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

DCA-25SSIU2 (60 HZ)— MUFFLER ASSY.

MUFFLER ASSY.

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Summary of Contents for WHISPERWATT DCA-25SSIU2

Page 1: ...S AND OPERATION MANUAL OPERATION AND PARTS MANUAL Revision 0 01 27 06 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES WHISPERWATTTM SERIES MODEL DCA 25SSIU2 60 Hz GENERATOR PARTS LIST NO M1870300...

Page 2: ...PAGE 2 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06...

Page 3: ...lustrations are basedontheDCA 25SSIU2 60HZ Whisperwatt Generator MultiquipInc reservestherighttodiscontinueorchangespecifications design or the information published in this publication at any time wi...

Page 4: ...nerator Outputs 26 GaugeReading 27 OutputTerminal 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 4...

Page 5: ...ght allowances when you order 10 or more line items via Web or Fax FedEx Ground Service at no charge for freight No other allowances on freight shipped by any other carrier Common nuts bolts and washe...

Page 6: ...7 1 n o i t p m u s n o C l e u F t a r h L 7 4 5 l a g 4 4 1 d a o l l l u f y r e t t a B 1 X A 5 2 5 F 0 A C C 7 2 l e u F l e u F l e s e i D 2 s n o i t a c i f i c e p S r o t a r e n e G 1 e l...

Page 7: ...N O I S N E M I D 3 E L B A T e c n e r e f e R r e t t e L m m t f n o i s n e m i D r e t t e L e c n e r e f e R m m t f n o i s n e m i D A m m 0 7 6 n i 7 3 6 2 F m m 0 5 8 1 n i 3 8 2 7 B m m 5...

Page 8: ...This gas is colorless and odorless and can cause DEATH if inhaled NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air Diesel fuel is extreme...

Page 9: ...he surrounding environment Thisgenerator otherproperty or the surrounding environment could be damaged if you do not follow instructions NOTE NEVER tamper with the factory settings of the engine gover...

Page 10: ...lead to serious injury or even DEATH This equipment is to be operated by trained and qualified personnel only This equipment is for industrial use only DANGER READTHIS MANUAL ALWAYS check the machine...

Page 11: ...the equipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC providesguidelinesforpropergroundingandspecifies that the cable ground shall be...

Page 12: ...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 co...

Page 13: ...H or less depending on type of terrain Place support blocks underneath the trailer s bumper to prevent tipping while parked Avoid sharp turns to prevent rolling DO NOT transport generator with fuel in...

Page 14: ...ety decals Figures 2 3 These 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 a...

Page 15: ...DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 15 1 DCA 25SSIU2 60 HZ GENERATOR DECALS Figure 3 Generator Decals Continued...

Page 16: ...PAGE 16 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 Figure 4 Typical Generator Grounding Application DCA 25SSIU2 60 HZ INSTALLATION...

Page 17: ...ound 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 tigh...

Page 18: ...ptacles CS 6369 50A Two auxiliary circuit breakers 50A Two 120V output receptacles GFCI 20A Two GFCI circuit breakers 20A Five output terminal lugs 3 power Battery Charger Optional Water Heater Option...

Page 19: ...y l b m e s s A l e n a P l a n i m r e T t u p t u O 2 y l b m e s s A s e l c a t p e c e R t u p t u O 3 y l b m e s s A r e t l i F r i A 4 y l b m e s s A r e l f f u M 5 y l b m e s s A k n a T...

Page 20: ...e 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 the AC...

Page 21: ...6 Ignition Switch Three position switch stop operation and start Insert ignition key to start and stop engine Figure 7 Engine Operating Panel 7 Pre heat Lamp This indicates when the engine is ready f...

Page 22: ...receptacles 2 20 amp GFCI Circuit Breaker 2 20 amps 1 pole Five 5 Output Terminal Lugs U V W O Ground OutputTerminal Panel TheOutputTerminalPanel Figure8 shownbelowislocated ontheright handside leftf...

Page 23: ...current on all three receptacles is dependent on the load requirements of the OutputTerminal Lugs Turn the voltage regulator control knob Figure 11 on the control panel to obtain the desired voltage T...

Page 24: ...d both the circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over cur rent relay must be pressed The over current relay is lo cated in...

Page 25: ...close attention to the required starting current capacity NOTE WATTS VOLTAGE x AMPERAGE Three Phase Load When calculating the power requirements for 3 phase power use the following equation NOTE An in...

Page 26: ...r Amperage Table 8 describes the generator s current output capability for both 1 phase and 3 phase applications GFCI Receptacle Load Capability The load capability of the GFCI receptacles is directly...

Page 27: ...position Figure 21 AC Ammeter Amp reading on U lug Figure 20 AC Ammeter Change Over Switch ReadingVoltage To determine the voltage between two terminal lugs set the AC Voltmeter Change Over Switch to...

Page 28: ...OutputTerminal Lugs 3 240 139Three Phase Connections 2 Connect the load wires to the OutputTerminal Lugs as shown in Figure 23 3 Turn the voltage regulator knob Figure 24 clockwise to increase voltage...

Page 29: ...ages 1 Place the voltage selector switch in the 3 480 277 position as shown in Figure 27 3 Turn the voltage regulator knob Figure 24 clockwise to increase voltage output turn counterclockwise to decre...

Page 30: ...on 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 leve...

Page 31: ...k DONOTwaitfor fuel to rise in filler neck Figure 35 Figure 35 Full Fuel Tank Figure 36 Fuel Expansion 2 Remove fuel cap and fill fuel tank as shown in Figure 34 Figure 34 Fueling the Generator ALWAYS...

Page 32: ...d the negative battery terminal disconnected Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the Isuzu Engine Owner s Manual Fan BeltTension A slack fan belt may c...

Page 33: ...fuel or oil lines are defective replace them immediately If the battery cable is connected incorrectly electricaldamagetothe generator will occur Pay close attention to the polarity of the battery wh...

Page 34: ...ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel Before Starting Figure 40 Engine Enclosure Doors 1 Place the main G F C I and aux circuit breakers Figure39 i...

Page 35: ...y Meter Hz 11 Use the voltage adjustment control knob Figure 46 to increase or decrease the desired voltage Figure 46 Voltage Adjusted Control Knob 13 The engine oil pressure gauge Figure 48 will indi...

Page 36: ...no load applied circuit breakers in the off position 3 Placetheignitionswitch Figure54 inthe STOP position remove the key and store in a safe place Figure 54 Ignition Switch Stop Position 4 Remove al...

Page 37: ...the element needs changing or service After changing the air element press the dust indicator button to reset the indicator E C N A N E T N I A M N O I T C E P S N I 4 1 E L B A T s r H 0 1 Y L I A D...

Page 38: ...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...

Page 39: ...When using the generator in hot climates there is no reason to apply power to jacket water heater However if the generator will be used in cold climates it is always a good idea to apply power to the...

Page 40: ...requirement from the tongue of the trailer 7 Coupler Type of hitch used on the trailer for towing 8 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and the width in millimeters 175...

Page 41: ...aulicsurgebrakingrequirestheinstallationofanactuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with th...

Page 42: ...sive wear elongation of bolt holes and loosening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 17 Figure 58 Major Suspension Componen...

Page 43: ...igure 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...

Page 44: ...PAGE 44 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 Figure 60 Trailer Towing Vehicle Wiring Diagram DCA 25SSIU2 60 HZ TRAILERWIRING DIAGRAM...

Page 45: ...DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 45 1 DCA 25SSIU2 60 HZ GENERATORWIRING DIAGRAM Figure 61 GeneratorWiring Diagram...

Page 46: ...PAGE 46 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU2 60 HZ ENGINEWIRING DIAGRAM Figure 62 Engine Wiring Diagram...

Page 47: ...n i t a t o R e v i t c e f e D e c a l p e r d n a k c e h C d l e i F r e t i c x E e v i t c e f e D 1 N C n o K J s s o r c a s m h o 3 7 1 r o f k c e h C t u p t u O e g a t l o V w o L t c e r...

Page 48: ...h y l e v i s s e c x E w o l t a l i o e n i g n e r o l e u f e r u t a r e p m e t l i o e n i g n e r o l e u f d e i f i c e p s e h t e s U r e b m u n e n a t e c w o l h t i w l e u F l e u f...

Page 49: ...l d e i f i c e p s e h t o t e c u d e R r o n r o w r e n i l d n a g n i r n o t s i P k c u t s e c a l p e r r o r i a p e R g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n o i s s...

Page 50: ...cular 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 A...

Page 51: ...ext pages of this book NOTE DCA 25SSIU2 60 HZ ULTRA SILENT GENRATOR W ISUZU AA 4LE2 ENGINE 1TO 3 UNITS Qty P N Description 5 2944566410 FILTER OIL 5 8943692993 FILTER FUEL 3 0602046321 ELEMENT AIR 1 8...

Page 52: ...PAGE 52 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU2 60 HZ GENERATOR ASSY GENERATOR ASSY...

Page 53: ...IT 1 1 11 0071906308 BEARING 6308DDU C3 1 2 0010308035 HEX HEAD BOLT 6 2A 0040008000 SPRINGWASHER 6 2B 0041208000 PLAINWASHER 6 3 0070506803 BEARING 6803ZZ 1 4 B1130201103 STATOR ASSY 1 4 1 0845041904...

Page 54: ...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...

Page 55: ...MATICVOLTAGE REGULATOR NTA 5A 2DB 1 13 0027105016 MACHINE SCREW 4 14 0601806115 CURRENTTRANSFORMER 812 943 50 5A 3 15 0027106016 MACHINE SCREW 6 16 0601820847 OVER CURRENT RELAY TA25DU 4 0 1 17 060182...

Page 56: ...PAGE 56 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 CONTROL BOX ASSY CONT DCA 25SSIU2 60 HZ CONTROL BOX ASSY...

Page 57: ...SWITCH VOLTMETER SL 2 VS 1 35 0601840073 RHEOSTAT VOLT REGULAT RA20A2SE102BJ 2W 1K 1 36 0601840121 KNOB 25N 1 37 M1223100004 STOPPER 1 38 0027105010 MACHINE SCREW 2 39 0027105010 MACHINE SCREW 4 40 M9...

Page 58: ...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 PANNEL ASSY...

Page 59: ...2 PREHEAT LAMP 1 INCLUDES ITEM W 2A 0601810245 BULB E 10T 10 DC18V 1 3 0602120095 TACHOMETER 1 4 0602122093 OIL PRESSURE GAUGE 1 5 0602123090 WATERTEMPERATURE GAUGE 1 6 0602121080 CHARGING AMMETER 1 7...

Page 60: ...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...

Page 61: ...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 S...

Page 62: ...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...

Page 63: ...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...

Page 64: ...0 HZ OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY THE SERIAL NUMBER MAY BE REQUIRED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLAC...

Page 65: ...LAINWASHER 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 OUTLE...

Page 66: ...PAGE 66 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU2 60 HZ BATTERY ASSY BATTERY ASSY...

Page 67: ...TTERY 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 SPRINGWASHER 2 6 M1348400204...

Page 68: ...PAGE 68 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU2 60 HZ MUFFLER ASSY MUFFLER ASSY...

Page 69: ...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 0...

Page 70: ...PAGE 70 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU2 60 HZ FUELTANK ASSY FUEL TANK ASSY...

Page 71: ...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 CAR...

Page 72: ...SIU2 60 HZ ENCLOSURE ASSY ENCLOSURE ASSY THE SERIAL NUMBER MAY BE REQUIRED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 W...

Page 73: ...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 020700600...

Page 74: ...60 HZ ENCLOSURE ASSY CONT ENCLOSURE ASSY CONT THE SERIAL NUMBER MAY BE REQUIRED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLAC...

Page 75: ...HEET 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...

Page 76: ...PAGE 76 DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 DCA 25SSIU2 60 HZ RUBBER SEALS ASSY ENCLOSURE ASSY...

Page 77: ...28800325 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...

Page 78: ...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...

Page 79: ...50010 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 C...

Page 80: ...icants g Decalsandpaperproducts h Itemspurchasedinkits 7 The sender will be notified of any materialreceivedthatisnotacceptable 8 Such material will be held for five workingdaysfromnotification pendin...

Page 81: ...DCA 25SSIU2 60 HZ OPERATION AND PARTS MANUAL REV 0 01 27 06 PAGE 81 1 NOTE PAGE...

Page 82: ...HERE S HOW TO GET HELP PLEASE HAVETHE MODEL AND SERIAL NUMBERON HANDWHENCALLING MQ POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Carson CA 90746 FAX 310 632 2656 Email mqpower multiquip co...

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