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Multiquip operation manual PAGE 2 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01

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PAGE 2 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

PAGE 2 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

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Multiquip operation manual PAGE 2 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01

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PARTS LIST NO PARTS AND OPERATION MANUALMQ POWER DCA-25SSAI WHISPERWATTTM GENERATOR SERVICE DEPARTMENTPAGE 2 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 SERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046 HERES HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046MQ POWER DCA-25SSAI AC GENERATOR TABLE OF CONTENTSSpecification and part number are subject to change without notice ISUZU C240 ENGINEExtra PARTS ORDERING PROCEDURESNow! Direct TOLL-FREE access to our Parts Department DiscountPAGE 6 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 GENERAL SAFETYRULES FOR SAFE OPERATION RULES FOR SAFE OPERATION RadiatorRULES FOR SAFE OPERATION BatteryLoading and Unloading Crane Transporting Maintenance SafetyRULES FOR SAFE OPERATION EmergenciesTowing Safety Precautions DCA-25SSAI -TOWING RULES FOR SAFE OPERATIONDCA-25SSAI - TRAILER-SAFETY GUIDELINES Explanation of ChartPAGE 12 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI -TRAILER-SPECIFICATIONSTable 1. Specifications MODELMODEL DCA-25SSAI -TRAILER-SPECIFICATIONSTable 1. Specifications Cont COUPLERTire Wear/Inflation DCA-25SSAI -TRAILER SAFETY GUIDELINESTires/Wheels/Lug Nuts SuspensionLug Nut Torque Requirements DCA-25SSAI -TRAILER SAFETY GUIDELINESTorque Ft.-Lbs Table 3. Suspension Torque RequirementsPAGE 16 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI -TRAILER-WIRING DIAGRAMLIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT DCA-25SSAI - GENERATOR DECALS DCA-25SSAI - GENERATOR DECALS PAGE 18 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01Engine Specifications DCA-25SSAI - SPECIFICATIONSGenerator Specifications Zig ZagEngine Operating Panel DCA-25SSAI - GENERAL INFORMATIONDCA-25SSAI FAMILIARIZATION Generator Generator Control PanelDCA-25SSAI - MAJOR COMPONENTS Figure 4. Major ComponentsPAGE 22 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI - DIMENSIONS TOP, SIDE AND FRONTFigure 5. Dimensions NOTE PAGE PAGE 24 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI - CONTROL PANELFigure 6. Control Panel DCA-25SSAI - CONTROL PANEL 1. Main Circuit Breaker - This three-pole, 60 amp main breaker is provided to protect the UVW voltage output terminals from overloadPAGE 26 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI - ENGINE OPERATING PANELFigure 7. Engine Operating Panel DCA-25SSAI - ENGINE OPERATING PANEL 120 Volt Receptacle Connecting LoadDCA-25SSAI - OUTPUTTERMINAL PANEL Circuit BreakersLegs “O” and Ground are considered Bonded Grounds DCA-25SSAI - OUTPUTTERMINAL PANELFigure 10. Output Terminal Description Output Terminal Panel Available Voltages DCA-25SSAI - OUTPUT AMPERAGE SETUPVoltage Selector Switch Locking Button Over Current RelayTable 8. Receptacle Use DCA-25SSAI - OUTPUT AMPERAGE SETUPHow To Read The Output Terminal Gauges Receptacle UseDCA-25SSAI - OUTPUT VOLTAGE SETUP 240/120V Hard Wire Hookup3 Phase, 480V, 440V, or 416 Volt DCA-25SSAI - OUTPUT VOLTAGE SETUPSingle Phase 480V, 440V, or 416 Volt Single Phase 277V, 254V, orSingle Phase 139V, 127V, or Single Phase 240V, 220V, or 208 Volt3 Phase, 240V, 220V, or 208 Volt DCA-25SSAI - OUTPUT VOLTAGE SETUPSingle Phase 120 Volt DCA-25SSAI - OUTPUT VOLTAGE SETUPVoltage Selector Switch- Single Phase 240/120V Position Single Phase, 240 VoltMounting DCA-25SSAI - INSTALLATIONOutdoor Installation DCA-25SSAI - INSTALLATION Figure 30. Typical Generator Grounding Application#10 Wire DCA-25SSAI - PRE-SETUPTable 9. Cable Selection 60 Hz, Single Phase Operation #12 WireDCA-25SSAI - PRE-SETUP Table 10. Recommended Motor OilLubrication Oil Figure 31. Engine Oil DipstickAdjusting Fan Belt Cleaning the Outer RadiatorAir Cleaner Fan Belt TensionWiring DCA-25SSAI - PRE-SETUPBattery Cable Installation Piping and Hose ConnectionDCA-25SSAI - LOAD APPLICATION Single Phase LoadThree Phase Load Before Starting Generator and Control Panel DCA-25SSAI - GENERATOR START-UP PROCEDUREBefore Starting Engine Figure 41. Ignition Switch ‘START’ DCA-25SSAI - GENERATOR START-UP PROCEDUREFigure 38. Voltage Selection Switch Figure 40. Ignition Switch ‘PREHEAT’ Figure 44. Voltage Meter VoltsDCA-25SSAI - GENERATOR START-UP PROCEDURE DCA-25SSAI - GENERATOR SHUTDOWN PROCEDURE ENGINE SHUTDOWNNOTE PAGE Cleaning the Fuel Strainer DCA-25SSAI - MAINTENANCEService Daily General InspectionINSPECTION / MAINTENANCE Generator StorageDCA-25SSAI - MAINTENANCE 10 HrsDCA-25SSAI - GENERATORWIRING DIAGRAM PAGE 50 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01DCA-25SSAI - ENGINEWIRING DIAGRAM SYMPTOM DCA-25SSAI -TROUBLESHOOTING ENGINETABLE 14. ENGINE TROUBLESHOOTING POSSIBLE PROBLEMSYMPTOM DCA-25SSAI -TROUBLESHOOTING ENGINETABLE 14. ENGINE TROUBLESHOOTING CONTINUED POSSIBLE PROBLEMSYMPTOM DCA-25SSAI -TROUBLESHOOTING GENERATORTABLE 17. GENERATOR TROUBLESHOOTING POSSIBLE PROBLEMNOTE PAGE Items Found In the “Remarks” Column How to read the marks and remarks used in this parts bookEXPLANATION OF CODE IN REMARKS COLUMN Items Found In the “Items Number” ColumnDCA-25SSAI W/ISUZU C240 DIESEL ENGINE 1 TO 3 UNITS DCA-25SSAI - SUGGESTED SPARE PARTSDescription PAGE 58 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- GENERATOR ASSYGENERATOR ASSY DCA-25SSAI GENERATOR ASSYDCA-25SSAI --- GENERATOR ASSY PAGE 60 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01REMARKS DCA-25SSAI --- GENERATOR ASSYPAGE 62 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- CONTROL BOX ASSYCONTROL BOX ASSY REMARKS CONTROL BOX ASSYDCA-25SSAI CONTROL BOX ASSYDCA-25SSAI --- CONTROL BOX ASSY PAGE 64 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01REMARKS DCA-25SSAICONTROL BOX ASSY PAGE 66 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI ENGINE AND RADIATOR ASSYENGINE AND RADIATOR ASSY REPLACES 0602000008 ISUZU C240 DCA-25SSAI ENGINE AND RADIATOR ASSYREMARKS REPLACES 0602040069FWG058036DCA-25SSAI ENGINE AND RADIATOR ASSY PAGE 68 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01EARTH CABLE DCA-25SSAI ENGINE AND RADIATOR ASSYREMARKS PAGE 70 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- ENGINE OPERATING PANEL ASSYENGINE OPERATING PANEL ASSY REPLACES 060212005225000KX3710 ENGINE OPERATING PANEL ASSYDCA-25SSAI BRACKET, ENGINE STOPPERDCA-25SSAI --- ENGINE OPERATING PANEL ASSY PAGE 72 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01REMARKS DCA-25SSAIENGINE OPERATING PANEL ASSY SET BOARD, OUTPUT TERMINALPAGE 74 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- BATTERY ASSYBATTERY ASSY REMARKS BATTERY ASSYDCA-25SSAI PAGE 76 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- MUFFLER ASSYMUFFLER ASSY REMARKS MUFFLER ASSYDCA-25SSAI 7342311002APAGE 78 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- FUEL TANK ASSYFUEL TANK ASSY REMARKS FUEL TANK ASSYDCA-25SSAI PAGE 80 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- ENCLOSURE ASSYENCLOSURE ASSY REMARKS ENCLOSURE ASSYDCA-25SSAI DCA-25SSAI --- ENCLOSURE ASSY PAGE 82 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01REMARKS DCA-25SSAIENCLOSURE ASSY PAGE 84 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 DCA-25SSAI --- DECALSDECAL ASSY REMARKS DECALSDCA-25SSAI PAGE 86 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 --- CYLINDER HEAD AND COVER ASSYCYLINDER HEAD AND COVER ASSY CYLINDER HEAD OIL COOLER PLUG ISUZU C240 --- CYLINDER HEAD AND COVER ASSYINLET AND EXHAUST VALVE SEAL REMARKSPAGE 88 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 --- CYLINDER BLOCK ASSYCYLINDER BLOCK ASSY TAPPET CHAMBER COVER ASSY ISUZU C240 --- CYLINDER BLOCK ASSYREMARKS TAPPET CHAMBER COVER CLIPPAGE 90 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 ---TIMING GEAR ASSYTIMING GEAR ASSY ISUZU C240 ---TIMING GEAR ASSY PAGE 92 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 FLYWHEEL HOUSING ASSYFLYWHEEL HOUSING ASSY ISUZU C240 FLYWHEEL HOUSING ASSY STIFFENER RIGHT SIDEPAGE 94 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 OIL PAN ASSYOIL PAN ASSY ISUZU C240 OIL PAN ASSY REMARKSPAGE 96 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 ---OIL PUMP ASSYOIL PUMP ASSY INCL. ITEMS W ISUZU C240 ---OIL PUMP ASSY22*% INCL. ITEMS W/#PAGE 98 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSYCRANKSHAFT, BRIDGE AND FLYWHEEL ASSY REMARKS CONNECTING ROD ASSYISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY 9-1@ISUZU C240 --- OIL AND FUEL FILTER ASSY OIL AND FUEL FILTER ASSYREMARKS ISUZU C240OIL AND FUEL FILTER ASSY ISUZU C240 --- OIL PIPE ASSY OIL PIPE ASSYISUZU C240 OIL PIPE ASSYISUZU C240 --- WATER PUMP AND FAN ASSY WATER PUMP AND FAN ASSYREMARKS ADJUSTING FAN BELT PLATEISUZU C240 --- WATER PUMP AND FAN ASSY WATER PUMP ASSYISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY INTAKE AND EXHAUST MAINIFOLD ASSYINTAKE AND EXHAUST MANIFOLD ASSY WIRE CONTROL BRACKETISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY ISUZU C240 --- AIR CLEANER ASSY AIR CLEANER ASSYAIR CLEANER ASSY ISUZU C240 --- AIR CLEANER ASSYAIR CLEANER ASSY REMARKSISUZU C240 --- ENGINE FOOT ASSY ENGINE FOOT ASSYENGINE FOOT ASSY ISUZU C240 --- ENGINE FOOT ASSYQTY. REMARKS ISUZU C240 --- INJECTION PUMP ASSY INJECTION PUMP ASSYREMARKS INJECTION PUMP ASSYISUZU C240 INJ. PUMP SPACER BRACKETISUZU C240 --- ELECTRICAL PARTS ELECTRICAL PARTSREMARKS ELECTRICAL PARTSISUZU C240 ELECTRICAL PARTSISUZU C240 --- ACCESSORIES ACCESSORIESREMARKS ACCESSORIESISUZU C240 DRIVE ASSYISUZU C240 ---INJECTION PUMP COMP. ASSY INJECTION PUMP COMP. ASSYISUZU C240 --- INJECTION PUMP COMP. ASSY REMARKSISUZU C240 --- INJECTION PUMP COMP. ASSY ISUZU C240 --- INJECTION PUMP COMP. ASSY ISUZU C240 --- INJECTION PUMP COMP. ASSY ISUZU C240 --- INJECTION PUMP COMP. ASSY QTY. REMARKSISUZU C240 ---GOVERNOR COMP. ASSY GOVERNOR COMP. ASSYREMARKS GOVERNOR COMP. ASSYISUZU C240 ISUZU C240 --- GOVERNOR COMP. ASSY REMARKS GOVERNOR COMP. ASSYISUZU C240 ISUZU C240 --- FEED PUMP COMP. ASSY FEED PUMP COMP. ASSYREMARKS FEED PUMP COMP. ASSYISUZU C240 ISUZU C240 --- AUTO TIMER COMP. ASSY AUTO TIMER COMP. ASSYISUZU C240 --- AUTO TIMER COMP. ASSY REMARKSISUZU C240 --- NOZZLE HOLDER COMP. ASSY NOZZLE HOLDER COMP. ASSYPUSH ROD ISUZU C240 --- NOZZLE HOLDER COMP. ASSYREMARKS ISUZU C240 ---STARTER COMP. ASSY STARTER COMP. ASSYISUZU C240 STARTER COMP. ASSYMAGNETIC SWITCH ASSY REMARKSISUZU C240 --- ALTERNATOR COMP. ASSY ALTERNATOR COMP. ASSY. OCT. 1992~REMARKS ALTERNATOR COMP. ASSYISUZU C240 10*#%ISUZU C240 ---ALTERNATOR COMP. ASSY ALTERNATOR COMP. ASSY. BEFORE OCTREMARKS ISUZU C240ALTERNATOR COMP. ASSY 27*#11. Credit issued will be applied to future purchases only Effective July 1TERMS AND CONDITIONS OF SALE - PARTS SPECIAL EXPEDITING SERVICENOTE PAGE SERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046 HERES HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046