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Multiquip DCA-25SSAI operation manual ISUZU C240 FLYWHEEL HOUSING ASSY, Flywheel Housing Assy

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ISUZU C240 FLYWHEEL HOUSING ASSY.

ISUZU C240 FLYWHEEL HOUSING ASSY.

FLYWHEEL HOUSING ASSY.

PAGE 92 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

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Multiquip DCA-25SSAI operation manual ISUZU C240 FLYWHEEL HOUSING ASSY, Flywheel Housing Assy

Contents

PARTS AND OPERATION MANUAL MQ POWER DCA-25SSAI WHISPERWATTTM GENERATORPARTS LIST NO SERVICE DEPARTMENTPAGE 2 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 HERES HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLINGSERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046 WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046TABLE OF CONTENTS Specification and part number are subject to change without noticeMQ POWER DCA-25SSAI AC GENERATOR ISUZU C240 ENGINEPARTS ORDERING PROCEDURES Now! Direct TOLL-FREE access to our Parts DepartmentExtra 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 Maintenance Safety RULES FOR SAFE OPERATIONTransporting EmergenciesTowing Safety Precautions DCA-25SSAI -TOWING RULES FOR SAFE OPERATIONDCA-25SSAI - TRAILER-SAFETY GUIDELINES Explanation of ChartDCA-25SSAI -TRAILER-SPECIFICATIONS Table 1. SpecificationsPAGE 12 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 MODELDCA-25SSAI -TRAILER-SPECIFICATIONS Table 1. Specifications ContMODEL COUPLERDCA-25SSAI -TRAILER SAFETY GUIDELINES Tires/Wheels/Lug NutsTire Wear/Inflation SuspensionDCA-25SSAI -TRAILER SAFETY GUIDELINES Torque Ft.-LbsLug Nut Torque Requirements 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 06/30/01DCA-25SSAI - SPECIFICATIONS Generator SpecificationsEngine Specifications Zig ZagDCA-25SSAI - GENERAL INFORMATION DCA-25SSAI FAMILIARIZATION GeneratorEngine Operating Panel 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 Connecting Load DCA-25SSAI - OUTPUTTERMINAL PANEL120 Volt Receptacle Circuit BreakersLegs “O” and Ground are considered Bonded Grounds DCA-25SSAI - OUTPUTTERMINAL PANELFigure 10. Output Terminal Description DCA-25SSAI - OUTPUT AMPERAGE SETUP Voltage Selector Switch Locking ButtonOutput Terminal Panel Available Voltages Over Current RelayDCA-25SSAI - OUTPUT AMPERAGE SETUP How To Read The Output Terminal GaugesTable 8. Receptacle Use Receptacle UseDCA-25SSAI - OUTPUT VOLTAGE SETUP 240/120V Hard Wire HookupDCA-25SSAI - OUTPUT VOLTAGE SETUP Single Phase 480V, 440V, or 416 Volt3 Phase, 480V, 440V, or 416 Volt Single Phase 277V, 254V, orSingle Phase 240V, 220V, or 208 Volt 3 Phase, 240V, 220V, or 208 VoltSingle Phase 139V, 127V, or DCA-25SSAI - OUTPUT VOLTAGE SETUPDCA-25SSAI - OUTPUT VOLTAGE SETUP Voltage Selector Switch- Single Phase 240/120V PositionSingle Phase 120 Volt Single Phase, 240 VoltMounting DCA-25SSAI - INSTALLATIONOutdoor Installation DCA-25SSAI - INSTALLATION Figure 30. Typical Generator Grounding ApplicationDCA-25SSAI - PRE-SETUP Table 9. Cable Selection 60 Hz, Single Phase Operation#10 Wire #12 WireTable 10. Recommended Motor Oil Lubrication OilDCA-25SSAI - PRE-SETUP Figure 31. Engine Oil DipstickCleaning the Outer Radiator Air CleanerAdjusting Fan Belt Fan Belt TensionDCA-25SSAI - PRE-SETUP Battery Cable InstallationWiring 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 DCA-25SSAI - GENERATOR START-UP PROCEDURE Figure 38. Voltage Selection SwitchFigure 41. Ignition Switch ‘START’ Figure 40. Ignition Switch ‘PREHEAT’ Figure 44. Voltage Meter VoltsDCA-25SSAI - GENERATOR START-UP PROCEDURE DCA-25SSAI - GENERATOR SHUTDOWN PROCEDURE ENGINE SHUTDOWNNOTE PAGE DCA-25SSAI - MAINTENANCE Service DailyCleaning the Fuel Strainer General InspectionGenerator Storage DCA-25SSAI - MAINTENANCEINSPECTION / MAINTENANCE 10 HrsDCA-25SSAI - GENERATORWIRING DIAGRAM PAGE 50 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01DCA-25SSAI - ENGINEWIRING DIAGRAM DCA-25SSAI -TROUBLESHOOTING ENGINE TABLE 14. ENGINE TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMDCA-25SSAI -TROUBLESHOOTING ENGINE TABLE 14. ENGINE TROUBLESHOOTING CONTINUEDSYMPTOM POSSIBLE PROBLEMDCA-25SSAI -TROUBLESHOOTING GENERATOR TABLE 17. GENERATOR TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMNOTE PAGE How to read the marks and remarks used in this parts book EXPLANATION OF CODE IN REMARKS COLUMNItems Found In the “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 CONTROL BOX ASSY DCA-25SSAIREMARKS 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 DCA-25SSAI ENGINE AND RADIATOR ASSY REMARKSREPLACES 0602000008 ISUZU C240 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 ENGINE OPERATING PANEL ASSY DCA-25SSAIREPLACES 060212005225000KX3710 BRACKET, ENGINE STOPPERDCA-25SSAI --- ENGINE OPERATING PANEL ASSY PAGE 72 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01DCA-25SSAI ENGINE OPERATING PANEL ASSYREMARKS 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 MUFFLER ASSY DCA-25SSAIREMARKS 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 ISUZU C240 --- CYLINDER HEAD AND COVER ASSY INLET AND EXHAUST VALVE SEALCYLINDER HEAD OIL COOLER PLUG REMARKSPAGE 88 - DCA-25SSAI - PARTS AND OPERATION MANUAL-FINAL COPY 06/30/01 ISUZU C240 --- CYLINDER BLOCK ASSYCYLINDER BLOCK ASSY ISUZU C240 --- CYLINDER BLOCK ASSY REMARKSTAPPET CHAMBER COVER ASSY 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 ISUZU C240 ---OIL PUMP ASSY 22*%INCL. ITEMS W 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 CONNECTING ROD ASSY ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSYREMARKS 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 ASSYADJUSTING FAN BELT PLATE ISUZU C240 --- WATER PUMP AND FAN ASSYREMARKS 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 ASSYISUZU C240 --- AIR CLEANER ASSY 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 ASSYINJECTION PUMP ASSY ISUZU C240REMARKS INJ. PUMP SPACER BRACKETISUZU C240 --- ELECTRICAL PARTS ELECTRICAL PARTSELECTRICAL PARTS ISUZU C240REMARKS ELECTRICAL PARTSISUZU C240 --- ACCESSORIES ACCESSORIESACCESSORIES ISUZU C240REMARKS 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. ASSYSTARTER COMP. ASSY MAGNETIC SWITCH ASSYISUZU C240 REMARKSISUZU C240 --- ALTERNATOR COMP. ASSY ALTERNATOR COMP. ASSY. OCT. 1992~ALTERNATOR COMP. ASSY ISUZU C240REMARKS 10*#%ISUZU C240 ---ALTERNATOR COMP. ASSY ALTERNATOR COMP. ASSY. BEFORE OCTISUZU C240 ALTERNATOR COMP. ASSYREMARKS 27*#Effective July 1 TERMS AND CONDITIONS OF SALE - PARTS11. Credit issued will be applied to future purchases only SPECIAL EXPEDITING SERVICENOTE PAGE HERES HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLINGSERVICE 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