OPERATION AND PARTS MANUAL
Standard
MODEL DCA25SSIU
WHISPERWATT GENERATOR
Page
Page
MQ POWER DCA-25SSIUAC GENERATOR
TABLE OF CONTENTS
ISUZU C240 ENGINE
PARTS ORDERING PROCEDURES
Order
When ordering parts, please supply
Ordering parts has never been easier
GENERAL SAFETY
RULES FOR SAFE OPERATION
RULES FOR SAFE OPERATION
Fluid Plugs
RULES FOR SAFE OPERATION
Battery
Loading and Unloading Crane
Maintenance Safety
Transporting
Emergencies
RULES FOR SAFE OPERATION
Towing Safety Precautions
DCA-25SSIU -TOWINGRULES FOR SAFE OPERATION
DCA-25SSIU- TRAILER-SAFETYGUIDELINES
Explanation of Chart
DCA-25SSIU —TRAILER-SPECIFICATIONS
Table 1. Specifications
MODEL
APPLICATION
DCA-25SSIU —TRAILER-SPECIFICATIONS
Table 1. Specifications Cont
MODEL
COUPLER
DCA-25SSIU —TRAILERSAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tire Wear/Inflation
Suspension
DCA-25SSIU —TRAILERSAFETY GUIDELINES
Item
Torque Ft.-Lbs
Lug Nut Torque Requirements
DCA-25SSIU —TRAILER-WIRINGDIAGRAM
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
DCA-25SSIU— GENERATOR DECALS
DCA-25SSIU— GENERATOR DECALS
DCA-25SSIU— SPECIFICATIONS
Generator Specifications
Engine Specifications
Zig Zag
DCA-25SSIU— GENERAL INFORMATION
DCA-25SSIUFAMILIARIZATION Generator
Engine Operating Panel
Generator Control Panel
DCA-25SSIU— MAJOR COMPONENTS
Figure 4. Major Components
DCA-25SSIU— DIMENSIONS TOP, SIDE AND FRONT
Figure 5. Dimensions
NOTE PAGE
DCA-25SSIU- CONTROL PANEL
Figure 6. Control Panel
DCA-25SSIU— CONTROL PANEL
1.Main Circuit Breaker – This three-pole,60 Amp main breaker is provided to protect the UNV voltage output terminals from overload
DCA-25SSIU— ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
DCA-25SSIU- ENGINE OPERATING PANEL
Connecting Load
DCA-25SSIU— OUTPUTTERMINAL PANEL
120 Volt Receptacle
Circuit Breakers
Figure 10. Output Terminal Description
DCA-25SSIU— OUTPUTTERMINAL PANEL
Legs “O” and Ground are considered Bonded Grounds
DCA-25SSIU— OUTPUT AMPERAGE SETUP
Voltage Selector Switch Locking Button
Output Terminal Panel Available Voltages
Over Current Relay
DCA-25SSIU— OUTPUT AMPERAGE SETUP
How To Read The Output Terminal Gauges
Table 8. Receptacle Use
Receptacle Use
DCA-25SSIU— OUTPUT VOLTAGE SETUP
240/120V Hard Wire Hookup
DCA-25SSIU— OUTPUT VOLTAGE SETUP
Single Phase: 480V, 440V, or 416 Volt
3 Phase, 480V, 440V, or 416 Volt
Single Phase: 277V, 254V, or
DCA-25SSIU— OUTPUTVOLTAGE SETUP
Single Phase: 240V, 220V, or 208 Volt
3 Phase, 240V, 220V, or 208 Volt
Single Phase: 139V, 127V, or
DCA-25SSIU— OUTPUTVOLTAGE SETUP
Single Phase: 120 Volt
Single Phase, 240 Volt
Position
Outdoor Installation
DCA-25SSIU— INSTALLATION
Mounting
DCA-25SSIU— INSTALLATION
DCA-25SSIU— PRE-SETUP
#10 Wire
#12 Wire
General Inspection Prior to Operation
Ambient Temperature Range
Table 10. Recommended Motor Oil
Lubrication Oil
Type Oil
Cleaning the Outer Radiator
Air Cleaner
Adjusting Fan Belt
Fan Belt Tension
DCA-25SSIU— PRE-SETUP
Battery Cable Installation
Wiring
Piping and Hose Connection
Three Phase Load
Single Phase Load
DCA-25SSIU- LOAD APPLICATION
Before Starting Engine
DCA-25SSIU— GENERATOR START-UPPROCEDURE
Before Starting Generator and Control Panel
DCA-25SSIU— GENERATOR START-UPPROCEDURE
DCA-25SSIU— GENERATOR START-UPPROCEDURE
DCA-25SSIU— GENERATOR SHUTDOWN PROCEDURE
ENGINE SHUTDOWN
NOTE PAGE
DCA-25SSIU— MAINTENANCE
Service Daily
Cleaning the Fuel Strainer
General Inspection
INSPECTION / MAINTENANCE
Generator Storage
DCA-25SSIU— MAINTENANCE
Check Air Cleaner
DCA-25SSIU— GENERATORWIRING DIAGRAM
DCA-25SSIU— ENGINEWIRING DIAGRAM
DCA-25SSIU —TROUBLESHOOTINGENGINE
TABLE 14. ENGINE TROUBLESHOOTING
SYMPTOM
SOLUTION
DCA-25SSIU —TROUBLESHOOTINGENGINE
TABLE 14. ENGINE TROUBLESHOOTING CONTINUED
SYMPTOM
POSSIBLE PROBLEM
DCA-25SSIU —TROUBLESHOOTINGGENERATOR/ENGINE
TABLE 15. GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
NOTE PAGE
EXPLANATION OF CODE IN REMARKS COLUMN
SAMPLE PARTS LIST
QTY. Column
NO. Column
Description
DCA-25SSIU— SUGGESTED SPARE PARTS
DCA-25SSIUW/ISUZUC240 DIESEL ENGINE 1 TO 3 UNITS
DCA-25SSIU ---GENERATOR ASSY
GENERATOR ASSY
DCA-25SSIU
GENERATOR ASSY
PART NO
ITEM
DCA-25SSIU ---CONTROL BOX ASSY
CONTROL BOX ASSY
CONTROL BOX ASSY
REMARKS
DCA-25SSIU
PART NO
DCA-25SSIU ---CONTROL BOX ASSY
DCA-25SSIU
CONTROL BOX ASSY
PART NO
ITEM
DCA-25SSIUENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
DCA-25SSIUENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
PART NO
ITEM
DCA-25SSIUENGINE AND RADIATOR ASSY
DCA-25SSIUENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
PART NO
ITEM
DCA-25SSIU ---ENGINE OPERATING PANEL ASSY
ENGINE OPERATING PANEL ASSY
ENGINE OPERATING PANEL ASSY
DCA-25SSIU
DCA-25SSIU ---OUTPUTTERMINAL ASSY
OUTPUT TERMINAL ASSY
OUTPUTTERMINAL ASSY
DCA-25SSIU
PART NO
ITEM
DCA-25SSIU ---BATTERY ASSY
BATTERY ASSY S/N7100001 TO S/N7100051~
BATTERY ASSY
DCA-25SSIU
PART NO
REMARKS
MUFFLER ASSY
DCA-25SSIU ---MUFFLER ASSY
S/N7100001 TO S/N7105049 S/N7105050~
MUFFLER ASSY
DCA-25SSIU
PART NO
ITEM
DCA-25SSIU ---FUELTANK ASSY
FUEL TANK ASSY
FUELTANK ASSY
DCA-25SSIU
PART NO
ITEM
DCA-25SSIU ---ENCLOSURE ASSY
ENCLOSURE ASSY
6 -CATERPILLARYELLOW
THE SERIAL NUMBER MAY BE REQUIRED
DCA-25SSIU
ENCLOSURE ASSY
PART NO
ITEM
6 -CATERPILLARYELLOW
DCA-25SSIU ---ENCLOSURE ASSY
THE SERIAL NUMBER MAY BE REQUIRED
DCA-25SSIU
ENCLOSURE ASSY
PART NO
ITEM
DCA-25SSIU ---RUBBER SEAL ASSY
RUBBER SEAL ASSY S/N7100001 TO S/N7101590~
DCA-25SSIU
RUBBER SEAL ASSY
PART NO
ITEM
DCA-25SSIU ---DECALS
DECAL ASSY
DECALS
DCA-25SSIU
PART NO
REMARKS
ISUZU C240 ---CYLINDER HEAD AND COVER ASSY
CYLINDER HEAD AND COVER ASSY
ISUZU C240 ---CYLINDER HEAD AND COVER ASSY
CYLINDER HEAD AND COVER ASSY
PART NO
ITEM
ISUZU C240 ---CYLINDER BLOCK ASSY
CYLINDER BLOCK ASSY
ISUZU C240 ---CYLINDER BLOCK ASSY
PART NO
ITEM
REMARKS
ISUZU C240 ---TIMINGGEAR ASSY
TIMING GEAR ASSY
PART NO
ISUZU C240 ---TIMINGGEAR ASSY
ITEM
ISUZU C240 FLYWHEEL HOUSING ASSY
FLYWHEEL HOUSING ASSY
ISUZU C240 FLYWHEEL HOUSING ASSY
FLYWHEEL HOUSING ASSY
PART NO
ITEM
ISUZU C240 OIL PAN ASSY
OIL PAN ASSY
ISUZU C240 OIL PAN ASSY
PART NO
ITEM
REMARKS
ISUZU C240 ---OILPUMP ASSY
OIL PUMP ASSY
ISUZU C240 ---OILPUMP ASSY
OIL PUMP ASSY
CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY
CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY
PART NO
ITEM
REMARKS
ISUZU C240 ---OIL AND FUEL FILTER ASSY
OIL AND FUEL FILTER ASSY
ISUZU C240
OIL AND FUEL FILTER ASSY
PART NO
ITEM
ISUZU C240 ---OIL PIPE ASSY
OIL PIPE ASSY
OIL PIPE ASSY
ISUZUC240
PART NO
ISUZU C240 ---WATER PUMP AND FAN ASSY
WATER PUMP AND FAN ASSY
ISUZU C240 ---WATER PUMP AND FAN ASSY
WATER PUMP AND FAN ASSY
PART NO
ITEM
ISUZU C240 ---INTAKE AND EXHAUST MANIFOLD ASSY
INTAKE AND EXHAUST MAINIFOLD ASSY
ISUZU C240 ---INTAKE AND EXHAUST MANIFOLD ASSY
INTAKE AND EXHAUST MANIFOLD ASSY
PART NO
ITEM
ISUZU C240 ---AIR CLEANER ASSY
AIR CLEANER ASSY
ISUZU C240 ---AIR CLEANER ASSY
PART NO
ITEM
REMARKS
ISUZU C240 ---ENGINE FOOT ASSY
ENGINE FOOT ASSY
QTY. REMARKS
ISUZU C240 ---ENGINE FOOT ASSY
PART NO
ISUZU C240 ---INJECTION PUMP ASSY
INJECTION PUMP ASSY
ISUZU C240 ---INJECTION PUMP ASSY
INJECTION PUMP ASSY
PART NO
ITEM
ISUZU C240 ---ELECTRICAL PARTS
ELECTRICAL PARTS
ELECTRICAL PARTS
ISUZU C240
PART NO
ITEM
ISUZU C240 ---ACCESSORIES
ACCESSORIES
ACCESSORIES
ISUZU C240
PART NO
ITEM
ISUZU C240 ---INJECTIONPUMP COMP. ASSY
INJECTION PUMP COMP. ASSY
ITEM
ISUZU C240 ---INJECTION PUMP COMP. ASSY
REMARKS
ISUZU C240 ---INJECTION PUMP COMP. ASSY
INJECTION PUMP COMP. ASSY
ISUZU C240 ---INJECTION PUMP COMP. ASSY
ITEM
ISUZU C240 ---INJECTION PUMP COMP. ASSY
ISUZU C240 ---INJECTION PUMP COMP. ASSY
INJECTION PUMP COMP. ASSY
PART NO
ITEM
ISUZU C240 ---GOVERNORCOMP. ASSY
GOVERNOR COMP. ASSY
ISUZUC240
GOVERNOR COMP. ASSY
PART NO
ITEM
ISUZU C240 ---GOVERNOR COMP. ASSY
GOVERNOR COMP. ASSY
ISUZUC240
PART NO
ITEM
ISUZU C240 ---FEED PUMP COMP. ASSY
FEED PUMP COMP. ASSY
FEED PUMP COMP. ASSY
ISUZUC240
PART NO
ITEM
ISUZU C240 ---AUTOTIMER COMP. ASSY
AUTO TIMER COMP. ASSY
ISUZU C240 ---AUTOTIMER COMP. ASSY
AUTO TIMER COMP. ASSY
PART NO
ITEM
ISUZU C240 ---NOZZLE HOLDER COMP. ASSY
NOZZLE HOLDER COMP. ASSY
NOZZLE HOLDER COMP. ASSY
ISUZU C240
PART NO
REMARKS
ISUZU C240 ---STARTERCOMP. ASSY
STARTER COMP. ASSY
STARTER COMP. ASSY
ISUZUC240
PART NO
ITEM
ISUZU C240 ---ALTERNATOR COMP. ASSY
ALTERNATOR COMP. ASSY. OCT. 1992~
ALTERNATOR COMP. ASSY
ISUZUC240
PART NO
ITEM
ISUZU C240 ---ALTERNATORCOMP. ASSY
ALTERNATOR COMP. ASSY. BEFORE OCT.
ISUZUC240
ALTERNATOR COMP. ASSY
PART NO
ITEM
TERMS AND CONDITIONS OF SALE — PARTS
SPECIAL EXPEDITING SERVICE
PAYMENT TERMS
FREIGHT POLICY
NOTES
HERE’S HOW TO GET HELP
NUMBER ON-HANDWHEN CALLING
Service Department
Warranty Department