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