Y/127, 240Y/139

416Y/240, 440Y/254, 480Y/277

0.8 1.0

Single Phase, 60 Hz

4.8 Kw (2.4 kW x 2)

1,797 lbs. (815 kg))

1,797 lbs. (815 kg)

Table 2. Engine Specifications

Water-cooled, direct injection, turbo-charged

3.35 in. x 3.78 in. (85 mm x 96 mm)

133 cu. in. (2.179 liter)

33.5 HP at 1800 rpm

2.3 gal. (8.8 liters)

2.8 gal. (10.5 liters)

API service class CJ-4 SAE or JASO DH-2

#2 Diesel Fuel (Ultra low sulfur diesel fuel only)

12.7 gal. (48 liters)

41.7 gal. (158 liters)

1.62 gal. (6.12 L)/hr at full load 1.26 gal. (4.77 L)/hr at 3/4 load

.94 gal. (3.57 L)/hr at 1/2 load 0.67 gal. (2.52 L)/hr at 1/4 load

27 (CCA 0°F 800A) X 1

SPECIFICATIONS

DCA25SSIU4F

240/120

60 Hz

1800 rpm

Isuzu 4LE2T

air cooled EGR

4 cylinders

Electric

DOC

1

2

PAGE 10 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

25

5,150

(2,335 kg)

DIMENSIONS

Figure 1. Dimensions

Table 3. Dimensions

Reference

Letter

A 22.91 (582) E 22.36 (568)

B 21.73 (552) F 71.65 (1,820)

C 22.36 (568) G 49.61 (1,260)

D 26.38 (670) H 31.10 (790)

Dimension in. (mm) Reference Letter Dimension in. (mm)

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 11

INSTALLATION

./2.4 M (MINIMUM)

CONNECTING THE GROUND

Consult with local Electrical and Safety Codes for proper
connection based on condition of use.

EXAMPLE of how to ground the unit if the condition
of use requires such a device:

The ground terminal on the generator should always be
used to connect the generator to a suitable ground when
required.

GENERATOR

GROUND LUG

The ground cable should be #8 size wire (aluminum)
minimum. If copper wire is used, #10 size wire minimum
should be used.

Connect one end of the ground cable terminal to the
generator ground point (Figure 2). Connect the other end
of the ground cable to a suitable earth ground (ground rod).

IF THE GENERATOR IS PROVIDING
ELECTRIC POWER TO A BUILDING

GROUND CABLE

REFERENCE

NEC 250

8 FT

VIA A TRANSFER SWITCH IT MUST
BE CONNECTED TO A GROUND ROD.

Figure 2. Typical Generator Grounding Application

PAGE 12 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

INSTALLATION

OUTDOOR INSTALLATION

Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide
or shift around. Also install the generator in a manner so
that the exhaust will not be discharged in the direction of
nearby homes.

The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.

Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.

CAUTION

Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.

GENERATOR GROUNDING

NOTICE

The Occupational Safety and Health Administration
(OSHA) and the National Electrical Code (NEC)
recommend that if the generator is providing electrical
power to a structure (home, office shop, trailer or
similar) it must be connected to a grounding electrode
system, such as driven ground rod (Figure 2).

If applicable, to guard against electrical shock and possible
damage to the equipment, it is important to provide a good
EARTH ground, (Figure 2).

NOTICE

ALWAYS check with State, Province, District and
Municipalities for electrical grounding requirements
before using generator.

Article 250 (Grounding) of the NEC handbook provides
guidelines 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.

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 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 54.1). 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.

NEC article 250 specifices 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 mm

b. Aluminum 8 AWG (8.4 mm

2

) or larger.

2

) or larger.

2. When grounding of the generator (Figure 2) is required,
connect one end of the ground cable to the ground lug
on the generator. Connect the other end of the ground
cable to the ground rod (earth ground).

3. NEC article 250 specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.

NOTICE

When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 13

GENERAL INFORMATION

GENERATOR

This generator (Figure 3) is designed 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.

OPERATING PANEL

The “Operating Panel” is provided with the following:

 ECU Controller
 Gauge Unit Assembly

• Oil Pressure Gauge

• Water Temperature Gauge

• Charging Voltmeter

• Fuel Gauge

• Tachometer

 Panel Light/Panel Light Switch
 Pre Heat Lamp
 Warning lamp (Diagnostic)
 Hour Meter
 Engine Speed Switch
 Auto Start/Stop Switch
 Fuel Leak Detected Alarm Lamp

CONTROL PANEL

The “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
 “Control Box” (located behind Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Starter Relay

OUTPUT TERMINAL PANEL

The “Output Terminal Panel” is provided with the following:

 Two 120/240V output receptacles (CS-6369), 50A
 Two auxiliary circuit breakers, 50A
 Two 120V output receptacles (GFCI), 20A
 Two GFCI circuit breakers, 20A
 Five output terminal lugs (3Ø power)
 Battery Charger (Option)
 Jacket Water Heater (Option)
 Low Coolant Switch (Option)

OPEN DELTA EXCITATION SYSTEM

Each generator is equipped with the state of the art “Open­Delta” excitation system. The open delta system consist

of an electrically independent winding wound among
stationary windings of the AC output section.

There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to D, and C to D. These three phases of the voltage
input to the voltage regulator are then rectified and are the
excitation current for the exciter section.

When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.

The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a “fixed ceiling” and responds
according the demands of the required load.

ENGINE

This generator is powered by a 4 cylinder, 4-cycle water
cooled, direct injection, turbocharged, EGR Isuzu 4LE2T

diesel engine. This engine is designed to meet every
performance requirement for the generator. Reference
Table 2 for engine specifications.

In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.

ELECTRIC GOVERNOR SYSTEM

The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.

EXTENSION CABLES

When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.

PAGE 14 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

Low Oil Pressre

High temp.

Over Crank

Over Speed

Engine Started

ECU

Intergrated Gauge Control

R

25

9

10

11

12

MAJOR COMPONENTS

Figure 3. Major Components

Table 4. Generator Major Components

ITEM NO. DESCRIPTION

1 Muffler Assembly

2 Voltage Selector Switch Assembly

3 Output Terminal Assembly

4 Generator Assembly

5 Output Receptacles Assembly

6 Battery Assembly

7 Engine Assembly

8 Fuel Tank Assembly

9 Generator Control Panel Assembly

10 Gauge Unit Assembly

11 Engine Control Panel Assembly

12 Circuit Breaker Assembly

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 15

LowOilPressre

Hightemp.

OverCrank

OverSpeed

EngineStarted

ECU

IntergratedGaugeControl

R

Low Oil Pressre

High temp.

Over Crank

Over Speed

Engine Started

ECU

IntergratedGauge Control

R

2

3

4

5

6

9

7

8

10

11

12

16

15

14

13

F

ENGINE/GENERATOR CONTROL PANEL

Figure 4. Engine/Generator Control Panel

The definitions below describe the controls and functions
of the Engine/Generator Control Panel (Figure 4).

1. Gauge Unit Assembly — This assembly houses the

various engine monitoring gauges. These gauges
indicate: oil pressure, water temperature, charging
voltmeter, fuel and engine speed RPM (tachometer).

A. Oil Pressure Gauge — During normal operation

this gauge should read between 50 psi.
(345 kPa). When starting the generator the oil
pressure may read a little higher, but after the
engine warms up the oil pressure should return
to the correct pressure range.

B. Water Temperature Gauge — During normal

operation this gauge should indicate approximately
180°F (82°).

C. Charging Voltmeter Gauge — During normal

operation this gauge indicate minimum 14 VDC

D. Fuel Gauge — Indicates amount of diesel fuel

available.

E. Tachometer — Indicates engine speed in RPM’s

for 60 Hz operation. This meter should indicate
1800 RPM’s when the rated load is applied.

PAGE 16 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

F. Warning LEDs

• Low Oil Pressure LED — This LED will light when

the engine oil pressure drops to 14.2 PSI. This
condition will cause the engine to shut down.

• High Temperature LED — This LED will light

when the coolant temperature has reached
212°F (100°C). This condition will cause the
engine to shut down.

• Over Crank LED — This LED will light when

the engine has attempted to start 3 times and
failed. The intervals between the 3 start cycles
is approximately 10 seconds.

• Over Speed LED — This LED will light when

the engine is running at an unsafe speed. This
condition will cause the engine to shut down.

• Engine Started LED — This LED will light when

the engine has started and is operating correctly.

2. Panel Light Switch — When activated will turn on

control panel light.

3. Panel Light — For operation at night, panel light

illuminates control panel for ease of reading meters
and gauges. Make sure panel light switch is in the OFF
position when light is not in use.

4. Frequency Meter — Indicates the output frequency

in hertz (Hz). Normally 60 Hz

ENGINE/GENERATOR CONTROL PANEL

5. AC Ammeter — Indicates the amount of current the

load is drawing from the generator per leg selected by
the ammeter phase-selector switch.

6. AC Voltmeter — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.

7. Fuel Leak Detected Alarm Lamp — This lamp when
ON indicates that fluids in the containment area have
reach a high level.

8. Warning Lamp — This lamp turns ON when an engine
fault/failure has occured, Reference Troubleshooting
Diagnostic Lamp section in this manual for fault code
details.

9. Hour Meter — Indicates the operational hours of the
generator.

10. Pre-Heat Lamp —

placed in the manual position, this lamp will illuminate to
indicate preheating of the engine glow plugs. When the
lamp turns off, this indicates that the preheat cycle is
complete and the engine can be started.

When the Auto Start/Stop Switch is

11. Auto Start-Stop Switch — This switch selects either
manual or automatic operation. Center position is OFF
(reset).

12. Engine Speed Switch — This switch controls the
speed of the engine low or high.

13. Voltage Regulator Control — Allows ±15% manual
adjustment of the generator’s output voltage.

14. 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.

15. 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.

16. Main Circuit Breaker — This three-pole, 60 amp main
breaker is provided to protect the U,V, and W Output

Terminal Lugs from overload.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 17

OUTPUT TERMINAL PANEL FAMILIARIZATION

1Ø AND 3Ø,

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 5) shown below is
located on the right-hand side (left from control panel) of
the generator. Lift up on the cover to gain access to
receptacles and terminal lugs.

NOTICE

Terminal legs “O” and “Ground” are considered bonded
grounds

OUTPUT TERMINALS

W

NEUTRAL

TERMINAL

O

480 -120 VAC

V

U

BLACK RED BLUE WHITE GREEN

GROUND

TERMINAL

OUTPUT TERMINAL FAMILIARIZATION

The “Output Terminal Panel ” (Figure 5) is provided with
the following:

 Two 240/139V output receptacles @ 50 amps

 Two Aux. Circuit Breakers @ 50 amps

 Two 120V GFCI receptacles @ 20 amp

 Two GFCI Circuit Breakers @ 20 amps

 Five Output Terminal Lugs ( U, V, W, O, Ground)

HARD WIRE

HOOKUP PANEL

120 VAC, 20 AMP

GFCI RECEPTACLES

RECEPTACLE

AND

CIRCUIT BREAKER

PANEL

CIRCUIT BREAKERS
FOR CS-6369 TWIST

LOCK RECEPTACLES

CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

AUX. POWER RECEPTACLES

240/120V, 50 AMPS

W

TWIST-LOCK

MQ POWER

CS-6369

ACCESS DOOR

LIFT TO OPEN

Y

X

PAGE 18 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

Figure 5. Output Terminal Panel

OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles provided on the output terminal panel.
These receptacles can be accessed in any voltage
selector switch position. Each receptacle is protected by a
20 amp circuit breaker. These breakers are located directly
above the GFCI receptacles. Remember the load output
(current) of both GFCI receptacles is dependent on the
load requirements of the U, V, and W output terminal lugs.

Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 6) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.

Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
GFCI receptacles. Remember the load output (current) on
both receptacles is dependent on the load requirements of
the output terminal lugs.

Turn the voltage regulator control knob (Figure 8) on the
control panel to obtain the desired voltage. Turning the knob
clockwise will increase the voltage, turning the knob
counter-clockwise will decrease the voltage.

Figure 8. Voltage Regulator Control Knob

Removing the Plastic Face Plate (Hard Wire
Hookup Panel)

The Output Terminal Lugs are protected by a plastic
face plate cover (Figure 9). Un-screw the securing bolts
and lift the plastic terminal cover to gain access to the
terminal enclosure.

Figure 6. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are two 240/139V, 50 amp auxiliary twist-lock
(CS-6369) receptacles (Figure 7) provided on the output
terminal panel. These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.

Figure 7. 240/120V Twist-Lock Auxiliary

Receptacles

After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.

Figure 9. Plastic Face Plate

(Output Terminal Lugs)

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 19

OUTPUT TERMINAL PANEL FAMILIARIZATION

LOAD

CS-6369

ACLES

Connecting Loads

Loads can be connected to the generator by various
methods, output terminal lugs, camlocks or the convenience
receptacles (Figure 10). Make sure to read the operation
manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole,
60A main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.

TWIST-LOCK

RECEPT

HARD WIRE

HOOKUP PANEL

U

V

W

NEUTRAL

O

GROUND

LOAD

GFCI

RECEPTACLE

LOAD

Over Current Relay

An over current relay (Figure 11) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over
current relay must be pressed. The over current relay is
located in the control box.

Figure 11. Over Current Relay

NOTICE

CAMLOCKS

Figure 10. Connecting Loads

Remember the overcurrent relay monitors the current
flowing from the U,V, and W Output Terminal Lugs
to the load.

In the event of a short circuit or over current condition,
it will automatically trip the 60 amp main breaker.

To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the

main circuit breaker in the closed position (ON).

PAGE 20 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

LOAD APPLICATION

SINGLE PHASE LOAD

Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.

Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require
130—150% more wattage than the rating on the nameplate,
as the wattage is influenced by the efficiency, power factor
and starting system of the equipment.

NOTICE

If wattage is not given on the equipment’s nameplate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 5 below
when connecting loads.

THREE PHASE LOAD

When calculating the power requirements for 3-phase
power use the following equation:

NOTICE

If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732

NOTICE

Motors and motor-driven equipment draw much greater
current for starting than during operation.

An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.

Table 5. Power Factor By Load

Type of Load Power Factor

Single-phase induction motors 0.4-0.75

Electric heaters, incandescent lamps 1.0

Fluorescent lamps, mercury lamps 0.4-0.9

Electronic devices, communication
equipment

1.0

Common power tools 0.8

Table 6. Cable Selection (60 Hz, Single Phase Operation)

Current

in

Amperes

2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.

5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.

7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.

10 1200 2400 250 ft. 150 ft. 100 ft.

15 1800 3600 150 ft. 100 ft. 65 ft.

20 2400 4800 125 ft. 75 ft. 50 ft.

Load in Watts Maximum Allowable Cable Length

At 100

Volts

CAUTION: Equipment damage can result from low voltage

At 200

Volts

#10 Wire #12 Wire #14 Wire #16 Wire

 When 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 licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 21

GENERATOR OUTPUTS

GENERATOR OUTPUT VOLTAGES

A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 12). To obtain some of
the voltages as listed in Table 7 (see below) will require a
fine adjustment using the voltage regulator (VR) control

knob located on the control panel.

Voltage Selector Switch

The voltage selector switch (Figure 12 is located above the
output terminal panel’s Hard Wire Hook-up Panel. It has
been provided for ease of voltage selection..

Maximum Amps

Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed.

Table 8. Generator Maximum Amps

Rated Voltage Maximum Amps

1Ø 120 Volt 55.6 amps (4 wire)

1Ø 240 Volt 27.8 amps (4 wire)

3Ø 240 Volt 60 amps

3Ø 480 Volt 30 amps

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly
related to the voltage being supplied at either the output
terminals or the three twist lock auxiliary receptacles.

Figure 15 and Table 10 show what amount of current is
available at the GFCI receptacles when the output terminals
and twist lock receptacles are in use. Be careful that your
load does not to exceed the available current capability at
the receptacles.

Figure 12. Voltage Selector Switch

CAUTION

NEVER change the position of the voltage selector
switch while the engine is running. ALWAYS place

circuit breaker in the OFF position before selecting
voltage.

Table 7. Voltages Available

UVWO Output
Terminal Lugs

Line-Line

3Ø

1Ø Line-Neutral 120V 127V 139V 240V 254V 277V

1Ø Line-Neutral/

Line-Line

Voltage Selector Switch

3-Phase 240/139V Position

208V 220V 240V 416V 440V 480V

Voltage Selector Switch Single-Phase 240/120V Position

120V

Line-Neutral

N/A N/A

Voltage Selector Switch

3-Phase 480/270V Position

240V

Line-Line

N/A N/A

Table 9. 1Ø GFCI Receptacle Load Capacity

KW in Use

Twist Lock (C6369)

1Ø 240/120V

Table 10. 3Ø Generator Maximum Amps

KVA in Use

(UVWO Terminals)

3Ø 240/480V

25 0

20.8 5 amps/receptacle

16.7 10 amps/receptacle

12.5 15 amps/receptacle

8.4 20 amps/receptacle

70

65.8

61.7

57.5

53.4

Available Load

Current (Amps)

GFCI Duplex

5-20R 120V

Available Load

Current (Amps)

GFCI Duplex

5-20R 120V

0 amps/receptacle

5 amps/receptacle

10 amps/receptacle

15 amps/receptacle

20 amps/receptacle

PAGE 22 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

GENERATOR OUTPUTS/GAUGE READING

HOW TO READ THE AC AMMETER AND AC
VOLTAGE GAUGES

The AC ammeter and AC voltmeter gauges are controlled
by the AC ammeter and AC voltmeter change-over switches.

Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.

Before taking a reading from either gauge, set the Voltage
Selector Switch (Figure 13) to the position which produces
the required voltage (For example, for 3Ø 240V, choose the
center 3Ø 240/139V position on the voltage selector switch

AC Ammeter Gauge Reading

Place the AC Ammeter Change-Over Switch (Figure 16)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 17). This process can be repeated for
terminals V and W.

Figure 16. AC Ammeter
Change-Over Switch

NOTICE

The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.

Figure 17. AC Ammeter

(Amp reading on U Lug)

Figure 13. Voltage Selector Switch-

Ø Position

240/3

AC Voltmeter Gauge Reading

Place the AC Voltmeter Change-Over Switch (Figure 14)
in the W-U position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 15).

Figure 14. AC Voltmeter
Change-Over Switch

Figure 15. AC Voltmeter Gauge
(Volt reading on W-U Lug)

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 23

OUTPUT TERMINAL PANEL CONNECTIONS

UVWO TERMINAL OUTPUT VOLTAGES

Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the position of the Voltage Selector Switch
and the adjustment of the Voltage Regulator Control
Knob.

Remember the voltage selector switch determines the
range of the output voltage. The voltage regulator (VR)
allows the user to increase or decrease the selected
voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 18.

3. Turn the voltage regulator knob (Figure 20) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.

Figure 20. Voltage Regulator Knob

3Ø-208V/1Ø-120V UVWO Term inal Output Voltag es

1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 18.

2. Connect the load wires to the UVWO terminals as
shown in Figure 21.

Figure 18. Voltage Selector Switch

3Ø-240/139V Position

2. Connect the load wires to the UVWO terminals as
shown in Figure 19.

Figure 19. UVWO Terminal Lugs

Figure 21. UVWO Terminal Lugs

3Ø-208/1Ø-120V Connections

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.

PAGE 24 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480/277V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 480/277

position as shown in Figure 22.

Figure 22. Voltage Selector Switch

3Ø-480/277V Position

2. Connect the load wires to the UVWO terminals as

shown in Figure 23.

1Ø-240/120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 24.

Figure 24. Voltage Selector Switch

1Ø-240/120V Position

2. Connect the load wires to the UVWO terminals as
shown in Figure 25.

Figure 23. UVWO Terminal Lugs 3Ø-480V

Connections

NOTICE

ALWAYS make sure that the connections to the UVWO
terminals are secure and tight. The possibility of arcing
exists, that could cause a fire.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 25

Figure 25. UVWO Terminal Lugs

1Ø-240/120V Connection

3. Turn the voltage regulator knob ("Figure 20. Voltage
Regulator Knob" on page 24) clockwise to increase
voltage output, turn counterclockwise to decrease
voltage output. Use voltage regulator adjustment knob
whenever fine tuning of the output voltage is required.

INSPECTION/SETUP

FUEL TANK

25

FUEL TANK

CAP

CIRCUIT BREAKERS

To protect the generator from an overload, a 3-pole, 60
amp, main circuit breaker is provided to protect the U , V,
and W Output Terminals from overload. In addition two
single-pole, 20 amp GFCI circuit breakers are provided to
protect the GFCI receptacles from overload. Three 50 amp
load circuit breakers have also been provided to protect the
auxiliary receptacles from overload. Make sure to switch
ALL circuit breakers to 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 26) on the dipstick. See Table 11 for
proper selection of engine oil.

Figure 26. Engine Oil Dipstick

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 Owner’s Manual. Oil should be warm
before draining.

FUEL CHECK

DANGER

Fuel spillage on a hot engine can cause
a fire or explosion. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.

Refilling the Fuel System

CAUTION

ONLY properly trained personnel who have read

and understand this section should refill the fuel tank
system.

ALWAYS fill the fuel tank (Figure 27) with clean fresh #2
diesel fuel. DO NOT fill the fuel tank beyond its capacity.

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.

When replacing engine oil please refill using

class CJ-4 SAE or JASO DH-2

engine oil.

Table 11. Recommended Motor Oil

PAGE 26 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

API service

Figure 27. Fuel Tank

INSPECTION/SETUP

Unlevel Ground

Unlevel Ground

Refueling Procedure:

WARNING

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 28).

CAUTION

ALWAYS place trailer on firm level ground before

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

25

70

DO NOT fill on
unlevel ground

!

!

2. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel
cap and fill tank (Figure 29).

Figure 29. Fueling the Generator

3. NEVER overfill fuel tank — It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait
for fuel to rise in filler neck (Figure 30).

=

Level Ground

Figure 28. Only Fill on Level Ground

NOTICE

ONLY use #2 diesel fuel when refueling.

Level Ground

Figure 30. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 31).

Figure 31. Fuel Expansion

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 27

INSPECTION/SETUP

COOLANT (ANTIFREEZE/SUMMER COOLANT/
WATER)

Isuzu recommends antifreeze/summer coolant for use in their

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.

WARNING

If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which can
cause severe burns.

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

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 battery terminal disconnected.

AIR CLEANER

Periodic cleaning/replacement is necessary. Inspect air
cleaner in accordance with the Isuzu Engine Owner’s

Manual.

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 Engine Owner’s Manual.

The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 32) when depressed with the thumb as shown
below.

Table 12. Coolant Capacity

Engine and Radiator 2.3 gal (8.8 liters)

Reserve Tank N/A

Operation in Freezing Weather

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

Table 13. Anti-Freeze

Operating Temperatures

Vol %

Anti-Freeze

50 -37 -34

NOTICE

When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.

Freezing Point

°C °F

Figure 32. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan

while the generator set is running.

PAGE 28 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

INSPECTION/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. Always keep the terminals firmly
tightened. Coating the terminals with an approved battery
terminal treatment compound. Replace battery with only
recommended type battery. The battery type used in this
generator is BCI Group 27.

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.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery
terminals when the Auto-Off/Reset-Manual Switch
is in either the AUTO or MANUAL position. ALWAYS
make sure that this switch is in the OFF/RESET
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.

NOTICE

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

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

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 33) 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.

CAUTION

ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.

NEGATIVE

POSITIVE

Figure 33. Battery Connections

ALTERNATOR

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 corrosion 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 (fuel or oil) lines are defective replace them
immediately.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 29

GENERATOR START-UP PROCEDURE (MANUAL)

INCORRECT

BEFORE STARTING

CAUTION

The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.

WARNING

NEVER manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.

1. Place the main, G.F.C.I., and aux. circuit breakers
(Figure 34) in the OFF position prior to starting the
engine.

STARTING (MANUAL)

1. Place the Auto-Off/Reset Manual Switch in the

MANUAL position to start the engine (Figure 36).

Figure 36. Auto-Off/Reset Manual;Switch

(Manual Position)

NOTICE

If engine fails to start in a specified number attempts,
the shutdown lamp will illuminate and the Auto-Off/
Reset Switch must be place in the Off/Reset position
before the engine can be restarted.

NOTICE

Engine will pre-heat automatically in cold weather
conditions." Glow Plug Hold " message will be displayed
and the engine will start automatically after pre-heating.

Figure 34. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been
configured for the desired output voltage.

3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 10. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.

4. Tighten terminal nuts securely to prevent load wires
from slipping out.

5. Close all engine enclosure doors (Figure 35).

CORRECT

2. Once the engine starts, let the engine run for 1-2
minutes (let engine idle longer in cold weather
conditions). Listen for any abnormal noises. If any
abnormalities exist, shut down the engine and correct

the problem.

3. The generator’s frequency meter (Figure 37) should be
displaying the 60 cycle output frequency in HERTZ.

Figure 37. Frequency Meter

Figure 35. Engine Enclosure Doors

PAGE 30 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

GENERATOR START-UP PROCEDURE (MANUAL)

4. The generator’s AC-voltmeter (Figure 38) will display

the generator’s output in VOLTS. If the voltage is not
within the specified tolerance.

Figure 38. Voltmeter

5. Use the voltage adjustment control knob (Figure 39)
to increase or decrease the desired voltage.

Figure 39. Voltage Adjust Control Knob

6. The ammeter (Figure 40) will indicate zero amps with
no load applied. When a load is applied, the ammeter
will indicate the amount of current that the load is
drawing from the generator.

180

140

100

WATER TEMP

220

°F

260

Figure 42. Coolant Temperature Gauge

9. The tachometer gauge (Figure 43) will indicate the

speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.

150

120

60

0

RPMX10

SPEED

180

210

Figure 43. Engine Tachometer Gauge

10. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 44).

Figure 40. Ammeter (No Load)

7. The engine oil pressure gauge (Figure 41) will indicate
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 35 to 65
psi. (193~586 kPa).

50

25

0

PSI

OIL PRESS

75

100

Figure 41. Oil Pressure Gauge

8. The coolant temperature gauge (Figure 42) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 180°~225°F (75°~95°C) (Green Zone).

Figure 44. Main, Aux. and GFCI

Circuit Breakers (ON)

11. Observe the generator’s ammeter (Figure 45) and
verify it reads the anticipated amount of current with
respect to the load. The ammeter will only display a
current reading if a load is in use.

Figure 45. Ammeter (Load)

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

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 31

GENERATOR START-UP PROCEDURE (AUTO MODE)

STARTING (AUTO MODE)

DANGER

Before connecting this generator to any
building’s electrical system, a licensed

electrician must install an isolation
(transfer) switch. Serious damage to

the building’s electrical system may occur
without this transfer switch.

CAUTION

When connecting the generator to a isolation (transfer)
switch, ALWAYS have power applied to the generator’s
internal battery charger. This will ensure that the engine
will not fail due to a dead battery.

NOTICE

When the generator is set in the AUTO mode, the
generator will automatically start in the event of
commercial power falling below a prescribed level
by means of a contact closure that is generated
automatically by a transfer switch.

When starting generator in AUTO mode use the “Manual
Start-up” procedure except where noted (see below).

1. Perform steps 1 through 5 in the Before Starting section
as outlined in the Manual Starting Procedure.

2. Place the Auto Off/Reset Manual Switch (Figure 46)
in the AUTO position.

Figure 46. Auto Off/Reset Manual Switch (AUTO)

3. Continue operating the generator as outlined in the
Manual Start-up procedure (start at step 3).

WARNING

When running the generator in the AUTO mode,
remember the generator can start up at any time without
warning. NEVER attempt to perform any maintenance
when the generator is in the auto mode.

CAUTION

The engine speed switch must be set to the “High”
position when running in the auto-start mode. Failing
to set the switch in the proper position can result in
damage to your generator when it turns on.

NOTICE

When the Auto Off/Reset Manual switch is placed
in the AUTO position, the engine glow plugs will be
warmed and the engine will start automatically.

PAGE 32 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

GENERATOR SHUT-DOWN PROCEDURES

WARNING

NEVER stop the engine suddenly except in an

emergency.

NORMAL SHUTDOWN PROCEDURE

To shutdown the generator, use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 47 to the OFF position.

Figure 47. Main, Aux. and GFCI

Circuit Breakers (OFF)

EMERGENCY SHUTDOWN PROCEDURE

1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 47 to the OFF position.

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
212° F (100° C), overspeed approximately +15%. The alarm
lamps on the ECU illuminate to signify the reason for the
shutdown.

NOTICE

Before inspecting generator, check that the Auto/
Manual switch is in the OFF/RESET position, and place
all circuit breakers in the OFF position. Allow sufficient
time for adequate cooling. When ready to restart,
complete all steps in the Generator Startup Procedure
section of this manual.

2. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.

3. Place the Auto Off/Reset Manual Switch (Figure 48)
in the OFF/RESET position.

Figure 48. Auto Off/Reset Manual Switch

(Off/Reset)

4. Verify that all status LEDs on the ECU control panel
are OFF (not lit).

5. Remove all loads from the generator.

6. Inspect entire generator for any damage or loosening of
components that may have occurred during operation.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 33

MAINTENANCE

Engine

Generator

Table 14. Inspection/Maintenance

Check Engine Oil and Coolant Levels X

Check Fuel Filter/Water Separator Bowl X

Check Air Cleaner X

Check Air Cleaner Element X

Check for Leaks/Hoses/Clamps X

Check for Loosening of Parts X

Change Engine Oil and Oil Filter *

Clean Unit, Inside and Outside X

Replace Fuel Filter Elements X

Check Engine Mounts X

Service Battery X

Check Air Intake Hoses X

Check Fan Belt Condition X

Check Automatic Belt Tensioner X

Check Electrical Ground Connection X

Clean Radiator, Check Cooling System X

Coolant Solution Analysis, Add SCA's As Required X

Pressure Test Cooling System X

Check Engine Speed X

Test Thermostats X

Test Glow Plugs X

Flush and Refill Cooling System 2 yrs. or 2000 hrs.

Clean Inside of Fuel Tank 1000 hrs.

Replace Air Cleaner Elements *

Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X

1

2

10 Hrs
DAILY

250 Hrs

X

500 Hrs

or Every

12 Months

3000 Hrs

or Every

36 Months

OTHER

As Required

1

*

During initial operation of a new engine, change oil and filter between a minimum of 100 hrs. and a maximum of 250 hrs. Service interval depends

on type of oil.

2

*

Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).

PAGE 34 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

MAINTENANCE

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 250 hours: Remove air cleaner element (Figure 49)
and clean the heavy duty paper element with light spray of
compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator (Figure 49) 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 needs changing or
service. After changing the air element, press the dust
indicator button to reset the indicator.

FUEL ADDITION

Add diesel fuel (the grade may vary according to season
and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally inspect the fuel tank
for water contamination and drain the contents if required.

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.

Cleaning Inside the Fuel Tank

Drain the fuel inside the fuel tank completely. Using a spray
washer (Figure 50) wash out any deposits or debris that
have accumulated inside the fuel tank.

Figure 49. Air Cleaner/Indicator

NOTICE

The air filter should not be changed until the indicator
reads “RED”. Dispose of old air filter. It may not be
cleaned or reused..

If the engine is operating in very dusty or dry grass
conditions, a 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 frequently if these conditions exist.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 35

Figure 50. Fuel Tank Cleaning

MAINTENANCE

FUEL TANK INSPECTION

In addition to cleaning the fuel tank, the following
components should be inspected for wear:

 Rubber Suspension — look for signs of wear or

deformity due to contact with oil. Replace the rubber
suspension if necessary.

 Fuel Hoses — inspect nylon and rubber hoses for signs

of wear, deterioration and hardening.

 Fuel Tank Lining — inspect the fuel tank lining for signs

of excessive amounts of oil or other foreign matter.

Replacing Fuel Filter

 Replace the fuel filter cartridge with new one every 500

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.

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. See the Isuzu Engine

Manual for details.

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 26.

Replacing Oil Filter

 Remove the old oil filter.

 Apply a film of oil to the gasket on the new oil filter.

 Install the new oil filter.

 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.

 Tighten both cocks and replace the overflow tank.

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.

PAGE 36 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

 Replace with coolant as recommended by the engine

manufacturer.

 Close radiator cap tightly.

 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.

WARNING

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

MAINTENANCE

RADIATOR CLEANING

The radiator (Figure 51) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fins or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fins and tube.

Figure 51. Radiator Cleaning

The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal

battery charger.

These receptacles will ONLY function when commercial
power has been supplied to them (Figure 52). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).

When using the generator in hot climates there is no
reason to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times.

To apply power to the jacket water heater simply apply
power to the jacket water heater receptacle via commercial
power using a power cord of adequate size.

TO CHASSIS

GROUND

BATTERY

CHARGER

GREEN 16 AWG.

TO STARTER “B”

TERMINAL

RED 16 AWG.

GENERATOR STORAGE

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

 Drain 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.

 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 blocks so tires do not touch the ground or block
and completely remove the tires.

JACKET WATER HEATER AND INTERNAL BATTERY
CHARGER 120 VAC INPUT RECEPTACLES
(OPTIONAL)

This generator can be optionally equipped with two 120
VAC, 20 amp input receptacles located on the output
terminal panel.

JACKET WATER

HEATER

OUTPUT TERMINAL

PANELASSEMBLY

BATTERY CHARGER/

JACKET WATER HEATER

120 VAC INPUT

RECEPTACLE

Figure 52. Battery Charger and Jacket Water

Heater Power Connections

If the generator will be used daily, the battery should
normally not require charging. If the generator will be idle
(not used) for long periods of time, apply power to the
battery charger receptacle via commercial power using a
power cord of adequate size.

NOTICE

If the generator will be idle (not used) for long periods
of time and to ensure adequate starting capability,
always have power applied to the generator's internal
battery charger.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 37

EMISSION CONTROL

The emission control system employed with the Isuzu
4LE2T diesel engine consist of a Diesel Oxidation Catalyst
(DOC).

This device oxidizes large amounts of harmful nitrogen
oxides (NOx) and particulate matter (PM) which are emitted
by diesel engines. These exhaust emissions pose serious
environmental and health risks. No maintenance or service
is required for the DOC device used on this generator.

Diesel Oxidation Catalyst (DOC)

The DOC does not filter particles it oxidizes them. This
catalyst (honeycomb like structure) uses a chemical
process to break down pollutants in the exhaust stream
into less harmful components. In general this catalyst
collects/burns accumulated particulates. The DOC contains
palladium and platinum which serve as a catalysts to oxidize
hydrocarbons and carbon monoxide.

MAINTENANCE

PAGE 38 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

TROUBLESHOOTING DIAGNOSTIC LAMP

The engine controller of this generator diagnoses problems
(faults/errors) that arise from the engine control system and
the engine itself.

When any engine faults occur during operation of the
generator the warning lamp (diagnostic lamp) located on
the control panel will turn on. If this conditions occurs please
perform immediately the engine fault code diagnostic
procedure below.

ENGINE FAULT CODE DIAGNOSTIC PROCEDURE

1. Remove all loads from the generator and place all
circuit breakers in the OFF position.

2. Stop the engine, release the retaing screws that secure
the control panel to the generator frame.

3. Next, slowly let the control panel fall forward so that
the control box is exposed.

4. To start the diagnostic process, place the diagnostic
switch to the ON (Figure 53) position.

6. Push and hold the diagnostic button to identify the
fault. and verify the following:

• Diagnostic lamp will start blinking with a pattern
according to the detected fault code 3 times at a interval
rate of 2.4 seconds.

• If two or more faults code are detected the diagnostic
lamp will repeat the detected fault codes blinking
pattern in ascending order. After all the detected fault
codes are shown, the process will repeat starting with
the first fault code.

• If no fault is detected the diagnostic lamp will blink
repeatedly at a interval rate of 2.4 seconds.

NOTICE

For a complete understanding of error codes and
troubleshooting procedures, refer to the enclosed
engine instruction manual.

NOTICE

ON

DIAGNOSTIC

SWITCH

DIAGNOSTIC

LAMP

FUEL PUMP

SWITCH

ON

DIAGNOSTIC

BUTTON

OFF

Figure 53. Diagnostic Panel

NOTICE

Make sure to place the diagnostic switch back to
the OFF position after completing engine fault code
diagnostic procedures.

5. Verify that the diagnostic lamp is ON. This indicates

that there is a fault/error in the engine or the engine
control system.

The diagnostic lamp will indicate the current fault code
with the previous fault code in ascending order.

Also when a fault is detected the fault code will
automatically be saved as the previous code in the
ECM even after the fault has been repaired.

NOTICE

If a fault occurs while the engine is running the
diagnostic lamp will turn on indicating only the current
fault. Please note that the fault code (blinking pattern)
cannot be shown while the engine is running.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 39

TROUBLESHOOTING GENERATOR

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 15 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business office or service plant.

Table 15. Generator Troubleshooting

Symptom Possible Problem Solution

AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Is AVR defective? Replace if necessary.

Defective Rotating Rectifier? Check and replace.

Defective Exciter Field? Check for approximately 19 ohms across J & K on CN1

Is engine speed correct? Turn engine throttle lever to “High”.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Short Circuit in load? Check load and repair.

Over current? Confirm load requirements and reduce.

Defective circuit breaker? Check and replace.

Over current Relay actuated? Confirm load requirement and replace.

PAGE 40 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

Symptom Possible Problem Solution

Engine will not start or start is delayed,
although engine can be turned over.

At low temperatures engine will not start.

Engine fi res but stops soon as starter is
switched off.

Engine stops by itself during normal
operation.

Low engine power, output and speed.

TROUBLESHOOTING ENGINE

Troubleshooting (Engine)

No Fuel reaching injection pump? Add fuel. Check entire fuel system.

Defective fuel pump? Replace fuel pump.

Fuel fi lter clogged? Replace fuel fi lter and clean tank.

Faulty fuel supply line? Replace or repair fuel line.

Compression too low?

Fuel pump not working correctly? Repair or replace fuel pump.

Oil pressure too low? Check engine oil pressure.

Low starting temperature limit exceeded?

Defective battery? Charge or replace battery.

Air or water mixed in fuel system?

Engine oil too thick?

Defective battery? Replace battery.

Fuel fi lter blocked? Replace fuel fi lter.

Fuel supply blocked? Check the entire fuel system.

Defective fuel pump? Replace fuel pump.

Fuel tank empty? Add fuel.

Fuel fi lter blocked? Replace fuel fi lter.

Defective fuel pump? Replace fuel pump.

Mechanical oil pressure shutdown sensor
stops the engine due to low oil?

Fuel tank empty? Replace fuel fi lter.

Fuel fi lter clogged? Replace fuel fi lter.

Fuel tank venting is inadequate? Ensure that tank is adequately vented.

Leaks at pipe unions?

Speed control lever does not remain in

selected position?

Engine oil level too full? Correct engine oil level.

Injection pump wear?

Check piston, cylinder and valves. Adjust or
repair per engine repair manual.

Comply with cold starting instructions and
proper oil viscosity.

Check carefully for loosened fuel line

coupling, loose cap nut, etc.

Refi ll engine crankcase with correct type of
oil for winter environment.

Add oil. Replace low oil shutdown sensor if
necessary.

Check threaded pipe unions tape and tighten
unions a required.

See engine manual for corrective action.

Use No. 2-D diesel fuel only. Check the fuel
injection pump element and delivery valve
assembly and replace as necessary.

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 41

TROUBLESHOOTING ENGINE (CONTINUED)

Symptom Possible Problem Solution

Low engine power output and low speed,
black exhaust smoke.

Engine overheats.

Troubleshooting (Engine) - continued

Air fi lter blocked? Clean or replace air fi lter.

Incorrect valve clearances? Adjust valves per engine specifi cation.

Malfunction at injector? See engine manual.

Too much oil in engine crankcase?

Entire cooling air system contaminated/
blocked?

Fan belt broken or elongated? Change belt or adjust belt tension.

Coolant insuffi cient? Replenish coolant.

Radiator net or radiator fi n clogged with dust? Clean net or fi n carefully.

Fan, radiator, or radiator cap defective? Replace defective part.

Thermostat defective? Check thermostat and replace if necessary.

Head gasket defective or water leakage? Replace parts.

Drain off engine oil down to uppermark on

dipstick.

Clean cooling air system and cooling fi n
areas.

PAGE 42 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

GENERATOR WIRING DIAGRAM

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 43

ENGINE WIRING DIAGRAM

PAGE 44 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

CONTROLLER WIRING WIRING DIAGRAM

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 45

BATTERY CHARGER WIRING DIAGRAM

AB

BLACK 14 AWG. LINE (L)120VAC INPUT

WHITE 14 AWG. NEUTRAL (N)

3

4

1

2

GREEN 14 AWG. GROUND (G)

TO CHASSIS

GROUND

GREEN 16 AWG.

TO STARTER “B”

TERMINAL

RED 16 AWG.

3

B

4

1

2

NOTES:

1

NEMA 5-15, 15A, 120 VAC, P/N EE6176 (HBL5278C/HUBBLE RECEPTACLE).

2

RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.

3

20 AMP, 5-20R RECEPTACLE, P/N EE6131 (HBL5369C/HUBBLE RECEPTACLE).

4

CORD, CAROL 3/C 14 AWG., P/N EE56557.

A

120 VAC INPUT, INSERT EXTERNAL

POWER CORD HERE.

PAGE 46 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

JACKET WATER HEATER WIRING DIAGRAM

AB

BLACK 14 AWG. LINE (L)120VAC INPUT

WHITE 14 AWG. NEUTRAL (N)

3

4

1

2

GREEN 14 AWG. GROUND (G)

BLOCK HEATER

(P/N 44558)

BLACK 14 AWG.

LINE (L)120VAC INPUT

3

B

4

1

NOTES:

1

NEMA 5-15, 15A, 120 VAC, P/N EE6176 (HBL5278C/HUBBLE RECEPTACLE).

2

RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.

3

20 AMP, 5-20R RECEPTACLE, P/N EE6131 (HBL5369C/HUBBLE RECEPTACLE).

4

CORD, CAROL 3/C 14 AWG., P/N EE56557.

WHITE 14 AWG.

NEUTRAL (N)

GREEN 14 AWG.

GROUND (G)

A

2

120 VAC INPUT, INSERT EXTERNAL

POWER CORD HERE.

TEMP.

SWITCH

120 VAC

GROUND

HEATING

ELEMENT

DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 47

OPERATION MANUAL

HERE’S HOW TO GET HELP

© COPYRIGHT 2018, MULTIQUIP INC.

Multiquip Inc

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

The information and specifi cations 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 specifi cations, design or the information published
in this publication at any time without notice and without incurring any obligations.

DENYO CO., LTD, JAPAN

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

UNITED STATES

Multiquip Corporate Office MQ Parts Department

18910 Wilmington Ave.
Carson, CA 90746
Contact: [e-mail]

Service Department Warranty Department

800-421-1244
310-537-3700

Technical Assistance

800-478-1244 Fax: [phone]

CANADA

Multiquip Multiquip (UK) Limited Head Office

4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [e-mail]

Tel. [phone]
Fax [phone]

Tel: [phone]
Tel: [phone]
Fax: [phone]

800-427-1244
310-537-3700

800-421-1244
310-537-3700

UNITED KINGDOM

Unit 2, Northpoint Industrial Estate,
Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: [e-mail]

Fax: [phone]

Fax: [phone]

Tel: [phone]
Fax: [phone]

, the MQ logo and the MQ Power logo

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.

Manufactured for

MQ Power Inc.

Your Local Dealer is:

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