MQ Power DCA125SSIU4F, DCA70SSIU4F Instruction Manual

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OPERATION MANUAL

WHISPERWATT™ SERIES

MODEL DCA125SSIU4F

60Hz GENERATOR

(ISUZU BR-4JJ1X DIESEL ENGINE)

Revision #0 (07/20/17)

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 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

DCA125SSIU4F 60Hz Generator

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

Table Of Contents .................................................... 3

Nameplate/Safety Information ................................. 4

Safety Decals ..................................................... 5-10

Speciﬁcations ........................................................ 11

Dimensions ............................................................ 12

Installation ........................................................ 14-15

General Information ............................................... 16

Major Components ................................................ 17

Engine Control Unit (ECU) .................................... 18

Engine/Generator Control Panel............................ 19

Output Terminal Panel Familiarization .............. 20-22

Load Application .................................................... 23

Generator Outputs ................................................. 24

Generator Outputs/Gauge Reading ....................... 25

Output Terminal Panel Connections ................. 26-27

Inspection/Setup ............................................... 28-32

Generator Start-Up Procedure (Manual) .......... 33-34

Generator Start-Up Procedure (Auto Mode) .......... 35

Generator Shut-Down Procedures ........................ 36

Maintenance ..................................................... 37-50

Generator Wiring Diagram ..................................... 51

Engine Wiring Diagram .......................................... 52

Controller Wiring Diagram ................................ 54-55

Battery Charger Wiring Diagram ........................... 56

Jacket Water Heater Wiring Diagram ..................... 57

Troubleshooting (Generator) .................................. 58

Troubleshooting (Diagnostics) ............................... 59

TABLE OF CONTENTS

NOTICE

Speciﬁcations are subject to change without notice.

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 3

SAFETY DECALS

Safety labels/decals are attached to the generator as shown in Figure 1. Keep these safety labels clean at all times. When the safety labels become worn or damaged, contact your nearest dealer or the Multiquip Parts Dept.

WARNING

MOVING PARTS can cause severe injury. DO NOT operate with doors open.

Stop engine before servicing.

FAN SHROUD

WARNING

ARC FLASH AND SHOCK HAZARD Appropriate PPE Required

Appropriate Personal Protection Equipment and Tools Required when working on this equipment.

Operation of this equipment may create sparks that can start fires around dry vegetation.

A spark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements.

M90420000

M90300000

M92010070

FRONT VIEW

HOT COOLANT can cause severe burns.

Do not remove cap if radiator is hot.

M91020000

WARNING

M90310000

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is a poison gas you cannot see or smell.

NEUTRAL BONDED TO FRAME

120V

120

GAC-2.2H

NEUTRE MIS A LA MASSE A

15A

LA CARCASSE DU MOTEUR

Honda Engines

211052

AC CIRCUIT BREAKER INTERRUPTEUR DE

OFF

GR PRISE DE

COURANT PRINCIPAL

TERRE

NEVER use inside a home

or garage. Even if doors and windows are open.

For safety label part numbers, reference parts manual..

CAUTION

Maximum capacity of lifting

bail is 14,050 lbs.

WARNING

ENVIRONMENTAL

This unit is designed to contain operating uids only The environmental containment is not designed to control uids from an external source. It is the operator’s responsibility to monitor uid levels at all times.

DO NOT EXCEED THE RECOMMENDED

MAXIMUM CAPACITY

DANGER

NEUTRAL BONDED TO FRAME

120V

120

GAC-2.2H

NEUTRE MIS A LA MASSE A

15A

LA CARCASSE DU MOTEUR

Honda Engines

211052

AC CIRCUIT BREAKER INTERRUPTEUR DE

OFF

GR PRISE DE

COURANT PRINCIPAL

TERRE

NEUTRAL BONDED TO FRAME

120V

120

GAC-2.2H

NEUTRE MIS A LA MASSE A

15A

LA CARCASSE DU MOTEUR

Honda Engines

211052

AC CIRCUIT BREAKER INTERRUPTEUR DE

OFF

GR PRISE DE

COURANT PRINCIPAL

TERRE

ONLY use OUTSIDE and far away from windows, doors, and vents.

Avoid other generator hazards. READ MANUAL BEFORE USE.

SAFETY INSTRUCTIONS

Improper operation of this machine can cause severe injury or death.

Read the instruction manual carefully before operation or servicing.

This machine should only be operated by a person with sufficient knowledge and skill to ensure safe operation.

High voltage circuits are located inside the output terminal cover and control panel.

Close the cover and control panel before operating.

Moving parts and hot surfaces are contained within the enclosure.

Close all doors and lock them before operating.

NOTICE

M35000220

TOP VIEW

M91110000

M90320010

CAUTION

Stop engine before switching.

INCREASE DECREASE

OFF

V-W

W-U

U-V

OFF

WHISPERWATT 125 kVA AC GENERATOR

WARNING

ELECTRIC SHOCK HAZARD

Do not touch internal wiring or connections while this machine is operating.

Turn power off before servicing.

M92010030

M92010020A

WARNING

ELECTRIC SHOCK HAZARD

Do not touch internal wiring or connections while this machine is operating.

Turn power off before servicing.

M92010000

U V W O

180

140

220

PSI

°F

VOLTS

100

260

OIL PRESS

WATER TEMP

BATTERY

150

120

180

°F

RPMX10

210

FUEL

SPEED

ECU

Series 800 Controller

Engine Started

Shutdown

Pre-Alarm

Alarm

Screen

Program

Option

Acknowledge

Change

Exit

CAUTION

DO NOT disconnect the Battery Cables

after shutting down the engine for

M92010000

at least 2-3 minutes

GROUND

M90130010

WARNING

ENGINE EXHAUST can cause severe injury or death.

Use only in open, well ventilated areas or vent exhaust outside.

M90320000

SIDE VIEW

WARNING

ELECTRIC SHOCK HAZARD

Do not touch output terminals while this machine is operating.

Turn power off before servicing.

WARNING

ELECTRIC SHOCK HAZARD Always complete the grounding path from the ground terminal on the genset to an external grounding source.

See instruction manual for details.

PAGE 4 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

CAUTION

This machine stops and starts automatically and without notice.

125

DANGER

HIGH VOLTAGE

WARNING

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch.

Serious injury or death may result without this transfer switch.

M92010050

Figure 1. Safety Decals

M92010060

125

M92010040

CAUTION

Ensure the “Auto-Off/Reset-Manual” switch is in the “Off/Reset” position. If it is not, when the battery cables are connected, the engine will crank and attempt to start.

CAUTION

HOT PARTS can burn skin.

DO NOT touch until the

machine has sufficiently cooled.

M91010000

SIDE VIEW

M91010040

SAFETY INFORMATION

DO NOT operate or service the generator before reading the entire manual. Safety precautions should be followed at all times when operating this generator. 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 generator 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.

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 5

SAFETY INFORMATION

GENERAL SAFETY



 NEVER use accessories or attachments that are not

recommended by MQ Power for this generator. 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

keep the generator in proper running condition.

Fix damage to generator and replace any broken parts

store generator properly when it is not being used. Generator should be stored in a clean, dry location out of the reach of children and unauthorized personnel.

CAUTION

NEVER operate this generator 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 generator when not

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

NEVER operate this generator under the inﬂ uence of

drugs or alcohol.

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

DO NOT use the generator for any purpose other than

its intended purposes or applications.

to the generator 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

 NEVER operate the generator in an explosive

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

bodily harm or even death.

DANGER

WARNING

NOTICE

This generator 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 generator modiﬁ cations. Unauthorized generator 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



immediately.

 ALWAYS

PAGE 6 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

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 in this generator

requires an adequate free ﬂ ow of cooling air. NEVER operate this generator 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 generator 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 generator 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 generator.

hours to burn off the accumulated unburned fuel.



local Health and Safety Administrator.

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 7

FUEL SAFETY

DANGER



ELECTRICAL SAFETY



 Backfeed to a utility system can cause electrocution

codes. Failure to do so could result in electrical shock or

while AC power from the

cables or cords when

connecting generator to generator. Inspect for cuts in the

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

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

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.

SAFETY INFORMATION

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

burn, causing serious injury or even death.

Power Cord/Cable Safety

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

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

DANGER

DO NOT touch output terminals during

operation. Contact with output terminals during operation can cause electrocution,

electrical shock or burn.

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.

DANGER

 NEVER let power cords or cables lay in water.

 NEVER stand in water

generator is being transferred to a load.

 NEVER use damaged or worn

insulation.

 NEVER grab or touch a live power

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

electrocution or death.

 Make sure power cables are securely

damage to the generator.

NOTICE

 ALWAYS

Chart in this manual.

NEVER insert any objects into the output

receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution

or death.

PAGE 8 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

SAFETY INFORMATION

Grounding Safety



BATTERY SAFETY

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

If the battery liquid (dilute sulfuric acid) comes into

, rinse skin or clothing

If the battery liquid (dilute sulfuric acid) comes into

, rinse eyes immediately with plenty

of water and contact the nearest doctor or hospital to

NEGATIVE battery terminal

keep battery cables in good working condition.

WARNING

DANGER

This generator is equipped with a grounding terminal attached to the enclosure. Electrical grounding requirements can differ by State, Province, District,

Municipality, and unique application settings.

For portable and vehicle-mounted generators, Multiquip recognizes the guidance provided in NEC Handbook Article 250.34 Parts A and B, and 29 CFR 1926.404 (f) (3) (i). If a more deﬁ nitive earth-to-ground safeguard is required, please consult a qualiﬁ ed electrician and reference appropriate National Electrical Code (NEC) guidelines in establishing an exterior grounding point

generator.

NEVER use gas piping as an electrical ground.

NOTICE

There is a permanent conductor bond between generator (stator winding) and the frame.

DANGER

DO NOT drop the battery. There is a possibility that the

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.

 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.



contact with clothing or skin immediately with plenty of water.



contact with eyes

seek medical attention.

CAUTION

 ALWAYS disconnect the

before performing service on the generator.

 ALWAYS

Repair or replace all worn cables.

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 9

SAFETY INFORMATION

ENVIRONMENTAL SAFETY/DECOMMISSIONING

Decommissioning is a controlled process used to safely retire a piece of generator that is no longer serviceable. If the generator 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 generator has been designed to reduce harmful levels of carbon monoxide (CO), hydrocarbons (HC) and nitrogen oxides (NOx) contained

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 generator 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

NOTICE

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 generator.

When the life cycle of this generator is over, remove

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

When the life cycle of this generator is over, it is

recommended that the generator 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.

NOTICE

in diesel exhaust emissions.

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.

PAGE 10 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

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 Tank Capacity

DEF Tank Capacity

Fuel Consumption

Battery

Includes engine and radiator hoses

Includes ﬁlters

Table 1. Generator Speciﬁcations

Revolving ﬁeld, self ventilated,

open protected type synchronous generator

3Ø 3Ø

110 kW (137.5 kVA) 79 kW

100 kW (125 kVA) 72 kW

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

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

N/A 240/120

0.8 1.0

Single Phase, 60 Hz

4.8 Kw (2.4 kW x 2)

5,291 lbs. (2,400 kg)

6.702 lbs. (3,040 kg)

Table 2. Engine Speciﬁcations

Isuzu BR-4HK1X Final Tier 4

Water-cooled, direct injection, turbo-charged

4.52 in. x 4.92 in. (115 mm x 125 mm)

317 cu. in. (5.2 liter)

170.8 HP at 1800 rpm

10.3 gal. (39 liters)

6.05 gal. (22.9 liters)

API service class CJ-4 SAE 15W-40

#2 Diesel Fuel (Ultra Low Sulfur Diesel Fuel Only)

169 gal. (640 liters)

7.4 gal. (28 liters)

7.1 gal. (26.9 L)/hr at full load 5.6 gal. (21.2 L)/hr at 3/4 load

4.1 gal. (15.5 L)/hr at 1/2 load 2.6 gal. (10.0 L)/hr at 1/4 load

4D (CCA 0°F 1050A) X 1

SPECIFICATIONS

DCA125SSIU4F

60 Hz

1800 rpm

air cooled EGR

4 cylinders

Electric

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 11

125

DIMENSIONS

14,050 lbs.

(6,370 kg)

PAGE 12 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Figure 2. Dimensions

Table 3. Dimensions

Reference

Letter

A 30.32 (770) E 37.80 (960)

B 30.32 (770) F 120.08 (3,050)

C 37.80 (960) G 72.83 (1,850)

D 42.52 (1,080) H 48.82 (1,240)

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

NOTES

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 13

GENERATOR

./2.4 M (MINIMUM)

GROUND LUG

GROUND CABLE

INSTALLATION

IF THE GENERATOR IS PROVIDING ELECTRIC POWER TO A BUILDING VIA A TRANSFER SWITCH IT MUST BE CONNECTED TO A GROUND ROD.

REFERENCE

NEC 250-83 (C)

8 FT

Figure 3. Typical Generator Grounding Application

PAGE 14 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

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 a 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

) or larger.

2. When grounding of the generator (Figure 2) is required, connect one end 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.

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 15

GENERAL INFORMATION

GENERATOR

This generator (Figure 4) 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 835 Controller  Gauge Unit Assembly

• Oil Pressure Gauge

• Water Temperature Gauge

• Charging Voltmeter

• Fuel Gauge

• Tachometer

 Panel Light/Panel Light Switch  Hour Check Button  Auto Start/Stop Switch  Engine Speed Switch  Emergency Stop Switch (Option)  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, 300 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:

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

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, air cooled EGR ISUZU BR-4HK1X 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 16 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

MAJOR COMPONENTS

125

3 4

125

Table 4. Generator Major Components

ITEM NO. DESCRIPTION

1 DOC/SCR Assembly

2 DEF Tank Assembly

3 Coolant Drain Plug

4 Oil Drain With Valve

5 Fuel Tank Assembly

6 Battery Assembly

INCREASE DECREASE

U-V

180

140

220

PSI

°F

VOLTS

100

260

OIL PRESS

WATER TEMP

BATTERY

150

120

180

°F

OFF

V-W

W-U

OFF

RPMX10

210

FUEL

SPEED

ECU

Series 800 Controller

Engine Started

Shutdown

Pre-Alarm

Alarm

Screen

Program

Option

Acknowledge

Change

Exit

7 Air Filter Assembly

8 Voltage Selector Switch Assembly

9 Output Terminal Panel Assembly

10 Emergency Stop Switch (Option)

11 Generator Assembly

12 Engine Assembly

13 DEF Supply Module Assembly

14 Mufﬂer Assembly

15 Generator Operating Panel Assembly

16 Gauge Unit Assembly

17 Auto Start/Stop Controller Assembly

18 Main Circuit Breaker Assembly

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 17

Figure 4. Major Components

ENGINE CONTROL UNIT (ECU)

180

INCREASE DECREASE

OFF

V-W

W-U

U-V

OFF

ECU

PSI

OIL PRESS

Alarm

Acknowledge

100

Series 800 Controller

Screen Change

140

220

°F

VOLTS

100

260

WATER TEMP

BATTERY

150

120

180

°F

RPMX10

210

FUEL

SPEED

Engine Started

Shutdown

Pre-Alarm

Program

Option

Exit

Figure 5. Engine Control Unit (ECU)

The deﬁnitions below describe the controls and functions of the Engine Control Unit (Figure 5).

1. ECU Controller — This auto start/stop controller

displays the parameters and the diagnostic troubleshooting messages of the engine.

A. ECU Display Screen — Engine fault diagnostic

messages are shown on this LCD display. screen

B. Engine Started Lamp — This lamp when lit

indicates engine is operating normally.

C. Engine Shutdown Lamp — When an engine

failure has occured this lamp will blink. Indicating the engine has been shutdown. The diagnostic fault message will be displayed on the LCD screen.

D. Pre Alarm Lamp — When an engine failure has

occured this lamp will blink. Indicating a pre-fault engine condition and the possibility of engine shutdown.The diagnostic fault message will be displayed on the LCD screen

ECU

Series 800 Controller

Alarm

Screen

Acknowledge

Change

E F

Engine Started

Program

Option

Exit

Shutdown

Pre-Alarm

E. Alarm Acknowledge Button — When the engine

experiences a fault, the "Pre Alarm Lamp" or the "Shutdown Lamp" will start blinking. Pushing this button will conﬁrm the fault message and the blinking lamp will change to a solid lamp display. The fault message will be displayed on the screen. When multiple engine faults occur, the lamp will continue blinking until all fault messages are conﬁrmed. The blinking lamp will change to a solid lamp display all current conﬁrmed fault messages will scrool across the screen.

F. Screen Change Button — When this button is

pushed during operation, the screen will cycle through each parameter screen.

G. Option Button — This button is not active. Do

not use.

H. Program/Exit Button — Push this button from the

home screen to enter the main menu.

PAGE 18 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

ENGINE/GENERATOR CONTROL PANEL

OIL PRESS

ECU

INCREASE DECREASE

OFF

V-W

W-U

U-V

OFF

The deﬁnitions below describe the controls and functions of the Engine/Generator Control Panel (Figure 6).

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 be should read between 42.1~85.6 psi. (290~590 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 be should read between 167° and 194°F (75°~90°C).

C. Charging Voltmeter Gauge — During normal

operation this gauge indicate minimum 12.5~14 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.

2. 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.

3. Panel Light Switch — When activated will turn on

control panel light.

PSI

Series 800 Controller

Alarm

Acknowledge

180

140

220

°F

VOLTS

100

260

WATER TEMP

BATTERY

150

120

180

°F

RPMX10

210

FUEL

SPEED

Engine Started

Shutdown

Pre-Alarm

Screen

Program

Option

Change

Exit

PSI

OIL PRESS

100

180

140

°F

WATER TEMP

°F

FUEL

B C

220

260

120

VOLTS

BATTERY

150

RPMX10

SPEED

180

210

Figure 6. Gauge Unit Assembly

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

5. Frequency Meter — Indicates the output frequency in hertz (Hz). Normally 60 Hz.

6. AC Ammeter — Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

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

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

9. 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.

10. 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.

11. Hour Check Button — With the engine stopped, press and hold ths button. The total running hours, fuel level, and battery voltage will be displayed.

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

13. Engine Speed Switch — This switch controls thespeed of the engine low or high.

14. Main Circuit Breaker — This three-pole, 200 amp main breaker is provided to protect the U,V, and W output terminal lugs from overload.

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 19

OUTPUT TERMINAL PANEL FAMILIARIZATION

GFCI RECEPT

1Ø AND 3Ø,

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 7) shown below is provided for the connection of electrical loads. 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

BLACK RED BLUE WHITE GREEN

480 -120 VAC

NEUTRAL

TERMINAL

GROUND

TERMINAL

OUTPUT TERMINAL FAMILIARIZATION

The “Output Terminal Panel” (Figure 7) is provided with the following:

 Three (3) 240/139V output receptacles @ 50 amp

 Three (3) Circuit Breakers @ 50 amps

 Two (2) 120V GFCI receptacles @ 20 amp

 Two (2) Duplex Circuit Breakers @ 20 amp

 Five (5) Output Terminal Lugs (U, V, W, O, Ground)

HARD WIRE

HOOKUP PANEL

FOR GFCI RECEPTACLES

120 VAC, 20 AMP

ACLES

RECEPTACLE

AND

CIRCUIT BREAKER

PANEL

CIRCUIT BREAKERS

CIRCUIT BREAKERS FOR CS-6369 TWIST

LOCK RECEPTACLES

AUX. POWER RECEPTACLES

240/120V, 50 AMPS

Figure 7. Output Terminal Panel

TWIST-LOCK

CS-6369

ACCESS DOOR

LIFT TO OPEN

PAGE 20 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

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 8) 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 all three receptacles is dependent on the load requirements of the output terminal lugs.

Turn the voltage regulator control knob (Figure 10) 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 10. 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 11). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

Figure 8. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 240/139V, 50 amp auxiliary twist-lock (CS-6369) receptacles (Figure 9) provided on the output terminal panel. These receptacles can only be accessed when the voltage change-over board is conﬁgured for single-phase 240/120 application

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

Figure 11. Plastic Face Plate

(Output Terminal Lugs)

Figure 9. 240/139V Twist-Lock Auxiliary

Receptacles

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 21

OUTPUT TERMINAL PANEL FAMILIARIZATION

LOAD

CS-6369

ACLES

Connecting Loads

Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 12).

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, 300A 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

NEUTRAL

GROUND

LOAD

GFCI

RECEPTACLE

LOAD

Over Current Relay

An over current relay (Figure 13) 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.

1 L1

3 L2 5 L3

RESET

BUTTON

CAMLOCKS

Figure 12. Connecting Loads

Figure 13. Over Current Relay

NOTICE

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 300 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 22 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

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 name plate, 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.

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

Common power tools 0.8

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

Current

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

1.0

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.

 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.

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 23

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 14). 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 14) is located above the output terminal panel’s Hard Wire Hook-up Panel. It has been provided for ease of voltage selection..

Figure 14. 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

NOTICE

This generator can provide variable output voltages via the voltage regulator control knob.

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

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

1Ø 240 Volt

277.8 X 2 amps (4 wire) 300 amps X 2 (Zigzag)

138.9 amps (4 wire) 300 amps (Zigzag)

3Ø 240 Volt 300 amps

3Ø 480 Volt 150 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 2 twist lock auxiliary receptacles.

Tables and 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.

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

72.0 0

70.8 5 amps/receptacle

69.6 10 amps/receptacle

68.4 15 amps/receptacle

67.2 20 amps/receptacle

125

121

117

113

108

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 24 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

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 15) to the position which produces the required voltage. 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 18) in the U position and observe the current reading (load drain) on the U terminal as indicated on the AC Ammeter Gauge (Figure 19). This process can be repeated for terminals V and W.

Figure 18. 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 19. AC Ammeter

(Amp reading on U Lug)

Figure 15. Voltage Selector Switch-

Ø Position

240/3

AC Voltmeter Gauge Reading

Place the AC Voltmeter Change-Over Switch (Figure 16) 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 17).

120

Figure 16. AC Voltmeter Change-Over Switch

Figure 17. AC Voltmeter Gauge (Volt reading on W-U Lug)

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 25

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 20

3. Turn the voltage regulator knob (Figure 22) 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 22. 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 20.

2. Connect the load wires to the UVWO terminals as shown in Figure 23.

Figure 20. Voltage Selector itch

3Ø-240/139V Position

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

Figure 21. UVWO Terminal Lugs

3Ø-240/1Ø-139 Connections

Figure 23. 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 26 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

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 24.

Figure 24. Voltage Selector itch

3Ø-480/277V Position

2. Connect the load wires to the UVWO terminals as

shown in Figure 25.

1Ø-240/120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 26.

Figure 26. Voltage Selector itch

1Ø-240/120V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

Figure 25. UVWO Terminal Lugs 3Ø-480V

Connections

NOTICE

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

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 27

Figure 27. UVWO Terminal Lugs

1Ø-240/120V Connection

INSPECTION/SETUP

CIRCUIT BREAKERS

To protect the generator from an overload, a 3-pole, 200 amp, main circuit breaker is provided to protect the U , V, and W Output Terminals from overload. In addition two single-pole, 20 amp duplex 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 28) on the dipstick. See Table 11 for proper selection of engine oil.

Figure 28. 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. Make sure engine is OFF before refueling.

Reﬁlling the Fuel System

CAUTION

ONLY properly trained personnel who have read

and understand this section should reﬁll the fuel tank system.

This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank (Figure 29). ALWAYS ﬁll the fuel tanks with clean fresh #2 diesel fuel. DO NOT ﬁll the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after ﬁlling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

Delo® engine oil is the recommended engine oil for this generator. When replacing engine oil please reﬁll using Delo® 400 LE SAE 15W-40 (API CJ-4) engine oil.

Table 11. Recommended Motor Oil

PAGE 28 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

125

INTERNAL

FUEL TANK

Figure 29. Internal Fuel Tank System

FUEL

CAP

NOTICE

DO NOT add fuel while engine is running. Stop engine and let cool before adding fuel.

INSPECTION/SETUP

Unlevel Ground

125

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 30).

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.

DO NOT fill on unlevel ground

Level Ground

Figure 30. Only Fill on Level Ground

Level Ground

3. NEVER overﬁll fuel tank — It is important to read the fuel gauge when ﬁlling the fuel tank. (Figure 32). The ECU controller must be powered ON in order to read the fuel guage.

Figure 32. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 33).

Figure 33. Fuel Expansion

NOTICE

ONLY use #2 diesel fuel (ultra low sulfur diesel fuel) when refueling.

2. Remove fuel cap and ﬁll tank as shown in Figure 31.

DIESEL

FUEL

Figure 31. Fueling the Generator

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 29

ANK

INSPECTION/SETUP

DEF Refueling

NOTICE

ONLY ﬁll the DEF tank with diesel exhaust ﬂuid. Any other type of ﬂuid may cause severe engine damage.

Diesel exhaust ﬂuid is an aqueous solution made with 32.5% high puirty urea (carbamide) and 67.5 deionized water. DEF is used as a consumable in selective catalytic reduction (SCR) in order to lower NOx concentration from diesel exhaust emissions.

1. Make sure engine is OFF.

2. Remove the ﬁller cap from the DEF tank (Figure 34).

3. Upon initial start up, completely ﬁll the DEF tank with

DEF ﬂuid. DO NOT overﬁll.

125

DEF FILLER

PORT

100

DEF

CAP

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.

Table 12. Coolant Capacity

Engine and Radiator 5.5 gal (21 liters)

Figure 34. DEF Tank Filling

DEF Refueling (Continuous Operation)

It is recommended to shut down the engine prior to reﬁlling the DEF tank. However, in special applications where shutdown is not possible, it is recommended to ONLY reﬁll the DEF tank when the ﬂuid level has been consumed down to 50%.

The DEF level sending unit requires a gradual DEF level decrease during continuous operation to validate proper operation. Failure of this sensor to report the decrease could result in an engine shutdown. A engine service technician would be required to remedy the shutdown.

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. Coolant Capacity

Climate

Warm

Cold

Outside

Temperature

10°F (-12°C) or

Above

-22°F (30°C) or Above

Longlife Coolant

Concentration

30%

50%

PAGE 30 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

INSPECTION/SETUP

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.

Fan belt tension is proper if the fan belt bends as represented in Figure 35 when depressed with the thumb as shown below. Adjust fan belt tension as required

CAUTION

NEVER place hands near the belts or fan

while the generator set is running.

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 4D.

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.

Belt

New

0.2 ~ 0.3 IN. (6 ~ 8 MM)

DEFLECTION

Figure 35. Fan Belt Tension

Table 14. Fan Belt Deﬂection

Standard Value

Amt. of Deﬂection

0.2~0.3 in. (6~8 mm)

Standard Value

(Vibration Frequency)

210 Hz.

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

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 31

INSPECTION/SETUP

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 36) 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 36. Battery Connections

When connecting battery do the following:

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.

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.

PAGE 32 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

GENERATOR START-UP PROCEDURE (MANUAL)

MAIN

DUPLEX

BREAKERS

CS-6369

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, duplex or auxiliary circuit breakers in the ON (closed) position.

1. Place the main, aux. and duplex circuit breakers

(Figure 37) in the OFF position prior to starting the engine.

CIRCUIT

BREAKER

OFF

AUX. CIRCUIT

BREAKERS

OFF

CIRCUIT

OFF

STARTING (MANUAL)

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

MANUAL position to start the engine (Figure 39).

Figure 39. 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 placed 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 37. Main, Aux. and Duplex

Circuit Breakers (OFF)

2. Make sure the voltage selector switch has been

conﬁgured for the desired output voltage.

3. Connect the load to the receptacles or the output

terminal lugs as shown in Figure 12. 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 38).

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 40) should be displaying the 60 cycle output frequency in HERTZ.

60 Hz

Figure 40. Frequency Meter

4. The generator’s AC-voltmeter (Figure 41) will display the generator’s output in VOLTS. If the voltage is not within the speciﬁed tolerance,

120

CORRECT

Figure 38. Engine Enclosure Doors

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 33

Figure 41. Voltmeter

MAIN

DUPLEX

BREAKERS

CS-6369

GENERATOR START-UP PROCEDURE (MANUAL)

5. Use the voltage adjustment control knob (Figure 42) to increase or decrease the desired voltage.

Figure 42. Voltage Adjust Control Knob

6. The ammeter (Figure 43) 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.

Figure 43. Ammeter (No Load)

7. The engine oil pressure gauge (Figure 44) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 42 to 86 psi. (290~590 kPa).

PSI

OIL PRESS

100

9. The tachometer gauge (Figure 46) will indicate the

speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s (high speed) and 1000 RPM's (low speed)

150

120

RPMX10

SPEED

180

210

Figure 46. Engine Tachometer Gauge

10. Place the main, aux, and duplex circuit breakers in the ON position (Figure 47).

CIRCUIT

BREAKER

AUX. CIRCUIT

BREAKERS

Figure 47. Main, Aux. and Duplex

Circuit Breakers (ON)

11. Observe the generator’s ammeter (Figure 48) 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 44. Oil Pressure Gauge

8. The coolant temperature gauge (Figure 45) will

indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 167°~194°F (75°~90°C).

180

140

100

220

°F

WATER TEMP

260

Figure 45. Coolant Temperature Gauge

PAGE 34 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Figure 48. Ammeter (Load)

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

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) itch, 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 49)

in the AUTO position.

Figure 49. Auto Off/Reset Manual Switch (AUTO)

3. Continue operating the generator as outlined in the

Manual Start-up procedure (start at step 2).

WARNING

NEVER stop the engine suddenly except in an

emergency.

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.

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.

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 35

GENERATOR SHUT-DOWN PROCEDURES

BREAKERS

MANUAL

(CENTER)

NORMAL SHUTDOWN PROCEDURE

To shutdown the generator, use the following procedure:

1. Place both the main, aux. and duplex circuit breakers as shown in Figure 50 to the OFF position.

MAIN

CIRCUIT

BREAKER

OFF

CS-6369

AUX. CIRCUIT

BREAKERS

OFF

Figure 50. Main, Aux. and Duplex

Circuit Breakers (OFF)

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 51) in the OFF/RESET position.

DUPLEX CIRCUIT

OFF

EMERGENCY SHUTDOWN PROCEDURE

1. If equipped (option), push the Emergency Stop Pushbutton Switch (Figure 52).

Figure 52. Emergency Stop Switch (Option)

2. If generator is not equipped with an emergency stop pushbutton switch , place the Auto Off/Reset Manual Switch (Figure 53) in the OFF/RESET position.

AUTO

OFF/RESET

(CENTER)

Figure 53. Auto Off/Reset Manual Switch (OFF)

MANUAL

AUTO

OFF/RESET

Figure 51. Auto Off/Reset Manual Switch

(Off/Reset Position)

4. Remove all loads from the generator.

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

PAGE 36 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

MAINTENANCE

Table 15. Inspection/Maintenance

Check Engine Oil and Coolant Levels X

Check Fuel Filter X

Check Air Cleaner/Element X

Clean or Replace 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

Engine

Generator

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.

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

Check and Adjust Engine Valve Clearance 1000 hrs.

Test Glow Plugs X

Replace DEF Filter (In Supply Module) 3000 hrs.

Check SCR System*

Inspect Dosing Module (SRC System) 4500 hrs

Flush and Reﬁll Cooling System*

Clean Inside of Fuel Tank 1000 hrs.

Clean DEF Tank As Required

Replace Air Cleaner Elements *

Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X

10 Hrs

DAILY

250 Hrs

500 Hrs

or Every

12 Months

3000 Hrs or Every

36 Months

OTHER

4500 hrs.

1 yr. or 2000 hrs.

As Required

*2 Perform inspection and maintenance of Urea SCR system every 4500 hours. The system does not need to replace/exchange if no problem is

found. Do not make any modiﬁcation, changes or remove the emission control system and related parts. Please contact your nearest dealer or Multiquip Service Dept. for SCR maintenance.

*3 Use fully formulated antifreeze/coolant.

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

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 37

MAINTENANCE

PUSH BUTTON TO RESET

AN)

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 15 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

Air Filter Dust 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.

The air ﬁlter indicator (Figure 54) is attached to the air ﬁlter. When the air ﬁlter element is clogged, air intake restriction becomes greater and the air ﬁlter indicator signal shows RED. When indicator is red, replace ﬁlter immediately. After changing the air ﬁlter, press the air ﬁlter indicator button to reset.

CAUTION

Wear protective equipment such as approved safety glasses or face shields and dust masks or respirators when cleaning air ﬁlters with compressed air.

Primary and Secondary Air Cleaner Elements

1. Release the latches (Figure 55) that secures the cover to the air cleaner body.

2. Remove the air cleaner cover and set aside.

3. Remove both the primary and secondary air cleaner elements.

4. Check the air cleaner daily or before starting the engine

5. Check for and correct heavy buildup of dirt and debris along with loose or damaged components.

NOTICE

Operating the engine with loose or damaged air cleaner components could allow unﬁltered air into the engine causing premature wear and failure.

Figure 54. Air Filter Dust Indicator

AIR CLEANER

NOTICE

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.

Every 250 hours: Remove air cleaner element (Figure 55) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

This Isuzu diesel engine is equipped with a replaceable, high-density paper air cleaner element. This air cleaner is also equipped with an inner element (secondary) that is used as a backup ﬁlter should the primary element becomes damaged.

25 INCHES HO

6.23 kPa

6. To clean the primary element (paper air ﬁlter) as referenced in (Figure 55), tap the filter element several times on a hard surface to remove dirt, or blow

compressed air (not to exceed 30 psi (207 kPa, 2.1

kgf/cm

BODY

) through the ﬁlter element from the inside out.

PRIMARY

AIR FILTER

ELEMENT

SECONDARY

AIR FILTER

ELEMENT

BLOW COMPRESSED

AIR FROM THE

INSIDE OUT

Figure 55. Air Cleaner

AIR FILTER

INDICATOR

LATCH

EVACUATOR

ARROW

(DUST P

VALV E

MARK

7. Clean the secondary element (paper air ﬁlter) as referenced in step 6.

8. Replace both elements if they are damaged or excessively dirty.

PAGE 38 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

FUEL

AIR BLEEDER

MAINTENANCE

TER BODY

9. Clean the inside of the air cleaner body.

10. Reinstall the primary and secondary air ﬁlter elements back into air cleaner body.

11. Reinstall the air cleaner cover, and secure with latches.

DRAINING FUEL FILTER ELEMENT

NOTICE

Inspect the fuel ﬁlter daily. If the fuel ﬁlter (Figure 56) has collected a signiﬁcant amount of water and sediment at the bottom of the cup, it should be drained off immediately.

1. Loosen the air bleeder plug (Figure 56) on the fuel ﬁlter body.

2. To discharge the fuel inside the fuel filter OPEN the drain valve on the fuel ﬁlter by turning the knob counterclockwise (A) approximately 3-1/2 turns until the valve drops down 1-inch (25.4 mm) and draining occurs(B).

FUEL FILTER ELEMENT REPLACEMENT

1. Use a filter wrench to remove the element case (Figure 57) from the fuel ﬁlter body.

AIR BLEEDER

PLUG

FIL

ELEMENT

FLOAT

O-RING

FILTER BODY

FILTER

DRAIN PLUG

PLUG

OPEN

DRAIN

Figure 56. Draining Fuel Filter

3. Let the residue or foreign substances inside the case ﬂow into a suitable container.

ELEMENT

CASE

O-RING

DRAIN PLUG

Figure 57. Fuel Filter Replacement

2. Wipe the inside of the ﬁlter body with a clean cloth to remove any foregn matter or debris that may have accumulated.

3. Insert the new fuel ﬁlter element into the element case.

4. Replace both o-rings. Coat each o-ring with a small amount of clean 15W-40 engine oil.

5. Reinstall element case ﬁrst by hand until it makes contact with the fuel ﬁlter body surface.

6. Torque element case to 22.4 lb-ft (30 N.m).

7. Torque drain plug to 1.4 lb-ft (2.0 N.m).

8. Remove the air from the fuel system. Reference Isuzu Owner's Manual, "Bleeding the Fuel System".

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 39

MAINTENANCE

FUEL

ELECTROMAGNETIC FUEL PUMP (500 HOURS)

The ﬁlter inside the fuel pump (Figure 58) is either a paper type or steel mesh type depending on fuel pump type. Clean or replace the fuel pump ﬁlter as follows:

1. Disconnect any electrical connections that are attached to the fuel pump.

2. Prepare a fuel collector to drain the fuel into. Secure any fuel lines to prevent fuel from spilling.

3. Remove fuel pump from air generator enclosure.

4. Next, remove the ﬁlter and gasket from the fuel pump

housing.

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

If necessary, drain the fuel inside the fuel tank completely. Using a spray washer (Figure 59) wash out any deposits or debris that have accumulated inside the fuel tank.

Figure 58. Electromagnetic Fuel Pump

NOTICE

When the fuel pump ﬁlter is removed, always make sure to replace both gaskets and clean the magnet portion inside the cover.

5. Clean or replace fuel pump ﬁlter. Replace both gaskets.

6. Reassemble fuel pump and mount back onto generator enclosure.

7. Reconnect all fuel lines and electrical components.

8. Check for fuel leaks.

TANK

Figure 59. Fuel Tank Cleaning

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.

PAGE 40 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

MAINTENANCE

(LOWER LIMIT)

OVERFILL

104

122

DRIVE BELT (DAILY)

Drive Belt Tension

A slack drive belt (Figure 60) may contribute to overheating, or to insufﬁcient charging of the battery, adjust drive belt in accordance with the Isuzu Operator's manual

Drive Belt Inspection

Inspect the drive belt for damage and wear. Horizontal cracks (across the belt) are acceptable. Vertical (direction of belt ribs) cracks that intersect with horizontal cracks are not acceptable.

Also, examine the belt and determine if it is oil soaked or "glazed " (hard shiny appearance on the sides of the belt). Either of these two conditions can cause the belt to run hot, which can weaken it and increase the danger of it breaking.

If the drive belt exhibits any of the above wear conditions, replace the drive belt immediately.

Figure 60. Drive Belt Inspection

ENGINE OIL (CHECK DAILY)

1. When checking or adding oil, place the machine so the engine is level.

2. Pull the engine oil dipstick from its holder.

3. Determine if engine oil is low. Oil level should be between the upper land lower limit (Figure 61) on the dipstick.

DO NOT

H (UPPER LIMIT)

Figure 61. Dipstick Engine Oil Level

4. If oil level is low, add correct amount of engine oil to bring oil level to a normal safe level (See Recommended Viscosity Grades.

5. Allow enough time for any added oil to make its way to the oil pan before rechecking.

Table 16. Oil Selection Chart

5W/40

10W

OIL: SAE

10W/30

10W/40

15W/40

20W/20

-14

-22

-40

-4

-10

-20

-30

-40

032

5W/30

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 41

DRAINING ENGINE OIL

1. Run the engine until the engine coolant reaches a temperature of 140° (60°C) Turn the engine off.

2. Remove the oil dipstick from its holder.

3. Next, remove oil drain cap (Figure 62)

4. Place the oil drain valve in then OPEN position and allow the oil to drain into a suitable container.

OIL DRAIN

COOLANT

DRAIN VALVE

(OPEN)

CAP

(REMOVE)

OPEN

OIL DRAIN VALV E

Figure 62. Draining Engine Oil

MAINTENANCE

6. Run the engine for several minutes. Watch for oil leakage. Shut the engine down and allow it to sit for several minutes. Top off the oil to the upper limit on the dipstick.

FLUSHING OUT RADIATOR AND REPLACING COOLANT

WARNING

DO NOT remove the pressure cap from the

radiator when the engine is hot! Wait until the coolant temperature is below 120°F (50°C) before removing pressure cap.

5. After engine oil has been completely drained, reinstall oil drain cap and tighten securely.

6. Place the oil drain valve in the CLOSED position.

ENGINE OIL FILTER REPLACEMENT

1. Clean the area around the lubricating oil ﬁlter head.

2. Using an oil ﬁlter wrench (Figure 63), remove engine oil ﬁlter.

RUBBER

SEAL

OIL

COAT SEAL

OIL FILTER

WRENCH

ENGINE

OIL FILTER

CARTRIDGE

WITH THIN

LAYER OF OIL

Heated coolant spray or steam can cause severe scalding and personal injury.

1. Place the coolant drain valve in the OPEN position

(Figure 64) and allow the coolant to drain into a suitable container.

Figure 63. Engine Oil Filter Removal

3. Coat the rubber seal (gasket) surface of oil ﬁlter (Figure 63) with clean 15W-40 engine oil.

4. Install new oil ﬁlter ﬁrst by hand until it makes contacts with the ﬁlter head surface. Tighten it another 3/4 turn using the ﬁlter wrench.

5. Fill engine crankcase with high quality detergent oil classiﬁed "For Service CI-4. Fill to the upper limit of dipstick. DO NOT overﬁll. Reference Table 2 for engine crankcase oil capacity.

PAGE 42 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Figure 64. Draining Engine Coolant

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

3. Remove and inspect radiator cap.

4. 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.

MAINTENANCE

5. Tighten water cock and replace the overﬂow tank.

6. Place the coolant drain valve in the CLOSED position.

7. Replace with coolant as recommended by the engine manufacturer.

8. Reinstall radiator cap. Tighten securely.

RADIATOR CLEANING

The radiator (Figure 65) 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.

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.

Figure 65. Radiator Cleaning

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 43

MAINTENANCE

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

This generator can be equipped as an option with a engine block heating element and an internal battery charger. They are provided with electric cords to connect

to a commercial power source.

The engine block heating element and internal battery charger both require 120 VAC in order to operate. A receptacle (Figure 66) has been provided on the output terminal panel to allow commercial power to be applied.

These units will ONLY function when commercial power has been supplied to them. When using extension cords, refer to Table 6 for the correct size and length.

The battery charger should always be connected to a commercial power source to ensure that the battery does not get discharged.

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

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

To ensure adequate starting capability, always have power applied to the generator's internal battery charger.

OUTPUT TERMINAL

PANELASSEMBLY

BATTERY

CHARGER

JACKET WATER

HEATER

BATTERY CHARGER/

JACKET WATER HEATER

120 VAC INPUT

RECEPTACLE

Figure 66. Jacket Water Heater and Battery Charger (Option)

PAGE 44 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

MAINTENANCE

EMISSION CONTROL

The emission control system employed with this ISUZU diesel engine consist of a Diesel Oxidation Catalyst (DOC) and a Selective Catalytic Reduction (SCR) catalyst as an exhaust gas after-treatment system that helps reducing harmful gases and destroying the organic fraction of the particulate matter produced from the exhaust gas to meet the requirement for EPA Tier 4 (Final) regulations.

The DOC device (Figure 67) helps in ﬁltering out 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. It is important to maintain and service the DOC emission safety device on a periodic basis.

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.

EMISSION CARBON CHECK

Deposition of carbon (soot, unburned fuel) in the exhaust pipe line and mufﬂer could cause not only system derates but also could lead to ﬁres.

To reduce soot and unburned fuel, run the unit at rated power until the exhaust gas become mostly colorless every 250 hours operation time. More carbon will be generated when the unit operates at less then 30% of rated power. In this case, perform the above procedures more frequently.

NOTICE

Applying a large load suddenly to the unit when the carbon deposition is generated in the exhaust system could produce sparks and will lead to abnormal combustion. Therefore, apply load gradually and observe the exhaust gas color during the process.

Figure 67. Diesel Oxidation Catalyst (DOC)

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 45

MAINTENANCE

SCR PURGE

SELECTIVE CATALYTIC REDUCTION (SCR)

Diesel engines can be run with a lean burn air-to-fuel ratio, to ensure the full combustion of soot and to prevent the exhaust of unburnt fuel. The excess of air necessarily leads to generation of nitrogen oxides (NOx), which are harmful pollutants, from the nitrogen in the air. Selective Catalytic Reduction is used to reduce the amount of NOx released into the atmosphere.

Diesel Exhaust Fluid (DEF) from a separate tank is injected into the exhaust pipeline, where the aqueous urea vaporizes and decomposes to form ammonia and carbon dioxide. Within the SCR catalyst, the NO reduced by the ammonia (NH3) into water (H2O) and nitrogen (N2), which are both harmless; and these are then released through the exhaust.

The SCR system creates a certain amount of amonia (NH that is stored in SCR catalyst. During purging operations the increase in temperature at regular intervals eleminates the stored ammonia.

The process of keeping accurate amonia storage amounts is by counting urea injection quantities from the Dosing Control Unit (DCU)

The SCR Purge symbol (Figure 68) will be displayed on the ECU controller during operation when either an automatic or forced system purge operation is in process.

The pre-alarm lamp is only ON during SCR forced system purging and OFF during automatic system purging

ECU

Series 800 Controller

are catalytically

Engine Started

Shutdown

Pre-Alarm

NOTICE

During urea SCR system purging, white smoke may be emitted from the exhaust tailpipe temporarily this shoud not be considered a failure. In addition the smell of amonia during the purging process should not be considered a failure.

If the purging process is underway while running a light load (0-30%) the unit may produce unusual sounds. This should not be considered a failure or malfunction.

SYSTEM PURGING GUIDELINES

NOTICE

DO NOT perform purging in conditions where it may be unsafe due to high exhasust temperatures.

)

For safe operation of equipment, the sourounding area and the prevention of bodily harm, use the guidelines below when system purging is required:

NOTICE

The area above and around the generator during the purging process should be free of any type of debris, ﬂammable or conbustible materials, as temperatures during the purging process can reach as high 1,022 °F (550 °C).

 DO NOT operate the unit in area with poor ventilation.

 If operating the engine indoors, install exhaust/ventilation

equipment and ensure that there is sufﬁcient ventilation.

 If you begin to feel sick, stop the unit immediately and

ventilate the area.

 Exhaust emissions from the tailpipe have a smell different

from those emitted from engines without urea SCR systems due to the exhaust emission reduction functions of the exhaust system.

Alarm

Acknowledge

Screen

Change

Option

Program

Exit

Figure 68. SCR Purge Symbol

PAGE 46 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

MAINTENANCE

If the diesel exhaust ﬂuid (DEF) symbol (Figure 69) is displayed during ECU controller operation, it indicates the following:

 DEF tank level is below 10%. Reference Table 17, DEF

Level System Action System.

 DEF quality is poor. Check DEF tank level and check

active diagnostics trouble codes (DTC).

ECU

Series 800 Controller

Alarm

Acknowledge

Screen

Change

DEF STAT

Program

Option

Engine Started

Shutdown

Pre-Alarm

Exit

DIESEL EXHAUST FLUID (DEF)

The amount of ﬂuid in the DEF tank will be shown on the ECU Controller main screen during operation. The symbol shown in Figure 70 will be shown on the ECU monitor indicating the level of ﬂuid in the DEF tank.

Figure 70. DEF Tank Level Guage

Figure 69. ECU DEF State Pre-Alarm

NOTICE

The unit will enter emergency shutdown when the DEF level has reached 0% and emergency protective measures are necessary. When this condition exist, the unit can only be restarted after the ESCAPE MODE is activated and the unit will run for 30 minutes. Reference "Escape Mode" section in this manual.

Table 17. DEF Level System Action System

DEF Level Over 10% Below 10% 0% Empty or After 4 hrs. From 0%

Controller Message — DEF<10% Tank Level DEF<10% Tank Level DEF Tank Empty Level

DEF Symbol —

Pre-Alarm Lamp — —

Shutdown Lamp — — —

Blinking Blinking

ON ON

Engine Shutdown

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 47

INDUCEMENT

When the system senses improper usage such as no supply of DEF, use of poor quality DEF, problems with DEF jets, or disconnection of sensors, a warning will be issued before the situation becomes critical. If the warnings are ignored and the unit enters intermittent operation, the emergency shutdown will activate. The three warning levels are referenced in Table 18:

Table 18. DEF Inducement

MAINTENANCE

Stage Controller Message

Stage 1

Warning Level 1

Stage 2

Warning Level 2

SCR System

Malfunction

SCR System

Malfunction

SCR System

Pop-Up

SCR SYS ERR

DEF Symbol

Pre-Alarm

Lamp

Shutdown

Lamp

—

Slow Blinking

Stage 3

Shutdown

SCR System

Malfunction

SCR SYS ERR

ON ON

Fast Blinking

When emergency shutdown occurs, inspection and repair should generally be performed promptly. However, if

emergency protective measures are necessary, unit will enter ESCAPE MODE and may require as much as 30 minutes to restart.

PAGE 48 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

HOW TO ACTIVE ESCAPE MODE

BUTTON

[PROGRAM EXIT]

BUTTON

If the ECU displays any messages referenced in Table 18, it may be necessary to restart via ESCAPE MODE.

Starting

1. Start the Diagnostic Mode as referenced in the "Troubleshooting Diagnostics" section in this manual.

2. Exit the Status Check Screen by pressing the [EXIT] button (Figure 71).

MAINTENANCE

SPEED

0000

DEF

CANBUS IS WORKING OK

DEF

HOURS

STATUS CHECK

26.8v

00018.3

CANBUS IS WORKING OK EXIT

[EXIT]

Figure 71. Status Check Screen

(Diagnostic Mode)

3. Next, press the [Program/Exit] button (Figure 72) to enter the Main Menu.

DIAGNOSTIC MODE

Alarm Screen

Change

Option

Program

Exit

Figure 72. Main Screen

4. Press the [DOWN] button (Figure 73) to scroll to the

Escape Mode item.

FAULT DIAGNOSTICS ABOUT UNIT USER LOGIN ESCAPE MODE

UP DOWN SELECT

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 49

[DOWN]

BUTTON

Figure 73. Main Menu (Down Button)

MAINTENANCE

[SELECT]

BUTTON

DEF

SCR TROUBLE-PURGE PROHIBITED

SCR SYS ERR

HOURS

00018.2

SD IN

MIN.

1800

SPEED

CHECK

5. Press the [SELECT] button (Figure 74) to enter the

“Escape Mode” menu.

FAULT DIAGNOSTICS ABOUT UNIT USER LOGIN ESCAPE MODE

UP DOWN SELECT

Figure 74. Main Menu (Select Button)

6. Press the [REQUEST] button (Figure 75) to send

"Escape Mode Request" signal to ECM.

7. Place the Auto Start/Stop Switch (Figure 76), to the “Off /Reset” position.

AUTO

OFF/RESET

(CENTER)

Figure 76. Auto Off/Reset Manual Switch

(Off/Reset Position)

MANUAL

8. Next, place the Auto Start/Stop Switch (Figure 77) to the “Manual” position to start the engine.

Figure 77. Auto-Off/Reset Manual Switch

(Manual Position)

9. The Escape Mode Timer (Figure 78) will appear on the main screen. This timer displays remaining driving possibility time.

ESCAPE MODE REQUEST

EMERGENCY RESERVE ENGINE RUN MAY BE POSSIBLE.

TO ATTEMPT ESCAPE MODE:

PRESS THE REQUEST SOFT KEY.

EXIT

REQUEST

[REQUEST]

Figure 75. Escape Mode Menu Screen

PAGE 50 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Figure 78. Escape Mode Timer

 If ESCAPE MODE is temporarily suspended, it is not

necessary to return to the ESCAPE MODE screen and press the [REQUEST] button. ESCAPE MODE operation will be available until around 30 minutes after operation has been ended.

 Once the ESCAPE MODE timer reaches zero minutes,

the engine will stop since the ESCAPE MODE time has expired. Please perform maintenance to return unit to proper operating condition.

 If the unit returns to Warning Level 1 while ESCAPE

MODE is running, ESCAPE MODE will be cancelled, the ESCAPE MODE timer display will close, and normal operation will resume.

GENERATOR WIRING DIAGRAM

SYMBOL

Fg ExAr ExFg

AVR

CT 1,2,3

~ F

CB1

CB2, 3, 4 CB5, 6

CON1, 2, 3 CON4, 5

RY1 RY2

CURRENT TRANSFORMERS (CT1 ~ 3)

REF. DES.

k l

NOTE: EACH CABLE IS PASSED TWICE THROUGH CURRENT TRANSFORMERS CT1, CT2 AND CT3.

DESIGNATION

MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING EXCITER ARMATURE WINDING EXCITER FIELD WINDING RECTIFIER AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR (RHEOSTAT) CURRENT TRANSFORMER CHANGE-OVER SWITCH,AMMETER AC.AMMETER

AC.VOLTMETER FREQUENCY METER CIRCUIT BREAKER, 3P 200A CIRCUIT BREAKER, 2P 50A

CIRCUIT BREAKER, 1P 20A

RECEPTACLE, CS6369, 250 VAC@ 50 AMPS

RECEPTACLE, GFCI, 125 VAC @ 20 AMPS X 2

OVER CURRENT RELAY

SELECTOR SWITCH RELAY UNIT

RELAY UNIT

MARK AT CT

NO MARK

CONNECTOR ARRANGEMENT

(WIRING VIEW)

A J C

CN1

CN3

CN4

DKB

2 3

V W

WIRE SIZE

125: 125 mm 100: 100 mm 80: 80 mm

22: 22 mm 14: 14 mm 8: 8 mm

5.5: 5.5 mm

NO MARK WIRE SIZE: 1.25

CN5

CN6

CN7

B B

432

CN8

432

CN9

CN10

41 98

2 1

2 3

S T

CODE/WIRE COLOR

BLACK BLUE BROWN GREEN GRAY VIOLET PINK

RED

WHITE

YELLOW

LIGHT BLUE

LIGHT GREEN

ORANGE

CN11

CN12

U1 U2 W2

3 2

V1U1W1

1 3

2 3

1 3

U2 W2

CN13

CN14

2 1

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 51

ENGINE WIRING DIAGRAM

125: 125 mm

100: 100 mm

80: 80 mm

22: 22 mm

14: 14 mm

5.5: 5.5 mm

8: 8 mm

NO MARK WIRE SIZE: 1.25

PAGE 52 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

RED

WHITE

YELLOW

LIGHT BLUE

LIGHT GREEN

ORANGE

RWYLBLG

CODE/WIRE COLOR

BLACK

BLUE

BROWN

GREEN

GRAY

VIOLET

PINK

BLBRGGRVP

WIRE SIZE

NOTES

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 53

CONTROLLER WIRING DIAGRAM

RED

WHITE

YELLOW

LIGHT BLUE

LIGHT GREEN

ORANGE

RWYLBLG

CODE/WIRE COLOR

BLACK

BLUE

BROWN

GREEN

GRAY

VIOLET

PINK

BLBRGGRVP

WIRE SIZE

8: 8 mm

100: 100 mm

125: 125 mm

80: 80 mm

22: 22 mm

5.5: 5.5 mm

14: 14 mm

NO MARK WIRE SIZE: 1.25

PAGE 54 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

CONTROLLER WIRING DIAGRAM

RED

WHITE

YELLOW

LIGHT BLUE

LIGHT GREEN

ORANGE

RWYLBLG

CODE/WIRE COLOR

BLACK

BLBRGGRVP

WIRE SIZE

125: 125 mm

BLUE

BROWN

GREEN

GRAY

100: 100 mm

80: 80 mm

22: 22 mm

14: 14 mm

VIOLET

PINK

8: 8 mm

5.5: 5.5 mm NO MARK WIRE SIZE: 1.25

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 55

BATTERY CHARGER WIRING DIAGRAM

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

BLACK 14 AWG. LINE (L)120VAC INPUT

WHITE 14 AWG. NEUTRAL (N)

GREEN 14 AWG. GROUND (G)

TO CHASSIS

GROUND

GREEN 16 AWG.

TO STARTER “B”

TERMINAL

RED 16 AWG.

NOTES:

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

120 VAC INPUT, INSERT EXTERNAL

POWER CORD HERE.

RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.

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

PAGE 56 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

JACKET WATER HEATER WIRING DIAGRAM

BLACK 14 AWG. LINE (L)120VAC INPUT

WHITE 14 AWG. NEUTRAL (N)

GREEN 14 AWG. GROUND (G)

BLACK 14 AWG.

LINE (L)120VAC INPUT

WHITE 14 AWG.

NEUTRAL (N)

GREEN 14 AWG.

GROUND (G)

BLOCK HEATER

(P/N 44558)

TEMP.

SWITCH

HEATING

120 VAC

GROUND

ELEMENT

NOTES:

NEMA 5-15, 15A, 120 VAC, HBL5278C/HUBBLE RECEPTACLE.

RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.

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

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

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 57

120 VAC INPUT, INSERT EXTERNAL

POWER CORD HERE.

TROUBLESHOOTING (GENERATOR)

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

Table 19. 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? Place engine speed switch in “High” position.

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 58 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

TROUBLESHOOTING (DIAGNOSTICS)

HOUR CHECK

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself.

1. With the engine stopped (OFF). Push and hold the

Hour Check Button (Figure 79) located on the control panel.

BUTTON

Figure 79. Hour Check Button

5. Push the Program/Exit Button on the ECU controller and select the Fault Diagnostics mode. This mode enables the ability to carry out the fault diagnostics as listed below:

 DM1 Active Faults — Displays active fault messages

and codes.

 DM2 Messages and Codes — Displays messages and

codes which previously occurred that are recorded in the Engine Control Module (ECM).

 Last Shutdown — Displays the messages and codes

that caused the most recent shutdown.

6. After perfoming diagnostic tests, place the Auto Off/ Reset Manual Switch in the OFF position

2. While keeping the Hour Check Button pressed, place the Auto Off/Reset Manual Switch (Figure 80) in the MANUAL position.

3. The Hour Check Menu Screen will be displayed on the ECU controller.

4. Releasing the Hour Check Button and pushing the Program/Exit Button on the ECU controller will return the controller to the main screen.

Figure 80. Auto-Off/Reset Switch

(Manual Position)

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 59

OPERATION MANUAL

HERE’S HOW TO GET HELP

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: mq@multiquip.com

Service Department Warranty Department

800-421-1244 310-537-3700

Technical Assistance

800-478-1244 Fax: 310-943-2238

CANADA

Multiquip Multiquip (UK) Limited Head Ofﬁce

4110 Industriel Boul. Laval, Quebec, Canada H7L 6V3 Contact: infocanda@multiquip.com

Tel. (800) 421-1244 Fax (310) 537-3927

Tel: (450) 625-2244 Tel: (877) 963-4411 Fax: (450) 625-8664

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: sales@multiquip.co.uk

Fax: 800-672-7877

Fax: 310-943-2249

Tel: 0161 339 2223 Fax: 0161 339 3226

, 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:

MQ Power DCA125SSIU4F, DCA70SSIU4F Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual