MQ POWER DCA-25SSAI WHISPERWATTTM GENERATOR
PARTS AND OPERATION MANUAL
PARTS LIST NO
SERVICE DEPARTMENT
PAGE 2 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
HERES HOW TO GET HELP
SERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046
WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046
Specification and part number are subject to change without notice
TABLE OF CONTENTS
MQ POWER DCA-25SSAI AC GENERATOR
ISUZU C240 ENGINE
Now! Direct TOLL-FREE access to our Parts Department
PARTS ORDERING PROCEDURES
Extra
Discount
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GENERAL SAFETY
RULES FOR SAFE OPERATION
Radiator
RULES FOR SAFE OPERATION
RULES FOR SAFE OPERATION
Battery
Loading and Unloading Crane
RULES FOR SAFE OPERATION
Maintenance Safety
Transporting
Emergencies
DCA-25SSAI -TOWING RULES FOR SAFE OPERATION
Towing Safety Precautions
Explanation of Chart
DCA-25SSAI - TRAILER-SAFETY GUIDELINES
Table 1. Specifications
DCA-25SSAI -TRAILER-SPECIFICATIONS
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MODEL
Table 1. Specifications Cont
DCA-25SSAI -TRAILER-SPECIFICATIONS
MODEL
COUPLER
Tires/Wheels/Lug Nuts
DCA-25SSAI -TRAILER SAFETY GUIDELINES
Tire Wear/Inflation
Suspension
Torque Ft.-Lbs
DCA-25SSAI -TRAILER SAFETY GUIDELINES
Lug Nut Torque Requirements
Table 3. Suspension Torque Requirements
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DCA-25SSAI -TRAILER-WIRING DIAGRAM
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
DCA-25SSAI - GENERATOR DECALS
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DCA-25SSAI - GENERATOR DECALS
Generator Specifications
DCA-25SSAI - SPECIFICATIONS
Engine Specifications
Zig Zag
DCA-25SSAI FAMILIARIZATION Generator
DCA-25SSAI - GENERAL INFORMATION
Engine Operating Panel
Generator Control Panel
Figure 4. Major Components
DCA-25SSAI - MAJOR COMPONENTS
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DCA-25SSAI - DIMENSIONS TOP, SIDE AND FRONT
Figure 5. Dimensions
NOTE PAGE
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DCA-25SSAI - CONTROL PANEL
Figure 6. Control Panel
1. Main Circuit Breaker - This three-pole, 60 amp main breaker is provided to protect the UVW voltage output terminals from overload
DCA-25SSAI - CONTROL PANEL
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DCA-25SSAI - ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
DCA-25SSAI - ENGINE OPERATING PANEL
DCA-25SSAI - OUTPUTTERMINAL PANEL
Connecting Load
120 Volt Receptacle
Circuit Breakers
Legs “O” and Ground are considered Bonded Grounds
DCA-25SSAI - OUTPUTTERMINAL PANEL
Figure 10. Output Terminal Description
Voltage Selector Switch Locking Button
DCA-25SSAI - OUTPUT AMPERAGE SETUP
Output Terminal Panel Available Voltages
Over Current Relay
How To Read The Output Terminal Gauges
DCA-25SSAI - OUTPUT AMPERAGE SETUP
Table 8. Receptacle Use
Receptacle Use
240/120V Hard Wire Hookup
DCA-25SSAI - OUTPUT VOLTAGE SETUP
Single Phase 480V, 440V, or 416 Volt
DCA-25SSAI - OUTPUT VOLTAGE SETUP
3 Phase, 480V, 440V, or 416 Volt
Single Phase 277V, 254V, or
3 Phase, 240V, 220V, or 208 Volt
Single Phase 240V, 220V, or 208 Volt
Single Phase 139V, 127V, or
DCA-25SSAI - OUTPUT VOLTAGE SETUP
Voltage Selector Switch- Single Phase 240/120V Position
DCA-25SSAI - OUTPUT VOLTAGE SETUP
Single Phase 120 Volt
Single Phase, 240 Volt
Mounting
DCA-25SSAI - INSTALLATION
Outdoor Installation
Figure 30. Typical Generator Grounding Application
DCA-25SSAI - INSTALLATION
Table 9. Cable Selection 60 Hz, Single Phase Operation
DCA-25SSAI - PRE-SETUP
#10 Wire
#12 Wire
Lubrication Oil
Table 10. Recommended Motor Oil
DCA-25SSAI - PRE-SETUP
Figure 31. Engine Oil Dipstick
Air Cleaner
Cleaning the Outer Radiator
Adjusting Fan Belt
Fan Belt Tension
Battery Cable Installation
DCA-25SSAI - PRE-SETUP
Wiring
Piping and Hose Connection
DCA-25SSAI - LOAD APPLICATION
Single Phase Load
Three Phase Load
Before Starting Generator and Control Panel
DCA-25SSAI - GENERATOR START-UP PROCEDURE
Before Starting Engine
Figure 38. Voltage Selection Switch
DCA-25SSAI - GENERATOR START-UP PROCEDURE
Figure 41. Ignition Switch ‘START’
Figure 40. Ignition Switch ‘PREHEAT’ Figure 44. Voltage Meter Volts
DCA-25SSAI - GENERATOR START-UP PROCEDURE
ENGINE SHUTDOWN
DCA-25SSAI - GENERATOR SHUTDOWN PROCEDURE
NOTE PAGE
Service Daily
DCA-25SSAI - MAINTENANCE
Cleaning the Fuel Strainer
General Inspection
DCA-25SSAI - MAINTENANCE
Generator Storage
INSPECTION / MAINTENANCE
10 Hrs
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DCA-25SSAI - GENERATORWIRING DIAGRAM
DCA-25SSAI - ENGINEWIRING DIAGRAM
TABLE 14. ENGINE TROUBLESHOOTING
DCA-25SSAI -TROUBLESHOOTING ENGINE
SYMPTOM
POSSIBLE PROBLEM
TABLE 14. ENGINE TROUBLESHOOTING CONTINUED
DCA-25SSAI -TROUBLESHOOTING ENGINE
SYMPTOM
POSSIBLE PROBLEM
TABLE 17. GENERATOR TROUBLESHOOTING
DCA-25SSAI -TROUBLESHOOTING GENERATOR
SYMPTOM
POSSIBLE PROBLEM
NOTE PAGE
EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts book
Items Found In the “Remarks” Column
Items Found In the “Items Number” Column
DCA-25SSAI W/ISUZU C240 DIESEL ENGINE 1 TO 3 UNITS
DCA-25SSAI - SUGGESTED SPARE PARTS
Description
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DCA-25SSAI --- GENERATOR ASSY
GENERATOR ASSY
GENERATOR ASSY
DCA-25SSAI
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DCA-25SSAI --- GENERATOR ASSY
DCA-25SSAI --- GENERATOR ASSY
REMARKS
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DCA-25SSAI --- CONTROL BOX ASSY
CONTROL BOX ASSY
DCA-25SSAI
CONTROL BOX ASSY
REMARKS
CONTROL BOX ASSY
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DCA-25SSAI --- CONTROL BOX ASSY
REMARKS
DCA-25SSAI
CONTROL BOX ASSY
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DCA-25SSAI ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
REMARKS
DCA-25SSAI ENGINE AND RADIATOR ASSY
REPLACES 0602000008 ISUZU C240
REPLACES 0602040069FWG058036
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DCA-25SSAI ENGINE AND RADIATOR ASSY
EARTH CABLE
DCA-25SSAI ENGINE AND RADIATOR ASSY
REMARKS
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DCA-25SSAI --- ENGINE OPERATING PANEL ASSY
ENGINE OPERATING PANEL ASSY
DCA-25SSAI
ENGINE OPERATING PANEL ASSY
REPLACES 060212005225000KX3710
BRACKET, ENGINE STOPPER
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DCA-25SSAI --- ENGINE OPERATING PANEL ASSY
ENGINE OPERATING PANEL ASSY
DCA-25SSAI
REMARKS
SET BOARD, OUTPUT TERMINAL
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DCA-25SSAI --- BATTERY ASSY
BATTERY ASSY
REMARKS
BATTERY ASSY
DCA-25SSAI
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DCA-25SSAI --- MUFFLER ASSY
MUFFLER ASSY
DCA-25SSAI
MUFFLER ASSY
REMARKS
7342311002A
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DCA-25SSAI --- FUEL TANK ASSY
FUEL TANK ASSY
REMARKS
FUEL TANK ASSY
DCA-25SSAI
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DCA-25SSAI --- ENCLOSURE ASSY
ENCLOSURE ASSY
REMARKS
ENCLOSURE ASSY
DCA-25SSAI
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DCA-25SSAI --- ENCLOSURE ASSY
REMARKS
DCA-25SSAI
ENCLOSURE ASSY
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DCA-25SSAI --- DECALS
DECAL ASSY
REMARKS
DECALS
DCA-25SSAI
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ISUZU C240 --- CYLINDER HEAD AND COVER ASSY
CYLINDER HEAD AND COVER ASSY
INLET AND EXHAUST VALVE SEAL
ISUZU C240 --- CYLINDER HEAD AND COVER ASSY
CYLINDER HEAD OIL COOLER PLUG
REMARKS
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ISUZU C240 --- CYLINDER BLOCK ASSY
CYLINDER BLOCK ASSY
REMARKS
ISUZU C240 --- CYLINDER BLOCK ASSY
TAPPET CHAMBER COVER ASSY
TAPPET CHAMBER COVER CLIP
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ISUZU C240 ---TIMING GEAR ASSY
TIMING GEAR ASSY
ISUZU C240 ---TIMING GEAR ASSY
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ISUZU C240 FLYWHEEL HOUSING ASSY
FLYWHEEL HOUSING ASSY
STIFFENER RIGHT SIDE
ISUZU C240 FLYWHEEL HOUSING ASSY
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ISUZU C240 OIL PAN ASSY
OIL PAN ASSY
REMARKS
ISUZU C240 OIL PAN ASSY
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ISUZU C240 ---OIL PUMP ASSY
OIL PUMP ASSY
22*%
ISUZU C240 ---OIL PUMP ASSY
INCL. ITEMS W
INCL. ITEMS W/#
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ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY
CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY
ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY
CONNECTING ROD ASSY
REMARKS
9-1@
OIL AND FUEL FILTER ASSY
ISUZU C240 --- OIL AND FUEL FILTER ASSY
REMARKS
ISUZU C240
OIL AND FUEL FILTER ASSY
OIL PIPE ASSY
ISUZU C240 --- OIL PIPE ASSY
OIL PIPE ASSY
ISUZU C240
WATER PUMP AND FAN ASSY
ISUZU C240 --- WATER PUMP AND FAN ASSY
ISUZU C240 --- WATER PUMP AND FAN ASSY
ADJUSTING FAN BELT PLATE
REMARKS
WATER PUMP ASSY
INTAKE AND EXHAUST MAINIFOLD ASSY
ISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY
INTAKE AND EXHAUST MANIFOLD ASSY
WIRE CONTROL BRACKET
ISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY
AIR CLEANER ASSY
ISUZU C240 --- AIR CLEANER ASSY
AIR CLEANER ASSY
ISUZU C240 --- AIR CLEANER ASSY
AIR CLEANER ASSY
REMARKS
ENGINE FOOT ASSY
ISUZU C240 --- ENGINE FOOT ASSY
ENGINE FOOT ASSY
ISUZU C240 --- ENGINE FOOT ASSY
QTY. REMARKS
INJECTION PUMP ASSY
ISUZU C240 --- INJECTION PUMP ASSY
ISUZU C240
INJECTION PUMP ASSY
REMARKS
INJ. PUMP SPACER BRACKET
ELECTRICAL PARTS
ISUZU C240 --- ELECTRICAL PARTS
ISUZU C240
ELECTRICAL PARTS
REMARKS
ELECTRICAL PARTS
ACCESSORIES
ISUZU C240 --- ACCESSORIES
ISUZU C240
ACCESSORIES
REMARKS
DRIVE ASSY
INJECTION PUMP COMP. ASSY
ISUZU C240 ---INJECTION PUMP COMP. ASSY
REMARKS
ISUZU C240 --- INJECTION PUMP COMP. ASSY
ISUZU C240 --- INJECTION PUMP COMP. ASSY
ISUZU C240 --- INJECTION PUMP COMP. ASSY
ISUZU C240 --- INJECTION PUMP COMP. ASSY
QTY. REMARKS
ISUZU C240 --- INJECTION PUMP COMP. ASSY
GOVERNOR COMP. ASSY
ISUZU C240 ---GOVERNOR COMP. ASSY
REMARKS
GOVERNOR COMP. ASSY
ISUZU C240
ISUZU C240 --- GOVERNOR COMP. ASSY
REMARKS
GOVERNOR COMP. ASSY
ISUZU C240
FEED PUMP COMP. ASSY
ISUZU C240 --- FEED PUMP COMP. ASSY
REMARKS
FEED PUMP COMP. ASSY
ISUZU C240
AUTO TIMER COMP. ASSY
ISUZU C240 --- AUTO TIMER COMP. ASSY
REMARKS
ISUZU C240 --- AUTO TIMER COMP. ASSY
NOZZLE HOLDER COMP. ASSY
ISUZU C240 --- NOZZLE HOLDER COMP. ASSY
PUSH ROD
ISUZU C240 --- NOZZLE HOLDER COMP. ASSY
REMARKS
STARTER COMP. ASSY
ISUZU C240 ---STARTER COMP. ASSY
MAGNETIC SWITCH ASSY
STARTER COMP. ASSY
ISUZU C240
REMARKS
ALTERNATOR COMP. ASSY. OCT. 1992~
ISUZU C240 --- ALTERNATOR COMP. ASSY
ISUZU C240
ALTERNATOR COMP. ASSY
REMARKS
10*#%
ALTERNATOR COMP. ASSY. BEFORE OCT
ISUZU C240 ---ALTERNATOR COMP. ASSY
ALTERNATOR COMP. ASSY
ISUZU C240
REMARKS
27*#
TERMS AND CONDITIONS OF SALE - PARTS
Effective July 1
11. Credit issued will be applied to future purchases only
SPECIAL EXPEDITING SERVICE
NOTE PAGE
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
HERES HOW TO GET HELP
SERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046
WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046