MQ Power DCA25SSIU4F, Operation Manual

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

Page 2: ...PAGE 2 DCA25SSIU4F 60 HZ GENERATOR OPERATION MANUAL REV 4 01 17 18 PROPOSITION 65 WARNING Diesel engine exhaust and some of ...

Page 3: ...ator Outputs 22 Generator Outputs Gauge Reading 23 Output Terminal Panel Connections 24 25 Inspection Setup 26 29 Generator Start Up Procedure Manual 30 31 Generator Start Up Procedure Auto Mode 32 Generator Shut Down Procedures 33 Maintenance 34 38 Troubleshooting Diagnostic Lamp 39 Troubleshooting Generator 40 Troubleshooting Engine 41 42 Generator Wiring Diagram 43 Engine Wiring Diagram 44 Cont...

Page 4: ...ety messages specifically address the level of exposure to the operator and are preceded by one of four words DANGER WARNING CAUTION or NOTICE SAFETY SYMBOLS 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 CAUTION Indicates a hazardous situation wh...

Page 5: ...recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result ALWAYS know the location of the nearest fire extinguisher ALWAYS know the location of the nearest first aid kit ALWAYS know the location of the nearest phone or keep a phone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be inval...

Page 6: ... NEVER tamper with the factory settings of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied When a diesel engine operates without sufficient load less than 40 of the rated output it will not ope...

Page 7: ...ating condition ALWAYS shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure on both towing vehicle and trailer Trailer tires should be inflated to 5...

Page 8: ...ator Inspect for cuts in the insulation NEVER grab or touch a live power cord or cable with wet hands The possibility exists of electrical shock electrocution or death Make sure power cables are securely connected to the generator s output receptacles Incorrect connections may cause electrical shock and damage to the generator NOTICE ALWAYS make certain that proper power or extension cord has been...

Page 9: ... this equipment is over remove battery and bring to appropriate facility for lead reclamation Use safety precautions when handling batteries that contain sulfuric acid When the life cycle of this equipment is over it is recommended that the trowel frame and all other metal parts be sent to a recycling center Metal recycling involves the collection of metal from discarded products and its transform...

Page 10: ... Kw 2 4 kW x 2 Dry Weight 1 797 lbs 815 kg Wet Weight 1 797 lbs 815 kg Table 2 Engine Specifications Model Isuzu 4LE2T Type Water cooled direct injection turbo charged air cooled EGR No of Cylinders 4 cylinders Bore x Stroke 3 35 in x 3 78 in 85 mm x 96 mm Displacement 133 cu in 2 179 liter Rated Output 33 5 HP at 1800 rpm Starting Electric Coolant Capacity 2 3 gal 8 8 liters 1 Lube Oil Capacity 2...

Page 11: ... 01 17 18 PAGE 11 DIMENSIONS 25 5 150 2 335 kg Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 22 91 582 E 22 36 568 B 21 73 552 F 71 65 1 820 C 22 36 568 G 49 61 1 260 D 26 38 670 H 31 10 790 Figure 1 Dimensions ...

Page 12: ...h local Electrical and Safety Codes for proper connection based on condition of use EXAMPLEofhowtogroundtheunitifthecondition of use requires such a device The ground terminal on the generator should always be used to connect the generator to a suitable ground when required The ground cable should be 8 size wire aluminum minimum If copper wire is used 10 size wire minimum should be used Connect on...

Page 13: ...They are to resist damage to the bottom of the generator and to maintain alignment 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 If applicable to guard against electrical shock and possible damage to the equipment it is important to ...

Page 14: ...ed 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 ef...

Page 15: ...12 Table 4 Generator Major Components ITEM NO DESCRIPTION 1 Muffler Assembly 2 Voltage Selector Switch Assembly 3 Output Terminal Assembly 4 Generator Assembly 5 Output Receptacles Assembly 6 Battery Assembly 7 Engine Assembly 8 Fuel Tank Assembly 9 Generator Control Panel Assembly 10 Gauge Unit Assembly 11 Engine Control Panel Assembly 12 Circuit Breaker Assembly Figure 3 Major Components ...

Page 16: ...temp Over Crank Over Speed Engine Started ECU Intergrated Gauge Control R Low Oil Pressre High temp Over Crank Over Speed Engine Started ECU Intergrated Gauge Control R 2 3 4 5 6 9 7 8 10 11 12 16 15 14 13 F F Warning LEDs LowOilPressureLED This LED will light when the engine oil pressure drops to 14 2 PSI This condition will cause the engine to shut down High Temperature LED This LED will light w...

Page 17: ...e preheating of the engine glow plugs When the lamp turns off this indicates that the preheat cycle is complete and the engine can be started 11 Auto Start Stop Switch This switch selects either manual or automatic operation Center position is OFF reset 12 Engine Speed Switch This switch controls the speed of the engine low or high 13 Voltage Regulator Control Allows 15 manual adjustment of the ge...

Page 18: ... Figure 5 is provided with the following Two 240 139V output receptacles 50 amps Two Aux Circuit Breakers 50 amps Two 120V GFCI receptacles 20 amp Two GFCI Circuit Breakers 20 amps Five Output Terminal Lugs U V W O Ground AUX POWER RECEPTACLES 240 120V 50 AMPS 120 VAC 20 AMP GFCI RECEPTACLES Y X W CS 6369 TWIST LOCK CIRCUIT BREAKERS FOR GFCI RECEPTACLES RECEPTACLE AND CIRCUIT BREAKER PANEL MQ POWE...

Page 19: ...9 receptacles Figure 7 provided on the output terminal panel These receptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position Figure 7 240 120V Twist Lock Auxiliary Receptacles 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 bot...

Page 20: ...I RECEPTACLE LOAD CS 6369 TWIST LOCK RECEPTACLES CAMLOCKS Over Current Relay An over current relay Figure 11 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over current relay must be pressed The over current relay is located in the control box Figure 11...

Page 21: ...tor By Load Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equipment 1 0 Common power tools 0 8 THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation Aninadequatesizeconnectingcablewhichcannotcarrythe required load can ca...

Page 22: ...gle Phase 240 120V Position 1Ø Line Neutral Line Line 120V Line Neutral N A N A 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 GFCI Receptacle Load Capability The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the three twist lock auxil...

Page 23: ...ition on the voltage selector switch Figure 13 Voltage Selector Switch 240 3Ø Position AC Voltmeter Gauge Reading Place the ACVoltmeter Change Over Switch Figure 14 in theW U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the ACVoltmeter Gauge Figure 15 Figure 14 ACVoltmeter Change Over Switch Figure15 ACVoltmeterGauge VoltreadingonW ULug AC A...

Page 24: ...own in Figure 18 Figure 18 Voltage Selector Switch 3Ø 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 19 Figure 19 UVWO Terminal Lugs 3 Turn the voltage regulator knob Figure 20 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required Figure ...

Page 25: ...e UVWO terminals are secure and tight The possibility of arcing exists that could cause a fire 1Ø 240 120V UVWOTerminal Output Voltages 1 Place the voltage selector switch in the 1Ø 240 120 position as shown in Figure 24 Figure 24 Voltage Selector Switch 1Ø 240 120V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 25 Figure 25 UVWO Terminal Lugs 1Ø 240 120V Connection 3 T...

Page 26: ...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 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 CHECK Refilling the Fuel System ALWAYS...

Page 27: ...ueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank Level Ground Unlevel Ground Level Ground Unlevel Ground DO NOT fill on unlevel ground 70 25 NOTICE ONLY use 2 diesel fuel when refueling 2 Open cabinet doors on the right side of the generator from generator control panel position Remove fuel cap and fill tank Figure 29 Figure 29 Fueling the Generator 3 NEV...

Page 28: ...e severe burns Table 12 Coolant Capacity Engine and Radiator 2 3 gal 8 8 liters Reserve Tank N A Table 13 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point C F 50 37 34 NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Periodically cl...

Page 29: ...terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the Auto Off Reset Manual Switch is in either the AUTO or MANUAL position ALWAYS make sure that this switch is in the OFF RESET position when connecting the battery 2 Place a small amount of battery terminal treatment compou...

Page 30: ... exhaust away from nearby personnel WARNING NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position INCORRECT CORRECT STARTING MANUAL 1 Place the Auto Off Reset Manual Switch in the MANUAL position to start the engine Figure 36 Figure 36 Auto Off Reset Manual Switch Manual Position 2 Once the engine starts let the engine run for 1 2 minutes let en...

Page 31: ...6 kPa Figure 41 Oil Pressure Gauge 8 The coolant temperature gauge Figure 42 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 180 225 F 75 95 C Green Zone PSI OIL PRESS 0 25 50 75 100 Figure 42 Coolant Temperature Gauge 9 The tachometer gauge Figure 43 will indicate the speed of the engine when the generator is operating Under normal...

Page 32: ...ch must be set to the High position when running in the auto start mode Failing to set the switch in the proper position can result in damage to your generator when it turns on NOTICE When the 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 t...

Page 33: ...r for any damage or loosening of components that may have occurred during operation WARNING NEVER stop the engine suddenly except in an emergency EMERGENCY SHUTDOWN PROCEDURE 1 Place both the MAIN GFCI and LOAD circuit breakers as shown in Figure 47 to the OFF position AUTOMATIC SHUT DOWN SYSTEM This unit is equipped with safety devices to automatically stoptheengineintheeventoflowoilpressure appr...

Page 34: ...an Belt Condition X Check Automatic Belt Tensioner X Check Electrical Ground Connection X Clean Radiator Check Cooling System X Coolant Solution Analysis Add SCA s As Required X Pressure Test Cooling System X Check Engine Speed X Test Thermostats X Test Glow Plugs X Flush and Refill Cooling System 2yrs or2000hrs Clean Inside of Fuel Tank 1000hrs Replace Air Cleaner Elements 2 As Required Generator...

Page 35: ... Figure 49 Air Cleaner Indicator 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 NOTICE The air filter should not be changed until the indicator reads RED Dispose of old air filt...

Page 36: ... automatic air bleeding system CHECK OIL LEVEL Check the crankcase oil level prior to each use or when the fuel tank is filled Insufficient oil may cause severe damage to the engine Make sure the generator is level The oil level must be between the two notches on the dipstick as shown in Figure 26 Replacing Oil Filter Remove the old oil filter Apply a film of oil to the gasket on the new oil filte...

Page 37: ...ese receptacles is to provide power via commercial power to the jacket water heater and internal battery charger These receptacles will ONLY function when commercial power has been supplied to them Figure 52 To apply commercial power to these receptacles a power cord of adequate size will be required See Table 6 When using the generator in hot climates there is no reason to apply power to jacket w...

Page 38: ...nes These exhaust emissions pose serious environmental and health risks No maintenance or service is required for the DOC device used on this generator Diesel Oxidation Catalyst DOC The DOC does not filter particles it oxidizes them This catalyst honeycomb like structure uses a chemical process to break down pollutants in the exhaust stream into less harmful components In general this catalyst col...

Page 39: ... PUMP SWITCH ON NOTICE Make sure to place the diagnostic switch back to the OFF position after completing engine fault code diagnostic procedures 6 Push and hold the diagnostic button to identify the fault and verify the following Diagnostic lamp will start blinking with a pattern according to the detected fault code 3 times at a interval rate of 2 4 seconds If two or more faults code are detected...

Page 40: ...iring connections loose Check wiring and repair Defective AVR Replace if necessary High Voltage Output Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary Circuit Breaker Tripped 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 require...

Page 41: ...gine oil too thick Refill engine crankcase with correct type of oil for winter environment Defective battery Replace battery Engine fires but stops soon as starter is switched off Fuel filter blocked Replace fuel filter Fuel supply blocked Check the entire fuel system Defective fuel pump Replace fuel pump Engine stops by itself during normal operation Fuel tank empty Add fuel Fuel filter blocked R...

Page 42: ... Too much oil in engine crankcase Drain off engine oil down to uppermark on dipstick Entire cooling air system contaminated blocked Clean cooling air system and cooling fin areas Fan belt broken or elongated Change belt or adjust belt tension Coolant insufficient Replenish coolant Radiator net or radiator fin clogged with dust Clean net or fin carefully Fan radiator or radiator cap defective Repla...

Page 43: ...DCA25SSIU4F 60 HZ GENERATOR OPERATION MANUAL REV 4 01 17 18 PAGE 43 GENERATOR WIRING DIAGRAM ...

Page 44: ...PAGE 44 DCA25SSIU4F 60 HZ GENERATOR OPERATION MANUAL REV 4 01 17 18 ENGINE WIRING DIAGRAM ...

Page 45: ...DCA25SSIU4F 60 HZ GENERATOR OPERATION MANUAL REV 4 01 17 18 PAGE 45 CONTROLLER WIRING WIRING DIAGRAM ...

Page 46: ...MA 5 15 15A 120 VAC P N EE6176 HBL5278C HUBBLE RECEPTACLE NOTES 1 2 RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY 20 AMP 5 20R RECEPTACLE P N EE6131 HBL5369C HUBBLE RECEPTACLE 3 4 CORD CAROL 3 C 14 AWG P N EE56557 120 VAC INPUT INSERT EXTERNAL POWER CORD HERE 3 1 2 4 BLACK 14 AWG LINE L 120VAC INPUT WHITE 14 AWG NEUTRAL N GREEN 14 AWG GROUND G 1 2 3 4 A B A B ...

Page 47: ...G NEUTRAL N GREEN 14 AWG GROUND G NOTES 1 2 RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY 20 AMP 5 20R RECEPTACLE P N EE6131 HBL5369C HUBBLE RECEPTACLE 3 GROUND 120 VAC 4 CORD CAROL 3 C 14 AWG P N EE56557 BLOCK HEATER P N 44558 120 VAC INPUT INSERT EXTERNAL POWER CORD HERE 3 1 2 4 HEATING ELEMENT TEMP SWITCH BLACK 14 AWG LINE L 120VAC INPUT WHITE 14 AWG NEUTRAL N GREEN 14 AWG GROUND G 1 2 3 ...

Page 48: ...co uk Tel 0161 339 2223 Fax 0161 339 3226 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 This manual MUST accompany the equipment at all times This manual is considered...