Multiquip DCA25SSIU User Manual

OPERATION AND PARTS MANUAL

®

MODEL DCA25SSIU

WHISPERWATT™ GENERATOR

(Standard)

Revision #7 (04/18/12)

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

PAGE 3 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

TABLE OF CONTENTS

Table Of Contents ....................................................... 4

Parts Ordering Procedures ......................................... 5

Rules for Safe Operation ......................................... 6-9

Towing and Transportation ........................................ 10

Trailer Safety Guidelines ...................................... 11-15

Trailer Wiring Diagram ............................................... 16

Operation Decals ................................................. 17-18

DCA-25SSIU Specifications ..................................... 19

General Information .................................................. 20

Major Components ................................................... 21

Dimensions ............................................................... 22

Control Panel Descriptions .................................. 24-25

Engine Operating Panel Descriptions .................. 26-27

Output Terminal Panel Descriptions ..................... 28-29

Output Amerage Setup ........................................ 30-31

Output Voltage Setup ........................................... 32-35

Installation ........................................................... 36-37

Pre Setup ............................................................ 38-41

Load Application ....................................................... 42

Generator Start-up Procedure ............................. 43-45

Generator Shutdown Procedure ................................ 46

Maintenance ........................................................ 47-48

Generator Wiring Diagram ......................................... 50

Engine Wiring Diagram ............................................. 51

Engine Troubleshooting ........................................ 52-53

Generator/Engine Troubleshooting ............................ 54

Explanation of Codes in Remarks Column ............... 56

Suggested Spare Parts ............................................ 57

ISUZU C240 ENGINE

Cylinder Head and Cover Assembly .................... 86-87

Cylinder Block Assembly .................................... 88-89

Timing Gear Assembly ........................................ 90-91

Flywheel Housing Assembly ............................... 92-93

Oil Pan Assembly ................................................ 94-95

Oil Pump Assembly ............................................ 96-97

Crankshaft, Bridge and Flywheel Assembly ........ 98-99

Oil and Fuel Filter Assembly ........................... 100-101

Oil Pipe Assembly ........................................... 102-103

Water Pump and Fan Assembly ...................... 104-105

Intake and Exhaust Manifold Assembly .......... 106-107

Air Cleaner Assembly ...................................... 108-109

Engine Foot Assembly .................................... 110-111

Injection Pump Assembly ............................... 112-113

Electrical Parts Assembly ............................... 114-115

Accessories .................................................... 116-117

Injection Pump Comp. Assembly .................... 118-121

Governor Comp. Assembly .............................. 122-127

Feed Pump Comp. Assembly .......................... 128-129

Auto Timer Assembly ...................................... 130-131

Nozzle Holder Comp. Assembly ...................... 132-133

Starter Comp. Assembly ................................. 134-135

Alternator Comp. Assembly ............................. 136-139

Terms and Conditions of Sales .............................. 140

MQ POWER DCA-25SSIU
AC GENERATOR

Generator Assembly ............................................ 58-59

Control Box Assembly ......................................... 60-61

Engine & Radiator Assembly ............................... 62-67

Engine Operating Panel Assembly ...................... 68-69

Output Terminal Assembly ................................... 70-71

Battery Assembly ................................................ 72-73

Muffler Assembly ................................................ 74-75

Fuel Tank Assembly ............................................ 76-77

Enclosure Assembly ........................................... 78-81

Rubber Seal Assembly ........................................ 82-83

Name Plate And Decals ...................................... 84-85

PAGE 4 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

NOTE

Specification and part number
are subject to change without
notice.

r

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

January 1

Effective:

st

, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■ View Parts Diagrams

■ Order Parts

■ Print Specification Information

Goto www.multiquip.com and click on

Order Par ts

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)

Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.

to log in and save!

Order via Phone:

If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.

com.

To obtain an MQ Account, contact you
District Sales Manager for more information.

Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*

Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.

Note: Discounts Are Subject To Change

Note: Discounts Are Subject To Change

❒ Dealer Account Number
❒ Dealer Name and Address
❒ Shipping Address (if different than billing address)
❒ Return Fax Number
❒ Applicable Model Number
❒ Quantity, Part Number and Description of Each Part

www.multiquip.com

PAGE 5 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

When ordering parts, please supply:

❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL

■ Priority One ✓ Tr uck

■ Ground

■ Next Day

■ Second/Third Day

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

WE ACCEPT ALL MAJOR CREDIT CARDS!

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Failure to follow instructions in this manual
may lead to serious injury or even death!
This equipment is to be operated by trained

and qualified personnel only! This equipment
is for industrial use only.

RULES FOR SAFE OPERATION

■

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

The following safety guidelines should always be used when
operating the DCA-25SSIU portable generator:

GENERAL SAFETY

■

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

■

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

■

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

■

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

■

NEVER operate this equipment under the
influence or drugs or alcohol.

■

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

generator engine gives off DEADLY carbon monoxide gas.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

hot

components can cause serious

■

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

:

■

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.

■

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.

PAGE 6 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

■

Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT smoke around or near

the machine. Fire or explosion could
result from fuel vapors, or if fuel is spilled
on a hot engine.

■

NEVER operate the generator in an

explosive atmosphere or near combustible
materials. An explosion or fire could result

causing severe

death.

■

Topping-off to filler port is

dangerous, as it tends to spill fuel.

bodily harm or even

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

■

NEVER touch output terminals during operation. This is
extremely dangerous. Always stop the machine when
contact with the output terminals is required.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

:

:

RULES FOR SAFE OPERATION

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Fluid Plugs

1. Radiator Cap - Removing the radiator cap while the
engine is hot, will result in high pressurized, boiling
water to spew out of the radiator, causing severe
scalding to any persons in the general area of the
generator.

2. Coolant Drain Plug - Removing the coolant drain
plug while the engine is hot will result in hot coolant
to flow out of the coolant drain plug, therefore causing
severe scalding to any persons in the general area
of the generator.

:

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.

■

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.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

■

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.

:

3. Engine Oil Drain Plug - Removing the engine oil
drain plug while the engine is hot will result in hot oil
to flow out of the oil drain plug, therefore causing
severe scalding to any persons in the general area
of the generator.

PAGE 7 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

RULES FOR SAFE OPERATION

■

Battery

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

The battery contains acids that can cause injury to the eyes
and skin. To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:

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

2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.

3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.

4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.

5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.

6. In case the battery liquid (dilute sulfuric acid) comes in
contact with
immediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.

:

Never over fill the battery with water above
the upper limit.

clothing or skin

, rinse skin or clothing

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

■

Always service air cleaner frequently to prevent carburetor
malfunction.

■

Always disconnect the battery before performing service
on the generator.

■

Always be sure the operator is familiar with proper safety
precaution s and operations techniques before using
generator.

■

Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.

■

DO NOT leave the generator running in the manual mode
unattended.

■

DO NOT allow unauthorized people to operate this
equipment.

■

Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.

■

Refer to the
technical questions or information.

Loading and Unloading (Crane)

■

Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.

■

Always drain fuel prior to lifting.

■

Always make sure crane or lifting device has been
properly secured to the hook of guard frame on generator.

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or rope) of sufficient
strength.

■

When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.

■

NEVER allow any person or animal to stand underneath
the machine while lifting.

Isuzu Engine Owner's Manual

for engine

■

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-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

RULES FOR SAFE OPERATION

Transporting

■

Always shutdown engine before transporting.

■

Tighten fuel tank cap securely.

■

Drain fuel when transporting generator over long distances
or rough terrains.

■

Always tie-down the generator during transportation by
securing the generator.

■

If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.

Emergencies

■

Always know the location of the nearest
and

first aid kit

Also know the phone numbers of the nearest

doctor

and

. Know the location of the nearest telephone.

fire department

.

fire extinguisher

ambulance

Maintenance Safety

■

NEVER lubricate components or attempt service on a
running machine.

■

Always allow the machine a proper amount of time to
cool before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always
replace broken parts.

■

Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.

■

DO NOT use plastic containers to dispose of hazardous
waste.

,

■

DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source.

PAGE 9 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — TOWING RULES FOR SAFE OPERATION

Towing Safety Precautions

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

Check with your county or state safety
towing regulations department before
towing your generator.

To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 1) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.

The following list of suggestions should be used when towing
your generator:

■

Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.

■

Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety
Chain".

■

ALWAYS attach trailer's safety chain to bumper of towing
vehicle.

■

ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.

■

The maximum speed unless otherwise posted for highway
towing is 55 MPH. It is not recommended for off-road
towing. However, if necessary, do not exceed 15 MPH
or less depending on type of terrain to prevent damage
to the axles.

■

Place

rolling,

■

Place
prevent

■

Use the trailer's hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.

■

Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

while parked.

support blocks

tipping

, while parked.

underneath wheel to prevent

underneath the trailer's bumper to

Figure 1. Generator with Trailer

PAGE 10 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — TRAILER-SAFETY GUIDELINES

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intended to provide the user with trailer ser­vice and maintenance information. The service and mainte­nance guidelines referenced in this section apply a wide range
of trailers. Remember periodic inspection of the trailer will
ensure safe towing of the equipment and will prevent dam­age to the equipment and personal injury.

It is the purpose of this section to cover the major mainte­nance components of the trailer. The following trailer com­ponents will be discussed in this section:



Tires



Lug Nut Torquing



Suspension



Electrical

Use the following definitions with reading Table 1.

1. Fuel Cell - Provides an adequate amount of fuel for the

equipment in use. Fuel cells must be empty when trans­porting equipment.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hy­draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the

maximum number of pounds the trailer can carry, in­cluding the fuel cell (empty).

4. Frame Length - This measurement is from the ball

hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to
fender.

6. Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 4 and Figure 5 or lug nut tightening and
sequence.

13. Axle - Indicates the maximum weight the axle can sup­port in pounds, and the diameter of the axle expressed
in inches (see Table 3). Please note that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.

14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.

16. Application - Indicates which units can be employed
on a particular trailer.

PAGE 11 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — TRAILER-SPECIFICATIONS

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PAGE 12 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — TRAILER-SPECIFICATIONS

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PAGE 13 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.

CAUTION:

DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked, the
air pressure in

the inner tube
may cause pieces of the rim to
explode (break off) with great force
and cause serious eye or bodily
injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation. DO
NOT bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.

Suspension

The leaf suspension springs and associated components
(Figure 2) should be visually inspected every 6,000 miles for
signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 3.

CAUTION:

NOTE

ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to
comply may result in serious injury.

PAGE 14 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

Figure 2. Major Suspension Components

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TLOB-U"2/106-XAM54-NIM

DCA-25SSIU — TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FIT ONLY.PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

-

RETAIN NUT

BOLT ASSEMBLY

.

.

05-XAM03-NIM

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 3. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 4.

3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.

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Figure 3. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

PAGE 15 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — TRAILER-WIRING DIAGRAM

NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 16 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — GENERATOR DECALS

The DCA-25SSIU generator is equipped with a number of safety decals. These decals are provided for operator safety
and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

PAGE 17 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — GENERATOR DECALS

PAGE 18 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

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DCA-25SSIU — SPECIFICATIONS

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PAGE 19 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

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DCA-25SSIU — GENERAL INFORMATION

DCA-25SSIU FAMILIARIZATION

Generator

The MQ Power Model DCA-25SSIU is a 20 kW
that is designed as a high quality portable (requires a trailer
for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:



Tachometer



Water Temperature Gauge



Oil Pressure Gauge



Charging Ammeter Gauge



Fuel level gauge



Engine Throttle Lever



Pre-Heat Light



Alarm Lights



Panel Light



Panel Light Switch



Starter Switch

generator

Open Delta Excitation System

The DCA-25SSIU generator is equipped with the state of
the art "
system consist of an electrically independent winding wound
among stationary windings of the AC output section.

There are four leads: A, B, C and D. During light loads, the
power to the
from the leads parallel connections of B&C. When loads
increase, the AVR switches and accepts power from leads
A&D. The output of leads A&D increase proportionally with
load. This of adding the voltages to each phase provides
better voltage response during heavy loads.

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

The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "
according the demands of the required load.

Engine

Open-Delta

" excitation system. The open delta

Automatic Voltage Regulator

fixed ceiling

(AVR) is supplied

" and responds

Generator Control Panel

The “Generator Control Panel” is provided with the following:



Output Voltage Adjustment Knob



Frequency Meter (Hz)



AC Ammeter (Amps)



AC Voltmeter (Volts)



Ammeter Change-Over Switch



Voltmeter Change-Over Switch



Main Circuit Breaker 60 amps



Over-Current Relay

Output Terminal Panel

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



Three 120V output receptacles, 50 amp



Two 120V output receptacles, 20 amp



3 Circuit Breakers 240V @65 amps



2 GFCI Circuit Breakers 120V@ 20amps

The DCA-25SSIU is powered by a 4 cycle, water cooled,
turbocharged Isuzu QD60(C640)
is designed to meet every performance requirement for the
generator. Reference Table 5, page 19 for engine
specifications.

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

The basic controls and indicators for the DCA-25SSIU
generator are addressed on the following pages.

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
to ±5%. The electronic governor option limits frequency
fluctuation to ±0.25%.

diesel

engine. This engine

PAGE 20 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — MAJOR COMPONENTS

Figure 4. Major Components

PAGE 21 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 5. Dimensions

PAGE 22 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

NOTE PAGE

PAGE 23 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — CONTROL PANEL

Figure 6. Control Panel

PAGE 24 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — CONTROL PANEL

The definitions below describe the controls and functions of
the DCA-25SSIU "

1. Main Circuit Breaker – This three-pole, 60 Amp main

breaker is provided to protect the UNV voltage output
terminals from overload.

2. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 63 Hz ±0.5 Hz .

3. AC Ammeter – Indicates the amount of current the

load is drawing from the generator.

4. AC Voltmeter – Indicates the output voltage present

at the UVW or output terminals.

5. Voltage Regulator Control – Allows manual

adjustment of the generator’s output voltage.

6. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off.

Control Panel

" (Figure 6).

7. Voltmeter Change-Over Switch – This switch allows

the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.

PAGE 25 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

PAGE 26 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of
the DCA-25SSIU "

1. 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.

2. Oil Pressure Lamp - This light will luminate if the oil

pressure exceeds 15 psi and will shut off the engine.

Engine Operating Panel

" (Figure 7).

3. Water Temperature Lamp - This light will luminate if

the water temperature exceeds 215

o

F and will shut off

the engine.

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

panel light.

5. Pre-Heat Indicator - This light will luminate once the

engine is warmed to an operating temperature.

6. Ignition Switch - This switch is used with a key to

start, preheat, and stop the engine..

7. Engine Throttle Lever - To change the speed of the

engine from idle to high, pull and turn the handle.

8. Tachometer – Indicates engine speed in RPM’s for 60

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

9. Fuel Gauge - Indicates amount of diesel fuel available

10. 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.

11. Water Temperature Gauge – During normal operation

this gauge be should read between 165

o

to 203oF.

12. Oil Pressure Gauge – Normal operation should be about

42~71 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.

PAGE 27 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — OUTPUT TERMINAL PANEL

Output Terminal Panel

The output control panel is located on the rear (control panel)
end of the generator. The UVW lugs are protected by a face
plate cover that can be secured in the close position by a
pad lock.

120 Volt Receptacle

One GFCI Duplex NEMA 5-20R (120V, 20 Amp) receptacle
is located on the output terminal. This receptacle can be
used anytime the generator is in operation. The receptacle
is controlled by the circuit breaker located on the control
panel.

The reset button will reset the receptacle after being tripped.
Pressing the "Test Button" (See Figure 8) in the center of
this receptacle will check the GFCI function. The receptacle
should be tested at least once a month.

Connecting Load

Loads can be connected to the generator by the UVW Lugs or
the duplex receptacle. (See Figure 9). Make sure to read the
operation manual before attempting to connect a load to the
generator.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 60 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 circuit breakers
have also been provided to protect the load side of the
generator from overload. Make sure to switch
breakers to the "OFF" position prior to starting the engine.

Figure 9. Connecting Loads

ALL

circuit

Figure 8. GFCI Test Button

PAGE 28 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

Maximum Output

The entire load connected to the UVW l ugs and all four slots in
the duplex receptacle must not exceed 22 kW in standby or 20
kW in prime output.

120V Receptacles - These receptacles can be used
anytime the generator is in operation. They are controlled
by the circuit breakers above them.

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 (see Figure 6, page 24). 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.

DCA-25SSIU — OUTPUT TERMINAL PANEL

Figure 10. Output Terminal Description

PAGE 29 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

NOTE

Legs “O” and Ground are
considered Bonded Grounds.

DCA-25SSIU — OUTPUT AMPERAGE SETUP

Output Terminal Panel Available Voltages

A wide range of voltages are available to supply load to
many different applications. Voltages may be selected by
using the voltage selector switch and depending how you
hookup your hard wire connection to the generator. To
obtain voltages listed, fine adjustment with the voltage
regulator on the control panel is necessary. See the table

Over Current Relay

An over current relay is connected to the circuit breaker.
During an over current situation, both the circuit breaker
and the over current relay may 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.
below (Table 6) for a list of available voltages the generator
is able to supply.

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TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

CAUTION :

Maximum Amps

NEVER switch the voltage selector switch

position while the engine is engaged.

The following table show the maximum amps the entire

generator can provide. Do not exceed the maximum amps

listed. (See Table 7)

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Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect
the generator and generator load from being switched while
the engine is running. To lock the voltage selector switch,
press in the red button located on the lower part of the
voltage selector switch, and use a pad lock to hold it into
this position.

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PAGE 30 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — OUTPUT AMPERAGE SETUP

Receptacle Use

When the UVWO terminals are providing power, the
receptacle power available decrease. Do not exceed
receptacle power available listed on Table 8.

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Figure 11. Voltage Selector Switch 240/120V

Single Phase Position

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Figure 12. AC Voltmeter

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4

Change-over switch

(Reading the W-U leg on

the output terminal panel)

How To Read The Output Terminal Gauges

The gauges (Figures 13 and 15) 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 produced at the UVWO legs.

When the voltage selector switch is in the 240/120V
position (see Figure 11), place the AC voltmeter change­over switch to the W-U position (Figure 12) and the AC
ammeter change-over switch to the U or W position (Figure

14) to read the output on the selected leg.

Figure 14. AC Ammeter

Change-over Switch

(Reading the U leg on the

output terminal panel)

Figure 13. AC Voltmeter

Gauge

(Volt reading on W-U Lug)

Figure 15. AC Ammeter

(Amp reading on U lug)

NOTE

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

PAGE 31 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — OUTPUT VOLTAGE SETUP

240/120V Hard Wire Hookup

With the voltage selector set and locked at ‘single phase
240/120’ and using single phase 120 volts, it will provide
two legs available with 60 amps each (Figure 16).

When using single phase 240 volts, it will provide one leg
with 60 amps available (Figure 16).

480/240V Hard Wire Hookup

With the voltage selector set and locked at ‘3 phase 480/
277’ (Figure 17) and using the 3-phase 240 volt hookup, it
will provide one circuit available at 108 amps with any two
wires plus the ground (Figure 18).

When using the 3-phase 480 volts hookup, it will provide
one circuit available at 50 amps available with all three wires
plus ground (Figure 18).

FIGURE 16. Hard Wire Hookup at 240/120V Position

FIGURE 17. Voltage Selector Switch 480/277V Three Phase

Position

FIGURE 18. Hard Wire Hookup For 240V or 480V

PAGE 32 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- 3 Phase 480/277V Position

The following are additional voltages available when the
voltage selector switch is in the 3 phase 480/277V
position.

Single Phase: 480V, 440V, or 416 Volt

This setting can provide single phase power at 480, 440,
or 416 volts. After hooking up the hard wires to the lugs
as shown in Figure 21, 480 volts can be obtained 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 lowest setting.

Figure 19. 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 20, 480 volts can be obtained 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 lowest setting.

Figure 21. Hard Wire Hookup for Single Phase 480V, 440V,

or 416V

Figure 20. Hard Wire Hookup for Three 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 22, 277 volts can be obtained the
voltage regulator knob turned toward maximum; 254 volts
can be obtained with the voltage regulator knob is turned
down; and 240 volts can be obtained with the voltage
regulator knob is at lowest setting.

Figure 22. Hard Wire Hookup for Single Phase 277V, 254V,

or 240V

PAGE 33 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- 3 Phase 240/139V Position

The following are additional voltages available when the
voltage selector switch is in the 3 phase 240/139V
position.

Single Phase: 240V, 220V, or 208 Volt

This setting can provide single phase power at 240, 220,
or 208 volts. After hooking up the hard wires to the lugs
as shown in Figure 25, 240 volts can be obtained 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 lowest setting.

Figure 25. Hard Wire Hookup for Single Phase 240V, 220V,

FIGURE 23. Voltage Selector Switch 240/139V Three Phase

Position

or 208V

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

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

This setting can provide 3-phase power at 240, 220, or
208 volts. After hooking up the hard wires to the lugs as
shown in Figure 24, 240 volts can be obtained 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

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 26, 139 volts can be obtained the
voltage regulator knob turned toward maximum; 127 volts
can be obtained with the voltage regulator knob is turned
down; and 120 volts can be obtained with the voltage
regulator knob is at lowest setting.

regulator knob is at lowest setting.

Figure 24. Hard Wire Hookup for Three Phase 240V, 220V, or

208V

Figure 26. Hard Wire Hookup for Single Phase 139V, 127V,

or 120V

PAGE 34 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- Single Phase 240/120V
Position

The following are additional voltages available when the
240/120V position.

Figure 27. Voltage Selector Switch 240/120V Single Phase

Position

Single Phase: 120 Volt

This setting can provide single phase power at 120 volts.
After hooking up the hard wires to the lugs as shown in
Figure 29, 120 volts can be obtained by using the voltage
regulator to fine tune.

Figure 29. Hard Wire Hookup for Single Phase, 120 volt

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 28, 240 volts can be obtained and using the
voltage regulator to fine tune.

Figure 28. Hard Wire Hookup for Single Phase 240 volt

PAGE 35 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — INSTALLATION

Outdoor Installation

Install the generator in a location where it will not be exposed
to rain or sunshine. Make sure the generator is on secure
level ground so that it cannot slide or shift around. Also
install the generator in a manner so that the exhaust will not
be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.

Mounting

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

:

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.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Generator Grounding

To guard against electrical shock and possible damage to

the equipment, it is important to provide a good EARTH

ground.

Article 250 (Grounding) of the National Electrical Code (NEC)

provides guide lines for proper grounding and specifies that

the cable ground shall be connected to the grounding system

of the building as close to the point of cable entry as

practical.

NEC articles 250-64(b) and 250-66 set the following

grounding requirements:

1. Use one of the following wire types to connect the
generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 30) 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.

When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.

:

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.

NOTE

PAGE 36 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — INSTALLATION

Figure 30. Typical Generator Grounding Application

PAGE 37 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — PRE-SETUP

General Inspection Prior to Operation

The DCA-25SSIU generator has been thoroughly inspected
and accepted prior to shipment from the factory. However,
be sure to check for damaged parts or components, or loose
nuts and bolts, which could have occurred in transit.

Extension Cable

When electric power is to be provided to various tools or
loads at some distance from the generator, extension
cords are normally used. Cables should be sized to allow
for distance in length and amperage so that the voltage
drop between the generator and point of use (load) is held
to a minimum. Use the Cable Selection Guide (Table 9)
as a guide for selecting proper cable size.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 60 amp,

main

circuit breaker is provided to protect the UVW 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
have also been provided to protect the load side of the
generator from overload. Make sure to switch
breakers to the "OFF" position prior to starting the engine.

load

circuit breakers

ALL

circuit

NOTE

ALWAYS consult with a licensed

electrician for correct extension
cord wire size.

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PAGE 38 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — PRE-SETUP

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way, verify that the oil level
is maintained between the two notches (Figure 31) on the
dipstick. See Table 10 for proper selection of engine oil. Use

Fuel

Fill the fuel tank with clean and fresh
fill the tank beyond capacity.

Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 19
Specification Table 5.

only CC grade or higher.

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 :CAUTION :

CAUTION :

CAUTION :CAUTION :

Coolant

diesel fuel

. DO NOT

Never fill the fuel tank while the engine is
running or in the dark. Gasoline spillage
on a hot engine can cause a fire or

explosion. If gasoline spillage occurs, wipe
up the spilled gasoline completely to
prevent fire hazards.

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

Figure 31. Engine Oil Dipstick

will be reduced. See maintenance section on page 42 and

43 on instructions to flush out radiator.
When checking the engine oil, be sure to check if the oil is
clean and viscous. If the oil is not clean, drain the oil by
removing the oil drain plug, and refill with the specified amount

An anticorrosion additive added to the water will help prevent

deposits and corrosion in the cooling system.
of oil as outlined in the Isuzu Engine Operator’s Manual.

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PAGE 39 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

)F04EAS

DCA-25SSIU — PRE-SETUP

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.

Day-to-day addition of coolant is done from the reserve tank.
When adding coolant to the radiator, DO NOT remove the
radiator cap until the unit has completely cooled. See Table11.
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.

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Operation in Freezing Weather

When operating in freezing weather, be certain the proper
amount of antifreeze (Table 12) has been added.

Cleaning the Outer Radiator

The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the radiator is
dangerous, so clean only with the engine turned off and the
battery disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Kubota Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the Kubota
Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 32) when depressed with the thumb as shown
below. Never place hands near the belts or fan while the
generator is running.

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water, the antifreeze mixing ratio must
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Figure 32. Fan Belt Tension

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

Never place hands near the belts or fan
while the generator set is running.

Adjusting Fan Belt

If the fan belt does not have the 10 to 15mm defection
follow the procedure below to adjust:



Loosen the alternator adjusting plate and alternator
mounding bolt.



Pivot the alternator at the mounting bolt toward the engine
left or right until the belt reflects the proper tension.



Tighten the mounting bolt and the adjusting bolt.

PAGE 40 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — PRE-SETUP

Battery

This unit is of negative ground. DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary. DO NOT over fill.

The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.

Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions. Always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help to inhibit corrosion.

Battery Cable Installation
ALWAYS be sure the battery cables (Figure 33) are properly

connected to the battery terminals as shown below. The
cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.

RED

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery
terminals when the key is in the ignition and is set in
'START' mode. ALWAYS remove the key from the
ignition and the ignition switch is in the OFF position
when connecting the battery.

2. Place a small amount of grease around both battery
terminals. This will ensure a good connection and will
help prevent corrosion around the battery terminals.

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

If the battery cable is connected
incorrectly, damage to the generator will
occur. Pay close attention to the polarity
of the battery when connecting the
battery.

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

Figure 33. Battery Connections

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.

PAGE 41 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.

Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.

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 output.

NOTE

If wattage is not given on the
equipment's name plate, approximate
wattage may be determined by
multiplying nameplate voltage by the
nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 1.0. See Table 13.
below when connecting loads.

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Three Phase Load

When calculating the power requirements for 3-phase power
use the following equation:

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CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can burn
out the appliance or tool and overheat the cable.



When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.



When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.



When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.

If wattage is not available on the equipment, approximate
wattage may be determined by multiplying the nameplate
voltage by the nameplate amperage for three-phase:
WATTS =1.732 x VOLTAGE x AMPERAGE

CAUTION:

:

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

Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.

NOTE

If output (kVA) is not given
on the equipment nameplate,
approximate output may be
determined by multiplying voltage by
amperage by and 1.732.

PAGE 42 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — GENERATOR START-UP PROCEDURE

WARNING:WARNING:

WARNING:

WARNING:WARNING:

The engine's exhaust contains harmful
emissions.
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 8 on page 33).

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.

ALWAYS

ventilate the

2. Connect the load to the UVW terminals as shown in
Figure 35. These terminals can be found on the output
terminal panel, (see page 29 Figure10). To gain access
to the output terminals lift the UVW cover. Tighten
terminal nuts securely to prevent load wires from slipping
out.

4. Check the fuel level on the fuel gauge. If fuel is low, fill
the fuel tank with clean fresh unleaded automotive diesel.
If diesel spillage occurs, completely wipe up the spilled
fuel immediately.

Before Starting

Generator and Control Panel

3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 36).

CAUTION:

NEVER start the engine with the

main, GFCI

in the ON position.

1. Be sure to disconnect the electrical load and switch the

main, load

the “OFF” position prior to starting the engine.

and

G.F.C.I.

or

load

circuit breakers

circuit breakers (Figure 34) to

Figure 35. UVW Terminal Lugs (Load)

NEGATIVE

POSTIVE

BATTERY

Figure 36. Battery Connections

Figure 34. Main, GFCI and

Load Circuit Breakers

PAGE 43 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — GENERATOR START-UP PROCEDURE

4. Close all engine enclosure doors (Figure 37).

Figure 37. Engine Enclosure Doors

8. Once the preheat indicator lights, turn the ignition

9. Pull the engine throttle and turn to the right until the

5. Check the voltage selection switch (Figure 38) is at
the desired voltage.

key to ‘START’ until the engine starts (Figure 41).
Then release the key to ‘RUN’.

Figure 41. Ignition Switch ‘START’

metal stop rests against the control panel (Figure 42).

Figure 42. Engine Throttle Lever (high)

Figure 38. Voltage Selection Switch

6. Make sure the engine throttle (Figure 39) is in
’start/idle’.

10. The generator's frequency meter (Figure 43) displays

Figure 39. Engine Throttle Lever (low)

7. Turn the ignition key to preheat (Figure 40), until the

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

preheat indicator turns on.

Figure 40. Ignition Switch ‘PREHEAT’

the 60 cycle output frequency in HERTZ.

Figure 43. Frequency Meter (Hz)

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

Figure 44. Voltage Meter (Volts)

PAGE 44 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — GENERATOR START-UP PROCEDURE

Figure 45. Voltage Adjust Control Knob

15. The charging ammeter will dindicate if the battery is being
properly charged or if the any current is being charged
properly.

12. The ammeter (Figure 46) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator’s alternator.

16. The tachometer (Figure 50) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800

40

20

0

60

75

RPM’s.

A

Figure 46. Ammeter (No Load)

13. The engine oil pressure gauge (Figure 47) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure is approximately
25 psi.

17. Turn the MAIN, GFCI and LOAD circuit breakers to
their ON position (Figure 51).

Figure 49. Charging Ammeter

Figure 50. Engine Tachometer

Figure 47. Oil Pressure Gauge

14. The coolant temperature gauge (Figure 48) will indicate

Figure 51. Main and GFCI Circuit Breakers

the coolant temperature. Under normal operating
conditions the coolant temperature is between 165 and
215 degrees Fahrenheit.

WATER

Figure 48. Coolant Temperature Gauge

PAGE 45 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

TEMP

DCA-25SSIU — GENERATOR SHUTDOWN PROCEDURE

18. Observe the generator's ammeter (Figure 52) and verify
it reads the anticipated amount of current with respect

ENGINE SHUTDOWN

To shutdown the generator, use the following procedure:
to the load. The ammeter will only display a current
reading if the load is in use.

40

20

0

60

75

1. Switch both the MAIN, GFCI and LOAD circuit breakers
(Figure 53) to the “OFF” position.

A

Figure 52. Ammeter (Load)

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

2. Set the engine throttle lever to (low) position.

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

4. Turn the ignition key to ‘STOP’ (Figure 54).

Figure 53. Main, GFCI and Load

circuit breakers

Figure 54. Ignition Switch ‘STOP’

5. Remove the load from the UVW terminal strip.

PAGE 46 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

NOTE PAGE

PAGE 47 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — MAINTENANCE

General Inspection

Prior to each use, the generator should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for fuel,
oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 50 hours: Remove air cleaner element and clean heavy
duty paper element with kerosene, or foam element with
liquid detergent and hot water. Wrap foam element in a cloth
and squeeze dry. For heavy duty paper element, wipe
excess kerosene with towel.

Fuel Addition

Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
cock and drain the contents. During cold weather, the more
empty volume inside the tank, the easier it is for water to
condense. This can be reduced by keeping the tank full as
much as possible.

Air Removal

If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure.

To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system.

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.

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 31, page 39.

Replacing Oil Filter



Detach the oil filter cartridge with a filter wrench.



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



Screw in the cartridge by hand. When the gasket is in
contact with the seal surface, tighten the cartridge one
or two more times by hand.



After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check
for leaks before adding more oil if needed. Clean
excessive oil from engine.

Replacing Fuel Filter



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



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



Vent any air.

Flushing Out Radiator and Replacing Coolant



Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overflow
tank and drain.



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



Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.



Tighten both cocks and replace the overflow tank.



Replace with coolant (see page 40, Table 12 for mixture).



Close radiator cap tightly.

CAUTION :CAUTION :

CAUTION :

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation or
once a month.

PAGE 48 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

CAUTION :CAUTION :

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

DCA-25SSIU — MAINTENANCE

Generator Storage

For storage of the generator for over 30 days, the following
is required:



Drain the fuel tank completely.



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



Clean all external parts of the generator with a cloth.



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

ECNANETNIAM/NOITCEPSNI

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PAGE 49 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

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X

DCA-25SSIU — GENERATOR WIRING DIAGRAM

PAGE 50 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — ENGINE WIRING DIAGRAM

PAGE 51 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DCA-25SSIU — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper
handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for

MOTPMYS MELBORPELBISSOP NOITULOS

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diagnosis based on the Engine Troubleshooting (Table 14). If
the problem cannot be remedied, consult our company's
business office or service plant.

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PAGE 52 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

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PAGE 53 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

DCA-25SSIU — 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 (Table15). If the
problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG.51ELBAT

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PAGE 54 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

NOTE PAGE

PAGE 55 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.

NOTICE

The contents and part numbers listed in the parts
section are subject to change without notice. Multiquip
does not guarantee the availability of the parts listed.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

QTY. Column

Numbers Used — Item quantity can be indicated by a

number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.

REMARKS Column

Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.

NOTICE

When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.

PART NO. Column

Numbers Used — Part numbers can be indicated by a

number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.

A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.

Serial Number Break — Used to list an effective serial
number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”

Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model number
variant.

Indicated by:

“XXXXX ONLY”
“NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items. Examples include battery cables, shims,
and certain washers and nuts.

“Not Sold Separately” — Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.

PAGE 56 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU — SUGGESTED SPARE PARTS

DCA-25SSIU W/ISUZU C240 DIESEL ENGINE
1 TO 3 UNITS

Qty. P/N Description

10 ............ 0602046356 ............ CIRCUIT BREAKER

20 ............ X132400150 ........... FUEL FILTER

20 ............ 8970246071 ............ OIL FILTER

5 .............. 5136710400 ............ FAN BELT

1 .............. 8943768300 ............ WATER PUMP

2 .............. 9136140430 ............ WATER PUMP GASKET

2 .............. 1823100080 ............ STARTER SWITCH

5 .............. KEYISUZUF ........... STARTER SWITCH KEY

3 .............. 0602122272 ............ OIL SENDING UNIT

2 .............. 5137700221 ............ THERMOSTAT

2 .............. X137130020 ........... THERMOSTAT GASKET

2 .............. 0602014504 ............ RADIATOR HOSE (UPPER)

2 .............. 0602014601 ............ RADIATOR HOSE (LOWER)

1 .............. 0605505070 ............ FUEL CAP

8 .............. 9825119783 ............ GLOW PLUGS

2 .............. 5153110060 ............ INJECTOR NOZZLES

1 .............. 5825500422 ............ EMERGENCY RELAY

1 .............. 5819000200 ............ STOPPER ENGINE

1 .............. 5812003411 ............ ALTERNATOR

1 .............. 8944532120 ............ STARTER

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

1 .............. 0601808810 ............ MAIN CIRCUIT BREAKER

1 .............. 0601840073 ............ VOLTAGE REGULATOR (RHEOSTAT)

1 .............. M1923100004 ......... SELECTOR SWITCH

1 .............. 47130106 ................ SELECTOR SWITCH KNOB

2 .............. 0601810245 ............ PREHEAT LAMP BULB

NOTE

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this

book.

PAGE 57 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

GENERATOR ASSY.

DCA-25SSIU --- GENERATOR ASSY.

PAGE 58 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 8351000002 ROTOR ASSY. 1
2 FIELD ASSY. 1
3 7961025004 RECTIFIER 1

4 0601822630 SURGE ABSORBER ............................ 1 ........... TNR26G471K

5 8001070003 FAN 1
6 8351611004 COUPLING DISK 2
7 8351612004 WASHER, COUPLING HUB 1
8 8351615003 BALANCING PLATE 1

9 0105091025 HEX. HEAD BOLT ................................. 4 ........... REPLACES 0010310025

10 0042610000 LOCK WASHER 4
11 0601000209 BALANCING WEIGHT KIT 1

12 042006308 BEARING .............................................. 1 ........... 6308DDUC3; REPLACES 0071906308

13 8351614003 COUPLING RING .................................. 1 ........... REPLACES M1163400103

14 0012108025 HEX. HEAD BOLT 6
15 0042508000 LOCK WASHER 6
16 0012108035 HEX. HEAD BOLT 6
17 0042508000 LOCK WASHER 6
18 B1130100203 STRATOR ASSY. 1
19 0845041904 GROMMET 1

20 8351350103A FIELD ASSY. EXCITER ........................ 1 ........... REPLACES 8351350103

21 0016008045 HEX. SOCKET HAD CAP SCREW 3
22 0042508000 LOCK WASHER 3
23 8351315003 END BRACKET 1

24 011208035 HEX. HEAD BOLT ................................. 6 ........... REPLACES 0017108035

25 8351312004 PACKING 1
26 8351331004 COVER, SUCTION 1
27 0017106016 HEX. HEAD BOLT 3

28 0105051045 HEX. HEAD BOLT ................................. 2 ........... S/N7100001 TO 7102574;

REPLACES 0012110045

0012310045 HEX. HEAD BOLT ................................. 2 ........... S/N7102575~

0207010000 HEX. NUT 2

030210250 LOCK WASHER 2 ........... S/N7100001 TO 7102574;

REPLACES 0042510000

020310080 HEX.NUT .............................................. 2 ........... REPLACES 0030010000

29 0012110040 HEX. HEAD BOLT ................................. 4 ........... S/N7100001 TO 7102574

0012310040 HEX. HEAD BOLT ................................. 4 ........... S/N7102575~

0207010000 HEX. NUT 4

030210250 LOCK WASHER .................................... 4 ........... S/N7100001 TO 7102574;

REPLACES 0042510000

30 8351332004 COVER, FAN 1
31 0010106030 HEX.HEAD BOLT 1

32 952404470 PLAIN WASHER ................................... 1 ........... REPLACES 0041206000

33 0605000008 RUBBER SUSPENSION ....................... 2 ........... EA1009

34 0030012000 HEX NUT 2

0040012000 LOCK WASHER 2

031112230 PLAIN WASHER ................................... 2 ........... REPLACES 0041212000

PAGE 59 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

CONTROL BOX ASSY.

DCA-25SSIU --- CONTROL BOX ASSY.

PAGE 60 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. ITEM QTY. REMARKS

M1246700514 WIRE HARNESS, GENERATOR................ 1 ......... UP TO S/N7106114

M1246700524 WIRE HARNESS, GENERATOR................ 1 ......... S/N7106115~

1 M1213000202 CONTROL BOX ......................................... 1 ......... S/N7100001 TO 7102144

M1213000212 CONTROL BOX ......................................... 1 ......... S/N7102145 TO 7102314

M1213000222 CONTROL BOX ......................................... 1 ......... S/N7102315~

2 0601808810 CIRCUIT BREAKER .................................. 1 ......... FAF340601021 3P 60A;

UP TO S/N7106114

0601808820 CIRCUIT BREAKER .................................. 1 ......... S/N7106115~

3 021005080 MACHINE SCREW 4

4 0601842384 RESISTOR ................................................. 1 ......... GG20W 50 OHM

5 0027104010 MACHINE SCREW 2

6 0601821370 RECTIFIER ................................................ 3 ......... DE4503; REPLACES 0601823240

7 0021004040 MACHINE SCREW 1

0040004000 LOCK WASHER 1

031104080 PLAIN WASHER ........................................ 1 ......... REPLACES 0041204000

8 0601815925 TERMINAL BOARD ................................... 1 ......... 202HB SP

9 0027104020 MACHINE SCREW 2

10 0601823863 RELAY UNIT .............................................. 2 ......... MSA9013A

11 0021304015 MACHINE SCREW .................................... 4 ......... REPLACES 0027104015

12 0601820671 AUTOMATIC VOLTAGE REGULATOR ........ 1 ......... NTA5A2DB

13 0027105010 MACHINE SCREW .................................... 4 ......... S/N7100001 TO 7102574

0027105015 MACHINE SCREW .................................... 4 ......... S/N7102575~

14 0601806115 CURRENT TRANSFORMER ...................... 3 ......... 812943 50/5A

15 011808015 MACHINE SCREW .................................... 6 ......... REPLACES 0027106015

16 0601820845 OVER CURRENT RELAY .......................... 1 ......... LR2D1308

17 0601820846 OVER CURRENT RELAY .......................... 1 ......... LR7D1064

18 M1260600004 FITTING BRACKET ................................... 1 ......... S/N7100001 TO 7102314

19 0021304015 MACHINE SCREW .................................... 2 ......... S/N7100001 TO 7102314;

REPLACES 0027104015

0030004000 HEX. NUT .................................................. 2 ......... REPLACES 0207004000

20 0027104010
21 M1213500203 CONTROL BOX COVER 1

22 011106015 HEX. HEAD BOLT ...................................... 4 ......... REPLACES 0016906015

23 M1923100004 SELECTOR SWITCH ................................. 1 ......... VY40

24 M1213600104 SWITCH BRACKET ................................... 1 ......... S/N7100001 TO 7102144

MACHINE SCREW 2

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 61 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

CONTROL BOX ASSY.

DCA-25SSIU --- CONTROL BOX ASSY.

PAGE 62 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. ITEM QTY. REMARKS

M1213600114 SWITCH BRACKET ................................... 1 ......... S/N7102145

25 0027103010 MACHINE SCREW 4

26 011106015 HEX. HEAD BOLT ...................................... 4 ......... REPLACES 0016906015

27 M1213600004 SWITCH COVER ................................................ 1 ........ S/N7100001 TO 7102144

M1213600014 SWITCH COVER ................................................ 1 ........ S/N7102145~

28 011106015 HEX. HEAD BOLT .............................................. 4 ........ S/N7100001 TO 7102059;

REPLACES 0016906015

011106015 HEX. HEAD BOLT .............................................. 3 ........ S/N7102059~;

REPLACES 0016906015

29 0016906015 HEX. HEAD BOLT 8

0040506000 TOOTHED WASHER 1

30 M1223000203 CONTROL PANEL 1

31 0601807630 FREQUENCY METER,264250DJDJ9; ............... 1 ........ REPLACES 0601807696

UP TO S/N7105234

0601807641 FREQUENCY METER, FCF6 45-65HZ 240V .... 1 ........ FROM S/N7105235~

32 0601808952 AC AMMETER,260240LSNT1 ........................... 1 ........ REPLACES 0601808991;

UP TO S/N7105234

32 0601808985 AC AMMETER, ACF60-50A,0-100A/5A ............. 1 ........FROM S/N7105235~

33 0601801040 CHANGE-OVER SWITCH, AMMETER .............. 1 ........ SL2AS

34 0601806813 AC VOLTMETER,260244SJSJ1; ........................ 1 ........ REPLACES 0601806896

UP TO S/N7105234

0601806859 AC VOLTMETER, SCF6 0-600V ........................ 1 ........ FROM S/N7105235~

35 0601801041 CHANGE-OVER SWITCH VOLTMETER ............ 1 ........ SL2VS

36 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ............... 1 ........ RA20A2SE102BJ 2W 1K OHM

37 0601840121 KNOB 1
38 M122310004 STOPPER 1

39 0027105015 MACHINE SCREW ............................................ 2 ........ S/N7100001 TO 7102674

0027105010 MACHINE SCREW ............................................ 2 ........ S/N7102675~

40 0027105015 MACHINE SCREW ............................................ 4 ........ S/N7100001 TO 7102674

0027105010 MACHINE SCREW ............................................ 4 ........ S/N7102675~

41 M9220100004 SET SCREW 1
42 0080200007 SNAP RING 1

43 5825500422 EMERGENCY RELAY ....................................... 1 ........ REPLACES 0602200400

44 06018020132 FUSE 1

45 011106015 HEX. HEAD BOLT .............................................. 4 ........ REPLACES 0016906015

46 0330000160 EDGING ............................................................. 2 ........ S/N7100131~

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 63 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

ENGINE AND RADIATOR ASSY.

DCA-25SSIU ENGINE AND RADIATOR ASSY.

PAGE 64 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 M1923200004A ENGINE .......................................... 1 ........... ISUZU QD60(C240) S/N7100001 TO 7102685

M1925200004 ENGINE .......................................... 1 ........... ISUZU QD60(C240) S/N7102686~

5136710400 FAN BELT ....................................... 1........... REPLACES 0602011401

2 8970246071 CARTRIDGE, OIL FILTER .............. 1 ........... REPLACES 0602041212

3 X132400150 CARTRIDGE, FUEL FILTER ........... 1........... REPLACES 0602042510

4 0602011996 RADIATOR ...................................... 1 ........... C2810010000

5 0602011065 CAP ................................................ 1 ........... C89C0115010

6 011008020 HEX. HEAD BOLT ........................... 6 ........... REPLACES 0016908020

7 0602014504 RADIATOR HOSE, UPER ............... 1........... S/N7100001 TO 7101005

M1310500103 RADIATOR HOSE, UPPER ............. 1 ........... S/N7101006~

8 06020146010 RADIATOR HOSE, LOWER ............ 1 ........... S/N7100001 TO 7101005

M1310500203 RADIATOR HOSE, LOWER ............ 1........... S/N7101006~

9 0602014334 HOSE BAND ...................................2 ........... S/N7100001 TO 7100050

0605515147 HOSE BAND ...................................2 ........... S/N7100051~

10 0602014332 HOSE BAND ...................................1 ........... S/N7100001 TO 7100050

0605515149 HOSE BAND ...................................1 ........... S/N7100051~

11 0602014333 HOSE BAND ...................................1 ........... S/N7100001 TO 7100050

0605515149 HOSE BAND ...................................1 ........... S/N710051~

12 0602046231 AIR CLEANER ................................ 1 ........... S/N7100001 TO S/N7104749

0602046580 AIR CLEANER ................................ 1 ........... S/N7104750~

0602046356 ELEMENT, AIR CLEANER .............. 1 ........... S/N7100001 TO S/N7104749;

0602046321 ELEMENT, AIR CLEANER 1 S/N7104750~

13 0602040650 INDICATOR, AIR CLEANER ........... 1........... S/N7100001 TO S/N7104749

0602040651 INDICATOR, AIR CLEANER ........... 1........... S/N7104750~

14 0602040593 BAND, AIR CLEANER .................... 2........... S/N7100001 TO 7104749

0602040552 BAND, AIR CLEANER .................... 1........... S/N7104750~

15 M1373200003 BRACKET, AIR CLEANER.............. 1 ........... S/N7100001 TO S/N7104749

16 012210025 HEX. HEAD BOLT ........................... 2 ........... S/N7100001 TO S/N7104749;

REPLACES 0016910025

17 011008020 HEX. HEAD BOLT ........................... 4 ........... S/N7100001 TO 7100050;

REPLACES 0016908020

18 0013003008 HEX. HEAD BOLT ...........................4 ........... S/N7100051 TO S/N7104749

0016908030 HEX. HEAD BOLT ........................... 2........... S/N7104750~

19 020108060 HEX. NUT ....................................... 4 ........... S/N7100001 TO 7100050;

REPLACES 0207008000

0036203000 HEX.NUT ........................................ 4........... S/N7100051 TO S/N7104749

020108060 HEX.NUT ........................................ 2 ........... S/N7104750~; REPLACES 0207008000

0043003000 LOCK WASHER .............................. 4 ........... S/N710051 TO S/N7104749

0043103000 PLAIN WASHER ............................. 4........... S/N7100051 TO S/N7104749

8352032303 HOSE, AIR CLEANER ....................1 ........... REPLACES M1373100103

20 M137310004 HOSE, AIR CLEANER 1

21 0605515010 HOSE BAND ...................................3 ........... S/N7100001 TO S/N7100050

060551547 HOSE BAND ................................... 3 ........... S/N7100051~

22 M1303200004 ENGINE FOOT 2

PAGE 65 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

ENGINE AND RADIATOR ASSY.

DCA-25SSIU ENGINE AND RADIATOR ASSY.

PAGE 66 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

23 012010030 HEX. HEAD BOLT ................................. 4 ........... REPLACES 0017110030

24 0207010000 HEX. NUT 4

25 060500006 RUBBER SUSPENSION ....................... 2 ........... EA1007

26 020701000 HEX. NUT 2

27 M1320200003 DRAIN PIPE ......................................... 1 ........... S/N7100001 TO S/N7100130

28 M1320300204 PACKING, OIL PAN SIDE ..................... 1 ........... S/N7100001 TO S/N7100130;

REPLACES M1320300204

29 9095720240 PACKING .............................................. 1 ........... S/N7100001 TO S/N7100130;

REPLACES 0602021107

30 M1320300104 JOINT BOLT ......................................... 1 ........... S/N7100001 TO S/N7100130

31 011206020 HEX. HEAD BOLT ................................. 2 ........... S/N7100001 TO S/N7100130;

REPLACES 0016906020

32 0207006000 HEX. NUT ............................................. 2 ........... S/N7100001 TO S/N7100130

33 M9300000003 RESERVE TANK 1
34 M9300100003 CAP, RESERVE TANK 1
35 M1316100204 BRACKET, RESERVE TANK 1

36 0229200300 RUBBER CUSHION .............................. 1 ........... S/N7100001 TO S/N7100150

37 011206020 HEX. HEAD BOLT ................................. 1 ........... S/N7100001 TO S/N7100150;

REPLACES 0016906020
38 0199100215 HOSE 1
39 0193601450 HOSE 1

40 0605515106 HOSE BAND ......................................... 1 ........... S/N7100001 TO S/N7100150

41 0194500600 HOSE .................................................... 1 ........... S/N7100001 TO S/N7100150

42 0605515003 HOSE BAND ......................................... 2 ........... S/N7100001 TO S/N7100150

43 M1483600503 CLAMP BAR ......................................... 1 ........... REPLACES M1483600103

44 5819000200 ENGINE STOPPER .............................. 1 ........... REPLACES 06022108020

06018020132 FUSE 1

45 011808015 MACHINE SCREW ............................... 3 ........... REPLACES 0027106015

46 0602220621 TERMINAL COVER .............................. 1 ........... S/N7100001 TO S/N7100150

47 0602022560 ADAPTER ............................................. 1 ........... S/N7100131~

48 M1320300304 PACKING .............................................. 1 ........... S/N7100131~

49 0602025561 90o ELBOW ........................................... 1 ........... S/N7100131~

50 0602022562 UNION ................................................... 1 ........... S/N7100131 TO S/N7104749

51 0602022792 SWIVEL ................................................ 1 ........... S/N 7100131 TO S/N7104749

52 0602021070 CAP ...................................................... 1 ........... S/N 7100131~

53 0602021570 DRAIN HOSE ........................................ 1 ........... S/N 7100131 TO S/N7104749

0269200660 DRAIN HOSE ........................................ 1 ........... S/N7104750~

54 0603306395 HOSE JOINT ........................................ 1 ........... S/N7104750~

55 0603306590 CONNECTOR ........................................ 1 ........... S/N7104750~

56 0603300285 ROCK NUT ............................................ 1 ........... S/N7104750~

57 0605511395 VALVE ................................................... 1 ........... S/N7104750~

PAGE 67 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

ENGINE OPERATING PANEL ASSY.

DCA-25SSIU --- ENGINE OPERATING PANEL ASSY.

PAGE 68 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.
NO. PART NO. ITEM QTY. REMARKS

M1357200102A WIRE HARNESS, ENGINE 1
1 M1354300304 SLIDE LEVER 1

2 0601840190 KNOB .................................................... 1 ........... REPLACES M9320000004

3 020108060 HEX. NUT ............................................. 1 ........... REPLACES 0036003000

4 M1354200004 BRACKET ............................................. 1 ........... ASK CUST. SVC. FOR COLOR

5 020108060 HEX. NUT ............................................. 1 ........... REPLACES 0030008000

6 0605010503 SNAP PIN 1
7 M1354300204 GOVERNOR ROD 1

8 0602180106 BALL JOINT .......................................... 2 ........... LHSA8DE161

9 020108060 HEX. NUT ............................................. 2 ........... REPLACES 0030008000

10 0207006000 HEX. NUT 2

0041206000 PLAIN WASHER 2

11 1823100080 STARTER SWITCH ............................... 1 ........... REPLACES 0602100004

12 8944626110 PREHEAT LAMP ................................... 1 ........... REPLACES 0602102066

13 0602120095 TACHOMETER ...................................... 1 ........... 103680

14 0602120480 PICK UP, TACHOMETER ...................... 1 ........... 7154400

15 0602122093 OIL PRESSURE GAUGE ...................... 1 ........... 100174

16 0602122272 OIL PRESSURE UNIT .......................... 1 ........... 102225; S/N7100001 TO S/N7101239;

REPLACES 0602122207
17 M9200100004 ADAPTER 1

18 0602123090 WATER TEMPERATURE GAUGE ......... 1 ........... 100683

19 0602123201 WATER TEMPERATURE UNIT ............. 1 ........... 0209400

20 9095720140 PACKING .............................................. 1 ........... REPLACES 0602121109

21 0602121080 CHARGING AMMETER ....................... 1 ........... 100158

22 0602128090 FUEL GAUGE ....................................... 1 ........... 100176

23 0602103092 ALARM LAMP ....................................... 2 ........... PL05

0601810245 BULB ..................................................... 2 ........... E10 T10 DC18V

24 0601810141 PANEL LIGHT ....................................... 1 ........... ISUZU 9826800370

25 0601831330 SWITCH, PANEL LIGHT ....................... 1 ........... 900001

26 020108060 HEX. NUT ............................................. 1 ........... REPLACES 0207008000

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 69 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

OUTPUT TERMINAL ASSY.

DCA-25SSIU --- OUTPUT TERMINAL ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

PAGE 70 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. ITEM QTY REMARKS

1 8091860103 TERMINAL PANEL ................................... 1 ................... REPLACES M1230700003

2 0801830104A OUTPUT TERMINAL BOLT ..................... 5 ................... REPLACES M922000004

3 0801832204 TIE BOLT ................................................. 5 ................... REPLACES M9220000104

4 0039308000 HEX. NUT 10
5 0040008000 LOCK WASHER 15
6 0041408000 PLAIN WASHER 20

7 011606025 HEX. HEAD BOLT .................................... 4 ................... S/N7100001 TO S/N7102674;

REPLACES 0016906025

011206020 HEX. HEAD BOLT .................................... 4 ................... S/N7102675~

8 M1236100303 TERMINAL COVER ................................. 1 ................... S/N7100001 TO S/N7102784

M1236100313 TERMINAL COVER ................................. 1 ................... S/N7102785~

9 M1236100404 OUTPUT WINDOW 1
10 0605010040 HINGE 2
11 0027103010 MACHINE SCREW 4

0207003000 HEX.NUT ................................................. 4 ................... REPLACES 0030003000

58413 PLAIN WASHER ...................................... 4 ................... REPLACES 0041203000

12 011206020 HEX. HEAD BOLT .................................... 2 ................... REPLACES 0016906020

13 011106015 HEX. HEAD BOLT .................................... 4 ................... REPLACES 0016906015

14 M1236400004 CABLE OUTLET COVER 1
15 M1236300004 SUPPORTER, CABLE OUTLET COVER 1

16 011206020 HEX. HEAD BOLT .................................... 6 ................... REPLACES 0016906020

17 0601808804 CIRCUIT BREAKER ................................ 2 ................... QOU250B 2P 50A

18 06018088030 CIRCUIT BREAKER ................................ 2 ................... QOU120B 1P 50A

19 M1260700204 BREAKER FITTING COVER 1
20 0222100115 CUSHION RUBBER 1

21 011206020 HEX. HEAD BOLT .................................... 2 ................... REPLACES 0016906020

22 0601812597 RECEPTACLE .......................................... 2 ................... GF530EM125V 20AX2

REPLACES 0601812549

23 0601811034 RECEPTACLE 2 CA6369 250V 50A ;

REPLACES 0601812538

24 0021304015 MACHINE SCREW .................................. 8 ................... REPLACES 0027104015

0030004000 HEX. NUT ................................................ 8 ................... REPLACES 0207004000

25 M1236100503 TERMINAL COVER 1

26 012212045 HEX.HEAD BOLT .................................... 2 ................... REPLACES 0010112045

27 031112230 PLAIN WASHER ...................................... 2 ................... REPLACES 0041212000

28 M9310200004 STAY RUBBER 2
29 0030012000 HEX. NUT 2
30 0027103010 MACHINE SCREW 4

0207003000 HEX. NUT ................................................ 4 ................... REPLACES 0030003000

PAGE 71 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

BATTERY ASSY.

DCA-25SSIU --- BATTERY ASSY.

S/N7100001 TO 7100050

S/N7100051~

PAGE 72 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 0602220185 BATTERY ....................................... 1 ........... 427MF

2 M9310500014 BATTERY SHEET 1
3 M9103000304 BATTERY BAND 1

4 M0602220920 BATTERY BOLT SET ..................... 2 ........... BHL10J;REPLACES M9103200004

5 0037808000 WING NUT ..................................... 2 ........... S/N7100001 TO S/N7100050

6 0040008000 LOCK WASHER ............................. 2 ........... S/N7100001 TO S/N7100050

0040006000 LOCK WASHER ............................. 2 ........... S/N7100051~

7 031108160 PLAIN WASHER ............................ 2 ........... S/N7100001 TO S/N7100050;

REPLACES 0041208000

8 0602220310 TERMINAL ASSY. ......................... 1 ........... NO.9P S/N7100001 TO S/N7100050

M134640004 BATTERY CABLE .......................... 1 ........... S/N7100051~

9 0602220311 TERMINAL ASSY. ......................... 1 ........... NO.9P S/N7100001 TO S/N7100050

M1346400104 BATTERY CABLE .......................... 1 ........... S/N7100051 TO S/N7101005

M2346400104 BATTERY CABLE .......................... 1 ........... S/N7101006~

10 M1346400004 TERMINAL COVER ....................... 1 ........... S/N7100001 TO S/N7100050;

REPLACES M9310000304

11 M1346400104 TERMINAL COVER ....................... 1 ........... S/N7100001 TO S/N7100050;

REPLACES M9310000204

12 0016910020 HEX. HEAD BOLT .......................... 1 ........... S/N7100051~

0040510000 TOOTHED WASHER ...................... 1 ........... S/N7100051~

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 73 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

MUFFLER ASSY.

DCA-25SSIU --- MUFFLER ASSY.

S/N7100001 TO S/N7105049

PAGE 74 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

S/N7105050~

DCA-25SSIU --- MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 0602300160 MUFFLER;MAM060249 ................. 1 ........... S/N7100001 TO 7105049

1 0602300390 MUFFLER ...................................... 1 ........... S/N7105050~

2 M133040004 MUFFLER SUPPORTER ............... 1 ........... S/N7100001 TO 7105049

3 011008020 HEX. HEAD BOLT .......................... 2 ........... REPLACES 0016908020;

S/N7100001 TO 7105049

3 011008020 HEX. HEAD BOLT .......................... 4 ........... REPLACES 0016908020; S/N7105050~

4 M1330400104 U BOLT 2 S/N7100001 TO 7105049

5 020108060 HEX. NUT ...................................... 4 ........... REPLACES 0037908000;

S/N7100001 TO 7105049

031108160 PLAIN WASHER ............................ 4 ........... REPLACES 0041208000;

S/N7100001 TO 7105049
6 M1333000703 EXHAUST PIPE 1

7 M1333000803 EXHAUST PIPE............................. 1 ........... S/N7100001 TO 7105049

8 8943811610 GASKET ........................................ 1 ........... REPLACES 0602320102

9 M1333200004 GASKET ........................................ 1 ........... S/N 7100001 TO S/N7100865

M1333200014 GASKET ........................................ 1 ........... S/N7100866~

10 9098400850 HEX. NUT ...................................... 3 ........... REPLACES 0602323001

0040010000 LOCK WASHER 3
11 0016908035 HEX. HEAD BOLT 4

12 M1333000604 TAIL PIPE ...................................... 1 ........... S/N7100001 TO 7105049

13 0602325021 SEAL CLAMP ................................ 1 ........... S/N7100001 TO 7105049

14 M1330400204 COVER 2

15 011106015 HEX. HEAD BOLT .......................... 4 ........... REPLACES 0016906015

16 0602325020 SEAL CLAMP ................................ 1 ........... S/N7100001 TO 7105049

17 011008020 HEX. HEAD BOLT .......................... 4 ........... REPLACES 0016908020;S/N7105050~

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 75 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

FUEL TANK ASSY.

DCA-25SSIU --- FUEL TANK ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

PAGE 76 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 M1363000202 FUEL TANK 1
2 0605505070 CAP, FUEL TANK 1
3 M1363200004 TANK BAND 2
4 M9310500104 SUPPORTER SHEET 4

5 011008020 HEX. HEAD BOLT .......................... 2 ........... REPLACES 0016908020

6 00379080000 HEX. NUT ...................................... 2 ........... S/N7100001 TO S/N7101449;

REPLACES 0037908000

0207308000 HEX. NUT ...................................... 2 ........... S/N7101450~

031108160 PLAIN WASHER ............................ 2 ........... S/N7100001 TO S/N7101449;

REPLACES 0041208000

7 0222100080 RUBBER SHEET 4

8 1502025103C DRAIN JOINT ................................ 1 ........... REPLACES M9200000003

9 M9200200004 DRAIN BOLT 1
10 0150000018 O RING 1

11 011206020 HEX. HEAD BOLT .......................... 2 ........... REPLACES 0016906020

12 M1363400104 DRAIN HOSE 1

13 06015515198 HOSE BAND .................................. 2 ........... REPLACES 0605515064

14 0602042420 FUEL FILTER ................................. 1 ........... PTG15P

15 0602220911 CLAMP 1
16 0191300730 SUCTION HOSE 1

17 0191300380 SUCTION HOSE ............................ 1 ........... S/N7100001 TO S/N7102685

0191300920 SUCTION HOSE ............................ 1 ........... S/N7102686~

18 0191301060 RETURN HOSE 1

19 0605515109 HOSE BAND .................................. 6 ........... S/N7100001 TO S/N7102685

0605515109 HOSE BAND .................................. 8 ........... S/N7102686~

20 0191300520 SUCTION HOSE ............................ 1 ........... S/N7102686~

21 1132008410 WATER SEDIMENTER .................. 1 ........... S/N7102686~; REPLACES 0602042512

22 0016908025 HEX. HEAD BOLT .......................... 2 ........... S/N7102686~

23 5154115680 PIPE .............................................. 2 ........... S/N7102686~; REPLACES 0602042660

AND 5154112231

24 1096751460 JOINT BOLT .................................. 2 ........... S/N7102686~; REPLACES 0602042620

AND 9099063251

25 9095720140 PACKING ....................................... 4 ........... S/N7102686~; REPLACES 0602042640

PAGE 77 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

ENCLOSURE ASSY.

DCA-25SSIU --- ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

PAGE 78 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 M1413000212 BASE ................................................... 1 ............. S/N7100291 TO S/N7104749

REPLACES M1413000202

M1413000222 BASE ................................................... 1 ............. S/N7104750~

2 M1413400004 UNDER COVER 1

3 011008020 HEX. HEAD BOLT ............................... 2 .............REPLACES 0016908020

4 M1423000302 FRONT FRAME .................................. 1 .............S/N7100001 TO 7105049

M1493100503 ACOUSTIC SHEET ............................ 1 .............S/N7100001 TO 7105049

M1423000312 FRONT FRAME .................................. 1 .............S/N7105050~

M1493100513 ACOUSTIC SHEET ............................ 1 .............S/N7105050~

5 011008020 HEX.HEAD BOLT ................................ 4 ............. REPLACES 0016908020

6 M1423200304 COVER, FRONT FRAME 1

M1493100604 ACOUSTIC SHEET 1

7 011008020 HEX HEAD BOLT .............................. 11 .............REPLACES 0016908020

8 M1433000203 CENTER FRAME 1
9 M1433000303 CENTER FRAME 1
10 0010114030 HEX. HEAD BOLT 8

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

031114260 PLAIN WASHER .................................. 8 .............REPLACES 0041214000

11 M1443000502 REAR FRAME 1

12 011008020 HEX. HEAD BOLT ............................... 4 .............REPLACES 0016908020

0040508000 TOOTHED WASHER 1

13 M1443300513 REAR COVER ..................................... 1 .............REPLACES M1443300503

M1493300304 ACOUSTIC SHEET 1

14 M1443300403 DUCT, REAR COVER 1

M1493300404 ACOUSTIC SHEET 1

15 0207006000 HEX. NUT 7

16 011008020 HEX. HEAD BOLT ............................... 6 ............. S/N7100001 TO S/N7100290;

REPLACES 0016908020

011008020 HEX. HEAD BOLT ............................... 7 ............. S/N7100291~; REPLACES 0016908020

17 M1443200613 REAR DOOR ...................................... 1 .............REPLACES M1443200603

18 M1443600004 WINDOW PLATE ................................ 1 .............S/N7100001 TO S/N7100725

M1443600104 WINDOW PLATE ................................ 1 .............S/N7100726 TO S/N7101589

M1443600114 WINDOW PLATE ................................ 1 .............S/N7101590~

19 020106050 HEX. NUT ............................................ 6 .............S/N7100001 TO S/N7101449;

REPLACES 0037906000

0027306000 HEX. NUT ............................................ 6 .............S/N7101450 TO S/N7101589

0207306000 HEX. NUT ............................................ 8 .............

952404470 PLAIN WASHER ................................ 12 .............S/N7100001 TO S/N7101449;

952404470 PLAIN WASHER .................................. 6 .............S/N7101450 TO S/N7101589;

952404470 PLAIN WASHER .................................. 8 .............S/N7101590~; REPLACES 0041206000

20 M911300002 DOOR HANDLE ASSY. 1
21 0021706015 MACHINE SCREW 4

020106050 HEX. NUT ............................................ 4 .............REPLACES 0030006000

S/N7101590~

REPLACES 0041206000

REPLACES 0041206000

PAGE 79 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

ENCLOSURE ASSY.

DCA-25SSIU --- ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

PAGE 80 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

22 M9110100204 HINGE 2
23 M9116100004 WASHER 2
24 0021808020 MACHINE SCREW 3

25 0845031504 BLIND PLUG ....................................... 2 .............REPLACES M9310000004

26 M1463000202 ROOF PANEL ..................................... 1 ............. S/N7100000 TO S/N7104749

26 M1463000212 ROOF PANEL ..................................... 1 ............. S/N7104750 TO S/N7105049

M1463000222 ROOF PANEL ..................................... 1 ............. S/N7105050~

M1493500203 ACOUSTIC SHEET ............................ 1 .............S/N7100000 TO S/N7104749

M1493500203 ACOUSTIC SHEET ............................ 1 .............S/N7104750~

27 011008020 HEX. HEAD BOLT ............................. 18 .............REPLACES 0016908020

28 1625165103 BONNET CAP ..................................... 1 .............REPLACES M9310000103

29 1625165204 CHAIN ASSY. ....................................... 1 .............REPLACES M1483600204

30 M1443100202 SPLASHER PANEL ............................. 1 .............S/N7100001 TO S/N7102784

M1443100212 SPLASHER PANEL ............................. 1 .............S/N7102785

31 0016908050 HEX. HEAD BOLT 2

32 011008020 HEX. HEAD BOLT ............................... 2 .............REPLACES 0016908020

33 M1453000703 SIDE DOOR 1

M1493400904 ACOUSTIC SHEET 1

34 M1453000903 SIDE DOOR 1

M1493401004 ACOUSTIC SHEET 1

35 M1453001003 SIDE DOOR 1

M1493401104 ACOUSTIC SHEET 1

36 M1453000803 SIDE DOOR 1

M1493400804 ACOUSTIC SHEET 1

37 M1453300503 DUCT 1
38 0207006000 HEX. NUT 4

39 B9114000002 DOOR HANDLE ASSY. ....................... 3 ............. REPLACES M9113000002

40 0027106016 MACHINE SCREW ........................... 12 .............REPLACES 0021806015

020106050 HEX. NUT .......................................... 12 ............. REPLACES 0030006000

41 M9110100204 HINGE 4
42 M9110100304 HINGE 4
43 M9116100004 WASHER 8
44 0021808020 MACHINE SCREW 9
45 0601850097 DOOR STOPPER 8
46 0027208025 MACHINE SCREW 8

47 0845031504 BLIND PLUG ....................................... 8 ............. REPLACES M9310000004

48 0600500090 EMBLEM 1
49 0021106015 MACHINE SCREW 2
50 012210025

0040510000 TOOTHED WASHER 1

51 011008020 HEX. HEAD BOLT ............................... 1 .............REPLACES 0016908020

0040508000 TOOTHED WASHER 1

HEX. HEAD BOLT ............................... 1 .............REPLACES 0016910025

PAGE 81 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

RUBBER SEAL ASSY.

DCA-25SSIU --- RUBBER SEAL ASSY.

S/N7100001 TO 7101589

S/N7101590~

PAGE 82 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 0228910300 RUBBER SEAL 2
2 0228900725 RUBBER SEAL 4
3 M1490300004 RUBBER SEAL 1
4 0228800360 RUBBER SEAL 1
5 0228900370 RUBBER SEAL 1
6 0228800605 RUBBER SEAL 2
7 0229200595 RUBBER SEAL 1
8 0228900645 RUBBER SEAL 1

9 0229200750 RUBBER SEAL ............................... 3 ........... S/N7100001 TO S/N7101589

0229200750 RUBBER SEAL ............................... 2 ........... S/N7101590~

10 0229200740 RUBBER SEAL 1
11 0228800670 RUBBER SEAL 2
12 0228800445 RUBBER SEAL 1
13 0228800485 RUBBER SEAL 1

14 0228100568 RUBBER SEAL ............................... 2 ........... S/N7100001 TO S/N7101589

0228100458 RUBBER SEAL ............................... 1 ........... S/N7101590~

15 0228100170 RUBBER SEAL ............................... 2 ........... S/N7100001 TO S/N7101589

0228100171 RUBBER SEAL ............................... 1 ........... S/N7101590~

16 0228100351 RUBBER SEAL ............................... 1 ........... S/N7101590~

17 0228100285 RUBBER SEAL ............................... 1 ........... S/N7101590~

18 0228100153 RUBBER SEAL ............................... 1 ........... S/N7101590~

19 0228100180 RUBBER SEAL ............................... 1 ........... S/N7101590~

PAGE 83 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

DECAL ASSY.

DCA-25SSIU --- DECALS

PAGE 84 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

DCA-25SSIU --- DECALS

DECAL ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 M1550000003 DECAL; ENGINE OPERATING .............................. 1 ..... M15000000

2 M1550000104 DECAL; NOTE ........................................................ 1 ..... M15000010

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

4 M1550000303 DECAL; AUXILLARY OUTPUT............................... 1 ..... M15000030

5 M1550000403 DECAL; GENERATOR CONTROL.......................... 1 ..... M15000040

6 M9500000004 DECAL; OIL DRAIN PLUG .....................................1 ..... M90000000

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

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

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

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

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

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

13 M9503000103 DECAL; WATER, OIL CHECK ................................ 1 ..... M90300000

14 M9503100004 DECAL; WARNING ................................................. 1 ..... M90310000

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

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

17 M9520100503 DECAL; WARNING ................................................. 1 ..... S/N7100001 TO 7100600;

REPLACES M9510100104

18 M9520100503 DECAL; WARNING ................................................. 1 ..... S/N7100001 TO 7100600;

REPLACES M9510100204

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

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

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

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

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

24 M9520100503 DECAL; WARNING ................................................. 1 ..... S/N7100001 TO 7100600;

REPLACES M9520100104

M9520100503 DECAL; WARNING ................................................. 1 ..... M92010050 M9100601~

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

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

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

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

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

30 M1560100403 STRIPE;WHISPERWATT 1
31 M1560100303 STRIPE; MQ POWER 2
32 M1560100004 STRIPE; 3
33 M1560100504 STRIPE; 25 2
34 M1560100104 STRIPE 1
35 M1560100204 STRIPE 1

PAGE 85 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

ISUZU C240 --- CYLINDER HEAD AND COVER ASSY.

CYLINDER HEAD AND COVER ASSY.

PAGE 86 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

ISUZU C240 --- CYLINDER HEAD AND COVER ASSY.

CYLINDER HEAD AND COVER ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 5111102070 CYLINDER HEAD ASSY. 1
3 1096000051 SEALING CUP, RR FACE D=44 1
3-1 5111290060 SEALING CUP, LOWER D=16 4
3-2 5112190080 SEALING CUP, UPPER D=18 5
3-3 5096000130 SEALING CUP, DRILLED D=12 4
4 9098605220 PLUG; LOWER CYLINDER HEAD PLATE 4
7 5117150230 VALVE SEAT INLET INSERT 4
8 5117110260 VALVE SEAT EXHAUST INSERT 4
9 5117210160 VALVE INLET HEAD GUIDE 4
9-1 5117210160 VALVE EXHAUST HEAD GUIDE 4
11 5111501080 HOT PLUG ASSY. 4
14 5125690060 INLET AND EXHAUST VALVE SEAL 8
16 9041108350 MANIFOLD STUD 3
16-1 9041108400 MAINFOLD STUD 3
16-2 9041108450 MANIFOLD STUD 1
21 5111410690 CYLINDER HEAD GASKET 1
22 5090090530 BOLT 19
29 5111702400 CYLINDER HEAD COVER ASSY. 1
30 9117510381 OIL FILLER CAP 1
31 5111790520 BREATHER NIPPLE 1
49 5111730170 HEAD COVER PACKING 1
51 9111798080 HEAD COVER FIX. PACKING 2
52 9111791320 WAHER 2
54 5090000960 BOLT 2
60 5096050050 CYLINDER HEAD OIL COOLER PLUG 1

PAGE 87 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

CYLINDER BLOCK ASSY.

ISUZU C240 --- CYLINDER BLOCK ASSY.

PAGE 88 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

ISUZU C240 --- CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 5112101771 CYLINDER BLOCK ASSY. 1
2 9098025910 BOLT 10
4 9096640340 PLUG; 1/2 TAPPET CHAMBER 2
4-1 5112190080 SEALING CUP CHAMBER D=18 2
5 5116100010 BEARING KIT; CAM. STANDARD 1
6 5112190180 SEALING CUP RR FACE D=36 1
6-1 5112190170 SEALING CUP RR FACE D=38 1
6-2 5112190150 SEALING CUP LH SIDE D=32 2
6-3 5096000130 SEALING CUP RR FACE D=12 1
6-4 1096000051 SEALING CUP LH SIDE D=45 3
7 9112612300 CYLINDER LINER 4
8 8942505140 PLUG; CAMSHAFT BRIDGE PLATE 1
9 5111290060 PLUG; OIL GALLERY PLATE 2
10 5112210020 DUCT; CYL. BLOCK WATER 1
11-1 5096050161 PLUG; OIL GALLERY 1/8 1
12-1 9992023160 PLUG; OIL GALLERY SCREW 1
13-1 9095714160 PLUG PACKING 1
26 5096500210 INJ. PUMP OIL FEED NIPPLE 1
27-1 9112976500 TAPPET CHAMBER COVER ASSY. 1
28 9113111530 FRONT CYL. BLOCK PLATE 1
29 5113120110 FRONT PLATE PACKING 1
31 9081510240 FRONT PLATE STRAIGHT PIN 2
32 9019008220 BOLT 3
36 9099022990 ROCKER OIL FEED NIPPLE 1
37 9081610320 REAR PLATE STRAIGHT PIN 1
42-1 9019008180 BOLT 12
42-2 9019008220 BOLT 2
43 9099168160 TAPPET CHAMBER COVER CLIP 2

46 5112920110 CHAMBER COVER PACKING ......................... 1 .......... REPLACES 5112920150

47-1 9097040380 WATER DRAIN COCK 1
52 9098785970 CRANK CASE PIN 2
54-2 8942008311 BOLT 1
55 9099138340 PIPE; VINYL WATER DRAIN 1
56 9112290490 CYLINDER BLOCK DOWEL 2
58-2 5117400211 BREATHER AIR ASSY. 1
59 9099210990 BREATHER PACKING 1
64-1 9097130870 PIPE; VINYL BREATHER 1
66 9099152380 CLIP 1
67 9019008180 BOLT 1
69 9091645080 WASHER 1
77 9123631120 SPACER; OIL SEAL 1
78 5096250360 CRANK SHAFT REAR SEAL 1
81 9113411940 REAR CYLINDER BLOCK PLATE 1
84 5090002270 BOLT 3
99 9112581080 OIL PAN BRIDGE CAP PACKING 2
117 5117490340 BREATHER HEAD PACKING 1
120 9019008180 BOLT 2
121 9019608180 BOLT 1
130 9092023080 PLUG; OIL GALLERY SCREW 1
131 9095714080 SCREW PLUG PACKING 1

PAGE 89 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

TIMING GEAR ASSY.

ISUZU C240 ---TIMING GEAR ASSY.

PAGE 90 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

ISUZU C240 --- TIMING GEAR ASSY.

TIMING GEAR ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 5113110282 TIMING GEAR CASE 1
2 9113211480 GEAR CASE COVER 1
3 9099206010 PACKING 1
4 901906140 BOLT 4
8 9113120460 PACKING 2
9 5096250790 OIL SEAL 1
12 9113270450 POINTER 1
14 9113120340 PACKING 1
17 9019108320 BOLT 9

PAGE 91 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

FLYWHEEL HOUSING ASSY.

ISUZU C240 FLYWHEEL HOUSING ASSY.

PAGE 92 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

ISUZU C240 FLYWHEEL HOUSING ASSY.

FLYWHEEL HOUSING ASSY.

NO. PART NO. ITEM QTY. REMARKS

1-5 5113410191 FLYWHEEL HOUSING 1
11 9113430391 COVER 1
12 9019006120 BOLT 6
21 5113490380 STIFFENER; RIGHT SIDE 1
22 5113490370 STIFFENER; LEFT SIDE 1
23 9019110200 BOLT 2
23-1 9019110180 BOLT 2
31 9019310450 BOLT 4
41 9019110350 BOLT 3
41 9010560400 BOLT 1
42 9091104100 NUT 2
46 9091505100 LOCK WASHER 2

PAGE 93 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

OIL PAN ASSY.

ISUZU C240 OIL PAN ASSY.

PAGE 94 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

ISUZU C240 OIL PAN ASSY.

OIL PAN ASSY.

NO. PART NO. ITEM QTY. REMARKS

1-2 5113601832 OIL PAN ASSY. ................................ 1 ................ INCL. ITEMS W/*

3* 5096050050 OIL DRAIN PLUG, 3/8 1
3-1 9992023200 OIL DRAIN PLUG 1
4-1* 9097205600 O RING PACKING 1
6 9112150810 CRANK CASE 1
17 5113670040 OIL CASE PACKING 1
24 9992023160 OIL THERMO PLUG 1
26 9095714160 PLUG PACKING 1
29 9019106160 BOLT 30
31 9112193160 DISTRIBUTION PLATE 1
32 9030906160 SCREW 4
36 9117606090 OIL LEVEL GAUGE 1
42 9019008220 BOLT 16
42-1 9019708450 BOLT 4

51 5117400870 OIL FILLER ASSY. ........................... 1 ................ INCL. ITEMS W/#

52# 5117410100 OIL FILLER 1
53# 5117500021 OIL FILLER CAP 1
56 9099207080 PACKING 1
57 9019008200 BOLT 2

PAGE 95 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

OIL PUMP ASSY.

ISUZU C240 ---OIL PUMP ASSY.

PAGE 96 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

ISUZU C240 ---OIL PUMP ASSY.

OIL PUMP ASSY.
NO. PART NO. ITEM QTY. REMARKS

1 9131008010 OIL PUMP ASSY. ................................. 1 ........... INCL. ITEMS W/*

6* 5131200040 ROTOR SET .......................................... 1 ........... INCL. ITEMS W/#

8*# 9131290170 PIN 1
11*# 9098780840 PIN 1
12* 9131280790 PINION 1
13* 9131130771 COVER 1
14* 9020408250 BOLT 4
15* 9091505080 LOCK WASHER 4
16* 9091505080 LOCK WASHER 4

21* 9131401200 OIL STRAINER ASSY. .......................... 1 ........... INCL. ITEM W/%

22*% 9131430100 OIL STRAINER GAUZE 1
41 9019708250 BOLT 2

PAGE 97 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

PAGE 98 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)

ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

NO. PART NO. ITEM QTY REMARKS

1 5115100211 CRANK BEARING KIT;STD 1
1-1 5115300211 CRANK BEARING KIT;-0.25 1
1-2 5115400211 CRANK BEARING KIT;-0.50 1
2 9115810570 THRUST BEARING 2
3 5121112020 PISTON;STD 4
4 5121210070 PISTON RING SET;STD 4
6 5122110090 PISTON PIN 4
7 5095870010 SNAP RING 8

8-1 5122300390 CONNECTING ROD ASSY. .................... 4 ..................... INCL. ITEMS W/@

9-1@ 5122510050 SMALL END BUSHING 4
11-1@ 512350090 BOLT 8
12@ 5094090160 NUT 8

13 8941422080 CONN. ROD BEARING SET;STD ........... 4 .................... REPLACES 5122710050

13-1 8941631740 BEARING SET;-0.25 4
13-2 8941631750 BEARING SET;-0.50 4

14 8941396690 CRANKSHAFT ASSY. ............................ 1 .................... INCL. ITEM W/#

15# 9081612200 STRAIGHT PIN 1
17 5098010010 RADIAL BALL BEARING 1

25-1 5123301100 FLYWHEEL ASSY. .................................. 1 .................... INCL. ITEM W/%

27% 9123330361 RING GEAR ............................................ 1 .................... Z=108

31 9098785320 STRAIGHT PIN 2
33 5090001461 BOLT 6
34 5123360100 WASHER 1
36 9080307430 FEATHER KEY 1

37 9125210420 CRANKSHAFT GEAR ............................. 1 .................... Z=21

38 9123620390 THROWER 1
60-1 9123736051 CRANKSHAFT PULLEY 1
64-1 9098026060 BOLT 1
67 9123736060 THROWER 1
69 9123790160 WASHER 1

PAGE 99 — DCA-25SSIU — PARTS AND OPERATION MANUAL (STD) — REV. #7 (04/18/12)

OIL AND FUEL FILTER ASSY.

ISUZU C240 --- OIL AND FUEL FILTER ASSY.

PAGE 100 — DCA-25SSIU — PARTS AND OPERATION MANUAL(STD) — REV. #7 (04/18//12)