Multiquip Mq Power Whisperwatt Generator Dca 25Ssi Users Manual

MQ Power Whisperwatt Generator DCA-25SSI Generators_portable_supersilent_DCA25SSI_rev_0__manual_DataId_19042_Version_1

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PARTS AND OPERATION MANUAL

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

SERVICE DEPARTMENT:

800-421-1244 800-835-2551

FAX: 310-537-3927 FAX: 310-638-8046

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

PARTS AND OPERATION MANUAL

MQ POWER

DCA-25SSI

WHISPERWATT

GENERATOR

PARTS LIST NO. M1870000274A

FINAL COPY (06/29/01)

PAGE 2 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HAND WHEN CALLING

PARAR

ARAR

ARTS DEPTS DEP

TS DEPTS DEP

TS DEP

ARAR

ARTMENTTMENT

TMENTTMENT

TMENT

800/427-1244 or 310/537-3700

FAX: 800/672-7877 or 310/637-3284

SERSER

SERVICE DEPVICE DEP

VICE DEPVICE DEP

VICE DEPARAR

ARAR

ARTMENTTMENT

TMENTTMENT

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

WARRANTY DEPARRANTY DEP

ARRANTY DEPARRANTY DEP

ARRANTY DEPARAR

ARAR

ARTMENTTMENT

TMENTTMENT

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

MAINMAIN

MAIN

800/421-1244 or 310/537-3700

FAX: 310/537-3927

PAGE 4 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

DCA-25SSI Specifications ............................................ 19

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

MQ POWER DCA-25SSI

AC GENERATOR

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

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

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

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

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

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

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

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

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

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

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

ISUZU C240 ENGINE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

NOTE

Specification and part numberSpecification and part number

Specification and part number

are subject to change withoutare subject to change without

are subject to change without

noticenotice

notice..

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

PARTS ORDERING PROCEDURES

Get special freight allowances

when you order 10 or more

line items via FAX!**

■

UPS Ground Service at no charge for freight

■

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

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price)

do not count towards the 10+ line items.

*DISCOUNTS ARE SUBJECT TO CHANGE*

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

For faxed orders only

UPS

Special

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers

and are received by fax qualify for the following extra

discounts:

Number of

line items ordered Additional Discount

1-9 items 3%

10+ items** 5%

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

■Dealer account number

■Dealer name and address

■Shipping address (if different than billing address)

■Return fax number

■Applicable model number

■Quantity, part number and description of each part

■Specify preferred method of shipment:

•UPS Ground

•UPS Second Day or Third Day*

•UPS Next Day*

•Federal Express Priority One (please provide us with your Federal

Express account number)*

•Airborne Express*

•Truck or parcel post

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

Extra Fax Discount

for Domestic USA

Dealers Only

PAGE 6 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

RULES FOR SAFE OPERATION

■

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow

these parts to cool before servicing

engine or generator.

■

The engine of this

generator requires an adequate

free flow of cooling air. Never

operate the generator in any

enclosed or narrow area where

free flow of the air is restricted.

If the air flow is restricted it will

cause serious damage to the

generator or engine and may

cause injury to people. The

generator engine gives off DEADLY carbon monoxide gas.

■

High Temperatures – Allow the engine to cool before

adding fuel or performing service and maintenance

functions. Contact with

hot

components can cause serious

burns.

Failure to follow instructions in this manual

may lead to serious injury or even death!

This equipment is to be operated by trained

and qualified personnel only! This equipment

is for industrial use only.

The following safety guidelines should always be used when

operating the DCA-25SSI portable generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment before

reading this entire manual.

■

This equipment should not be operated by

persons under 18 years of age.

■

NEVER operate this equipment without proper

protective clothing, shatterproof glasses, steel-

toed boots and other protective devices

required by the job.

■

NEVER operate this equipment when not feeling

well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the

influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not

recommended by MQ Power for this equipment. Damage

to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any

accident due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and

safety decals when they become difficult read.

■

Always check the machine for loosened threads or bolts

before starting.

CAUTION

■

Always use extreme caution when

working with flammable liquids. When

refueling, stop the engine and allow it

to cool. DO NOT smoke around or near

the machine. Fire or explosion could

result from fuel vapors, or if fuel is spilled

on a hot engine.

■

NEVER operate the generator in an

explosive atmosphere or near combustible

materials. An explosion or fire could result

causing severe

bodily harm or even

death.

■

Topping-off to filler port is

dangerous, as it tends to spill fuel.

■

Always refuel in a well-ventilated area,

away from sparks and open flames.

CAUTION:

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

RULES FOR SAFE OPERATION

CAUTION

■

Backfeed to a utility system can cause electrocution

and/or property damage. Do not connect to any

building's electrical system except through an approved

device or after building main switch is opened.

■

Never use damaged or worn cables when connecting

power tools or equipment to the generator. Make sure

power connecting cables are securely connected to the

generator’s output terminals, insufficient tightening of the

terminal connections may cause damage to the generator

and electrical shock.

CAUTION

DO NOT touch or open any of the below

mentioned components while the

generator is running. Always allow

sufficient time for the engine and generator

to cool before performing maintenance.

Radiator

1. Radiator Cap - Removing the radiator cap while the

engine is hot will result in high pressurized, boiling water

to gush out of the radiator, causing severe scalding to

any persons in the general area of the generator.

2. Coolant Drain Plug - Removing the coolant drain plug

while the engine is hot will result in hot coolant to gush

out of the coolant drain plug, therefore causing severe

scalding to any persons in the general area of the

generator.

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

plug while the engine is hot will result in hot oil to gush

out of the oil drain plug, therefore causing severe

scalding to any persons in the general area of the

generator.

CAUTION

■

NEVER touch output terminals during operation. This is

extremely dangerous.

Always stop the machine when

contact with the output terminals is required.

PAGE 8 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

RULES FOR SAFE OPERATION

■

NEVER Run engine without air filter. Severe engine

damage may occur.

■

Always service air cleaner frequently to prevent carburetor

malfunction.

■

Always disconnect the battery before performing service

on the generator.

■

Always be sure the operator is familiar with proper safety

precaution s and operations techniques before using

generator.

■

Always store equipment properly when not in use.

Equipment should be stored in a clean, dry location out of

the reach of children.

■

DO NOT leave the generator running in the manual mode

unattended.

■

DO NOT allow unauthorized people to operate this

equipment.

■

Always read, understand, and follow procedures in

Operator’s Manual before attempting to operate equipment.

■

Refer to the

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

Isuzu Engine Owner's Manual

for engine

technical questions or information.

Loading and Unloading (Crane)

■

Before lifting, make sure the generator's lifting hook is

secure and that there is no apparent damage to the

generator itself (loose screws, nuts and bolts). If any

part is loose or damaged, please take corrective action

before lifting.

■

Always drain fuel prior to lifting.

■

Always make sure crane or lifting device has been

properly secured to the hook of guard frame on generator.

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or rope) of sufficient

strength.

■

When lifting the generator, always use the balanced

center-point suspension hook and lift straight upwards.

■

NEVER allow any person or animal to stand underneath

the machine while lifting.

■

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.

Battery

Never over fill the battery with water above

the upper limit.

CAUTION

The battery contains acids that can cause injury to the eyes

and skin. To avoid eye irritation, always wear safety glasses.

Use well insulated gloves when picking up the battery. Use

the following guidelines when handling the battery:

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

that the battery may explode.

2. DO NOT expose the battery to open flames, sparks,

cigarettes etc. The battery contains combustible gases

and liquids. If these gases and liquids come in contact

with a flame or spark, an explosion could occur.

3. Always keep the battery charged. If the battery is not

charged a buildup of combustible gas will occur.

4. Always keep battery charging and booster cables in good

working condition. Repair or replace all worn cables.

5. Always recharge the battery in an open air environment,

to avoid risk of a dangerous concentration of combustible

gases.

6. In case the battery liquid (dilute sulfuric acid) comes in

contact with

clothing or skinclothing or skin

clothing or skin

, rinse skin or clothing

immediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes in

contact with your eyes, rinse eyes immediately with

plenty of water, then contact the nearest doctor or hospital,

and seek medical attention.

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

Transporting

■

Always shutdown engine before transporting.

■

Tighten fuel tank cap securely.

■

Drain fuel when transporting generator over long distances

or bad roads.

■

Always tie-down the generator during transportation by

securing the generator.

■

If generator is mounted on a trailer, make sure trailer

complies with all local and state safety transportation

laws. See page 10 for basic towing procedures.

Emergencies

■

Always know the location of the nearest

fire extinguisherfire extinguisher

fire extinguisher

and

first aid kitfirst aid kit

first aid kit

. Know the location of the nearest telephone.

Also know the phone numbers of the nearest

ambulanceambulance

ambulance

doctordoctor

doctor

and

fire departmentfire department

fire department

RULES FOR SAFE OPERATION

Maintenance Safety

■

NEVER lubricate components or attempt service on a

running machine.

■

Always allow the machine a proper amount of time to

cool before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always

replace broken parts.

■

Dispose of hazardous waste properly. Examples of

potentially hazardous waste are used motor oil, coolant,

fuel, and fuel filters.

■

DO NOT use plastic containers to dispose of hazardous

waste.

■

DO NOT pour waste, oil, coolant or fuel directly onto the

ground, down a drain or into any water source.

PAGE 10 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

To reduce the possibility of an accident while transporting

the generator on public roads, always make sure the trailer

(Figure 1) that supports the generator and the towing vehicle

are in good operating condition and both units are

mechanically sound.

The following list of suggestions should be used when towing

your generator:

CAUTION :

Towing Safety Precautions

Check with your county or state safety

towing regulations department before

towing your generator.

■

Make sure the hitch and coupling of the towing vehicle

are rated equal to, or greater than the trailer "gross vehicle

weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER

tow a trailer with defective hitches, couplings, chains

etc.

■

Check the tire air pressure on both towing vehicle and

trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety

Chain".

DCA-25SSI — TOWING RULES FOR SAFE OPERATION

■

ALWAYS attach trailer’s safety chain to bumper of towing

vehicle.

■

ALWAYS make sure the vehicle and trailer directional,

backup, brake, and trailer lights are connected and

working properly.

■

The maximum speed for highway towing is 45 MPH

unless posted otherwise. Recommended off-road towing

is not to exceed 10 MPH or less depending on type of

terrain.

■

Place

chocked blocks

underneath wheel to prevent

rolling, while parked.

■

Place

support blocks

underneath the trailer’s bumper to

prevent tipping, while parked.

■

Use the trailer’s hand winch to adjust the height of the

trailer, then insert locking pin to lock wheel stand in place,

while parked.

■

Avoid sudden stops and starts. This can cause skidding,

or jack-knifing. Smooth, gradual starts and stops will

improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

Figure 1. Generator with Trailer

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

Explanation of Chart:

This section is intended to provide the user with trailer ser-

vice and maintenance information. The service and mainte-

nance guidelines referenced in this section apply a wide range

of trailers. Remember periodic inspection of the trailer will

ensure safe towing of the equipment and will prevent dam-

age to the equipment and personal injury.

It is the purpose of this section to cover the major mainte-

nance components of the trailer. The following trailer com-

ponents will be discussed in this section:



Tires



Lug Nut Torquing



Suspension



Electrical

Use the following definitions with reading Table 1.

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

equipment in use. Fuel cells must be empty when trans-

porting equipment.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hy-

draulic, hydraulic-surge and air.

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

maximum number of pounds the trailer can carry, in-

cluding the fuel cell (empty).

4. Frame Length - This measurement is from the ball

hitch to the rear bumper (reflector).

DCA-25SSI — TRAILER-SAFETY GUIDELINES

5. Frame Width - This measurement is from fender to

fender.

6. Jack Stand - Trailer support device with maximum

pound requirement from the tongue of the trailer.

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

8. Tire Size - Indicates the diameter of the tire in inches

(10,12,14, etc.), and the width in millimeters

(175,185,205, etc.). The tire diameter must match the

diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;

2-ply,4-ply,6-ply, etc.

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

axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must

match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.

Always use a torque wrench to tighten down the lug

nuts. See Table 4 and Figure 5 or lug nut tightening and

sequence.

13. Axle - Indicates the maximum weight the axle can sup-

port in pounds, and the diameter of the axle expressed

in inches (see Table 3). Please note that some trailers

have a double axle. This will be shown as 2-6000 lbs.,

meaning two axles with a total weight capacity of 6000

pounds.

14. Suspension - Protects the trailer chassis from shocks

transmitted through the wheels. Types of suspension

used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided

with the trailer so the brake lights and turn signals can

be connected to the towing vehicle.

16. Application - Indicates which units can be employed

on a particular trailer.

CAUTION:

ALWAYS make sure the trailer is in good

operating condition. Check the tires for

proper inflation and wear. Also check the

wheel lug nuts for proper tightness.

PAGE 12 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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DCA-25SSI — TRAILER-SPECIFICATIONS

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

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DCA-25SSI — TRAILER-SPECIFICATIONS

PAGE 14 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical

components of the trailer. When specifying or replacing the

trailer wheels it is important the wheels, tires, and axle are

properly matched.

CAUTION:

DO NOT attempt to repair or modify a

wheel. DO NOT install in inner tube to

correct a leak through the rim. If the rim

is cracked, the

air pressure in

the inner tube

may cause pieces of the rim to

explode (break off) with great force

and cause serious eye or bodily

injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life.

Pressure should be checked cold before operation. DO

NOT bleed air from tires when they are hot. Check inflation

pressure weekly during use to insure the maximum tire life

and tread wear.

Table 2 (Tire Wear Troubleshooting) will help pinpoint the

causes and solutions of tire wear problems.

CAUTION:

NOTE

ALWAYS wear safety glasses when removing

or installing force fitted parts. Failure to

comply may result in serious injury.

Suspension

The leaf suspension springs and associated components

(Figure 2) should be visually inspected every 6,000 miles for

signs of excessive wear, elongation of bolt holes, and

loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components

as detailed in Table 3.

DCA-25SSI — TRAILER SAFETY GUIDELINES

Figure 2. Major Suspension Components

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

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Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel

mounting torque on the trailer. Be sure to use only the

fasteners matched to the cone angle of the wheel. Proper

procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 3. DO NOT

torque the wheel lug nuts all the way down. Tighten

each lug nut in 3 separate passes as defined by Table 4.

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

Check all wheel lug nuts periodically.

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-25SSI — TRAILER SAFETY GUIDELINES

Figure 3. Wheel Lug Nuts Tightening Sequence

PAGE 16 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

NOTE:

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

DCA-25SSI — TRAILER-WIRING DIAGRAM

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

DCA-25SSI — GENERATOR DECALS

The DCA-25SSI generator is equipped with a number of safety decals. These decals are provided for operator safety and

maintenance information. The illustration below and on the preceding pages show the decals as they appear on the

machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

PAGE 18 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — GENERATOR DECALS

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

DCA-25SSI — SPECIFICATIONS

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PAGE 20 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — GENERAL INFORMATION

DCA-25SSI FAMILIARIZATION

Generator

The MQ Power Model DCA-25SSI is a 20 kW

genergener

generatorator

atorator

ator

that is designed as a high quality portable (requires a trailer

for transport) power source for telecom sites, lighting

facilities, power tools, submersible pumps and other

industrial and construction machinery.

Engine Operating Panel

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

Tachometer

Water Temperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Fuel level gauge

Engine Throttle Lever

Pre-Heat Light

Alarm Lights

Panel Light

Panel Light Switch

Starter Switch

Generator Control Panel

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

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Output Terminal Panel

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

Three 120/240V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 240V @50 amps

2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 60 amps

Over-Current Relay

Engine

The DCA-25SSI is powered by a 4 cycle, water cooled,

turbocharged Isuzu QD60(C240)

diesel diesel

diesel

engine. This engine

is designed to meet every performance requirement for the

generator. Reference Table 5, page 19 for engine

specifications.

In keeping with MQ Power’s policy of constantly improving

its products, the specifications quoted herein are subject to

change without prior notice.

The basic controls and indicators for the DCA-25SSI

generator are addressed on the following pages.

Mechanical Governor System

The mechanical governor system control the RPM of the

engine. When the engine demands increase or decrease,

the mechanical governor system regulates the frequency

variation to ±1.5%. The electronic governor option in-

creases frequency variation to ±.25%.

Open Delta Excitation System

The DCA-25SSI generator is equipped with the state of the

art "

Open-DeltaOpen-Delta

Open-Delta

" excitation system. The open delta system

consist of an electrically independent winding wound among

stationary windings of the AC output section.

There are four leads: A, B, C and D. During light loads, the

power to the

Automatic utomatic

utomatic utomatic

utomatic

Voltage Regulator oltage Regulator

oltage Regulator oltage Regulator

oltage Regulator

(AVR) is supplied

from the leads parallel connections of B&C. When loads

increase, the AVR switches and accepts power from leads

A&D. The output of leads A&D increase proportionally with

load. This of adding the voltages to each phase provides

better voltage response during heavy loads.

The connections of the AVR to the AC output windings are

for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation

current, offering maximum motor starting capabilities. The

excitation does not have a "

fixed ceilingfixed ceiling

fixed ceiling

" and responds

according the demands of the required load.

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

DCA-25SSI — MAJOR COMPONENTS

Figure 4. Major Components

PAGE 22 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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

Figure 5. Dimensions

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

NOTE PAGE

PAGE 24 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — CONTROL PANEL

Figure 6. Control Panel

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

DCA-25SSI — CONTROL PANEL

The definitions below describe the controls and functions of

the DCA-25SSI "

Control Panel Control Panel

Control Panel

" (Figure 6).

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

breaker is provided to protect the UNV voltage output

terminals from overload.

2. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz ±1 Hz .

3. AC Ammeter – Indicates the amount of current the

load is drawing from the generator.

4. AC Voltmeter – Indicates the single phase output

voltage present at the UNV terminals.

5. Voltage Regulator Control – Allows manual

adjustment of the generator’s output voltage.

6. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the

load connected to any phase of the output terminals, or

to be switched off.

7. Voltmeter Change-Over Switch – This switch allows

the AC voltmeter to indicate phase to phase voltage

between any two phases of the output terminals or to

be switched off.

PAGE 26 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

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

The definitions below describe the controls and functions of

the DCA-25SSI "

Engine Operating Panel Engine Operating Panel

Engine Operating Panel

" (Figure 7).

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

When activated, panel will luminate. When the generator

is not in use, turn the panel light switch to the ‘OFF’

position.

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

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

3. Water Temperature Indicator - This light will luminate

if the water temperature exceeds 2150 and will shut off

the engine.

DCA-25SSI — ENGINE OPERATING PANEL

9. Fuel Gauge - Indicates amount of diesel fuel available

10. Charging Ammeter Gauge – Indicates the current

being supplied by the engine’s alternator which provides

current for generator’s control circuits and battery

charging system.

11. Water Temperature Gauge – During normal operation

this gauge be should read between 165o to 215o.

12. Oil Pressure Gauge – Normal operation should be about

25 psi. When starting the generator the oil pressure

may read a bit higher, but after the engine warms up

the oil pressure should return to normal.

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

panel light.

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

engine is warmed to an operating temperature.

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

start, preheat, and stop the engine..

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

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

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

Hz operation. This meter should indicate 1800 RPM’s

when the rated load is applied. In addition a built in hour

meter will record the number of operational hours that

the generator has been in use.

PAGE 28 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — OUTPUT TERMINAL PANEL

Output Terminal Panel

The output control panel is located on the rear (control panel)

end of the generator. The UNV lugs are protected by a face

plate cover that can be secured in the close position by a

pad lock.

120 Volt Receptacle

One GFCI Duplex NEMA 5-20R (120V, 20 Amp) receptacle

is located on the output terminal. This receptacle can be

used anytime the generator is in operation. The receptacle

is controlled by the circuit breaker located on the control

panel.

The reset button will reset the receptacle after being tripped.

Pressing the "Test Button" (See Figure 8) in the center of

this receptacle will check the GFCI function. The receptacle

should be tested at least once a month.

Figure 8. GFCI Test Button

Connecting Load

Loads can be connected to the generator by the UNV Lugs or

the duplex receptacle. (See Figure 9). Make sure to read the

operation manual before attempting to connect a load to the

generator.

Figure 9. Connecting Loads

Circuit Breakers

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

main main

main

circuit breaker is provided to protect the UVWO output

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

GFCIGFCI

GFCI

circuit breakers are provided to protect the GFCI

receptacles from overload. Three 50 amp

loadload

load

circuit

breakers have also been provided to protect the load side of

the generator from overload. Make sure to switch

ALLALL

ALL

circuit

breakers to the "OFF" position prior to starting the engine.

Maximum Output

The entire load connected to the UNV l ugs and all four slots in

the duplex receptacle must not exceed 22 kW in standby or 20

kW in prime output.

120V Receptacles - These receptacles can be used

anytime the generator is in operation. They are controlled

by the circuit breakers above them.

Twist Lock Dual Voltage Receptacles - To use these

receptacles, place the voltage selector switch in the single

phase 240/120 voltage position and adjust the output

voltage to 240 volts with the voltage regulator on the

control panel (see Figure 6, page 24). Place the voltmeter

change-over switch to the U-W position and the ammeter

change-over switch to the U or W to read the output.

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

Legs “O” and Ground are

considered Bonded Grounds.

NOTE

Figure 10. Output Terminal Description

DCA-25SSI — OUTPUT TERMINAL PANEL

PAGE 30 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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Output Terminal Panel Available Voltages

A wide range of voltages are available to supply load to

many different applications. Voltages may be selected by

using the voltage selector switch and depending how you

hookup your hard wire connection to the generator. To

obtain voltages listed, fine adjustment with the voltage

regulator on the control panel is necessary. See the table

below (Table 6) for a list of available voltages the generator

is able to supply.

CAUTION :

NEVER switch the voltage selector switch

position while the engine is engaged.

Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect

the generator and generator load from being switched while

the engine is running. To lock the voltage selector switch,

press in the red button located on the lower part of the

voltage selector switch, and use a pad lock to hold it into

this position.

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Maximum Amps

The following table show the maximum amps the entire

generator can provide. Do not exceed the maximum amps

listed. (See Table 7)

DCA-25SSI — OUTPUT AMPERAGE SETUP

Over Current Relay

An over current relay is connected to the circuit breaker.

During an over current situation, both the circuit breaker

and the over current relay may trip. If the circuit breaker

can not be reset, the reset button on the over current relay

must be pressed. The over current relay is located inside

the control box.

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

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Receptacle Use

When the UVWO terminals are providing power, the

receptacle power available decrease. Do not exceed

receptacle power available listed on Table 8.

How To Read The Output Terminal Gauges

The gauges (Figures 13 and 15) and change-over switches

on the control panel DO NOT effect the generator output.

They are to help observe how much power is being

supplied produced at the UVWO legs.

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

position (see Figure 11), place the AC voltmeter change-

over switch to the W-U position (Figure 12) and the AC

ammeter change-over switch to the U or W position (Figure

14) to read the output on the selected leg.

Figure 11. Voltage Selector Switch 240/120V

Single Phase Position

Figure 12. AC Voltmeter

Change-over switch

(Reading the W-U leg on

the output terminal panel)

Figure 15. AC Ammeter

(Amp reading on U lug)

Figure 14. AC Ammeter

Change-over Switch

(Reading the U leg on the

output terminal panel)

Figure 13. AC Voltmeter

Gauge

(Volt reading on W-U Lug)

When using plural single phase

voltages, make sure to balance

the load on each of the single

phase legs.

NOTE

DCA-25SSI — OUTPUT AMPERAGE SETUP

PAGE 32 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

240/120V Hard Wire Hookup

With the voltage selector set and locked at ‘single phase

240/120’ and using single phase 120 volts, it will provide

three legs available with 100 amps each on three different

circuits (Figure 16).

When using single phase 240 volts, it will provide one leg

with 50 amps available (Figure 16).

480/240V Hard Wire Hookup

With the voltage selector set and locked at ‘3 phase 480/

277’ (Figure 17) and using the 3-phase 240 volt hookup, it

will provide one circuit available at 108 amps with any two

wires plus the ground (Figure 18).

When using the 3-phase 480 volts hookup, it will provide

one circuit available at 50 amps available with all three wires

plus ground (Figure 18).

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

Position

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

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

DCA-25SSI — OUTPUT VOLTAGE SETUP

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

Voltage Selector Switch- 3 Phase 480/277V Position

The following are additional voltages available when the

voltage selector switch is in the 3 phase 480/277V

position.

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

This setting can provide 3-phase power at 480, 440, or

416 volts. After hooking up the hard wires to the lugs as

shown in Figure 20, 480 volts can be obtained the

voltage regulator knob turned toward maximum; 440 volts

can be obtained with the voltage regulator knob is turned

down; and 416 volts can be obtained with the voltage

regulator knob is at lowest setting.

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

This setting can provide single phase power at 480, 440,

or 416 volts. After hooking up the hard wires to the lugs

as shown in Figure 21, 480 volts can be obtained the

voltage regulator knob turned toward maximum; 440 volts

can be obtained with the voltage regulator knob is turned

down; and 416 volts can be obtained with the voltage

regulator knob is at lowest setting.

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

This setting can provide single phase power at 277, 254

or 240 volts. After hooking up the hard wires to the lugs

as shown in Figure 22, 277 volts can be obtained the

voltage regulator knob turned toward maximum; 254 volts

can be obtained with the voltage regulator knob is turned

down; and 240 volts can be obtained with the voltage

regulator knob is at lowest setting.

Figure 19. Voltage Regulator Knob

Figure 20. Hard Wire Hookup for Three Phase

480V, 440V, or 416V

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

or 240V

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

or 416V

DCA-25SSI — OUTPUT VOLTAGE SETUP

PAGE 34 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

Voltage Selector Switch- 3 Phase 240/139V Position

The following are additional voltages available when the

voltage selector switch is in the 3 phase 240/139V

position.

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

This setting can provide 3-phase power at 240, 220, or

208 volts. After hooking up the hard wires to the lugs as

shown in Figure 24, 240 volts can be obtained the

voltage regulator knob turned toward maximum; 220 volts

can be obtained with the voltage regulator knob is turned

down; and 208 volts can be obtained with the voltage

regulator knob is at lowest setting.

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

This setting can provide single phase power at 240, 220,

or 208 volts. After hooking up the hard wires to the lugs

as shown in Figure 25, 240 volts can be obtained the

voltage regulator knob turned toward maximum; 220 volts

can be obtained with the voltage regulator knob is turned

down; and 208 volts can be obtained with the voltage

regulator knob is at lowest setting.

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

This setting can provide single phase power at 139, 127,

or 120 volts. After hooking up the hard wires to the lugs

as shown in Figure 26, 139 volts can be obtained the

voltage regulator knob turned toward maximum; 127 volts

can be obtained with the voltage regulator knob is turned

down; and 120 volts can be obtained with the voltage

regulator knob is at lowest setting.

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

Position

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

208V

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

or 208V

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

or 120V

DCA-25SSI — OUTPUT VOLTAGE SETUP

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

Voltage Selector Switch- Single Phase 240/120V

Position

The following are additional voltages available when the

240/120V position.

Single Phase, 240 Volt

This setting can provide single phase power at 240 volts.

After hooking up the hard wires to the lugs as shown in

Figure 28, 240 volts can be obtained and using the

voltage regulator to fine tune.

Single Phase: 120 Volt

This setting can provide single phase power at 120 volts.

After hooking up the hard wires to the lugs as shown in

Figure 29, 120 volts can be obtained by using the voltage

regulator to fine tune.

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

Position

Figure 28. Hard Wire Hookup for Single Phase 240 volt

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

DCA-25SSI — OUTPUT VOLTAGE SETUP

PAGE 36 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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.

Generator Grounding

To guard against electrical shock and possible damage to

the equipment, it is important to provide a good EARTH

ground.

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

provides guide lines for proper grounding and specifies that

the cable ground shall be connected to the grounding system

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

practical.

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

grounding requirements:

1. Use one of the following wire types to connect the

generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.

b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 30) connect the

ground cable between the lock washer and the nut on

the generator and tighten the nut fully. Connect the other

end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground

rod should be buried a minimum of 8 ft. into the ground.

DCA-25SSI — INSTALLATION

NOTE

When connecting the generator to any buildings

electrical system ALWAYS consult with a licensed

electrician.

Outdoor Installation

Install the generator in a location where it will not be exposed

to rain or sunshine. Make sure the generator is on secure

level ground so that it cannot slide or shift around. Also

install the generator in a manner so that the exhaust will not

be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture

and dust. All electrical equipment should be protected from

excessive moisture. Failure to do will result in deterioration

of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive

materials have a tendency to cause excessive wear to

engine and alternator parts.

CAUTION :

Pay close attention to ventilation when

operating the generator inside tunnels and

caves. The engine exhaust contains

noxious elements. Engine exhaust must

be routed to a ventilated area.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.

Whenever an engine is installed indoors the exhaust fumes

must be vented to the outside. The engine should be installed

at least two feet from any outside wall. Using an exhaust

pipe which is too long or too small can cause excessive

back pressure which will cause the engine to heat

excessively and possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (such

as concrete) and set firmly on the foundation to isolate

vibration of the generator when it is running. The generator

must set at least 6 inches above the floor or grade level (in

accordance to NFPA 110, Chapter 5-4.1). DO NOT remove

the metal skids on the bottom of the generator. They are to

resist damage to the bottom of the generator and to maintain

alignment.

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

Figure 30. Typical Generator Grounding Application

DCA-25SSI — INSTALLATION

PAGE 38 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

General Inspection Prior to Operation

The DCA-25SSI generator has been thoroughly inspected

and accepted prior to shipment from the factory. However,

be sure to check for damaged parts or components, or loose

nuts and bolts, which could have occurred in transit.

Extension Cable

When electric power is to be provided to various tools or

loads at some distance from the generator, extension

cords are normally used. Cables should be sized to allow

for distance in length and amperage so that the voltage

drop between the generator and point of use (load) is held

to a minimum. Use the Cable Selection Guide (Table 9)

as a guide for selecting proper cable size.

Circuit Breakers

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

main main

main

circuit breaker is provided to protect the UNV output

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

GFCIGFCI

GFCI

circuit breakers are provided to protect the GFCI

receptacles from overload. Three 50 amp

loadload

load

circuit breakers

have also been provided to protect the load side of the

generator from overload. Make sure to switch

ALLALL

ALL

circuit

breakers to the "OFF" position prior to starting the engine.

DCA-25SSI — PRE-SETUP

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ALWAYS consult with a licensed

electrician for correct extension

cord wire size.

NOTE

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

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler

hole, but do not overfill. Make sure the generator is level.

With the dipstick inserted all the way, but without being screw

into the filler hole, verify that the oil level is maintained

between the two notches (Figure 31) on the dipstick. See

Table 10 for proper selection of engine oil.

DCA-25SSI — PRE-SETUP

Figure 31. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is

clean and viscous. If the oil is not clean, drain the oil by

removing the oil drain plug, and refill with the specified amount

of oil as outlined in the Isuzu Engine Operator’s Manual.

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Fuel

Fill the fuel tank with clean and fresh

diesel fueldiesel fuel

diesel fuel

. DO NOT

fill the tank beyond capacity.

Pay attention to the fuel tank capacity when replenishing

fuel. Refer to the fuel tank capacity listed on page 19

Specification Table 5.

The fuel tank cap must be closed tightly after filling. Handle

fuel in a safety container. If the container does not have a

spout, use a funnel. Wipe up any spilled fuel immediately.

CAUTION :

Never fill the fuel tank while the engine is

running or in the dark. Gasoline spillage

on a hot engine can cause a fire or

explosion. If gasoline spillage occurs, wipe

up the spilled gasoline completely to

prevent fire hazards.

Coolant

Use only drinkable tap water. If hard water or water with

many impurities is used, the inside of the engine and radiator

may become coated with deposits and cooling efficiency

will be reduced. See maintenance section on page 42 and

43 on instructions to flush out radiator.

An anticorrosion additive added to the water will help prevent

deposits and corrosion in the cooling system.

PAGE 40 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — PRE-SETUP

Day-to-day addition of coolant is done from the reserve tank.

When adding coolant to the radiator, DO NOT remove the

radiator cap until the unit has completely cooled. See Table11.

for engine, radiator, and reserve tank coolant capacities. Make

sure the coolant level in the reserve tank is always between

the "H" and the "L" markings.

CAUTION :

When adding coolant or antifreeze to the

radiator, do not remove the radiator cap

until the unit has completely cooled.

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Operation in Freezing Weather

When operating in freezing weather, be certain the proper

amount of antifreeze (Table 12) has been added.

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NOTE

Cleaning the Outer Radiator

The engine may overheat if the radiator fins become

overloaded with dust or debris. Periodically clean the radiator

fins with compressed air. Cleaning inside the radiator is

dangerous, so clean only with the engine turned off and the

battery disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in

accordance with the Kubota Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to

insufficient charging of the battery. Inspect the fan belt for

damage and wear and adjust it in accordance with the Kubota

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15

mm (Figure 32) when depressed with the thumb as shown

below. Never place hands near the belts or fan while the

generator is running.

Figure 32. Fan Belt Tension

Never place hands near the belts or fan

while the generator set is running.

CAUTION :

Adjusting Fan Belt

If the fan belt does not have the 10 to 15mm defection

follow the procedure below to adjust:

Loosen the alternator adjusting plate and alternator

mounding bolt.

Pivot the alternator at the mounting bolt toward the engine

left or right until the belt reflects the proper tension.

Tighten the mounting bolt and the adjusting bolt.

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

DCA-25SSI — PRE-SETUP

Battery Cable Installation

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

connected to the battery terminals as shown below. The

REDRED

RED

cable is connected to the positive terminal of the battery,

and the BLACK cable is connected to the negative terminal

of the battery.

CAUTION :

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery

terminals when the key is in the ignition and is set in

'START' mode. ALWAYS remove the key from the

ignition and the ignition switch is in the OFF position

when connecting the battery.

2. Place a small amount of grease around both battery

terminals. This will ensure a good connection and will

help prevent corrosion around the battery terminals.

CAUTION :

Inadequate battery connections may

cause poor starting of the generator, and

create other malfunctions.

Wiring

Inspect the entire generator for bad or worn electrical wiring

or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for

wear and tightness. Tighten all hose clamps and check hoses

for leaks.

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

immediately.

Figure 33. Battery Connections

If the battery cable is connected

incorrectly, damage to the generator will

occur. Pay close attention to the polarity

of the battery when connecting the

battery.

Battery

This unit is of negative ground. DO NOT connect in reverse.

Always maintain battery fluid level between the specified

marks. Battery life will be shortened, if the fluid level is not

properly maintained. Add only distilled water when

replenishment is necessary. DO NOT over fill.

The battery is sufficiently charged if the specific gravity of

the battery fluid is 1.28 (at 68° F). If the specific gravity

should fall to 1.245 or lower, it indicates that the battery is

dead and needs to be recharged or replaced.

Check to see whether the battery cables are loose. Poor

contact may result in poor starting or malfunctions. Always

keep the terminals firmly tightened. Coating the terminals

with a thin film of grease will help to inhibit corrosion.

PAGE 42 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator

and equipment to insure the wattage, amperage and

frequency requirements are satisfactorily supplied by the

generator for operating the equipment.

Generally, the wattage listed on the nameplate of the

equipment is its rated output. Equipment may require 130—

150% more wattage than the rating on the nameplate, as

the wattage is influenced by the efficiency, power factor and

starting system of the equipment.

When the voltage selector switch is in single phase (240/

120V position), place the AC voltmeter change-over switch

to the U-W position and the AC ammeter change over-switch

to the U or W position to read the output.

Motors and motor-driven equipment draw

much greater current for starting than

during operation.

An inadequate size connecting cable which cannot carry

the required load can cause a voltage drop which can burn

out the appliance or tool and overheat the cable.

When connecting a resistance load such as an

incandescent lamp or electric heater, a capacity of up

to the generating set’s rated output (kW) can be used.

When connecting a fluorescent or mercury lamp, a

capacity of up to the generating set’s rated output (kW)

multiplied by 0.6 can be used.

When connecting an electric drill or other power tools,

pay close attention to the required starting current

capacity.

If wattage is not available on the equipment, approximate

wattage may be determined by multiplying the nameplate

voltage by the nameplate amperage for three-phase:

WATTS =1.732 x VOLTAGE x AMPERAGE

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NOTE

If wattage is not given on the

equipment's name plate, approximate

wattage may be determined by

multiplying nameplate voltage by the

nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 1.0. See Table 13.

below when connecting loads. Before connecting this generator to any

building’s electrical system, a licensed

electrician must install an isolation

(transfer) switch. Serious injury or death

may result without this transfer switch.

CAUTION:

Three Phase Load

When calculating the power requirements for 3-phase power

use the following equation:

CAUTION

NOTE

If output (kVA) is not given on the

equipment nameplate, approximate

output may be determined by

multiplying voltage by amperage by

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

WARNING:

Before Starting

Engine

1. Check the lubricating oil level prior to starting the engine.

Make sure the generator is level. The oil level must be

maintained between two notches on the dipstick.

2. When there is not enough lubricating oil, fill the crankcase

with high grade motor oil. Use a high quality detergent

oil classified CC or higher (See Table 8 on page 33).

3. Check the coolant level in the radiator and subtank.

Replenish with antifreeze as necessary. Always maintain

the coolant level between the FULL and LOW markings

on the coolant container. Be sure that the radiator cap is

fastened securely.

4. Check the fuel level on the fuel gauge. If fuel is low, fill

the fuel tank with clean fresh unleaded automotive diesel.

If diesel spillage occurs, completely wipe up the spilled

fuel immediately.

Before Starting

Generator and Control Panel

CAUTION:

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

main, load main, load

main, load

and

G.FG.F

G.F

.C.C

.C.I..I.

.I..I.

.I.

circuit breakers (Figure 34) to

the “OFF” position prior to starting the engine.

NEVER start the engine with the

main,main,

main,

GFCI GFCI

GFCI

loadload

load

circuit breakers

in the ON position.

The engine's exhaust contains harmful

emissions.

ALAL

ALWW

WAA

AYS YS

YS YS

ventilate the

exhaust when operating inside tunnels,

excavations or buildings. Direct exhaust

away from nearby personnel.

Figure 34. Main, GFCI and

Load Circuit Breakers

DCA-25SSI — GENERATOR START-UP PROCEDURE

2. Connect the load to the UNV terminals as shown in

Figure 35. These terminals can be found on the output

terminal panel, (see page 29 Figure10). To gain access

to the output terminals lift the UNV cover. Tighten

terminal nuts securely to prevent load wires from slipping

out.

Figure 35. UNV Terminal Lugs (Load)

NEGATIVE

POSTIVE

BATTERY

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

negative post on the battery (Figure 36).

Figure 36. Battery Connections

PAGE 44 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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

the 60 cycle output frequency in HERTZ.

Figure 44. Voltage Meter (Volts)

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

120 VAC in VOLTS. If the voltage is not within the

specified frequency tolerance, use the voltage

adjustment control knob (Figure 45) to increase or

decrease the desired voltage.

Figure 38. Voltage Selection Switch

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

Figure 37. Engine Enclosure Doors

DCA-25SSI — GENERATOR START-UP PROCEDURE

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

the desired voltage.

6. Make sure the engine throttle (Figure 39) is in

’start/idle’.

8. Once the preheat indicator lights, turn the ignition

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

Then release the key to ‘RUN’.

Figure 39. Engine Throttle Lever (low)

Figure 41. Ignition Switch ‘START’

Figure 43. Frequency Meter (Hz)

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

preheat indicator turns on.

Figure 40. Ignition Switch ‘PREHEAT’

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

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

Figure 42. Engine Throttle Lever (high)

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

Figure 46. Ammeter (No Load)

Figure 45. Voltage Adjust Control Knob

12. The ammeter (Figure 46) will indicate zero amps with no

load applied. When a load is applied, this meter will

indicate the amount of current that the load is drawing

from the generator’s alternator.

Figure 49. Engine Tachometer

DCA-25SSI — GENERATOR START-UP PROCEDURE

13. The engine oil pressure gauge (Figure 47) will indicate

the oil pressure (kg/ cm2) of the engine. Under normal

operating conditions the oil pressure is approximately

25 psi.

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

the coolant temperature. Under normal operating

conditions the coolant temperature is between 165 and

215 degrees Fahrenheit.

WATER TEMP

Figure 48. Coolant Temperature Gauge

Figure 47. Oil Pressure Gauge

15. The tachometer (Figure 49) will indicate the speed of

the engine when the generator is operating. Under normal

operating conditions this speed is approximately 1800

RPM’s.

17. Observe the generator's ammeter (Figure 51) and verify

it reads the anticipated amount of current with respect

to the load. The ammeter will only display a current

reading if the load is in use.

18. The generator will run until manually stopped or an

abnormal condition occurs.

Figure 50. Main and GFCI Circuit Breakers

Figure 51. Ammeter (Load)

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

their ON position (Figure 50).

PAGE 46 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENGINE SHUTDOWN

To shutdown the generator, use the following procedure:

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

(Figure 52) to the “OFF” position.

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

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

load applied.

5. Remove the load from the UNV terminal strip.

Figure 52. Main, GFCI and Load

circuit breakers

DCA-25SSI — GENERATOR SHUTDOWN PROCEDURE

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

Figure 53. Ignition Switch ‘STOP’

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

NOTE PAGE

PAGE 48 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — MAINTENANCE

General Inspection

Prior to each use, the generator should be cleaned and

inspected for deficiencies. Check for loose, missing or

damaged nuts, bolts or other fasteners. Also check for fuel,

oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 50 hours: Remove air cleaner element and clean heavy

duty paper element with kerosene, or foam element with

liquid detergent and hot water. Wrap foam element in a cloth

and squeeze dry. For heavy duty paper element, wipe

excess kerosene with towel.

Fuel Addition

Add diesel fuel (the grade may vary according to season

and locations). Always pour through the mesh filter.

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate

in the bottom of the tank. Occasionally remove the drain

cock and drain the contents. During cold weather, the more

empty volume inside the tank, the easier it is for water to

condense. This can be reduced by keeping the tank full as

much as possible.

Air Removal

If air enters the fuel injection system of a diesel engine,

starting becomes impossible. After running out of fuel, or

after disassembling the fuel system, bleed the system

according to the following procedure.

To restart after running out of fuel, turn the switch to the

“ON” position for 15-30 seconds. Try again, if needed. This

unit is equipped with an automatic air bleeding system.

Service Daily

If the engine is operating in very dusty or dry grass

conditions, a clogged air cleaner will result. This can lead to

a loss of power, excessive carbon buildup in the combustion

chamber in high fuel consumption.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove

dust or water in the strainer cap and wash it in gasoline.

Securely fasten the fuel strainer cap so that fuel will not

leak. Check the fuel strainer every 200 hours of operation or

once a month.

Check Oil Level

Check the crankcase oil level prior to each use, or when

the fuel tank is filled. Insufficient oil may cause severe

damage to the engine. Make sure the generator is level.

The oil level must be between the two notches on the dipstick

as shown in Figure 31, page 39.

Replacing Oil Filter

Detach the oil filter cartridge with a filter wrench.

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

Screw in the cartridge by hand. When the gasket is in

contact with the seal surface, tighten the cartridge one

or two more times by hand.

After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and check

for leaks before adding more oil if needed. Clean

excessive oil from engine.

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 400

hours or so.

Apply fuel oil thinly over the gasket and hand-tighten

the cartridge into position.

Vent any air.

Flushing Out Radiator and Replacing Coolant

Open both cocks located at the crankcase side and at

the lower part of the radiator and drain coolant. Open

the radiator cap while draining. Remove the overflow

tank and drain.

Check hoses for softening and kinks. Check clamps

for signs of leakage.

Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO

NOT clean radiator core with any objects, such as a

screwdriver.

Tighten both cocks and replace the overflow tank.

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

Close radiator cap tightly.

CAUTION :

Allow engine to cool when flushing out

radiator. Flushing the radiator while hot

will damage radiator.

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

DCA-25SSI — MAINTENANCE

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Generator Storage

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

is required:

Drain the fuel tank completely.

Completely drain the oil from the crankcase and refill

with fresh oil.

Clean all external parts of the generator with a cloth.

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

PAGE 50 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — GENERATOR WIRING DIAGRAM

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

DCA-25SSI — ENGINE WIRING DIAGRAM

PAGE 52 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper

handling and maintenance inspections, but in the event of a

breakdown, use the tables shown for

diagnosis based on the Engine Troubleshooting (Table 14). If

the problem cannot be remedied, consult our company's

business office or service plant.

GNITOOHSELBUORTENIGNE.41ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

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

DCA-25SSI — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.41ELBAT

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PAGE 54 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

GNITOOHSELBUORTROTARENEG.51ELBAT

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DCA-25SSI — TROUBLESHOOTING (GENERATOR

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

NOTE PAGE

PAGE 56 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

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.

EXPLANATION OF CODE IN REMARKS COLUMN

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

DCA-25SSI DCA-25SSI

DCA-25SSI W/ISUZU C240 DIESEL ENGINEW/ISUZU C240 DIESEL ENGINE

W/ISUZU C240 DIESEL ENGINEW/ISUZU C240 DIESEL ENGINE

W/ISUZU C240 DIESEL ENGINE

1 1

TO 3 UNITSO 3 UNITS

O 3 UNITSO 3 UNITS

O 3 UNITS

DCA-25SSI — SUGGESTED SPARE PARTS

NOTE

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this

book.

Qty. P/N Description

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

PAGE 58 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI --- GENERATOR ASSY.

GENERATOR ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

DCA-25SSI --- GENERATOR ASSY.

GENERATOR ASSY.

1 8011000302 ROTOR ASSY. 1

1-1 FIELD ASSY. 1

1-2 8001070003 FAN 1

1-3 0012108035 HEX. HEAD BOLT 6

1-4 0042508000 LOCK WASHER 6

1-5 8351611004 COUPLING DISK .................................. 3 ............ REPLACES 8001611004

1-6 8351615003 BALANCING PLATE .............................1 ............ REPLACES 8001015003

1-7 0105091025 HEX. HEAD BOLT ................................5 ............ REPLACES 0010310025

1-8 0042610000 LOCK WASHER 5

1-9 8001026013 SET PLATE, RECTIFIER 1

1-10 0601821349 RECTIFIER 2

1-11 0601822601 SURGER ABSORBER .......................... 1 ........... ERZM14JK621A

1-12 8001020004 INSULATOR WASHER 1

1-13 8001020504 INSULATOR WASHER 1

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

1-15 0040008000 LOCK WASHER 4

1-16 0601000209 BALANCING WEIGHT KIT 1

1-17 0070806307 BEARING 1

2 8011614003 COUPLING RING 1

3 0012108025 HEX. HEAD BOLT 6

4 0042508000 LOCK WASHER 6

5 8011340503 STATOR ASSY. 1

6 0845041904 GROMMET 1

7 8001315002 END BRACKET 1

8 8001350023 FIELD ASSY., EXCITER 1

9 0010308055 HEX. HEAD BOLT 4

10 0042608000 LOCK WASHER 4

11 031108160 PLAIN WASHER ................................... 4 ........... REPLACES 0041208000

12 0010108025 HEX. HEAD BOLT 6

13 0040008000 LOCK WASHER 6

14 031108160 PLAIN WASHER ................................... 6 ........... REPLACES 0041208000

15 0601000001 WAVE WASHER................................... 1 ........... BWW6307

16 8001310004 COVER, BEARING 1

17 8001312004 GASKET, BEARING 1

18 8001331004 COVER, END BRACKET 1

19 0105050616 HEX. HEAD BOLT ................................ 7 ........... REPLACES 0017106012

20 8001333003 COVER, END BRACKET 1

PAGE 60 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI --- GENERATOR ASSY.

GENERATOR ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

DCA-25SSI --- GENERATOR ASSY.

GENERATOR ASSY.

21 0010106030 HEX. HEAD BOLT 2

22 0040006000 LOCK WASHER 2

23 952404470 PLAIN WASHER ................................... 2 ........... REPLACES 0041206000

24 0012110035 HEX. HEAD BOLT 6

25 030210250 LOCK WASHER .................................... 6 ........... REPLACES 0042510000

26 020310080 HEX. NUT ............................................. 6 ........... REPLACES 0030310000

27 031110160 PLAIN WASHER ................................... 6 ........... REPLACES 0041210000

28 8001332003 COVER, FAN 1

29 0605000008 RUBBER SUSPENSION 2

30 0030012000 HEX. NUT 4

0040012000 LOCK WASHER 4

PAGE 62 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

DCA-25SSI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

1 8011812602 CONTROL BOX 1

2 0601801143 CURRENT TRANSFORMER, AMMETER ........ 3 ...... CT3.5MR 100/5A

3 0027104010 MACHINE SCREW 6

4 0601823863 RELAY UNIT .................................................... 2 ...... MSA9013A

5 0027104016 MACHINE SCREW 4

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

7 0027105012 MACHINE SCREW 2

10 5825500422 EMERGENCY RELAY ...................................... 1 ...... REPLACES 5825500191

& 0602200406

11 9822531070 REGULATOR ................................................... 1 ...... REPLACES 0602201305

12 0027106016 MACHINE SCREW 2

0040004000 LOCK WASHER 2

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

15 M1923100004 SELECTOR SWITCH ....................................... 1 ...... REPLACES 8010153104

16 0020004010 MACHINE SCREW ........................................... 4 ...... REPLACES 0021104010

17 8011839504 BRACKET, SELECTOR SWITCH 1

18 0021003010 MACHINE SCREW 4

19 0017106016 HEX. HEAD BOLT 2

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

20 3331823513 CONTROL PANEL 1

21 0601800460 FREQUENCY METER ...................................... 1 ...... PAK60 220V 45~65Hz

22 0601800783 AC AMMETER ................................................. 1 ...... PSK60 0~50A 0~100A

23 0601801040 CHANGE-OVER SW., AMMETER ................... 1 ...... SL2AS

24 0601800212 AC VOLTMETER ............................................. 1 ...... PCK60 0~600V; REPLACES

0601800217

25 0601801041 CHANGE OVER SW., VOLTMETER ............... 1 ...... SL2VS

26 0601810072 PILOT LAMP .................................................... 1 ...... LP132DC 220V

0601810261 BULB 1

27 0601840073 VOLTAGE REGULATOR(RHEOSTAT) ............ 1 ...... RA20A2SE102BJ2W 1KOHM

28 0601840121 KNOB 1

29 3901824004 STOPPER, CONTROL PANEL 1

30 0027105016 MACHINE SCREW 2

0030005000 HEX. NUT 2

31 0805001304 SET SCREW 2

32 031108160 PLAIN WASHER .............................................. 2 ...... REPLACES 0041208000

33 020108060 HEX. NUT ......................................................... 2 ...... REPLACES 0030008000

34 0027105010 MACHINE SCREW 4

35 8011827503 COVER 1

39 0017106016 HEX. HEAD BOLT 5

37 011008020 HEX. HEAD BOLT ............................................ 4 ...... REPLACES 0017108020

020108060 HEX. NUT ......................................................... 4 ...... REPLACES 0207008000

PAGE 64 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

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

DCA-25SSI ENGINE AND RADIATOR ASSY.

NO. PART NO.ITEM QTY.REMARKS

ENGINE AND RADIATOR ASSY.

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

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

3 011008020 HEX. HEAD BOLT .......................... 8 ........... REPLACES 0017108020

4 9214311960 RADIATOR HOSE .......................... 1 ........... REPLACES 0602013008

5 9214311980 RADIATOR HOSE .......................... 1 ........... REPLACES 0602013109

6 914311970 RADIATOR HOSE .......................... 1 ........... REPLACES 0602013108

7 3332011504 RADIATOR PIPE 1

8 3332012504 CLAMPER 1

9 0602014000 HOSE BAND 5

10 0602014004 HOSE BAND 1

11 0602046287 AIR CLEANER ................................ 1 ........... FWG058176

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

12 0602040690 DUST INDICATOR .......................... 1 ........... RBX002252

13 0602040587 BAND, AIR CLEANER .................... 2 ........... AAH008278

14 3332031103 BRACKET, AIR CLEANER 1

15 011008020 HEX. HEAD BOLT .......................... 4 ........... REPLACES 0017108020

16 0017110025 HEX. HEAD BOLT 2

17 1322036004 HOSE, AIR CLEANER 1

18 0605515010 HOSE BAND 2

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

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

21 3335112204 ENGINE FOOT 2

22 0010110035 HEX. HEAD BOLT 4

23 031110160 PLAIN WASHER ............................. 4 ........... REPLACES 0041210000

24 0040010000 LOCK WASHER 4

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

26 0605000008 RUBBER SUSPENSION 2

27 031110160 PLAIN WASHER ............................. 4 ........... REPLACES 0041610000

28 0040010000 LOCK WASHER 4

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

30 0802020403 DRAIN PIPE 1

31 0805006304 PACKING, INNER OIL PAN SIDE 1

32 0602021100 PACKING, OUTER ......................... 1 ........... 9099209590

33 0805006204 JOINT BOLT 1

34 011206020 HEX. HEAD BOLT .......................... 2 ........... REPLACES 0017106020

36 0802081403 RESERVE TANK 1

37 0802081104 CAP, RESERVE TANK 1

38 8012082103 BRACKET, RESERVE TANK ......... 1 ........... REPLACES 3335182123

PAGE 66 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

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

DCA-25SSI ENGINE AND RADIATOR ASSY.

NO. PART NO.ITEM QTY.REMARKS

ENGINE AND RADIATOR ASSY.

39 011606025 HEX.HEAD BOLT ........................... 1 ........... REPLACES 0017106025

40 0199500550 HOSE 1

41 0199500220 HOSE 1

42 0193600970 HOSE 1

43 0605515013 HOSE BAND 4

44 0194500600 BREATHER HOSE 1

45 0605515022 HOSE BAND 2

46 0193000500 HOSE 1

47 0605515005 HOSE BAND 1

48 0193100200 HOSE 1

49 0605515000 HOSE BAND 1

50 9829315110 EARTH CABLE ............................... 1 ........... REPLACES 0602220000

PAGE 68 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENGINE OPERATING PANEL ASSY.

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

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

ENGINE OPERATING PANEL ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

1 3332111603 OPERATING PANEL 1

2 3332142014 SLIDE BAR 1

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

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

5 3332140504 BRACKET, GOVERNOR ROD 1

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

7 0605010503 SNAP PIN 1

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

9 5814200330 PREHEAT LAMP .................................. 1 ........... REPLACES 982530109 & 0602102002

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

11 0602120167 CABLE, TACHOMETER ....................... 1 ........... 62100KB3900 L=1000

12 0602122050 OIL PRESSURE GAUGE 1

13 0602122260 UNIT, OIL PRESSURE ......................... 1 ........... 53000AC0101

14 0602123060 WATER TEMPERATURE GAUGE ....... 1 ........... 4000KB5111

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

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

17 0602103092 ALARM LAMP 2

0601810245 BULB 2

18 0601830420 SWITCH, LAMP CHECK 1

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

0601810291 BULB 1

20 0040520000 TOOTHED LOCK WASHER 1

21 0601830710 SWITCH, PANEL LIGHT 1

22 011008040 HEX.HEAD BOLT ................................. 4 ........... REPLACES 0010108040

0040008000 LOCK WASHER 4

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

23 3335312412 SUPPORT LEG 1

24 012010030 HEX. HEAD BOLT ................................ 5 ........... REPLACES 0017110030

25 0602210802 ENGINE STOPPER .............................. 1 ........... 5819000200

26 5819000200 BRACKET, ENGINE STOPPER ........... 1 ........... REPLACES 3332159204

27 0027106016 MACHINE SCREW 3

28 011008020 HEX. HEAD BOLT ................................ 2 ........... REPLACES 0017108020

29 3332152704 GOVERNOR ROD 1

30 0602180106 BALL JOINT 2

31 020108060 HEX. NUT ............................................. 2 ........... REPLACES 0030008000

32 8091860103 SET BOARD, OUTPUT TERMINAL 1

33 0801830104A OUTPUT TERMINAL 5

34 0801830604 HEX. HEAD BOLT 5

35 0039308000 HEX. NUT 10

36 0040008000 LOCK WASHER 15

37 0041408000 PLAIN WASHER 20

38 0017106030 HEX. HEAD BOLT 4

39 8011866504 COVER, OUTPUT TERMINAL 1

40 0605010051 HINGE 2

PAGE 70 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENGINE OPERATING PANEL ASSY.

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

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

NO. PART NO.ITEM QTY REMARKS

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

ENGINE OPERATING PANEL ASSY.

41 0027103016 MACHINE SCREW 12

0207003000 HEX. NUT 6

42 0017106016 HEX. HEAD BOLT 2

43 0601811034 RECEPTACLE, CS6369 2

44 0601811030 RECEPTACLE, 5-20R 2

45 0027103010 MACHINE SCREW 8

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

58413 PLAIN WASHER ................................... 8 ........... REPLACES 0041203000

46 0601805315 CIRCUIT BREAKER ............................. 2 ........... KM51 265V 30A

47 0601805840 CIRCUIT BREAKER ............................. 2 ........... KM52 265V 50A

48 3331817114 BRACKET, CIRCUIT BREAKER 1

0222100150 RUBBER SHEET 1

49 0017106016 HEX. HEAD BOLT 2

50 8085182004 RUBBER COVER 1

51 8085183004 SET FRAME, RUBBER COVER 1

52 011206020 HEX. HEAD BOLT ................................ 6 ........... REPLACES 0017106020

53 3331866533 COVER, RECEPTACLE 1

54 012212045 HEX. HEAD BOLT ................................ 2 ........... REPLACES 0010012045

55 031112230 PLAIN WASHER ................................... 4 ........... REPLACES 0041612000

56 0805009804 RUBBER WASHER 2

57 0030012000 HEX. NUT 2

58 0040506000 TOOTHED WASHER 1

59 011206020 HEX. HEAD BOLT ................................ 1 ........... REPLACES 0017106020

60 0601820015 RECTIFIER 4

61 0601802132 FUSE, 10A 1

PAGE 72 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI --- BATTERY ASSY.

BATTERY ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

DCA-25SSI --- BATTERY ASSY.

BATTERY ASSY.

1 0160012100 BATTERY ....................................... 1 ........... 65D31R; REPLACES 0168306531

2 3312251004 BATTERY SHEET 1

3 3332250004 BATTERY BAND 1

4 0805002404 BATTERY BOLT 2

5 031108160 PLAIN WASHER ............................ 2 ........... REPLACES 0041208000

6 0040008000 LOCK WASHER 2

7 0037808000 WING NUT 2

8 0215260160 BATTERY CABLE 1

9 0215860110 BATTERY CABLE 1

10 0602220310 TERMINAL ASSY. ......................... 1 ........... NO.9P

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

11 0602220311 TERMINAL ASSY. ......................... 1 ........... NO.9N

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

PAGE 74 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI --- MUFFLER ASSY.

MUFFLER ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

DCA-25SSI --- MUFFLER ASSY.

MUFFLER ASSY.

1 3332350513 EXHAUST PIPE 1

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

3 0040010000 LOCK WASHER 3

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

5 7342311002A MUFFLER 1

6 011008020 HEX. HEAD BOLT ......................... 4 ........... REPLACES 0017108020

7 7342356004 GASKET 1

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

9 031108160 PLAIN WASHER ............................ 4 ........... REPLACES 0041208000

10 0040008000 LOCK WASHER 4

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

12 7342354004 COVER 2

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

PAGE 76 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI --- FUEL TANK ASSY.

FUEL TANK ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

DCA-25SSI --- FUEL TANK ASSY.

FUEL TANK ASSY.

1 3335510903 FUEL TANK 1

1-1 0810105004 CAP, FUEL TANK 1

1-2 0810105400 FUEL FILTER 1

1-3 0193100255 FUEL GAUGE HOSE 1

1-4 0605515079 HOSE BAND 2

2 3335523304 TANK BAND 2

3 0805003414 PAD, TANK BAND 4

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

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

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

7 0222100320 TANK SHEET 2

8 0131906000 CAP 1

9 0191300620 SUCTION HOSE 1

10 0191300970 RETURN HOSE 1

11 0605515014 HOSE BAND 4

12 0845032204 DRAIN JOINT 1

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

14 0802011104 PLUG 1

PAGE 78 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENCLOSURE ASSY.

DCA-25SSI --- ENCLOSURE ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

ENCLOSURE ASSY.

DCA-25SSI --- ENCLOSURE ASSY.

1 8015110202 BASE 1

2 3335116014 FLOOR PANEL 1

3 011008020 HEX. HEAD BOLT ......................... 8 ........... REPLACES 0017108020

4 3335116504 COVER 1

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

6 3335121914 FRONT FRAME 1

3335109203 LINING 1

7 011008020 HEX. HEAD BOLT ......................... 8 ........... REPLACES 0017108020

8 3335162804 RUBBER SEAL 1

9 011206020 HEX. HEAD BOLT ......................... 4 ........... REPLACES 0017106020

10 3335126704 COVER, FRONT FRAME 1

11 011008020 HEX. HEAD BOLT ........................12 ........... REPLACES 0017108020

12 3335125224 COVER, FRONT FRAME 1

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

14 33351331513 CENTER FRAME 1

15 7345131103 CENTER FRAME 1

16 0010114035 HEX. HEAD BOLT 8

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

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

031114260 PLAIN WASHER ...........................16 ........... REPLACES 0041214000

17 3335140122 REAR FRAME 1

18 011008020 HEX. HEAD BOLT ......................... 4 ........... REPLACES 0017108020

19 3335180112 COVER, REAR FRAME 1

335109324 LINING 1

20 011008020 HEX.HEAD BOLT .......................... 8 ........... REPLACES 0017108020

21 3335180204 GUIDE PANEL, AIR 1

22 011008020 HEX. HEAD BOLT ......................... 8 ........... REPLACES 0017108020

23 3335142213 DOOR, REAR FRAME 1

24 7345147004 WINDOW PLATE 1

25 0021006020 MACHINE SCREW 6

26 0845028303 HINGE 2

27 011208025 HEX. HEAD BOLT ......................... 4 ........... REPLACES 0017108025

28 3335161902 ROOF PANEL 1

3335109503 LINING 1

29 3335132204 HANGER 1

30 0010120070 HEX. HEAD BOLT 2

31 0041220000 PLAIN WASHER 4

32 0030020000 HEX. NUT 2

33 011008020 HEX. HEAD BOLT ........................14 ........... REPLACES 0017108020

34 3335181942 SPLASHER PANEL 1

35 0010108055 HEX. HEAD BOLT 4

0040008000 LOCK WASHER 4

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

36 3335124213 SIDE DOOR 1

3335109604 LINING 1

37 3335124313 SIDE DOOR 1

PAGE 80 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ENCLOSURE ASSY.

DCA-25SSI --- ENCLOSURE ASSY.

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

3335109704 LINING 1

38 3335175004 GUIDE PANEL, AIR 1

39 7345175104 GUIDE PANEL, AIR 1

40 011008020 HEX. HEAD BOLT ......................... 8 ........... REPLACES 0017108020

41 3335124023 SIDE DOOR 1

3335109814 LINING 1

42 3335124113 SIDE DOOR 1

3335109904 LINING 1

43 0845028203 HINGE 4

45 011208025 HEX.HEAD BOLT .........................16 ........... REPLACES 0017108025

46 0601850097 RUBBER CUSHION 8

47 0845031504 CAP 10

48 0600500090 EMBLEM........................................ 1 ........... REPLACES 6360510003

49 0021106020 MACHINE SCREW 2

57 3335104104 RUBBER SEAL 2

58 3335104204 RUBBER SEAL 2

59 3335104304 RUBBER SEAL 1

60 3335104414 RUBBER SEAL 1

61 3335104514 RUBBER SEAL 1

62 3335104604 RUBBER SEAL 1

63 3335104714 RUBBER SEAL 1

64 3335104804 RUBBER SEAL 2

65 3335104904 RUBBER SEAL 2

66 3335103004 RUBBER SEAL 2

67 3335103104 RUBBER SEAL 2

ENCLOSURE ASSY.

DCA-25SSI --- ENCLOSURE ASSY.

NO. PART NO.ITEM QTY.REMARKS

PAGE 82 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

DCA-25SSI --- DECALS

DECAL ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

DCA-25SSI --- DECALS

DECAL ASSY.

CONTROL BOX GROUP

1-1 B1551000202 DECAL; CONTROL PANEL ....................................1 ..... B15100020

1-4 0840623504 DECAL; OVER CURRENT RELAY ......................... 1 ..... S2844

1-5 3330670704 DECAL; CAUTION .................................................. 1 ..... S2518

1-9 0840647604 DECAL; DANGER .................................................. 1 ..... S4089

1-7 0820610404 DECAL; WARNING ................................................. 1 ..... S3627

ENGINE OPERATING PANEL GROUP

2-1 3330670002 DECAL; OPERATING PANEL ................................ 1 ..... S2360B

OUTPUT TERMINAL GROUP

3-1 0840614104 DECAL; GROUND .................................................. 1 ..... S2635

3-2 0840627103 DECAL; CABLE JOINING ......................................1 ..... S3245

3-3 8010670503 DECAL; CIRCUIT BREAKER AND RECEPTACLE 1 ..... S3493

3-4 0840631404 DECAL; CAUTION .................................................. 1 ..... S3351

3-5 0840619904 DECAL; DANGER .................................................. 1 ..... S2731

3-6 8010670714 DECAL; CAUTION .................................................. 1 ..... S3492B

BATTERY GROUP

4-1 0800689404 DECAL;+ ................................................................ 1 ..... S2090

4-2 0800689504 DECAL;- .................................................................1 ..... S2091

FUEL TANK GROUP

5-1 1320620904 DECAL; DIESEL FUEL .......................................... 1 ..... S1756

5-23 6360620004 DECAL; FUEL DRAIN PLUG .................................. 1 ..... S1883

ENCLOSURES GROUP

6-1 1320610603 DECAL; WATER-OIL ...............................................1 ..... S1760

6-2 6360610304 DECAL; WATER ..................................................... 1 ..... S1880

6-3 6360620204 DECAL; OIL DRAIN PLUG .....................................1 ..... S1885

6-4 6360610604 DECAL; WARNING ................................................. 1 ..... S1948

6-5 1320621504 DECAL; SUPPORT HOOK..................................... 2 ..... S2257

6-6 0840625902 DECAL; MQ ...........................................................1 ..... S3057

6-7 B1561100403 STRIPE 1

6-8 3330630303 STRIPE .................................................................. 1 ..... REPLACES B1561100503

6-9 B1561100804 STRIPE 2

6-10 B1561100903 STRIPE 2

6-11 3330630704 STRIPE .................................................................. 2 ..... REPLACES B1561100704

6-12 B1561100603 STRIPE 1

6-13 8700611904 DECAL; DANGER .................................................. 1 ..... S4985

6-14 8700611804 DECAL; WARNING ................................................. 1 ..... S4984

PAGE 84 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- CYLINDER HEAD AND COVER ASSY.

CYLINDER HEAD AND COVER ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- CYLINDER HEAD AND COVER ASSY.

CYLINDER HEAD AND COVER ASSY.

1 5111102070 CYLINDER HEAD ASSY. 1

3 1096000051 SEALING CUP, RR FACE D=44 1

3-1 5111290060 SEALING CUP, LOWER D=16 4

3-2 5112190080 SEALING CUP, UPPER D=18 5

3-3 5096000130 SEALING CUP, DRILLED D=12 4

4 9098605220 PLUG; LOWER CYLINDER HEAD PLATE 4

7 5117150230 VALVE SEAT INLET INSERT 4

8 5117110260 VALVE SEAT EXHAUST INSERT 4

9 5117210160 VALVE INLET HEAD GUIDE 4

9-1 5117210160 VALVE EXHAUST HEAD GUIDE 4

11 5111501080 HOT PLUG ASSY. 4

14 5125690060 INLET AND EXHAUST VALVE SEAL 8

16 9041108350 MANIFOLD STUD 3

16-1 9041108400 MAINFOLD STUD 3

16-2 9041108450 MANIFOLD STUD 1

21 5111410690 CYLINDER HEAD GASKET 1

22 5090090530 BOLT 19

29 5111702400 CYLINDER HEAD COVER ASSY. 1

30 9117510381 OIL FILLER CAP 1

31 5111790520 BREATHER NIPPLE 1

49 5111730170 HEAD COVER PACKING 1

51 9111798080 HEAD COVER FIX. PACKING 2

52 9111791320 WAHER 2

54 5090000960 BOLT 2

60 5096050050 CYLINDER HEAD OIL COOLER PLUG 1

PAGE 86 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

1 5112101771 CYLINDER BLOCK ASSY. 1

2 9098025910 BOLT 10

4 9096640340 PLUG; 1/2 TAPPET CHAMBER 2

4-1 5112190080 SEALING CUP CHAMBER D=18 2

5 5116100010 BEARING KIT; CAM. STANDARD 1

6 5112190180 SEALING CUP RR FACE D=36 1

6-1 5112190170 SEALING CUP RR FACE D=38 1

6-2 5112190150 SEALING CUP LH SIDE D=32 2

6-3 5096000130 SEALING CUP RR FACE D=12 1

6-4 1096000051 SEALING CUP LH SIDE D=45 3

7 9112612300 CYLINDER LINER 4

8 8942505140 PLUG; CAMSHAFT BRIDGE PLATE 1

9 5111290060 PLUG; OIL GALLERY PLATE 2

10 5112210020 DUCT; CYL. BLOCK WATER 1

11-1 5096050161 PLUG; OIL GALLERY 1/8 1

12-1 9992023160 PLUG; OIL GALLERY SCREW 1

13-1 9095714160 PLUG PACKING 1

26 5096500210 INJ. PUMP OIL FEED NIPPLE 1

27-1 9112976500 TAPPET CHAMBER COVER ASSY. 1

28 9113111530 FRONT CYL. BLOCK PLATE 1

29 5113120110 FRONT PLATE PACKING 1

31 9081510240 FRONT PLATE STRAIGHT PIN 2

32 9019008220 BOLT 3

36 9099022990 ROCKER OIL FEED NIPPLE 1

37 9081610320 REAR PLATE STRAIGHT PIN 1

42-1 9019008180 BOLT 12

42-2 9019008220 BOLT 2

43 9099168160 TAPPET CHAMBER COVER CLIP 2

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

47-1 9097040380 WATER DRAIN COCK 1

52 9098785970 CRANK CASE PIN 2

54-2 8942008311 BOLT 1

55 9099138340 PIPE; VINYL WATER DRAIN 1

56 9112290490 CYLINDER BLOCK DOWEL 2

58-2 5117400211 BREATHER AIR ASSY. 1

59 9099210990 BREATHER PACKING 1

64-1 9097130870 PIPE; VINYL BREATHER 1

66 9099152380 CLIP 1

67 9019008180 BOLT 1

69 9091645080 WASHER 1

77 9123631120 SPACER; OIL SEAL 1

78 5096250360 CRANK SHAFT REAR SEAL 1

81 9113411940 REAR CYLINDER BLOCK PLATE 1

84 5090002270 BOLT 3

99 9112581080 OIL PAN BRIDGE CAP PACKING 2

117 5117490340 BREATHER HEAD PACKING 1

120 9019008180 BOLT 2

121 9019608180 BOLT 1

130 9092023080 PLUG; OIL GALLERY SCREW 1

131 9095714080 SCREW PLUG PACKING 1

PAGE 88 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 ---TIMING GEAR ASSY.

TIMING GEAR ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

1 5113110282 TIMING GEAR CASE 1

2 9113211480 GEAR CASE COVER 1

3 9099206010 PACKING 1

4 901906140 BOLT 4

8 9113120460 PACKING 2

9 5096250790 OIL SEAL 1

12 9113270450 POINTER 1

14 9113120340 PACKING 1

17 9019108320 BOLT 9

ISUZU C240 --- TIMING GEAR ASSY.

TIMING GEAR ASSY.

PAGE 90 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 FLYWHEEL HOUSING ASSY.

FLYWHEEL HOUSING ASSY.

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

ISUZU C240 FLYWHEEL HOUSING ASSY.

NO. PART NO.ITEM QTY.REMARKS

1-5 5113410191 FLYWHEEL HOUSING 1

11 9113430391 COVER 1

12 9019006120 BOLT 6

21 5113490380 STIFFENER; RIGHT SIDE 1

22 5113490370 STIFFENER; LEFT SIDE 1

23 9019110200 BOLT 2

23-1 9019110180 BOLT 2

31 9019310450 BOLT 4

41 9019110350 BOLT 3

41 9010560400 BOLT 1

42 9091104100 NUT 2

46 9091505100 LOCK WASHER 2

FLYWHEEL HOUSING ASSY.

PAGE 92 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 OIL PAN ASSY.

OIL PAN ASSY.

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

ISUZU C240 OIL PAN ASSY.

NO. PART NO.ITEM QTY.REMARKS

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

3* 5096050050 OIL DRAIN PLUG, 3/8 1

3-1 9992023200 OIL DRAIN PLUG 1

4-1* 9097205600 O RING PACKING 1

6 9112150810 CRANK CASE 1

17 5113670040 OIL CASE PACKING 1

24 9992023160 OIL THERMO PLUG 1

26 9095714160 PLUG PACKING 1

29 9019106160 BOLT 30

31 9112193160 DISTRIBUTION PLATE 1

32 9030906160 SCREW 4

36 9117606090 OIL LEVEL GAUGE 1

42 9019008220 BOLT 16

42-1 9019708450 BOLT 4

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

52# 5117410100 OIL FILLER 1

53# 5117500021 OIL FILLER CAP 1

56 9099207080 PACKING 1

57 9019008200 BOLT 2

OIL PAN ASSY.

PAGE 94 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

OIL PUMP ASSY.

ISUZU C240 ---OIL PUMP ASSY.

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

OIL PUMP ASSY.

ISUZU C240 ---OIL PUMP ASSY.

NO. PART NO.ITEM QTY.REMARKS

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

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

8*# 9131290170 PIN 1

11*# 9098780840 PIN 1

12* 9131280790 PINION 1

13* 9131130771 COVER 1

14* 9020408250 BOLT 4

15* 9091505080 LOCK WASHER 4

16* 9091505080 LOCK WASHER 4

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

22*% 9131430100 OIL STRAINER GAUZE 1

41 9019708250 BOLT 2

PAGE 96 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

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

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

NO. PART NO.ITEM QTY REMARKS

1 5115100211 CRANK BEARING KIT;STD 1

1-1 5115300211 CRANK BEARING KIT;-0.25 1

1-2 5115400211 CRANK BEARING KIT;-0.50 1

2 9115810570 THRUST BEARING 2

3 5121112020 PISTON;STD 4

4 5121210070 PISTON RING SET;STD 4

6 5122110090 PISTON PIN 4

7 5095870010 SNAP RING 8

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

9-1@ 5122510050 SMALL END BUSHING 4

11-1@ 512350090 BOLT 8

12@ 5094090160 NUT 8

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

13-1 8941631740 BEARING SET;-0.25 4

13-2 8941631750 BEARING SET;-0.50 4

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

15# 9081612200 STRAIGHT PIN 1

17 5098010010 RADIAL BALL BEARING 1

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

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

31 9098785320 STRAIGHT PIN 2

33 5090001461 BOLT 6

34 5123360100 WASHER 1

36 9080307430 FEATHER KEY 1

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

38 9123620390 THROWER 1

60-1 9123736051 CRANKSHAFT PULLEY 1

64-1 9098026060 BOLT 1

67 9123736060 THROWER 1

69 9123790160 WASHER 1

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

CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.

PAGE 98 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- OIL AND FUEL FILTER ASSY.

OIL AND FUEL FILTER ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

2 9885131071 OIL FILTER ELEMENT KIT ........ 1 .............. INCL. ITEMS W/*

3*9132130350 O RING PACKING COVER 1

4 9099211920 CENTER PIPE PACKING 1

5-1 9099209780 DRAIN PIPE PACKING 1

6*9099221100 FELT RING 1

7 9132121240 OIL FILTER COVER 1

8 9099410540 COIL COMPRESSION SPRING 1

9 9132390330 SPRING SEAT 1

10 9132316030 CENTER PIPE 1

11 9098621170 DRAIN PLUG 1

12 9132110950 OIL FILTER BODY 1

13 9132390320 ELEMENT HOLDER 1

14 9099522170 SNAP RING 1

23 9132260130 ADAPTER 1

24 9099208410 PLUG PACKING 1

25 9098640150 SCREW PLUG 1

26 5132600080 SAFETY VALVE ASSY. .............. 1 .............. INCL. ITEM W/%

27% 1096231630 O RING PACKING 1

28 5131600030 RELIEF VALVE ASSY. ................ 1 .............. INCL. ITEM W/#

29# 9099209750 RELIEF VALE PACKING 1

70 8941434770 FUEL CART. FILTER ASSY. ....... 1 .............. INCL. ITEMS W/$

72$ 8941434790 FUEL ELEMENT 1

77$ 9095720140 OVERFLOW VALVE PACKING 2

80$ 5132120750 FUEL FILTER COVER 1

86$ 9132600561 OVERFLOW VALVE ASSY. 1

91 9197518010 FUEL FILTER BRACKET 1

92 9020608180 BOLT 2

93 9091506080 LOCK WASHER .......................... 2 .............. REPLACES 9091508080

94 9091645080 PLAIN WASHER 2

96 9019110320 BOLT 2

100 9132190570 OIL FILTER PACKING 1

101-1 9019008350 BOLT 4

110 8941208540 OIL FILTER ASSY....................... 1 .............. INCL. ITEMS W/@

111@ 8941564550 OIL FILTER CARTRIDGE 1

112@ 8941564540 OIL FILTER BODY 1

113@ 9132260090 ADAPTER 1

114@ 5131600030 RELIEF VALVE ASSY. 1

115@ 9099206200 PACKING ADAPTER 1

ISUZU C240 --- OIL AND FUEL FILTER ASSY.

OIL AND FUEL FILTER ASSY.

PAGE 100 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- OIL PIPE ASSY.

OIL PIPE ASSY.

PAGE 101 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

1 9133119810 OIL PUMP ASSY. 1

2 5133111141 ROCKER OIL FEED PIPE 1

3 9099061051 BOLT 1

4 9099209000 PACKING 2

9 5133111740 OIL INJECTION PIPE 1

10 5096750220 ADAPTER 1

11 9095720080 PACKING 2

13 901906120 BOLT 1

ISUZU C240 --- OIL PIPE ASSY.

OIL PIPE ASSY.

PAGE 102 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- WATER PUMP AND FAN ASSY.

WATER PUMP AND FAN ASSY.

PAGE 103 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

1 5136101673 WATER PUMP ASSY. ................... 1 ............ INCL. ITEMS W/*

3*5878101391 WATER PUMP REPAIR KIT .......... 1 ............ INCL. ITEMS W.#

6*# 5136310080 BEARING UNIT 1

7*# 9136210760 IMPELLER 1

8*# 9136136070 PACKING 1

9*# 8942366870 SEAL UNIT ASSY. 1

10*# 5096050050 SCREW HEATER PLUG 1

11*# 5098140010 SCREW 1

12*# 9091505080 LOCK WASHER 1

13*# 5136420640 FAN CENTER 1

16*# 9136120530 WATER PUMP COVER 1

18*# 9030408160 SCREW 1

24*# 9136390010 BRIDGE UNIT THROWER 1

31 9136140430 PACKING 1

33 5090000890 BOLT 2

33-1 5090000880 BOLT 4

41 5136750390 ADJUSTING FAN BELT PLATE 1

50 9136416160 FAN PULLEY 1

51 9136420770 FAN SPACER 1

54 9136608090 FAN ASSY. 1

59 9019108450 BOLT 4

64 5136710400 COOLING FAN BELT 1

71 9137130380 OUTLET PIPE 1

72 5137700221 THERMOSTAT 1

73 5096050050 HEATER PLUG 1

76 5096370130 PACKING 1

77 9019708300 BOLT 2

78 9099168190 CLIP 1

90 9137168042 THERMOSTAT HOUSING 1

91 5137430050 HOUSING PACKING 1

92 9019708200 BOLT 2

92 9019108220 BOLT 2

93 9137211322 RUBBER BYPASS HOSE 1

94 9099156441 HOSE CLIP 2

ISUZU C240 --- WATER PUMP AND FAN ASSY.

WATER PUMP AND FAN ASSY.

PAGE 104 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

INTAKE AND EXHAUST MAINIFOLD ASSY.

ISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY.

PAGE 105 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

INTAKE AND EXHAUST MANIFOLD ASSY.

ISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY.

1 9141126954 INLET MANIFOLD 1

3 9041108500 INTAKE STUD 2

20 9141416142 EXHAUST MANIFOLD 1

21 5093020020 EXHAUST STUD 1

30 5141111290 INLET PIPE 2

46 5141460180 GASKET 1

48 9091646080 PLAIN WASHER 7

49 9091505080 LOCK WASHER 7

51 9091104080 NUT 7

52 5090000870 BOLT 2

66 5143101961 INTAKE SHUTTER ASSY. 1

76 5096370150 THROTTLE VALVE PACKING 3

77 9091104080 NUT 3

78 9091505080 LOCK WASHER 2

83 5093600530 HOSE 1

97 5143340780 WIRE CONTROL BRACKET 1

PAGE 106 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

AIR CLEANER ASSY.

ISUZU C240 --- AIR CLEANER ASSY.

PAGE 107 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

AIR CLEANER ASSY.

ISUZU C240 --- AIR CLEANER ASSY.

NO. PART NO.ITEM QTY.REMARKS

3 5142102130 AIR CLEANER ASSY. ................... 1 ............ INCL. ITEMS W/*

5*5142150140 ELEMENT 1

27*5142110670 COVER 1

38*9142191410 INDICATOR 1

59*5142120560 DUST W/BAFFLE PAN 1

76*5142170040 CLAMP 1

81*9142170620 BOLT W/GASKET WASHER ......... 1 ............ INCL. ITEMS W/#

82*# 9142191770 GASKET WASHER 3

200 9142176020 BAND ASSY. W/BOLT 2

PAGE 108 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- ENGINE FOOT ASSY.

ENGINE FOOT ASSY.

PAGE 109 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- ENGINE FOOT ASSY.

ENGINE FOOT ASSY.

1 9117712070 ENGINE FOOT, RIGHT SIDE 1

1-1 5117710501 ENGINE FOOT, LEFT SIDE 1

6 9029510250 FOOT BOLT, RIGHT SIDE 4

6-1 9029510250 BOLT FOOT, LEFT SIDE 1

6-2 9029560400 BOLT FOOT, LEFT SIDE 3

8 9098518660 PLAIN WASHER 8

11 5197110010 ALTERNATOR BRACKET 1

30 9091505080 LOCK WASHER 1

31 9091114080 NUT 1

32 9091605120 PLAIN WASHER 1

33 9829315110 CABLE ASSY. 1

34 9019312450 BOLT 2

36 9010558320 BOLT 2

37 9019108400 BOLT 1

38 9091647080 PLAIN WASHER 1

39 9091505080 LOCK WASHER 2

40 9091605080 PLAIN WASHER 2

41 9117770750 FRONT LIFTING HANGER 1

41-1 9117771360 REAR LIFTING HANGER 1

42 9141491730 REAR HANGER PIECE 2

43 9091105080 NUT 2

44 5197190060 ALTERNATOR FAN COVER 1

46 9091104080 NUT 1

47 9091505080 LOCK WASHER 1

51 5113190570 FRONT PLATE PACKING 1

52 8942059870 BOLT 2

52-1 9019108320 BOLT 4

PAGE 110 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- INJECTION PUMP ASSY.

INJECTION PUMP ASSY.

PAGE 111 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- INJECTION PUMP ASSY.

INJECTION PUMP ASSY.

5 8943864440 INJECTION PUMP ASSY. .................... 1 ..................... REPLACES 5156010252

INCL. ITEMS W/*

15*5157201400 GOVERNOR ASSY. 1

20*8941415340 FEED PUMP ASSY. 1

35*5157400720 AUTOMATIC TIMER 1

38*9197510790 INJ. PUMP SPACER BRACKET 1

40*9099205760 O RING PACKING 1

42*5125240660 INJ. PUMP GEAR 1

PAGE 112 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- ELECTRICAL PARTS

ELECTRICAL PARTS

PAGE 113 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- ELECTRICAL PARTS

ELECTRICAL PARTS

1 5811000801 STARTER 1

2 5812003410 ALTERNATOR .................................... 1 ......................... UP TO OCT. 1992

9822007640 ALTERNATOR .................................... 1 ......................... OCT. 1992~

4 9822531070 REGULATOR 1

8 9829317430 CABLE ASSY. 1

12 9825119780 GLOW PLUG 4

14 9825301090 CONTROL 1

19 9829513240 INSULATOR CAP 2

20 9829513250 INSULATOR CAP 2

21 9829513320 CABLE CAP 1

23 9197326100 CONNECTOR 1

30 5824500140 SWITCH 1

34 5825500190 EMERGENCY RELAY 1

36 1823100080 STARTER SWITCH 1

38-1 1823170070 KEY 1

50 9091114080 NUT 1

51 9091505080 LOCK WASHER 1

PAGE 114 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- ACCESSORIES

ACCESSORIES

PAGE 115 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- ACCESSORIES

ACCESSORIES

50 5193100060 DRIVE ASSY. ....................................... 1 ..................... INCL. ITEMS W/*

51*9193110240 CASE 1

52*9193110200 COVER 1

53*9193120060 PACKING 1

54*9193160270 GEAR 1

56*9193160170 GEAR 1

58*9019006160 BOLT 4

59*9090310100 NIPPLE 1

61*9099243550 OIL SEAL 1

66 9019008220 BOLT 2

67 9099211070 PACKING 1

91 5819000020 STOPPER ASSY. 1

91-1 5828480360 CABLE ASSY. 1

PAGE 116 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 ---INJECTION PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

PAGE 117 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- INJECTION PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

5 5156110460 HOUSING ASSY. .................................. 1 ..................... INCL. ITEMS W/*

15*9812151150 STUD 3

16*9812350170 ADAPTER 1

18*1156190240 BOLT 2

20*1156390080 GASKET 1

21*1156390080 GASKET 1

22*5156120080 COVER 1

23*1156190030 SCREW 2

24*9812151440 GASKET 2

27*9091505060 LOCK WASHER 3

28*9091104060 NUT 3

29*1096230130 PACKING 1

31*5156310090 PLUNGER ASSY. 4

32*9812411030 DELIVERY VALVE 4

34*5156430020 DELIVERY VALVE SPRING 4

35*9812450140 GASKET 4

36*5156440050 HOLDER 4

40*5156490160 PLATE ASSY. 2

43*9812212230 TAPPET ASSY. ..................................... 4 ..................... INCL. ITEMS W/#

45*# 9812212200 PIN TAPPET 4

47*# 1156220030 TAPPET ROLLER 4

48*# 1156290010 TAPPET BUSHING 4

49*# 5156190410 TAPPET GUIDE 4

55*5156190340 TAPPET SHIM .................................. A/R ..................... T=0.30

55-1*5156190350 TAPPET SHIM .................................. A/R ..................... T=0.40

55-2*5156190360 TAPPET SHIM .................................. A/R ..................... T=0.50

55-3*5156190010 TAPPET SHIM .................................. A/R ..................... T=0.60

55-4*5156190020 TAPPET SHIM .................................. A/R ..................... T=0.70

55-5*5156190030 TAPPET SHIM .................................. A/R ..................... T=0.80

55-6*5156190040 TAPPET SHIM .................................. A/R ..................... T=0.90

55-7*5156190050 TAPPET SHIM .................................. A/R ..................... T=1.00

55-8*5156190070 TAPPET SHIM .................................. A/R ..................... T=1.10

55-9*5156190080 TAPPET SHIM .................................. A/R ..................... T=1.20

55-10*5156190090 TAPPET SHIM .................................. A/R ..................... T=1.30

55-11*5156190100 TAPPET SHIM .................................. A/R ..................... T=1.40

55-12*5156190110 TAPPET SHIM .................................. A/R ..................... T=0.55

55-13*5156190120 TAPPET SHIM .................................. A/R ..................... T=0.65

55-14*5156190130 TAPPET SHIM .................................. A/R ..................... T=0.75

55-15*5156190150 TAPPET SHIM .................................. A/R ..................... T=0.85

55-16*9812350420 TAPPET SHIM .................................. A/R ..................... T=0.95

55-17*9812350430 TAPPET SHIM .................................. A/R ..................... T=1.05

55-18*9812350440 TAPPET SHIM .................................. A/R ..................... T=1.15

55-19*9812350450 TAPPET SHIM .................................. A/R ..................... T=1.25

55-20*5156190250 TAPPET SHIM .................................. A/R ..................... T=0.25

PAGE 118 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- INJECTION PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

PAGE 119 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- INJECTION PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

55-21*5156190260 TAPPET SHIM ................................ A/R ....................... T=0.26

55-22*5156190270 TAPPET SHIM ................................ A/R ....................... T=0.35

55-23*5156190370 TAPPET SHIM ................................ A/R ....................... T=0.45

55-24*5156191060 TAPPET SHIM ................................ A/R ....................... T=1.50

55-25*5156191070 TAPPET SHIM ................................ A/R ....................... T=1.60

55-26*5156191080 TAPPET SHIM ................................ A/R ....................... T=1.35

55-27*5156191090 TAPPET SHIM ................................ A/R ....................... T=1.45

55-28*5156191100 TAPPET SHIM ................................ A/R ....................... T=1.55

57*9812314070 PLUNGER SPRING 4

58*9812350150 PLUNGER SEAT 4

59*9812350210 PLUNGER SEAT 4

60*9812250580 SLEEVE 4

61*9812250570 PINION 4

62*9812350030 SCREW 4

66*5156370020 CONTROL RACK 1

67*1156390030 SCREW 1

75*5156210170 CAM SHAFT 1

73*9812232010 BALL BEARING, CAMSHAFT 1

76-2*9000906770 BALL BEARING, CAMSHAFT 1

77*9812232010 BALL BEARING, GOV. SIDE 1

77-2*9000906770 BALL BEARING, GOV. SIDE 1

82*9812250470 CAMSHAFT RING 1

83*9812250470 CAM RING, GOV. SIDE 1

84*5156290150 CAMSHAFT SHIM .......................... A/R ....................... T=0.10

84-1*5156290160 CAMSHAFT SHIM .......................... A/R ....................... T=0.12

84-2*5156290170 CAMSHAFT SHIM .......................... A/R ....................... T=0.14

84-3*5156290180 CAMSHAFT SHIM .......................... A/R ....................... T=0.16

84-4*5156290190 CAMSHAFT SHIM .......................... A/R ....................... T=0.18

84-5*5156290200 CAMSHAFT SHIM .......................... A/R ....................... T=0.50

84-6*5156190380 CAMSHAFT SHIM .......................... A/R ....................... T=1.00

84-7*5156290210 CAMSHAFT SHIM .......................... A/R ....................... T=0.30

84-8*5156190390 CAMSHAFT SHIM .......................... A/R ....................... T=0.70

84-9*1156190900 CAMSHAFT SHIM .......................... A/R ....................... T=1.40

85*5156290150 CAMSHAFT SHIM .......................... A/R ....................... T=0.10

85-1*5156290160 CAMSHAFT SHIM .......................... A/R ....................... T=0.30

85-2*5156290170 CAMSHAFT SHIM .......................... A/R ....................... T=0.14

85-3*5156290180 CAMSHAFT SHIM .......................... A/R ....................... T=0.16

85-4*5156290190 CAMSHAFT SHIM .......................... A/R ....................... T=0.18

85-5*5156290200 CAMSHAFT SHIM .......................... A/R ....................... T=0.50

85-6*5156190380 CAMSHAFT SHIM .......................... A/R ....................... T=1.00

85-7*5156290210 CAMSHAFT SHIM .......................... A/R ....................... T=0.30

85-8*5156190390 CAMSHAFT SHIM .......................... A/R ....................... T=0.70

85-9*1156190900 CAMSHAFT SHIM .......................... A/R ....................... T=1.40

93*5156290050 HOUSING COVER 1

95*9019006140 BOLT 4

PAGE 120 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- INJECTION PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

PAGE 121 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- INJECTION PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

108*9812214110 KEY 1

111*1156190820 BOLT 1

113*1157590010 PACKING 2

137*9097060370 BOLT 1

138*1096350070 PACKING 2

150*9812150780 TAPPET PLUG 4

162*9091606100 PLAIN WASHER 4

163*9091505100 LOCK WASHER 4

164*5156390020 NUT 4

180*9197510790 BRACKET 1

181*9099205760 O RING PACKING 1

PAGE 122 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 ---GOVERNOR COMP. ASSY.

GOVERNOR COMP. ASSY.

PAGE 123 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- GOVERNOR COMP. ASSY.

COVERNOR COMP. ASSY.

5 1157210040 HOUSING ............................................. 1 ..................... INCL. ITEMS W/*

12*1157290150 O RING PACKING 1

13*9813150650 ADAPTER 1

14*9019008180 BOLT 1

15*9813253970 HOUSING PLATE 1

16*901906140 BOLT 6

18*5157291230 SCREW 1

19*9813252370 NUT 2

20*1157290380 HOUSING PLUG 1

26*9813251820 SCREW 1

27*9813261120 NUT 1

30*5157210080 COVER 1

32*5157290530 PLUG 2

34*5157290540 BOLT 2

35*5157290330 BOLT 2

36*5157291230 SCREW 1

40*9813211860 COVER 1

42*9813919070 O RING PACKING 1

43*5157290630 BOLT 2

44*9019006160 BOLT 2

47*9812350340 CAP 1

50*9813213230 FLYWEIGHT ASSY. 1

52*5156190490 KEY 1

53*5157290340 LOCK WASHER 1

54*9813250860 NUT 1

57*5157190080 SLEEVE ................................................ 1 ..................... INCL. ITEM W/#

58*# 9000902290 BEARING 1

60*9813250880 SHIM ................................................. A/R ..................... T=0.20

60-1*9813255510 SHIM ................................................. A/R ..................... T=0.30

60-2*9813255520 SHIM ................................................. A/R ..................... T=0.40

60-3*9813255530 SHIM ................................................. A/R ..................... T=1.00

63*9813222100 GOVERNOR SPRING 1

64*5157230820 LINK SPRING 1

67*1157230200 CAPSULE SPRING 1

68*9813932040 NUT 1

69*1156390080 GASKET 2

73*9813216360 CAPSULE SPRING 1

74*9008130230 NUT 1

77*9813217210 LEVER 1

80*9813250990 BUSHING 2

81*9813212050 O RING PACKING 2

82*9091854150 SNAP RING 2

PAGE 124 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- GOVERNOR COMP. ASSY.

GOVERNOR COMP. ASSY.

PAGE 125 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- GOVERNOR COMP. ASSY.

GOVERNOR COMP. ASSY.

83* 9813212200 OIL SEAL 1

84* 9813251730 SHIM ..................................................... 1 ..................... T=0.50

85* 9813250970 SHIM ................................................. A/R ..................... T=0.30

86* 9813253180 PLUG 1

88* 9813250300 KEY 1

89* 9813913070 COLLAR 1

90* 9813254880 WASHER A/R

93* 5157250160 GUIDE LEVER ASSY. 1

100* 9813217130 LINK 1

101* 1157290230 SNAP RING 1

102* 5157250170 TENSION LEVER 1

103* 9813250620 PIN 1

104* 5157250490 LEVER 1

116* 1157290010 GASKET 1

117* 1157290020 GASKET 1

148* 5157291120 BOLT 1

150* 5157230880 SPRING 1

PAGE 126 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- FEED PUMP COMP. ASSY.

FEED PUMP COMP. ASSY.

PAGE 127 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- FEED PUMP COMP. ASSY.

FEED PUMP COMP. ASSY.

5 5157510120 HOUSING ........................................... 1 ....................... INCL. ITEMS W/*

9* 9813512050 PISTON 1

10* 9813513030 SPRING 1

11* 9813550230 PLUG 1

12* 9813550350 GASKET 1

15* 5157540010 TAPPET ASSY. ................................... 1 ....................... INCL. ITEMS W/*

16*# 9813514030 ROLLER 1

17*# 9813514100 PIN 1

18*# 1157590020 GUIDE 2

26* 9813516020 CHECK VALVE 2

27* 1096230160 GASKET 1

28* 9813517020 SPRING 2

31* 9099063260 BOLT 1

32* 1156190820 BOLT 1

33* 1157590010 PACKING 4

35* 1157590030 ADAPTER 1

40* 1096230160 PACKING 1

42* 9813550250 RING 1

44* 9813521040 PUMP ................................................. 1 ....................... REPLACES 5157610050

45* 9813550330 COVER 1

PAGE 128 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- AUTO TIMER COMP. ASSY.

AUTO TIMER COMP. ASSY.

PAGE 129 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- AUTO TIMER COMP. ASSY.

AUTO TIMER COMP. ASSY.

5 9813435050 FLYWEIGHT .................................. 2.............................. INCL. ITEMS W/*

6* 9813450430 SHIM A/R

6-1* 9813450440 SHIM A/R

6-2* 9813450450 SHIM A/R

6-3* 5157490090 SHIM A/R

6-4* 5157490100 SHIM A/R

6-5* 5157490110 SHIM A/R

6-6* 5157490680 SHIM A/R

6-7* 5157490690 SHIM A/R

6-8* 5157490700 SHIM A/R

6-9* 5157490710 SHIM A/R

7* 9813450720 TIMER SPRING 2

11* 9813453380 WASHER 1

12* 9813453250 SHIM A/R

12-1* 9813453260 SHIM A/R

12-2* 9813453400 SHIM A/R

12-3* 9813453270 SHIM A/R

12-4* 9813453280 SHIM A/R

12-5* 9813453290 SHIM A/R

12-6* 9813453300 SHIM A/R

12-7* 9813453310 SHIM A/R

12-8* 9813453320 SHIM A/R

13* 5157490070 WASHER 1

14* 9813450520 PLATE 1

15* 9813453060 NUT 1

17* 5125240660 GEAR 1

20-1* 5156190480 LOCK WASHER 1

21* 1156190010 NUT 1

26* 5157490080 BOLT 6

27* 9813433050 FLANGE 1

28* 5157490280 HOLDER 1

PAGE 130 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- NOZZLE HOLDER COMP. ASSY.

NOZZLE HOLDER COMP. ASSY.

PAGE 131 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- NOZZLE HOLDER COMP. ASSY.

NOZZLE HOLDER COMP. ASSY.

5 5153410020 PUSH ROD ......................................... 4 ....................... INCL. ITEMS W/*

7* 5153430020 SPRING 4

9* 9153396010 SCREW 4

11* 5153340030 NUT 4

12* 9153390560 GASKET 4

13* 9153390570 WASHER 4

21* 9153326030 NUT 4

22* 9153520050 GASKET 4

23* 9153510070 CONNECTOR 4

31* 5153490010 BOLT 4

32* 9095714080 GASKET 8

38* 9153596010 SCREW 4

PAGE 132 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 ---STARTER COMP. ASSY.

STARTER COMP. ASSY.

PAGE 133 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- STARTER COMP. ASSY.

STARTER COMP. ASSY.

6 5811210160 ARMATURE ASSY. .................................... 1 ................ INCL. ITEMS W/*

13* 5811291050 PINION STOPPER 1

14* 5811290030 WASHER SET 1

22* 5811120100 FIELD COIL ASSY. .................................... 1 ................ INCL. ITEM W/>

25*> 5811160480 BRUSH, + 1

30* 5811150130 REAR COVER ASSY. ................................ 1 ................ INCL. ITEM W/%

32*% 5811190120 REAR METAL 1

33* 5811160180 BRUSH HOLDER ....................................... 1 ................ INCL. ITEMS W/@

35*@ 5811170060 BRUSH SPRING 4

37*@ 5811160490 BRUSH, - 2

50* 5811190130 BRACKET ASSY. ...................................... 1 ................ INCL. ITEM W/&

52*& 9821121340 CENTER METAL 1

55* 5811230070 CLUTCH ASSY. 1

65* 5811130170 GEAR CASE ASSY. .................................. 1 ................ INCL. ITEM W/#

66*# 5811190260 FRONT METAL 1

67* 5811290680 DUST COVER 1

75* 5811270130 SHIFT LEVER ASSY. 1

80* 5811510290 MAGNETIC SWITCH ASSY. 1

85* 5811290710 BOLT 2

86* 5811290730 WASHER 2

PAGE 134 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 --- ALTERNATOR COMP. ASSY.

ALTERNATOR COMP. ASSY. (OCT. 1992~)

PAGE 135 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- ALTERNATOR COMP. ASSY.

ALTERNATOR COMP. ASSY. (OCT. 1992~)

3 5812210630 ROTOR ASSY. ........................................................ 1 ..... INCL. ITEMS W/* AND W/>

4*> 9000901810 BALL BEARING 1

5* 5812110580 STRATOR ASSY. 1

7* 5812141310 REAR COVER ASSY. ............................................1 ..... INCL. ITEMS W/#

8*# 5812141320 REAR COVER 1

9*# 5812190360 BRUSH REGULATOR .............................................1 ..... INCL. ITEMS W/%

10*#% 5812150460 BRUSH ASSY. 1

11*#% 5812291660 BOLT 2

12*#% 5812150400 BRUSH 2

13*#% 5812700040 REGULATOR ASSY. 1

14*# 5812620050 RECTIFIER 1

17* 5812130430 FRONT COVER ASSY. .......................................... 1 ..... INCL. ITEMS W/&

18*& 5812290290 RETAINER 1

19*& 5098000870 BALL BEARING 1

22*& 5812291650 SCREW KIT 1

23* 5812220760 PULLEY ASSY. 1

24* 9822350150 NUT 1

26* 5812291820 BOLT 2

27* 5812291830 BOLT 1

PAGE 136 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

ISUZU C240 ---ALTERNATOR COMP. ASSY.

ALTERNATOR COMP. ASSY. (BEFORE OCT. 1992)

PAGE 137 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NO. PART NO.ITEM QTY.REMARKS

ISUZU C240 --- ALTERNATOR COMP. ASSY.

ALTERNATOR COMP. ASSY. (BEFORE OCT. 1992)

5 5812210100 ROTOR ASSY. ....................................................... 1 ..... INCL. ITEMS W/*

8* 9000901810 BALL BEARING 1

18* 9822250270 KEY 1

20* 5812110090 STRATOR ASSY. 1

25* 5812140010 COVER ASSY. .......................................................1 ..... INCL. ITEMS W/#

27*# 9822316190 RECTIFIER ASSY. 1

30*# 5812150010 HOLDER ASSY. 1

33*# 9822316170 BRUSH 1

34*# 9822316180 BRUSH 1

35*# 9822350700 BOLT ASSY. 1

39*# 9822319040 RECTIFIER COVER 1

50* 9822313080 FRONT COVER ASSY. .......................................... 1 ..... INCL. ITEMS W/&

52*& 9822158230 PACKING 1

53*& 9822158240 RETAINER 1

54*& 9822159170 RETAINER BRIDGE 1

55*& 9000901820 FRONT BALL BEARING 1

75* 5812220140 PULLEY ASSY. 1

80* 9822350740 NUT 1

90* 9822350720 BOLT ...................................................................... 2 ..... L=85

91* 9822350730 BOLT ...................................................................... 2 ..... L=95

PAGE 138 — DCA-25SSI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or

prepaid with the charges added to the invoice.

All shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a

signed manifest has been obtained from the

carrier, and any claim for shortage or damage

must be settled between the consignee and the

carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip

is $15.00 net. Customers will be asked for

instructions regarding handling of orders not

meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit

will be allowed, subject to the following

provisions:

1. A Returned Material Authorization must

be approved by Multiquip prior to shipment.

2. To obtain a Return Material Authorization,

a list must be provided to Multiquip Parts

Sales that defines item numbers,

quantities, and descriptions of the items

to be returned.

a. The parts numbers and descriptions

must match the current parts price

list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which

the items were originally purchased.

e. The list must include the name and

phone number of the person

requesting the RMA.

3. A copy of the Return Material

Authorization must accompany the return

shipment.

PRICING AND REBATES

Prices are subject to change without prior

notice. Price changes are effective on a specific

date and all orders received on or after that date

will be billed at the revised price. 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.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $20.00 to $50.00 surcharge will be added to

the invoice for special handling including bus

shipments, insured parcel post or in cases

where Multiquip must personally deliver the

parts to the carrier.

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, and in no event shall Multiquip be

liable for loss of profit or good will or for any

other special, consequential or incidental

damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made

in connection with the sale of parts or trade

accessories nor as to any engine not

manufactured by Multiquip. Such warranties

made in connection with the sale of new,

complete units are made exclusively by a

statement of warranty packaged with such

units, 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. A part

from such written statement of warranty, there

are no warranties, express, implied or statutory,

which extend beyond the description of the

products on the face hereof.

4. Freight is at the sender’s expense. All

parts must be returned freight prepaid to

Multiquip’s designated receiving point.

5. Parts must be in new and resalable

condition, in the original Multiquip package

(if any), and with Muiltiquip part numbers

clearly marked.

6. The following items are not returnable:

a. Obsolete parts. (If an item is listed

in the parts price book as being

replaced by another item, it is

obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings,

and other rubber parts) that were

purchased more than six months

prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7. The sender will be notified of any material

received that is not acceptable.

8. Such material will be held for 5 working

days from notification, pending

instructions. If a reply is not received

within 5 days, the material will be returned

to the sender at his expense.

9. Credit on returned parts will be issued at

dealer net price at time of the original

purchase, less a 15% restocking charge.

10. In cases where an item is accepted for

which the original purchase document

can not be determined, the price will be

based on the list price that was effective

twelve months prior to the RMA date.

11. Credit issued will be applied to future

purchases only.

Effective: July 1, 2000 TERMS AND CONDITIONS OF SALE — PART S

PAGE 139 — DCA-25SSI — PARTS AND OPERATION MANUAL—FINAL COPY(06/29/01)

NOTE PAGE

PARTS AND OPERATION MANUAL

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

SERVICE DEPARTMENT:

800-421-1244 800-835-2551

FAX: 310-537-3927 FAX: 310-638-8046

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

PARTS AND OPERATION MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HAND WHEN CALLING

PARAR

ARAR

ARTS DEPTS DEP

TS DEPTS DEP

TS DEP

ARAR

ARTMENTTMENT

TMENTTMENT

TMENT

800/427-1244 or 310/537-3700

FAX: 800/672-7877 or 310/637-3284

SERSER

SERVICE DEPVICE DEP

VICE DEPVICE DEP

VICE DEPARAR

ARAR

ARTMENTTMENT

TMENTTMENT

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

WARRANTY DEPARRANTY DEP

ARRANTY DEPARRANTY DEP

ARRANTY DEPARAR

ARAR

ARTMENTTMENT

TMENTTMENT

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

MAINMAIN

MAIN

800/421-1244 or 310/537-3700

FAX: 310/537-3927

Multiquip Mq Power Whisperwatt Generator Dca 25Ssi Users Manual

MQ Power Whisperwatt Generator DCA-25SSI Generators_portable_supersilent_DCA25SSI_rev_0__manual_DataId_19042_Version_1

DCA-25SSI to the manual 5c6fd9ea-9ac9-4f92-9b96-f49fb99db5a4

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