PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
MQ POWER
DCA-60SSAI
TM
WHISPERWATT
GENERATOR
(Standard)
PARTS LIST NO. 7451201B
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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — 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 Decals ..................................................... 21-22
DCA -60SSI2 Specifications ................................... 23
General Information ................................................. 24
Major Components .................................................. 55
Dimensions.............................................................. 26
Control Panel Descriptions ...................................... 28-29
Engine Operating Panel Descriptions ...................... 30-31
OutputTerminal Panel Descriptions ......................... 32-33
Output Amperage Setup .......................................... 34-35
Output Voltage Setup............................................... 36-39
Installation ............................................................... 40-41
Pre Set-up ............................................................... 42-45
Load Application ...................................................... 46
Generator Start-up Procedure ................................. 47-49
Generator Shut-down Procedure.............................. 50
Maintenance ............................................................ 52-55
GeneratorWiring Diagram ........................................ 56
EngineWiring Diagram ............................................ 57
EngineTroubleshooting ............................................ 58-59
Generator/EngineTroubleshooting ........................... 60
Explanation of Codes in Remarks Column .............. 62
Suggested Spare Parts ........................................... 63
ISUZU 6BD1 ENGINE
Cylinder Head Cover Assembly ............................90-91
Cylinder Head Assembly ......................................92-93
Cylinder Block Assembly ..................................... 94-97
Oil Pan and Level Gauge Assembly ..................... 98-99
Camshaft and Valve Assembly............................. 100-101
Crankshaft Piston and Flywheel Assembly .......... 102-103
Timing Gear and Flywheel Housing Assembly .....104-105
Inlet Manifold Assembly .......................................106-107
Exhaust Manifold Assembly................................. 108-109
Ventilation Assembly ............................................ 110-111
Water Pump and Corrosion Resistor Assembly ....112-113
Thermostat and Housing Assembly ..................... 114-115
Engine Water Piping Assembly.............................116-117
Fan and Fan Belt Assembly ................................. 118-119
Fuel Injection Assembly .......................................120-121
Fuel Filter and Bracket Assembly ........................122-123
Fuel Pump and Pipe Assembly ............................124-125
Oil Cooler and Oil Filter Assembly ....................... 126-127
Oil Pump and Oil Strainer Assembly .................... 128-129
Oil and Vacuum Piping Assembly ........................ 130-131
Electrical Control Assembly ................................. 132-133
Starter Components Assembly ............................134-135
Alternator Components Assembly ........................136-137
Injection Pump Components Assembly ...............138-141
Governor Components Assembly .........................142-145
Feed Pump Assembly .......................................... 146-147
Misc. Injection Pump Assembly ...........................148-149
Coupling Assembly............................................... 150-151
Water Sedimenter Assembly ................................ 152-153
Switch and Relay Assembly................................. 154-155
Terms and Condition of Sale — Parts .................. 156
MQ POWER DCA-60SSAI
AC GENERATOR
Generator Assembly................................................ 64-65
Control Box Assembly............................................. 66-67
Engine & Radiator Assembly................................... 68-71
Engine Operating Panel Assembly .......................... 72-75
Battery Assembly .................................................... 76-77
Muffler Assembly .................................................... 78-79
Fuel Tank Assembly ................................................ 80-81
Enclosure Assembly ............................................... 82-85
Rubber Seal Assembly ............................................ 86-87
Name Plate And Decals .......................................... 88-89
NOTE
Specification and part number
are subject to change without
notice.
PAGE 4 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — 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-60SSAI 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
This equipment should not be operated by
persons under 18 years of age.
is restricted it will cause
serious damage to the
generator or engine and
may cause injury to
people. The generator
engine gives off DEADLY
NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel-
toed boots and other protective devices
required by the job.
carbon monoxide gas.
I
I
I
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
CAUTION
:
NEVER operate this equipment under the
influence or drugs or alcohol.
I
Always refuel in a well-ventilated area,
away from sparks and open flames.
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
Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT smoke around or near
the machine. Fire or explosion could
result from fuel vapors, or if fuel is spilled
on a hot engine.
I
I
I
Manufacturer does not assume responsibility for any
accident due to equipment modifications.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Always check the machine for loosened threads or bolts
before starting.
I
NEVER operate the generator in an
explosive atmosphere or near combustible
materials. An explosion or fire could result
causing severe bodily harm or even
death.
I
Topping-off to filler port is
dangerous, as it tends to spill fuel.
PAGE 6 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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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
:
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.
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.
CAUTION
:
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
Never use damaged or worn cables when connecting
power tools or equipment to the generator. Make sure
power connecting cables are securely connected to the
generator’s output terminals, insufficient tightening of the
terminal connections may cause damage to the generator
and electrical shock.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 7
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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
precaution s 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 9
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DCA-60SSAI —TOWING RULES FOR SAFE OPERATION
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 jack-knifing. 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI —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.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. 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.
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.
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:
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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 11
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DCA-60SSAI —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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI —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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 13
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DCA-60SSAI —TRAILER SAFETY GUIDELINES
Brakes
If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow
the brake shoes and drums to seat properly. After the first
200 mile interval, inspect the brakes every 3,000 miles. If
driving over rough terrain, inspect the brakes more
frequently.
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-60SSAI —TRAILER SAFETY GUIDELINES
Figure 2. Electrical Brake Components
Hydraulic/Air/Surge Brakes
Figure 3 below displays the major hydraulic/air/surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 6 as referenced in the electric brake adjustments
section.
Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such
as shoe and lining replacement. These brakes can be
adjusted in the same manner as electric brakes. Brake
lines should be periodically checked for cracks, kinks, or
blockage.
Figure 3. Hydraulic Brake Components
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 15
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DCA-60SSAI —TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked, the
air pressure in
the inner tube
may cause pieces of the rim to
explode (break off) with great force
and cause serious eye or bodily
injury.
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-60SSAI —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.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 17
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DCA-60SSAI —TRAILER-WIRING DIAGRAM
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
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DCA-60SSAI —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
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 19
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DCA-60SSAI —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.
PAGE 20 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI — GENERATOR DECALS
The DCA -100SSJU generator is wquipped with a number of safety decals. These decals are provided for operator safety
and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 21
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DCA-60SSAI — GENERATOR DECALS
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DCA-60SSAI — SPECIFICATIONS
Table 7. Specifications
Generator Specifications
Model
Type
DCA-60SSI2
Revolving field, self ventilated, open protected type synchronous generator
Armature Connection
Phase
Star with Neutral
3
Zig Zag
Single
Standby Output
Prime Output
Voltage
72 KVA (57.6 KW)
60 KVA (48 KW)
240V or 480V
41.5KW
34.6KW
240/120V
Frequency
Speed
60 Hz
1800 rpm
Power Factor
Aux. AC Power
Voltage
0.8
1
Single Phase, 60 Hz
120 V
Output
4.8 KW (2.4 KW x 2)
Engine Specifications
Model
Type
ISUZU A-6BG1
4 Cycle, water-cooled, direct injection
6 cylinders
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
4.1 in. x 4.9 in. (105 mm x 125 mm)
77HP/1800 rpm
396 cu. in. (6494 cc)
Electric
Coolant Capacity
Lube Oil Capacity
7.8 gal. (29.5 liters)
5.1 gal. (19.3 liters)
3.9 gal. (14.9L)/hr at full load
2.4 gal. (9.1L)/hr at 1/2 load
3.0 gal. (11.4L)/hr at 3/4 load
1.9 gal. (7.2L)/hr at 1/4 load
Fuel Consumption
Battery
Fuel
12V- 100AH x 2
#2 Diesel Fuel
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 23
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DCA-60SSAI — GENERAL INFORMATION
DCA-60SSAI FAMILIARIZATION
Generator
Open Delta Excitation System
The DCA-60SSAI 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-60SSAI is a 48 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
Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Engine Throttle Lever
Panel Light
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.
Panel Light Switch
Oil Pressure and WaterTemp. Indicator lights
Generator Control Panel
The “Generator Control Panel”is provided with the following:
Engine
z
z
z
z
z
z
Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
The DCA-60SSAI is powered by a 4 cycle, water cooled,
Isuzu A-6BG1diesel engine. This engine is designed to
meet every performance requirement for the generator.
Reference Table 1, page13 for engine specifications.
In keeping with Multiquip's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Output Terminal Panel
The basic controls and indicators for the DCA-60SSAI
generator are addressed on the following pages.
The “Output Terminal Panel” is provided with the following:
z
z
z
z
Three 120/240V output receptacles, 50 amp
Two 120V input receptacles, 20 amp
3 Load Circuit Breakers 240V @50 amps
2 Load GFCI Circuit Breakers 120V@ 20amps
Mechanical Governor System
The mechanical governor system control the RPM of the
engine. When the engine demands increase or decrease,
the mechanical governor system regulates the frequency
variation to 1.5%. The electronic governor option in-
creases frequency variation to .25%.
Control Box
The “Control Box” is provided with the following:
z
z
Main Circuit Breaker 150 amps
Over-Current Relay
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DCA-60SSAI — MAJOR COMPONENTS
Figure 6. Major Components
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 25
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DCA-60SSAI — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 7. Dimensions
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NOTE PAGE
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DCA-60SSAI — CONTROL PANEL
Figure 8. Control Panel
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DCA-60SSAI — CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-60SSAI " Control Panel " (Figure 8).
1. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz 1 Hz .
2. AC Ammeter – Indicates the amount of current the
load is drawing from the generator.
3. ACVoltmeter – Indicates the single phase output
voltage present at the UNV terminals.
4. Pilot Lamp - This lamp indicates the load is not properly
set. Readjust the load, or use the voltmeter change-
over switch to adjust phase position.
5. Main Circuit Breaker – This three-pole, 150 amp main
breaker is provided to protect the UNV voltage output
terminals from overload.
6. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
7. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off.
8. Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage.
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DCA-60SSAI — ENGINE OPERATING PANEL
Figure 9. Engine Operating Panel
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DCA-60SSAI — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-60SSAI " Engine Operating Panel " (Figure 9).
1. Oil Pressure Gauge –Normal operation should be about
25 psi. When starting the generator the oil pressure
may read a bit higher, but after the engine warms up
the oil pressure should return to normal.
2. Panel light - Normally used in dark places or at night.
When activated, panel will luminate. When the generator
is not in use, turn the panel light switch to the ‘OFF’
position.
3. WaterTemperature Gauge – During normal operation
this gauge be should read between 165o to 215o.
4. 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.
5. Indicator Lights - These lights indicate if the oil
pressure or water temperature is at dangerous levels
and will shut off the engine. The oil pressure indicator
will initially light at start-up, but will go off once the
pressure rises.
6. Panel light switch-When activiated, will turn on control
panel light.
7. Lamp Check Switch - This is used to check the
indicator lights. Turn on the engine, then press this to
check the bulbs. If they don’t light, replace the bulbs.
8. EngineThrottle Lever - Pull or push this lever to change
the speed of the engine when a load is applied.
9. Pre-Heat Indicator – Under cold conditions, turn the
starter key to preheat. Once the indicator lights, the
engine is ready to start.
10. Starter Switch - Turn this to start, stop, and preheat
the engine.
11. Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the engine is at full speed and a load is applied.
In addition, a built in hour meter will record the number
of operational hours that the generator has been in use.
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DCA-60SSAI — 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, 150 amp,
main circuit breaker is provided to protect the UVWO output
terminals from overload. In addition two single-pole, 20 amp
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload. Three 50 amp load circuit
breakers have also been provided to protect the load side of
the generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
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 UVWO lugs, all four slots in
the duplex receptacles, and the must not exceed 52.8 kW in
standby or 48 kW in prime output.
Generator Grounding
Make sure to ground the generator in EVERY application
prior to connecting a load. Generators are NOT grounded
just because they are mounted on trailers or other vehicles
that are on rubber tires.
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DCA-60SSAI — OUTPUTTERMINALVOLTAGE SELECTION
DCA-60SSAI
NOTE
Legs
O
and Ground are
considered Bonded Grounds.
Figure 12. Output Panel Location
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 33
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DCA-60SSAI — 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. Voltage Available
3 Phase
(Switchable)
208 VOLT
120 VOLT
220 VOLT
127 VOLT
240 VOLT
139 VOLT
416 VOLT
240 VOLT
440 VOLT
254 VOLT
480 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
133.3 amps (4 wire)
120 Volt
Single Phase
66.7 amps (4 wire)
240 Volt
Three Phase
144 amps
240 Volt
Three Phase
72 amps
480 Volt
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DCA-60SSAI — OUTPUT AMPERAGE SETUP
Receptacle Use
When the UVWO terminals are providing power, the recep-
tacle power availability will decrease.
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.
Figure 14 and 15. AC Voltmeter Change-over switch
and Voltmeter 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.
Figure 16 and 17. AC Ammeter Change-over Switch
and Ammeter Gauge
NOTE
When using plural single phase
voltages, make sure to balance
the load on each of the single
phase legs.
Figure 13. Voltage Selector Switch 240/120V Single
Phase
Position
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 35
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DCA-60SSAI — OUTPUTVOLTAGE SETUP
480/240V Hard Wire Hookup
240/120V Hard Wire Hookup
With the voltage selector set and locked at ‘3 phase 480/
277’ (Figure 19) and using the 3-phase 240 hookup, it will
provide one circuit available at 108 amps with any two wires
plus the ground (Figure 20).
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-60SSAI — 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-60SSAI — 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-60SSAI — 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-60SSAI — 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 it cannot slide or shift around. Also install
the generator so 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.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to the
engine and alternator parts.
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.
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.
NEC articles 25064(b) a and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
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.
2. When grounding the generator (Figure 32) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully.Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
NOTE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
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DCA-60SSAI — INSTALLATION
Figure 32. Typical Generator Grounding Application
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DCA-60SSAI — PRE-SETUP
General Inspection Prior to Operation
Circuit Breakers
The DCA-60SSAI generator has been thoroughly inspected To protect the generator from an overload, a 3-pole, 150 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 10)
as a guide for selecting proper cable size.
NOTE
ALWAYS consult with a licensed
electrician for correct extension
cord wire size.
Table 10. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
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 fromlow voltage.
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DCA-60SSAI — PRE-SETUP
Lubrication Oil
Fuel
Fill the fuel tank with clean and fresh diesel fuel. DO NOT
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way, but without being screw
into the filler hole, verify that the oil level is maintained
between the two notches (Figure 33) on the dipstick. See
Table 11 for proper selection of engine oil.
fill the tank beyond capacity.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 23,
Specification Table 7.
The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel. Wipe up any spilled fuel immediately.
CAUTION
:
Never fill the fuel tank while the engine is
running or in the dark. Diesel spillage on
a hot engine can cause a fire or
explosion. If diesel spillage occurs, wipe
up the spilled diesel completely to
prevent fire hazards.
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.
Figure 33. Engine Oil Dipstick
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
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.
Table 11. Recommended Motor Oil
Temperature Range
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
SAE 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
SAE 10W or SAE 10W-30
Below 5° C (-15°)
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DCA-60SSAI — PRE-SETUP
CAUTION :
Cleaning the Outer Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
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
12.for engine, radiator, and reserve tank coolant capacities.
Make sure the coolant level in the reserve tank is always
between the "H" and the "L" markings.
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 12. Coolant Capacity
Engine and Radiator
Reserve Tank
7.8 Gal. (29.5 Liter)
.95 Gal. (2 Liter)
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 34) when depressed with the thumb as shown
below. Never place hands near the belts or fan while the
generator is running.
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Table 13. Anti-Freeze Operating Temperatures
Figure 34. 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-60SSAI — 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 35) are properly
connected to the battery terminals as shown below.The RED
cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.
CAUTION :
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 35. 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-60SSAI — 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 the voltage selector switch is in single phase (240/
120V position), place the AC voltmeter change-over switch
to the U-W position and the AC ammeter change over-switch
to the U or W position to read the ouput.
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 mulitplying 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 14.
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 14. 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-60SSAI — GENERATOR START-UP PROCEDURE
WARNING:
2. Connect the load to the UVW terminals as shown in
The engine's exhaust contains harmful
Figure 37. These terminals can be found on the output
terminal panel, (see page 22 Figure 6). To gain access
to the output terminals lift the UVW cover. Tighten
terminal nuts securely to prevent load wires from slipping
out.
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 11 on page 43).
3. Check the coolant level in the radiator and subtank.
Replenish with antifreeze as necessary.Always maintain
the coolant level between the FULL and LOW markings
on the coolant container.Be sure that the radiator cap is
fastened securely.
Figure 37. UVW 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 38).
Before Starting
Generator and Control Panel
CAUTION:
NEVER start the engine with the
main, GFCI or load circuit breakers
in the ON position.
1.
Be sure to disconnect the
electrical load and switch the main, load and G.F.C.I.
circuit breakers (Figure 12) to the “OFF” position prior to
starting the engine.
Y
TTER
BA
Figure 38. Battery Connections
Figure 36. Main, GFCI and
Load Circuit Breakers
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DCA-60SSAI — GENERATOR START-UP PROCEDURE
4. Close all engine enclosure doors (Figure 39).
8.
Once the preheat indicator lights, turn the key to
‘START’ (Figure 43). After the engine cranks,
release the key to ‘RUN’.
Figure 43. Starter Switch (Start)
Figure 39. Engine Enclosure Doors
9.
Pull the engine throttle lever and turn left until the
lever sets on the knob (Figure 44).
5. Check the voltage selection switch (Figure 40) is
at the desired voltage.
Figure 44. Engine Throttle Lever (Up)
Figure 40. Voltage Selection Switch
10. The generator's frequency meter (Figure 45) displays
the 60 cycle output frequency in HERTZ.
6.
Check to see if the engine throttle lever (Figure
41) is pushed in.
Figure 45. Frequency Meter (Hz)
Figure 41. Engine Throttle Lever
11. The generator's voltage meter (Figure 46) displays the
120 VAC in VOLTS. If the voltage is not within the
specified frequency tolerance, use the voltage
adjustment control knob (Figure 47) to increase or
decrease the desired voltage.
7. Turn the starter switch to ‘PREHEAT’ (Figure 42)
until the indicator light turns on. The oil pressure
indicator light will initially turn on, but should turn off
once the pressure rises.
Figure 42. Key Switch (Preheat)
Figure 46. Voltage Meter (Volts)
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DCA-60SSAI — GENERATOR START-UP PROCEDURE
15. The charging ammeter (Figure 51) will indicate if the
battery is properly charged.
Figure 47. Voltage Adjust Control
Figure 51. Charging Ammeter
Knob
16. The tachometer (Figure 52) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800
RPM’s.
12. The ammeter (Figure 48) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator’s alternator.
40
20
60
0
75
A
Figure 52. Engine Tachometer
Figure 48. Ammeter (No Load)
17. Turn the MAIN, GFCI and LOAD circuit breakers to
their ON position (Figure 53).
13. The engine oil pressure gauge (Figure 49) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure is approximately
25 psi.
Figure 53. Main and GFCI Circuit Breakers
18. Observe the generator's ammeter (Figure 54) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if the load is in use.
Figure 49. Oil Pressure Gauge
14. The coolant temperature gauge (Figure 50) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature is between 165 and
215 degrees fahrenheit.
40
20
60
0
75
A
WATER TEMP
Figure 54. Ammeter (Load)
19. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 50. Coolant Temperature Gauge
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DCA-60SSAI — GENERATOR SHUT-DOWN 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 55)to the “OFF” position.
2. Turn the key switch to ‘STOP’.
Figure 55. Main, GFCI and Load
circuit breakers
2. Turn to the right and press in the engine throttle lever
(Figure 56).
Figure 56. Engine Throttle Lever
3. Let the engine cool by running it for 3-5 minutes with no
load applied.
4. Turn the key switch to ‘STOP’’ (Figure 57).
Figure 57. Key Switch (OFF)
5. Remove the load from the UVW terminal strip.
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DCA-60SSAI — 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.
1. Detach the oil filter cartridge with a filter wrench.
2. Apply a film of oil to the gasket for the cartridge.
3. Screw in the cartridge by hand. When the gasket is in
contact with the seal surface, tighten the cartridge one
or two more times by hand.
Fuel Addition
Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.
4. After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check
for leaks before adding more oil if needed. Clean
excessive oil from engine.
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
1. Replace the fuel filter cartridge with new one every 400
hours or so.
2. Apply fuel oil thinly over the gasket and hand-tighten
the cartridge into position.
Air Removal
3. 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.
4. Fuel Injection Nozzle
5. 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.
6. Abnormal fuel consumption will lead to a lowered output
and blackish exhaust smoke. The required injection
starting pressure should be 14.7MPa (150kg/cm2,
2130psi).
Service Daily
If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result. This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber in high fuel consumption.
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DCA-60SSAI — MAINTENANCE
Feed Pump Strainer Cleaning
The strainer is incorporated in the feed pump inlet side joint
bolt. Clean the strainer with compressed air and rinse it in
the fuel oil.
Flushing Out Radiator and Replacing Coolant
1. Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overflow
tank and drain.
2. Check hoses for softening and kinks. Check clamps for
signs of leakage.
3. Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.
4. Tighten both cocks and replace the overflow tank.
5. Replace with coolant (see page 44,Table 14 for mixture).
6. Close radiator cap tightly.
CAUTION :
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot will
damage radiator.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 53
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DCA-60SSAI — 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 15. Valve Adustment
(I=Inlet; E=Exhaust)
Cylinder No.
1
2
3
4
Valve Arrangement
I
E
X
I
E
I
E
X
I
E
Figure 58. Valve Adjustment
When No. 1 is at top
dead center in the
compression stoke
X
X
NOTE:
When No. 4 is at top
dead center in the
compression stroke
O
O
O
O
Take necessary precautions to prevent dust and
foreign particles in the pump interior when timing
adjustments are made.
PAGE 54 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI — 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
ENGINE
Drain Bottom of Fuel Tank
Clean Unit, Inside and Outside
Change Fuel Filter *2
X
X
Clean Radiator and Check Coolant Protection
Level
Replace Air Filter Element
Change Corrosion Resistor
Check all Hoses and Clamps
Clean Inside of Fuel Tank
X
X
X
X
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
For storage of the generator for over 30 days, the following
is required:
y
y
Fill the fuel tank completely.
Completely drain the oil from the crankcase and refill
with fresh oil.
y
y
Clean all external parts of the generator with a cloth.
Cover the generating set and store in a clean, dry place.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 55
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DCA-60SSAI — GENERATOR WIRING DIAGRAM
PAGE 56 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI — ENGINEWIRING DIAGRAM
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 57
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DCA-60SSAI —TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper diagnosis based on the EngineTroubleshooting (Table 16).If
handling and maintenance inspections, but in the event of a the problem cannot be remedied, consult our company's
breakdown, use the tables shown for
business office or service plant.
TABLE 16. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
No fuel?
Replenish fuel.
Air in the fuel system?
Water in the fuel system?
Fuel pipe clogged?
Fuel filter clogged?
Bleed system.
Remove water from fuel tank.
Clean fuel pipe.
Clean or change fuel filter.
Excessively high viscosity of fuel
or engine oil at low temperature?
Use the specified fuel or engine oil.
Use the specified fuel.
Tighten nut.
Fuel with low cetane number?
Fuel leak due to loose injection
pipe retaining nut?
Incorrect injection timing?
Fuel cam shaft worn?
Adjust.
Engine does not start.
Replace.
Injection nozzle clogged?
Injection pump malfunctioning?
Clean injection nozzle.
Repair or replace.
Seizure of crankshaft, camshaft,
piston, cylinder liner or bearing?
Repair or replace.
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Compression leak from cylinder?
Improper valve timing?
Piston ring and liner worn?
Excessive valve clearance?
Starter malfunctioning?
Wiring disconnected?
Correct or replace timing gear.
Replace.
Adjust.
Repair or replace.
Connect wiring.
Starter does not run.
PAGE 58 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI —TROUBLESHOOTING (ENGINE)
TABLE 16. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
POSSIBLE PROBLEM
Fuel filter clogged or dirty?
Air cleaner clogged?
SOLUTION
Clean or change.
Clean or change.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Repair or replace.
Adjust.
Injection pump malfunctioning?
Engine revolution is not smooth.
Incorrect nozzle opening
pressure?
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe clogged?
Governor malfunctioning?
Excessive engine oil?
Clean.
Repair.
Reduce to the specified level.
Piston ring and liner worn or
stuck?
Repair or replace.
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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 59
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DCA-60SSAI —TROUBLESHOOTING (GENERATOR/ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table 7).If the problem
cannot be remedied, consult our company's business office or service plant.
TABLE 17. ENGINE & GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
Dead battery?
SOLUTION
Replace battery.
Replace switch.
Replace fuse.
Engine fails to start and starter
does not rotated.
Defective starter switch?
Fuse F5 burned out?
Broken pre-heat circuit?
No fuel?
Check pre-heat circuit.
Add fuel.
Engine fails to start and starter
rotates.
Defective wiring?
Check wiring.
Clogged fuel strainer?
Clogged air cleaner?
Disconnected wiring?
Clean or replace.
Clean or replace.
Check and repair wiring.
Engine starts and remains at low
speed.
No voltage present in AC power
source?
Replace rectifier (RE1).
Defective rotor?
Replace rotor.
Engine speed rises and no
volteage is present n AC power
source.
Defective voltmeter?
Disconnected wiring?
Replace voltmeter.
Check and repair wiring.
Layer short-circuit in armature
winding?
Replace armature.
Defective circuit breaker (protector)?
Replace circuit breaker (protector).
Repair or replace armature.
Engine speed rises and AC power
voltage is too low or cannot be
used.
Layer short-circuit, broken wires in
armature winding?
Defective engine regulator?
Defective wiring?
Replace regulator.
Engine speed rises and battery
discharges too soon.
Repair or replace wiring.
Repair or replace alternator.
Replace alternator bearings.
Defective alternator?
Engine speed rises and engine
seems overloaded.
Damaged alternator bearing?
PAGE 60 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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NOTE PAGE
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI — SUGGESTED SPARE PARTS
DCA-60SSAIW/ISUZU 6BD1 DIESEL ENGINE
1 TO 3 UNITS
Qty.
P/N
Description
1 ......... 0601805869 ......... CIRCUIT BREAKER
1 ......... 0601820671 ......... AUTOMATICVOLTAGE REGULATOR
1 ......... 0601840073 ......... RHEOSTAT VOLTAGE REGULATOR
1 ......... 0601840121 ......... KNOB REHOSTAT
1 ......... 0602013901 ......... RADIATOR HOSE, UPPER
1 ......... 0602013160 ......... RADIATOR HOSE, LOWER
5 ......... 1878100753 ......... OIL FILTER
5 ......... X132400240 ........ FUEL FILTER
5 ......... 0602040193 ......... ELEMENT, AIR
1 ......... 0602122200 ......... UNIT OIL PRESSURE
1 ......... 0602123204 ......... UNIT WATER PRESSURE
1 ......... 0601810244 ......... BULB, ALARM LAMP
1 ......... 0601808507 ......... TRANSDUCERWATT METER
1 ......... 8972322520 ......... FAN BELT
1 ......... 1823100080 ......... STARTER SWITCH
3 ......... KEYISUZUF ........ KEY, STARTER SWITCH
NOTE
Part number on this Suggested Spare
Parts list may supercede/replace the
P/N shown in the text pages of this
book.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 63
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DCA-60SSAI --- GENERATOR ASSY.
GENE
PAGE 64 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
PART NO.
ITEM
QTY.
REMARKS
7451040000
3361010112
7461042003
3361080003
3361032003
3361085003
3341610003
3361025003
3361026003
0601820067
0010004020
0041604000
0040004000
0030004000
0601822601
0801841004
0801841104
0010005020
0041605000
0040005000
0030005000
0017105012
3331014004
0070206310
008000050
3361070003
3341611003
3341613004
0010312030
060160000
0601610700
0601610511
0040010000
0010310030
7451340000
3361320122
3361342024
7451361113
0801350104
3361315013
FIELD ASSY.
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
10
11
12
13
14
15
16
16-1
16-2
16-3
17
SHAFT
FIELD CORE
FIELD COIL
ARMATURE CORE, EXCITER
ARMATURE COIL, EXCITER
COUPLING HUB
RECTIFIER ASSY.
SET PLATE, RECTIFIER
RECTIFIER
HEX. HEAD BOLT
PLAIN WASHER
LOCKWASHER
HEX. NUT
SURGE ABSORBER
INSULATORWASHER
INSULATORWASHER
HEX. HEAD BOLT
PLAIN WASHER
LOCKWASHER
HE. NUT
HE.HEAD BOLT
BEARING FLANGE
BEARING
3 ........... PB2510
3
6
3
3
1 ........... ERZM14JK621A
1
1
1
2
1
1
4
1
1 ........... 6310RS
1
1
1 ........... (80 0
5
10
SNAP RING
FAB
COUPLING DISC
LOCKWASHER
HEX. HEAD BOLT
COUPLING RING
LOCKWASHER
BOLT SET
LOCKWASHER
HEX. HEAD BOLT
STATOR ASSY.
GENERATOR FRAME
ARMATURE CORE
ARMATURE COIL
GROMMET
1 ........... 92612590050
9 ........... 9091505100
1
9
9
1
1
1
1
1
1
18
END BRACKET
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 65
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DCA-60SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
PAGE 66 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
19
19-1
19-2
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
3361350030
3361352023
3361362303
0041608000
0040008000
0010008060
0040010000
0010010030
3801312004
3331310104
0040006000
0010006055
3361331003
0017106010
0040010000
0010310025
3341332103
0041606000
0040006000
0010006030
0605000011
0040016000
0030116000
FIELD ASSY., EXCITER
FIELD CORE, EXCITER
FIELD COIL, EXCITER
PLAIN WASHER
LOCKWASHER
HEX. HEAD BOLT
LOCKWASHER
HEX. HEAD BOLT
GASKET, BERAING
COVER, BEARING
LOCKWASHER
HEX. HEAD BOLT
COVER, END BRACKET
HEX. HEAD BOLT
LOCKWASHER
1
1
1
4
4
4
6
6
1
1
4
4
1
8
6
6
1
1
1
1
2
4
4
HEX. HEAD BOLT
COVER, FAN
PLAIN WASHER
LOCKWASHER
HEX. HEAD BOLT
RUBBER SUSPENSION
LOCKWASHER
HEX. NUT
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 67
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DCA-60SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 68 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
7451810002
7451810012
7451810022
3361870603
0017106016
0601801143
0027104010
0800225201
0027106010
0601820042
0027103010
0601842058
0027105010
0601820851
0027104016
0601805352
0041604000
0040004000
0021004020
0601830625
0601840191
0601830614
0021104016
0021104014
7451822503
0601800460
0601800784
0601801040
0601800217
0601801041
0601810072
0601810261
CONTROL BOX
CONTROL BOX
CONTROL BOX
1 .......UPTO S/N3311616
1 .......S/N3311617TO 3312672
1 .......S/N3312673~
3
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
CURRENTTRANSORMER
HEX. HEAD BOLT
CURRENTTRANSORMER, AMMETER
MACHINE SCREW
AUTOMATICVOLTAGE REGULATOR
MACHINE SCREW
RECTIFIE
MACHINE SCREW
RESISTOR
MACHINE SCREW
OVER CURENT RELAY
MACHINE SCREW
CIRCUIT BREAKER
PLAIN WASHER
6
2 .......CT3.5MR 100/5A
4
1 .......AE2206A
6
1 .......16T60
4
1 .......RWH80V 200KOHMS
2
1 .......THK20
2
1 .......KM203 550V 150AT
4
4
4
1
1
1
4
2
1
1 .......PAK60 220V 45~65Hz
1 .......PSK60 0~100A 0~200a
1 .......SL2AS
1 .......PCK60 0~600V
1 .......SL2VS
1
1
LOCKWASHER
MACHINE SCREW
CHANGE-OVER SW.VOLTAGE
SWITCH CAP
PLATE
19
20
21
22
23
24
25
26
27
MACHINE SCREW
MACHINE SCREW
CONTROL PANEL
FREQUENCY METER
AC AMMETER
CHANGE-OVER SW., AMMETER
AC VOLTMETER
CHANGE OVER SW., VOLTMETER
PILOT LAMP
BULB
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 69
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DCA-60SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 70 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
28
29
30
31
32
33
34
35
36
37
0601840031
0601840120
3331824003
0027105016
0030005000
0805001304
0041608000
0030008000
0027105010
7451826504
7451826514
0017106016
0017108020
0030008000
0601815933
0601815934
0027105020
VOLTAGE REGULATOR
KNOB
STOPPER, CONTROL PANEL
MACHINE SCREW
HEX. NUT
SET SCREW, CONTROL PANEL
PLAIN WASHER
HEX. NUT
MACHINE SCREW
SIDE PANEL, CONTROL BOX
SIDE PANEL, CONTROL BOX
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX., NUT
1 ....... RA30A2FE202BJ
1
1
2
2
2
2
2
4
1 ....... UPTO S/N3311616
1 ....... S/N3312178~
2
4
38
39
40
41
42
43
4
TERMINAL
TERMINAL
MACHINE SCREW
1 ....... S/N3312673~; AYBS0431
1 ....... S/N3312673~; AYBS0441
4 ....... S/N3312673~
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 71
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DCA-60SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 72 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
3
4
5
6
7
0602000100
0602010802
0602013901
0602013160
0602014302
0602014303
0602040090
0602040193
0602040690
0602040598
0017108020
0030008000
7452032303
0605515008
0602041106
0602042106
3345112403
3345112503
0040010000
0010710025
0605000009
0040012000
ENGINE ........................................... 1 ......... ISUZU 6BD1
RADIATOR....................................... 1 ......... H190110000
RADIATOR HOSE ........................... 1 ......... B400008
RADIATOR HOSE ........................... 1 ......... B400007
HOSE BAND
HOSE BAND
3
1
AIR CLEANER ................................. 1 ......... FWG088006
ELEMENT, AIR CLEANER .............. 1 ......... P104972
DUST INDICATOR ........................... 1 ......... RBX002252
BAND, AIR CLEANER ..................... 2 ......... AAH008263
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
HEX. HEAD BOLT
HEX. NUT
HOSE, AIR CLEANER
HOSE BAND
4
4
1
2
ELEMENT, OIL FILTER................... 1 ......... 1878100750
ELEMENT, FUEL FILTER ............... 1 ......... 9885111911
ENGIEN FOOT
ENGIEN FOOT
1
1
LOCK WASHER
HEX.HEAD BOLT
RUBBER SUSPENSION
LOCK WASHER
8
8
2
4
0030112000HEX. NUT
4
0017108020
0602210803
7452215104
0027106016
0017108020
7452051104
0805013704
0805014204
HEX. HEAD BOLT
6
ENGINE STOPPER ......................... 1 ......... 1819000161
BRACKET, ENGINE STOPPER
MACHINE SCREW
HEX. HEAD BOLT
DRAIN JOINT
PACKING, OIL PAN SIDE
PACKING
1
3
2
1
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 73
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DCA-60SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 74 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
31
32
33
34
35
36
37
38
39
41
42
43
44
45
46
47
48
49
50
51
52
PART NO.
ITEM
QTY.
1
1
1
1
1
2
2
2
1
1
2
1
1
1
1
4
REMARKS
3362054104
3362051003
0802024004
0802010204
7452052104
0605515003
0017108020
0030008000
0845031303
7452082504
0017108020
0017106025
0199500470
0199500175
0193602000
0605515013
0193100950
0605515007
0193800850
0605515019
7452220404
JOINT BOLT
DRIAN JOINT
PACKING
PLUG
DRAIN HOSE
HOSE BAND
HEX. HEAD BOLT
HEX. NUT
RESERVE TANK
BRAKET, RESERVE TANK
HE. HEAD BOLT
HEX. HEAD BOLT
HOSE
HOSE
HOSE
HOSE BAND
HOSE
HOSE BAND
HOSE
1
1
1
1
HOSE BAND
EARTH CABLE
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 75
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DCA-60SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 76 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
1
PART NO.
ITEM
OPERATING PANEL
SLIDE BAR
REMARKS
7452111103
7452142004
7452142014
0805012904
0080200006
0036003000
7452140504
0030008000
0605010503
0602100004
0602102005
0602120052
0602120161
0602122060
0602122200
0131300000
0602123061
0602123204
0602121052
0602103060
0601810244
0601830420
0601810120
0040520000
0601830710
0041608000
0040008000
0010008040
0017108020
0030008000
7452183004
0010010025
0041610000
0030010000
7452182004
7452152004
0602180101
0030008000
0602180100
0030006000
0041606000
7455188103
0017108020
0602200405
0027106016
0601823706
2
SLIDE BAR
KNOB
SNAP RING
HEX. NUT
BRACKET, GOVERNOR ROD
HEX., NUT
SNAP PIN
STARTER SWITCH
PREHEAT LAMP
TACHOMETER
CABLE, TACHOMETER
OIL PRESSURE GAUGE
UNIT, OIL PRESSURE
STREET SOCKET
WATER TEMPERATURE GAUGE
UNIT, WATER TEMPERATURE
CHARGING AMMETER
ALARM LAMP
1 ......... S/N3313038~
3
4
1
1 ......... UPTO S/N3313037
1 ......... S/N3313038~
1
2
1
1 ......... 1823100080
1 ......... 9825300430
1 ......... 25000KX3710
1 ......... 62100KA0910 L=1700
1 ......... 42000KX1410
1 ......... 53000AC0101
1
1 ......... 40000KX0910
1 ......... 51400KA1200
1 ......... 43000KV0300
2
5
6
7
8
9
10
11
12
13
14
15
16
17
18
BULB
2
19
20
21
22
23
24
25
26
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
SWITCH, LAMP CHECK
PANEL LIGHT
1 ......... SB61A
1 ......... DL31000
TOITHED LOCKWASHER
SWITCH, PANEL LIGHT
PLAIN WASHER
LOCKWASHER
HEX. HEAD BOLT
HEX. HEAE BOLT
HEX. NUT
LINK, GOBERNOR ROD
HEX. HEAD BOLT
PLAINWASHER2
HE.X NUT
GOVERNOR ROD
GOBERNOR ROD
BALL JOINT
HEX. NUT
BALL JOINT
1
1
2
2
2
2
2
1
1
1
1
1
2
2
2
3
1
HEX. NUT
PLAIN WASHER
SET PANEL, ELECTRIC PARTS
HEX. HEAD BOLT
EMERGENCY RELAY
MACHINE SCREW
RELAY
1
5
1 ......... 1825500730
4
1 ......... JH1A DC24V
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 77
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DCA-60SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 78 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
47
48
49
50
51
52
53
54
55
56
57
58
0027104016
7451860203
0801830204
0801830704
0041412000
0040012000
0039312000
0601805318
0041608000
0040008000
0010008030
0601811032
0601811032
0601811037
0601811034
0601811031
0601811092
0601811030
0027103010
0041603000
0030003000
0601805353
0601805319
0601805306
0601805311
7451816004
7451816014
0027106016
7451865503
0805012304
0041612000
0805019704
0030012000
0605010505
0601850091
0021003010
0601802133
0601820015
7451865603
7451855503
7451855703
0021304015
0040004000
0041204000
0030104000
0030104000
MACHINE SCREW
SET BOARD, OUTPUT TERMINAL 1
2
OUTPUTTERMINAL
HEX. HEAD BOLT
PLAIN WASHER
LOCKWASHER
HEX, .NUT
CIRCUIT BREAKER
PLAIN WSHER
LOCKWASHER
HEX. HEAD BOLT
RECEPTACLE
RECEPTACLE
RECEPTACLE
RECEPTACLE
RECEPTACLE
RECEPTACLE
RECEPTACLE
MACHINE SCREW
PLAIN WASHER
HEX. NUT
CIRCUIT BREAKER
CIRCUIT BREAKER
CIRCUIT BREAKER
CIRCUIT BREAKER
BRACKET, CIRCUIT BREAKER
BRACKET, CIRCUIT BREAKER
MACHINE SCREW
COVER, OUTPUT TERMINAL
HEX. HEAD BOLT
PLAIN WASHER
RUBBERWASHER
HEX. NUT
4
4
16
12
8
1 ......... S/N3312673~;KM52 265V 20A
5
5
5
2 ......... UPTO S/N3312672;L6-20R 250V 20A
1 ......... S/N3312673~; L620R 250V 20A
2 ......... UP TO S/N3312672; CS8269 250V 20A
2 ......... S/N3312672~; CS6369 250V 50A
2 ......... UP TO S/N3312672; L530R 125V 30A
2 ......... S/N3312673~; L520R 125V 20A
2 ......... 5-20R 125V 20Ax2
16
16
59
60
61
62
63
64
65
16
2 ......... UP TO S/N3312672; KM101 265V 75A
2 ......... S/N3312673~; KM52 265V 40A
2 ......... UP TO S/N3312672; KM51 265V 40A
2 ......... S/N3312673~; KM51 265V 50A
1 ......... UPTO S/N3312672
1 ......... S/N3312673~
2
1
2
4
2
2
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
SNAP PIN
2
RUBBER CUSHION
MACHINE SCREW
FUSE
RECTIFIER
COVER, OUTPUT TERMINAL
HINGE
2 ......... SK156
2
1 ......... F5 5A
4 ......... 1S2762
1 ......... FROM S/N3312331
1 ......... FROM S/N3312331
1 ......... FROM S/N3312331
4 ......... FROM S/N3312331
4 ......... FROM S/N3312331
8 ......... FROM S/N3312331
4 ......... FROM S/N3312331
4 ......... SN3312672~
HINGE
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
HEX. NUT
HEX. NUT
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 79
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DCA-60SSAI --- BATTERY ASSY.
BATTERY ASSY.
PAGE 80 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- BATTERY ASSY.
BATTERY ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
3
4
5
6
7
8
0160012100
0805003904
0805004004
0805002904
0041608000
0040008000
0037808000
0215260065
BATTERY ......................................... 2 ......... N1000 12V 100Ah
BATTERY SHEET
BATTERY BAND
BATTERY BOLT
PLAIN WASHER
LOCKWASHER
WING NUT
2
2
4
4
4
4
1
1
1
BATTERY CABLE
9
10
11
02511160180 BATTERY CABLE
0215860100
0602220310
0208008000
0602220311
0208008000
BATTERY CABLE
TERMINAL ASSY. (+) ...................... 2 ......... NO.9P
WING NUT ....................................... 2
TERMINAL ASSY.(-) ........................ 2 ......... NO.9N
WING NUT ....................................... 2
12
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 81
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DCA-60SSAI --- MUFFLER ASSY.
MUFFLER ASSY.
PAGE 82 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
ITEM
EXHAUST PIPE
GASKET
HEX. NUT
MUFFLER
HEX. HEAD BOLT
EXHAUST PIPE
GASKET
HEX. HEAD BOLT
PLAIN WASHER
LOCKWASHER
HEX. NUT
PIPE BAND
HEX. HEAD BOLT
PLAIN WASHER
HEX. NUT
QTY.
1
1 ......... 9221160010
6 ......... 9091103100
REMARKS
7452330103
0602320000
0602323002
3802311122
0017110020
7452330303
3342356104
0010108035
0041608000
0040008000
0030008000
1382320003
0010008030
0041608000
0030008000
3342354104
3342354004
3342328104
0030008000
3342359004
0017108025
1
4
1
1
4
4
4
4
1
1
1
1
1
1
1
4
2
4
9
10
11
12
13
14
15
16
17
18
19
20
21
COVER
COVER
PIPE CLAMPER
HEX. NUT
COVER SHEET
HEX. HEAD BOLT
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 83
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DCA-60SSAI --- FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 84 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- FUELTANK ASSY.
FUEL TANK ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
7455510123
7455510303
0810105004
0810105400
0802010304
0602021042
7455523104
7455523304
0805003404
0017108020
0041608000
0040008000
0030008000
3805522004
0191300530
0191300650
0605515014
0845032204
0150000018
0802011104
0193100255
0605515079
0131906000
FUEL TANK
FUEL TANK
CAP, FUEL TANK
FUEL FILTER
PACKING
1 ......... UPTO S/N3312672
1 ......... S/N3312673~
1
1
1 ......... UPTO S/N3312672
1 ......... UPTO S/N3312672;960922101
2 ......... UPTO S/N3312672
2 ......... S/N3312673~
4
2
2
2
2
4
1
1
1-1
1-2
2
3
4
PLUG
TANK BAND
TANK BAND
PAD, TANK BAND
HEX. HEAD BOLT
PLAIN WASHER
LOCKWASHER
HEX. NUT
TANK SHEET
SUCTION HOSR
RETURN HOSE
HOSE BAND
DRAIN JOINT
O RING
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
4
1
1
1
1
2
PLUG
FUEL GAUGE HOSE
HOSE BAND
CAP
1 ......... S/N3312673~
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 85
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DCA-60SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 86 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
7455111012
7455111102
7455109104
7455116004
0017108020
7455121012
7455109203
7450630503
7450630703
6360510003
0021106020
0017108020
0800251201
0027106016
7455125003
7455125503
7455109304
7450630303
0017108020
7455125303
0017108020
3385155104
0017106020
7455125104
7455109404
0017108020
7455125204
7455125704
7455109504
0017108020
7455132013
7455132203
00101141040
0041614000
0040014000
0030014000
0010012030
0040012000
0041612000
BASE
1 ............UP TO S/N3312672
BASE
1 ............S/N3312673~
1
1
12
1
1
1
1
2
4
6
1
2
3
ACOUSTIC SHEET
FLOOR PANEL
HEX. HEAD BOLT
FRONT FRAME
ACOUSTIC SHEET
STRIPE, LEFT SIDE
STRIPE, RIGHT SIDE
EMBLEM
MACHINE SCREW
HEX. HEAD BOLT
FILTER COVER
MACHINE SCREW
COVER, FRONT FRAME
5
6
7
8
9
10
11
12
13
14
2
1 ............UP TO S/N3312672
15
16
17
18
19
20
21
22
23
24
25
ACOUSTIC SHEET
STRIPE
HEX., HEAD BOLT
COVER, FRONT FRAME
HEX.HEAD BOLT
COVER
HEX. HEAD BOLT
COVER, FROT FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT
COVER, FRONT FRAME
COVER, FRONT FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT
CENTER FRAME
CENTER FRAME
HEX. HEAD BOLT
PLAIN WASHER
LOCK WASHER
HEX. NUT
1
1
16
1
12
2
8
1
1
6
1 ............UP TO S/N3312672
1 ............S/N3312673~
1
4
1
1
8
16
8
8
10
10
10
26
27
28
29
30
31
32
33
34
35
36
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
2-WHITE
5 -BLACK
6 -CATERPILLAR YELLOW
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 87
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DCA-60SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 88 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
37
7455141102
7455141112
7455109603
7450630904
0017108020
7455155003
7455109703
0041608000
0040008000
0010008040
7455143103
7455143113
1320632003
3805147104
0021006020
0041606000
0040006000
0030006000
0845028303
0017108025
7455161012
7455109803
0017108020
7455165004
7455109904
0017108020
7455181202
7455181212
7455105004
0010008055
0040008000
001608000
REAR FRAME
REAR FRAME
ACOUSTIC SHEET
STRIPE
1 ............UP TO S/N3311616
1 ............S/N3312178~
1
2
4
1
1
8
38
39
40
41
42
43
44
45
46
HEX. HEAD BOLT
COVER, REAR FRAME
ACOUSTIC SHEET
PLAIN WASHER
LOCK WASHER
HEX. HEAD BOLT
DOOR, REAR FRAME
DOOR, REAR FRAME
STICKER
WINDOW PLATE
MACHINE SCREW
PLAIN WASHER
LOCK WASHER
HEX. NUT
8
8
1 ............UP TO S/N3311616
1 ............S/N3312178~
1
1
6
6
6
6
2
4
1
1
16
2
2
8
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
HINGE
HEX. HEAD BOLT
ROOF PANEL
ACOUSTIC SHEET
HEX. HEAD BOLT
GUIDE PANEL, AIR
ACOUSTIC SHEET
HEX. HEAD BOLT
SPLASHER PANEL
SPLASHER PANEL
ACOUSTIC SHEET
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
1 ............UP TO S/N3312672
1 ............S/N3312673~
1
6
6
6
62
63
64
65
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
2-WHITE
5 -BLACK
6 -CATERPILLAR YELLOW
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 89
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DCA-60SSAI --- RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
PAGE 90 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
66
7455171403
7455171413
7455105104
7455171503
7455171513
7455105204
7450631104
7455171603
7455171613
7455105304
7450631304
7455171703
7455171713
7455105404
7450631504
0845028203
0845028303
0017108025
0845031504
0605010910
0027103010
0605010911
0027104010
7455104104
7455104204
7455104304
7455104404
7455104504
7455104604
7455104704
7455104804
7455104904
7455116504
0017108020
SIDE DOOR, LEFT SIDE
SIDE DOOR, LEFT SIDE
ACOUSTIC SHEET
SIDE DOOR, RIGHT SIDE
SIDE DOOR, RIGHT SIDE
ACOUSTIC SHEET
STRIPE
SIDE DOOR, LEFT SIDE
SIDE DOR, LEFT SIDE
ACOUSTIC SHEET
STRIPE
SIDE DOOR, RIGHT SIDE
SIDE DOOR, RIGHT SIDE
ACOUSTIC SHEET
STRIPE
HINGE
HINGE
HEX. HEAD BOLT
CAP
LATCH
MACHIEN SCREW
LATCH
MACHIEN SCREW
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
COVER
1 ............UP TO S/N3311616
1 ............S/N3312178~
67
68
1
1 ............UP TO S/N3311616
1 ............S/N3312178~
1
2
1 ............UP TO S/N3311616
1 ............S/N3312178~
1
1
1 ............UP TO S/N3311616
1 ............S/N3312178~
1 ............
1
4
4
16
10
1 ............UP TO S/N3311616
7 ............UP TO S/N3311616
2 ............UP TO S/N3311616
14 ..........UP TO S/N3311616
2
2
3
1
1
1
1
2
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
2
1 ............S/N3312673~
2 ............S/N3312673~
HEX. HEAD BOLT
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 91
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DCA-60SSAI --- DECALS
DECAL ASSY.
PAGE 92 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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DCA-60SSAI --- DECALS
DECAL ASSY.
NO.
PART NO.
ITEM
QTY. REMARKS
1
2
3
4
5
6
7
8
B9521100504
B4551005902
0800520904
0800520804
B9521100404
B9531100604
3340670002
8050670113
B1551001604
0840614104
0840619904
0840627103
8080670514
B9531100604
B9511100404
B9531100504
B9511100304
0800689404
0800689504
1320620904
1320610603
6360610304
6360620004
6360620204
0840627304
1320621504
0840625902
B9504200004
B9504000404
B9504500004
B9504100104
B9504000304
7450630703
B4561100403
B4561100503
B4561100604
B4561100304
B4561100003
DECAL; CAUTION....................................................... 1 ....... B92110050
DECAL; CONTROL PANEL ........................................ 1 ....... B45100590
PLATE; AMMETER CHANGE-OVER SWITCH .......... 1 ....... N2438
PLATE; VOLTAGE CHANGE-OVER SWITCH ........... 1 ....... N2439
DECAL; SAFETY INSTRUCTION .............................. 1 ....... B92110040
DECAL; WARNING ..................................................... 1 ....... B93110060
DECAL; OPERATING PANEL ..................................... 1 ....... S2361A
DECAL; RECEPTABLE & CIRCUIT BREAKER.......... 1 ....... S3349A
DECAL; NOTE............................................................. 1 ....... B15100160
DECAL; GROUND MARK ........................................... 1 ....... S2635
DECAL; CAUTION....................................................... 1 ....... S2731
DECAL; CABLE JOINING ........................................... 1 ....... S3245
DECAL; CAUTION....................................................... 1 ....... S3696B
DECAL; WARNING ELECTRIC SHOCK HAZARD .... 1 ....... B93110060
DECAL; WARNING ELECTRIC SHOCK HAZARD .... 1 ....... B91110040
DECAL; WARNING ELECTRIC SHOCK HAZARD .... 1 ....... B93110050
DECAL; WARNING ..................................................... 1 ....... B91110030
DECAL; + ..................................................................... 1 ....... S2090
DECAL; - ...................................................................... 1 ....... S2091
DECAL; DIESEL FUEL................................................ 1 ....... S1756
DECAL; WATER, OIL .................................................. 1 ....... S1760
DECAL; WATER .......................................................... 1 ....... S1880
DECAL; FUEL DRAIN PLUG ...................................... 1 ....... S1883
DECAL; OIL DRAIN PLUG.......................................... 1 ....... S1885
DECAL; WARNING ..................................................... 1 ....... S3247
DECAL; SUPPORT HOOK ......................................... 2 ....... S2257
DECAL; MQ ................................................................. 1 ....... S3057
DECAL; WARNING ENGINE EXHAUST .................... 1 ....... B90420000
DECAL; WARNING MOVING PARTS ......................... 2 ....... M90400040
DECAL; WARNING DIESEL FUEL ............................. 1 ....... B90450000
DECAL; WARNING HOT COOLANT ......................... 1 ....... B90410010
DECAL; CAUTION HOT PARTS................................. 1 ........ B90400030
STRIPE........................................................................ 1 ........ REPLACES B4561100103
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
STRIPE
STRIPE
STRIPE
STRIPE
STRIPE
2
1
1
2
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 93
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ISUZU 6BD1 — CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.
PAGE 94 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
1
1111105271
1111106141
1096000051
9111291280
5112190150
5096000130
1096000160
1096000160
9096600340
9117156070
1117150540
1117110260
1117110430
5117210010
9111296010
9041108250
9041108750
9098301790
9096300260
1093000180
9098301630
5125690010
1125690150
1111410902
1111411950
5090090180
1090701010
5090090170
1090390030
1090701000
1111709281
1111801531
9117510381
5111790520
1111730590
9111790300
9111791050
9111750110
CYLINDER HEAD
1 .......... UP TO AUG. 85; REPLACES 1111105270
CYLINDER HEAD
1 .......... AUG. 85~; INCL. ITEMS W/#
1
3
3
6 .......... REPLACES 9111296010
5
6
6
6 .......... UP TO APR. 85
6 .......... MAY 85~
6 .......... UP TO JUL. 85
6 .......... AUG. 85~
12
5
3
9
2
EA1013
3#
REAR SEALING CUP, D=44.5
LOWER SEALING CUP, D=20
EXH. SEALING CUP, D=31.75
DRILLED SEALING CUP, D=12
TOP FACE SEALING CUP, D=25
INL. MAN. SEALING CUP
PLUG
INLET VALVE SEAT INSERT
INLET VALVE SEAT INSERT
EXH. VALVE SEAT INSERT
EXH. VALVE SEAT INSERT
VALVE GUIDE, EXH. & INL.
SEALING CUP, DRILLED D=12
INLET MANIFOLD STUD
EXH. MANIFOLD STUD
EXH. MANIFOLD STUD, L1=88
EXH. MANIFOLD STUD, L1=86
NOZZLE HOLDER STUD, L1-40
ROCKER ARM NUT STUD, L1=83 4
VALVE GUIDE, INL & EXH. SEAL 12 ........ UP TO JUL. 85
VALVE GUIDE, INL & EXH. SEAL 12 ........ AUG. 85~
CYLINDER HEAD GASKET
CYLINDER HEAD GASKET
BOLT, L=115
BOLT, L=113
BOLT, L=102
BOLT, L=106
BOLT, L=100
CYL. HEAD COVER ASSY.
CYL. HEAD COVER ASSY.
OIL FILLER CAP
BREATHER HOSE NIPPLE
CYL. HEAD COVER PACKING
COVER PACKING
WASHER
3-1#
3-2#
3-3#
3-4#
3-5#
4#
7#
8#
9#
10
15
16
12
12
17
18
20
21
1 .......... AUG. 84.TO AUG. 85
1 .......... AUG. 85~; REPLACES 1111411710
20 ........ UP TO SEPT. 88
20 ........ OCT.88~;REPLACES 1090700630
6 .......... UP TO JUL. 84
6 .......... AUG. 84~JUL. 86
6 .......... JUL. 86~; REPLACES 1090700620
1
22
22-1
29-1
29-2
30
36
49
51
52
53
1
1
1 .......... REPLACES 9143193681
1
4
4
4
NUT
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 95
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ISUZU 6BD1 — CYLINDER BLOCK ASSY.
PAGE 96 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
NO.
1
PART NO.
1112102790
PART NAME
QTY.
REMARKS
CYLINDER BLOCK ASSY...................................... 1 .......... UP TO S/NE518004;
INCL. ITEMS W/#
1112103324
1090004691
8943706360
CYLINDER BLOCK ASSY...................................... 1 .......... REPLACES 1112103320
BOLT ...................................................................... 14 ........ REPLACES 5090001330
BRIDGE CAP NO.4 DOWEL................................. 1 .......... REPLACES 5112570010;
UP TO MAY 89
2#
4#
5112570010
9116110480
9116130350
1096000520
5112190140
1096000121
1112611180
9098600190
1096050660
5096050180
1096050681
1096050681
1096050791
9992023140
9992023120
9095714140
9095714120
5096540130
9112916050
1112910441
5112901450
1097400780
9112246021
5093000231
9081510180
1090520211
9095720080
1112920200
1096800240
1096660360
1096301150
9099148600
8970157540
9112298010
5117401220
9091105080
BRIDGE CAP NO. 4 DOWEL ................................ 1 .......... JUNE 89~
FRONT CAM METAL ............................................ 1 .......... REPLACES 911690480
INNER AND REAR CAM METAL .......................... 5 .......... REPLACES 9116930350
5#
5-1#
6#
6-1#
6-2#
7#
SEALING FACE CUP, D=60
LEFT SEALING CUP, D=28
TAPPET CHAMBER SEALING CUP
2
2
3
CYLINDER LINER ................................................. 6 .......... REPLACES 5112610040
8#
11
REAR END CAMSHAFT PLUG
OIL GALLERY PLUG, PT 3/8
OIL GALLERY PLUG, PT 1/8
FRONT OIL GALLERY PLUG, PT 1/2
REAR OIL GALLERY PLUG, PT 1/2
TURBO FEEDING PLUG
CYL. BLOCK PLUG, LEFT SIDE
CYL. BLOCK PLUG, RIGHT SIDE
PLUG PACKING, LEFT SIDE
PLUG PACKING
1
1
10
1
1
1
1
1
1
1
1
1
1
1
11-1
11-2
11-3
11-4
12
12-1
13
13-1
26
27
27-1
27-2
32
33
35
37
42
44
46
47
48
49
50
NIPPLE, INJ. PUMP, PT 1/8
TAPPET CHAMBER COVER
TAPPET CHAMBER COVER
TAPPET CHAMBER COVER ASSY.
TIMING GEAR CASE PIN ..................................... 1 .......... REPLACES 9081510500
OIL PUMP DRIVE SHAFT BUSHING
FLYWHEEL HOUSING STUD
FLYWHEEL HOUSING PIN
1
1
2
CHAMBER COVER FIXTURE............................... 2 .......... REPLACES 1090520221
CHAMBER COVER PACKING
CYLINDER BLOCK COVER PACKING
WATER DRAIN COCK ASSY.
DRAIN COCK JOINT
6
3
1
1
WATER DRAIN COCK PACKING ......................... 1 .......... REPLACES 9099212420
VINYL PIPE WITH DRAIN, L=510
RUBBER HOSE CLIP
CYLINDER HEAD DOWEL
AIR BREATHER ASSY.
1
1
2
1
54
56
58
60
NUT ........................................................................ 2 .......... REPLACES 9091104080
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 97
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ISUZU 6BD1 — CYLINDER BLOCK ASSY.
PAGE 98 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
61
63
64
9091505080
1093604390
9117426140
1117420211
5093609780
9097130740
9097150670
9099156661
1097040570
0208006250
0208008140
9091505080
8970233390
LOCK WASHER
2
1
BREATHER COVER HOSE
DRAIN PIPE, H=32 ................................................ 1 .......... UP TO MAR. 84
DRAIN PIPE, H=26 ................................................ 1 .......... APR. 84~
RUBBER
HOSE
CLIP
61-1
65
66
1
1
1
1
2
66-1
66-3
67
CLIP
CLIP
BOLT ...................................................................... 2 .......... REPLACES 9020406250
BOLT ...................................................................... 2 .......... REPLACE 9020508140
LOCK WASHER
OIL RELIEF VALVE ASSY. ..................................... 1 .......... REPLACES 9131606062;
INCL. ITEMS W/&
68
69
96
2
97&
98
110
5096230350
5111290030
1112190983
1112191630
9019708180
VALVE PACKING
SEALING CUP
1
1
OIL PORT COVER ................................................ 1 .......... UP TO JUL. 90
OIL PORT COVER ................................................ 1 .......... AUG. 90~
BOLT ...................................................................... 2 .......... UP TO JUL. 90;
111
120
REPLACES 0501408180
0501408200
8942351570
BOLT ...................................................................... 2 .......... AUG. 90~
DISTANCE CLIP PIECE ........................................ 2 .......... NOT SHOWN
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 99
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ISUZU 6BD1 —TIMING GEAR CASE ASSY.
TIMING GEAR CASE ASSY.
PAGE 100 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 —TIMING GEAR CASE ASSY.
TIMING GEAR CASE ASSY.
NO.
1
2
3
4
PART NO.
PART NAME
TIMING GEAR CASE
STRAIGHT PIN
GEAR PACKING .............................................1.......... REPLACES 1113120100
BOLT ...............................................................2.......... REPLACES 9019108450
BOLT ...............................................................4.......... REPLACES 9019108200
GEAR CASE COVER
GEAR CASE PACKING ..................................1.......... UP TO JUN. 90
GEAR CASE PACKING ..................................1.......... JUL. 90~
CRANKSHAFT OIL SEAL ............................... 1.......... UP TO OCT. 87
CRANKSHAFT OIL SEAL ............................... 1.......... NOV. 87~;REPLACES 1096253190
TIMER POINTER; L1=33
BOLT ...............................................................7.......... REPLACES 9019708250
BOLT ...............................................................5.......... REPLACES 9010558550
PLAIN WASHER
LOCKWASHER
TIMING CHECK COVER
COVER PACKING ........................................... 2.......... REPLACES 1112820090
BOLT ...............................................................4.......... REPLACES 9019006140
QTY.
1
1
REMARKS
5113110113
9081510180
1113120140
0500408450
0500408200
1113210790
1113220360
8943632690
5096250540
1096254380
5113270090
0501408250
5090000841
9091605080
9091505080
5113210090
1112820130
0500406140
7
8
1
9
12
13
1
14
17
18
19
22
5
5
2
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 101
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ISUZU 6BD1 — FLYWHEEL HOUSING ASSY.
FLYWHEEL HOUSING ASSY.
PAGE 102 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — FLYWHEEL HOUSING ASSY.
FLYWHEEL HOUSING ASSY.
NO.
1
6
7
8
15
41
45
46
47
48
PART NO.
PART NAME
FLYWHEEL HOUSING
DRAIN PLUG
DRAIN PLUG PACKING
NUT .................................................................3.......... REPLACES 9944112280
PLUG
BOLT ...............................................................7.......... REPLACE 9019108250
BOLT ...............................................................5.......... REPLACES 9910664500
NUT
QTY.
REMARKS
9113416098
9992023160
9095714160
9944112350
992023160
0500408250
9910664500
999104140
9096510690
5096250141
1096253620
9123631460
1
1
1
1
1
8
PLAIN WASHER
OIL SEAL ........................................................1.......... UP TO MAR. 84
OIL SEAL ........................................................1.......... APR. 84~
OIL SEAL SPACER
49
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 103
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ISUZU 6BD1 —OIL PAN ASSY.
OIL PAN ASSY.
PAGE 104 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — OIL PAN ASSY.
OIL PAN ASSY.
NO
1
3#
4#
6
7
17
20
21
29
32
36
51-2
51-5
52&
53&
53-2
58
PART NO
PART NAME
QTY.
REMARKS
1113604421
9096620120
1096230570
9992023160
9095714160
1113670961
9992023240
9095714240
0500408180
9112290700
1117602000
5117401102
1117402011
5117410131
1117500060
1117500241
9099129760
9099155531
9091104080
9091505080
OIL PAN ...................................... 1 ........ INCL. ITEMS W/#
PLUG, M=20
1
PACKING, ID=24 ........................ 1 ........ REPLACES 1096231830
OIL PAN PLUG
OIL PAN PACKING
CYL. BLOCK PACKING .............. 1 ........ REPLACES 1113670720
OIL PAN PLUG
OIL PAN PACKING
BOLT ......................................... 32 ........ REPLACES 9019108180
CLIP
1
1
1
1
1
1
OIL LEVEL GAUGE
OIL FILLER ASSY. ..................... 1 ........ INCL. ITEMS W/&; UP TO APR. 89
OIL FILLER ASSY. ..................... 1 ........ INCL. ITEMS W/&; MAY 89~
OIL FILLER
1
CAP ............................................ 1 ........ REPLACES 1117500120; UP TO APR. 89
OIL FILLER CAP ........................ 1 ........ MAY 89~
RUBBER HOSE
CLIP
NUT
LOCKWASHER
1
2
1
1
59
62
63
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 105
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ISUZU 6BD1 — OIL PUMP ASSY.
OIL PUMP ASSY.
PAGE 106 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — OIL PUMP ASSY.
OIL PUMP ASSY.
NO.
1
1-2
2#&
PART NO.
PART NAME
QTY.
REMARKS
5131000913
1131002330
1131130470
OIL PUMP...................................... 1 ........... UP TO AUG. 88; INCL. ITEMS W/#
OIL PUMP...................................... 1 ........... SEP. 88~; INCL. ITEMS W/&
COVER........................................... 1 ........... INCL. ITEMS W/$
4#&$ 1131190030
DOWEL
GEAR ASSY.
GEAR
PIPE
O RING
TOP CASE
OIL SPACER
BOTTOM CASE
BOLT, L=115
BOLT, L=60
LOCKWASHER
BALL
1
1
1
1
1
1
1
1
4
4
4
1
1
1
1
1
1
1
1
6#&
8#&
9#
11#
12#
13#
14#
16#
5131210050
5131250010
5131190020
9095612230
1131410210
1131190020
5131410020
9098010741
16-2# 1090440470
17# 9091505080
18#& 5098430030
19#& 5095800980
21#& 5131650040
22#& 9081040300
23#& 1131230160
24#& 1131280180
26#& 9131190100
36#& 1131400860
SPRING
VALVE SEAT
VALVE PIN
COUPLING
PINION
COLLAR
STRAINER ASSY.
41
43
0500410250
9131190100
BOLT .............................................. 2 ........... REPLACES 9019110250
COLLER
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 107
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ISUZU 6BD1 — CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
PAGE 108 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
1115100400
1115100742
1115300400
1115300742
1115400400
1115400742
1116800012
5121110682
1121110690
5121210050
912216040
METAL KIT ..................................... 1 ........... UP TO S//N E518727; INCL. ITEMS W/#
METAL KIT ..................................... 1 ........... S/N E518728~
1-1
1-2
METAL KIT, -.025MM ..................... 1 ........... UP TO S/N E518727
METAL KIT, -0.25MM ..................... 1 ........... S/N E518728~
METAL KIT, -0.50MM ..................... 1 ........... UP TO S/N E518727
METAL KIT, -0.50MM ..................... 1 ........... S/N E518728~
METAL SET, THRUST
PISTON .......................................... 6 ........... UP TO MAR. 90
PISTON .......................................... 6 ........... APR. 90~
2#
3
2
4
6
7
8
RING SET
PISTON PIN
6
6
8941075750
5122300361
1122301041
5122510060
1122510270
5122350051
1122350271
9122716080
9122736080
9122746080
1123104370
9081512200
1098001560
1098002140
5123310641
9123336070
9920616380
5123360081
5097380010
9125210430
1123620031
5123712072
5123620031
9098401071
9098514310
SNAP RING.................................. 12 ........... REPLACES 1095870480
ROD ASSY. .................................... 6 ........... UP TO JUL. 85
ROD ASSY. .................................... 6 ........... AUG. 85~; INCL. ITEMS W/&
BUSHING ....................................... 6 ........... UP TO JUL 85
BUSHING ....................................... 6 ........... AUG. 85~
BOLT ............................................ 12 ........... UP TO JUL. 85
BOLT ............................................ 12 ........... AUG. 85~
METAL SET, STD.
METAL SET, -0.25MM
METAL SET, -0.50MM
CRANKSHAFT ASSY. .................... 1 ........... INCL. ITEMS W/$
STRAIGHT PIN
PILOT BEARING ............................ 1 ........... REPLACES 9000901570; UP TO DEC. 87
PILOT BEARING ............................ 1 ........... JAN. 87~
FLYWHEEL
RING GEAR, Z=129 T=22
9&
11&
13
6
6
6
13-1
13-2
14
17$
19
1
26
27
33
34
36
37
38
60
67
81
83
1
1
BOLT .............................................. 6 ........... REPLACES 9098013340
WASHER, ID=48
FEATHER KEY
CRANKSHAFT GEAR
THROWER
PULLEY
THROWER
1
1
1
1
1
1
1
1
CLAW
WASHER
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 109
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ISUZU 6BD1 — CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.
CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.
PAGE 110 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.
CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.
NO.
1
6
7
8
PART NO.
PART NAME
TIMING CAMSHAFT
GEAR, FC25
FEATHER KEY
BOLT
WASHER
THRUST PLATE
BOLT ................................................... 2 .............REPLACES 9019108250
IDLE GEAR SHAFT
GEAR
QTY.
REMARKS
9125148030
9125221471
9080307130
9920614280
9098518502
9116810150
0500408250
9125310300
9125238013
5125350011
9010510550
9091505100
1125510830
1125511390
1125520520
112561080
1
1
1
1
1
1
9
11
12
21
22
24
26
27
31
1
1
1
THRUST COLLAR
BOLT ................................................... 2 .............REPLACES 9010510550
LOCKWASHER
INLET VALVE...................................... 6 .............UP TO APR. 85
INLET VALVE...................................... 6 .............MAY 85~
EXHAUST VALVE ............................... 6 .............REPLACES 1125520250
VALVE SPRING .................................12 .............REPLACES 5125610090
UPPER VALVE SEAT ........................12 .............UP TO APR. 85
UPPER VALVE SEAT ........................12 .............MAY 85~
LOWER VALVE SEAT ........................12 .............UP TO AUG. 88
LOWER VALVE SEAT ........................12 .............SEP. 88~
COLLAR
TAPPET
PUSH ROD
ROCKER ARM
SCREW
2
32
33
35
1125630300
8941145790
1125630351
5125630010
5125650060
5125710032
1125750360
5126110310
9126160420
9091115080
9126211301
5126200210
1126210621
9126260050
5126280112
5126280120
5126280060
9126281050
1095803350
5126230011
9091800190
5096230600
9029508650
1090005670
9096021480
9098514300
9098514300
1094001160
9098514300
36
38
43
44
51
53
54
56-1
56-2
24
12
12
12
12
12
1
NUT
REAR ROCKER ARM SHAFT
ROCKER ARM SHAFT ....................... 1 .............UP TO AUG. 87
ROCKER ARM SHAFT ....................... 1 .............SEP. 87~
ROCKER ARM PLUG
FRONT ROCKER ARM BRACKET..... 1 .............UP TO AUG. 87
FRONT ROCKER ARM BRACKET..... 1 .............SEP. 87~
REAR ROCKER ARM BRACKET
INTER ROCKER ARM BRACKET
ROCKER ARM SPRING
CONNECTOR
SNAP RING
PACKING
BOLT ................................................... 9 .............UP TO AUG. 87
BOLT ................................................... 8 .............SEP. 87~
BOLT, FRONT BRACKET
PLAIN WASHER ................................10 .............UP TO AUG. 87
PLAIN WASHER ................................. 9 .............SEPT. 87~
NUT ..................................................... 4 .............REPLACES 9091123080
57
58
2
58-1
58-2
59
60
61
62
64
1
6
5
1
1
1
64-1
66
1
67
68
PLAIN WASHER
4
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 111
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ISUZU 6BD1 — OIL AND FUEL FILTER ASSY.
OIL AND FUEL FILTER ASSY.
PAGE 112 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — OIL AND FUEL FILTER ASSY.
OIL AND FUEL FILTER ASSY.
NO.
1
2#
3#&
4#
5#
6#
8#
9#
12#
16#
17#
21#
28#
29#$
70
PART NO.
PART NAME
QTY.
REMARKS
5132000726
1878100752
9099203110
9099206940
1096230550
5132120212
1132310420
9098621610
5132110100
9099412830
9132390250
1090001050
5132600061
1096231630
1132003322
1878105650
OIL FILTER ASSY.......................................... 1 ........ INCL. ITEMS W#
ELEMENT KIT ............................................... 1 ........ INCL. ITEMS W/&
COVER PACKING
CENTER BOLT PACKING
O RING PACKING
OIL FILTER COVER
BOLT
PLUG
OIL FILTER CASE
SPRING
1
1
1
1
1
1
1
1
1
1
SPRING SEAT
DRAIN PLUG
OVER FLOW VALVE ASSY. .......................... 1 ........ INCL. ITEMS W/$
O RING PACKING
FUEL FILTER ASSY. ..................................... 1 ........ INCL. ITEMS W/@
ELEMENT KIT ............................................... 1 ........ REPLACES 988511911;
INCL. ITEMS W/?
1
72
73@? 9097205420
71@? 9132136010
75@? 9097205410
76@? 9099202550
PACKING
COVER BODY PACKING
O RING
DRAIN PLUG O RING
FUEL FILTER CASE
UPPER COVER
BOLT
ELEMENT SPRING SEAT
ELEMENT SET SPRING
DRAIN PLUG
2
1
1
1
1
1
1
1
1
1
1
1
78@
80@
81@
82@
83@
84@
86@
87@
100
5132110151
9132128040
1132310330
9096510680
9097421090
9098620680
1132600470
1096300850
1132191000
1132191940
9019710350
0501410350
VALVE ASSY.
PACKING
PACKING ....................................................... 1 ........ UP TO OCT. 87
PACKING ....................................................... 1 ........ NOV. 87~
BOLT .............................................................. 2 ........ UP TO OCT. 87
BOLT .............................................................. 2 ........ NOV. 87~
101
BOLT, L=145
2
2
2
2
2
LOCKWSAHER
PLAIN WASHER
NUT
OIL FILTER PACKING
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 113
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ISUZU 6BD1 — OIL AND AIR PIPE ASSY.
OIL AND AIR PIPE ASSY.
PAGE 114 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — OIL AND AIR PIPE ASSY.
OIL AND AIR PIPE ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
5133110890
133115322
9099211880
0500408400
5133111190
1096232820
1096234620
0500408400
5133112050
9099171050
1096308830
9098440220
OIL PUMP ASSY. ................. 1 ..................... UP TO MAR. 84
OIL PUMP ASSY. ................. 1 ..................... APR. 4~
2
3
4
6
PACKING
BOLT .................................... 4 ..................... REPLACES 9019108400
COOLER PIPE ASSY.
O RING ................................. 2 ..................... UP TO OCT. 87
O RING ................................. 2 ..................... NOV. 87~
BOLT .................................... 4 ..................... REPLACES 9019108400
OIL PIPE ASSY.................... 1 ..................... INCL. ITEM W/#
CLIP
2
1
7
9
10#
11
12
1
2
1
PACKING
NUT
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 115
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ISUZU 6BD1 — COOLING SYSTEM ASSY.
COOLING SYSTEM ASSY.
PAGE 116 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — COOLING SYSTEM ASSY.
COOLING SYSTEM ASSY.
NO.
1
2#
3#%
4#%
6#%
PART NO.
PART NAME
QTY.
REMARKS
5136101452
1136108770
1878102772
5136310090
5098000510
WATER PUMP ASSY ................ 1 ................ INCL. ITEMS W/#
PUMP KIT W/ GASKET ............ 1 ................ INCL. ITEMS W/%
REPAIR KIT............................... 1 ................ REPLACES 5878100983
WATER PUMP SHAFT
BALL BEARING, FRONT
BALL BEARING, REAR
BALL SPACKER
SNAP RING
C RING
SEAL UNIT
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
6-1#% 5098000500
7#%
8#%
9#%
5136340020
9099521430
9091801520
11#% 5136200061
12#% 9136218020
13#% 5136420072
16#% 9136128020
17#% 9136136130
18#% 9030908200
20#% 5096250550
21#% 1095030700
22#% 5136390010
IMPELLER
FAN AND PULLEY CENTER
WATER PUMP COVER
PACKING
SCREW
SECONDARY SEAL
WASHER
DUSTTHROWER
31%
1136140100
1136140131
5090300101
0500410500
0500410350
0500410250
9136756330
5136410171
9136428032
1136420250
9034406100
9019108160
1136600870
1090440720
9091505080
9091647080
5136710910
5136710160
1136711430
5137160260
1137130371
5137700310
1137700700
9096640050
9096620340
5137210152
PACKING ................................... 1 ................ UP TO OCT. 87
PACKING ................................... 1 ................ NOV. 87~
33
BOLT
1
BOLT ......................................... 2 ................ REPLACES 5090000880
BOLT ......................................... 1 ................ REPLACES 9019110350
BOLT ......................................... 1 ................ REPLACES 9019110250
33-1
41
50
PLATE
PULLEY
1
1
51
SPACER .................................... 1 ................ UP TO MAR. 87
SPACER .................................... 1 ................ APR. 87~
52
53
54
59
61
62
64
SCREW
BOLT
2
4
FAN ASSY., D=550,6,BLOWER 1
BOLT, L=65
LOCKWASHER
PLAIN WASHER
4
4
4
BELT ASSY., L=997 .................. 1 ................ UP TO APR. 85
BELT ASSY., L1225 .................. 1 ................ MAY 85 TO MAR. 87
BELT ASSY., L=1226 ................ 1 ................ APR 87~
68
71
72
THERMOSTAT HOUSING
1
THERMOSTAT JOINT ............... 1 ................ REPLACES 5137130161
THERMOSTAT, 82-95C .............. 1 ................ UP TO APR. 85
THERMOSTAT, 85-95C .............. 1 ................ MAY 85~
73
74
75
COCK PLUG
HEATER PLUG
WATER PIPE
1
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 117
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ISUZU 6BD1 — COOLING SYSTEM ASSY.
COOLING SYSTE
PAGE 118 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — COOLING SYSTEM ASSY.
COOLING SYSTEM ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
76
9137436030
1137430160
0501408250
9096610050
9095714160
1137410100
0108060950
0501410350
5137210141
5097040460
9091505100
9091605100
1112800051
5112800053
PACKING ................................... 1 ................ UP TO APR. 86
PACKING ................................... 1 ................ MAY 86~
BOLT ......................................... 3 ................ REPLACES 9019708250
77
79
80
91
92
92-1
93
PLUG
PAKING
1
1
PACKING ................................... 1 ................ REPLACES 1137410080
BOLT ......................................... 3 ................ REPLACES 9010560950
BOLT ......................................... 3 ................ REPLACES 9019710350
HOSE
CLIP
LOCKWASHER
PLAIN WASHER
1
2
3
3
94
106
107
119
120
WATER DUCT COVER .............. 1 ................ REPLACES 9112808016
OIL COOLER ASSY. ................. 1 ................ INCL. ITEMS W/@
OIL COOLER ELEMENT ASSY 1
GASKET.................................... 2 ................ UP TO SEP. 88
GASKET.................................... 2 ................ OCT. 88~
BY PASS PLUG VALVE ............ 1 ................ REPLACES 5096040100
121@ 5112820070
122@ 5112820060
1112820140
123@ 9132630100
124@ 9095622150
125@ 5095800920
126@ 5112880010
127@ 5096050170
128@ 9091114100
129@ 9091645100
130@ 5112810081
PACKING
SPRING
BY PASS VALVE
TAPER PLUG
1
1
1
2
NUT ........................................... 4 ................ REPLACES 50904000280
PLAIN WASHER ........................ 4 ................ REPLACES 5095030720
COOLER BODY
1
141
1112820080
1112820120
8942059861
PACKING, COVER .................... 1 ................ UP TO AUG. 88
PACKING, COVER .................... 1 ................ SEP. 88~
142
BOLT
1
142-1 0501408280
0501408200
BOLT ....................................... 15 ................ REPLACES 9019708280
BOLT ......................................... 2 ................ UP TO APR. 91;REPLACES 9019708200
BOLT ......................................... 2 ................ MAY 91~
1090300910
0501408450
9091605080
BOLT ....................................... 12 ................ REPLACES 9019708450
144
PLAIN WASHER
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 119
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ISUZU 6BD1 — INTAKE AND EXHAUST ASSY.
INTAKE AND EXHAUST ASSY.
PAGE 120 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — INTAKE AND EXHAUST ASSY.
INTAKE AND EXHAUST ASSY.
NO.
1
3
4
20
PART NO.
PART NAME
QTY.
REMARKS
5141112434
9040108280
9044110280
9141406130
INLET MANIFOLD W/O STUD 1
STUD
FUEL FILTER STUD
MAINFOLD ASSY................... 1 ................... INCL. ITEM W/#
3
2
20-1# 9141418030
MANIFOLD ASSY.
SEALING EXHAUST RING
EXHAUST STUD
EXHAUST GASKET
BUT
INLET PIPE............................ 1 ................... UP TO NOV. 88
INLET PIPE, H=57 ................. 1 ................... DEC. 88~
INLET PIPE
INTAKE PIPE STUD
NUT
1
3
3
3
21
22
24
27
30
9141496530
9044110300
5141450040
9098445650
5141112511
1141123150
5141111100
9044110250
9091104080
9091104100
9091505080
9091505100
9091605080
9091605100
1141150360
1141150520
9091605080
9091505080
9091104080
9019708280
0501408280
1141150370
1141150540
1096370560
9091104100
9091505100
5093603200
109700870
12
30-1
31
32
1
2
3
2
3
2
3
2
32-1
33
33-1
34
34-1
46
NUT
LOCKWASHER
LOCKWASHER
PLAIN WASHER
PLAIN WASHER
INLET HEAD PACKING.......... 1 ................... UP TO AUG. 88
INLET HEAD PACKING.......... 1 ................... SEP. 88~
PLAIN WASHER
LOCKWASHER
NUT
BOLT ...................................... 9 ................... UP TO APR. 90;REPLACES 9019708250
BOLT ...................................... 9 ................... MAY 90~
INLET PACKING..................... 1 ................... UP TO OCT. 87
INLET PACKING..................... 1 ................... NOV. 87~
SHUTTER PIPE PACKING .... 1 ................... REPLACES 1096370470
NUT
48
49
50
51
3
3
3
76
76-1
77
78
83
86
2
2
1
1
LOCKWASHER
RUBBER HOSE
CLIP
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 121
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ISUZU 6BD1 — FUEL SYSTEM ASSY.
FUEL SYSTEM ASSY.
PAGE 122 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — FUEL SYSTEM ASSY.
FUEL SYSTEM ASSY.
NO.
1
PART NO.
PART NAME
NOZZLE ASSY.
PACKING
COVER
NUT
LOCKWASHER
PIPE ASSY., INJ. NO. 1
PIPE ASSY., INJ. NO. 2
PIPE ASSY., INJ. NO. 3 .................... 1 ........ UP TO MAR. 89
PIPE ASSY., INJ. NO. 3 .................... 1 ........ APR. 89~
PIPE ASSY., INJ. NO. 4
PIPE ASSY., INJ. NO. 5
PIPE ASSY., INJ. NO. 6
PIPE ASSY., FUEL PUMP FILTER
PIPE ASSY., INJECTION FILTER
BOLT
QTY.
6
6
REMARKS
5153001031
5153150030
9153390510
9091104080
9091505080
5154116952
5154116962
5154116971
1154148131
5154116982
5154116992
5154117002
5154115060
5154115070
1096750860
1096300850
1154124711
1096750371
9095714080
9154196120
9095245550
5154112231
5097091030
509709104
11
12
13
14
15
16
17
6
12
12
1
1
18
19
20
21
22
23
24
31
32
33
34
35
36
37
38
39
39-1
41-5
41-6
43
47
48
49
54
56
1
1
1
1
1
2
6
FUEL PIPE PACKING
INJECTION LEAK OFF PIPE ASSY. 1
BOLT
LEAK OFF PIPE PACKING
CLIP
CLIP
1
2
6
1
1
2
2
2
SUCTION FEED PUMP PIPE
CLIP
CLIP
BOLT
9019006250
0500406300
5154112231
1154129180
1096300850
5197890030
9091505100
0208010200
5132600101
1096300850
BOLT ................................................. 2 ........ REPLACES 9019006300
FILTER LEAK OFF PIPE ASSY.
FILTER LEAK OFF PIPE ASSY.
PACKING
BRACKET
LOCKWASHER
BOLT ................................................. 2 ........ REPLACES 9020510200
OVER FLOW VALVE
VALVE FIXTURE PACKING
1
1
2
1
2
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 123
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ISUZU 6BD1 — ENGINE FOOT AND HANGER ASSY.
ENGINE FOOT AND HANGER ASSY.
PAGE 124 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — ENGINE FOOT AND HANGER ASSY.
ENGINE FOOT AND HANGER ASSY.
NO.
8
PART NO.
PART NAME
RIGHT FOOT STUD, L1=18.5
ALTERNATOR BRACKET
BOLT ......................................... 1 ................ REPLACES 9019110250
BOLT ......................................... 2 ................ REPLACES 9019110350
BOLT
PLAIN WASHER
LOCKWASHER
NUT
COVER
NUT
QTY.
1
1
REMARKS
1093000530
5197110312
0500410250
0500410350
1090001331
9091605140
9091505140
9991104140
1197190362
9991104120
9091505120
0208012400
9091607120
9091505120
9991104120
9117776221
9019110200
9019110220
9019110220
0500410220
0208014250
9091504140
1113190080
1113190090
0108058600
9091505080
9091605080
9099167550
9098008790
0208006100
9091505060
5197510042
9020510200
0500410200
9091505100
9091607100
9091646100
9091607100
9091505100
9091104100
11
13
13-1
15
16
17
18
19
31
32
35
36
37
38
41
42
1
1
1
1
1
3
3
LOCKWASHER
BOLT ......................................... 1 ................ REPLACES 9910562400
PLAIN WSAHER
LOCKWASHER
ADJUSTING NUT
1
1
1
RR. ENGINE LIFTING HANGER 1
BOLT ......................................... 2 ................ UP TO APR. 90
BOLT ......................................... 2 ................ MAY 90~
BOLT ......................................... 1 ................ UP TO APR. 90
BOLT ......................................... 1 ................ MAY 90~
BOLT ......................................... 1 ................ REPLACES 9920514250
LOCKWASHER
INJECTION PUMP BRACKET .. 1 ................ UP TO OCT. 87
INJECTION PUMP BRACKET .. 1 ................ NOV. 87~
42-1
42-2
43
51
1
52
55
56
62
63
BOLT ......................................... 7 ................ REPLACES 9010558600
LOCKWASHER
PLAIN WASHER
CLIP
7
7
1
BOLT ......................................... 1 ................ UP TO APR. 92
BOLT ......................................... 1 ................ MAY 92~; REPLACES 9020406100
LOCKWASHER
BRACKET
BOLT ......................................... 2 ................ UP TO SEP. 87
BOLT ......................................... 2 ................ OCT. 87~; REPLACES 9019110200
LOCKWASHER
PLAIN WASHER
PLAIN WASHER ........................ 1 ................ UP TO SEP. 87
PLAIN WASHER ........................ 1 ................ OCT. 87~
LOCKWASHER
NUT
64
80
81
1
1
82
83
84
2
2
85
87
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 125
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ISUZU 6BD1 — INJECTION PUMP ASSY.
INJECTION PUMP ASSY.
PAGE 126 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — INJECTION PUMP ASSY.
INJECTION PUMP ASSY.
NO.
5
PART NO.
1156020451
PART NAME
QTY.
REMARKS
INJECTION PUMP ASSY.......... 1 ................ UP TO NOV. 89; REPLACES 1156010605
INCL. ITEMS W/#
1156026800
1157203470
1157704760
1157500480
5157810030
1197510400
9884105020
5156190480
9096620070
1095390070
INJECTION PUMP ASSY.......... 1 ................ DEC. 89~
GOVERNOR ASSY. ................... 1 ................ UP TO NOV. 89
GOVERNOR ASSY. ................... 1 ................ DEC. 89~
FEED PUMP ASSY. .................. 1 ................ REPLACES 1157500280
15#
20#
36#
37#
38#
39#
40#
41#
INJ. PUMP COUPLING
BRACKET
NUT
WASHER
BOLT
1
1
1
1
1
PLATE ....................................... 1 ................ REPLACES 5095390060
41-2# 1156192450
PLATE
GEAR
BOLT
1
1
6
42#
43#
5125240570
9019006140
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 127
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ISUZU 6BD1 — ELECTRICAL ASSY.
ELECTRICAL ASSY.
PAGE 128 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — ELECTRICAL ASSY.
ELECTRICAL ASSY.
NO.
3
7
PART NO.
PART NAME
STARTER
ALTERNATOR
QTY.
1
1
REMARKS
1811001910
1812002050
5831510030
9827200690
9099022380
9831514320
1823200010
1823100080
1823130030
1823170070
5824500141
1825500732
9825139288
5197320010
5197320020
9825300430
1819000161
1819001931
1828490430
9829322110
22
OIL PRESSURE SWITCH ADAPTER ...1 ............... INCL. ITEMS W/#
OIL PRESSURE WARNING SW.
ADAPTER
THERMOMETER, OIL
BATTERY SW. ASSY.............................1 ............... REPLACES 9827300090
STARTER SWITCH ASSY. ....................1 ............... INCL. ITEMS W/&
STARTER SWITCH
LOCK WITH KEY BARREL
OVER HEAT SW.
EMERGENCY RELAY
GLOW PLUG, 20.5V
GLOW PLUG CONNECTOR
GLOW PLUG CONNECTOR
RESISTANCE CONTROL, 24V
23#
24#
29
30
31
32&
33&
37
40
64
1
1
1
1
1
1
1
6
1
1
1
65
65-1
67
82
ENGINE STOPPER ASSY. ...................1 ............... INCL. ITEM W/%
ENGINE STOPPER ASSY. W/COVER 1
CABLE ASSY., L=460
82-1
83%
109
1
1
STARTER-FRAME CABLE ASSY.
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 129
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ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
PAGE 130 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
NO.
5
PART NO.
PART NAME
HOUSING ASSY.
ADAPTER
STUD
ADAPTER
BOLT
GASKET
COVER
SCREW
GASEKT
WAWSHER
NUT
O RING
PLUNGER ASSY.
DELIVERY VALVE ASSY.
SPRING
GASKET
HOLDER
PLATE ASSY
O RING
QTY.
1
1
3
1
3
1
1
2
2
3
3
1
6
6
6
6
REMARKS
1156110750
5156190440
9812151150
9812350170
1156190240
8941445880
1156290500
1156190030
9812151440
9091505060
1157290060
1096230130
5156310070
1156410160
515630010
14
15
16
18
20
22
23
24
27
28
29
31
32
34
35
36
40
41
43
45#
47#
48#
49#
55
1156490010
5156440100
5156250010
1096230520
9812212230
9812212200
1156220030
1156290010
5156190410
5156190010
5156190020
5156190030
5156190040
5156190050
5156190070
5156190080
5156190090
5156191080
5156190100
5156191090
5156191060
5156191100
5156191070
5156190110
5156190120
5156190130
5156190150
5156190250
5156190260
6
3
3
TAPPET ASSY. .........................6................. INCL. ITEMS W/#
PIN
ROLLER
BUSHING
6
6
6
6
GUIDE
SHIM, T=+0.60
SHIM, T=+0.70
SHIM, T=+0.80
SHIM, T=+0.90
SHIM, T=+1.00
SHIM, T=+1.10
SHIM, T=+1.20
SHIM, T=+1.30
SHIM, T=+1.35
SHIM, T=+1.40
SHIM, T=+1.45
SHIM, T=+1.50
SHIM, T=+1.55
SHIM, T=+1.60
SHIM, T=+0.55
SHIM, T=+0.65
SHIM, T=+0.75
SHIM, T=+0.85
SHIM, T=+0.20
SHIM, T=+0.25
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 131
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ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
PAGE 132 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
5156190270
5156190340
5156190350
5156190360
5156190370
9812350420
9812350430
9812350440
9812350450
5156430090
9812350150
9812350210
9812250580
9812250570
9812350030
5156370030
1156390030
1156210630
1156210630
1156290020
1156290030
5098000380
9000906770
5156290240
9812250470
9812250490
9812250500
9812250510
9812250520
9812250530
9812250540
1156290070
5156190380
5156190390
1156190900
5156290150
5156290160
5156290170
5156290180
51562901190
5156290200
5156290210
SHIM, T=+0.35
SHIM, T=+0.30
SHIM, T=+0.40
SHIM, T=+0.50
SHIM, T=+0.45
SHIM, T=+0.95
SHIM, T=+1.05
SHIM, T=+1.15
SHIM, T=+1.25
SPRING
SEAT
SEAT
SLEEVE
PINION
SCREW
RACK
SCREW
CAMSHAFT
CAMSHAFT
BALL BEARING, OVERSIZE AR
BALL BEARING, STD AR
BALL BEARING, OVERSIZE AR
BALL BEARING, STD
RING
6
6
6
6
6
6
1
1
1
1
58
59
60
61
62
66
67
75-3
75-4
76
77
AR
1
1
82
83
84
RING
SHIM, T=+0.10
SHIM, T=+0.12
SHIM, T=+0.14
SHIM, T=+0.16
SHIM, T=+0.18
SHIM, T=+0.50
SHIM, T=+1.00
SHIM, T=1.00
SHIM, T=+0.70
SHIM, T=+1.40
SHIM, T=+0.10
SHIM, T=+0.12
SHIM, T=+0.14
SHIM, T=+0.16
SHIM, T=+0.18
SHIM, T=+0.50
SHIM, T=+0.30
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 133
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ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
PAGE 134 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — INJ. PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
NO.
87
88
89
93
PART NO.
PART NAME
QTY.
REMARKS
1156190330
9884100660
9812250430
1156290470
1156192820
5835390240
5156191360
9091606100
9091506100
5156390020
1156192660
1156290490
9041010300
1156290480
BEARING
SCREW
WASHER
COVER
BOLT
WOODRUFF KEY
PLUB
WASHER
WASHER
NUT
BRACKET
PACKING
STUD
1
2
2
1
4
1
6
4
4
4
1
1
4
1
95
108
150
162
163
164
180
181
182
183
GASKET
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 135
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ISUZU 6BD1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
PAGE 136 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
NO.
5
PART NO.
PART NAME
QTY.
REMARKS
5157210040
1157290150
9813150650
9019008180
9813253970
9019006140
5157291230
9813252370
1157290380
9813251820
9813261120
5157210200
9813254290
5157290530
5157290540
5157290330
9813251770
5157291020
9884100270
5157210210
9813919070
9019006160
1157290280
9812350340
9091505060
5157220080
5156190490
5157290340
9813250860
5157190080
9000902290
9813250880
9813255510
9813255520
9813255530
5157292860
5157292870
9008121300
9813222350
5157231240
5157292090
1156390080
5157230990
9008130230
9813217210
1157292930
9813212050
9091854150
HOUSING ...................................1 ...................... INCL. ITEMS W/#
12#
13#
14#
15#
16#
18#
19#
50#
26#
27#
30#
31#
32#
34#
35#
36#
37#
38#
40#
42#
44#
46#
47#
48#
50#
52#
53#
54#
57#
58#
60#
O RING
ADAPTER
BOLT
PLATE
BOLT
SCREW
NUT
PLUG
SCREW
NUT
COVER
BUSHING
PLUG
BOLT
BOLT
SCRWE
BLT
NUT
COVER
O RING
BOLT
BOLT
CAP
LOCK WASHER
FLYWEIGHT ASSY.
KEY
LOCK WASHER
NUT
SLEEVE
BEARING
SHIM, T=0.20
SHIM, T=+0.30
SHIM, T=+0.40
SHIM, T=+1.00
SHIM, T=+0.50
SHIM, T=+0.50
SPRING
SPRING
CAPSULE
NUT
1
1
1
1
6
1
2
1
1
1
1
1
2
2
4
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
63#
64#
67#
68#
69#
73#
74#
77#
80#
81#
82#
1
1
1
1
2
1
1
1
2
2
2
GASKET
CAPSULE
NUT
LEVER
BUSH
O RING
SNAP RING
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 137
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ISUZU 6BD1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
PAGE 138 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
83#
1157290980
OIL SEAL
1
84#
85#
86#
89#
90#
93#
100#
101#
102#
103#
104#
107#
108#
109#
110#
1157290990
9813250970
9813253180
1157293010
9813254880
5157250570
1157250110
9091854040
5157250170
9813250620
5157250410
5157250810
9019006160
9813919060
1157292990
1157292980
1157292980
1157292970
1157292960
1157292950
1157292940
9813252100
5157230640
1157290010
1157290020
5157250420
5157291120
9091505080
5157230880
SHIM
SHIM, T=0.30
PLUG
COLLAR
WASHER
LEVER
LINK
SNAP RING
LEVER
PIN
LEVER
1
1
1
1
1
1
1
1
1
1
1
1
LEVER
BOLT
O RING
SHIM, T=0.50
SHIM, T=+0.50
SHIM, T=+0.40
SHIM, T=+3.35
SHIM, T=+0.30
SHIM, T=+0.25
SHIM, T=+0.20
CAP
111#
112#
116#
117#
120#
148#
149#
150#
1
1
1
1
1
1
1
1
SPRING
GASKET
GASKET
LEVER ASSY.
BOLT
LOCK WASHER
SPRING
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 139
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ISUZU 6BD1 —FEED PUMP ASSY.
FEED PUMP ASSY.
PAGE 140 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — FEED PUMP ASSY.
FEED PUMP ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1157500480
5157510120
9813512050
9813513020
9813550230
9813550350
5157540010
FEED PUMP ASSY. .......................1.................. INCL. ITEMS W#
5#
9#
10#
11#
12#
15#
HOUSING
PISTON
SPRING
PLUG
1
1
1
1
1
GASKET
TAPPET ASSY. ............................... 1.................. INCL. ITEMS W/%
16#% 9813514030
17#% 9813514100
18#% 1157590020
ROLLER
PIN
GUIDE
VALVE
1
1
2
2
26#
27#
28#
31#
32#
33#
35#
40#
42#
44#
9813516020
1196230160
9813517020
1096750630
1157590110
1157590120
1157590030
1196230160
9813550250
8941311300
O RING ........................................... 1.................. REPLACES 1096230160
SPRING
BOLT
BOLT
PACKING
ADAPTER
O RING ........................................... 1.................. REPLACES 1096230160
SNAP RING
PUMP
2
1
1
4
1
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 141
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ISUZU 6BD1 — NOZZLE ASSY.
NOZZLE ASSY.
PAGE 142 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — NOZZLE ASSY.
NOZZLE ASSY.
NO.
1
2
PART NO.
5153110191
5153300191
PART NAME
QTY.
REMARKS
NOZZLE ASSY. ......................... 6 ................ REPLACES 5153110190
HOLDER ASSY. ........................ 6 ................ REPLACES 5153300190;
INCL. ITEMS W/#
5#
6#
7#
8#
5153410010
9153470030
9153430130
5153450010
9153390570
5153340010
9153390560
5153320020
5153390030
5153490020
5153490010
9095714080
PUSH ROD
PIN
SPRING
SCREW
WASHE
NUT
GASKET
NUT
GASKET
CONNECTOR
BOLT
6
12
6
6
6
6
6
6
6
9#
10#
12#
21#
22#
23#
31#
32#
6
6
12
PAKCING, T=1.0
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 143
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ISUZU 6BD1 — STARTER ASSY,
STARTER ASSY.
PAGE 144 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — STARTER ASSY.
STARTER ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1811001910
1811210370
1811293950
1811293850
5811291560
1811160440
1811293840
1811293960
5811292210
1811150610
STARTER ASSY. ..................................1 ............. INCL. ITEMS W/#
6#
7#
8#
18#
21#
22#
23#
24#
30#
ARMATURE ASSY.
BALL BEARING
BALL BEARING
WASHER
LEAD WIRE
TERMINAL
1
1
1
2
1
1
1
4
FIELD COIL
SCREW
COVER .................................................1 ............. INCL.. ITEMS W/@
31#@ 1811150620
34#@ 1811180360
35#@ 1811170140
37#@ 1811160430
38#@ 1811160420
REAR COVER
BRUSH HOLDER
BRUSH SPRNG
BRUSH, (-)
BRUSH, (+)
RELAY SAFETY SWITCH
HOLDER
1
1
4
2
2
1
1
1
40#
41#
42#
50#
52#&
53#
55#
56#
57#
58#
59#
60#
61#&
64#
65#
66#
67#
76#
77#
78#
79#
80#
84#
87#
88#
89#
91#
92#
93#
94#
97#
98#
99#
100#
1825530230
1811180390
1811294010
1811230250
1811293970
5811291420
5811220160
5811291440
5811291450
1811130260
1811293870
1811230240
1811293860
5811291600
5811291590
5811291580
1811130730
1811270310
1811291850
1811291840
5811291470
5811510360
5811291460
9821161400
5811291480
5811180190
5811291510
5811291520
5811291500
9821161420
5811291490
1811291140
5811292140
1811293940
BOLT
FRONT COVER...................................1 ............. INCL. ITEMS W/$
METAL COVER
DISH LUG
CLUTCH
CLIP RIG
PINION STOPPER
CENTER BRACKET
BOLT
1
1
1
2
1
1
3
SHAFT ASSY........................................1 ............. INCL. ITEMS W/&
BALL BEARING
SHAFT WASHER
SHAFT WASHER
INSULATE WASHER
CENTER COVER
SHIFT LEVER
LEVER PIN
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
2
1
NUT
PLATE
MAGNETIC SWITCH ASSY.
PLUNGER
INSULATE BUSING
CONNECTOR
HOLDER
WASHER
BOLT
TERMINAL ASSY
WASHER
CLI RING
WASHER
BOLT
STARTER SEAL KIT
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 145
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ISUZU 6BD1 — ALTERNATOR ASSY.
ALTERNATOR ASSY.
PAGE 146 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — ALTERNATOR ASSY.
ALTERNATOR ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1812002050
1812210300
1812292250
1812292240
1812292310
1812240090
1812291610
1812291620
9822160600
1812291630
1812291640
1812291950
ALTERNATOR ASSY. ................1................. INCL. ITEMS W/#
5#
7#
8#
9#
10#
11#
12#
13#
14#
15#
16#
ROTOR ASSY.
BEARING
BALL BEARING
ROTOR PACKING
SLIP RING
ROTOR RETAINER
ROTOR PACKING
ROTOR RETAINER
ROTOR RETAINER
ROTOR RETAINER
ROTOR CLIP
ROTOR CLIP
COLLAR
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
16-1# 1812292300
17#
18#
19#
20#
25#
1812291600
1812291650
1812291230
1812110310
1812140810
PACKING
PLATE
STATOR
REAR COVER ASSY.................1................. INCL. ITEMS W/@
26#@ 1812140820
27#@ 1812190330
33#@ 1812292270
40#@ 1812293100
41#@ 1812292350
43#@ 1812292340
45#@ 1811180110
REAR COVER
RECTIFIER ASSY.
WASHER
BOLT
BUSH
TUBE
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
3
CLIP
COVER
51#
52#
55#
56#
60#
61#
62#
63#
75#
90#
95#
97#
99#
1812130240
1812291670
181240830
BUSHING
COVER
PACKING
WASHER
HOLDER ASSY.
PACKING
PACKIG
PULLEY ASSY.
BOLT
VOLTAGE REGULATOR ............1................. NOT SHOWN
1812292330
1812291350
1812170230
1812292260
1812292320
1812220340
1812290970
1812510240
1812295960
9822190270
NUT
LOCKWASHER
1
1
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 147
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ISUZU 6BD1 — ACCESSORIES
ACCESSORIES
PAGE 148 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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ISUZU 6BD1 — ACCESSORIES
ACCESSORIES
NO.
50
55
PART NO.
PART NAME
QTY.
REMARKS
9839101011
1096231800
1096234650
0500408200
TACHO DRIVE ELBOW ASSY. .1
PACKING ...................................1................. UP TO OCT. 87
PACKING ...................................1................. NOV. 87~
BOLT .........................................2................. REPLACES 9019108200
60
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 149
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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 150 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
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NOTE PAGE
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 151
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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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