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MQ Power WHISPERWATT DCA-25SSI Operation Manual

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PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
WHISPERWATT
GENERATOR
MQ POWER
DCA-25SSI
PARTS LIST NO. M1870000274A
FINAL COPY (06/29/01)
MULTIQUIP INC.
18910 WILMINGTON AVE.
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
FAX: 310-537-3927
E-mail:mq@multiquip.com
TM
PARTS DEPARTMENT:
800-427-1244
SERVICE DEPARTMENT:
800-835-2551
FAX: 310-638-8046
•
www:multiquip.com

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  • Page 1 PARTS AND OPERATION MANUAL PARTS AND OPERATION MANUAL MQ POWER DCA-25SSI WHISPERWATT GENERATOR PARTS LIST NO. M1870000274A FINAL COPY (06/29/01) MULTIQUIP INC. PARTS DEPARTMENT: 18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 SERVICE DEPARTMENT: 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046 •...
  • Page 2 PAGE 2 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

  • Page 3: Here's How To Get Help

    HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING P P P P P AR TS DEP TS DEP TMENT TMENT ARTS DEP TS DEP TS DEPAR ARTMENT TMENT TMENT 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284 VICE DEP VICE DEP TMENT...

  • Page 4: Table Of Contents

    Engine Troubleshooting ..........52-53 Generator/Engine Troubleshooting ......... 54 Terms and Conditions of Sales ........140 Explanation of Codes in Remarks Column ....56 Suggested Spare Parts ..........57 MQ POWER DCA-25SSI AC GENERATOR NOTE Generator Assembly ..........58-59 Specification and part number...

  • Page 5: Parts Ordering Procedures

    PARTS ORDERING PROCEDURES I Dealer account number I Dealer name and address I Shipping address (if different than billing address) I Return fax number I Applicable model number I Quantity, part number and description of each part I Specify preferred method of shipment: •...

  • Page 6: Rules For Safe Operation

    I NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage Always use extreme caution when to the equipment and/or injury to user may result.
  • Page 7 RULES FOR SAFE OPERATION CAUTION: CAUTION: DO NOT touch or open any of the below mentioned components while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance. I NEVER touch output terminals during operation. This is Radiator extremely dangerous.
  • Page 8 RULES FOR SAFE OPERATION I NEVER Run engine without air filter. Severe engine Battery damage may occur. CAUTION: I Always service air cleaner frequently to prevent carburetor Never over fill the battery with water above malfunction. the upper limit. I Always disconnect the battery before performing service on the generator.
  • Page 9 RULES FOR SAFE OPERATION Transporting Maintenance Safety I Always shutdown engine before transporting. I NEVER lubricate components or attempt service on a running machine. I Tighten fuel tank cap securely. I Always allow the machine a proper amount of time to I Drain fuel when transporting generator over long distances cool before servicing.

  • Page 10: Towing And Transportation

    DCA-25SSI — TOWING RULES FOR SAFE OPERATION I ALWAYS attach trailer’s safety chain to bumper of towing Towing Safety Precautions vehicle. CAUTION : I ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and Check with your county or state safety working properly.

  • Page 11: Trailer Safety Guidelines

    DCA-25SSI — TRAILER-SAFETY GUIDELINES CAUTION: Frame Width - This measurement is from fender to fender. ALWAYS make sure the trailer is in good Jack Stand - Trailer support device with maximum operating condition. Check the tires for pound requirement from the tongue of the trailer. proper inflation and wear.
  • Page 12 DCA-25SSI — TRAILER-SPECIFICATIONS " 6 " 0 " 6 " 0 " 6 " 0 " 5 " 2 " 4 " 5 " 4 " 8 " 4 " 5 " 4 " 5 " 6 " 7 " 8 "...
  • Page 13 DCA-25SSI — TRAILER-SPECIFICATIONS i f i o i t ) t ' " 2 X " " 0 B " X " " 5 . B " X " " 5 . B " " 5 . B " " 5 . "...
  • Page 14 DCA-25SSI — TRAILER SAFETY GUIDELINES Tires/Wheels/Lug Nuts Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched. CAUTION: DO NOT attempt to repair or modify a wheel.
  • Page 15 DCA-25SSI — TRAILER SAFETY GUIDELINES e r i e t I - . t ) . s " 8 / " 6 " 2 / SHACKLE BOLT SNUG FIT ONLY PARTS MUST ROTATE FREELY SPRING EYE BOLT LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT BOLT ASSEMBLY SHOULDER TYPE...

  • Page 16: Trailer Wiring Diagram

    DCA-25SSI — TRAILER-WIRING DIAGRAM NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT PAGE 16 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

  • Page 17: Operation Decals

    DCA-25SSI — GENERATOR DECALS The DCA-25SSI generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the machine.
  • Page 18 DCA-25SSI — GENERATOR DECALS PAGE 18 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

  • Page 19: Dca-25Ssi Specifications

    DCA-25SSI — SPECIFICATIONS f i c a c i o i t r o t f i c a c i o i t i v l e i f , d l l e s a l i t i t c r a t h t i...

  • Page 20: General Information

    " Open-Delta Open-Delta gener gener ator ator The MQ Power Model DCA-25SSI is a 20 kW gener gener generator ator ator consist of an electrically independent winding wound among that is designed as a high quality portable (requires a trailer stationary windings of the AC output section.

  • Page 21: Major Components

    DCA-25SSI — MAJOR COMPONENTS Figure 4. Major Components PAGE 21 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 22: Dimensions

    DCA-25SSI — DIMENSIONS (TOP, SIDE AND FRONT) Figure 5. Dimensions PAGE 22 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 23 NOTE PAGE PAGE 23 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 24: Control Panel Descriptions

    DCA-25SSI — CONTROL PANEL Figure 6. Control Panel PAGE 24 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 25 DCA-25SSI — CONTROL PANEL The definitions below describe the controls and functions of the DCA-25SSI " Control Panel Control Panel Control Panel Control Panel Control Panel " (Figure 6). Main Circuit Breaker – This three-pole, 60 amp main breaker is provided to protect the UNV voltage output terminals from overload.

  • Page 26: Engine Operating Panel Descriptions

    DCA-25SSI — ENGINE OPERATING PANEL Figure 7. Engine Operating Panel PAGE 26 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 27 DCA-25SSI — ENGINE OPERATING PANEL The definitions below describe the controls and functions of the DCA-25SSI " Engine Operating Panel Engine Operating Panel Engine Operating Panel Engine Operating Panel " (Figure 7). Engine Operating Panel Panel light - Normally used in dark places or at night. When activated, panel will luminate.

  • Page 28: Output Terminal Panel Descriptions

    DCA-25SSI — OUTPUT TERMINAL PANEL Output Terminal Panel Connecting Load Loads can be connected to the generator by the UNV Lugs or The output control panel is located on the rear (control panel) the duplex receptacle. (See Figure 9). Make sure to read the end of the generator.
  • Page 29 DCA-25SSI — OUTPUT TERMINAL PANEL NOTE Legs “O” and Ground are considered Bonded Grounds. Figure 10. Output Terminal Description PAGE 29 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 30: Output Amerage Setup

    DCA-25SSI — OUTPUT AMPERAGE SETUP Over Current Relay Output Terminal Panel Available Voltages An over current relay is connected to the circuit breaker. A wide range of voltages are available to supply load to During an over current situation, both the circuit breaker many different applications.
  • Page 31 DCA-25SSI — OUTPUT AMPERAGE SETUP Receptacle Use When the UVWO terminals are providing power, the receptacle power available decrease. Do not exceed receptacle power available listed on Table 8. l i a Figure 11. Voltage Selector Switch 240/120V Single Phase Position t s i x e l Figure 12.

  • Page 32: Output Voltage Setup

    DCA-25SSI — OUTPUT VOLTAGE SETUP 240/12 0V Hard Wire Hookup 480/240V Hard Wire Hookup With the voltage selector set and locked at ‘3 phase 480/ With the voltage selector set and locked at ‘single phase 277’ (Figure 17) and using the 3-phase 240 volt hookup, it 240/120’...
  • Page 33 DCA-25SSI — OUTPUT VOLTAGE SETUP Voltage Selector Switch- 3 Phase 480/277V Position Single Phase: 480V, 440V, or 416 Volt The following are additional voltages available when the This setting can provide single phase power at 480, 440, voltage selector switch is in the 3 phase 480/277V or 416 volts.
  • Page 34 DCA-25SSI — OUTPUT VOLTAGE SETUP Single Phase: 240V, 220V, or 208 Volt Voltage Selector Switch- 3 Phase 240/139V Position This setting can provide single phase power at 240, 220, The following are additional voltages available when the voltage selector switch is in the 3 phase 240/139V or 208 volts.
  • Page 35 DCA-25SSI — OUTPUT VOLTAGE SETUP Single Phase: 120 Volt Voltage Selector Switch- Single Phase 240/120V This setting can provide single phase power at 120 volts. Position After hooking up the hard wires to the lugs as shown in The following are additional voltages available when the Figure 29, 120 volts can be obtained by using the voltage 240/120V position.

  • Page 36: Installation

    DCA-25SSI — INSTALLATION CAUTION : Outdoor Installation Install the generator in a location where it will not be exposed An electric shock may happen when to rain or sunshine. Make sure the generator is on secure vibrators are used. Pay close attention to level ground so that it cannot slide or shift around.
  • Page 37 DCA-25SSI — INSTALLATION Figure 30. Typical Generator Grounding Application PAGE 37 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 38: Pre Setup

    DCA-25SSI — PRE-SETUP General Inspection Prior to Operation Circuit Breakers The DCA-25SSI generator has been thoroughly inspected To protect the generator from an overload, a 3-pole, 60 amp, main main main circuit breaker is provided to protect the UNV output and accepted prior to shipment from the factory.
  • Page 39 DCA-25SSI — PRE-SETUP Lubrication Oil Fuel Fill the fuel tank with clean and fresh diesel fuel diesel fuel diesel fuel diesel fuel . DO NOT diesel fuel Fill the engine crankcase with lubricating oil through the filler fill the tank beyond capacity. hole, but do not overfill.
  • Page 40 DCA-25SSI — PRE-SETUP CAUTION : Cleaning the Outer Radiator The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator When adding coolant or antifreeze to the fins with compressed air. Cleaning inside the radiator is radiator, do not remove the radiator cap dangerous, so clean only with the engine turned off and the until the unit has completely cooled.
  • Page 41 DCA-25SSI — PRE-SETUP CAUTION : Battery This unit is of negative ground. DO NOT connect in reverse. If the battery cable is connected Always maintain battery fluid level between the specified incorrectly, damage to the generator will marks. Battery life will be shortened, if the fluid level is not occur.

  • Page 42: Load Application

    DCA-25SSI — LOAD APPLICATION Single Phase Load CAUTION: Motors and motor-driven equipment draw Always be sure to check the nameplate on the generator much greater current for starting than and equipment to insure the wattage, amperage and during operation. frequency requirements are satisfactorily supplied by the generator for operating the equipment.

  • Page 43: Generator Start-Up Procedure

    DCA-25SSI — GENERATOR START-UP PROCEDURE WARNING: 2. Connect the load to the UNV terminals as shown in The engine's exhaust contains harmful Figure 35. These terminals can be found on the output A LW W W W W A A A A A Y S emissions.
  • Page 44 DCA-25SSI — GENERATOR START-UP PROCEDURE 4. Close all engine enclosure doors (Figure 37). 8. Once the preheat indicator lights, turn the ignition key to ‘START’ until the engine starts (Figure 41). Then release the key to ‘RUN’. Figure 41. Ignition Switch ‘START’ Figure 37.
  • Page 45 DCA-25SSI — GENERATOR START-UP PROCEDURE 15. The tachometer (Figure 49) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s. Figure 45. Voltage Adjust Control Knob 12. The ammeter (Figure 46) will indicate zero amps with no load applied.

  • Page 46: Generator Shutdown Procedure

    DCA-25SSI — GENERATOR SHUTDOWN PROCEDURE ENGINE SHUTDOWN To shutdown the generator, use the following procedure: 1. Switch both the MAIN, GFCI and LOAD circuit breakers (Figure 52) to the “OFF” position. Figure 52. Main, GFCI and Load circuit breakers Set the engine throttle lever to (low) position. 3.
  • Page 47 NOTE PAGE PAGE 47 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 48: Maintenance

    DCA-25SSI — MAINTENANCE General Inspection Check Oil Level Prior to each use, the generator should be cleaned and Check the crankcase oil level prior to each use, or when inspected for deficiencies. Check for loose, missing or the fuel tank is filled. Insufficient oil may cause severe damaged nuts, bolts or other fasteners.
  • Page 49 DCA-25SSI — MAINTENANCE Generator Storage For storage of the generator for over 30 days, the following is required: Drain the fuel tank completely. Completely drain the oil from the crankcase and refill with fresh oil. Clean all external parts of the generator with a cloth. Cover the generating set and store in a clean, dry place.

  • Page 50: Generator Wiring Diagram

    DCA-25SSI — GENERATOR WIRING DIAGRAM PAGE 50 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

  • Page 51: Engine Wiring Diagram

    DCA-25SSI — ENGINE WIRING DIAGRAM PAGE 51 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 52: Engine Troubleshooting

    DCA-25SSI — TROUBLESHOOTING (ENGINE) Practically all breakdowns can be prevented by proper diagnosis based on the Engine Troubleshooting (Table 14). If handling and maintenance inspections, but in the event of a the problem cannot be remedied, consult our company's breakdown, use the tables shown for business office or service plant.
  • Page 53 DCA-25SSI — TROUBLESHOOTING (ENGINE) l i f r e t o l c t r i r i A e l c i t c . t u i n i i t c f l a i t c c a l i t u l .

  • Page 54: Generator/Engine Troubleshooting

    DCA-25SSI — TROUBLESHOOTING (GENERATOR a t l r e t c e f v i t a t l i s u l o v . r e i r i i t c i r i . r i c e f v i t c a l...
  • Page 55 NOTE PAGE PAGE 55 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 56: Explanation Of Codes In Remarks Column

    EXPLANATION OF CODE IN REMARKS COLUMN How to read the marks and remarks used in this parts book. Items Found In the “Remarks” Column Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used. Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.

  • Page 57: Suggested Spare Parts

    DCA-25SSI — SUGGESTED SPARE PARTS DCA-25SSI DCA-25SSI W/ISUZU C240 DIESEL ENGINE W/ISUZU C240 DIESEL ENGINE DCA-25SSI DCA-25SSI W/ISUZU C240 DIESEL ENGINE DCA-25SSI W/ISUZU C240 DIESEL ENGINE W/ISUZU C240 DIESEL ENGINE 1 1 1 1 1 T T T T T O 3 UNITS O 3 UNITS O 3 UNITS O 3 UNITS...

  • Page 58: Generator Assembly

    DCA-25SSI --- GENERATOR ASSY. GENERATOR ASSY. PAGE 58 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 59 DCA-25SSI --- GENERATOR ASSY. GENERATOR ASSY. PART NO. ITEM QTY. REMARKS 8011000302 ROTOR ASSY. FIELD ASSY. 8001070003 0012108035 HEX. HEAD BOLT 0042508000 LOCK WASHER 8351611004 COUPLING DISK ........3 .... REPLACES 8001611004 8351615003 BALANCING PLATE ......1 .... REPLACES 8001015003 0105091025 HEX.

  • Page 60: Control Box Assembly

    DCA-25SSI --- GENERATOR ASSY. GENERATOR ASSY. PAGE 60 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 61 DCA-25SSI --- GENERATOR ASSY. GENERATOR ASSY. PART NO. ITEM QTY. REMARKS 0010106030 HEX. HEAD BOLT 0040006000 LOCK WASHER 952404470 PLAIN WASHER ........2 ... REPLACES 0041206000 0012110035 HEX. HEAD BOLT 030210250 LOCK WASHER ........6 ... REPLACES 0042510000 020310080 HEX. NUT ..........6 ... REPLACES 0030310000 031110160 PLAIN WASHER ........

  • Page 62: Engine & Radiator Assembly

    DCA-25SSI --- CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 62 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 63 DCA-25SSI --- CONTROL BOX ASSY. CONTROL BOX ASSY. PART NO. ITEM QTY. REMARKS 8011812602 CONTROL BOX 0601801143 CURRENT TRANSFORMER, AMMETER ..3 ..CT3.5MR 100/5A 0027104010 MACHINE SCREW 0601823863 RELAY UNIT ............ 2 ..MSA9013A 0027104016 MACHINE SCREW 0601820671 AUTOMATIC VOLTAGE REGULATOR ... 1 ..NTA5A2D; REPLACES 0601820628 0027105012 MACHINE SCREW 5825500422...
  • Page 64 DCA-25SSI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PAGE 64 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 65 DCA-25SSI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PART NO. ITEM QTY. REMARKS C240PR12 ENGINE .......... 1 ... ISUZU C240; REPLACES 0602000008 0602010067 RADIATOR ........1 ... TCR38253 011008020 HEX. HEAD BOLT ......8 ... REPLACES 0017108020 9214311960 RADIATOR HOSE ......1 ... REPLACES 0602013008 9214311980 RADIATOR HOSE ......
  • Page 66 DCA-25SSI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PAGE 66 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 67 DCA-25SSI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PART NO. ITEM QTY. REMARKS 011606025 HEX.HEAD BOLT ......1 ... REPLACES 0017106025 0199500550 HOSE 0199500220 HOSE 0193600970 HOSE 0605515013 HOSE BAND 0194500600 BREATHER HOSE 0605515022 HOSE BAND 0193000500 HOSE 0605515005 HOSE BAND 0193100200 HOSE...

  • Page 68: Engine Operating Panel Assembly

    DCA-25SSI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY. PAGE 68 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 69 DCA-25SSI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY. PART NO. ITEM QTY. REMARKS 3332111603 OPERATING PANEL 3332142014 SLIDE BAR 0601840190 KNOB ............ 1 ... REPLACES 0805012904 020108060 HEX. NUT ..........1 ... REPLACES 0036003000 3332140504 BRACKET, GOVERNOR ROD 020108060 HEX.

  • Page 70: Output Terminal Assembly

    DCA-25SSI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY. PAGE 70 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 71 DCA-25SSI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY. PART NO. ITEM REMARKS 0027103016 MACHINE SCREW 0207003000 HEX. NUT 0017106016 HEX. HEAD BOLT 0601811034 RECEPTACLE, CS6369 0601811030 RECEPTACLE, 5-20R 0027103010 MACHINE SCREW 0207003000 HEX. NUT ..........8 ... REPLACES 0030003000 58413 PLAIN WASHER ........

  • Page 72: Battery Assembly

    DCA-25SSI --- BATTERY ASSY. BATTERY ASSY. PAGE 72 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 73 DCA-25SSI --- BATTERY ASSY. BATTERY ASSY. PART NO. ITEM QTY. REMARKS 0160012100 BATTERY ........1 ... 65D31R; REPLACES 0168306531 3312251004 BATTERY SHEET 3332250004 BATTERY BAND 0805002404 BATTERY BOLT 031108160 PLAIN WASHER ......2 ... REPLACES 0041208000 0040008000 LOCK WASHER 0037808000 WING NUT 0215260160 BATTERY CABLE...

  • Page 74: Muffler Assembly

    DCA-25SSI --- MUFFLER ASSY. MUFFLER ASSY. PAGE 74 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 75 DCA-25SSI --- MUFFLER ASSY. MUFFLER ASSY. PART NO. ITEM QTY. REMARKS 3332350513 EXHAUST PIPE 9141450760 GASKET ........1 ... REPLACES 0602320001 0040010000 LOCK WASHER 9098400850 HEX. NUT ........3 ... REPLACES 0602323001 7342311002A MUFFLER 011008020 HEX. HEAD BOLT ......4 ... REPLACES 0017108020 7342356004 GASKET 011008035...

  • Page 76: Fuel Tank Assembly

    DCA-25SSI --- FUEL TANK ASSY. FUEL TANK ASSY. PAGE 76 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 77 DCA-25SSI --- FUEL TANK ASSY. FUEL TANK ASSY. PART NO. ITEM QTY. REMARKS 3335510903 FUEL TANK 0810105004 CAP, FUEL TANK 0810105400 FUEL FILTER 0193100255 FUEL GAUGE HOSE 0605515079 HOSE BAND 3335523304 TANK BAND 0805003414 PAD, TANK BAND 011008020 HEX. HEAD BOLT ......2 ... REPLACES 0017108020 020108060 HEX.

  • Page 78: Enclosure Assembly

    DCA-25SSI --- ENCLOSURE ASSY. ENCLOSURE ASSY. PAGE 78 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 79 DCA-25SSI --- ENCLOSURE ASSY. ENCLOSURE ASSY. PART NO. ITEM QTY. REMARKS 8015110202 BASE 3335116014 FLOOR PANEL 011008020 HEX. HEAD BOLT ......8 ... REPLACES 0017108020 3335116504 COVER 011008020 HEX. HEAD BOLT ......2 ... REPLACES 0017108020 3335121914 FRONT FRAME 3335109203 LINING 011008020 HEX.
  • Page 80 DCA-25SSI --- ENCLOSURE ASSY. ENCLOSURE ASSY. PAGE 80 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 81 DCA-25SSI --- ENCLOSURE ASSY. ENCLOSURE ASSY. PART NO. ITEM QTY. REMARKS 3335109704 LINING 3335175004 GUIDE PANEL, AIR 7345175104 GUIDE PANEL, AIR 011008020 HEX. HEAD BOLT ......8 ... REPLACES 0017108020 3335124023 SIDE DOOR 3335109814 LINING 3335124113 SIDE DOOR 3335109904 LINING 0845028203 HINGE 011208025...

  • Page 82: Rubber Seal Assembly

    DCA-25SSI --- DECALS DECAL ASSY. PAGE 82 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 83 DCA-25SSI --- DECALS DECAL ASSY. PART NO. ITEM QTY. REMARKS CONTROL BOX GROUP B1551000202 DECAL; CONTROL PANEL ........1 ..B15100020 0840623504 DECAL; OVER CURRENT RELAY ......1 ..S2844 3330670704 DECAL; CAUTION ..........1 ..S2518 0840647604 DECAL; DANGER ..........1 ..S4089 0820610404 DECAL;...

  • Page 84: Name Plate And Decals

    ISUZU C240 --- CYLINDER HEAD AND COVER ASSY. CYLINDER HEAD AND COVER ASSY. PAGE 84 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 85 ISUZU C240 --- CYLINDER HEAD AND COVER ASSY. CYLINDER HEAD AND COVER ASSY. PART NO. ITEM QTY. REMARKS 5111102070 CYLINDER HEAD ASSY. 1096000051 SEALING CUP, RR FACE D=44 5111290060 SEALING CUP, LOWER D=16 5112190080 SEALING CUP, UPPER D=18 5096000130 SEALING CUP, DRILLED D=12 9098605220 PLUG;...

  • Page 86: Cylinder Head And Cover Assembly

    ISUZU C240 --- CYLINDER BLOCK ASSY. CYLINDER BLOCK ASSY. PAGE 86 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 87 ISUZU C240 --- CYLINDER BLOCK ASSY. CYLINDER BLOCK ASSY. PART NO. ITEM QTY. REMARKS 5112101771 CYLINDER BLOCK ASSY. 9098025910 BOLT 9096640340 PLUG; 1/2 TAPPET CHAMBER 5112190080 SEALING CUP CHAMBER D=18 5116100010 BEARING KIT; CAM. STANDARD 5112190180 SEALING CUP RR FACE D=36 5112190170 SEALING CUP RR FACE D=38 5112190150...

  • Page 88: Cylinder Block Assembly

    ISUZU C240 ---TIMING GEAR ASSY. TIMING GEAR ASSY. PAGE 88 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 89 ISUZU C240 --- TIMING GEAR ASSY. TIMING GEAR ASSY. PART NO. ITEM QTY. REMARKS 5113110282 TIMING GEAR CASE 9113211480 GEAR CASE COVER 9099206010 PACKING 901906140 BOLT 9113120460 PACKING 5096250790 OIL SEAL 9113270450 POINTER 9113120340 PACKING 9019108320 BOLT PAGE 89 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 90: Timing Gear Assembly

    ISUZU C240 FLYWHEEL HOUSING ASSY. FLYWHEEL HOUSING ASSY. PAGE 90 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

  • Page 91: Flywheel Housing Assembly

    ISUZU C240 FLYWHEEL HOUSING ASSY. FLYWHEEL HOUSING ASSY. PART NO. ITEM QTY. REMARKS 5113410191 FLYWHEEL HOUSING 9113430391 COVER 9019006120 BOLT 5113490380 STIFFENER; RIGHT SIDE 5113490370 STIFFENER; LEFT SIDE 9019110200 BOLT 23-1 9019110180 BOLT 9019310450 BOLT 9019110350 BOLT 9010560400 BOLT 9091104100 9091505100 LOCK WASHER PAGE 91 —...
  • Page 92 ISUZU C240 OIL PAN ASSY. OIL PAN ASSY. PAGE 92 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 93 ISUZU C240 OIL PAN ASSY. OIL PAN ASSY. PART NO. ITEM QTY. REMARKS 5113601832 OIL PAN ASSY......... 1 ....INCL. ITEMS W/* 5096050050 OIL DRAIN PLUG, 3/8 9992023200 OIL DRAIN PLUG 4-1* 9097205600 O RING PACKING 9112150810 CRANK CASE 5113670040 OIL CASE PACKING 9992023160...

  • Page 94: Oil Pan Assembly

    ISUZU C240 ---OIL PUMP ASSY. OIL PUMP ASSY. PAGE 94 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 95 ISUZU C240 ---OIL PUMP ASSY. OIL PUMP ASSY. PART NO. ITEM QTY. REMARKS 9131008010 OIL PUMP ASSY........1 ... INCL. ITEMS W/* 5131200040 ROTOR SET .......... 1 ... INCL. ITEMS W/# 9131290170 11*# 9098780840 9131280790 PINION 9131130771 COVER 9020408250 BOLT 9091505080 LOCK WASHER...

  • Page 96: Oil Pump Assembly

    ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY. CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY. PAGE 96 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 97 ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY. CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY. PART NO. ITEM REMARKS 5115100211 CRANK BEARING KIT;STD 5115300211 CRANK BEARING KIT;-0.25 5115400211 CRANK BEARING KIT;-0.50 9115810570 THRUST BEARING 5121112020 PISTON;STD 5121210070 PISTON RING SET;STD 5122110090 PISTON PIN 5095870010 SNAP RING 5122300390...

  • Page 98: Crankshaft, Bridge And Flywheel Assembly

    ISUZU C240 --- OIL AND FUEL FILTER ASSY. OIL AND FUEL FILTER ASSY. PAGE 98 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 99 ISUZU C240 --- OIL AND FUEL FILTER ASSY. OIL AND FUEL FILTER ASSY. PART NO. ITEM QTY. REMARKS 9885131071 OIL FILTER ELEMENT KIT ..1 ....INCL. ITEMS W/ 9132130350 O RING PACKING COVER 9099211920 CENTER PIPE PACKING 9099209780 DRAIN PIPE PACKING 9099221100 FELT RING 9132121240...

  • Page 100: Oil And Fuel Filter Assembly

    ISUZU C240 --- OIL PIPE ASSY. OIL PIPE ASSY. PAGE 100 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 101 ISUZU C240 --- OIL PIPE ASSY. OIL PIPE ASSY. PART NO. ITEM QTY. REMARKS 9133119810 OIL PUMP ASSY. 5133111141 ROCKER OIL FEED PIPE 9099061051 BOLT 9099209000 PACKING 5133111740 OIL INJECTION PIPE 5096750220 ADAPTER 9095720080 PACKING 901906120 BOLT PAGE 101 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 102: Oil Pipe Assembly

    ISUZU C240 --- WATER PUMP AND FAN ASSY. WATER PUMP AND FAN ASSY. PAGE 102 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 103 ISUZU C240 --- WATER PUMP AND FAN ASSY. WATER PUMP AND FAN ASSY. PART NO. ITEM QTY. REMARKS 5136101673 WATER PUMP ASSY....1 .... INCL. ITEMS W/ 5878101391 WATER PUMP REPAIR KIT ..1 .... INCL. ITEMS W.# 5136310080 BEARING UNIT 9136210760 IMPELLER...

  • Page 104: Water Pump And Fan Assembly

    ISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY. INTAKE AND EXHAUST MAINIFOLD ASSY. PAGE 104 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 105 ISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY. INTAKE AND EXHAUST MANIFOLD ASSY. PART NO. ITEM QTY. REMARKS 9141126954 INLET MANIFOLD 9041108500 INTAKE STUD 9141416142 EXHAUST MANIFOLD 5093020020 EXHAUST STUD 5141111290 INLET PIPE 5141460180 GASKET 9091646080 PLAIN WASHER 9091505080 LOCK WASHER 9091104080 5090000870 BOLT...

  • Page 106: Intake And Exhaust Manifold Assembly

    ISUZU C240 --- AIR CLEANER ASSY. AIR CLEANER ASSY. PAGE 106 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 107 ISUZU C240 --- AIR CLEANER ASSY. AIR CLEANER ASSY. PART NO. ITEM QTY. REMARKS 5142102130 AIR CLEANER ASSY....1 .... INCL. ITEMS W/ 5142150140 ELEMENT 5142110670 COVER 9142191410 INDICATOR 5142120560 DUST W/BAFFLE PAN 5142170040 CLAMP 9142170620 BOLT W/GASKET WASHER ..1 .... INCL. ITEMS W/# 9142191770 GASKET WASHER 9142176020...

  • Page 108: Air Cleaner Assembly

    ISUZU C240 --- ENGINE FOOT ASSY. ENGINE FOOT ASSY. PAGE 108 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 109 ISUZU C240 --- ENGINE FOOT ASSY. ENGINE FOOT ASSY. PART NO. ITEM QTY. REMARKS 9117712070 ENGINE FOOT, RIGHT SIDE 5117710501 ENGINE FOOT, LEFT SIDE 9029510250 FOOT BOLT, RIGHT SIDE 9029510250 BOLT FOOT, LEFT SIDE 9029560400 BOLT FOOT, LEFT SIDE 9098518660 PLAIN WASHER 5197110010 ALTERNATOR BRACKET...

  • Page 110: Engine Foot Assembly

    ISUZU C240 --- INJECTION PUMP ASSY. INJECTION PUMP ASSY. PAGE 110 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 111 ISUZU C240 --- INJECTION PUMP ASSY. INJECTION PUMP ASSY. PART NO. ITEM QTY. REMARKS 8943864440 INJECTION PUMP ASSY..... 1 ..... REPLACES 5156010252 INCL. ITEMS W/ 5157201400 GOVERNOR ASSY. 8941415340 FEED PUMP ASSY. 5157400720 AUTOMATIC TIMER 9197510790 INJ. PUMP SPACER BRACKET 9099205760 O RING PACKING 5125240660...

  • Page 112: Injection Pump Assembly

    ISUZU C240 --- ELECTRICAL PARTS ELECTRICAL PARTS PAGE 112 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 113 ISUZU C240 --- ELECTRICAL PARTS ELECTRICAL PARTS PART NO. ITEM QTY. REMARKS 5811000801 STARTER 5812003410 ALTERNATOR ........1 ......UP TO OCT. 1992 9822007640 ALTERNATOR ........1 ......OCT. 1992~ 9822531070 REGULATOR 9829317430 CABLE ASSY. 9825119780 GLOW PLUG 9825301090 CONTROL 9829513240 INSULATOR CAP 9829513250...

  • Page 114: Electrical Parts Assembly

    ISUZU C240 --- ACCESSORIES ACCESSORIES PAGE 114 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 115 ISUZU C240 --- ACCESSORIES ACCESSORIES PART NO. ITEM QTY. REMARKS 5193100060 DRIVE ASSY........1 ..... INCL. ITEMS W/ 9193110240 CASE 9193110200 COVER 9193120060 PACKING 9193160270 GEAR 9193160170 GEAR 9019006160 BOLT 9090310100 NIPPLE 9099243550 OIL SEAL 9019008220 BOLT 9099211070 PACKING 5819000020 STOPPER ASSY.
  • Page 116 ISUZU C240 ---INJECTION PUMP COMP. ASSY. INJECTION PUMP COMP. ASSY. PAGE 116 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 117 ISUZU C240 --- INJECTION PUMP COMP. ASSY. INJECTION PUMP COMP. ASSY. PART NO. ITEM QTY. REMARKS 5156110460 HOUSING ASSY........1 ..... INCL. ITEMS W/ 9812151150 STUD 9812350170 ADAPTER 1156190240 BOLT 1156390080 GASKET 1156390080 GASKET 5156120080 COVER 1156190030 SCREW 9812151440 GASKET 9091505060 LOCK WASHER...

  • Page 118: Injection Pump Comp. Assembly

    ISUZU C240 --- INJECTION PUMP COMP. ASSY. INJECTION PUMP COMP. ASSY. PAGE 118 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 119 ISUZU C240 --- INJECTION PUMP COMP. ASSY. INJECTION PUMP COMP. ASSY. PART NO. ITEM QTY. REMARKS 55-21 5156190260 TAPPET SHIM ........ A/R ....... T=0.26 55-22 5156190270 TAPPET SHIM ........ A/R ....... T=0.35 55-23 5156190370 TAPPET SHIM ........ A/R ....... T=0.45 55-24 5156191060 TAPPET SHIM ........
  • Page 120 ISUZU C240 --- INJECTION PUMP COMP. ASSY. INJECTION PUMP COMP. ASSY. PAGE 120 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 121 ISUZU C240 --- INJECTION PUMP COMP. ASSY. INJECTION PUMP COMP. ASSY. PART NO. ITEM QTY. REMARKS 9812214110 1156190820 BOLT 1157590010 PACKING 9097060370 BOLT 1096350070 PACKING 9812150780 TAPPET PLUG 9091606100 PLAIN WASHER 9091505100 LOCK WASHER 5156390020 9197510790 BRACKET 9099205760 O RING PACKING PAGE 121 —...

  • Page 122: Governor Comp. Assembly

    ISUZU C240 ---GOVERNOR COMP. ASSY. GOVERNOR COMP. ASSY. PAGE 122 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 123 ISUZU C240 --- GOVERNOR COMP. ASSY. COVERNOR COMP. ASSY. PART NO. ITEM QTY. REMARKS 1157210040 HOUSING ..........1 ..... INCL. ITEMS W/ 1157290150 O RING PACKING 9813150650 ADAPTER 9019008180 BOLT 9813253970 HOUSING PLATE 901906140 BOLT 5157291230 SCREW 9813252370 1157290380 HOUSING PLUG 9813251820 SCREW 9813261120...
  • Page 124 ISUZU C240 --- GOVERNOR COMP. ASSY. GOVERNOR COMP. ASSY. PAGE 124 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 125 ISUZU C240 --- GOVERNOR COMP. ASSY. GOVERNOR COMP. ASSY. PART NO. ITEM QTY. REMARKS 9813212200 OIL SEAL 9813251730 SHIM ............. 1 ..... T=0.50 9813250970 SHIM ..........A/R ..... T=0.30 9813253180 PLUG 9813250300 9813913070 COLLAR 9813254880 WASHER 5157250160 GUIDE LEVER ASSY. 100* 9813217130 LINK...
  • Page 126 ISUZU C240 --- FEED PUMP COMP. ASSY. FEED PUMP COMP. ASSY. PAGE 126 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 127 ISUZU C240 --- FEED PUMP COMP. ASSY. FEED PUMP COMP. ASSY. PART NO. ITEM QTY. REMARKS 5157510120 HOUSING ........... 1 ....... INCL. ITEMS W/* 9813512050 PISTON 9813513030 SPRING 9813550230 PLUG 9813550350 GASKET 5157540010 TAPPET ASSY........1 ....... INCL. ITEMS W/* 16*# 9813514030 ROLLER...

  • Page 128: Feed Pump Comp. Assembly

    ISUZU C240 --- AUTO TIMER COMP. ASSY. AUTO TIMER COMP. ASSY. PAGE 128 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 129 ISUZU C240 --- AUTO TIMER COMP. ASSY. AUTO TIMER COMP. ASSY. PART NO. ITEM QTY. REMARKS 9813435050 FLYWEIGHT ........2......INCL. ITEMS W/* 9813450430 SHIM 6-1* 9813450440 SHIM 6-2* 9813450450 SHIM 6-3* 5157490090 SHIM 6-4* 5157490100 SHIM 6-5* 5157490110 SHIM 6-6* 5157490680 SHIM...

  • Page 130: Auto Timer Assembly

    ISUZU C240 --- NOZZLE HOLDER COMP. ASSY. NOZZLE HOLDER COMP. ASSY. PAGE 130 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 131 ISUZU C240 --- NOZZLE HOLDER COMP. ASSY. NOZZLE HOLDER COMP. ASSY. PART NO. ITEM QTY. REMARKS 5153410020 PUSH ROD ......... 4 ....... INCL. ITEMS W/* 5153430020 SPRING 9153396010 SCREW 5153340030 9153390560 GASKET 9153390570 WASHER 9153326030 9153520050 GASKET 9153510070 CONNECTOR 5153490010 BOLT 9095714080 GASKET...

  • Page 132: Nozzle Holder Comp. Assembly

    ISUZU C240 ---STARTER COMP. ASSY. STARTER COMP. ASSY. PAGE 132 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 133 ISUZU C240 --- STARTER COMP. ASSY. STARTER COMP. ASSY. PART NO. ITEM QTY. REMARKS 5811210160 ARMATURE ASSY........1 ....INCL. ITEMS W/* 5811291050 PINION STOPPER 5811290030 WASHER SET 5811120100 FIELD COIL ASSY........1 ....INCL. ITEM W/> 25*> 5811160480 BRUSH, + 5811150130...

  • Page 134: Starter Comp. Assembly

    ISUZU C240 --- ALTERNATOR COMP. ASSY. ALTERNATOR COMP. ASSY. (OCT. 1992~) PAGE 134 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 135 ISUZU C240 --- ALTERNATOR COMP. ASSY. ALTERNATOR COMP. ASSY. (OCT. 1992~) PART NO. ITEM QTY. REMARKS 5812210630 ROTOR ASSY............1 ..INCL. ITEMS W/* AND W/> 4*> 9000901810 BALL BEARING 5812110580 STRATOR ASSY. 5812141310 REAR COVER ASSY..........1 ..INCL. ITEMS W/# 5812141320 REAR COVER 5812190360...

  • Page 136: Alternator Comp. Assembly

    ISUZU C240 ---ALTERNATOR COMP. ASSY. ALTERNATOR COMP. ASSY. (BEFORE OCT. 1992) PAGE 136 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
  • Page 137 ISUZU C240 --- ALTERNATOR COMP. ASSY. ALTERNATOR COMP. ASSY. (BEFORE OCT. 1992) PART NO. ITEM QTY. REMARKS 5812210100 ROTOR ASSY............1 ..INCL. ITEMS W/* 9000901810 BALL BEARING 9822250270 5812110090 STRATOR ASSY. 5812140010 COVER ASSY............1 ..INCL. ITEMS W/# 27*# 9822316190 RECTIFIER ASSY.
  • Page 138 TERMS AND CONDITIONS OF SALE — PARTS Effective: July 1, 2000 PAYMENT TERMS Freight is at the sender’s expense. All PRICING AND REBATES parts must be returned freight prepaid to Terms of payment for parts are net 10 days. Prices are subject to change without prior Multiquip’s designated receiving point.
  • Page 139 NOTE PAGE PAGE 139 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

  • Page 140: Terms And Conditions Of Sales

    PARTS AND OPERATION MANUAL PARTS AND OPERATION MANUAL HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING P P P P P AR ARTS DEP TS DEP TS DEP TS DEP TS DEPAR ARTMENT TMENT TMENT TMENT...

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