MULTIQUIP POWER WHISPERWATT DCA-25SSAI Parts And Operation Manual

PARTS AND OPERATION MANUAL

PARTS AND OPERATION MANUAL

MQ POWER

DCA-25SSAI

TM

WHISPERWATT

GENERATOR

© COPYRIGHT 2001, MULTIQUIP INC.

PARTS LIST NO. 3336000

Final Copy (06/30/01)

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
800-421-1244 800-835-2551
FAX: [phone] FAX: [phone]

E-mail:[e-mail] • www:multiquip.com

SERVICE DEPARTMENT:

PAGE 2 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

HERE'S HOW TO GET HELP

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

PP

ARAR

TS DEPTS DEP

P

AR

TS DEP

PP

ARAR

TS DEPTS DEP
800/427-1244 or 310/537-3700
FAX: [phone] or 310/637-3284

SERSER

VICE DEPVICE DEP

SER

VICE DEP

SERSER

VICE DEPVICE DEP
800/835-2551 or 310/537-3700
FAX: [phone]

WW

ARRANTY DEPARRANTY DEP

W

ARRANTY DEP

WW

ARRANTY DEPARRANTY DEP
800/835-2551 or 310/537-3700
FAX: [phone]

ARAR

TMENTTMENT

AR

TMENT

ARAR

TMENTTMENT

ARAR

AR

ARAR

TMENTTMENT

TMENT

TMENTTMENT

ARAR

TMENTTMENT

AR

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ARAR

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MAINMAIN

MAIN

MAINMAIN
800/421-1244 or 310/537-3700
FAX: [phone]

PAGE 3 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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 ............................................ 11-15

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

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

DCA-25SSAI Specifications .......................................... 19

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ISUZU C240 ENGINE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

MQ POWER DCA-25SSAI
AC GENERATOR

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

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

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

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

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

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

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

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

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

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

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

PAGE 4 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

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

PAGE 5 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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-25SSAI portable generator:

GENERAL SAFETY

■

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

■

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

■

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

■

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

■

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

■

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

generator engine gives off DEADLY carbon monoxide gas.

hot

components can cause serious

■

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

CAUTION

■

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-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

RULES FOR SAFE OPERATION

CAUTION

■

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

CAUTION

:

Always stop the machine when

:

CAUTION

Radiator

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

:

DO NOT touch or open any of the below

mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.

■

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

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.

:

2. Coolant Drain Plug - Removing the coolant drain plug

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

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.

PAGE 7 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

■

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
precaution s and operations techniques before using
generator.

■

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

■

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

■

DO NOT allow unauthorized people to operate this
equipment.

■

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

■

Refer to the
technical questions or information.

Loading and Unloading (Crane)

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-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

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.

PAGE 9 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — TOWING RULES FOR SAFE OPERATION

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 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 jack-knifing. 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

■

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

Figure 1. Generator with Trailer

PAGE 10 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — 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 intended to provide the user with trailer ser­vice and maintenance information. The service and mainte­nance guidelines referenced in this section apply a wide range
of trailers. Remember periodic inspection of the trailer will
ensure safe towing of the equipment and will prevent dam­age to the equipment and personal injury.

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



Tires



Lug Nut Torquing



Suspension



Electrical

Use the following definitions with reading Table 1.

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

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

2. Braking System - System employed in stopping the

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

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

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

4. Frame Length - This measurement is from the ball

hitch to the rear bumper (reflector).

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

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

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

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

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

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

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

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

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

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

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

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

PAGE 11 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — TRAILER-SPECIFICATIONS

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PAGE 12 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — TRAILER-SPECIFICATIONS

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PAGE 13 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

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

CAUTION:

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

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

Tire Wear/Inflation

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

Suspension

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

CAUTION:

NOTE

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

PAGE 14 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

Figure 2. Major Suspension Components

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TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

DCA-25SSAI — TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FIT ONLY.PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

-

RETAIN NUT

BOLT ASSEMBLY

.

.

05-XAM03-NIM

Lug Nut Torque Requirements

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

1. Start all wheel lug nuts by hand.

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

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

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"3152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

PAGE 15 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

stnemeriuqeReuqroTeriT.4elbaT

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Figure 3. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-25SSAI — TRAILER-WIRING DIAGRAM

NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 16 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — GENERATOR DECALS

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

PAGE 17 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — GENERATOR DECALS

PAGE 18 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

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DCA-25SSAI — SPECIFICATIONS

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PAGE 19 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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DCA-25SSAI — GENERAL INFORMATION

DCA-25SSAI FAMILIARIZATION

Generator

genergener

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

Engine Operating Panel

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

z

Tachometer

z

Water Temperature Gauge

z

Oil Pressure Gauge

z

Charging Ammeter Gauge

z

Fuel level gauge

z

Engine Throttle Lever

z

Pre-Heat Light

z

Alarm Lights

z

Panel Light

z

Panel Light Switch

z

Starter Switch

gener

genergener

atorator

ator

atorator

Open Delta Excitation System

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

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

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

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

Engine

Open-DeltaOpen-Delta

Open-Delta

Open-DeltaOpen-Delta

AA

utomatic utomatic

A

utomatic

AA

utomatic utomatic

" excitation system. The open delta

VV

oltage Regulator oltage Regulator

V

oltage Regulator

VV

oltage Regulator oltage Regulator

fixed ceilingfixed ceiling

fixed ceiling

fixed ceilingfixed ceiling

(AVR) is supplied

" and responds

Generator Control Panel

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

z

Output Voltage Adjustment Knob

z

Frequency Meter (Hz)

z

AC Ammeter (Amps)

z

AC Voltmeter (Volts)

z

Ammeter Change-Over Switch

z

Voltmeter Change-Over Switch

Output Terminal Panel

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

z

Three 120/240V output receptacles, 50 amp

z

Two 120V input receptacles, 20 amp

z

3 Load Circuit Breakers 240V @50 amps

z

2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:

z

Main Circuit Breaker 60 amps

z

Over-Current Relay

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

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

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

Mechanical Governor System

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

diesel diesel

diesel

engine. This engine

diesel diesel

PAGE 20 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — MAJOR COMPONENTS

PAGE 21 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

Figure 4. Major Components

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

PAGE 22 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

Figure 5. Dimensions

NOTE PAGE

PAGE 23 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — CONTROL PANEL

PAGE 24 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

Figure 6. Control Panel

DCA-25SSAI — CONTROL PANEL

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

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

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

2. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz ±1 Hz .

3. AC Ammeter – Indicates the amount of current the

load is drawing from the generator.

4. AC Voltmeter – Indicates the single phase output

voltage present at the UVW 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 6).

7. Voltmeter Change-Over Switch – This switch allows

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

8. Pilot Lamp- This will light if the oil pressure or water

temperature is not within normal limits. If the lamp does
not illuminate when the lamp switch is turned on, the
bulb should be replaced.

PAGE 25 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — ENGINE OPERATING PANEL

PAGE 26 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

Figure 7. Engine Operating Panel

DCA-25SSAI — ENGINE OPERATING PANEL

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

1. Oil Pressure Gauge – Normal operation should be about

25 psi. When starting the generator the oil pressure
may read a bit higher, but after the engine warms up
the oil pressure should return to normal.

2. Panel light - Normally used in dark places or at night.

When activated, panel will luminate. When the generator
is not in use, turn the panel light switch to the ‘OFF’
position.

Engine Operating Panel Engine Operating Panel

Engine Operating Panel

Engine Operating Panel Engine Operating Panel

" (Figure 7).

3. Water Temperature Gauge – During normal operation

o

this gauge be should read between 165

to 215o.

4. Charging Ammeter Gauge – Indicates the current

being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.

5. Oil Pressure Indicator - This light will luminate if the

oil pressure exceeds 35 psi and will shut off the engine.

6. Water Temperature Indicator - This light will luminate

if the water temperature exceeds 215

0

and will shut off

the engine.

7. Lamp Check Switch (see Control Panel)- Test switch

for the lamp indicator on the control panel that the oil
pressure and water temperature warning system is
working properly.

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

panel light.

9. Speed Control Handle- To change the speed of the

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

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

engine is warmed to an operating temperature.

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

start, preheat, and stop the engine..

12. 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.

PAGE 27 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — OUTPUT TERMINAL PANEL

Output Terminal Panel

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

Connecting Load

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

120 Volt Receptacle

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

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

Circuit Breakers

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

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.

Figure 9. Connecting Loads

loadload

load

loadload

ALLALL

ALL

ALLALL

circuit

circuit

Figure 8. GFCI Test Button

Maximum Output

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

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

Twist Lock Dual Voltage Receptacles - To use these
receptacles, place the voltage selector switch in the single
phase 240/120 voltage position and adjust the output
voltage to 240 volts with the voltage regulator on the
control panel (see Figure 6, page 24). Place the voltmeter
change-over switch to the U-W position and the ammeter
change-over switch to the U or W to read the output.

PAGE 28 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — OUTPUT TERMINAL PANEL

Figure 10. Output Terminal Description

PAGE 29 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

NOTE

Legs “O” and Ground are
considered Bonded Grounds.

DCA-25SSAI — OUTPUT AMPERAGE SETUP

Output Terminal Panel Available Voltages

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

Over Current Relay

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

the control box.
below (Table 6) for a list of available voltages the generator
is able to supply.

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TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

CAUTION :

Maximum Amps

NEVER switch the voltage selector switch

position while the engine is engaged.

The following table show the maximum amps the entire

generator can provide. Do not exceed the maximum amps

listed. (See Table 7)

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Voltage Selector Switch Locking Button

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

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PAGE 30 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — OUTPUT AMPERAGE SETUP

Receptacle Use

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

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Figure 11. Voltage Selector Switch 240/120V

Single Phase Position

8.022.312.1

7.61214.2

Figure 12. AC Voltmeter

5.218.016.3

4.86.98.4

Change-over switch

(Reading the W-U leg on

the output terminal panel)

How To Read The Output Terminal Gauges

The gauges (Figures 13 and 15) and change-over switches
on the control panel DO NOT effect the generator output.
They are to help observe how much power is being
supplied produced at the UVWO legs.

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

14) to read the output on the selected leg.

Figure 14. AC Ammeter

Change-over Switch

(Reading the U leg on the

output terminal panel)

Figure 13. AC Voltmeter

Gauge

(Volt reading on W-U Lug)

Figure 15. AC Ammeter

(Amp reading on U lug)

NOTE

PAGE 31 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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

DCA-25SSAI — OUTPUT VOLTAGE SETUP

240/120V Hard Wire Hookup

With the voltage selector set and locked at ‘single phase
240/120’ and using single phase 120 volts, it will provide
three legs available with 100 amps each on three different
circuits (Figure 16).

When using single phase 240 volts, it will provide one leg
with 50 amps available (Figure 16).

480/240V Hard Wire Hookup

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

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

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

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

Position

PAGE 32 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

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

DCA-25SSAI — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- 3 Phase 480/277V Position

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

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

This setting can provide single phase power at 480, 440,
or 416 volts. After hooking up the hard wires to the lugs
as shown in Figure 21, 480 volts can be obtained the
voltage regulator knob turned toward maximum; 440 volts
can be obtained with the voltage regulator knob is turned
down; and 416 volts can be obtained with the voltage
regulator knob is at lowest setting.

Figure 19. Voltage Regulator Knob

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

This setting can provide 3-phase power at 480, 440, or
416 volts. After hooking up the hard wires to the lugs as
shown in Figure 20, 480 volts can be obtained the
voltage regulator knob turned toward maximum; 440 volts
can be obtained with the voltage regulator knob is turned
down; and 416 volts can be obtained with the voltage
regulator knob is at lowest setting.

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

or 416V

Figure 20. Hard Wire Hookup for Three Phase

480V, 440V, or 416V

Single Phase: 277V, 254V, or 240V

This setting can provide single phase power at 277, 254
or 240 volts. After hooking up the hard wires to the lugs
as shown in Figure 22, 277 volts can be obtained the
voltage regulator knob turned toward maximum; 254 volts
can be obtained with the voltage regulator knob is turned
down; and 240 volts can be obtained with the voltage
regulator knob is at lowest setting.

PAGE 33 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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

or 240V

DCA-25SSAI — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- 3 Phase 240/139V Position

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

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

This setting can provide single phase power at 240, 220,
or 208 volts. After hooking up the hard wires to the lugs
as shown in Figure 25, 240 volts can be obtained the
voltage regulator knob turned toward maximum; 220 volts
can be obtained with the voltage regulator knob is turned
down; and 208 volts can be obtained with the voltage
regulator knob is at lowest setting.

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

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

Position

or 208V

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

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

This setting can provide 3-phase power at 240, 220, or
208 volts. After hooking up the hard wires to the lugs as
shown in Figure 24, 240 volts can be obtained the
voltage regulator knob turned toward maximum; 220 volts
can be obtained with the voltage regulator knob is turned
down; and 208 volts can be obtained with the voltage

This setting can provide single phase power at 139, 127,
or 120 volts. After hooking up the hard wires to the lugs
as shown in Figure 26, 139 volts can be obtained the
voltage regulator knob turned toward maximum; 127 volts
can be obtained with the voltage regulator knob is turned
down; and 120 volts can be obtained with the voltage
regulator knob is at lowest setting.

regulator knob is at lowest setting.

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

208V

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

or 120V

PAGE 34 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- Single Phase 240/120V
Position

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

Single Phase: 120 Volt

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

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

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

Position

Single Phase, 240 Volt

This setting can provide single phase power at 240 volts.
After hooking up the hard wires to the lugs as shown in
Figure 28, 240 volts can be obtained and using the
voltage regulator to fine tune.

Figure 28. Hard Wire Hookup for Single Phase 240 volt

PAGE 35 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — 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 30) 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 36 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — INSTALLATION

Figure 30. Typical Generator Grounding Application

PAGE 37 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — PRE-SETUP

General Inspection Prior to Operation

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

Extension Cable

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

Circuit Breakers

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

main main

main

circuit breaker is provided to protect the UVW 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 38 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — 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 31) on the dipstick. See
Table 10 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 19
Specification Table 5.

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

CAUTION :

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 to
prevent fire hazards.

. DO NOT

Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency

Figure 31. Engine Oil Dipstick

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 Operator’s Manual.

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will be reduced. See maintenance section on page 42 and
43 on instructions to flush out radiator.

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

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PAGE 39 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

)°51-(C°5woleB03-W01EASroW01EAS

DCA-25SSAI — 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 Table11.
for engine, radiator, and reserve tank coolant capacities. Make
sure the coolant level in the reserve tank is always between
the "H" and the "L" markings.

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Operation in Freezing Weather

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

Cleaning the Outer Radiator

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

Air Cleaner

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

Fan Belt Tension

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

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

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When the antifreeze is mixed with

When the antifreeze is mixed withWhen the antifreeze is mixed with
ww

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ater

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Figure 32. Fan Belt Tension

CAUTION :

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

Adjusting Fan Belt

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

y

Loosen the alternator adjusting plate and alternator
mounding bolt.

y

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

y

Tighten the mounting bolt and the adjusting bolt.

PAGE 40 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — PRE-SETUP

Battery

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

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

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

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

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

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.

Figure 33. Battery Connections

Wiring

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

Piping and Hose Connection

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

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

PAGE 41 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — 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.

z

When the voltage selector switch is in single phase (240/
120V position), place the AC voltmeter change-over switch

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.

to the U-W position and the AC ammeter change over-switch
to the U or W position to read the output.

z

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

z

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

If wattage is not available on the equipment, approximate
wattage may be determined by multiplying the nameplate
voltage by the nameplate amperage for three-phase:

WATTS =1.732 x VOLTAGE x AMPERAGE
The power factor of this generator is 1.0. See Table 13.
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 42 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — GENERATOR START-UP PROCEDURE

WARNING:

The engine's exhaust contains harmful

ALAL

WW

AA

W

WW

YS YS

A

YS

ventilate the

AA

YS YS

emissions.
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.

Before Starting

Engine

1. Check the lubricating oil level prior to starting the engine.
Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.

2. When there is not enough lubricating oil, fill the crankcase
with high grade motor oil. Use a high quality detergent
oil classified CC or higher (See Table 8 on page 33).

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

AL

ALAL

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

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

Before Starting

Generator and Control Panel

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

CAUTION:

NEVER start the engine with the

main,main,

GFCI GFCI

main,

GFCI

main,main,

GFCI GFCI

in the ON position.

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

main, load main, load

main, load

main, load main, load

the “OFF” position prior to starting the engine.

and

G.FG.F

G.F

G.FG.F

.C.C

.I..I.

.C

.I.

circuit breakers (Figure 34) to

.C.C

.I..I.

or

loadload

load

circuit breakers

loadload

Figure 35. UVW Terminal Lugs (Load)

NEGATIVE

POSTIVE

BATTERY

Figure 36. Battery Connections

Figure 34. Main, GFCI and

Load Circuit Breakers

PAGE 43 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — GENERATOR START-UP PROCEDURE

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

Figure 37. Engine Enclosure Doors

8. Once the preheat indicator lights, turn the ignition

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

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

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

Figure 41. Ignition Switch ‘START’

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

Figure 42. Engine Throttle Lever (high)

Figure 38. Voltage Selection Switch

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

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

Figure 39. Engine Throttle Lever (low)

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

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

preheat indicator turns on.

Figure 40. Ignition Switch ‘PREHEAT’

the 60 cycle output frequency in HERTZ.

Figure 43. Frequency Meter (Hz)

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

PAGE 44 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

Figure 44. Voltage Meter (Volts)

DCA-25SSAI — GENERATOR START-UP PROCEDURE

15. 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 45. Voltage Adjust Control Knob

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

40

20

0

60

75

16. Turn the MAIN, GFCI and LOAD circuit breakers to

A

Figure 46. Ammeter (No Load)

their ON position (Figure 50).

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

Figure 50. Main and GFCI Circuit Breakers

17. 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

Figure 47. Oil Pressure Gauge

reading if the load is in use.

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

Figure 49. Engine Tachometer

40

20

0

60

75

A

WATER

TEMP

Figure 48. Coolant Temperature Gauge

PAGE 45 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

Figure 51. Ammeter (Load)

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

DCA-25SSAI — 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. Set the engine throttle lever to (low) position.

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

load applied.

4. Turn the ignition key to ‘STOP’ (Figure 53).

Figure 53. Ignition Switch ‘STOP’

5. Remove the load from the UVW terminal strip.

PAGE 46 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

NOTE PAGE

PAGE 47 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — MAINTENANCE

General Inspection

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

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

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

Fuel Addition

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

Removing Water from the Fuel Tank

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

Air Removal

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

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

Service Daily

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

Check Oil Level

Check the crankcase oil level prior to each use, or when
the fuel tank is filled. Insufficient oil may cause severe
damage to the engine. Make sure the generator is level.
The oil level must be between the two notches on the dipstick
as shown in Figure 31, page 39.

Replacing Oil Filter

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

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

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

Replacing Fuel Filter

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

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

Vent any air.

Flushing Out Radiator and Replacing Coolant

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

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

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

Tighten both cocks and replace the overflow tank.
Replace with coolant (see page 40, Table 12 for mixture).
Close radiator cap tightly.

Cleaning the Fuel Strainer

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

PAGE 48 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

CAUTION :

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

DCA-25SSAI — MAINTENANCE

Generator Storage

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

z

Drain the fuel tank completely.

z

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

z

Clean all external parts of the generator with a cloth.

z

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

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PAGE 49 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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DCA-25SSAI — GENERATOR WIRING DIAGRAM

PAGE 50 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — ENGINE WIRING DIAGRAM

PAGE 51 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSAI — TROUBLESHOOTING (ENGINE)

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

MOTPMYS MELBORPELBISSOP NOITULOS

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

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PAGE 52 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

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PAGE 53 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-25SSAI — TROUBLESHOOTING (GENERATOR)

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

GNITOOHSELBUORTROTARENEG.71ELBAT

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 54 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

NOTE PAGE

PAGE 55 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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 56 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI — SUGGESTED SPARE PARTS

DCA-25SSAI DCA-25SSAI

DCA-25SSAI

DCA-25SSAI DCA-25SSAI
1 1

TT

O 3 UNITSO 3 UNITS

1

T

O 3 UNITS

1 1

TT

O 3 UNITSO 3 UNITS

Qty. P/N Description

10 ............ 0601804971 ............ CIRCUIT BREAKER

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

20 ............ 5873103370 ............ OIL FILTER

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

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

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

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

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

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

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

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

2 .............. 9214311960 ............ RADIATOR HOSE (UPPER)

2 .............. 9214311980 ............ RADIATOR HOSE (LOWER)

1 .............. 0810105004 ............ FUEL CAP

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

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

1 .............. 5825500191 ............ EMERGENCY RELAY

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

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

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

1 .............. 0800225200 ............ AUTOMATIC VOLTAGE REGULATOR

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

1 .............. 0601840031 ............ VOLTAGE REGULATOR (RHEOSTAT)

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

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

2 .............. 5814200330 ............ PREHEAT LAMP BULB

W/ISUZU C240 DIESEL ENGINEW/ISUZU C240 DIESEL ENGINE

W/ISUZU C240 DIESEL ENGINE

W/ISUZU C240 DIESEL ENGINEW/ISUZU C240 DIESEL ENGINE

PAGE 57 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

NOTE

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this

book.

GENERATOR ASSY.

DCA-25SSAI --- GENERATOR ASSY.

PAGE 58 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3331040400 FIELD ASSY. 1
1-1 3331010112 SHAFT 1
1-2 3331042303 FIELD CORE 1
1-3 3331080013 FIELD COIL 1
1-4 7511032103 ARMATURE CORE, EXCITER 1
1-5 7511085103 ARMATURE COIL, EXCITER 1
1-6 3331610003 COUPLING HUB 1
2 7511025103 RECTIFIER ASSY. 1
2-1 3361026003 SET PLATE, RECTIFIER 1

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

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

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

2-7 0601822601 SURGE ABSORBER ............................ 1 ........... ERZ,14JK621A

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 042006309 BEARING .............................................. 1 ........... 6309ZZ; REPLACES 0070506309

4 0080000045 SNAP RING 1
5 3331070002 FAN 1
6 3331611002 COUPLING DISK 1(4)
7 3331612004 WASHER, COUPLING HUB 1
8 0040008000 LOCK WASHER 6

9 014208020 HEX. HEAD BOLT ................................ 6 ........... REPLACES 0010308020

10 3331614002 COUPLING RING 1
11 0040008000 LOCK WASHER 6

12 011208025 HEX. HEAD BOLT ................................ 6 ........... REPLACES 0010308025

13 004000800 LOCK WASHER 6

14 011008040 HEX.HEAD BOLT ................................. 6 ........... REPLACES 0010308040

15 3331341600 STATOR ASSY. 1
15-1 3331320502 GENERATOR FRAME 1
15-2 7511342114 ARMATURE CORE 1
15-3 3331366013 ARMATURE COIL 1
16 0801350104 GROMMET 1
17 0601850264 GROMMET 2
18 7511315103 END BRACKET 1
19 7511350000 FIELD ASSY. EXCITER 1
19-1 7511352103 FIELD CORE, EXCITER 1
19-2 7511362103 FIELD COIL, EXCITER 1

PAGE 59 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

GENERATOR ASSY.

DCA-25SSAI --- GENERATOR ASSY.

PAGE 60 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

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

21 0040008000 LOCK WASHER 4
22 0010008055 HEX. HEAD BOLT 4
23 0040008000 LOCK WASHER 6

24 011208030 HEX. HEAD BOLT ................................ 6 ........... REPLACES 0010008030

25 3331310104 COVER, BEARING 1

26 0105050616 HEX. HEAD BOLT ................................ 4 ........... REPLACES 0010006012

27 7511331104 COVER, END BRACKET 1

28 0105050616 HEX. HEAD BOLT ................................ 4 ........... REPLACES 0017106012

31 012010040 HEX.HEAD BOLT ................................. 6 ........... REPLACES 0010310040

32 031110160 PLAIN WASHER ................................... 6 ........... REPLACES 0041610000

33 0040010000 LOCK WASHER 6
34 0030310000 HEX. NUT 6
35 7511332103 COVER, FAN 1
36 0041606000 PLAIN WASHER 1

37 952404470 LOCK WASHER .................................... 1 ........... REPLACES 0040006000

38 0010006030 HEX. HEAD BOLT 1
39 0605000008 RUBBER SUSPENSION 2

40 031110160 PLAIN WASHER ................................... 4 ........... REPLACES 0041610000

41 0040010000 LOCK WASHER 4

42 020310080 HEX. NUT ............................................. 4 ........... REPLACES 0030110000

PAGE 61 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

CONTROL BOX ASSY.

DCA-25SSAI --- CONTROL BOX ASSY.

PAGE 62 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3331813502 CONTROL BOX ......................................... 1 ......... UP TO S/N3311929

3331813512 CONTROL BOX ......................................... 1 ......... S/N3311930~

2 7511870103 CURRENT TRANSOFRMER 1
3 0017106016 HEX. HEA DBOLT 4

4 0601801192 CURRENT TRANSFORMER, AMMETER . 2 ......... CT3.5MR 50/5A

5 0027104010 MACHINE SCREW 4

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

7 0027106010 MACHINE SCRE 6

8 0601820042 RECTIFIER ................................................ 1 ......... 16T60

9 0027103010 MACHINE SCREW 4
10 0601842057 RESITOR 1
11 0027105010 MACHINE SCREW 2
12 0601820851 OVER CURRENT RELAY 1
13 0027104016 MACHINE SCREW 2

14 0601804971 CIRCUIT BREAKER .................................. 1 ......... TO100CC500V 60AT

15 0041604000 PLAIN WASHER 2
16 0040004000 LOCK WASHER 2
17 0021004060 MACHINE SCREW 2

18 0601830625 CHANGE-OVER SWITCH, VOLTAGE ....... 1 ......... VY40

19 0021104016 MACHINE SCREW 4

20 0020004010 MACHINE SCREW .................................... 2 ......... UP TO S/N331929

0020004020 MACHINE SCREW .................................... 2 ......... S/N331930~

21 3331823513 CONTROL PANEL 1

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

23 0601800783 AC AMMETER ........................................... 1 ......... PSK60 0~50A 0~100A

24 0601801040 CHANGE-OVER SWITCH, AMMETER ..... 1 ......... SL2AS

25 0601800217 AC VOLTMETER ....................................... 1 ......... PCK60 0~600V

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

27 0601810072 PILOT LAMP .............................................. 1 ......... LP132DC 220V

0601810261 BULB 1

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

29 0601840120 KNOB 1

PAGE 63 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

CONTROL BOX ASSY.

DCA-25SSAI --- CONTROL BOX ASSY.

PAGE 64 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. ITEM QTY. REMARKS

30 3901824004 STOPPER, CONTROL PANEL 1
31 0027105016 MACHINE SCREW 2
32 0030005000 HEX. NUT 2
33 0805001304 SET SCREW, CONTROL PANEL 2

34 031108160 PLAIN WSHER .......................................... 2 ......... REPLACES 0041608000

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

36 0027105010 MACHINE SCREW 4

37 3331814703 COVER, CONTROL BOX .......................... 1 ......... UP TO S/N3311929

3331814713 COVER, CONTROL BOX .......................... 1 ......... S/N3311930~

38 0017106016 HEX. HEAD BOLT 5

39 3331826713 SIDE PANEL, CONTROL BOX .................. 1 ......... UP TO S/N3311929

3331826723 SIDE PANEL, CONTROL BOX .................. 1 ......... S/N3311930~

40 3331826804 COVER, SIDE PANEL ............................... 1 ......... UP TO S/N3311929

41 0017106016 HEX. HEAD BOLT ..................................... 6 ......... UP TO S/N3311929

0017106016 HEX. HEAD BOLT ..................................... 4 ......... S/N3311930~

42 011008020 HEX. HEAD BOLT ..................................... 4 ......... REPLACES 0017108020

43 020108060 HEX. NUT .................................................. 4 ......... REPLACES 0030008000

44 5825500422 EMERGENCY RELAY ............................... 1 ......... REPLACES 0602200406 AND 5825500191

45 9822531070 REGULATOR ............................................. 1 ......... REPLACES 0602201305

46 0027106016 MACHINE SCREW 6
47 0601830614 SWITCH CAP 1

PAGE 65 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENGINE AND RADIATOR ASSY.

DCA-25SSAI ENGINE AND RADIATOR ASSY.

PAGE 66 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 C240PR12 ENGINE .......................................... 1........... REPLACES 0602000008; ISUZU C240

2 0602010067 RADIATOR...................................... 1........... TCR38253

3 9214311960 RADIATOR HOSE ..........................1 ........... REPLACES 0602013008

4 9214311980 RADIATOR HOSE ..........................1 ........... REPLACES 0602013109

5 9214311970 RADIATOR HOSE ..........................1 ........... REPLACES 0602013108

6 3332011504 RADIATOR PIPE 1
7 3332012504 CLAMPER 1
8 0602014000 HOSE BAND 5
9 0602014004 HOSE BAND 1

10 8941521130 AIR CLEANER ................................ 1 ........... REPLACES 0602040069;FWG058036

5142150140 ELEMENT, AIR CLEANER .............1 ........... REPLACES 0602040175;P105629

11 0602040690 DUST INDICATOR .......................... 1........... RPX002252

12 0602040593 BAND, AIR CLEANER .................... 2 ........... 9002348

13 3332031103 BRACKET, AIR CLEANER 1

14 011008020 HEX. HEAD BOLT .......................... 4 ........... REPLACES 0017108020

15 020108060 HEX. NUT ....................................... 4 ........... REPLACES 0030008000

16 0017110025 HEX. HEAD BOLT 2
17 1322036004 HOSE,AIR CLEANER 1
18 0605515010 HOSE BAND 2

19 8970246071 CARTRIDGE, OIL FILTER .............. 1 ........... REPLACES 0602041175 AND 8941564550

20 8971725490 CARTRIDGE, FUEL FILTER ...........1 ........... REPLACES 0602042102 AND 8941434790

21 3335112204 ENGINE FOOT 2

22 012210035 HEX. HEAD BOLT .......................... 4 ........... REPLACES 0010010035

23 031110160 PLAIN WASHER .............................4 ........... REPLACES 0041610000

24 0040010000 LOCK WASHER 4

25 020310080 HEX. NUT ....................................... 4 ........... REPLACES 0030010000

26 0605000008 RUBBER SUSPENSION 2

27 0041610000 PLAIN WASHER .............................4 ........... REPLACES 0041610000

28 0040010000 LOCK WASHER 4

29 020310080 HEX. NUT ....................................... 4 ........... REPLACES 0030110000

30 011008020 HEX. HEAD BOLT .......................... 8 ........... REPLACES 0017108020

31 0802020403 DRAIN PIPE 1
32 0805006304 PACKING, OIL PAN SIDE 1

33 0602021100 PACKING ........................................ 1 ........... 9099209590

34 0805006204 JOINT BOLT 1

35 011206020 HEX. HEAD BOLT .......................... 2 ........... REPLACES 0017106020

36 020106050 HEX. NUT ....................................... 2 ........... REPLACES 0030006000

37 0802081403 RESERVE TANK 1
38 0802081104 CAP, RESERVE TANK 1

39 8012082103 BRACKET, RESERVE TANK ......... 1 ........... REPLACES 3335182123

40 011606025 HEX. HEAD BOLT .......................... 1 ........... REPLACES 0017106025

41 0199500550 HOSE 1
42 0199500220 HOSE 1
43 0193600970 HOSE 1
44 0605515013 HOSE BAND 4

PAGE 67 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENGINE AND RADIATOR ASSY.

DCA-25SSAI ENGINE AND RADIATOR ASSY.

PAGE 68 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

45 0194500600 BREATHER HOSE 1
46 0605515022 HOSE BAND 2
47 0193000500 HOSE 1
48 0605515005 HOSE BAND 1
49 0193100200 HOSE 1
50 0605515000 HOSE BAND 1

51 9829315110 EARTH CABLE ............................... 1 ........... REPLACES 0602220000

PAGE 69 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENGINE OPERATING PANEL ASSY.

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

PAGE 70 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

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

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

1 3332111603 OPERATING PANEL 1
2 3332142004 SLIDE BAR 1

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

4 0080200006 SNAP RING 1
5 3332140504 BRACKET, GOVERNOR ROD 1

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

7 0605010503 SNAP PIN 1

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

9 5814200330 PREHEAT LAMP ................................... 1 ........... REPLACES 0602102002 AND 9825301090

10 0602120053 TACHOMETER...................................... 1 ........... REPLACES 0602120052;25000KX3710

11 0602120167 CABLE, TACHOMETER ........................ 1 ........... 62100KB3900L=1000

12 0602122050 OIL PRESSURE GAUGE ...................... 1 ........... 42000KX1412

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

14 0602123060 WATER TEMPERATURE GAUGE ......... 1 ........... 40000KB5111

15 0602123201 UNIT, WATER TEMPERATURE ............. 1 ........... 51400KV0200

16 0602121052 CHARGING AMMETER ........................ 1 ........... 43000KV0300

17 0602103061 ALARM LAMP 2

0601810245 BULB 2

18 0601830420 SWITCH, LAMP CHECK....................... 1 ........... SB61A

19 0601810141 PANEL LIGHT ....................................... 1 ........... 9826800370

20 0040520000 TOOTHED LOCK WASHER 1
21 0601830710 SWITCH, PANEL LIGHT 1

22 031108160 PLAIN WASHER ................................... 4 ........... REPLACES 0041608000

23 0040008000 LOCK WASHER 4

24 011008040 HEX. HEAD BOLT ................................. 4 ........... REPLACES 0010008040

25 3335312402 SUPPORT LEG 1

26 012010030 HEX. HEAD BOLT ................................. 5 ........... REPLACES 0017110030

27 020310080 HEX. NUT ............................................. 2 ........... REPLACES 0030010000

28 5819000200 ENGINE STOPPER .............................. 1 ........... REPLACES 0602210802

29 3332159204 BRACKET, ENGINE STOPPER 1
30 0027106016 MACHINE SCREW 3

31 011008020 HEX. HEAD BOLT ................................. 2 ........... REPLACES 0017108020

32 3332152704 GOVERNOR ROD 1
33 0602180101 BALL JOINT 2

PAGE 71 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENGINE OPERATING PANEL ASSY.

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

PAGE 72 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

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

ENGINE OPERATING PANEL ASSY.

NO. PART NO. ITEM QTY REMARKS

34 020108060 HEX. NUT ............................................. 2 ........... REPLACES 0030008000

35 3331860803 SET BOARD, OUTPUT TERMINAL 1

36 0801830104A OUTPUT TERMINAL ............................. 4 ........... REPLACES 0801830104

37 0801830604 HEX. HEAD BOLT 4
38 0041408000 PLAIN WASHER 16
39 0040008000 LOCK WASHER 12
40 0039308000 HEX. NUT 8

42 952404470 PLAIN WASHER ................................... 4 ........... REPLACES 0041606000

43 0040006000 LOCK WASHER 4
44 0010006030 HEX. HEAD BOLT 4

45 0601811030 RECEPTACLE, 5-20R ........................... 1 ........... 125V 20Ax2

46 0601811031 RECEPTACLE, L5-30R ......................... 1 ........... 125V 30A

47 0601811032 RECEPTACLE, L6-20R ......................... 1 ........... 250V 20A

48 0601811037 RECEPTACLE, CS8269 ........................ 1 ........... 250V 50A

49 0027103010 MACHINE SCREW 8
50 0041603000 PLAIN WASHER 8

51 0207003000 HEX. NUT ............................................. 8 ........... REPLACES 0030003000

52 0601804887 CIRCUIT BREAKER ............................. 2 ........... KM51 265V 20A; REPLACES 0601805313

53 0601805315 CIRCUIT BREAKER ............................. 2 ........... KM51 265V 30A

54 7451816004 BRACKET, CIRCUIT BREAKER 1
55 0027106016 MACHINE SCREW 2

56 3331867503 COVER, OUTPUT TERMINAL .............. 1 ........... UP TO S/N3311929; REPLACES 3331866503

3331866513 COVER, OUTPUT TERMINAL .............. 1 ........... S/N3311930~

57 0805012304 HEX.HEAD BOLT 2

58 031112230 PLAIN WASHER ................................... 4 ........... REPLACES 0041612000

59 0805009804 RUBBER WASHER 2
60 0030012000 HEX. NUT 2
61 0605010505 SNAP PIN 2
62 0601802132 FUSE, 10A 1

63 0601820015 RECTIFIER ........................................... 4 ........... 1S2762

64 3331867503 COVER, OUTPUT TERMINAL .............. 1 ........... S/N3312316~

65 3331855503A HINGE ................................................... 1 ........... S/N3312316~

66 3331855703 HINGE ................................................... 1 ........... S/N3312316~

67 0021304015 MACHINE SCREW ............................... 4 ........... S/N3312316~

68 0040004000 LOCK WASHER .................................... 4 ........... S/N3312316~

69 031104080 PLAIN WASHER ................................... 8 ........... S/N3312316~; REPLACES 0041204000

70 OEMAA8 HEX. NUT ............................................. 4 ........... S/N3312316~; REPLACES 0030104000

PAGE 73 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

BATTERY ASSY.

DCA-25SSAI --- BATTERY ASSY.

PAGE 74 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 0160012070 BATTERY ...................................... 1 ........... N70 12V 70Ah

2 3312251004 BATTERY SHEET 1
3 3332250004 BATTERY BAND 1
4 0805002404 BATTERY BOLT 2

5 031108160 PLAIN WASHER ............................ 2 ........... REPLACES 0041608000

6 0040008000 LOCK WASHER 2
7 0037808000 WING NUT 2
8 0215260160 BATTERY CABLE 1
9 0215860110 BATTERY CABLE 1

10 0602220310 TERMINAL ASSY. (+) ................... 1 ........... NO. 9N

0037808000 WING NUT ..................................... 1 ........... REPLACES 0208008000

11 0602220311 TERMINAL ASSY. (-) .................... 1 ........... NO. 9N

0037808000 WING NUT ..................................... 1 ........... REPLACES 0208008000

PAGE 75 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

MUFFLER ASSY.

DCA-25SSAI --- MUFFLER ASSY.

PAGE 76 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3332350503 EXHAUST PIPE 1

2 9141450760 GASKET ........................................ 1 ........... REPLACES 0602320001

3 0040010000 LOCK WASHER 3

4 9098400850 HEX. NUT ...................................... 3 ........... REPLACES 0602323001

5 7342311002A MUFFLER 1

6 01008020 HEX.HEAD BOLT .......................... 4 ........... REPLACES 0017108020

7 7342356004 GASKET 1

8 011008035 HEX. HEAD BOLT ......................... 4 ........... REPLACES 0010108035

9 031108160 PLAIN WASHER ............................ 4 ........... REPLACES 0041608000

10 0040008000 LOCK WASHER 4

11 020108060 HEX. NUT ...................................... 4 ........... REPLACES 0030008000

12 7342354004 COVER 2

13 011008020 HEX. HEAD BOLT ......................... 4 ........... REPLACES 0017108020

PAGE 77 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

FUEL TANK ASSY.

DCA-25SSAI --- FUEL TANK ASSY.

PAGE 78 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3335510413 FUEL TANK 1
1-1 0810105004 CAP, FUEL TANK 1
1-2 0810105400 FUEL FILTER 1
2 3335523104 TANK BAND 2
3 0805003404 PAD, TANK BAND 4

4 011008020 HEX. HEAD BOLT ......................... 2 ........... REPLACES 0017108020

5 031108160 PLAIN WASHER ............................ 2 ........... REPLACES 0041608000

6 0040008000 LOCK WASHER 2

7 020108060 HEX. NUT ...................................... 2 ........... REPLACES 0030008000

8 3805522004 TANK SHEET 2
9 0191300620 SUCTION HOSE 1
10 0191300970 RETURN HOSE 1
11 0605515014 HOSE BAND 4
12 0845032204 DRAIN JOINT 1

13 0150000018 O RING .......................................... 1 ........... REPLACES 0150000018

14 0802011104 PLUG 1
15 0193100255 FUEL GAUGE HOSE 1
16 0605515079 HOSE BAND 2

PAGE 79 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENCLOSURE ASSY.

DCA-25SSAI --- ENCLOSURE ASSY.

PAGE 80 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3335110102 BASE 1
2 3335109104 LINING 1
3 3335116014 FLOOR PANEL 1

4 011008020 HEX. HEAD BOLT............................... 8 .............REPLACES 0017108020

5 3335121904 FRONT FRAME 1
6 3335109203 LINING 1
7 3330630103 STRIPE 1

8 3330630303 STRIPE ................................................ 1 .............LT. SIDE

9 B1561100603 STRIPE ................................................ 1 ............. RT. SIDE; REPLACES 3330630503

10 0600500090 EMBLEM .............................................. 1 ............. REPLACES 6360510003

11 0021106020 MACHINE SCREW 2

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

13 3335162804 RUBBER SEAL 1

14 011206020 HEX. HEAD BOLT............................... 4 .............REPLACES 0017106020

15 7345125104 COVER, FRONT FRAME 1

16 011008020 HEX. HEAD BOLT............................. 12 .............REPLACES 0017108020

17 3335125224 COVER, FRONT FRAME 1

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

19 3335131503 CENTER FRAME 1
20 7345131103 CENTER FRAME 1

21 012214035 HEX. HEAD BOLT............................... 8 .............REPLACES 0010014035

22 0041614000 PLAIN WASHER 16

23 030214350 LOCK WASHER.................................. 8 .............REPLACES 0040014000

24 020114110 HEX. NUT ............................................ 4 .............REPLACES 0030014000

25 3335140102 REAR FRAME ..................................... 1 ............. UP TO S/N3311929

3335140112 REAR FRAME ..................................... 1 ............. S/N3311930~

26 3330630704 STRIPE 2

27 011008020 HEX. HEAD BOLT............................... 4 .............REPLACES 0017108020

28 7345181013 COVER, REAR FRAME 1
29 335109304 LINING 1
30 7345181704 GUIDE PANEL, AIR 1
31 3335109404 LINING 1

32 011008020 HEX. HEAD BOLT............................... 4 .............REPLACES 0017108020

33 011008020 HEX. HEAD BOLT............................... 8 .............REPLACES 0017108020

34 3335142203 DOOR, REAR FRAME ........................ 1 .............UP TO S/N3311929

3335142213 DOOR, REAR FRAME ........................ 1 .............S/N3311930~

35 0840625902 STICKER ............................................. 1 ............. REPLACES 1320632003

36 7345147004 WINDOW PLATE 1
37 0021006020 MACHINE SCREW 6

38 952404470 PLAIN WASHER ................................. 6 ............. REPLACES 0041606000

39 0040006000 LOCK WASHER 6

40 020106050 HEX. NUT ............................................ 6 .............REPLACES 0030006000

41 0845028303 HINGE 2

42 011208025 HEX.HEAD BOLT ............................... 4 .............REPLACES 0017108025

43 3335161902 ROOF PANEL 1

PAGE 81 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENCLOSURE ASSY.

DCA-25SSAI --- ENCLOSURE ASSY.

PAGE 82 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

44 3335109503 LINING 1
45 3335132204 HANGER 1
46 0010020070 HEX. HEAD BOLT 2

47 0401450200 PLAIN WASHER ................................. 4 ............. REPLACES 0041620000

48 0030020000 HEX. NUT 2

49 011008020 HEX. HEAD BOLT............................. 14 .............REPLACES 0017108020

50 3335181902 SPLASHER PANEL ............................ 1 ............. UP TO S/N3311929

3335181912 SPLASHER PANEL ............................ 1 .............S/N3311930~

52 0010008055 HEX. HEAD BOLT 4
53 0040008000 LOCK WASHER 4

54 031108160 PLAIN WASHER ................................. 4 ............. REPLACES 0041608000

55 3335124203 SIDE DOOR, LEFT SIDE .................... 1 .............UP TO S/N3311929

3335124213 SIDE DOOR, LEFT SIDE .................... 1 .............S/N3311930~

56 3335109604 LINING 1

57 3335124303 SIDE DOOR, RIGHT SIDE ................. 1 .............UP TO S/N3311929

3335124313 SIDE DOOR, RIGHT SIDE ................. 1 .............S/N3311930~

58 3335109704 LINING 1

59 B1561100804 STRIPE ................................................ 2 .............REPLACES 3330630904

60 3335175004 GUIDE PANEL, AIR 1
61 7345175104 GUIDE PANEL, AIR 1

62 011008020 HEX. HEAD BOLT............................... 8 .............REPLACES 0017108020

63 3335124003 SIDE DOOR, LEFT SIDE .................... 1 .............UP TO S/N3311929

3335124013 SIDE DOOR, LEFT SIDE .................... 1 .............S/N3311930~

64 3335109804 LINING 1

65 B1561100804 STRIPE ................................................ 1 .............REPLACES 3330631304

66 3335124103 SIDE DOOR, RIGHT SIDE ................. 1 .............UP TO S/N3311929

3335124113 SIDE DOOR, RIGHT SIDE ................. 1 .............S/N3311930~

67 3335109904 LINING 1

68 B1561100903 STRIPE ................................................ 1 .............REPLACES 3330631104

69 0845028203 HINGE 4
70 0845028303 HINGE 4

71 011208025 HEX. HEAD BOLT............................. 16 .............REPLACES 0017108025

72 0845031504 CAP 10

73 0605010910 LATCH................................................. 1 .............UP TO S/N3311929

74 0027103010 MACHINE SCREW ............................. 7 .............UP TO S/N3311929

75 0605010911 LATCH................................................. 2 .............UP TO S/N3311929

76 0027104010 MACHINE SCREW ........................... 14 ............. UP TO S/N3311929

77 3335104104 RUBBER SEAL 2
78 3335104204 RUBBER SEAL 2
79 3335104304 RUBBER SEAL 3
80 3335104404 RUBBER SEAL 1
81 3335104504 RUBBER SEAL 1
82 3335104604 RUBBER SEAL 1
83 3335104704 RUBBER SEAL 1
84 3335104804 RUBBER SEAL 2
85 3335104904 RUBBER SEAL 2
86 3335103004 RUBBER SEAL 2
87 3335103104 RUBBER SEAL 2

PAGE 83 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DECAL ASSY.

DCA-25SSAI --- DECALS

PAGE 84 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

DCA-25SSAI --- DECALS

DECAL ASSY.

NO. PART NO. ITEM QTY. REMARKS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

17 M9520100503 DECAL; WARNING ................................................. 1 ..... REPLACES M9510100104

18 M9520100503 DECAL; WARNING ................................................. 1 ..... REPLACES M9510100204

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

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

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

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

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

24 M9520100503 DECAL; WARNING ................................................. 1 ..... REPLACES M9520100104

M9520100503 DECAL; WARNING ................................................. 1 ..... M92010050 M9100601~

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

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

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

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

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

30 M1560100403 STRIPE;WHISPERWATT 1
31 M1560100303 STRIPE;MQ POWER 2
32 M1560100004 STRIPE; 3
33 M1560100504 STRIPE; 25 2
34 M1560100104 STRIPE 1
35 M1560100204 STRIPE 1

PAGE 85 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- CYLINDER HEAD AND COVER ASSY.

CYLINDER HEAD AND COVER ASSY.

PAGE 86 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

ISUZU C240 --- CYLINDER HEAD AND COVER ASSY.

CYLINDER HEAD AND COVER ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 5111102070 CYLINDER HEAD ASSY. 1
3 1096000051 SEALING CUP, RR FACE D=44 1
3-1 5111290060 SEALING CUP, LOWER D=16 4
3-2 5112190080 SEALING CUP, UPPER D=18 5
3-3 5096000130 SEALING CUP, DRILLED D=12 4
4 9098605220 PLUG; LOWER CYLINDER HEAD PLATE 4
7 5117150230 VALVE SEAT INLET INSERT 4
8 5117110260 VALVE SEAT EXHAUST INSERT 4
9 5117210160 VALVE INLET HEAD GUIDE 4
9-1 5117210160 VALVE EXHAUST HEAD GUIDE 4
11 5111501080 HOT PLUG ASSY. 4
14 5125690060 INLET AND EXHAUST VALVE SEAL 8
16 9041108350 MANIFOLD STUD 3
16-1 9041108400 MAINFOLD STUD 3
16-2 9041108450 MANIFOLD STUD 1
21 5111410690 CYLINDER HEAD GASKET 1
22 5090090530 BOLT 19
29 5111702400 CYLINDER HEAD COVER ASSY. 1
30 9117510381 OIL FILLER CAP 1
31 5111790520 BREATHER NIPPLE 1
49 5111730170 HEAD COVER PACKING 1
51 9111798080 HEAD COVER FIX. PACKING 2
52 9111791320 WAHER 2
54 5090000960 BOLT 2
60 5096050050 CYLINDER HEAD OIL COOLER PLUG 1

PAGE 87 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

CYLINDER BLOCK ASSY.

ISUZU C240 --- CYLINDER BLOCK ASSY.

PAGE 88 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

ISUZU C240 --- CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 5112101771 CYLINDER BLOCK ASSY. 1
2 9098025910 BOLT 10
4 9096640340 PLUG; 1/2 TAPPET CHAMBER 2
4-1 5112190080 SEALING CUP CHAMBER D=18 2
5 5116100010 BEARING KIT; CAM. STANDARD 1
6 5112190180 SEALING CUP RR FACE D=36 1
6-1 5112190170 SEALING CUP RR FACE D=38 1
6-2 5112190150 SEALING CUP LH SIDE D=32 2
6-3 5096000130 SEALING CUP RR FACE D=12 1
6-4 1096000051 SEALING CUP LH SIDE D=45 3
7 9112612300 CYLINDER LINER 4
8 8942505140 PLUG; CAMSHAFT BRIDGE PLATE 1
9 5111290060 PLUG; OIL GALLERY PLATE 2
10 5112210020 DUCT; CYL. BLOCK WATER 1
11-1 5096050161 PLUG; OIL GALLERY 1/8 1
12-1 9992023160 PLUG; OIL GALLERY SCREW 1
13-1 9095714160 PLUG PACKING 1
26 5096500210 INJ. PUMP OIL FEED NIPPLE 1
27-1 9112976500 TAPPET CHAMBER COVER ASSY. 1
28 9113111530 FRONT CYL. BLOCK PLATE 1
29 5113120110 FRONT PLATE PACKING 1
31 9081510240 FRONT PLATE STRAIGHT PIN 2
32 9019008220 BOLT 3
36 9099022990 ROCKER OIL FEED NIPPLE 1
37 9081610320 REAR PLATE STRAIGHT PIN 1
42-1 9019008180 BOLT 12
42-2 9019008220 BOLT 2
43 9099168160 TAPPET CHAMBER COVER CLIP 2

46 5112920110 CHAMBER COVER PACKING ......................... 1 .......... REPLACES 5112920150

47-1 9097040380 WATER DRAIN COCK 1
52 9098785970 CRANK CASE PIN 2
54-2 8942008311 BOLT 1
55 9099138340 PIPE; VINYL WATER DRAIN 1
56 9112290490 CYLINDER BLOCK DOWEL 2
58-2 5117400211 BREATHER AIR ASSY. 1
59 9099210990 BREATHER PACKING 1
64-1 9097130870 PIPE; VINYL BREATHER 1
66 9099152380 CLIP 1
67 9019008180 BOLT 1
69 9091645080 WASHER 1
77 9123631120 SPACER; OIL SEAL 1
78 5096250360 CRANK SHAFT REAR SEAL 1
81 9113411940 REAR CYLINDER BLOCK PLATE 1
84 5090002270 BOLT 3
99 9112581080 OIL PAN BRIDGE CAP PACKING 2
117 5117490340 BREATHER HEAD PACKING 1
120 9019008180 BOLT 2
121 9019608180 BOLT 1
130 9092023080 PLUG; OIL GALLERY SCREW 1
131 9095714080 SCREW PLUG PACKING 1

PAGE 89 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

TIMING GEAR ASSY.

ISUZU C240 ---TIMING GEAR ASSY.

PAGE 90 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

ISUZU C240 --- TIMING GEAR ASSY.

TIMING GEAR ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 5113110282 TIMING GEAR CASE 1
2 9113211480 GEAR CASE COVER 1
3 9099206010 PACKING 1
4 901906140 BOLT 4
8 9113120460 PACKING 2
9 5096250790 OIL SEAL 1
12 9113270450 POINTER 1
14 9113120340 PACKING 1
17 9019108320 BOLT 9

PAGE 91 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

FLYWHEEL HOUSING ASSY.

ISUZU C240 FLYWHEEL HOUSING ASSY.

PAGE 92 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

ISUZU C240 FLYWHEEL HOUSING ASSY.

FLYWHEEL HOUSING ASSY.

NO. PART NO. ITEM QTY. REMARKS

1-5 5113410191 FLYWHEEL HOUSING 1
11 9113430391 COVER 1
12 9019006120 BOLT 6
21 5113490380 STIFFENER; RIGHT SIDE 1
22 5113490370 STIFFENER; LEFT SIDE 1
23 9019110200 BOLT 2
23-1 9019110180 BOLT 2
31 9019310450 BOLT 4
41 9019110350 BOLT 3
41 9010560400 BOLT 1
42 9091104100 NUT 2
46 9091505100 LOCK WASHER 2

PAGE 93 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

OIL PAN ASSY.

ISUZU C240 OIL PAN ASSY.

PAGE 94 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

ISUZU C240 OIL PAN ASSY.

OIL PAN ASSY.

NO. PART NO. ITEM QTY. REMARKS

1-2 5113601832 OIL PAN ASSY. ................................ 1 ................ INCL. ITEMS W/*

3* 5096050050 OIL DRAIN PLUG, 3/8 1
3-1 9992023200 OIL DRAIN PLUG 1
4-1* 9097205600 O RING PACKING 1
6 9112150810 CRANK CASE 1
17 5113670040 OIL CASE PACKING 1
24 9992023160 OIL THERMO PLUG 1
26 9095714160 PLUG PACKING 1
29 9019106160 BOLT 30
31 9112193160 DISTRIBUTION PLATE 1
32 9030906160 SCREW 4
36 9117606090 OIL LEVEL GAUGE 1
42 9019008220 BOLT 16
42-1 9019708450 BOLT 4

51 5117400870 OIL FILLER ASSY. ........................... 1 ................ INCL. ITEMS W/#

52# 5117410100 OIL FILLER 1
53# 5117500021 OIL FILLER CAP 1
56 9099207080 PACKING 1
57 9019008200 BOLT 2

PAGE 95 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

OIL PUMP ASSY.

ISUZU C240 ---OIL PUMP ASSY.

PAGE 96 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

ISUZU C240 ---OIL PUMP ASSY.

OIL PUMP ASSY.
NO. PART NO. ITEM QTY. REMARKS

1 9131008010 OIL PUMP ASSY. ................................. 1 ........... INCL. ITEMS W/*

6* 5131200040 ROTOR SET .......................................... 1 ........... INCL. ITEMS W/#

8*# 9131290170 PIN 1
11*# 9098780840 PIN 1
12* 9131280790 PINION 1
13* 9131130771 COVER 1
14* 9020408250 BOLT 4
15* 9091505080 LOCK WASHER 4
16* 9091505080 LOCK WASHER 4

21* 9131401200 OIL STRAINER ASSY. .......................... 1 ........... INCL. ITEM W/%

22*% 9131430100 OIL STRAINER GAUZE 1
41 9019708250 BOLT 2

PAGE 97 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

PAGE 98 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)

ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

NO. PART NO. ITEM QTY REMARKS

1 5115100211 CRANK BEARING KIT;STD 1
1-1 5115300211 CRANK BEARING KIT;-0.25 1
1-2 5115400211 CRANK BEARING KIT;-0.50 1
2 9115810570 THRUST BEARING 2
3 5121112020 PISTON;STD 4
4 5121210070 PISTON RING SET;STD 4
6 5122110090 PISTON PIN 4
7 5095870010 SNAP RING 8

8-1 5122300390 CONNECTING ROD ASSY. .................... 4 ..................... INCL. ITEMS W/@

9-1@ 5122510050 SMALL END BUSHING 4
11-1@ 512350090 BOLT 8
12@ 5094090160 NUT 8

13 8941422080 CONN. ROD BEARING SET;STD ........... 4 .................... REPLACES 5122710050

13-1 8941631740 BEARING SET;-0.25 4
13-2 8941631750 BEARING SET;-0.50 4

14 8941396690 CRANKSHAFT ASSY. ............................ 1 .................... INCL. ITEM W/#

15# 9081612200 STRAIGHT PIN 1
17 5098010010 RADIAL BALL BEARING 1

25-1 5123301100 FLYWHEEL ASSY. .................................. 1 .................... INCL. ITEM W/%

27% 9123330361 RING GEAR ............................................ 1 .................... Z=108

31 9098785320 STRAIGHT PIN 2
33 5090001461 BOLT 6
34 5123360100 WASHER 1
36 9080307430 FEATHER KEY 1

37 9125210420 CRANKSHAFT GEAR ............................. 1 .................... Z=21

38 9123620390 THROWER 1
60-1 9123736051 CRANKSHAFT PULLEY 1
64-1 9098026060 BOLT 1
67 9123736060 THROWER 1
69 9123790160 WASHER 1

PAGE 99 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

OIL AND FUEL FILTER ASSY.

ISUZU C240 --- OIL AND FUEL FILTER ASSY.

PAGE 100 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)