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Multiquip DCA25SSIU manual Table Of Contents, ISUZU C240 ENGINE, MQ POWER DCA-25SSIUAC GENERATOR

Models: DCA25SSIU

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TABLE OF CONTENTS

Table Of Contents	4
Parts Ordering Procedures	5
Rules for Safe Operation	6-9
Towing and Transportation	10
Trailer Safety Guidelines	11-15
Trailer Wiring Diagram	16
Operation Decals	17-18
DCA-25SSIU Specifications	19
General Information	20
Major Components	21
Dimensions	22
Control Panel Descriptions	24-25
Engine Operating Panel Descriptions	26-27
Output Terminal Panel Descriptions	28-29
Output Amerage Setup	30-31
Output Voltage Setup	32-35
Installation	36-37
Pre Setup	38-41
Load Application	42
Generator Start-up Procedure	43-45
Generator Shutdown Procedure	46
Maintenance	47-48
Generator Wiring Diagram	50
Engine Wiring Diagram	51
Engine Troubleshooting	52-53
Generator/Engine Troubleshooting	54
Explanation of Codes in Remarks Column	56
Suggested Spare Parts	57

TABLE OF CONTENTS

ISUZU C240 ENGINE

Cylinder Head and Cover Assembly	86-87
Cylinder Block Assembly	88-89
Timing Gear Assembly	90-91
Flywheel Housing Assembly	92-93
Oil Pan Assembly	94-95
Oil Pump Assembly	96-97
Crankshaft, Bridge and Flywheel Assembly	98-99
Oil and Fuel Filter Assembly	100-101
Oil Pipe Assembly	102-103
Water Pump and Fan Assembly	104-105
Intake and Exhaust Manifold Assembly	106-107
Air Cleaner Assembly	108-109
Engine Foot Assembly	110-111
Injection Pump Assembly	112-113
Electrical Parts Assembly	114-115
Accessories	116-117
Injection Pump Comp. Assembly	118-121
Governor Comp. Assembly	122-127
Feed Pump Comp. Assembly	128-129
Auto Timer Assembly	130-131
Nozzle Holder Comp. Assembly	132-133
Starter Comp. Assembly	134-135
Alternator Comp. Assembly	136-139
Terms and Conditions of Sales	140

MQ POWER DCA-25SSIU AC GENERATOR

Generator Assembly	58-59
Control Box Assembly	60-61
Engine & Radiator Assembly	62-67
Engine Operating Panel Assembly	68-69
Output Terminal Assembly	70-71
Battery Assembly	72-73
Muffler Assembly	74-75
Fuel Tank Assembly	76-77
Enclosure Assembly	78-81
Rubber Seal Assembly	82-83
Name Plate And Decals	84-85

NOTE

Specification and part number are subject to change without notice.

PAGE 4 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

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Multiquip DCA25SSIU manual Table Of Contents, ISUZU C240 ENGINE, MQ POWER DCA-25SSIUAC GENERATOR

Contents

OPERATION AND PARTS MANUAL StandardMODEL DCA25SSIU WHISPERWATT GENERATORPage Page MQ POWER DCA-25SSIUAC GENERATOR TABLE OF CONTENTSISUZU C240 ENGINE PARTS ORDERING PROCEDURES OrderWhen ordering parts, please supply Ordering parts has never been easierGENERAL SAFETY RULES FOR SAFE OPERATIONRULES FOR SAFE OPERATION Fluid PlugsRULES FOR SAFE OPERATION BatteryLoading and Unloading Crane Maintenance Safety TransportingEmergencies RULES FOR SAFE OPERATIONTowing Safety Precautions DCA-25SSIU -TOWINGRULES FOR SAFE OPERATIONDCA-25SSIU- TRAILER-SAFETYGUIDELINES Explanation of ChartDCA-25SSIU —TRAILER-SPECIFICATIONS Table 1. SpecificationsMODEL APPLICATIONDCA-25SSIU —TRAILER-SPECIFICATIONS Table 1. Specifications ContMODEL COUPLERDCA-25SSIU —TRAILERSAFETY GUIDELINES Tires/Wheels/Lug NutsTire Wear/Inflation SuspensionDCA-25SSIU —TRAILERSAFETY GUIDELINES ItemTorque Ft.-Lbs Lug Nut Torque RequirementsDCA-25SSIU —TRAILER-WIRINGDIAGRAM LIGHTS ARE ORIENTED FROM THE DRIVER’S SEATDCA-25SSIU— GENERATOR DECALS DCA-25SSIU— GENERATOR DECALS DCA-25SSIU— SPECIFICATIONS Generator SpecificationsEngine Specifications Zig ZagDCA-25SSIU— GENERAL INFORMATION DCA-25SSIUFAMILIARIZATION GeneratorEngine Operating Panel Generator Control PanelDCA-25SSIU— MAJOR COMPONENTS Figure 4. Major ComponentsDCA-25SSIU— DIMENSIONS TOP, SIDE AND FRONT Figure 5. DimensionsNOTE PAGE DCA-25SSIU- CONTROL PANEL Figure 6. Control PanelDCA-25SSIU— CONTROL PANEL 1.Main Circuit Breaker – This three-pole,60 Amp main breaker is provided to protect the UNV voltage output terminals from overloadDCA-25SSIU— ENGINE OPERATING PANEL Figure 7. Engine Operating PanelDCA-25SSIU- ENGINE OPERATING PANEL Connecting Load DCA-25SSIU— OUTPUTTERMINAL PANEL120 Volt Receptacle Circuit BreakersFigure 10. Output Terminal Description DCA-25SSIU— OUTPUTTERMINAL PANELLegs “O” and Ground are considered Bonded Grounds DCA-25SSIU— OUTPUT AMPERAGE SETUP Voltage Selector Switch Locking ButtonOutput Terminal Panel Available Voltages Over Current RelayDCA-25SSIU— OUTPUT AMPERAGE SETUP How To Read The Output Terminal GaugesTable 8. Receptacle Use Receptacle UseDCA-25SSIU— OUTPUT VOLTAGE SETUP 240/120V Hard Wire HookupDCA-25SSIU— OUTPUT VOLTAGE SETUP Single Phase: 480V, 440V, or 416 Volt3 Phase, 480V, 440V, or 416 Volt Single Phase: 277V, 254V, orDCA-25SSIU— OUTPUTVOLTAGE SETUP Single Phase: 240V, 220V, or 208 Volt3 Phase, 240V, 220V, or 208 Volt Single Phase: 139V, 127V, orDCA-25SSIU— OUTPUTVOLTAGE SETUP Single Phase: 120 VoltSingle Phase, 240 Volt PositionOutdoor Installation DCA-25SSIU— INSTALLATIONMounting DCA-25SSIU— INSTALLATION DCA-25SSIU— PRE-SETUP #10 Wire#12 Wire General Inspection Prior to OperationAmbient Temperature Range Table 10. Recommended Motor OilLubrication Oil Type OilCleaning the Outer Radiator Air CleanerAdjusting Fan Belt Fan Belt TensionDCA-25SSIU— PRE-SETUP Battery Cable InstallationWiring Piping and Hose ConnectionThree Phase Load Single Phase LoadDCA-25SSIU- LOAD APPLICATION Before Starting Engine DCA-25SSIU— GENERATOR START-UPPROCEDUREBefore Starting Generator and Control Panel DCA-25SSIU— GENERATOR START-UPPROCEDURE DCA-25SSIU— GENERATOR START-UPPROCEDURE DCA-25SSIU— GENERATOR SHUTDOWN PROCEDURE ENGINE SHUTDOWNNOTE PAGE DCA-25SSIU— MAINTENANCE Service DailyCleaning the Fuel Strainer General InspectionINSPECTION / MAINTENANCE Generator StorageDCA-25SSIU— MAINTENANCE Check Air CleanerDCA-25SSIU— GENERATORWIRING DIAGRAM DCA-25SSIU— ENGINEWIRING DIAGRAM DCA-25SSIU —TROUBLESHOOTINGENGINE TABLE 14. ENGINE TROUBLESHOOTINGSYMPTOM SOLUTIONDCA-25SSIU —TROUBLESHOOTINGENGINE TABLE 14. ENGINE TROUBLESHOOTING CONTINUEDSYMPTOM POSSIBLE PROBLEMDCA-25SSIU —TROUBLESHOOTINGGENERATOR/ENGINE TABLE 15. GENERATOR TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMNOTE PAGE EXPLANATION OF CODE IN REMARKS COLUMN SAMPLE PARTS LISTQTY. Column NO. ColumnDescription DCA-25SSIU— SUGGESTED SPARE PARTSDCA-25SSIUW/ISUZUC240 DIESEL ENGINE 1 TO 3 UNITS DCA-25SSIU ---GENERATOR ASSY GENERATOR ASSYDCA-25SSIU GENERATOR ASSYPART NO ITEMDCA-25SSIU ---CONTROL BOX ASSY CONTROL BOX ASSYCONTROL BOX ASSY REMARKSDCA-25SSIU PART NODCA-25SSIU ---CONTROL BOX ASSY DCA-25SSIU CONTROL BOX ASSYPART NO ITEMDCA-25SSIUENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSYDCA-25SSIUENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSYPART NO ITEMDCA-25SSIUENGINE AND RADIATOR ASSY DCA-25SSIUENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSYPART NO ITEMDCA-25SSIU ---ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSYENGINE OPERATING PANEL ASSY DCA-25SSIUDCA-25SSIU ---OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSYOUTPUTTERMINAL ASSY DCA-25SSIUPART NO ITEMDCA-25SSIU ---BATTERY ASSY BATTERY ASSY S/N7100001 TO S/N7100051~BATTERY ASSY DCA-25SSIUPART NO REMARKSMUFFLER ASSY DCA-25SSIU ---MUFFLER ASSYS/N7100001 TO S/N7105049 S/N7105050~ MUFFLER ASSY DCA-25SSIUPART NO ITEMDCA-25SSIU ---FUELTANK ASSY FUEL TANK ASSYFUELTANK ASSY DCA-25SSIUPART NO ITEMDCA-25SSIU ---ENCLOSURE ASSY ENCLOSURE ASSY6 -CATERPILLARYELLOW THE SERIAL NUMBER MAY BE REQUIREDDCA-25SSIU ENCLOSURE ASSYPART NO ITEM6 -CATERPILLARYELLOW DCA-25SSIU ---ENCLOSURE ASSYTHE SERIAL NUMBER MAY BE REQUIRED DCA-25SSIU ENCLOSURE ASSYPART NO ITEMDCA-25SSIU ---RUBBER SEAL ASSY RUBBER SEAL ASSY S/N7100001 TO S/N7101590~DCA-25SSIU RUBBER SEAL ASSYPART NO ITEMDCA-25SSIU ---DECALS DECAL ASSYDECALS DCA-25SSIUPART NO REMARKSISUZU C240 ---CYLINDER HEAD AND COVER ASSY CYLINDER HEAD AND COVER ASSYISUZU C240 ---CYLINDER HEAD AND COVER ASSY CYLINDER HEAD AND COVER ASSYPART NO ITEMISUZU C240 ---CYLINDER BLOCK ASSY CYLINDER BLOCK ASSYISUZU C240 ---CYLINDER BLOCK ASSY PART NOITEM REMARKSISUZU C240 ---TIMINGGEAR ASSY TIMING GEAR ASSYPART NO ISUZU C240 ---TIMINGGEAR ASSYITEM ISUZU C240 FLYWHEEL HOUSING ASSY FLYWHEEL HOUSING ASSYISUZU C240 FLYWHEEL HOUSING ASSY FLYWHEEL HOUSING ASSYPART NO ITEMISUZU C240 OIL PAN ASSY OIL PAN ASSYISUZU C240 OIL PAN ASSY PART NOITEM REMARKSISUZU C240 ---OILPUMP ASSY OIL PUMP ASSYISUZU C240 ---OILPUMP ASSY OIL PUMP ASSYCRANKSHAFT, BRIDGE AND FLYWHEEL ASSY CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY PART NOITEM REMARKSISUZU C240 ---OIL AND FUEL FILTER ASSY OIL AND FUEL FILTER ASSYISUZU C240 OIL AND FUEL FILTER ASSYPART NO ITEMISUZU C240 ---OIL PIPE ASSY OIL PIPE ASSYOIL PIPE ASSY ISUZUC240PART NO ISUZU C240 ---WATER PUMP AND FAN ASSY WATER PUMP AND FAN ASSYISUZU C240 ---WATER PUMP AND FAN ASSY WATER PUMP AND FAN ASSYPART NO ITEMISUZU C240 ---INTAKE AND EXHAUST MANIFOLD ASSY INTAKE AND EXHAUST MAINIFOLD ASSYISUZU C240 ---INTAKE AND EXHAUST MANIFOLD ASSY INTAKE AND EXHAUST MANIFOLD ASSYPART NO ITEMISUZU C240 ---AIR CLEANER ASSY AIR CLEANER ASSYISUZU C240 ---AIR CLEANER ASSY PART NOITEM REMARKSISUZU C240 ---ENGINE FOOT ASSY ENGINE FOOT ASSYQTY. REMARKS ISUZU C240 ---ENGINE FOOT ASSYPART NO ISUZU C240 ---INJECTION PUMP ASSY INJECTION PUMP ASSYISUZU C240 ---INJECTION PUMP ASSY INJECTION PUMP ASSYPART NO ITEMISUZU C240 ---ELECTRICAL PARTS ELECTRICAL PARTSELECTRICAL PARTS ISUZU C240PART NO ITEMISUZU C240 ---ACCESSORIES ACCESSORIESACCESSORIES ISUZU C240PART NO ITEMISUZU C240 ---INJECTIONPUMP COMP. ASSY INJECTION PUMP COMP. ASSYITEM ISUZU C240 ---INJECTION PUMP COMP. ASSYREMARKS ISUZU C240 ---INJECTION PUMP COMP. ASSY INJECTION PUMP COMP. ASSY ISUZU C240 ---INJECTION PUMP COMP. ASSYITEM ISUZU C240 ---INJECTION PUMP COMP. ASSY ISUZU C240 ---INJECTION PUMP COMP. ASSY INJECTION PUMP COMP. ASSYPART NO ITEMISUZU C240 ---GOVERNORCOMP. ASSY GOVERNOR COMP. ASSYISUZUC240 GOVERNOR COMP. ASSYPART NO ITEMISUZU C240 ---GOVERNOR COMP. ASSY GOVERNOR COMP. ASSY ISUZUC240PART NO ITEMISUZU C240 ---FEED PUMP COMP. ASSY FEED PUMP COMP. ASSYFEED PUMP COMP. ASSY ISUZUC240PART NO ITEMISUZU C240 ---AUTOTIMER COMP. ASSY AUTO TIMER COMP. ASSYISUZU C240 ---AUTOTIMER COMP. ASSY AUTO TIMER COMP. ASSYPART NO ITEMISUZU C240 ---NOZZLE HOLDER COMP. ASSY NOZZLE HOLDER COMP. ASSYNOZZLE HOLDER COMP. ASSY ISUZU C240PART NO REMARKSISUZU C240 ---STARTERCOMP. ASSY STARTER COMP. ASSYSTARTER COMP. ASSY ISUZUC240PART NO ITEMISUZU C240 ---ALTERNATOR COMP. ASSY ALTERNATOR COMP. ASSY. OCT. 1992~ALTERNATOR COMP. ASSY ISUZUC240PART NO ITEMISUZU C240 ---ALTERNATORCOMP. ASSY ALTERNATOR COMP. ASSY. BEFORE OCT.ISUZUC240 ALTERNATOR COMP. ASSYPART NO ITEMTERMS AND CONDITIONS OF SALE — PARTS SPECIAL EXPEDITING SERVICEPAYMENT TERMS FREIGHT POLICYNOTES HERE’S HOW TO GET HELP NUMBER ON-HANDWHEN CALLINGService Department Warranty Department