Multiquip DCA-40SSAI User Manual

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PARTS AND OPERATION MANUAL

MQ POWER

DCA-40SSAI

WHISPERWATT

GENERATOR

PARTS LIST NO.M3340163804

FINAL COPY

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046

E-mail:mq@multiquip.com • www:multiquip.com

SERVICE DEPARTMENT:

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

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

ARAR

TS DEPTS DEP

TS DEP

ARAR

TS DEPTS DEP 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284

SERSER

VICE DEPVICE DEP

SER

VICE DEP

SERSER

VICE DEPVICE DEP 800/835-2551 or 310/537-3700 FAX: 310/638-8046

ARRANTY DEPARRANTY DEP

ARRANTY DEP

ARRANTY DEPARRANTY DEP 800/835-2551 or 310/537-3700 FAX: 310/638-8046

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

ARAR

TMENTTMENT

TMENT

TMENTTMENT

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

MAINMAIN

MAIN

MAINMAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help ................................................... 3

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

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

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

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

Trailer Safety Guidelines ........................................... 11-17

Trailer Wiring Diagram .................................................... 18

Electric Brake Troubleshooting ...................................... 19

Hydraulic Brake Troubleshooting .................................... 20

Operation and Safety Decals.................................... 21-22

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ISUZU 4BD1 ENGINE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

MQ POWER DCA-40SSAI AC GENERATOR

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

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

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

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

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

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

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

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

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

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

NOTE

Specification and part numberSpecification and part number

Specification and part number

Specification and part numberSpecification and part number are subject to change withoutare subject to change without

are subject to change without

are subject to change withoutare subject to change without noticenotice

notice

noticenotice

PARTS ORDERING PROCEDURES

■ Dealer account number

■ Dealer name and address

■ Shipping address (if different than billing address)

■ Return fax number

■ Applicable model number

■ Quantity, part number and description of each part

■ Specify preferred method of shipment:

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

•

Express account number)*

Airborne Express*

•

Truck or parcel post

•

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts:

Number of line items ordered Additional Discount

1-9 items 3%

10+ items** 5%

Get special freight allowances when you order 10 or more line items via FAX!**

■

UPS Ground Service at no charge for freight

■

PS Third Day Service at one-half of actual freight cost

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price) do not count towards the 10+ line items.

Extra Fax Discount

for Domestic USA

Dealers Only

UPS

Special

For faxed orders only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

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

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

RULES FOR SAFE OPERATION

CAUTION:

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

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

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

GENERAL SAFETY

■

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

■

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

■

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

■

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

■

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

■

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

CAUTION

hot

components can cause serious

■

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.

■

NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

Always check the machine for loosened threads or bolts before starting.

■

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

■

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

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

■

NEVER operate the generator in an

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

causing severe

death.

■

Topping-off to filler port is

dangerous, as it tends to spill fuel.

bodily harm or even

PAGE 6 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

RULES FOR SAFE OPERATION

CAUTION

■

NEVER touch output terminals during operation. This is extremely dangerous. contact with the output terminals is required.

CAUTION

■

Backfeed to a utility system can cause electrocution and.or property damage. Do not connect to any building's electrical system except through an approved device or after building main switch is opened.

Always stop the machine when

CAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the

2. Coolant Drain Plug - Removing the coolant drain plug

3. Engine Oil Drain Plug - Removing the engine oil drain

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.

engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

while the engine is hot will result in hot coolant to gush out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

plug while the engine is hot will result in hot oil to gush out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

CAUTION

Never use damaged or worn cables when

connecting power tools or equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient

tightening of the terminal connections may cause damage to the generator and electrical shock.

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

■

Battery

CAUTION

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.

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

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 precautions and operations techniques before using generator.

■

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

■

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

■

DO NOT allow unauthorized people to operate this equipment.

■

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

■

Refer to the technical questions or information.

Loading and Unloading (Crane)

RULES FOR SAFE OPERATION

Isuzu Engine Owner's Manual Isuzu Engine Owner's Manual

Isuzu Engine Owner's Manual

Isuzu Engine Owner's Manual Isuzu Engine Owner's Manual

for engine

■

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.

clothing or skinclothing or skin

clothing or skin

clothing or skinclothing or skin

, rinse skin or clothing

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

■

Always drain fuel prior to lifting.

■

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

■

NEVER lift the machine while the engine is running.

■

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

■

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

■

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

■

When loading the generator on a truck, be sure to use the front and back frame bars as a means to secure the generator during transport.

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

RULES FOR SAFE OPERATION

Transporting

■

Always shutdown engine before transporting.

■

Tighten fuel tank cap securely.

■

Drain fuel when transporting generator over long distances or bad roads.

■

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

■

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

Emergencies

■

Always know the location of the nearest

first aid kitfirst aid kit

and

first aid kit

first aid kitfirst aid kit

Also know the phone numbers of the nearest

doctordoctor

doctor

and

doctordoctor

. Know the location of the nearest telephone.

fire departmentfire department

fire department

fire departmentfire department

fire extinguisherfire extinguisher

fire extinguisher

fire extinguisherfire extinguisher

ambulanceambulance

ambulance

ambulanceambulance

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

■

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

■

Keep the machinery in proper running condition.

■

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

■

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

■

DO NOT use plastic containers to dispose of hazardous waste.

■

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

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

DCA-40SSAI — TOWING AND TRANSPORTATION

Towing Safety Precautions

CAUTION :

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

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

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

■

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

■

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

■

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

■

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

■

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

■

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

■

The maximum speed for highway towing is 45 MPH unless posted otherwise. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain.

■

Place rolling, while parked.

■

Place prevent tipping, while parked.

■

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

■

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

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

underneath wheel to prevent

underneath the trailer’s bumper to

Figure 1. Generator with Trailer

PAGE 10 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — TRAILER-SAFETY GUIDELINES

CAUTION:

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

Explanation of Chart:

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

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



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions with reading Table 1.

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length - This measurement is from the ball hitch to the rear bumper (reflector).

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

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

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

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

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

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

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

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

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches (see Table 3). Please not that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

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

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

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

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

DCA-40SSAI —TRAILER-SPECIFICATIONS

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LEDOM NOITACILPPA LEUF

LLEC

W01-RLRT ,522WDS

003WLT,052WGS

01-RLRT ,21GLT,01ACD

51-ACD

FX01-RLRT ,21-GLT,01ACD

003-WLT,51ACD

W522-RLRT ,SREDLEW

SS0007AD

004WLB-RLRT 004-WLBONCIRTCELESBL0072"451TSAM/W

X05-RLRT 52-ACDONONSBL0072"421"55.BL008

FX05-RLRT 52-ACDLAG14ONSBL0072"421"55.BL008

W07-RLRT 07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002

X07-RLRT 07,06-,54-ACDTPOEGRUSSBL0007"831"66.BL0002

FX07-RLRT 07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002

FX001-RLRT 521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002

521/58-RLRT ,001,58-ACD

521

FX051-RLRT 081,051-ACDLAG002EGRUSCILUARDYHSBL06111"402"48.BL0005

FX022-RLRT 022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005

FX003-RLRT 003-ACDLAG052EGRUSCILUARDYHSBL00081"832"38.BL0005

FX004-RLRT 004-ACDLAG053CIRTCELESBL00081"832"38.BL0005

FX006-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

XS008-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

ONONSBL0091"69"05.BL008

LAG25ONSBL0091"69"05.BL008

ONONSBL0022"58"24.BL008

LAG541CILUARDYHSBL00001"681"77.BL0002

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

DCA-40SSAI —TRAILER-SPECIFICATIONS

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LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE

W01-RLRT SSALCLLAB"2

ELBATSUJDA2

01-RLRT SSALCLLAB"2

ELBATSUJDA2

FX01-RLRT SSALCLLAB"2

ELBATSUJDA2

W522-RLRT SSALCLLAB"2

ELBATSUJDA2

WLB-RLRT

004

X05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

FX05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

W07-RLRT SSALCLLAB"2

X07-RLRT SSALCLLAB"2

FX07-RLRT SSALCLLAB"2

FX001-RLRT 6/5-2ELBATSUJDA

SSALCLLAB"2

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ELBATSUJDA"3

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C31-571"05.4X"312X2#0022GUL5FAEL3/WMOOLERIW4

C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4

B31-571"5.4X312X2#0022GUL5XELFQTALFELOP4

C31-571"5.4X312X2#0022GUL5FAEL3TALFELOP4

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)4(SAIB

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"7X"61sbl0006-)2(GUL8XELFQMOOLERIW4

"7X"61.sbl0007-)3(GUL8XELFQMOOLERIW4

"7X"61sbl00001-)3(GUL8FAEL7MOOLERIW6

"7X"61sbl00001-)3(GUL8EDIR-RIAMOOLERIW6

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

DCA-40SSAI —TRAILER SAFETY GUIDELINES

Brakes

If your trailer has a braking system, the brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to hydraulic brakes. The basic difference is that hydraulic brakes are actuated by an electromagnet. Listed below are some of the advantages that electric brakes have over hydraulic brakes:



Brake system can be manually adjusted to provide

the corrected braking capability for varying road and load conditions



Brake system can be modulated to provide more or

less braking force, thus easing the brake load on the towing vehicle



Brake system has very little lag time between the time

the vehicle’s brakes are actuated and the trailer’s brakes are actuated



Brake system can provide an independent emergency

brake system

Remember in order to properly synchronize the tow vehicle’s braking to the trailer’s braking, can only be accomplished by road testing. Brake lockup, grabbiness or harshness is due to lack of synchronization between the tow vehicle and the trailer being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be made, the trailer brakes should be burnished-in by applying the brakes 20-30 times with approximately a 20 m.p.h. decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for brakes to cool between application. This allows the brake shoes to slightly be seated into the brake drum surface.

Figure 2 displays the major electric brake components that will require inspection and maintenance. Please inspect these components as required.

Electric Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer to the ground.

8. Repeat steps 1 through 6 on the remaining brakes.

PAGE 14 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — TRAILER SAFETY GUIDELINES

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. These brakes can be adjusted in the same manner as electric brakes. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 3 below displays the major hydraulic/air/surge brake components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 6 as referenced in the electric brake adjustments section.

Figure 3. Hydraulic Brake Components

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

DCA-40SSAI — TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

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

CAUTION:

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

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

Tire Wear/Inflation

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

Suspension

The leaf suspension springs and associated components (Figure 4) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components as detailed in Table 3.

CAUTION:

NOTE

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

PAGE 16 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

Figure 4. Major Suspension Components

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TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

DCA-40SSAI —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 5. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 4.

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

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Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

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

DCA-40SSAI —TRAILER-WIRING DIAGRAM

NOTE:

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

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

DCA-40SSAI —TRAILER-BRAKE TROUBLESHOOTING

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

DCA-40SSAI —TRAILER-BRAKE TROUBLESHOOTING

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

DCA-40SSAI — GENERATOR DECALS

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

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

DCA-40SSAI — GENERATOR DECALS

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

DCA-40SSAI — SPECIFICATIONS

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

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DCA-40SSAI — GENERAL INFORMATION

DCA-40SSAI FAMILIARIZATION

Generator

genergener

The MQ Power Model DCA-40SSAI is a 26 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 Speed Control

Pre-Heat Button

Panel Light

Panel Light Switch

Starter /Preheat Switch

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

Voltage Regulator

Output Terminal Panel

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

gener

genergener

atorator

ator

atorator

Open Delta Excitation System

The DCA-40SSAI 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

The DCA-40SSAI is powered by a 4 cycle, water cooled, Isuzu 4BD1 every performance requirement for the generator. Reference Table 7, page 23 for engine specifications.

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

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

Open-DeltaOpen-Delta

Open-Delta

Open-DeltaOpen-Delta

utomatic utomatic

utomatic

utomatic utomatic

diesel diesel

diesel

diesel diesel

" excitation system. The open delta

engine. This engine is designed to meet

oltage Regulator oltage Regulator

oltage Regulator

oltage Regulator oltage Regulator

fixed ceilingfixed ceiling

fixed ceiling

fixed ceilingfixed ceiling

(AVR) is supplied

" and responds

Two 120V, 20A receptacles

Two 240V, 20A receptacles

One twist-lock 120V, 50A receptacle

50A and 30A circuit breakers

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 100 amps

Over-Current Relay

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

Mechanical Governor System

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

NOTE PAGE

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

DCA-40SSAI — MAJOR COMPONENTS

Figure 6. Major Components

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

DCA-40SSAI — DIMENSIONS

Figure 7. Dimensions

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

DCA-40SSAI — CONTROL PANEL DESCRIPTION

Figure 8. Control Panel

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

DCA-40SSAI — CONTROL PANEL DESCRIPTION

The definitions below describe the controls and functions of the DCA-40SSAI "

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

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

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

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

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

6. Ammeter Change-Over Switch – This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off.

Control Panel Control Panel

Control Panel

Control Panel Control Panel

" (Figure 8).

7. Voltmeter Change-Over Switch – This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

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

DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION

Figure 9. Engine Operating Panel

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

DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION

The definitions below describe the controls and functions of the DCA-40SSAI "

1. Fuel Gauge - Indicates amount of diesel fuel available.

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

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

3. Charging Ammeter Gauge – Indicates the current being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

Engine Operating Panel Engine Operating Panel

Engine Operating Panel

Engine Operating Panel Engine Operating Panel

" (Figure 9).

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

5. Oil Pressure Gauge – Normal operation should be about 25 psi. When starting the generator the oil pressure may read a bit higher, but after the engine warms up the oil pressure should return to normal.

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

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

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

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

10. Panel light - Normally used in dark places or at night. When activated, panel will luminate. When the generator is not in use, turn the panel light switch to the ‘OFF’ position.

to 215o.

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

DCA-40SSAI — OUTPUT TERMINAL PANEL

Output Terminal Panel

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

120 Volt Receptacle

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

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

Twist Lock Dual Voltage Receptacles - To use these receptacles, place the voltage selector switch in the single phase 240/120 voltage position and adjust the output voltage to 240 volts with the voltage regulator on the Control Panel (Figure 8, page 28). Place the voltmeter change-over switch to the U-W position and the ammeter change-over switch to the U or W to read the output.

Connecting Load

Loads can be connected to the generator by the UVWO lugs or the duplex receptacles. (See figure 3). Make sure to read the operation manual before attempting to connect a load to the generator.

Circuit Breakers

Figure 10. GFCI Test Button

Generator Grounding

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

To protect the generator from an overload,

main main

main

circuit breaker is provided to protect the UVWO output

main main

terminals from overload. In addition two single-pole, 20 amp

GFCIGFCI

GFCI

circuit breakers are provided to protect the GFCI

GFCIGFCI

receptacles from overload. Three 50 amp 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.

Maximum Output

The entire load connected to the UNV Lugs, all four slots in the duplex receptacles, and the must not exceed 37.4 kW in standby or 36 kW in prime output.

Generator Grounding

Make sure to ground the generator in EVERY application prior to connecting a load. Generators are NOT grounded just because they are mounted on trailers or other vehicles that are on rubber tires. See page X for further details.

Figure 11. Load Application

a 3-pole, 110 amp,

loadload

load

loadload

ALLALL

ALL

ALLALL

circuit

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

DCA-40SSAI — OUTPUT TERMINAL VOLTAGE SELECTION

DCA-40SSAI

NOTE

Legs O and Ground are considered Bonded Grounds.

Figure 12. Output Panel Location

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

DCA-40SSAI — OUTPUT AMPERAGE SETUP

Output Terminal Panel Available Voltages

A wide range of voltages are available to supply load to many different applications. Voltages may be selected by using the voltage selector switch and depending how you hookup your hard wire connection to the generator. To obtain some of the voltages listed, fine adjustment with the voltage regulator on the control panel is necessary. See Table 8 for available voltages the generator will supply.

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TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

Over Current Relay

An over current relay is connected to the circuit breaker. During an over current situation, both the circuit breaker and the over current relay will trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located inside the control box.

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CAUTION :

Maximum Amps

NEVER switch Voltage Selector Switch

position while the engine is engaged.

Voltage Selector Switch Locking Button

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

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

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

DCA-40SSAI — OUTPUT AMPERAGE SETUP

Receptacle Use

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

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Figure 13. Voltage Selector Switch 240/120V Single

Phase Position

54620

9.048.422.1

7.636.324.2

6.234.226.3

4.822.128.4

Figure 14 and 15. AC Voltmeter Change-over switch

How To Read The Output Terminal Gauges.

The gauges (Figure 15 and 17) and change-over switches on the control panel DO NOT effect the generator output. They are to help observe how much power is being supplied at the UVWO legs.

When the voltage selector switch is in the 240/120V posi-

Figure 16 and 17. AC Ammeter Change-over Switch

tion (Figure 13), place the AC voltmeter change-over switch to the W-U position (Figure 14) and the AC ammeter changeover switch to the U or W position (Figure 16) to read the output on the selected leg.

and Voltmeter Gauge

and Ammeter Gauge

NOTE

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

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

DCA-40SSAI — OUTPUT VOLTAGE SETUP

240/120V Hard Wire Hookup

With the voltage selector set and locked at ‘single phase 240/120’ and using single phase 120 volts, the generator will provide three legs available with 100 amps each on three different circuits (Figure 18).

480/240V Hard Wire Hookup

With the voltage selector set and locked at ‘3 phase 480/ 277’ (Figure 19) and using the 3-phase 240 hookup, it will provide one circuit available at 108 amps with any two wires plus the ground (Figure 20).

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

Figure 18. Hard Wire Hookup at 240/120V Position

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

Position

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

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

DCA-40SSAI — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- 3 Phase 480/277V Position

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

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

This setting can provide single phase power at 480, 440, or 416 volts. After hooking up the hard wires to the lugs as shown in Figure 23, 480 volts can be obtained with the voltage regulator knob turned toward maximum; 440 volts can be obtained with the voltage regulator knob is turned down; and 416 volts can be obtained with the voltage regulator knob is at the lowest setting.

Figure 21. Voltage Regulator Knob

3 Phase, 480V, 440V, or 416 Volt

This setting can provide 3-phase power at 480, 440, or 416 volts. After hooking up the hard wires to the lugs as shown in Figure 22, 480 volts can be obtained with the voltage regulator knob turned toward maximum; 440 volts can be obtained with the voltage regulator knob is turned down; and 416 volts can be obtained with the voltage regulator knob is at the lowest setting.

Figure 23. Hard Wire Hookup for Single Phase 480V, 440V,

or 416V

Figure 22. 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 24, 277 volts can be obtained with the voltage regulator knob turned toward maximum; 254 volts can be obtained with the voltage regulator knob is turned down; and 240 volts can be obtained with the voltage regulator knob is at the lowest setting.

Figure 24. Hard Wire Hookup for Single Phase 277V, 254V,

or 240V

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

DCA-40SSAI — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- 3 Phase 240/139V Position

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

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

This setting can provide single phase power at 240, 220, or 208 volts. After hooking up the hard wires to the lugs as shown in Figure 27, 240 volts can be obtained with the voltage regulator knob turned toward maximum; 220 volts can be obtained with the voltage regulator knob is turned down; and 208 volts can be obtained with the voltage regulator knob is at the lowest setting.

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

Figure 25. 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 26, 240 volts can be obtained with the voltage regulator knob turned toward maximum; 220 volts can be obtained with the voltage regulator knob is turned down; and 208 volts can be obtained with the voltage regulator knob is

This setting can provide single phase power at 139, 127, or 120 volts. After hooking up the hard wires to the lugs as shown in Figure 28, 139 volts can be obtained with the voltage regulator knob turned toward maximum; 127 volts can be obtained with the voltage regulator knob is turned down; and 120 volts can be obtained with the voltage regulator knob is at the lowest setting.

at the lowest setting.

Figure 26. Hard Wire Hookup for Three Phase 240V, 220V, or

208V

Figure 28. Hard Wire Hookup for Single Phase 139V, 127V,

or 120V

PAGE 38 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- Single Phase 240/120V Position

The following are additional voltages available when the voltage selector switch is in the ‘single phase 240/120V’ posi- tion.

Figure 29. 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 31, 120 volts can be obtained with the voltage regulator knob turned to fine tune.

Figure 31. Hard Wire Hookup for Single Phase, 120 volt

Single Phase, 240 Volt

This setting can provide single phase power at 240 volts. After hooking up the hard wires to the lugs as shown in Figure 30, 240 volts can be obtained with the voltage regulator knob turned to fine tune.

Figure 30. Hard Wire Hookup for Single Phase 240 volt

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

DCA-40SSAI — INSTALLATION

Outdoor Installation

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

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

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

CAUTION :

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

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.

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.

2. When grounding the generator (Figure 31) connect the ground cable between the lock washer and the nut on

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.

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.

NOTE

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

DCA-40SSAI — INSTALLATION

Figure 31. Typical Generator Grounding Application

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

DCA-40SSAI — PRE-SETUP

General Inspection Prior to Operation

The DCA-40SSAI generator has been thoroughly inspected and accepted prior to shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts, which could have occurred in transit.

Extension Cable

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the Cable Selection Guide (Table 11 ) as a guide for selecting proper cable size.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 100 amp,

main main

main

circuit breaker is provided to protect the UNV output

main main

terminals from overload. In addition two single-pole, 20 amp

GFCIGFCI

GFCI

circuit breakers are provided to protect the GFCI

GFCIGFCI

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.

loadload

load

circuit breakers

loadload

ALLALL

ALL

circuit

ALLALL

NOTE

ALWAYS consult with a licensed

electrician for correct extension cord wire size.

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

DCA-40SSAI — PRE-SETUP

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but do not overfill. Make sure the generator is level. With the dipstick inserted all the way, but without being screw into the filler hole, verify that the oil level is maintained between the two notches (Figure 32) on the dipstick. See Table 12 for proper selection of engine oil.

Fuel

Fill the 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 23 Specification Table 7.

The fuel tank cap must be closed tightly after fillin fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

CAUTION :

to prevent fire hazards.

Coolant

diesel fueldiesel fuel

diesel fuel

diesel fueldiesel fuel

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

. DO NOT

g. Handle

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 32. Engine Oil Dipstick

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

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

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

DCA-40SSAI — PRE-SETUP

CAUTION :

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

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

13. for engine, radiator, and reserve tank coolant capacities. Make sure the coolant level in the reserve tank is always between the "H" and the "L" markings.

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Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 14) 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 Isuzu Engine Owner's Manual.

Fan Belt Tension

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

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 33) 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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CAUTION :

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

Adjusting Fan Belt

If the fan belt does not have the 10 to 15 mm defection follow the procedure below to adjust: Loosen the alternator adjusting plate and alternator mounding bolt. Pivot the alternator at the mounting bolt toward the engine left or right until the belt reflects the proper tension. Tighten the mounting bolt and the adjusting bolt.

PAGE 44 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — PRE-SETUP

Battery

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

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

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

Battery Cable Installation ALWAYS be sure the battery cables (Figure 34) 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.

REDRED

RED

REDRED

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 :

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.

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

Figure 34. Battery Connections

Alternator

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

Do not put water directly on the alternator. Entry of water into the alternator leads an electrolyte corrosion causing an alternator failure.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

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

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

DCA-40SSAI — LOAD APPLICATION

Single Phase Load

CAUTION

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

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

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.

the wattage is influenced by the efficiency, power factor and starting system of the equipment.

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)

NOTE

multiplied by 0.6 can be used.

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

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 The power factor of this generator is 1.0. See Table 15. below when connecting loads.

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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

Three Phase Load

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

PAGE 46 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — GENERATOR START-UP PROCEDURE

WARNING:

The engine's exhaust contains harmful

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ventilate the

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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 12 on page 43).

3. Check the coolant level in the radiator and subtank. Replenish with antifreeze as necessary. Always maintain the coolant level between the FULL and LOW markings on the coolant container. Be sure that the radiator cap is fastened securely.

ALAL

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

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

CAUTION:

NEVER start the engine with the

main,main,

GFCI GFCI

main,

GFCI

main,main,

GFCI GFCI

in the ON position.

1. Be sure to disconnect the electrical load and switch the circuit breakers (Figure 35) to the “OFF” position prior to starting the engine.

loadload

load

circuit breakers

loadload

main, load main, load

main, load

main, load main, load

and

G.FG.F

G.F

G.FG.F

.C.C

.I..I.

.I.

.I..I.

Figure 36. UNV Terminal Lugs (Load)

negative post on the battery (Figure 37).

NEGATIVE

POSTIVE

BATTERY

Figure 37. Battery Connections

Figure 35. Main, GFCI and

Load Circuit Breakers

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

DCA-40SSAI — GENERATOR START-UP PROCEDURE

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

Figure 38. Engine Enclosure Doors

8. Once the engine is warm and the engine is

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

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

Figure 39. Voltage Selection Switch

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

Figure 42. Engine Speed Switch (high)

the 60 cycle output frequency in HERTZ.

Figure 43. Frequency Meter (Hz)

6. Turn and push the engine throttle control lever

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

(Figure 40) to ‘Low’.

Figure 40. Engine Throttle Control Lever (low)

7. Preheat the engine by turning the ignition key to the left. Once the preheat lamp luminates, turn the key to the farthest right to start the engine. Once the engine start to crank, release the key to ‘operation’ (Figure 41).

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)

Figure 41. Starter Switch

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

Figure 45. Voltage Adjust Control Knob

DCA-40SSAI — GENERATOR START-UP PROCEDURE

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

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

Figure 46. Ammeter (No Load)

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

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

Figure 49. Engine Tachometer

Figure 47. Oil Pressure Gauge

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

Figure 50. Main and GFCI Circuit Breakers

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

16. Observe the generator's ammeter (Figure 51) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if the load is in use.

WATER

Figure 48. Coolant Temperature Gauge

TEMP

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

Figure 51. Ammeter (Load)

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

DCA-40SSAI — GENERATOR SHUTDOWN PROCEDURE

ENGINE SHUTDOWN

To shutdown the generator, use the following procedure:

1. Switch both the MAIN, GFCI and LOAD circuit breakers (Figure 52) to the “OFF” position.

Figure 52. Main, GFCI and Load

circuit breakers

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

53) to the idle (low) position.

Figure 53. Engine Throttle Control Lever

EMERGENCY STOP

1. To stop the engine in the event of an emergency, switch the MAIN, GFCI and LOAD circuit breakers to ‘OFF’ position.

2. Turn the starter switch key to ‘Stop’ position.

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

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

54).

Figure 54. Off/Manual Auto Switch

5. Remove the load from the UNV terminal strip.

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

NOTE PAGE

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

DCA-40SSAI — MAINTENANCE

General Inspection

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

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

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

The air cleaner is equipped with an indicator. After the dirty air cleaner has been replaced, press the dust indicator button to reset the indicator.

Fuel Addition

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

Removing Water from the Fuel Tank

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

Air Removal

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

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

Service Daily

Cleaning the Fuel Strainer

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

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 32, page 43.

Replacing Oil Filter

Detach the oil filter cartridge with a filter wrench. Apply a film of oil to the gasket for the cartridge. Screw in the cartridge by hand. When the gasket is in

contact with the seal surface, tighten the cartridge one or two more times by hand.

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

Replacing Fuel Filter

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

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

Vent any air.

Fuel Injection Nozzle

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

Abnormal fuel consumption will lead to a lowered output and blackish exhaust smoke. The required injection starting pressure should be 14.7MPa (150kg/cm2, 2130psi).

If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber in high fuel consumption.

PAGE 52 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — MAINTENANCE

Feed Pump Strainer Cleaning

The strainer is incorporated in the feed pump inlet side joint bolt. Clean the strainer with compressed air and rinse it in the fuel oil.

Flushing Out Radiator and Replacing Coolant

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

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

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

Tighten both cocks and replace the overflow tank. Replace with coolant (see page 44, Table 14 for mixture). Close radiator cap tightly.

CAUTION :

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

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

DCA-40SSAI — MAINTENANCE

Valve Clearance Check

1. In order to bring No. 1 or No. 4 cylinder to top dead center in the compression stroke, align the notched line on the crank pulley with TDC mark on the timing gear case cover.

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

3. After adjustment started from either piston top center, turn the crankshaft 360

to align the notched line with the TDC mark to do the adjustment again on the remaining valve. See Table 16 and Figure 55 for valve

3. Remove the timing check hole cover at the front of injection pump to check the alignment between the pointer “a” on the injection pump gear lock plate and the projected area mark “b” on the timing gear case.

4. If “a” and “b” are in alignment, the timing is set correctly. If not, follow nos. 1-3 until the “a” and “b” are aligned.

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

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

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

arrangement.

8. Delivery valve holder tightening torque: 39~44Nm(29~33lbft.)

Injection Timing Check and Adjustment

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

2. Turn the crankshaft pulley clockwise (viewed at engine front) and align the notched line on the crank pulley with the TDC mark on the timing gear case cover.

9. Slowly turn the crankshaft pulley clockwise and at the same time continue to feed the fuel with pumping the Feed pump. When the fuel stop to flow out from No. 1 delivery valve holder, stop pumping.

10. Observe and make sure which mark (injection starting angle line) on the timing gear case cover is aligning with the notched line on the crank pulley.

crank angle.

Figure 55. Valve Adjustment

NOTE:

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

11. The timing line shows the injection starting crank angle of the engine.

12. The injection starting crank angle should be at the 14

timing mark.

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

DCA-40SSAI — MAINTENANCE

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Generator Storage

For storage of the generator for over 30 days, the following

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

DCA-40SSAI — ENGINE WIRING DIAGRAM

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

DCA-40SSAI — GENERATOR WIRING DIAGRAM

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

DCA-40SSAI — TROUBLESHOOTING (ENGINE)

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

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.redlohelzzondnagulp

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

DCA-40SSAI — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)2TRAP(GNITOOHSELBUORTENIGNE.71ELBAT

esooloteudkaelleuF

?tungniniaterepipnoitcejni

pmupnoitcejnI

?gninoitcnuflam

.htooms

tonsinoituloverenignE

?erusserp

?deggolc

.devresbosisag

tsuahxeeulbroetihwrehtiE

?kcutsro

?daolrevO .daolehtnesseL

gninepoelzzontcerrocnI

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?gninoitcnuflamronrevoG .riapeR

?lioenigneevissecxE .leveldeificepsehtotecudeR

nrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

.tunnethgiT

.ecalperroriapeR

.tsujdA

.ecalperroriapeR

.naelC

.ecalperroriapeR

?desuleufedargwoL .leufdeificepsehtesU

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

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

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

strapgnivoms'enignE

?gniziesebotmees

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?kaelnoisserpmoC

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.redlohelzzondnagulp

wolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

DCA-40SSAI — TROUBLESHOOTING (GENERATOR/ENGINE)

GNITOOHSELBUORTROTARENEG.71ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

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?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

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?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

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

NOTE PAGE

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 61

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column Serial Numbers-Where indicated, this indicates a serial

number range (inclusive) where a particular part is used. Model Number-Where indicated, this shows that the

corresponding part is utilized only with this specific model number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column, *, #, +, or %, belong to the same assembly or kit.

Note: If more than one of the same reference number is listed, the last one listed indicates newest (or latest) part available.

PAGE 62 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

DCA-40SSAI — SUGGESTED SPARE PARTS

DCA-40SSAI DCA-40SSAI

DCA-40SSAI

DCA-40SSAI DCA-40SSAI 1 1

O 3 UNITSO 3 UNITS

O 3 UNITS

1 1

O 3 UNITSO 3 UNITS

Qty. P/N Description

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

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

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

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

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

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

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

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

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

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

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

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

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

1 ......... 8970208220 .............. FAN BELT

1 ......... 1823100080 .............. STARTER SWITCH

3 ......... KEYISUZUF .............KEY, STARTER SWITCH

W/ISUZU 4BD1 DIESEL ENGINEW/ISUZU 4BD1 DIESEL ENGINE

W/ISUZU 4BD1 DIESEL ENGINE

W/ISUZU 4BD1 DIESEL ENGINEW/ISUZU 4BD1 DIESEL ENGINE

NOTE

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this

book.

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

GENERATOR ASSY.

DCA-40SSAI --- GENERATOR ASSY.

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

DCA-40SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3341040300 FIELD ASSY. 1 1-1 3341010102 SHAFT 1 1-2 9521002693 FIELD CORE 1 1-3 3341080003 FIELD COIL 1 1-4 3361032003 ARMATURE CORE, EXCITER 1 1-5 33610850003 ARMATURE COIL, EXCITER 1 1-6 334110003 COUPLING HUB 1 2 3361025003 RECTIFIER ASSY. 1 2-1 3361026003 SET PLATE, RECTIFIER 1

2-2 0601820067 RECTIFIER .......................................... 3 ............PB2510

2-3 0010004020 HEX. HEAD BOLT 3 2-4 0041604000 PLAIN WASHER 6 2-5 0040004000 LOCK WASHER 3

2-6 OEMAA8 HEX. NUT ............................................. 3 ............REPLACES 0030004000

2-7 0601822601 SURGE ABSORBER ........................... 1 ............ERZM14K621A

2-8 0801841004 INSULATOR WASHER 1 2-9 0801841104 INSULATOR WASHER 1

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

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

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

2-13 0030005000 HEX. NUT 1

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

3 3331014004 BEARING FLANGE 1 4 0070206310 BEARING 1 5 0080000050 SNAP RING 1 6 3341070002 FAN 1 7 3341611003 COUPLING DISK 1(8) 8 3341612003 WASHER, COUPLING HUB 1 9 3341613004 LOCK WASHER 5

10 0131151240 HEX. HEAD BOLT ................................ 10 .......... REPLACES 0010312030

11 0601600000 COUPLING RING ................................ 1 ............9261290050

12 030212300 LOCK WASHER ................................... 9 ............ REPLACES 0601610700 & 9091505100

13 0601610511 BOLT SET 1 14 0040010000 LOCK WASHER 9

15 012010030 HEX. HEAD BOLT ................................ 9 ............REPLACES 0010310030

16 3341341400 STATOR ASSY. 1 16-1 3341320312 GENERATOR FRAME 1 16-2 3801342114 ARMATURE CORE 1 16-3 3341361503 ARMATURE COIL 1 17 0801350104 GROMMET 1 18 3361315013 END BRACKET 1 19 3361350030 FIELD ASSY. EXCITER 1 19-1 3361352023 FIELD CORE, EXCITER 1 19-2 3361362303 FIELD COIL, EXCITER 1

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

GENERATOR ASSY.

DCA-40SSAI --- GENERATOR ASSY.

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

DCA-40SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

20 031108160 PLAIN WASHER .................................. 4 ............REPLACES 0041608000

21 0040008000 LOCK WASHER 4 22 0010008060 HEX. HEAD BOLT 4 23 0040010000 LOCK WASHER 6

24 012010030 HEX. HEAD BOLT ................................ 6 ............REPLACES 0010010030

25 3801312004 GASKET, BEARING 1 26 3331310104 COVER, BEARING 1 27 0040006000 LOCK WASHER 4 28 0040006055 HEX. HEAD BOLT 4 29 3361331003 COVER, END BRACKET 1

30 011006010 HEX. HEAD BOLT ................................ 8 ............REPLACES 0017106010

31 0040010000 LOCK WASHER 6

32 0105091025 HEX. HEAD BOLT ................................ 6 ............ REPLACES 0010310025

33 3361332003 COVER, FAN 1

34 952404470 PLAIN WASHER .................................. 1 ............REPLACES 0041606000

35 0040006000 LOCK WASHER 1 36 0010006030 HEX. HEAD BOLT 1 37 0605000011 RUBBER SUSPENSION 2 38 0040016000 LOCK WASHER 4

39 020316130 HEX. NUT ............................................. 4 ............REPLACES 0030116000

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

CONTROL BOX ASSY.

DCA-40SSAI --- CONTROL BOX ASSY.

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

DCA-40SSAI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 7451810002 CONTROL BOX ............................................. 1 ....... UP TO S/N3311949

7451810012 CONTROL BOX ............................................. 1 ....... S/N3311950

2 3361870603 CURRENT TRANSFORMER 3 3 0017106016 HEX.HEAD BOLT 6

4 0601801142 CURRENT TRANSFORMER, AMMETER ..... 2 ....... CT3.5MR 75/5A

5 0027104010 MACHINE SCREW 4

6 0800225200 AUTOMATIC VOLTAGE REGULATOR ........ 1 ....... AE2206A

7 0027106010 MACHINE SCREW 6 8 0601820042 RECTIFER 1 9 0027103010 MACHINE SCREW 4

10 0601842058 RESISTOR .................................................... 1 ....... 80V 200OHMS

11 0027108010 MACHINE SCREW 2

14 0601804970 CIRCUIT BREAKER ...................................... 1 ....... TO100CC 500V 100AT

15 0041604000 PLAIN WASHER 2 16 0040004000 LOCK WASHER 2 17 0021004060 MACHINE SCREW 2 18 0601830625 CHANGE-OVER SW. VOLTAGE 1 19 0021104016 MACHINE SCREW 4 20 0021104014 MACHINE SCREW 2 21 3341822503 CONTROL PANEL 1

22 0601800460 FREQUENCY METER ................................... 1 ....... PAK60 220V 45~65Hz

23 0601800729 AC AMMETER .............................................. 1 ....... PSK60 0~75A 0~150A

24 0601801040 CHANGE-OVER SW. AMMETER ................. 1 ....... SL2AS

25 0601800212 AC VOLTMETER .......................................... 1 ....... PCK60 0~600V; REPLACES

0601800217

26 0601801041 CHANGE-OVER SW. VOLTMETER ............. 1 ....... SL2VS

27 0601810072 PILOT LAMP 1

0601810261 BULB 1

28 0601840031 VOLTAGE REGULATOR .............................. 1 ....... RA30A2FE202BJ

29 0601840120 KNOB 1 30 3331824003 STOPPER, CONTROL PANEL 1 31 0027105016 MACHINE SCREW 2 32 0030005000 HEX. NUT 2 33 0805001304 SET SCREW, CONTROL PANEL 2

34 031108160 PLAIN WASHER ........................................... 2 ....... REPLACES 0041608000

35 020108060 HEX. NUT ...................................................... 2 ....... REPLACES 0030008000

36 0027105010 MACHINE SCREW 4

37 7451826504 SIDE PANEL, CONTROL BOX ..................... 1 ....... UP TO S/N3311949

7451826514 SIDE PANEL, CONTROL BOX ..................... 1 ....... S/N3311950~

38 0017106016 HEX. HEAD BOLT 2

39 011008020 HEX. HEAD BOLT ......................................... 4 ....... REPLACES 0017108020

40 020108060 HEX. NUT ...................................................... 4 ....... REPLACES 0030008000

41 0601840191 SWITCH CAP 1 42 0601830614 PLATE 1

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

ENGINE AND RADIATOR ASSY.

DCA-40SSAI ENGINE AND RADIATOR ASSY.

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

DCA-40SSAI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY. NO. PART NO. ITEM QTY. REMARKS

1 4B01PD02 ENGINE .......................................... 1 .......... ISUZU 4BD1; REPLACES 0602000078

2 0602010800 RADIATOR ...................................... 1 .......... B961110002

3 0602011303 RADIATOR NECK ........................... 1 .......... 4079111300

4 0602011102 HOSE .............................................. 1 .......... B9611111910

5 0602014062 HOSE BAND ................................... 2 .......... G000100131

6 0602011000 RADIATOR CA ................................ 1 .......... 7880K11100

7 3345123104 BRACKET, RADIATOR 2

8 011008020 HEX. HEAD BOLT ........................... 12 ........ REPLACES 0017108020

9 0602013086 RADIATOR HOSE ........................... 1 .......... 4B128

10 0602013186 RADIATOR HOSE ........................... 1 .......... 4B129

11 0602014000 HOSE BAND 2 12 0602014000 HOSE BAND 1 13 0602014071 HOSE BAND 1

14 0602040094 AIR CLEANER ................................ 1 .......... FQG068002

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

15 0602040690 DUST INDICATOR ........................... 1 .......... RBX002252

16 0602040595 BAND, AIR CLEANER .................... 2 .......... P007191

17 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

18 020108060 HEX. NUT ....................................... 4 .......... REPLACES 0030008000

19 3342032103 HOSE, AIR CLEANER 1 20 0605515011 HOSE BAND 1 21 0605515028 HOSE BAND 1

22 1878102201 ELEMENT, OIL FILTER .................. 1 .......... REPLACES 0602041107

23 5878100500 ELEMENT, FUEL FILTER ............... 1 .......... REPLACES 0602042108

24 3345112503 ENGINE FOOT 1 25 3345112403 ENGINE FOOT 1

26 031110160 PLAIN WASHER ............................. 8 .......... REPLACES 0041610000

27 0040010000 LOCK WASHER 8

28 0105091025 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010710025

29 0605000009 RUBBER SUSPENSION 2 30 0040012000 LOCK WASHER 4

31 0039312000 HEX. NUT ....................................... 4 .......... REPLACES 0030112000

32 1819001931 ENGINE STOPPER ........................ 1 .......... REPLACES 0602210803 AND 1819000161

33 0027106016 MACHINE SCREW 3

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

ENGINE AND RADIATOR ASSY.

DCA-40SSAI ENGINE AND RADIATOR ASSY.

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

DCA-40SSAI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY. NO. PART NO. ITEM QTY. REMARKS

34 3342054104 DRAIN JOINT 1 35 0805013704 PACKING, OIL PAN SIDE 1 36 0805014204 PACKING 1 37 3362054104 JOINT BOLT 1 38 3342051104 DRAIN JOINT 1 39 0802024004 PACKING 1 40 0802010204 PLUG 1 41 3342022104 DRAIN HOSE 1 42 0605515003 HOSE BAND 2

43 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

44 020108060 HEX. NUT ....................................... 2 .......... REPLACES 0030008000

45 0845031303 RESERVE TANK 1 46 0802081104 CAP, RESERVE TANK 1 47 3342082304 BRACKET, RESERVE TANK 1

48 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

49 011606025 HEX. HEAD BOLT ........................... 1 .......... REPLACES 0017106025

50 0199500950 HOSE 1 51 0199500175 HOSE 1 52 0193601000 HOSE 1 53 0605515013 HOSE 1 53 0605515013 HOSE BAND 4 54 0193900750 BREATHER HOSE 1 55 0605515030 HOSE BAND 2 56 0193100700 HOSE 1 57 0605515007 HOSE BAND 1 58 0193800750 HOSE 1 59 0605515019 HOSE BAND 1 60 3342220604 EARTH CABLE 1 61 0017106016 HEX. HEAD BOLT 4

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

ENGINE OPERATING PANEL ASSY.

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

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

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

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

1 3342101003 OPERATING PANEL 1 2 7452142004 SLIDE BAR 1

3 0601840190 KNOB .............................................. 1 .......... REPLACES 0805012904

4 0080200006 SNAP RING 1 5 7452140504 BRACKET, GOVERNOR ROD 1

6 020108060 HEX. NUT ....................................... 2 .......... REPLACES 0030008000

7 0605010503 SNAP PIN 1

8 1823100080 STARTER SWITCH ........................ 1 ........... REPLACES 0602100004

9 9825300460 PREHEAT LAMP ............................ 1........... REPLACES 0602102006 AND 9825301080

10 0602120052 TACHOMETER ............................... 1........... 25000KX3710; REPLACES 0602120052

11 0602120154 CABLE, TACHOMETER ................. 1 ........... 62100KA6710 L=1150

12 0602122060 OIL PRESSURE GAUGE ............... 1 ........... 42000KX1410

13 0602122200 UNIT, OIL PRESSURE ...................1 ........... 53000AC0101

14 0131300000 STREET SOCKET 1

15 0602123061 WATER TEMPERATURE GAUGE . 1 ........... 40000KX0910

16 0602123201 UNIT, WATER TEMPERATURE ..... 1 ........... 51400KV0200

17 0602121052 CHARGINE AMMETER .................. 1 ........... 43000KV0300

18 0602103091 ALARM LAMP ................................. 2 ........... REPLACES 0602103060

0601810244 BULB 2 19 0601830420 SWITCH, LAMP CHECK 1 20 0601810120 PANEL LIGHT 1 21 0040520000 TOOTHED LOCK WASHER 1 22 0601830710 SWITCH, PANEL LIGHT 1

23 031108160 PLAIN WASHER ............................. 2 .......... REPLACES 0041608000

24 0040008000 LOCK WASHER 2

25 011008040 HEX. HEAD BOLT .......................... 2 .......... REPLACES 0010008040

26 011008020 HEX. HEAD BOLT .......................... 2 .......... REPLACES 0017108020

27 3345312003 SUPPORT LEG 1 28 0017110025 HEX. HEAD BOLT 2

29 011208025 HEX. HEAD BOLT .......................... 2 .......... REPLACES 0017108025

30 0030008000 HEX. NUT 2 31 3342183004 LINK, GOVERNOR ROD 1 32 0010010025 HEX. HEAD BOLT 1

33 031110160 PLAIN WASHER ............................. 2 .......... REPLACES 0041610000

34 020310080 HEX. NUT ....................................... 1 .......... REPLACES 0030010000

35 3342182004 GOVERNOR ROD 1 36 3342152114 GOVERNOR ROD 1 37 0602180101 BALL JOINT 2

38 020108060 HEX. NUT ....................................... 2 .......... REPLACES 0030008000

39 0602180100 BALL JOINT 1

40 020106050 HEX. NUT ....................................... 3 .......... REPLACES 0030006000

41 952404470 PLAIN WASHER ............................. 1 .......... REPLACES 0041606000

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

ENGINE OPERATING PANEL ASSY.

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

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

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

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

42 3345188203 SET PANEL, ELECTRIC PARTS 1

43 011008020 HEX. HEAD BOLT .......................... 6 .......... REPLACES 0017108020

44 1825500732 EMERGENCY RELAY .................... 1 ........... REPLACES 0602200405

45 0027106016 MACHINE SCREW 4 46 0601823706 RELAY 1 47 0027104016 MACHINE SCREW 2 48 3341860103 SET BOARD, OUTPUT TERMINAL 1 49 0801831704A OUTPUT TERMINAL 4

50 012210020 HEX. HEAD BOLT .......................... 4 .......... REPLACES 0801831804

51 0041410000 PLAIN WASHER 16 52 0040010000 LOCK WASHER 12 53 0039310000 HEX. NUT 8

55 031108160 PLAIN WASHER ............................. 5 .......... REPLACES 0041608000

56 0040008000 LOCK WASHER 5

57 011208030 HEX. HEAD BOLT .......................... 5 .......... REPLACES 0010008030

58 0601811032 RECEPTACLE ................................ 2 ........... L620R 250V 20A

59 0601811037 RECEPTACLE ................................ 2........... CS8269 250V 50A

60 0601811031 RECEPTACLE ................................ 2 ........... L530R 125V 30A

61 0601811030 RECEPTACLE ................................ 2........... 520R 125V 20Ax2

62 0027103010 MACHINE SCREW 16 63 0041603000 PLAIN WSAHER 16

64 0207003000 HEX. NUT ....................................... 16 ........ REPLACES 0030003000

65 0601805311 CIRCUIT BREAKER ....................... 2 ........... KM51 265V 50A

66 0601805315 CIRCUIT BREAKER ....................... 2 ........... KM51 265V 30A

67 7451816004 BRACKET, CIRCUIT BREAKER 1 68 0027106016 MACHINE SCREW 2 69 3341865803 COVER, OUTPUT TERMINAL 1 70 0805012304 HEX. HEAD BOLT 2

71 031112230 PLAIN WASHER ............................. 4 .......... REPLACES 0041612000

72 0805019704 RUBBER WASHER 2 73 0030012000 HEX. NUT 2 74 0605010505 SNAP PIN 2 75 0601850091 RUBBER CUSHION 2 76 0021003010 MACHINE SCREW 2 77 0601802133 FUSE, 5A 1

78 0601820015 RECTIFIER ..................................... 4 ........... 1S2762

79 3341865903 COVER, OUPUT TERMINAL .......... 1........... S/N3312326~

80 7451855503 HING ............................................... 1........... S/N3312326~

81 7451855703 HINGE ............................................. 1 ........... S/N3312326~

82 0021304015 MACHINE SCREW ......................... 4........... S/N3312326~

83 0040004000 LOCK WASHER .............................. 4........... S/N3312326~

84 031104080 PLAIN WASHER ............................. 8........... S/N3312326~; REPLACES 0041204000

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

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

BATTERY ASSY.

DCA-40SSAI --- BATTERY ASSY.

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

DCA-40SSAI --- BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 0160012100 BATTERY ......................................... 2 ......... N100 12V 100Ah

2 0805003904 BATTERY SHEET 2 3 0805004004 BATTERY BAND 2 4 3802252004 BATTERY BOLT 4 5 0041608000 PLAIN WASHER 4

6 031108160 LOCK WASHER ............................... 4 ......... REPLACES 0040008000

7 0037808000 WING NUT 4 8 0215260050 BATTERY CABLE 1 9 0211160160 BATTERY CABLE 1 10 0215860045 BATTERY CABLE 1

11 0602220310 TERMINAL ASSY. (+) ...................... 2 ......... NO.9P

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

12 0602220311 TERMINAL ASSY (-) ........................ 2 ......... NO.9N

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

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

MUFFLER ASSY.

DCA-40SSAI --- MUFFLER ASSY.

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

DCA-40SSAI --- MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3342350103 EXHAUST PIPE 1

2 1141450690 GASKET ......................................... 1 .......... REPLACES 0602320000 AND 9221160010

3 9091103100 HEX. NUT ....................................... 6 .......... REPLACES 0602323002

4 3342311102 MUFFLER 1 5 3342359104 MUFFLER SHEET 1

6 011208025 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108025

7 012210020 HEX.HEAD BOLT ........................... 2 .......... REPLACES 0017110020

8 3342356104 GASKET 1

9 011008035 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0010108035

10 031108160 PLAIN WASHER ............................. 4 .......... REPLACES 0041608000

11 0040008000 LOCK WASHER 4

12 020108060 HEX. NUT ....................................... 4 .......... REPLACES 0030008000

13 3342354104 COVER 1 14 3342354004 COVER 1 15 3342328104 PIPE CLAMPER 1

16 020108060 HEX. NUT ....................................... 4 .......... REPLACES 0030008000

17 3342359004 COVER SHEET 2

18 0112508025 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108025

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

FUEL TANK ASSY.

DCA-40SSAI --- FUEL TANK ASSY.

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

DCA-40SSAI --- FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3345510323 FUEL TANK 1 1-1 0810105004 CAP, FUEL TANK 1 1-2 0810105400 FUEL FILTER 1 2 0802010304 PACKING 1

3 0602021042 PLUG .............................................. 1 ........... 960922101

4 3345523304 TANK BAND 2 5 0805003404 PAD, TANK BAND 4

6 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

7 031108160 PLAIN WASHER ............................. 2 .......... REPLACES 0041608000

8 0040008000 LOCK WASHER 2

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

10 3805522004 TANK SHEET 4 11 0191300600 SUCTION HOSE 1 12 0191300700 RETURN HOSE 1 13 0605515014 HOSE BAND 4 14 0845032204 DRAIN JOINT 1 15 0150000018 O RING 1 16 0802011104 PLUG 1 17 0193100225 FUEL GAUGE HOSE 1 18 0605515079 HOSE BAND 2

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

ENCLOSURE ASSY.

DCA-40SSAI --- ENCLOSURE ASSY.

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

DCA-40SSAI --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3345111322 BASE 1 2 3345116214 FLOOR PANEL 1

3 011008020 HEX. HEAD BOLT ........................... 10 ........ REPLACES 0017108020

4 3345121122 FRONT FRAME 1 5 3345109103 LINING 1

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

7 3340630503 STRIPE, RIGHT SIDE 1

8 0600500090 EMBLEM......................................... 2 .......... REPLACES 6360510003

9 0021106020 MACHINE SCREW 4

10 011008020 HEX. HEAD BOLT ........................... 6 .......... REPLACES 0017108020

11 3345122604 BRACKET, RADIATOR NECK 1

12 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

13 3345125103 COVER, FRONT FRAME 1 14 3345109204 LINING 1

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

16 011008020 HEX. HEAD BOLT ........................... 16 ........ REPLACES 0017108020

18 011008020 HEX. HEAD BOLT ........................... 10 ........ REPLACES 0017108020

19 3385155104 COVER 2

20 011206020 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0017106020

21 3345125204 COVER, FRONT FRAME 1

22 011008020 HEX. HEAD BOLT ........................... 6 .......... REPLACES 0017108020

23 3345132113 CENTER FRAME 1 24 3345132203 CENTER FRAME 1

25 012210040 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010014040

26 0041614000 PLAIN WASHER 16

27 030214350 LOCK WASHER .............................. 8 .......... REPLACES 0040014000

28 0030014000 HEX. NUT 8

29 012012030 HEX. HEAD BOLT ........................... 10 ........ REPLACES 0010012030

30 0040012000 LOCK WASHER 10

31 031112230 PLAIN WASHER ............................. 10 ........ REPLACES 0041612000

32 3345141202 REAR FRAME ................................ 1 .......... UP TO S/N3311949

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

33 3345109303 LINING 1

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

35 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

36 3345155103 COVER, REAR FRAME 1 37 3345109403 LINING 1

38 031108160 PLAIN WASHER ............................. 8 .......... REPLACES 0041608000

39 0040008000 LOCK WASHER 8

40 011008040 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010008040

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

ENCLOSURE ASSY.

DCA-40SSAI --- ENCLOSURE ASSY.

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

DCA-40SSAI --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

41 3345143303 DOOR, REAR FRAME .................... 1 .......... UP TO S/N3311949

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

42 1320332003 STICKER 1

43 3805147104 WINDOW PLATE ............................. 1 .......... REPLACES 33805147104

44 0021006020 MACHINE SCREW 6

45 952404470 PLAIN WASHER ............................. 6 .......... REPLACES 0041606000

46 0040006000 LOCK WASHER 6

47 020106050 HEX. NUT ....................................... 6 .......... REPLACES 0030006000

48 0845028303 HINGE 2

49 011208025 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108025

50 3345161212 ROOF PANEL 1 51 3345109503 LINING 1

52 011008020 HEX. HEAD BOLT ........................... 16 ........ REPLACES 0017108020

53 3345165104 GUIDE PANEL, AIR 2 54 3345109604 LINING 2

55 011008020 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0017108020

56 3345181202 SPLASHER PANEL 1 57 3345105304 LINING 1 58 0010008055 HEX. HEAD BOLT 6 59 0040008000 LOCK WASHER 6

60 031108160 PLAIN WASHER ............................. 6 .......... REPLACES 0041608000

61 3345124003 SIDE DOOR, LEFT SIDE ............... 1 .......... UP TO S/N3311949

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

62 3345109704 LINING 1

63 3345124103 SIDE DOOR, RIGHT SIDE ............. 1 .......... UP TO S/N3311949

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

64 3345109804 LINING 1 65 3340630904 STRIPE 2 66 3345175104 GUDE PANEL, AIR 2 67 3345105104 LINING 2

68 011008020 HEX. HEAD BOLT ........................... 12 ........ REPLACES 0017108020

69 3345171803 SIDE DOOR, LEFT SIDE ............... 1 .......... UP TO S/N3311949

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

70 33451009904 LINING 1 71 3340631104 STRIPE 1 72 3345175004 GUIDE PANEL, AIR 1 73 3345105204 LINING 1

74 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

75 3345171903 SIDE DOOR, RIGHT SIDE ............. 1 .......... UP TO S/N3311949

76 3345105004 LINING 1

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

78 0845028203 HINGE 4 79 0845028303 HINGE 4

80 011208025 HEX. HEAD BOLT ........................... 16 ........ REPLACES 0017108025

81 0845031504 CAP 10

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

ENCLOSURE ASSY.

DCA-40SSAI --- ENCLOSURE ASSY.

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

DCA-40SSAI --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

82 0605010910 LATCH ............................................. 1 .......... UP TO S/N3311949; REPLACES 0605010910

83 0027103010 MACHINE SCREW ......................... 7 .......... UP TO S/N3311949

84 0605010910 LATCH ............................................. 2 .......... UP TO S/N3311949

85 0027104010 MACHINE SCREW ......................... 14 ........ UP TO S/N3311949

86 3345104104 RUBBER SEAL 2 87 3345104204 RUBBER SEAL 2 88 3345104304 RUBBER SEAL 3 89 3345104404 RUBBER SEAL 1 90 3345104504 RUBBER SEAL 1 91 3345104604 RUBBER SEAL 1 92 3345104704 RUBBER SEAL 1 93 3345104804 RUBBER SEAL 2 94 3345104904 RUBBER SEAL 2

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

DECAL ASSY.

DCA-40SSAI --- DECALS

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

DCA-40SSAI --- DECALS

DECAL ASSY.

NO. PART NO. ITEM QTY. REMARKS

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

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

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

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

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

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

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 ...... M90310000

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

CYLINDER HEAD COVER ASSY.

ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.

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

ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.

CYLINDER HEAD COVER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 5111101680 CYLINDER HEAD ASSY. .................1 .......... INCL. ITEMS W/#

2# 9117156070 VALVE SEAT, INTAKE 4 3# 9117118030 VALVE SEAT, EXHAUST 4

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

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

5-2# 1096000160 SEALING CUP, INLET SIDE FACE 4 5-3# 9111291280 SEALING CUP, LOWER FACE 2 5-4# 1096000160 SEALING CUP, TOP FAC 3 5-5# 50960000130 SEALING CUP, DRILLED PASS 4 6# 909600340 PLUG 4 7# 5117210010 VALVE GUIDE 8 9 9111296010 SEAL CUP 4 10 5093000650 ROCKER ARM STUD 3 11 1093000180 INJ. NOZZLE STUD 8 12 9092023100 PLUG, TOP FACE 1 13 9095714100 PACKING, COMMET 1 15 1125690150 VALVE GUIDE SEAL 8

16 9041108200 STUD, INL. MANIFOLD .................... 2 .......... REPLACES 9041108250

17 9098301770 STUD, EXH. MANIFOLD 3 20 8941458390 GASKET, CYL. HEAD 1

22 8943674370 BOLT ................................................18 ........ REPLACES 8943674380

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

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

33 9111791050 WASHER

34 1096390320 PACKING, HEAD COVER ................3 .......... REPLACES 9111790300

50 5111730160 PACKING, CYL. HEAD 1 51 9111750120 NUT 1

EA1013

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

CYLINDER BLOCK ASSY.

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

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

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

NO PART NO PART NAME QTY. REMARKS

1 8941303284 CYL. BLOCK ASSY ........................... 1 ........ INCL. ITEMS W/#

2# 5878131240 LINING ............................................... 4 ........ REPLACES 1112611180

3# 5112570011 DOWEL 1 4# 1090004691 BOLT 10

5# 9116910480 CAM., FRONT METAL....................... 1 ........ REPLACES 9116110480

5-1# 9116930350 CAM., REAR AND CENTER ............. 2 ........ REPLACES 9116130350

6# 1096000520 CEALING CUP, FRONT AND REAR 2 6-1# 5112190140 SEALING CUP, CYL. BLOCK 1 6-2# 1096000121 SEALING CUP, TAPPET D=32 2 8 9098600190 PLUG, CAMSHAFT PLATE 1 9 8941480790 DOWEL 2 10 1096050681 PLUG, HEADLESS PT 1/2 2

11 5096050050 OIL PLUG, GALLERY ........................ 1 ........ REPLACES 9992055170

11-1 5096050180 PLUG 7 12 9992023140 OIL PLUG, GALLERY 1 13 9095720140 PACKING 1 14 1097400780 STRAIGHT PIN, GEAR CASE 1 15-1 9081510180 STRAIGHT PIN, FLYWHEEL HSG. 2 18 8941075600 INJ. PUMP NIPPLE 1 19 5112240040 BUSHING, OIL PUMP DRIVE SHAFT1 20 5112901450 COVER, TAPPET CHAMBER 1 21 8943673680 PACKING, CYL. BLOCK COVER 2 22 8941075662 BOLT 2 22-1 8944299951 BOLT 2 23 9095720080 PACKING, GROMMET 4 27 1096253620 SEAL, REAR OIL CRANK 1 30 5111290030 SEALING CUP, LEVEL GAUGE 1 36 8941745290 COVER, OIL DRAIN 1 37 8943210180 PACKING, COVER 1 38 0500408180 BOLT 2 43 1093000530 STUD, ENGINE FOOT 1 49 5096800110 WATER DRAIN COCK 1 53 9099135050 PIPE 1 54 5097070041 DRAIN PIPE CLIP 1 56 5117401200 AIR BREATHER ASSY. 1

57 1094400401 NUT ................................................... 2 ........ REPLACES 9091104080

59 1099851770 LOCK WASHER ................................. 2 ........ REPLACES 9091505080

60 9091645080 PLAIN WASHER 2 61 8944338700 BREATHER HOSE 1

62 8941625680 CLIP .................................................. 2 ........ REPLACES 1097071340

66 5093608820 VINYL PIPE ...................................... 1 ........ REPLACES 9097130740

69 5097040331 CLIP 1

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

CYLINDER BLOCK ASSY.

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

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

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

NO PART NO PART NAME QTY. REMARKS

70 0500408160 BOLT 1 71 9091606080 PLAIN WASHER 1 80 8941405811 OIL FILLER ASSY. 1 81 1117500120 OIL FILLER CAP 1

82 1094400401 NUT ................................................... 1 ........ REPLACES 9091104080

83 1099851770 LOCK WASHER ................................. 1 ........ REPLACES 9091505080

85 9099129760 HOSE 1 86 9099155531 CLIP 2

92 8970233390 VALVE RELIEF ASSY. ...................... 1 ........ INCL. ITEM W/@

93@ 5096230350 PACKING 1

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

TIMING GEAR ASSY.

ISUZU 4BD1 — TIMING GEAR ASSY.

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

ISUZU 4BD1 — TIMING GEAR ASSY.

TIMING GEAR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 5113110113 CASE 1 2 9081510180 STRAIGHT PIN 1

3 8943706710 PACKING ........................................................ 1.......... REPLACES 1113120140

4 0500408450 BOLT ...............................................................6 .......... REPLACES 0500408200

6 1113210790 COVER 1 7 8943632690 PACKING 1

8 1096254380 SEAL ............................................................... 1 .......... REPLACES 1096253190

9 9113276020 POINTER 1 10 0500408250 BOLT 7

10 8941500451 BOLT ............................................................... 5.......... REPLACES 5090000841

12 5113210090 COVER, GEAR CHECK 2

13 8971186980 GASKET ......................................................... 2.......... REPLACES 1112820130

14 0500406140 BOLT 4

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

FLYWHEEL HOUSING ASSY.

ISUZU 4BD1 — FLYWHEEL HOUSING ASSY.

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

Multiquip DCA-40SSAI User Manual

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Frequently Asked Questions

User Manual