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