PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
MQ POWER
DCA-40SSAI
TM
WHISPERWATT
GENERATOR
PARTS LIST NO.M3340163804
FINAL COPY
MULTIQUIPINC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
SERVICE DEPARTMENT:
800-835-2551
FAX:310-537-3927
FAX:310-638-8046
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PAGE 2 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 3
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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 andTransportation ............................................. 10
Trailer Safety Guidelines........................................... 11-17
TrailerWiring 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
OutputTerminal 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
EngineWiring Diagram ............................................. 56-57
GeneratorWiring Diagram .............................................. 58
EngineTroubleshooting ............................................. 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)
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PARTS ORDERING PROCEDURES
I Dealer account number
I Dealer name and address
I Shipping address (if different than billing address)
I Return fax number
I Applicable model number
I Quantity, part number and description of each part
I Specify preferred method of shipment:
UPS Ground
•
UPS Second Day or Third Day*
•
UPS Next Day*
•
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
Airborne Express*
•
Truck or parcel post
•
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
Additional Discount
1-9 items
3%
10+ items**
5%
only
s
der
ed or
x
a
f
For
Get special freight allowances
when you order 10 or more
line items via FAX!**
Now! Direct TOLL-FREE access
to our Parts Department!
I
UPS Ground Service at no charge for freight
I
PS Third Day Service at one-half of actual freight cost
Toll-free nationwide:
800-421-1244
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.
Toll-free FAX:
*DISCOUNTS ARE SUBJECT TO CHANGE*
800/6-PARTS-7 • 800-672-7877
Fax order discount and UPS special programs revised June 1, 1995
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 5
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RULES FOR SAFE OPERATION
CAUTION:
I
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
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:
I
I
High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with hot components can cause serious
burns.
GENERAL SAFETY
I
I
I
DONOToperateorservicethisequipmentbefore
reading this entire manual.
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.
This equipment should not be operated by
persons under 18 years of age.
NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel-
toed boots and other protective devices
required by the job.
CAUTION
:
I
Always refuel in a well-ventilated area,
away from sparks and open flames.
I
I
I
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
I
Always use extreme caution when
NEVER operate this equipment under the
influence or drugs or alcohol.
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 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.
I
NEVER operate the generator in an
I
I
I
Manufacturer does not assume responsibility for any
accident due to equipment modifications.
explosive atmosphere or near combustible
materials. An explosion or fire could result
causing severe bodily harm or even
death.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Always check the machine for loosened threads or bolts
before starting.
I
Topping-off to filler port is
dangerous, as it tends to spill fuel.
PAGE 6 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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RULES FOR SAFE OPERATION
CAUTION
:
CAUTION
:
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
I
NEVER touch output terminals during operation. This is
extremely dangerous. Always stop the machine when
contact with the output terminals is required.
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.
CAUTION
:
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.
I
Backfeed to a utility system can cause electrocution
and.or property damage. Do not connect to any
building's electrical system except through an approved
device or after building main switch is opened.
CAUTION
:
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
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RULES FOR SAFE OPERATION
Battery
I
I
I
I
NEVER Run engine without air filter. Severe engine
damage may occur.
CAUTION
:
Always service air cleaner frequently to prevent carburetor
malfunction.
Never over fill the battery with water above
the upper limit.
Always disconnect the battery before performing service
on the generator.
Always be sure the operator is familiar with proper safety
precautions and operations techniques before using
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:
I
Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.
I
I
I
I
DO NOT leave the generator running in the manual mode
unattended.
DO NOT allow unauthorized people to operate this
equipment.
1. DO NOT drop the battery. There is the possibility of risk
Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
that the battery may explode.
2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.
Refer to the Isuzu Engine Owner's Manual for engine
technical questions or information.
Loading and Unloading (Crane)
I
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.
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.
I
I
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.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
I
I
NEVER lift the machine while the engine is running.
Use adequate lifting cable (wire or rope) of sufficient
strength.
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.
I
I
I
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)
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RULES FOR SAFE OPERATION
Transporting
I
I
I
Always shutdown engine before transporting.
Tighten fuel tank cap securely.
Drain fuel when transporting generator over long distances
or bad roads.
I
I
Keep the machinery in proper running condition.
I
I
Always tie-down the generator during transportation by
securing the generator.
Fix damage to the machine immediately and always
replace broken parts.
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.
I
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
Emergencies
I
I
DO NOT use plastic containers to dispose of hazardous
waste.
I
Always know the location of the nearest fire extinguisher
and first aid kit. Know the location of the nearest telephone.
Also know the phone numbers of the nearest ambulance,
doctor and fire department.
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
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DCA-40SSAI —TOWING ANDTRANSPORTATION
Towing Safety Precautions
I
I
ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
CAUTION :
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
Check with your county or state safety
towing regulations department before towing
your generator.
I
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.
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.
I
I
I
Place chocked blocks underneath wheel to prevent
rolling, while parked.
Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
The following list of suggestions should be used when towing
your generator:
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.
I
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
I
Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
I
ALWAYS inspect the hitch and coupling for wear.NEVER
tow a trailer with defective hitches, couplings, chains
etc.
I
I
I
Avoid sharp turns to prevent rolling.
I
I
Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 1. Generator with Trailer
PAGE 10 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI —TRAILER-SAFETY GUIDELINES
4.
5.
6.
Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
Frame Width - This measurement is from fender to
fender.
Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.
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.
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.
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 en-
sure safe towing of the equipment and will prevent damage
to the equipment and personal injury.
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.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
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. SeeTable 4 and Figure 5 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port 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.
Brakes
Tires
Lug NutTorquing
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 trans-
porting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
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
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DCA-40SSAI —TRAILER-SPECIFICATIONS
Table 1. Specifications
MODEL
APPLICATION
FUEL
CELL
BRAKE
SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
TRLR-10W
TRLR-10
SDW225,
SGW250,TLW300
NO
NO
1900LBS
1900LBS
1900LBS
2200LBS
2700LBS
2700LBS
2700LBS
7000LBS
7000LBS
7000LBS
7000LBS
10000LBS
11160LBS
14000LBS
18000LBS
18000LBS
30000LBS
30000LBS
96"
96"
96"
85"
50"
50"
50"
42"
800LB.
FULL TILT WHEEL
DCA10, TLG12,
DCA-15
NO
NO
800LB.
FULL TILT WHEEL
TRLR-10XF
TRLR-225W
TRLR-BLW400
TRLR-50X
DCA10, TLG-12,
DCA15, TLW-300
52 GAL
NO
NO
NO
800LB.
FULL TILT WHEEL
WELDERS,
DA7000SS
800LB.
FULL TILT WHEEL
BLW-400
NO
ELECTRIC
NO
W/MAST 154"
W/O 124"
55"
(78" TALL)
800LB.
FULL TILT WHEEL
DCA-25
NO
124"
124"
186"
138"
138"
190"
186"
204"
222"
238"
238"
384"
384"
55"
55"
77"
66"
66"
76"
77"
84"
83"
83"
83"
96"
96"
800LB.
FULL TILT WHEEL
TRLR-50XF
TRLR-70W
DCA-25
41 GAL
NO
NO
800LB.
FULL TILT WHEEL
DCA-45, -60, 70
DCA-45, -60, 70
DCA-45, -60, 70
DCA-100, 125
SURGE
2000LB.
FLAT PAD
TRLR-70X
OPT
SURGE
2000LB.
FLAT PAD
TRLR-70XF
TRLR-100XF
TRLR-85/125
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800SX
53 GAL
150 GAL
145 GAL
200 GAL
250 GAL
250 GAL
350 GAL
550 GAL
550 GAL
SURGE
2000LB.
FLAT PAD
HYDRAULIC SURGE
HYDRAULIC
HYDRAULIC SURGE
HYDRAULIC SURGE
HYDRAULIC SURGE
ELECTRIC
AIR
2000LB.
FLAT PAD
DCA-85, 100,
125
2000LB.
FLAT PAD
DCA-150, 180
5000 LB.
FLAT PAD
DCA-220
5000 LB.
FLAT PAD
DCA-300
5000 LB.
FLAT PAD
DCA-400
5000 LB.
FLAT PAD
DCA-600, 800
DCA-600, 800
5000 LB.
FLAT PAD
AIR
5000 LB.
FLAT PAD
PAGE 12 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI —TRAILER-SPECIFICATIONS
Table 1. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS SUSPENSION
ELECTRICAL
TRLR-10W
2" BALL CLASS
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X2
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
6 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
3 LEAF
3 LEAF
3 LEAF
Q FLEX
3 LEAF
4 LEAF
4 LEAF
5 LEAF
5 LEAF
5 LEAF
5 LEAF
7 LEAF
7 LEAF
Q FLEX
Q FLEX
Q FLEX
7 LEAF
AIR-RIDE
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10
TRLR-10XF
TRLR-225W
2"BALL CLASS
2 ADJUSTABLE
175-13C
175-13C
13"X4.5"
13"X4.5"
13X4.5"
13 X 4.5"
13"X4.50"
13"X4.50"
14"X5"
2200#2X2
2200#2X2
2200#2X2
2200#2X2
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
2"BALL CLASS
2 ADJUSTABLE
2"BALL CLASS
2 ADJUSTABLE
175-13B
TRLR-BLW
400
2"BALL CLASS
2 ADJUSTABLE
175-13C
TRLR-50X
TRLR-50XF
TRLR-70W
TRLR-70X
TRLR-70XF
2" BALL CLASS
B78-13LRC
B78-13LRC
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
2" BALL CLASS
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
3500lbs.
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs.
3"
4 POLE RUBBER
FLAT
TRLR-100XF ADJUSTABLE 2-5/6
205-15C
BIAS (4)
14"X5.5"
14"x6"
3500lbs
3"
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
6 WIRE LOOM
6 WIRE LOOM
OPT 3" EYE
TRLR-85/125 ADJUSTABLE 2-5/6
ST225/75R15D
RADIAL (4)
(2)-6000lbs
(2)-6000lbs
(2)-7000lbs
(2)-6000lbs
(3)-7000lbs.
(3)-10000lbs
(3)-10000lbs
OPT 3" EYE
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800AR
3" BALL EYE
750-16 E
BIAS (4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 13
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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.
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.
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:
Figure 2 displays the major electric brake components that
will require inspection and maintenance. Please inspect
these components as required.
Electric Brake Adjustment
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
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.
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.
8. Repeat steps 1 through 6 on the remaining brakes.
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DCA-40SSAI —TRAILER SAFETY GUIDELINES
Figure 2. Electrical Brake Components
Hydraulic/Air/Surge Brakes
Figure 3 below displays the major hydraulic/air/surge brake
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.
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
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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.
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.
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.
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
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DCA-40SSAI —TRAILER SAFETY GUIDELINES
Table 3. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-60
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAIN NUT-BOLT ASSEMBLY.
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
Lug NutTorque 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 byTable 4.
3.
After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 4. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 5. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
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DCA-40SSAI —TRAILER-WIRING DIAGRAM
NOTE:
LIGHTS ARE ORIENTED FROMTHE DRIVER’S SEAT
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DCA-40SSAI —TRAILER-BRAKETROUBLESHOOTING
Table 5. Electric Brake Troubleshooting
Symptom
Possible Cause
Any open circuits or broken wires?
Any short circuits?
Solution
No Brakes or Intermittent Brakes
Find and correct.
Find and correct.
Test and correct.
Find and repair.
Find and secure.
Clean or replace.
Faulty controller?
Any loose connections?
Ground wire secure?
Weak Brakes or Brakes Pull to
One Side
Grease or oil on magnets or linings?
Connections corroded?
Clean and correct cause
of corrosion.
Brake drums scored or grooved?
Brakes synchronized?
Machine or replace.
Correct.
Locking Brakes
Noisy Brakes
Brake components loose, bent or broken?
Brake drums out-of-round?
Replace components.
Replace.
System lubricated?
Lubricate.
Brake components correct?
Bearings of the wheel adjusted?
Replace and correct.
Adjust.
Dragging Brakes
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DCA-40SSAI —TRAILER-BRAKETROUBLESHOOTING
Table 6. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Brake line broken or kinked?
Brake lining glazed?
Solution
Repair or replace.
Reburnish or replace.
Correct weight.
No Brakes
Weak Brakes or Brakes Pull to
One Side
Trailer overloaded?
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or broken?
Brake drums out-of-round?
System lubricated?
Locking Brakes
Noisy Brakes
Replace components.
Replace.
Lubricate.
Brake components correct?
Replace and correct.
Dragging Brakes
Brake lining thickness correct or in right
wrong position?
Install new shoes and
linings.
Enough brake fluid or correct fluid?
Replace rubber parts
fill with dot4 fluid.
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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.
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DCA-40SSAI — GENERATOR DECALS
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DCA-40SSAI — SPECIFICATIONS
Table 7. Specifications
Generator Specifications
Model
Type
DCA-40SSAI
Revolving field, self ventilated, open protected type synchronous generator
Armature Connection
Phase
Star with Neutral
3
Standby Output
Prime Output
Voltage
46.8 KVA (37.4 KW)
40 KVA (32 KW)
240V or 480V
Frequency
Speed
60 Hz
1800 rpm
Power Factor
Aux. AC Power
Voltage
0.8
Single Phase, 60 Hz
120/240 V
Output
11.5 KW (13.4 KW)
Engine Specifications
ISUZU QD100 (4BD1)
4 Cycle, water-cooled, swirl combustion chamber type
4 cylinders
Model
Type
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
4 in. x 4.6 in. (102 mm x 118 mm)
52 HP/1800 rpm
235 cu. in. (3856 cc)
Electric
Coolant Capacity
Lube Oil Capacity
4 gal. (15 liters)
3.4 gal. (12.9 liters)
2.3 gal. (8.7L)/hr at full load
1.5 gal. (5.7L)/hr at 1/2 load
2.0 gal. (7.6L)/hr at 3/4 load
1.1 gal. (4.2L)/hr at 1/4 load
Fuel Consumption
Battery
Fuel
12V- 100AH x 2
#2 Diesel Fuel
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 23
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DCA-40SSAI — GENERAL INFORMATION
DCA-40SSAI FAMILIARIZATION
Generator
Open Delta Excitation System
The DCA-40SSAI generator is equipped with the state of
the art "Open-Delta" excitation system. The open delta
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
The MQ Power Model DCA-40SSAI is a 26 kW generator
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 There are four leads: A, B, C and D. During light loads, the
industrial and construction machinery.
power to the Automatic Voltage Regulator (AVR) is supplied
from the leads parallel connections of B&C. When loads
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.
Engine Operating Panel
The “Engine Operating Panel”is provided with the following:
z
z
z
z
z
z
z
z
z
z
Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel level gauge
Engine Speed Control
Pre-Heat Button
Panel Light
Panel Light Switch
Starter /Preheat Switch
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
excitation does not have a "fixed ceiling" and responds
according the demands of the required load.
Generator Control Panel
Engine
The “Generator Control Panel”is provided with the following:
The DCA-40SSAI is powered by a 4 cycle, water cooled,
Isuzu 4BD1 diesel engine.This engine is designed to meet
every performance requirement for the generator.Reference
Table 7, page 23 for engine specifications.
z
z
z
z
z
z
z
Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
In keeping with Multiquip's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
The basic controls and indicators for the DCA-40SSAI
generator are addressed on the following pages.
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
Mechanical Governor System
z
z
z
z
Two 120V, 20A receptacles
Two 240V, 20A receptacles
One twist-lock 120V, 50A receptacle
50A and 30A circuit breakers
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 in-
creases frequency variation to .25%.
Control Box
The “Control Box” is provided with the following:
z
z
Main Circuit Breaker 100 amps
Over-Current Relay
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NOTE PAGE
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DCA-40SSAI — MAJOR COMPONENTS
Figure 6. Major Components
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DCA-40SSAI — DIMENSIONS
Figure 7. Dimensions
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DCA-40SSAI — CONTROL PANEL DESCRIPTION
Figure 8. Control Panel
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DCA-40SSAI — CONTROL PANEL DESCRIPTION
The definitions below describe the controls and functions of
the DCA-40SSAI " Control Panel " (Figure 8).
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.
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DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION
Figure 9. Engine Operating Panel
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DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION
The definitions below describe the controls and functions of
the DCA-40SSAI " Engine Operating Panel " (Figure 9).
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. WaterTemperature Gauge – During normal operation
this gauge be should read between 165o to 215o.
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.
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DCA-40SSAI — OUTPUTTERMINAL PANEL
Output Terminal Panel
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.
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
Connecting Load
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.
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.
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.
Figure 11. Load Application
Circuit Breakers
To protect the generator from an overload, a 3-pole, 110 amp,
main circuit breaker is provided to protect the UVWO output
terminals from overload. In addition two single-pole, 20 amp
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload. Three 50 amp load circuit
breakers have also been provided to protect the load side of
the generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
Figure 10. GFCI Test Button
Generator Grounding
Make sure the generator is properly grounded before
applying load. Generators are NOT considered grounded
when mounted on a trailer.
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.
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DCA-40SSAI — OUTPUTTERMINALVOLTAGE SELECTION
DCA-40SSAI
NOTE
Legs
O
and Ground are
considered Bonded Grounds.
Figure 12. Output Panel Location
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DCA-40SSAI — OUTPUT AMPERAGE SETUP
Over Current Relay
Output Terminal Panel Available Voltages
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.
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.
Table 8. Voltages Available
Three Phase
(Switchable)
208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 480 VOLT
120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 277 VOLT
Single Phase
(Switchable)
CAUTION :
Maximum Amps
Table 9 shows the maximum amps the generator will pro-
vide. Do not exceed the maximum amps listed.
NEVER switch Voltage Selector Switch
position while the engine is engaged.
Voltage Selector Switch Locking Button
Table 9. Maximum Amps
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.
Rated
Maximum Amps
Voltage
Single Phase
100 amps (4 wire)
120 Volt
Single Phase
50 amps (4 wire)
240 Volt
Three Phase
108 amps
240 Volt
Three Phase
54 amps
480 Volt
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DCA-40SSAI — OUTPUT AMPERAGE SETUP
Receptacle Use
When the UVWO terminals are providing power, the recep-
tacle power availability will decrease. Do not exceed recep-
tacle power as listed on Table 10.
Table 10. Receptacle Use
Receptacle
Power in Use
Power
Available
Figure 13. Voltage Selector Switch 240/120V Single
Phase Position
240/120V
240/480V Single Phase
Duplex
NEMA
5-20R 120V
3-Phase
or Twist
Lock CS6369
KVA
45
KW
26
KW
0
40.9
36.7
32.6
28.4
24.8
23.6
22.4
21.2
1.2
2.4
3.6
4.8
Figure 14 and 15. AC Voltmeter Change-over switch
and Voltmeter Gauge
40
20
60
0
75
HowTo ReadThe OutputTerminal 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.
A
Figure 16 and 17. AC Ammeter Change-over Switch
and Ammeter Gauge
When the voltage selector switch is in the 240/120V posi-
tion (Figure 13), place the AC voltmeter change-over switch
to theW-U position (Figure 14) and the AC ammeter change-
over switch to the U or W position (Figure 16) to read the
output on the selected leg.
NOTE
When using plural single phase
voltages, make sure to balance
the load on each of the single
phase legs.
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DCA-40SSAI — OUTPUTVOLTAGE SETUP
480/240V Hard Wire Hookup
240/120V HardWire 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).
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).
When using the 3-phase 480 volts hookup, it will provide
one circuit available at 50 amps with all three wires plus
ground.
Figure 19. Voltage Selector Switch 480/277V Three Phase
Position
Figure 18. Hard Wire Hookup at 240/120V Position
Figure 20. Hard Wire Hookup at 480/240V Position
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DCA-40SSAI — OUTPUTVOLTAGE SETUP
Voltage Selector Switch- 3 Phase 480/277V Position
Single Phase: 480V, 440V, or 416 Volt
The following are additional voltages available when the 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 volt-
age 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.
age selector switch is in the ‘3 phase 480/277V’ position.
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 volt-
age 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
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DCA-40SSAI — OUTPUTVOLTAGE SETUP
Voltage Selector Switch- 3 Phase 240/139V Position
Single Phase: 240V, 220V, or 208 Volt
The following are additional voltages available when the 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 volt-
age 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.
age selector switch is in the ‘3 phase 240/139V’ position.
Figure 27. Hard Wire Hookup for Single Phase 240V, 220V,
or 208V
Figure 25. Voltage Selector Switch 240/139V Three Phase
Position
Single Phase: 139V, 127V, or 120V
3 Phase, 240V, 220V, or 208 Volt
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 volt-
age 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.
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.
Figure 28. Hard Wire Hookup for Single Phase 139V, 127V,
or 120V
Figure 26. Hard Wire Hookup for Three Phase 240V, 220V, or
208V
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DCA-40SSAI — OUTPUTVOLTAGE SETUP
Voltage Selector Switch- Single Phase 240/120V
Position
Single Phase: 120 Volt
This setting can provide single phase power at 120 volts.
The following are additional voltages available when the volt-
age selector switch is in the ‘single phase 240/120V’ posi-
tion.
After hooking up the hard wires to the lugs as shown in
Figure 31, 120 volts can be obtained with the voltage regula-
tor knob turned to fine tune.
Figure 31. Hard Wire Hookup for Single Phase, 120 volt
Figure 29. Voltage Selector Switch 240/120V Single Phase
Position
Single Phase, 240 Volt
This setting can provide single phase power at 240 volts.
After hooking up the hard wires to the lugs as shown in
Figure 30, 240 volts can be obtained with the voltage regula-
tor knob turned to fine tune.
Figure 30. Hard Wire Hookup for Single Phase 240 volt
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DCA-40SSAI — INSTALLATION
Outdoor Installation
CAUTION
:
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.
An electric shock may happen when
vibrators are used. Pay close attention to
handling when operating vibrators and
always use rubber boots and gloves to
insulate the body from electrical shock.
Generator Grounding
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.
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.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
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.
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 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.
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.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
NOTE
Mounting
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
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.
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DCA-40SSAI — INSTALLATION
Figure 31. Typical Generator Grounding Application
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DCA-40SSAI — PRE-SETUP
General Inspection Prior to Operation
Circuit Breakers
The DCA-40SSAI generator has been thoroughly inspected To protect the generator from an overload, a 3-pole, 100 amp,
and accepted prior to shipment from the factory. However, main circuit breaker is provided to protect the UNV output
be sure to check for damaged parts or components, or loose terminals from overload. In addition two single-pole, 20 amp
nuts and bolts, which could have occurred in transit.
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload.Three 50 amp load circuit breakers
have also been provided to protect the load side of the
generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
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.
NOTE
ALWAYS consult with a licensed
electrician for correct extension
cord wire size.
Table 11. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Maximum Allowable Cable Length
Current in
Amperes
At 120 At 240
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
Volts
2.5
5
300
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
600
900
1200
1800
2400
3600
4800
7.5
10
15
20
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage.
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DCA-40SSAI — PRE-SETUP
Fuel
Lubrication Oil
Fill the fuel tank with clean and fresh diesel fuel. DO NOT
fill the tank beyond capacity.
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.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 23
Specification Table 7.
The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel. Wipe up any spilled fuel immediately.
CAUTION :
Never fill the fuel tank while the engine is
running or in the dark. 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.
Figure 32. Engine Oil Dipstick
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.
Table 12. Recommended Motor Oil
Temperature Range
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
SAE 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
SAE 10W or SAE 10W-30
Below 5° C (-15°)
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DCA-40SSAI — PRE-SETUP
Cleaning the Outer Radiator
CAUTION :
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.
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.
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Isuzu Engine Owner's Manual.
Fan BeltTension
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.
Table 13. Coolant Capacity
Engine and Radiator
Reserve Tank
4 Gal. (15 L)
0.26 Gal. (1L)
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.
Table 14. Anti-Freeze Operating Temperatures
Figure 33. Fan Belt Tension
CAUTION :
Freezing Point
Boiling Point
Vol %
Never place hands near the belts or fan
while the generator set is running.
Anti-Freeze
°C
-24
-37
°F
°C
°F
40
50
-12
-34
106
108
222
226
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.
NOTE
When the antifreeze is mixed with
water, the antifreeze mixing ratio must
be less than 50%.
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DCA-40SSAI — PRE-SETUP
Battery
CAUTION :
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.
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.
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.
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.
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.
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
connected to the battery terminals as shown below.The RED
cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.
CAUTION :
Inadequate battery connections may
cause poor starting of the generator, and
create other malfunctions.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness.Tighten all hose clamps and check hoses
for leaks.
If any hose (fuel or oil) lines are defective replace them
immediately.
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.
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DCA-40SSAI — LOAD APPLICATION
Single Phase Load
CAUTION
:
Motors and motor-driven equipment draw
much greater current for starting than
during operation.
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.
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
z
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.
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.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
WATTS = VOLTAGE x AMPERAGE
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
The power factor of this generator is 1.0. See Table 15.
below when connecting loads.
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.
Table 15. Power Factor By Load
Type Of Load
Power Factor
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
NOTE
Fluorescent lamps, mercury lamps
If output (kVA) is not given on the
equipment nameplate, approximate
output may be determined by
multiplying voltage by amperage by
Electronic devices, communication
equipment
Common power tools
0.8
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
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DCA-40SSAI — GENERATOR START-UP PROCEDURE
WARNING:
2. Connect the load to the UNV terminals as shown in
The engine's exhaust contains harmful
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.
emissions. ALWAYS ventilate the
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.
Figure 36. UNV Terminal Lugs (Load)
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.
3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 37).
Before Starting
Generator and Control Panel
CAUTION:
NEVER start the engine with the
main, GFCI or load circuit breakers
in the ON position.
1.
Be sure to disconnect the
electrical load and switch the main, load and G.F.C.I.
circuit breakers (Figure 35) to the “OFF” position prior to
starting the engine.
Y
TTER
BA
Figure 37. Battery Connections
Figure 35. Main, GFCI and
Load Circuit Breakers
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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 42. Engine Speed Switch (high)
9. The generator's frequency meter (Figure 43) displays
Figure 38. Engine Enclosure Doors
the 60 cycle output frequency in HERTZ.
5.
6.
Check the voltage selection switch (Figure 39) is
at the desired voltage.
Figure 43. Frequency Meter (Hz)
Figure 39. Voltage Selection Switch
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.
Turn and push the engine throttle control lever
(Figure 40) to ‘Low’.
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 45.Voltage Adjust Control Knob
Figure 41. Starter Switch
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DCA-40SSAI — GENERATOR START-UP PROCEDURE
11. The ammeter (Figure 46) will indicate zero amps with no 14. The tachometer (Figure 49) will indicate the speed of
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.
the engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800
RPM’s.
40
20
60
0
75
A
Figure 46. Ammeter (No Load)
12. The engine oil pressure gauge (Figure 47) will indicate
the oil pressure (kg/ cm2) 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.
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.
WATER TEMP
40
20
60
0
75
Figure 48. Coolant Temperature Gauge
A
Figure 51. Ammeter (Load)
17. The generator will run until manually stopped or an
abnormal condition occurs.
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DCA-40SSAI — GENERATOR SHUTDOWN PROCEDURE
EMERGENCY STOP
ENGINE SHUTDOWN
To shutdown the generator, use the following procedure:
1. To stop the engine in the event of an emergency, switch
the MAIN, GFCI and LOAD circuit breakers to ‘OFF’
position.
1. Switch both the MAIN, GFCI and LOAD circuit breakers
(Figure 52) to the “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.
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DCA-40SSAI — MAINTENANCE
General Inspection
Cleaning the Fuel Strainer
Prior to each use, the generator should be cleaned and Clean the fuel strainer if it contains dust or water. Remove
inspected for deficiencies. Check for loose, missing or dust or water in the strainer cap and wash it in gasoline.
damaged nuts, bolts or other fasteners. Also check for fuel, Securely fasten the fuel strainer cap so that fuel will not
oil, and coolant leaks.
leak. Check the fuel strainer every 200 hours of operation or
once a month.
Engine Side (Refer to the Engine Instruction Manual)
Air Cleaner
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.
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.
Replacing Oil Filter
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.
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.
Fuel Addition
Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.
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.
Removing Water from the FuelTank
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.
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.
Air Removal
Vent any air.
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.
Fuel Injection Nozzle
z
Use an injection nozzle tester to check the static injection
starting pressure and the fuel spray conditions.
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.
z
Abnormal fuel consumption will lead to a lowered output
and blackish exhaust smoke. The required injection
starting pressure should be 14.7MPa (150kg/cm2,
2130psi).
Service Daily
If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result. This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber in high fuel consumption.
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DCA-40SSAI — MAINTENANCE
Feed Pump Strainer Cleaning
The strainer is incorporated in the feed pump inlet side joint
bolt. Clean the strainer with compressed air and rinse it in
the fuel oil.
Flushing Out Radiator and Replacing Coolant
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 — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 53
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DCA-40SSAI — MAINTENANCE
Valve Clearance Check
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.
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.
4. If “a” and “b” are in alignment, the timing is set correctly.
If not, follow nos. 1-3 until the “a” and “b” are aligned.
2. Do the adjustment on the circle marked valves in the
below table where No. 1 cylinder is at the center in the 5. Reversely turn the crankshaft pulley counterclockwise
compression stroke.
viewed at the engine front about 30o crank angle.
3. After adjustment started from either piston top center, 6. Remove No. 1 injection pipe from the engine.
turn the crankshaft 360o to align the notched line with
7. Remove the injection pump No. 1 delivery valve holder,
the TDC mark to do the adjustment again on the
delivery valve and spring and reinstall the delivery valve
remaining valve. See Table 16 and Figure 55 for valve
holder on the original place.
arrangement.
8. Delivery valve holder tightening torque:
39~44Nm(29~33lbft.)
Injection Timing Check and Adjustment
9. Slowly turn the crankshaft pulley clockwise and at the
1. Bring No. cylinder to the top dead center on the
compression stroke.
same time continue to feed the fuel with pumping the
Feed pump. When the fuel stop to flow out from No. 1
delivery valve holder, stop pumping.
2. Turn the crankshaft pulley clockwise (viewed at engine
front) and align the notched line on the crank pulley with 10. Observe and make sure which mark (injection starting
the TDC mark on the timing gear case cover.
angle line) on the timing gear case cover is aligning with
the notched line on the crank pulley.
11. The timing line shows the injection starting crank angle
of the engine.
12. The injection starting crank angle should be at the 14o
timing mark.
Table 16. Valve Adustment
(I=Inlet; E=Exhaust)
Cylinder No.
1
2
3
4
Figure 55.Valve Adjustment
Valve Arrangement
I
E
X
I
E
I
E
X
I
E
When No. 1 is at top
dead center in the
compression stoke
X
X
NOTE:
Take necessary precautions to prevent dust and
foreign particles in the pump interior when timing
adjustments are made.
When No. 4 is at top
dead center in the
compression stroke
O
O
O
O
PAGE 54 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI — MAINTENANCE
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
INSPECTION / MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Replace Engine Oil and Filter *1
Clean Air Filter
X
X
X
X
Drain Bottom of Fuel Tank
ENGINE
Clean Unit, Inside and Outside
Change Fuel Filter *2
X
X
Clean Radiator and Check Coolant Protection
Level
Test Fuel Injection Nozzle
Replace Air Filter Element
Check all Hoses and Clamps
Check Valve Clearance
X
X
X
X
X
X
Check Injection Nozzle
X
Clean Inside of Fuel Tank
X
Measure Insulation Resistance Over 3M ohms
GENERATOR
1
*
*
Replace engine oil anf filter at 100 hours, first time only.
Replace fuel filter at 250 Hours, first time only.
2
Generator Storage
z
z
Clean all external parts of the generator with a cloth.
Cover the generating set and store in a clean, dry place.
For storage of the generator for over 30 days, the following
is required:
z
z
Fill the fuel tank completely.
Completely drain the oil from the crankcase and refill
with fresh oil.
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 55
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DCA-40SSAI — ENGINEWIRING DIAGRAM
PAGE 56 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI — GENERATORWIRING DIAGRAM
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 57
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DCA-40SSAI —TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper diagnosis based on the Engine Troubleshooting (Table 1 7).
handling and maintenance inspections, but in the event of a If the problem cannot be remedied, consult our company's
breakdown, use the tables shown for
business office or service plant.
TABLE 17. ENGINE TROUBLESHOOTING (PART 1)
SYMPTOM
POSSIBLE PROBLEM
No fuel?
SOLUTION
Replenish fuel.
Air in the fuel system?
Water in the fuel system?
Fuel pipe clogged?
Bleed system.
Remove water from fuel tank.
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity
of fuel or engine oil at low
temperature?
Use the specified fuel or engine oil.
Fuel with low cetane
number?
Use the specified fuel.
Tighten nut.
Fuel leak due to loose
injection pipe retaining nut?
Engine does not start.
Incorrect injection timing?
Fuel cam shaft worn?
Adjust.
Replace.
Injection nozzle clogged?
Clean injection nozzle.
Injection pump
malfunctioning?
Repair or replace.
Repair or replace.
Seizure of crankshaft,
camshaft, piston, cylinder
liner or bearing?
Compression leak from
cylinder?
Replace head gasket, tighten cylinder head bolt, glow
plug and nozzle holder.
Improper valve timing?
Correct or replace timing gear.
Piston ring and liner worn? Replace.
Excessive valve clearance? Adjust.
PAGE 58 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI —TROUBLESHOOTING (ENGINE)
TABLE 17. ENGINE TROUBLESHOOTING (PART 2)
SYMPTOM
POSSIBLE PROBLEM
Fuel filter clogged or dirty?
Air cleaner clogged?
SOLUTION
Clean or change.
Clean or change.
Fuel leak due to loose
Tighten nut.
injection pipe retaining nut?
Injection pump
malfunctioning?
Repair or replace.
Adjust.
Engine revolution is not
smooth.
Incorrect nozzle opening
pressure?
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe
clogged?
Clean.
Repair.
Governor malfunctioning?
Excessive engine oil?
Reduce to the specified level.
Repair or replace.
Piston ring and liner worn
or stuck?
Either white or blue exhaust
gas is observed.
Incorrect injection timing?
Deficient compression?
Overload?
Adjust.
Adjust top clearance.
Lessen the load.
Use the specified fuel.
Clean or change.
Clean or change.
Repair or replace the nozzle.
Adjust.
Low grade fuel used?
Fuel filter clogged?
Either black or dark gray
exhaust gas is observed.
Air cleaner clogged?
Deficient nozzle injection?
Incorrect injection timing?
Engine's moving parts
seem to be seizing?
Repair or replace.
Deficient output.
Uneven fuel injection?
Repair or replace the injection pump.
Repair or replace the nozzle.
Deficient nozzle injection?
Replace head gasket, tighten cylinder head bolt, glow
plug and nozzle holder.
Compression leak?
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 59
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DCA-40SSAI —TROUBLESHOOTING (GENERATOR/ENGINE)
TABLE 17. GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
No Voltage Output
AC Voltmeter defective?
Is wiring connection loose?
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Low Voltage Output
Turn engine throttle lever to "High".
Check wiring and repair.
Replace if necessary.
High Voltage Output
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Circuit Breaker Tripped
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
PAGE 60 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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NOTE PAGE
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 61
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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)
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DCA-40SSAI — SUGGESTED SPARE PARTS
DCA-40SSAIW/ISUZU 4BD1 DIESEL ENGINE
1 TO 3 UNITS
Qty. P/N
Description
1 ......... 0601808811 ..............CIRCUIT BREAKER
1 ......... 0601820671 ..............AUTOMATICVOLTAGE 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
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DCA-40SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
PAGE 64 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
3341040300
3341010102
9521002693
3341080003
3361032003
33610850003
334110003
3361025003
3361026003
0601820067
0010004020
0041604000
0040004000
OEMAA8
FIELD ASSY.
SHAFT
FIELD CORE
FIELD COIL
ARMATURE CORE, EXCITER
ARMATURE COIL, EXCITER
COUPLING HUB
RECTIFIER ASSY.
SET PLATE, RECTIFIER
1
1
1
1
1
1
1
1
1
1-1
1-2
1-3
1-4
1-5
1-6
2
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
3
4
5
6
7
8
9
10
11
12
13
14
15
RECTIFIER .......................................... 3 ............PB2510
HEX. HEAD BOLT
PLAIN WASHER
LOCK WASHER
HEX. NUT ............................................. 3 ............REPLACES 0030004000
SURGE ABSORBER ........................... 1 ............ERZM14K621A
INSULATOR WASHER
INSULATOR WASHER
HEX. HEAD BOLT................................ 1 ............REPLACES 0010005020
PLAIN WASHER .................................. 2 ............REPLACES 0041605000
LOCK WASHER................................... 1 ............REPLACES 0040005000
3
6
3
0601822601
0801841004
0801841104
0017105020
58151
1
1
0032005000
0030005000
0011305100
3331014004
0070206310
0080000050
3341070002
3341611003
3341612003
3341613004
0131151240
0601600000
030212300
0601610511
0040010000
012010030
3341341400
3341320312
3801342114
3341361503
0801350104
3361315013
3361350030
3361352023
3361362303
HEX. NUT
1
HEX. HEAD BOLT................................ 4 ............REPLACES 0017105012
BEARING FLANGE
BEARING
SNAP RING
FAN
COUPLING DISK
WASHER, COUPLING HUB
LOCK WASHER
HEX. HEAD BOLT................................ 10 ..........REPLACES 0010312030
COUPLING RING ................................ 1 ............9261290050
LOCK WASHER................................... 9 ............REPLACES 0601610700 & 9091505100
BOLT SET
1
1
1
1
1(8)
1
5
1
9
LOCK WASHER
HEX. HEAD BOLT................................ 9 ............REPLACES 0010310030
STATOR ASSY.
GENERATOR FRAME
ARMATURE CORE
ARMATURE COIL
GROMMET
16
1
1
1
1
1
1
1
1
1
16-1
16-2
16-3
17
18
19
END BRACKET
FIELD ASSY. EXCITER
FIELD CORE, EXCITER
FIELD COIL, EXCITER
19-1
19-2
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 65
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DCA-40SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
PAGE 66 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
NO.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
PART NO.
ITEM
QTY.
REMARKS
031108160
0040008000
0010008060
0040010000
012010030
3801312004
3331310104
0040006000
0040006055
3361331003
011006010
0040010000
0105091025
3361332003
952404470
0040006000
0010006030
0605000011
0040016000
020316130
PLAIN WASHER .................................. 4 ............REPLACES 0041608000
LOCK WASHER
HEX. HEAD BOLT
LOCK WASHER
4
4
6
HEX. HEAD BOLT................................ 6 ............REPLACES 0010010030
GASKET, BEARING
COVER, BEARING
LOCK WASHER
HEX. HEAD BOLT
COVER, END BRACKET
HEX. HEAD BOLT................................ 8 ............REPLACES 0017106010
LOCK WASHER
HEX. HEAD BOLT................................ 6 ............REPLACES 0010310025
COVER, FAN
PLAIN WASHER .................................. 1 ............REPLACES 0041606000
1
1
4
4
1
6
1
LOCK WASHER
1
1
2
4
HEX. HEAD BOLT
RUBBER SUSPENSION
LOCK WASHER
HEX. NUT ............................................. 4 ............REPLACES 0030116000
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 67
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DCA-40SSAI --- CONTROL BOX ASSY.
CONTRO
PAGE 68 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
7451810002
7451810012
3361870603
0017106016
0601801142
0027104010
0800225200
0027106010
0601820042
0027103010
0601842058
0027108010
0601804970
0041604000
0040004000
0021004060
0601830625
0021104016
0021104014
3341822503
0601800460
0601800729
0601801040
0601800212
CONTROL BOX............................................. 1 ....... UP TO S/N3311949
CONTROL BOX............................................. 1 ....... S/N3311950
2
3
4
5
6
7
8
9
10
11
14
15
16
17
18
19
20
21
22
23
24
25
CURRENT TRANSFORMER
HEX.HEAD BOLT
3
6
CURRENT TRANSFORMER, AMMETER ..... 2 ....... CT3.5MR 75/5A
MACHINE SCREW
AUTOMATIC VOLTAGE REGULATOR ........ 1 ....... AE2206A
4
MACHINE SCREW
RECTIFER
MACHINE SCREW
6
1
4
RESISTOR .................................................... 1 ....... 80V 200OHMS
MACHINE SCREW
CIRCUIT BREAKER ...................................... 1 ....... TO100CC 500V 100AT
2
PLAIN WASHER
LOCK WASHER
MACHINE SCREW
CHANGE-OVER SW. VOLTAGE
MACHINE SCREW
MACHINE SCREW
CONTROL PANEL
2
2
2
1
4
2
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
0601800217
26
27
0601801041
CHANGE-OVER SW. VOLTMETER ............. 1 ....... SL2VS
0601810072
0601810261
0601840031
0601840120
3331824003
0027105016
0030005000
0805001304
031108160
020108060
0027105010
7451826504
7451826514
0017106016
011008020
020108060
0601840191
0601830614
PILOT LAMP
BULB
1
1
28
29
30
31
32
33
34
35
36
37
VOLTAGE REGULATOR .............................. 1 ....... RA30A2FE202BJ
KNOB
1
1
2
2
2
STOPPER, CONTROL PANEL
MACHINE SCREW
HEX. NUT
SET SCREW, CONTROL PANEL
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~
38
39
40
41
42
HEX. HEAD BOLT
2
HEX. HEAD BOLT......................................... 4 ....... REPLACES 0017108020
HEX. NUT...................................................... 4 ....... REPLACES 0030008000
SWITCH CAP
PLATE
1
1
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 69
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DCA-40SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 70 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
3
4
5
6
7
8
4B01PD02
ENGINE .......................................... 1 .......... ISUZU 4BD1; REPLACES 0602000078
RADIATOR ...................................... 1 .......... B961110002
RADIATOR NECK ........................... 1 .......... 4079111300
HOSE .............................................. 1 .......... B9611111910
HOSE BAND ................................... 2 .......... G000100131
RADIATOR CA ................................ 1 .......... 7880K11100
0602010800
0602011303
0602011102
0602014062
0602011000
3345123104
011008020
0602013086
0602013186
0602014000
0602014000
0602014071
0602040094
0602040197
0602040690
0602040595
011008020
020108060
3342032103
0605515011
0605515028
1878102201
5878100500
3345112503
3345112403
031110160
0040010000
0105091025
0605000009
0040012000
0039312000
1819001931
0027106016
BRACKET, RADIATOR
2
HEX. HEAD BOLT........................... 12 ........ REPLACES 0017108020
RADIATOR HOSE ........................... 1 .......... 4B128
RADIATOR HOSE ........................... 1 .......... 4B129
9
10
11
12
13
14
HOSE BAND
HOSE BAND
HOSE BAND
2
1
1
AIR CLEANER ................................ 1 .......... FQG068002
ELEMENT, AIR CLEANER.............. 1 .......... P104873
DUST INDICATOR........................... 1 .......... RBX002252
BAND, AIR CLEANER .................... 2 .......... P007191
HEX. HEAD BOLT........................... 4 .......... REPLACES 0017108020
HEX. NUT ....................................... 4 .......... REPLACES 0030008000
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
HOSE, AIR CLEANER
HOSE BAND
HOSE BAND
1
1
1
ELEMENT, OIL FILTER .................. 1 .......... REPLACES 0602041107
ELEMENT, FUEL FILTER ............... 1 .......... REPLACES 0602042108
ENGINE FOOT
ENGINE FOOT
1
1
PLAIN WASHER ............................. 8 .......... REPLACES 0041610000
LOCKWASHER
HEX. HEAD BOLT........................... 8 .......... REPLACES 0010710025
8
RUBBER SUSPENSION
LOCKWASHER
2
4
HEX. NUT ....................................... 4 .......... REPLACES 0030112000
ENGINE STOPPER ........................ 1 .......... REPLACES 0602210803 AND 1819000161
MACHINE SCREW
3
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 71
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DCA-40SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 72 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
53
54
55
56
57
58
59
60
61
3342054104
0805013704
0805014204
3362054104
3342051104
0802024004
0802010204
3342022104
0605515003
011008020
020108060
0845031303
0802081104
3342082304
011008020
011606025
0199500950
0199500175
0193601000
0605515013
0605515013
0193900750
0605515030
0193100700
0605515007
0193800750
0605515019
3342220604
0017106016
DRAIN JOINT
PACKING, OIL PAN SIDE
PACKING
JOINT BOLT
DRAIN JOINT
PACKING
PLUG
DRAIN HOSE
HOSE BAND
HEX. HEAD BOLT........................... 2 .......... REPLACES 0017108020
HEX. NUT ....................................... 2 .......... REPLACES 0030008000
RESERVE TANK
CAP, RESERVE TANK
BRACKET, RESERVE TANK
HEX. HEAD BOLT........................... 2 .......... REPLACES 0017108020
HEX. HEAD BOLT........................... 1 .......... REPLACES 0017106025
HOSE
HOSE
HOSE
HOSE
HOSE BAND
BREATHER HOSE
HOSE BAND
HOSE
HOSE BAND
HOSE
HOSE BAND
EARTH CABLE
HEX. HEAD BOLT
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
1
2
1
1
1
1
1
4
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 73
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DCA-40SSAI --- ENGINE OPERATING PANEL ASSY.
EN
PAGE 74 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
3
4
5
6
7
8
3342101003
7452142004
0601840190
0080200006
7452140504
020108060
0605010503
1823100080
9825300460
0602120052
0602120154
0602122060
0602122200
0131300000
0602123061
0602123201
0602121052
0602103091
0601810244
0601830420
0601810120
0040520000
0601830710
031108160
0040008000
011008040
011008020
3345312003
0017110025
011208025
0030008000
3342183004
0010010025
031110160
020310080
3342182004
3342152114
0602180101
020108060
0602180100
020106050
952404470
OPERATING PANEL
SLIDE BAR
KNOB .............................................. 1 .......... REPLACES 0805012904
SNAP RING
BRACKET, GOVERNOR ROD
HEX. NUT ....................................... 2 .......... REPLACES 0030008000
SNAP PIN
STARTER SWITCH ........................1........... REPLACES 0602100004
PREHEAT LAMP ............................1........... REPLACES 0602102006 AND 9825301080
TACHOMETER ...............................1........... 25000KX3710; REPLACES 0602120052
CABLE, TACHOMETER .................1........... 62100KA6710 L=1150
OIL PRESSURE GAUGE ...............1........... 42000KX1410
UNIT, OIL PRESSURE ...................1........... 53000AC0101
STREET SOCKET
WATER TEMPERATURE GAUGE .1........... 40000KX0910
UNIT, WATER TEMPERATURE.....1........... 51400KV0200
CHARGINE AMMETER .................. 1........... 43000KV0300
ALARM LAMP.................................2........... REPLACES 0602103060
1
1
1
1
1
9
10
11
12
13
14
15
16
17
18
1
BULB
2
1
1
1
1
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
SWITCH, LAMP CHECK
PANEL LIGHT
TOOTHED LOCK WASHER
SWITCH, PANEL LIGHT
PLAIN WASHER ............................. 2 .......... REPLACES 0041608000
LOCK WASHER
HEX. HEAD BOLT .......................... 2 .......... REPLACES 0010008040
HEX. HEAD BOLT .......................... 2 .......... REPLACES 0017108020
SUPPORT LEG
HEX. HEAD BOLT
HEX. HEAD BOLT .......................... 2 .......... REPLACES 0017108025
HEX. NUT
LINK, GOVERNOR ROD
HEX. HEAD BOLT
PLAIN WASHER ............................. 2 .......... REPLACES 0041610000
HEX. NUT ....................................... 1 .......... REPLACES 0030010000
GOVERNOR ROD
GOVERNOR ROD
BALL JOINT
HEX. NUT ....................................... 2 .......... REPLACES 0030008000
BALL JOINT
2
1
2
2
1
1
1
1
2
1
HEX. NUT ....................................... 3 .......... REPLACES 0030006000
PLAIN WASHER ............................. 1 .......... REPLACES 0041606000
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 75
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DCA-40SSAI --- ENGINE OPERATING PANEL ASSY.
EN
PAGE 76 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
PART NO.
ITEM
QTY.
1
REMARKS
42
43
44
45
46
47
48
49
50
51
52
53
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
3345188203
011008020
1825500732
0027106016
0601823706
0027104016
3341860103
SET PANEL, ELECTRIC PARTS
HEX. HEAD BOLT .......................... 6 .......... REPLACES 0017108020
EMERGENCY RELAY ....................1........... REPLACES 0602200405
MACHINE SCREW
RELAY
MACHINE SCREW
4
1
2
SET BOARD, OUTPUT TERMINAL 1
0801831704A OUTPUT TERMINAL
4
012210020
0041410000
0040010000
0039310000
031108160
0040008000
011208030
0601811032
0601811037
0601811031
0601811030
0027103010
0041603000
0207003000
0601805311
0601805315
7451816004
0027106016
3341865803
0805012304
031112230
0805019704
0030012000
0605010505
0601850091
0021003010
0601802133
0601820015
3341865903
7451855503
7451855703
0021304015
0040004000
031104080
OEMAA8
HEX. HEAD BOLT .......................... 4 .......... REPLACES 0801831804
PLAIN WASHER
LOCK WASHER
HEX. NUT
16
12
8
PLAIN WASHER ............................. 5 .......... REPLACES 0041608000
LOCK WASHER
HEX. HEAD BOLT .......................... 5 .......... REPLACES 0010008030
RECEPTACLE ................................2........... L620R 250V 20A
RECEPTACLE ................................2........... CS8269 250V 50A
RECEPTACLE ................................2........... L530R 125V 30A
RECEPTACLE ................................2........... 520R 125V 20Ax2
MACHINE SCREW
PLAIN WSAHER
HEX. NUT ....................................... 16 ........ REPLACES 0030003000
CIRCUIT BREAKER .......................2........... KM51 265V 50A
CIRCUIT BREAKER .......................2........... KM51 265V 30A
BRACKET, CIRCUIT BREAKER
MACHINE SCREW
COVER, OUTPUT TERMINAL
HEX. HEAD BOLT
PLAIN WASHER ............................. 4 .......... REPLACES 0041612000
RUBBER WASHER
HEX. NUT
5
16
16
1
2
1
2
2
2
2
2
2
1
SNAP PIN
RUBBER CUSHION
MACHINE SCREW
FUSE, 5A
RECTIFIER .....................................4........... 1S2762
COVER, OUPUT TERMINAL ..........1........... S/N3312326~
HING ...............................................1........... S/N3312326~
HINGE .............................................1........... S/N3312326~
MACHINE SCREW .........................4........... S/N3312326~
LOCK WASHER.............................. 4........... S/N3312326~
PLAIN WASHER .............................8........... S/N3312326~; REPLACES 0041204000
HEX. NUT .......................................4........... S/N3312326~; REPLACES 0030104000
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 77
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DCA-40SSAI --- BATTERY ASSY.
BATTERY ASSY.
PAGE 78 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- BATTERY ASSY.
BATTERY ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
3
4
5
6
7
8
0160012100
0805003904
0805004004
3802252004
0041608000
031108160
0037808000
0215260050
0211160160
0215860045
0602220310
0037808000
0602220311
0037808000
BATTERY ......................................... 2 ......... N100 12V 100Ah
BATTERY SHEET
BATTERY BAND
BATTERY BOLT
PLAIN WASHER
LOCKWASHER ............................... 4 ......... REPLACES 0040008000
WING NUT
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
TERMINAL ASSY. (+) ...................... 2 ......... NO.9P
WING NUT ....................................... 2 ......... REPLACES 0208008000
TERMINAL ASSY (-)........................ 2 ......... NO.9N
2
2
4
4
4
1
1
1
9
10
11
12
WING NUT ....................................... 2 ......... REPLACES 0208008000
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 79
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DCA-40SSAI --- MUFFLER ASSY.
MUFFLER ASSY.
PAGE 80 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
ITEM
EXHAUST PIPE
QTY.
REMARKS
3342350103
1141450690
9091103100
3342311102
3342359104
011208025
012210020
3342356104
011008035
031108160
0040008000
020108060
3342354104
3342354004
3342328104
020108060
3342359004
0112508025
1
GASKET ......................................... 1 .......... REPLACES 0602320000 AND 9221160010
HEX. NUT ....................................... 6 .......... REPLACES 0602323002
MUFFLER
MUFFLER SHEET
HEX. HEAD BOLT........................... 2 .......... REPLACES 0017108025
HEX.HEAD BOLT ........................... 2 .......... REPLACES 0017110020
1
1
GASKET
1
9
HEX. HEAD BOLT........................... 4 .......... REPLACES 0010108035
PLAIN WASHER ............................. 4 .......... REPLACES 0041608000
LOCKWASHER
HEX. NUT ....................................... 4 .......... REPLACES 0030008000
COVER
COVER
PIPE CLAMPER
HEX. NUT ....................................... 4 .......... REPLACES 0030008000
COVER SHEET
HEX. HEAD BOLT........................... 4 .......... REPLACES 0017108025
10
11
12
13
14
15
16
17
18
4
1
1
1
2
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 81
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DCA-40SSAI --- FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 82 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- FUELTANK ASSY.
FUEL TANK ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
3345510323
0810105004
0810105400
0802010304
0602021042
3345523304
0805003404
011008020
031108160
0040008000
020108060
3805522004
0191300600
0191300700
0605515014
0845032204
0150000018
0802011104
0193100225
0605515079
FUEL TANK
1
1
1
1
1-1
1-2
2
3
4
5
6
7
8
CAP, FUEL TANK
FUEL FILTER
PACKING
PLUG ..............................................1........... 960922101
TANK BAND
PAD, TANK BAND
HEX. HEAD BOLT........................... 2 .......... REPLACES 0017108020
PLAIN WASHER ............................. 2 .......... REPLACES 0041608000
2
4
LOCKWASHER
2
9
HEX. NUT ....................................... 2 .......... REPLACES 0030008000
10
11
12
13
14
15
16
17
18
TANK SHEET
SUCTION HOSE
RETURN HOSE
HOSE BAND
DRAIN JOINT
O RING
PLUG
FUEL GAUGE HOSE
HOSE BAND
4
1
1
4
1
1
1
1
2
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 83
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DCA-40SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 84 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
3
4
3345111322
3345116214
011008020
3345121122
3345109103
BASE
FLOOR PANEL
1
1
HEX. HEAD BOLT........................... 10 ........ REPLACES 0017108020
FRONT FRAME
LINING
1
1
5
6
7
8
9
B3561100103 STRIPE, LEFT SIDE ...................... 1 .......... REPLACES 3340630303
3340630503
0600500090
0021106020
011008020
3345122604
011008020
3345125103
3345109204
STRIPE, RIGHT SIDE
EMBLEM......................................... 2 .......... REPLACES 6360510003
MACHINE SCREW
HEX. HEAD BOLT........................... 6 .......... REPLACES 0017108020
BRACKET, RADIATOR NECK
HEX. HEAD BOLT........................... 2 .......... REPLACES 0017108020
1
4
10
11
12
13
14
15
16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
COVER, FRONT FRAME
LINING
1
1
B3561100003 STRIPE ........................................... 1 .......... REPLACES 3340630103
011008020
011008020
3385155104
011206020
3345125204
011008020
3345132113
3345132203
012210040
0041614000
030214350
0030014000
012012030
0040012000
031112230
3345141202
3345141212
3345109303
HEX. HEAD BOLT........................... 16 ........ REPLACES 0017108020
HEX. HEAD BOLT........................... 10 ........ REPLACES 0017108020
COVER
HEX. HEAD BOLT........................... 8 .......... REPLACES 0017106020
COVER, FRONT FRAME
HEX. HEAD BOLT........................... 6 .......... REPLACES 0017108020
2
1
CENTER FRAME
CENTER FRAME
1
1
HEX. HEAD BOLT........................... 8 .......... REPLACES 0010014040
PLAIN WASHER 16
LOCKWASHER .............................. 8 .......... REPLACES 0040014000
HEX. NUT
HEX. HEAD BOLT........................... 10 ........ REPLACES 0010012030
LOCKWASHER 10
8
PLAIN WASHER ............................. 10 ........ REPLACES 0041612000
REAR FRAME ................................ 1 .......... UPTO S/N3311949
REAR FRAME ................................ 1 .......... S/N3311950~
33
34
35
36
37
38
39
40
LINING
1
B3561100204 STRIPE ........................................... 2 .......... REPLACES 3340630704
011008020
3345155103
3345109403
031108160
0040008000
011008040
HEX. HEAD BOLT........................... 4 .......... REPLACES 0017108020
COVER, REAR FRAME
LINING
1
1
PLAIN WASHER ............................. 8 .......... REPLACES 0041608000
LOCKWASHER
HEX. HEAD BOLT........................... 8 .......... REPLACES 0010008040
8
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 85
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DCA-40SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 86 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
41
3345143303
DOOR, REAR FRAME .................... 1 .......... UPTO S/N3311949
DOOR, REAR FRAME .................... 1 .......... S/N3311950~
3345143313
1320332003
3805147104
0021006020
952404470
0040006000
020106050
0845028303
011208025
3345161212
3345109503
011008020
3345165104
3345109604
011008020
3345181202
3345105304
0010008055
0040008000
031108160
3345124003
3345124013
3345109704
3345124103
3345124113
3345109804
3340630904
3345175104
3345105104
011008020
3345171803
3345171813
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
STICKER
WINDOW PLATE............................. 1 .......... REPLACES 33805147104
MACHINE SCREW
PLAIN WASHER ............................. 6 .......... REPLACES 0041606000
LOCKWASHER
HEX. NUT ....................................... 6 .......... REPLACES 0030006000
HINGE
HEX. HEAD BOLT........................... 4 .......... REPLACES 0017108025
1
6
6
2
ROOF PANEL
LINING
1
1
HEX. HEAD BOLT........................... 16 ........ REPLACES 0017108020
GUIDE PANEL, AIR
LINING
2
2
HEX. HEAD BOLT........................... 8 .......... REPLACES 0017108020
SPLASHER PANEL
LINING
HEX. HEAD BOLT
LOCKWASHER
1
1
6
6
PLAIN WASHER ............................. 6 .......... REPLACES 0041608000
SIDE DOOR, LEFT SIDE ............... 1 .......... UPTO S/N3311949
SIDE DOOR, LEFT SIDE ............... 1 .......... S/N3311950~
62
63
LINING
1
SIDE DOOR, RIGHT SIDE ............. 1 .......... UPTO S/N3311949
SIDE DOOR, RIGHT SIDE ............. 1 .......... S/N3311950~
64
65
66
67
68
69
LINING
STRIPE
GUDE PANEL, AIR
LINING
1
2
2
2
HEX. HEAD BOLT........................... 12 ........ REPLACES 0017108020
SIDE DOOR, LEFT SIDE ............... 1 .......... UPTO S/N3311949
SIDE DOOR, RIGHT SIDE ............. 1 .......... S/N3311950~
70
71
72
73
74
75
76
77
78
79
80
81
33451009904 LINING
1
1
1
1
3340631104
3345175004
3345105204
011008020
3345171903
3345105004
STRIPE
GUIDE PANEL, AIR
LINING
HEX. HEAD BOLT........................... 4 .......... REPLACES 0017108020
SIDE DOOR, RIGHT SIDE ............. 1 .......... UPTO S/N3311949
LINING
1
B3561100403 STRIPE ........................................... 1 .......... REPLACES 3340631304
0845028203
0845028303
011208025
0845031504
HINGE
HINGE
4
4
HEX. HEAD BOLT........................... 16 ........ REPLACES 0017108025
CAP 10
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 87
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DCA-40SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 88 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
82
83
84
85
86
87
88
89
90
91
92
93
94
PART NO.
ITEM
QTY.
REMARKS
0605010910
0027103010
0605010910
0027104010
3345104104
3345104204
3345104304
3345104404
3345104504
3345104604
3345104704
3345104804
3345104904
LATCH ............................................. 1 .......... UPTO S/N3311949;REPLACES 0605010910
MACHINE SCREW ......................... 7 .......... UPTO S/N3311949
LATCH ............................................. 2 .......... UPTO S/N3311949
MACHINE SCREW ......................... 14 ........ UPTO S/N3311949
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
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
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DCA-40SSAI --- DECALS
DECAL ASSY
PAGE 90 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI --- DECALS
DECAL ASSY.
NO.
1
PART NO.
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
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 91
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ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.
PAGE 92 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.
NO
1
2#
3#
5#
5-1#
5-2#
5-3#
5-4#
5-5#
6#
7#
9
10
11
12
13
15
16
17
20
22
27
28&
33
34
50
51
PART NO
PART NAME
QTY.
REMARKS
5111101680
9117156070
9117118030
1096000580
1096000121
1096000160
9111291280
1096000160
CYLINDER HEAD ASSY. .................1 .......... INCL. ITEMS W/#
VALVE SEAT, INTAKE
VALVE SEAT, EXHAUST
SEALING CUP, REAR FACE ...........1 .......... REPLACES 1096000051
SEALING CUP, EXHAUST MAN. ....2 .......... REPLACES 5112190150
SEALING CUP, INLET SIDE FACE 4
SEALING CUP, LOWER FACE
SEALING CUP, TOP FAC
4
4
EA1013
2
3
4
4
8
4
3
8
1
1
8
50960000130 SEALING CUP, DRILLED PASS
909600340
5117210010
9111296010
5093000650
1093000180
9092023100
9095714100
1125690150
9041108200
9098301770
8941458390
8943674370
5111702672
1117510051
9111791050
1096390320
5111730160
9111750120
PLUG
VALVE GUIDE
SEAL CUP
ROCKER ARM STUD
INJ. NOZZLE STUD
PLUG, TOP FACE
PACKING, COMMET
VALVE GUIDE SEAL
STUD, INL. MANIFOLD ....................2 .......... REPLACES 9041108250
STUD, EXH. MANIFOLD
GASKET, CYL. HEAD
BOLT ................................................18 ........ REPLACES 8943674380
CYL. HEAD COVER ASSY. .............1 .......... INCL. ITEMS W/&
CAP, OIL FILLER .............................1 .......... REPLACES 9117510381
WASHER
PACKING, HEAD COVER ................3 .......... REPLACES 9111790300
PACKING, CYL. HEAD
NUT
3
1
1
1
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 93
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ISUZU 4BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
PAGE 94 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
1
8941303284
CYL. BLOCK ASSY........................... 1 ........ INCL. ITEMS W/#
2#
3#
4#
5#
5-1#
6#
6-1#
6-2#
8
5878131240
5112570011
1090004691
9116910480
9116930350
1096000520
5112190140
1096000121
9098600190
8941480790
1096050681
5096050050
5096050180
9992023140
9095720140
1097400780
9081510180
8941075600
5112240040
5112901450
8943673680
8941075662
8944299951
9095720080
1096253620
5111290030
8941745290
8943210180
0500408180
1093000530
5096800110
9099135050
5097070041
5117401200
1094400401
1099851770
9091645080
8944338700
8941625680
5093608820
5097040331
LINING............................................... 4 ........ REPLACES 1112611180
DOWEL
BOLT
1
10
CAM., FRONT METAL....................... 1 ........ REPLACES 9116110480
CAM., REAR AND CENTER ............. 2 ........ REPLACES 9116130350
CEALING CUP, FRONT AND REAR 2
SEALING CUP, CYL. BLOCK
SEALING CUP, TAPPET D=32
PLUG, CAMSHAFT PLATE
DOWEL
1
2
1
2
2
9
10
11
11-1
12
13
14
15-1
18
19
20
21
22
22-1
23
27
30
36
37
38
43
49
53
54
56
57
59
60
61
62
66
69
PLUG, HEADLESS PT 1/2
OIL PLUG, GALLERY........................ 1 ........ REPLACES 9992055170
PLUG
OIL PLUG, GALLERY
PACKING
STRAIGHT PIN, GEAR CASE
STRAIGHT PIN, FLYWHEEL HSG.
INJ. PUMP NIPPLE
7
1
1
1
2
1
BUSHING, OIL PUMP DRIVE SHAFT1
COVER, TAPPET CHAMBER
PACKING, CYL. BLOCK COVER
BOLT
1
2
2
2
4
1
1
1
1
2
1
1
1
1
1
BOLT
PACKING, GROMMET
SEAL, REAR OIL CRANK
SEALING CUP, LEVEL GAUGE
COVER, OIL DRAIN
PACKING, COVER
BOLT
STUD, ENGINE FOOT
WATER DRAIN COCK
PIPE
DRAIN PIPE CLIP
AIR BREATHER ASSY.
NUT ................................................... 2 ........ REPLACES 9091104080
LOCKWASHER................................. 2 ........ REPLACES 9091505080
PLAIN WASHER
BREATHER HOSE
2
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
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ISUZU 4BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
PAGE 96 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
70
71
80
81
82
83
85
86
92
93@
0500408160
9091606080
8941405811
1117500120
1094400401
1099851770
9099129760
9099155531
8970233390
5096230350
BOLT
1
1
1
1
PLAIN WASHER
OIL FILLER ASSY.
OIL FILLER CAP
NUT ................................................... 1 ........ REPLACES 9091104080
LOCKWASHER................................. 1 ........ REPLACES 9091505080
HOSE
CLIP
1
2
VALVE RELIEF ASSY. ...................... 1 ........ INCL. ITEM W/@
PACKING
1
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 97
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ISUZU 4BD1 —TIMING GEAR ASSY.
TIMING GEAR ASSY.
PAGE 98 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 —TIMING GEAR ASSY.
TIMING GEAR ASSY.
NO.
1
2
3
4
6
7
8
9
10
10
12
13
14
PART NO.
PART NAME
CASE
STRAIGHT PIN
QTY.
1
1
REMARKS
5113110113
9081510180
8943706710
0500408450
1113210790
8943632690
1096254380
9113276020
0500408250
8941500451
5113210090
8971186980
0500406140
PACKING ........................................................ 1.......... REPLACES 1113120140
BOLT ...............................................................6.......... REPLACES 0500408200
COVER
1
1
PACKING
SEAL...............................................................1.......... REPLACES 1096253190
POINTER
BOLT
BOLT ...............................................................5.......... REPLACES 5090000841
COVER, GEAR CHECK
GASKET ......................................................... 2.......... REPLACES 1112820130
BOLT
1
7
2
4
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 99
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ISUZU 4BD1 — FLYWHEEL HOUSING ASSY.
FLYWHEEL HOUSING ASSY.
PAGE 100 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — FLYWHEEL HOUSING ASSY.
FLYWHEEL HOUSING ASSY.
NO.
1
3
4
5
9
9-1
11
PART NO.
PART NAME
QTY.
1
1
REMARKS
8943213303
8943218380
5096000090
9095714160
9910664500
0500408250
9096510690
HOUSING
PLUG, PICK UP HOSE
DRAIN PLUG ..................................................1.......... REPLACES 9992023160
PACKING
BOLT
BOLT
1
8
7
8
PLAIN WASHER
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 101
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ISUZU 4BD1 — OIL PAN ASSY.
OIL PAN ASSY.
PAGE 102 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — OIL PAN ASSY.
OIL PAN ASSY.
NO
1
3#
3-1#
3-2#
4#
4-1#
4-2#
7
PART NO
PART NAME
OIL PAN ...................................... 1 ........ INCL. ITEMS W/#
PLUG
PLUG, THERMO SWITCH .......... 2 ........ REPLACES 9992023160
HEATER PLUG ........................... 1 ........ REPLACES 9992023240
O RING ....................................... 1 ........ REPLACES 1096230570
QTY.
REMARKS
8941340361
9096620120
5096000090
1096040230
1096231830
9095714160
9095714240
8943708360
8943706660
0500408180
5117601501
1
PACKING
PACKING
2
1
OIL PAN PACKING ..................... 1 ........ UP TO MAR. 94
OIL PAN PACKING ..................... 1 ........ APR. 94~
9
15
BOLT
24
GAUGE ASSY. ............................ 1 ........ REPLACES 5117601500
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 103
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ISUZU 4BD1 — OIL PUMP ASSY.
OIL PUMP ASSY.
PAGE 104 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — OIL PUMP ASSY.
OIL PUMP ASSY.
NO.
1
2#
PART NO.
PART NAME
QTY.
REMARKS
5131001373
5878102022
5131130351
OIL PUMP ASSY. .......................... 1 ........... INCL. ITEMS W/#
GEAR SET..................................... 1 ........... INCL. ITEMS W/&
3#
COVER ASSY.
1
4#
5#&
7#
DOWEL .......................................... 1 ........... CANNOT ORDER SEPARATELY
5131210140
5131250020
5131190060
5131410171
1131190010
0108058000
1099851770
5098430030
5095800980
5131650040
9081040300
SHAFT ASSY.
GEAR
PIPE
CASE
SPACER
1
1
1
1
1
9#
15#
16#
17#
19#
21#
22#
23#
24#
BOLT .............................................. 4 ........... REPLACES 9010458000
LOCKWASHER ............................. 4 ........... REPLACES 9091505080
OIL RELIEF BALL
COIL SPRING
RELIEF VALVE SEAT
PIN
COUPING
PINION
1
1
1
1
1
1
2
27#& 1131230160
28#& 1131280180
32
0500410250
BOLT
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 105
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ISUZU 4BD1 — CRANKSHAFT. PISTON, FLYWHEEL ASSY.
CRANKSHAFT, PISTON, FLYWHEEL ASSY
PAGE 106 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — CRANKSHAFT. PISTON, FLYWHEEL ASSY.
CRANKSHAFT, PISTON, FLYWHEEL ASSY.
NO.
1
1-1
1-2
1-3
1-4
2#
3
4
5
6
PART NO.
PART NAME
QTY.
REMARKS
8941170322
8941474660
8941474670
8941474680
8941474690
8941145652
8971766340
5121210050
9122116040
8941075751
1122301041
1122510270
1122350271
8970110310
9122736080
9122746080
9122756080
9122766080
5123101631
9081612200
8941075970
8971379100
8944493661
5123780020
5095030240
1098002140
8970461810
9123336070
5123360030
5123340060
CRANKSHAFT ASSY. ..................... 1 ......... INCL. ITEMS W/#
METAL KIT, 0.25
METAL KIT, 0.50
METAL KIT, 0.75
METAL KIT, 1.00
METAL SET, THRUST
PISTON SET ................................... 4 ......... REPLACES 5121112111
RING SET, PISTON
PISTON PIN
SNAP RING ..................................... 8 ......... REPLACES 8941075750
CONNECTION ROD ASSY. ............. 4 ......... INCL. ITEMS W/&
BUSHING, SMALL END
BOLT
1
1
1
1
2
4
4
7
8&
9&
11
11-1
11-2
11-3
11-4
14
15$
17
18
20
23
4
8
METAL SET, STD ............................ 4 ......... REPLACES 9122716080
METAL SET, 0.25
METAL SET, 0.50
METAL SET, 0.75
METAL SET, 1.00
CRANSHAFT ASSY......................... 1 ......... INCL. ITEMS W/$
FLYWHEEL PIN
FEATHER KEY
CRANKSHAFT GEAR...................... 1 ......... REPLACES 9125210430
PULLEY ........................................... 1 ......... REPLACES 8944493660
NUT
4
4
4
4
1
2
1
1
24
25
30
31%
33
WASHER
BALL BEARING ............................... 1 ......... REPLACES 9000901570
FLYWHEEL ASSY............................ 1 ......... INCL. ITEMS W/%
RING GEAR
WASHER
BOLT
1
1
6
34
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 107
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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)
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ISUZU 4BD1 — CAMSHAFT, IDLE GEAR, ROCKER ASSY.
CAMSHAFT, IDLE GEAR, ROCKER ASSY.
NO.
1
2
3
4
5
6
7
PART NO.
PART NAME
QTY.
REMARKS
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
CAMSHAFT
1
GEAR ............................................. 1 ........... REPLACES 9125221471
FEATHER KEY
THRUST PLATE
BOLT
BOLT
WASHER
IDLE GEAR SHAFT
IDLE GEAR
THRUST COLLAR
BOLT
INLET VALVE
EXHAUST VALVE
VALVE SPRING
SPRING SEAT, LOWER
SPRING SEAT, VALVE
SPLIT COLLAR
TAPPET
1
1
2
1
1
1
1
1
2
4
4
8
8
8
16
8
8
8
8
8
1
2
1
4
3
6
6
1
1
3
3
10
11
13
14
17
18
19
21
22
23
24
25
30
31
32
33
34
35
36
37
38
39
40
41
42
43
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
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 109
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ISUZU 4BD1 — OIL AND FUEL FILTER ASSY.
OIL AND FUEL FILTER ASSY.
PAGE 110 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — OIL AND FUEL FILTER ASSY.
OIL AND FUEL FILTER ASSY.
NO.
1
PART NO.
5132002262
PART NAME
OIL FILTER ASSY. ............................. 1 ............. INCL. ITEMS W/#;
REPLACES 5132002262
QTY.
REMARKS
2#
10
1878102201
8943706700
OIL FILTER ELEMENT KIT
PACKING ............................................ 2 ............. UP TO MAR. 94;
REPLACES 1132191940
PACKING ............................................ 2 ............. APR. 94~
1
8943706700
5132190261
5090000071
030210250
9091645100
9132004193
11
13
14
15
SPACER
BOLT
1
4
LOCKWASHER .................................. 4 .............REPLACES 9091505100
PLAIN WASHER ................................. 4 .............REPLACES 9091605100
FUEL FILTER ASSY. .......................... 1 ............. INCL. ITEMS W/&
50#
52#& 5878100500
60 0501510350
FUEL FILTER ELEMENT KIT
BOLT
1
2
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 111
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ISUZU 4BD1 — OIL PIPING ASSY.
OIL PIPING ASSY.
PAGE 112 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — OIL PIPING ASSY.
OIL PIPING ASSY.
NO.
1
2
3
5
6
7
7-1
10
12
13
PART NO.
PART NAME
OIL PUMP ASSY.
PACKING
BOLT
FILTER PIPE ASSY.
PACKING
QTY.
REMARKS
8941753012
9099211880
0501408450
5133112561
1096234620
0500408350
0500408320
8944284630
9095720100
909840220
1
2
4
1
2
2
2
1
2
1
BOLT
BOLT
OIL INJECTION PIPE ASSY.
PACKING
NUT
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 113
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ISUZU 4BD1 — COOLING ASSY.
COOLING ASSY.
PAGE 114 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — COOLING ASSY.
COOLING ASSY.
NO.
1
PART NO.
PART NAME
QTY.
REMARKS
5136101582
8943763780
5878101145
5136310100
1098002620
5136320010
9099521030
9091801470
1136200200
WATER PUMP ASSY. ...................... 1 ......... INCL. ITEMS W/#
WATER PUMP KIT ........................... 1 ......... INCL. ITEMS W/%
WATER PUMP REPAIR KIT ............. 1 ......... INCL. ITEMS W/&
2#
3&
4&
5&
6&
7&
8&
9%&
SHAFT
1
BALL BEARING ............................... 2 ......... REPLACES 5098000520
SPACER
SNAP RING
SNAP RING
1
1
1
SEAL UNIT ASSY. ........................... 1 ......... REPLACES 8942366870
11%& 5136210110
IMPELLER
FAN
WATER PUMP COVER
1
1
1
13&
14%
5136420530
5136120100
15%& 8944728780
17%& 9030906200
PACKING .......................................... 1 ......... REPLACES 5136130070
SCREW ............................................ 3 ......... REPLACES 9030908200
19&
21&
5136390020
5136340030
DUST COVER
SPACER
1
1
23%& 5096250780
SEAL ................................................ 1 ......... REPLACES 5096250570
27
5096050050
PLUG
1
28%& 8943706610
PACKING .......................................... 1 ......... REPLACES 9136140440
29
0500410400
0500410500
5090300101
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
BOLT
BOLT
1
2
2
1
1
1
1
1
1
1
4
BOLT, WATER PUMP
HOSE, BY-PASS
CLIP, D=38
CLIP, D=36
FAN ASSY.
PULLEY
31
32
35
37
38
40
41
43
48
49
50
52
53
SPACKER
BELT
BOLT
LOCKWASHER................................ 4 ......... REPLACES 9098516490
THERMOSTAT .................................. 1 ......... REPLACES 5137700320
PACKING
THERMOSTAT HOUSING
THERMO PLUG
1
1
1
PACKING .......................................... 1 ......... UP TO DEC. 93
PACKING .......................................... 1 ......... DEC. 93~
60
62
63
65
PACKING .......................................... 1 ......... REPLACES 8943210100
WATER PIPE
1
3
1
2
4
1
BOLT
BOLT
BOLT
BOLT
80
81
83
WATER DUCT COVER ASSY.
OIL COOLER PACKING ................... 1 ......... REPLACES 8943210130
BOLT
BOLT
BOLT
BOLT
2
11
8
1
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 115
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ISUZU 4BD1 — INTAKE AND EXHAUST ASSY.
INTAKE AND EXHAUST ASSY.
PAGE 116 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — INTAKE AND EXHAUST ASSY.
INTAKE AND EXHAUST ASSY.
NO.
1
3
4
5
PART NO.
PART NAME
QTY.
REMARKS
5141112070
8970241220
1094400401
1099851770
0500408250
8970225710
5141111160
5141112360
0501510300
0500510300
5141410360
5093020020
8944046100
1094400401
1099851770
8942059871
0500408600
INTAKE MANIFOLD
1
GASKET, INTAKE ..................... 1 ................ REPLACES 8943632700
NUT ........................................... 2 ................ REPLACES 9091104080
LOCKWASHER......................... 2 ................ REPLACES 9091505080
BOLT
PACKING ................................... 2 ................ REPLACES 5096370281
INTAKE PIPE
INTAKE PIPE ............................ 1 ................ REPLACES 5141111970
8
6
39
50
50-1
51
51-1
60
61
62
66
67
69
1
BOLT
BOLT
2
2
1
3
EXHAUST MANIFOLD
STUD, EXHAUST
GASKET, EXHAUST ................. 2 ................ REPLACES 5141450040
NUT ........................................... 5 ................ REPLACES 9091104080
LOCKWASHER......................... 5 ................ REPLACES 9091505080
BOLT, L=75
BOLT, FIXED
2
1
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 117
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ISUZU 4BD1 — FUEL INJECTION ASSY.
FUEL INJECTION ASSY.
PAGE 118 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — FUEL INJECTION ASSY.
FUEL INJECTION ASSY.
NO.
1
3
5
8
PART NO.
PART NAME
QTY.
REMARKS
5153001032
1153150131
9153390510
1094400401
1099851770
8944636740
8944636750
8944636760
8944636770
5154190131
NOZZLE
4
PACKING ................................ 4 ................... REPLACES 5153150030
DUST COVER
NUT ........................................ 8 ................... REPLACES 9091104080
LOCKWASHER...................... 8 ................... REPLACES 9091505080
PIPE, NO. 1
PIPE, NO. 2
PIPE, NO. 3
PIPE, NO. 4
4
9
11
12
13
14
15
1
1
1
1
CLIP ASSY., D6X2 ................. 3 ................... INCL. ITEMS W/#
15-1# 9154196130
15-2# 9154196140
15-3#
CLIP, A
CLIP, B
3
3
BOLT ...................................... 3 ................... NOT SOLD SEPARATELY FROM KIT
16
5154190040
5154190051
0501406160
5154112290
5132600101
5154115730
5154118580
5154115680
5154116030
9099063141
9095714080
9095720140
1095751460
9095720140
5097091030
9097161240
0500406250
CLIP, INTAKE MANIFOLD
CLIP, INTAKE MANIFOLD
BOLT
1
1
1
1
1
1
1
16-1
16-2
18
PIPE
20
27
OVERFLOW VALVE ASSY.
PIPE
FILTER LEAK PIPE ASSY.
EYE JOINT ............................ 1 ................... REPLACES 5154112231
FILTER PIPE ASSY.
BOLT
PACKING, GROMMET
PACKING, FUEL PIPE
BOLT ...................................... 2 ................... REPLACES 9099063251
PACKING
CLIP A
29
29-1
30
1
1
2
6
31
32
33
34
42
49
3
2
49-1
49-2
CLIP B .................................... 2 ................... REPLACES 5097091040
CLIP BOLT
2
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 119
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ISUZU 4BD1 — ENGINE FOOT ASSY.
ENGINE FOOT ASSY.
PAGE 120 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — ENGINE FOOT ASSY.
ENGINE FOOT ASSY.
NO.
1
2
3
4
PART NO.
PART NAME
FOOT, FRONT RIGHT
FOOT, FRONT LEFT
BOLT
QTY.
REMARKS
9117712470
9117712480
8943134650
9091105100
030210250
5117770080
9117778050
0500410200
5197110620
0501408350
0501408400
0500410000
0500410450
5090300101
8943717120
8942790500
1099851770
9091606080
5136740320
0500408400
9091647080
1
1
7
1
NUT
5
LOCKWASHER...................... 1 ................... REPLACES 9091505100
17
18
19
20
22
HANGER, FRONT
HANGER, R. REAR
BOLT
BRACKET
BOLT
BOLT
BOLT
BOLT
BOLT, L=75
COVER, PULLEY
NUT ........................................ 1 ................... REPLACES 9091105080
LOCKWASHER...................... 1 ................... REPLACES 9091505080
PLAIN WASHER
PLATE
1
1
2
1
1
1
1
1
1
1
27
27
28
29
30
31
35
39
42
1
1
1
1
BOLT
PLAIN WASHER
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 121
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ISUZU 4BD1 — ENGINE CONTROL ASSY.
ENGINE CONTROL ASSY.
PAGE 122 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — ENGINE CONTROL ASSY.
ENGINE CONTROL ASSY.
NO.
2
PART NO.
5197890041
PART NAME
QTY.
REMARKS
BRACKET ................................. 1 ................ REPLACES 5197890040
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 123
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ISUZU 4BD1 — INJECTION PUMP ASSY.
INJECTION PUMP ASSY.
PAGE 124 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — INJECTION PUMP ASSY.
INJECTION PUMP ASSY.
NO.
1
3#
PART NO.
PART NAME
INJECTION PUMP ASSY.......... 1 ................ INCL. ITEMS W/#
GOVERNOR ASSY.
FEED PUMP ASSY. .................. 1 ................ REPLACES 8941327040
GEAR ........................................ 1 ................ REPLACES 5125240650
QTY.
REMARKS
8943440260
8943440280
8941327042
5125240890
1156192450
9096620070
5157810030
8944575170
9884105020
5156190480
1113190090
8941500451
5197510150
0500410250
9091105100
9091645100
030210250
1
5#
14#
15#
16#
17#
18#
19#
20#
32
33
35
36
38
PLATE
BOLT
COUPLING
BOLT
NUT
LOCKWASHER
PACKING
1
1
1
6
1
1
1
BOLT ......................................... 7 ................ REPLACES 5090000841
BRACKET
BOLT
NUT
1
2
1
39
40
PLAIN WASHER ........................ 1 ................ REPLACES 9091605100
LOCKWASHER......................... 1 ................ REPLACES 9091505100
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 125
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ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY.
ELECTRICAL COMPONENTS ASSY.
PAGE 126 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY.
ELECTRICAL COMPONENTS ASSY.
NO.
1
6
6
7
PART NO.
PART NAME
STARTER ASSY
BOLT
BOLT
PLAIN WASHER
CABLE ASSY.
QTY.
REMARKS
1811001910
0500512280
0500512350
9091605120
9829315110
5812002121
9827200690
5824100160
1825130430
5197320021
9825300460
5824500141
8970299880
1819001931
1
1
2
1
1
1
1
1
8
10
16
16-1
19
20
23
35
35-1
78
ALTERNATOR ASSY.
OIL PRESS. WARNING SW.
OIL PRESS. WARNING SW.
GLOW PLUG (24V) ........................ 4 ................... REPLACES 9825139288
CONNECTOR ................................. 1 ................... REPLACES 5197320020
RESISTANCE CONTROLLER
OVERHEAT SWITCH, M16
OVERHEAT SWITCH, 3/8
1
1
1
STOP ASSY. .................................. 1 ................... INCL. ITEM W/%; REPLACES
1819000161
79% 1828490430
CABLE ASSY.
1
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 127
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ISUZU 4BD1 — FEED PUMP COMP. ASSY.
FEED PUMP COMP. ASSY.
PAGE 128 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — FEED PUMP COMP. ASSY.
FEED PUMP COMP. ASSY.
NO.
1
5#
PART NO.
PART NAME
QTY.
REMARKS
8941327042
5157510120
9813512050
9813513020
9813550230
9813550350
5157540010
FEED PUMP ASSY. .................. 1 ........... INCL. ITEMS W/ #; REPLACES 8941327040
PUMP HOUSING
PISTON
SPRING
PLUG
GASKET
1
1
1
1
1
9#
10#
11#
12#
15#
TAPPET ASSY. ......................... 1 ........... INCL. ITEMS W/%
16#% 9813514030
17#% 9813514100
18#% 1157590020
ROLLER
PIN
GUIDE
SPRING
VALVE
1
1
2
2
2
20#
26#
27#
31#
32#
33#
35#
37#
40#
42#
44#
9813517020
9813516020
1156290650
5157590270
1156190820
1157590010
1157590030
5157590120
1156290650
9813550250
1157610060
O RING ...................................... 1 ........... REPLACES 1096230160
BOLT
BOLT
GASKET
ADAPTER
JOINT
O RING ...................................... 1 ........... REPLACES 1096230160
SNAP RING
PRIMING PUMP ASSY. ............ 1 ........... REPLACES 8941311300
1
1
1
1
1
1
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 129
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ISUZU 4BD1 — NOZZLE ASSY.
NOZZLE ASSY.
PAGE 130 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — NOZZLE ASSY.
NOZZLE ASSY.
NO.
1
2
4#
6#
PART NO.
PART NAME
QTY.
REMARKS
5153110191
1153300941
5153410010
9153430130
5153450010
5153320100
9153390560
9153390570
1153320170
5153390030
5153510010
1096750371
1153390100
9153470030
INJ. NOZZLE ............................. 4 ................ REPLACES 5153110190
HOLDER ASSY. ........................ 4 ................ INCL. ITEMS W/#
PUSH ROD
SPRING
ADJ. SCREW
NUT
GASKET
WASHER
RETAINING NUT
GASKET
CONNECTOR
4
4
4
4
4
4
4
4
4
8#
10#
11#
12#
20#
21#
22#
30#
31#
32#
BOLT ......................................... 8 ................ REPLACES 1153390090
GASKET
PIN
8
8
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 131
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ISUZU 4BD1 — OIL FILTER ASSY.
OIL FILTER ASSY.
PAGE 132 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — OIL FILTER ASSY.
OIL FILTER ASSY.
NO.
1
2#
4#&
5#&
6#&
7#&
8#
PART NO.
PART NAME
QTY.
REMARKS
5132002262
1878102201
9097205550
5096230670
9099211950
9132490090
5132120681
9132316020
9099410980
9132390310
9098621170
9000975270
9099408600
8941326650
9099208410
9132260110
9099208410
5132110201
OIL FILTER ASSY. .................... 1 ................ INCL. ITEMS W/#
OIL FILTER ELEMENT KIT....... 1 ................ INCL. ITEMS W/&
PACKING ................................... 1 ................ REPLACES 9099209780
PACKING
PACKING
PACKING, UPPER
BODY
BOLT
SPRING
SEAT
DRAIN PLUG
OVER FLOW VALVE
SPRING
1
1
1
1
1
1
1
1
1
1
1
9#
10#
11#
12#
15#
16#
17#
18#
20#
21#
22#
VALVE PLUG
PACKING ................................... 1 ................ REPLACES 9099205260
PLUG
PACKING ................................... 1 ................ REPLACES 9099205260
CASE
1
1
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 133
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ISUZU 4BD1 — FUEL FILTER ASSY.
FUEL FILTER ASSY.
PAGE 134 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — FUEL FILTER ASSY.
FUEL FILTER ASSY.
NO.
1
2#
3#%
4#%
5#
6#%
7#
PART NO.
PART NAME
QTY.
REMARKS
9132004193
5878100500
9099203270
9132136010
9099208410
5096230241
9095720140
1132600470
9099203260
FUEL FILTER ASSY. ................. 1 ................ INCL. ITEMS W/#
ELEMENT KIT........................... 1 ................ INCL. ITEMS W/%
O RING ELEMENT, UPPER
PACKING
O RING
O RING
PACKING
VALVE
PACKING
SPRING SEAT
ELEMENT SPRING
BOLT
DRAIN PLUG
CASE
1
1
1
1
2
1
1
1
1
1
1
1
1
8#
9#
10#% 9098518100
11#
12#
13#
14#
15#
9099409010
9132310660
9098620680
9132111071
9132128040
COVER
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 135
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ISUZU 4BD1 — ENGINE ACCESSORIES
ENGINE ACCESSORIES
PAGE 136 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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ISUZU 4BD1 — ENGINE ACCESSORIES
ENGINE ACCESSORIES
NO.
1
3
PART NO.
PART NAME
QTY.
REMARKS
8944533001
1096234650
0500408200
TACHOMETER DRIVE ASSY.... 1 ................ REPLACES 8944533000
PACKING
BOLT
1
2
4
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 137
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TERMS AND CONDITIONS OF SALE — PARTS
Effective: July 1, 2000
PAYMENT TERMS
4. Freight is at the sender’s expense. All PRICINGANDREBATES
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
Terms of payment for parts are net 10 days.
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspecific
5. Parts must be in new and resalable dateandallordersreceivedonorafterthatdate
condition,intheoriginalMultiquippackage willbebilledattherevisedprice.Rebatesfor
(ifany),andwithMuiltiquippartnumbers price declines and added charges for price
FREIGHTPOLICY
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signedmanifesthasbeenobtainedfromthe
carrier,andanyclaimforshortageordamage
mustbesettledbetweentheconsigneeandthe
carrier.
clearly marked.
increaseswillnotbemadeforstockonhand
atthetimeofanypricechange.
6. Thefollowingitemsarenotreturnable:
Multiquipreservestherighttoquoteandsell
directtoGovernmentagencies,andtoOriginal
EquipmentManufactureraccountswhouse
our products as integral parts of their own
products.
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,
andotherrubberparts)thatwere
purchasedmorethansixmonths
priortothereturndate.
MINIMUMORDER
SPECIALEXPEDITINGSERVICE
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
A$20.00to$50.00surchargewillbeaddedto
theinvoiceforspecialhandlingincludingbus
c. Anylineitemwithanextendeddealer shipments, insured parcel post or in cases
netpriceoflessthan$5.00.
where Multiquip must personally deliver the
partstothecarrier.
d. Special order items.
RETURNEDGOODSPOLICY
e. Electricalcomponents.
LIMITATIONSOFSELLER’SLIABILITY
Returnshipmentswillbeacceptedandcredit
will be allowed, subject to the following
provisions:
f.
Paint,chemicals,andlubricants.
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
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.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
beapprovedbyMultiquippriortoshipment.
7. Thesenderwillbenotifiedofanymaterial
receivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Sales that defines item numbers,
quantities,anddescriptionsoftheitems
tobereturned.
8. Such material will be held for 5 working
days from notification, pending
instructions. If a reply is not received
within5days,thematerialwillbereturned
tothesenderathisexpense.
LIMITATIONOFWARRANTIES
a. Thepartsnumbersanddescriptions
mustmatchthecurrentpartsprice
list.
Nowarranties,expressorimplied,aremade
in connection with the sale of parts or trade
accessories nor as to any engine not
manufacturedbyMultiquip.Suchwarranties
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
connectionwiththesaleofitsproducts.Apart
fromsuchwrittenstatementofwarranty,there
arenowarranties,express,impliedorstatutory,
which extend beyond the description of the
productsonthefacehereof.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. Thelistmustbetypedorcomputer
generated.
10. In cases where an item is accepted for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. Thelistmuststatethereason(s)for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhich
theitemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. Thelistmustincludethenameand
phonenumberoftheperson
requestingtheRMA.
3. A copy of the Return Material
Authorizationmustaccompanythereturn
shipment.
PAGE 138 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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NOTE PAGE
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 139
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PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
MULTIQUIPINC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
SERVICE DEPARTMENT:
800-835-2551
FAX:310-537-3927
FAX:310-638-8046
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