whisperwatt series model dca-25ssiu2 · 2016. 12. 28. · dca-25ssiu2 (60 hz)— operation and...

PARTS AND OPERATION MANUALOPERATION AND PARTS MANUAL

Revision #0 (01/27/06)

THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALL TIMES.

WHISPERWATTTM SERIESMODEL DCA-25SSIU2

60 Hz GENERATOR

PARTS LIST NO. M1870300804

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

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

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© COPYRIGHT 2005, MULTIQUIP INC.

MQ Power Inc, Ultra-Silent series, and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used,reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used withpermission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment andshould 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 arebased on the DCA-25SSIU2 (60 HZ)Whisperwatt™ Generator. Multiquip Inc. reserves the right to discontinue or change specifications,design or the information published in this publication at any time without notice and without incurring any obligations.

To find the latest revision of thispublication, visit our website at:

www.mqpower.com

HERE'S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLINGMQ POWER CORPORATE OFFICE18910 Wilmington Ave. 800-421-1244Carson, CA 90746 FAX: 310-632-2656Email: [email protected]: www.mqpower.comPARTS DEPARTMENT800-427-1244 FAX: 800-672-7877310-537-3700 FAX: 310-637-3284SERVICE DEPARTMENT800-835-2551 FAX: 310-638-8046310-537-3700TECHNICAL ASSISTANCE800-835-2551 FAX: 310-638-8046WARRANTY DEPARTMENT800-835-2551, EXT. 279 FAX: 310-638-8046310-537-3700, EXT. 279


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)WHISPERWHISPERWHISPERWHISPERWHISPERWWWWWAAAAATT™ GENERATT™ GENERATT™ GENERATT™ GENERATT™ GENERATORTORTORTORTORCalifornia Proposition 65 Warning ..................................... 2Here's How To Get Help .................................................... 3Table Of Contents ............................................................. 4Parts Ordering Procedures ............................................... 5Specifications ................................................................... 6Dimensions ( Side, Front) ................................................. 7Safety Message Alert Symbols .................................... 8-9Rules for Safe Operation ........................................... 10-13Generator Decals ....................................................... 14-15Installation ................................................................. 16-17General Information ........................................................ 18Major Components ......................................................... 19Generator Control Panel ................................................. 20Engine Operating Panel .................................................. 21Output Terminal Panel Familiarization ........................ 22-24Load Application ............................................................. 25Generator Outputs .......................................................... 26Gauge Reading ............................................................... 27Output Terminal Panel Connections ........................... 28-29Pre Setup .................................................................. 30-33Generator Start-up Procedure ................................... 34-36Generator Shut-Down Procedure .................................... 36Maintenance .............................................................. 37-38Trailer Maintenance .................................................... 39-42Trailer Wiring Diagram ..................................................... 43Generator Wiring Diagram ............................................... 44Engine Wiring Diagram ................................................... 45Generator Troubleshooting .............................................. 46Engine Troubleshooting ............................................. 47-48Explanation of Code in Remarks Column ....................... 50Suggested Spare Parts .................................................. 51

COMPONENT DRACOMPONENT DRACOMPONENT DRACOMPONENT DRACOMPONENT DRAWINGSWINGSWINGSWINGSWINGSGenerator Assembly ............................................ 52-53Control Box Assembly .......................................... 54-57Engine Operating Panel Assembly ...................... 58-59Engine & Radiator Assembly ............................... 60-63Output Terminal Assy. .......................................... 64-65Battery Assembly ................................................. 66-67Muffler Assembly ................................................. 68-69Fuel Tank Assembly ............................................. 70-71Enclosure Assembly ............................................ 72-75Rubber Seal Assembly ........................................ 72-73Name Plate And Decals ....................................... 74-75Rubber Seal Assembly ........................................ 76-77Nameplate and Decals ........................................ 78-79

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

Specification and partnumber are subject tochange without notice.

NOTE


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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✓ Truck

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

Extra Discounts!All parts orders which include complete part numbers andare received by our automated web parts order system, orby fax qualify for the following extra discounts:

Ordered Standard Stock ordersvia orders ($750 list and above)Fax 3% 10%

Web 5% 10%

Special freight allowanceswhen you order 10 or moreline items via Web or Fax!**FedEx Ground Service at no charge for freightNo other allowances on freight shipped by any other carrier.**Common nuts, bolts and washers (all items under $1.00list price) do not count towards the 10+ line items.

Place Your Parts Order Via Web or FaxFor Even More Savings!

(Domestic USA Dealers Only)

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

Here’s how to get help...Please have the model and serial numberon hand when calling.

MQ POWER CORPORATE OFFICE18910 Wilmington Ave. 800-421-1244Carson, CA 90746 FAX: 310-632-2656Email: [email protected]: www.mqpower.comPARTS DEPARTMENT800-427-1244 FAX: 800-672-7877310-537-3700 FAX: 310-637-3284SERVICE DEPARTMENT800-835-2551 FAX: 310-638-8046310-537-3700TECHNICAL ASSISTANCE800-835-2551 FAX: 310-638-8046WARRANTY DEPARTMENT800-835-2551, EXT. 279 FAX: 310-638-8046310-537-3700, EXT. 279

Direct TOLL-FREE accessto our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7 (800/672-7877)

PARTS ORDERING PROCEDURES

MQPOWERA Division of Multiquip Inc.POST OFFICE BOX 6254CARSON, CA 90749310-537-3700 • 800-421-1244FAX: 310-632-2656E-MAIL: [email protected]: www.mqpower.com


DCA-25SSIU2 (60 HZ)— SPECIFICATIONS

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1

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

Figure 1. Dimensions

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Before using this generator, ensure that the operatingindividual has read and understands all instructions inthis manual.

Safety precautions should be followed at all times whenoperating this equipment. Failure to read and understand theSafety Messages and Operating Instructions could result ininjury to yourself and others.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS! HAZARD SYMBOLS

Potential hazards associated with the operation of thisequipment will be referenced with "Hazard Symbols" whichappear throughout this manual, and will be referenced inconjunction with Safety "Message Alert Symbols".

NOTE

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

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform youabout potential hazards that could injure you or others. TheSafety Messages specifically address the level of exposureto the operator, and are preceded by one of three words:DANGER, WARNING, or CAUTION.

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

You CAN be injured if you do not follow directions

Diesel engine exhaust gases containpoisonous carbon monoxide. This gas iscolorless and odorless, and can causeDEATH if inhaled. NEVER operate this

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

Diesel fuel is extremely flammable, andits vapors can cause an explosion ifignited. DO NOT start the engine nearspilled fuel or combustible fluids.DO NOT fill the fuel tank while the engineis running or hot.

DO NOT overfill tank, since spilled fuel could ignite if itcomes into contact with hot engine parts or sparks fromthe ignition system. Store fuel in approved containers, inwell-ventilated areas and away from sparks and flames.NEVER use fuel as a cleaning agent.

Engine components can generate extremeheat. To prevent burns, DO NOT touch theseareas while the engine is running orimmediately after operations. NEVERoperate the engine with heat shields or heatguards removed.

WARNING

CAUTION

WARNING - LETHAL EXHAUST GASES

WARNING - BURN HAZARDS

WARNING - EXPLOSIVE FUEL

During operation of this generator, thereexists the possibility of electrocution,electrical shock or burn, which can causesevere bodily harm or even DEATH!

DANGER - ELECTROCUTION HAZARDS

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

DANGER

This Operation and Parts Manualhas been developed to providecomplete instructions for the safeand efficient operation of the MQPower Model DCA-25SSIU2(60Hz) Whisperwatt™ Generator.


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

ALWAYS place the Engine ON/OFFswitch in the OFF position and removethe ignition key when the pump is not inuse.

ALWAYS wear approved respiratoryprotection.

ALWAYS wear approved eye andhearing protection.

Other important messages are provided throughout thismanual to help prevent damage to your generator, otherproperty, or the surrounding environment.

This generator, other property, orthe surrounding environmentcould be damaged if you do notfollow instructions.

NOTE

NEVER tamper with the factory settingsof the engine governor or settings.Personal injury and damage to the engineor equipment can result if operating inspeed ranges above maximum allowable.

CAUTION - OVER-SPEED CONDITIONS

CAUTION - ACCIDENTAL STARTING

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

NEVER operate equipment with covers,or guards removed. Keep fingers, hands,hair and clothing away from all movingparts to prevent injury.

WARNING - ROTATING PARTS


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

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

General Safety:

■ DO NOT operate or service thisequipment before reading this entiremanual.

The operator MUST BE familiar with proper safetyprecautions and operations techniques before usinggenerator.

■ This equipment should not be operated by persons under18 years of age.

■ NEVER operate this equipment without proper protectiveclothing, shatterproof glasses, steel-toed boots and otherprotective devices required by the job.

■ NEVER operate this equipment when notfeeling well due to fatigue, illness or takingmedicine.

■ NEVER operate this equipment under the influence ordrugs or alcohol.

■ NEVER use accessories or attachments, which are notrecommended by MQ Power for this equipment. Damageto the equipment and/or injury to user may result.

■ Manufacturer does not assume responsibility for anyaccident due to equipment modifications. Unauthorizedequipment modification will void all warranties.

■ Whenever necessary, replace nameplate, operation andsafety decals when they become difficult read.

Failure to follow instructions in this manual may lead toserious injury or even DEATH! This equipment is to beoperated by trained and qualified personnel only! Thisequipment is for industrial use only.

DANGER - READ THIS MANUAL!■ ALWAYS check the machine for loosened threads or bolts

before starting.

■ NEVER operate the generator in an explosive atmosphereor near combustible materials. An explosion or fire couldresult causing severe bodily harm or even death.

■ NEVER touch the hot exhaust manifold, muffleror cylinder. Allow these parts to cool beforeservicing engine or generator.

■ High Temperatures – Allow the engineto cool before performing service andmaintenance functions. Contact withhot! components can cause seriousburns.

■ The engine of this generator requires an adequate freeflow of cooling air. NEVER operate the generator in anyenclosed or narrow area where free flow of the air isrestricted. If the air flow isrestricted it will cause seriousdamage to the generator orengine and may cause injuryto people. The generatorengine gives off DEADLYcarbon monoxide gas.

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

■ NEVER run engine without air filter. Severe engine damagemay occur.

■ DO NOT leave the generator running in the manual modeunattended.

■ Refer to the Isuzu Engine Owner's Manual for enginetechnical questions or information.

■ ALWAYS store equipment properly when it is not beingused. Equipment should be stored in a clean, dry locationout of the reach of children.


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POWERCORD

(POWER ON)

WETHANDS

During operation of this generator, thereexists the possibility of electrocution,electrical shock or burn, which can causesevere bodily harm or even DEATH!

To avoid these hazards:

NEVER use damaged or worn cables when connectingequipment to the generator. Make sure power connectingcables are securely connected to the generator’s outputterminals, insufficient tightening of the terminal connectionsmay cause damage to the generatorand electrical shock.

NEVER grab or touch a live powercord with wet hands.

NEVER touch output terminalsduring operation. This is extremelydangerous. ALWAYS stop themachine and place the circuitbreaker in the OFF position whencontact with the output terminals isrequired.

Backfeed to a utility system cancause electrocution and or propertydamage. DO NOT connect to anybuilding's electrical system exceptthrough an approved device or afterbuilding main switch is opened.ALWAYS have a licensed electricianperform the installation

DANGER - ELECTROCUTION HAZARDSGenerator Grounding

To guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground.

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

The following safety recommendations should also befollowed:

■ ALWAYS make sure generator is properly grounded.

■ NEVER use gas piping as an electrical ground.

■ ALWAYS make sure that electrical circuits are properlygrounded per the National Electrical Code (NEC) andlocal codes before operating generator. Severe injury orDEATH! by electrocution can result from operating anungrounded generator.

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

Electrical Safety

■ ALWAYS have a qualified electrician perform thegenerator wiring installation.

■ ALWAYS make sure generator installation is accordancewith the National Electrical Code (NEC) and local codesbefore operating generator.

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

■ NEVER use a extension cord that is frayed or damagedwhere the insulation has been cut.

■ ALWAYS make certain that proper extension cord hasbeen selected for the job. See Table 6.

■ NEVER power cables or cords lay in water.

■ NEVER stand in water while AC power from the generatoris being transfer to a load.


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

Use the following guidelines when handling the battery:

■ The battery contains acids that cancause injury to the eyes and skin. Toavoid eye irritation, always wear safetyglasses.

■ Use well insulated gloves when picking up the battery.

Maintenance Safety

■ The electrical voltage required to operate the generatorcan cause severe injury or even death through physicalcontact with live circuits. Turn all circuit breakers OFFbefore performing maintenance on the generator.

■ NEVER lubricate components or attempt service on arunning machine.

■ ALWAYS disconnect the NEGATIVE battery terminalbefore performing service on the generator.

■ Follow all Battery Safety Guidelines listed in this manualwhen handling or servicing the generator.

■ ALWAYS allow the machine a proper amount of time tocool before servicing.

■ Keep the machinery in proper running condition.

■ Fix damage to the machine immediately and alwaysreplace broken parts.

■ ALWAYS service air cleaner frequently to prevent enginemalfunction.

To prevent burns, DO NOT touch or open any of the belowmentioned components while the engine isrunning or immediately after operations.Always allow sufficient time for the engineand generator to cool before performingmaintenance.

■ Radiator Cap - Removing the radiator cap while theengine is hot will result in high pressurized, boiling waterto gush out of the radiator, causing severe scalding toany persons in the general area of the generator.

■ Coolant Drain Plug - Removing the coolant drain plugwhile the engine is hot will result in hot coolant gushingout of the coolant drain plug, therefore causing severescalding to any persons in the general area of thegenerator.

■ Engine Oil Drain Plug - Removing the engine oil drainplug while the engine is hot will result in hot oil gushingout of the oil drain plug, therefore causing severescalding to any persons in the general area of thegenerator.

WARNING - BURN HAZARDS■■■■■ 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 workingcondition. Repair or replace all worn cables.

■■■■■ ALWAYS recharge the battery in an vented airenvironment, to avoid risk of a dangerous concentrationof combustible gases.

■■■■■ In case the battery liquid (dilute sulfuric acid) comes incontact with clothing or skin, rinse skin or clothingimmediately with plenty of water.

■■■■■ In case the battery liquid (dilute sulfuric acid) comes incontact with your EYES, rinse eyes immediately withplenty of water and contact the nearest doctor or hospitalto seek medical attention.

The risk of an explosion exists when performing serviceon the battery. To avoid severe injury or DEATH:

■■■■■ DO NOT drop the battery. Thereis the possibility of risk that thebattery may explode.

■■■■■ DO NOT expose the battery toopen flames, sparks, cigarettesetc. The battery contains combustible gases and liquids.If these gases and liquids come in contact with a flameor spark, an explosion could occur.

DANGER - EXPLOSION HAZARDS


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Emergencies

■ ALWAYS know the location of thenearest fire extinguisher.

■ ALWAYS know the location of thenearest and first aid kit.

■ ALWAYS know the location of thenearest phone or keep a phone onthe job site, in case of emergencies.

■ ALWAYS have easy access to the phonenumbers of the nearest Ambulance, Doctorand Fire Department. This information willbe invaluable in the case of an emergency.


Check with your local county or state safety towingregulations, in addition to meeting Department ofTransportation (DOT) Safety Towing Regulations, beforetowing your generator.

CAUTION - FOLLOW TOWING REGULATIONS

■ The maximum speed for highway towing is 55 MPHunless posted otherwise. Recommended off-road towingis not to exceed 15 MPH or less depending on type ofterrain.

■ Place chock blocks underneath wheel to prevent rolling,while parked.

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

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

■ Avoid sharp turns.

■ Trailer should be adjusted to a level position at all timeswhen towing.

■ Raise and lock trailer wheel stand in up position whentransporting.

■ The maximum speed for highway towing is 55 MPHunless posted otherwise. Recommended off-road towingis not to exceed 15 MPH or less depending on type ofterrain.

■ Place support blocks underneath the trailer’s bumper toprevent tipping, while parked.

■ Avoid sharp turns to prevent rolling.

■ DO NOT transport generator with fuel in tank.

Towing & Transporting Safety

To reduce the possibility of an accident while transportingthe generator on public roads, always make sure the trailerthat supports the generator and the towing vehicle are ingood operating condition and both units are mechanicallysound.

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

■ ALWAYS shutdown engine before transporting.

■ Tighten both fuel tank caps securely.

■ If generator is mounted on a trailer, make sure trailercomplies with all local and state safety transportationlaws. Follow the listed Towing & Transporting Safetyguidelines for basic towing techniques.

■ Make sure the hitch and coupling of the towing vehicleare rated equal to, or greater than the trailer "gross vehicleweight rating.”

■ ALWAYS inspect the hitch and coupling for wear. NEVERtow a trailer with defective hitches, couplings, chains etc.

■ Check the tire air pressure on both towing vehicle andtrailer. Trailer tires should be inflated to 50 psi cold.Also check the tire tread wear on both vehicles.

■ ALWAYS make sure the trailer is equipped with a "SafetyChain".

■ ALWAYS attach trailer’s safety chains to towing vehicleproperly.

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

■ DOT Requirements include the following: Connect and test electric brake operation. Secure portable power cables in cable tray with tie

wraps.


The DCA-25SSIU2 (60 Hz) Whisperwatt™ Generator is equipped with a number of safety decals (Figures 2 & 3). Thesedecals are provided for operator safety and maintenance information. The illustration below and on the preceding pageshow the decals as they appear on the machine. Should any of these decals become unreadable, replacements can beobtained from your dealer.

DCA-25SSIU2 (60 HZ)— GENERATOR DECALS

Figure 2. Generator Decals


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DCA-25SSIU2 (60 HZ)— GENERATOR DECALS

Figure 3. Generator Decals (Continued)


Figure 4. Typical Generator Grounding Application

DCA-25SSIU2 (60 HZ)— INSTALLATION


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Outdoor Installation

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

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

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

Generator Grounding

To guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground. 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 thatthe cable ground shall be connected to the grounding systemof the building as close to the point of cable entry aspractical.

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

1. Use one of the following wire types to connect thegenerator 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 theground cable between the lock washer and the nut onthe generator and tighten the nut fully. Connect the otherend of the ground cable to earth ground.

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

When connecting the generatorto any buildings electricalsystem ALWAYS consult witha licensed electrician.

DCA-25SSIU2 (60 HZ)— INSTALLATION

NOTE

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.Whenever an engine is installed indoors the exhaust fumesmust be vented to the outside. The engine should be installedat least two feet from any outside wall. Using an exhaustpipe which is too long or too small can cause excessiveback pressure which will cause the engine to heat excessivelyand possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (suchas concrete) and set firmly on the foundation to isolatevibration of the generator when it is running. The generatormust set at least 6 inches above the floor or grade level (inaccordance to NFPA 110, Chapter 5-4.1). DO NOT removethe metal skids on the bottom of the generator. They are toresist damage to the bottom of the generator and to maintainalignment.

Pay close attention to ventilation when operating thegenerator inside tunnels and caves. The engine exhaustcontains noxious elements. Engine exhaust must be routedto a ventilated area.

CAUTION - EXHAUST HAZARD


DCA-25SSIU2 (60 HZ)— GENERAL INFORMATIONDCA-25SSIU2 (60 Hz) Series FamiliarizationGeneratorThe MQ Power Model DCA-25SSIU2 (60 Hz) is a 20 kWgenerator (Figure 5) that is designed as a high quality portable(requires a trailer for transport) power source for telecomsites, lighting facilities, power tools, submersible pumps andother industrial and construction machinery.Engine Operating PanelThe “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

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

■■■■■ 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 PanelThe “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)

Open Delta Excitation SystemThe DCA-25SSIU2 (60 HZ) generator is equipped with thestate of the art "Open-Delta" excitation system. The opendelta system consist of an electrically independent windingwound 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 regulatoris supplied from the parallel connections of A to B, A to D,and C to D. These three phases of the voltage input to thevoltage regulator are then rectified and are the excitationcurrent for the exciter section.When a heavy load, such as a motor starting or a shortcircuit occurs, the automatic voltage regulator (AVR)switches the configuration of the open delta to the seriesconnection of B to C. This has the effect of adding the voltagesof each phase to provide higher excitation to the excitersection and thus better voltage response during theapplication of heavy loads.The connections of the AVR to the AC output windings arefor sensing only. No power is required from these windings.The open-delta design provides virtually unlimited excitationcurrent, offering maximum motor starting capabilities. Theexcitation does not have a "fixed ceiling" and respondsaccording the demands of the required load.


1

DCA-25SSIU2 (60 HZ)— MAJOR COMPONENTS

Figure 5. Major Components

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

The definitions below describe the controls and functions of theDCA-25SSIU2 (60 HZ) Generator Control Panel (Figure 6).

1. Main Circuit Breaker – This three-pole, 60A mainbreaker is provided to protect the U,V, and W OutputTerminal Lugs from overload.

2. Voltage Regulator Control – Allows ±15% manualadjustment of the generator’s output voltage

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

4. AC Ammeter – Indicates the amount of current the loadis drawing from the generator per leg selected by theammeter phase-selector switch.

5. AC Voltmeter – Indicates the output voltage present atthe U,V, and W Output Terminal Lugs.

6. Ammeter Change-Over Switch – This switch allowsthe AC ammeter to indicate the current flowing to theload connected to any phase of the output terminals, orto be switched off. This switch does not effect thegenerator output in any fashion, it is for current readingonly.

7. Voltmeter Change-Over Switch – This switch allowsthe AC voltmeter to indicate phase to phase voltagebetween any two phases of the output terminals or tobe switched off.

Located behind the generator control panel is the GeneratorControl Box. This box contains some of the necessaryelectronic components required to make the generatorfunction.

The Control Box is equipped with the following majorcomponents:■■■■■ Over-Current Relay■■■■■ Voltage Rectifier (AVR)■■■■■ Starter Relay■■■■■ Current Transformer■■■■■ Voltage Selector Switch

Figure 6. Generator Control Panel

Remember the overcurrentrelay monitors the currentflowing from the U,V, and WOutput Terminal Lugs to theload.

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

To restore power to the Output Terminal Panel, press thereset button on the overcurrent relay and place the maincircuit breaker in the closed position (ON).

NOTE


1

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

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

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

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

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

4. Water Temperature Alarm Lamp - Indicates that thewater temperature is outside of normal range and willshut down the engine.

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

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

Figure 7. Engine Operating Panel

7. Pre-heat Lamp - This indicates when the engine isready for starting during cold weather operatingconditions.

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

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

10. Charging Ammeter Gauge – Indicates the currentbeing supplied by the engine’s alternator which providescurrent for generator’s control circuits and batterycharging system.

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

12. Oil Pressure Gauge – Normal operation should bebetween 28 ~71 psi (193 ~490 kPa). When starting thegenerator the oil pressure may read a bit higher, butafter the engine warms up the oil pressure should returnto normal.


Output Terminal Familiarization

The “Output Terminal Panel ” (Figure 9) is provided with thefollowing:

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

■■■■■ 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)

Output Terminal Panel

The Output Terminal Panel (Figure 8) shown below is locatedon the right-hand side (left from control panel) of the generator.Lift up on the cover to gain access to receptacles and terminallugs.

NOTE Terminal legs “O” and “Ground”are considered bonded grounds.

Figure 8. Output Terminal Panel

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


1

120 VAC GFCI Receptacles

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

Pressing the reset button resets the GFCI receptacle afterbeing tripped. Pressing the Test Button (See Figure 9) inthe center of the receptacle will check the GFCI function.Both receptacles should be tested at least once a month.

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

Each auxiliary receptacle is protected by a 50 amp circuitbreaker. These breakers are located directly above the GFCIreceptacles. Remember the load output (current) on all threereceptacles is dependent on the load requirements of theOutput Terminal Lugs.Turn the voltage regulator control knob (Figure 11) on thecontrol panel to obtain the desired voltage. Turning the knobclockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 10. 120/240V Twist-LockAuxiliary Receptacles


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 outputterminal panel. These receptacles can only be accessedwhen the voltage selector switch is placed in the single-phase 240/120 position.

Figure 11. Voltage Regulator Control Knob

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The Output Terminal Lugs are protected by a plastic faceplate cover (Figure 12). Un-screw the securing bolts and liftthe plastic terminal cover to gain access to the terminalenclosure.

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


Figure 13. Connecting Loads

Connecting Loads

Loads can be connected to the generator by the OutputTerminal Lugs or the convenience receptacles (Figure 13).Make sure to read the operation manual before attemptingto connect a load to the generator.

To protect the output terminals from overload, a3-pole, 60A main circuit breaker is provided. Make sure toswitch ALL circuit breakers to the OFF position prior tostarting the engine.


Over Current RelayAn over current relay (Figure 14) is connected to the maincircuit breaker. In the event of an overload, both the circuitbreaker and the over current relay may trip. If the circuitbreaker can not be reset, the reset button on the over cur-rent relay must be pressed. The over current relay is lo-cated in the control box.

Figure 14. Over Current Relay

Blower Fan

This unit has an intake fan located at the rear of the machineto draw outside air into the cabinet to cool the engine. Thefan has a 10 amp AC fuse located beneath the VoltageSelector Switch (Figure 15).

Figure 15. Blower Fan Fuse

This fuse has current running through it any time the engineis running. This fuse is NOT connected to the main circuitbreaker of the generator. Attempting to replace the fusewith the engine and/or generator operatingcould result in electrocution and severebodily harm. ALWAYS turn the unitcompletely off before attempting to replaceor handle this fuse.

DANGER - ELECTROCUTION HAZARDS


1

DCA-25SSIU2 (60 HZ)— LOAD APPLICATIONSingle Phase Load

Always be sure to check the nameplate on the generatorand equipment to insure the wattage, amperage, frequency,and voltage requirements are satisfactorily supplied by thegenerator for operating the equipment.

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

Motors and motor-drivenequipment draw much greatercurrent for starting than duringoperation.

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

If wattage is not given on theequipment's name plate,approximate wattage may bedetermined by multiplyingnameplate voltage by thenameplate amperage.

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

If 3Ø load (kVA) is not given onthe equipment nameplate,approximate 3Ø load outputmaybe determined by multiplyingvoltage by amperage by 1.732.

■■■■■ When connecting a resistance load such as anincandescent lamp or electric heater, a capacity of up tothe generating set’s rated output (kW) can be used.

■■■■■ When connecting a fluorescent or mercury lamp, acapacity 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 currentcapacity.

NOTE

WATTS = VOLTAGE x AMPERAGE

Three Phase Load

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

NOTE

An inadequate size connecting cable which cannot carry therequired load can cause a voltage drop which can burn outthe appliance or tool and overheat the cable. See Table 6.

NOTE

Before connecting this generator to any building’s electricalsystem, a licensed electrician must install an isolation(transfer) switch. Serious damage to the building’selectrical system may occur without this transfer switch.

DANGER - ELECTRICAL SYSTEM HAZARDS

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Voltage Selector SwitchThe voltage selector switch (Figure 16) is located abovethe output terminal panel’s Hard Wire Hook-up Panel. Ithas been provided for ease of voltage selection.

Voltage Selector Switch Locking ButtonThe voltage selector switch has a locking button to protectthe generator and load from being switched while the engineis running. To lock the voltage selector switch, press andhold the red button located at the bottom of the switch.

Figure 16. Voltage Selector Switch

DCA-25SSIU2 (60 HZ)— GENERATOR OUTPUTS

NEVER change the position of the voltage selector switchwhile the engine is running. ALWAYS place circuit breakerin the open position before selecting voltage.

CAUTION - CHANGING VOLTAGES

Generator Output VoltagesA wide range of voltages are available to supply voltage formany different applications. Voltages are selected by usingthe voltage selector switch (Figure 16). To obtain some ofthe voltages as listed in Table 7 (see below) will require afine adjustment using the voltage regulator (VR) controlknob located on the control panel.

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Generator AmperageTable 8 describes the generator’s current output capabilityfor both 1Ø-phase and 3Ø phase applications.

GFCI Receptacle Load CapabilityThe load capability of the GFCI receptacles is directly re-lated to the voltage being supplied at either the output termi-nals or the 2 twist lock auxiliary receptacles.

Tables 9 and 10 show what amount of current is available atthe GFCI receptacles when the output terminals and twistlock receptacles are in use. Be careful that your load doesnot to exceed the available current capability at the recep-tacles.

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1

DCA-25SSIU2 (60 HZ)— GAUGE READINGHow to Read the Output Terminal Gauges.The gauges and selector switches on the control panelDO NOT effect the generator output. They are provided tohelp observe how much power is being supplied at theOutput terminals lugs.Before taking a reading off either gauge, set the VoltageSelector Switch (Figure 17) to the position which producesthe required voltage (For example, for 3Ø 240V,choose the center 3Ø 240/139V position on the volt-age selector switch.)

Figure 17. VoltageSelector Switch 240/

139V Three PhasePosition

Figure 18. AC VoltmeterChange-Over Switch

Figure 19. AC Voltmeter Gauge

For 3Ø 208V/1Ø,120V, placethe Voltage Selector Switchin the 3 Phase 240/139position.

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

Figure 20. AC AmmeterChange-Over Switch

Reading VoltageTo determine the voltage between two terminal lugs, set theAC Voltmeter Change-Over Switch to the appropriatesetting (Figure 18) to activate the AC Voltmeter Gauge(Figure 19) and read the available voltage between the twolugs.

For example, to measure the voltage between the W and Uterminal lugs, set the AC Voltmeter Change-Over Switchto W-U and read the AC Voltmeter Gauge.

NOTE

Reading AmperageTo determine the amperage at a terminal lug, set theAC Ammeter Change-Over Switch to the appropriatesetting (Figure 20) to activate the AC Ammeter Gauge(Figure 21) and read the available amperage at the terminallug.

For example, to measure the amperage at the Uterminal lug, set the AC Ammeter Change-Over Switch toU and read the AC Ammeter Gauge.

The ammeter gauge will onlyshow a reading when theOutput Terminal Lugs areconnected to a load and in use.

NOTE


Figure 22. Voltage Selector Switch 240/139VThree-Phase Position

DCA-25SSIU2 (60 HZ)— OUTPUT TERMINAL PANEL CONNECTIONSUVWO Terminal Output VoltagesVarious output voltages can be obtained using the OutputTerminal Lugs.. The voltages at the terminals are depen-dent on the position of the Voltage Selector Switch and theadjustment of the Voltage Regulator Control Knob.Remember the voltage selector switch determines the rangeof the output voltage. The voltage regulator (VR) allows theuser to increase or decrease the selected voltage.

3Ø-240/139 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139position as shown in (Figure 22).

Figure 23. Output Terminal Lugs3Ø-240/139 Three Phase Connections

2. Connect the load wires to the Output Terminal Lugs asshown in (Figure 23).

3. Turn the voltage regulator knob (Figure 24) clockwise toincrease voltage output, turn counterclockwise todecrease voltage output.

3Ø 208V/1Ø120V Output Terminal Lug Voltages

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

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

Use this position for3Ø-208 or 1Ø120V.

2. Connect the load wires to the Output Terminal Lugs asshown in Figure 26.

NOTE

To achieve a 3Ø 208V outputthe voltage selector switchmust be in the 3Ø-240/139position and the voltageregulator must be adjusted to208V.

Figure 26. Output Terminal Lugs3Ø-208/120V Connections

Figure 25. VoltageSelector Switch 240/139V

Three-Phase Position



1

Figure 28. Output Terminal Lugs3Ø-480/277V Three Phase Connections

2. Connect the load wires to the Output Terminal Lugs asshown in Figure 28.

Figure 30. Output Terminal Lugs1Ø-240/120V Connections

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

Figure 27. Voltage Selector Switch 480/277VThree-Phase Position

3Ø 480/277 Output Terminal Lug Voltages1. Place the voltage selector switch in the 3Ø 480/277

position as shown in Figure 27.


1Ø 240V/120V Output Terminal Lug Voltages

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

2. Connect the load wires to the Output Terminal Lugs asshown in (Figure 30).

Figure 29. Voltage Selector Switch 240/120VSingle-Phase Position



DCA-25SSIU2 (60 HZ)— PRE-SETUP

Figure 31. Engine Oil Dipstick

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

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

■■■■■ API Service Classification CC/SC■■■■■ API Service Classification CC/SD■■■■■ API Service Classification CC/SE■■■■■ API Service Classification CC/SF

Circuit Breakers

To protect the generator from an overload, a 3-pole, 60 amp,main circuit breaker is provided to protect the U,V, and WOutput Terminals from overload. In addition two single-pole,20 amp GFCI circuit breakers are provided to protect theGFCI receptacles from overload. Two 50 amp, 2-pole circuitbreakers have also been provided to protect the auxiliaryreceptacles from overload. Make sure to switch ALL circuitbreakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the fillerhole, but DO NOT overfill. Make sure the generator is level,and verify that the oil level is maintained between the twonotches (Figure 31) on the dipstick. See Table 11 for properselection of engine oil.

Figure 32. Internal Fuel Tank System

Refilling the Fuel System

Fuel Check

Located at the bottom-front of the cabinet (Figure 32) is theinternal fuel tank. Some generators may be equipped with atrailer mounted fuel tank (option). ALWAYS fill the either fueltank with clean and fresh #2 diesel fuel. DO NOT fill the fueltanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishingfuel. The fuel tank cap must be closed tightly after filling.Handle fuel in a safety container. If the container does nothave a spout, use a funnel. Wipe up any spilled fuelimmediately.

ONLY properly trained personnel who have read andunderstand this section should refill the fuel tank system.

CAUTION - REFUELING THE GENERATOR

Fuel spillage on a hot engine can cause a fire or explosion.If fuel spillage occurs, wipe up the spilled fuel completelyto prevent fire hazards. NEVER smoke around or near thegenerator.

DANGER - EXPLOSION/FIRE HAZARDS


1

DCA-25SSIU2 (60 HZ)— PRE-SETUPRefueling Procedure:

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

Figure 33. Only Fill on Level Ground

ONLY! use #2 diesel fuel whenrefueling.

NOTE

3. NEVER overfill fuel tank – It is important to read thefuel gauge when filling trailer fuel tank. DO NOT wait forfuel 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 GeneratorALWAYS place trailer on firm level ground before refuelingto prevent spilling and maximize the amount of fuel thatcan be pumped into the tank.


Diesel fuel and its vapors are dangerousto your health and the surroundingenvironment. Avoid skin contact and/orinhaling fumes.

WARNING - RESPIRATORY HAZARDS

DO NOT OVERFILL fuel system. Leave room for fuelexpansion. Fuel expands when heated (Figure 36).



Coolant (Isuzu Antifreeze/Summer Coolant/Water)Isuzu recommends Isuzu Antifreeze/Summer Coolant foruse 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.

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

Operation Freezing Weather

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

Cleaning the Radiator

The engine may overheat if the radiator fins becomeoverloaded with dust or debris. Periodically clean the radiatorfins with compressed air. Cleaning inside the machine isdangerous, so clean only with the engine turned off and thenegative battery terminal disconnected.

Air Cleaner

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

Fan Belt Tension

A slack fan belt may contribute to overheating, or toinsufficient charging of the battery. Inspect the fan belt fordamage and wear and adjust it in accordance with the IsuzuEngine Owner's Manual.

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

Figure 37. Fan Belt Tension

DCA-25SSIU2 (60 HZ)— PRE-SETUP

When the antifreeze is mixed withwater, the antifreeze mixing ratiomust be less than 50%.

NOTE

If adding coolant/antifreeze mix to theradiator, DO NOT remove the radiator capuntil the unit has completely cooled. Thepossibility of hot! coolant exists whichcan cause severe burns.


NEVER place hands near the belts or fan while thegenerator set is running.

CAUTION - ROTATING PARTS

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1

DCA-25SSIU2 (60 HZ)— PRE-SETUPWhen connecting battery do the following:

1. NEVER connect the battery cables to the batteryterminals when the ignition is in the operate or startposition.

2. Place a small amount of battery terminal treatmentcompound around both battery terminals. This will ensurea good connection and will help prevent corrosion aroundthe battery terminals.

Figure 38. Battery Connections

ALWAYS disconnect the negative terminal FIRST andreconnect negative terminal LAST.

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

Alternator

The polarity of the alternator is negative grounding type. Whenan inverted circuit connection takes place, the circuit will bein short circuit instantaneously resulting the alternator failure.

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

Wiring

Inspect the entire generator for bad or worn electrical wiringor 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 forwear and tightness. Tighten all hose clamps and check hosesfor leaks.

If any hose (fuel or oil) lines are defective replace themimmediately.

If the battery cable is connectedincorrectly, electrical damage to thegenerator will occur. Pay closeattention to the polarity of thebattery when connecting thebattery.

NOTE

Battery

This unit is of negative ground DO NOT connect in reverse.Always maintain battery fluid level between the specifiedmarks. Battery life will be shortened, if the fluid level are notproperly maintained. Add only distilled water whenreplenishment is necessary.

DO NOT over fill. Check to see whether the battery cablesare loose. Poor contact may result in poor starting ormalfunctions. Always keep the terminals firmly tightened.Coating the terminals with an approved battery terminaltreatment compound. Replace battery with onlyrecommended type battery. The battery type used in thisgenerator is BCI Group 27.

The battery is sufficiently charged if the specific gravity ofthe battery fluid is 1.28 (at 68° F). If the specific gravityshould fall to 1.245 or lower, it indicates that the battery isdead 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 be sure the battery cables (Figure 38) are properlyconnected to the battery terminals as shown below. The RedCable is connected to the positive terminal of the battery,and the Black Cable is connected to the negative terminalof the battery.

CAUTION - BATTERY SERVICING SAFETY

CAUTION - BATTERY SERVICING SAFETY


6. Preheat the engine glow plugs by turning the ignitionkey (Figure 42) to the “OPERATION” position.

Figure 43. Pre-Heat Indicator Lamp

8. Let the engine run for 3-5 minutes, listen and check forany abnormal sounds or smells. Check for fuel leaks,and noises that would associate with a loose cover orhardware. If any of the above mentioned conditionsexists, shut-down the engine and correct the problem.

7. When the preheat lamp illuminates (Figure 43), turn theignition key to the “START” position. Once the enginestarts, release the ignition key and allow it to return tothe “OPERATION” position (Figure 42).

Figure 42. Ignition Switch (OperationPre-Heat Position)

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

The engine's exhaust contains harmful emissions.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(Figure 39) in the OFF position prior to starting the engine.

2. Connect the load to the receptacles or the OutputTerminal Lugs as shown in Figure 13. These loadconnection points can be found on the output terminalpanel and the output terminal panel’s hard wire hookuppanel.

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 fromslipping out.

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

Figure 39. Main, Aux. and GFCICircuit Breakers (OFF)

NEVER! manually start the engine with the main, GFCIor auxiliary circuit breakers in the ON (closed) position.

5. Place the voltage selector switch in the desired voltageposition (Figure 41).

Figure 41. VoltageSelector Switch

CAUTION - LETHAL EXHAUST HAZARD

WARNING - STARTING THE GENERATOR


1

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

Figure 47. Ammeter (No Load)

12. The ammeter (Figure 47) will indicate zero amps with noload applied. When a load is applied, this meter willindicate the amount of current that the load is drawingfrom the generator.

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

10. The generator's voltage meter (Figure 45) displays the120 VAC in VOLTS. If the voltage is not within the specifiedfrequency tolerance,

Figure 45. AC Voltmeter

Figure 44. Frequency Meter (Hz)

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

Figure 46. Voltage Adjusted Control Knob

13. The engine oil pressure gauge (Figure 48) will indicatethe oil pressure (kg/cm2) of the engine. Under normaloperating conditions the oil pressure is between 28 ~71psi (193 ~490 kPa).

Figure 48. Oil Pressure Gauge

14. The coolant temperature gauge (Figure 49) will indicatethe coolant temperature. Under normal operatingconditions the coolant temperature is between 165 and203 degrees Fahrenheit (74 ~ 95 degrees Celsius).

Figure 49. Coolant Temperature Gauge

Figure 50. Engine Tachometer

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


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).

Figure 53. Main, AUX. and GFCI Circuit Breakers (OFF)

EMERGENCY SHUT-DOWN SHUTDOWN

1. To shut-down the engine in the event of an emergency,switch the MAIN, GFCI and LOAD (Figure 55) circuitbreakers to “OFF” position.

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

2. Let the engine cool by running it for 3-5 minutes with noload 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 54. Ignition Switch (Stop Position)

4. Remove all loads from the generator.

Figure 55. Ignition Switch (Off Position)

DCA-25SSIU2 (60 HZ)— GEN. START-UP PROCEDURE/SHUTDOWN16. Turn the main, GFCI, and aux. circuit breakers to the

“ON” position (Figure 51).

17. Observe the generator's ammeter (Figure 52) and verifyit reads the anticipated amount of current with respectto the load. The ammeter will only display a currentreading if the load is in use.

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

Figure 52. Ammeter (Load)

Figure 51. Main, AUX. and GFCI Circuit Breakers (ON)


1

DCA-25SSIU2 (60 HZ)— MAINTENANCE

Service Daily

If the engine is operating in very dusty or dry grassconditions, a clogged air cleaner will result. This can lead toa loss of power, excessive carbon buildup in the combustionchamber and high fuel consumption. Change air cleanermore frequently if these conditions exists.

Fuel Addition

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

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulatein the bottom of the tank. Occasionally inspect the fueltank for water contamination and drain the contents ifrequired.

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

General Inspection

Prior to each use, the generator should be cleaned andinspected for deficiencies. Check for loose, missing ordamaged nuts, bolts or other fasteners. Also check for fuel,oil, and coolant leaks. Use Table 14 as a general maintenanceguidelineEngine Side (Refer to the Engine InstructionManual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean theheavy duty paper element with light spray of compressedair. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the aircleaner element is clogged, air intake restriction becomesgreater and the dust indicator signal shows RED meaningthe element needs changing or service. After changing theair element, press the dust indicator button to reset theindicator.

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DCA-25SSIU2 (60 HZ)— MAINTENANCE

Allow engine to cool when flushing outradiator. Flushing the radiator while hotcould cause serious burns from water o rsteam.


Generator StorageFor longe term storage of the generator the following isrecommended:

Fill the fuel tank completely. Treat with a fuel stabilizerif necessary.

Completely drain the oil from the crankcase and refill ifnecessary 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 removetires.

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 theradiator cap while draining. Remove the overflow tankand drain.

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

Flush the radiator by running clean tap water throughradiator until signs of rust and dirt are removed. DO NOTclean radiator core with any objects, such as ascrewdriver.

Tighten both cocks and replace the overflow tank.

Replace with coolant (Table 13 for correct mixture). Close radiator cap tightly.

Air RemovalIf air enters the fuel injection system of a diesel engine,starting becomes impossible. After running out of fuel, orafter disassembling the fuel system, bleed the systemaccording 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. Thisunit is equipped with an automatic air bleeding system.

Cleaning the Fuel StrainerClean the fuel strainer if it contains dust or water. Removedust or water in the strainer cap and wash it in gasoline.Securely fasten the fuel strainer cap so that fuel will notleak. Check the fuel strainer every 200 hours of operation oronce a month.

Check Oil LevelCheck the crankcase oil level prior to each use, or when thefuel tank is filled. Insufficient oil may cause severe damageto the engine. Make sure the generator is level. The oil levelmust be between the two notches on the dipstick as shownin (Figure 31).

Replacing Oil Filter 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 turningclockwise. DO NOT over tighten.

After the oil filter has been replaced, the engine oil willdrop slightly. Run the engine for a while and check forleaks before adding more oil if needed. Clean excessiveoil 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 mixedwater. DO NOT spill the fuel during disassembly.

Vent any air..


1

DCA-25SSIU2 (60 HZ)— MAINTENANCEJacket Water Heater and Internal Battery Charger120 VAC Input Receptacles (OPTIONAL)

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

The purpose of these receptacles is to provide power viacommercial power to the jacket water heater and internalbattery charger.These receptacles will ONLY function when commercialpower has been supplied to them (Figure 56). To applycommercial power to these receptacles, a power cord ofadequate size will be required (See Table 6).

When using the generator in hot climates there is no reasonto apply power to jacket water heater. However, if thegenerator will be used in cold climates it is always a goodidea to apply power to the jacket water heater at all times. Toapply power to the jacket water heater simply apply power tothe jacket water heater receptacle via commercial powerusing an power cord of adequate size.

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

To ensure adequate startingcapability, always have powerapplied to the generator'sinternal battery charger.

Figure 56. DCA-25SSIU2 Battery Charger &Jacket Water Heater Power Connections

NOTE


Trailer Maintenance

This section is intended to provide the user with generictrailer service and maintenance information. The service andmaintenance guidelines referenced in this section refer to awide range of trailers.

Remember periodic inspection of the trailer will ensure safetowing of the generator and will prevent personal injury anddamage to the equipment.

The definitions below describe some of the major componentsof a typical trailer that would be used with the DCA-25SSIU2Whisperwatt™ Generator.

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

2. Braking System - System employed in stopping thetrailer. Typical braking systems are electric, surge, hy-draulic, hydraulic-surge and air.

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

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

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum poundrequirement 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(175,185,205, etc.). The tire diameter must match thediameter 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’saxle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim mustmatch 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 lugnuts. See Table 18 and Figure 58 for lug nut tighteningand sequence.

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

14. Suspension - Protects the trailer chassis from shockstransmitted through the wheels. Types of suspensionused are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are providedwith the trailer so the brake lights and turn signals canbe connected to the towing vehicle.

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

DCA-25SSIU2 (60 HZ)— TRAILER MAINTENANCE


1

DCA-25SSIU2 (60 HZ)— TRAILER MAINTENANCEHydraulic Surge BrakesHydraulic surge brakes (Figure 56) should not require anyspecial attention with the exception of routine maintenancesuch as shoe and lining replacement. Brake lines should beperiodically checked for cracks, kinks, or blockage.

Figure 57. Hydraulic Brake Components

BrakesTrailer brakes should be inspected the first 200 miles ofoperation. This will allow the brake shoes and drums to seatproperly. After the first 200 mile interval, inspect the brakesevery 3,000 miles. If driving over rough terrain, inspect thebrakes more frequently.

Figure 57 displays the major hydraulic surge brakecomponents that will require inspection and maintenance.Please inspect these components as required using steps 1through 8 and Table 15 as shown below:

Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

4. With a screwdriver or standard adjusting tool, rotate thestar wheel of the adjuster assembly to expand the brakeshoes.

5. Adjust the brake shoes outward until the pressure of thelining against the wheel drum makes the wheel difficultto turn.

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

7. Replace the adjusting hole cover and lower the trailer tothe ground.

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

ActuatorHydraulic surge braking requires the installation of an actuatorat the tongue of the trailer. Remember the surge or push ofthe trailer toward the tow vehicle automatically synchronizesthe trailer brakes with the tow vehicle brakes. As the trailerpushes against the tow vehicle the actuator telescopestogether and applies force to the master cylinder, supplyinghydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator” to makesure that it is functioning correctly. Never use an undersizeactuator.

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DCA-25SSIU2 (60 HZ)— TRAILER MAINTENANCETires/Wheels/Lug NutsTires and wheels are a very important and criticalcomponents of the trailer. When specifying or replacing thetrailer wheels it is important the wheels, tires, and axle areproperly matched.

Tire Wear/InflationTire inflation pressure is the most important factor in tire life.Pressure should be checked cold before operation DO NOTbleed air from tires when they are hot!. Check inflationpressure weekly during use to insure the maximum tire lifeand tread wear.

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

SuspensionThe leaf suspension springs and associated components(Figure 58) should be visually inspected every 6,000 milesfor signs of excessive wear, elongation of bolt holes, andloosening of fasteners. Replace all damaged parts(suspension) immediately. Torqued suspension componentsas detailed in Table 17.

Figure 58. Major Suspension Components

DO NOT attempt to repair or modify a wheel. DO NOTinstall in inner tube to correct a leak through the rim. If therim is cracked, the air pressure in the innertube may cause pieces of the rim toexplode (break off) with great force andcause serious eye or bodily injury.

CAUTION - REPAIRING TRAILER WHEELS

ALWAYS wear safety glasses whenremoving or installing force fitted parts.Failure to comply may result in seriousinjury.

CAUTION - EYESIGHT HAZARD

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SHACKLE BOLT

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SNUG FIT ONLY. PARTS MUST ROTATE FREELY.LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT-BOLT ASSEMBLY.

SHOULDER TYPE

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1

DCA-25SSIU2 (60 HZ)— TRAILER MAINTENANCELug Nut Torque Requirements

It is extremely important to apply and maintain proper wheelmounting torque on the trailer. Be sure to use only thefasteners matched to the cone angle of the wheel. Properprocedure 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 NOTtorque the wheel lug nuts all the way down. Tighten eachlug 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.

NEVER use an pneumatic airgun to tighten wheel lug nuts.

Figure 59. Wheel Lug NutsTightening Sequence

NOTE

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Figure 60. Trailer/Towing Vehicle Wiring Diagram

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


1

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

Figure 61. Generator Wiring Diagram


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

Figure 62. Engine Wiring Diagram


1

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

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

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DCA-25SSIU2 (60 HZ)— TROUBLESHOOTING (ENGINE)Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of abreakdown, use Table 21 (Engine Troubleshooting) as a basic guideline for troubleshooting the Engine. If the problemcannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTENIGNE.12ELBAT


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

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whisperwatt series model dca-25ssiu2 · 2016. 12. 28. · dca-25ssiu2 (60 hz)— operation and...

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