MQ Power DCA125SSIU4F Instruction Manual
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MQ Power DCA125SSIU4F Instruction Manual

Whisperwatt series 60hz generator (isuzu br-4jj1x diesel engine)
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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.

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  • Page 1 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.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

  • Page 3: Table Of Contents

    Battery Charger Wiring Diagram ......56 Jacket Water Heater Wiring Diagram ..... 57 Troubleshooting (Generator) ........58 Troubleshooting (Diagnostics) ....... 59 NOTICE Specifications are subject to change without notice. DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 3...

  • Page 4: Nameplate/Safety Information

    SAFETY DECALS SAFETY DECALS NOTICE Safety labels/decals are attached to the generator as shown For safety label part numbers, reference parts manual.. 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.
  • Page 5 COULD result in DEATH or SERIOUS INJURY. CAUTION Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY. NOTICE Addresses practices not related to personal injury. DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 5...

  • Page 6: Safety Decals

    SAFETY INFORMATION GENERAL SAFETY „ NEVER use accessories or attachments that are not recommended by MQ Power for this generator. Damage CAUTION to the generator and/or injury to user may result. „ NEVER operate this generator without proper protective „ ALWAYS know the location of the nearest clothing, shatterproof glasses, respiratory protection, fi re extinguisher.
  • Page 7 „ NEVER touch the hot exhaust manifold, local Health and Safety Administrator. muffl er or cylinder. Allow these parts to cool before servicing generator. DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 7...
  • Page 8 SAFETY INFORMATION FUEL SAFETY „ Backfeed to a utility system can cause electrocution and/or property damage. NEVER DANGER connect the generator to a building’s electrical system without a transfer „ DO NOT start the engine near spilled fuel or combustible switch or other approved device.
  • Page 9 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. DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 9...
  • Page 10 SAFETY INFORMATION ENVIRONMENTAL SAFETY/DECOMMISSIONING EMISSIONS INFORMATION NOTICE NOTICE Decommissioning is a controlled process used to safely The diesel engine used in this generator has been designed retire a piece of generator that is no longer serviceable. to reduce harmful levels of carbon monoxide (CO), If the generator poses an unacceptable and unrepairable hydrocarbons (HC) and nitrogen oxides (NOx) contained safety risk due to wear or damage or is no longer cost...

  • Page 11: Specifications

    4.1 gal. (15.5 L)/hr at 1/2 load 2.6 gal. (10.0 L)/hr at 1/4 load Battery 4D (CCA 0°F 1050A) X 1 Includes engine and radiator hoses Includes filters DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 11...

  • Page 12: Dimensions

    DIMENSIONS 14,050 lbs. (6,370 kg) Figure 2. Dimensions Table 3. Dimensions Reference Dimension in. (mm) Reference Letter Dimension in. (mm) Letter 30.32 (770) 37.80 (960) 30.32 (770) 120.08 (3,050) 37.80 (960) 72.83 (1,850) 42.52 (1,080) 48.82 (1,240) PAGE 12 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)
  • Page 13 NOTES DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 13...

  • Page 14: Installation

    INSTALLATION GENERATOR GROUND LUG IF THE GENERATOR IS PROVIDING ELECTRIC POWER TO A BUILDING VIA A TRANSFER SWITCH IT MUST GROUND CABLE BE CONNECTED TO A GROUND ROD. I M U M I N 2 . 4 T . / REFERENCE NEC 250-83 (C) Figure 3.
  • Page 15 ALWAYS consult with a licensed They are to resist damage to the bottom of the generator electrician. and to maintain alignment. DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 15...

  • Page 16: General Information

    Reference Table 2 for engine specifications. „ 3-Pole, 300 amp Main Circuit Breaker „ “Control Box” (Located Behind Control Panel) In keeping with MQ Power’s policy of constantly improving • Automatic Voltage Regulator its products, the specifications quoted herein are subject •...

  • Page 17: Major Components

    Engine Assembly DEF Supply Module Assembly Muffler Assembly Generator Operating Panel Assembly Gauge Unit Assembly Auto Start/Stop Controller Assembly Main Circuit Breaker Assembly Figure 4. Major Components DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 17...

  • Page 18: Engine Control Unit (Ecu)

    ENGINE CONTROL UNIT (ECU) Series 800 Controller Engine Started °F VOLTS INCREASE DECREASE OIL PRESS WATER TEMP BATTERY Shutdown ½ °F RPMX10 Pre-Alarm FUEL SPEED Series 800 Controller Engine Started Shutdown Pre-Alarm Alarm Screen Program Alarm Screen Program Option Option Acknowledge Change Exit...

  • Page 19: Engine/Generator Control Panel

    14. Main Circuit Breaker — This three-pole, 200 amp control panel light. 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...

  • Page 20: Output Terminal Panel Familiarization

    OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel (Figure 7) shown below is The “Output Terminal Panel” (Figure 7) is provided with provided for the connection of electrical loads. Lift up on the following: the cover to gain access to receptacles and terminal lugs.
  • Page 21 These receptacles can only be accessed when the voltage change-over board is configured for single-phase 240/120 application 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...
  • Page 22 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Over Current Relay Loads can be connected to the generator by the Output An over current relay (Figure 13) is connected to the main Terminal Lugs or the convenience receptacles (Figure 12). circuit breaker. In the event of an overload, both the circuit Make sure to read the operation manual before attempting breaker and the over current relay may trip.

  • Page 23: Load Application

    150 ft. 100 ft. 1800 3600 150 ft. 100 ft. 65 ft. 2400 4800 125 ft. 75 ft. 50 ft. CAUTION: Equipment damage can result from low voltage DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 23...

  • Page 24: Generator Outputs

    GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES Maximum Amps Table 8 shows the maximum amps the generator can A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using provide. DO NOT exceed the maximum amps as listed. the voltage selector switch (Figure 14).

  • Page 25: Generator Outputs/Gauge Reading

    W and U terminals as indicated on the AC Voltmeter Gauge (Figure 17). Figure 16. AC Voltmeter Figure 17. AC Voltmeter Gauge Change-Over Switch (Volt reading on W-U Lug) DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 25...

  • Page 26: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES 3. Turn the voltage regulator knob (Figure 22) clockwise to increase voltage output, turn counterclockwise to Various output voltages can be obtained using the UVWO decrease voltage output. Use voltage regulator output terminal lugs. The voltages at the terminals are adjustment knob whenever fine tuning of the output dependent on the position of the Voltage Selector Switch voltage is required...
  • Page 27 ALWAYS make sure that the connections to the voltage is required. 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...

  • Page 28: Inspection/Setup

    INSPECTION/SETUP CIRCUIT BREAKERS FUEL CHECK To protect the generator from an overload, a 3-pole, 200 DANGER amp, main circuit breaker is provided to protect the U,V, Fuel spillage on a hot engine can cause and W Output Terminals from overload. In addition two a fire or explosion.
  • Page 29 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...
  • Page 30 INSPECTION/SETUP DEF Refueling COOLANT (ANTIFREEZE/SUMMER COOLANT/ WATER) NOTICE Isuzu recommends antifreeze/summer coolant for use in their ONLY fill the DEF tank with diesel exhaust fluid. Any engines, which can be purchased in concentrate (and mixed other type of fluid may cause severe engine damage. with 50% demineralized water) or pre-diluted.
  • Page 31 DEFLECTION Figure 35. Fan Belt Tension Table 14. Fan Belt Deflection Standard Value Standard Value Belt Amt. of Deflection (Vibration Frequency) 0.2~0.3 in. 210 Hz. (6~8 mm) DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 31...
  • Page 32 INSPECTION/SETUP Battery Cable Installation ALTERNATOR ALWAYS be sure the battery cables (Figure 36) are The polarity of the alternator is negative grounding type. properly connected to the battery terminals as shown below. When an inverted circuit connection takes place, the The red cable is connected to the positive terminal of the circuit will be in short circuit instantaneously resulting the battery, and the black cable is connected to the negative...

  • Page 33: Generator Start-Up Procedure (Manual)

    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, CORRECT INCORRECT Figure 38. Engine Enclosure Doors Figure 41. Voltmeter DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 33...

  • Page 34: Generator Start-Up Procedure (Manual)

    GENERATOR START-UP PROCEDURE (MANUAL) 5. Use the voltage adjustment control knob (Figure 42) 9. The tachometer gauge (Figure 46) will indicate the to increase or decrease the desired voltage. 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) Figure 42.

  • Page 35: Generator Start-Up Procedure (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...

  • Page 36: Generator Shut-Down Procedures

    GENERATOR SHUT-DOWN PROCEDURES EMERGENCY SHUTDOWN PROCEDURE NORMAL SHUTDOWN PROCEDURE 1. If equipped (option), push the Emergency Stop To shutdown the generator, use the following procedure: Pushbutton Switch (Figure 52). 1. Place both the main, aux. and duplex circuit breakers as shown in Figure 50 to the OFF position. MAIN CS-6369 DUPLEX...

  • Page 37: Maintenance

    Multiquip Service Dept. for SCR maintenance. Use fully formulated antifreeze/coolant. Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 37...
  • Page 38 MAINTENANCE GENERAL INSPECTION CAUTION Prior to each use, the generator should be cleaned and Wear protective equipment such as inspected for deficiencies. Check for loose, missing or approved safety glasses or face shields damaged nuts, bolts or other fasteners. Also check for and dust masks or respirators when fuel, oil, and coolant leaks.
  • Page 39 8. Remove the air from the fuel system. Reference Isuzu 3. Let the residue or foreign substances inside the case Owner's Manual, "Bleeding the Fuel System". flow into a suitable container. DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 39...
  • Page 40 MAINTENANCE ELECTROMAGNETIC FUEL PUMP (500 HOURS) Removing Water from the Fuel Tank After prolonged use, water and other impurities accumulate The filter inside the fuel pump (Figure 58) is either a paper in the bottom of the tank. Occasionally inspect the fuel tank type or steel mesh type depending on fuel pump type.
  • Page 41 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. DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 41...
  • Page 42 MAINTENANCE 6. Run the engine for several minutes. Watch for oil leakage. Shut the engine down and allow it to sit for OIL DRAIN several minutes. Top off the oil to the upper limit on (REMOVE) the dipstick. OPEN FLUSHING OUT RADIATOR AND REPLACING DRAIN COOLANT VALVE...
  • Page 43 „ 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...
  • Page 44 MAINTENANCE JACKET WATER HEATER AND INTERNAL BATTERY When using the generator in hot climates there is no need to apply power to jacket water heater. However, if the CHARGER 120 VAC INPUT RECEPTACLES generator will be used in cold climates, it is best to apply (OPTIONAL) power to the jacket water heater at all times.
  • Page 45 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. Figure 67. Diesel Oxidation Catalyst (DOC) DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 45...
  • Page 46 MAINTENANCE SELECTIVE CATALYTIC REDUCTION (SCR) NOTICE Diesel engines can be run with a lean burn air-to-fuel ratio, During urea SCR system purging, white smoke may to ensure the full combustion of soot and to prevent the be emitted from the exhaust tailpipe temporarily this exhaust of unburnt fuel.
  • Page 47 — DEF<10% Tank Level DEF<10% Tank Level DEF Tank Empty Level DEF Symbol — Blinking Blinking Pre-Alarm Lamp — — Shutdown Lamp — — — Engine Shutdown DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 47...
  • Page 48 MAINTENANCE 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.
  • Page 49 Figure 71. Status Check Screen (Diagnostic Mode) DOWN SELECT 3. Next, press the [Program/Exit] button (Figure 72) to enter the Main Menu. [DOWN] BUTTON Figure 73. Main Menu (Down Button) DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 49...
  • Page 50 MAINTENANCE 5. Press the [SELECT] button (Figure 74) to enter the 7. Place the Auto Start/Stop Switch (Figure 76), to the “Escape Mode” menu. “Off /Reset” position. FAULT DIAGNOSTICS ABOUT UNIT MANUAL AUTO USER LOGIN ESCAPE MODE OFF/RESET (CENTER) Auto Off/Reset Manual Figure 76.

  • Page 51: Generator Wiring Diagram

    LIGHT GREEN VIOLET NOTE: EACH CABLE IS PASSED TWICE THROUGH 8 mm ORANGE CURRENT TRANSFORMERS CT1, CT2 AND CT3. 5.5: 5.5 mm PINK NO MARK WIRE SIZE: 1.25 DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 51...

  • Page 52: Engine Wiring Diagram

    ENGINE WIRING DIAGRAM PAGE 52 — DCA12SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)
  • Page 53 NOTES DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 53...

  • Page 54: Controller Wiring Diagram

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

  • Page 55: Controller Wiring Diagram

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

  • Page 56: Battery Charger Wiring Diagram

    BATTERY CHARGER WIRING DIAGRAM 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. 120 VAC INPUT, INSERT EXTERNAL POWER CORD HERE. NOTES: NEMA 5-15, 15A, 120 VAC, P/N HBL5278C/HUBBLE RECEPTACLE.

  • Page 57: Jacket Water Heater Wiring Diagram

    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...

  • Page 58: Troubleshooting (Generator)

    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.

  • Page 59: Troubleshooting (Diagnostics)

    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. DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 59...
  • Page 60 © COPYRIGHT 2017, MULTIQUIP INC. Multiquip Inc , the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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