Multiquip DCA-25SSIU2 User Manual 2

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

MODEL DCA-25SSIU2

60 Hz GENERATOR

PARTS LIST NO. M1870300804

Revision #0 (01/27/06)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

This manual should remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the design or the information published in this publication at any time without notice and without incurring any obligations.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and

DCA-25SSIU2 (60 HZ)Whisperwatt™ Generator

. Multiquip Inc. reserves the right to discontinue or change specifications,

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 3

TABLE OF CONTENTS

MQ POWER DCA-25SSIU2 (60 HZ)MQ POWER DCA-25SSIU2 (60 HZ)

MQ POWER DCA-25SSIU2 (60 HZ)

MQ POWER DCA-25SSIU2 (60 HZ)MQ POWER DCA-25SSIU2 (60 HZ)

WHISPERWHISPER

WHISPER

WHISPERWHISPER

California Proposition 65 Warning ..................................... 2

Here's How To Get Help ....................................................3

Table Of Contents ............................................................. 4

Parts Ordering Procedures ............................................... 5

Specifications ................................................................... 6

Dimensions ( Side, Front) .................................................7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals....................................................... 14-15

Installation ................................................................. 16-17

General Information ........................................................ 18

Major Components ......................................................... 19

Generator Control Panel ................................................. 20

Engine Operating Panel .................................................. 21

Output Terminal Panel Familiarization ........................ 22-24

Load Application ............................................................. 25

Generator Outputs .......................................................... 26

Gauge Reading ............................................................... 27

Output Terminal Panel Connections ........................... 28-29

Pre Setup .................................................................. 30-33

Generator Start-up Procedure ................................... 34-36

Generator Shut-Down Procedure .................................... 36

Maintenance .............................................................. 37-38

Trailer Maintenance .................................................... 39-42

Trailer Wiring Diagram .....................................................43

Generator Wiring Diagram ............................................... 44

Engine Wiring Diagram ................................................... 45

Generator Troubleshooting .............................................. 46

Engine Troubleshooting ............................................. 47-48

Explanation of Code in Remarks Column ....................... 50

Suggested Spare Parts .................................................. 51

TT™ GENERATT™ GENERA

TT™ GENERA

TT™ GENERATT™ GENERA

TORTOR

TOR

TORTOR

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly ............................................ 52-53

Control Box Assembly.......................................... 54-57

Engine Operating Panel Assembly...................... 58-59

Engine & Radiator Assembly ............................... 60-63

Output Terminal Assy. .......................................... 64-65

Battery Assembly ................................................. 66-67

Muffler Assembly ................................................. 68-69

Fuel Tank Assembly ............................................. 70-71

Enclosure Assembly ............................................ 72-75

Rubber Seal Assembly ........................................ 72-73

Name Plate And Decals ....................................... 74-75

Rubber Seal Assembly ........................................ 76-77

Nameplate and Decals ........................................ 78-79

Terms and Condition of Sale — Parts ...................... 80

NOTE

Specification and part number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ Dealer account number

❒❒ ❒❒

❒ Dealer name and address

❒❒ ❒❒

❒ Shipping address (if different than billing address)

❒❒ ❒❒

❒ Return fax number

❒❒ ❒❒

❒ Applicable model number

❒❒ ❒❒

❒ Quantity, part number and description of each part

❒❒ ❒❒

❒ Specify preferred method of shipment:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u c k

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

EXT. EXT.

279 279

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other carrier. **Common nuts, bolts and washers (all items under $1.00

list price) do not count towards the 10+ line items.

at no charge for freight

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-MAIL: mqpower@multiquip.com INTERNET: www.mqpower.com

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

DCA-25SSIU2 (60 HZ)— SPECIFICATIONS

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)WK02(AVK52WK4.41

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8.01

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snoitacificepSenignE.2elbaT

ledoM2EL4-AAUZUSI

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)sretil5.8(.lag42.2

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)mm69xmm58(.ni87.3x.ni53.3

1X)A525F°0ACC(72

PAGE 6 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— DIMENSIONS (TOP, SIDE AND FRONT)

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm076(.ni73.62F ).mm058,1(.ni38.27

B).mm53

C).mm535(.ni60.12H ).mm057(.ni25.92

D).mm516(.ni12.42

E).mm535(.ni60.12

Figure 1. Dimensions

6(.ni00.52G ).mm000,1(.ni73.93

).mm(.tfnoisnemiDretteLecnerefeR).mm(.tfnoisnemiD

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 7

DCA-25SSIU2 (60 HZ) — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others.

This

NOTE

Operation and Parts

has been developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA-25SSIU2

Manual

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " appear throughout this manual, and will be referenced in conjunction with Safety "

WARNING - LETHAL EXHAUST GASES

(60Hz) Whisperwatt™ Generator.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

equipment in a confined area or enclosed structure that does not provide ample free flow air.

WARNING - EXPLOSIVE FUEL

DO NOT overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

Hazard Symbols

Message Alert Symbols

Diesel engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

Diesel fuel

its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.

is extremely flammable, and

" which

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

PAGE 8 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

electrical shock or burn, severe bodily harm

electrocution,

which can cause

or even

DEATH!

DCA-25SSIU2 (60 HZ) — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the Engine ON/OFF

switch in the OFF position and remove the ignition key when the pump is not in use.

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings

of the engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

This generator, other property, or

NOTE

the surrounding environment could be damaged if you do not follow instructions.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 9

DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the DCA-25SSIU2 (60 HZ) Generator:

General Safety:

■

DO NOT operate or service this equipment before reading this entire manual.

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

or even

DEATH

! This equipment is to be

ALWAYS check the machine for loosened threads or bolts before starting.

■

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

■

High Temperatures – Allow the engine to cool before performing service and maintenance functions. Contact with

hot!

components can cause serious

burns.

■

The engine of this generator requires an adequate free flow of cooling air. enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

bodily harm or even death.

NEVER

operate the generator in any

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

NEVER run engine without air filter. Severe engine damage may occur.

DO NOT leave the generator running in the unattended.

Refer to the technical questions or information.

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

Isuzu Engine Owner's Manual

manual mode

for engine

PAGE 10 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION

Generator Grounding

DANGER - ELECTROCUTION HAZARDS

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

During operation of this generator, there exists the possibility of

electrical shock or burn,

Article 250 (Grounding) of the

National Electrical Code

severe bodily harm

(NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

The following safety recommendations should also be followed:

To avoid these hazards: NEVER use damaged or worn cables when connecting

equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

DEATH!

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

ungrounded generator.

■

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

and electrical shock. NEVER grab or touch a live power

cord with wet hands. NEVER touch output terminals

during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

electrocution,

which can cause

or even

DEATH!

POWER

CORD

(POWER ON)

WET

HANDS

Electrical Safety

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

ALWAYS make sure generator installation is accordance with the

National Electrical Code

(NEC) and local codes

before operating generator.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been selected for the job. See Table 6.

■

NEVER power cables or cords

■

NEVER

stand in water

while AC power from the generator

lay in wate

is being transfer to a load.

Backfeed to a utility system can cause

electrocution

and or property damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened. ALWAYS have a licensed electrician perform the installation

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 11

DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION

Maintenance Safety

■

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn all circuit breakers OFF before performing maintenance on the generator.

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the before performing service on the generator.

■

Follow all Battery Safety Guidelines listed in this manual when handling or servicing the generator.

■

ALWAYS allow the machine a proper amount of time to cool before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace broken parts.

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

WARNING - BURN HAZARDS

To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

■

Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

NEGATIVE battery terminal

Battery Safety

Use the following guidelines when handling the battery:

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, glasses.

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid

■■

DO NOT drop the battery. There

■

■■

is the possibility of risk that the battery may explode.

■■

■

DO NOT expose the battery to

■■

open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.

ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables.

ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.

In case the battery liquid (dilute sulfuric acid) comes in contact with immediately with plenty of water.

In case the battery liquid (dilute sulfuric acid) comes in contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

always

wear safety

severe injury

clothing or skin

EYES

, rinse skin or clothing

, rinse eyes immediately with

DEATH:

■

Engine Oil Drain Plug - Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

PAGE 12 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION

■

Towing & Transporting Safety

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed guidelines for basic towing techniques.

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”

■

ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Emergencies

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle properly.

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■

DOT Requirements include the following:

 

Trailer tires should be inflated to 50 psi cold.

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 13

■

ALWAYS know the location of the nearest

ALWAYS know the location of the nearest and

ALWAYS know the location of the nearest phone or

the job site,

ALWAYS have easy access to the phone

numbers of the nearest and be invaluable in the case of an emergency.

fire extinguisher

first aid kit

keep a phone on

in case of emergencies.

Fire Department

Ambulance, Doctor

. This information will

DCA-25SSIU2 (60 HZ)— GENERATOR DECALS

The

DCA-25SSIU2 (60 Hz) Whisperwatt™ Generator

decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

is equipped with a number of safety decals (Figures 2 & 3). These

Figure 2. Generator Decals

PAGE 14 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— GENERATOR DECALS

Figure 3. Generator Decals (Continued)

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 15

DCA-25SSIU2 (60 HZ)— INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 16 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— INSTALLATION

Outdoor Installation

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION - EXHAUST HAZARD

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

Indoor Installation

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground. See Figure 4 for a typical grounding configuration.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger. b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 5) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground rod should be buried aminimum of 8 ft. into the ground.

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

NOTE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 17

DCA-25SSIU2 (60 HZ)— GENERAL INFORMATION

DCA-25SSIU2 (60 Hz) Series Familiarization Generator

The MQ Power Model DCA-25SSIU2 (60 Hz) is a 20 kW generator (Figure 5) that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:

■■

■

Tachometer

■■

■

Water Temperature Gauge

■■

Water Temperature Alarm Lamp

■

■■

■

Oil Pressure Gauge

■■

■

Oil Pressure Alarm Lamp

■■

■

Charging Ammeter Gauge

■■

■

Fuel Level Gauge

■■

■

Pre-heat Lamp

■■

■

Panel Light/Panel Light Switch

■■

■

Ignition Switch

■■

■

Fuel Filter Water Level Alarm Lamp

■■

Open Delta Excitation System

The DCA-25SSIU2 (60 HZ) generator is equipped with the state of the art " delta system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The

Generator Control Panel

The “Generator Control Panel” is provided with the following:

excitation does not have a " according the demands of the required load.

Open-Delta

" excitation system. The open

fixed ceiling

" and responds

■■

■

Frequency Meter (Hz)

■■

■

AC Ammeter (Amps)

■■

■

AC Voltmeter (Volts)

■■

■

Ammeter Change-Over Switch

■■

■

Voltmeter Change-Over Switch

■■

■

Voltage Regulator

■■

■

3-Pole, 60 amp Main Circuit Breaker

■■

■

“Control Box” (located behind the Gen. Control Panel)

■■

■

Automatic Voltage Regulator

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifier

■■

■

Starter Relay

■■

■

Voltage Selector Switch

■■

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

■■

■

Two 120/240V output receptacles (CS-6369), 50A

■■

■

Two auxiliary circuit breakers, 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Five output terminal lugs (3Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

PAGE 18 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— MAJOR COMPONENTS

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DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 19

Figure 5. Major Components

DCA-25SSIU2 (60 HZ)— GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel

The definitions below describe the controls and functions of the

DCA-25SSIU2 (60 HZ) Generator Control Panel

(Figure 6).

1. Main Circuit Breaker – This three-pole, 60A main breaker is provided to protect the

Terminal Lugs

from overload.

U,V, and W Output

2. Voltage Regulator Control – Allows ±15% manual

adjustment of the generator’s output voltage

3. Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz.

4. AC Ammeter – Indicates the amount of current the load

Located behind the generator control panel is the

Control Box

electronic components required to make the generator function.

The Control Box is equipped with the following major components:

■■

■

Over-Current Relay

■■

■

Voltage Rectifier (AVR)

■■

■

Starter Relay

■■

■

Current Transformer

■■

■

Voltage Selector Switch

■■

is drawing from the generator per leg selected by the ammeter phase-selector switch.

5. AC Voltmeter – Indicates the output voltage present at the

U,V, and W Output Terminal Lugs

NOTE

6. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

7. Voltmeter Change-Over Switch – This switch allows

In the event of a short circuit or over current condition, it will automatically trip the 60 amp main breaker.

To restore power to the

reset

button on the overcurrent relay and place the

circuit breaker in the

the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

overcurrent

U,V, and W

to the

load.

Output Terminal Panel

, press the

main

closed

position (ON).

PAGE 20 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

The definitions below describe the controls and functions of the DCA-25SSIU2 (60 HZ) " (Figure 7).

1. Panel Light - Normally used in dark places or at night. When activated, panel will illuminate. When the generator is not in use, turn the panel light switch to the ‘OFF’ position.

2. Panel Light Switch- When activated, will turn on control panel light.

3. Oil Pressure Alarm Lamp - Indicates that the oil pressure is too low or high and will shut down the engine.

4. Water Temperature Alarm Lamp - Indicates that the water temperature is outside of normal range and will shut down the engine.

5. Fuel Filter Water Lever Alarm Lamp - Indicates that water level in the fuel level has risen. Drain the water in the fuel filter strainer when this condition occurs.

6. Ignition Switch – Three position switch, stop, operation and start. Insert ignition key to start and stop engine.

Engine Operating Panel

7. Pre-heat Lamp - This indicates when the engine is

ready for starting during cold weather operating conditions.

8. Tachometer – Indicates engine speed in RPM’s for 50 Hz operation. This meter should indicate 1500 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

9. Fuel Gauge - Indicates amount of diesel fuel available.

10. Charging Ammeter Gauge – Indicates the current

being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

11. Water Temperature Gauge – During normal operation this gauge be should read between 165o F to 203o F.

12. Oil Pressure Gauge – Normal operation should be between 28 ~71 psi (193 ~490 kPa). When starting the generator the oil pressure may read a bit higher, but after the engine warms up the oil pressure should return to normal.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 21

DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The

Output Terminal Panel

(Figure 8) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal

Output Terminal Familiarization

The “

Output Terminal Panel

following:

■■

■

120/240V output receptacles (2) @ 50 amp

■■

lugs.

■■

■

Circuit Breakers (2) @ 50 amps, 2-pole

■■

120V GFCI receptacles (2) @ 20 amp

■

■■

GFCI Circuit Breaker (2) @ 20 amps, 1-pole

■

■■

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

■

■■

NOTE

Terminal legs “O” and “Ground”

are considered

bonded grounds

” (Figure 9) is provided with the

Figure 8. Output Terminal Panel

PAGE 22 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL PANEL FAMILIARIZATION

Figure 11. Voltage Regulator Control Knob

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three

Figure 9. G.F.C.I. Receptacle

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the being tripped. Pressing the the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

(See Figure 9) in

receptacles is dependent on the load requirements of the

Output Terminal Lugs

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The plate cover (Figure 12). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.

voltage regulator control knob

increase

decrease

Output Terminal Lugs

(Figure 11) on the

the voltage, turning the knob counter-

the voltage.

are protected by a plastic face

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are two 120/240V, 50 amp auxiliary twist-lock (CS-6369) receptacles (Figure 10) provided on the output terminal panel. These receptacles can when the voltage selector switch is placed in the

phase 240/120 position.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 23

only

be accessed

single-

DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

Terminal Lugs

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 60A switch ALL circuit breakers to the OFF position prior to starting the engine.

or the convenience receptacles (Figure 13).

main

circuit breaker is provided. Make sure to

Output

Blower Fan

This unit has an intake fan located at the rear of the machine to draw outside air into the cabinet to cool the engine. The fan has a 10 amp AC fuse located beneath the

Selector Switch

Voltage

(Figure 15).

Figure 15. Blower Fan Fuse

Figure 13. Connecting Loads

Figure 14. Over Current Relay

Over Current Relay

over current relay

circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the rent relay must be pressed. The over current relay is located in the control box.

(Figure 14) is connected to the main

reset button

on the over cur-

DANGER - ELECTROCUTION HAZARDS

This fuse has current running through it any time the engine is running. This fuse is NOT connected to the main circuit breaker of the generator. Attempting to replace the fuse with the engine and/or generator operating could result in

bodily harm

completely off before attempting to replace or handle this fuse.

electrocution

. ALWAYS turn the unit

and

severe

PAGE 24 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage,

frequency

Three Phase Load

When calculating the power requirements for 3-phase power use the following equation:

, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130— 150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and

NOTE

starting system of the equipment.

If wattage is not given on the equipment's name plate,

NOTE

approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

NOTE

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 5 below when connecting loads.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out

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If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

Motors and motor-driven equipment draw much greater current for starting than during operation.

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■■

■

When connecting a resistance load such as an

■■

incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

■■

■

When connecting a fluorescent or mercury lamp, a

■■

capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

■■

■

When connecting an electric drill or other power tools,

■■

pay close attention to the required starting current capacity.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

(transfer) switch

licensed electrician

must install an

. Serious damage to the building’s

isolation

electrical system may occur without this transfer switch.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 25

DCA-25SSIU2 (60 HZ)— GENERATOR OUTPUTS

Voltage Selector Switch

voltage selector

The

switch (Figure 16) is located above

the output terminal panel’s

Hard Wire Hook-up Panel

Generator Amperage

Table 8 describes the generator’s current output capability

. It

for both 1Ø-phase and 3Ø phase applications.

has been provided for ease of voltage selection.

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles.

Tables 9 and 10 show what amount of current is available at

Figure 16. Voltage Selector Switch

the GFCI receptacles when the output terminals and twist lock receptacles are in use. Be careful that your load does

Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect

not to exceed the available current capability at the receptacles.

the generator and load from being switched while the engine is running. To lock the voltage selector switch,

hold

the

red button

located at the bottom of the switch.

press

and

CAUTION - CHANGING VOLTAGES

NEVER change the position of the

voltage selector switch

while the engine is running. ALWAYS place circuit breaker in the open position before selecting voltage.

Generator Output Voltages

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A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the

voltage selector

switch (Figure 16). To obtain some of the voltages as listed in Table 7 (see below) will require a fine adjustment using the

knob

located on the control panel.

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PAGE 26 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

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DCA-25SSIU2 (60 HZ)— GAUGE READING

How to Read the Output Terminal Gauges.

The gauges and selector switches on the control panel DO NOT effect the generator output. They are provided to help observe how much power is being supplied at the

Output terminals lugs

Before taking a reading off either gauge, set the

Selector Switch

the required voltage (For example, for 3Ø 240V, choose the center 3Ø 240/ 139V position on the voltage selector switch.)

Figure 17. Voltage

Selector Switch 240/

139V Three Phase

Position

Voltage

(Figure 17) to the position which produces

Reading Amperage

To determine the amperage at a terminal lug, set the

AC Ammeter Change-Over Switch

setting (Figure 20) to activate the (Figure 21) and read the available amperage at the terminal lug.

For example, to measure the amperage at the U terminal lug, set the U and read the AC Ammeter Gauge.

Figure 20. AC Ammeter

Change-Over Switch

to the appropriate

AC Ammeter Gauge

AC Ammeter Change-Over Switch

Figure 21. AC Ammeter (Amp reading on U lug)

For 3Ø 208V/1Ø,120V, place

NOTE

Reading Voltage

To determine the voltage between two terminal lugs, set the

AC Voltmeter Change-Over Switch

setting (Figure 18) to activate the (Figure 19) and read the available voltage between the two lugs.

For example, to measure the voltage between the W and U terminal lugs, set the to W-U and read the

AC Voltmeter Change-Over Switch

AC Voltmeter Gauge

the Voltage Selector Switch in the 3 Phase 240/139 position.

to the appropriate

AC Voltmeter Gauge

NOTE

The

ammeter

show a reading when the

Output Terminal Lugs

connected to a load and in use.

gauge will only

are

Figure 18. AC Voltmeter

Change-Over Switch

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 27

Figure 19. AC Voltmeter Gauge

DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the

Terminal Lugs

dent on the position of the adjustment of the

Remember the voltage selector switch determines the of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240/139 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139

position as shown in (Figure 22).

.. The voltages at the terminals are depen-

Voltage Selector Switch

Voltage Regulator Control Knob

Output

and the

range

3Ø 208V/1Ø120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 25.

2. Connect the load wires to the shown in Figure 26.

Use this position for 3Ø-208 or 1Ø120V.

Figure 25. Voltage

Selector Switch 240/139V

Three-Phase Position

Output Terminal Lugs

Figure 22. Voltage Selector Switch 240/139V

Three-Phase Position

2. Connect the load wires to the shown in (Figure 23).

Figure 23. Output Terminal Lugs

3Ø-240/139 Three Phase Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Output Terminal Lugs

Figure 26. Output Terminal Lugs

3Ø-208/120V Connections

3. Turn the voltage regulator knob (Figure 25) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

To achieve a 3Ø 208V output the voltage selector switch

NOTE

must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to 208V.

Figure 24. Voltage Regulator Knob (139V/240V)

PAGE 28 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL PANEL CONNECTIONS

3Ø 480/277 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 27.

Figure 27. Voltage Selector Switch 480/277V

Three-Phase Position

2. Connect the load wires to the shown in Figure 28.

Output Terminal Lugs

1Ø 240V/120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 29.

Figure 29. Voltage Selector Switch 240/120V

2. Connect the load wires to the shown in (Figure 30).

Single-Phase Position

Output Terminal Lugs

Figure 28. Output Terminal Lugs

3Ø-480/277V Three Phase Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 29

Figure 30. Output Terminal Lugs

1Ø-240/120V Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

DCA-25SSIU2 (60 HZ)— PRE-SETUP

Circuit Breakers

Fuel Check

To protect the generator from an overload, a 3-pole, 60 amp,

main

circuit breaker is provided to protect the

Output Terminals

20 amp

GFCI

from overload. In addition two single-pole,

circuit breakers are provided to protect the

U,V, and W

GFCI receptacles from overload. Two 50 amp, 2-pole circuit breakers have also been provided to protect the auxiliary

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level, and verify that the oil level is maintained between the two notches (Figure 31) on the dipstick. See Table 11 for proper selection of engine oil.

Refilling the Fuel System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personnel who have read and

understand this section should refill the fuel tank system.

Figure 31. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Isuzu Engine Owner's Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements:

■■

■

API Service Classification CC/SC

■■

■

API Service Classification CC/SD

■■

■

API Service Classification CC/SE

■■

■

API Service Classification CC/SF

■■

Located at the bottom-front of the cabinet (Figure 32) is the internal fuel tank. Some generators may be equipped with a trailer mounted fuel tank (option). tank with clean and fresh tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

hot

engine can cause a

ALWAYS

#2 diesel fuel.

fire

explosion

fill the either fuel

DO NOT fill the fuel

Figure 32. Internal Fuel Tank System

PAGE 30 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— PRE-SETUP

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 33).

CAUTION - REFUELING THE GENERATOR

ALWAYS

to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

place trailer on firm level ground before refueling

2. Remove fuel cap and fill fuel tank as shown in Figure 34.

3. NEVER overfill fuel tank – It is important to read the

Figure 34. Fueling the Generator

fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 35).

Figure 33. Only Fill on Level Ground

NOTE

ONLY! use

refueling.

#2 diesel fuel

when

Figure 35. Full Fuel Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 36).

Figure 36. Fuel Expansion

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 31

DCA-25SSIU2 (60 HZ)— PRE-SETUP

Coolant (Isuzu Antifreeze/Summer Coolant/Water)

Isuzu recommends Isuzu Antifreeze/Summer Coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the Isuzu Engine Owner's Manual for further details.

Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the

negative

WARNING - BURN HAZARDS

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 12 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

hot!

coolant exists which

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the Isuzu Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the Isuzu

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 37) when depressed with the thumb as shown below.

battery terminal disconnected.

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Operation Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

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When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

less than 50%.

Figure 37. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near the belts or fan while the

generator set is running.

PAGE 32 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— PRE-SETUP

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the ignition is in the position.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTE

CAUTION - BATTERY SERVICING SAFETY

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

operate

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

start

ALWAYS be sure the battery cables (Figure 38) are properly connected to the battery terminals as shown below. The Red Cable is connected to the positive terminal of the battery,

and the Black Cable is connected to the negative terminal of the battery.

CAUTION - BATTERY SERVICING SAFETY

ALWAYS

reconnect negative terminal LAST.

disconnect the negative terminal FIRST and

Alternator

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator.

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose ( immediately.

fuel

oil

) lines are defective replace them

Figure 38. Battery Connections

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 33

DCA-25SSIU2 (60 HZ)— GENERATOR START-UP PROCEDURE

Before Starting

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER!

1. Place the

manually start the engine with the

auxiliary

(Figure 39) in the OFF position prior to starting the engine.

circuit breakers in the ON (closed) position.

main, G.F.C.I.,

and

aux.

main, GFCI

circuit breakers

5. Place the position (Figure 41).

6. Preheat the engine

key (Figure 42) to the “OPERATION” position.

voltage selector switch

Figure 41. Voltage

Selector Switch

glow plugs

in the desired voltage

by turning the ignition

Figure 39. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Connect the load to the

Terminal Lugs

connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

3. The output terminal lugs are protected by a plastic cover. Remove this cover to gain access to the terminals. Tighten terminal nuts securely to prevent load wires from slipping out.

4. Close all engine enclosure doors (Figure 40).

as shown in Figure 13. These load

receptacles or

the

Output

7. When the preheat lamp illuminates (Figure 43), turn the

8. Let the engine run for 3-5 minutes, listen and check for

Figure 42. Ignition Switch (Operation

Pre-Heat Position)

ignition key to the “START” position. Once the engine starts, release the ignition key and allow it to return to the “OPERATION” position (Figure 42).

Figure 43. Pre-Heat Indicator Lamp

any abnormal sounds or smells. Check for fuel leaks, and noises that would associate with a loose cover or hardware. If any of the above mentioned conditions exists, shut-down the engine and correct the problem.

Figure 40. Engine Enclosure Doors

PAGE 34 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— GENERATOR START-UP PROCEDURE

9. The generator's frequency meter (Figure 44) displays the 60 cycle output frequency in HERTZ.

Figure 44. Frequency Meter (Hz)

10. The generator's voltage meter (Figure 45) displays the 120 VAC in VOLTS. If the voltage is not within the specified frequency tolerance,

13. The engine oil pressure gauge (Figure 48) will indicate the oil pressure (kg/cm operating conditions the oil pressure is between 28 ~71 psi (193 ~490 kPa).

14. The coolant temperature gauge (Figure 49) will indicate the coolant temperature. Under normal operating conditions the coolant temperature is between 165 and 203 degrees Fahrenheit (74 ~ 95 degrees Celsius).

of the engine. Under normal

Figure 48. Oil Pressure Gauge

Figure 45. AC Voltmeter

11. Use the voltage adjustment control knob (Figure 46) to increase or decrease the desired voltage.

Figure 46. Voltage Adjusted Control Knob

12. The ammeter (Figure 47) will indicate zero amps with no load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator.

15. The tachometer (Figure 50) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 49. Coolant Temperature Gauge

Figure 50. Engine Tachometer

Figure 47. Ammeter (No Load)

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 35

DCA-25SSIU2 (60 HZ)— GEN. START-UP PROCEDURE/SHUTDOWN

16. Turn the “ON” position (Figure 51).

17. Observe the generator's ammeter (Figure 52) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if the load is in use.

main, GFCI

Figure 51. Main, AUX. and GFCI

Circuit Breakers (ON)

, and

aux

. circuit breakers to the

2. Let the engine cool by running it for 3-5 minutes with no load applied (circuit breakers in the off position).

3. Place the ignition switch (Figure 54) in the “STOP” position, remove the key and store in a safe place.

Figure 53. Main, AUX. and GFCI

Circuit Breakers (OFF)

4. Remove

Figure 52. Ammeter (Load)

18. The generator will run until manually stopped or an abnormal condition occurs.

NORMAL SHUT-DOWN

To shutdown the generator, use the following procedure:

1. Switch the MAIN, AUX and GFCI circuit breakers (Figure 53) to the “OFF” position (no load).

EMERGENCY SHUT-DOWN SHUTDOWN

1. To shut-down the engine in the event of an emergency, switch the breakers to “OFF” position.

2. Turn the ignition switch key to the “STOP” position.

Figure 54. Ignition Switch (Stop Position)

all

loads from the generator.

MAIN, GFCI

Figure 55. Ignition Switch (Off Position)

and

LOAD

(Figure 55) circuit

PAGE 36 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— MAINTENANCE

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General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guidelineEngine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean the heavy duty paper element with light spray of compressed

Service Daily

If the engine is operating in very conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more

frequently

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

air. Replace the air cleaner as needed.

After prolonged use, water and other impurities accumulate

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the

in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

indicator.

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dusty

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if these conditions exists.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 37

DCA-25SSIU2 (60 HZ)— MAINTENANCE

Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure.

To restart after running out of fuel, turn the switch to the “ON” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in (Figure 31).

Replacing Oil Filter

Flushing Out Radiator and Replacing Coolant



Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.



Check hoses for softening and kinks. Check clamps for signs of leakage.



Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.



Tighten both cocks and replace the overflow tank.



Replace with coolant (Table 13 for correct mixture).



Close radiator cap tightly.

WARNING - BURN HAZARDS

Allow engine to radiator. Flushing the radiator while hot could cause serious burns from water o r steam.

cool

when flushing out



To remove the oil filter, grip the filter body and turn counter-clockwise



Apply a film of oil to the rubber seal gasket.



Place the oil filter body onto the oil filter spindle by turning clockwise. DO NOT over tighten.



After the oil filter has been replaced, the engine oil will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

Replacing Fuel Filter



Replace the fuel filter cartridge with new one every 500 hours or so.



Loosen the drain plug at the lower top of the fuel filter. Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.



Vent any air.

Generator Storage

For longe term storage of the generator the following is recommended:



Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.



Completely drain the oil from the crankcase and refill if necessary with fresh oil.



Clean the entire generator, internal and external.



Cover the generating set and store in a clean, dry place.



Disconnect the battery.



Make sure engine coolant is at proper level.



If generator is mounted on a trailer, jack trailer up and place on block so tires do touch the ground or remove tires.

PAGE 38 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— MAINTENANCE

Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the

battery charger

These receptacles will ONLY function when commercial power has been supplied to them (Figure 56). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

When using the generator in to apply power to jacket water heater. However, if the generator will be used in idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

jacket water heater

hot

climates there is no reason

cold

climates it is always a good

and

internal

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using an power cord of adequate size.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger

Figure 56. DCA-25SSIU2 Battery Charger &

Jacket Water Heater Power Connections

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 39

DCA-25SSIU2 (60 HZ)— TRAILER MAINTENANCE

Trailer Maintenance

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with the DCA-25SSIU2

™

Whisperwatt

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch to the rear bumper (reflector).

Generator.

8. Tire Size - Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 18 and Figure 58 for lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can sup- port in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed on a particular trailer.

PAGE 40 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— TRAILER MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles

. If driving over rough terrain, inspect the

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 56) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

brakes more frequently. Figure 57 displays the major hydraulic surge brake

components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 15 as shown below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the

Figure 57. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake shoes.

Actuator

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying

7. Replace the adjusting hole cover and lower the trailer to

hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “

8. Repeat steps 1 through 7 on the remaining brakes.

sure that it is functioning correctly. Never use an undersize actuator.

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DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 41

DCA-25SSIU2 (60 HZ)— TRAILER MAINTENANCE

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

Suspension

The

leaf suspension

(Figure 58) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components

CAUTION - EYESIGHT HAZARD

ALWAYS

wear safety glasses when

as detailed in Table 17.

removing or installing force fitted parts. Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

DO NOT attempt to repair or modify a wheel. DO NOT

install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

springs and associated components

Figure 58. Major Suspension Components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are

hot!

. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 16 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

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LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

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05-XAM03-NIM

PAGE 42 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— TRAILER MAINTENANCE

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 59). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 18.

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

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Figure 59. Wheel Lug Nuts

Tightening Sequence

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 43

DCA-25SSIU2 (60 HZ)— TRAILER WIRING DIAGRAM

Figure 60. Trailer/Towing Vehicle Wiring Diagram

PAGE 44 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— GENERATOR WIRING DIAGRAM

Figure 61. Generator Wiring Diagram

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 45

DCA-25SSIU2 (60 HZ)— ENGINE WIRING DIAGRAM

Figure 62. Engine Wiring Diagram

PAGE 46 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 20 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company's business office or service plant.

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?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 47

DCA-25SSIU2 (60 HZ)— TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 21 (Engine Troubleshooting) as a basic guideline for troubleshooting the Engine. If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTENIGNE.12ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

foytisocsivhgihylevissecxE

woltalioenigneroleuf

?erutarepmet

.lioenigneroleufdeificepsehtesU

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

.tratstonseodenignE

?tungniniaterepip

morfkaelnoisserpmoC

?rednilyc

?gninoitcnuflamretratS .ecalperroriapeR

noitcejniesooloteudkaelleuF

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.tunnethgiT

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

.nurtonseodretratS

?detcennocsidgniriW .gniriwtcennoC

PAGE 48 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.12ELBAT

?tungniniaterepip

.htoomstonsinoituloverenignE

?erusserp

?deggolc

?lioenigneevissecxE .leveldeificepsehtotecudeR

.devresbosi

sagtsuahxeeulbroetihwrehtiE

?kcuts

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

.tunnethgiT

.tsujdA

.ecalperroriapeR

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?gnizieseb

?kaelnoisserpmoC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 49

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column, *, #, +, %, or <, belong to the same assembly or kit.

If more than one of the same

NOTE

reference number is listed, the last one listed indicates newest (or latest) part available.

NOTE

The contents of this catalog are subject to change without notice

PAGE 50 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— SUGGESTED SPARE PARTS

DCA-25SSIU2 (60 HZ) ULTRA-SILENT GENRATOR

W/ISUZU AA-4LE2 ENGINE

1 TO 3 UNITS

Qty. P/N Description

5 ......... 2944566410 ........ FILTER, OIL

5 ......... 8943692993 ........ FILTER, FUEL

3 ......... 0602046321 ........ ELEMENT, AIR

1 ......... 8972606490 ........ BELT, FAN

1 ......... 0605505070 ........ CAP. FUEL TANK

1 ......... 9831401570 ........ UNIT, OIL PRESSURE

1 ......... 8970785920 ........ UNIT, WATER TEMPERATURE

1 ......... 8944032410 ........ SENDER, WATER SWITCH (ENGINE SIDE)

1 ......... 9827200690 ........ SENDER, OIL SWITCH (ENGINE SIDE)

NOTE

Part number on this Suggested Spare Parts list may supercede/replace the P/N shown in the text pages of this book.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 51

GENERATOR ASSY.

DCA-25SSIU2 (60 HZ)— GENERATOR ASSY.

PAGE 52 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B1110200602 ROTOR ASSY. ............................................... 1 ................ INCLUDES ITEMS W/

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10 1-11 2 0010308035 HEX, HEAD BOLT 6 2A 0040008000 SPRING WASHER 6 2B 0041208000 PLAIN WASHER 6 3 0070506803 BEARING, 6803ZZ 1 4 B1130201103 STATOR ASSY. 1 4-1 0845041904 GROMMET 1 5 B1138000003 FIELD ASSY. EXCITER 1 6 0016008045 HEX, SOCKET HEAD CAP SCREW S=22 3 7 0042508000 SPRING WASHER 3 8 8351315003 END BRACKET 1 9 0017108035 HEX, HEAD BOLT 6 10 8351312004 PACKING 1 11 8351331004 COVER, SUCTION 1 12 0017106016 HEX, HEAD BOLT 3 13 0010310030 HEX, HEAD BOLT 6 13A 0040010000 SPRING WASHER 6 13B 0041210000 PLAIN WASHER 6 14 B0155400204 COVER, FAN 1 15 0010106030 HEX, HEAD BOLT 1 16 0041206000 PLAIN WASHER 1 17 0600815000 NUT, USN-6O01 1 18 M9312600004 RUBBER SUSPENSION 2 19 0207010000 HEX, NUT 2

7961025004 RECTIFIER 1 0601822630 SURGE ABSORBER, TNR23G471K 1 8001070003 FAN 1 8351611004 COUPLING DISK 2 8351612004 WASHER, COUPLING HUB 1

B1112300003 BALANCING PLATE ......................................1 ................ PURCHASE SET OF 1-10

0010310025 HEX, HEAD BOLT 4 0042510000 SPRING WASHER 4 0601000209 BALANCING WEIGHT KIT 1

0071906308 BEARING, 6308DDU C3 1

FIELD ASSY. 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 53

CONTROL BOX ASSY.

DCA-25SSIU2 (60 HZ)— CONTROL BOX ASSY.

PAGE 54 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1213000902 CONTROL BOX 1 2 0601870430 CIRCUIT BREAKER, GD3060D33 3P 60A T.C. 12V DC 1 3 0021004075 MACHINE SCREW 4 4 0601842384 RESISTOR, GG20W 50 OHM 1 5 0021004010 MACHINE SCREW 2 6 0601823240 RECTIFIER, DE45 2 7 0027104030 MACHINE SCREW 1 8 0601815759 TERMINAL BOARD, KT-20 6P 1 9 0027104020 MACHINE SCREW 2 10 0601823863 RELAY UNIT, MSA9013A 2 11 0027104016 MACHINE SCREW 4 12 0601820671 AUTOMATIC VOLTAGE REGULATOR, NTA-5A-2DB 1 13 0027105016 MACHINE SCREW 4 14 0601806115 CURRENT TRANSFORMER, 812-943 50/5A 3 15 0027106016 MACHINE SCREW 6 16 0601820847 OVER CURRENT RELAY, TA25DU 4.0 1 17 0601820848 OVER CURRENT RELAY, DB25/25A 1 18 0027104016 MACHINE SCREW 2 18A 0207004000 HEX, NUT 2 19 M1213500203 CONTROL BOX COVER 1 20 0016906016 HEX, HEAD BOLT 4 21 M1923100004 SELECTOR SWITCH, VY-40 1 21A 47130106 KNOB, SELECTOR SWITCH 1 22 M1213600114 SWITCH BRACKET 1 23 0330000160 EDGING 2 24 0027103010 MACHINE SCREW 4 25 0016906016 HEX, HEAD BOLT 4 26 M1213600014 SWITCH COVER 1 27 0016906016 HEX, HEAD BOLT 3 28 0016906016 HEX, HEAD BOLT 8 28A 0040506000 TOOTHED WASHER 1 29 M1223000403 CONTROL PANEL 1 30 0601807641 FREQUENCY METER, FCF-6 45~65Hz 240V 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 55

CONTROL BOX ASSY.(CONT.)

DCA-25SSIU2 (60 HZ)— CONTROL BOX ASSY.

PAGE 56 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— CONTROL BOX ASSY.

CONTROL BOX ASSY.(CONT.)

NO. PART NO. PART NAME QTY. REMARKS

31 0601808985 AC AMMETER, ACF-6 0~50A/100A:5A 1 32 0601801040 CHANGE-OVER SWITCH, AMMETER, SL-2 AS 1 33 0601806859 AC VOLTMETER, SCF-6, 0~600V 1 34 0601801041 CHANGE-OVER SWITCH, VOLTMETER, SL-2 VS 1 35 0601840073 RHEOSTAT (VOLT. REGULAT.) RA20A2SE102BJ 2W 1K 36 0601840121 KNOB, 25N 1 37 M1223100004 STOPPER 1 38 0027105010 MACHINE SCREW 2 39 0027105010 MACHINE SCREW 4 40 M9220100004 SET SCREW 1 41 0080200007 SNAP RING 1 42 8973259120 ENGINE CONTROLLER 1 43 0016906016 HEX, HEAD BOLT 2 43A 0207006000 HEX, NUT 2 44 8944299470 RELAY 2 45 8944001061 GLOW RELAY 1 46 0027105016 MACHINE SCREW 4 47 M1246702304 WIRE HARNESS, GENERATOR 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 57

DCA-25SSIU2 (60 HZ)— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANNEL ASSY.

PAGE 58 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8970444180 IGNITION SWITCH ................................................ 1 ........... INCLUDES ITEM W/

2 0602103092 PREHEAT LAMP .................................................... 1 ........... INCLUDES ITEM W/#

2A# 0601810245 BULB, E-10 T-10 DC18V 1 3 0602120095 TACHOMETER, 1 4 0602122093 OIL PRESSURE GAUGE 1 5 0602123090 WATER TEMPERATURE GAUGE 1 6 0602121080 CHARGING AMMETER 1 7 0602125090 FUEL GAUGE 1

8 0602103092 ALARM LAMP ........................................................ 3 ........... INCLUDES ITEM W/+

8A+ 0601810245 BULB, E-10 T-10 DC18V 3 9 0601810141 PANEL LIGHT 1 10 0601831330 SWITCH, PANEL LIGHT 1 11 M1357201212 WIRE HARNESS, ENGINE 1 12 983101570 UNIT, OIL PRESSURE 1 13 894032410 SENDER, OVERHEAT SWITCH 1

8944024980 KEYS, IGNITION SWITCH 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 59

ENGINE & RADIATOR ASSY.

DCA-25SSIU2 (60 HZ)— ENGINE & RADIATOR ASSY.

PAGE 60 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1923200044 ENGINE, ISUZU AA-4LE2 DA-05 1 1-1 0602041210 CARTRIDGE, OIL FILTER, ISUZU 894456-7411 1 2 M1305200304 ENGINE FOOT 1 3 M1305200204 ENGINE FOOT 1 4 0010310025 HEX, HEAD BOLT 8 5 0040010000 SPRING WASHER 8 6 0041210000 PLAIN WASHER 8 7 0605000066 RUBBER SUSPENSION, KA-50 2 8 0207010000 HEX, NUT 2 9 0602012776 RADIATOR, 2951-292-0000 1 9-1 0602011079 CAP, RADIATOR, 6713-092-0901 1 10 M9312200104 MOUNT RUBBER 2 11 0016908040 HEX, HEAD BOLT 2 12 0207008000 HEX, NUT 2 13 M1310500803 RADIATOR HOSE 1 14 M1310500903 RADIATOR HOSE 1 15 0605515149 HOSE BAND 4 16 M1310200003 FAN SHROUD 1 17 M1310200103 FAN SHROUD 1 17A M1493105004 ACOUSTIC SHEET 1 18 0016908020 HEX, HEAD BOLT 8 19 M1310300703 FAN GUARD 1 20 M1310300803 FAN GUARD 1 21 0016908020 HEX, HEAD BOLT 8 22 0602046580 AIR CLEANER, FPG05-7513 1 22A 0602046321 ELEMENT, AIR CLEANER, P82-1575 1 23 0602040651 INDICATOR, AIR CLEANER, X00-2352 1 24 0602040552 BRACKET, AIR CLEANER, P77-7730 1 25 0016908030 HEX, HEAD BOLT 2 26 M1373100303 HOSE, AIR CLEANER 1 27 M1373100503 HOSE, AIR CLEANER 1 28 0605515147 HOSE BAND 3 29 0602022560 ADAPTER, 10-M20X1.5 F80X-S 1 30 M1320300304 PACKING 1 31 0602011430 FAN BELT, ISUZU 897224-9990 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 61

DCA-25SSIU2 (60 HZ)— ENGINE & RADIATOR ASSY. (CONT.)

ENGINE & RADIATOR ASSY.(CONT.)

PAGE 62 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— ENGINE & RADIATOR ASSY. (CONT.)

ENGINE & RADIATOR ASSY.(CONT.)

NO. PART NO. PART NAME QTY. REMARKS

31 0602022561 90 DEGREE ELBOW, 33982-10-10+ 1 32 0603306590 CONNECTOR, 10WFTX-S 1 33 0603300285 LOCKNUT, 10WLN 1 34 0605511395 VALVE, XV500P-8 1 35 0603306395 HOSE JOINT, 30182-8-10 1 36 0602021070 CAP, 10FNTX-S 1 37 0269200280 DRAIN HOSE, 836-10 1 38 M9602000003 DRAIN JOINT 1 39 M9200200004 PLUG 1 40 0150000018 O RING, A P18 1 41 0016906020 HEX, HEAD BOLT 2 42 0199900600 DRAIN HOSE 1 43 0199900500 DRAIN HOSE 1 44 0605515106 HOSE BAND, RS-8006 4 45 M9300000003 RESERVE TANK 1 46 M9300100003 CAP, RESERVE TANK 1 47 0199100215 HOSE 1 48 M1317100004 BRACKET, RESERVE TANK 1 49 0199100350 HOSE 1 50 0193600850 HOSE 1 51 0605515106 HOSE BAND, RS-8006 2 52 0602120481 PICK UP, TACHOMETER, 71255-00 1 53 9827200690 SENDER, OIL SWITCH 1 54 M9200100004 ADAPTER 1 55 8970785920 UNIT, WATER TEMPERATURE 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 63

OUTPUT TERMINAL ASSY.

DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 64 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1230700003 TERMINAL PANEL 1 2 M9220000004 OUTPUT TERMINAL BOLT 5 3 M9220000104 TIE BOLT 5 4 0039308000 HEX, NUT 10 5 0040008000 SPRING WASHER 15 6 0041408000 PLAIN WASHER 20 7 0016906020 HEX, HEAD BOLT 4 8 M1236100313 TERMINAL COVER 1 9 M1236100404 OUTPUT WINDOW 1 10 0605010040 HINGE, TH-TM122 2 11 0027103010 MACHINE SCREW 4 11A 0030003000 HEX, NUT 4 11B 0041203000 PLAIN WASHER 4 12 0027103010 MACHINE SCREW 4 12B 0030003000 HEX, NUT 4 13 0016906020 HEX, HEAD BOLT 2 14 0016906016 HEX, HEAD BOLT 4 15 M1236400004 CABLE OUTLET COVER 1 16 M1236300004 SUPPORTER, CABLE OUTLET COVER 1 17 0016906020 HEX, HEAD BOLT 6 18 0601870441 CIRCUIT BREAKER, QCF 2050 2P 50A 2 19 0601870440 CIRCUIT BREAKER, QCF 1020 1P 20A 2 20 M1260700404 BREAKER FITTING COVER 1 20-1 0222100080 CUSHION RUBBER 1 21 0016906020 HEX, HEAD BOLT 2 22 0601812598 RECEPTACLE, GF-53 OEM 125V 20AX2 2 23 0601812538 RECEPTACLE CS6369 250V 50A 2 24 0027104016 MACHINE SCREW 8 24A 0207004000 HEX, NUT 4 25 M1236100503 TERMINAL COVER 1 26 0010112045 HEX, HEAD BOLT 2 27 0041212000 PLAIN WASHER 2 28 M9310200004 STAY RUBBER 2 29 0030012000 HEX, NUT 2

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 65

BATTERY ASSY.

DCA-25SSIU2 (60 HZ)— BATTERY ASSY.

PAGE 66 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602220185 BATTERY 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 SPRING WASHER 2 6 M1348400204 BATTERY CABLE 1 7 M2346400104 BATTERY CABLE 1 8 0016910020 HEX HEAD BOLT 1 9 0040510000 TOOTHED WASHER 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 67

MUFFLER ASSY.

DCA-25SSIU2 (60 HZ)— MUFFLER ASSY.

PAGE 68 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602300390 MUFFLER 1 2 0016908020 HEX HEAD BOLT 4 3 M1333201703 EXHAUST PIPE 1

4 8970420280 GASKET .......................................................... 1 ......... REPLACES P/N 0602320100

5 M1333200014 GASKET 1 6 0207008000 HEX NUT 4 7 0016908035 HEX HEAD BOLT 4 8 M1330400204 COVER 2 9 0016906016 HEX HEAD BOLT 4

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 69

FUEL TANK ASSY.

DCA-25SSIU2 (60 HZ)— FUEL TANK ASSY.

PAGE 70 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1363000212 FUEL TANK 1 2 0605505070 CAP, FUEL TANK 1 3 M1363200004 TANK BAND 2 4 M9310500104 SUPPORTER SHEET 4 5 0016908020 HEX HEAD BOLT 2 6 0207308000 HEX NUT 2 7 0222100080 RUBBER SHEET 4 8 M9200000003 DRAIN JOINT 1 9 M9200200004 DRAIN BOLT 1 10 0150000018 O RING 1 11 0016906020 HEX HEAD BOLT 2 12 M1363400104 DRAIN HOSE 1 13 0605515198 HOSE BAND 2

14 8943672922 FILTER, FUEL ........................................... 1 .................... INCLUDES ITEM W/

.......................................................................................... REPLACES P/N 0602042202

14A*8943692993 CARTRIDGE, FUEL FILTER ..................... 1 .................... REPLACES P/N 0602042700

15 M1366700104 BRACKET, FUEL FILTER 1 16 0016908020 HEX HEAD BOLT 6

17 8970398340 FUEL PUMP .............................................. 1 .................... REPLACES P/N 0602023177

17A 8944370220 FILTER, FUEL PUMP 18 0016906025 HEX HEAD BOLT 2 19 0191200900 SUCTION HOSE 1 20 0191200300 SUCTION HOSE 1 21 0191200650 SUCTION HOSE 1 22 0191201100 RETURN HOSE 1 23 0605515108 HOSE BAND 5 24 0605515198 HOSE BAND 3

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 71

ENCLOSURE ASSY.

DCA-25SSIU2 (60 HZ)— ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 72 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1413002802 BASE 1 2 M1413400004 UNDER COVER 1 3 0016908020 HEX HEAD BOLT 2 4 M1423001802 FRONT FRAME 1 4A M1493104903 ACOUSTIC SHEET 1 5 0016908020 HEX HEAD BOLT 4 6 M1423200304 COVER, FRONT FRAME 1 6A M1493100604 ACOUSTIC SHEET 1 7 0016908020 HEX HEAD BOLT 11 8 M1433000203 CENTER FRAME 1 9 M1433000303 CENTER FRAME 1 10 0010114030 HEX HEAD BOLT 8 10A 0040014000 SPRING WASHER 8 10B 0041214000 PLAIN WASHER 8 11 M1443001402 REAR FRAME 1 12 0016908020 HEX HEAD BOLT 4 13 M1443300513 REAR COVER 1 13A M1493300304 ACOUSTIC SHEET 1 14 M1443301503 DUCT, REAR COVER 1 14A M1493300404 ACOUSTIC SHEET 1 15 0207006000 HEX NUT 7 16 0016908020 HEX HEAD BOLT 7 17 M1443200613 REAR DOOR 1 18 M1443600114 WINDOW PLATE 1 19 0037906000 HEX NUT 8 19A 0041206000 PLAIN WASHER 8 20 M9113000002 DOOR HANDLE ASSY 1 21 0021806016 MACHINE SCREW 4 21A 0030006000 HEX NUT 4 22 M9110100204 HINGE 2 23 M9116100004 WASHER 2 24 0016908020 MACHINE SCREW 3 25 M9310000004 BLIND PLUG 2 26 M1463001702 ROOF PANEL 1 26A M1493502903 ACOUSTIC SHEET 1 27 0016908020 HEX HEAD BOLT 18 28 M9310000103 BONNET CAP 1 29 M1483600204 CHAIN ASSY 1 29-1 0016908020 HEX HEAD BOLT 1 30 M1453200702 SPLASHER PANEL 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 73

ENCLOSURE ASSY.(CONT.)

DCA-25SSIU2 (60 HZ)— ENCLOSURE ASSY. (CONT.)

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 74 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— ENCLOSURE ASSY. (CONT.)

ENCLOSURE #1 ASSY.(CONT.)

NO. PART NO. PART NAME QTY. REMARKS

31 0016908055 HEX HEAD BOLT 2 32 0016908020 HEX HEAD BOLT 2 33 M1453003803 SIDE DOOR 1 33A M1493405604 ACOUSTIC SHEET 1 34 M1453003903 SIDE DOOR 1 34A M1493405704 ACOUSTIC SHEET 1 35 M1453004003 SIDE DOOR 1 35A M1493405804 ACOUSTIC SHEET 1 36 M1453004103 SIDE DOOR 1 36A M1493405904 ACOUSTIC SHEET 1 37 M1453301203 DUCT 1 38 0207006000 HEX NUT 4 39 M9113000002 DOOR HANDLE ASSY 3 40 0021806016 MACHINE SCREW 12 40A 0030006000 HEX NUT 12 41 M9110100204 HINGE 4 42 M9110100304 HINGE 4 43 M9116100004 WASHER 8 44 0021808020 MACHINE SCREW 9 45 0601850097 DOOR STOPPER 8 46 0027208025 MACHINE SCREW 8 47 M9310000004 BLIND PLUG 8 48 0600500090 EMBLEM 1 49 0021106016 MACHINE SCREW 2 50 0016910020 HEX HEAD BOLT 1 50A 0040510000 TOOTHED WASHER 1 51 0016908020 HEX HEAD BOLT 1 51A 0040508000 TOOTHED WASHER 1 52 0016906020 HEX HEAD BOLT 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 75

ENCLOSURE ASSY.

DCA-25SSIU2 (60 HZ)— RUBBER SEALS ASSY.

PAGE 76 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— RUBBER SEALS ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0228901170 SEAL RUBBER 2 2 0228900695 SEAL RUBBER 3 3 0228900725 SEAL RUBBER 1 4 M1490300004 SEAL RUBBER 1 5 0228800325 SEAL RUBBER 1 6 0228900370 SEAL RUBBER 1 7 0228900550 SEAL RUBBER 1 8 0228900560 SEAL RUBBER 1 9 0229200595 SEAL RUBBER 1 10 0228900620 SEAL RUBBER 1 11 0229200750 SEAL RUBBER 2 12 0229200740 SEAL RUBBER 1 13 0228800670 SEAL RUBBER 2 14 0228800445 SEAL RUBBER 1 15 0228800485 SEAL RUBBER 1 16 0228100458 SEAL RUBBER 1 17 0228100171 SEAL RUBBER 1 18 0228100351 SEAL RUBBER 1 19 0228100285 SEAL RUBBER 1 20 0228100153 SEAL RUBBER 1 21 0228100180 SEAL RUBBER 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 77

NAMEPLATE AND DECALS ASSY.

DCA-25SSIU2 (60 HZ)— NAMEPLATE AND DECALS

PAGE 78 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

DCA-25SSIU2 (60 HZ)— NAMEPLATE AND DECALS

NAMEPLATE AND DECALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1550000104 DECAL; NOTE ..................................................................1 ............. M15000010

2 M1550000204 DECAL; NOTE ..................................................................1 ............. M15000020

3 M1550001603 DECAL; GENERATOR CONTROL .................................... 1 ............. M15000160

4 M1550017003 DECAL; ENGINE OPERATING ........................................1 ............. M15000170

5 M1550001803 DECAL; AUXILLARY OUTPUT ......................................... 1 ............. M15000180

6 M1550001904 DECAL; CAUTION ............................................................ 1 ............. M15000190

7 M9500000004 DECAL; OIL DRAIN PLUG ............................................... 1 ............. M90000000

8 M9500100004 DECAL; WATER ................................................................1 ............. M90010000

9 M9500100104 DECAL; WATER DRAIN ....................................................1 ............. M90010010

10 M9500300004 DECAL; - .......................................................................... 1 ............. M90030000

11 M9500300104 DECAL; + ......................................................................... 1 ............. M90030010

12 M9500500004 DECAL; DIESEL FUEL ..................................................... 1 ............. M90050000

13 M9500500104 DECAL; FUEL DRAIN PLUG ............................................ 1 ............. M90050010

14 M9503000004 DECAL; WARNING ........................................................... 2 ............. M90300000

15 M9503000103 DECAL; WATER - OIL CHECK ......................................... 1 ............. M90300010

16 M9503100004 DECAL; WARNING ........................................................... 1 ............. M90310000

17 M9503100004 DECAL; WARNING ........................................................... 1 ............. M90320000

18 M9510100004 DECAL; CAUTION ............................................................ 1 ............. M91010000

19 M9510200002 DECAL; MQ ......................................................................1 ............. M91020000

20 M9520000004 DECAL; GROUND ............................................................ 1 ............. M92000000

21 M9520000104 DECAL; AMMETER CHANGE-OVER SW. .......................1 ............. M92000010

22 M9520000204 DECAL; VOLTMETER CHANGE-OVER SW. .................... 1............. M92000020

23 M9520100004 DECAL; WARNING ........................................................... 2 ............. M92010000

24 M9520100503 DECAL; WARNING ........................................................... 1 ............. M92010050

25 M9520100204 DECAL; CAUTION ............................................................ 1 ............. M92010020A

26 M9520100304 DECAL; SAFETY INSTRUCTIONS ..................................1 ............. M92010030

27 M9520100404 DECAL; DANGER .............................................................1 ............. M92010040

28 M9520200003 DECAL; CONNECTION OF OUTPUT CABLE ..................1 ............. M92020000

29 M9520200404 DECAL; OVER CURRENT RELAY ................................... 1 ............. M92020040

30 M1560100403 STRIPE; WHISPERWATT 1 31 M1560100504 STRIPE; 25 2 32 M1560101604 DECAL; MQ POWER 2 33 M1560101704 STRIPE 2 34 M1560101804 STRIPE 2 35 M9521000004 DECAL; TERMINAL 1

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 79

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1. A Returned Material Authorization must be approved by Multiquip prior to shipment.

2. To obtain a Return Material Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions

must match the current parts price list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and

phone number of the person requesting the RMA.

3. A copy of the Return Material Authorization must accompany the return shipment.

4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point.

5. Parts must be in new and resalable con-

6. The following items are not returnable:

7. The sender will be notified of any

8. Such material will be held for five

9. Credit on returned parts will be issued at

10. In cases where an item is accepted, for

11. Credit issued will be applied to future

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates

for price declines and added charges for price dition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

a. Obsolete parts. (If an item is in the

price book and shows as being replaced by another item, it is obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber par ts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants. g. Decals and paper products.

h. Items purchased in kits.

material received that is not acceptable.

working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

dealer net price at time of the original purchase, less a 15% restocking charge.

which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

purchases only.

increases will not be made for stock on hand at

the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade

accessories nor as to any engine not manufac-

tured by Multiquip. Such warranties made in

connection with the sale of new, complete units

are made exclusively by a statement of war-

ranty packaged with such units, and Multiquip

neither assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such written statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

PAGE 80 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)

NOTE PAGE

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 81

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Your Local Dealer is:

Manufactured for Multiquip Inc.

DENYO CO., LTD, JAPAN

MQ POWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-mail: mqpower@multiquip.com Internet: www.mqpower.com

Multiquip DCA-25SSIU2 User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual