MULTIQUIP Power WHISPERWATT DCA-40SSI Parts And Operation Manual

PARTS AND OPERATION MANUAL

PARTS AND OPERATION MANUAL

MQ POWER

DCA-40SSI

TM

WHISPERWATT

GENERATOR

© COPYRIGHT 2001, MULTIQUIP INC.

PARTS LIST NO. 8051204

FINAL COPY

MULTIQUIP INC

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

..

. PARTS DEPARTMENT:

..

SERVICE DEPARTMENT:

PAGE 2 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

HERE'S HOW TO GET HELP

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

PARTS DEPARTMENT

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

SERVICE DEPARTMENT

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

WARRANTY DEPARTMENT

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

MAIN

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 3

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

DCA-40SSI Specifications ............................................ 23

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Engine Troubleshooting ............................................. 60-61

Generator/Engine Troubleshooting ................................. 62

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

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

MQ POWER DCA-40SSI
AC GENERATOR

Generator Assembly .................................................66-67

Control Box Assembly ..............................................68-71

Engine & Radiator Assembly .................................... 72-73

Engine Operating Panel Assembly ...........................74-75

Output Terminal Assembly ........................................76-77

Battery Assembly .....................................................78-79

Muffler Assembly ..................................................... 80-81

Fuel Tank Assembly .................................................82-83

Enclosure Assembly ................................................84-87

Rubber Seal Assembly ............................................. 88-89

Name Plate And Decals ........................................... 90-91

ISUZU 4BG1 ENGINE

Cylinder Head Cover Assembly ................................92-93

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

Cylinder Block Assembly ......................................... 96-97

Oil Pan and Level Gauge Assembly .........................98-99

Camshaft and Valve Assembly.............................. 100-101

Crankshaft, Piston and Flywheel Assembly .......... 102-103

Timing Gear and Flywheel Housing Assembly ...... 104-105

Engine Mounting Assembly ................................... 106-107

Inlet Manifold Assembly ........................................ 108-109

Exhaust Manifold Assembly .................................. 110-111

Ventilation Assembly ............................................. 112-113

Water Pump and Corrosion Resistor Assembly ..... 114-115

Thermostat and Housing Assembly ...................... 116-117

Engine Water Piping Assembly.............................. 118-119

Fan and Fan Belt Assembly .................................. 120-121

Fuel Injection Assembly ........................................ 122-123

Fuel Filter and Bracket Assembly ......................... 124-125

Fuel Pump and Piping Assembly .......................... 126-127

Oil Cooler and Oil Filter Assembly ........................ 128-129

Oil Pump and Oil Strainer Assembly ..................... 130-131

Oil and Vacuum Piping Assembly ......................... 132-133

Electrical Control Assembly ..................................134-135

Battery Relay Assembly ........................................ 136-137

Starter Component Assembly ............................... 138-139

Inj. Pump Component Assembly ........................... 140-143

Governor Component Assembly ............................ 144-147

Feed Pump Assembly ........................................... 148-149

Misc. Inj. Pump Assembly ..................................... 150-151

Coupling Assembly ................................................152-153

Accelerator Pedal Assembly ................................. 154-155

Air Duct Assembly ................................................ 156-157

Water Sedimenter Assembly ................................. 158-159

Clutch Assembly ................................................... 160-161

Switch and Relay Assembly .................................. 162-163

Terms and Condition of Sale — Parts ....................... 164

NOTE

Specification and part number
are subject to change without
notice.

PAGE 4 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

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 DiscountExtra Fax Discount

Extra Fax Discount

Extra Fax DiscountExtra Fax Discount

for Domestic USAfor Domestic USA

for Domestic USA

for Domestic USAfor Domestic USA

Dealers OnlyDealers Only

Dealers Only

Dealers OnlyDealers Only

UPS

Special

For faxed orders only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

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

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

RULES FOR SAFE OPERATION

■

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

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

GENERAL SAFETY

■

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

■

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

■

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

■

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

■

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

■

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.

■

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

■

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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

hot

components can cause serious

:

■

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.

■

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

■

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

■

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

PAGE 6 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

■

NEVER operate the generator in an

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

causing severe

death.

■

Topping-off to filler port is

dangerous, as it tends to spill fuel.

bodily harm or even

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

■

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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

:

:

RULES FOR SAFE OPERATION

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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.

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

:

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.

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

■

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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

:

Never use damaged or worn cables when

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

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

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.

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 7

RULES FOR SAFE OPERATION

■

Battery

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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

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

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

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

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

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

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

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

:

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

clothing or skin

, rinse skin or clothing

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

■

Always service air cleaner frequently to prevent carburetor
malfunction.

■

Always disconnect the battery before performing service
on the generator.

■

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

■

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

■

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

■

DO NOT allow unauthorized people to operate this
equipment.

■

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

■

Refer to the
technical questions or information.

Loading and Unloading (Crane)

■

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

■

Always drain fuel prior to lifting.

■

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

■

NEVER lift the machine while the engine is running.

■

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

■

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

■

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

Isuzu Engine Owner's Manual

for engine

PAGE 8 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

■

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.

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
and

first aid kit

Also know the phone numbers of the nearest

doctor

and

. Know the location of the nearest telephone.

fire department

.

fire extinguisher

ambulance

Maintenance Safety

■

NEVER lubricate components or attempt service on a
running machine.

■

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

■

Keep the machinery in proper running condition.

■

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

■

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

■

DO NOT use plastic containers to dispose of hazardous
waste.

,

■

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 9

DCA-40SSI — TOWING RULES FOR SAFE OPERATION

Towing Safety Precautions

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

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

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

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

■

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

■

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

■

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

■

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

■

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

■

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

■

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

■

Place
rolling, while parked.

■

Place
prevent tipping, while parked.

■

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

■

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

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

underneath wheel to prevent

underneath the trailer’s bumper to

Figure 1. Generator with Trailer

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

DCA-40SSI — TRAILER-SAFETY GUIDELINES

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

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

Explanation of Chart:

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

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



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions with reading Table 1.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

or lug nut tightening and

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 11

DCA-40SSI —TRAILER-SPECIFICATIONS

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PAGE 12 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI —TRAILER-SPECIFICATIONS

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DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 13

DCA-40SSI —TRAILER SAFETY GUIDELINES

Brakes

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

Electric Brakes

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



Brake system can be manually adjusted to provide

the corrected braking capability for varying road and
load conditions



Brake system can be modulated to provide more or

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



Brake system has very little lag time between the time

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



Brake system can provide an independent emergency

brake system

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

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

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

Electric Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

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

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

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

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

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

PAGE 14 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — TRAILER SAFETY GUIDELINES

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such
as shoe and lining replacement. These brakes can be
adjusted in the same manner as electric brakes. Brake

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

lines should be periodically checked for cracks, kinks, or
blockage.

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 15

Figure 3. Hydraulic Brake Components

DCA-40SSI — TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

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

CAUTION:

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

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

Tire Wear/Inflation

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

Suspension

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

CAUTION:

NOTE

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

PAGE 16 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

Figure 4. Major Suspension Components

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DCA-40SSI —TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FIT ONLY.PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

-

RETAIN NUT

BOLT ASSEMBLY

.

.

05-XAM03-NIM

Lug Nut Torque Requirements

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

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 5. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 4.

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

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DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 17

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Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-40SSI —TRAILER-WIRING DIAGRAM

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

NOTE:

DCA-40SSI —TRAILER-BRAKE TROUBLESHOOTING

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DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 19

DCA-40SSI —TRAILER-BRAKE TROUBLESHOOTING

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PAGE 20 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — GENERATOR DECALS

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 21

DCA-40SSI — GENERATOR DECALS

PAGE 22 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — SPECIFICATIONS

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DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 23

DCA-40SSI — GENERAL INFORMATION

DCA-40SSI FAMILIARIZATION

Generator

The MQ Power Model DCA-40SSI is a 26 kW
that is designed as a high quality portable (requires a trailer
for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.

Engine Operating Panel

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

z

Tachometer

z

Water Temperature Gauge

z

Oil Pressure Gauge

z

Charging Ammeter Gauge

z

Fuel level gauge

z

Engine Speed Control

z

Pre-Heat Button

z

Panel Light

z

Panel Light Switch

z

Starter /Preheat Switch

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

z

Voltage Regulator

Output Terminal Panel

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

generator

Open Delta Excitation System

The DCA-40SSI generator is equipped with the state of the
art "

Open-Delta

consist of an electrically independent winding wound among
stationary windings of the AC output section.

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

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

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

Engine

The DCA-40SSI is powered by a 4 cycle, water cooled,
turbocharged Isuzu 4BG1
designed to meet every performance requirement for the
generator. Reference Table 7, page 23 for engine
specifications.

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

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

" excitation system. The open delta system

Automatic Voltage Regulator

fixed ceiling

diesel

(AVR) is supplied

" and responds

engine. This engine is

z

Three 120/240V output receptacles, 50 amp

z

Two 120V input receptacles, 20 amp

z

3 Load Circuit Breakers 240/120V @50 amps

z

2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:

z

Main Circuit Breaker 110 amps

z

Over-Current Relay

PAGE 24 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

Mechanical Governor System

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

DCA-40SSI — MAJOR COMPONENTS

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 25

Figure 6. Major Components

DCA-40SSI — DIMENSIONS (SIDE AND BACK)

PAGE 26 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

Figure 7a. Dimensions

DCA-40SSI — DIMENSIONS (TOP AND FRONT)

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 27

Figure 7b. Dimensions

DCA-40SSI — CONTROL PANEL

PAGE 28 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

Figure 8. Control Panel

DCA-40SSI — CONTROL PANEL

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

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

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

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

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

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

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

Control Panel

" (Figure 8).

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 29

DCA-40SSI — ENGINE OPERATING PANEL

PAGE 30 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

Figure 9. Engine Operating Panel

DCA-40SSI — ENGINE OPERATING PANEL

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

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

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

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

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

4. Water Temperature Gauge – During normal operation
this gauge be should read between 165o to 215o.

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

Engine Operating Panel

" (Figure 9).

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

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

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

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

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 31

DCA-40SSI — OUTPUT TERMINAL PANEL

Output Terminal Panel

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

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

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.

Connecting Load

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

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

Circuit Breakers

Figure 10. GFCI Test Button

To protect the generator from an overload,

main

circuit breaker is provided to protect the UVWO output

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

Generator Grounding

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

GFCI

circuit breakers are provided to protect the GFCI
receptacles from overload. Three 50 amp
breakers have also been provided to protect the load side of
the generator from overload. Make sure to switch
breakers to the "OFF" position prior to starting the engine.

Maximum Output

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

Generator Grounding

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

Figure 11. Load Application

a 3-pole, 110 amp,

load

ALL

circuit

circuit

PAGE 32 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — OUTPUT TERMINAL VOLTAGE SELECTION

DCA-40SSI

Figure 12. Output Panel Location

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 33

NOTE

Legs O and Ground are
considered Bonded Grounds.

DCA-40SSI — OUTPUT AMPERAGE SETUP

Output Terminal Panel Available Voltages

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

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Over Current Relay

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

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CAUTION :

Maximum Amps

NEVER switch Voltage Selector Switch

position while the engine is engaged.

Voltage Selector Switch Locking Button

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

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

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PAGE 34 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — OUTPUT AMPERAGE SETUP

Receptacle Use

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

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Figure 13. Voltage Selector Switch 240/120V Single

Phase Position

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226.3

Figure 14 and 15. AC Voltmeter Change-over switch

How To Read The Output Terminal Gauges.

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

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

Figure 16 and 17. AC Ammeter Change-over Switch

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

and Voltmeter Gauge

40

20

0

60

A

and Ammeter Gauge

NOTE

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

75

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 35

DCA-40SSI — OUTPUT VOLTAGE SETUP

240/120V Hard Wire Hookup

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

480/240V Hard Wire Hookup

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

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

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

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

Position

PAGE 36 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

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

DCA-40SSI — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- 3 Phase 480/277V Position

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

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

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

Figure 21. Voltage Regulator Knob

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

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

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

or 416V

Figure 22. Hard Wire Hookup for Three Phase 480V, 440V, or

416V

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

This setting can provide single phase power at 277, 254, or
240 volts. After hooking up the hard wires to the lugs as
shown in Figure 24, 277 volts can be obtained with the volt­age regulator knob turned toward maximum; 254 volts can
be obtained with the voltage regulator knob is turned down;
and 240 volts can be obtained with the voltage regulator
knob is at the lowest setting.

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

or 240V

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 37

DCA-40SSI — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- 3 Phase 240/139V Position

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

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

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

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

Figure 25. Voltage Selector Switch 240/139V Three Phase

Position

or 208V

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

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

This setting can provide 3-phase power at 240, 220, or 208
volts. After hooking up the hard wires to the lugs as shown
in Figure 26, 240 volts can be obtained with the voltage
regulator knob turned toward maximum; 220 volts can be
obtained with the voltage regulator knob is turned down; and
208 volts can be obtained with the voltage regulator knob is

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

at the lowest setting.

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

208V

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

or 120V

PAGE 38 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — OUTPUT VOLTAGE SETUP

Voltage Selector Switch- Single Phase 240/120V
Position

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

Figure 29. Voltage Selector Switch 240/120V Single Phase

Position

Single Phase: 120 Volt

This setting can provide single phase power at 120 volts.
After hooking up the hard wires to the lugs as shown in
Figure 31, 120 volts can be obtained with the voltage regula­tor knob turned to fine tune.

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

Single Phase, 240 Volt

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

Figure 30. Hard Wire Hookup for Single Phase 240 volt

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 39

DCA-40SSI — 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 it cannot slide or shift around. Also install
the generator so 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 the
engine and alternator parts.

CAUTION :CAUTION :

CAUTION :

CAUTION :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.

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.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Generator Grounding

To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.

Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.

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

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

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

2. When grounding the generator (Figure 31) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.

:

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.

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

NOTE

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

DCA-40SSI — INSTALLATION

Figure 31. Typical Generator Grounding Application

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 41

DCA-40SSI — PRE-SETUP

General Inspection Prior to Operation

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

Extension Cable

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

Circuit Breakers

To protect the generator from an overload, a 3-pole, 110 amp,

main

circuit breaker is provided to protect the UNV output

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

GFCI

circuit breakers are provided to protect the GFCI
receptacles from overload. Three 50 amp
have also been provided to protect the load side of the
generator from overload. Make sure to switch
breakers to the "OFF" position prior to starting the engine.

load

circuit breakers

ALL

circuit

NOTE

ALWAYS consult with a licensed

electrician for correct extension
cord wire size.

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PAGE 42 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — PRE-SETUP

Lubrication Oil

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

Fuel

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

Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 23
Specification Table 7.

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

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

to prevent fire hazards.

Coolant

diesel fuel

Never fill the fuel tank while the engine is
running or in the dark. Gasoline spillage

on a hot engine can cause a fire or
explosion. If gasoline spillage occurs,
wipe up the spilled gasoline completely

. DO NOT

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

Figure 32. Engine Oil Dipstick

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

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

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DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 43

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DCA-40SSI — PRE-SETUP

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

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

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

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

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Operation in Freezing Weather

When operating in freezing weather, be certain the proper
amount of antifreeze (Table 14) has been added.

Cleaning the Outer Radiator

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

Air Cleaner

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

Fan Belt Tension

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

The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 33) when depressed with the thumb as shown
below. Never place hands near the belts or fan while the
generator is running.

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water, the antifreeze mixing ratio must
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CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

Adjusting Fan Belt

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

Figure 33. Fan Belt Tension

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

PAGE 44 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — PRE-SETUP

Battery

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

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

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

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

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

RED

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

When connecting battery do the following:

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

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

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

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

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

Wiring

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

Piping and Hose Connection

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

Figure 34. Battery Connections

Alternator

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

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

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

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 45

DCA-40SSI — LOAD APPLICATION

Single Phase Load

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

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

NOTE

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

WATTS = VOLTAGE x AMPERAGE

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

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CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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

z

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

z

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

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

CAUTION:

:

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

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

NOTE

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

Three Phase Load

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

PAGE 46 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — GENERATOR START-UP PROCEDURE

WARNING:WARNING:

WARNING:

WARNING:WARNING:

The engine's exhaust contains harmful
emissions.
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.

Before Starting

Engine

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

2. When there is not enough lubricating oil, fill the crankcase
with high grade motor oil. Use a high quality detergent
oil classified CC or higher (See Table 12 on page 43).

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

ALWAYS

ventilate the

2. Connect the load to the UNV terminals as shown in
Figure 36. These terminals can be found on the output
terminal panel,
to the output terminals lift the UNV cover. Tighten
terminal nuts securely to prevent load wires from slipping
out.

(see page 33 Figure 12). To gain access

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

Before Starting

Generator and Control Panel

3. Connect the negative battery cable (BLACK) to the

CAUTION:

NEVER start the engine with the

main, GFCI

in the ON position.

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

or

load

circuit breakers

main, load

and

G.F.C.I.

Figure 36. UNV Terminal Lugs (Load)

negative post on the battery (Figure 37).

NEGATIVE

POSTIVE

BATTERY

Figure 37. Battery Connections

Figure 35. Main, GFCI and

Load Circuit Breakers

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 47

DCA-40SSI — GENERATOR START-UP PROCEDURE

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

Figure 38. Engine Enclosure Doors

8. Once the engine is warm and the engine is

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

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

Figure 39. Voltage Selection Switch

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

Figure 42. Engine Speed Switch (high)

the 60 cycle output frequency in HERTZ.

Figure 43. Frequency Meter (Hz)

6. Turn and push the engine throttle control lever

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

(Figure 40) to ‘Low’.

Figure 40. Engine Throttle Control Lever (low)

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

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

Figure 44. Voltage Meter (Volts)

Figure 41. Starter Switch

PAGE 48 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

Figure 45. Voltage Adjust Control Knob

DCA-40SSI — GENERATOR START-UP PROCEDURE

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

40

20

0

60

75

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

A

Figure 46. Ammeter (No Load)

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

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

Figure 49. Engine Tachometer

Figure 47. Oil Pressure Gauge

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

Figure 50. Main and GFCI Circuit Breakers

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

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

WATER

Figure 48. Coolant Temperature Gauge

TEMP

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

40

20

0

60

75

A

Figure 51. Ammeter (Load)

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 49

DCA-40SSI — GENERATOR SHUTDOWN PROCEDURE

ENGINE SHUTDOWN

To shutdown the generator, use the following procedure:

EMERGENCY STOP

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

1. Switch both the MAIN, GFCI and LOAD circuit breakers

position.

(Figure 52) to the “OFF” position.

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

Figure 52. Main, GFCI and Load

circuit breakers

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

53) to the idle (low) position.

Figure 53. Engine Throttle Control Lever

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

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

54).

Figure 54. Off/Manual Auto Switch

5. Remove the load from the UNV terminal strip.

PAGE 50 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

NOTE PAGE

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 51

DCA-40SSI — MAINTENANCE

General Inspection

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

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

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

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

Fuel Addition

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

Removing Water from the Fuel Tank

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

Air Removal

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

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

Service Daily

Cleaning the Fuel Strainer

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

Check Oil Level

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

Replacing Oil Filter

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

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

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

Replacing Fuel Filter

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

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

Vent any air.

Fuel Injection Nozzle

z

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

z

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

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

PAGE 52 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

Feed Pump Strainer Cleaning

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

Flushing Out Radiator and Replacing Coolant

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

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

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

Tighten both cocks and replace the overflow tank.

DCA-40SSI — MAINTENANCE

Replace with coolant (see page 44, Table 14 for mixture).
Close radiator cap tightly.

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 53

DCA-40SSI — MAINTENANCE

Valve Clearance Check

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

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

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

o

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

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

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

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

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

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

arrangement.

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

Injection Timing Check and Adjustment

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

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

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

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

o

crank angle.

Figure 55. Valve Adjustment

NOTE:

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

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

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

o

timing mark.

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XXX X

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OO OO

PAGE 54 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — MAINTENANCE

ECNANETNIAM/NOITCEPSNI

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

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1

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ENIGNE

2

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leveL

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srH01

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X

X

X

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ROTARENEG

1

*

2

*

Generator Storage

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

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z

Clean all external parts of the generator with a cloth.

z

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

is required:

z

Fill the fuel tank completely.

z

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

X

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DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 55

DCA-40SSI — ENGINE WIRING DIAGRAM

PAGE 56 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — ENGINE WIRING DIAGRAM

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 57

DCA-40SSI — GENERATOR WIRING DIAGRAM

PAGE 58 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

NOTE PAGE

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 59

DCA-40SSI — 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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?deggolcretlifleuF .retlifleufegnahcronaelC

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

?tungniniaterepip

diagnosis based on the Engine Troubleshooting (Table 1 7).
If the problem cannot be remedied, consult our company's
business office or service plant.

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.tunnethgiT

GNITOOHSELBUORTENIGNE.71ELBAT

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.ecalperroriapeR

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.redlohelzzon

.nurtonseodretratS

?detcennocsidgniriW .gniriwtcennoC

PAGE 60 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

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?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.71ELBAT

?tungniniaterepip

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?erusserp

?deggolc

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.devresbosi

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.devresbosisag

?kcuts

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?deggolcrenaelcriA .egnahcronaelC

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rokcutselzzonnoitcejnI

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?gninoitcnuflamronrevoG .riapeR

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.tunnethgiT

.tsujdA

.ecalperroriapeR

.ecalperroriapeR

.tuptuotneicifeD

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 61

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

?gnizieseb

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?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-40SSI — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table18) . If the
problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG.81ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

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?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

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tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

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?RVAevitcefeD .yrassecenfiecalpeR

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?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 62 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

NOTE PAGE

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 63

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 64 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI — SUGGESTED SPARE PARTS

DCA-40SSI W/ISUZU 4BG1 DIESEL ENGINE
1 TO 3 UNITS

Qty. P/N Description

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 65

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-40SSI --- GENERATOR ASSY.

PAGE 66 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI --- GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 8051000032 ROTOR ASSY. 1
1-1 FIELD ASSY. 1
1-2 8051070003 FAN 1

1-3 0105091025 HEX. HEAD BOLT ............................8 .......... REPLACES 0010310025

1-4 030210250 LOCK WASHER ...............................8 .......... REPLACES 0042510000

1-5 8041611004 COUPLING DISK 4
1-6 8041015003 BALANCING PLATE 1

1-7 0105091025 HEX. HEAD BOLT ............................6 .......... REPLACES 0010310025

1-8 0042610000 LOCK WASHER 6
1-9 8001026013 SET PLATE, RECTIFIER 1

1-10 0601821349 RECTIFIER ......................................2 .......... PT 3610

1-11 0601822601 SURGE ABSORBER ....................... 1 .......... ERZ-M14JK621A

1-12 8001020004 INSULATOR WASHER 1
1-13 8001020504 INSULATOR WASHER 1

1-14 011008020 HEX. HEAD BOLT ............................4 .......... REPLACES 0010108020

1-15 0040080000 LOCK WASHER 4
1-16 0601000209 BALANCING WEIGHT KIT 1

1-17 0070806309 BEARING .........................................1 .......... 6309DU

2 8051614003 COUPLING RING .............................1 .......... REPLACES M1163400203

3 8051653004 REAMER BOLT 1

4 012010030 HEX. HEAD BOLT ............................7 .......... REPLACES 0012110030

5 030210250 LOCK WASHER ...............................9 .......... REPLACES 0042510000

6 8051340503 STRATOR ASSY. 1
7 0845041904 GROMMET 2
8 8041315102 END BRACKET 1
9 8041350013 FIELD ASSY. EXCITER 1
10 0010308065 HEX. HEAD BOLT 4
11 0042608000 LOCK WASHER 4

12 031108160 PLAIN WASHER .............................. 4 .......... REPLACES 0041208000

13 0010108025 HEX. HEAD BOLT 6
14 0040008000 LOCK WASHER 6

15 031108160 PLAIN WASHER .............................. 6 .......... REPLACES 0041208000

16 060100003 WAVE WASHER ...............................1 .......... BWW6309

17 8041310014 COVER, BEARING 1
18 8041312004 GASKET, BEARING 1
19 8041331014 COVER, END BRACKET 1

20 0105050616 HEX. HEAD BOLT ............................ 8 .......... REPLACES 0017106012

21 8001333003 COVER, END BRACKET 1
22 0010106030 HEX. HEAD BOLT 2
23 0040006000 LOCK WASHER 2

24 952404470 PLAIN WASHER .............................. 2 .......... REPLACES 0041206000

25 0105091025 HEX. HEAD BOLT ............................ 6 .......... REPLACES 0010310025

26 030210250 LOCK WASHER ...............................6 .......... REPLACES 0042510000

27 8051332003 COVER, FAN 1
28 0605000010 RUBBER SUSPENSION 2
29 0030012000 HEX. NUT 4

0040012000 LOCK WASHER 4

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 67

CONTROL BOX ASSY.

DCA-40SSI --- CONTROL BOX ASSY.

PAGE 68 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 8081812502 CONTROL BOX 1

2 0601801145 CURRENT TRANSFORMER, AMMETER ..... 3 ......... CT3.5MR 150/5A

3 0027104010 MACHINE SCREW 6

4 0601823860 RELAY UNIT .................................................. 2 ......... MSA9013

5 0027104016 MACHINE SCREW 4

6 0601820671 AUTOMATIC VOLTAGE REGULATOR............ 1 ......... NTA5A2D; REPLACES 0601820628

7 0027105012 MACHINE SCREW 4

8 0601820892 OVER CURRENT RELAY .............................. 1 ......... THK20KP; REPLACES 0601820853

9 0027104016 MACHINE SCREW 2

10 1825500732 EMERGENCY RELAY ................................... 1 ......... REPLACES 1825500730

& 0602200405
11 0027106016 MACHINE SCREW 4

12 0601823706 RELAY ........................................................... 1 ......... JH1A DC24V

13 0027104016 MACHINE SCREW 2

14 0601806522 CURCUIT BREAKER .................................... 1 ......... XE100CS 100AT

15 0021004060 MACHINE SCREW 2

0040004000 LOCK WASHER 2

031104080 PLAIN WASHER ............................................ 2 ......... REPLACES 0041204000

16 M1923100004 SELECTOR SWITCH .................................... 1 ......... REPLACES 8010153104

17 0020004010 MACHINE SCREW ........................................ 4 ......... REPLACES 0021104010

18 8051839504 BRACKET, SELECTOR SWITCH 1
19 0021003010 MACHINE SCREW 4
20 0017106016 HEX. HEAD BOLT 2

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

21 3341822503 CONTROL PANEL 1

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

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

24 0601801040 CHG. OVER SW., AMMETER ....................... 1 ......... SL2VS

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

0601810261 BULB 1

28 0601840073 VOLTAGE REGULATOR ................................ 1 ......... RA20A2SE102BJ 2W 1KOHM

29 0601840121 KNOB 1
30 3331824003 STOPPER, CONTROL PANEL 1
31 0027105016 MACHINE SCREW 2

0030005000 HEX. NUT 2
32 0805001304 SET SCREW 2

33 031108160 PLAIN WASHER ............................................ 2 ......... REPLACES 0041208000

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

35 0027105010 MACHINE SCREW 4
36 8051814304 COVER 1
37 0017106016 HEX. HEAD BOLT 11
38 8081814604 SIDE PANEL 1
39 0017106016 HEX. HEAD BOLT 4
40 0017100025 HEX. HEAD BOLT 4

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 69

ENGINE AND RADIATOR ASSY.

DCA-40SSI ENGINE AND RADIATOR ASSY.

PAGE 70 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI ENGINE AND RADIATOR ASSY.

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

1 4BD1PD02 ENGINE .......................................... 1 .......... ISUZU 4BD1; REPLACES 0602000078

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

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

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

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

6 0602011000 RADIATOR CAP .............................. 1 .......... 7880K11100

7 0017106016 HEX.HEAD BOLT 4
8 3345123104 BRACKET, RADIATOR 2

9 011008020 HEX. HEAD BOLT ........................... 12 ........ REPLACES 0017108020

10 0602013086 RADIATOR HOSE 1
11 0602013186 RADIATOR HOSE 1
12 0602014000 HOSE BAND 2
13 0602014006 HOSE BAND 1
14 0602014071 HOSE BAND 1

15 0602040094 AIR CLEANER ................................ 1 .......... FWG068002

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

16 0602040690 DUST INDICATOR ........................... 1 .......... RBX002252; REPLACES 062040690

17 0602040587 BAND, AIR CLEANER .................... 2 .......... AAH008218

18 0017108020 HEX. HEAD BOLT 4
19 3342032103 HOSE, AIR CLEANER 1
20 0605515011 HSOE BAND 1
21 0605515028 HOSE BAND 1

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

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

24 3345112503 ENGINE FOOT 1
25 3345112403 ENGINE FOOT 1
26 0041210000 PLAIN WSAHER 8
27 0040010000 LOCK WASHER 8

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

29 0605000009 RUBBER SUSPENSION 2
30 0040012000 LOCK WASHER 4

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

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

33 0027106016 MACHINE SCREW 3
34 3342054104 DRAIN JOINT 1
35 0805013704 PACKING, OIL PAN SIDE 1
36 0805014204 PACKING 1
37 3362054104 JOINT BOLT 1
38 3342051104 DRAIN JOINT 1
39 0802024004 PACKING 1

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 71

ENGINE AND RADIATOR ASSY.

DCA-40SSI ENGINE AND RADIATOR ASSY.

PAGE 72 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI ENGINE AND RADIATOR ASSY.

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

40 0802010204 PLUG 1
41 3342022104 DRAIN HOSE 1
42 0605515003 HOSE BAND 2

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

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

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

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

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

50 0199500950 HOSE 1
51 0199500175 HOSE 1
52 0193601000 HOSE 1
53 06055150013 HOSE BAND 4
54 0193900750 BREATHER HOSE 1
55 0605515030 HOSE BAND 2
56 0193100700 HOSE 1
57 0605515007 HOSE BAND 1
58 0193800750 HOSE 1
59 0605515019 HOSE BAND 1
60 3342220604 EARTH CABLE 1

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 73

ENGINE OPERATING PANEL ASSY.

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

PAGE 74 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

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

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

1 3342101003 OPERATING PANEL 1
2 7452142014 SLIDE BAR 1

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

4 020108060 HEX. NUT ....................................... 1 .......... REPLACES 0036003000

5 7452140504 BRACKET, GOVERNOR ROD 1

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

7 0605010503 SNAP PIN 1

8 0602100004 STARTER SWITCH ......................... 1 .......... 18231000080

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

10 0602120054 TACHOMETER ................................ 1 .......... 25000KX4110

11 0602120154 CABLE, TACHOMETER .................. 1 .......... 6211000KA6710 L=1150

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

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

14 0131300000 STREET SOCKET 1

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

16 0602123201 UNIT, WATER TEMPERATURE ....... 1 .......... 54100KV0200

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

18 0602103091 ALARM LAMP ................................. 2 .......... REPLACES 0602103090

0601810214 BULB ............................................... 2 .......... REPLACES 0601810244

19 0601830420 SWITCH, LAMP CHECK 1

20 0601810120 PANEL LIGHT ................................. 1 .......... DL31000

0601810201 BULB 1
21 0040520000 TOOTHED LOCK WASHER 1
22 0601830710 SWITCH, PANEL LIGHT 1

23 011008040 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0010008040

0040008000 LOCK WASHER 2

031108160 PLAIN WASHER ............................. 2 .......... REPLACES 0041208000

24 0017108020 HEX. HEAD BOLT 2
25 8055312103 SUPPORT LEG 1
26 0017110025 HEX. HEAD BOLT 2

27 011208025 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108025

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 75

ENGINE OPERATING PANEL ASSY.

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

PAGE 76 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

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

ENGINE OPERATING PANEL ASSY.

NO. PART NO. ITEM QTY. REMARKS
28 3342183004 LINK, GOVERNOR ROD 1

29 0105091025 HEX. HEAD BOLT ........................... 1 .......... REPLACES 0010010025

30 031110160 PLAIN WASHER ............................. 2 .......... REPLACES 0041210000

31 020310080 HEX. NUT ....................................... 1 .......... REPLACES 0030010000

32 3342182014 GOVERNOR ROD 1
33 3342152114 GOVERNOR ROD 1
34 0602180106 BALL JOINT 2

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

36 0602180108 BALL JOINT 1

37 020106050 HEX. NUT ....................................... 3 .......... REPLACES 0030006000

38 952404470 PLAIN WASHER ............................. 1 .......... REPLACES 0041606000

39 8111860303 SET BOARD, OUTPUT TERMINAL 1

40 0801831704A OUTPUT TERMINAL ....................... 5 .......... REPLACES 0801831704

41 012210020 HEX. HEAD BOLT ........................... 5 .......... REPLACES 0801831804

42 0039310000 HEX. NUT 10
43 0040010000 LOCK WASHER 15
44 0041410000 PLAIN WASHER 20

45 011208030 HEX .HEAD BOLT .......................... 5 .......... REPLACES 0017108030

46 8051865904 COVER, OUTPUT TERMINAL 1
47 0605010051 HINGE 2
48 0027103016 MACHINE SCREW 12

0207003000 HEX. NUT 6
49 0017106016 HEX. HEAD BOLT 2

50 0601811034 RECEPTACLE ................................. 3 .......... CS6369 250V 50A

51 0601811030 RECEPTACLE ................................. 2 .......... 5-20R 125V 20A x 2

52 0027103010 MACHINE SCREW 10

0207003000 HEX. NUT ....................................... 10 ........ REPLACES 0030003000

58413 PLAIN WASHER ............................. 10 ........ REPLACES 0041203000

53 0601805306 CURCUIT BREAKER ...................... 2 .......... KM51 265V 40A

54 0601805840 CIRCUIT BREAKER ....................... 2 .......... KM52 265V 50A

55 8081816303 BRACKET, CIRCUIT BREAKER 1

0223300200 RUBBER SHEET 1
56 0017106016 HEX. HEAD BOLT 2
57 8085182004 RUBBER COVER 1
58 8085183004 SET FRAME, RUBBER COVER 1

59 011206020 HEX. HEAD BOLT ........................... 6 .......... REPLACES 0017106020

60 8051865703 COVER, RECEPTACLE 1

61 012212045 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0010012045

62 031112230 PLAIN WASHER ............................. 4 .......... REPLACES 0041212000

63 0805009804 RUBBER WASHER ......................... 2 .......... REPLACES 0805009804

64 0030012000 HEX. NUT 2
65 0601820015 RECTIFIER 4
66 0601802133 FUSE, 5A 1

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 77

BATTERY ASSY.

DCA-40SSI --- BATTERY ASSY.

PAGE 78 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI --- BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 0168409541 BATTERY ........................................ 2 ........... 95E41R

2 0805003904 BATTERY SHEET 2
3 0805004004 BATTERY BAND 2
4 3802252004 BATTERY BOLT 4

5 031108160 PLAIN WASHER ............................. 4 .......... REPLACES 0041208000

6 0040008000 LOCK WASHER 4
7 0037808000 WING NUT 4
8 0215260050 BATTERY CABLE 1
9 0211160160 BATTERY CABLE 1
10 0215860045 BATTERY CABLE 1

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

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

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

0027808000 WING NUT ...................................... 2 ........... REPLACES 0208008000

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 79

MUFFLER ASSY.

DCA-40SSI --- MUFFLER ASSY.

PAGE 80 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI --- MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3342350103 EXHAUST PIPE 1

2 1141450690 GASKET ......................................... 1 .......... REPLACES 0602320000

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

4 3342311102 MUFFLER 1
5 3342359104 MUFFLER SHEET 1

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

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

8 3342356104 GASKET 1

9 011208035 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108035

10 031108160 PLAIN WASHER ............................. 4 .......... REPLACES 0041208000

11 020108060 LOCK WASHER .............................. 4 .......... REPLACES 0030008000

12 3342354104 COVER 1
13 3342354004 COVER 1
14 3342328104 PIPE CLAMPER 1

15 031108160 PLAIN WASHER ............................. 2 .......... REPLACES 0041208000

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

17 3342359004 COVER SHEET 2

18 011208025 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108025

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 81

FUEL TANK ASSY.

DCA-40SSI --- FUEL TANK ASSY.

PAGE 82 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI --- FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 3345510703 FUEL TANK 1
1-1 0810105004 CAP, FUEL TANK 1
1-2 0810105400 FUEL FILTER 1
1-3 0193100255 FUEL GAUGE HOSE 1
1-4 0605515079 HOSE BAND 2
2 3345523504 TANK BAND 2
3 0805003414 PAD, TANK BAND 4

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

5 020108060 HEX .NUT ....................................... 2 .......... REPLACES 0207008000

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

7 3805522004 TANK SHEET 4
8 0131906000 CAP 1
9 0191300670 SUCTION HOSE 1
10 0191300630 RETURN HOSE 1
11 0605515014 HOSE BAND 4
12 0845032204 DRAIN JOINT 1
13 0150000018 O RING 1
14 0802011104 PLUG 1

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 83

ENCLOSURE ASSY.

DCA-40SSI --- ENCLOSURE ASSY.

PAGE 84 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 8055111102 BASE 1
2 3345116214 FLOOR PANEL 1

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

4 3345116504 COVER 1

5 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

6 3345121302 FRONT FRAME 1

3345109103 LINING 1

7 011008020 HEX. HEAD BOLT ........................... 6 .......... REPLACES 0017108020

8 3345122604 BRACKET, RADIATOR NECK 1

9 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020

10 3345125503 COVER, FRONT FRAME 1

3345109204 LINING 1

11 011008020 HEX. HEAD BOLT ........................... 16 ........ REPLACES 0017108020

12 3345125403 COVER, FRONT FRAME 1

13 011008020 HEX. HEAD BOLT ........................... 10 ........ REPLACES 0017108020

14 3385155104 COVER 2

15 011206020 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0017106020

16 3345125204 COVER, FRONT FRAME 1

17 011008020 HEX .HEAD BOLT .......................... 6 .......... REPLACES 0017108020

18 3345132113 CENTER FRAME 1
19 3345132213 CENTER FRAME 1

20 012210040 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010014040

020114110 HEX. NUT ....................................... 8 .......... REPLACES 0030014000

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

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

21 012012030 HEX .HEAD BOLT .......................... 10 ........ REPLACES 0010012030

0040012000 LOCK WASHER 10

031112230 PLAIN WASHER ............................. 10 ........ REPLACES 0041212000

22 3345141222 REAR FRAME 1

3345109303 LINING 1

23 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

24 3345155113 COVER, REAR FRAME 1

3345109413 LINING 1
25 0010008050 HEX. HEAD BOLT 8

0040008000 LOCK WASHER 8

031108160 PLAIN WASHER ............................. 8 .......... REPLACES 0041208000

26 3345143313 DOOR, REAR FRAME 1
27 3805147104 WINDOW PLATE 1
28 0021006020 MACHINE SCREW 6

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

0040006000 LOCK WASHER 6

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 85

ENCLOSURE ASSY.

DCA-40SSI --- ENCLOSURE ASSY.

PAGE 86 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

952404470 PLAIN WASHER ............................. 6 .......... REPLACES 0041206000

29 0845028303 HINGE 2

30 011208025 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108025

31 3345161212 ROOF PANEL 1

3345109503 LINING 1

32 011008020 HEX .HEAD BOLT .......................... 16 ........ REPLACES 0017108020

33 3345165104 GUIDE PANEL, AIR 2

3345109604 LINING 2

34 011008020 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0017108020

35 8055181102 SPLASHER PANEL 1

3345105314 LINING 1
36 0010008055 HEX. HEAD BOLT 6

0040008000 LOCK WASHER 6

031108160 PLAIN WASHER ............................. 6 .......... REPLACES 0041208000

37 3345124013 SIDE DOOR 1

3345109704 LINING 1
38 3345124113 SIDE DOOR 1

3345109804 LINING 1
39 3345175104 GUIDE PANEL, AIR 2

3345105104 LINING 2

40 011008020 HEX. HEAD BOLT ........................... 12 ........ REPLACES 0017108020

41 3345171813 SIDE DOOR 1

3345109904 LINING 1
42 3345175004 GUIDE PANEL, AIR 1

3345105204 LINING 1

43 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

44 3345171923 SIDE DOOR 1

3345105014 LINING 1
45 0845028203 HINGE 4
46 0845028303 HINGE 4

47 011208025 HEX. HEAD BOLT ........................... 16 ........ REPLACES 0017108025

48 0601850097 RUBBER CUSHION 8
49 0845031504 CAP 10

50 0600500090 EMBLEM......................................... 2 .......... REPLACES 6360510003

51 0021106020 MACHINE SCREW 4

52 B3561100003 STRIPE ........................................... 1 .......... REPLACES 3340630103

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

54 3340630503 STRIPE, RIGHT SIDE 1

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 87

ENCLOSURE ASSY.

DCA-40SSI --- ENCLOSURE ASSY.

PAGE 88 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

55 3340630904 STRIPE 2

56 B3561100403 STRIPE ........................................... 1 .......... REPLACES 3340631104

57 B3561100403 STRIPE ........................................... 1 .......... REPLACES 3340631304

58 B3561100204 STRIPE ........................................... 2 .......... REPLACES 3340630704

59 3345104104 RUBBER SEAL 2
60 3345104204 RUBBER SEAL 2
61 3345104304 RUBBER SEAL 3
62 3345104404 RUBBER SEAL 1
63 3345104514 RUBBER SEAL 1
64 3345104614 RUBBER SEAL 1
65 3345104714 RUBBER SEAL 1
66 3345104804 RUBBER SEAL 2
67 3345104904 RUBBER SEAL 2
68 0225100395 RUBBER SEAL 1
69 0220100395 RUBBER SEAL 1
70 0220200750 RUBBER SEAL 2

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 89

DECAL ASSY.

DCA-40SSI --- DECALS

PAGE 90 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

DCA-40SSI --- DECALS

DECAL ASSY.

NO. PART NO. ITEM QTY. REMARKS

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

2 3340670112 DECAL; GENERATOR CONTROL.......................... 1 ...... S2358B

3 3340670002 DECAL; ENGINE OPERATING .............................. 1 ...... S2361A

4 8050670103 DECAL; AUXILIARY OUTPUT ............................... 1 ...... S3349

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

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

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

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

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

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

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

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

13 M9503000103 DECAL; WATER, OIL CHECK ................................ 1 ...... M90310000

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 91

CYLINDER HEAD COVER ASSY.

ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.

PAGE 92 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.

CYLINDER HEAD COVER ASSY.

NO PART NO PART NAME QTY. REMARKS

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

2# 9117156070 VALVE SEAT, INTAKE 4
3# 9117118030 VALVE SEAT, EXHAUST 4
5# 1096000051 SEALING CUP, REAR FACE 1
5-1# 5112190150 SEALING CUP, EXHAUST MAN. 2
5-2# 1096000160 SEALING CUP, INLET SIDE FACE 4
5-3# 9111291280 SEALING CUP, LOWER FACE 2
5-4# 1096000160 SEALING CUP, TOP FAC 3
5-5# 50960000130 SEALING CUP, DRILLED PASS 4
6# 909600340 PLUG 4
7# 5117210010 VALVE GUIDE 8
9 9111296010 SEAL CUP 4
10 5093000650 ROCKER ARM STUD 3
11 1093000180 INJ. NOZZLE STUD 8
12 9092023100 PLUG, TOP FACE 1
13 9095714100 PACKING, COMMET 1
15 1125690150 VALVE GUIDE SEAL 8
16 9041108250 STUD, INL. MANIFOLD 2
17 9098301770 STUD, EXH. MANIFOLD 3
20 8941458390 GASKET, CYL. HEAD 1

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

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

28& 9117510381 CAP, OIL FILLER 1
33 9111791050 WSAHER
34 9111790300 PACKING, HEAD COVER 3
50 5111730160 PACKING, CYL. HEAD 1
51 9111750120 NUT 1

EA1013

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 93

CYLINDER BLOCK ASSY.

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

PAGE 94 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

NO PART NO PART NAME QTY. REMARKS

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

2# 1112611180 LINING 4
3# 5112570011 DOWEL 1
4# 1090004691 BOLT 10
5# 9116110480 CAM., FRONT METAL 1
5-1# 9116130350 CAM., REAR AND CENTER 2
6# 1096000520 CEALING CUP, FRONT AND REAR 2
6-1# 5112190140 SEALING CUP, CYL. BLOCK 1
6-2# 1096000121 SEALING CUP, TAPPET D=32 2
8 9098600190 PLUG, CAMSHAFT PLATE 1
9 8941480790 DOWEL 2
10 1096050681 PLUG, HEADLESS PT 1/2 2
11 9992055170 OIL PLUG, GALLERY 1
11-1 5096050180 PLUG 7
12 9992023140 OIL PLUG, GALLERY 1
13 9095720140 PACKING 1
14 1097400780 STRAIGHT PIN, GEAR CASE 1
15-1 9081510180 STRAIGHT PIN, FLYWHEEL HSG. 2
18 8941075600 INJ. PUMP NIPPLE 1
19 5112240040 BUSHING, OIL PUMP DRIVE SHAFT1
20 5112901450 COVER, TAPPET CHAMBER 1
21 8943673680 PACKING, CYL. BLOCK COVER 2
22 8941075662 BOLT 2
22-1 8944299951 BOLT 2
23 9095720080 PACKING, COMET 4
27 1096253620 SEAL, REAR OIL CRANK 1
30 5111290030 SEALING CUP, LEVEL GAUGE 1
36 8941745290 COVER, OIL DRAIN 1
37 8943210180 PACKING, COVER 1
38 0500408180 BOLT 2
43 1093000530 STUD, ENGINE FOOT 1
49 5096800110 WATER DRAIN COCK 1
53 9099135050 PIPE 1
54 5097070041 DRAIN PIPE CLIP 1
56 5117401200 AIR BREATHER ASSY. 1
57 9091104080 NUT 2
59 9091505080 LOCK WASHER 2
60 9091645080 PLAIN WASHER 2
61 8944338700 BREATHER HOSE 1

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

66 9097130740 OUOE 1
69 5097040331 CLIP 1

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 95

CYLINDER BLOCK ASSY.

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

PAGE 96 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

ISUZU 4BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

NO PART NO PART NAME QTY. REMARKS

70 0500408160 BOLT 1
71 9091606080 PLAIN WASHER 1
80 8941405811 OIL FILLER ASSY. 1
81 1117500120 OIL FILLER CAP 1
82 9091104080 NUT 1
83 9091505080 LOCK WASHER 1
85 9099129760 HOSE 1
86 9099155531 CLIP 2
92 8970233390 VALVE RELIEF ASSY. 1
93 5096230350 PACKING 1

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 97

TIMING GEAR ASSY.

ISUZU 4BD1 — TIMING GEAR ASSY.

PAGE 98 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)

ISUZU 4BD1 — TIMING GEAR ASSY.

TIMING GEAR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 5113110113 CASE 1
2 9081510180 STRAIGHT PIN 1
3 1113120140 PACKING 1

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

6 1113210790 COVER 1
7 8943632690 PACKING 1
8 1096253190 SEAL 1
9 9113276020 POINTER 1
10 0500408250 BOLT 7
10 5090000841 BOLT 5
12 5113210090 COVER, GEAR CHECK 2
13 1112820130 GASKET 2
14 0500406140 BOLT 4

DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01) — PAGE 99

FLYWHEEL HOUSING ASSY.

ISUZU 4BD1 — FLYWHEEL HOUSING ASSY.

PAGE 100 — DCA-40SSI — PARTS AND OPERATION MANUAL— FINAL COPY (07/10/01)