MQ Power DCA40SSAI Operating instructions

MQ Power DCA40SSAI Operating instructions

PARTS AND OPERATION MANUAL

PARTS AND OPERATION MANUAL

MQ POWER

DCA-40SSAI

WHISPERWATT

TM

GENERATOR

PARTS LIST NO.M3340163804

FINAL COPY

MULTIQUIP INC.

18910 WILMINGTON AVE.

PARTS DEPARTMENT:

800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

SERVICE DEPARTMENT:

800-421-1244

FAX: 310-537-3927

800-835-2551

FAX: 310-638-8046

E-mail:[email protected]

www:multiquip.com

PAGE 2 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HAND WHEN CALLING

P AR TS DEP AR TMENT

800/427-1244 or 310/537-3700

FAX: 800/672-7877 or 310/637-3284

SER VICE DEP

AR

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

W ARRANTY DEP

AR

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

800/421-1244 or 310/537-3700

FAX: 310/537-3927

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — 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 and Safety Decals .................................... 21-22

DCA-40SSAI Specifications .......................................... 23

General Information ....................................................... 24

Major Components ........................................................ 25

Dimensions ............................................................... 26-27

Control Panel Descriptions ....................................... 28-29

Engine Operating Panel Descriptions ....................... 30-31

Output Terminal Panel Description ............................ 32-33

Output Amperage Setup ........................................... 34-35

Output Voltage Setup ................................................ 36-39

Installation ................................................................ 40-41

Pre Setup ................................................................. 42-45

Load Application ............................................................ 46

Generator Start-up Procedure .................................. 47-49

Generator Shutdown Procedure ..................................... 50

Maintenance ............................................................. 52-55

Engine Wiring Diagram ............................................. 56-57

Generator Wiring Diagram .............................................. 58

Engine Troubleshooting ............................................. 60-62

Explanation of Codes in Remarks Column .................... 64

Suggested Spare Parts ................................................. 65

ISUZU 4BD1 ENGINE

Cylinder Head Cover Assembly ................................ 94-95

Cylinder Block Assembly .........................................96-99

Timing Gear Assembly .......................................... 100-101

Flywheel Housing Assembly ................................. 102-103

Oil Pan Assembly .................................................. 104-105

Oil Pump Assembly .............................................. 106-107

Crankshaft Piston, Flywheel Assembly ................. 108-109

Valve Assembly .................................................... 110-111

Oil and Fuel Filter Assembly ................................. 112-113

Oil Piping Assembly .............................................. 114-115

Cooling Assembly ................................................. 116-117

Air Intake and Exhaust Assembly ......................... 118-119

Fuel Injection Assembly ........................................ 120-121

Engine Foot Assembly .......................................... 122-123

Engine Control Assembly ...................................... 124-125

Injection Pump Assembly ..................................... 126-127

Electrical Parts Assembly ..................................... 128-129

Feed Pump Assembly ........................................... 130-131

Nozzle Assembly .................................................. 132-133

Oil Filter Assembly ................................................ 134-135

Fuel Filter Assembly ............................................. 136-137

Accessories .......................................................... 138-139

Terms and Condition of Sale — Parts ....................... 140

MQ POWER DCA-40SSAI

AC GENERATOR

Generator Assembly ................................................. 66-69

Control Box Assembly .............................................. 70-71

Engine & Radiator Assembly .................................... 72-75

Engine Operating Panel Assembly ...........................76-79

Battery Assembly .....................................................80-81

Muffler Assembly .....................................................82-83

Fuel Tank Assembly ................................................. 84-85

Enclosure Assembly ................................................86-91

Name Plate And Decals ........................................... 92-93

NOTE

Specification and part number are subject to change without notice

.....

PAGE 4 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

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:

Extra Fax Discount for Domestic USA

Dealers Only

Number of line items ordered

1-9 items

10+ items**

Additional Discount

3%

5%

UPS

Special

For fa xed or ders only

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.

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

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — 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.

The following safety guidelines should always be used when operating the DCA-40SSAI portable generator:

GENERAL SAFETY

DO NOT operate or service this equipment before reading this entire manual.

■ This equipment should not be operated by persons under 18 years of age.

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steeltoed boots and other protective devices required by the job.

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with hot components can cause serious burns.

■ The engine of this generator requires an adequate free flow of cooling air. Never operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

CAUTION:

■ Always refuel in a well-ventilated area, away from sparks and open flames.

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 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

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.

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.

CAUTION:

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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 7

RULES FOR SAFE OPERATION

Battery

NEVER Run engine without air filter. Severe engine damage may occur.

CAUTION:

Never over fill the battery with water above

■ Always service air cleaner frequently to prevent carburetor malfunction.

the upper limit.

■ Always disconnect the battery before performing service on the generator.

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:

1. DO NOT drop the battery. There is the possibility of risk that the battery may explode.

■ Always be sure the operator is familiar with proper safety precautions 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.

■ Always read, understand, and follow procedures in

Operator’s Manual before attempting to operate equipment.

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.

technical questions or information.

Loading and Unloading (Crane)

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 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.

■ 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

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

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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 9

DCA-40SSAI — TOWING AND TRANSPORTATION

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 jackknifing. 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 11

DCA-40SSAI —TRAILER-SPECIFICATIONS

M O D E L A P P L I C A T I O N F U E L

C E L L

N O

T a b l e 1 .

S p e c i f i c a t i o n s

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PAGE 12 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI —TRAILER-SPECIFICATIONS

M O D E L

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5 H

R A D I A L ( 8 )

W H E E L

1 3 " X 4 .

5 0 "

1 3 " X 4 .

5 "

1 3 " X 4 .

5 "

1 3 X 4 .

5 "

1 3 X 4 .

5 "

1 3 " X 4 .

5 0 "

1 3 " X 4 .

5 0 "

1 4 " X 5 "

1 4 " X 5 "

1 4 " X 5 "

1 4 " X 5 .

5 "

1 4 " x 6 "

1 6 " X 7 "

1 6 " X 7 "

1 6 " X 7 "

1 6 " X 7 "

1 6 " X 7 "

1 6 " X 7 "

S A X L E

2 2 0 0 # 2 X 2

2 2 0 0 # 2 X 2

H U B S S U S P E N S I O N

5 L U G 3 L E A F

5 L U G 3 L E A F

E L E C T R I C A L

4 W I R E

4 P O

L

L E

O O M

F L A T

W /

4 P O L E F L A T

2 2 0 0 # 2 X 2 5 L U G

2 2 0 0 # 2 X 2 5 L U G

2 2 0 0 # 2 X 2 5 L U G

3 5 0 0 l b s .

2 3 / 8 "

3 5 0 0 l b s .

2 3 / 8 "

3 5 0 0 l b s .

3 "

3 5 0 0 l b s

3 "

3 5 0 0 l b s .

3 "

3 5 0 0 l b s

3 "

( 2 ) 6 0 0 0 l b s

5 L U G

5 L U G

5 L U G

5 L U G

5 L U G

5 L U G

6 L U G

( 2 ) 6 0 0 0 l b s 8 L U G

( 2 ) 7 0 0 0 l b s 8 L U G

( 2 ) 6 0 0 0 l b s 8 L U G

( 3 ) 7 0 0 0 l b s .

8 L U G

( 3 ) 1 0 0 0 0 l b s 8 L U G

( 3 ) 1 0 0 0 0 l b s 8 L U G

3 L E A F

Q F L E X

3 L E A F

4 L E A F

4 L E A F

5 L E A F

5 L E A F

5 L E A F

5 L E A F

7 L E A F

7 L E A F

Q F L E X

Q F L E X

Q F L E X

7 L E A F

A I R R I D E

4 P O L E F L A T

4 P O L E F L A T

4 P O L E F L A T

4 P O L E R U

F L A T

B B E R

4 P O L E R U B B E R

F L A T

4 P O L E R U

F L A T

B B E R

4 P O L E R U

F L A T

B B E R

4 P O L E R U

F L A T

B B E R

4 W I R E L O O M

4 W I R E L O O M

4 W I R E L O O M

4 W I R E L O O M

4 W I R E L O O M

4 W I R E L O O M

6 W I R E L O O M

6 W I R E L O O M

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 13

DCA-40SSAI —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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 15

DCA-40SSAI — 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI —TRAILER SAFETY GUIDELINES

T a b l e 3 .

S u s p e n s i o n T o r q u e R e q u i r e m e n t s

I t e m

3 / 8 " U B O L T

7 / 1 6 " U B O L T

1 / 2 " U B O L T

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

T o r q u e ( F t .

L b s .

)

M I N 3 0 M A X 3 5

M I N 4 5 M A X 6 0

M I N 4 5 M A X 6 0

SNUG FIT ONLY

.

PARTS MUST ROTATE FREELY

.

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAIN NUT

-

BOLT ASSEMBLY

.

M I N 3 0 M A X 5 0

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.

T a b l e 4 .

T i r e T o r q u e R e q u i r e m e n t s

W h e e l S i z e F i r s t P a s s

F T L B S

S e c o n d P a s s

F T L B S

T h i r d P a s s

F T L B S

1 2 " 2 0 2 5 3 5 4 0 5 0 6 5

1 3 "

1 4 "

1 5 "

1 6 "

2 0 2 5

2 0 2 5

2 0 2 5

2 0 2 5

3 5 4 0

5 0 6 0

5 0 6 0

5 0 6 0

5 0 6 5

9 0 1 2 0

9 0 1 2 0

9 0 1 2 0

Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 17

DCA-40SSAI —TRAILER-WIRING DIAGRAM

NOTE:

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI —TRAILER-BRAKE TROUBLESHOOTING

T a b l e 5 .

E l e c t r i c B r a k e T r o u b l e s h o o t i n g

S y m p t o m

N o B r a k e s o r I n t e r m i t t e n t B r a k e s

W e a k B r a k e

O s n o r e

B r a

S i d e k e s P u ll t o

P o s s i b l e C a u s e

A n y o p e n c i r c u i t s o r b r o k e n w i r e s ?

A n y s h o r t c i r c u i t s ?

F a u l t y c o n t r o ll e r ?

A n y l o o s e c o n n e c t i o n s ?

G r o u n d w i r e s e c u r e ?

G r e a s e o r o li o n m a g n e t s o r il n i n g s ?

C o n n e c t i o n s c o r r o d e d ?

L o c k i n g B r a k e s

N o i s y B r a k e s

D r a g g i n g B r a k e s

B r a k e d r u m s s c o r e d o r g r o o v e d ?

B r a k e s s y n c h r o n i z e d ?

B r a k e c o m p o n e n t s l o o s e , b e n t o r b r o k e n ?

B r a k e d r u m s o u t o f r o u n d ?

S y s t e m l u b r i c a t e d ?

B r a k e c o m p o n e n t s c o r r e c t ?

B e a r i n g s o f t h e w h e e l a d j u s t e d ?

S o l u t i o n

F i n d a n d c o r r e c t .

F i n d a n d c o r r e c t .

T e s t a n d c o r r e c t .

F i n d a n d r e p a i r .

F i n d a n d s e c u r e .

C l e a n o r r e p l a c e .

C l e a n a n d o f c o c o r r r o s r e c t i o n .

c a u s e

M a c h i n e o r r e p l a c e .

C o r r e c t .

R e p l a c e c o m p o n e n t s .

R e p l a c e .

L u b r i c a t e .

R e p l a c e a n d c o r r e c t .

A d j u s t .

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 19

DCA-40SSAI —TRAILER-BRAKE TROUBLESHOOTING

S y m p t o m

N o B r a k e s

W e a k B r a k e s o

O n e r B r a

S i d e k e s P u ll t o

T a b l e 6 .

H y d r a u l i c B r a k e T r o u b l e s h o o t i n g

P o s s i b l e C a u s e

B r a k e il n e b r o k e n o r k i n k e d ?

B r a k e il n i n g g l a z e d ?

T r a li e r o v e r l o a d e d ?

B r a k e d r u m s s c o r e d o r g r o o v e d ?

L o c k i n g B r a k e s

N o i s y B r a k e s

D r a g g i n g B r a k e s

T i r e p r e s s u r e c o r r e c t ?

T i r e s u n m a t c h e d o n t h e s a m e a x l e ?

B r a k e c o m p o n e n t s l o o s e , b e n t o r b r o k e n ?

B r a k e d r u m s o u t o f r o u n d ?

S y s t e m l u b r i c a t e d ?

B r a k e c o m p o n e n t s c o r r e c t ?

B r a k e il n i n g t h i c w r o k n n g e s s c o r r e c t p o s i t i o n ?

o r i n r i g h t

E n o u g h b r a k e f l u i d o r c o r r e c t f l u i d ?

S o l u t i o n

R e p a i r o r r e p l a c e .

R e b u r n i s h o r r e p l a c e .

C o r r e c t w e i g h t .

M a c h i n e o r r e p l a c e .

I n f l a t e a ll t i r e s e q u a ll y .

M a t c h t i r e s .

R e p l a c e c o m p o n e n t s .

R e p l a c e .

L u b r i c a t e .

R e p l a c e a n d c o r r e c t .

I n s t a ll n e w s h o e s il n i n g s .

a n d

R e p l a c e f i ll w i t h r u b b e r d o t 4 f l p u i a r d .

t s

PAGE 20 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — GENERATOR DECALS

The DCA-40SSAI generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 21

DCA-40SSAI — GENERATOR DECALS

PAGE 22 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

M o d e l

T y p e

A r m a t u r e C o n n e c it o n

P h a s e

S t a n d b y O u t p u t

P ir m e O u t p u t

V o tl a g e

F r e q u e n c y

S p e e d

P o w e r F a c t o r

A u x .

A C P o w e r

V o tl a g e

O u t p u t

M o d e l

T y p e

N o .

o f C y il n d e r s

B o r e x S t r o k e

R a t e d O u t p u t

D i s p l a c e m e n t

S t a r it n g

C o o l a n t C a p a c ti y

L u b e O li C a p a c ti y

F u e l C o n s u m p it o n

B a tt e r y

F u e l

DCA-40SSAI — SPECIFICATIONS

T a b l e 7 .

S p e c i if c a it o n s

G e n e r a t o r S p e c i if c a it o n s

D C A 4 0 S S A I

R e v o l v i n g if e l d , s e fl v e n t li a t e d , o p e n p r o t e c t e d t y p e s y n c h r o n o u s g e n e r a t o r

S t a r w i t h N e u t r a l

3

4 6 .

8 K V A ( 3 7 .

4 K W )

4 0 K V A ( 3 2 K W )

2 4 0 V o r 4 8 0 V

6 0 H z

1 8 0 0 r p m

0 .

8

S i n g l e P h a s e , 6 0 H z

1 2 0 / 2 4 0 V

1 1 .

5 K W ( 1 3 .

4 K W )

E n g i n e S p e c i if c a it o n s

I S U Z U Q D 1 0 0 ( 4 B D 1 )

4 C y c l e , w a t e r c o o l e d , s w i lr c o m b u s it o n c h a m b e r t y p e

4 c y il n d e r s

4 i n .

x 4 .

6 i n .

( 1 0 2 m m x 1 1 8 m m )

5 2 H P / 1 8 0 0 r p m

2 3 5 c u .

i n .

( 3 8 5 6 c c )

E l e c t ir c

4 g a .l

( 1 5 l ti e r s )

2 .

3 g a .l

( 8 .

7 L ) / h r a t

f u ll l o

3 .

4 g a .l

( 1 2 .

9 l ti e r s )

a d

2 .

0 g a .l

( 7 .

6 L ) / h r a t

3 / 4 l o a d

1 .

5 g a .l

( 5 .

7 L ) / h r a t

1 / 2 l o a d

1 2 V 1 0 0 A H

# 2 D i e s e l

1 .

1 g a .l

( 4 .

2 L ) / h r a t

1 / 4 l o a d

F u x e l

2

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 23

DCA-40SSAI — GENERAL INFORMATION

DCA-40SSAI FAMILIARIZATION

Generator

gener ator that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following: z Tachometer z Water Temperature Gauge z Oil Pressure Gauge z Charging Ammeter Gauge z Fuel level gauge z Engine Speed Control z Pre-Heat Button z Panel Light z Panel Light Switch z Starter /Preheat Switch

Generator Control Panel

The “Generator Control Panel” is provided with the following: z Output Voltage Adjustment Knob z Frequency Meter (Hz) z AC Ammeter (Amps) z AC Voltmeter (Volts) z Ammeter Change-Over Switch z Voltmeter Change-Over Switch z Voltage Regulator

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

Open Delta Excitation System

The DCA-40SSAI generator is equipped with the state of system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four leads: A, B, C and D. During light loads, the

A utomatic V oltage Regulator from the leads parallel connections of B&C. When loads increase, the AVR switches and accepts power from leads

A&D. The output of leads A&D increase proportionally with load. This of adding the voltages to each phase provides better voltage response during heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The according the demands of the required load.

Engine

The DCA-40SSAI is powered by a 4 cycle, water cooled, every performance requirement for the generator. Reference

Table 7, page 23 for engine specifications.

In keeping with Multiquip's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

The basic controls and indicators for the DCA-40SSAI generator are addressed on the following pages.

z Two 120V, 20A receptacles z Two 240V, 20A receptacles z One twist-lock 120V, 50A receptacle z 50A and 30A circuit breakers

Mechanical Governor System

The mechanical governor system control the RPM of the engine. When the engine demands increase or decrease, the mechanical governor system regulates the frequency variation to ±1.5%. The electronic governor option increases frequency variation to ±.25%.

Control Box

The “Control Box” is provided with the following: z Main Circuit Breaker 100 amps z Over-Current Relay

PAGE 24 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

NOTE PAGE

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 25

DCA-40SSAI — MAJOR COMPONENTS

Figure 6. Major Components

PAGE 26 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — DIMENSIONS

Figure 7. Dimensions

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 27

DCA-40SSAI — CONTROL PANEL DESCRIPTION

Figure 8. Control Panel

PAGE 28 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — CONTROL PANEL DESCRIPTION

The definitions below describe the controls and functions of

1.

Main Circuit Breaker – This three-pole, 110 amp main breaker is provided to protect the UNV voltage output terminals from overload.

2.

AC Ammeter – Indicates the amount of current the load is drawing from the generator.

3.

Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz ±1 Hz .

4.

AC Voltmeter – Indicates the single phase output voltage present at the UNV terminals.

5.

Voltage Regulator Control – Allows manual adjustment of the generator’s output voltage.

6.

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.

7.

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.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 29

DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION

Figure 9. Engine Operating Panel

PAGE 30 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION

The definitions below describe the controls and functions of

1.

Fuel Gauge - Indicates amount of diesel fuel available.

2.

Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

3.

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.

4.

Water Temperature Gauge – During normal operation this gauge be should read between 165 o

to 215 o

.

5.

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.

6.

Starter Switch- Use key to preheat, start and stop engine.

7.

Pre-Heat Button – Press hold this button until the preheat lamp is lit (ON).

8.

Engine speed Handle- This handle will change the speed of the engine from high to low.

9.

Panel light switch- When activated, will turn on control panel light.

10. 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.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 31

DCA-40SSAI — 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 10. GFCI Test Button

Figure 11. Load Application

Circuit Breakers

To protect the generator from an overload, a 3-pole, 110 amp, terminals from overload. In addition two single-pole, 20 amp

Generator Grounding

Make sure the generator is properly grounded before applying load. Generators are NOT considered grounded when mounted on a trailer.

breakers have also been provided to protect the load side of breakers to the "OFF" position prior to starting the engine.

Maximum Output

The entire load connected to the UNV Lugs, all four slots in the duplex receptacles, and the must not exceed 37.4 kW in standby or 36 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. See page X for further details.

PAGE 32 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — OUTPUT TERMINAL VOLTAGE SELECTION

DCA-40SSAI

NOTE

Legs O and Ground are considered Bonded Grounds.

Figure 12. Output Panel Location

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 33

DCA-40SSAI — 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.

T h r e e P h a s e

( S w i t c h a b l e )

S i n g l e P h a s e

( S w i t c h a b l e )

T a b l e 8 .

V o l t a g e s A v a i l a b l e

2 0 8 V O L T 2 2 0 V O L T 2 4 0 V O L T 4 1 6 V O L T 4 4 0 V O L T 4 8 0 V O L T

1 2 0 V O L T 1 2 7 V O L T 1 3 9 V O L T 2 4 0 V O L T 2 5 4 V O L T 2 7 7 V O L T

CAUTION :

NEVER switch Voltage Selector Switch position while the engine is engaged.

Maximum Amps

Table 9 shows the maximum amps the generator will provide. Do not exceed the maximum amps listed.

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.

T a b l e 9 .

M a x i m u m A m p s

R a t e d

V o l t a g e

S i n g l e

1 2 0

P h a s e

V o l t

S i n g l e

2 4 0

P h a s e

V o l t

T h r e e

2 4 0

P h a s e

V o l t

T h r e e

4 8 0

P h a s e

V o l t

1

M

5

0

a

0

0

x

a

1

i

5

m

a m m

0

4 p

8

u

p s s a

m

a

( m m

(

4

A

4 p p s

m

w w s i r i

p s

r e e

)

)

PAGE 34 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — OUTPUT AMPERAGE SETUP

Receptacle Use

When the UVWO terminals are providing power, the receptacle power availability will decrease. Do not exceed receptacle power as listed on Table 10.

2 4 0 / 4 8 0 V

3 P h a s e

K V A

4 5

4 0 .

9

3 6 .

7

3 2 .

6

2 8 .

4

P

T a b l e 1 0 .

R e c e p t a c l e U s e o w e r i n U s e

R e c e p t a c l e

P o w e r

A v a i l a b l e

S i

2 4 0 / 1 2 0 V n g l e P h a s e o r

L o c k

T w i s t

C S 6 3 6 9

K W

2 6

2 4 .

8

2 3 .

6

2 2 .

4

2 1 .

2

D u p l e x

5 2

N E M A

0 R 1 2 0 V

K W

0

1 .

2

2 .

4

3 .

6

4 .

8

Figure 13. Voltage Selector Switch 240/120V Single

Phase Position

Figure 14 and 15. AC Voltmeter Change-over switch and Voltmeter Gauge

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.

0

20

40

60

75

A

Figure 16 and 17. AC Ammeter Change-over Switch and Ammeter Gauge

NOTE

When using plural single phase voltages, make sure to balance the load on each of the single phase legs.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 35

DCA-40SSAI — OUTPUT VOLTAGE SETUP

240/12

0V 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).

480/240V Hard Wire Hookup

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 18. Hard Wire Hookup at 240/120V Position

Figure 19. Voltage Selector Switch 480/277V Three Phase

Position

Figure 20. Hard Wire Hookup at 480/240V Position

PAGE 36 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 37

DCA-40SSAI — 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.

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 25. Voltage Selector Switch 240/139V Three Phase

Position

Figure 27. Hard Wire Hookup for Single Phase 240V, 220V, or 208V

3 Phase, 240V, 220V, or 208 Volt

This setting can provide 3-phase power at 240, 220, or 208 volts. After hooking up the hard wires to the lugs as shown in Figure 26, 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.

Single Phase: 139V, 127V, or 120V

This setting can provide single phase power at 139, 127, or

120 volts. After hooking up the hard wires to the lugs as shown in Figure 28, 139 volts can be obtained with the voltage regulator knob turned toward maximum; 127 volts can be obtained with the voltage regulator knob is turned down; and 120 volts can be obtained with the voltage regulator knob is 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — 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 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 31. Hard Wire Hookup for Single Phase, 120 volt

Figure 30. Hard Wire Hookup for Single Phase 240 volt

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 39

DCA-40SSAI — 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 that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

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.

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 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.

Mounting

The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

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 250-64(b) 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 mm

2

) or larger.

b. Aluminum - 8 AWG (8.4 mm 2 ) or larger.

2. When grounding the generator (Figure 31) 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — INSTALLATION

Figure 31. Typical Generator Grounding Application

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 41

DCA-40SSAI — PRE-SETUP

General Inspection Prior to Operation

The DCA-40SSAI 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

When electric power is to be provided to various tools or loads at some distance from the generator, extension 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 11 ) as a guide for selecting proper cable size.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 100 amp, terminals from overload. In addition two single-pole, 20 amp have also been provided to protect the load side of the breakers to the "OFF" position prior to starting the engine.

NOTE

ALWAYS consult with a licensed electrician for correct extension cord wire size.

T a b l e 1 1 .

C a b l e S e l e c t i o n ( 6 0 H z , S i n g l e P h a s e O p e r a t i o n )

M a x i m u m A ll o w a b l e C a b l e L e n g t h L o a d I n W a t t s

C u r r e n t i n

A m p e r e s

A t 1 2 0

V o l t s

A t 2 4 0

V o l t s

2 .

5 3 0 0 6 0 0

# 1 0 W i r e

1 0 0 0 f .t

# 1 2 W i r e

6 0 0 f .t

# 1 4 W i r e

3 7 5 f .t

# 1 6 W i r e

2 5 0 f .t

5

7 .

5

6 0 0

9 0 0

1 2 0 0

1 8 0 0

5 0 0 f .t

3 5 0 f .t

3 0 0 f .t

2 0 0 f .t

2 0 0 f .t

1 2 5 f .t

1 2 5 f .t

1 0 0 f .t

1

1

0

5

1

1

2

8

0

0

0

0

2

3

4

6

0

0

0

0

2

1

5

5

0

0 f f

.t

.t

2 0 2 4 0 0 4 8 0 0 1 2 5 f .t

C A U T I O N : E q u i p m e n t d a m a g e c a n r e s u tl f r o m l o w v o tl a g e .

1 5 0 f .t

1 0 0 f .t

7 5 f .t

1 0 0 f .t

6 5 f .t

5 0 f .t

PAGE 42 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — 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 32) on the dipstick. See

Table 12 for proper selection of engine oil.

Fuel

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 fillin g.

Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

Figure 32. Engine Oil Dipstick

CAUTION :

Never fill the fuel tank while the engine is running or in the dark. Gasoline spillage on a hot engine can cause a fire or explosion. If gasoline spillage occurs, wipe up the spilled gasoline completely to prevent fire hazards.

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. See maintenance section on page 52 and

53 on instructions to flush out radiator.

When checking the engine oil, be sure to check if the oil is clean and viscous. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Isuzu Engine Owner's Manual.

An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system.

T a b l e 1 2 .

R e c o m m e n d e d M o t o r O li

T y p e O li T e m p e r a t u r e R a n g e

1 0 4 °

( 4 0 °

F

C

~

~

2 3 ° F

5 ° C )

( -

2 3 °

5 ° C

F

~

~ 5 ° F

1 5 ° C )

B e l o w 5 ° C ( 1 5 ° )

S A E 3 0

S A E 2 0 o r S A E 1 0 W 3 0

S A E 1 0 W o r S A E 1 0 W 3 0

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 43

DCA-40SSAI — 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

13. 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.

T a b l e 1 3 .

C o o l a n t C a p a c ti y

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.

E n g i n e a n d R a d i a t o r 4 G a .l

( 1 5 L )

R e s e r v e T a n k 0 .

2 6 G a .l

( 1 L )

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 33) 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 14) has been added.

T a b l e 1 4 .

A n t -i F r e e z e O p e r a it n g T e m p e r a t u r e s

F r e e z i n g P o i n t B o i il n g P o i n t

A n t

V

-i o

F l r

% e e z e

° C ° F ° C ° F

4 0

5 0 -

2

3

4

7 -

1

3

2

4

1

1

0

0

6

8

2 2 2

2 2 6

NOTE

w ater , the antifreez e mixing r atio m ust

Figure 33. 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — 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.

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.

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 34) are properly

CAUTION :

cable is connected to the positive terminal of the battery, and the BLACK cable is connected to the negative terminal of the battery.

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

Figure 34. Battery Connections

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.

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.

If any hose (fuel or oil) lines are defective replace them immediately.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 45

DCA-40SSAI — LOAD APPLICATION

Single Phase Load

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.

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.

CAUTION:

Motors and motor-driven equipment draw much greater current for starting than during operation.

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.

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.

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 15.

below when connecting loads.

T a b l e 1 5 .

P o w e r F a c t o r B y L o a d

T y p e O f L o a d

S i n g l e p h a s e i n d u c t i o n m o t o r s l

E l a e c m p t r i c s h e a t e r s , i n c a n d e s c e n t

F l u o r e s c e n t l a m p s , m e r c u r y l a m p s

E l e e c t r q u i p o n i c m e n t d e v i c e s , c o m m u n i c a t i o n

C o m m o n p o w e r t o o l s

P o w e r F a c t o r

0 .

4 0 .

7 5

1 .

0

0 .

4 0 .

9

1 .

0

0 .

8 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 multiplying 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — GENERATOR START-UP PROCEDURE

WARNING:

The engine's exhaust contains harmful

A L W A Y S exhaust when operating inside tunnels, excavations or buildings. Direct exhaust away from nearby personnel.

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 12 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.

Before Starting

Generator and Control Panel

CAUTION:

2. Connect the load to the UNV terminals as shown in

Figure 36. These terminals can be found on the output terminal panel, (see page 33 Figure 12). To gain access to the output terminals lift the UNV cover. Tighten terminal nuts securely to prevent load wires from slipping out.

Figure 36. UNV Terminal Lugs (Load)

3. Connect the negative battery cable (BLACK) to the negative post on the battery (Figure 37).

NEVER start the engine with the in the ON position.

1.

Be sure to disconnect the

G.F

.C

.I.

circuit breakers (Figure 35) to the “OFF” position prior to starting the engine.

NEGA

TIVE

POSTIVE

BATTER

Y

Figure 37. Battery Connections

Figure 35. Main, GFCI and

Load Circuit Breakers

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 47

DCA-40SSAI — GENERATOR START-UP PROCEDURE

4. Close all engine enclosure doors (Figure 38).

8. Once the engine is warm and the engine is running properly, pull and turn the engine throttle control lever to ‘High’ (Figure 42).

Figure 38. Engine Enclosure Doors

5. Check the voltage selection switch (Figure 39) is at the desired voltage.

Figure 42. Engine Speed Switch (high)

9. The generator's frequency meter (Figure 43) displays the 60 cycle output frequency in HERTZ.

Figure 39. Voltage Selection Switch

6. Turn and push the engine throttle control lever

(Figure 40) to ‘Low’.

Figure 43. Frequency Meter (Hz)

10. The generator's voltage meter (Figure 44) displays the

120 VAC in VOLTS. If the voltage is not within the specified frequency tolerance, use the voltage adjustment control knob (Figure 45) to increase or decrease the desired voltage.

Figure 40. Engine Throttle Control Lever (low)

7. Preheat the engine by turning the ignition key to the left. Once the preheat lamp luminates, turn the key to the farthest right to start the engine. Once the engine start to crank, release the key to

‘operation’ (Figure 41).

Figure 44. Voltage Meter (Volts)

Figure 41. Starter Switch

Figure 45. Voltage Adjust Control Knob

PAGE 48 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — GENERATOR START-UP PROCEDURE

11. The ammeter (Figure 46) 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.

14. The tachometer (Figure 49) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800

RPM’s.

0

20

40

60

75

A

Figure 46. Ammeter (No Load)

12. The engine oil pressure gauge (Figure 47) will indicate the oil pressure (kg/ cm

2

) of the engine. Under normal operating conditions the oil pressure is approximately

25 psi.

Figure 49. Engine Tachometer

15. Turn the MAIN, GFCI and LOAD circuit breakers to their ON position (Figure 50).

Figure 47. Oil Pressure Gauge

13. The coolant temperature gauge (Figure 48) will indicate the coolant temperature. Under normal operating conditions the coolant temperature is between 165 and

215 degrees Fahrenheit.

WATER TEMP

Figure 48. Coolant Temperature Gauge

Figure 50. Main and GFCI Circuit Breakers

16. Observe the generator's ammeter (Figure 51) 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.

40

20

60

0

75

A

Figure 51. Ammeter (Load)

17. The generator will run until manually stopped or an abnormal condition occurs.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 49

DCA-40SSAI — GENERATOR SHUTDOWN PROCEDURE

ENGINE SHUTDOWN

To shutdown the generator, use the following procedure:

1. Switch both the MAIN, GFCI and LOAD circuit breakers

(Figure 52) to the “OFF” position.

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 starter switch key to ‘Stop’ position.

Figure 52. Main, GFCI and Load

circuit breakers

2. Turn and push the engine throttle control lever (Figure

53) to the idle (low) position.

Figure 53. Engine Throttle Control Lever

3. Let the engine cool by running it for 3-5 minutes with no load applied.

4. Turn the starter switch key to ‘Stop” position (Figure

54).

Figure 54. Off/Manual Auto Switch

5. Remove the load from the UNV terminal strip.

PAGE 50 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

NOTE PAGE

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 51

DCA-40SSAI — MAINTENANCE

General Inspection

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.

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.

Cleaning the Fuel Strainer

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.

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

Detach the oil filter cartridge with a filter wrench.

Apply a film of oil to the gasket for the cartridge.

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.

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

Replace the fuel filter cartridge with new one every 400 hours or so.

Apply fuel oil thinly over the gasket and hand-tighten the cartridge into position.

Vent any air.

Fuel Injection Nozzle

z Use an injection nozzle tester to check the static injection starting pressure and the fuel spray conditions.

z Abnormal fuel consumption will lead to a lowered output and blackish exhaust smoke. The required injection starting pressure should be 14.7MPa (150kg/cm

2

,

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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

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

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.

Check hoses for softening and kinks. Check clamps for signs of leakage.

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.

Tighten both cocks and replace the overflow tank.

Replace with coolant (see page 44, Table 14 for mixture).

Close radiator cap tightly.

CAUTION :

Allow engine to cool when flushing out radiator. Flushing the radiator while hot will damage radiator.

DCA-40SSAI — MAINTENANCE

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 53

DCA-40SSAI — 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.

2. Do the adjustment on the circle marked valves in the below table where No. 1 cylinder is at the center in the compression stroke.

3. After adjustment started from either piston top center, turn the crankshaft 360 o to align the notched line with the TDC mark to do the adjustment again on the remaining valve. See Table 16 and Figure 55 for valve arrangement.

Injection Timing Check and Adjustment

1. Bring No. cylinder to the top dead center on the compression stroke.

2. Turn the crankshaft pulley clockwise (viewed at engine front) and align the notched line on the crank pulley with the 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.

5. Reversely turn the crankshaft pulley counterclockwise viewed at the engine front about 30 o crank angle.

6. Remove No. 1 injection pipe from the engine.

7. Remove the injection pump No. 1 delivery valve holder, delivery valve and spring and reinstall the delivery valve holder on the original place.

8. Delivery valve holder tightening torque:

39~44Nm(29~33lbft.)

9. Slowly turn the crankshaft pulley clockwise and at the 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.

10. Observe and make sure which mark (injection starting 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 14 o timing mark.

C y l i n d e r N o .

T a b l e 1 6 .

V a l v e A d u s t m e

( I = I n l e t ; E = E x h a u s t ) n t

1 2 3 4

Figure 55. Valve Adjustment

Take necessary precautions to prevent dust and foreign particles in the pump interior when timing adjustments are made.

NOTE:

V a l v e A r r a n g e m e n t I E I E I E I E

W h e n d e a d

N o .

1 c e n t e r i s i a t n t o p t h e c o m p r e s s i o n s t o k e

W h e n N o .

4 i s a t t o p d e a d c e n t e r c o m p r e s s i o n i n t h e s t r o k e

X X X

O O

X

O O

PAGE 54 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — MAINTENANCE

I N S P E C T I O N / M A I N T E N A N C E

E N G I N E

G E N E R A T O R

C h e c k E n g i n e F l u i d L e v e l s

C h e c k A ri C l e a n e r

C h e c k B a tt e r y A c i d L e v e l

C h e c k F a n B e tl C o n d i it o n

C h e c k f o r L e a k s

C h e c k f o r L o o s e n i n g o f P a r t s

R e p l a c e E n g i n e O li a n d F i tl e r *

1

C l e a n A ri F i tl e r

D r a i n B o tt o m o f F u e l T a n k

C l e a n U n i ,t I n s i d e a n d O u t s i d e

C h a n g e F u e l F i tl e r *

2

C l e a n

L e v e l

R a d i a t o r a n d C h e c k C o o l a n t P r o t e c it o n

T e s t F u e l I n j e c it o n N o z z l e

R e p l a c e A ri F i tl e r E l e m e n t

C h e c k a ll H o s e s a n d C l a m p s

C h e c k V a l v e C l e a r a n c e

C h e c k I n j e c it o n N o z z l e

C l e a n I n s i d e o f F u e l T a n k

M e a s u r e I n s u l a it o n R e s i s t a n c e O v e r 3 M o h m s

1 0 H r s

D A I L Y

X

X

X

X

X

X

2 5 0 H r s 5 0 0 H r s 1 0 0 0 H r s

X

X

X

X

X

X

X

X

X

X

X

X

X

X

* 1 R e p l a c e e n g i n e o li a n f if tl e r a t 1 0 0 h o u r s , f ri s t it m e o n l y .

*

2

R e p l a c e f u e l if tl e r a t 2 5 0 H o u r s , f ri s t it m e o n l y .

Generator Storage

For storage of the generator for over 30 days, the following is required: z Fill the fuel tank completely.

z Completely drain the oil from the crankcase and refill with fresh oil.

z Clean all external parts of the generator with a cloth.

z Cover the generating set and store in a clean, dry place.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 55

DCA-40SSAI — ENGINE WIRING DIAGRAM

PAGE 56 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — GENERATOR WIRING DIAGRAM

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 57

DCA-40SSAI — 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 1 7).

If the problem cannot be remedied, consult our company's business office or service plant.

S Y M P T O M

E n g i n e d o e s n o t s t a r .t

T A B L E 1 7 .

E N G I N E T R O U B L E S H O O T I N G ( P A R T 1 )

P O S S I B L E P R O B L E M

N o f u e l ?

A ri i n t h e f u e l s y s t e m ?

W a t e r i n t h e f u e l s y s t e m ?

S O L U T I O N

R e p l e n i s h f u e .l

B l e e d s y s t e m .

R e m o v e w a t e r f r o m f u e l t a n k .

F u e l p i p e c l o g g e d ?

F u e l if tl e r c l o g g e d ?

t

E o e f x c e f u m p s e l e s i r o a v e l y t r u r e n e ?

h i g h g i n e o v i li s c a t o s l ti y o w

F u n e l w u m b e r ti h

?

l o w c e t a n e

C

U

U l s s e e e a t n

C l e a n f t h e h e u o r e l p i p s p e c i s p e c i e .

c h a n g e if e d if e d f u e l f u e l f u e

I

I i

F u e l n j e c it l e o a k n p i d p u e e r t o e t a l i o o s e n i n g n u t ?

T i g h t e n n u .t

n

F u n j c o e l e c r r it c e c t a m o n i n j e c s h a n o tf it z z l e o n w o r it c l o g m n ?

i n g ?

g e d ?

A d j u s .t

R e p l a c e .

C l e a n i n j e c it o n n o z z l e .

.l

if o tl e r

.r

e n g i n e o i .l

I n j e c m a fl u it o n c n it p u m p o n i n g ?

S il c n e i a z u r e m e r s h o r a f b o f

,t e a c p i s r a n t o k n , s h ir n g ?

c a f y il

,t n d e r

C c y o il m n p r d e e s r ?

I m p r o p e r s i o n v a l v e l e a k it m f r o m i n g ?

R

R e e p p a a ri ri o o r r r r e e p p l l a a c c e e .

.

R p l e p l a u g a c e n d h e n o a d z z l g e a s k e h o l d

,t e .r

it g h t e n c y il n d e r h e a d b o l ,t g l o w

C o r r e c t o r r e p l a c e it m i n g g e a .r

P i s t o n ir n g a n d il n e r w o r n ?

E x c e s s i v e v a l v e c l e a r a n c e ?

R e p l a c e .

A d j u s .t

PAGE 58 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — TROUBLESHOOTING (ENGINE)

S Y M P T O M

T A B L E 1 7 .

E N G I N E T R O U B L E S H O O T I N G ( P A R T 2 )

S O L U T I O N

F u e l

A ri c

P O S S I B L E P R O B L E M

if l e tl e r a n e r c l o c l g g e d o g g e o r d ?

d ri t y ?

C l e a n o r c h a n g e .

C l e a n o r c h a n g e .

i

F u e l n j e c it l e o a k n p i d p u e e r t o e t a l i o o s e n i n g n u t ?

T i g h t e n n u .t

E n s m g i n e o o t h .

r e v o l u it o n i s n o t

I n j e c m a fl u it o n c n it p u m p o n i n g ?

I p n c o r r e s s r e u r c t e ?

n o z z l e o p e n i n g

I c n j l o e c g g it e o n d ?

n o z z l e s t u c k o r

F u e l c l o g o v e r g e d ?

lf o w p i p e

G o v e r n o r m a fl u n c it o n i n g ?

E x c e s s i v e e n g i n e o li ?

E g a ti h e r s i s w h o b s ti e e r o r v e b d .

l u e e x h a u s t

P i s t o r s o n t u c k ir n

?

g a n d il n e r w o r n

I n c o r r e c t i n j e c it o n it m i n g ?

D e if c i e n t c o m p r e s s i o n ?

O v e lr o a d ?

L o w g r a d e f u e l u s e d ?

E e x ti h e r h a u s b t l a g c k a s o r i s d a o r k b s e r g r a y v e d .

F u e l if tl e r c l o g g e d ?

A ri c l e a n e r c l o g g e d ?

D e if c i e n t n o z z l e i n j e c it o n ?

D e if c i e n t o u t p u .t

I n c o r r e c t i n j e c it o n it m i n g ?

E n g i s e e m n e ' s t o m o b e v i s e n g i z i n p a g r

?

t s

U n e v e n f u e l i n j e c it o n ?

D e if c i e n t n o z z l e i n j e c it o n ?

C o m p r e s s i o n l e a k ?

R e p a ri o r r e p l a c e .

A d j u s .t

R e p a ri o r r e p l a c e .

C l e a n .

R e p a i .r

R e d u c e t o t h e s p e c i if e d l e v e .l

R e p a ri o r r e p l a c e .

A d j u s .t

A d j u s t t o p c l e a r a n c e .

L e s s e n t h e l o a d .

U s e t h e s p e c i if e d f u e .l

C l e a n o r c h a n g e .

C l e a n o r c h a n g e .

R e p a ri o r r e p l a c e t h e n o z z l e .

A d j u s .t

R e p a ri o r r e p l a c e .

R e p a ri o r r e p l a c e t h e i n j e c it o n p u m p .

R e p a ri o r r e p l a c e t h e n o z z l e .

R p l e p l a u g a c e n d h e n o a d z z l g e a s k e h o l d

,t e .r

it g h t e n c y il n d e r h e a d b o l ,t g l o w

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 59

S Y M P T O M

N o V o tl a g e O u t p u t

L o w V o tl a g e O u t p u t

H i g h V o tl a g e O u t p u t

C ri c u ti B r e a k e r T ir p p e d

DCA-40SSAI — TROUBLESHOOTING (GENERATOR/ENGINE)

T A B L E 1 7 .

G E N E R A T O R T R O U B L E S H O O T I N G

P O S S I B L E P R O B L E M

A C V o tl m e t e r d e f e c it v e ?

I s w i ir n g c o n n e c it o n l o o s e ?

I s A V R d e f e c it v e ?

D e f e c it v e R o t a it n g R e c it if e r ?

I s e n g i n e s p e e d c o r r e c t ?

I s w i ir n g c o n n e c it o n s l o o s e ?

D e f e c it v e A V R ?

I s w i ir n g c o n n e c it o n s l o o s e ?

D e f e c it v e A V R ?

S h o r t C ri c u ti i n l o a d ?

O v e r c u r r e n t ?

D e f e c it v e c ri c u ti b r e a k e r ?

O v e r c u r r e n t R e l a y a c t u a t e d ?

S O L U T I O N

C h e c k o u t p u t v o tl a g e u s i n g a v o tl m e t e .r

C h e c k w i ir n g a n d r e p a i .r

R e p l a c e fi n e c e s s a r y .

C h e c k a n d r e p l a c e .

T u r n e n g i n e t h r o t lt e l e v e r t o " H i g h " .

C h e c k w i ir n g a n d r e p a i .r

R e p l a c e fi n e c e s s a r y .

C h e c k w i ir n g a n d r e p a i .r

R e p l a c e fi n e c e s s a r y .

C h e c k l o a d a n d r e p a i .r

C o n f ri m l o a d r e q u ri e m e n t s a n d r e d u c e .

C h e c k a n d r e p l a c e .

C o n f ri m l o a d r e q u ri e m e n t a n d r e p l a c e .

PAGE 60 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

NOTE PAGE

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — SUGGESTED SPARE PARTS

DCA-40SSAI W/ISUZU 4BD1 DIESEL ENGINE

1

T O 3 UNITS

Qty.

P/N Description

1 ......... 0601808811 .............. CIRCUIT BREAKER

1 ......... 0601820671 .............. AUTOMATIC VOLTAGE REGULATOR

1 ......... 0601840073 .............. RHEOSTAT VOLTAGE REGULATOR

1 ......... 0601840121 .............. KNOB RHEOSTAT

1 ......... M1310500403 ........... RADIATOR HOSE

1 ......... M1310500303 ........... RADIATOR HOSE

1 ......... 8941324900 .............. RADIATOR HOSE

5 ......... 8943212191 .............. OIL FILTER

5 ......... X132400240 ............. FUEL FILTER

5 ......... 0602046368 .............. AIR ELEMENT

1 ......... 0602122272 .............. UNIT, OIL PRESSURE

1 ......... 0602123260 .............. UNIT WATER TEMPERATURE

1 ......... 0601810245 .............. BULB, ALARM LAMP

1 ......... 8970208220 .............. 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-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 63

GENERATOR ASSY.

DCA-40SSAI --- GENERATOR ASSY.

PAGE 64 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

NO.

PART NO.

ITEM QTY.

REMARKS

2-5

2-6

2-7

2-8

2-1

2-2

2-3

2-4

1-4

1-5

1-6

2

1

1-1

1-2

1-3

3341040300 FIELD ASSY.

3341010102 SHAFT

9521002693 FIELD CORE

3341080003 FIELD COIL

3361032003 ARMATURE CORE, EXCITER

33610850003 ARMATURE COIL, EXCITER

334110003 COUPLING HUB

3361025003 RECTIFIER ASSY.

1

1

1

1

1

1

1

1

3361026003 SET PLATE, RECTIFIER 1

0601820067 RECTIFIER .......................................... 3 ............PB2510

0010004020 HEX. HEAD BOLT

0041604000 PLAIN WASHER

3

6

0040004000 LOCK WASHER

OEMAA8

3

HEX. NUT ............................................. 3 ............REPLACES 0030004000

0601822601 SURGE ABSORBER ........................... 1 ............ERZM14K621A

0801841004 INSULATOR WASHER 1

9

10

11

12

5

6

7

8

2-9 0801841104 INSULATOR WASHER 1

2-10 0017105020 HEX. HEAD BOLT ................................ 1 ............REPLACES 0010005020

2-11 58151 PLAIN WASHER .................................. 2 ............REPLACES 0041605000

2-12 0032005000 LOCK WASHER ................................... 1 ............REPLACES 0040005000

3

4

2-13 0030005000 HEX. NUT 1

2-14 0011305100 HEX. HEAD BOLT ................................ 4 ............REPLACES 0017105012

3331014004 BEARING FLANGE

0070206310 BEARING

1

1

0080000050

3341070002

3341611003

3341612003

3341613004

0131151240

0601600000

030212300

SNAP RING

FAN

COUPLING DISK

WASHER, COUPLING HUB

LOCK WASHER

1

1

1(8)

1

5

HEX. HEAD BOLT ................................ 10 .......... REPLACES 0010312030

COUPLING RING ................................ 1 ............9261290050

LOCK WASHER ................................... 9 ............REPLACES 0601610700 & 9091505100

13

14

15

16

0601610511 BOLT SET

0040010000 LOCK WASHER

1

9

012010030 HEX. HEAD BOLT ................................ 9 ............REPLACES 0010310030

3341341400 STATOR ASSY.

1

16-1 3341320312 GENERATOR FRAME

16-2 3801342114 ARMATURE CORE

16-3 3341361503 ARMATURE COIL

17 0801350104 GROMMET

1

1

1

1

18

19

3361315013

3361350030

END BRACKET

FIELD ASSY. EXCITER

19-1 3361352023 FIELD CORE, EXCITER

19-2 3361362303 FIELD COIL, EXCITER

1

1

1

1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 65

GENERATOR ASSY.

DCA-40SSAI --- GENERATOR ASSY.

PAGE 66 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

NO.

PART NO.

20 031108160

30

31

32

33

34

35

36

37

38

39

25

26

27

28

29

21

22

23

24

ITEM QTY.

REMARKS

PLAIN WASHER .................................. 4 ............REPLACES 0041608000

0040008000 LOCK WASHER

0010008060 HEX. HEAD BOLT

4

4

0040010000 LOCK WASHER

012010030

6

HEX. HEAD BOLT ................................ 6 ............REPLACES 0010010030

3801312004 GASKET, BEARING

3331310104 COVER, BEARING

0040006000 LOCK WASHER

0040006055 HEX. HEAD BOLT

3361331003 COVER, END BRACKET

1

1

4

4

1

011006010 HEX. HEAD BOLT ................................ 8 ............REPLACES 0017106010

0040010000 LOCK WASHER 6

0105091025 HEX. HEAD BOLT ................................ 6 ............REPLACES 0010310025

3361332003 COVER, FAN 1

952404470 PLAIN WASHER .................................. 1 ............REPLACES 0041606000

0040006000 LOCK WASHER

0010006030 HEX. HEAD BOLT

1

1

0605000011 RUBBER SUSPENSION

0040016000 LOCK WASHER

020316130

2

4

HEX. NUT ............................................. 4 ............REPLACES 0030116000

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 67

CONTROL BOX ASSY.

DCA-40SSAI --- CONTROL BOX ASSY.

PAGE 68 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO.

PART NO.

38

39

40

41

42

33

34

35

36

29

30

31

32

37

1

7

8

5

6

2

3

4

7451810002

7451810012

3361870603

0017106016

0601801142

15

16

17

18

9

10

11

14

0027104010

0800225200

0027106010

0601820042

0027103010

0601842058

0027108010

0601804970

19

20

21

22

0041604000

0040004000

0021004060

0601830625

0021104016

0021104014

3341822503

0601800460

23

24

0601800729

0601801040

25 0601800212

0601800217

26

27

28

0601801041

0601810072

0601810261

0601840031

0601840120

3331824003

0027105016

0030005000

0805001304

031108160

020108060

0027105010

7451826504

7451826514

0017106016

011008020

020108060

0601840191

0601830614

ITEM QTY.

REMARKS

CONTROL BOX ............................................. 1 ....... UP TO S/N3311949

CONTROL BOX ............................................. 1 ....... S/N3311950

CURRENT TRANSFORMER 3

HEX.HEAD BOLT 6

CURRENT TRANSFORMER, AMMETER ..... 2 ....... CT3.5MR 75/5A

MACHINE SCREW 4

AUTOMATIC VOLTAGE REGULATOR ........ 1 ....... AE2206A

MACHINE SCREW

RECTIFER

6

1

MACHINE SCREW 4

RESISTOR .................................................... 1 ....... 80V 200OHMS

MACHINE SCREW 2

CIRCUIT BREAKER ...................................... 1 ....... TO100CC 500V 100AT

PLAIN WASHER

LOCK WASHER

MACHINE SCREW

CHANGE-OVER SW. VOLTAGE

2

1

2

2

MACHINE SCREW

MACHINE SCREW

4

2

CONTROL PANEL 1

FREQUENCY METER ................................... 1 ....... PAK60 220V 45~65Hz

AC AMMETER .............................................. 1 ....... PSK60 0~75A 0~150A

CHANGE-OVER SW. AMMETER ................. 1 ....... SL2AS

AC VOLTMETER .......................................... 1 ....... PCK60 0~600V; REPLACES

CHANGE-OVER SW. VOLTMETER ............. 1 ....... SL2VS

PILOT LAMP 1

BULB 1

VOLTAGE REGULATOR .............................. 1 ....... RA30A2FE202BJ

KNOB

STOPPER, CONTROL PANEL

MACHINE SCREW

HEX. NUT

1

1

2

2

SET SCREW, CONTROL PANEL 2

PLAIN WASHER ........................................... 2 ....... REPLACES 0041608000

HEX. NUT ...................................................... 2 ....... REPLACES 0030008000

MACHINE SCREW 4

SIDE PANEL, CONTROL BOX ..................... 1 ....... UP TO S/N3311949

SIDE PANEL, CONTROL BOX ..................... 1 ....... S/N3311950~

HEX. HEAD BOLT 2

HEX. HEAD BOLT ......................................... 4 ....... REPLACES 0017108020

HEX. NUT ...................................................... 4 ....... REPLACES 0030008000

SWITCH CAP 1

PLATE 1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 69

ENGINE AND RADIATOR ASSY.

DCA-40SSAI ENGINE AND RADIATOR ASSY.

PAGE 70 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI ENGINE AND RADIATOR ASSY.

27

28

29

30

23

24

25

26

31

32

33

19

20

21

22

15

16

17

18

ENGINE AND RADIATOR ASSY.

NO.

PART NO.

ITEM

12

13

14

8

9

10

11

6

7

4

5

1

2

3

4B01PD02

0602010800

0602011303

011008020

QTY.

REMARKS

ENGINE .......................................... 1 .......... ISUZU 4BD1; REPLACES 0602000078

RADIATOR ...................................... 1 .......... B961110002

RADIATOR NECK ........................... 1 .......... 4079111300

0602011102 HOSE .............................................. 1 .......... B9611111910

0602014062 HOSE BAND ................................... 2 .......... G000100131

0602011000 RADIATOR CA ................................ 1 .......... 7880K11100

3345123104 BRACKET, RADIATOR

0602014000 HOSE BAND

0602014000 HOSE BAND

0602014071 HOSE BAND

2

HEX. HEAD BOLT ........................... 12 ........ REPLACES 0017108020

0602013086 RADIATOR HOSE ........................... 1 .......... 4B128

0602013186 RADIATOR HOSE ........................... 1 .......... 4B129

2

1

1

0602040094 AIR CLEANER ................................ 1 .......... FQG068002

0602040197 ELEMENT, AIR CLEANER .............. 1 .......... P104873

0602040690 DUST INDICATOR ........................... 1 .......... RBX002252

0602040595 BAND, AIR CLEANER .................... 2 .......... P007191

011008020

020108060

HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

HEX. NUT ....................................... 4 .......... REPLACES 0030008000

3342032103 HOSE, AIR CLEANER

0605515011 HOSE BAND

1

1

0605515028 HOSE BAND 1

1878102201 ELEMENT, OIL FILTER .................. 1 .......... REPLACES 0602041107

5878100500 ELEMENT, FUEL FILTER ............... 1 .......... REPLACES 0602042108

3345112503 ENGINE FOOT 1

3345112403 ENGINE FOOT

031110160

1

PLAIN WASHER ............................. 8 .......... REPLACES 0041610000

0040010000 LOCK WASHER 8

0105091025 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010710025

0605000009 RUBBER SUSPENSION

0040012000 LOCK WASHER

2

4

0039312000 HEX. NUT ....................................... 4 .......... REPLACES 0030112000

1819001931 ENGINE STOPPER ........................ 1 .......... REPLACES 0602210803 AND 1819000161

0027106016 MACHINE SCREW 3

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 71

ENGINE AND RADIATOR ASSY.

DCA-40SSAI ENGINE AND RADIATOR ASSY.

PAGE 72 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO.

PART NO.

ITEM

56

57

58

59

60

61

53

53

54

55

49

50

51

52

45

46

47

48

41

42

43

44

37

38

39

40

34

35

36

QTY.

REMARKS

3342054104 DRAIN JOINT

0805013704 PACKING, OIL PAN SIDE

0805014204 PACKING

3362054104 JOINT BOLT

3342051104 DRAIN JOINT

0802024004 PACKING

0802010204 PLUG

1

1

1

1

1

1

1

3342022104 DRAIN HOSE

0605515003 HOSE BAND

011008020

020108060

1

2

HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

HEX. NUT ....................................... 2 .......... REPLACES 0030008000

0845031303 RESERVE TANK

0802081104 CAP, RESERVE TANK

1

1

3342082304 BRACKET, RESERVE TANK

011008020

1

HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

011606025 HEX. HEAD BOLT ........................... 1 .......... REPLACES 0017106025

0199500950 HOSE 1

0199500175 HOSE

0193601000 HOSE

1

1

0605515013 HOSE

0605515013 HOSE BAND

0193900750 BREATHER HOSE

0605515030 HOSE BAND

1

4

1

2

0193100700 HOSE

0605515007 HOSE BAND

0193800750 HOSE

0605515019 HOSE BAND

3342220604 EARTH CABLE

0017106016 HEX. HEAD BOLT

1

1

1

1

1

4

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 73

ENGINE OPERATING PANEL ASSY.

DCA-40SSAI --- ENGINE OPERATING PANEL ASSY.

PAGE 74 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- ENGINE OPERATING PANEL ASSY.

29

30

31

32

25

26

27

28

19

20

21

22

23

24

37

38

39

40

33

34

35

36

41

ENGINE OPERATING PANEL ASSY.

NO.

PART NO.

ITEM

10

11

12

13

8

9

6

7

1

4

5

2

3

14

15

16

17

18

3342101003 OPERATING PANEL

0080200006 SNAP RING

7452140504 BRACKET, GOVERNOR ROD

QTY.

1

REMARKS

7452142004 SLIDE BAR 1

0601840190 KNOB .............................................. 1 .......... REPLACES 0805012904

1

1

020108060 HEX. NUT ....................................... 2 .......... REPLACES 0030008000

0605010503 SNAP PIN 1

1823100080 STARTER SWITCH ........................ 1 ........... REPLACES 0602100004

9825300460 PREHEAT LAMP ............................ 1 ........... REPLACES 0602102006 AND 9825301080

0602120052 TACHOMETER ............................... 1 ........... 25000KX3710; REPLACES 0602120052

0602120154 CABLE, TACHOMETER ................. 1 ........... 62100KA6710 L=1150

0602122060 OIL PRESSURE GAUGE ............... 1 ........... 42000KX1410

0602122200 UNIT, OIL PRESSURE ................... 1 ........... 53000AC0101

0131300000 STREET SOCKET 1

0602123061 WATER TEMPERATURE GAUGE . 1 ........... 40000KX0910

0602123201 UNIT, WATER TEMPERATURE ..... 1 ........... 51400KV0200

0602121052 CHARGINE AMMETER .................. 1 ........... 43000KV0300

0602103091 ALARM LAMP ................................. 2 ........... REPLACES 0602103060

0601810244 BULB 2

0601830420 SWITCH, LAMP CHECK

0601810120 PANEL LIGHT

1

1

0040520000 TOOTHED LOCK WASHER

0601830710 SWITCH, PANEL LIGHT

1

1

031108160 PLAIN WASHER ............................. 2 .......... REPLACES 0041608000

0040008000 LOCK WASHER 2

011008040

011008020

HEX. HEAD BOLT .......................... 2 .......... REPLACES 0010008040

HEX. HEAD BOLT .......................... 2 .......... REPLACES 0017108020

3345312003 SUPPORT LEG

0017110025 HEX. HEAD BOLT

1

2

011208025 HEX. HEAD BOLT .......................... 2 .......... REPLACES 0017108025

0030008000 HEX. NUT 2

3342183004 LINK, GOVERNOR ROD

0010010025 HEX. HEAD BOLT

1

1

031110160

020310080

PLAIN WASHER ............................. 2 .......... REPLACES 0041610000

HEX. NUT ....................................... 1 .......... REPLACES 0030010000

3342182004 GOVERNOR ROD

3342152114 GOVERNOR ROD

1

1

0602180101 BALL JOINT

020108060

2

HEX. NUT ....................................... 2 .......... REPLACES 0030008000

0602180100 BALL JOINT

020106050

1

HEX. NUT ....................................... 3 .......... REPLACES 0030006000

952404470 PLAIN WASHER ............................. 1 .......... REPLACES 0041606000

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 75

ENGINE OPERATING PANEL ASSY.

DCA-40SSAI --- ENGINE OPERATING PANEL ASSY.

PAGE 76 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO.

PART NO.

ITEM

69

70

71

72

65

66

67

68

61

62

63

64

57

58

59

60

52

53

55

56

48

49

50

51

42

43

44

45

46

47

81

82

83

84

85

77

78

79

80

73

74

75

76

QTY.

REMARKS

3345188203 SET PANEL, ELECTRIC PARTS 1

011008020 HEX. HEAD BOLT .......................... 6 .......... REPLACES 0017108020

1825500732 EMERGENCY RELAY .................... 1 ........... REPLACES 0602200405

0027106016 MACHINE SCREW 4

0601823706 RELAY

0027104016 MACHINE SCREW

1

2

3341860103 SET BOARD, OUTPUT TERMINAL 1

0801831704A OUTPUT TERMINAL 4

012210020 HEX. HEAD BOLT .......................... 4 .......... REPLACES 0801831804

0041410000 PLAIN WASHER 16

0040010000 LOCK WASHER

0039310000 HEX. NUT

12

8

031108160 PLAIN WASHER ............................. 5 .......... REPLACES 0041608000

0040008000 LOCK WASHER 5

011208030 HEX. HEAD BOLT .......................... 5 .......... REPLACES 0010008030

0601811032 RECEPTACLE ................................ 2 ........... L620R 250V 20A

0601811037 RECEPTACLE ................................ 2 ........... CS8269 250V 50A

0601811031 RECEPTACLE ................................ 2 ........... L530R 125V 30A

0601811030 RECEPTACLE ................................ 2 ........... 520R 125V 20Ax2

0027103010 MACHINE SCREW 16

0041603000 PLAIN WSAHER 16

0207003000 HEX. NUT ....................................... 16 ........ REPLACES 0030003000

0601805311 CIRCUIT BREAKER ....................... 2 ........... KM51 265V 50A

0601805315 CIRCUIT BREAKER ....................... 2 ........... KM51 265V 30A

7451816004 BRACKET, CIRCUIT BREAKER 1

0027106016 MACHINE SCREW 2

3341865803 COVER, OUTPUT TERMINAL

0805012304 HEX. HEAD BOLT

1

2

031112230 PLAIN WASHER ............................. 4 .......... REPLACES 0041612000

0805019704 RUBBER WASHER 2

0030012000 HEX. NUT

0605010505 SNAP PIN

0601850091 RUBBER CUSHION

0021003010 MACHINE SCREW

2

2

2

2

0601802133 FUSE, 5A 1

0601820015 RECTIFIER ..................................... 4 ........... 1S2762

3341865903 COVER, OUPUT TERMINAL .......... 1 ........... S/N3312326~

7451855503 HING ............................................... 1 ........... S/N3312326~

7451855703 HINGE ............................................. 1 ........... S/N3312326~

0021304015 MACHINE SCREW ......................... 4 ........... S/N3312326~

0040004000 LOCK WASHER .............................. 4 ........... S/N3312326~

031104080 PLAIN WASHER ............................. 8 ........... S/N3312326~; REPLACES 0041204000

OEMAA8 HEX. NUT ....................................... 4 ........... S/N3312326~; REPLACES 0030104000

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 77

BATTERY ASSY.

DCA-40SSAI --- BATTERY ASSY.

PAGE 78 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- BATTERY ASSY.

9

10

11

7

8

5

6

BATTERY ASSY.

2

3

NO.

PART NO.

1 0160012100

ITEM QTY.

REMARKS

BATTERY ......................................... 2 ......... N100 12V 100Ah

4

0805003904

0805004004

3802252004

BATTERY SHEET

BATTERY BAND

BATTERY BOLT

2

2

4

12

0041608000 PLAIN WASHER

031108160 LOCK WASHER ............................... 4 ......... REPLACES 0040008000

0037808000 WING NUT

0215260050 BATTERY CABLE

0211160160 BATTERY CABLE

0215860045 BATTERY CABLE

4

4

1

1

1

0602220310 TERMINAL ASSY. (+) ...................... 2 ......... NO.9P

0037808000 WING NUT ....................................... 2 ......... REPLACES 0208008000

0602220311 TERMINAL ASSY (-) ........................ 2 ......... NO.9N

0037808000 WING NUT ....................................... 2 ......... REPLACES 0208008000

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 79

MUFFLER ASSY.

DCA-40SSAI --- MUFFLER ASSY.

PAGE 80 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- MUFFLER ASSY.

13

14

15

16

9

10

11

12

17

18

7

8

5

6

3

4

1

2

MUFFLER ASSY.

NO.

PART NO.

ITEM QTY.

REMARKS

3342350103 EXHAUST PIPE 1

1141450690 GASKET ......................................... 1 .......... REPLACES 0602320000 AND 9221160010

9091103100 HEX. NUT ....................................... 6 .......... REPLACES 0602323002

3342311102 MUFFLER 1

3342359104 MUFFLER SHEET

011208025

1

HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108025

012210020 HEX.HEAD BOLT ........................... 2 .......... REPLACES 0017110020

3342356104 GASKET 1

011008035

031108160

HEX. HEAD BOLT ........................... 4 .......... REPLACES 0010108035

PLAIN WASHER ............................. 4 .......... REPLACES 0041608000

0040008000 LOCK WASHER

020108060

4

HEX. NUT ....................................... 4 .......... REPLACES 0030008000

3342354104 COVER

3342354004 COVER

1

1

3342328104 PIPE CLAMPER

020108060

1

HEX. NUT ....................................... 4 .......... REPLACES 0030008000

3342359004 COVER SHEET 2

0112508025 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108025

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 81

FUEL TANK ASSY.

DCA-40SSAI --- FUEL TANK ASSY.

PAGE 82 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- FUEL TANK ASSY.

FUEL TANK ASSY.

NO.

PART NO.

ITEM QTY.

REMARKS

16

17

18

12

13

14

15

8

9

10

11

6

7

4

5

1 3345510323 FUEL TANK 1

2

3

1-1 0810105004 CAP, FUEL TANK

1-2 0810105400 FUEL FILTER

0802010304 PACKING

1

1

1

0602021042 PLUG .............................................. 1 ........... 960922101

3345523304 TANK BAND

0805003404 PAD, TANK BAND

011008020

031108160

2

4

HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

PLAIN WASHER ............................. 2 .......... REPLACES 0041608000

0040008000 LOCK WASHER

020108060

2

HEX. NUT ....................................... 2 .......... REPLACES 0030008000

3805522004 TANK SHEET

0191300600 SUCTION HOSE

4

1

0191300700 RETURN HOSE

0605515014 HOSE BAND

0845032204 DRAIN JOINT

0150000018 O RING

0802011104 PLUG

0193100225 FUEL GAUGE HOSE

0605515079 HOSE BAND

1

1

2

1

1

1

4

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 83

ENCLOSURE ASSY.

DCA-40SSAI --- ENCLOSURE ASSY.

PAGE 84 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- ENCLOSURE ASSY.

33

34

35

36

37

38

39

40

ENCLOSURE ASSY.

NO.

PART NO.

27

28

29

30

23

24

25

26

31

32

19

20

21

22

14

15

16

18

10

11

12

13

8

9

6

7

1

4

5

2

3

ITEM QTY.

REMARKS

3345111322 BASE 1

3345116214 FLOOR PANEL

011008020

1

HEX. HEAD BOLT ........................... 10 ........ REPLACES 0017108020

3345121122 FRONT FRAME

3345109103 LINING

1

1

B3561100103 STRIPE, LEFT SIDE ...................... 1 .......... REPLACES 3340630303

3340630503 STRIPE, RIGHT SIDE 1

0600500090 EMBLEM ......................................... 2 .......... REPLACES 6360510003

0021106020 MACHINE SCREW 4

011008020 HEX. HEAD BOLT ........................... 6 .......... REPLACES 0017108020

3345122604 BRACKET, RADIATOR NECK 1

011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

3345125103 COVER, FRONT FRAME 1

3345109204 LINING 1

B3561100003 STRIPE ........................................... 1 .......... REPLACES 3340630103

011008020

011008020

HEX. HEAD BOLT ........................... 16 ........ REPLACES 0017108020

HEX. HEAD BOLT ........................... 10 ........ REPLACES 0017108020

3385155104 COVER

011206020

2

HEX. HEAD BOLT ........................... 8 .......... REPLACES 0017106020

3345125204 COVER, FRONT FRAME

011008020

1

HEX. HEAD BOLT ........................... 6 .......... REPLACES 0017108020

3345132113 CENTER FRAME

3345132203 CENTER FRAME

1

1

012210040 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010014040

0041614000 PLAIN WASHER 16

030214350 LOCK WASHER .............................. 8 .......... REPLACES 0040014000

0030014000 HEX. NUT 8

012012030 HEX. HEAD BOLT ........................... 10 ........ REPLACES 0010012030

0040012000 LOCK WASHER 10

031112230 PLAIN WASHER ............................. 10 ........ REPLACES 0041612000

3345141202 REAR FRAME ................................ 1 .......... UP TO S/N3311949

3345141212 REAR FRAME ................................ 1 .......... S/N3311950~

3345109303 LINING 1

B3561100204 STRIPE ........................................... 2 .......... REPLACES 3340630704

011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

3345155103 COVER, REAR FRAME

3345109403 LINING

1

1

031108160 PLAIN WASHER ............................. 8 .......... REPLACES 0041608000

0040008000 LOCK WASHER 8

011008040 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010008040

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 85

ENCLOSURE ASSY.

DCA-40SSAI --- ENCLOSURE ASSY.

PAGE 86 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- ENCLOSURE ASSY.

79

80

81

75

76

77

78

70

71

72

73

74

64

65

66

67

68

69

58

59

60

61

54

55

56

57

50

51

52

53

46

47

48

49

42

43

44

45

ENCLOSURE ASSY.

NO.

41

PART NO.

ITEM QTY.

REMARKS

3345143303 DOOR, REAR FRAME .................... 1 .......... UP TO S/N3311949

3345143313 DOOR, REAR FRAME .................... 1 .......... S/N3311950~

1320332003

3805147104

0021006020

952404470

STICKER

MACHINE SCREW

1

WINDOW PLATE ............................. 1 .......... REPLACES 33805147104

6

PLAIN WASHER ............................. 6 .......... REPLACES 0041606000

0040006000

020106050

011008020

LOCK WASHER 6

HEX. NUT ....................................... 6 .......... REPLACES 0030006000

0845028303 HINGE

011208025

2

HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108025

3345161212 ROOF PANEL

3345109503 LINING

1

1

HEX. HEAD BOLT ........................... 16 ........ REPLACES 0017108020

3345165104 GUIDE PANEL, AIR 2

62

63

3345109604 LINING

011008020 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0017108020

3345181202 SPLASHER PANEL

3345105304 LINING

0010008055 HEX. HEAD BOLT

0040008000 LOCK WASHER

2

1

1

6

6

031108160 PLAIN WASHER ............................. 6 .......... REPLACES 0041608000

3345124003 SIDE DOOR, LEFT SIDE ............... 1 .......... UP TO S/N3311949

3345124013 SIDE DOOR, LEFT SIDE ............... 1 .......... S/N3311950~

3345109704 LINING 1

3345124103 SIDE DOOR, RIGHT SIDE ............. 1 .......... UP TO S/N3311949

3345124113 SIDE DOOR, RIGHT SIDE ............. 1 .......... S/N3311950~

3345109804 LINING

3340630904 STRIPE

3345175104 GUDE PANEL, AIR

3345105104 LINING

1

2

2

2

011008020 HEX. HEAD BOLT ........................... 12 ........ REPLACES 0017108020

3345171803 SIDE DOOR, LEFT SIDE ............... 1 .......... UP TO S/N3311949

3345171813 SIDE DOOR, RIGHT SIDE ............. 1 .......... S/N3311950~

33451009904 LINING 1

3340631104 STRIPE

3345175004 GUIDE PANEL, AIR

1

1

3345105204 LINING

011008020

1

HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

3345171903 SIDE DOOR, RIGHT SIDE ............. 1 .......... UP TO S/N3311949

3345105004 LINING 1

B3561100403 STRIPE ........................................... 1 .......... REPLACES 3340631304

0845028203 HINGE 4

0845028303 HINGE

011208025

4

HEX. HEAD BOLT ........................... 16 ........ REPLACES 0017108025

0845031504 CAP 10

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 87

ENCLOSURE ASSY.

DCA-40SSAI --- ENCLOSURE ASSY.

PAGE 88 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO.

PART NO.

89

90

91

92

93

94

85

86

87

88

82

83

84

0605010910

0027103010

0605010910

3345104804

3345104904

ITEM QTY.

REMARKS

LATCH ............................................. 1 .......... UP TO S/N3311949; REPLACES 0605010910

MACHINE SCREW ......................... 7 .......... UP TO S/N3311949

LATCH ............................................. 2 .......... UP TO S/N3311949

0027104010 MACHINE SCREW ......................... 14 ........ UP TO S/N3311949

3345104104 RUBBER SEAL

3345104204 RUBBER SEAL

3345104304 RUBBER SEAL

3345104404 RUBBER SEAL

3345104504 RUBBER SEAL

3345104604 RUBBER SEAL

3345104704 RUBBER SEAL

RUBBER SEAL

RUBBER SEAL

2

2

3

1

1

1

1

2

2

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 89

DECAL ASSY.

DCA-40SSAI --- DECALS

PAGE 90 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI --- DECALS

DECAL ASSY.

NO.

PART NO.

23

24

25

26

27

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

5

6

3

4

1

2

ITEM QTY.

REMARKS

M1550000204 DECAL; NOTE ........................................................ 1 ...... M15000020

M1550001003 DECAL; GENERATOR CONTROL .......................... 1 ...... M15000100

M1550000603 DECAL; ENGINE OPERATING .............................. 1 ...... M15000060

M1550000703 DECAL; AUXILIARY OUTPUT ............................... 1 ...... M15000070

M1550000804 DECAL; NOTE ........................................................ 1 ...... M15000080

M9500000004 DECAL; OIL DRAIN PLUG ..................................... 1 ...... M9000000

M9500100004 DECAL; WATER ..................................................... 1 ...... M90010000

M9500300004 DECAL; - ................................................................ 1 ...... M90030000

M9500300104 DECAL; + ............................................................... 1 ...... M90030010

M9500500004 DECAL; DIESEL FUEL .......................................... 1 ...... M90050000

M9500500104 DECAL; FUEL DRAIN PLUG .................................. 1 ...... M90050010

M9503000004 DECAL; WARNING ................................................. 2 ...... M90300000

M9503000103 DECAL; WATER, OIL CHECK ................................ 1 ...... M90310000

M9503100004 DECAL; WARNING ................................................. 1 ...... M90320000

M9503200004 DECAL; WARNING ................................................. 1 ...... M90320000

M9510100004 DECAL; CAUTION .................................................. 1 ...... M91010000

M9510200002 DECAL; MQ ........................................................... 1 ...... M91020000

M9520000004 DECAL; GROUND .................................................. 1 ...... M92000000

M9520000104 DECAL; AMMETER CHANGE-OVER SWITCH ..... 1 ...... M92000010

M9520000204 DECAL; VOLTMETER CHANGE-OVER SWITCH .. 1 ...... M92000020

M9520100004 DECAL; WARNING ................................................. 2 ...... M92010000

M9520100204 DECAL; CAUTION .................................................. 1 ...... M92010020A

M9520100304 DECAL; SAFETY INSTRUCTIONS ........................ 1 ...... M92010030

M9520100404 DECAL; DANGER .................................................. 1 ...... M92010040

M9520100503 DECAL; WARNING ................................................. 1 ...... M92010050

M9520200003 DECAL; CONNECTION OF OUTPUT CABLE ....... 1 ...... M92020000

M9520200104 DECAL; OVER CURRENT RELAY ......................... 1 ...... M92020010

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 91

CYLINDER HEAD COVER ASSY.

ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.

PAGE 92 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.

CYLINDER HEAD COVER ASSY.

NO PART NO

1 5111101680

PART NAME QTY.

REMARKS

CYLINDER HEAD ASSY. .................1 .......... INCL. ITEMS W/#

2#

3#

9117156070

9117118030

VALVE SEAT, INTAKE

VALVE SEAT, EXHAUST

4

4

5# 1096000580 SEALING CUP, REAR FACE ...........1 .......... REPLACES 1096000051

5-1# 1096000121 SEALING CUP, EXHAUST MAN. ....2 .......... REPLACES 5112190150

5-2# 1096000160 SEALING CUP, INLET SIDE FACE 4

5-3# 9111291280 SEALING CUP, LOWER FACE 2

9

10

11

12

5-4# 1096000160 SEALING CUP, TOP FAC 3

5-5# 50960000130 SEALING CUP, DRILLED PASS 4

6#

7#

909600340

5117210010

PLUG

VALVE GUIDE

4

8

9111296010

5093000650

1093000180

9092023100

SEAL CUP

ROCKER ARM STUD

INJ. NOZZLE STUD

PLUG, TOP FACE

8

1

4

3

33

34

50

51

13

15

16

17

9095714100 PACKING, COMMET

1125690150 VALVE GUIDE SEAL

1

8

9041108200 STUD, INL. MANIFOLD ....................2 .......... REPLACES 9041108250

9098301770 STUD, EXH. MANIFOLD 3

20

22

8941458390 GASKET, CYL. HEAD 1

8943674370 BOLT ................................................18 ........ REPLACES 8943674380

27 5111702672 CYL. HEAD COVER ASSY. .............1 .......... INCL. ITEMS W/&

28& 1117510051 CAP, OIL FILLER .............................1 .......... REPLACES 9117510381

9111791050 WASHER

1096390320 PACKING, HEAD COVER ................3 .......... REPLACES 9111790300

5111730160 PACKING, CYL. HEAD

9111750120 NUT

1

1

EA1013

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 93

CYLINDER BLOCK ASSY.

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

PAGE 94 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

59

60

61

62

53

54

56

57

66

69

NO PART NO

1 8941303284

2#

3#

4#

5878131240

5112570011

1090004691

5# 9116910480

5-1# 9116930350

6# 1096000520

6-1# 5112190140

6-2# 1096000121

8 9098600190

9

10

8941480790

1096050681

11 5096050050

11-1 5096050180

12

13

9992023140

9095720140

37

38

43

49

23

27

30

36

14 1097400780

15-1 9081510180

18

19

8941075600

5112240040

20

21

5112901450

8943673680

22 8941075662

22-1 8944299951

9095720080

1096253620

5111290030

8941745290

8943210180

0500408180

1093000530

5096800110

9099135050

5097070041

5117401200

1094400401

1099851770

9091645080

8944338700

8941625680

5093608820

5097040331

PART NAME QTY.

REMARKS

CYL. BLOCK ASSY ........................... 1 ........ INCL. ITEMS W/#

LINING ............................................... 4 ........ REPLACES 1112611180

DOWEL 1

BOLT 10

CAM., FRONT METAL ....................... 1 ........ REPLACES 9116110480

CAM., REAR AND CENTER ............. 2 ........ REPLACES 9116130350

CEALING CUP, FRONT AND REAR 2

SEALING CUP, CYL. BLOCK 1

SEALING CUP, TAPPET D=32

PLUG, CAMSHAFT PLATE

DOWEL

PLUG, HEADLESS PT 1/2

2

2

2

1

OIL PLUG, GALLERY ........................ 1 ........ REPLACES 9992055170

PLUG 7

OIL PLUG, GALLERY

PACKING

1

1

STRAIGHT PIN, GEAR CASE 1

STRAIGHT PIN, FLYWHEEL HSG.

2

INJ. PUMP NIPPLE 1

BUSHING, OIL PUMP DRIVE SHAFT1

COVER, TAPPET CHAMBER 1

PACKING, CYL. BLOCK COVER 2

BOLT

BOLT

2

2

PACKING, GROMMET

SEAL, REAR OIL CRANK

SEALING CUP, LEVEL GAUGE

COVER, OIL DRAIN

PACKING, COVER

BOLT

STUD, ENGINE FOOT

WATER DRAIN COCK

1

1

1

2

1

1

4

1

PIPE

DRAIN PIPE CLIP

1

1

AIR BREATHER ASSY.

1

NUT ................................................... 2 ........ REPLACES 9091104080

LOCK WASHER ................................. 2 ........ REPLACES 9091505080

PLAIN WASHER 2

BREATHER HOSE 1

CLIP .................................................. 2 ........ REPLACES 1097071340

VINYL PIPE ...................................... 1 ........ REPLACES 9097130740

CLIP 1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 95

CYLINDER BLOCK ASSY.

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

PAGE 96 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

NO PART NO

81

82

83

85

70

71

80

0500408160

9091606080

8941405811

1117500120

1094400401

1099851770

9099129760

86

92

9099155531

8970233390

[email protected] 5096230350

PART NAME QTY.

REMARKS

BOLT

PLAIN WASHER

OIL FILLER ASSY.

1

1

1

OIL FILLER CAP 1

NUT ................................................... 1 ........ REPLACES 9091104080

LOCK WASHER ................................. 1 ........ REPLACES 9091505080

HOSE 1

CLIP 2

VALVE RELIEF ASSY. ...................... 1 ........ INCL. ITEM W/@

PACKING 1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 97

TIMING GEAR ASSY.

ISUZU 4BD1 — TIMING GEAR ASSY.

PAGE 98 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — TIMING GEAR ASSY.

TIMING GEAR ASSY.

10

12

13

14

7

8

9

10

4

6

2

3

NO.

PART NO.

1 5113110113

9081510180

8943706710

0500408450

1113210790

8943632690

1096254380

9113276020

0500408250

8941500451

5113210090

8971186980

0500406140

PART NAME

CASE

QTY.

REMARKS

1

STRAIGHT PIN 1

PACKING ........................................................ 1 .......... REPLACES 1113120140

BOLT ............................................................... 6 .......... REPLACES 0500408200

COVER 1

PACKING 1

SEAL ............................................................... 1 .......... REPLACES 1096253190

POINTER

BOLT

1

7

BOLT ............................................................... 5 .......... REPLACES 5090000841

COVER, GEAR CHECK 2

GASKET ......................................................... 2 .......... REPLACES 1112820130

BOLT 4

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 99

FLYWHEEL HOUSING ASSY.

ISUZU 4BD1 — FLYWHEEL HOUSING ASSY.

PAGE 100 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — FLYWHEEL HOUSING ASSY.

FLYWHEEL HOUSING ASSY.

5

9

3

4

NO.

PART NO.

1 8943213303

8943218380

5096000090

9095714160

9910664500

9-1 0500408250

11 9096510690

PART NAME

HOUSING

QTY.

REMARKS

1

PLUG, PICK UP HOSE 1

DRAIN PLUG .................................................. 1 .......... REPLACES 9992023160

PACKING

BOLT

1

8

BOLT

PLAIN WASHER

7

8

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 101

OIL PAN ASSY.

ISUZU 4BD1 — OIL PAN ASSY.

PAGE 102 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

OIL PAN ASSY.

NO PART NO

1 8941340361

3# 9096620120

3-1# 5096000090

3-2# 1096040230

4# 1096231830

4-1# 9095714160

4-2# 9095714240

7

9

15

8943708360

8943706660

0500408180

5117601501

ISUZU 4BD1 — OIL PAN ASSY.

PART NAME QTY.

REMARKS

OIL PAN ...................................... 1 ........ INCL. ITEMS W/#

PLUG 1

PLUG, THERMO SWITCH .......... 2 ........ REPLACES 9992023160

HEATER PLUG ........................... 1 ........ REPLACES 9992023240

O RING ....................................... 1 ........ REPLACES 1096230570

PACKING

PACKING

2

1

OIL PAN PACKING ..................... 1 ........ UP TO MAR. 94

OIL PAN PACKING ..................... 1 ........ APR. 94~

BOLT 24

GAUGE ASSY. ............................ 1 ........ REPLACES 5117601500

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 103

OIL PUMP ASSY.

ISUZU 4BD1 — OIL PUMP ASSY.

PAGE 104 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — OIL PUMP ASSY.

OIL PUMP ASSY.

NO.

PART NO.

1 5131001373

PART NAME QTY.

REMARKS

OIL PUMP ASSY. .......................... 1 ........... INCL. ITEMS W/#

2# 5878102022 GEAR SET ..................................... 1 ........... INCL. ITEMS W/&

3#

4#

5131130351 COVER ASSY.

1

DOWEL .......................................... 1 ........... CANNOT ORDER SEPARATELY

5#& 5131210140 SHAFT ASSY.

7# 5131250020 GEAR

1

1

9# 5131190060 PIPE

15# 5131410171 CASE

1

1

16# 1131190010 SPACER 1

17# 0108058000 BOLT .............................................. 4 ........... REPLACES 9010458000

19# 1099851770 LOCK WASHER ............................. 4 ........... REPLACES 9091505080

21# 5098430030 OIL RELIEF BALL 1

22# 5095800980 COIL SPRING

23# 5131650040 RELIEF VALVE SEAT

1

1

24# 9081040300 PIN

27#& 1131230160 COUPING

28#& 1131280180 PINION

32 0500410250 BOLT

1

2

1

1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 105

ISUZU 4BD1 — CRANKSHAFT. PISTON, FLYWHEEL ASSY.

CRANKSHAFT, PISTON, FLYWHEEL ASSY

PAGE 106 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — CRANKSHAFT. PISTON, FLYWHEEL ASSY.

CRANKSHAFT, PISTON, FLYWHEEL ASSY.

6

7

8&

9&

4

5

2#

3

NO.

PART NO.

1 8941170322

1-1 8941474660

1-2 8941474670

1-3 8941474680

1-4 8941474690

8941145652

8971766340

5121210050

9122116040

8941075751

1122301041

1122510270

1122350271

11 8970110310

11-1 9122736080

11-2 9122746080

11-3 9122756080

11-4 9122766080

14 5123101631

15$ 9081612200

17 8941075970

18

20

23

24

8971379100

8944493661

5123780020

5095030240

25

30

1098002140

8970461810

31% 9123336070

33 5123360030

34 5123340060

PART NAME QTY.

REMARKS

CRANKSHAFT ASSY. ..................... 1 ......... INCL. ITEMS W/#

METAL KIT, 0.25

METAL KIT, 0.50

METAL KIT, 0.75

METAL KIT, 1.00

1

1

1

1

METAL SET, THRUST 2

PISTON SET ................................... 4 ......... REPLACES 5121112111

RING SET, PISTON

PISTON PIN

4

4

SNAP RING ..................................... 8 ......... REPLACES 8941075750

CONNECTION ROD ASSY. ............. 4 ......... INCL. ITEMS W/&

BUSHING, SMALL END

BOLT

4

8

METAL SET, STD ............................ 4 ......... REPLACES 9122716080

METAL SET, 0.25

4

METAL SET, 0.50

METAL SET, 0.75

4

4

METAL SET, 1.00

4

CRANSHAFT ASSY. ........................ 1 ......... INCL. ITEMS W/$

FLYWHEEL PIN

FEATHER KEY

1

2

CRANKSHAFT GEAR...................... 1 ......... REPLACES 9125210430

PULLEY ........................................... 1 ......... REPLACES 8944493660

NUT

WASHER

1

1

BALL BEARING ............................... 1 ......... REPLACES 9000901570

FLYWHEEL ASSY. ........................... 1 ......... INCL. ITEMS W/%

RING GEAR

WASHER

1

1

BOLT 6

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 107

ISUZU 4BD1 — CAMSHAFT, IDLE GEAR, ROCKER ASSY.

CAMSHAFT, IDLE GEAR, ROCKER ASSY.

PAGE 108 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — CAMSHAFT, IDLE GEAR, ROCKER ASSY.

CAMSHAFT, IDLE GEAR, ROCKER ASSY.

37

38

39

40

33

34

35

36

41

42

43

24

25

30

31

32

19

21

22

23

13

14

17

18

6

7

10

11

4

5

2

3

NO.

PART NO.

1 8944094120

1125220162

9080107200

9116810150

0500408250

5090002360

9098518503

9125310300

9125238014

5125350011

5090300381

1125510501

1125520251

5125610090

1125630351

8941145760

5125650060

5125710032

1125750360

5126110310

9126160420

9091115080

8941295510

9126260050

5126280120

9126281050

1095803350

1090005670

9098514300

9091800190

5096230600

1094001160

9098514300

PART NAME

CAMSHAFT

QTY.

1

REMARKS

GEAR ............................................. 1 ........... REPLACES 9125221471

FEATHER KEY 1

THRUST PLATE

BOLT

1

2

BOLT

WASHER

IDLE GEAR SHAFT

IDLE GEAR

THRUST COLLAR

BOLT

INLET VALVE

EXHAUST VALVE

1

1

1

1

1

2

4

4

VALVE SPRING

SPRING SEAT, LOWER

SPRING SEAT, VALVE

SPLIT COLLAR

TAPPET

PUSH ROD

ROCKER ARM ASSY.

ADJUSTING SCREW

NUT

ROCKER ARM SHAFT

ROCKER ARM PLUG

BRACKET, FRONT

BRACKET, INNER

SPRING

BOLT

WASHER

SNAP RING

O RING PACKING

NUT

PLAIN WASHER

8

16

8

8

8

8

8

8

8

1

2

1

4

3

6

6

1

1

3

3

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 109

OIL AND FUEL FILTER ASSY.

ISUZU 4BD1 — OIL AND FUEL FILTER ASSY.

PAGE 110 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — OIL AND FUEL FILTER ASSY.

2#

10

11

13

14

OIL AND FUEL FILTER ASSY.

NO.

PART NO.

1 5132002262

15

50#

52#&

60

1878102201

8943706700

8943706700

5132190261

5090000071

030210250

9091645100

9132004193

5878100500

0501510350

PART NAME QTY.

REMARKS

OIL FILTER ASSY. ............................. 1 ............. INCL. ITEMS W/#;

REPLACES 5132002262

OIL FILTER ELEMENT KIT 1

PACKING ............................................ 2 ............. UP TO MAR. 94;

REPLACES 1132191940

PACKING ............................................ 2 ............. APR. 94~

SPACER 1

BOLT 4

LOCK WASHER .................................. 4 ............. REPLACES 9091505100

PLAIN WASHER ................................. 4 ............. REPLACES 9091605100

FUEL FILTER ASSY. .......................... 1 ............. INCL. ITEMS W/&

FUEL FILTER ELEMENT KIT

BOLT

1

2

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 111

OIL PIPING ASSY.

ISUZU 4BD1 — OIL PIPING ASSY.

PAGE 112 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

OIL PIPING ASSY.

5

6

2

3

NO.

PART NO.

1 8941753012

9099211880

0501408450

5133112561

1096234620

7 0500408350

7-1 0500408320

10

12

8944284630

9095720100

13 909840220

PART NAME

OIL PUMP ASSY.

PACKING

BOLT

FILTER PIPE ASSY.

PACKING

BOLT

BOLT

OIL INJECTION PIPE ASSY.

PACKING

NUT

ISUZU 4BD1 — OIL PIPING ASSY.

1

2

2

2

1

QTY.

REMARKS

1

1

2

2

4

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 113

COOLING ASSY.

ISUZU 4BD1 — COOLING ASSY.

PAGE 114 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — COOLING ASSY.

COOLING ASSY.

NO.

PART NO.

1

2#

3&

4&

5&

6&

5136101582

8943763780

5878101145

5136310100

1098002620

5136320010

7&

8&

9099521030

9091801470

9%& 1136200200

11%& 5136210110

13& 5136420530

14% 5136120100

15%& 8944728780

17%& 9030906200

19& 5136390020

21& 5136340030

23%& 5096250780

27 5096050050

80

81

83

60

62

63

65

43

48

49

50

52

53

35

37

38

40

41

28%& 8943706610

29 0500410400

0500410500

5090300101

31

32

5093610700

5097040313

1097040940

9136600930

5136630311

5136420581

5136710450

0500405600

8943127330

9137700941

8941760310

5137160451

9096610050

5096050050

9095713160

8943706740

5137130351

0500408250

0501410250

0500410400

0501410350

5112800111

8970196530

0500408200

0500408250

0500408450

8942059861

PART NAME QTY.

REMARKS

WATER PUMP ASSY. ...................... 1 ......... INCL. ITEMS W/#

WATER PUMP KIT ........................... 1 ......... INCL. ITEMS W/%

WATER PUMP REPAIR KIT ............. 1 ......... INCL. ITEMS W/&

SHAFT 1

BALL BEARING ............................... 2 ......... REPLACES 5098000520

SPACER 1

SNAP RING

SNAP RING

1

1

SEAL UNIT ASSY. ........................... 1 ......... REPLACES 8942366870

IMPELLER 1

FAN

WATER PUMP COVER

1

1

PACKING .......................................... 1 ......... REPLACES 5136130070

SCREW ............................................ 3 ......... REPLACES 9030908200

DUST COVER

SPACER

1

1

SEAL ................................................ 1 ......... REPLACES 5096250570

PLUG 1

PACKING .......................................... 1 ......... REPLACES 9136140440

BOLT 1

BOLT

BOLT, WATER PUMP

2

2

HOSE, BY-PASS

CLIP, D=38

CLIP, D=36

FAN ASSY.

1

1

1

1

PULLEY

SPACKER

BELT

BOLT

1

1

1

4

LOCK WASHER ................................ 4 ......... REPLACES 9098516490

THERMOSTAT .................................. 1 ......... REPLACES 5137700320

PACKING

THERMOSTAT HOUSING

1

1

THERMO PLUG 1

PACKING .......................................... 1 ......... UP TO DEC. 93

PACKING .......................................... 1 ......... DEC. 93~

PACKING .......................................... 1 ......... REPLACES 8943210100

WATER PIPE

BOLT

BOLT

BOLT

1

3

1

2

BOLT

WATER DUCT COVER ASSY.

4

1

OIL COOLER PACKING ................... 1 ......... REPLACES 8943210130

BOLT 2

BOLT

BOLT

BOLT

11

8

1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 115

INTAKE AND EXHAUST ASSY.

ISUZU 4BD1 — INTAKE AND EXHAUST ASSY.

PAGE 116 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — INTAKE AND EXHAUST ASSY.

INTAKE AND EXHAUST ASSY.

4

5

8

39

NO.

PART NO.

1 5141112070

3 8970241220

1094400401

1099851770

0500408250

8970225710

60

61

62

66

50 5141111160

50-1 5141112360

51 0501510300

51-1 0500510300

67

69

5141410360

5093020020

8944046100

1094400401

1099851770

8942059871

0500408600

PART NAME

INTAKE MANIFOLD

QTY.

1

REMARKS

GASKET, INTAKE ..................... 1 ................ REPLACES 8943632700

NUT ........................................... 2 ................ REPLACES 9091104080

LOCK WASHER ......................... 2 ................ REPLACES 9091505080

BOLT 6

PACKING ................................... 2 ................ REPLACES 5096370281

INTAKE PIPE 1

INTAKE PIPE ............................ 1 ................ REPLACES 5141111970

BOLT

BOLT

2

2

EXHAUST MANIFOLD

STUD, EXHAUST

1

3

GASKET, EXHAUST ................. 2 ................ REPLACES 5141450040

NUT ........................................... 5 ................ REPLACES 9091104080

LOCK WASHER ......................... 5 ................ REPLACES 9091505080

BOLT, L=75 2

BOLT, FIXED 1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 117

FUEL INJECTION ASSY.

ISUZU 4BD1 — FUEL INJECTION ASSY.

PAGE 118 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — FUEL INJECTION ASSY.

FUEL INJECTION ASSY.

8

9

3

5

NO.

PART NO.

1 5153001032

1153150131

9153390510

1094400401

1099851770

11

12

13

14

8944636740

8944636750

8944636760

8944636770

15 5154190131

15-1# 9154196130

15-2# 9154196140

15-3#

16 5154190040

16-1 5154190051

16-2 0501406160

18 5154112290

20

27

5132600101

5154115730

29 5154118580

29-1 5154115680

30

31

32

33

5154116030

9099063141

9095714080

9095720140

34

42

1095751460

9095720140

49 5097091030

49-1 9097161240

49-2 0500406250

PART NAME

NOZZLE

QTY.

4

REMARKS

PACKING ................................ 4 ................... REPLACES 5153150030

DUST COVER 4

NUT ........................................ 8 ................... REPLACES 9091104080

LOCK WASHER ...................... 8 ................... REPLACES 9091505080

PIPE, NO. 1

PIPE, NO. 2

PIPE, NO. 3

PIPE, NO. 4

1

1

1

1

CLIP ASSY., D6X2 ................. 3 ................... INCL. ITEMS W/#

CLIP, A 3

CLIP, B 3

BOLT ...................................... 3 ................... NOT SOLD SEPARATELY FROM KIT

CLIP, INTAKE MANIFOLD 1

CLIP, INTAKE MANIFOLD 1

BOLT

PIPE

1

1

OVERFLOW VALVE ASSY.

1

PIPE 1

FILTER LEAK PIPE ASSY.

1

EYE JOINT ............................ 1 ................... REPLACES 5154112231

FILTER PIPE ASSY.

BOLT

PACKING, GROMMET

PACKING, FUEL PIPE

2

6

1

1

BOLT ...................................... 2 ................... REPLACES 9099063251

PACKING 3

CLIP A 2

CLIP B .................................... 2 ................... REPLACES 5097091040

CLIP BOLT 2

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 119

ENGINE FOOT ASSY.

ISUZU 4BD1 — ENGINE FOOT ASSY.

PAGE 120 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — ENGINE FOOT ASSY.

ENGINE FOOT ASSY.

35

39

42

28

29

30

31

18

19

20

22

3

4

5

17

NO.

PART NO.

1 9117712470

2 9117712480

8943134650

9091105100

030210250

5117770080

27

27

9117778050

0500410200

5197110620

0501408350

0501408400

0500410000

0500410450

5090300101

8943717120

8942790500

1099851770

9091606080

5136740320

0500408400

9091647080

PART NAME

FOOT, FRONT RIGHT

FOOT, FRONT LEFT

QTY.

1

1

REMARKS

BOLT

NUT

7

1

LOCK WASHER ...................... 1 ................... REPLACES 9091505100

HANGER, FRONT 1

HANGER, R. REAR

BOLT

BRACKET

BOLT

BOLT

BOLT

BOLT

BOLT, L=75

1

2

1

1

1

1

1

1

COVER, PULLEY 1

NUT ........................................ 1 ................... REPLACES 9091105080

LOCK WASHER ...................... 1 ................... REPLACES 9091505080

PLAIN WASHER 1

PLATE

BOLT

PLAIN WASHER

1

1

1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 121

ENGINE CONTROL ASSY.

ISUZU 4BD1 — ENGINE CONTROL ASSY.

PAGE 122 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — ENGINE CONTROL ASSY.

ENGINE CONTROL ASSY.

NO.

PART NO.

2 5197890041

PART NAME QTY.

REMARKS

BRACKET ................................. 1 ................ REPLACES 5197890040

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 123

INJECTION PUMP ASSY.

ISUZU 4BD1 — INJECTION PUMP ASSY.

PAGE 124 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — INJECTION PUMP ASSY.

INJECTION PUMP ASSY.

36

38

39

40

NO.

PART NO.

1 8943440260

3#

5#

8943440280

8941327042

14# 5125240890

15# 1156192450

16# 9096620070

17# 5157810030

18# 8944575170

19# 9884105020

20# 5156190480

32 1113190090

33

35

8941500451

5197510150

0500410250

9091105100

9091645100

030210250

PART NAME QTY.

REMARKS

INJECTION PUMP ASSY. ......... 1 ................ INCL. ITEMS W/#

GOVERNOR ASSY.

1

FEED PUMP ASSY. .................. 1 ................ REPLACES 8941327040

GEAR ........................................ 1 ................ REPLACES 5125240650

PLATE 1

BOLT

COUPLING

BOLT

NUT

6

1

1

1

LOCK WASHER

PACKING

1

1

BOLT ......................................... 7 ................ REPLACES 5090000841

BRACKET 1

BOLT

NUT

2

1

PLAIN WASHER ........................ 1 ................ REPLACES 9091605100

LOCK WASHER ......................... 1 ................ REPLACES 9091505100

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 125

ELECTRICAL COMPONENTS ASSY.

ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY.

PAGE 126 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY.

ELECTRICAL COMPONENTS ASSY.

6

6

NO.

PART NO.

1 1811001910

7

8

10

16

0500512280

0500512350

9091605120

9829315110

5812002121

9827200690

16-1 5824100160

19 1825130430

20

23

5197320021

9825300460

35 5824500141

35-1 8970299880

78 1819001931

1819000161

79% 1828490430

PART NAME

STARTER ASSY

BOLT

BOLT

PLAIN WASHER

CABLE ASSY.

ALTERNATOR ASSY.

OIL PRESS. WARNING SW.

QTY.

1

1

2

1

1

1

1

REMARKS

OIL PRESS. WARNING SW.

1

GLOW PLUG (24V) ........................ 4 ................... REPLACES 9825139288

CONNECTOR ................................. 1 ................... REPLACES 5197320020

RESISTANCE CONTROLLER 1

OVERHEAT SWITCH, M16

OVERHEAT SWITCH, 3/8

1

1

STOP ASSY. .................................. 1 ................... INCL. ITEM W/%; REPLACES

CABLE ASSY.

1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 127

FEED PUMP COMP. ASSY.

ISUZU 4BD1 — FEED PUMP COMP. ASSY.

PAGE 128 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — FEED PUMP COMP. ASSY.

FEED PUMP COMP. ASSY.

NO.

PART NO.

1 8941327042

5#

9#

5157510120

9813512050

10# 9813513020

11# 9813550230

12# 9813550350

15# 5157540010

16#% 9813514030

17#% 9813514100

18#% 1157590020

20# 9813517020

26# 9813516020

27# 1156290650

31# 5157590270

32# 1156190820

33# 1157590010

35# 1157590030

37# 5157590120

40# 1156290650

42# 9813550250

44# 1157610060

PART NAME QTY.

REMARKS

FEED PUMP ASSY. .................. 1 ........... INCL. ITEMS W/ #; REPLACES 8941327040

PUMP HOUSING

PISTON

SPRING

PLUG

1

1

1

1

GASKET 1

TAPPET ASSY. ......................... 1 ........... INCL. ITEMS W/%

ROLLER

PIN

1

1

GUIDE

SPRING

2

2

VALVE 2

O RING ...................................... 1 ........... REPLACES 1096230160

BOLT

BOLT

GASKET

ADAPTER

1

1

1

1

JOINT 1

O RING ...................................... 1 ........... REPLACES 1096230160

SNAP RING 1

PRIMING PUMP ASSY. ............ 1 ........... REPLACES 8941311300

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 129

NOZZLE ASSY.

ISUZU 4BD1 — NOZZLE ASSY.

PAGE 130 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — NOZZLE ASSY.

NOZZLE ASSY.

NO.

PART NO.

1

2

4#

6#

5153110191

1153300941

5153410010

9153430130

8# 5153450010

10# 5153320100

11# 9153390560

12# 9153390570

20# 1153320170

21# 5153390030

22# 5153510010

30# 1096750371

31# 1153390100

32# 9153470030

PART NAME QTY.

REMARKS

INJ. NOZZLE ............................. 4 ................ REPLACES 5153110190

HOLDER ASSY. ........................ 4 ................ INCL. ITEMS W/#

PUSH ROD

SPRING

4

4

ADJ. SCREW

NUT

GASKET

WASHER

RETAINING NUT

GASKET

4

4

CONNECTOR 4

BOLT ......................................... 8 ................ REPLACES 1153390090

GASKET

PIN

8

8

4

4

4

4

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 131

OIL FILTER ASSY.

ISUZU 4BD1 — OIL FILTER ASSY.

PAGE 132 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — OIL FILTER ASSY.

OIL FILTER ASSY.

NO.

PART NO.

1

2#

5132002262

1878102201

4#& 9097205550

5#& 5096230670

6#& 9099211950

7#& 9132490090

8#

9#

5132120681

9132316020

10# 9099410980

11# 9132390310

12# 9098621170

15# 9000975270

16# 9099408600

17# 8941326650

18# 9099208410

20# 9132260110

21# 9099208410

22# 5132110201

PART NAME QTY.

REMARKS

OIL FILTER ASSY. .................... 1 ................ INCL. ITEMS W/#

OIL FILTER ELEMENT KIT ....... 1 ................ INCL. ITEMS W/&

PACKING ................................... 1 ................ REPLACES 9099209780

PACKING 1

PACKING

PACKING, UPPER

BODY

BOLT

SPRING

SEAT

DRAIN PLUG

OVER FLOW VALVE

1

1

1

1

1

1

1

1

SPRING

VALVE PLUG

1

1

PACKING ................................... 1 ................ REPLACES 9099205260

PLUG 1

PACKING ................................... 1 ................ REPLACES 9099205260

CASE 1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 133

FUEL FILTER ASSY.

ISUZU 4BD1 — FUEL FILTER ASSY.

PAGE 134 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — FUEL FILTER ASSY.

FUEL FILTER ASSY.

NO.

PART NO.

1 9132004193

2# 5878100500

3#% 9099203270

4#% 9132136010

5# 9099208410

6#% 5096230241

7# 9095720140

8#

9#

1132600470

9099203260

10#% 9098518100

11# 9099409010

12# 9132310660

13# 9098620680

14# 9132111071

15# 9132128040

PART NAME QTY.

REMARKS

FUEL FILTER ASSY. ................. 1 ................ INCL. ITEMS W/#

ELEMENT KIT ........................... 1 ................ INCL. ITEMS W/%

O RING ELEMENT, UPPER 1

PACKING

O RING

1

1

O RING

PACKING

VALVE

PACKING

SPRING SEAT

ELEMENT SPRING

BOLT

DRAIN PLUG

CASE

COVER

1

2

1

1

1

1

1

1

1

1

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 135

ENGINE ACCESSORIES

ISUZU 4BD1 — ENGINE ACCESSORIES

PAGE 136 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — ENGINE ACCESSORIES

ENGINE ACCESSORIES

NO.

PART NO.

1

3

4

8944533001

1096234650

0500408200

PART NAME QTY.

REMARKS

TACHOMETER DRIVE ASSY. ... 1 ................ REPLACES 8944533000

PACKING 1

BOLT 2

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 137

Effective: July 1, 2000

TERMS AND CONDITIONS OF SALE — PARTS

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.

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.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1.

A Returned Material Authorization must be approved by Multiquip prior to shipment.

2.

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.

The parts numbers and descriptions must match the current parts price list.

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.

The list must include the name and phone number of the person requesting the RMA.

3.

A copy of the Return Material

Authorization must accompany the return shipment.

4.

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.

c.

Any line item with an extended dealer net price of less than $5.00.

d.

Special order items.

e.

Electrical components.

f.

Paint, chemicals, and lubricants.

g.

Decals and paper products.

h.

Items purchased in kits.

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.

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.

LIMITATIONS OF SELLER’S LIABILITY

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.

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 138 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

NOTE PAGE

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 139

PARTS AND OPERATION MANUAL

PARTS AND OPERATION MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HAND WHEN CALLING

P AR TS DEP AR TMENT

800/427-1244 or 310/537-3700

FAX: 800/672-7877 or 310/637-3284

SER VICE DEP

AR

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

W ARRANTY DEP

AR

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

800/421-1244 or 310/537-3700

FAX: 310/537-3927

MULTIQUIP INC.

18910 WILMINGTON AVE.

PARTS DEPARTMENT:

800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

SERVICE DEPARTMENT:

800-421-1244

FAX: 310-537-3927

800-835-2551

FAX: 310-638-8046

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