MQ Power DCA25SSIU4F Operation Manual
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MQ Power DCA25SSIU4F Operation Manual

Whisperwatt series 60hz generator isuzu 4le2t diesel engine
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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL DCA25SSIU4F
60Hz GENERATOR
(ISUZU 4LE2T DIESEL ENGINE)
Revision #4 (01/17/18)
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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  • Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA25SSIU4F 60Hz GENERATOR (ISUZU 4LE2T DIESEL ENGINE) Revision #4 (01/17/18) To find the latest revision of this publication, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 3: Table Of Contents

    Controller Wiring Wiring Diagram ......45 Battery Charger Wiring Diagram ......46 Jacket Water Heater Wiring Diagram ..... 47 NOTICE Specifications are subject to change without notice. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 3...

  • Page 4: Safety Information

    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. PAGE 4 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)
  • Page 5  ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 5...
  • Page 6  NEVER touch the hot exhaust manifold, local Health and Safety Administrator. muffl er or cylinder. Allow these parts to cool before servicing equipment. PAGE 6 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)
  • Page 7  Use the trailer’s swivel jack to adjust the trailer height to  ALWAYS shutdown engine before transporting a level position while parked. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 7...
  • Page 8  ALWAYS recharge the battery in a well-ventilated possibility exists of electrical shock, environment to avoid the risk of a dangerous concentration electrocution or death. of combustible gasses. PAGE 8 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 9: Safety Information

    Recyclers and manufacturers alike promote the process of recycling metal. Using a metal recycling center promotes energy cost savings. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 9...

  • Page 10: Specifications

    .94 gal. (3.57 L)/hr at 1/2 load 0.67 gal. (2.52 L)/hr at 1/4 load Exhaust Gas After-Treatment System Battery 27 (CCA 0°F 800A) X 1 Includes engine and radiator hoses Includes filters PAGE 10 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 11: Dimensions

    Table 3. Dimensions Reference Dimension in. (mm) Reference Letter Dimension in. (mm) Letter 22.91 (582) 22.36 (568) 21.73 (552) 71.65 (1,820) 22.36 (568) 49.61 (1,260) 26.38 (670) 31.10 (790) DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 11...

  • Page 12: Installation

    BE CONNECTED TO A GROUND ROD. I M U M I N 2 . 4 T . / REFERENCE NEC 250 Figure 2. Typical Generator Grounding Application PAGE 12 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)
  • Page 13 ALWAYS consult with a licensed They are to resist damage to the bottom of the generator electrician. and to maintain alignment. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 13...

  • Page 14: General Information

    Use the cable selection chart (Table 6) as a „ Battery Charger (Option) guide for selecting proper extension cable size. „ Jacket Water Heater (Option) „ Low Coolant Switch (Option) PAGE 14 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 15: Major Components

    Output Receptacles Assembly Battery Assembly Engine Assembly Fuel Tank Assembly Generator Control Panel Assembly Gauge Unit Assembly Engine Control Panel Assembly Figure 3. Major Components Circuit Breaker Assembly DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 15...

  • Page 16: Engine/Generator Control Panel

    Make sure panel light switch is in the OFF position when light is not in use. 4. Frequency Meter — Indicates the output frequency in hertz (Hz). Normally 60 Hz PAGE 16 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)
  • Page 17 16. Main Circuit Breaker — This three-pole, 60 amp main breaker is provided to protect the U,V, and W Output Terminal Lugs from overload. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 17...

  • Page 18: Output Terminal Panel Familiarization

    120 VAC, 20 AMP GFCI RECEPTACLES ACCESS DOOR LIFT TO OPEN RECEPTACLE CIRCUIT BREAKER PANEL CS-6369 TWIST-LOCK AUX. POWER RECEPTACLES 240/120V, 50 AMPS Figure 5. Output Terminal Panel PAGE 18 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)
  • Page 19 240/120 position. Figure 9. Plastic Face Plate (Output Terminal Lugs) Figure 7. 240/120V Twist-Lock Auxiliary Receptacles DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 19...
  • Page 20 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). Figure 10. Connecting Loads PAGE 20 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 21: Load Application

    100 ft. transfer switch. 1800 3600 150 ft. 100 ft. 65 ft. 2400 4800 125 ft. 75 ft. 50 ft. CAUTION: Equipment damage can result from low voltage DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 21...

  • Page 22: Generator Outputs

    GFCI Duplex 3Ø 240/480V 5-20R 120V 1Ø Line-Neutral/ 120V 240V Line-Neutral Line-Line Line-Line 0 amps/receptacle 65.8 5 amps/receptacle 61.7 10 amps/receptacle 57.5 15 amps/receptacle 53.4 20 amps/receptacle PAGE 22 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 23: Generator Outputs/Gauge Reading

    W and U terminals as indicated on the AC Voltmeter Gauge (Figure 15). Figure 14. AC Voltmeter Figure 15. AC Voltmeter Gauge Change-Over Switch (Volt reading on W-U Lug) DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 23...

  • Page 24: Output Terminal Panel Connections

    To achieve a 3Ø 208V output the voltage selector switch must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to 208V. Figure 19. UVWO Terminal Lugs PAGE 24 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)
  • Page 25 The possibility of arcing voltage output. Use voltage regulator adjustment knob exists, that could cause a fire. whenever fine tuning of the output voltage is required. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 25...

  • Page 26: Inspection/Setup

    When replacing engine oil please refill using API service class CJ-4 SAE or JASO DH-2 engine oil. Table 11. Recommended Motor Oil FUEL TANK Figure 27. Fuel Tank PAGE 26 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)
  • Page 27 ONLY use #2 diesel fuel when refueling. DO NOT OVERFILL fuel system. Leave room for fuel expansion. Fuel expands when heated (Figure 31). Figure 31. Fuel Expansion DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 27...
  • Page 28 Freezing Point Vol % Anti-Freeze °C °F NOTICE When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%. PAGE 28 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 29: Inspection/Setup

    Tighten all hose clamps and check hoses for leaks. If any hose (fuel or oil) lines are defective replace them Figure 33. Battery Connections immediately. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 29...

  • Page 30: Generator Start-Up Procedure (Manual)

    4. Tighten terminal nuts securely to prevent load wires from slipping out. 5. Close all engine enclosure doors (Figure 35). Figure 37. Frequency Meter CORRECT INCORRECT Figure 35. Engine Enclosure Doors PAGE 30 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 31: Generator Start-Up Procedure (Manual)

    Under normal operating conditions the coolant temperature should 12. The generator will run until manually stopped or an be between 180°~225°F (75°~95°C) (Green Zone). abnormal condition occurs. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 31...

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

  • Page 33: Generator Shut-Down Procedures

    OFF (not lit). 5. Remove all loads from the generator. 6. Inspect entire generator for any damage or loosening of components that may have occurred during operation. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 33...

  • Page 34: Maintenance

    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. Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H PAGE 34 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)
  • Page 35 This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exist. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 35...
  • Page 36 NOT clean radiator core with any objects, such as a screwdriver. WARNING Allow engine to cool when flushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam. PAGE 36 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)
  • Page 37 This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 37...

  • Page 38: Maintenance

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

  • Page 39: Troubleshooting Diagnostic Lamp

    OFF position after completing engine fault code diagnostic procedures. 5. Verify that the diagnostic lamp is ON. This indicates that there is a fault/error in the engine or the engine control system. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 39...

  • Page 40: Troubleshooting Generator

    Check load and repair. Over current? Confirm load requirements and reduce. Circuit Breaker Tripped Defective circuit breaker? Check and replace. Over current Relay actuated? Confirm load requirement and replace. PAGE 40 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 41: Troubleshooting Engine

    Correct engine oil level. Use No. 2-D diesel fuel only. Check the fuel Injection pump wear? injection pump element and delivery valve assembly and replace as necessary. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 41...
  • Page 42 Radiator net or radiator fi n clogged with dust? Clean net or fi n carefully. Fan, radiator, or radiator cap defective? Replace defective part. Thermostat defective? Check thermostat and replace if necessary. Head gasket defective or water leakage? Replace parts. PAGE 42 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 43: Generator Wiring Diagram

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

  • Page 44: Engine Wiring Diagram

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

  • Page 45: Controller Wiring Wiring Diagram

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

  • Page 46: Battery Charger Wiring Diagram

    NEMA 5-15, 15A, 120 VAC, P/N EE6176 (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. PAGE 46 — DCA25SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (01/17/18)

  • Page 47: Jacket Water Heater Wiring Diagram

    NEMA 5-15, 15A, 120 VAC, P/N EE6176 (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. DCA25SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #4 (01/17/18) — PAGE 47...
  • Page 48 © COPYRIGHT 2018, 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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