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