PARTS AND OPERATION MANUAL PARTS AND OPERATION MANUAL

MQ POWER DCA-40SSAI TM WHISPERWATT GENERATOR
© COPYRIGHT 2001, MULTIQUIP INC.

PARTS LIST NO.M3340163804

FINAL COPY
MULTIQUIP INC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 SERVICE DEPARTMENT: 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046 E-mail:mq@multiquip.com • www:multiquip.com

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

HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING PARTS DEPARTMENT ARTS DEPAR ARTMENT 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284 SERVICE DEPARTMENT ARTMENT SERVICE DEPAR 800/835-2551 or 310/537-3700 FAX: 310/638-8046 WARRANTY DEPARTMENT DEPAR ARTMENT 800/835-2551 or 310/537-3700 FAX: 310/638-8046 MAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927

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

82-83 Fuel Tank Assembly ................................... 23 General Information ............................................................................................. 52-55 Engine Wiring Diagram .................................................................92-93 NOTE Specification and part number are subject to change without notice.............................................................................................. 136-137 Accessories ............................................................ 21-22 DCA-40SSAI Specifications ........ 102-103 Oil Pan Assembly .. 34-35 Output Voltage Setup ...... 138-139 Terms and Condition of Sale — Parts ............................................................................................ 5 Rules for Safe Operation .......................... 112-113 Oil Piping Assembly ..........84-85 Enclosure Assembly ...................................................................................................................................................76-79 Battery Assembly ........................................................................ 26-27 Control Panel Descriptions ...................................... 116-117 Air Intake and Exhaust Assembly ........................................................................................................................................... 120-121 Engine Foot Assembly ....96-99 Timing Gear Assembly ........ 19 Hydraulic Brake Troubleshooting . 28-29 Engine Operating Panel Descriptions .................................... 11-17 Trailer Wiring Diagram .................................................................................................. 50 Maintenance .86-91 Name Plate And Decals ......................... 140 MQ POWER DCA-40SSAI AC GENERATOR Generator Assembly ................................... 122-123 Engine Control Assembly ..................................................... 134-135 Fuel Filter Assembly ............66-69 Control Box Assembly ............. 32-33 Output Amperage Setup ........ 56-57 Generator Wiring Diagram ............................................................. 25 Dimensions ...............................................94-95 Cylinder Block Assembly ......................................... 114-115 Cooling Assembly ...................... 47-49 Generator Shutdown Procedure ................................. 60-62 Explanation of Codes in Remarks Column ................................................................. 4 Parts Ordering Procedures ...... Flywheel Assembly .... 10 Trailer Safety Guidelines ............................................. 130-131 Nozzle Assembly ............ 65 ISUZU 4BD1 ENGINE Cylinder Head Cover Assembly ................................................................. 58 Engine Troubleshooting ..................................................................................... 40-41 Pre Setup ........... 126-127 Electrical Parts Assembly ........................................................................................................ 36-39 Installation ............................... 132-133 Oil Filter Assembly .......................... 108-109 Valve Assembly ...... 24 Major Components ............................................................................... 110-111 Oil and Fuel Filter Assembly ................... PAGE 4 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) ...................................................................................... 106-107 Crankshaft Piston.................... 46 Generator Start-up Procedure ........ 64 Suggested Spare Parts ..........TABLE OF CONTENTS Here's How To Get Help .... 100-101 Flywheel Housing Assembly ...... 6-9 Towing and Transportation ................................ 30-31 Output Terminal Panel Description .................................................................................70-71 Engine & Radiator Assembly .... 42-45 Load Application .........72-75 Engine Operating Panel Assembly ........................................................ 128-129 Feed Pump Assembly .................................................................................................................................................. 20 Operation and Safety Decals .......................... 3 Table Of Contents ...................................................................................................... 18 Electric Brake Troubleshooting ....................................... 104-105 Oil Pump Assembly ................................... 118-119 Fuel Injection Assembly ............................................................ 124-125 Injection Pump Assembly .80-81 Muffler Assembly ..........................................

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 1-9 items 10+ items** Additional Discount 3% 5% count ax Dis F Extra USA estic m for Do Only ealers D Get special freight allowances when you order 10 or more line items via FAX!** I UPS Ground Service at no charge for freight I PS Third Day Service at one-half of actual freight cost No other allowances on freight shipped by any other carrier. *DISCOUNTS ARE SUBJECT TO CHANGE* Fax order discount and UPS special programs revised June 1.00 list price) do not count towards the 10+ line items. 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. **Common nuts. bolts and washers (all items under $1.PARTS ORDERING PROCEDURES I I I I I I I Dealer account number Dealer name and address Shipping address (if different than billing address) Return fax number Applicable model number Quantity. if prior to 2PM west coast time. 1995 nly ders o xed or For fa UPS l Specia Now! Direct TOLL-FREE access to our Parts Department! Toll-free nationwide: 800-421-1244 Toll-free FAX: 800/6-PARTS-7 • 800-672-7877 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 5 .

I Topping-off to filler por t is dangerous. The generator engine gives off DEADLY carbon I NEVER operate this equipment without proper monoxide gas. replace nameplate.RULES FOR SAFE OPERATION CAUTION: Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only. I Always use extreme caution when working with flammable liquids. I Whenever necessary. I Always refuel in a well-ventilated area. shatterproof glasses. PAGE 6 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . I NEVER operate this equipment when not feeling well due to fatigue. Never operate the generator in any I This equipment should not be operated by enclosed or narrow area where free flow of the air is persons under 18 years of age. steeltoed boots and other protective devices CAUTION: required by the job. I The engine of this generator requires an adequate free flow of cooling air. illness or taking medicine. The following safety guidelines should always be used when I High Temperatures – Allow the engine to cool before operating the DCA-40SSAI portable generator: adding fuel or performing service and maintenance GENERAL SAFETY functions. I DO NOT operate or service this equipment before reading this entire manual. I Manufacturer does not assume responsibility for any accident due to equipment modifications. stop the engine and allow it to cool. I NEVER operate this equipment under the influence or drugs or alcohol. DO NOT smoke around or near the machine. away from sparks and open flames. An explosion or fire could result causing severe bodily harm or even death. as it tends to spill fuel. which are not recommended by MQ Power for this equipment. When refueling. I NEVER use accessories or attachments. Allow these parts to cool before servicing engine or generator. protective clothing. Fire or explosion could result from fuel vapors. Damage to the equipment and/or injury to user may result. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. or if fuel is spilled on a hot engine. I Always check the machine for loosened threads or bolts before starting. operation and safety decals when they become difficult read. muffler or cylinder. Contact with hot components can cause serious burns. I NEVER operate the generator in an explosive atmosphere or near combustible materials. I NEVER touch the hot exhaust manifold. restricted.

therefore causing severe scalding to any persons in the general area of the generator. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 7 . CAUTION: I Backfeed to a utility system can cause electrocution and. Radiator 1. Do not connect to any building's electrical system except through an approved device or after building main switch is opened. Always allow sufficient time for the engine and generator to cool before performing maintenance.Removing the coolant drain plug while the engine is hot will result in hot coolant to gush out of the coolant drain plug. Make sure power connecting cables are securely connected to the generator’s output terminals. I NEVER touch output terminals during operation. insufficient tightening of the terminal connections may cause damage to the generator and electrical shock.Removing the radiator cap while the engine is hot will result in high pressurized. This is extremely dangerous. boiling water to gush out of the radiator. therefore causing severe scalding to any persons in the general area of the generator.or property damage. CAUTION: Never use damaged or worn cables when connecting power tools or equipment to the generator. 2. Engine Oil Drain Plug . 3. Coolant Drain Plug . causing severe scalding to any persons in the general area of the generator.Removing the engine oil drain plug while the engine is hot will result in hot oil to gush out of the oil drain plug. Always stop the machine when contact with the output terminals is required. Radiator Cap .RULES FOR SAFE OPERATION CAUTION: CAUTION: DO NOT touch or open any of the below mentioned components while the generator is running.

I DO NOT leave the generator running in the manual mode unattended. 6. 5. and follow procedures in Operator’s Manual before attempting to operate equipment. If any part is loose or damaged. then contact the nearest doctor or hospital. Repair or replace all worn cables. I DO NOT allow unauthorized people to operate this equipment. I NEVER lift the machine while the engine is running. DO NOT drop the battery. In case the battery liquid (dilute sulfuric acid) comes in contact with your eyes. Always keep the battery charged. an explosion could occur. Use the following guidelines when handling the battery: PAGE 8 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . sparks. I When lifting the generator. I 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. There is the possibility of risk that the battery may explode. understand. Never over fill the battery with water above the upper limit. dry location out of the reach of children. I NEVER allow any person or animal to stand underneath the machine while lifting. Equipment should be stored in a clean. 7. Use well insulated gloves when picking up the battery. If the battery is not charged a buildup of combustible gas will occur. always use the balanced center-point suspension hook and lift straight upwards. In case the battery liquid (dilute sulfuric acid) comes in contact with clothing or skin. I Always service air cleaner frequently to prevent carburetor malfunction. 4. Loading and Unloading (Crane) I Before lifting. To avoid eye irritation. please take corrective action before lifting. DO NOT expose the battery to open flames. CAUTION: The battery contains acids that can cause injury to the eyes and skin. rinse skin or clothing immediately with plenty of water. always wear safety glasses. I Always disconnect the battery before performing service on the generator. I Refer to the Isuzu Engine Owner's Manual for engine technical questions or information. I Always be sure the operator is familiar with proper safety precautions and operations techniques before using generator. 3. I Always store equipment properly when not in use. rinse eyes immediately with plenty of water. If these gases and liquids come in contact with a flame or spark. Always keep battery charging and booster cables in good working condition. Always recharge the battery in an open air environment. to avoid risk of a dangerous concentration of combustible gases. I Always make sure crane or lifting device has been properly secured to the hook of guard frame on generator. The battery contains combustible gases and liquids. I Always drain fuel prior to lifting. Severe engine damage may occur. 1.RULES FOR SAFE OPERATION Battery I NEVER Run engine without air filter. nuts and bolts). I Always read. make sure the generator's lifting hook is secure and that there is no apparent damage to the generator itself (loose screws. cigarettes etc. I Use adequate lifting cable (wire or rope) of sufficient strength. 2. and seek medical attention.

I Always allow the machine a proper amount of time to cool before servicing. I DO NOT use plastic containers to dispose of hazardous waste. fuel. down a drain or into any water source. Maintenance Safety I NEVER lubricate components or attempt service on a running machine. Also know the phone numbers of the nearest ambulance. I Fix damage to the machine immediately and always replace broken parts. and fuel filters. I Drain fuel when transporting generator over long distances or bad roads. I Tighten fuel tank cap securely. I DO NOT pour waste. See page 10 for basic towing procedures. I If generator is mounted on a trailer. Emergencies I Always know the location of the nearest fire extinguisher and first aid kit. doctor and fire department. Know the location of the nearest telephone. coolant. I Keep the machinery in proper running condition. oil. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 9 . I Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil.RULES FOR SAFE OPERATION Transporting I Always shutdown engine before transporting. coolant or fuel directly onto the ground. I Always tie-down the generator during transportation by securing the generator. make sure trailer complies with all local and state safety transportation laws.

I The maximum speed for highway towing is 45 MPH unless posted otherwise. while parked. I Check the tire air pressure on both towing vehicle and trailer. while parked. To reduce the possibility of an accident while transporting the generator on public roads. then insert locking pin to lock wheel stand in place. gradual starts and stops will improve gas milage. Also check the tire tread wear on both vehicles. I ALWAYS make sure the trailer is equipped with a "Safety Chain". This can cause skidding. I ALWAYS make sure the vehicle and trailer directional. or greater than the trailer "gross vehicle weight rating" (GVWR). I Place support blocks underneath the trailer’s bumper to prevent tipping.DCA-40SSAI — TOWING AND TRANSPORTATION Towing Safety Precautions I ALWAYS attach trailer’s safety chain to bumper of towing vehicle. while parked. I Use the trailer’s hand winch to adjust the height of the trailer. I ALWAYS inspect the hitch and coupling for wear. and trailer lights are connected and working properly. I DO NOT transport generator with fuel in tank. I Place chocked blocks underneath wheel to prevent rolling. or jackknifing. chains etc. I Avoid sharp turns to prevent rolling. I Remove wheel stand when transporting. Smooth. brake. I Avoid sudden stops and starts. NEVER tow a trailer with defective hitches. Figure 1. couplings. Generator with Trailer PAGE 10 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . CAUTION : Check with your county or state safety towing regulations department before towing your generator. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain. backup. 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: I Make sure the hitch and coupling of the towing vehicle are rated equal to.

etc. 15. Tire Size . 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. hydraulic-surge and air.. 5. Wheel Hub . etc. 1. Application . 2.Protects the trailer chassis from shocks transmitted through the wheels.The wheel hub is connected to the trailer’s axle.This measurement is from the ball hitch to the rear bumper (reflector).DCA-40SSAI — TRAILER-SAFETY GUIDELINES CAUTION: ALWAYS make sure the trailer is in good operating condition. Please not that some trailers have a double axle.Trailer support device with maximum pound requirement from the tongue of the trailer.4-ply. 13. 11.Tires mounted on a tire rim. 14. meaning two axles with a total weight capacity of 6000 pounds. and air ride. The service and maintenance guidelines referenced in this section apply a wide range of trailers. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 11 .Type of hitch used on the trailer for towing. Tire Ply . Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.185. 8. 7. This will be shown as 2-6000 lbs. Explanation of Chart: This section is to provide the user with trailer service and maintenance information. 4.14.System employed in stopping the trailer. Q-flex. Braking System . Also check the wheel lug nuts for proper tightness. Fuel cells must be empty when transporting equipment. is the maximum number of pounds the trailer can carry. Tire Rim . including the fuel cell (empty). hydraulic. 3. 10.). Frame Width . Typical braking systems are electric.Used to secure the wheel to the wheel hub. 9. Electrical . Axle .Provides an adequate amount of fuel for the equipment in use.The tire ply (layers) number is rated in letters. Check the tires for proper inflation and wear.Gross Vehicle Weight Rating (GVWR). See Table 4 and Figure 5 or lug nut tightening and sequence.Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle. etc.Indicates the maximum weight the axle can support in pounds. GVWR. Types of suspension used are leaf.Indicates the diameter of the tire in inches (10. Lug Nuts . and the diameter of the axle expressed in inches (see Table 3).205. Coupler . surge.Indicates which units can be employed on a particular trailer. Jack Stand . The tire rim must match the size of the tire. 12. Frame Length . Always use a torque wrench to tighten down the lug nuts. 6.). The tire diameter must match the diameter of the tire rim. 2-ply. and the width in millimeters (175. Fuel Cell .12. It is the purpose of this section to cover the major maintenance components of the trailer.6-ply. 16. Suspension .This measurement is from fender to fender.

FLAT PAD 5000 LB .TLW300 DCA10. 800 FU E L C E LL NO NO 52 GAL NO NO NO 41 GAL NO OPT 53 GAL 150 GAL 145 GAL 200 GAL 250 GAL 250 GAL 350 GAL 550 GAL 550 GAL BRAKE SYSTEM NO NO NO NO ELECTRIC NO NO SURGE SURGE SURGE HYDRAULIC SURGE HYDRAULIC HYDRAULIC SURGE HYDRAULIC SURGE HYDRAULIC SURGE ELECTRIC AIR AIR GVWR 1900LB S 1900LB S 1900LB S 2200LB S 2700LB S 2700LB S 2700LB S 7000LB S 7000LB S 7000LB S 7000LB S 10000LB S 11160LBS 14000LB S 18000LB S 18000LB S 30000LB S 30000LB S FRAME LENGTH 96" 96" 96" 85" W/MAST 154" W/O 124" 124" 124" 186" 138" 138" 190" 186" 204" 222" 238" 238" 384" 384" FRAME WIDTH 50" 50" 50" 42" 55" (78" TALL) 55" 55" 77" 66" 66" 76" 77" 84" 83" 83" 83" 96" 96" JACK STAND 800LB . FULL TILT WHEEL 800LB . 100. FLAT PAD 2000LB . -60. TLW-300 WELDERS. FULL TILT WHEEL 800LB . FLAT PAD 5000 LB . FLAT PAD 5000 LB . DCA15. 180 DCA-220 DCA-300 DCA-400 DCA-600. FLAT PAD 2000LB . FLAT PAD 5000 LB . 125 DCA-150. FULL TILT WHEEL 800LB . FLAT PAD PAGE 12 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . DCA-15 DCA10. Specifications MODEL TRLR-10W TRLR-10 TRLR-10XF TRLR-225W TRLR-BLW400 TRLR-50X TRLR-50XF TRLR-70W TRLR-70X TRLR-70XF TRLR-100XF TRLR-85/125 TRLR-150XF TRLR-220XF TRLR-300XF TRLR-400XF TRLR-600XF TRLR-800SX APPLICATION SDW225. 125 DCA-85. FLAT PAD 5000 LB . 70 DCA-45. FULL TILT WHEEL 2000LB . FULL TILT WHEEL 800LB . 70 DCA-45. FLAT PAD 2000LB . FLAT PAD 5000 LB . 70 DCA-100. SGW250. D A 7000S S BLW-400 DCA-25 DCA-25 DCA-45. TLG12. FULL TILT WHEEL 800LB . TLG-12.DCA-40SSAI —TRAILER-SPECIFICATIONS Table 1. 800 DCA-600. -60. FULL TILT WHEEL 800LB . FLAT PAD 2000LB . -60.

5H RADIAL (8) WHEELS 13"X4.5" 13X4. 3" 3500lbs 3" 3500lbs.5" 14"x6" 16" X 7" 16" X 7" 16" X 7" 16" X 7" 16" X 7" 16" X 7" AXLE 2200# 2X 2 2200#2X 2 2200#2X 2 2200#2X 2 2200#2X 2 3500lbs. (3)-10000lbs (3)-10000lbs HUBS SUSPENSION 5 LUG 5 LUG 5 LUG 5 LUG 5 LUG 5 LUG 5 LUG 5 LUG 5 LUG 5 LUG 5 LUG 6 LUG 8 LUG 8 LUG 8 LUG 8 LUG 8 LUG 8 LUG 3 LE A F 3 LE A F 3 LE A F Q F LE X 3 LE A F 4 LE A F 4 LE A F 5 LE A F 5 LE A F 5 LE A F 5 LE A F 7 LE A F 7 LE A F Q F LE X Q F LE X Q F LE X 7 LE A F AIR-RIDE ELECTRICAL 4 WIRE LOOM W/ 4 POLE FLAT 4 POLE FLAT 4 POLE FLAT 4 POLE FLAT 4 POLE FLAT 4 POLE RUBBER FLAT 4 POLE RUBBER FLAT 4 POLE RUBBER FLAT 4 POLE RUBBER FLAT 4 POLE RUBBER FLAT 4 WIRE LOOM 4 WIRE LOOM 4 WIRE LOOM 4 WIRE LOOM 4 WIRE LOOM 4 WIRE LOOM 6 WIRE LOOM 6 WIRE LOOM DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 13 . 3" 3500lbs 3" (2)-6000lbs (2)-6000lbs (2)-7000lbs (2)-6000lbs (3)-7000lbs. Specifications (Con't) MODEL TRLR-10W TRLR-10 TRLR-10XF TRLR-225W TRLR-BLW 400 TRLR-50X TRLR-50XF TRLR-70W TRLR-70X TRLR-70XF TRLR-100XF TRLR-85/125 TRLR-150XF TRLR-220XF TRLR-300XF TRLR-400XF TRLR-600XF TRLR-800AR COUPLER 2" B A LL C LA S S 2 ADJUSTABLE 2" B A LL C LA S S 2 ADJUSTABLE 2" B A LL C LA S S 2 ADJUSTABLE 2" B A LL C LA S S 2 ADJUSTABLE 2" B A LL C LA S S 2 ADJUSTABLE 2" B A LL C LA S S 2" B A LL C LA S S 2" B A LL C LA S S 3" ADJUSTABLE 2" B A LL C LA S S 3" ADJUSTABLE 2" B A LL C LA S S 3" ADJUSTABLE ADJUSTABLE 2-5/6 OPT 3" EYE ADJUSTABLE 2-5/6 OPT 3" EYE 3" BALL EYE 3" EYE ADJUSTABLE 3" EYE ADJUSTABLE 3" EYE ADJUSTABLE 5TH WHEEL 5TH WHEEL TIRES 175-13C 175-13C 175-13C 175-13B 175-13C B78-13LRC B78-13LRC 205-14C BIAS (4) 205-14C BIAS (4) 205-14C BIAS (4) 205-15C BIAS (4) ST225/75R15D RADIAL (4) 750-16 E BIAS (4) ST235/85R16E RADIAL(4) ST235/85R16E RADIAL(6) ST235/85R16E RADIAL(6) ST215/75R17. 2-3/8" 3500lbs.5" 13"X4.5H RADIAL (8) ST215/75R17.DCA-40SSAI —TRAILER-SPECIFICATIONS Table 1.50" 13"X4.5" 13 X 4.50" 14" X 5" 14" X 5" 14" X 5" 14"X5.50" 13"X4.5" 13"X4. 2-3/8" 3500lbs.

Place the trailer on jack stands. Replace the adjusting hole cover and lower the trailer to the ground. the brakes should be inspected the first 200 miles of operation.000 miles. PAGE 14 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .h. rotate the star wheel of the adjuster assembly to expand the brake shoes. 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. Please inspect these components as required.h. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn. Electric Brake Adjustment 1. inspect the brakes more frequently. Electric Brakes Electrically actuated brakes (Figure 2) are similar to hydraulic brakes. 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. 5. 4. This will allow the brake shoes and drums to seat properly. If driving over rough terrain. the trailer brakes should be burnished-in by applying the brakes 20-30 times with approximately a 20 m. Figure 2 displays the major electric brake components that will require inspection and maintenance.DCA-40SSAI —TRAILER SAFETY GUIDELINES Brakes If your trailer has a braking system. 8. to 20 m. Repeat steps 1 through 6 on the remaining brakes.p.g. Allow ample time for brakes to cool between application. 2. grabbiness or harshness is due to lack of synchronization between the tow vehicle and the trailer being towed or under-adjusted brakes. 6. 40 m.p. e. Check the wheel and drum for free rotation. This allows the brake shoes to slightly be seated into the brake drum surface. After the first 200 mile interval. inspect the brakes every 3. With a screwdriver or standard adjusting tool. can only be accomplished by road testing. Before any brake synchronizations adjustments can be made. Make sure the jack stands are placed on secure level ground. The basic difference is that hydraulic brakes are actuated by an electromagnet. 3.h.p. 7. Brake lockup. decrease in speed. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate. Rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

Please inspect these components as required using steps 1 through 6 as referenced in the electric brake adjustments section. 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.DCA-40SSAI — TRAILER SAFETY GUIDELINES Figure 2. Brake lines should be periodically checked for cracks. Hydraulic Brake Components DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 15 . Figure 3. Figure 3 below displays the major hydraulic/air/surge brake components that will require inspection and maintenance. or blockage. kinks.

DCA-40SSAI — TRAILER SAFETY GUIDELINES Tires/Wheels/Lug Nuts Tires and wheels are a very important and critical components of the trailer. Torqued suspension components as detailed in Table 3. elongation of bolt holes. If the rim is cracked. Major Suspension Components PAGE 16 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . Failure to comply may result in serious injury. Figure 4. and axle are properly matched. DO NOT install in inner tube to correct a leak through the rim. CAUTION: NOTE ALWAYS wear safety glasses when removing or installing force fitted parts. CAUTION: DO NOT attempt to repair or modify a wheel. 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. 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. Replace all damaged parts (suspension) immediately. Tire Wear/Inflation Tire inflation pressure is the most important factor in tire life. Check inflation pressure weekly during use to insure the maximum tire life and tread wear. and loosening of fasteners. When specifying or replacing the trailer wheels it is important the wheels. Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot.000 miles for signs of excessive wear. tires.

Check all wheel lug nuts periodically. retorque all lug nuts in sequence. 3. Wheel Lug Nuts Tightening Sequence NOTE NEVER use an pneumatic air gun to tighten wheel lug nuts. DO NOT torque the wheel lug nuts all the way down. See Figure 5. Torque all lug nuts in sequence. SHOULDER TYPE SHACKLE BOLT MIN-30 MAX-50 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. After first road use.) MIN-30 MAX-35 MIN-45 MAX-60 MIN-45 MAX-60 SNUG FIT ONLY. Tighten each lug nut in 3 separate passes as defined by Table 4. 2. PARTS MUST ROTATE FREELY.-Lbs. Start all wheel lug nuts by hand. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 17 . Table 4.DCA-40SSAI —TRAILER SAFETY GUIDELINES Table 3. Tire Torque Requirements Wheel Size 12" 13" 14" 15" 16" First Pass FT-LBS 20-25 20-25 20-25 20-25 20-25 Second Pass FT-LBS 35-40 35-40 50-60 50-60 50-60 Third Pass FT-LBS 50-65 50-65 90-120 90-120 90-120 Figure 5. Suspension Torque Requirements Item 3/8" U-BOLT 7/16" U-BOLT 1/2" U-BOLT SHACKLE BOLT SPRING EYE BOLT Torque (Ft. LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT-BOLT ASSEMBLY. Proper procedure for attachment of the wheels is as follows: 1.

DCA-40SSAI —TRAILER-WIRING DIAGRAM NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT PAGE 18 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

Replace. Clean or replace. Clean and correct cause of corrosion. Replace and correct. Find and correct.DCA-40SSAI —TRAILER-BRAKE TROUBLESHOOTING Table 5. bent or broken? Brake drums out-of-round? Noisy Brakes System lubricated? Brake components correct? Dragging Brakes Bearings of the wheel adjusted? Solution Find and correct. Find and secure. Test and correct. Replace components. Find and repair. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 19 . Adjust. Electric Brake Troubleshooting Symptom No Brakes or Intermittent Brakes Possible Cause Any open circuits or broken wires? Any shor t circuits? Faulty controller? Any loose connections? Ground wire secure? Weak Brakes or Brakes Pull to One Side Grease or oil on magnets or linings? Connections corroded? Brake drums scored or grooved? Brakes synchronized? Locking Brakes Brake components loose. Machine or replace. Correct. Lubricate.

DCA-40SSAI —TRAILER-BRAKE TROUBLESHOOTING Table 6. Match tires. Lubricate. Replace rubber par ts fill with dot4 fluid. Replace. Replace components. Reburnish or replace. bent or broken? Brake drums out-of-round? Noisy Brakes System lubricated? Brake components correct? Dragging Brakes Brake lining thickness correct or in right wrong position? Enough brake fluid or correct fluid? Solution Repair or replace. Inflate all tires equally. Replace and correct. Machine or replace. Install new shoes and linings. Correct weight. Hydraulic Brake Troubleshooting Symptom No Brakes Weak Brakes or Brakes Pull to One Side Possible Cause Brake line broken or kinked? Brake lining glazed? Trailer overloaded? Brake drums scored or grooved? Tire pressure correct? Tires unmatched on the same axle? Locking Brakes Brake components loose. PAGE 20 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

The illustration below and on the preceding page show the decals as they appear on the machine. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 21 . These decals are provided for operator safety and maintenance information. Should any of these decals become unreadable.DCA-40SSAI — GENERATOR DECALS The DCA-40SSAI generator is equipped with a number of safety decals. replacements can be obtained from your dealer.

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

8 KVA (37. (102 mm x 118 mm) 52 HP/1800 rpm 235 cu.DCA-40SSAI — SPECIFICATIONS Table 7.7L)/hr at 1/2 load Battery Fuel 1.1 gal.8 Single Phase.3 gal. swirl combustion chamber type 4 cylinders 4 in. x 4. (4.5 gal. 60 Hz 120/240 V 11. (15 liters) 3.100AH x 2 #2 Diesel Fuel ISUZU QD100 (4BD1) 4 Cycle. (5. self ventilated. (7.6 in. open protected type synchronous generator Star with Neutral 3 46.4 gal.4 KW) Engine Specifications Model Type No. AC Power Voltage Output DCA-40SSAI Revolving field.2L)/hr at 1/4 load 12V. in. (8. of Cylinders Bore x Stroke Rated Output Displacement Starting Coolant Capacity Lube Oil Capacity Fuel Consumption 1. (3856 cc) Electric 4 gal.7L)/hr at full load 2.9 liters) 2. Specifications Generator Specifications Model Type Armature Connection Phase Standby Output Prime Output Voltage Frequency Speed Power Factor Aux. (12. water-cooled.4 KW) 40 KVA (32 KW) 240V or 480V 60 Hz 1800 rpm 0.5 KW (13.6L)/hr at 3/4 load DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 23 .0 gal.

submersible pumps and other There are four leads: A.5%. This of adding the voltages to each phase provides Water Temperature Gauge better voltage response during heavy loads. power to the Automatic Voltage Regulator (AVR) is supplied from the leads parallel connections of B&C. C and D. water cooled. The open delta generator that is designed as a high quality portable (requires a trailer system consist of an electrically independent winding wound for transport) power source for telecom sites. The “Output Terminal Panel” is provided with the following: Two 120V. The electronic governor option increases frequency variation to ±. 50A receptacle 50A and 30A circuit breakers Control Box The “Control Box” is provided with the following: Main Circuit Breaker 100 amps Over-Current Relay Mechanical Governor System The mechanical governor system control the RPM of the engine. 20A receptacles Two 240V. the AVR switches and accepts power from leads The “Engine Operating Panel” is provided with the following: A&D. the industrial and construction machinery. the specifications quoted herein are subject to Voltmeter Change-Over Switch change without prior notice. AC Voltmeter (Volts) In keeping with Multiquip's policy of constantly improving Ammeter Change-Over Switch its products. Oil Pressure Gauge The connections of the AVR to the AC output windings are Charging Ammeter Gauge for sensing only. facilities. power tools. When loads Engine Operating Panel increase. B. The Panel Light excitation does not have a "fixed ceiling" and responds Panel Light Switch according the demands of the required load. Reference AC Ammeter (Amps) Table 7. No power is required from these windings. During light loads. Output Voltage Adjustment Knob Isuzu 4BD1 diesel engine. lighting among stationary windings of the AC output section. offering maximum motor starting capabilities. This engine is designed to meet Frequency Meter (Hz) every performance requirement for the generator. Voltage Regulator The basic controls and indicators for the DCA-40SSAI Output Terminal Panel generator are addressed on the following pages. the mechanical governor system regulates the frequency variation to ±1. When the engine demands increase or decrease. Fuel level gauge Engine Speed Control The open-delta design provides virtually unlimited excitation Pre-Heat Button current. 20A receptacles One twist-lock 120V. The output of leads A&D increase proportionally with Tachometer load.DCA-40SSAI — GENERAL INFORMATION DCA-40SSAI FAMILIARIZATION Generator Open Delta Excitation System The DCA-40SSAI generator is equipped with the state of The MQ Power Model DCA-40SSAI is a 26 kW generator the art "Open-Delta" excitation system.25%. page 23 for engine specifications. Starter /Preheat Switch Generator Control Panel Engine The “Generator Control Panel” is provided with the following: The DCA-40SSAI is powered by a 4 cycle. PAGE 24 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

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

DCA-40SSAI — MAJOR COMPONENTS Figure 6. Major Components PAGE 26 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

Dimensions DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 27 .DCA-40SSAI — DIMENSIONS Figure 7.

Control Panel PAGE 28 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .DCA-40SSAI — CONTROL PANEL DESCRIPTION Figure 8.

Frequency Meter – Indicates the output frequency in hertz (Hz). AC Voltmeter – Indicates the single phase output voltage present at the UNV terminals. 110 amp main breaker is provided to protect the UNV voltage output terminals from overload. or to be switched off. 6. Normally 60 Hz ±1 Hz . Main Circuit Breaker – This three-pole. 2. 4. 1. 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. Voltage Regulator Control – Allows manual adjustment of the generator’s output voltage. 5. 7.DCA-40SSAI — CONTROL PANEL DESCRIPTION The definitions below describe the controls and functions of the DCA-40SSAI " Control Panel " (Figure 8). DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 29 . 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. AC Ammeter – Indicates the amount of current the load is drawing from the generator. 3.

Engine Operating Panel PAGE 30 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION Figure 9.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 31 . 7. 4. 3.Normally used in dark places or at night. Pre-Heat Button – Press hold this button until the preheat lamp is lit (ON). 5. When starting the generator the oil pressure may read a bit higher.This handle will change the speed of the engine from high to low. 8. Oil Pressure Gauge – Normal operation should be about 25 psi. turn the panel light switch to the ‘OFF’ position. Starter Switch. Panel light . Water Temperature Gauge – During normal operation this gauge be should read between 165o to 215o. When activated. Fuel Gauge .DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION The definitions below describe the controls and functions of the DCA-40SSAI " Engine Operating Panel " (Figure 9). Engine speed Handle. 9. but after the engine warms up the oil pressure should return to normal. Tachometer – Indicates engine speed in RPM’s for 60 Hz operation. start and stop engine. panel will luminate. 2. Panel light switch. 10. 6. 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. will turn on control panel light.When activated.Indicates amount of diesel fuel available. When the generator is not in use. 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.Use key to preheat. 1.

20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. and the must not exceed 37. 20 Amp) receptacle is located on the output terminal. all four slots in the duplex receptacles. main circuit breaker is provided to protect the UVWO output terminals from overload. Three 50 amp load circuit breakers have also been provided to protect the load side of the generator from overload. This receptacle can be used anytime the generator is in operation. 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. Generators are NOT grounded just because they are mounted on trailers or other vehicles that are on rubber tires. The receptacle should be tested at least once a month. In addition two single-pole. PAGE 32 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . Connecting Load Loads can be connected to the generator by the UVWO lugs or the duplex receptacles. 120 Volt Receptacle One GFCI Duplex NEMA 5-20R (120V. a 3-pole. The reset button will reset the receptacle after being tripped. Maximum Output The entire load connected to the UNV Lugs.DCA-40SSAI — OUTPUT TERMINAL PANEL Output Terminal Panel The output control panel is located on the rear (control panel) end of the generator. 110 amp. See page X for further details. Load Application Circuit Breakers Figure 10. Twist Lock Dual Voltage Receptacles . (See figure 3). Make sure to read the operation manual before attempting to connect a load to the generator. Generator Grounding Make sure to ground the generator in EVERY application prior to connecting a load. Figure 11. Pressing the :Test Button” (Figure 8) in the center of this receptacle will check the GFCI function. Generators are NOT considered grounded when mounted on a trailer. The receptacle is controlled by the circuit breaker located on the control panel. page 28). 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. Make sure to switch ALL circuit breakers to the "OFF" position prior to starting the engine.To use these receptacles. To protect the generator from an overload.4 kW in standby or 36 kW in prime output. GFCI Test Button Generator Grounding Make sure the generator is properly grounded before applying load. The UNV lugs are protected by a face plate cover that can be secured in the close position by a pad lock.

DCA-40SSAI — OUTPUT TERMINAL VOLTAGE SELECTION DCA-40SSAI NOTE Legs O and Ground are considered Bonded Grounds. Figure 12. Output Panel Location DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 33 .

The over current relay is located inside the control box. both the circuit breaker and the over current relay will trip. 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. See Table 8 for available voltages the generator will supply. Maximum Amps Rated Voltage Single Phase 120 Volt Single Phase 240 Volt Three Phase 240 Volt Three Phase 480 Volt Maximum Amps 100 amps (4 wire) 50 amps (4 wire) 108 amps 54 amps PAGE 34 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . If the circuit breaker can not be reset. Voltages Available Three Phase (Sw itchable) Single Phase (Sw itchable) 208 VOLT 120 VOLT 220 VOLT 127 VOLT 240 VOLT 139 VOLT 416 VOLT 240 VOLT 440 VOLT 254 VOLT 480 VOLT 277 VOLT CAUTION : NEVER switch Voltage Selector Switch position while the engine is engaged. Over Current Relay An over current relay is connected to the circuit breaker. fine adjustment with the voltage regulator on the control panel is necessary. the reset button on the over current relay must be pressed. press in the red button located on the voltage selector switch. Voltages may be selected by using the voltage selector switch and depending how you hookup your hard wire connection to the generator. Maximum Amps Table 9 shows the maximum amps the generator will provide. Table 8. Table 9.DCA-40SSAI — OUTPUT AMPERAGE SETUP Output Terminal Panel Available Voltages A wide range of voltages are available to supply load to many different applications. Do not exceed the maximum amps listed. and use a pad lock to hold it into this position. During an over current situation. To obtain some of the voltages listed. To lock the voltage selector switch.

Table 10.DCA-40SSAI — OUTPUT AMPERAGE SETUP Receptacle Use When the UVWO terminals are providing power.9 36. AC Voltmeter Change-over switch and Voltmeter Gauge 20 0 40 60 75 How To Read The Output Terminal Gauges.4 3. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 35 .8 23.6 28. Do not exceed receptacle power as listed on Table 10. They are to help observe how much power is being supplied at the UVWO legs.2 R eceptacle P o w er Available D uplex N EMA 5-20R 120V KW 0 1. 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. A Figure 16 and 17.8 Figure 13. the receptacle power availability will decrease.6 22.6 4. make sure to balance the load on each of the single phase legs.4 21.7 32.2 2. Receptacle Use Pow er in U se 240/120V Single Phase or Tw ist L o ck C S 6369 KW 26 24. When the voltage selector switch is in the 240/120V position (Figure 13). AC Ammeter Change-over Switch and Ammeter Gauge NOTE When using plural single phase voltages. The gauges (Figure 15 and 17) and change-over switches on the control panel DO NOT effect the generator output. Voltage Selector Switch 240/120V Single Phase Position 240/480V 3-Phase K VA 45 40.4 Figure 14 and 15.

With the voltage selector set and locked at ‘3 phase 480/ 277’ (Figure 19) and using the 3-phase 240 hookup. the generator will provide three legs available with 100 amps each on three different circuits (Figure 18).DCA-40SSAI — OUTPUT VOLTAGE SETUP 240/120V Hard Wire Hookup 480/240V Hard Wire Hookup With the voltage selector set and locked at ‘single phase 240/120’ and using single phase 120 volts. When using the 3-phase 480 volts hookup. Hard Wire Hookup at 240/120V Position Figure 20. it will provide one circuit available at 50 amps with all three wires plus ground. it will provide one circuit available at 108 amps with any two wires plus the ground (Figure 20). Voltage Selector Switch 480/277V Three Phase Position Figure 18. Hard Wire Hookup at 480/240V Position PAGE 36 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . Figure 19.

or 416 volts. or 416 Volt This setting can provide single phase power at 480. or 416V Figure 24. 440V. Voltage Regulator Knob 3 Phase. or 416 Volt This setting can provide 3-phase power at 480. Hard Wire Hookup for Single Phase 277V. and 416 volts can be obtained with the voltage regulator knob is at the lowest setting. 480V. 480 volts can be obtained with the voltage regulator knob turned toward maximum. 254V. 480 volts can be obtained with the voltage regulator knob turned toward maximum. Figure 22. Figure 23. 440. After hooking up the hard wires to the lugs as shown in Figure 24. or 240 volts. and 416 volts can be obtained with the voltage regulator knob is at the lowest setting. 254. Single Phase: 480V. 440 volts can be obtained with the voltage regulator knob is turned down. After hooking up the hard wires to the lugs as shown in Figure 22. Hard Wire Hookup for Single Phase 480V. 440 volts can be obtained with the voltage regulator knob is turned down. or 240V DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 37 .DCA-40SSAI — OUTPUT VOLTAGE SETUP Voltage Selector Switch. After hooking up the hard wires to the lugs as shown in Figure 23.3 Phase 480/277V Position The following are additional voltages available when the voltage selector switch is in the ‘3 phase 480/277V’ position. or 240V This setting can provide single phase power at 277. Hard Wire Hookup for Three Phase 480V. 440. 440V. or 416 volts. 440V. 277 volts can be obtained with the voltage regulator knob turned toward maximum. or 416V Single Phase: 277V. 440V. Figure 21. 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. 254V.

or 208 volts. 220. or 120 volts. 127V. 240V. or 208V 3 Phase.3 Phase 240/139V Position The following are additional voltages available when the voltage selector switch is in the ‘3 phase 240/139V’ position. Hard Wire Hookup for Single Phase 139V. or 120V PAGE 38 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . or 208 Volt This setting can provide 3-phase power at 240. 220 volts can be obtained with the voltage regulator knob is turned down. 220V. 240 volts can be obtained with the voltage regulator knob turned toward maximum. Hard Wire Hookup for Single Phase 240V. and 208 volts can be obtained with the voltage regulator knob is at the lowest setting. or 208 Volt This setting can provide single phase power at 240. 220 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. Hard Wire Hookup for Three Phase 240V. and 208 volts can be obtained with the voltage regulator knob is at the lowest setting. After hooking up the hard wires to the lugs as shown in Figure 26. Figure 25. 220. After hooking up the hard wires to the lugs as shown in Figure 27. Voltage Selector Switch 240/139V Three Phase Position Figure 27. 220V.DCA-40SSAI — OUTPUT VOLTAGE SETUP Voltage Selector Switch. 240 volts can be obtained with the voltage regulator knob turned toward maximum. 220V. or 120V This setting can provide single phase power at 139. 127V. or 208 volts. or 208V Figure 28. Figure 26. 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. Single Phase: 240V. 220V. 127. Single Phase: 139V. 127 volts can be obtained with the voltage regulator knob is turned down.

After hooking up the hard wires to the lugs as shown in Figure 30. 240 Volt This setting can provide single phase power at 240 volts. 240 volts can be obtained with the voltage regulator knob turned to fine tune. 120 volts can be obtained with the voltage regulator knob turned to fine tune. Single Phase: 120 Volt This setting can provide single phase power at 120 volts. Figure 30. Voltage Selector Switch 240/120V Single Phase Position Single Phase. Hard Wire Hookup for Single Phase. Figure 31.Single Phase 240/120V Position The following are additional voltages available when the voltage selector switch is in the ‘single phase 240/120V’ position.DCA-40SSAI — OUTPUT VOLTAGE SETUP Voltage Selector Switch. After hooking up the hard wires to the lugs as shown in Figure 31. Hard Wire Hookup for Single Phase 240 volt DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 39 . 120 volt Figure 29.

3 mm2) or larger. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes. 3. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110. Connect the other end of the ground cable to earth ground. Copper . sand. CAUTION : Pay close attention to ventilation when operating the generator inside tunnels and caves. Foreign materials such as dust. PAGE 40 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . 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. Generator Grounding To guard against electrical shock and possible damage to the equipment. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. Engine exhaust must be routed to a ventilated area. The installation site must be relatively free from moisture and dust. The engine exhaust contains noxious elements.4 mm2) or larger. Chapter 5-4. They are to resist damage to the bottom of the generator and to maintain alignment. lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts. DO NOT remove the metal skids on the bottom of the generator. a. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.8 AWG (8. into the ground. The engine should be installed at least two feet from any outside wall. NOTE When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician. CAUTION : 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.1). NEC articles 250-64(b) and 250-66 set the following grounding requirements: 1. Make sure the generator is on secure level ground so that it cannot slide or shift around. Use one of the following wire types to connect the generator to earth ground. b. 2. 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. Indoor Installation Exhaust gases from diesel engines are extremely poisonous. Mounting The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. NEC article 250-52(c) specifies that the earth ground rod should be buried a minimum of 8 ft. 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. it is important to provide a good EARTH ground.DCA-40SSAI — INSTALLATION Outdoor Installation Install the generator in a location where it will not be exposed to rain or sunshine.10 AWG (5. All electrical equipment should be protected from excessive moisture. Aluminum .

DCA-40SSAI — INSTALLATION Figure 31. Typical Generator Grounding Application DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 41 .

350 ft.DCA-40SSAI — PRE-SETUP General Inspection Prior to Operation The DCA-40SSAI generator has been thoroughly inspected and accepted prior to shipment from the factory. main circuit breaker is provided to protect the UNV output terminals from overload. a 3-pole.5 5 7. CAUTION: Equipment damage can result from low voltage. Table 11. 125 ft. 75 ft. 200 ft. Make sure to switch ALL circuit loads at some distance from the generator. 100 amp. #14 Wire 375 ft. Cable Selection (60 Hz. 65 ft. 250 ft. NOTE ALWAYS consult with a licensed electrician for correct extension cord wire size. 300 ft. 150 ft. 125 ft. Use the Cable Selection Guide (Table 11 ) as a guide for selecting proper cable size. cords are normally used. 200 ft. However. be sure to check for damaged parts or components. In addition two single-pole. or loose nuts and bolts. #16 Wire 250 ft. 100 ft. 125 ft. #12 Wire 600 ft. PAGE 42 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . 150 ft. Extension Cable Circuit Breakers To protect the generator from an overload.5 10 15 20 300 600 900 1200 1800 2400 600 1200 1800 2400 3600 4800 Maximum Allowable Cable Length #10 Wire 1000 ft. 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. 100 ft. 50 ft. 100 ft. Three 50 amp load circuit breakers have also been provided to protect the load side of the When electric power is to be provided to various tools or generator from overload. 500 ft. extension breakers to the "OFF" position prior to starting the engine. Single Phase Operation) Load In Watts Current in Amperes At 120 At 240 Volts Volts 2. 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. which could have occurred in transit.

If the container does not have a spout. be sure to check if the oil is clean and viscous. verify that the oil level is maintained between the two notches (Figure 32) on the dipstick. If hard water or water with many impurities is used. With the dipstick inserted all the way. Engine Oil Dipstick When checking the engine oil. Make sure the generator is level. CAUTION : 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. Table 12. The fuel tank cap must be closed tightly after filling. An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system. Recommended Motor Oil Temperature Range 104° F ~ 23° F (40° C ~ -5°C) 23° F ~ 5° F (-5° C ~ -15°C) Below 5° C (-15°) Type Oil SAE 30 SAE 20 or SAE 10W-30 SAE 10W or SAE 10W-30 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 43 . If gasoline spillage occurs. See Table 12 for proper selection of engine oil. Refer to the fuel tank capacity listed on page 23 Specification Table 7. the inside of the engine and radiator may become coated with deposits and cooling efficiency will be reduced. See maintenance section on page 52 and 53 on instructions to flush out radiator. Fuel Fill the fuel tank with clean and fresh diesel fuel. DO NOT fill the tank beyond capacity. use a funnel. If the oil is not clean. Pay attention to the fuel tank capacity when replenishing fuel. Figure 32. and refill with the specified amount of oil as outlined in the Isuzu Engine Owner's Manual.DCA-40SSAI — PRE-SETUP Lubrication Oil Fill the engine crankcase with lubricating oil through the filler hole. but without being screw into the filler hole. Handle fuel in a safety container. Coolant Use only drinkable tap water. but do not overfill. drain the oil by removing the oil drain plug. wipe up the spilled gasoline completely to prevent fire hazards. Wipe up any spilled fuel immediately.

See Table 13. PAGE 44 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . Air Cleaner Periodic cleaning/replacement is necessary. for engine. Inspect the fan belt for damage and wear and adjust it in accordance with the Isuzu Engine Owner's Manual.DCA-40SSAI — PRE-SETUP CAUTION : When adding coolant or antifreeze to the radiator. When adding coolant to the radiator. Day-to-day addition of coolant is done from the reserve tank. Never place hands near the belts or fan while the generator is running. Cleaning the Outer Radiator The engine may overheat if the radiator fins become overloaded with dust or debris. or to insufficient charging of the battery. antifreeze ratio must be less than 50%. Periodically clean the radiator fins with compressed air. 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. Inspect it in accordance with the Isuzu Engine Owner's Manual. be certain the proper amount of antifreeze (Table 14) has been added. so clean only with the engine turned off and the battery disconnected. Fan Belt Tension A slack fan belt may contribute to overheating. Fan Belt Tension CAUTION : Never place hands near the belts or fan while the generator set is running. Tighten the mounting bolt and the adjusting bolt. Table 14. 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. the antifreeze mixing ratio must ater. Pivot the alternator at the mounting bolt toward the engine left or right until the belt reflects the proper tension. DO NOT remove the radiator cap until the unit has completely cooled. Coolant Capacity Engine and Radiator Reserve Tank 4 Gal. do not remove the radiator cap until the unit has completely cooled. Table 13. NOTE When the antifreeze is mixed with w ater.26 Gal. Anti-Freeze Operating Temperatures Freezing Point Vol % Anti-Freeze °C 40 50 -24 -37 °F -12 -34 °C 106 108 °F 222 226 Boiling Point Figure 33. and reserve tank coolant capacities. radiator. (1L) Operation in Freezing Weather When operating in freezing weather. (15 L) 0. Cleaning inside the radiator is dangerous. Make sure the coolant level in the reserve tank is always between the "H" and the "L" markings.

and the BLACK cable is connected to the negative terminal of the battery. DO NOT connect the battery cables to the battery terminals when the key is in the ignition and is set in 'START' mode.DCA-40SSAI — PRE-SETUP Battery This unit is of negative ground. Place a small amount of grease around both battery terminals. The battery is sufficiently charged if the specific gravity of the battery fluid is 1. When an inverted circuit connection takes place. When connecting battery do the following: 1. Always keep the terminals firmly tightened. Figure 34.28 (at 68° F). Wiring Inspect the entire generator for bad or worn electrical wiring or connections.245 or lower. Entry of water into the alternator leads an electrolyte corrosion causing an alternator failure. CAUTION : If the battery cable is connected incorrectly. DO NOT over fill. 2. Pay close attention to the polarity of the battery when connecting the battery. Coating the terminals with a thin film of grease will help to inhibit corrosion. Add only distilled water when replenishment is necessary. The RED cable is connected to the positive terminal of the battery. the circuit will be in short circuit instantaneously resulting the alternator failure. CAUTION : Inadequate battery connections may cause poor starting of the generator. Before charging the battery with an external electric source. Poor contact may result in poor starting or malfunctions. oil hose. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 45 . DO NOT connect in reverse. Piping and Hose Connection Inspect all piping. Tighten all hose clamps and check hoses for leaks. Alternator The polarity of the alternator is negative grounding type. ALWAYS remove the key from the ignition and the ignition switch is in the OFF position when connecting the battery. Check to see whether the battery cables are loose. Battery Connections If any hose (fuel or oil) lines are defective replace them immediately. If any wiring or connections are exposed (insulation missing) replace wiring immediately. if the fluid level is not properly maintained. Battery life will be shortened. be sure to disconnect the battery cables. damage to the generator will occur. Do not put water directly on the alternator. Battery Cable Installation ALWAYS be sure the battery cables (Figure 34) are properly connected to the battery terminals as shown below. it indicates that the battery is dead and needs to be recharged or replaced. and create other malfunctions. If the specific gravity should fall to 1. This will ensure a good connection and will help prevent corrosion around the battery terminals. Always maintain battery fluid level between the specified marks. and fuel hose connections for wear and tightness.

732 x VOLTAGE x AMPERAGE NOTE If wattage is not given on the equipment's name plate. approximate wattage may be determined by multiplying the nameplate voltage by the nameplate amperage for three-phase: WATTS =1.75 1.0 0. a capacity of up to the generating set’s rated output (kW) multiplied by 0. approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage. mercury lamps Electronic devices. amperage and frequency requirements are satisfactorily supplied by the generator for operating the equipment. Equipment may require 130— 150% more wattage than the rating on the nameplate. a capacity of up to the generating set’s rated output (kW) can be used. Serious injury or death may result without this transfer switch. below when connecting loads. pay close attention to the required starting current capacity. as the wattage is influenced by the efficiency. When connecting an electric drill or other power tools. incandescent lamps Fluorescent lamps.DCA-40SSAI — LOAD APPLICATION Single Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage. When connecting a resistance load such as an incandescent lamp or electric heater. See Table 15. Generally. the wattage listed on the nameplate of the equipment is its rated output. WATTS = VOLTAGE x AMPERAGE The power factor of this generator is 1. Power Factor By Load Type Of Load Single-phase induction motors Electric heaters.0. NOTE If output (kVA) is not given on the equipment nameplate.0.4 .0.6 can be used. If wattage is not available on the equipment. a licensed electrician must install an isolation (transfer) switch.9 1. 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. approximate output may be determined by multiplying voltage by amperage by Three Phase Load When calculating the power requirements for 3-phase power use the following equation: PAGE 46 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .8 CAUTION: Before connecting this generator to any building’s electrical system. When connecting a fluorescent or mercury lamp.4 . CAUTION: Motors and motor-driven equipment draw much greater current for starting than during operation.0 0. communication equipment Common power tools Power Factor 0. Table 15. power factor and starting system of the equipment.

C. IVE ST PO E TIV GA NE TE AT B RY Figure 37. Direct exhaust away from nearby personnel. A L W AY S ventilate the exhaust when operating inside tunnels. G. completely wipe up the spilled fuel immediately. 1. When there is not enough lubricating oil. Be sure to disconnect the electrical load and switch the main. UNV Terminal Lugs (Load) 3. Make sure the generator is level. Replenish with antifreeze as necessary. 3.DCA-40SSAI — GENERATOR START-UP PROCEDURE WARNING: The engine's exhaust contains harmful LW emissions. fill the fuel tank with clean fresh unleaded automotive diesel. GFCI or load circuit breakers in the ON position. excavations or buildings. 2. Connect the load to the UNV terminals as shown in Figure 36. Check the lubricating oil level prior to starting the engine. circuit breakers (Figure 35) to the “OFF” position prior to starting the engine. Before Starting Generator and Control Panel 2.I.F. Check the coolant level in the radiator and subtank. To gain access to the output terminals lift the UNV cover. Check the fuel level on the fuel gauge. CAUTION: NEVER start the engine with the main.I. Tighten terminal nuts securely to prevent load wires from slipping out. The oil level must be maintained between two notches on the dipstick. Figure 36. load and G. GFCI and Load Circuit Breakers DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 47 .C. Use a high quality detergent oil classified CC or higher (See Table 12 on page 43). Connect the negative battery cable (BLACK) to the negative post on the battery (Figure 37). If diesel spillage occurs. Always maintain the coolant level between the FULL and LOW markings on the coolant container. If fuel is low. These terminals can be found on the output terminal panel. Main. Be sure that the radiator cap is fastened securely.F. fill the crankcase with high grade motor oil.C . 4. Before Starting Engine 1. Battery Connections Figure 35. (see page 33 Figure 12).

Starter Switch Figure 45. 10.DCA-40SSAI — GENERATOR START-UP PROCEDURE 4. Voltage Meter (Volts) Figure 41. Once the preheat lamp luminates. 8. Engine Enclosure Doors 9. Frequency Meter (Hz) 6. turn the key to the farthest right to start the engine. Figure 39. 5. The generator's frequency meter (Figure 43) displays the 60 cycle output frequency in HERTZ. Turn and push the engine throttle control lever (Figure 40) to ‘Low’. Once the engine start to crank. Figure 42. Check the voltage selection switch (Figure 39) is at the desired voltage. The generator's voltage meter (Figure 44) displays the 120 VAC in VOLTS. Close all engine enclosure doors (Figure 38). pull and turn the engine throttle control lever to ‘High’ (Figure 42). Voltage Selection Switch Figure 43. Once the engine is warm and the engine is running properly. Voltage Adjust Control Knob PAGE 48 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . Figure 40. Engine Speed Switch (high) Figure 38. release the key to ‘operation’ (Figure 41). If the voltage is not within the specified frequency tolerance. Preheat the engine by turning the ignition key to the left. Figure 44. Engine Throttle Control Lever (low) 7. use the voltage adjustment control knob (Figure 45) to increase or decrease the desired voltage.

Oil Pressure Gauge 13. When a load is applied. The generator will run until manually stopped or an abnormal condition occurs. Under normal operating conditions the oil pressure is approximately 25 psi. Observe the generator's ammeter (Figure 51) and verify it reads the anticipated amount of current with respect to the load. Ammeter (No Load) 12. Engine Tachometer 15. The engine oil pressure gauge (Figure 47) will indicate the oil pressure (kg/ cm2) of the engine. Turn the MAIN. The tachometer (Figure 49) will indicate the speed of the engine when the generator is operating. 20 0 40 60 75 14. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 49 . Coolant Temperature Gauge A Figure 51. 20 0 40 60 75 WATER TEMP Figure 48. this meter will indicate the amount of current that the load is drawing from the generator’s alternator. GFCI and LOAD circuit breakers to their ON position (Figure 50). Under normal operating conditions this speed is approximately 1800 RPM’s. Main and GFCI Circuit Breakers 16.DCA-40SSAI — GENERATOR START-UP PROCEDURE 11. Figure 50. Figure 47. The ammeter (Figure 46) will indicate zero amps with no load applied. Ammeter (Load) 17. A Figure 46. Under normal operating conditions the coolant temperature is between 165 and 215 degrees Fahrenheit. The coolant temperature gauge (Figure 48) will indicate the coolant temperature. The ammeter will only display a current reading if the load is in use. Figure 49.

Turn and push the engine throttle control lever (Figure 53) to the idle (low) position. EMERGENCY STOP 1. Figure 53. 4. 2. Main. GFCI and Load circuit breakers 2. To stop the engine in the event of an emergency. Let the engine cool by running it for 3-5 minutes with no load applied. GFCI and LOAD circuit breakers (Figure 52) to the “OFF” position.DCA-40SSAI — GENERATOR SHUTDOWN PROCEDURE ENGINE SHUTDOWN To shutdown the generator. Figure 52. Switch both the MAIN. Figure 54. PAGE 50 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . Turn the starter switch key to ‘Stop’ position. Engine Throttle Control Lever 3. GFCI and LOAD circuit breakers to ‘OFF’ position. use the following procedure: 1. Off/Manual Auto Switch 5. Turn the starter switch key to ‘Stop” position (Figure 54). Remove the load from the UNV terminal strip. switch the MAIN.

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

The air cleaner is equipped with an indicator. Fuel Addition Add diesel fuel (the grade may vary according to season and locations). the more empty volume inside the tank. or after disassembling the fuel system. When the gasket is in contact with the seal surface.DCA-40SSAI — MAINTENANCE General Inspection Prior to each use. Insufficient oil may cause severe damage to the engine. Service Daily If the engine is operating in very dusty or dry grass conditions. To restart after running out of fuel. After the oil cartridge has been replaced. if needed. tighten the cartridge one or two more times by hand. Check Oil Level Check the crankcase oil level prior to each use. oil. and coolant leaks. Securely fasten the fuel strainer cap so that fuel will not leak. For heavy duty paper element. Check the fuel strainer every 200 hours of operation or once a month. 2130psi). bleed the system according to the following procedure. Apply fuel oil thinly over the gasket and hand-tighten the cartridge into position. Removing Water from the Fuel Tank After prolonged use. During cold weather. bolts or other fasteners. starting becomes impossible. Remove dust or water in the strainer cap and wash it in gasoline. turn the switch to the “ON” position for 15-30 seconds. the engine oil will drop slightly. Make sure the generator is level. Fuel Injection Nozzle Use an injection nozzle tester to check the static injection starting pressure and the fuel spray conditions. press the dust indicator button to reset the indicator. After the dirty air cleaner has been replaced. Run the engine for a while and check for leaks before adding more oil if needed. the generator should be cleaned and inspected for deficiencies. Also check for fuel. Try again. The oil level must be between the two notches on the dipstick as shown in Figure 32. Screw in the cartridge by hand.7MPa (150kg/cm 2. This can lead to a loss of power. Clean excessive oil from engine. Check for loose. a clogged air cleaner will result. After running out of fuel. or when the fuel tank is filled. This can be reduced by keeping the tank full as much as possible. wipe excess kerosene with towel. missing or damaged nuts. This unit is equipped with an automatic air bleeding system. Replacing Oil Filter Detach the oil filter cartridge with a filter wrench. page 43. excessive carbon buildup in the combustion chamber in high fuel consumption. Abnormal fuel consumption will lead to a lowered output and blackish exhaust smoke. Apply a film of oil to the gasket for the cartridge. the easier it is for water to condense. Vent any air. The required injection starting pressure should be 14. 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. PAGE 52 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . Wrap foam element in a cloth and squeeze dry. water and other impurities accumulate in the bottom of the tank. Air Removal If air enters the fuel injection system of a diesel engine. Occasionally remove the drain cock and drain the contents. or foam element with liquid detergent and hot water. Cleaning the Fuel Strainer Clean the fuel strainer if it contains dust or water. Replacing Fuel Filter Replace the fuel filter cartridge with new one every 400 hours or so. Always pour through the mesh filter.

Clean the strainer with compressed air and rinse it in the fuel oil. Check hoses for softening and kinks. Flushing the radiator while hot will damage radiator. Close radiator cap tightly. 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. Remove the overflow tank and drain. Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. Table 14 for mixture). Tighten both cocks and replace the overflow tank. CAUTION : Allow engine to cool when flushing out radiator. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 53 . DO NOT clean radiator core with any objects. Open the radiator cap while draining. Replace with coolant (see page 44.DCA-40SSAI — MAINTENANCE Feed Pump Strainer Cleaning The strainer is incorporated in the feed pump inlet side joint bolt. Check clamps for signs of leakage. such as a screwdriver.

The injection starting crank angle should be at the 14o timing mark. When the fuel stop to flow out from No. Delivery valve holder tightening torque: 39~44Nm(29~33lbft. Remove the injection pump No. Do the adjustment on the circle marked valves in the below table where No. 8. 1 delivery valve holder. stop pumping. O O O O PAGE 54 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . the TDC mark to do the adjustment again on the delivery valve and spring and reinstall the delivery valve remaining valve. Bring No. 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 cylinder to top dead center in the compression stroke. same time continue to feed the fuel with pumping the Feed pump. 2. Slowly turn the crankshaft pulley clockwise and at the 1. After adjustment started from either piston top center. If not. Remove No. 1 injection pipe from the engine. 1 delivery valve holder. viewed at the engine front about 30o crank angle. 1 I X E X I X 2 E I 3 E X I 4 E Figure 55. align the notched line on the crank pulley with TDC mark on the timing gear case cover. 6. Observe and make sure which mark (injection starting the TDC mark on the timing gear case cover. 11. See Table 16 and Figure 55 for valve holder on the original place. The timing line shows the injection starting crank angle of the engine. Table 16. turn the crankshaft 360o to align the notched line with 7.DCA-40SSAI — MAINTENANCE Valve Clearance Check 1. If “a” and “b” are in alignment. 1 cylinder is at the center in the 5. 3. Valve Adjustment Valve Arrangement When No. angle line) on the timing gear case cover is aligning with the notched line on the crank pulley. In order to bring No. 3. 1-3 until the “a” and “b” are aligned. E=Exhaust) Cylinder No. 2. the timing is set correctly.) Injection Timing Check and Adjustment 9. Valve Adustment (I=Inlet. 1 is at top dead center in the compression stoke When No. 4. 4 is at top dead center in the compression stroke NOTE: Take necessary precautions to prevent dust and foreign particles in the pump interior when timing adjustments are made. 1 or No. arrangement. 12. follow nos. cylinder to the top dead center on the compression stroke. Turn the crankshaft pulley clockwise (viewed at engine front) and align the notched line on the crank pulley with 10. Reversely turn the crankshaft pulley counterclockwise compression stroke.

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 55 . first time only. dry place. Cover the generating set and store in a clean. the following is required: Fill the fuel tank completely. first time only. Inside and Outside Change Fuel Filter *2 Clean Radiator and Check Coolant Protection Level Test Fuel Injection Nozzle Replace Air Filter Element Check all Hoses and Clamps Check Valve Clearance Check Injection Nozzle Clean Inside of Fuel Tank GENERATOR Measure Insulation Resistance Over 3M ohms *1 Replace engine oil anf filter at 100 hours. Clean all external parts of the generator with a cloth. *2 Replace fuel filter at 250 Hours. Generator Storage For storage of the generator for over 30 days. Completely drain the oil from the crankcase and refill with fresh oil.DCA-40SSAI — MAINTENANCE 10 Hrs DAILY X X X X X X X X X X X X X X X X X X X X INSPECTION / MAINTENANCE Check Engine Fluid Levels Check Air Cleaner Check Battery Acid Level Check Fan Belt Condition Check for Leaks Check for Loosening of Parts Replace Engine Oil and Filter *1 Clean Air Filter Drain Bottom of Fuel Tank 250 Hrs 500 Hrs 1000 Hrs ENGINE Clean Unit.

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

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

tighten cylinder head bolt. PAGE 58 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . TABLE 17. Tighten nut. Replace. Clean fuel pipe. If the problem cannot be remedied. Use the specified fuel. Adjust.DCA-40SSAI — TROUBLESHOOTING (ENGINE) Practically all breakdowns can be prevented by proper handling and maintenance inspections. Incorrect injection timing? Fuel cam shaft worn? Injection nozzle clogged? Injection pump malfunctioning? Seizure of crankshaft. camshaft. use the tables shown for diagnosis based on the Engine Troubleshooting (Table 1 7). Clean or change fuel filter. Replace. Use the specified fuel or engine oil. consult our company's business office or service plant. Repair or replace. Bleed system. Remove water from fuel tank. Correct or replace timing gear. Adjust. Clean injection nozzle. but in the event of a breakdown. Replace head gasket. piston. glow plug and nozzle holder. ENGINE TROUBLESHOOTING (PART 1) SYMPTOM POSSIBLE PROBLEM SOLUTION No fuel? Air in the fuel system? Water in the fuel system? Fuel pipe clogged? Fuel filter clogged? Excessively high viscosity of fuel or engine oil at low temperature? Fuel with low cetane number? Fuel leak due to loose injection pipe retaining nut? Engine does not start. Repair or replace. cylinder liner or bearing? Compression leak from cylinder? Improper valve timing? Piston ring and liner worn? Excessive valve clearance? Replenish fuel.

Adjust. Clean or change. Repair or replace. DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 59 . Use the specified fuel. Repair or replace. ENGINE TROUBLESHOOTING (PART 2) SYMPTOM POSSIBLE PROBLEM SOLUTION Fuel filter clogged or dirty? Air cleaner clogged? Fuel leak due to loose injection pipe retaining nut? Injection pump malfunctioning? Engine revolution is not smooth. Clean or change. Repair or replace the injection pump. Adjust. Clean or change. tighten cylinder head bolt. Repair or replace.DCA-40SSAI — TROUBLESHOOTING (ENGINE) TABLE 17. Lessen the load. Reduce to the specified level. Repair or replace the nozzle. Repair or replace the nozzle. Replace head gasket. Uneven fuel injection? Deficient nozzle injection? Compression leak? Clean or change. Adjust top clearance. Tighten nut. Fuel filter clogged? Air cleaner clogged? Deficient nozzle injection? Incorrect injection timing? Engine's moving parts seem to be seizing? Deficient output. Incorrect injection timing? Deficient compression? Overload? Low grade fuel used? Either black or dark gray exhaust gas is observed. Repair or replace. Clean. Adjust. Incorrect nozzle opening pressure? Injection nozzle stuck or clogged? Fuel over flow pipe clogged? Governor malfunctioning? Excessive engine oil? Piston ring and liner worn Either white or blue exhaust or stuck? gas is observed. glow plug and nozzle holder. Repair.

Check load and repair. Confirm load requirement and replace.DCA-40SSAI — TROUBLESHOOTING (GENERATOR/ENGINE) TABLE 17. Replace if necessary. Turn engine throttle lever to "High". Replace if necessary. Check and replace. Check wiring and repair. Replace if necessary. GENERATOR TROUBLESHOOTING SYMPTOM No Voltage Output POSSIBLE PROBLEM AC Voltmeter defective? Is wiring connection loose? Is AVR defective? Defective Rotating Rectifier? Low Voltage Output Is engine speed correct? Is wiring connections loose? Defective AVR? High Voltage Output Is wiring connections loose? Defective AVR? Circuit Breaker Tripped Short Circuit in load? Over current? Defective circuit breaker? Over current Relay actuated? SOLUTION Check output voltage using a voltmeter. Check wiring and repair. Confirm load requirements and reduce. PAGE 60 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . Check and replace. Check wiring and repair.

NOTE PAGE

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

EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts book. Items Found In the “Remarks” Column Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used. Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant. Items Found In the “Items Number” Column All parts with same symbol in the number column, , #, * +, or %, belong to the same assembly or kit. Note: If more than one of the same reference number is listed, the last one listed indicates newest (or latest) part available.

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

DCA-40SSAI — SUGGESTED SPARE PARTS
DCA-40SSAI W/ISUZU 4BD1 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

NOTE Part number on this Suggested Spare Parts list may supercede/replace the P/N shown in the text pages of this book.

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

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

...................... 4 ..PB2510 HEX.REPLACES 0010310030 STATOR ASSY............... 1 ....... COUPLING HUB 1 LOCK WASHER 5 HEX...... EXCITER 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 65 ...... EXCITER 1 COUPLING HUB 1 RECTIFIER ASSY....9261290050 LOCK WASHER ... RECTIFIER 1 RECTIFIER ...... NUT .........REPLACES 0040005000 HEX..DCA-40SSAI --.. 9 ..........ERZM14K621A INSULATOR WASHER 1 INSULATOR WASHER 1 HEX........REPLACES 0601610700 & 9091505100 BOLT SET 1 LOCK WASHER 9 HEX......... HEAD BOLT ............. REMARKS FIELD ASSY......... HEAD BOLT .... 3 ...................... HEAD BOLT .......................................... 10 . NO.........GENERATOR ASSY............................ 1 GENERATOR FRAME 1 ARMATURE CORE 1 ARMATURE COIL 1 GROMMET 1 END BRACKET 1 FIELD ASSY............... EXCITER 1 ARMATURE COIL.......... 1 SET PLATE... EXCITER 1 FIELD CORE....REPLACES 0041605000 LOCK WASHER ..REPLACES 0017105012 BEARING FLANGE 1 BEARING 1 SNAP RING 1 FAN 1 COUPLING DISK 1(8) WASHER......... 1 . 1 ...... 2 ................. HEAD BOLT 3 PLAIN WASHER 6 LOCK WASHER 3 HEX.................................... 9 ....... PART NO..... 1 1-1 1-2 1-3 1-4 1-5 1-6 2 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16-1 16-2 16-3 17 18 19 19-1 19-2 3341040300 3341010102 9521002693 3341080003 3361032003 33610850003 334110003 3361025003 3361026003 0601820067 0010004020 0041604000 0040004000 OEMAA8 0601822601 0801841004 0801841104 0017105020 58151 0032005000 0030005000 0011305100 3331014004 0070206310 0080000050 3341070002 3341611003 3341612003 3341613004 0131151240 0601600000 030212300 0601610511 0040010000 012010030 3341341400 3341320312 3801342114 3341361503 0801350104 3361315013 3361350030 3361352023 3361362303 ITEM QTY..............REPLACES 0010312030 COUPLING RING ...... EXCITER 1 FIELD COIL........ GENERATOR ASSY... NUT 1 HEX.......... HEAD BOLT ..................REPLACES 0010005020 PLAIN WASHER ........................................ 3 .. 1 ..................REPLACES 0030004000 SURGE ABSORBER .............................. 1 SHAFT 1 FIELD CORE 1 FIELD COIL 1 ARMATURE CORE............................

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

..DCA-40SSAI --......................REPLACES 0010010030 0017106010 0010310025 0041606000 0030116000 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 67 ... GENERATOR ASSY...... 8 ... END BRACKET 1 HEX...REPLACES GASKET............ HEAD BOLT 1 RUBBER SUSPENSION 2 LOCK WASHER 4 HEX....... 1 .... 6 .......... HEAD BOLT .... HEAD BOLT 4 LOCK WASHER 6 HEX......REPLACES COVER...........REPLACES LOCK WASHER 4 HEX.. BEARING 1 LOCK WASHER 4 HEX.... HEAD BOLT ..... FAN 1 PLAIN WASHER ........ 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 031108160 0040008000 0010008060 0040010000 012010030 3801312004 3331310104 0040006000 0040006055 3361331003 011006010 0040010000 0105091025 3361332003 952404470 0040006000 0010006030 0605000011 0040016000 020316130 ITEM QTY.........................GENERATOR ASSY................. BEARING 1 COVER.... NUT ..... HEAD BOLT ........ NO. HEAD BOLT 4 COVER........... PART NO...............REPLACES LOCK WASHER 6 HEX....................... 6 .REPLACES LOCK WASHER 1 HEX.................................................... 4 .................. REMARKS 0041608000 PLAIN WASHER ... 4 ....

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

.......................... REMARKS CONTROL BOX . UP TO S/N3311949 CONTROL BOX ... CONTROL PANEL 1 MACHINE SCREW 2 HEX.............. TO100CC 500V 100AT PLAIN WASHER 2 LOCK WASHER 2 MACHINE SCREW 2 CHANGE-OVER SW......HEAD BOLT 6 CURRENT TRANSFORMER........................... CT3............................... VOLTAGE 1 MACHINE SCREW 4 MACHINE SCREW 2 CONTROL PANEL 1 FREQUENCY METER ......CONTROL BOX ASSY...... 1 ... AMMETER ......5MR 75/5A MACHINE SCREW 4 AUTOMATIC VOLTAGE REGULATOR ....... 1 ..................... SL2AS AC VOLTMETER ................. RA30A2FE202BJ KNOB 1 STOPPER.... 1 . 2 ...... S/N3311950~ HEX.......... PART NO. CONTROL BOX ASSY....................................... CONTROL BOX .............................. 1 ............................... 1 ......... NUT ................. CONTROL BOX .............................. HEAD BOLT 2 HEX....................... SL2VS PILOT LAMP 1 BULB 1 VOLTAGE REGULATOR . NUT 2 SET SCREW.... 1 7451810002 7451810012 2 3361870603 3 0017106016 4 0601801142 5 0027104010 6 0800225200 7 0027106010 8 0601820042 9 0027103010 10 0601842058 11 0027108010 14 0601804970 15 0041604000 16 0040004000 17 0021004060 18 0601830625 19 0021104016 20 0021104014 21 3341822503 22 0601800460 23 0601800729 24 0601801040 25 0601800212 0601800217 26 0601801041 27 0601810072 0601810261 28 0601840031 29 0601840120 30 3331824003 31 0027105016 32 0030005000 33 0805001304 34 031108160 35 020108060 36 0027105010 37 7451826504 7451826514 38 0017106016 39 011008020 40 020108060 41 0601840191 42 0601830614 ITEM QTY............................... 2 .. NUT . 2 ...................................... S/N3311950 CURRENT TRANSFORMER 3 HEX... UP TO S/N3311949 SIDE PANEL.. 1 .......... 1 .... VOLTMETER .. AE2206A MACHINE SCREW 6 RECTIFER 1 MACHINE SCREW 4 RESISTOR .....DCA-40SSAI --............. 4 ..... CONTROL PANEL 2 PLAIN WASHER . 1 ............................................... REPLACES 0041608000 HEX... PAK60 220V 45~65Hz AC AMMETER ............................ 80V 200OHMS MACHINE SCREW 2 CIRCUIT BREAKER .................. NO.. HEAD BOLT ................................................ PSK60 0~75A 0~150A CHANGE-OVER SW..... 1 ...... 4 .. 1 ........... REPLACES 0017108020 HEX....... 1 ........... 1 .. PCK60 0~600V............................... REPLACES 0030008000 MACHINE SCREW 4 SIDE PANEL.. AMMETER .................... REPLACES 0030008000 SWITCH CAP 1 PLATE 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 69 ............. 1 . REPLACES CHANGE-OVER SW.....

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

. OIL FILTER ... ISUZU 4BD1.................................. 1 .. AIR CLEANER 1 20 0605515011 HOSE BAND 1 21 0605515028 HOSE BAND 1 22 1878102201 ELEMENT................................ AIR CLEANER .......... B9611111910 5 0602014062 HOSE BAND .......................... 4B128 10 0602013186 RADIATOR HOSE ...... 1 ...... 4 ...... 1 . REMARKS 1 4B01PD02 ENGINE ........................... REPLACES 0602041107 23 5878100500 ELEMENT..... 1 ...................... ITEM QTY.............. HEAD BOLT .. 4B129 11 0602014000 HOSE BAND 2 12 0602014000 HOSE BAND 1 13 0602014071 HOSE BAND 1 14 0602040094 AIR CLEANER ................ P007191 17 011008020 HEX...... 4 ............. RBX002252 16 0602040595 BAND...... 8 ............... 4 .......... 1 ..... RADIATOR 2 8 011008020 HEX. 8 ............................. 1 ............. FUEL FILTER ..................... 2 .......... 1 ......... REPLACES 0030112000 32 1819001931 ENGINE STOPPER .......... 1 .............................. REPLACES 0041610000 27 0040010000 LOCK WASHER 8 28 0105091025 HEX.............................. G000100131 6 0602011000 RADIATOR CA ........... REPLACES 0602210803 AND 1819000161 33 0027106016 MACHINE SCREW 3 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 71 . REPLACES 0017108020 9 0602013086 RADIATOR HOSE ................................. PART NO. NO...................... 7880K11100 7 3345123104 BRACKET............................ B961110002 3 0602011303 RADIATOR NECK ........................ 1 . 4079111300 4 0602011102 HOSE ........ AIR CLEANER .................. 1 ............ REPLACES 0010710025 29 0605000009 RUBBER SUSPENSION 2 30 0040012000 LOCK WASHER 4 31 0039312000 HEX. REPLACES 0030008000 19 3342032103 HOSE....................... REPLACES 0602042108 24 3345112503 ENGINE FOOT 1 25 3345112403 ENGINE FOOT 1 26 031110160 PLAIN WASHER .......... 2 ................. 1 .......... 1 ......................................... NUT .... REPLACES 0602000078 2 0602010800 RADIATOR ................... HEAD BOLT ........... NUT .......................... 12 ........... FQG068002 0602040197 ELEMENT....... 1 ............ HEAD BOLT ........... ENGINE AND RADIATOR ASSY.....................................DCA-40SSAI ENGINE AND RADIATOR ASSY.. REPLACES 0017108020 18 020108060 HEX............... P104873 15 0602040690 DUST INDICATOR .

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

.. HEAD BOLT ............DCA-40SSAI ENGINE AND RADIATOR ASSY............ 2 .. ENGINE AND RADIATOR ASSY.... REMARKS 34 3342054104 DRAIN JOINT 1 35 0805013704 PACKING...... NO.......................... PART NO. ITEM QTY.................... 2 ........... HEAD BOLT . REPLACES 0017108020 44 020108060 HEX............ RESERVE TANK 1 48 011008020 HEX... 1 .... OIL PAN SIDE 1 36 0805014204 PACKING 1 37 3362054104 JOINT BOLT 1 38 3342051104 DRAIN JOINT 1 39 0802024004 PACKING 1 40 0802010204 PLUG 1 41 3342022104 DRAIN HOSE 1 42 0605515003 HOSE BAND 2 43 011008020 HEX... HEAD BOLT 4 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 73 ... 2 ..... RESERVE TANK 1 47 3342082304 BRACKET..... NUT ................. REPLACES 0030008000 45 0845031303 RESERVE TANK 1 46 0802081104 CAP............ HEAD BOLT ....... REPLACES 0017106025 50 0199500950 HOSE 1 51 0199500175 HOSE 1 52 0193601000 HOSE 1 53 0605515013 HOSE 1 53 0605515013 HOSE BAND 4 54 0193900750 BREATHER HOSE 1 55 0605515030 HOSE BAND 2 56 0193100700 HOSE 1 57 0605515007 HOSE BAND 1 58 0193800750 HOSE 1 59 0605515019 HOSE BAND 1 60 3342220604 EARTH CABLE 1 61 0017106016 HEX. REPLACES 0017108020 49 011606025 HEX.....

PAGE 74 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .ENGINE OPERATING PANEL ASSY.DCA-40SSAI --. ENGINE OPERATING PANEL ASSY.

.. REPLACES 0041606000 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 75 ...... REPLACES 0602120052 11 0602120154 CABLE........ REPLACES 0602100004 9 9825300460 PREHEAT LAMP .... HEAD BOLT ..... NUT ........................ REPLACES 0017108020 27 3345312003 SUPPORT LEG 1 28 0017110025 HEX... 1 ...... WATER TEMPERATURE ....... PART NO.... 62100KA6710 L=1150 12 0602122060 OIL PRESSURE GAUGE ........... 1 ........................................... REPLACES 0041610000 34 020310080 HEX.............................................. 1 ........ LAMP CHECK 1 20 0601810120 PANEL LIGHT 1 21 0040520000 TOOTHED LOCK WASHER 1 22 0601830710 SWITCH.......... 1 . REPLACES 0030010000 35 3342182004 GOVERNOR ROD 1 36 3342152114 GOVERNOR ROD 1 37 0602180101 BALL JOINT 2 38 020108060 HEX...ENGINE OPERATING PANEL ASSY...... HEAD BOLT 2 29 011208025 HEX........... GOVERNOR ROD 1 6 020108060 HEX....................................... REPLACES 0602102006 AND 9825301080 10 0602120052 TACHOMETER .......... 2 ..... HEAD BOLT 1 33 031110160 PLAIN WASHER ................................. PANEL LIGHT 1 23 031108160 PLAIN WASHER .......... REPLACES 0030008000 39 0602180100 BALL JOINT 1 40 020106050 HEX....... 42000KX1410 13 0602122200 UNIT... 1 ..... REPLACES 0030008000 7 0605010503 SNAP PIN 1 8 1823100080 STARTER SWITCH .. 1 . 40000KX0910 16 0602123201 UNIT..... ITEM QTY............... REPLACES 0010008040 26 011008020 HEX...................... ENGINE OPERATING PANEL ASSY........... 1 .......... NUT ............. NO......... 2 .. GOVERNOR ROD 1 32 0010010025 HEX............. 1 ... NUT 2 31 3342183004 LINK...... REPLACES 0805012904 4 0080200006 SNAP RING 1 5 7452140504 BRACKET............................ 3 ................ REPLACES 0030006000 41 952404470 PLAIN WASHER .......... REMARKS 1 3342101003 OPERATING PANEL 1 2 7452142004 SLIDE BAR 1 3 0601840190 KNOB ............................ 2 ......... 1 .......... 2 ...... 25000KX3710......... OIL PRESSURE ............... REPLACES 0017108025 30 0030008000 HEX...... HEAD BOLT .......................... TACHOMETER ...................... NUT ............. 51400KV0200 17 0602121052 CHARGINE AMMETER ........................ REPLACES 0602103060 0601810244 BULB 2 19 0601830420 SWITCH..... 2 ............ HEAD BOLT ............... 2 .............. 1 ..... 2 ...................... 2 .............. 53000AC0101 14 0131300000 STREET SOCKET 1 15 0602123061 WATER TEMPERATURE GAUGE .. REPLACES 0041608000 24 0040008000 LOCK WASHER 2 25 011008040 HEX........DCA-40SSAI --.. 1 ............ 43000KV0300 18 0602103091 ALARM LAMP .. 1 ................... NUT .................

ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY.DCA-40SSAI --. PAGE 76 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

. 2 ....... ITEM 42 43 44 45 46 47 48 49 50 51 52 53 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 3345188203 011008020 1825500732 0027106016 0601823706 0027104016 3341860103 0801831704A 012210020 0041410000 0040010000 0039310000 031108160 0040008000 011208030 0601811032 0601811037 0601811031 0601811030 0027103010 0041603000 0207003000 0601805311 0601805315 7451816004 0027106016 3341865803 0805012304 031112230 0805019704 0030012000 0605010505 0601850091 0021003010 0601802133 0601820015 3341865903 7451855503 7451855703 0021304015 0040004000 031104080 OEMAA8 QTY........ 2 ............................... 1S2762 COVER.............. S/N3312326~ PLAIN WASHER ......... 16 ...... HEAD BOLT 2 PLAIN WASHER ......... 4 ...... 5 ........... 1 ....................... CS8269 250V 50A RECEPTACLE ... REPLACES 0030003000 CIRCUIT BREAKER ............. REMARKS SET PANEL..... OUPUT TERMINAL ........................ REPLACES 0041612000 RUBBER WASHER 2 HEX...... 4 ......... NUT ........................... HEAD BOLT .......... CIRCUIT BREAKER 1 MACHINE SCREW 2 COVER.... 2 .................................... REPLACES 0030104000 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 77 ................................ S/N3312326~ LOCK WASHER . KM51 265V 50A CIRCUIT BREAKER ....................... S/N3312326~ HING .................. 4 .............................................. NO.......... L620R 250V 20A RECEPTACLE ....... 6 ............................... 2 ................... OUTPUT TERMINAL 1 OUTPUT TERMINAL 4 HEX........ 2 ... REPLACES 0602200405 MACHINE SCREW 4 RELAY 1 MACHINE SCREW 2 SET BOARD..................................................... KM51 265V 30A BRACKET... REPLACES 0801831804 PLAIN WASHER 16 LOCK WASHER 12 HEX................... 1 ............ 2 .................. S/N3312326~ HINGE ........ NUT 8 PLAIN WASHER ........ENGINE OPERATING PANEL ASSY..................... HEAD BOLT ................ S/N3312326~ MACHINE SCREW ...... 5A 1 RECTIFIER .... S/N3312326~... PART NO......... REPLACES 0041204000 HEX........... 8 ........ L530R 125V 30A RECEPTACLE ............. 1 ................. S/N3312326~............. HEAD BOLT ... NUT 2 SNAP PIN 2 RUBBER CUSHION 2 MACHINE SCREW 2 FUSE......... 1 ..... NUT . REPLACES 0010008030 RECEPTACLE ............. 4 ... ELECTRIC PARTS 1 HEX..... OUTPUT TERMINAL 1 HEX............................................DCA-40SSAI --.. REPLACES 0017108020 EMERGENCY RELAY ........... REPLACES 0041608000 LOCK WASHER 5 HEX......................... 5 ... 4 ... 520R 125V 20Ax2 MACHINE SCREW 16 PLAIN WSAHER 16 HEX. 4 ................................ ENGINE OPERATING PANEL ASSY...............

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

................ REMARKS BATTERY . 2 ........... 4 .. NO.....9P WING NUT ... PART NO.............................................DCA-40SSAI --..........9N WING NUT .. 2 ..... REPLACES 0208008000 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 79 ............. N100 12V 100Ah BATTERY SHEET 2 BATTERY BAND 2 BATTERY BOLT 4 PLAIN WASHER 4 LOCK WASHER ......... 2 ............. NO. (+) . REPLACES 0040008000 WING NUT 4 BATTERY CABLE 1 BATTERY CABLE 1 BATTERY CABLE 1 TERMINAL ASSY.......... 2 .......................................... 1 0160012100 2 0805003904 3 0805004004 4 3802252004 5 0041608000 6 031108160 7 0037808000 8 0215260050 9 0211160160 10 0215860045 11 0602220310 0037808000 12 0602220311 0037808000 ITEM QTY.................... BATTERY ASSY......... NO..... 2 .............. REPLACES 0208008000 TERMINAL ASSY (-) ..................BATTERY ASSY.....

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

.................. 2 ......... REMARKS EXHAUST PIPE 1 GASKET ...MUFFLER ASSY.....DCA-40SSAI --.....HEAD BOLT .................... 4 ... 4 .................................... REPLACES 0041608000 LOCK WASHER 4 HEX....... 6 ............... REPLACES 0017108025 HEX.. REPLACES 0017108025 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 81 .............. 1 ...... HEAD BOLT .................... REPLACES 0030008000 COVER 1 COVER 1 PIPE CLAMPER 1 HEX........................ REPLACES 0602320000 AND 9221160010 HEX....................... REPLACES 0602323002 MUFFLER 1 MUFFLER SHEET 1 HEX....... REPLACES 0010108035 PLAIN WASHER ......... 4 ..................... NUT ..... REPLACES 0017110020 GASKET 1 HEX........... 2 ...................................... HEAD BOLT ... MUFFLER ASSY...... 4 ....................... 1 3342350103 2 1141450690 3 9091103100 4 3342311102 5 3342359104 6 011208025 7 012210020 8 3342356104 9 011008035 10 031108160 11 0040008000 12 020108060 13 3342354104 14 3342354004 15 3342328104 16 020108060 17 3342359004 18 0112508025 ITEM QTY....... 4 .......... HEAD BOLT ..... PART NO............ NUT ..... REPLACES 0030008000 COVER SHEET 2 HEX............ NUT ....... NO........

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

............ FUEL TANK 1 FUEL FILTER 1 PACKING 1 PLUG ...... REMARKS FUEL TANK 1 CAP.. REPLACES 0041608000 LOCK WASHER 2 HEX............ 1 ........ 1 3345510323 1-1 0810105004 1-2 0810105400 2 0802010304 3 0602021042 4 3345523304 5 0805003404 6 011008020 7 031108160 8 0040008000 9 020108060 10 3805522004 11 0191300600 12 0191300700 13 0605515014 14 0845032204 15 0150000018 16 0802011104 17 0193100225 18 0605515079 ITEM QTY............. FUEL TANK ASSY........................... 2 .................... 2 .. REPLACES 0030008000 TANK SHEET 4 SUCTION HOSE 1 RETURN HOSE 1 HOSE BAND 4 DRAIN JOINT 1 O RING 1 PLUG 1 FUEL GAUGE HOSE 1 HOSE BAND 2 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 83 ....................DCA-40SSAI --........ NO..............FUEL TANK ASSY.... NUT . 960922101 TANK BAND 2 PAD.. PART NO..................... 2 ............ TANK BAND 4 HEX. HEAD BOLT . REPLACES 0017108020 PLAIN WASHER .......

DCA-40SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.

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

DCA-40SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY. NO. PART NO. 1 3345111322 2 3345116214 3 011008020 4 3345121122 5 3345109103 6 B3561100103 7 3340630503 8 0600500090 9 0021106020 10 011008020 11 3345122604 12 011008020 13 3345125103 14 3345109204 15 B3561100003 16 011008020 18 011008020 19 3385155104 20 011206020 21 3345125204 22 011008020 23 3345132113 24 3345132203 25 012210040 26 0041614000 27 030214350 28 0030014000 29 012012030 30 0040012000 31 031112230 32 3345141202 3345141212 33 3345109303 34 B3561100204 35 011008020 36 3345155103 37 3345109403 38 031108160 39 0040008000 40 011008040 ITEM QTY. REMARKS BASE 1 FLOOR PANEL 1 HEX. HEAD BOLT ........................... 10 ........ REPLACES 0017108020 FRONT FRAME 1 LINING 1 STRIPE, LEFT SIDE ...................... 1 .......... REPLACES 3340630303 STRIPE, RIGHT SIDE 1 EMBLEM ......................................... 2 .......... REPLACES 6360510003 MACHINE SCREW 4 HEX. HEAD BOLT ........................... 6 .......... REPLACES 0017108020 BRACKET, RADIATOR NECK 1 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020 COVER, FRONT FRAME 1 LINING 1 STRIPE ........................................... 1 .......... REPLACES 3340630103 HEX. HEAD BOLT ........................... 16 ........ REPLACES 0017108020 HEX. HEAD BOLT ........................... 10 ........ REPLACES 0017108020 COVER 2 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0017106020 COVER, FRONT FRAME 1 HEX. HEAD BOLT ........................... 6 .......... REPLACES 0017108020 CENTER FRAME 1 CENTER FRAME 1 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010014040 PLAIN WASHER 16 LOCK WASHER .............................. 8 .......... REPLACES 0040014000 HEX. NUT 8 HEX. HEAD BOLT ........................... 10 ........ REPLACES 0010012030 LOCK WASHER 10 PLAIN WASHER ............................. 10 ........ REPLACES 0041612000 REAR FRAME ................................ 1 .......... UP TO S/N3311949 REAR FRAME ................................ 1 .......... S/N3311950~ LINING 1 STRIPE ........................................... 2 .......... REPLACES 3340630704 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020 COVER, REAR FRAME 1 LINING 1 PLAIN WASHER ............................. 8 .......... REPLACES 0041608000 LOCK WASHER 8 HEX. HEAD BOLT ........................... 8 .......... REPLACES 0010008040

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

DCA-40SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.

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

. RIGHT SIDE ...... 1 ........ 1 .... UP TO S/N3311949 SIDE DOOR. PART NO.. 6 ... RIGHT SIDE . 1 .. HEAD BOLT ................ 1 .... REPLACES 0041606000 LOCK WASHER 6 HEX.............. 16 ........ LEFT SIDE ................... REPLACES 0017108020 SIDE DOOR................... LEFT SIDE ..... HEAD BOLT ..................... HEAD BOLT .......... 4 ..... REPLACES 0017108025 ROOF PANEL 1 LINING 1 HEX.................. 1 . UP TO S/N3311949 DOOR................... AIR 1 LINING 1 HEX.... HEAD BOLT .......... UP TO S/N3311949 SIDE DOOR........... REPLACES 0017108020 GUIDE PANEL...... REPLACES 0017108020 SIDE DOOR................................ 1 .... REAR FRAME . 1 .. RIGHT SIDE ...DCA-40SSAI --... 6 ... 1 ... 4 ......................... 8 .......... HEAD BOLT ...... REPLACES 0017108025 CAP 10 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 87 ........................... S/N3311950~ LINING 1 STRIPE 1 GUIDE PANEL............ REMARKS DOOR...... 1 .................. REPLACES 3340631304 HINGE 4 HINGE 4 HEX. ENCLOSURE ASSY.............................. NO............ HEAD BOLT 6 LOCK WASHER 6 PLAIN WASHER ... HEAD BOLT .. S/N3311950~ LINING 1 STRIPE 2 GUDE PANEL...... REAR FRAME ............. AIR 2 LINING 2 HEX..................... S/N3311950~ STICKER 1 WINDOW PLATE . 12 .............. NUT .. AIR 2 LINING 2 HEX................ REPLACES 0017108020 SPLASHER PANEL 1 LINING 1 HEX... REPLACES 33805147104 MACHINE SCREW 6 PLAIN WASHER ... REPLACES 0030006000 HINGE 2 HEX...................ENCLOSURE ASSY......... UP TO S/N3311949 SIDE DOOR. UP TO S/N3311949 LINING 1 STRIPE .............................. 6 ..... 1 ....... RIGHT SIDE .. LEFT SIDE .................... 1 ....... 41 3345143303 3345143313 42 1320332003 43 3805147104 44 0021006020 45 952404470 46 0040006000 47 020106050 48 0845028303 49 011208025 50 3345161212 51 3345109503 52 011008020 53 3345165104 54 3345109604 55 011008020 56 3345181202 57 3345105304 58 0010008055 59 0040008000 60 031108160 61 3345124003 3345124013 62 3345109704 63 3345124103 3345124113 64 3345109804 65 3340630904 66 3345175104 67 3345105104 68 011008020 69 3345171803 3345171813 70 33451009904 71 3340631104 72 3345175004 73 3345105204 74 011008020 75 3345171903 76 3345105004 77 B3561100403 78 0845028203 79 0845028303 80 011208025 81 0845031504 ITEM QTY......................................................... S/N3311950~ LINING 1 SIDE DOOR............. REPLACES 0041608000 SIDE DOOR... 16 ................

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

................... PART NO........... NO.. 2 ........DCA-40SSAI --.............. REPLACES 0605010910 MACHINE SCREW ................... UP TO S/N3311949 MACHINE SCREW ..ENCLOSURE ASSY................... 7 ......... 1 .. 82 0605010910 83 0027103010 84 0605010910 85 0027104010 86 3345104104 87 3345104204 88 3345104304 89 3345104404 90 3345104504 91 3345104604 92 3345104704 93 3345104804 94 3345104904 ITEM QTY........... UP TO S/N3311949 LATCH ..... ENCLOSURE ASSY... REMARKS LATCH ....... UP TO S/N3311949.................. 14 ............. UP TO S/N3311949 RUBBER SEAL 2 RUBBER SEAL 2 RUBBER SEAL 3 RUBBER SEAL 1 RUBBER SEAL 1 RUBBER SEAL 1 RUBBER SEAL 1 RUBBER SEAL 2 RUBBER SEAL 2 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 89 ........................

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

...... WARNING ....................... M15000070 DECAL............... 2 ... 1 . DANGER ............. M90320000 DECAL..................... M90050010 DECAL................... M90030010 DECAL. + .................. DIESEL FUEL ...... GENERATOR CONTROL ..................................................................... M90030000 DECAL........ 2 ...... M90310000 DECAL................................... M92010020A DECAL.. VOLTMETER CHANGE-OVER SWITCH .. NO................................................... WARNING ...... M92020010 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 91 ................ ENGINE OPERATING ........... M92010000 DECAL.................. 1 .... CONNECTION OF OUTPUT CABLE ..................1 .... 1 ......................... 1 ....1 ......... PART NO........................................ M92020000 DECAL.. WATER............................................. 1 ......... OIL CHECK ................. 1 M1550000204 2 M1550001003 3 M1550000603 4 M1550000703 5 M1550000804 6 M9500000004 7 M9500100004 8 M9500300004 9 M9500300104 10 M9500500004 11 M9500500104 12 M9503000004 13 M9503000103 14 M9503100004 15 M9503200004 16 M9510100004 17 M9510200002 18 M9520000004 19 M9520000104 20 M9520000204 21 M9520100004 22 M9520100204 23 M9520100304 24 M9520100404 25 M9520100503 26 M9520200003 27 M9520200104 ITEM QTY.................. M92000000 DECAL. M15000020 DECAL.............1 .... WATER ...................... M9000000 DECAL.............. SAFETY INSTRUCTIONS .......... M92000010 DECAL..........1 . M90300000 DECAL................................ 1 . M15000100 DECAL............. M92000020 DECAL...................... AMMETER CHANGE-OVER SWITCH ....................... .... 1 .......... M91010000 DECAL.... REMARKS DECAL...... M92010040 DECAL......1 ........... WARNING ...........1 ........................... MQ ............ 1 ........ WARNING .......... OIL DRAIN PLUG . CAUTION ... M91020000 DECAL............... NOTE ........ GROUND ... NOTE ............1 ......... 1 ...............1 ..... CAUTION .. M90010000 DECAL......... M92010030 DECAL................. 1 ......... 1 ................................. 1 ... M90050000 DECAL. M15000060 DECAL....................... M15000080 DECAL..................... M92010050 DECAL. WARNING ....1 ....DCA-40SSAI --....................1 .................... OVER CURRENT RELAY ........ FUEL DRAIN PLUG ............................................................................. 1 .... AUXILIARY OUTPUT ........................ M90320000 DECAL........................................................................................... 1 ........ 1 ...DECALS DECAL ASSY...............

ISUZU 4BD1 — CYLINDER HEAD COVER ASSY. CYLINDER HEAD COVER ASSY. PAGE 92 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

....... REPLACES 8943674380 27 5111702672 CYL..... REPLACES 5112190150 5-2# 1096000160 SEALING CUP..... REAR FACE .. EXHAUST MAN. COMMET 1 15 1125690150 VALVE GUIDE SEAL 8 16 9041108200 STUD........... LOWER FACE 2 5-4# 1096000160 SEALING CUP............ EXHAUST 4 5# 1096000580 SEALING CUP.....18 ........ HEAD COVER ASSY....... ITEMS W/# 2# 9117156070 VALVE SEAT.......... REPLACES 9117510381 33 9111791050 WASHER 34 1096390320 PACKING... .. REMARKS 1 5111101680 CYLINDER HEAD ASSY........ INTAKE 4 3# 9117118030 VALVE SEAT...... REPLACES 1096000051 5-1# 1096000121 SEALING CUP.............. EXH............ HEAD 1 22 8943674370 BOLT .... INLET SIDE FACE 4 5-3# 9111291280 SEALING CUP. CYL.. 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..... REPLACES 9111790300 50 5111730160 PACKING. MANIFOLD ..... CYL.. OIL FILLER ....1 ..ISUZU 4BD1 — CYLINDER HEAD COVER ASSY.. . INCL....1 ......... HEAD 1 51 9111750120 NUT 1 EA1013 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 93 .. INL........... TOP FACE 1 13 9095714100 PACKING... NOZZLE STUD 8 12 9092023100 PLUG..3 .... INCL....... NO PART NO PART NAME QTY...1 ...........2 .... CYLINDER HEAD COVER ASSY. TOP FAC 3 5-5# 50960000130 SEALING CUP. MANIFOLD 3 20 8941458390 GASKET... REPLACES 9041108250 17 9098301770 STUD..................... ITEMS W/& 28& 1117510051 CAP.......... HEAD COVER ....1 ..... ..2 .............

CYLINDER BLOCK ASSY. PAGE 94 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .ISUZU 4BD1 — CYLINDER BLOCK ASSY.

. REMARKS CYL.. NO PART NO 1 8941303284 2# 5878131240 3# 5112570011 4# 1090004691 5# 9116910480 5-1# 9116930350 6# 1096000520 6-1# 5112190140 6-2# 1096000121 8 9098600190 9 8941480790 10 1096050681 11 5096050050 11-1 5096050180 12 9992023140 13 9095720140 14 1097400780 15-1 9081510180 18 8941075600 19 5112240040 20 5112901450 21 8943673680 22 8941075662 22-1 8944299951 23 9095720080 27 1096253620 30 5111290030 36 8941745290 37 8943210180 38 0500408180 43 1093000530 49 5096800110 53 9099135050 54 5097070041 56 5117401200 57 1094400401 59 1099851770 60 9091645080 61 8944338700 62 8941625680 66 5093608820 69 5097040331 PART NAME QTY... CYL........... FRONT AND REAR 2 SEALING CUP.......... REAR AND CENTER ... REPLACES 9116110480 CAM........... 2 INJ.. CYL. 1 ................. 4 ...... 2 .... BLOCK ASSY ....... REPLACES 1112611180 DOWEL 1 BOLT 10 CAM.... ITEMS W/# LINING .......... LEVEL GAUGE 1 COVER......... FRONT METAL .... REPLACES 9091104080 LOCK WASHER ... BLOCK COVER 2 BOLT 2 BOLT 2 PACKING........................... REPLACES 9097130740 CLIP 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 95 ................... TAPPET D=32 2 PLUG. 1 ...... GROMMET 4 SEAL........ REPLACES 9091505080 PLAIN WASHER 2 BREATHER HOSE 1 CLIP ..... OIL PUMP DRIVE SHAFT1 COVER.................ISUZU 4BD1 — CYLINDER BLOCK ASSY.. CAMSHAFT PLATE 1 DOWEL 2 PLUG... ENGINE FOOT 1 WATER DRAIN COCK 1 PIPE 1 DRAIN PIPE CLIP 1 AIR BREATHER ASSY........... TAPPET CHAMBER 1 PACKING........... FLYWHEEL HSG. GALLERY 1 PACKING 1 STRAIGHT PIN............... REPLACES 9992055170 PLUG 7 OIL PLUG. PUMP NIPPLE 1 BUSHING.................. 2 ..................... REAR OIL CRANK 1 SEALING CUP............ GALLERY .............. 2 ....... HEADLESS PT 1/2 2 OIL PLUG........ 1 ........ REPLACES 1097071340 VINYL PIPE ....... 1 .... 2 ... OIL DRAIN 1 PACKING................. 1 NUT ...... INCL............. BLOCK 1 SEALING CUP..... GEAR CASE 1 STRAIGHT PIN............... CYLINDER BLOCK ASSY......... COVER 1 BOLT 2 STUD....... REPLACES 9116130350 CEALING CUP..

ISUZU 4BD1 — CYLINDER BLOCK ASSY. PAGE 96 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . CYLINDER BLOCK ASSY.

...... REMARKS BOLT 1 PLAIN WASHER 1 OIL FILLER ASSY........... 1 .......... INCL............ 1 .................. ... REPLACES 9091505080 HOSE 1 CLIP 2 VALVE RELIEF ASSY......................... 1 . ITEM W/@ PACKING 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 97 ... CYLINDER BLOCK ASSY............... REPLACES 9091104080 LOCK WASHER .... NO PART NO 70 0500408160 71 9091606080 80 8941405811 81 1117500120 82 1094400401 83 1099851770 85 9099129760 86 9099155531 92 8970233390 93@ 5096230350 PART NAME QTY.....ISUZU 4BD1 — CYLINDER BLOCK ASSY............. 1 OIL FILLER CAP 1 NUT ...........

PAGE 98 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .ISUZU 4BD1 — TIMING GEAR ASSY. TIMING GEAR ASSY.

.............. REPLACES 0500408200 COVER 1 PACKING 1 SEAL ................ 1 2 3 4 6 7 8 9 10 10 12 13 14 PART NO...................................................................................ISUZU 4BD1 — TIMING GEAR ASSY.......... 2 ............................................... REPLACES 5090000841 COVER..................... 5 ..................................................... 1 ... TIMING GEAR ASSY....... 5113110113 9081510180 8943706710 0500408450 1113210790 8943632690 1096254380 9113276020 0500408250 8941500451 5113210090 8971186980 0500406140 PART NAME QTY............. REPLACES 1113120140 BOLT ... 1 .................. GEAR CHECK 2 GASKET ...................... REPLACES 1096253190 POINTER 1 BOLT 7 BOLT ... NO. REPLACES 1112820130 BOLT 4 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 99 .................. REMARKS CASE 1 STRAIGHT PIN 1 PACKING ............. 6 ..............

ISUZU 4BD1 — FLYWHEEL HOUSING ASSY. FLYWHEEL HOUSING ASSY. PAGE 100 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

FLYWHEEL HOUSING ASSY........ NO..... REMARKS HOUSING 1 PLUG.. 1 3 4 5 9 9-1 11 PART NO...... 1 ........................... PICK UP HOSE 1 DRAIN PLUG ..ISUZU 4BD1 — FLYWHEEL HOUSING ASSY....... 8943213303 8943218380 5096000090 9095714160 9910664500 0500408250 9096510690 PART NAME QTY.... REPLACES 9992023160 PACKING 1 BOLT 8 BOLT 7 PLAIN WASHER 8 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 101 ......

ISUZU 4BD1 — OIL PAN ASSY. OIL PAN ASSY. PAGE 102 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

..................... APR................ OIL PAN ASSY........ 94 OIL PAN PACKING ...... ...................... 1 ...... NO 1 3# 3-1# 3-2# 4# 4-1# 4-2# 7 9 15 PART NO 8941340361 9096620120 5096000090 1096040230 1096231830 9095714160 9095714240 8943708360 8943706660 0500408180 5117601501 PART NAME QTY.... REPLACES 9992023240 O RING .......................... 1 . 1 .... REPLACES 1096230570 PACKING 2 PACKING 1 OIL PAN PACKING . ITEMS W/# PLUG 1 PLUG.......................... REPLACES 9992023160 HEATER PLUG ......ISUZU 4BD1 — OIL PAN ASSY....................... INCL..... 1 .... 94~ BOLT 24 GAUGE ASSY. REMARKS OIL PAN .. THERMO SWITCH . 1 ...... 1 ...... REPLACES 5117601500 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 103 .... 2 ... UP TO MAR...............................................

ISUZU 4BD1 — OIL PUMP ASSY. OIL PUMP ASSY. PAGE 104 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

...... REPLACES 9010458000 LOCK WASHER ................................. 1 DOWEL ........ CANNOT ORDER SEPARATELY SHAFT ASSY....ISUZU 4BD1 — OIL PUMP ASSY..... INCL... REPLACES 9091505080 OIL RELIEF BALL 1 COIL SPRING 1 RELIEF VALVE SEAT 1 PIN 1 COUPING 1 PINION 1 BOLT 2 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 105 ..................... OIL PUMP ASSY... 5131001373 5878102022 5131130351 5131210140 5131250020 5131190060 5131410171 1131190010 0108058000 1099851770 5098430030 5095800980 5131650040 9081040300 1131230160 1131280180 0500410250 PART NAME QTY................. ITEMS W/# GEAR SET ... 1 ............ 1 .................. ............. 4 . INCL................. 4 ........... ITEMS W/& COVER ASSY..... 1 2# 3# 4# 5#& 7# 9# 15# 16# 17# 19# 21# 22# 23# 24# 27#& 28#& 32 PART NO............................... 1 ............ 1 GEAR 1 PIPE 1 CASE 1 SPACER 1 BOLT ........... REMARKS OIL PUMP ASSY....... NO.....

PISTON. FLYWHEEL ASSY.ISUZU 4BD1 — CRANKSHAFT. FLYWHEEL ASSY PAGE 106 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . PISTON. CRANKSHAFT.

....25 4 METAL SET....... REPLACES 8941075750 CONNECTION ROD ASSY... INCL.... 0........ ... 1 ... 1 ... ITEMS W/% RING GEAR 1 WASHER 1 BOLT 6 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 107 ............ ... PISTON 4 PISTON PIN 4 SNAP RING ............ 1...................... INCL.... SMALL END 4 BOLT 8 METAL SET....... 0......... 4 .... 8941170322 8941474660 8941474670 8941474680 8941474690 8941145652 8971766340 5121210050 9122116040 8941075751 1122301041 1122510270 1122350271 8970110310 9122736080 9122746080 9122756080 9122766080 5123101631 9081612200 8941075970 8971379100 8944493661 5123780020 5095030240 1098002140 8970461810 9123336070 5123360030 5123340060 PART NAME QTY.. 0............ PISTON... 8 .................... STD . 1 .............. 0... 4 ...... 1 1-1 1-2 1-3 1-4 2# 3 4 5 6 7 8& 9& 11 11-1 11-2 11-3 11-4 14 15$ 17 18 20 23 24 25 30 31% 33 34 PART NO...75 1 METAL KIT......... INCL..... ITEMS W/$ FLYWHEEL PIN 1 FEATHER KEY 2 CRANKSHAFT GEAR.. 4 .. 1 .... CRANKSHAFT......... REPLACES 9125210430 PULLEY ......... REPLACES 5121112111 RING SET.. FLYWHEEL ASSY.. REPLACES 9122716080 METAL SET.............50 1 METAL KIT..50 4 METAL SET.......... 0.................75 4 METAL SET...ISUZU 4BD1 — CRANKSHAFT..00 4 CRANSHAFT ASSY......... .. PISTON. . REPLACES 9000901570 FLYWHEEL ASSY.... 0.. REPLACES 8944493660 NUT 1 WASHER 1 BALL BEARING ......... ITEMS W/# METAL KIT......... NO................................... ITEMS W/& BUSHING.. 1 .......... 1 ..... THRUST 2 PISTON SET ....... 1..... REMARKS CRANKSHAFT ASSY.............. INCL...........00 1 METAL SET............25 1 METAL KIT..... FLYWHEEL ASSY...

ISUZU 4BD1 — CAMSHAFT, IDLE GEAR, ROCKER ASSY.
CAMSHAFT, IDLE GEAR, ROCKER ASSY.

PAGE 108 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

ISUZU 4BD1 — CAMSHAFT, IDLE GEAR, ROCKER ASSY.
CAMSHAFT, IDLE GEAR, ROCKER ASSY. NO. 1 2 3 4 5 6 7 10 11 13 14 17 18 19 21 22 23 24 25 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PART NO. 8944094120 1125220162 9080107200 9116810150 0500408250 5090002360 9098518503 9125310300 9125238014 5125350011 5090300381 1125510501 1125520251 5125610090 1125630351 8941145760 5125650060 5125710032 1125750360 5126110310 9126160420 9091115080 8941295510 9126260050 5126280120 9126281050 1095803350 1090005670 9098514300 9091800190 5096230600 1094001160 9098514300 PART NAME QTY. REMARKS CAMSHAFT 1 GEAR ............................................. 1 ........... REPLACES 9125221471 FEATHER KEY 1 THRUST PLATE 1 BOLT 2 BOLT 1 WASHER 1 IDLE GEAR SHAFT 1 IDLE GEAR 1 THRUST COLLAR 1 BOLT 2 INLET VALVE 4 EXHAUST VALVE 4 VALVE SPRING 8 SPRING SEAT, LOWER 8 SPRING SEAT, VALVE 8 SPLIT COLLAR 16 TAPPET 8 PUSH ROD 8 ROCKER ARM ASSY. 8 ADJUSTING SCREW 8 NUT 8 ROCKER ARM SHAFT 1 ROCKER ARM PLUG 2 BRACKET, FRONT 1 BRACKET, INNER 4 SPRING 3 BOLT 6 WASHER 6 SNAP RING 1 O RING PACKING 1 NUT 3 PLAIN WASHER 3

DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 109

ISUZU 4BD1 — OIL AND FUEL FILTER ASSY.
OIL AND FUEL FILTER ASSY.

PAGE 110 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)

............ 1 ... REPLACES 9091505100 PLAIN WASHER .... OIL AND FUEL FILTER ASSY. 1 2# 10 11 13 14 15 50# 52#& 60 PART NO.................... INCL....... APR... 1 ............................ REMARKS OIL FILTER ASSY. ITEMS W/#.................................. ITEMS W/& FUEL FILTER ELEMENT KIT 1 BOLT 2 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 111 ..... ........ 2 . NO..................................... 5132002262 1878102201 8943706700 8943706700 5132190261 5090000071 030210250 9091645100 9132004193 5878100500 0501510350 PART NAME QTY....... 2 ........................ REPLACES 5132002262 OIL FILTER ELEMENT KIT 1 PACKING .......ISUZU 4BD1 — OIL AND FUEL FILTER ASSY.. REPLACES 1132191940 PACKING ..... 4 .................. 4 ................. REPLACES 9091605100 FUEL FILTER ASSY. 94.................. 94~ SPACER 1 BOLT 4 LOCK WASHER ..................... .. UP TO MAR. INCL...............

OIL PIPING ASSY. PAGE 112 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .ISUZU 4BD1 — OIL PIPING ASSY.

8941753012 9099211880 0501408450 5133112561 1096234620 0500408350 0500408320 8944284630 9095720100 909840220 PART NAME OIL PUMP ASSY. OIL PIPING ASSY. 1 2 3 5 6 7 7-1 10 12 13 PART NO. PACKING BOLT FILTER PIPE ASSY. PACKING NUT QTY. PACKING BOLT BOLT OIL INJECTION PIPE ASSY.ISUZU 4BD1 — OIL PIPING ASSY. 1 2 4 1 2 2 2 1 2 1 REMARKS DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 113 . NO.

PAGE 114 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .ISUZU 4BD1 — COOLING ASSY. COOLING ASSY.

................... 2 ......... 1 OIL COOLER PACKING ..... 1 PULLEY 1 SPACKER 1 BELT 1 BOLT 4 LOCK WASHER .... 93 PACKING ........................... REPLACES 5136130070 SCREW ........ INCL............. REPLACES 5137700320 PACKING 1 THERMOSTAT HOUSING 1 THERMO PLUG 1 PACKING .................... 5136101582 8943763780 5878101145 5136310100 1098002620 5136320010 9099521030 9091801470 1136200200 5136210110 5136420530 5136120100 8944728780 9030906200 5136390020 5136340030 5096250780 5096050050 8943706610 0500410400 0500410500 5090300101 5093610700 5097040313 1097040940 9136600930 5136630311 5136420581 5136710450 0500405600 8943127330 9137700941 8941760310 5137160451 9096610050 5096050050 9095713160 8943706740 5137130351 0500408250 0501410250 0500410400 0501410350 5112800111 8970196530 0500408200 0500408250 0500408450 8942059861 PART NAME QTY..... 1 2# 3& 4& 5& 6& 7& 8& 9%& 11%& 13& 14% 15%& 17%& 19& 21& 23%& 27 28%& 29 31 32 35 37 38 40 41 43 48 49 50 52 53 60 62 63 65 80 81 83 PART NO................. 4 .............................................. ITEMS W/& SHAFT 1 BALL BEARING .. INCL................ ..................................ISUZU 4BD1 — COOLING ASSY.................................... 1 .. REMARKS WATER PUMP ASSY... 1 ............................. INCL.. BY-PASS 1 CLIP.......... ......... 1 . UP TO DEC.............. 1 ......... 1 .......... DEC..... REPLACES 9136140440 BOLT 1 BOLT 2 BOLT.................................... REPLACES 9098516490 THERMOSTAT ............... D=36 1 FAN ASSY...................... 1 ......... WATER PUMP 2 HOSE........... 1 ........... 1 ..... 1 ................... REPLACES 5096250570 PLUG 1 PACKING .......... D=38 1 CLIP..................................... REPLACES 9030908200 DUST COVER 1 SPACER 1 SEAL ......... COOLING ASSY...... ITEMS W/# WATER PUMP KIT .......... 1 .................... 1 .......... REPLACES 8942366870 IMPELLER 1 FAN 1 WATER PUMP COVER 1 PACKING ... 93~ PACKING .......................... REPLACES 8943210130 BOLT 2 BOLT 11 BOLT 8 BOLT 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 115 ..... 1 ........... NO.. ITEMS W/% WATER PUMP REPAIR KIT .. 3 ........ REPLACES 8943210100 WATER PIPE 1 BOLT 3 BOLT 1 BOLT 2 BOLT 4 WATER DUCT COVER ASSY................ REPLACES 5098000520 SPACER 1 SNAP RING 1 SNAP RING 1 SEAL UNIT ASSY...

PAGE 116 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .ISUZU 4BD1 — INTAKE AND EXHAUST ASSY. INTAKE AND EXHAUST ASSY.

............... EXHAUST ........ REPLACES 9091104080 LOCK WASHER .. 2 ...................... 2 .............. EXHAUST 3 GASKET..................... 1 ..... 2 ............................................... 1 3 4 5 8 39 50 50-1 51 51-1 60 61 62 66 67 69 PART NO...................... REPLACES 5096370281 INTAKE PIPE 1 INTAKE PIPE ..................... NO........... FIXED 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 117 ......... REPLACES 8943632700 NUT .. L=75 2 BOLT....... 1 ............................ INTAKE AND EXHAUST ASSY........ REPLACES 5141450040 NUT ........................................ REPLACES 9091505080 BOLT 6 PACKING .... REMARKS INTAKE MANIFOLD 1 GASKET................ REPLACES 9091505080 BOLT.. 5 . 5141112070 8970241220 1094400401 1099851770 0500408250 8970225710 5141111160 5141112360 0501510300 0500510300 5141410360 5093020020 8944046100 1094400401 1099851770 8942059871 0500408600 PART NAME QTY........... 2 ........ REPLACES 9091104080 LOCK WASHER ...ISUZU 4BD1 — INTAKE AND EXHAUST ASSY...................... REPLACES 5141111970 BOLT 2 BOLT 2 EXHAUST MANIFOLD 1 STUD............... 5 .. INTAKE ..........

FUEL INJECTION ASSY.ISUZU 4BD1 — FUEL INJECTION ASSY. PAGE 118 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

............ 1 ... 3 ...... A 3 CLIP.... B 3 BOLT .... GROMMET 2 PACKING....... NO............... FUEL PIPE 6 BOLT ........... REPLACES 9091104080 LOCK WASHER .... 1 1 PIPE. 4 ................ 4 1 CLIP ASSY...... 2 1 PIPE........................... 5153001032 1153150131 9153390510 1094400401 1099851770 8944636740 8944636750 8944636760 8944636770 5154190131 9154196130 9154196140 5154190040 5154190051 0501406160 5154112290 5132600101 5154115730 5154118580 5154115680 5154116030 9099063141 9095714080 9095720140 1095751460 9095720140 5097091030 9097161240 0500406250 PART NAME QTY........ REPLACES 9091505080 PIPE... 1 PIPE 1 FILTER LEAK PIPE ASSY........... 3 1 PIPE.. ITEMS W/# CLIP..... NO..........................ISUZU 4BD1 — FUEL INJECTION ASSY......... 8 .... NOT SOLD SEPARATELY FROM KIT CLIP....................... 1 BOLT 1 PACKING...... 2 .. NO......... REPLACES 9099063251 PACKING 3 CLIP A 2 CLIP B ............... INCL.............. FUEL INJECTION ASSY........................................ REPLACES 5154112231 FILTER PIPE ASSY........................ REPLACES 5153150030 DUST COVER 4 NUT ........ 1 3 5 8 9 11 12 13 14 15 15-1# 15-2# 15-3# 16 16-1 16-2 18 20 27 29 29-1 30 31 32 33 34 42 49 49-1 49-2 PART NO... REPLACES 5097091040 CLIP BOLT 2 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 119 ...... INTAKE MANIFOLD 1 CLIP............................ 3 ............... NO.......... D6X2 ... 2 ............ NO... REMARKS NOZZLE 4 PACKING .... 1 EYE JOINT ......... 8 . INTAKE MANIFOLD 1 BOLT 1 PIPE 1 OVERFLOW VALVE ASSY..........

ENGINE FOOT ASSY.ISUZU 4BD1 — ENGINE FOOT ASSY. PAGE 120 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

.......... REAR 1 BOLT 2 BRACKET 1 BOLT 1 BOLT 1 BOLT 1 BOLT 1 BOLT....... REPLACES 9091105080 LOCK WASHER ........... NO..... FRONT RIGHT 1 FOOT........ REPLACES 9091505080 PLAIN WASHER 1 PLATE 1 BOLT 1 PLAIN WASHER 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 121 ...... ENGINE FOOT ASSY...ISUZU 4BD1 — ENGINE FOOT ASSY.. 1 ......... FRONT LEFT 1 BOLT 7 NUT 1 LOCK WASHER ........... 1 ......... 9117712470 9117712480 8943134650 9091105100 030210250 5117770080 9117778050 0500410200 5197110620 0501408350 0501408400 0500410000 0500410450 5090300101 8943717120 8942790500 1099851770 9091606080 5136740320 0500408400 9091647080 PART NAME QTY.............. FRONT 1 HANGER... PULLEY 1 NUT ..... REPLACES 9091505100 HANGER......... REMARKS FOOT. L=75 1 COVER......................... 1 2 3 4 5 17 18 19 20 22 27 27 28 29 30 31 35 39 42 PART NO...... 1 ... R.......

ISUZU 4BD1 — ENGINE CONTROL ASSY. PAGE 122 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . ENGINE CONTROL ASSY.

. REPLACES 5197890040 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 123 ........ 1 ......... NO........ 5197890041 PART NAME QTY..........ISUZU 4BD1 — ENGINE CONTROL ASSY.... 2 PART NO........ REMARKS BRACKET .. ENGINE CONTROL ASSY.....

INJECTION PUMP ASSY. PAGE 124 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .ISUZU 4BD1 — INJECTION PUMP ASSY.

.. INJECTION PUMP ASSY. INCL................. 7 .............. ITEMS W/# GOVERNOR ASSY.. REMARKS INJECTION PUMP ASSY................ REPLACES 8941327040 GEAR .............................. 1 3# 5# 14# 15# 16# 17# 18# 19# 20# 32 33 35 36 38 39 40 PART NO......... 1 . REPLACES 5125240650 PLATE 1 BOLT 1 COUPLING 1 BOLT 6 NUT 1 LOCK WASHER 1 PACKING 1 BOLT ............... 1 ............................ 1 .......... 1 FEED PUMP ASSY..... 1 ............... ..................................... .... 1 ... REPLACES 9091505100 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 125 ...... REPLACES 9091605100 LOCK WASHER ...... NO..... 8943440260 8943440280 8941327042 5125240890 1156192450 9096620070 5157810030 8944575170 9884105020 5156190480 1113190090 8941500451 5197510150 0500410250 9091105100 9091645100 030210250 PART NAME QTY.......ISUZU 4BD1 — INJECTION PUMP ASSY...... REPLACES 5090000841 BRACKET 1 BOLT 2 NUT 1 PLAIN WASHER ........................

ELECTRICAL COMPONENTS ASSY. PAGE 126 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY.

...... ITEM W/%........ NO........ WARNING SW.. 1 OIL PRESS....... 1 OIL PRESS.ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY........ REMARKS STARTER ASSY 1 BOLT 1 BOLT 2 PLAIN WASHER 1 CABLE ASSY.. 1 . REPLACES 9825139288 CONNECTOR ................ 1 ....... M16 1 OVERHEAT SWITCH...... ......................... 3/8 1 STOP ASSY.. REPLACES 5197320020 RESISTANCE CONTROLLER 1 OVERHEAT SWITCH.......... PART NO....... ELECTRICAL COMPONENTS ASSY.............. 1 ALTERNATOR ASSY. WARNING SW. REPLACES CABLE ASSY..... 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 127 .......... 4 .... 1 GLOW PLUG (24V) ..... 1 1811001910 6 0500512280 6 0500512350 7 9091605120 8 9829315110 10 5812002121 16 9827200690 16-1 5824100160 19 1825130430 20 5197320021 23 9825300460 35 5824500141 35-1 8970299880 78 1819001931 1819000161 79% 1828490430 PART NAME QTY... INCL.......

ASSY. PAGE 128 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . FEED PUMP COMP.ISUZU 4BD1 — FEED PUMP COMP. ASSY.

.... ITEMS W/% ROLLER 1 PIN 1 GUIDE 2 SPRING 2 VALVE 2 O RING . REMARKS FEED PUMP ASSY.. REPLACES 1096230160 SNAP RING 1 PRIMING PUMP ASSY....... INCL.................. 8941327042 5157510120 9813512050 9813513020 9813550230 9813550350 5157540010 9813514030 9813514100 1157590020 9813517020 9813516020 1156290650 5157590270 1156190820 1157590010 1157590030 5157590120 1156290650 9813550250 1157610060 PART NAME QTY......... 1 5# 9# 10# 11# 12# 15# 16#% 17#% 18#% 20# 26# 27# 31# 32# 33# 35# 37# 40# 42# 44# PART NO.. 1 .... REPLACES 8941311300 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 129 ... . ........... ASSY.... ............... 1 ........ REPLACES 1096230160 BOLT 1 BOLT 1 GASKET 1 ADAPTER 1 JOINT 1 O RING ............. ASSY........... REPLACES 8941327040 PUMP HOUSING 1 PISTON 1 SPRING 1 PLUG 1 GASKET 1 TAPPET ASSY........................................... ITEMS W/ #.. NO.. FEED PUMP COMP........ISUZU 4BD1 — FEED PUMP COMP....... INCL.......... 1 .. 1 ... 1 ..........

ISUZU 4BD1 — NOZZLE ASSY. NOZZLE ASSY. PAGE 130 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

...... 1 2 4# 6# 8# 10# 11# 12# 20# 21# 22# 30# 31# 32# PART NO.................................. 5153110191 1153300941 5153410010 9153430130 5153450010 5153320100 9153390560 9153390570 1153320170 5153390030 5153510010 1096750371 1153390100 9153470030 PART NAME QTY........... 4 ......... 8 ....... REPLACES 5153110190 HOLDER ASSY.. SCREW 4 NUT 4 GASKET 4 WASHER 4 RETAINING NUT 4 GASKET 4 CONNECTOR 4 BOLT ............... ITEMS W/# PUSH ROD 4 SPRING 4 ADJ..... ... NO...... NOZZLE .............. 4 ..ISUZU 4BD1 — NOZZLE ASSY... INCL............ NOZZLE ASSY. REMARKS INJ... REPLACES 1153390090 GASKET 8 PIN 8 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 131 ...................

ISUZU 4BD1 — OIL FILTER ASSY. OIL FILTER ASSY. PAGE 132 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

... REPLACES 9099205260 PLUG 1 PACKING ........ 5132002262 1878102201 9097205550 5096230670 9099211950 9132490090 5132120681 9132316020 9099410980 9132390310 9098621170 9000975270 9099408600 8941326650 9099208410 9132260110 9099208410 5132110201 PART NAME QTY................. NO........... INCL........... REMARKS OIL FILTER ASSY................ ITEMS W/& PACKING .............. REPLACES 9099209780 PACKING 1 PACKING 1 PACKING. 1 .................................. UPPER 1 BODY 1 BOLT 1 SPRING 1 SEAT 1 DRAIN PLUG 1 OVER FLOW VALVE 1 SPRING 1 VALVE PLUG 1 PACKING ........... 1 .... 1 ...... INCL.......... . REPLACES 9099205260 CASE 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 133 ......... 1 ............. 1 2# 4#& 5#& 6#& 7#& 8# 9# 10# 11# 12# 15# 16# 17# 18# 20# 21# 22# PART NO..... 1 .... OIL FILTER ASSY.................... ITEMS W/# OIL FILTER ELEMENT KIT .......ISUZU 4BD1 — OIL FILTER ASSY.................

PAGE 134 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . FUEL FILTER ASSY.ISUZU 4BD1 — FUEL FILTER ASSY.

............ 1 2# 3#% 4#% 5# 6#% 7# 8# 9# 10#% 11# 12# 13# 14# 15# PART NO......... ITEMS W/% O RING ELEMENT. REMARKS FUEL FILTER ASSY..... INCL............................. FUEL FILTER ASSY. INCL. 1 ........ . NO.ISUZU 4BD1 — FUEL FILTER ASSY.. 9132004193 5878100500 9099203270 9132136010 9099208410 5096230241 9095720140 1132600470 9099203260 9098518100 9099409010 9132310660 9098620680 9132111071 9132128040 PART NAME QTY...... ITEMS W/# ELEMENT KIT .. UPPER 1 PACKING 1 O RING 1 O RING 1 PACKING 2 VALVE 1 PACKING 1 SPRING SEAT 1 ELEMENT SPRING 1 BOLT 1 DRAIN PLUG 1 CASE 1 COVER 1 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 135 . 1 .......

ISUZU 4BD1 — ENGINE ACCESSORIES ENGINE ACCESSORIES PAGE 136 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) .

..ISUZU 4BD1 — ENGINE ACCESSORIES ENGINE ACCESSORIES NO... REMARKS TACHOMETER DRIVE ASSY... REPLACES 8944533000 PACKING 1 BOLT 2 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 137 ... 1 3 4 PART NO...... . 8944533001 1096234650 0500408200 PART NAME QTY.... 1 ..

c. LIMITATION OF WARRANTIES No warranties. PAGE 138 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) . Obsolete parts. point of origin. f. consequential or incidental damages. Special order items. The following items are not returnable: a. g. 3. 9. and in no event shall Multiquip be liable for loss of profit or good will or for any other special. subject to the following provisions: 1.00 surcharge will be added to the invoice for special handling including bus shipments. Decals and paper products. 7. 4. c. and Multiquip neither assumes not authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed. 6.B. “O” rings. Parts must be in new and resalable condition. less a 15% restocking charge. Paint. e. Such warranties made in connection with the sale of new. express. In cases where an item is accepted for which the original purchase document can not be determined. d. a list must be provided to Multiquip Parts Sales that defines item numbers. and other rubber parts) that were purchased more than six months prior to the return date. the material will be returned to the sender at his expense. b. Such material will be held for 5 working days from notification. PRICING AND REBATES Prices are subject to change without prior notice. FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice.00. e. and descriptions of the items to be returned. The list must reference the sales order(s) or invoice(s) under which the items were originally purchased. All shipments are F.O. implied or statutory. b. Customers will be asked for instructions regarding handling of orders not meeting this requirement. The parts numbers and descriptions must match the current parts price list. 2. Items purchased in kits. and lubricants. the price will be based on the list price that was effective twelve months prior to the RMA date. and with Muiltiquip part numbers clearly marked. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier. it is obsolete. complete units are made exclusively by a statement of warranty packaged with such units. and any claim for shortage or damage must be settled between the consignee and the carrier. (If an item is listed in the parts price book as being replaced by another item. seals. Credit on returned parts will be issued at dealer net price at time of the original purchase. 11. A Returned Material Authorization must be approved by Multiquip prior to shipment. To obtain a Return Material Authorization. Any line item with an extended dealer net price of less than $5. A part from such written statement of warranty. pending instructions. a. chemicals. Multiquip reserves the right to quote and sell direct to Government agencies. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change. The list must state the reason(s) for the return. MINIMUM ORDER The minimum charge for orders from Multiquip is $15. 10. and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products. The list must include the name and phone number of the person requesting the RMA.Effective: July 1. SPECIAL EXPEDITING SERVICE A $20. LIMITATIONS OF SELLER’S LIABILITY Multiquip shall not be liable here under for damages in excess of the purchase price of the item with respect to which damages are claimed. quantities. there are no warranties.00 net. All parts must be returned freight prepaid to Multiquip’s designated receiving point.) Any parts with a limited shelf life (such as gaskets. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. The list must be typed or computer generated. Credit issued will be applied to future purchases only. in the original Multiquip package (if any). If a reply is not received within 5 days. 2000 PAYMENT TERMS Terms of payment for parts are net 10 days. insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier. 8. d.00 to $50. which extend beyond the description of the products on the face hereof. express or implied. 5. A copy of the Return Material Authorization must accompany the return shipment. are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Electrical components. h. TERMS AND CONDITIONS OF SALE — PARTS Freight is at the sender’s expense. The sender will be notified of any material received that is not acceptable.

NOTE PAGE DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 139 .

CALIFORNIA 90746 FAX: 800-672-7877 SERVICE DEPARTMENT: 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046 E-mail:mq@multiquip. 800-427-1244 CARSON. PARTS DEPARTMENT: 18910 WILMINGTON AVE.PARTS AND OPERATION MANUAL PARTS AND OPERATION MANUAL HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING PARTS DEPARTMENT ARTS DEPAR ARTMENT 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284 SERVICE DEPARTMENT ARTMENT SERVICE DEPAR 800/835-2551 or 310/537-3700 FAX: 310/638-8046 WARRANTY DEPARTMENT DEPAR ARTMENT 800/835-2551 or 310/537-3700 FAX: 310/638-8046 MAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927 © COPYRIGHT 2001. MULTIQUIP INC. MULTIQUIP INC.com • www:multiquip.com .

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