DCA125SSIU4F Rev 3 60 HZ Op Manual

OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL DCA125SSIU4F
60Hz GENERATOR
(ISUZU BR-4HK1X DIESEL ENGINE)
PARTS LIST NO. M3844300504
Revision #3 (01/16/18)
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA125SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (01/16/18)

TABLE OF CONTENTS
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
NOTICE
Specifications are subject to change without notice.
DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 3

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.
WARNING WARNING
MOVING PARTS can cause
severe injury.
CAUTION CAUTION
DO NOT operate with doors
HOT COOLANT can cause
severe burns. Maximum capacity of lifting Stop engine before
switching.
open.
Do not remove cap if bail is 14,050 lbs.
Stop engine before servicing. radiator is hot. M92010020A
M35000220
M90300000
M90310000
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
TOP VIEW GROUND
FAN SHROUD
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 25
50
75 140
180
220 12
18
24
PSI °F VOLTS
INCREASE DECREASE 0 100 100 6
M91110000 260 30
OIL PRESS WATER TEMP BATTERY
WARNING V E
½
°F
F 0
60
120
150
RPMX10
180
210
ARC FLASH AND SHOCK HAZARD U W

FUEL SPEED
Appropriate PPE Required OFF
Appropriate Personal Protection

Equipment and Tools Required
when working on this equipment.
V-W
ECU Series 800 Controller
DANGER
Engine Started
M92010070 U-V W-U
Shutdown
OFF
Pre-Alarm
Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is
a poison gas you cannot see or smell. Alarm Screen Program
Option
Acknowledge Change Exit
M91020000
211052
GAC-2.2H
POWERED by
Honda Engines
120V
15A
V 120
NEUTRAL BONDED TO FRAME
NEUTRE MIS A LA MASSE A

LA CARCASSE DU MOTEUR
AC CIRCUIT BREAKER
WHISPERWATT
OFF
INTERRUPTEUR DE
GR PRISE DE COURANT PRINCIPAL
TERRE
GAC-2.2H 120V
15A
V 120
NEUTRE MIS A LA MASSE A

LA CARCASSE DU MOTEUR GAC-2.2H 120V V 120
POWERED by
15A NEUTRE MIS A LA MASSE A
LA CARCASSE DU MOTEUR
POWERED by
Honda Engines Honda Engines
211052
AC CIRCUIT BREAKER
OFF
INTERRUPTEUR DE 211052
AC CIRCUIT BREAKER
GR PRISE DE COURANT PRINCIPAL
OFF
INTERRUPTEUR DE
TERRE GR PRISE DE COURANT PRINCIPAL
TERRE
125 kVA AC GENERATOR

NEVER use inside a home ONLY use OUTSIDE and
or garage. Even if doors far away from windows,
and windows are open. doors, and vents.
Avoid other generator hazards.

READ MANUAL BEFORE USE.
M90320010
SAFETY INSTRUCTIONS
FRONT VIEW Improper operation of this machine can cause
CAUTION
severe injury or death.
Read the instruction manual carefully
before operation or servicing.
WARNING
This machine should only be operated by a
Do not touch internal wiring
person with sufficient knowledge and skill
to ensure safe operation. or connections while this DO NOT disconnect the Battery Cables
Operation of this equipment may create High voltage circuits are located inside the machine is operating. after shutting down the engine for
Turn power off before
sparks that can start fires around dry output terminal cover and control panel.
servicing. at least 2-3 minutes M90130010
M90130010
Close the cover and control panel before
vegetation.
M92010000
operating.
A spark arrestor may be required. Moving parts and hot surfaces are contained
The operator should contact local fire within the enclosure.
agencies for laws or regulations Close all doors and lock them before
operating.
relating to fire prevention requirements. M92010030
M90420000
WARNING
ENGINE EXHAUST can cause
CAUTION CAUTION
severe injury or death. This machine stops and starts automatically HOT PARTS can burn skin.
Use only in open, well
ventilated areas or
and without notice. DO NOT touch until the
vent exhaust outside. M92010060
machine has sufficiently
M90320000
cooled.
M91010000
125 125
DANGER
HIGH VOLTAGE M92010040
SIDE VIEW SIDE VIEW
WARNING
WARNING
WARNING CAUTION
Before connecting this generator to any building’s Ensure the “Auto-Off/Reset-Manual” switch is
Do not touch output Always complete the grounding electrical system, a licensed electrician must install
terminals while this path from the ground terminal an isolation (transfer) switch. in the “Off/Reset” position. If it is not, when
machine is operating. on the genset to an external the battery cables are connected, the engine
Turn power off before grounding source.
Serious injury or death may result without this
will crank and attempt to start. M91010040
servicing. See instruction manual for
transfer switch.
details. M92010050
Figure 1. Safety Decals

SAFETY INFORMATION
DO NOT operate or service the generator before reading Potential hazards associated with the operation of this
the entire manual. Safety precautions should be followed at generator will be referenced with hazard symbols which
all times when operating this generator. Failure to read and may appear throughout this manual in conjunction with
understand the safety messages and operating instructions safety messages.
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 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
COULD result in DEATH or SERIOUS INJURY.
CAUTION
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.

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, fire extinguisher.
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations. 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
NEVER operate this generator when not fire department. This information will be invaluable in
feeling well due to fatigue, illness or when the case of an emergency.
under medication.
NEVER operate this generator under the influence of
drugs or alcohol.
GENERATOR SAFETY
DANGER
NEVER operate the generator in an explosive
ALWAYS check the generator for loosened threads or atmosphere or near combustible materials. An
bolts before starting. explosion or fire could result causing severe
bodily harm or even death.
DO NOT use the generator for any purpose other than
its intended purposes or applications. WARNING
NOTICE NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
This generator should only be operated by trained and Disconnection of these devices can cause severe injury,
qualified personnel 18 years of age and older. bodily harm or even death. Disconnection of any of these
Whenever necessary, replace nameplate, operation and devices will void all warranties.
safety decals when they become difficult read. CAUTION
Manufacturer does not assume responsibility for any NEVER lubricate components or attempt service on a
accident due to generator modifications. Unauthorized running machine.
generator modification will void all warranties.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the generator in proper running condition.
Fix damage to generator and replace any broken parts
immediately.
ALWAYS 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.

SAFETY INFORMATION
ENGINE SAFETY NOTICE
DANGER NEVER run engine without an air filter or with a dirty air
filter. Severe engine damage may occur. Service air filter
The engine fuel exhaust gases contain poisonous carbon
frequently to prevent engine malfunction.
monoxide. This gas is colorless and odorless, and can
cause death if inhaled. NEVER tamper with the factory settings
of the engine or engine governor. Damage
The engine in this generator
to the engine or generator can result if
requires an adequate free
operating in speed ranges above the
flow of cooling air. NEVER
maximum allowable.
operate this generator in
any enclosed or narrow area Wet stacking is a common problem with diesel engines
where free flow of the air is which are operated for extended periods with light or
restricted. If the air flow is no load applied. When a diesel engine operates without
restricted it will cause injury to people and property and sufficient load (less than 40% of the rated output), it will
serious damage to the generator or engine. not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
WARNING
which can foul the fuel injectors, engine valves and
DO NOT place hands or fingers inside engine exhaust system, including turbochargers, and reduce
compartment when engine is running. the operating performance.
NEVER operate the engine with heat shields or In order for a diesel engine to operate at peak efficiency,
guards removed. it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
Keep fingers, hands hair and clothing away to completely burn all of the fuel.
from all moving parts to prevent injury.
Wet stacking does not usually cause any permanent
DO NOT remove the radiator cap while the damage and can be alleviated if additional load is
engine is hot. High pressure boiling water applied to relieve the condition. It can reduce the system
will gush out of the radiator and severely performance and increase maintenance. Applying an
scald any persons in the general area of increasing load over a period of time until the excess
the generator. fuel is burned off and the system capacity is reached
DO NOT remove the coolant drain plug while the engine usually can repair the condition. This can take several
is hot. Hot coolant will gush out of the coolant tank and hours to burn off the accumulated unburned fuel.
severely scald any persons in the general area of the State Health Safety Codes and Public Resources
generator. Codes specify that in certain locations, spark arresters
DO NOT remove the engine oil drain plug while the must be used on internal combustion engines that use
engine is hot. Hot oil will gush out of the oil tank and hydrocarbon fuels. A spark arrester is a device designed
severely scald any persons in the general area of the to prevent accidental discharge of sparks or flames
generator. from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
CAUTION purpose. In order to comply with local laws regarding
NEVER touch the hot exhaust manifold, spark arresters, consult the engine distributor or the
muffler or cylinder. Allow these parts to cool local Health and Safety Administrator.
before servicing generator.

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
DO NOT start the engine near spilled fuel or combustible electrical system without a transfer
fluids. Diesel fuel is extremely flammable and its vapors switch or other approved device. All
can cause an explosion if ignited. installations should be performed by a
licensed electrician in accordance
ALWAYS refuel in a well-ventilated area, away from with all applicable laws and electrical
sparks and open flames. codes. Failure to do so could result in electrical shock or
ALWAYS use extreme caution when working with burn, causing serious injury or even death.
flammable liquids. Power Cord/Cable Safety
DO NOT fill the fuel tank while the engine is running
DANGER
or hot.
NEVER let power cords or cables lay in water.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from NEVER stand in water while AC power from the
the ignition system. generator is being transferred to a load.
Store fuel in appropriate containers, in well-ventilated NEVER use damaged or worn cables or cords when
areas and away from sparks and flames. connecting generator to generator. Inspect for cuts in the
insulation.
NEVER use fuel as a cleaning agent.
NEVER grab or touch a live power
DO NOT smoke around or near the
cord or cable with wet hands. The
generator. Fire or explosion could result
possibility exists of electrical shock,
from fuel vapors or if fuel is spilled on a
electrocution or death.
hot engine.
Make sure power cables are securely
ELECTRICAL SAFETY connected to the generator’s output receptacles.
DANGER Incorrect connections may cause electrical shock and
damage to the generator.
DO NOT touch output terminals during
operation. Contact with output terminals NOTICE
during operation can cause electrocution, ALWAYS make certain that proper power or extension
electrical shock or burn. cord has been selected for the job. See Cable Selection
The electrical voltage required to Chart in this manual.
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility
exists of electrical shock, electrocution
or death.

SAFETY INFORMATION
Grounding Safety WARNING
DANGER ALWAYS wear safety glasses when
This generator is equipped with a grounding terminal handling the battery to avoid eye irritation.
attached to the enclosure. Electrical grounding The battery contains acids that can cause
requirements can differ by State, Province, District, injury to the eyes and skin.
Municipality, and unique application settings. Use well-insulated gloves when picking up the battery.
For portable and vehicle-mounted generators, Multiquip
recognizes the guidance provided in NEC Handbook ALWAYS keep the battery charged. If the battery is not
Article 250.34 Parts A and B, and 29 CFR 1926.404 charged, combustible gas will build up.
(f) (3) (i). If a more definitive earth-to-ground safeguard ALWAYS recharge the battery in a well-ventilated
is required, please consult a qualified electrician and
reference appropriate National Electrical Code (NEC) environment to avoid the risk of a dangerous concentration
guidelines in establishing an exterior grounding point of combustible gasses.
generator. If the battery liquid (dilute sulfuric acid) comes into
NEVER use gas piping as an electrical ground. contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
NOTICE
If the battery liquid (dilute sulfuric acid) comes into
There is a permanent conductor bond between contact with eyes, rinse eyes immediately with plenty
generator (stator winding) and the frame. of water and contact the nearest doctor or hospital to
seek medical attention.
BATTERY SAFETY
CAUTION
DANGER
ALWAYS disconnect the NEGATIVE battery terminal
DO NOT drop the battery. There is a possibility that the before performing service on the generator.
battery will explode.
ALWAYS keep battery cables in good working condition.
DO NOT expose the battery to open flames, Repair or replace all worn cables.
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.

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 in diesel exhaust emissions.
effective to maintain (beyond life-cycle reliability) and is to
This engine has been certified to meet US EPA Evaporative
be decommissioned (demolition and dismantlement),be
emissions requirements in the installed configuration.
sure to follow rules below.
Attempting to modify or make adjustments to the engine
DO NOT pour waste or oil directly onto the ground, down
emission system by unauthorized personnel without proper
a drain or into any water source.
training could damage the generator or create an unsafe
Contact your country's Department of condition.
Public Works or recycling agency in your
area and arrange for proper disposal of Additionally, modifying the fuel system may adversely affect
any electrical components, waste or oil evaporative emissions, resulting in fines or other penalties.
associated with this generator.
When the life cycle of this generator is over, remove Emission Control Label
battery(s) and bring to an appropriate facility for lead The emission control label is an integral part of the emission
reclamation. Use safety precautions when handling
batteries that contain sulfuric acid. system and is strictly controlled by regulations.
When the life cycle of this generator is over, it is The label must remain with the engine for its entire life.
recommended that the generator frame and all other
metal parts be sent to a recycling center. If a replacement emission label is needed, please contact
your authorized engine distributor.
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.

SPECIFICATIONS
Table 1. Generator Specifications

Model DCA125SSIU4F
Revolving field, self ventilated,
Type
open protected type synchronous generator
Armature Connection Star with Neutral Zigzag
Phase 3Ø 3Ø
Standby Output 110 kW (137.5 kVA) 79 kW
Prime Output 100 kW (125 kVA) 72 kW
3Ø Voltage (L-L/L-N)
208Y/120, 220Y/127, 240Y/139 N/A
Voltage Selector Switch at 3Ø 240/139
416Y/240, 440Y/254, 480Y/277 N/A
N/A 240/120
Power Factor 0.8 1.0
Frequency 60 Hz
Speed 1800 rpm
Aux. AC Power Single Phase, 60 Hz
Aux. Voltage/Output 4.8 Kw (2.4 kW x 2)
Dry Weight 5,291 lbs. (2,400 kg)
Wet Weight 6.702 lbs. (3,040 kg)
Table 2. Engine Specifications
Model Isuzu BR-4HK1X Final Tier 4
Water-cooled, direct injection, turbo-charged
Type
air cooled EGR
No. of Cylinders 4 cylinders
Bore x Stroke 4.52 in. x 4.92 in. (115 mm x 125 mm)
Displacement 317 cu. in. (5.2 liter)
Rated Output 170.8 HP at 1800 rpm
Starting Electric
Coolant Capacity 10.3 gal. (39 liters)1
Lube Oil Capacity 6.05 gal. (22.9 liters)2
Lubricating Type Oil API service class CJ-4 SAE 15W-40
Fuel Type #2 Diesel Fuel (Ultra Low Sulfur Diesel Fuel Only)
Fuel Tank Capacity 169 gal. (640 liters)
DEF Tank Capacity 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
Fuel Consumption
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
1
Includes engine and radiator hoses
2
Includes filters

DIMENSIONS
14,050 lbs.
(6,370 kg)
125
Figure 2. Dimensions
Table 3. Dimensions
Reference
Dimension in. (mm) Reference Letter Dimension in. (mm)
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)

NOTES

INSTALLATION
CONNECTING THE GROUND The ground cable should be #8 size wire (aluminum)
minimum. If copper wire is used, #10 size wire minimum
Consult with local Electrical and Safety Codes for proper should be used.
connection based on condition of use.
Connect one end of the ground cable terminal to the
EXAMPLE of how to ground the unit if the condition generator ground point (Figure 3). Connect the other end
of use requires such a device: of the ground cable to a suitable earth ground (ground rod).
The ground terminal on the generator should always be
used to connect the generator to a suitable ground when
required.
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.
)
IM UM
MIN
M(
2.4
T./
REFERENCE 8F
NEC 250
Figure 3. Typical Generator Grounding Application

INSTALLATION
OUTDOOR INSTALLATION GENERATOR GROUNDING
Install the generator in a area that is free of debris, NOTICE
bystanders, and overhead obstructions. Make sure the The Occupational Safety and Health Administration
generator is on secure level ground so that it cannot slide (OSHA) and the National Electrical Code (NEC)
or shift around. Also install the generator in a manner so recommend that if the generator is providing electrical
that the exhaust will not be discharged in the direction of power to a structure (home, office shop, trailer or
nearby homes. similar) it must be connected to a grounding electrode
The installation site must be relatively free from moisture system, such a driven ground rod (Figure 3).
and dust. All electrical equipment should be protected from If applicable, to guard against electrical shock and possible
excessive moisture. Failure to do will result in deterioration damage to the equipment, it is important to provide a good
of the insulation and will result in short circuits and EARTH ground, (Figure 3).
grounding.
NOTICE
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to ALWAYS check with State, Province, District and
engine and alternator parts. Municipalities for electrical grounding requirements
before using generator.
CAUTION
Pay close attention to ventilation when operating the Article 250 (Grounding) of the NEC handbook provides
generator inside tunnels and caves. The engine exhaust guidelines for proper grounding and specifies that the cable
contains noxious elements. Engine exhaust must be ground shall be connected to the grounding system of the
routed to a ventilated area. building as close to the point of cable entry as practical.
NEC article 250 specifices the following grounding
INDOOR INSTALLATION requirements:
Exhaust gases from diesel engines are extremely 1. Use one of the following wire types to connect the
poisonous. Whenever an engine is installed indoors the generator to earth ground.
exhaust fumes must be vented to the outside. The engine a. Copper 10 AWG (5.3 mm2) or larger.
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can b. Aluminum 8 AWG (8.4 mm2) or larger.
cause excessive back pressure which will cause the engine
2. When grounding of the generator (Figure 3) is required,
to heat excessively and possibly burn the valves.
connect one end the ground cable to the ground lug
MOUNTING on the generator. Connect the other end of the ground
cable to the ground rod (earth ground).
The generator must be mounted on a solid foundation
(such as concrete) and set firmly on the foundation to 3. NEC article 250 specifies that the earth ground rod
isolate vibration of the generator when it is running. The should be buried a minimum of 8 ft. into the ground.
generator must set at least 6 inches above the floor or grade NOTICE
level (in accordance to NFPA 110, Chapter 54.1). DO NOT
remove the metal skids on the bottom of the generator. When connecting the generator to any buildings
They are to resist damage to the bottom of the generator electrical system ALWAYS consult with a licensed
and to maintain alignment. electrician.

GENERAL INFORMATION
GENERATOR OPEN DELTA EXCITATION SYSTEM
This generator (Figure 4) is designed as a high quality Each generator is equipped with the state of the art “Open-
portable (requires a trailer for transport) power source for Delta” excitation system. The open delta system consist
telecom sites, lighting facilities, power tools, submersible of an electrically independent winding wound among
pumps and other industrial and construction machinery. stationary windings of the AC output section.
OPERATING PANEL There are four connections of the open delta A, B, C and
The “Operating Panel” is provided with the following: D. During steady state loads, the power from the voltage
ECU 835 Controller regulator is supplied from the parallel connections of A to
Gauge Unit Assembly B, A to D, and C to D. These three phases of the voltage
• Oil Pressure Gauge input to the voltage regulator are then rectified and are the
excitation current for the exciter section.
• Water Temperature Gauge
• Charging Voltmeter When a heavy load, such as a motor starting or a short
• Fuel Gauge circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
• Tachometer
connection of B to C. This has the effect of adding the
Panel Light/Panel Light Switch
voltages of each phase to provide higher excitation to the
Hour Check Button exciter section and thus better voltage response during the
Auto Start/Stop Switch application of heavy loads.
Engine Speed Switch The connections of the AVR to the AC output windings are
Emergency Stop Switch (Option) for sensing only. No power is required from these windings.
Fuel Leak Detected Alarm Lamp The open-delta design provides virtually unlimited excitation
CONTROL PANEL current, offering maximum motor starting capabilities. The
The “Control Panel” is provided with the following: excitation does not have a “fixed ceiling” and responds
Frequency Meter (Hz) according the demands of the required load.
AC Ammeter (Amps) ENGINE
AC Voltmeter (Volts) This generator is powered by a 4 cylinder, 4-cycle water
Ammeter Change-Over Switch cooled, direct injection, turbocharged, air cooled EGR
Voltmeter Change-Over Switch ISUZU BR-4HK1X diesel engine. This engine is designed
Voltage Regulator to meet every performance requirement for the generator.
3-Pole, 300 amp Main Circuit Breaker Reference Table 2 for engine specifications.
“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
• Current Transformer to change without prior notice.
• Over-Current Relay
ELECTRIC GOVERNOR SYSTEM
• Starter Relay
The electric governor system controls the RPMs of the engine.
OUTPUT TERMINAL PANEL When the engine demand increases or decreases, the
The “Output Terminal Panel” is provided with the following: governor system regulates the frequency variation to ±.25%.
Three 240/120V output receptacles (CS-6369), 50A EXTENSION CABLES
Three auxiliary circuit breakers, 50A
When electric power is to be provided to various tools or
Two 120V output duplex receptacles (GFCI), 20A
loads at some distance from the generator, extension cords
Two duplex circuit breakers, 20A are normally used. Cables should be sized to allow for
Five output terminal lugs (3Ø power) distance in length and amperage so that the voltage drop
Battery Charger (Optional) between the generator and point of use (load) is held to
Jacket Water Heater (Optional) a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.

MAJOR COMPONENTS
125
2
6
5 4 3
7 8
125
14
9
10 Table 4. Generator Major Components

ITEM NO. DESCRIPTION
13 11
1 DOC/SCR Assembly
2 DEF Tank Assembly
12 3 Coolant Drain Plug
4 Oil Drain With Valve
5 Fuel Tank Assembly
6 Battery Assembly
15
7 Air Filter Assembly
16 8 Voltage Selector Switch Assembly
50 180 18
25 75 140 220 12 24
PSI °F VOLTS
INCREASE DECREASE 0 100 100 260 6 30
½ 150
120 180
60
V E
°F
F 0
RPMX10
210
FUEL SPEED
U W
OFF
U-V
V-W
OFF
W-U
Engine Started
Shutdown
Pre-Alarm
17 9 Output Terminal Panel Assembly

10 Emergency Stop Switch (Option)
Alarm Screen Option Program
11 Generator Assembly
18 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
Figure 4. Major Components

ENGINE CONTROL UNIT (ECU)
1

B
50 180 18
25 75 140 220 12 24
INCREASE DECREASE 0
PSI
100 100
°F
260 6
VOLTS
30 Engine Started
½
120
150
180 Shutdown C
A
60
V E
°F
F 0
RPMX10
210
Pre-Alarm
D
FUEL SPEED
U W
OFF
V-W
Engine Started
U-V W-U
Shutdown
OFF
Pre-Alarm
Alarm Screen
Acknowledge Change
Option Program
Exit Alarm Screen Option Program
E F G H
Figure 5. Engine Control Unit (ECU)
The definitions below describe the controls and functions E. Alarm Acknowledge Button — When the engine
of the Engine Control Unit (Figure 5). experiences a fault, the "Pre Alarm Lamp" or the
"Shutdown Lamp" will start blinking. Pushing this
1. ECU Controller — This auto start/stop controller
button will confirm the fault message and the
displays the parameters and the diagnostic
blinking lamp will change to a solid lamp display.
troubleshooting messages of the engine.
The fault message will be displayed on the screen.
A. ECU Display Screen — Engine fault diagnostic When multiple engine faults occur, the lamp will
messages are shown on this LCD display. screen continue blinking until all fault messages are
confirmed. The blinking lamp will change to a solid
B. Engine Started Lamp — This lamp when lit lamp display all current confirmed fault messages
indicates engine is operating normally. will scrool across the screen.
C. Engine Shutdown Lamp — When an engine F. Screen Change Button — When this button is
failure has occured this lamp will blink. Indicating pushed during operation, the screen will cycle
the engine has been shutdown. The diagnostic through each parameter screen.
fault message will be displayed on the LCD screen.
G. Option Button — This button is not active. Do
D. Pre Alarm Lamp — When an engine failure has not use.
occured this lamp will blink. Indicating a pre-fault
engine condition and the possibility of engine H. Program/Exit Button — Push this button from the
shutdown. The diagnostic fault message will be home screen to enter the main menu.
displayed on the LCD screen

ENGINE/GENERATOR CONTROL PANEL
1
2 4
8 3 25
50
75
A 180
B 18
C
140 220 12 24
PSI
50 180 18
25 75 140 220 12 24
°F VOLTS
0 100 100 260 6 30
14 5
PSI °F VOLTS
INCREASE DECREASE 0 100 100 260 6 30
9 ½
120
150
180
60
V E
°F
F 0
RPMX10
210
D E
FUEL SPEED
U W
OFF 6 ½
120
150
180
60
°F RPMX10
V-W
E F 0 210
10 U-V W-U
Engine Started
OFF 7 Shutdown
Pre-Alarm
FUEL SPEED

11 Figure 6. Gauge Unit Assembly

12 13
4. Fuel Leak Detected Alarm Lamp — This lamp when

ON indicates that fluids in the containment area have
The definitions below describe the controls and functions reach a high level.
of the Engine/Generator Control Panel (Figure 6).
5. Frequency Meter — Indicates the output frequency
1. Gauge Unit Assembly — This assembly houses the in hertz (Hz). Normally 60 Hz.
various engine monitoring gauges. These gauges
6. AC Ammeter — Indicates the amount of current the
indicate: oil pressure, water temperature, charging
load is drawing from the generator per leg selected by
voltmeter, fuel and engine speed RPM (tachometer).
the ammeter phase-selector switch.
A. Oil Pressure Gauge — During normal operation
7. AC Voltmeter — Indicates the output voltage present
this gauge should read between 42.1~85.6 psi.
at the U,V, and W Output Terminal Lugs.
(290~590 kPa). When starting the generator the
oil pressure may read a little higher, but after the 8. Voltage Regulator Control — Allows ±15% manual
engine warms up the oil pressure should return to adjustment of the generator’s output voltage.
the correct pressure range.
9. Ammeter Change-Over Switch — This switch allows
B. Water Temperature Gauge — During normal the AC ammeter to indicate the current flowing to the load
operation this gauge should read between 167° connected to any phase of the output terminals, or to be
and 194°F (75°~90°C). switched off. This switch does not effect the generator
output in any fashion, it is for current reading only.
C. Charging Voltmeter Gauge — During normal
operation this gauge indicate minimum 12.5~14 10. Voltmeter Change-Over Switch — This switch allows
VDC. the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
D. Fuel Gauge — Indicates amount of diesel fuel
be switched off.
available.
11. Hour Check Button — With the engine stopped, press
E. Tachometer — Indicates engine speed in RPM’s
and hold this button. The total running hours, fuel level,
for 60 Hz operation. This meter should indicate
and battery voltage will be displayed.
1800 RPM’s when the rated load is applied.
2. Panel Light — For operation at night, panel light 12. Auto/Start Switch — This switch selects either manual
illuminates control panel for ease of reading meters or automatic operation. Center position is OFF (reset).
and gauges. Make sure panel light switch is in the OFF 13. Engine Speed Switch — This switch controls the
position when light is not in use.
speed of the engine low or high.
3. Panel Light Switch — When activated will turn on
control panel light. 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.

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.
Three (3) 240/139V output receptacles @ 50 amp
NOTICE
Three (3) Circuit Breakers @ 50 amps
Terminal legs “O” and “Ground” are considered bonded
Two (2) 120V GFCI receptacles @ 20 amp
grounds
Two (2) Duplex Circuit Breakers @ 20 amp
Five (5) Output Terminal Lugs (U, V, W, O, Ground)
1Ø AND 3Ø,
NEUTRAL GROUND
480 -120 VAC
TERMINAL TERMINAL
OUTPUT TERMINALS
HARD WIRE
HOOKUP PANEL
U V W O
BLACK RED BLUE WHITE GREEN
CIRCUIT BREAKERS
CIRCUIT BREAKERS
FOR GFCI RECEPTACLES
FOR CS-6369 TWIST
LOCK RECEPTACLES
120 VAC, 20 AMP

GFCI RECEPTACLES
ACCESS DOOR
LIFT TO OPEN
RECEPTACLE
AND
CIRCUIT BREAKER
PANEL Y
W X
CS-6369
TWIST-LOCK
AUX. POWER RECEPTACLES
240/120V, 50 AMPS
Figure 7. Output Terminal Panel

120 VAC GFCI Receptacles Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
There are two 120 VAC, 20 amp GFCI (Duplex Nema GFCI receptacles. Remember the load output (current) on
5-20R) receptacles provided on the output terminal panel. all three receptacles is dependent on the load requirements
These receptacles can be accessed in any voltage of the output terminal lugs.
selector switch position. Each receptacle is protected by a
20 amp circuit breaker. These breakers are located directly Turn the voltage regulator control knob (Figure 10) on
above the GFCI receptacles. Remember the load output the control panel to obtain the desired voltage. Turning the
(current) of both GFCI receptacles is dependent on the knob clockwise will increase the voltage, turning the knob
load requirements of the U, V, and W output terminal lugs. counter-clockwise will decrease the voltage.
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.
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.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
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 selector switch is configured for single-
phase 240/120 application
Figure 11. Plastic Face Plate

(Output Terminal Lugs)
Figure 9. 240/139V Twist-Lock Auxiliary

Receptacles

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. If the circuit
to connect a load to the generator. breaker can not be reset, the reset button on the over
current relay must be pressed. The over current relay is
To protect the output terminals from overload, a 3-pole,
located in the control box.
300A main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting 1 L1 3 L2 5 L3
the engine.
CS-6369
TWIST-LOCK
RECEPTACLES
HARD WIRE
HOOKUP PANEL
LOAD
RESET
BUTTON
U
V O
W
GFCI
RECEPTACLE
LOAD GROUND LOAD
NEUTRAL
CAMLOCKS
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
Figure 12. Connecting Loads the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).

LOAD APPLICATION
SINGLE PHASE LOAD THREE PHASE LOAD
Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase
and equipment to insure the wattage, amperage, frequency, power use the following equation:
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 NOTICE
130—150% more wattage than the rating on the nameplate, If 3Ø load (kVA) is not given on the equipment
as the wattage is influenced by the efficiency, power factor nameplate, approximate 3Ø load may be determined
and starting system of the equipment. by multiplying voltage by amperage by 1.732
NOTICE
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying Motors and motor-driven equipment draw much greater
nameplate voltage by the nameplate amperage. current for starting than during operation.
An inadequate size connecting cable which cannot carry the

WATTS = VOLTAGE x AMPERAGE
required load can cause a voltage drop which can burn out
The power factor of this generator is 0.8. See Table 5 below the appliance or tool and overheat the cable. See Table 6.
when connecting loads.
When connecting a resistance load such as an
Table 5. Power Factor By Load incandescent lamp or electric heater, a capacity of up
Type of Load Power Factor to the generating set’s rated output (kW) can be used.
Single-phase induction motors 0.4-0.75 When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
Electric heaters, incandescent lamps 1.0 multiplied by 0.6 can be used.
Fluorescent lamps, mercury lamps 0.4-0.9
When connecting an electric drill or other power tools,
Electronic devices, communication pay close attention to the required starting current
1.0
equipment capacity.
Common power tools 0.8
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
Table 6. Cable Selection (60 Hz, Single Phase Operation) be used.
Load in Watts Maximum Allowable Cable Length
Current
in
DANGER
At 100 At 200 #10 Wire #12 Wire #14 Wire #16 Wire
Amperes Volts Volts
Before connecting this generator to any building’s
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
electrical system, a licensed electrician must install
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
an isolation (transfer) switch. Serious damage to
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft. the building’s electrical system may occur without this
10 1200 2400 250 ft. 150 ft. 100 ft. transfer switch.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
CAUTION: Equipment damage can result from low voltage

GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES Maximum Amps
A wide range of voltages are available to supply voltage for Table 8 shows the maximum amps the generator can
many different applications. Voltages are selected by using provide. DO NOT exceed the maximum amps as listed.
the voltage selector switch (Figure 14). To obtain some of
the voltages as listed in Table 7 (see below) will require a Table 8. Generator Maximum Amps
fine adjustment using the voltage regulator (VR) control Rated Voltage Maximum Amps
knob located on the control panel.
277.8 X 2 amps (4 wire)
1Ø 120 Volt
Voltage Selector Switch 300 amps X 2 (Zigzag)
138.9 amps (4 wire)
The voltage selector switch (Figure 14) is located above 1Ø 240 Volt
300 amps (Zigzag)
the output terminal panel’s Hard Wire Hook-up Panel. It
3Ø 240 Volt 300 amps
has been provided for ease of voltage selection..
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.
Figure 14. Voltage Selector Switch
Table 9. 1Ø GFCI Receptacle Load Capacity
CAUTION KW in Use Available Load
Twist Lock (C6369) Current (Amps)
NEVER change the position of the voltage selector GFCI Duplex
1Ø 240/120V
switch while the engine is running. ALWAYS place 5-20R 120V
circuit breaker in the OFF position before selecting 72.0 0
voltage. 70.8 5 amps/receptacle
69.6 10 amps/receptacle
Table 7. Voltages Available 68.4 15 amps/receptacle
UVWO Output Voltage Selector Switch Voltage Selector Switch 67.2 20 amps/receptacle
Terminal Lugs 3-Phase 240/139V Position 3-Phase 480/270V Position
3Ø Line-Line 208V 220V 240V 416V 440V 480V

Table 10. 3Ø Generator Maximum Amps
1Ø Line-Neutral 120V 127V 139V 240V 254V 277V
KVA in Use Available Load
Voltage Selector Switch Single-Phase 240/120V Position
(UVWO Terminals) Current (Amps)
1Ø Line-Neutral/ 120V 240V
Line-Neutral N/A N/A Line-Line N/A N/A GFCI Duplex
Line-Line 3Ø 240/480V
5-20R 120V
NOTICE 125 0 amps/receptacle

121 5 amps/receptacle
This generator can provide variable output voltages via
the voltage regulator control knob. 117 10 amps/receptacle

GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE AC AMMETER AND AC AC Ammeter Gauge Reading
VOLTAGE GAUGES
Place the AC Ammeter Change-Over Switch (Figure 18)
The AC ammeter and AC voltmeter gauges are controlled in the U position and observe the current reading (load
by the AC ammeter and AC voltmeter change-over switches. drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 19). This process can be repeated for
Both of these switches are located on the control panel and terminals V and W.
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.
Figure 18. AC Ammeter Figure 19. AC Ammeter
Change-Over Switch (Amp reading on U Lug)
NOTICE
The ammeter gauge will only show a reading when
the output terminal lugs are connected to a load
and in use.
Figure 15. Voltage Selector Switch-

240/3Ø Position
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 Figure 17. AC Voltmeter Gauge

Change-Over Switch (Volt reading on W-U Lug)

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
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 Figure 22. Voltage Regulator Knob
voltage.
3Ø-208V/1Ø-120V UVWO Terminal Output Voltages
3Ø-240V UVWO Terminal Output Voltages 1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 20.
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

Figure 23. UVWO Terminal Lugs
3Ø-240/139V Position
3Ø-208/1Ø-120V Connections
2. Connect the load wires to the UVWO terminals as
shown in Figure 21 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.

3Ø-240/1Ø-139 Connections

OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480/277V UVWO Terminal Output Voltages 1Ø-240/120V UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 480/277 1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 24. position as shown in Figure 26.
Figure 24. Voltage Selector itch Figure 26. Voltage Selector itch
3Ø-480/277V Position 1Ø-240/120V Position
2. Connect the load wires to the UVWO terminals as 2. Connect the load wires to the UVWO terminals as
shown in Figure 25. shown in Figure 27.

Figure 25. UVWO Terminal Lugs 3Ø-480V 1Ø-240/120V Connection
Connections
3. Turn the voltage regulator knob (Figure 22) clockwise
to increase voltage output, turn counterclockwise
NOTICE to decrease voltage output. Use voltage regulator
ALWAYS make sure that the connections to the adjustment knob whenever fine tuning of the output
UVWO and Ground terminals are secure and tight. voltage is required.
The possibility of arcing exists, that could cause a fire.

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,
and W Output Terminals from overload. In addition two Fuel spillage on a hot engine can cause
single-pole, 20 amp duplex circuit breakers are provided a fire or explosion. If fuel spillage occurs,
to protect the GFCI receptacles from overload. Three 50 wipe up the spilled fuel completely to
amp load circuit breakers have also been provided to prevent fire hazards. NEVER smoke
protect the auxiliary receptacles from overload. Make sure around or near the generator. Make sure
to switch ALL circuit breakers to the OFF position prior to engine is OFF before refueling.
starting the engine.
LUBRICATION OIL Refilling the Fuel System
Fill the engine crankcase with lubricating oil through the
filler hole, but DO NOT overfill. Make sure the generator is CAUTION
level and verify that the oil level is maintained between the ONLY properly trained personnel who have read
two notches (Figure 28) on the dipstick. See Table 11 for and understand this section should refill the fuel tank
proper selection of engine oil. 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
Figure 28. Engine Oil Dipstick tanks beyond their capacities.
When checking the engine oil, be sure to check if the oil is Pay attention to the fuel tank capacity when replenishing
clean. If the oil is not clean, drain the oil by removing the fuel. The fuel tank cap must be closed tightly after filling.
oil drain plug, and refill with the specified amount of oil as Handle fuel in a safety container. If the container does not
outlined in the Isuzu Owner’s Manual. Oil should be warm have a spout, use a funnel. Wipe up any spilled fuel
before draining. immediately.
Delo® engine oil is the recommended engine oil for this
generator. When replacing engine oil please refill using 125
Delo® 400 LE SAE 15W-40 (API CJ-4) engine oil.
INTERNAL FUEL
Table 11. Recommended Motor Oil FUEL TANK CAP
Figure 29. Internal Fuel Tank System
NOTICE
DO NOT add fuel while engine is running. Stop engine
and let cool before adding fuel.

INSPECTION/SETUP
Refueling Procedure: 3. NEVER overfill fuel tank — It is important to read the
fuel gauge when filling the fuel tank. (Figure 32). The
WARNING ECU controller must be powered ON in order to read
Diesel fuel and its vapors are dangerous the fuel guage.
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 Figure 32. Full Fuel Tank
ALWAYS place trailer on firm level ground before CAUTION
refueling to prevent spilling and maximize the amount
DO NOT OVERFILL fuel system. Leave room for fuel
of fuel that can be pumped into the tank.
expansion. Fuel expands when heated (Figure 33).
125
DO NOT fill on
unlevel ground
=
!
!
und
und Gro
vel
Gro Unle
vel
Unle Level Ground
Level Ground
Figure 33. Fuel Expansion

Figure 30. Only Fill on Level Ground
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

INSPECTION/SETUP
DEF Refueling COOLANT (ANTIFREEZE/SUMMER COOLANT/
NOTICE WATER)
ONLY fill the DEF tank with diesel exhaust fluid. Any Isuzu recommends antifreeze/summer coolant for use in their
other type of fluid may cause severe engine damage. engines, which can be purchased in concentrate (and mixed
with 50% demineralized water) or pre-diluted. See the Isuzu
Diesel exhaust fluid is an aqueous solution made with 32.5% Engine Owner’s Manual for further details.
high puirty urea (carbamide) and 67.5 deionized water. DEF
is used as a consumable in selective catalytic reduction WARNING
(SCR) in order to lower NOx concentration from diesel exhaust If adding coolant/antifreeze mix to the
emissions. radiator, DO NOT remove the radiator cap
1. Make sure engine is OFF. until the unit has completely cooled. The
possibility of hot! coolant exists which can
2. Remove the filler cap from the DEF tank (Figure 34). cause severe burns.
3. Upon initial start up, completely fill the DEF tank with
DEF fluid. DO NOT overfill. Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
125
the radiator cap until the unit has completely cooled. See
Table 12 for engine, radiator, and recovery tank coolant
DEF FILLER
PORT 100
capacities. Make sure the coolant level in the recovery tank
75
is always between the “H” and the “L” markings.
50
25 CAP
0 DE
TA F
Table 12. Coolant Capacity
NK
Engine and Radiator 5.5 gal (21 liters)
Figure 34. DEF Tank Filling Reserve Tank N/A
DEF Refueling (Continuous Operation) Operation in Freezing Weather

It is recommended to shut down the engine prior to refilling When operating in freezing weather, be certain the proper
the DEF tank. However, in special applications where shutdown amount of antifreeze (Table 13) has been added.
is not possible, it is recommended to ONLY refill the DEF tank
when the fluid level has been consumed down to 50%. Table 13. Coolant Capacity
Outside Longlife Coolant
The DEF level sending unit requires a gradual DEF level Climate
Temperature Concentration
decrease during continuous operation to validate proper
operation. Failure of this sensor to report the decrease could 10°F (-12°C) or
Warm 30%
result in an engine shutdown. A engine service technician Above
would be required to remedy the shutdown. -22°F (30°C) or
Cold 50%
Above

INSPECTION/SETUP
Cleaning the Radiator CAUTION
The engine may overheat if the radiator fins become NEVER place hands near the belts or fan
overloaded with dust or debris. Periodically clean the while the generator set is running.
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 BATTERY
Periodic cleaning/replacement is necessary. Inspect air This unit is of negative ground DO NOT connect in reverse.
cleaner in accordance with the Isuzu Engine Owner’s Always maintain battery fluid level between the specified
Manual. marks. Battery life will be shortened, if the fluid level are
not properly maintained. Add only distilled water when
FAN BELT TENSION replenishment is necessary.
A slack fan belt may contribute to overheating, or to DO NOT over fill. Check to see whether the battery
insufficient charging of the battery. Inspect the fan belt for cables are loose. Poor contact may result in poor starting
damage and wear and adjust it in accordance with the or malfunctions. Always keep the terminals firmly
Isuzu Engine Owner’s Manual. tightened. Coating the terminals with an approved battery
terminal treatment compound. Replace battery with only
Fan belt tension is proper if the fan belt bends as
recommended type battery. The battery type used in this
represented in Figure 35 when depressed with the thumb
generator is BCI Group 4D.
as shown below. Adjust fan belt tension as required
The battery is sufficiently charged if the specific gravity
of the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
0.2 ~ 0.3 IN.

(6 ~ 8 MM)
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.
New 210 Hz.
(6~8 mm)

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 alternator failure.
terminal of the battery.
DO NOT put water directly on the alternator. Entry of water
CAUTION into the alternator can cause corrosion and damage the
alternator.
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST. WIRING
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
NEGATIVE
POSITIVE (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.
Figure 36. Battery Connections If any hose (fuel or oil) lines are defective replace them
immediately.
When connecting battery do the following:
1. NEVER connect the battery cables to the battery
terminals when the Auto-Off/Reset-Manual Switch
is in either the AUTO or MANUAL position. ALWAYS
make sure that this switch is in the OFF/RESET
position when connecting the battery.
2. Place a small amount of battery terminal treatment
compound around both battery terminals. This will
ensure a good connection and will help prevent
corrosion around the battery terminals.
NOTICE
If the battery cable is connected incorrectly, electrical
damage to the generator will occur. Pay close attention
to the polarity of the battery when connecting the battery.
CAUTION
Inadequate battery connections may cause poor
starting of the generator, and create other malfunctions.

GENERATOR START-UP PROCEDURE (MANUAL)
BEFORE STARTING STARTING (MANUAL)
1. Place the Auto-Off/Reset Manual Switch in the
CAUTION
MANUAL position to start the engine (Figure 39).
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING Figure 39. Auto-Off/Reset Manual Switch

NEVER manually start the engine with the main, duplex (Manual Position)
or auxiliary circuit breakers in the ON (closed) position. NOTICE
1. Place the main, aux. and duplex circuit breakers If engine fails to start in a specified number attempts,
(Figure 37) in the OFF position prior to starting the the shutdown lamp will illuminate and the Auto-Off/
engine. Reset Switch must be placed in the Off/Reset position
MAIN CS-6369 DUPLEX before the engine can be restarted.
CIRCUIT AUX. CIRCUIT CIRCUIT
BREAKER BREAKERS BREAKERS
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..
OFF
OFF
OFF
OFF
OFF
OFF
OFF
2. Once the engine starts, let the engine run for 1-2
minutes Let engine idle longer in cold weather
Figure 37. Main, Aux. and Duplex conditions. Listen for any abnormal noises. If any
Circuit Breakers (OFF) abnormalities exist, shut down the engine and correct
2. Make sure the voltage selector switch has been the problem.
configured for the desired output voltage. 3. The generator’s frequency meter (Figure 40) should be
displaying the 60 cycle output frequency in HERTZ.
3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 12. These load 60 Hz
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.
Figure 40. Frequency Meter
5. Close all engine enclosure doors (Figure 38).
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 INCORRECT
Figure 38. Engine Enclosure Doors

Figure 41. Voltmeter

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)
150
Figure 42. Voltage Adjust Control Knob 60
120 180
RPMX10
6. The ammeter (Figure 43) will indicate zero amps with 0 210
no load applied. When a load is applied, the ammeter

will indicate the amount of current that the load is SPEED
drawing from the generator.

Figure 46. Engine Tachometer Gauge
10. Place the main, aux, and duplex circuit breakers in
the ON position (Figure 47).
MAIN CS-6369 DUPLEX
Figure 43. Ammeter (No Load)
ON
ON
ON
ON
ON
ON
ON
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
Figure 47. Main, Aux. and Duplex
psi. (290~590 kPa).
Circuit Breakers (ON)
25
50
75 11. Observe the generator’s ammeter (Figure 48) and
PSI
verify it reads the anticipated amount of current with
0 100
respect to the load. The ammeter will only display a
OIL PRESS 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).
Figure 48. Ammeter (Load)
140
180
220
12. The generator will run until manually stopped or an
abnormal condition occurs.
°F
100 260
WATER TEMP
Figure 45. Coolant Temperature Gauge

GENERATOR START-UP PROCEDURE (AUTO MODE)
STARTING (AUTO MODE) When starting generator in AUTO mode use the “Manual
Start-up” procedure except where noted (see below).
DANGER
1. Perform steps 1 through 5 in the Before Starting section
Before connecting this generator to any as outlined in the Manual Starting Procedure.
building’s electrical system, a licensed
electrician must install an isolation 2. Place the Auto Off/Reset Manual Switch (Figure 49)
(transfer) switch. Serious damage to in the AUTO position.
the building’s electrical system may occur
without this transfer switch.
CAUTION
Figure 49. Auto Off/Reset Manual Switch (AUTO)
When connecting the generator to a isolation (transfer)
itch, ALWAYS have power applied to the generator’s 3. Continue operating the generator as outlined in the
internal battery charger. This will ensure that the engine Manual Start-up procedure (start at step 2).
will not fail due to a dead battery.
WARNING
NOTICE NEVER stop the engine suddenly except in an
emergency.
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.
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.

GENERATOR SHUT-DOWN PROCEDURES
NORMAL SHUTDOWN PROCEDURE EMERGENCY SHUTDOWN PROCEDURE
To shutdown the generator, use the following procedure: 1. If equipped (option), push the Emergency Stop
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
Figure 52. Emergency Stop Switch (Option)

2. If generator is not equipped with an emergency stop
pushbutton switch , place the Auto Off/Reset Manual
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Switch (Figure 53) in the OFF/RESET position.
Figure 50. Main, Aux. and Duplex

Circuit Breakers (OFF) AUTO MANUAL
2. Let the engine cool by running it at low speed for 3-5 OFF/RESET
(CENTER)
minutes with no load applied.
3. Place the Auto Off/Reset Manual Switch (Figure 51) Figure 53. Auto Off/Reset Manual Switch (OFF)
in the OFF/RESET position.
AUTO MANUAL
OFF/RESET
(CENTER)
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.

MAINTENANCE
500 Hrs 3000 Hrs
10 Hrs
Table 15. Inspection/Maintenance 250 Hrs or Every or Every OTHER
DAILY
12 Months 36 Months
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 * 1
X
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 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* 2
4500 hrs.
Inspect Dosing Module (SRC System) 4500 hrs
Flush and Refill Cooling System* 3
1 yr. or 2000 hrs.
Clean Inside of Fuel Tank 1000 hrs.
Clean DEF Tank As Required
Replace Air Cleaner Elements * 4
As Required
Measure Insulation Resistance Over 3M ohms X
Generator
Check Rotor Rear Support Bearing X
*1 During initial operation of a new engine, change oil and filter between a minimum of 100 hrs. and a maximum of 250 hrs. Service interval depends
on type of oil.
*2 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).

MAINTENANCE
GENERAL INSPECTION CAUTION
Prior to each use, the generator should be cleaned and
inspected for deficiencies. Check for loose, missing or Wear protective equipment such as
damaged nuts, bolts or other fasteners. Also check for approved safety glasses or face shields
fuel, oil, and coolant leaks. Use Table 15 as a general and dust masks or respirators when
maintenance guideline Engine Side (Refer to the Engine cleaning air filters with compressed air.
Instruction Manual)
Primary and Secondary Air Cleaner Elements
Air Filter Dust Indicator
1. Release the latches (Figure 55) that secures the cover
NOTICE to the air cleaner body.
The air filter should not be changed until the indicator 2. Remove the air cleaner cover and set aside.
reads “RED”. Dispose of old air filter. It may not be 3. Remove both the primary and secondary air cleaner
cleaned or reused. elements.
4. Check the air cleaner daily or before starting the engine
The air filter indicator (Figure 54) is attached to the air filter.
5. Check for and correct heavy buildup of dirt and debris
When the air filter element is clogged, air intake restriction along with loose or damaged components.
becomes greater and the air filter indicator signal shows
RED. When indicator is red, replace filter immediately. NOTICE
After changing the air filter, press the air filter indicator
button to reset. Operating the engine with loose or damaged air cleaner
PUSH BUTTON TO RESET components could allow unfiltered air into the engine
causing premature wear and failure.
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
25 INCHES H2O
compressed air (not to exceed 30 psi (207 kPa, 2.1
kgf/cm2) through the filter element from the inside out.
6.23 kPa
Figure 54. Air Filter Dust Indicator BODY
AIR CLEANER
PRIMARY
AIR FILTER
ELEMENT
NOTICE SECONDARY
AIR FILTER
If the engine is operating in very dusty or dry grass ELEMENT
conditions, a clogged air cleaner will result. This can

lead to a loss of power, excessive carbon buildup in BLOW COMPRESSED
AIR FILTER
INDICATOR
LATCH
the combustion chamber and high fuel consumption. AIR FROM THE
INSIDE OUT
Change air cleaner more frequently if these conditions
exist. ARROW
MARK
(DUST PAN)
Every 250 hours: Remove air cleaner element (Figure 55)
EVACUATOR
and clean the heavy duty paper element with light spray of VALVE
compressed air. Replace the air cleaner as needed. Figure 55. Air Cleaner
This Isuzu diesel engine is equipped with a replaceable,
high-density paper air cleaner element. This air cleaner 7. Clean the secondary element (paper air filter) as
is also equipped with an inner element (secondary) that referenced in step 6.
is used as a backup filter should the primary element 8. Replace both elements if they are damaged or
becomes damaged. excessively dirty.

MAINTENANCE
9. Clean the inside of the air cleaner body. FUEL FILTER ELEMENT REPLACEMENT
10. Reinstall the primary and secondary air filter elements 1. Use a filter wrench to remove the element case
back into air cleaner body. (Figure 57) from the fuel filter body.
11. Reinstall the air cleaner cover, and secure with latches.
DRAINING FUEL FILTER ELEMENT
NOTICE
AIR BLEEDER
Inspect the fuel filter daily. If the fuel filter (Figure 56) has PLUG
collected a significant amount of water and sediment

at the bottom of the cup, it should be drained off FILTER BODY
immediately.
1. Loosen the air bleeder plug (Figure 56) on the fuel

filter body.
ELEMENT
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 FLOAT
the valve drops down 1-inch (25.4 mm) and draining
occurs(B). O-RING
AIR BLEEDER
PLUG
ELEMENT
FILTER BODY
CASE
FUEL FILTER
O-RING
DRAIN PLUG
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.
A 3. Insert the new fuel filter element into the element case.
B 4. Replace both o-rings. Coat each o-ring with a small
C amount of clean 15W-40 engine oil.
OPEN
5. Reinstall element case first by hand until it makes

DRAIN CLOSE 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).
Figure 56. Draining Fuel Filter
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.

MAINTENANCE
ELECTROMAGNETIC FUEL PUMP (500 HOURS) Removing Water from the Fuel Tank
The filter inside the fuel pump (Figure 58) is either a paper After prolonged use, water and other impurities accumulate
type or steel mesh type depending on fuel pump type. Clean in the bottom of the tank. Occasionally inspect the fuel tank
or replace the fuel pump filter as follows: for water contamination and drain the contents if required.
1. Disconnect any electrical connections that are attached During cold weather, the more empty volume inside the
to the fuel pump. tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
2. Prepare a fuel collector to drain the fuel into. Secure
any fuel lines to prevent fuel from spilling. Cleaning Inside the Fuel Tank
3. Remove fuel pump from air generator enclosure. If necessary, drain the fuel inside the fuel tank completely.
4. Next, remove the filter and gasket from the fuel pump Using a spray washer (Figure 59) wash out any deposits
housing. or debris that have accumulated inside the fuel tank.
K
Figure 58. Electromagnetic Fuel Pump AN
E LT
FU
NOTICE
When the fuel pump filter is removed, always make sure Figure 59. Fuel Tank Cleaning
to replace both gaskets and clean the magnet portion
inside the cover. FUEL TANK INSPECTION
5. Clean or replace fuel pump filter. Replace both gaskets. In addition to cleaning the fuel tank, the following
components should be inspected for wear:
6. Reassemble fuel pump and mount back onto generator
enclosure. Rubber Suspension — look for signs of wear or
deformity due to contact with oil. Replace the rubber
7. Reconnect all fuel lines and electrical components. suspension if necessary.
8. Check for fuel leaks. 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.

MAINTENANCE
DRIVE BELT (DAILY) ENGINE OIL (CHECK DAILY)
Drive Belt Tension 1. When checking or adding oil, place the machine so
the engine is level.
A slack drive belt (Figure 60) may contribute to overheating,
2. Pull the engine oil dipstick from its holder.
or to insufficient charging of the battery, adjust drive belt in
accordance with the Isuzu Operator's manual 3. Determine if engine oil is low. Oil level should be
between the upper land lower limit (Figure 61) on the
Drive Belt Inspection dipstick.
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 DO NOT
not acceptable. OVERFILL H (UPPER LIMIT)
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, L (LOWER LIMIT)
which can weaken it and increase the danger of it breaking.
If the drive belt exhibits any of the above wear conditions, Figure 61. Dipstick Engine Oil Level
replace the drive belt immediately. 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.
NO Table 16. Oil Selection Chart
F C OIL: SAE
122 50
104 40
86 30
40
68 20
5W/40
30
10W/30
10W/40
15W/40
5W/30
20W/20
50 10
NO 32 0
10W
-14 -10
Figure 60. Drive Belt Inspection -4 -20
-22 -30
-40 -40
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.

MAINTENANCE
6. Run the engine for several minutes. Watch for oil
OIL DRAIN leakage. Shut the engine down and allow it to sit for
CAP
(REMOVE) several minutes. Top off the oil to the upper limit on
the dipstick.
OPEN
OIL
DRAIN
FLUSHING OUT RADIATOR AND REPLACING
VALVE 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
Figure 62. Draining Engine Oil (50°C) before removing pressure cap.
5. After engine oil has been completely drained, reinstall Heated coolant spray or steam can cause severe
oil drain cap and tighten securely. scalding and personal injury.
6. Place the oil drain valve in the CLOSED position.
ENGINE OIL FILTER REPLACEMENT 1. Place the coolant drain valve in the OPEN position
(Figure 64) and allow the coolant to drain into a suitable
1. Clean the area around the lubricating oil filter head. container.
2. Using an oil filter wrench (Figure 63), remove engine
oil filter.
RUBBER
SEAL
OIL COOLANT
DRAIN VALVE
(OPEN)
COAT SEAL
OIL FILTER WITH THIN
WRENCH ENGINE LAYER OF OIL
OIL FILTER
CARTRIDGE
Figure 64. Draining Engine Coolant

Figure 63. Engine Oil Filter Removal
2. Check hoses for softening and kinks. Check clamps
3. Coat the rubber seal (gasket) surface of oil for signs of leakage.
filter (Figure 63) with clean 15W-40 engine oil.
3. Remove and inspect radiator cap.
4. Install new oil filter first by hand until it makes contacts
with the filter head surface. Tighten it another 3/4 turn 4. Flush the radiator by running clean tap water through
using the filter wrench. radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
5. Fill engine crankcase with high quality detergent oil screwdriver.
classified "For Service CI-4. Fill to the upper limit of
dipstick. DO NOT overfill. Reference Table 2 for engine
crankcase oil capacity.
MAINTENANCE
5. Tighten water cock and replace the overflow tank. GENERATOR STORAGE
6. Place the coolant drain valve in the CLOSED position. For long term storage of the generator the following is
7. Replace with coolant as recommended by the engine recommended:
manufacturer. Drain the fuel tank completely. Treat with a fuel stabilizer
8. Reinstall radiator cap. Tighten securely. if necessary.
RADIATOR CLEANING Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
The radiator (Figure 65) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt Clean the entire generator, internal and external.
and debris have accumulated on the cooling fins or tube. Cover the generating set and store in a clean, dry place.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to Disconnect the battery.
the fins and tube. 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

MAINTENANCE
JACKET WATER HEATER AND INTERNAL BATTERY When using the generator in hot climates there is no
CHARGER 120 VAC INPUT RECEPTACLES need to apply power to jacket water heater. However, if the
(OPTIONAL) generator will be used in cold climates, it is best to apply
power to the jacket water heater at all times.
This generator can be equipped as an option with a
engine block heating element and an internal battery If the generator will be used daily, the battery should
charger. They are provided with electric cords to connect normally not require charging. If the generator will be idle
to a commercial power source. (not used) for long periods of time, apply power to the
battery charger receptacle via commercial power using a
The engine block heating element and internal battery power cord of adequate size.
charger both require 120 VAC in order to operate. A
receptacle (Figure 66) has been provided on the output NOTICE
terminal panel to allow commercial power to be applied.
If the generator will be idle (not used) for long periods
These units will ONLY function when commercial power of time and to ensure adequate starting capability,
has been supplied to them. When using extension cords, always have power applied to the generator's internal
refer to Table 6 for the correct size and length. battery charger.
BATTERY
CHARGER
JACKET WATER
HEATER
OUTPUT TERMINAL
PANEL ASSEMBLY
BATTERY CHARGER/
JACKET WATER HEATER
120 VAC INPUT
RECEPTACLE
Figure 66. Jacket Water Heater and Battery Charger (Option)

MAINTENANCE
EMISSION CONTROL EMISSION CARBON CHECK
The emission control system employed with this ISUZU Deposition of carbon (soot, unburned fuel) in the exhaust
diesel engine consist of a Diesel Oxidation Catalyst (DOC) pipe line and muffler could cause not only system derates
and a Selective Catalytic Reduction (SCR) catalyst as but also could lead to fires.
an exhaust gas after-treatment system that helps reducing
To reduce soot and unburned fuel, run the unit at rated
harmful gases and destroying the organic fraction of the
power until the exhaust gas become mostly colorless every
particulate matter produced from the exhaust gas to meet
250 hours operation time. More carbon will be generated
the requirement for EPA Tier 4 (Final) regulations.
when the unit operates at less then 30% of rated power. In
The DOC device (Figure 67) helps in filtering out large this case, perform the above procedures more frequently.
amounts of harmful Nitrogen Oxides (NOx) and Particulate
Matter (PM) which are emitted by diesel engines. These NOTICE
exhaust emissions pose serious environmental and health Applying a large load suddenly to the unit when the
risks. It is important to maintain and service the DOC carbon deposition is generated in the exhaust system
emission safety device on a periodic basis. could produce sparks and will lead to abnormal
Diesel Oxidation Catalyst (DOC) combustion. Therefore, apply load gradually and
observe the exhaust gas color during the process.
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.
Figure 67. Diesel Oxidation Catalyst (DOC)

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. The excess of air necessarily leads shoud not be considered a failure. In addition the smell
to generation of nitrogen oxides (NOx), which are harmful of amonia during the purging process should not be
pollutants, from the nitrogen in the air. Selective Catalytic considered a failure.
Reduction is used to reduce the amount of NOx released
into the atmosphere. If the purging process is underway while running a light
load (0-30%) the unit may produce unusual sounds.
Diesel Exhaust Fluid (DEF) from a separate tank is This should not be considered a failure or malfunction.
injected into the exhaust pipeline, where the aqueous urea
vaporizes and decomposes to form ammonia and carbon SYSTEM PURGING GUIDELINES
dioxide. Within the SCR catalyst, the NOx are catalytically
reduced by the ammonia (NH3) into water (H2O) and NOTICE
nitrogen (N2), which are both harmless; and these are then
DO NOT perform purging in conditions where it may be
released through the exhaust.
unsafe due to high exhasust temperatures.
The SCR system creates a certain amount of amonia (NH3)
that is stored in SCR catalyst. During purging operations For safe operation of equipment, the sourounding area and
the increase in temperature at regular intervals eleminates the prevention of bodily harm, use the guidelines below
the stored ammonia. when system purging is required:
The process of keeping accurate amonia storage amounts NOTICE
is by counting urea injection quantities from the Dosing
Control Unit (DCU) The area above and around the generator during the
purging process should be free of any type of debris,
The SCR Purge symbol (Figure 68) will be displayed on the flammable or conbustible materials, as temperatures
ECU controller during operation when either an automatic during the purging process can reach as high 1,022
or forced system purge operation is in process. °F (550 °C).
The pre-alarm lamp is only ON during SCR forced system
DO NOT operate the unit in area with poor ventilation.
purging and OFF during automatic system purging
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
Engine Started
ventilate the area.
SCR PURGE
Shutdown
Exhaust emissions from the tailpipe have a smell different
Pre-Alarm
from those emitted from engines without urea SCR
systems due to the exhaust emission reduction functions
of the exhaust system.

Figure 68. SCR Purge Symbol

MAINTENANCE
If the diesel exhaust fluid (DEF) symbol (Figure 69) is DIESEL EXHAUST FLUID (DEF)
displayed during ECU controller operation, it indicates the
following: The amount of fluid in the DEF tank will be shown on the
ECU Controller main screen during operation. The symbol
DEF tank level is below 10%. Reference Table 17, DEF shown in Figure 70 will be shown on the ECU monitor
Level System Action System. indicating the level of fluid in the DEF tank.
DEF quality is poor. Check DEF tank level and check
active diagnostics trouble codes (DTC).

Engine Started
Figure 70. DEF Tank Level Guage
DEF STAT Shutdown
Pre-Alarm

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 — ON Blinking Blinking
Pre-Alarm Lamp — — ON ON
Shutdown Lamp — — — ON
Engine Shutdown

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. The three warning levels
are referenced in Table 18:
Table 18. DEF Inducement

SCR System Pre-Alarm Shutdown
Stage Controller Message DEF Symbol
Pop-Up Lamp Lamp
Stage 1 SCR System

SCR SYS ERR ON —
Warning Level 1 Malfunction
Stage 2 SCR System

SCR SYS ERR ON —
Warning Level 2 Malfunction
Slow Blinking
Stage 3 SCR System

SCR SYS ERR ON ON
Shutdown1 Malfunction
Fast Blinking
1
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.

MAINTENANCE
HOW TO ACTIVATE ESCAPE MODE
SPEED
If the ECU displays any messages referenced in Table 18, 0000
it may be necessary to restart via ESCAPE MODE.
E F
Starting E F
DEF
1. Start the Diagnostic Mode as referenced in the
"Troubleshooting Diagnostics" section in this manual. CANBUS IS WORKING OK
2. Exit the Status Check Screen by pressing the [EXIT]

button (Figure 71).
E F STATUS CHECK
E F
DEF
HOURS 26.8v Alarm Screen
Change
Option Program
Exit
00018.3
CANBUS IS WORKING OK
EXIT [PROGRAM EXIT]
BUTTON
Figure 72. Main Screen

4. Press the [DOWN] button (Figure 73) to scroll to the
Escape Mode item.
FAULT DIAGNOSTICS
ABOUT UNIT
USER LOGIN
[EXIT] DIAGNOSTIC MODE ESCAPE MODE
BUTTON
Figure 71. Status Check Screen
(Diagnostic Mode)
UP DOWN SELECT
3. Next, press the [Program/Exit] button (Figure 72) to
enter the Main Menu.
[DOWN]
BUTTON
Figure 73. Main Menu (Down Button)

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 AUTO MANUAL
USER LOGIN
ESCAPE MODE
OFF/RESET
(CENTER)
UP DOWN SELECT Figure 76. Auto Off/Reset Manual Switch

(Off/Reset Position)
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

[SELECT] (Manual Position)
BUTTON 9. The Escape Mode Timer (Figure 78) will appear on
Figure 74. Main Menu (Select Button) the main screen. This timer displays remaining driving
possibility time.
6. Press the [REQUEST] button (Figure 75) to send
"Escape Mode Request" signal to ECM. SPEED SD IN CHECK
1800 18 MIN.
ESCAPE MODE REQUEST
E F HOURS
EMERGENCY RESERVE ENGINE
RUN MAY BE POSSIBLE. E F 00018.2
DEF
TO ATTEMPT ESCAPE MODE: SCR SYS ERR
PRESS THE REQUEST SOFT KEY. SCR TROUBLE-PURGE PROHIBITED
EXIT REQUEST 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
[REQUEST] proper operating condition.
BUTTON
If the unit returns to Warning Level 1 while ESCAPE
Figure 75. Escape Mode Menu Screen MODE is running, ESCAPE MODE will be cancelled,
the ESCAPE MODE timer display will close, and normal
operation will resume.

GENERATOR WIRING DIAGRAM
SYMBOL DESIGNATION
Ar MAIN GENERATOR ARMATURE WINDING
Fg MAIN GENERATOR FIELD WINDING
ExAr EXCITER ARMATURE WINDING
ExFg EXCITER FIELD WINDING
Re RECTIFIER
AVR AUTOMATIC VOLTAGE REGULATOR
VR VOLTAGE REGULATOR (RHEOSTAT)
CT 1,2,3 CURRENT TRANSFORMER
AS CHANGE-OVER SWITCH,AMMETER
A AC.AMMETER CONNECTOR ARRANGEMENT
~
V AC.VOLTMETER (WIRING VIEW)
~ 3 2 1
F FREQUENCY METER 1 2 3
1 2 3 4
1 2
W1 V1 U1
2 1
CB1 CIRCUIT BREAKER, 3P 200A A J C CN5 V2 V2 - + CN8 41 98
CN11 CN13 2 1
CIRCUIT BREAKER, 2P 50A CN1 1 U2
CB2, 3, 4 B K D 3 W2
CB5, 6 CIRCUIT BREAKER, 1P 20A
3 2 1 1 2
1 2 3 1 2 3 4
CON1, 2, 3 RECEPTACLE, CS6369, 250 VAC@ 50 AMPS
CN3 U V W CN6 V1 V1 - + CN9 6 4 2 1 2 3
CN14 12
CON4, 5 RECEPTACLE, GFCI, 125 VAC @ 20 AMPS X 2 U1 V1 W1
OC OVER CURRENT RELAY CN12 U2 1
1 2 1 2 3
SW SELECTOR SWITCH
2 1
W2 3
CN4 13 CN7 B B CN10 R S T
RY1 RELAY UNIT
RY2 RELAY UNIT
WIRE SIZE CODE/WIRE COLOR

CURRENT TRANSFORMERS (CT1 ~ 3) 125: 125 mm2 B BLACK R RED
REF. DES. MARK AT CT 100: 100 mm
2
L BLUE W WHITE
k X1
l NO MARK 80: 80 mm2 BR BROWN Y YELLOW
22: 22 mm
2
K H1 G GREEN LB LIGHT BLUE
L NO MARK 14: 14 mm2 GR GRAY LG LIGHT GREEN
NOTE: EACH CABLE IS PASSED TWICE THROUGH
CURRENT TRANSFORMERS CT1, CT2 AND CT3.
8: 8 mm
2
V VIOLET O ORANGE
5.5: 5.5 mm
2
P PINK
NO MARK WIRE SIZE: 1.25 mm
2

2
125: 125 mm B BLACK R RED
2
100: 100 mm L BLUE W WHITE
80: 80 mm2 BR BROWN Y YELLOW
2
22: 22 mm G GREEN LB LIGHT BLUE
14: 14 mm2 GR GRAY LG LIGHT GREEN
2
8: 8 mm V VIOLET O ORANGE
2
5.5: 5.5 mm P PINK
2

ENGINE WIRING DIAGRAM
NOTES

2
125: 125 mm B BLACK R RED
2
22: 22 mm2 G GREEN LB LIGHT BLUE
2
14: 14 mm GR GRAY LG LIGHT GREEN
2
2
5.5: 5.5 mm P PINK

2
CONTROLLER WIRING DIAGRAM
125: 125 mm2 B BLACK R RED
2
22: 22 mm2 G GREEN LB LIGHT BLUE
2

14: 14 mm GR GRAY LG LIGHT GREEN
2
2
5.5: 5.5 mm P PINK
2
CONTROLLER WIRING DIAGRAM
BATTERY CHARGER WIRING DIAGRAM
BLACK 14 AWG. LINE (L)120VAC INPUT
WHITE 14 AWG. NEUTRAL (N)

A B
3 4
1 2
GREEN 14 AWG. GROUND (G)
TO CHASSIS
GROUND
GREEN 16 AWG.
TO STARTER “B”
TERMINAL
RED 16 AWG.
4
A
1 2
120 VAC INPUT, INSERT EXTERNAL
POWER CORD HERE.
NOTES:
1 NEMA 5-15, 15A, 120 VAC, P/N HBL5278C/HUBBLE RECEPTACLE.
2 RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.
3 20 AMP, 5-20R RECEPTACLE, P/N HBL5369C/HUBBLE RECEPTACLE.
4 CORD, CAROL 3/C 14 AWG., P/N EE56557.

JACKET WATER HEATER WIRING DIAGRAM
BLACK 14 AWG. LINE (L)120VAC INPUT
WHITE 14 AWG. NEUTRAL (N)

A B
3 4
1 2
GREEN 14 AWG. GROUND (G)
BLOCK HEATER
(P/N 44558)
BLACK 14 AWG. TEMP.

LINE (L)120VAC INPUT SWITCH
HEATING
WHITE 14 AWG. 120 VAC ELEMENT
3 NEUTRAL (N)
GREEN 14 AWG.
B GROUND (G)
GROUND
4
A
1 2
120 VAC INPUT, INSERT EXTERNAL
POWER CORD HERE.
NOTES:
1 NEMA 5-15, 15A, 120 VAC, HBL5278C/HUBBLE RECEPTACLE.
2 RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.
3 20 AMP, 5-20R RECEPTACLE, P/N EE6131 (HBL5369C/HUBBLE RECEPTACLE).
4 CORD, CAROL 3/C 14 AWG., P/N EE56557.

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 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.
Low Voltage Output Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
High Voltage Output
Defective AVR? Replace if necessary.
Short Circuit in load? 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.

TROUBLESHOOTING (DIAGNOSTICS)
The engine controller of this generator diagnoses problems 5. Push the Program/Exit Button on the ECU controller
that arise from the engine control system and the engine and select the Fault Diagnostics mode. This mode
itself. enables the ability to carry out the fault diagnostics
as listed below:
1. With the engine stopped (OFF). Push and hold the
Hour Check Button (Figure 79) located on the control DM1 Active Faults — Displays active fault messages
panel. and codes.
HOUR CHECK
BUTTON 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
Figure 79. Hour Check Button

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

(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.

OPERATION MANUAL
HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office MQ Parts Department
18910 Wilmington Ave. Tel. (800) 421-1244 800-427-1244 Fax: 800-672-7877
Carson, CA 90746 Fax (310) 537-3927 310-537-3700
Contact: mq@multiquip.com
Service Department Warranty Department
800-421-1244 800-421-1244 Fax: 310-943-2249
310-537-3700 310-537-3700
Technical Assistance
800-478-1244 Fax: 310-943-2238
CANADA UNITED KINGDOM
Multiquip Multiquip (UK) Limited Head Office
4110 Industriel Boul. Tel: (450) 625-2244 Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223
Laval, Quebec, Canada H7L 6V3 Tel: (877) 963-4411 Globe Lane, Fax: 0161 339 3226
Contact: infocanda@multiquip.com Fax: (450) 625-8664 Dukinfield, Cheshire SK16 4UJ
Contact: sales@multiquip.co.uk
© 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 a permanent part of the equipment and should remain with the unit if resold.
The information and specifications 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 specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
Manufactured for
MQ Power Inc.
by
Your Local Dealer is: DENYO CO., LTD, JAPAN

DCA125SSIU4F Rev 3 60 HZ Op Manual

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OPERATION MANUAL

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Diesel engine exhaust and some of

PAGE 2 — DCA125SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (01/16/18)

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 3

DO NOT EXCEED THE RECOMMENDED

OIL PRESS WATER TEMP BATTERY

ARC FLASH AND SHOCK HAZARD U W

Appropriate PPE Required OFF

Appropriate Personal Protection

Using a generator indoors CAN KILL YOU IN MINUTES.

NEUTRE MIS A LA MASSE A

NEUTRE MIS A LA MASSE A

125 kVA AC GENERATOR

Avoid other generator hazards.

SIDE VIEW SIDE VIEW

Figure 1. Safety Decals

PAGE 4 — DCA125SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (01/16/18)

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 5

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DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 7

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DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 9

PAGE 10 — DCA125SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (01/16/18)

Table 1. Generator Specifications

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 11

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DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 13

IF THE GENERATOR IS PROVIDING

Figure 3. Typical Generator Grounding Application

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DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 15

PAGE 16 — DCA125SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (01/16/18)

10 Table 4. Generator Major Components

OIL PRESS WATER TEMP BATTERY

17 9 Output Terminal Panel Assembly

Figure 4. Major Components

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 17

ECU Series 800 Controller

Figure 5. Engine Control Unit (ECU)

PAGE 18 — DCA125SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (01/16/18)

OIL PRESS WATER TEMP BATTERY

Alarm Screen Option Program

11 Figure 6. Gauge Unit Assembly

4. Fuel Leak Detected Alarm Lamp — This lamp when

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 19

BLACK RED BLUE WHITE GREEN

120 VAC, 20 AMP

Figure 7. Output Terminal Panel

PAGE 20 — DCA125SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (01/16/18)

Removing the Plastic Face Plate (Hard Wire

Twist Lock Dual Voltage 120/240 VAC Receptacles

Figure 11. Plastic Face Plate

Figure 9. 240/139V Twist-Lock Auxiliary

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 21

LOAD GROUND LOAD

PAGE 22 — DCA125SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (01/16/18)

An inadequate size connecting cable which cannot carry the

DCA125SSIU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #3 (01/16/18) — PAGE 23

GFCI Receptacle Load Capability

3Ø Line-Line 208V 220V 240V 416V 440V 480V

NOTICE 125 0 amps/receptacle

PAGE 24 — DCA125SSIU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #3 (01/16/18)