MULTIQUIP WHISPERWATT DCA-25SSIU2 Guide

PARTS 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. M1870300804

PAGE 2 — 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
1
© 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 with
permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and
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
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 this
publication, visit our website at:
www.mqpower.com
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
Carson, CA 90746 FAX: [phone]
Email:[e-mail]
Internet:www.mqpower.com
PARTS DEPARTMENT
800-427-1244 FAX: [phone]
310-537-3700
FAX: [phone]
SERVICE DEPARTMENT
800-835-2551 FAX: [phone]
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551 FAX: [phone]
WARRANTY DEPARTMENT
800-835-2551, EXT. 279 FAX: [phone]
310-537-3700, EXT. 279

PAGE 4 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
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
WHISPERWHISPER
WHISPERWW
WW
WAA
AA
ATT™ GENERATT™ GENERA
TT™ GENERATT™ GENERA
TT™ GENERATORTOR
TORTOR
TOR
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
COMPONENT DRACOMPONENT DRA
COMPONENT DRACOMPONENT DRA
COMPONENT DRAWINGSWINGS
WINGSWINGS
WINGS
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
Specification and part
number are subject to
change without notice.
NOTE

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 5
1
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.
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 at no charge for freight
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.
Place Your Parts Order Via Web or Fax
For Even More Savings!
(Domestic USA Dealers Only)
NOTE:DISCOUNTS ARESUBJECT TO CHANGE
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
Carson, CA 90746
FAX: [phone]
Email: [e-mail]
Internet: www.mqpower.com
PARTS DEPARTMENT
800-427-1244 FAX: [phone]
310-537-3700 FAX: [phone]
SERVICE DEPARTMENT
800-835-2551 FAX: [phone]
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551 FAX: [phone]
WARRANTY DEPARTMENT
800-835-2551, EXT. 279 FAX: [phone]
310-537-3700,
EXT. 279
Direct TOLL-FREE access
to our Parts Department:
Toll-free nationwide — 800-427-1244
Toll-free FAX — 800-6-PARTS-7 (800/672-7877)
PARTS ORDERING PROCEDURES
MQPOWER
A Division of Multiquip Inc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: [phone]
E-MAIL: [email protected]
INTERNET: www.mqpower.com

PAGE 6 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— SPECIFICATIONS
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DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 7
1
DCA-25SSIU2 (60 HZ)— DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
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PAGE 8 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
Before using this generator,ensure that the operating
individual has read and understands all instructions in
this manual.
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.
FOR YOUR SAFETY AND THE SAFETY OF OTHERS! HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "
Hazard Symbols " which
appear throughout this manual, and will be referenced in
conjunction 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 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.
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
You CAN be injured if you do not follow directions
Diesel engine exhaust gases contain
poisonous carbon monoxide. 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 extremely flammable, and
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.
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.
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.
WARNING
CAUTION
WARNING - LETHAL EXHAUST GASES
WARNING - BURN HAZARDS
WARNING - EXPLOSIVE FUEL
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
DANGER - ELECTROCUTION HAZARDS
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
DANGER
This Operation and Parts Manual
has been developed to provide
complete instructions for the safe
and efficient operation of the MQ
Power
Model DCA-25SSIU2
(60Hz) Whisperwatt™ Generator.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 9
1
DCA-25SSIU2 (60 HZ) — SAFETY MESSAGE ALERT SYMBOLS
ALWAYS place the Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump is not in
use.
ALWAYS wear approved respiratory
protection.
ALWAYS wear approved eye and
hearing protection.
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
This generator, other property, or
the surrounding environment
could be damaged if you do not
follow instructions.
NOTE
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.
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 moving
parts to prevent injury.
WARNING - ROTATING PARTS

PAGE 10 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION
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.
■ 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.
Failure to follow instructions in this manual may 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 - READ THIS MANUAL!
■ 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
bodily harm or even death.
■ NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or generator.
■ HighTemperatures – 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. NEVER operate the generator in any
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.
■ 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 manual mode
unattended.
■ Refer to the Isuzu Engine Owner's Manual for engine
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.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 11
1
DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION
POWER
CORD
(POWER ON)
WET
HANDS
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn,
which can cause
severe bodily harm or even DEATH!
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
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.
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
DANGER - ELECTROCUTION HAZARDS
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
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.
The following safety recommendations should also be
followed:
■ ALWAYS make sure generator is properly grounded.
■ NEVER use gas piping as an electrical ground.
■ ALWAYS make sure that electrical circuits are properly
grounded per the National Electrical Code (NEC) and
local codes before operating generator. Severe injury or
DEATH! 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.
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 lay in wate r.
■ NEVER stand in water while AC power from the generator
is being transfer to a load.

PAGE 12 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION
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, always wear safety
glasses.
■ Use well insulated gloves when picking up the battery.
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 NEGATIVE battery terminal
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.
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.
■ 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.
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 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 clothing or skin , rinse skin or clothing
immediately with plenty of water.
■■
■■
■ In case the battery liquid (dilute sulfuric acid) comes in
contact with your EYES , rinse eyes immediately with
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
The risk of an explosion exists when performing service
on the battery. To avoid
severe injury or DEATH:
■■
■■
■
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.
DANGER - EXPLOSION HAZARDS

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 13
1
Emergencies
■ ALWAYS know the location of the
nearest fire extinguisher .
■ ALWAYS know the location of the
nearest and first aid kit .
■ ALWAYS know the location of the
nearest phone or keep a phone on
the job site, in case of emergencies.
■ ALWAYS have easy access to the phone
numbers of the nearest Ambulance , Doctor
and Fire Department . This information will
be invaluable in the case of an emergency.
DCA-25SSIU2 (60 HZ)— RULES FOR SAFE OPERATION
Check with your local county or state safety towing
regulations, in addition to meeting
Department of
Transportation (DOT) SafetyTowing Regulations , before
towing your generator.
CAUTION - FOLLOW TOWING REGULATIONS
■ 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 chock blocks underneath wheel to prevent rolling,
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 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 tank.
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:
■ 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 Towing & Transporting Safety
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.
■ Check the tire air pressure on both towing vehicle and
trailer. 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 "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:
 Connect and test electric brake operation.
 Secure portable power cables in cable tray with tie
wraps.

PAGE 14 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
The DCA-25SSIU2 (60 Hz)Whisperwatt ™ Generator is equipped with a number of safety 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 any of these decals become unreadable, replacements can be
obtained from your dealer.
DCA-25SSIU2 (60 HZ)— GENERATOR DECALS
Figure 2. Generator Decals

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 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
Figure 4. Typical Generator Grounding Application
DCA-25SSIU2 (60 HZ)— INSTALLATION

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 17
1
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.
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.
When connecting the generator
to any buildings electrical
system ALWAYS consult with
a 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 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.
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.
CAUTION - EXHAUST HAZARD

PAGE 18 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
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
Generator Control Panel
The “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 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)
Open Delta Excitation System
The DCA-25SSIU2 (60 HZ) generator is equipped with the
state of the art "
Open-Delta " excitation system. The open
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
excitation does not have a "
fixed ceiling " and responds
according the demands of the required load.

DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06) — PAGE 19
1
DCA-25SSIU2 (60 HZ)— MAJOR COMPONENTS
Figure 5. Major Components
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PAGE 20 — DCA-25SSIU2 (60 HZ)— OPERATION AND PARTS MANUAL — REV. #0 (01/27/06)
DCA-25SSIU2 (60 HZ)— 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 U,V, and W Output
Terminal Lugs from overload.
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
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 .
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
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
Located behind the generator control panel is the Generator
Control Box . This box contains some of the necessary
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
Figure 6. Generator Control Panel
Remember the overcurrent
relay monitors the current
flowing from the U,V, and W
Output Terminal Lugs to the
load.
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 Output Terminal Panel , press the
reset button on the overcurrent relay and place the main
circuit breaker in the closed position (ON).
NOTE