PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
© COPYRIGHT 2001, MULTIQUIP INC.
MQ POWER
DCA-60SSAI
TM
WHISPERWATT
GENERATOR
(Standard)
PARTS LIST NO. 7451201B
FINAL COPY
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
E-mail:mq@multiquip.com • www:multiquip.com
PAGE 2 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PAR
TS DEP
AR
TMENT
ARTS
DEPAR
ARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
VICE DEP
AR
TMENT
SER
ARTMENT
SERVICE
DEPAR
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEP
AR
TMENT
DEPAR
ARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 3
TABLE OF CONTENTS
Here's How To Get Help ........................................... 3
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Rules for Safe Operation ......................................... 6-9
Towing and Transportation ....................................... 10
Trailer Safety Guidelines .......................................... 11-17
Trailer Wiring Diagram .............................................. 18
Electric Brake Troubleshooting ................................ 19
Hydraulic Brake Troubleshooting .............................. 20
Operation Decals ..................................................... 21-22
DCA -60SSI2 Specifications ................................... 23
General Information ................................................. 24
Major Components .................................................. 55
Dimensions .............................................................. 26
Control Panel Descriptions ...................................... 28-29
Engine Operating Panel Descriptions ...................... 30-31
Output Terminal Panel Descriptions ......................... 32-33
Output Amperage Setup .......................................... 34-35
Output Voltage Setup ............................................... 36-39
Installation ............................................................... 40-41
Pre Set-up ............................................................... 42-45
Load Application ...................................................... 46
Generator Start-up Procedure ................................. 47-49
Generator Shut-down Procedure .............................. 50
Maintenance ............................................................ 52-55
Generator Wiring Diagram ........................................ 56
Engine Wiring Diagram ............................................ 57
Engine Troubleshooting ............................................ 58-59
Generator/Engine Troubleshooting ........................... 60
Explanation of Codes in Remarks Column .............. 62
Suggested Spare Parts ........................................... 63
ISUZU 6BD1 ENGINE
MQ POWER DCA-60SSAI
AC GENERATOR
Terms and Condition of Sale — Parts .................. 156
Generator Assembly ................................................ 64-65
Control Box Assembly ............................................. 66-67
Engine & Radiator Assembly ................................... 68-71
Engine Operating Panel Assembly .......................... 72-75
Battery Assembly .................................................... 76-77
Muffler Assembly .................................................... 78-79
Fuel Tank Assembly ................................................ 80-81
Enclosure Assembly ............................................... 82-85
Rubber Seal Assembly ............................................ 86-87
Name Plate And Decals .......................................... 88-89
Cylinder Head Cover Assembly ............................ 90-91
Cylinder Head Assembly ...................................... 92-93
Cylinder Block Assembly ..................................... 94-97
Oil Pan and Level Gauge Assembly ..................... 98-99
Camshaft and Valve Assembly ............................. 100-101
Crankshaft Piston and Flywheel Assembly .......... 102-103
Timing Gear and Flywheel Housing Assembly ..... 104-105
Inlet Manifold Assembly ....................................... 106-107
Exhaust Manifold Assembly ................................. 108-109
Ventilation Assembly ............................................ 110-111
Water Pump and Corrosion Resistor Assembly .... 112-113
Thermostat and Housing Assembly ..................... 114-115
Engine Water Piping Assembly ............................. 116-117
Fan and Fan Belt Assembly ................................. 118-119
Fuel Injection Assembly ....................................... 120-121
Fuel Filter and Bracket Assembly ........................ 122-123
Fuel Pump and Pipe Assembly ............................ 124-125
Oil Cooler and Oil Filter Assembly ....................... 126-127
Oil Pump and Oil Strainer Assembly .................... 128-129
Oil and Vacuum Piping Assembly ........................ 130-131
Electrical Control Assembly ................................. 132-133
Starter Components Assembly ............................ 134-135
Alternator Components Assembly ........................ 136-137
Injection Pump Components Assembly ............... 138-141
Governor Components Assembly ......................... 142-145
Feed Pump Assembly .......................................... 146-147
Misc. Injection Pump Assembly ........................... 148-149
Coupling Assembly ............................................... 150-151
Water Sedimenter Assembly ................................ 152-153
Switch and Relay Assembly ................................. 154-155
NOTE
Specification and part number
are subject to change without
notice.
PAGE 4 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
PARTS ORDERING PROCEDURES
■
■
■
■
■
■
■
Dealer account number
Dealer name and address
Shipping address (if different than billing address)
Return fax number
Applicable model number
Quantity, part number and description of each part
Specify preferred method of shipment:
•
•
•
•
UPS Ground
UPS Second Day or Third Day*
UPS Next Day*
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
•
Airborne Express*
Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
1-9 items
Additional Discount
3%
10+ items**
5%
Get special freight allowances
when you order 10 or more
line items via FAX!**
■ UPS Ground Service at no charge for freight
■ PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
*DISCOUNTS ARE SUBJECT TO CHANGE*
ount
c
s
i
D
Fax
Extra
c USA
i
t
s
e
m
for Do
Only
s
r
e
l
Dea
UPS l
Specia
nly
ders o
xed or
For fa
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
Fax order discount and UPS special programs revised June 1, 1995
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 5
RULES FOR SAFE OPERATION
CAUTION:
Failure to follow instructions in this manual
may lead to serious injury or even death!
This equipment is to be operated by trained
and qualified personnel only! This equipment
is for industrial use only.
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
The following safety guidelines should always be used when ■ High Temperatures – Allow the engine to cool before
operating the DCA-60SSAI portable generator:
adding fuel or performing service and maintenance
GENERAL SAFETY
functions. Contact with hot components can cause serious
burns.
■ DO NOT operate or service this equipment before
reading this entire manual.
■ The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
■ This equipment should not be operated by
enclosed or narrow area where free flow of the air is
persons under 18 years of age.
restricted. If the air flow
is restricted it will cause
serious damage to the
■ NEVER operate this equipment without proper
generator or engine and
protective clothing, shatterproof glasses, steelmay cause injury to
toed boots and other protective devices
people. The generator
required by the job.
engine gives off DEADLY
carbon monoxide gas.
■ NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
CAUTION:
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
■ Manufacturer does not assume responsibility for any
accident due to equipment modifications.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ Always check the machine for loosened threads or bolts
before starting.
■ Always refuel in a well-ventilated area,
away from sparks and open flames.
■ Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT smoke around or near
the machine. Fire or explosion could
result from fuel vapors, or if fuel is spilled
on a hot engine.
■
NEVER operate the generator in an
explosive atmosphere or near combustible
materials. An explosion or fire could result
causing severe bodily harm or even
death.
■
Topping-off to filler por t is
dangerous, as it tends to spill fuel.
PAGE 6 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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.
■ NEVER touch output terminals during operation. This is
extremely dangerous. Always stop the machine when
contact with the output terminals is required.
CAUTION:
■ Backfeed to a utility system can cause electrocution
and.or property damage. Do not connect to any
building's electrical system except through an approved
device or after building main switch is opened.
CAUTION:
Radiator
1. Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
■ Never use damaged or worn cables when connecting
power tools or equipment to the generator. Make sure
power connecting cables are securely connected to the
generator’s output terminals, insufficient tightening of the
terminal connections may cause damage to the generator
and electrical shock.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 7
RULES FOR SAFE OPERATION
■ NEVER Run engine without air filter. Severe engine
damage may occur.
Battery
CAUTION:
Never over fill the battery with water above
the upper limit.
The battery contains acids that can cause injury to the eyes
and skin. To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
■ Always service air cleaner frequently to prevent carburetor
malfunction.
■ Always disconnect the battery before performing service
on the generator.
■ Always be sure the operator is familiar with proper safety
precaution s and operations techniques before using
generator.
■ Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.
■ DO NOT leave the generator running in the manual mode
unattended.
■ DO NOT allow unauthorized people to operate this
equipment.
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.
■ Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
■ Refer to the Isuzu Engine Owner's Manual for engine
technical questions or information.
Loading and Unloading (Crane)
■ Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.
■ Always drain fuel prior to lifting.
■ Always make sure crane or lifting device has been
properly secured to the hook of guard frame on generator.
■ NEVER lift the machine while the engine is running.
■ Use adequate lifting cable (wire or rope) of sufficient
strength.
■ When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.
■ NEVER allow any person or animal to stand underneath
the machine while lifting.
■ When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure the
generator during transport.
PAGE 8 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
RULES FOR SAFE OPERATION
Transporting
■ Always shutdown engine before transporting.
■ Tighten fuel tank cap securely.
■ Drain fuel when transporting generator over long distances
or bad roads.
■ Always tie-down the generator during transportation by
securing the generator.
■ If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
Emergencies
■ Always know the location of the nearest fire extinguisher
and first aid kit. Know the location of the nearest telephone.
Also know the phone numbers of the nearest ambulance,
doctor and fire department.
Maintenance Safety
■ NEVER lubricate components or attempt service on a
running machine.
■ Always allow the machine a proper amount of time to
cool before servicing.
■ Keep the machinery in proper running condition.
■ Fix damage to the machine immediately and always
replace broken parts.
■ Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
■ DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 9
DCA-60SSAI — TOWING RULES FOR SAFE OPERATION
Towing Safety Precautions
CAUTION :
Check with your county or state safety
towing regulations department before towing
your generator.
To reduce the possibility of an accident
while transporting the generator on public roads, always
make sure the trailer (Figure 1) that supports the generator
and the towing vehicle are in good operating condition and
both units are mechanically sound.
The following list of suggestions should be used when towing
your generator:
■ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■ ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■ Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■ ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ The maximum speed for highway towing is 45 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of
terrain.
■ Place chocked blocks underneath wheel to prevent
rolling, while parked.
■ Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
■ Use the trailer’s hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.
■ Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve gas milage.
■ Avoid sharp turns to prevent rolling.
■ Remove wheel stand when transporting.
■ DO NOT transport generator with fuel in tank.
Figure 1. Generator with Trailer
PAGE 10 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — TRAILER-SAFETY GUIDELINES
CAUTION:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
Explanation of Chart:
This section is to provide the user with trailer service and
maintenance information. The service and maintenance
guidelines referenced in this section apply a wide range of
trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage
to the equipment and personal injury.
It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:
„
„
„
„
„
„
Brakes
Tires
Lug Nut Torquing
Suspension
Electrical
Brake Troubleshooting Tables
Use the following definitions with reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when transporting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, including the fuel cell (empty).
4.
Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
5. Frame Width - This measurement is from fender to
fender.
6.
Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 4 and Figure 5 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed
in inches (see Table 3). Please not that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 11
DCA-60SSAI —TRAILER-SPECIFICATIONS
Table 1. Specifications
MODEL
APPLICATION
FU E L
C E LL
BRAKE
SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
TRLR-10W
SDW225,
SGW250,TLW300
NO
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-10
DCA10, TLG12,
DCA-15
NO
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-10XF
DCA10, TLG-12,
DCA15, TLW-300
52 GAL
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-225W
WELDERS,
D A 7000S S
NO
NO
2200LB S
85"
42"
800LB .
FULL TILT WHEEL
TRLR-BLW400
BLW-400
NO
ELECTRIC
2700LB S
W/MAST 154"
W/O 124"
55"
(78" TALL)
800LB .
FULL TILT WHEEL
TRLR-50X
DCA-25
NO
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TRLR-50XF
DCA-25
41 GAL
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TRLR-70W
DCA-45, -60, 70
NO
SURGE
7000LB S
186"
77"
2000LB .
FLAT PAD
TRLR-70X
DCA-45, -60, 70
OPT
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TRLR-70XF
DCA-45, -60, 70
53 GAL
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TRLR-100XF
DCA-100, 125
150 GAL
HYDRAULIC SURGE
7000LB S
190"
76"
2000LB .
FLAT PAD
TRLR-85/125
DCA-85, 100,
125
145 GAL
HYDRAULIC
10000LB S
186"
77"
2000LB .
FLAT PAD
TRLR-150XF
DCA-150, 180
200 GAL
HYDRAULIC SURGE
11160LBS
204"
84"
5000 LB .
FLAT PAD
TRLR-220XF
DCA-220
250 GAL
HYDRAULIC SURGE
14000LB S
222"
83"
5000 LB .
FLAT PAD
TRLR-300XF
DCA-300
250 GAL
HYDRAULIC SURGE
18000LB S
238"
83"
5000 LB .
FLAT PAD
TRLR-400XF
DCA-400
350 GAL
ELECTRIC
18000LB S
238"
83"
5000 LB .
FLAT PAD
TRLR-600XF
DCA-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
TRLR-800SX
DCA-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
PAGE 12 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI —TRAILER-SPECIFICATIONS
Table 1. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS SUSPENSION
ELECTRICAL
TRLR-10W
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X 2
5 LUG
3 LE A F
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-10XF
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-225W
2" B A LL C LA S S
2 ADJUSTABLE
175-13B
13X4.5"
2200#2X 2
5 LUG
Q F LE X
4 POLE FLAT
TRLR-BLW
400
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13 X 4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-50X
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE RUBBER
FLAT
TRLR-50XF
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE RUBBER
FLAT
TRLR-70W
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-70X
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-70XF
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-100XF
ADJUSTABLE 2-5/6
OPT 3" EYE
205-15C
BIAS (4)
14"X5.5"
3500lbs
3"
5 LUG
5 LE A F
4 WIRE LOOM
TRLR-85/125
ADJUSTABLE 2-5/6
OPT 3" EYE
ST225/75R15D
RADIAL (4)
14"x6"
(2)-6000lbs
6 LUG
7 LE A F
4 WIRE LOOM
TRLR-150XF
3" BALL EYE
750-16 E
BIAS (4)
16" X 7"
(2)-6000lbs
8 LUG
7 LE A F
4 WIRE LOOM
TRLR-220XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16" X 7"
(2)-7000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-300XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(2)-6000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-400XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(3)-7000lbs.
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-600XF
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
7 LE A F
6 WIRE LOOM
TRLR-800AR
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
AIR-RIDE
6 WIRE LOOM
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 13
DCA-60SSAI —TRAILER SAFETY GUIDELINES
Brakes
If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow
the brake shoes and drums to seat properly. After the first
200 mile interval, inspect the brakes every 3,000 miles. If
driving over rough terrain, inspect the brakes more
frequently.
Electric Brakes
Electrically actuated brakes (Figure 2) are similar to
hydraulic brakes. The basic difference is that hydraulic
brakes are actuated by an electromagnet.
Listed below are some of the advantages that electric
brakes have over hydraulic brakes:
„ Brake system can be manually adjusted to provide
the corrected braking capability for varying road and
load conditions
„ Brake system can be modulated to provide more or
less braking force, thus easing the brake load on the
towing vehicle
„ Brake system has very little lag time between the time
the vehicle’s brakes are actuated and the trailer’s brakes
are actuated
„ Brake system can provide an independent emergency
brake system
Remember in order to properly synchronize the tow vehicle’s
braking to the trailer’s braking, can only be accomplished
by road testing. Brake lockup, grabbiness or harshness is
due to lack of synchronization between the tow vehicle
and the trailer being towed or under-adjusted brakes.
Before any brake synchronizations adjustments can be
made, the trailer brakes should be burnished-in by applying
the brakes 20-30 times with approximately a 20 m.p.h.
decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample
time for brakes to cool between application. This allows
the brake shoes to slightly be seated into the brake drum
surface.
Figure 2 displays the major electric brake components that
will require inspection and maintenance. Please inspect
these components as required.
Electric Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting
slot at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.
6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer
to the ground.
8. Repeat steps 1 through 6 on the remaining brakes.
PAGE 14 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — TRAILER SAFETY GUIDELINES
Figure 2. Electrical Brake Components
Hydraulic/Air/Surge Brakes
Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such
as shoe and lining replacement. These brakes can be
adjusted in the same manner as electric brakes. Brake
lines should be periodically checked for cracks, kinks, or
blockage.
Figure 3 below displays the major hydraulic/air/surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 6 as referenced in the electric brake adjustments
section.
Figure 3. Hydraulic Brake Components
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 15
DCA-60SSAI — 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. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked, the
air pressure in
the inner tube
may cause pieces of the rim to
explode (break off) with great force
and cause serious eye or bodily
injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Suspension
The leaf suspension springs and associated components
(Figure 4) should be visually inspected every 6,000 miles for
signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 3.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.
Figure 4. Major Suspension Components
PAGE 16 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI —TRAILER SAFETY GUIDELINES
Table 3. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
3/8" U-BOLT
MIN-30 MAX-35
7/16" U-BOLT
MIN-45 MAX-60
1/2" U-BOLT
MIN-45 MAX-60
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
SPRING EYE BOLT
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAIN NUT-BOLT ASSEMBLY.
MIN-30 MAX-50
SHOULDER TYPE
SHACKLE BOLT
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 5. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 4.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 4. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
20-25
35-40
50-65
13"
20-25
35-40
50-65
14"
20-25
50-60
90-120
15"
20-25
50-60
90-120
16"
20-25
50-60
90-120
Figure 5. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 17
DCA-60SSAI —TRAILER-WIRING DIAGRAM
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
PAGE 18 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI —TRAILER-BRAKE TROUBLESHOOTING
Table 5. Electric Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes or Intermittent Brakes
Any open circuits or broken wires?
Find and correct.
Any shor t circuits?
Find and correct.
Faulty controller?
Test and correct.
Any loose connections?
Find and repair.
Ground wire secure?
Find and secure.
Grease or oil on magnets or linings?
Clean or replace.
Connections corroded?
Clean and correct cause
of corrosion.
Brake drums scored or grooved?
Machine or replace.
Brakes synchronized?
Correct.
Brake components loose, bent or broken?
Replace components.
Brake drums out-of-round?
Replace.
System lubricated?
Lubricate.
Brake components correct?
Replace and correct.
Bearings of the wheel adjusted?
Adjust.
Weak Brakes or Brakes Pull to
One Side
Locking Brakes
Noisy Brakes
Dragging Brakes
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 19
DCA-60SSAI —TRAILER-BRAKE TROUBLESHOOTING
Table 6. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Repair or replace.
Weak Brakes or Brakes Pull to
One Side
Brake lining glazed?
Reburnish or replace.
Trailer overloaded?
Correct weight.
Brake drums scored or grooved?
Machine or replace.
Tire pressure correct?
Inflate all tires equally.
Tires unmatched on the same axle?
Match tires.
Brake components loose, bent or broken?
Replace components.
Brake drums out-of-round?
Replace.
System lubricated?
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness correct or in right
wrong position?
Install new shoes and
linings.
Enough brake fluid or correct fluid?
Replace rubber par ts
fill with dot4 fluid.
Locking Brakes
Noisy Brakes
Dragging Brakes
PAGE 20 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — GENERATOR DECALS
The DCA -100SSJU generator is wquipped 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. Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 21
DCA-60SSAI — GENERATOR DECALS
PAGE 22 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — SPECIFICATIONS
Table 7. Specifications
Generator Specifications
Model
DCA-60SSI2
Type
Revolving field, self ventilated, open protected type synchronous generator
Armature Connection
Star with Neutral
Zig Zag
Phase
3
Single
Standby Output
72 KVA (57.6 KW)
41.5KW
Prime Output
60 KVA (48 KW)
34.6KW
Voltage
240V or 480V
240/120V
Frequency
60 Hz
Speed
1800 rpm
Power Factor
0.8
1
Aux. AC Power
Single Phase, 60 Hz
Voltage
120 V
Output
4.8 KW (2.4 KW x 2)
Engine Specifications
Model
ISUZU A-6BG1
Type
4 Cycle, water-cooled, direct injection
No. of Cylinders
6 cylinders
Bore x Stroke
4.1 in. x 4.9 in. (105 mm x 125 mm)
Rated Output
77HP/1800 rpm
Displacement
396 cu. in. (6494 cc)
Starting
Electric
Coolant Capacity
7.8 gal. (29.5 liters)
Lube Oil Capacity
5.1 gal. (19.3 liters)
3.9 gal. (14.9L)/hr at full load
3.0 gal. (11.4L)/hr at 3/4 load
2.4 gal. (9.1L)/hr at 1/2 load
1.9 gal. (7.2L)/hr at 1/4 load
Fuel Consumption
Battery
12V- 100AH x 2
Fuel
#2 Diesel Fuel
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 23
DCA-60SSAI — GENERAL INFORMATION
DCA-60SSAI FAMILIARIZATION
Open Delta Excitation System
Generator
The DCA-60SSAI generator is equipped with the state of
ator the art "Open-Delta" excitation system. The open delta
The MQ Power Model DCA-60SSAI is a 48 kW gener
generator
that is designed as a high quality portable (requires a trailer system consist of an electrically independent winding wound
for transport) power source for telecom sites, lighting among stationary windings of the AC output section.
facilities, power tools, submersible pumps and other There are four leads: A, B, C and D. During light loads, the
industrial and construction machinery.
power to the Automatic Voltage Regulator (AVR) is supplied
from the leads parallel connections of B&C. When loads
Engine Operating Panel
increase, the AVR switches and accepts power from leads
The “Engine Operating Panel” is provided with the following: A&D. The output of leads A&D increase proportionally with
z Tachometer
load. This of adding the voltages to each phase provides
z Water Temperature Gauge
better voltage response during heavy loads.
z Oil Pressure Gauge
The connections of the AVR to the AC output windings are
z Charging Ammeter Gauge
for sensing only. No power is required from these windings.
z Engine Throttle Lever
z Panel Light
The open-delta design provides virtually unlimited excitation
z Panel Light Switch
current, offering maximum motor starting capabilities. The
z Oil Pressure and WaterTemp. Indicator lights
excitation does not have a "fixed ceiling" and responds
according the demands of the required load.
Generator Control Panel
The “Generator Control Panel” is provided with the following: Engine
z Output Voltage Adjustment Knob
The DCA-60SSAI is powered by a 4 cycle, water cooled,
z Frequency Meter (Hz)
Isuzu A-6BG1diesel engine. This engine is designed to
z AC Ammeter (Amps)
meet every performance requirement for the generator.
z AC Voltmeter (Volts)
Reference Table 1, page13 for engine specifications.
z Ammeter Change-Over Switch
In keeping with Multiquip's policy of constantly improving
z Voltmeter Change-Over Switch
its products, the specifications quoted herein are subject to
change without prior notice.
Output Terminal Panel
The basic controls and indicators for the DCA-60SSAI
The “Output Terminal Panel” is provided with the following:
generator are addressed on the following pages.
z Three 120/240V output receptacles, 50 amp
z Two 120V input receptacles, 20 amp
z 3 Load Circuit Breakers 240V @50 amps
z 2 Load GFCI Circuit Breakers 120V@ 20amps
Mechanical Governor System
The mechanical governor system control the RPM of the
Control Box
engine. When the engine demands increase or decrease,
The “Control Box” is provided with the following:
the mechanical governor system regulates the frequency
z Main Circuit Breaker 150 amps
variation to ±1.5%. The electronic governor option inz Over-Current Relay
creases frequency variation to ±.25%.
PAGE 24 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — MAJOR COMPONENTS
Figure 6. Major Components
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 25
DCA-60SSAI — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 7. Dimensions
PAGE 26 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
NOTE PAGE
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 27
DCA-60SSAI — CONTROL PANEL
Figure 8. Control Panel
PAGE 28 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-60SSAI " Control Panel " (Figure 8).
1.
Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
2.
AC Ammeter – Indicates the amount of current the
load is drawing from the generator.
3.
ACVoltmeter – Indicates the single phase output
voltage present at the UNV terminals.
4.
Pilot Lamp - This lamp indicates the load is not properly
set. Readjust the load, or use the voltmeter changeover switch to adjust phase position.
Main Circuit Breaker – This three-pole, 150 amp main
breaker is provided to protect the UNV voltage output
terminals from overload.
5.
6.
Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
7.
Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off.
8.
Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 29
DCA-60SSAI — ENGINE OPERATING PANEL
Figure 9. Engine Operating Panel
PAGE 30 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-60SSAI " Engine Operating Panel " (Figure 9).
1.
Oil Pressure Gauge – Normal operation should be about
25 psi. When starting the generator the oil pressure
may read a bit higher, but after the engine warms up
the oil pressure should return to normal.
2.
Panel light - Normally used in dark places or at night.
When activated, panel will luminate. When the generator
is not in use, turn the panel light switch to the ‘OFF’
position.
3.
Water Temperature Gauge – During normal operation
this gauge be should read between 165o to 215o.
Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
Indicator Lights - These lights indicate if the oil
pressure or water temperature is at dangerous levels
and will shut off the engine. The oil pressure indicator
will initially light at start-up, but will go off once the
pressure rises.
4.
5.
6.
Panel light switch- When activiated, will turn on control
panel light.
7.
Lamp Check Switch - This is used to check the
indicator lights. Turn on the engine, then press this to
check the bulbs. If they don’t light, replace the bulbs.
8.
Engine Throttle Lever - Pull or push this lever to change
the speed of the engine when a load is applied.
9.
Pre-Heat Indicator – Under cold conditions, turn the
starter key to preheat. Once the indicator lights, the
engine is ready to start.
10. Starter Switch - Turn this to start, stop, and preheat
the engine.
11. Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the engine is at full speed and a load is applied.
In addition, a built in hour meter will record the number
of operational hours that the generator has been in use.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 31
DCA-60SSAI — OUTPUT TERMINAL PANEL
Output Terminal Panel
The output control panel is located on the rear (control panel)
end of the generator. The UNV lugs are protected by a face
plate cover that can be secured in the close position by a
pad lock.
120 Volt Receptacle
One GFCI Duplex NEMA 5-20R (120V, 20 Amp) receptacle
is located on the output terminal. This receptacle can be
used anytime the generator is in operation. The receptacle
is controlled by the circuit breaker located on the control
panel.
The reset button will reset the receptacle after being tripped.
Pressing the :Test Button” (Figure 8) in the center of this
receptacle will check the GFCI function. The receptacle
should be tested at least once a month.
Twist Lock Dual Voltage Receptacles - To use these
receptacles, place the voltage selector switch in the single
phase 240/120 voltage position and adjust the output
voltage to 240 volts with the voltage regulator on the
Control Panel (Figure 8, page 28). Place the voltmeter
change-over switch to the U-W position and the ammeter
change-over switch to the U or W to read the output.
Connecting Load
Loads can be connected to the generator by the UVWO lugs or
the duplex receptacles. (See figure 3). Make sure to read the
operation manual before attempting to connect a load to the
generator.
Figure 11. Load Application
Circuit Breakers
Figure 10. GFCI Test Button
Generator Grounding
Make sure the generator is properly grounded before
applying load. Generators are NOT considered grounded
when mounted on a trailer.
To protect the generator from an overload, a 3-pole, 150 amp,
main circuit breaker is provided to protect the UVWO output
terminals from overload. In addition two single-pole, 20 amp
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload. Three 50 amp load circuit
breakers have also been provided to protect the load side of
the generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
Maximum Output
The entire load connected to the UVWO lugs, all four slots in
the duplex receptacles, and the must not exceed 52.8 kW in
standby or 48 kW in prime output.
Generator Grounding
Make sure to ground the generator in EVERY application
prior to connecting a load. Generators are NOT grounded
just because they are mounted on trailers or other vehicles
that are on rubber tires.
PAGE 32 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — OUTPUT TERMINAL VOLTAGE SELECTION
DCA-60SSAI
NOTE
Legs O and Ground are
considered Bonded Grounds.
Figure 12. Output Panel Location
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 33
DCA-60SSAI — OUTPUT AMPERAGE SETUP
Output Terminal Panel Available Voltages
A wide range of voltages are available to supply load to
many different applications. Voltages may be selected by
using the voltage selector switch and depending how you
hookup your hard wire connection to the generator. To obtain
some of the voltages listed, fine adjustment with the voltage
regulator on the control panel is necessary. See Table 8 for
available voltages the generator will supply.
Over Current Relay
An over current relay is connected to the circuit breaker.
During an over current situation, both the circuit breaker and
the over current relay will trip. If the circuit breaker can not
be reset, the reset button on the over current relay must be
pressed. The over current relay is located inside the control
box.
Table 8. Voltage Available
3 Phase
(Switchable)
208 VOLT
220 VOLT
240 VOLT
416 VOLT
440 VOLT
480 VOLT
Single Phase
(Switchable)
120 VOLT
127 VOLT
139 VOLT
240 VOLT
254 VOLT
277 VOLT
CAUTION :
NEVER switch Voltage Selector Switch
position while the engine is engaged.
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and generator load from being switched while
the engine is running. To lock the voltage selector switch,
press in the red button located on the voltage selector switch,
and use a pad lock to hold it into this position.
Maximum Amps
Table 9 shows the maximum amps the generator will provide. Do not exceed the maximum amps listed.
Table 9. Maximum Amps
Rated
Voltage
Maximum Amps
Single Phase
120 Volt
133.3 amps (4 wire)
Single Phase
240 Volt
66.7 amps (4 wire)
Three Phase
240 Volt
144 amps
Three Phase
480 Volt
72 amps
PAGE 34 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — OUTPUT AMPERAGE SETUP
Receptacle Use
When the UVWO terminals are providing power, the receptacle power availability will decrease.
How To Read The Output Terminal Gauges.
The gauges (Figure 15 and 17) and change-over switches
on the control panel DO NOT effect the generator output.
They are to help observe how much power is being supplied
at the UVWO legs.
When the voltage selector switch is in the 240/120V position (Figure 13), place the AC voltmeter change-over switch
to the W-U position (Figure 14) and the AC ammeter changeover switch to the U or W position (Figure 16) to read the
output on the selected leg.
Figure 14 and 15. AC Voltmeter Change-over switch
and Voltmeter Gauge
Figure 16 and 17. AC Ammeter Change-over Switch
and Ammeter Gauge
NOTE
Figure 13. Voltage Selector Switch 240/120V Single
Phase
Position
When using plural single phase
voltages, make sure to balance
the load on each of the single
phase legs.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 35
DCA-60SSAI — OUTPUT VOLTAGE SETUP
240/120V Hard Wire Hookup
480/240V Hard Wire Hookup
With the voltage selector set and locked at ‘single phase
240/120’ and using single phase 120 volts, the generator
will provide three legs available with 100 amps each on three
different circuits (Figure 18).
With the voltage selector set and locked at ‘3 phase 480/
277’ (Figure 19) and using the 3-phase 240 hookup, it will
provide one circuit available at 108 amps with any two wires
plus the ground (Figure 20).
When using the 3-phase 480 volts hookup, it will provide
one circuit available at 50 amps with all three wires plus
ground.
Figure 19. Voltage Selector Switch 480/277V Three Phase
Position
Figure 18. Hard Wire Hookup at 240/120V Position
Figure 20. Hard Wire Hookup at 480/240V Position
PAGE 36 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — OUTPUT VOLTAGE SETUP
Voltage Selector Switch- 3 Phase 480/277V Position
The following are additional voltages available when the voltage selector switch is in the ‘3 phase 480/277V’ position.
Single Phase: 480V, 440V, or 416 Volt
This setting can provide single phase power at 480, 440, or
416 volts. After hooking up the hard wires to the lugs as
shown in Figure 23, 480 volts can be obtained with the voltage regulator knob turned toward maximum; 440 volts can
be obtained with the voltage regulator knob is turned down;
and 416 volts can be obtained with the voltage regulator
knob is at the lowest setting.
Figure 21. Voltage Regulator Knob
3 Phase, 480V, 440V, or 416 Volt
This setting can provide 3-phase power at 480, 440, or 416
volts. After hooking up the hard wires to the lugs as shown
in Figure 22, 480 volts can be obtained with the voltage
regulator knob turned toward maximum; 440 volts can be
obtained with the voltage regulator knob is turned down; and
416 volts can be obtained with the voltage regulator knob is
at the lowest setting.
Figure 23. Hard Wire Hookup for Single Phase 480V, 440V,
or 416V
Single Phase: 277V, 254V, or 240V
This setting can provide single phase power at 277, 254, or
240 volts. After hooking up the hard wires to the lugs as
shown in Figure 24, 277 volts can be obtained with the voltage regulator knob turned toward maximum; 254 volts can
be obtained with the voltage regulator knob is turned down;
and 240 volts can be obtained with the voltage regulator
knob is at the lowest setting.
Figure 22. Hard Wire Hookup for Three Phase 480V, 440V, or
416V
Figure 24. Hard Wire Hookup for Single Phase 277V, 254V,
or 240V
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 37
DCA-60SSAI — OUTPUT VOLTAGE SETUP
Voltage Selector Switch- 3 Phase 240/139V Position
The following are additional voltages available when the voltage selector switch is in the ‘3 phase 240/139V’ position.
Figure 25. Voltage Selector Switch 240/139V Three Phase
Position
Single Phase: 240V, 220V, or 208 Volt
This setting can provide single phase power at 240, 220, or
208 volts. After hooking up the hard wires to the lugs as
shown in Figure 27, 240 volts can be obtained with the voltage regulator knob turned toward maximum; 220 volts can
be obtained with the voltage regulator knob is turned down;
and 208 volts can be obtained with the voltage regulator
knob is at the lowest setting.
Figure 27. Hard Wire Hookup for Single Phase 240V, 220V,
or 208V
Single Phase: 139V, 127V, or 120V
3 Phase, 240V, 220V, or 208 Volt
This setting can provide single phase power at 139, 127, or
This setting can provide 3-phase power at 240, 220, or 208 120 volts. After hooking up the hard wires to the lugs as
volts. After hooking up the hard wires to the lugs as shown shown in Figure 28, 139 volts can be obtained with the voltin Figure 26, 240 volts can be obtained with the voltage age regulator knob turned toward maximum; 127 volts can
regulator knob turned toward maximum; 220 volts can be be obtained with the voltage regulator knob is turned down;
obtained with the voltage regulator knob is turned down; and and 120 volts can be obtained with the voltage regulator
208 volts can be obtained with the voltage regulator knob is knob is at the lowest setting.
at the lowest setting.
Figure 26. Hard Wire Hookup for Three Phase 240V, 220V, or
208V
Figure 28. Hard Wire Hookup for Single Phase 139V, 127V,
or 120V
PAGE 38 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — OUTPUT VOLTAGE SETUP
Voltage Selector Switch- Single Phase 240/120V
Position
The following are additional voltages available when the voltage selector switch is in the ‘single phase 240/120V’ position.
Single Phase: 120 Volt
This setting can provide single phase power at 120 volts.
After hooking up the hard wires to the lugs as shown in
Figure 31, 120 volts can be obtained with the voltage regulator knob turned to fine tune.
Figure 31. Hard Wire Hookup for Single Phase, 120 volt
Figure 29. Voltage Selector Switch 240/120V Single Phase
Position
Single Phase, 240 Volt
This setting can provide single phase power at 240 volts.
After hooking up the hard wires to the lugs as shown in
Figure 30, 240 volts can be obtained with the voltage regulator knob turned to fine tune.
Figure 30. Hard Wire Hookup for Single Phase 240 volt
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 39
DCA-60SSAI — INSTALLATION
Outdoor Installation
Install the generator in a location where it will not be exposed
to rain or sunshine. Make sure the generator is on secure
level ground so it cannot slide or shift around. Also install
the generator so the exhaust will not be discharged in the
direction of nearby homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to the
engine and alternator parts.
CAUTION :
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
CAUTION :
An electric shock may happen when
vibrators are used. Pay close attention to
handling when operating vibrators and
always use rubber boots and gloves to
insulate the body from electrical shock.
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.
NEC articles 25064(b) a and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 32) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
NOTE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
PAGE 40 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — INSTALLATION
Figure 32.
Typical Generator Grounding Application
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 41
DCA-60SSAI — PRE-SETUP
General Inspection Prior to Operation
Circuit Breakers
The DCA-60SSAI generator has been thoroughly inspected
and accepted prior to shipment from the factory. However,
be sure to check for damaged parts or components, or loose
nuts and bolts, which could have occurred in transit.
Extension Cable
To protect the generator from an overload, a 3-pole, 150 amp,
main circuit breaker is provided to protect the UNV output
terminals from overload. In addition two single-pole, 20 amp
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload. Three 50 amp load circuit breakers
have also been provided to protect the load side of the
When electric power is to be provided to various tools or generator from overload. Make sure to switch ALL circuit
loads at some distance from the generator, extension breakers to the "OFF" position prior to starting the engine.
cords are normally used. Cables should be sized to allow
for distance in length and amperage so that the voltage
drop between the generator and point of use (load) is held
to a minimum. Use the Cable Selection Guide (Table 10)
as a guide for selecting proper cable size.
NOTE
ALWAYS consult with a licensed
electrician for correct extension
cord wire size.
Table 10. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Current in
Amperes At 120 At 240
Volts
Volts
Maximum Allowable Cable Length
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
300
600
1000 ft.
600 ft.
375 ft.
250 ft.
5
600
1200
500 ft.
300 ft.
200 ft.
125 ft.
7.5
900
1800
350 ft.
200 ft.
125 ft.
100 ft.
10
1200
2400
250 ft.
150 ft.
100 ft.
15
1800
3600
150 ft.
100 ft.
65 ft.
20
2400
4800
125 ft.
75 ft.
50 ft.
CAUTION: Equipment damage can result from low voltage.
PAGE 42 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — PRE-SETUP
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way, but without being screw
into the filler hole, verify that the oil level is maintained
between the two notches (Figure 33) on the dipstick. See
Table 11 for proper selection of engine oil.
Fuel
Fill the fuel tank with clean and fresh diesel fuel. DO NOT
fill the tank beyond capacity.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 23,
Specification Table 7.
The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel. Wipe up any spilled fuel immediately.
CAUTION:
Never fill the fuel tank while the engine is
running or in the dark. Diesel spillage on
a hot engine can cause a fire or
explosion. If diesel spillage occurs, wipe
up the spilled diesel completely to
prevent fire hazards.
Figure 33. Engine Oil Dipstick
Coolant
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.
An anticorrosion additive added to the water will help prevent
When checking the engine oil, be sure to check if the oil is deposits and corrosion in the cooling system. See the engine
clean and viscous. If the oil is not clean, drain the oil by manual for further details.
removing the oil drain plug, and refill with the specified amount
of oil as outlined in the Isuzu Engine Owner's Manual.
Table 11. Recommended Motor Oil
Temperature Range
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
SAE 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
Below 5° C (-15°)
SAE 10W or SAE 10W-30
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 43
DCA-60SSAI — PRE-SETUP
CAUTION :
When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.
Day-to-day addition of coolant is done from the reserve tank.
When adding coolant to the radiator, DO NOT remove the
radiator cap until the unit has completely cooled. See Table
12. for engine, radiator, and reserve tank coolant capacities.
Make sure the coolant level in the reserve tank is always
between the "H" and the "L" markings.
Table 12. Coolant Capacity
Engine and Radiator
7.8 Gal. (29.5 Liter)
Reserve Tank
.95 Gal. (2 Liter)
Cleaning the Outer Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the radiator is
dangerous, so clean only with the engine turned off and the
battery disconnected.
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Isuzu Engine Owner's Manual.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the Isuzu
Engine Owner's Manual.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 34) when depressed with the thumb as shown
below. Never place hands near the belts or fan while the
generator is running.
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Table 13. Anti-Freeze Operating Temperatures
Freezing Point
Boiling Point
Vol %
Anti-Freeze
°C
°F
°C
°F
40
-24
-12
106
222
50
-37
-34
108
226
NOTE
When the antifreeze is mixed with
w ater
atio m
ust
ater,, the antifreez
antifreezee mixing rratio
must
be less than 50%.
Figure 34. Fan Belt Tension
CAUTION :
Never place hands near the belts or fan
while the generator set is running.
Adjusting Fan Belt
If the fan belt does not have the 10 to 15 mm defection
follow the procedure below to adjust:
Loosen the alternator adjusting plate and alternator mounding
bolt.
Pivot the alternator at the mounting bolt toward the engine
left or right until the belt reflects the proper tension.
Tighten the mounting bolt and the adjusting bolt.
PAGE 44 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — PRE-SETUP
Battery
This unit is of negative ground. DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary. DO NOT over fill.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions. Always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help to inhibit corrosion.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 35) are properly
connected to the battery terminals as shown below. The RED
cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.
CAUTION :
If the battery cable is connected
incorrectly, damage to the generator will
occur. Pay close attention to the polarity
of the battery when connecting the
battery.
When connecting battery do the following:
1. DO NOT connect the battery cables to the battery
terminals when the key is in the ignition and is set in
'START' mode. ALWAYS remove the key from the
ignition and the ignition switch is in the OFF position
when connecting the battery.
2. Place a small amount of grease around both battery
terminals. This will ensure a good connection and will
help prevent corrosion around the battery terminals.
CAUTION :
Inadequate battery connections may
cause poor starting of the generator, and
create other malfunctions.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check hoses
for leaks.
Figure 35. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
Alternator
The polarity of the alternator is negative grounding type.
When an inverted circuit connection takes place, the circuit
will be in short circuit instantaneously resulting the alternator
failure.
Do not put water directly on the alternator. Entry of water
into the alternator leads an electrolyte corrosion causing an
alternator failure.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 45
DCA-60SSAI — LOAD APPLICATION
Single Phase Load
CAUTION:
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
Motors and motor-driven equipment draw
much greater current for starting than
during operation.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can burn
out the appliance or tool and overheat the cable.
When the voltage selector switch is in single phase (240/
120V position), place the AC voltmeter change-over switch
to the U-W position and the AC ammeter change over-switch
to the U or W position to read the ouput.
NOTE
If wattage is not given on the
equipment's name plate, approximate
wattage may be determined by
multiplying nameplate voltage by the
nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 1.0. See Table 14.
below when connecting loads.
Table 14. Power Factor By Load
Type Of Load
Power Factor
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
Fluorescent lamps, mercury lamps
0.4 - 0.9
Electronic devices, communication
equipment
1.0
Common power tools
0.8
z When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.
z When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
z When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
If wattage is not available on the equipment, approximate
wattage may be determined by mulitplying the nameplate
voltage by the nameplate amperage for three-phase:
WATTS =1.732 x VOLTAGE x AMPERAGE
CAUTION:
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.
NOTE
If output (kVA) is not given on the
equipment nameplate, approximate
output may be determined by
multiplying voltage by amperage by
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
PAGE 46 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — GENERATOR START-UP PROCEDURE
WARNING:
The engine's exhaust contains harmful
W AY S ventilate the
emissions. A LLW
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.
2. Connect the load to the UVW terminals as shown in
Figure 37. These terminals can be found on the output
terminal panel, (see page 22 Figure 6). To gain access
to the output terminals lift the UVW cover. Tighten
terminal nuts securely to prevent load wires from slipping
out.
Before Starting
Engine
1. Check the lubricating oil level prior to starting the engine.
Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.
2. When there is not enough lubricating oil, fill the crankcase
with high grade motor oil. Use a high quality detergent
oil classified CC or higher (See Table 11 on page 43).
3. Check the coolant level in the radiator and subtank.
Replenish with antifreeze as necessary. Always maintain
the coolant level between the FULL and LOW markings
on the coolant container. Be sure that the radiator cap is
fastened securely.
4. Check the fuel level on the fuel gauge. If fuel is low, fill
the fuel tank with clean fresh unleaded automotive diesel.
If diesel spillage occurs, completely wipe up the spilled
fuel immediately.
Figure 37. UVW Terminal Lugs (Load)
3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 38).
Before Starting
Generator and Control Panel
CAUTION:
NEVER start the engine with the
main, GFCI or load circuit breakers
in the ON position.
1.
Be sure to disconnect the
.C
.I.
electrical load and switch the main, load and G.F
G.F.C
.C.I.
circuit breakers (Figure 12) to the “OFF” position prior to
starting the engine.
IVE
ST
PO
E
TIV
GA
NE
RY
E
TT
A
B
Figure 38. Battery Connections
Figure 36. Main, GFCI and
Load Circuit Breakers
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 47
DCA-60SSAI — GENERATOR START-UP PROCEDURE
4. Close all engine enclosure doors (Figure 39).
8.
Once the preheat indicator lights, turn the key to
‘START’ (Figure 43). After the engine cranks,
release the key to ‘RUN’.
Figure 43. Starter Switch (Start)
Figure 39. Engine Enclosure Doors
5.
Check the voltage selection switch (Figure 40) is
at the desired voltage.
9.
Pull the engine throttle lever and turn left until the
lever sets on the knob (Figure 44).
Figure 44. Engine Throttle Lever (Up)
Figure 40. Voltage Selection Switch
6.
Check to see if the engine throttle lever (Figure
41) is pushed in.
10. The generator's frequency meter (Figure 45) displays
the 60 cycle output frequency in HERTZ.
Figure 45. Frequency Meter (Hz)
Figure 41. Engine Throttle Lever
7.
Turn the starter switch to ‘PREHEAT’ (Figure 42)
until the indicator light turns on. The oil pressure
indicator light will initially turn on, but should turn off
once the pressure rises.
Figure 42. Key Switch (Preheat)
11. The generator's voltage meter (Figure 46) displays the
120 VAC in VOLTS. If the voltage is not within the
specified frequency tolerance, use the voltage
adjustment control knob (Figure 47) to increase or
decrease the desired voltage.
Figure 46. Voltage Meter (Volts)
PAGE 48 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — GENERATOR START-UP PROCEDURE
15. The charging ammeter (Figure 51) will indicate if the
battery is properly charged.
Figure 47. Voltage Adjust Control
Knob
12. The ammeter (Figure 48) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator’s alternator.
20
40
0
Figure 51. Charging Ammeter
16. The tachometer (Figure 52) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800
RPM’s.
60
75
A
Figure 52. Engine Tachometer
Figure 48. Ammeter (No Load)
13. The engine oil pressure gauge (Figure 49) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure is approximately
25 psi.
17. Turn the MAIN, GFCI and LOAD circuit breakers to
their ON position (Figure 53).
Figure 53. Main and GFCI Circuit Breakers
Figure 49. Oil Pressure Gauge
14. The coolant temperature gauge (Figure 50) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature is between 165 and
215 degrees fahrenheit.
18. Observe the generator's ammeter (Figure 54) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if the load is in use.
20
40
0
60
75
A
WATER
TEMP
Figure 54. Ammeter (Load)
19. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 50. Coolant Temperature Gauge
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 49
DCA-60SSAI — GENERATOR SHUT-DOWN PROCEDURE
ENGINE SHUTDOWN
To shutdown the generator, use the following procedure:
1. Switch both the MAIN, GFCI and LOAD circuit breakers
(Figure 55)to the “OFF” position.
EMERGENCY STOP
1. To stop the engine in the event of an emergency, switch
the MAIN, GFCI and LOAD circuit breakers to ‘OFF’
position.
2.
Turn the key switch to ‘STOP’.
Figure 55. Main, GFCI and Load
circuit breakers
2. Turn to the right and press in the engine throttle lever
(Figure 56).
Figure 56. Engine Throttle Lever
3. Let the engine cool by running it for 3-5 minutes with no
load applied.
4.
Turn the key switch to ‘STOP’’ (Figure 57).
Figure 57. Key Switch (OFF)
5.
Remove the load from the UVW terminal strip.
PAGE 50 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
NOTE PAGE
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 51
DCA-60SSAI — MAINTENANCE
General Inspection
Cleaning the Fuel Strainer
Prior to each use, the generator should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for fuel,
oil, and coolant leaks.
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation or
once a month.
Engine Side (Refer to the Engine Instruction Manual)
Air Cleaner
Every 50 hours: Remove air cleaner element and clean heavy
duty paper element with kerosene, or foam element with
liquid detergent and hot water. Wrap foam element in a cloth
and squeeze dry. For heavy duty paper element, wipe
excess kerosene with towel.
The air cleaner is equipped with an indicator. After the dirty
air cleaner has been replaced, press the dust indicator button
to reset the indicator.
Fuel Addition
Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.
Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
cock and drain the contents. During cold weather, the more
empty volume inside the tank, the easier it is for water to
condense. This can be reduced by keeping the tank full as
much as possible.
Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil level
must be between the two notches on the dipstick as shown
in Figure 32, page 43.
Replacing Oil Filter
1. Detach the oil filter cartridge with a filter wrench.
2. Apply a film of oil to the gasket for the cartridge.
3. Screw in the cartridge by hand. When the gasket is in
contact with the seal surface, tighten the cartridge one
or two more times by hand.
4. After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check
for leaks before adding more oil if needed. Clean
excessive oil from engine.
Replacing Fuel Filter
1. Replace the fuel filter cartridge with new one every 400
hours or so.
2. Apply fuel oil thinly over the gasket and hand-tighten
the cartridge into position.
3. Vent any air.
4. Fuel Injection Nozzle
5. Use an injection nozzle tester to check the static injection
starting pressure and the fuel spray conditions.
6. Abnormal fuel consumption will lead to a lowered output
and blackish exhaust smoke. The required injection
starting pressure should be 14.7MPa (150kg/cm2,
2130psi).
Service Daily
If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result. This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber in high fuel consumption.
PAGE 52 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — MAINTENANCE
Feed Pump Strainer Cleaning
The strainer is incorporated in the feed pump inlet side joint
bolt. Clean the strainer with compressed air and rinse it in
the fuel oil.
Flushing Out Radiator and Replacing Coolant
1. Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overflow
tank and drain.
2. Check hoses for softening and kinks. Check clamps for
signs of leakage.
3. Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.
4. Tighten both cocks and replace the overflow tank.
5. Replace with coolant (see page 44, Table 14 for mixture).
6. Close radiator cap tightly.
CAUTION :
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot will
damage radiator.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 53
DCA-60SSAI — MAINTENANCE
Valve Clearance Check
1. In order to bring No. 1 or No. 4 cylinder to top dead center
in the compression stroke, align the notched line on the
crank pulley with TDC mark on the timing gear case
cover.
3. Remove the timing check hole cover at the front of
injection pump to check the alignment between the
pointer “a” on the injection pump gear lock plate and the
projected area mark “b” on the timing gear case.
4. If “a” and “b” are in alignment, the timing is set correctly.
If not, follow nos. 1-3 until the “a” and “b” are aligned.
2. Do the adjustment on the circle marked valves in the
below table where No. 1 cylinder is at the center in the 5. Reversely turn the crankshaft pulley counterclockwise
viewed at the engine front about 30o crank angle.
compression stroke.
3. After adjustment started from either piston top center, 6. Remove No. 1 injection pipe from the engine.
turn the crankshaft 360o to align the notched line with 7. Remove the injection pump No. 1 delivery valve holder,
the TDC mark to do the adjustment again on the
delivery valve and spring and reinstall the delivery valve
remaining valve. See Table 16 and Figure 55 for valve
holder on the original place.
arrangement.
8. Delivery valve holder tightening torque:
39~44Nm(29~33lbft.)
Injection Timing Check and Adjustment
9. Slowly turn the crankshaft pulley clockwise and at the
1. Bring No. cylinder to the top dead center on the
compression stroke.
same time continue to feed the fuel with pumping the
Feed pump. When the fuel stop to flow out from No. 1
delivery valve holder, stop pumping.
2. Turn the crankshaft pulley clockwise (viewed at engine
front) and align the notched line on the crank pulley with 10. Observe and make sure which mark (injection starting
the TDC mark on the timing gear case cover.
angle line) on the timing gear case cover is aligning with
the notched line on the crank pulley.
11. The timing line shows the injection starting crank angle
of the engine.
12. The injection starting crank angle should be at the 14o
timing mark.
Table 15. Valve Adustment
(I=Inlet; E=Exhaust)
Cylinder No.
Figure 58. Valve Adjustment
NOTE:
Take necessary precautions to prevent dust and
foreign particles in the pump interior when timing
adjustments are made.
1
2
Valve Arrangement
I
E
I
When No. 1 is at top
dead center in the
compression stoke
X
X
X
When No. 4 is at top
dead center in the
compression stroke
3
E
I
4
E
I
E
O
O
X
O
O
PAGE 54 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — MAINTENANCE
INSPECTION / MAINTENANCE
ENGINE
GENERATOR
10 Hrs
DAILY
Check Engine Fluid Levels
X
Check Air Cleaner
X
Check Battery Acid Level
X
Check Fan Belt Condition
X
Check for Leaks
X
Check for Loosening of Parts
X
250 Hrs
Replace Engine Oil and Filter *1
X
Clean Air Filter
X
Drain Bottom of Fuel Tank
X
Clean Unit, Inside and Outside
X
500 Hrs
Change Fuel Filter *2
X
Clean Radiator and Check Coolant Protection
Level
X
1000 Hrs
Replace Air Filter Element
X
Change Corrosion Resistor
X
Check all Hoses and Clamps
X
Clean Inside of Fuel Tank
X
Measure Insulation Resistance Over 3M ohms
X
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Replace fuel filter at 250 Hours, first time only.
Generator Storage
For storage of the generator for over 30 days, the following
is required:
y Fill the fuel tank completely.
y Completely drain the oil from the crankcase and refill
with fresh oil.
y Clean all external parts of the generator with a cloth.
y Cover the generating set and store in a clean, dry place.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 55
DCA-60SSAI — GENERATOR WIRING DIAGRAM
PAGE 56 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — ENGINE WIRING DIAGRAM
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 57
DCA-60SSAI — TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper
handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for
diagnosis based on the Engine Troubleshooting (Table 16). If
the problem cannot be remedied, consult our company's
business office or service plant.
TABLE 16. ENGINE TROUBLESHOOTING
SYMPTOM
Engine does not start.
POSSIBLE PROBLEM
SOLUTION
No fuel?
Replenish fuel.
Air in the fuel system?
Bleed system.
Water in the fuel system?
Remove water from fuel tank.
Fuel pipe clogged?
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity of fuel
or engine oil at low temperature?
Use the specified fuel or engine oil.
Fuel with low cetane number?
Use the specified fuel.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Incorrect injection timing?
Adjust.
Fuel cam shaft worn?
Replace.
Injection nozzle clogged?
Clean injection nozzle.
Injection pump malfunctioning?
Repair or replace.
Seizure of crankshaft, camshaft,
piston, cylinder liner or bearing?
Repair or replace.
Compression leak from cylinder?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Improper valve timing?
Correct or replace timing gear.
Piston ring and liner worn?
Replace.
Excessive valve clearance?
Adjust.
Starter malfunctioning?
Repair or replace.
Wiring disconnected?
Connect wiring.
Starter does not run.
PAGE 58 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — TROUBLESHOOTING (ENGINE)
TABLE 16. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
Engine revolution is not smooth.
Either white or blue exhaust gas
is observed.
Either black or dark gray exhaust
gas is observed.
Deficient output.
POSSIBLE PROBLEM
SOLUTION
Fuel filter clogged or dirty?
Clean or change.
Air cleaner clogged?
Clean or change.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Injection pump malfunctioning?
Repair or replace.
Incorrect nozzle opening
pressure?
Adjust.
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe clogged?
Clean.
Governor malfunctioning?
Repair.
Excessive engine oil?
Reduce to the specified level.
Piston ring and liner worn or
stuck?
Repair or replace.
Incorrect injection timing?
Adjust.
Deficient compression?
Adjust top clearance.
Overload?
Lessen the load.
Low grade fuel used?
Use the specified fuel.
Fuel filter clogged?
Clean or change.
Air cleaner clogged?
Clean or change.
Deficient nozzle injection?
Repair or replace the nozzle.
Incorrect injection timing?
Adjust.
Engine's moving parts seem to
be seizing?
Repair or replace.
Uneven fuel injection?
Repair or replace the injection pump.
Deficient nozzle injection?
Repair or replace the nozzle.
Compression leak?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 59
DCA-60SSAI — TROUBLESHOOTING (GENERATOR/ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table 7). If the problem
cannot be remedied, consult our company's business office or service plant.
TABLE 17. ENGINE & GENERATOR TROUBLESHOOTING
SYMPTOM
Engine fails to start and starter
does not rotated.
Engine fails to start and starter
rotates.
Engine starts and remains at low
speed.
Engine speed rises and no
volteage is present n AC power
source.
POSSIBLE PROBLEM
SOLUTION
Dead battery?
Replace battery.
Defective starter switch?
Replace switch.
Fuse F5 burned out?
Replace fuse.
Broken pre-heat circuit?
Check pre-heat circuit.
No fuel?
Add fuel.
Defective wiring?
Check wiring.
Clogged fuel strainer?
Clean or replace.
Clogged air cleaner?
Clean or replace.
Disconnected wiring?
Check and repair wiring.
No voltage present in AC power
source?
Replace rectifier (RE1).
Defective rotor?
Replace rotor.
Defective voltmeter?
Replace voltmeter.
Disconnected wiring?
Check and repair wiring.
Layer short-circuit in armature
winding?
Replace armature.
Engine speed rises and AC power Defective circuit breaker (protector)?
voltage is too low or cannot be
Layer short-circuit, broken wires in
used.
armature winding?
Engine speed rises and battery
discharges too soon.
Engine speed rises and engine
seems overloaded.
Replace circuit breaker (protector).
Repair or replace armature.
Defective engine regulator?
Replace regulator.
Defective wiring?
Repair or replace wiring.
Defective alternator?
Repair or replace alternator.
Damaged alternator bearing?
Replace alternator bearings.
PAGE 60 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
NOTE PAGE
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 61
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.
Items Found In the “Items Number” Column
All parts with same symbol in the number column, , #,
*
+, or %, belong to the same assembly or kit.
Note: If more than one of the same reference number is
listed, the last one listed indicates newest (or latest)
part available.
PAGE 62 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI — SUGGESTED SPARE PARTS
DCA-60SSAI W/ISUZU 6BD1 DIESEL ENGINE
1 TO 3 UNITS
Qty.
P/N
Description
1 ......... 0601805869 ......... CIRCUIT BREAKER
1 ......... 0601820671 ......... AUTOMATIC VOLTAGE REGULATOR
1 ......... 0601840073 ......... RHEOSTAT VOLTAGE REGULATOR
1 ......... 0601840121 ......... KNOB REHOSTAT
1 ......... 0602013901 ......... RADIATOR HOSE, UPPER
1 ......... 0602013160 ......... RADIATOR HOSE, LOWER
5 ......... 1878100753 ......... OIL FILTER
5 ......... X132400240 ........ FUEL FILTER
5 ......... 0602040193 ......... ELEMENT, AIR
1 ......... 0602122200 ......... UNIT OIL PRESSURE
1 ......... 0602123204 ......... UNIT WATER PRESSURE
1 ......... 0601810244 ......... BULB, ALARM LAMP
1 ......... 0601808507 ......... TRANSDUCER WATT METER
1 ......... 8972322520 ......... FAN BELT
1 ......... 1823100080 ......... STARTER SWITCH
3 ......... KEYISUZUF ........ KEY, STARTER SWITCH
NOTE
Part number on this Suggested Spare
Parts list may supercede/replace the
P/N shown in the text pages of this
book.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 63
DCA-60SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
PAGE 64 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
NO.
PART NO.
1
7451040000
1-1
3361010112
1-2
7461042003
1-3
3361080003
1-4
3361032003
1-5
3361085003
1-6
3341610003
2
3361025003
2-1
3361026003
2-2
0601820067
2-3
0010004020
2-4
0041604000
2-5
0040004000
2-6
0030004000
2-7
0601822601
2-8
0801841004
2-9
0801841104
2-10 0010005020
2-11 0041605000
2-12 0040005000
2-13 0030005000
2-14 0017105012
3
3331014004
4
0070206310
5
008000050
6
3361070003
7
3341611003
8
3341613004
10
0010312030
11
060160000
12
0601610700
13
0601610511
14
0040010000
15
0010310030
16
7451340000
16-1 3361320122
16-2 3361342024
16-3 7451361113
17
0801350104
18
3361315013
ITEM
FIELD ASSY.
SHAFT
FIELD CORE
FIELD COIL
ARMATURE CORE, EXCITER
ARMATURE COIL, EXCITER
COUPLING HUB
RECTIFIER ASSY.
SET PLATE, RECTIFIER
RECTIFIER
HEX. HEAD BOLT
PLAIN WASHER
LOCK WASHER
HEX. NUT
SURGE ABSORBER
INSULATOR WASHER
INSULATOR WASHER
HEX. HEAD BOLT
PLAIN WASHER
LOCK WASHER
HE. NUT
HE.HEAD BOLT
BEARING FLANGE
BEARING
SNAP RING
FAB
COUPLING DISC
LOCK WASHER
HEX. HEAD BOLT
COUPLING RING
LOCK WASHER
BOLT SET
LOCK WASHER
HEX. HEAD BOLT
STATOR ASSY.
GENERATOR FRAME
ARMATURE CORE
ARMATURE COIL
GROMMET
END BRACKET
QTY.
REMARKS
1
1
1
1
1
1
1
1
1
3 ........... PB2510
3
6
3
3
1 ........... ERZM14JK621A
1
1
1
2
1
1
4
1
1 ........... 6310RS
1
1
1 ........... (80 0
5
10
1 ........... 92612590050
9 ........... 9091505100
1
9
9
1
1
1
1
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 65
DCA-60SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
PAGE 66 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
NO.
PART NO.
19
3361350030
19-1 3361352023
19-2 3361362303
20
0041608000
21
0040008000
22
0010008060
23
0040010000
24
0010010030
25
3801312004
26
3331310104
27
0040006000
28
0010006055
29
3361331003
30
0017106010
31
0040010000
32
0010310025
33
3341332103
34
0041606000
35
0040006000
36
0010006030
37
0605000011
38
0040016000
39
0030116000
ITEM
FIELD ASSY., EXCITER
FIELD CORE, EXCITER
FIELD COIL, EXCITER
PLAIN WASHER
LOCK WASHER
HEX. HEAD BOLT
LOCK WASHER
HEX. HEAD BOLT
GASKET, BERAING
COVER, BEARING
LOCK WASHER
HEX. HEAD BOLT
COVER, END BRACKET
HEX. HEAD BOLT
LOCK WASHER
HEX. HEAD BOLT
COVER, FAN
PLAIN WASHER
LOCK WASHER
HEX. HEAD BOLT
RUBBER SUSPENSION
LOCK WASHER
HEX. NUT
QTY.
1
1
1
4
4
4
6
6
1
1
4
4
1
8
6
6
1
1
1
1
2
4
4
REMARKS
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 67
DCA-60SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 68 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
7451810002
7451810012
7451810022
3361870603
0017106016
0601801143
0027104010
0800225201
0027106010
0601820042
0027103010
0601842058
0027105010
0601820851
0027104016
0601805352
0041604000
0040004000
0021004020
0601830625
0601840191
0601830614
0021104016
0021104014
7451822503
0601800460
0601800784
0601801040
0601800217
0601801041
0601810072
0601810261
ITEM
CONTROL BOX
CONTROL BOX
CONTROL BOX
CURRENT TRANSORMER
HEX. HEAD BOLT
CURRENT TRANSORMER, AMMETER
MACHINE SCREW
AUTOMATIC VOLTAGE REGULATOR
MACHINE SCREW
RECTIFIE
MACHINE SCREW
RESISTOR
MACHINE SCREW
OVER CURENT RELAY
MACHINE SCREW
CIRCUIT BREAKER
PLAIN WASHER
LOCK WASHER
MACHINE SCREW
CHANGE-OVER SW. VOLTAGE
SWITCH CAP
PLATE
MACHINE SCREW
MACHINE SCREW
CONTROL PANEL
FREQUENCY METER
AC AMMETER
CHANGE-OVER SW., AMMETER
AC VOLTMETER
CHANGE OVER SW., VOLTMETER
PILOT LAMP
BULB
QTY.
REMARKS
1 ....... UP TO S/N3311616
1 ....... S/N3311617 TO 3312672
1 ....... S/N3312673~
3
6
2 ....... CT3.5MR 100/5A
4
1 ....... AE2206A
6
1 ....... 16T60
4
1 ....... RWH80V 200KOHMS
2
1 ....... THK20
2
1 ....... KM203 550V 150AT
4
4
4
1
1
1
4
2
1
1 ....... PAK60 220V 45~65Hz
1 ....... PSK60 0~100A 0~200a
1 ....... SL2AS
1 ....... PCK60 0~600V
1 ....... SL2VS
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 69
DCA-60SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 70 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
0601840031
0601840120
3331824003
0027105016
0030005000
0805001304
0041608000
0030008000
0027105010
7451826504
7451826514
0017106016
0017108020
0030008000
0601815933
0601815934
0027105020
ITEM
VOLTAGE REGULATOR
KNOB
STOPPER, CONTROL PANEL
MACHINE SCREW
HEX. NUT
SET SCREW, CONTROL PANEL
PLAIN WASHER
HEX. NUT
MACHINE SCREW
SIDE PANEL, CONTROL BOX
SIDE PANEL, CONTROL BOX
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX., NUT
TERMINAL
TERMINAL
MACHINE SCREW
QTY.
REMARKS
1 ....... RA30A2FE202BJ
1
1
2
2
2
2
2
4
1 ....... UP TO S/N3311616
1 ....... S/N3312178~
2
4
4
1 ....... S/N3312673~; AYBS0431
1 ....... S/N3312673~; AYBS0441
4 ....... S/N3312673~
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 71
DCA-60SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 72 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
0602000100
ENGINE ........................................... 1 ......... ISUZU 6BD1
2
0602010802
RADIATOR ....................................... 1 ......... H190110000
3
0602013901
RADIATOR HOSE ........................... 1 ......... B400008
4
0602013160
RADIATOR HOSE ........................... 1 ......... B400007
5
0602014302
HOSE BAND
3
6
0602014303
HOSE BAND
1
7
0602040090
AIR CLEANER ................................. 1 ......... FWG088006
0602040193
ELEMENT, AIR CLEANER .............. 1 ......... P104972
8
0602040690
DUST INDICATOR ........................... 1 ......... RBX002252
9
0602040598
BAND, AIR CLEANER ..................... 2 ......... AAH008263
10
0017108020
HEX. HEAD BOLT
4
11
0030008000
HEX. NUT
4
12
7452032303
HOSE, AIR CLEANER
1
13
0605515008
HOSE BAND
2
14
0602041106
ELEMENT, OIL FILTER ................... 1 ......... 1878100750
15
0602042106
ELEMENT, FUEL FILTER ............... 1 ......... 9885111911
16
3345112403
ENGIEN FOOT
1
17
3345112503
ENGIEN FOOT
1
18
0040010000
LOCK WASHER
8
19
0010710025
HEX.HEAD BOLT
8
20
0605000009
RUBBER SUSPENSION
2
21
0040012000
LOCK WASHER
4
22
0030112000HEX. NUT
4
23
0017108020
HEX. HEAD BOLT
6
24
0602210803
ENGINE STOPPER ......................... 1 ......... 1819000161
25
7452215104
BRACKET, ENGINE STOPPER
1
26
0027106016
MACHINE SCREW
3
27
0017108020
HEX. HEAD BOLT
2
28
7452051104
DRAIN JOINT
1
29
0805013704
PACKING, OIL PAN SIDE
1
30
0805014204
PACKING
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 73
DCA-60SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 74 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
PART NO.
ITEM
31
3362054104
JOINT BOLT
32
3362051003
DRIAN JOINT
33
0802024004
PACKING
34
0802010204
PLUG
35
7452052104
DRAIN HOSE
36
0605515003
HOSE BAND
37
0017108020
HEX. HEAD BOLT
38
0030008000
HEX. NUT
39
0845031303
RESERVE TANK
41
7452082504
BRAKET, RESERVE TANK
42
0017108020
HE. HEAD BOLT
43
0017106025
HEX. HEAD BOLT
44
0199500470
HOSE
45
0199500175
HOSE
46
0193602000
HOSE
47
0605515013
HOSE BAND
48
0193100950
HOSE
49
0605515007
HOSE BAND
50
0193800850
HOSE
51
0605515019
HOSE BAND
52
7452220404
EARTH CABLE
QTY.
1
1
1
1
1
2
2
2
1
1
2
1
1
1
1
4
1
1
1
1
1
REMARKS
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 75
DCA-60SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 76 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
7452111103
OPERATING PANEL
1
2
7452142004
SLIDE BAR
1 ......... UP TO S/N3313037
7452142014
SLIDE BAR
1 ......... S/N3313038~
3
0805012904
KNOB
1
4
0080200006
SNAP RING
1 ......... UP TO S/N3313037
0036003000
HEX. NUT
1 ......... S/N3313038~
5
7452140504
BRACKET, GOVERNOR ROD
1
6
0030008000
HEX., NUT
2
7
0605010503
SNAP PIN
1
8
0602100004
STARTER SWITCH
1 ......... 1823100080
9
0602102005
PREHEAT LAMP
1 ......... 9825300430
10
0602120052
TACHOMETER
1 ......... 25000KX3710
11
0602120161
CABLE, TACHOMETER
1 ......... 62100KA0910 L=1700
12
0602122060
OIL PRESSURE GAUGE
1 ......... 42000KX1410
13
0602122200
UNIT, OIL PRESSURE
1 ......... 53000AC0101
14
0131300000
STREET SOCKET
1
15
0602123061
WATER TEMPERATURE GAUGE 1 ......... 40000KX0910
16
0602123204
UNIT, WATER TEMPERATURE
1 ......... 51400KA1200
17
0602121052
CHARGING AMMETER
1 ......... 43000KV0300
18
0602103060
ALARM LAMP
2
0601810244
BULB
2
19
0601830420
SWITCH, LAMP CHECK
1 ......... SB61A
20
0601810120
PANEL LIGHT
1 ......... DL31000
21
0040520000
TOITHED LOCK WASHER
1
22
0601830710
SWITCH, PANEL LIGHT
1
23
0041608000
PLAIN WASHER
2
24
0040008000
LOCK WASHER
2
25
0010008040
HEX. HEAD BOLT
2
26
0017108020
HEX. HEAE BOLT
2
30
0030008000
HEX. NUT
2
31
7452183004
LINK, GOBERNOR ROD
1
32
0010010025
HEX. HEAD BOLT
1
33
0041610000
PLAIN WASHER2
34
0030010000
HE.X NUT
1
35
7452182004
GOVERNOR ROD
1
36
7452152004
GOBERNOR ROD
1
37
0602180101
BALL JOINT
2
38
0030008000
HEX. NUT
2
39
0602180100
BALL JOINT
2
40
0030006000
HEX. NUT
3
41
0041606000
PLAIN WASHER
1
42
7455188103
SET PANEL, ELECTRIC PARTS
1
43
0017108020
HEX. HEAD BOLT
5
44
0602200405
EMERGENCY RELAY
1 ......... 1825500730
45
0027106016
MACHINE SCREW
4
46
0601823706
RELAY
1 ......... JH1A DC24V
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 77
DCA-60SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 78 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
47
0027104016
MACHINE SCREW
2
48
7451860203
SET BOARD, OUTPUT TERMINAL 1
49
0801830204
OUTPUT TERMINAL
4
50
0801830704
HEX. HEAD BOLT
4
51
0041412000
PLAIN WASHER
16
52
0040012000
LOCK WASHER
12
53
0039312000
HEX, .NUT
8
54
0601805318
CIRCUIT BREAKER
1 ......... S/N3312673~;KM52 265V 20A
55
0041608000
PLAIN WSHER
5
56
0040008000
LOCK WASHER
5
57
0010008030
HEX. HEAD BOLT
5
58
0601811032
RECEPTACLE
2 ......... UP TO S/N3312672; L6-20R 250V 20A
0601811032
RECEPTACLE
1 ......... S/N3312673~; L620R 250V 20A
59
0601811037
RECEPTACLE
2 ......... UP TO S/N3312672; CS8269 250V 20A
0601811034
RECEPTACLE
2 ......... S/N3312672~; CS6369 250V 50A
60
0601811031
RECEPTACLE
2 ......... UP TO S/N3312672; L530R 125V 30A
0601811092
RECEPTACLE
2 ......... S/N3312673~; L520R 125V 20A
61
0601811030
RECEPTACLE
2 ......... 5-20R 125V 20Ax2
62
0027103010
MACHINE SCREW
16
63
0041603000
PLAIN WASHER
16
64
0030003000
HEX. NUT
16
65
0601805353
CIRCUIT BREAKER
2 ......... UP TO S/N3312672; KM101 265V 75A
0601805319
CIRCUIT BREAKER
2 ......... S/N3312673~; KM52 265V 40A
66
0601805306
CIRCUIT BREAKER
2 ......... UP TO S/N3312672; KM51 265V 40A
0601805311
CIRCUIT BREAKER
2 ......... S/N3312673~; KM51 265V 50A
67
7451816004
BRACKET, CIRCUIT BREAKER
1 ......... UP TO S/N3312672
7451816014
BRACKET, CIRCUIT BREAKER
1 ......... S/N3312673~
68
0027106016
MACHINE SCREW
2
69
7451865503
COVER, OUTPUT TERMINAL
1
70
0805012304
HEX. HEAD BOLT
2
71
0041612000
PLAIN WASHER
4
72
0805019704
RUBBER WASHER
2
73
0030012000
HEX. NUT
2
74
0605010505
SNAP PIN
2
75
0601850091
RUBBER CUSHION
2 ......... SK156
76
0021003010
MACHINE SCREW
2
77
0601802133
FUSE
1 ......... F5 5A
78
0601820015
RECTIFIER
4 ......... 1S2762
79
7451865603
COVER, OUTPUT TERMINAL
1 ......... FROM S/N3312331
80
7451855503
HINGE
1 ......... FROM S/N3312331
81
7451855703
HINGE
1 ......... FROM S/N3312331
82
0021304015
MACHINE SCREW
4 ......... FROM S/N3312331
83
0040004000
LOCK WASHER
4 ......... FROM S/N3312331
84
0041204000
PLAIN WASHER
8 ......... FROM S/N3312331
85
0030104000
HEX. NUT
4 ......... FROM S/N3312331
0030104000
HEX. NUT
4 ......... SN3312672~
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 79
DCA-60SSAI --- BATTERY ASSY.
BATTERY ASSY.
PAGE 80 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- BATTERY ASSY.
BATTERY ASSY.
NO.
PART NO.
1
0160012100
2
0805003904
3
0805004004
4
0805002904
5
0041608000
6
0040008000
7
0037808000
8
0215260065
9
02511160180
10
0215860100
11
0602220310
0208008000
12
0602220311
0208008000
ITEM
QTY.
REMARKS
BATTERY ......................................... 2 ......... N1000 12V 100Ah
BATTERY SHEET
2
BATTERY BAND
2
BATTERY BOLT
4
PLAIN WASHER
4
LOCK WASHER
4
WING NUT
4
BATTERY CABLE
1
BATTERY CABLE
1
BATTERY CABLE
1
TERMINAL ASSY. (+) ...................... 2 ......... NO.9P
WING NUT ....................................... 2
TERMINAL ASSY.(-) ........................ 2 ......... NO.9N
WING NUT ....................................... 2
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 81
DCA-60SSAI --- MUFFLER ASSY.
MUFFLER ASSY.
PAGE 82 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- MUFFLER ASSY.
MUFFLER ASSY.
NO.
PART NO.
1
7452330103
2
0602320000
3
0602323002
4
3802311122
5
0017110020
6
7452330303
7
3342356104
8
0010108035
9
0041608000
10
0040008000
11
0030008000
12
1382320003
13
0010008030
14
0041608000
15
0030008000
16
3342354104
17
3342354004
18
3342328104
19
0030008000
20
3342359004
21
0017108025
ITEM
EXHAUST PIPE
GASKET
HEX. NUT
MUFFLER
HEX. HEAD BOLT
EXHAUST PIPE
GASKET
HEX. HEAD BOLT
PLAIN WASHER
LOCK WASHER
HEX. NUT
PIPE BAND
HEX. HEAD BOLT
PLAIN WASHER
HEX. NUT
COVER
COVER
PIPE CLAMPER
HEX. NUT
COVER SHEET
HEX. HEAD BOLT
QTY.
REMARKS
1
1 ......... 9221160010
6 ......... 9091103100
1
4
1
1
4
4
4
4
1
1
1
1
1
1
1
4
2
4
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 83
DCA-60SSAI --- FUEL TANK ASSY.
FUEL TANK ASSY.
PAGE 84 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- FUEL TANK ASSY.
FUEL TANK ASSY.
NO.
PART NO.
1
1-1
1-2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
7455510123
7455510303
0810105004
0810105400
0802010304
0602021042
7455523104
7455523304
0805003404
0017108020
0041608000
0040008000
0030008000
3805522004
0191300530
0191300650
0605515014
0845032204
0150000018
0802011104
0193100255
0605515079
0131906000
ITEM
FUEL TANK
FUEL TANK
CAP, FUEL TANK
FUEL FILTER
PACKING
PLUG
TANK BAND
TANK BAND
PAD, TANK BAND
HEX. HEAD BOLT
PLAIN WASHER
LOCK WASHER
HEX. NUT
TANK SHEET
SUCTION HOSR
RETURN HOSE
HOSE BAND
DRAIN JOINT
O RING
PLUG
FUEL GAUGE HOSE
HOSE BAND
CAP
QTY.
REMARKS
1 ......... UP TO S/N3312672
1 ......... S/N3312673~
1
1
1 ......... UP TO S/N3312672
1 ......... UP TO S/N3312672; 960922101
2 ......... UP TO S/N3312672
2 ......... S/N3312673~
4
2
2
2
2
4
1
1
4
1
1
1
1
2
1 ......... S/N3312673~
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 85
DCA-60SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 86 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
PART NO.
1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
7455111012
7455111102
7455109104
7455116004
0017108020
7455121012
7455109203
7450630503
7450630703
6360510003
0021106020
0017108020
0800251201
0027106016
7455125003
7455125503
7455109304
7450630303
0017108020
7455125303
0017108020
3385155104
0017106020
7455125104
7455109404
0017108020
7455125204
7455125704
7455109504
0017108020
7455132013
7455132203
00101141040
0041614000
0040014000
0030014000
0010012030
0040012000
0041612000
ITEM
QTY.
REMARKS
BASE
BASE
ACOUSTIC SHEET
FLOOR PANEL
HEX. HEAD BOLT
FRONT FRAME
ACOUSTIC SHEET
STRIPE, LEFT SIDE
STRIPE, RIGHT SIDE
EMBLEM
MACHINE SCREW
HEX. HEAD BOLT
FILTER COVER
MACHINE SCREW
COVER, FRONT FRAME
1 ............UP TO S/N3312672
1 ............S/N3312673~
1
1
12
1
1
1
1
2
4
6
1
2
1 ............UP TO S/N3312672
ACOUSTIC SHEET
STRIPE
HEX., HEAD BOLT
COVER, FRONT FRAME
HEX.HEAD BOLT
COVER
HEX. HEAD BOLT
COVER, FROT FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT
COVER, FRONT FRAME
COVER, FRONT FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT
CENTER FRAME
CENTER FRAME
HEX. HEAD BOLT
PLAIN WASHER
LOCK WASHER
HEX. NUT
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
1
1
16
1
12
2
8
1
1
6
1 ............UP TO S/N3312672
1 ............S/N3312673~
1
4
1
1
8
16
8
8
10
10
10
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5 -BLACK
2-WHITE
6 -CATERPILLAR YELLOW
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 87
DCA-60SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 88 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
PART NO.
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
7455141102
7455141112
7455109603
7450630904
0017108020
7455155003
7455109703
0041608000
0040008000
0010008040
7455143103
7455143113
1320632003
3805147104
0021006020
0041606000
0040006000
0030006000
0845028303
0017108025
7455161012
7455109803
0017108020
7455165004
7455109904
0017108020
7455181202
7455181212
7455105004
0010008055
0040008000
001608000
ITEM
REAR FRAME
REAR FRAME
ACOUSTIC SHEET
STRIPE
HEX. HEAD BOLT
COVER, REAR FRAME
ACOUSTIC SHEET
PLAIN WASHER
LOCK WASHER
HEX. HEAD BOLT
DOOR, REAR FRAME
DOOR, REAR FRAME
STICKER
WINDOW PLATE
MACHINE SCREW
PLAIN WASHER
LOCK WASHER
HEX. NUT
HINGE
HEX. HEAD BOLT
ROOF PANEL
ACOUSTIC SHEET
HEX. HEAD BOLT
GUIDE PANEL, AIR
ACOUSTIC SHEET
HEX. HEAD BOLT
SPLASHER PANEL
SPLASHER PANEL
ACOUSTIC SHEET
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
QTY.
REMARKS
1 ............UP TO S/N3311616
1 ............S/N3312178~
1
2
4
1
1
8
8
8
1 ............UP TO S/N3311616
1 ............S/N3312178~
1
1
6
6
6
6
2
4
1
1
16
2
2
8
1 ............UP TO S/N3312672
1 ............S/N3312673~
1
6
6
6
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5 -BLACK
2-WHITE
6 -CATERPILLAR YELLOW
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 89
DCA-60SSAI --- RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
PAGE 90 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
NO.
PART NO.
ITEM
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
7455171403
7455171413
7455105104
7455171503
7455171513
7455105204
7450631104
7455171603
7455171613
7455105304
7450631304
7455171703
7455171713
7455105404
7450631504
0845028203
0845028303
0017108025
0845031504
0605010910
0027103010
0605010911
0027104010
7455104104
7455104204
7455104304
7455104404
7455104504
7455104604
7455104704
7455104804
7455104904
7455116504
0017108020
SIDE DOOR, LEFT SIDE
SIDE DOOR, LEFT SIDE
ACOUSTIC SHEET
SIDE DOOR, RIGHT SIDE
SIDE DOOR, RIGHT SIDE
ACOUSTIC SHEET
STRIPE
SIDE DOOR, LEFT SIDE
SIDE DOR, LEFT SIDE
ACOUSTIC SHEET
STRIPE
SIDE DOOR, RIGHT SIDE
SIDE DOOR, RIGHT SIDE
ACOUSTIC SHEET
STRIPE
HINGE
HINGE
HEX. HEAD BOLT
CAP
LATCH
MACHIEN SCREW
LATCH
MACHIEN SCREW
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
COVER
HEX. HEAD BOLT
QTY.
REMARKS
1 ............UP TO S/N3311616
1 ............S/N3312178~
1
1 ............UP TO S/N3311616
1 ............S/N3312178~
1
2
1 ............UP TO S/N3311616
1 ............S/N3312178~
1
1
1 ............UP TO S/N3311616
1 ............S/N3312178~
1 ............
1
4
4
16
10
1 ............UP TO S/N3311616
7 ............UP TO S/N3311616
2 ............UP TO S/N3311616
14 ..........UP TO S/N3311616
2
2
3
1
1
1
1
2
2
1 ............S/N3312673~
2 ............S/N3312673~
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 91
DCA-60SSAI --- DECALS
DECAL ASSY.
PAGE 92 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
DCA-60SSAI --- DECALS
DECAL ASSY.
NO.
PART NO.
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
DECAL; CAUTION ....................................................... 1 ....... B92110050
DECAL; CONTROL PANEL ........................................ 1 ....... B45100590
PLATE; AMMETER CHANGE-OVER SWITCH .......... 1 ....... N2438
PLATE; VOLTAGE CHANGE-OVER SWITCH ........... 1 ....... N2439
DECAL; SAFETY INSTRUCTION .............................. 1 ....... B92110040
DECAL; WARNING ..................................................... 1 ....... B93110060
DECAL; OPERATING PANEL ..................................... 1 ....... S2361A
DECAL; RECEPTABLE & CIRCUIT BREAKER .......... 1 ....... S3349A
DECAL; NOTE ............................................................. 1 ....... B15100160
DECAL; GROUND MARK ........................................... 1 ....... S2635
DECAL; CAUTION ....................................................... 1 ....... S2731
DECAL; CABLE JOINING ........................................... 1 ....... S3245
DECAL; CAUTION ....................................................... 1 ....... S3696B
DECAL; WARNING ELECTRIC SHOCK HAZARD .... 1 ....... B93110060
DECAL; WARNING ELECTRIC SHOCK HAZARD .... 1 ....... B91110040
DECAL; WARNING ELECTRIC SHOCK HAZARD .... 1 ....... B93110050
DECAL; WARNING ..................................................... 1 ....... B91110030
DECAL; + ..................................................................... 1 ....... S2090
DECAL; - ...................................................................... 1 ....... S2091
DECAL; DIESEL FUEL ................................................ 1 ....... S1756
DECAL; WATER, OIL .................................................. 1 ....... S1760
DECAL; WATER .......................................................... 1 ....... S1880
DECAL; FUEL DRAIN PLUG ...................................... 1 ....... S1883
DECAL; OIL DRAIN PLUG .......................................... 1 ....... S1885
DECAL; WARNING ..................................................... 1 ....... S3247
DECAL; SUPPORT HOOK ......................................... 2 ....... S2257
DECAL; MQ ................................................................. 1 ....... S3057
DECAL; WARNING ENGINE EXHAUST .................... 1 ....... B90420000
DECAL; WARNING MOVING PARTS ......................... 2 ....... M90400040
DECAL; WARNING DIESEL FUEL ............................. 1 ....... B90450000
DECAL; WARNING HOT COOLANT ......................... 1 ....... B90410010
DECAL; CAUTION HOT PARTS ................................. 1 ........ B90400030
STRIPE ........................................................................ 1 ........ REPLACES B4561100103
STRIPE
2
STRIPE
1
STRIPE
1
STRIPE
2
STRIPE
1
B9521100504
B4551005902
0800520904
0800520804
B9521100404
B9531100604
3340670002
8050670113
B1551001604
0840614104
0840619904
0840627103
8080670514
B9531100604
B9511100404
B9531100504
B9511100304
0800689404
0800689504
1320620904
1320610603
6360610304
6360620004
6360620204
0840627304
1320621504
0840625902
B9504200004
B9504000404
B9504500004
B9504100104
B9504000304
7450630703
B4561100403
B4561100503
B4561100604
B4561100304
B4561100003
QTY.
REMARKS
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 93
ISUZU 6BD1 — CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.
PAGE 94 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
1
1111105271
CYLINDER HEAD
1 .......... UP TO AUG. 85; REPLACES 1111105270
1111106141
CYLINDER HEAD
1 .......... AUG. 85~; INCL. ITEMS W/#
EA1013
3#
1096000051
REAR SEALING CUP, D=44.5
1
3-1# 9111291280
LOWER SEALING CUP, D=20
3
3-2# 5112190150
EXH. SEALING CUP, D=31.75
3
3-3# 5096000130
DRILLED SEALING CUP, D=12
6 .......... REPLACES 9111296010
3-4# 1096000160
TOP FACE SEALING CUP, D=25 5
3-5# 1096000160
INL. MAN. SEALING CUP
6
4#
9096600340
PLUG
6
7#
9117156070
INLET VALVE SEAT INSERT
6 .......... UP TO APR. 85
1117150540
INLET VALVE SEAT INSERT
6 .......... MAY 85~
8#
1117110260
EXH. VALVE SEAT INSERT
6 .......... UP TO JUL. 85
1117110430
EXH. VALVE SEAT INSERT
6 .......... AUG. 85~
9#
5117210010
VALVE GUIDE, EXH. & INL.
12
10
9111296010
SEALING CUP, DRILLED D=12
5
15
9041108250
INLET MANIFOLD STUD
3
16
9041108750
EXH. MANIFOLD STUD
9
9098301790
EXH. MANIFOLD STUD, L1=88
2
9096300260
EXH. MANIFOLD STUD, L1=86
12
17
1093000180
NOZZLE HOLDER STUD, L1-40
12
18
9098301630
ROCKER ARM NUT STUD, L1=83 4
20
5125690010
VALVE GUIDE, INL & EXH. SEAL 12 ........ UP TO JUL. 85
1125690150
VALVE GUIDE, INL & EXH. SEAL 12 ........ AUG. 85~
21
1111410902
CYLINDER HEAD GASKET
1 .......... AUG. 84. TO AUG. 85
1111411950
CYLINDER HEAD GASKET
1 .......... AUG. 85~; REPLACES 1111411710
22
5090090180
BOLT, L=115
20 ........ UP TO SEPT. 88
1090701010
BOLT, L=113
20 ........ OCT. 88~;REPLACES 1090700630
22-1 5090090170
BOLT, L=102
6 .......... UP TO JUL. 84
1090390030
BOLT, L=106
6 .......... AUG. 84~JUL. 86
1090701000
BOLT, L=100
6 .......... JUL. 86~; REPLACES 1090700620
29-1 1111709281
CYL. HEAD COVER ASSY.
1
29-2 1111801531
CYL. HEAD COVER ASSY.
1
30
9117510381
OIL FILLER CAP
1
36
5111790520
BREATHER HOSE NIPPLE
1 .......... REPLACES 9143193681
49
1111730590
CYL. HEAD COVER PACKING
1
51
9111790300
COVER PACKING
4
52
9111791050
WASHER
4
53
9111750110
NUT
4
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 95
ISUZU 6BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
PAGE 96 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
1112102790
2#
4#
1112103324
1090004691
8943706360
5#
5-1#
6#
6-1#
6-2#
7#
8#
11
11-1
11-2
11-3
11-4
12
12-1
13
13-1
26
27
27-1
27-2
32
33
35
37
42
44
46
47
48
49
50
54
56
58
60
5112570010
9116110480
9116130350
1096000520
5112190140
1096000121
1112611180
9098600190
1096050660
5096050180
1096050681
1096050681
1096050791
9992023140
9992023120
9095714140
9095714120
5096540130
9112916050
1112910441
5112901450
1097400780
9112246021
5093000231
9081510180
1090520211
9095720080
1112920200
1096800240
1096660360
1096301150
9099148600
8970157540
9112298010
5117401220
9091105080
CYLINDER BLOCK ASSY. ..................................... 1 .......... UP TO S/NE518004;
INCL. ITEMS W/#
CYLINDER BLOCK ASSY. ..................................... 1 .......... REPLACES 1112103320
BOLT ...................................................................... 14 ........ REPLACES 5090001330
BRIDGE CAP NO.4 DOWEL ................................. 1 .......... REPLACES 5112570010;
UP TO MAY 89
BRIDGE CAP NO. 4 DOWEL ................................ 1 .......... JUNE 89~
FRONT CAM METAL ............................................ 1 .......... REPLACES 911690480
INNER AND REAR CAM METAL .......................... 5 .......... REPLACES 9116930350
SEALING FACE CUP, D=60
2
LEFT SEALING CUP, D=28
2
TAPPET CHAMBER SEALING CUP
3
CYLINDER LINER ................................................. 6 .......... REPLACES 5112610040
REAR END CAMSHAFT PLUG
1
OIL GALLERY PLUG, PT 3/8
1
OIL GALLERY PLUG, PT 1/8
10
FRONT OIL GALLERY PLUG, PT 1/2
1
REAR OIL GALLERY PLUG, PT 1/2
1
TURBO FEEDING PLUG
1
CYL. BLOCK PLUG, LEFT SIDE
1
CYL. BLOCK PLUG, RIGHT SIDE
1
PLUG PACKING, LEFT SIDE
1
PLUG PACKING
1
NIPPLE, INJ. PUMP, PT 1/8
1
TAPPET CHAMBER COVER
1
TAPPET CHAMBER COVER
1
TAPPET CHAMBER COVER ASSY.
1
TIMING GEAR CASE PIN ..................................... 1 .......... REPLACES 9081510500
OIL PUMP DRIVE SHAFT BUSHING
1
FLYWHEEL HOUSING STUD
1
FLYWHEEL HOUSING PIN
2
CHAMBER COVER FIXTURE ............................... 2 .......... REPLACES 1090520221
CHAMBER COVER PACKING
6
CYLINDER BLOCK COVER PACKING
3
WATER DRAIN COCK ASSY.
1
DRAIN COCK JOINT
1
WATER DRAIN COCK PACKING ......................... 1 .......... REPLACES 9099212420
VINYL PIPE WITH DRAIN, L=510
1
RUBBER HOSE CLIP
1
CYLINDER HEAD DOWEL
2
AIR BREATHER ASSY.
1
NUT ........................................................................ 2 .......... REPLACES 9091104080
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 97
ISUZU 6BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
PAGE 98 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
NO.
PART NO.
PART NAME
61
63
64
61-1
65
66
66-1
66-3
67
68
69
96
97&
98
110
9091505080
1093604390
9117426140
1117420211
5093609780
9097130740
9097150670
9099156661
1097040570
0208006250
0208008140
9091505080
8970233390
111
5096230350
5111290030
1112190983
1112191630
9019708180
120
0501408200
8942351570
QTY.
REMARKS
LOCK WASHER
2
BREATHER COVER HOSE
1
DRAIN PIPE, H=32 ................................................ 1 .......... UP TO MAR. 84
DRAIN PIPE, H=26 ................................................ 1 .......... APR. 84~
RUBBER
1
HOSE
1
CLIP
1
CLIP
1
CLIP
2
BOLT ...................................................................... 2 .......... REPLACES 9020406250
BOLT ...................................................................... 2 .......... REPLACE 9020508140
LOCK WASHER
2
OIL RELIEF VALVE ASSY. ..................................... 1 .......... REPLACES 9131606062;
INCL. ITEMS W/&
VALVE PACKING
1
SEALING CUP
1
OIL PORT COVER ................................................ 1 .......... UP TO JUL. 90
OIL PORT COVER ................................................ 1 .......... AUG. 90~
BOLT ...................................................................... 2 .......... UP TO JUL. 90;
REPLACES 0501408180
BOLT ...................................................................... 2 .......... AUG. 90~
DISTANCE CLIP PIECE ........................................ 2 .......... NOT SHOWN
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 99
ISUZU 6BD1 — TIMING GEAR CASE ASSY.
TIMING GEAR CASE ASSY.
PAGE 100 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — TIMING GEAR CASE ASSY.
TIMING GEAR CASE ASSY.
NO.
1
2
3
4
7
8
9
12
13
14
17
18
19
22
PART NO.
5113110113
9081510180
1113120140
0500408450
0500408200
1113210790
1113220360
8943632690
5096250540
1096254380
5113270090
0501408250
5090000841
9091605080
9091505080
5113210090
1112820130
0500406140
PART NAME
QTY.
REMARKS
TIMING GEAR CASE
1
STRAIGHT PIN
1
GEAR PACKING ............................................. 1 .......... REPLACES 1113120100
BOLT ............................................................... 2 .......... REPLACES 9019108450
BOLT ............................................................... 4 .......... REPLACES 9019108200
GEAR CASE COVER
1
GEAR CASE PACKING .................................. 1 .......... UP TO JUN. 90
GEAR CASE PACKING .................................. 1 .......... JUL. 90~
CRANKSHAFT OIL SEAL ............................... 1 .......... UP TO OCT. 87
CRANKSHAFT OIL SEAL ............................... 1 .......... NOV. 87~; REPLACES 1096253190
TIMER POINTER; L1=33
1
BOLT ............................................................... 7 .......... REPLACES 9019708250
BOLT ............................................................... 5 .......... REPLACES 9010558550
PLAIN WASHER
5
LOCK WASHER
5
TIMING CHECK COVER
2
COVER PACKING ........................................... 2 .......... REPLACES 1112820090
BOLT ............................................................... 4 .......... REPLACES 9019006140
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 101
ISUZU 6BD1 — FLYWHEEL HOUSING ASSY.
FLYWHEEL HOUSING ASSY.
PAGE 102 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — FLYWHEEL HOUSING ASSY.
FLYWHEEL HOUSING ASSY.
NO.
1
6
7
8
15
41
45
46
47
48
49
PART NO.
9113416098
9992023160
9095714160
9944112350
992023160
0500408250
9910664500
999104140
9096510690
5096250141
1096253620
9123631460
PART NAME
QTY.
REMARKS
FLYWHEEL HOUSING
1
DRAIN PLUG
1
DRAIN PLUG PACKING
1
NUT ................................................................. 3 .......... REPLACES 9944112280
PLUG
1
BOLT ............................................................... 7 .......... REPLACE 9019108250
BOLT ............................................................... 5 .......... REPLACES 9910664500
NUT
1
PLAIN WASHER
8
OIL SEAL ........................................................ 1 .......... UP TO MAR. 84
OIL SEAL ........................................................ 1 .......... APR. 84~
OIL SEAL SPACER
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 103
ISUZU 6BD1 —OIL PAN ASSY.
OIL PAN ASSY.
PAGE 104 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — OIL PAN ASSY.
OIL PAN ASSY.
NO
1
3#
4#
6
7
17
20
21
29
32
36
51-2
51-5
52&
53&
53-2
58
59
62
63
PART NO
1113604421
9096620120
1096230570
9992023160
9095714160
1113670961
9992023240
9095714240
0500408180
9112290700
1117602000
5117401102
1117402011
5117410131
1117500060
1117500241
9099129760
9099155531
9091104080
9091505080
PART NAME
QTY.
REMARKS
OIL PAN ...................................... 1 ........ INCL. ITEMS W/#
PLUG, M=20
1
PACKING, ID=24 ........................ 1 ........ REPLACES 1096231830
OIL PAN PLUG
1
OIL PAN PACKING
1
CYL. BLOCK PACKING .............. 1 ........ REPLACES 1113670720
OIL PAN PLUG
1
OIL PAN PACKING
1
BOLT ......................................... 32 ........ REPLACES 9019108180
CLIP
1
OIL LEVEL GAUGE
1
OIL FILLER ASSY. ..................... 1 ........ INCL. ITEMS W/&; UP TO APR. 89
OIL FILLER ASSY. ..................... 1 ........ INCL. ITEMS W/&; MAY 89~
OIL FILLER
1
CAP ............................................ 1 ........ REPLACES 1117500120; UP TO APR. 89
OIL FILLER CAP ........................ 1 ........ MAY 89~
RUBBER HOSE
1
CLIP
2
NUT
1
LOCK WASHER
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 105
ISUZU 6BD1 — OIL PUMP ASSY.
OIL PUMP ASSY.
PAGE 106 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — OIL PUMP ASSY.
OIL PUMP ASSY.
NO.
1
1-2
2#&
4#&$
6#&
8#&
9#
11#
12#
13#
14#
16#
16-2#
17#
18#&
19#&
21#&
22#&
23#&
24#&
26#&
36#&
41
43
PART NO.
5131000913
1131002330
1131130470
1131190030
5131210050
5131250010
5131190020
9095612230
1131410210
1131190020
5131410020
9098010741
1090440470
9091505080
5098430030
5095800980
5131650040
9081040300
1131230160
1131280180
9131190100
1131400860
0500410250
9131190100
PART NAME
QTY.
REMARKS
OIL PUMP ...................................... 1 ........... UP TO AUG. 88; INCL. ITEMS W/#
OIL PUMP ...................................... 1 ........... SEP. 88~; INCL. ITEMS W/&
COVER........................................... 1 ........... INCL. ITEMS W/$
DOWEL
1
GEAR ASSY.
1
GEAR
1
PIPE
1
O RING
1
TOP CASE
1
OIL SPACER
1
BOTTOM CASE
1
BOLT, L=115
4
BOLT, L=60
4
LOCK WASHER
4
BALL
1
SPRING
1
VALVE SEAT
1
VALVE PIN
1
COUPLING
1
PINION
1
COLLAR
1
STRAINER ASSY.
1
BOLT .............................................. 2 ........... REPLACES 9019110250
COLLER
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 107
ISUZU 6BD1 — CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
PAGE 108 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
NO.
1
1-1
1-2
2#
3
4
6
7
8
9&
11&
13
13-1
13-2
14
17$
19
26
27
33
34
36
37
38
60
67
81
83
PART NO.
1115100400
1115100742
1115300400
1115300742
1115400400
1115400742
1116800012
5121110682
1121110690
5121210050
912216040
8941075750
5122300361
1122301041
5122510060
1122510270
5122350051
1122350271
9122716080
9122736080
9122746080
1123104370
9081512200
1098001560
1098002140
5123310641
9123336070
9920616380
5123360081
5097380010
9125210430
1123620031
5123712072
5123620031
9098401071
9098514310
PART NAME
QTY.
REMARKS
METAL KIT ..................................... 1 ........... UP TO S//N E518727; INCL. ITEMS W/#
METAL KIT ..................................... 1 ........... S/N E518728~
METAL KIT, -.025MM ..................... 1 ........... UP TO S/N E518727
METAL KIT, -0.25MM ..................... 1 ........... S/N E518728~
METAL KIT, -0.50MM ..................... 1 ........... UP TO S/N E518727
METAL KIT, -0.50MM ..................... 1 ........... S/N E518728~
METAL SET, THRUST
2
PISTON .......................................... 6 ........... UP TO MAR. 90
PISTON .......................................... 6 ........... APR. 90~
RING SET
6
PISTON PIN
6
SNAP RING .................................. 12 ........... REPLACES 1095870480
ROD ASSY. .................................... 6 ........... UP TO JUL. 85
ROD ASSY. .................................... 6 ........... AUG. 85~; INCL. ITEMS W/&
BUSHING ....................................... 6 ........... UP TO JUL 85
BUSHING ....................................... 6 ........... AUG. 85~
BOLT ............................................ 12 ........... UP TO JUL. 85
BOLT ............................................ 12 ........... AUG. 85~
METAL SET, STD.
6
METAL SET, -0.25MM
6
METAL SET, -0.50MM
6
CRANKSHAFT ASSY. .................... 1 ........... INCL. ITEMS W/$
STRAIGHT PIN
1
PILOT BEARING ............................ 1 ........... REPLACES 9000901570; UP TO DEC. 87
PILOT BEARING ............................ 1 ........... JAN. 87~
FLYWHEEL
1
RING GEAR, Z=129 T=22
1
BOLT .............................................. 6 ........... REPLACES 9098013340
WASHER, ID=48
1
FEATHER KEY
1
CRANKSHAFT GEAR
1
THROWER
1
PULLEY
1
THROWER
1
CLAW
1
WASHER
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 109
ISUZU 6BD1 — CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.
CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.
PAGE 110 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.
CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.
NO.
1
6
7
8
9
11
12
21
22
24
26
27
31
32
33
35
36
38
43
44
51
53
54
56-1
56-2
57
58
58-1
58-2
59
60
61
62
64
64-1
66
67
68
PART NO.
9125148030
9125221471
9080307130
9920614280
9098518502
9116810150
0500408250
9125310300
9125238013
5125350011
9010510550
9091505100
1125510830
1125511390
1125520520
112561080
1125630300
8941145790
1125630351
5125630010
5125650060
5125710032
1125750360
5126110310
9126160420
9091115080
9126211301
5126200210
1126210621
9126260050
5126280112
5126280120
5126280060
9126281050
1095803350
5126230011
9091800190
5096230600
9029508650
1090005670
9096021480
9098514300
9098514300
1094001160
9098514300
PART NAME
QTY.
REMARKS
TIMING CAMSHAFT
1
GEAR, FC25
1
FEATHER KEY
1
BOLT
1
WASHER
1
THRUST PLATE
1
BOLT ................................................... 2 ............. REPLACES 9019108250
IDLE GEAR SHAFT
1
GEAR
1
THRUST COLLAR
1
BOLT ................................................... 2 ............. REPLACES 9010510550
LOCK WASHER
2
INLET VALVE ...................................... 6 ............. UP TO APR. 85
INLET VALVE ...................................... 6 ............. MAY 85~
EXHAUST VALVE ............................... 6 ............. REPLACES 1125520250
VALVE SPRING .................................12 ............. REPLACES 5125610090
UPPER VALVE SEAT ........................12 ............. UP TO APR. 85
UPPER VALVE SEAT ........................12 ............. MAY 85~
LOWER VALVE SEAT ........................12 ............. UP TO AUG. 88
LOWER VALVE SEAT ........................12 ............. SEP. 88~
COLLAR
24
TAPPET
12
PUSH ROD
12
ROCKER ARM
12
SCREW
12
NUT
12
REAR ROCKER ARM SHAFT
1
ROCKER ARM SHAFT ....................... 1 ............. UP TO AUG. 87
ROCKER ARM SHAFT ....................... 1 ............. SEP. 87~
ROCKER ARM PLUG
2
FRONT ROCKER ARM BRACKET ..... 1 ............. UP TO AUG. 87
FRONT ROCKER ARM BRACKET ..... 1 ............. SEP. 87~
REAR ROCKER ARM BRACKET
1
INTER ROCKER ARM BRACKET
6
ROCKER ARM SPRING
5
CONNECTOR
1
SNAP RING
1
PACKING
1
BOLT ................................................... 9 ............. UP TO AUG. 87
BOLT ................................................... 8 ............. SEP. 87~
BOLT, FRONT BRACKET
1
PLAIN WASHER ................................10 ............. UP TO AUG. 87
PLAIN WASHER ................................. 9 ............. SEPT. 87~
NUT ..................................................... 4 ............. REPLACES 9091123080
PLAIN WASHER
4
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 111
ISUZU 6BD1 — OIL AND FUEL FILTER ASSY.
OIL AND FUEL FILTER ASSY.
PAGE 112 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — OIL AND FUEL FILTER ASSY.
OIL AND FUEL FILTER ASSY.
NO.
1
2#
3#&
4#
5#
6#
8#
9#
12#
16#
17#
21#
28#
29#$
70
72
PART NO.
5132000726
1878100752
9099203110
9099206940
1096230550
5132120212
1132310420
9098621610
5132110100
9099412830
9132390250
1090001050
5132600061
1096231630
1132003322
1878105650
73@?
71@?
75@?
76@?
78@
80@
81@
82@
83@
84@
86@
87@
100
9097205420
9132136010
9097205410
9099202550
5132110151
9132128040
1132310330
9096510680
9097421090
9098620680
1132600470
1096300850
1132191000
1132191940
9019710350
0501410350
9098009281
9091505100
9091605100
9091104100
9095720100
101
101-1
102
103
104
106
PART NAME
QTY.
REMARKS
OIL FILTER ASSY. ......................................... 1 ........ INCL. ITEMS W#
ELEMENT KIT ............................................... 1 ........ INCL. ITEMS W/&
COVER PACKING
1
CENTER BOLT PACKING
1
O RING PACKING
1
OIL FILTER COVER
1
BOLT
1
PLUG
1
OIL FILTER CASE
1
SPRING
1
SPRING SEAT
1
DRAIN PLUG
1
OVER FLOW VALVE ASSY. .......................... 1 ........ INCL. ITEMS W/$
O RING PACKING
1
FUEL FILTER ASSY. ..................................... 1 ........ INCL. ITEMS W/@
ELEMENT KIT ............................................... 1 ........ REPLACES 988511911;
INCL. ITEMS W/?
PACKING
2
COVER BODY PACKING
1
O RING
1
DRAIN PLUG O RING
1
FUEL FILTER CASE
1
UPPER COVER
1
BOLT
1
ELEMENT SPRING SEAT
1
ELEMENT SET SPRING
1
DRAIN PLUG
1
VALVE ASSY.
1
PACKING
1
PACKING ....................................................... 1 ........ UP TO OCT. 87
PACKING ....................................................... 1 ........ NOV. 87~
BOLT .............................................................. 2 ........ UP TO OCT. 87
BOLT .............................................................. 2 ........ NOV. 87~
BOLT, L=145
2
LOCK WSAHER
2
PLAIN WASHER
2
NUT
2
OIL FILTER PACKING
2
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 113
ISUZU 6BD1 — OIL AND AIR PIPE ASSY.
OIL AND AIR PIPE ASSY.
PAGE 114 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — OIL AND AIR PIPE ASSY.
OIL AND AIR PIPE ASSY.
NO.
1
2
3
4
6
7
9
10#
11
12
PART NO.
5133110890
133115322
9099211880
0500408400
5133111190
1096232820
1096234620
0500408400
5133112050
9099171050
1096308830
9098440220
PART NAME
QTY.
REMARKS
OIL PUMP ASSY. ................. 1 ..................... UP TO MAR. 84
OIL PUMP ASSY. ................. 1 ..................... APR. 4~
PACKING
2
BOLT .................................... 4 ..................... REPLACES 9019108400
COOLER PIPE ASSY.
1
O RING ................................. 2 ..................... UP TO OCT. 87
O RING ................................. 2 ..................... NOV. 87~
BOLT .................................... 4 ..................... REPLACES 9019108400
OIL PIPE ASSY. ................... 1 ..................... INCL. ITEM W/#
CLIP
1
PACKING
2
NUT
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 115
ISUZU 6BD1 — COOLING SYSTEM ASSY.
COOLING SYSTEM ASSY.
PAGE 116 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — COOLING SYSTEM ASSY.
COOLING SYSTEM ASSY.
NO.
1
2#
3#%
4#%
6#%
6-1#%
7#%
8#%
9#%
11#%
12#%
13#%
16#%
17#%
18#%
20#%
21#%
22#%
31%
33
33-1
41
50
51
52
53
54
59
61
62
64
68
71
72
73
74
75
PART NO.
5136101452
1136108770
1878102772
5136310090
5098000510
5098000500
5136340020
9099521430
9091801520
5136200061
9136218020
5136420072
9136128020
9136136130
9030908200
5096250550
1095030700
5136390010
1136140100
1136140131
5090300101
0500410500
0500410350
0500410250
9136756330
5136410171
9136428032
1136420250
9034406100
9019108160
1136600870
1090440720
9091505080
9091647080
5136710910
5136710160
1136711430
5137160260
1137130371
5137700310
1137700700
9096640050
9096620340
5137210152
PART NAME
QTY.
REMARKS
WATER PUMP ASSY ................ 1 ................ INCL. ITEMS W/#
PUMP KIT W/ GASKET ............ 1 ................ INCL. ITEMS W/%
REPAIR KIT ............................... 1 ................ REPLACES 5878100983
WATER PUMP SHAFT
1
BALL BEARING, FRONT
1
BALL BEARING, REAR
1
BALL SPACKER
1
SNAP RING
1
C RING
1
SEAL UNIT
1
IMPELLER
1
FAN AND PULLEY CENTER 1
WATER PUMP COVER
1
PACKING
1
SCREW
3
SECONDARY SEAL
1
WASHER
1
DUST THROWER
1
PACKING ................................... 1 ................ UP TO OCT. 87
PACKING ................................... 1 ................ NOV. 87~
BOLT
1
BOLT ......................................... 2 ................ REPLACES 5090000880
BOLT ......................................... 1 ................ REPLACES 9019110350
BOLT ......................................... 1 ................ REPLACES 9019110250
PLATE
1
PULLEY
1
SPACER .................................... 1 ................ UP TO MAR. 87
SPACER .................................... 1 ................ APR. 87~
SCREW
2
BOLT
4
FAN ASSY., D=550,6,BLOWER 1
BOLT, L=65
4
LOCK WASHER
4
PLAIN WASHER
4
BELT ASSY., L=997 .................. 1 ................ UP TO APR. 85
BELT ASSY., L1225 .................. 1 ................ MAY 85 TO MAR. 87
BELT ASSY., L=1226 ................ 1 ................ APR 87~
THERMOSTAT HOUSING
1
THERMOSTAT JOINT ............... 1 ................ REPLACES 5137130161
THERMOSTAT, 82-95C .............. 1 ................ UP TO APR. 85
THERMOSTAT, 85-95C .............. 1 ................ MAY 85~
COCK PLUG
1
HEATER PLUG
1
WATER PIPE
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 117
ISUZU 6BD1 — COOLING SYSTEM ASSY.
COOLING SYSTEM ASSY.
PAGE 118 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — COOLING SYSTEM ASSY.
COOLING SYSTEM ASSY.
NO.
76
77
79
80
91
92
92-1
93
94
106
107
119
120
121@
122@
123@
124@
125@
126@
127@
128@
129@
130@
141
142
142-1
144
PART NO.
9137436030
1137430160
0501408250
9096610050
9095714160
1137410100
0108060950
0501410350
5137210141
5097040460
9091505100
9091605100
1112800051
5112800053
5112820070
5112820060
1112820140
9132630100
9095622150
5095800920
5112880010
5096050170
9091114100
9091645100
5112810081
1112820080
1112820120
8942059861
0501408280
0501408200
1090300910
0501408450
9091605080
PART NAME
QTY.
REMARKS
PACKING ................................... 1 ................ UP TO APR. 86
PACKING ................................... 1 ................ MAY 86~
BOLT ......................................... 3 ................ REPLACES 9019708250
PLUG
1
PAKING
1
PACKING ................................... 1 ................ REPLACES 1137410080
BOLT ......................................... 3 ................ REPLACES 9010560950
BOLT ......................................... 3 ................ REPLACES 9019710350
HOSE
1
CLIP
2
LOCK WASHER
3
PLAIN WASHER
3
WATER DUCT COVER .............. 1 ................ REPLACES 9112808016
OIL COOLER ASSY. ................. 1 ................ INCL. ITEMS W/@
OIL COOLER ELEMENT ASSY 1
GASKET .................................... 2 ................ UP TO SEP. 88
GASKET .................................... 2 ................ OCT. 88~
BY PASS PLUG VALVE ............ 1 ................ REPLACES 5096040100
PACKING
1
SPRING
1
BY PASS VALVE
1
TAPER PLUG
2
NUT ........................................... 4 ................ REPLACES 50904000280
PLAIN WASHER ........................ 4 ................ REPLACES 5095030720
COOLER BODY
1
PACKING, COVER .................... 1 ................ UP TO AUG. 88
PACKING, COVER .................... 1 ................ SEP. 88~
BOLT
1
BOLT ....................................... 15 ................ REPLACES 9019708280
BOLT ......................................... 2 ................ UP TO APR. 91;REPLACES 9019708200
BOLT ......................................... 2 ................ MAY 91~
BOLT ....................................... 12 ................ REPLACES 9019708450
PLAIN WASHER
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 119
ISUZU 6BD1 — INTAKE AND EXHAUST ASSY.
INTAKE AND EXHAUST ASSY.
PAGE 120 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — INTAKE AND EXHAUST ASSY.
INTAKE AND EXHAUST ASSY.
NO.
1
3
4
20
20-1#
21
22
24
27
30
30-1
31
32
32-1
33
33-1
34
34-1
46
48
49
50
51
76
76-1
77
78
83
86
PART NO.
5141112434
9040108280
9044110280
9141406130
9141418030
9141496530
9044110300
5141450040
9098445650
5141112511
1141123150
5141111100
9044110250
9091104080
9091104100
9091505080
9091505100
9091605080
9091605100
1141150360
1141150520
9091605080
9091505080
9091104080
9019708280
0501408280
1141150370
1141150540
1096370560
9091104100
9091505100
5093603200
109700870
PART NAME
QTY.
REMARKS
INLET MANIFOLD W/O STUD 1
STUD
3
FUEL FILTER STUD
2
MAINFOLD ASSY. .................. 1 ................... INCL. ITEM W/#
MANIFOLD ASSY.
1
SEALING EXHAUST RING 3
EXHAUST STUD
3
EXHAUST GASKET
3
BUT
12
INLET PIPE ............................ 1 ................... UP TO NOV. 88
INLET PIPE, H=57 ................. 1 ................... DEC. 88~
INLET PIPE
1
INTAKE PIPE STUD
2
NUT
3
NUT
2
LOCK WASHER
3
LOCK WASHER
2
PLAIN WASHER
3
PLAIN WASHER
2
INLET HEAD PACKING .......... 1 ................... UP TO AUG. 88
INLET HEAD PACKING .......... 1 ................... SEP. 88~
PLAIN WASHER
3
LOCK WASHER
3
NUT
3
BOLT ...................................... 9 ................... UP TO APR. 90;REPLACES 9019708250
BOLT ...................................... 9 ................... MAY 90~
INLET PACKING ..................... 1 ................... UP TO OCT. 87
INLET PACKING ..................... 1 ................... NOV. 87~
SHUTTER PIPE PACKING .... 1 ................... REPLACES 1096370470
NUT
2
LOCK WASHER
2
RUBBER HOSE
1
CLIP
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 121
ISUZU 6BD1 — FUEL SYSTEM ASSY.
FUEL SYSTEM ASSY.
PAGE 122 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — FUEL SYSTEM ASSY.
FUEL SYSTEM ASSY.
NO.
1
11
12
13
14
15
16
17
18
19
20
21
22
23
24
31
32
33
34
35
36
37
38
39
39-1
41-5
41-6
43
47
48
49
54
56
PART NO.
5153001031
5153150030
9153390510
9091104080
9091505080
5154116952
5154116962
5154116971
1154148131
5154116982
5154116992
5154117002
5154115060
5154115070
1096750860
1096300850
1154124711
1096750371
9095714080
9154196120
9095245550
5154112231
5097091030
509709104
9019006250
0500406300
5154112231
1154129180
1096300850
5197890030
9091505100
0208010200
5132600101
1096300850
PART NAME
QTY.
REMARKS
NOZZLE ASSY.
6
PACKING
6
COVER
6
NUT
12
LOCK WASHER
12
PIPE ASSY., INJ. NO. 1
1
PIPE ASSY., INJ. NO. 2
1
PIPE ASSY., INJ. NO. 3 .................... 1 ........ UP TO MAR. 89
PIPE ASSY., INJ. NO. 3 .................... 1 ........ APR. 89~
PIPE ASSY., INJ. NO. 4
1
PIPE ASSY., INJ. NO. 5
1
PIPE ASSY., INJ. NO. 6
1
PIPE ASSY., FUEL PUMP FILTER 1
PIPE ASSY., INJECTION FILTER 1
BOLT
2
FUEL PIPE PACKING
6
INJECTION LEAK OFF PIPE ASSY. 1
BOLT
1
LEAK OFF PIPE PACKING
2
CLIP
6
CLIP
1
SUCTION FEED PUMP PIPE
1
CLIP
2
CLIP
2
BOLT
2
BOLT ................................................. 2 ........ REPLACES 9019006300
FILTER LEAK OFF PIPE ASSY.
1
FILTER LEAK OFF PIPE ASSY.
1
PACKING
2
BRACKET
1
LOCK WASHER
2
BOLT ................................................. 2 ........ REPLACES 9020510200
OVER FLOW VALVE
1
VALVE FIXTURE PACKING
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 123
ISUZU 6BD1 — ENGINE FOOT AND HANGER ASSY.
ENGINE FOOT AND HANGER ASSY.
PAGE 124 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — ENGINE FOOT AND HANGER ASSY.
ENGINE FOOT AND HANGER ASSY.
NO.
8
11
13
13-1
15
16
17
18
19
31
32
35
36
37
38
41
42
42-1
42-2
43
51
52
55
56
62
63
64
80
81
82
83
84
85
87
PART NO.
1093000530
5197110312
0500410250
0500410350
1090001331
9091605140
9091505140
9991104140
1197190362
9991104120
9091505120
0208012400
9091607120
9091505120
9991104120
9117776221
9019110200
9019110220
9019110220
0500410220
0208014250
9091504140
1113190080
1113190090
0108058600
9091505080
9091605080
9099167550
9098008790
0208006100
9091505060
5197510042
9020510200
0500410200
9091505100
9091607100
9091646100
9091607100
9091505100
9091104100
PART NAME
QTY.
REMARKS
RIGHT FOOT STUD, L1=18.5 1
ALTERNATOR BRACKET
1
BOLT ......................................... 1 ................ REPLACES 9019110250
BOLT ......................................... 2 ................ REPLACES 9019110350
BOLT
1
PLAIN WASHER
1
LOCK WASHER
1
NUT
1
COVER
1
NUT
3
LOCK WASHER
3
BOLT ......................................... 1 ................ REPLACES 9910562400
PLAIN WSAHER
1
LOCK WASHER
1
ADJUSTING NUT
1
RR. ENGINE LIFTING HANGER 1
BOLT ......................................... 2 ................ UP TO APR. 90
BOLT ......................................... 2 ................ MAY 90~
BOLT ......................................... 1 ................ UP TO APR. 90
BOLT ......................................... 1 ................ MAY 90~
BOLT ......................................... 1 ................ REPLACES 9920514250
LOCK WASHER
1
INJECTION PUMP BRACKET .. 1 ................ UP TO OCT. 87
INJECTION PUMP BRACKET .. 1 ................ NOV. 87~
BOLT ......................................... 7 ................ REPLACES 9010558600
LOCK WASHER
7
PLAIN WASHER
7
CLIP
1
BOLT ......................................... 1 ................ UP TO APR. 92
BOLT ......................................... 1 ................ MAY 92~; REPLACES 9020406100
LOCK WASHER
1
BRACKET
1
BOLT ......................................... 2 ................ UP TO SEP. 87
BOLT ......................................... 2 ................ OCT. 87~; REPLACES 9019110200
LOCK WASHER
2
PLAIN WASHER
2
PLAIN WASHER ........................ 1 ................ UP TO SEP. 87
PLAIN WASHER ........................ 1 ................ OCT. 87~
LOCK WASHER
1
NUT
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 125
ISUZU 6BD1 — INJECTION PUMP ASSY.
INJECTION PUMP ASSY.
PAGE 126 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — INJECTION PUMP ASSY.
INJECTION PUMP ASSY.
NO.
5
PART NO.
1156020451
1156026800
1157203470
1157704760
20#
1157500480
36#
5157810030
37#
1197510400
38#
9884105020
39#
5156190480
40#
9096620070
41#
1095390070
41-2# 1156192450
42#
5125240570
43#
9019006140
15#
PART NAME
QTY.
REMARKS
INJECTION PUMP ASSY. ......... 1 ................ UP TO NOV. 89; REPLACES 1156010605
INCL. ITEMS W/#
INJECTION PUMP ASSY. ......... 1 ................ DEC. 89~
GOVERNOR ASSY. ................... 1 ................ UP TO NOV. 89
GOVERNOR ASSY. ................... 1 ................ DEC. 89~
FEED PUMP ASSY. .................. 1 ................ REPLACES 1157500280
INJ. PUMP COUPLING
1
BRACKET
1
NUT
1
WASHER
1
BOLT
1
PLATE ....................................... 1 ................ REPLACES 5095390060
PLATE
1
GEAR
1
BOLT
6
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 127
ISUZU 6BD1 — ELECTRICAL ASSY.
ELECTRICAL ASSY.
PAGE 128 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — ELECTRICAL ASSY.
ELECTRICAL ASSY.
NO.
3
7
22
23#
24#
29
30
31
32&
33&
37
40
64
65
65-1
67
82
82-1
83%
109
PART NO.
1811001910
1812002050
5831510030
9827200690
9099022380
9831514320
1823200010
1823100080
1823130030
1823170070
5824500141
1825500732
9825139288
5197320010
5197320020
9825300430
1819000161
1819001931
1828490430
9829322110
PART NAME
QTY.
REMARKS
STARTER
1
ALTERNATOR
1
OIL PRESSURE SWITCH ADAPTER ...1 ............... INCL. ITEMS W/#
OIL PRESSURE WARNING SW.
1
ADAPTER
1
THERMOMETER, OIL
1
BATTERY SW. ASSY. ............................1 ............... REPLACES 9827300090
STARTER SWITCH ASSY. ....................1 ............... INCL. ITEMS W/&
STARTER SWITCH
1
LOCK WITH KEY BARREL
1
OVER HEAT SW.
1
EMERGENCY RELAY
1
GLOW PLUG, 20.5V
6
GLOW PLUG CONNECTOR
1
GLOW PLUG CONNECTOR
1
RESISTANCE CONTROL, 24V
1
ENGINE STOPPER ASSY. ...................1 ............... INCL. ITEM W/%
ENGINE STOPPER ASSY. W/COVER 1
CABLE ASSY., L=460
1
STARTER-FRAME CABLE ASSY.
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 129
ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
PAGE 130 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
NO.
5
14
15
16
18
20
22
23
24
27
28
29
31
32
34
35
36
40
41
43
45#
47#
48#
49#
55
PART NO.
1156110750
5156190440
9812151150
9812350170
1156190240
8941445880
1156290500
1156190030
9812151440
9091505060
1157290060
1096230130
5156310070
1156410160
515630010
1156490010
5156440100
5156250010
1096230520
9812212230
9812212200
1156220030
1156290010
5156190410
5156190010
5156190020
5156190030
5156190040
5156190050
5156190070
5156190080
5156190090
5156191080
5156190100
5156191090
5156191060
5156191100
5156191070
5156190110
5156190120
5156190130
5156190150
5156190250
5156190260
PART NAME
QTY.
REMARKS
HOUSING ASSY.
1
ADAPTER
1
STUD
3
ADAPTER
1
BOLT
3
GASKET
1
COVER
1
SCREW
2
GASEKT
2
WAWSHER
3
NUT
3
O RING
1
PLUNGER ASSY.
6
DELIVERY VALVE ASSY.
6
SPRING
6
GASKET
6
HOLDER
6
PLATE ASSY
3
O RING
3
TAPPET ASSY. ......................... 6 ................. INCL. ITEMS W/#
PIN
6
ROLLER
6
BUSHING
6
GUIDE
6
SHIM, T=+0.60
SHIM, T=+0.70
SHIM, T=+0.80
SHIM, T=+0.90
SHIM, T=+1.00
SHIM, T=+1.10
SHIM, T=+1.20
SHIM, T=+1.30
SHIM, T=+1.35
SHIM, T=+1.40
SHIM, T=+1.45
SHIM, T=+1.50
SHIM, T=+1.55
SHIM, T=+1.60
SHIM, T=+0.55
SHIM, T=+0.65
SHIM, T=+0.75
SHIM, T=+0.85
SHIM, T=+0.20
SHIM, T=+0.25
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 131
ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
PAGE 132 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
NO.
58
59
60
61
62
66
67
75-3
75-4
76
77
82
83
84
PART NO.
5156190270
5156190340
5156190350
5156190360
5156190370
9812350420
9812350430
9812350440
9812350450
5156430090
9812350150
9812350210
9812250580
9812250570
9812350030
5156370030
1156390030
1156210630
1156210630
1156290020
1156290030
5098000380
9000906770
5156290240
9812250470
9812250490
9812250500
9812250510
9812250520
9812250530
9812250540
1156290070
5156190380
5156190390
1156190900
5156290150
5156290160
5156290170
5156290180
51562901190
5156290200
5156290210
PART NAME
SHIM, T=+0.35
SHIM, T=+0.30
SHIM, T=+0.40
SHIM, T=+0.50
SHIM, T=+0.45
SHIM, T=+0.95
SHIM, T=+1.05
SHIM, T=+1.15
SHIM, T=+1.25
SPRING
SEAT
SEAT
SLEEVE
PINION
SCREW
RACK
SCREW
CAMSHAFT
CAMSHAFT
BALL BEARING, OVERSIZE
BALL BEARING, STD
BALL BEARING, OVERSIZE
BALL BEARING, STD
RING
RING
SHIM, T=+0.10
SHIM, T=+0.12
SHIM, T=+0.14
SHIM, T=+0.16
SHIM, T=+0.18
SHIM, T=+0.50
SHIM, T=+1.00
SHIM, T=1.00
SHIM, T=+0.70
SHIM, T=+1.40
SHIM, T=+0.10
SHIM, T=+0.12
SHIM, T=+0.14
SHIM, T=+0.16
SHIM, T=+0.18
SHIM, T=+0.50
SHIM, T=+0.30
QTY.
REMARKS
6
6
6
6
6
6
1
1
1
1
AR
AR
AR
AR
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 133
ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
PAGE 134 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
NO.
87
88
89
93
95
108
150
162
163
164
180
181
182
183
PART NO.
1156190330
9884100660
9812250430
1156290470
1156192820
5835390240
5156191360
9091606100
9091506100
5156390020
1156192660
1156290490
9041010300
1156290480
PART NAME
BEARING
SCREW
WASHER
COVER
BOLT
WOODRUFF KEY
PLUB
WASHER
WASHER
NUT
BRACKET
PACKING
STUD
GASKET
QTY.
1
2
2
1
4
1
6
4
4
4
1
1
4
1
REMARKS
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 135
ISUZU 6BD1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
PAGE 136 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
NO.
5
12#
13#
14#
15#
16#
18#
19#
50#
26#
27#
30#
31#
32#
34#
35#
36#
37#
38#
40#
42#
44#
46#
47#
48#
50#
52#
53#
54#
57#
58#
60#
63#
64#
67#
68#
69#
73#
74#
77#
80#
81#
82#
PART NO.
5157210040
1157290150
9813150650
9019008180
9813253970
9019006140
5157291230
9813252370
1157290380
9813251820
9813261120
5157210200
9813254290
5157290530
5157290540
5157290330
9813251770
5157291020
9884100270
5157210210
9813919070
9019006160
1157290280
9812350340
9091505060
5157220080
5156190490
5157290340
9813250860
5157190080
9000902290
9813250880
9813255510
9813255520
9813255530
5157292860
5157292870
9008121300
9813222350
5157231240
5157292090
1156390080
5157230990
9008130230
9813217210
1157292930
9813212050
9091854150
PART NAME
QTY.
REMARKS
HOUSING ...................................1 ...................... INCL. ITEMS W/#
O RING
1
ADAPTER
1
BOLT
1
PLATE
1
BOLT
6
SCREW
1
NUT
2
PLUG
1
SCREW
1
NUT
1
COVER
1
BUSHING
1
PLUG
2
BOLT
2
BOLT
4
SCRWE
1
BLT
1
NUT
1
COVER
1
O RING
1
BOLT
3
BOLT
1
CAP
1
LOCK WASHER
1
FLYWEIGHT ASSY.
1
KEY
1
LOCK WASHER
1
NUT
1
SLEEVE
1
BEARING
1
SHIM, T=0.20
SHIM, T=+0.30
SHIM, T=+0.40
SHIM, T=+1.00
SHIM, T=+0.50
SHIM, T=+0.50
SPRING
1
SPRING
1
CAPSULE
1
NUT
1
GASKET
2
CAPSULE
1
NUT
1
LEVER
1
BUSH
2
O RING
2
SNAP RING
2
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 137
ISUZU 6BD1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
PAGE 138 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
NO.
PART NO.
PART NAME
QTY.
83#
84#
85#
86#
89#
90#
93#
100#
101#
102#
103#
104#
107#
108#
109#
110#
1157290980
1157290990
9813250970
9813253180
1157293010
9813254880
5157250570
1157250110
9091854040
5157250170
9813250620
5157250410
5157250810
9019006160
9813919060
1157292990
1157292980
1157292980
1157292970
1157292960
1157292950
1157292940
9813252100
5157230640
1157290010
1157290020
5157250420
5157291120
9091505080
5157230880
OIL SEAL
SHIM
SHIM, T=0.30
PLUG
COLLAR
WASHER
LEVER
LINK
SNAP RING
LEVER
PIN
LEVER
LEVER
BOLT
O RING
SHIM, T=0.50
SHIM, T=+0.50
SHIM, T=+0.40
SHIM, T=+3.35
SHIM, T=+0.30
SHIM, T=+0.25
SHIM, T=+0.20
CAP
SPRING
GASKET
GASKET
LEVER ASSY.
BOLT
LOCK WASHER
SPRING
1
1
111#
112#
116#
117#
120#
148#
149#
150#
REMARKS
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 139
ISUZU 6BD1 —FEED PUMP ASSY.
FEED PUMP ASSY.
PAGE 140 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — FEED PUMP ASSY.
FEED PUMP ASSY.
NO.
PART NO.
1157500480
5#
5157510120
9#
9813512050
10#
9813513020
11#
9813550230
12#
9813550350
15#
5157540010
16#% 9813514030
17#% 9813514100
18#% 1157590020
26#
9813516020
27#
1196230160
28#
9813517020
31#
1096750630
32#
1157590110
33#
1157590120
35#
1157590030
40#
1196230160
42#
9813550250
44#
8941311300
PART NAME
QTY.
REMARKS
FEED PUMP ASSY. ....................... 1 .................. INCL. ITEMS W#
HOUSING
1
PISTON
1
SPRING
1
PLUG
1
GASKET
1
TAPPET ASSY. ............................... 1 .................. INCL. ITEMS W/%
ROLLER
1
PIN
1
GUIDE
2
VALVE
2
O RING ........................................... 1 .................. REPLACES 1096230160
SPRING
2
BOLT
1
BOLT
1
PACKING
4
ADAPTER
1
O RING ........................................... 1 .................. REPLACES 1096230160
SNAP RING
1
PUMP
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 141
ISUZU 6BD1 — NOZZLE ASSY.
NOZZLE ASSY.
PAGE 142 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — NOZZLE ASSY.
NOZZLE ASSY.
NO.
1
2
PART NO.
5153110191
5153300191
5#
6#
7#
8#
9#
10#
12#
21#
22#
23#
31#
32#
5153410010
9153470030
9153430130
5153450010
9153390570
5153340010
9153390560
5153320020
5153390030
5153490020
5153490010
9095714080
PART NAME
QTY.
REMARKS
NOZZLE ASSY. ......................... 6 ................ REPLACES 5153110190
HOLDER ASSY. ........................ 6 ................ REPLACES 5153300190;
INCL. ITEMS W/#
PUSH ROD
6
PIN
12
SPRING
6
SCREW
6
WASHE
6
NUT
6
GASKET
6
NUT
6
GASKET
6
CONNECTOR
6
BOLT
6
PAKCING, T=1.0
12
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 143
ISUZU 6BD1 — STARTER ASSY,
STARTER ASSY.
PAGE 144 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — STARTER ASSY.
STARTER ASSY.
NO.
PART NO.
1811001910
6#
1811210370
7#
1811293950
8#
1811293850
18#
5811291560
21#
1811160440
22#
1811293840
23#
1811293960
24#
5811292210
30#
1811150610
31#@ 1811150620
34#@ 1811180360
35#@ 1811170140
37#@ 1811160430
38#@ 1811160420
40#
1825530230
41#
1811180390
42#
1811294010
50#
1811230250
52#& 1811293970
53#
5811291420
55#
5811220160
56#
5811291440
57#
5811291450
58#
1811130260
59#
1811293870
60#
1811230240
61#& 1811293860
64#
5811291600
65#
5811291590
66#
5811291580
67#
1811130730
76#
1811270310
77#
1811291850
78#
1811291840
79#
5811291470
80#
5811510360
84#
5811291460
87#
9821161400
88#
5811291480
89#
5811180190
91#
5811291510
92#
5811291520
93#
5811291500
94#
9821161420
97#
5811291490
98#
1811291140
99#
5811292140
100# 1811293940
PART NAME
QTY.
REMARKS
STARTER ASSY. ..................................1 ............. INCL. ITEMS W/#
ARMATURE ASSY.
1
BALL BEARING
1
BALL BEARING
1
WASHER
2
LEAD WIRE
1
TERMINAL
1
FIELD COIL
1
SCREW
4
COVER .................................................1 ............. INCL.. ITEMS W/@
REAR COVER
1
BRUSH HOLDER
1
BRUSH SPRNG
4
BRUSH, (-)
2
BRUSH, (+)
2
RELAY SAFETY SWITCH
1
HOLDER
1
BOLT
1
FRONT COVER ...................................1 ............. INCL. ITEMS W/$
METAL COVER
1
DISH LUG
1
CLUTCH
1
CLIP RIG
2
PINION STOPPER
1
CENTER BRACKET
1
BOLT
3
SHAFT ASSY. .......................................1 ............. INCL. ITEMS W/&
BALL BEARING
1
SHAFT WASHER
1
SHAFT WASHER
2
INSULATE WASHER
1
CENTER COVER
1
SHIFT LEVER
1
LEVER PIN
1
NUT
1
PLATE
1
MAGNETIC SWITCH ASSY.
1
PLUNGER
1
INSULATE BUSING
1
CONNECTOR
1
HOLDER
1
WASHER
2
BOLT
2
TERMINAL ASSY
1
WASHER
1
CLI RING
2
WASHER
2
BOLT
2
STARTER SEAL KIT
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 145
ISUZU 6BD1 — ALTERNATOR ASSY.
ALTERNATOR ASSY.
PAGE 146 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — ALTERNATOR ASSY.
ALTERNATOR ASSY.
NO.
5#
7#
8#
9#
10#
11#
12#
13#
14#
15#
16#
16-1#
17#
18#
19#
20#
25#
26#@
27#@
33#@
40#@
41#@
43#@
45#@
51#
52#
55#
56#
60#
61#
62#
63#
75#
90#
95#
97#
99#
PART NO.
1812002050
1812210300
1812292250
1812292240
1812292310
1812240090
1812291610
1812291620
9822160600
1812291630
1812291640
1812291950
1812292300
1812291600
1812291650
1812291230
1812110310
1812140810
1812140820
1812190330
1812292270
1812293100
1812292350
1812292340
1811180110
1812130240
1812291670
181240830
1812292330
1812291350
1812170230
1812292260
1812292320
1812220340
1812290970
1812510240
1812295960
9822190270
PART NAME
QTY.
REMARKS
ALTERNATOR ASSY. ................ 1 ................. INCL. ITEMS W/#
ROTOR ASSY.
1
BEARING
1
BALL BEARING
1
ROTOR PACKING
1
SLIP RING
1
ROTOR RETAINER
1
ROTOR PACKING
1
ROTOR RETAINER
1
ROTOR RETAINER
1
ROTOR RETAINER
1
ROTOR CLIP
1
ROTOR CLIP
1
COLLAR
1
PACKING
1
PLATE
1
STATOR
1
REAR COVER ASSY. ................ 1 ................. INCL. ITEMS W/@
REAR COVER
1
RECTIFIER ASSY.
1
WASHER
2
BOLT
1
BUSH
1
TUBE
1
CLIP
1
COVER
1
BUSHING
1
COVER
1
PACKING
1
WASHER
1
HOLDER ASSY.
1
PACKING
1
PACKIG
1
PULLEY ASSY.
1
BOLT
3
VOLTAGE REGULATOR ............ 1 ................. NOT SHOWN
NUT
1
LOCK WASHER
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 147
ISUZU 6BD1 — ACCESSORIES
ACCESSORIES
PAGE 148 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
ISUZU 6BD1 — ACCESSORIES
ACCESSORIES
NO.
50
55
60
PART NO.
9839101011
1096231800
1096234650
0500408200
PART NAME
QTY.
REMARKS
TACHO DRIVE ELBOW ASSY. . 1
PACKING ................................... 1 ................. UP TO OCT. 87
PACKING ................................... 1 ................. NOV. 87~
BOLT ......................................... 2 ................. REPLACES 9019108200
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 149
TERMS AND CONDITIONS OF SALE — PARTS
Effective: July 1, 2000
4.
PAYMENT TERMS
Terms of payment for parts are net 10 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and the
carrier.
Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
5.
Parts must be in new and resalable
condition, in the original Multiquip package
(if any), and with Muiltiquip part numbers
clearly marked.
6.
The following items are not returnable:
a.
Obsolete parts. (If an item is listed
in the parts price book as being
replaced by another item, it is
obsolete.)
b.
Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
MINIMUM ORDER
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
c.
Any line item with an extended dealer
net price of less than $5.00.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a specific
date and all orders received on or after that date
will be billed at the revised price. Rebates for
price declines and added charges for price
increases will not be made for stock on hand
at the time of any price change.
Multiquip reserves the right to quote and sell
direct to Government agencies, and to Original
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
SPECIAL EXPEDITING SERVICE
A $20.00 to $50.00 surcharge will be added to
the invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
d.
Special order items.
RETURNED GOODS POLICY
e.
Electrical components.
Return shipments will be accepted and credit
will be allowed, subject to the following
provisions:
f.
Paint, chemicals, and lubricants.
LIMITATIONS OF SELLER’S LIABILITY
g.
Decals and paper products.
1.
h.
Items purchased in kits.
Multiquip shall not be liable here under for
damages in excess of the purchase price of the
item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
2.
A Returned Material Authorization must
be approved by Multiquip prior to shipment.
To obtain a Return Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
a.
b.
The list must be typed or computer
generated.
c.
The list must state the reason(s) for
the return.
d.
The list must reference the sales
order(s) or invoice(s) under which
the items were originally purchased.
e.
3.
The parts numbers and descriptions
must match the current parts price
list.
The list must include the name and
phone number of the person
requesting the RMA.
A copy of the Return Material
Authorization must accompany the return
shipment.
7.
The sender will be notified of any material
received that is not acceptable.
8.
Such material will be held for 5 working
days from notification, pending
instructions. If a reply is not received
within 5 days, the material will be returned
to the sender at his expense.
9.
Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.
10. In cases where an item is accepted for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
11. Credit issued will be applied to future
purchases only.
LIMITATION OF WARRANTIES
No warranties, express or implied, are made
in connection with the sale of parts or trade
accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes not
authorizes any person to assume for it any
other obligation or liability whatever in
connection with the sale of its products. A part
from such written statement of warranty, there
are no warranties, express, implied or statutory,
which extend beyond the description of the
products on the face hereof.
PAGE 150 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
NOTE PAGE
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 151
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
© COPYRIGHT 2001, MULTIQUIP INC.
PAR
TS DEP
AR
TMENT
ARTS
DEPAR
ARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
VICE DEP
AR
TMENT
SER
DEPAR
ARTMENT
SERVICE
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEP
AR
TMENT
DEPAR
ARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
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
E-mail:mq@multiquip.com • www:multiquip.com