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Multiquip DCA-25SSAI operation manual Parts And Operation Manual, Final Copy 06/30/01

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PARTS AND OPERATION MANUAL

MQ POWER

DCA-25SSAI

WHISPERWATTTM

GENERATOR

PARTS LIST NO. 3336000

Final Copy (06/30/01)

MULTIQUIP INC.	PARTS DEPARTMENT:
18910 WILMINGTON AVE.	800-427-1244
CARSON, CALIFORNIA 90746	FAX: 800-672-7877
310-537-3700	SERVICE DEPARTMENT:
800-421-1244	800-835-2551
FAX:310-537-3927	FAX:310-638-8046

E-mail:mq@multiquip.com • www:multiquip.com

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Multiquip operation manual Parts And Operation Manual, MQ POWER DCA-25SSAI WHISPERWATTTM GENERATOR, Final Copy 06/30/01

Contents

MQ POWER DCA-25SSAI WHISPERWATTTM GENERATOR PARTS AND OPERATION MANUALPARTS LIST NO SERVICE DEPARTMENTPAGE 2 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING HERES HOW TO GET HELPSERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046 WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046Specification and part number are subject to change without notice TABLE OF CONTENTSMQ POWER DCA-25SSAI AC GENERATOR ISUZU C240 ENGINENow! Direct TOLL-FREE access to our Parts Department PARTS ORDERING PROCEDURESExtra DiscountRULES FOR SAFE OPERATION GENERAL SAFETYPAGE 6 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 Radiator RULES FOR SAFE OPERATIONLoading and Unloading Crane BatteryRULES FOR SAFE OPERATION RULES FOR SAFE OPERATION Maintenance SafetyTransporting EmergenciesDCA-25SSAI -TOWING RULES FOR SAFE OPERATION Towing Safety PrecautionsExplanation of Chart DCA-25SSAI - TRAILER-SAFETY GUIDELINESTable 1. Specifications DCA-25SSAI -TRAILER-SPECIFICATIONSPAGE 12 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 MODELTable 1. Specifications Cont DCA-25SSAI -TRAILER-SPECIFICATIONSMODEL COUPLERTires/Wheels/Lug Nuts DCA-25SSAI -TRAILER SAFETY GUIDELINESTire Wear/Inflation SuspensionTorque Ft.-Lbs DCA-25SSAI -TRAILER SAFETY GUIDELINESLug Nut Torque Requirements Table 3. Suspension Torque RequirementsLIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT DCA-25SSAI -TRAILER-WIRING DIAGRAMPAGE 16 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI - GENERATOR DECALS PAGE 18 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI - GENERATOR DECALSGenerator Specifications DCA-25SSAI - SPECIFICATIONSEngine Specifications Zig ZagDCA-25SSAI FAMILIARIZATION Generator DCA-25SSAI - GENERAL INFORMATIONEngine Operating Panel Generator Control PanelFigure 4. Major Components DCA-25SSAI - MAJOR COMPONENTSFigure 5. Dimensions DCA-25SSAI - DIMENSIONS TOP, SIDE AND FRONTPAGE 22 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 NOTE PAGE Figure 6. Control Panel DCA-25SSAI - CONTROL PANELPAGE 24 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 1. Main Circuit Breaker - This three-pole, 60 amp main breaker is provided to protect the UVW voltage output terminals from overload DCA-25SSAI - CONTROL PANELFigure 7. Engine Operating Panel DCA-25SSAI - ENGINE OPERATING PANELPAGE 26 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI - ENGINE OPERATING PANEL DCA-25SSAI - OUTPUTTERMINAL PANEL Connecting Load120 Volt Receptacle Circuit BreakersFigure 10. Output Terminal Description DCA-25SSAI - OUTPUTTERMINAL PANELLegs “O” and Ground are considered Bonded Grounds Voltage Selector Switch Locking Button DCA-25SSAI - OUTPUT AMPERAGE SETUPOutput Terminal Panel Available Voltages Over Current RelayHow To Read The Output Terminal Gauges DCA-25SSAI - OUTPUT AMPERAGE SETUPTable 8. Receptacle Use Receptacle Use240/120V Hard Wire Hookup DCA-25SSAI - OUTPUT VOLTAGE SETUPSingle Phase 480V, 440V, or 416 Volt DCA-25SSAI - OUTPUT VOLTAGE SETUP3 Phase, 480V, 440V, or 416 Volt Single Phase 277V, 254V, or3 Phase, 240V, 220V, or 208 Volt Single Phase 240V, 220V, or 208 VoltSingle Phase 139V, 127V, or DCA-25SSAI - OUTPUT VOLTAGE SETUPVoltage Selector Switch- Single Phase 240/120V Position DCA-25SSAI - OUTPUT VOLTAGE SETUPSingle Phase 120 Volt Single Phase, 240 VoltOutdoor Installation DCA-25SSAI - INSTALLATIONMounting Figure 30. Typical Generator Grounding Application DCA-25SSAI - INSTALLATIONTable 9. Cable Selection 60 Hz, Single Phase Operation DCA-25SSAI - PRE-SETUP#10 Wire #12 WireLubrication Oil Table 10. Recommended Motor OilDCA-25SSAI - PRE-SETUP Figure 31. Engine Oil DipstickAir Cleaner Cleaning the Outer RadiatorAdjusting Fan Belt Fan Belt TensionBattery Cable Installation DCA-25SSAI - PRE-SETUPWiring Piping and Hose ConnectionThree Phase Load Single Phase LoadDCA-25SSAI - LOAD APPLICATION Before Starting Engine DCA-25SSAI - GENERATOR START-UP PROCEDUREBefore Starting Generator and Control Panel Figure 38. Voltage Selection Switch DCA-25SSAI - GENERATOR START-UP PROCEDUREFigure 41. Ignition Switch ‘START’ Figure 40. Ignition Switch ‘PREHEAT’ Figure 44. Voltage Meter VoltsDCA-25SSAI - GENERATOR START-UP PROCEDURE ENGINE SHUTDOWN DCA-25SSAI - GENERATOR SHUTDOWN PROCEDURENOTE PAGE Service Daily DCA-25SSAI - MAINTENANCECleaning the Fuel Strainer General InspectionDCA-25SSAI - MAINTENANCE Generator StorageINSPECTION / MAINTENANCE 10 HrsPAGE 50 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI - GENERATORWIRING DIAGRAMDCA-25SSAI - ENGINEWIRING DIAGRAM TABLE 14. ENGINE TROUBLESHOOTING DCA-25SSAI -TROUBLESHOOTING ENGINESYMPTOM POSSIBLE PROBLEMTABLE 14. ENGINE TROUBLESHOOTING CONTINUED DCA-25SSAI -TROUBLESHOOTING ENGINESYMPTOM POSSIBLE PROBLEMTABLE 17. GENERATOR TROUBLESHOOTING DCA-25SSAI -TROUBLESHOOTING GENERATORSYMPTOM POSSIBLE PROBLEMNOTE PAGE EXPLANATION OF CODE IN REMARKS COLUMN How to read the marks and remarks used in this parts bookItems Found In the “Remarks” Column Items Found In the “Items Number” ColumnDescription DCA-25SSAI - SUGGESTED SPARE PARTSDCA-25SSAI W/ISUZU C240 DIESEL ENGINE 1 TO 3 UNITS GENERATOR ASSY DCA-25SSAI --- GENERATOR ASSYPAGE 58 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 GENERATOR ASSY DCA-25SSAIPAGE 60 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- GENERATOR ASSYDCA-25SSAI --- GENERATOR ASSY REMARKSCONTROL BOX ASSY DCA-25SSAI --- CONTROL BOX ASSYPAGE 62 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI CONTROL BOX ASSYREMARKS CONTROL BOX ASSYPAGE 64 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- CONTROL BOX ASSYCONTROL BOX ASSY DCA-25SSAIREMARKS ENGINE AND RADIATOR ASSY DCA-25SSAI ENGINE AND RADIATOR ASSYPAGE 66 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 REMARKS DCA-25SSAI ENGINE AND RADIATOR ASSYREPLACES 0602000008 ISUZU C240 REPLACES 0602040069FWG058036PAGE 68 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI ENGINE AND RADIATOR ASSYREMARKS DCA-25SSAI ENGINE AND RADIATOR ASSYEARTH CABLE ENGINE OPERATING PANEL ASSY DCA-25SSAI --- ENGINE OPERATING PANEL ASSYPAGE 70 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI ENGINE OPERATING PANEL ASSYREPLACES 060212005225000KX3710 BRACKET, ENGINE STOPPERPAGE 72 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- ENGINE OPERATING PANEL ASSYENGINE OPERATING PANEL ASSY DCA-25SSAIREMARKS SET BOARD, OUTPUT TERMINALBATTERY ASSY DCA-25SSAI --- BATTERY ASSYPAGE 74 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI BATTERY ASSYREMARKS MUFFLER ASSY DCA-25SSAI --- MUFFLER ASSYPAGE 76 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI MUFFLER ASSYREMARKS 7342311002AFUEL TANK ASSY DCA-25SSAI --- FUEL TANK ASSYPAGE 78 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI FUEL TANK ASSYREMARKS ENCLOSURE ASSY DCA-25SSAI --- ENCLOSURE ASSYPAGE 80 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI ENCLOSURE ASSYREMARKS PAGE 82 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- ENCLOSURE ASSYENCLOSURE ASSY DCA-25SSAIREMARKS DECAL ASSY DCA-25SSAI --- DECALSPAGE 84 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI DECALSREMARKS CYLINDER HEAD AND COVER ASSY ISUZU C240 --- CYLINDER HEAD AND COVER ASSYPAGE 86 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 INLET AND EXHAUST VALVE SEAL ISUZU C240 --- CYLINDER HEAD AND COVER ASSYCYLINDER HEAD OIL COOLER PLUG REMARKSCYLINDER BLOCK ASSY ISUZU C240 --- CYLINDER BLOCK ASSYPAGE 88 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 REMARKS ISUZU C240 --- CYLINDER BLOCK ASSYTAPPET CHAMBER COVER ASSY TAPPET CHAMBER COVER CLIPTIMING GEAR ASSY ISUZU C240 ---TIMING GEAR ASSYPAGE 90 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 ---TIMING GEAR ASSY FLYWHEEL HOUSING ASSY ISUZU C240 FLYWHEEL HOUSING ASSYPAGE 92 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 STIFFENER RIGHT SIDE ISUZU C240 FLYWHEEL HOUSING ASSYOIL PAN ASSY ISUZU C240 OIL PAN ASSYPAGE 94 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 REMARKS ISUZU C240 OIL PAN ASSYOIL PUMP ASSY ISUZU C240 ---OIL PUMP ASSYPAGE 96 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 22*% ISUZU C240 ---OIL PUMP ASSYINCL. ITEMS W INCL. ITEMS W/#CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSYPAGE 98 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY CONNECTING ROD ASSYREMARKS 9-1@OIL AND FUEL FILTER ASSY ISUZU C240 --- OIL AND FUEL FILTER ASSYOIL AND FUEL FILTER ASSY ISUZU C240REMARKS OIL PIPE ASSY ISUZU C240 --- OIL PIPE ASSYOIL PIPE ASSY ISUZU C240WATER PUMP AND FAN ASSY ISUZU C240 --- WATER PUMP AND FAN ASSYISUZU C240 --- WATER PUMP AND FAN ASSY ADJUSTING FAN BELT PLATEREMARKS WATER PUMP ASSYINTAKE AND EXHAUST MAINIFOLD ASSY ISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSYISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY WIRE CONTROL BRACKETINTAKE AND EXHAUST MANIFOLD ASSY AIR CLEANER ASSY ISUZU C240 --- AIR CLEANER ASSYAIR CLEANER ASSY ISUZU C240 --- AIR CLEANER ASSYAIR CLEANER ASSY REMARKSENGINE FOOT ASSY ISUZU C240 --- ENGINE FOOT ASSYQTY. REMARKS ISUZU C240 --- ENGINE FOOT ASSYENGINE FOOT ASSY INJECTION PUMP ASSY ISUZU C240 --- INJECTION PUMP ASSYISUZU C240 INJECTION PUMP ASSYREMARKS INJ. PUMP SPACER BRACKETELECTRICAL PARTS ISUZU C240 --- ELECTRICAL PARTSISUZU C240 ELECTRICAL PARTSREMARKS ELECTRICAL PARTSACCESSORIES ISUZU C240 --- ACCESSORIESISUZU C240 ACCESSORIESREMARKS DRIVE ASSYINJECTION PUMP COMP. ASSY ISUZU C240 ---INJECTION PUMP COMP. ASSYREMARKS ISUZU C240 --- INJECTION PUMP COMP. ASSYISUZU C240 --- INJECTION PUMP COMP. ASSY ISUZU C240 --- INJECTION PUMP COMP. ASSY ISUZU C240 --- INJECTION PUMP COMP. ASSY QTY. REMARKS ISUZU C240 --- INJECTION PUMP COMP. ASSYGOVERNOR COMP. ASSY ISUZU C240 ---GOVERNOR COMP. ASSYISUZU C240 GOVERNOR COMP. ASSYREMARKS ISUZU C240 --- GOVERNOR COMP. ASSY ISUZU C240 GOVERNOR COMP. ASSYREMARKS FEED PUMP COMP. ASSY ISUZU C240 --- FEED PUMP COMP. ASSYISUZU C240 FEED PUMP COMP. ASSYREMARKS AUTO TIMER COMP. ASSY ISUZU C240 --- AUTO TIMER COMP. ASSYREMARKS ISUZU C240 --- AUTO TIMER COMP. ASSYNOZZLE HOLDER COMP. ASSY ISUZU C240 --- NOZZLE HOLDER COMP. ASSYREMARKS ISUZU C240 --- NOZZLE HOLDER COMP. ASSYPUSH ROD STARTER COMP. ASSY ISUZU C240 ---STARTER COMP. ASSYMAGNETIC SWITCH ASSY STARTER COMP. ASSYISUZU C240 REMARKSALTERNATOR COMP. ASSY. OCT. 1992~ ISUZU C240 --- ALTERNATOR COMP. ASSYISUZU C240 ALTERNATOR COMP. ASSYREMARKS 10*#%ALTERNATOR COMP. ASSY. BEFORE OCT ISUZU C240 ---ALTERNATOR COMP. ASSYALTERNATOR COMP. ASSY ISUZU C240REMARKS 27*#TERMS AND CONDITIONS OF SALE - PARTS Effective July 111. Credit issued will be applied to future purchases only SPECIAL EXPEDITING SERVICENOTE PAGE PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING HERES HOW TO GET HELPSERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046 WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046

PARTS AND OPERATION MANUAL

MQ POWER

PARTS LIST NO. 3336000

Final Copy (06/30/01)

MULTIQUIP INC.