Multiquip Mq Power Whisperwatt Generator Dca 60Ss12 Users Manual

DCA-60SS12 to the manual 792cbb98-6d46-4486-b42c-8ab0775adb2e

2015-02-09

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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-60SSI2

WHISPERWATT

GENERATOR

PARTS LIST NO. 8081500G

REV. #3 (09/15/01)

PAGE 2 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 3

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-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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 .......................................... 11-17

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

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

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

Operation Decals ..................................................... 21-22

DCA -60SSI2 Specifications ................................... 23

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

Major Components .................................................. 55

Dimensions .............................................................. 26

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

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

Output Terminal Panel Descriptions ......................... 32-33

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

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

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

Pre Set-up ............................................................... 42-45

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

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

Generator Shut-down Procedure .............................. 50

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

Generator Wiring Diagram ........................................ 56

Engine Wiring Diagram ............................................ 57

Engine Troubleshooting ............................................ 58-59

Generator/Engine Troubleshooting ........................... 60

Explanation of Codes in Remarks Column .............. 62

Suggested Spare Parts ........................................... 63

MQ POWER DCA-60SSI2

AC GENERATOR

Generator Assembly ................................................ 64-65

Control Box Assembly ............................................. 66-67

Engine & Radiator Assembly................................... 68-71

Engine Operating Panel Assembly .......................... 72-75

Battery Assembly .................................................... 76-77

Muffler Assembly .................................................... 78-79

Fuel Tank Assembly ................................................ 80-81

Enclosure Assembly ............................................... 82-85

Rubber Seal Assembly ............................................ 86-87

Name Plate And Decals .......................................... 88-89

ISUZU 6BG1 ENGINE

Cylinder Head Cover Assembly ............................ 90-91

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

Cylinder Block Assembly ..................................... 94-97

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

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

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

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

Inlet Manifold Assembly ....................................... 106-107

Exhaust Manifold Assembly ................................. 108-109

Ventilation Assembly ............................................ 110-111

Water Pump and Corrosion Resistor Assembly .... 112-113

Thermostat and Housing Assembly ..................... 114-115

Engine Water Piping Assembly ............................. 116-117

Fan and Fan Belt Assembly ................................. 118-119

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

Fuel Filter and Bracket Assembly ........................ 122-123

Fuel Pump and Pipe Assembly ............................ 124-125

Oil Cooler and Oil Filter Assembly ....................... 126-127

Oil Pump and Oil Strainer Assembly .................... 128-129

Oil and Vacuum Piping Assembly ........................ 130-131

Electrical Control Assembly ................................. 132-133

Starter Components Assembly ............................ 134-135

Alternator Components Assembly ........................ 136-137

Injection Pump Components Assembly ............... 138-141

Governor Components Assembly ......................... 142-145

Feed Pump Assembly .......................................... 146-147

Misc. Injection Pump Assembly ........................... 148-149

Coupling Assembly............................................... 150-151

Water Sedimenter Assembly ................................ 152-153

Switch and Relay Assembly ................................. 154-155

Terms and Condition of Sale — Parts .................. 156

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..

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 5

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-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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-60SSI2 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:

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 7

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-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 9

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-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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-60SSI2 — 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

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 11

Explanation of Chart:

This section is to provide the user with trailer service and

maintenance information. The service and maintenance

guidelines referenced in this section apply a wide range of

trailers. Remember periodic inspection of the trailer will en-

sure safe towing of the equipment and will prevent damage

to the equipment and personal injury.

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

nance components of the trailer. The following trailer com-

ponents will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions with reading Table 1.

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

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

DCA-60SSIU — TRAILER-SAFETY GUIDELINES

4. Frame Length - This measurement is from the ball

hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to

fender.

6. Jack Stand - Trailer support device with maximum

pound requirement from the tongue of the trailer.

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

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

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

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

diameter of the tire rim.

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

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

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

axle.

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

match the size of the tire.

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

Always use a torque wrench to tighten down the lug

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

sequence.

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

port in pounds, and the diameter of the axle expressed

in inches (see Table 3). Please not that some trailers

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

meaning two axles with a total weight capacity of 6000

pounds.

14. Suspension - Protects the trailer chassis from shocks

transmitted through the wheels. Types of suspension

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

15. Electrical - Electrical connectors (looms) are provided

with the trailer so the brake lights and turn signals can

be connected to the towing vehicle.

16. Application - Indicates which units can be employed

on a particular trailer.

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-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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DCA-60SSIU —TRAILER-SPECIFICATIONS

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 13

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DCA-60SSIU —TRAILER-SPECIFICATIONS

PAGE 14 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSIU —TRAILER SAFETY GUIDELINES

Brakes

If your trailer has a braking system, the brakes should be

inspected the first 200 miles of operation. This will allow

the brake shoes and drums to seat properly. After the first

200 mile interval, inspect the brakes every 3,000 miles. If

driving over rough terrain, inspect the brakes more

frequently.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to

hydraulic brakes. The basic difference is that hydraulic

brakes are actuated by an electromagnet.

Listed below are some of the advantages that electric

brakes have over hydraulic brakes:



Brake system can be manually adjusted to provide

the corrected braking capability for varying road and

load conditions



Brake system can be modulated to provide more or

less braking force, thus easing the brake load on the

towing vehicle



Brake system has very little lag time between the time

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

are actuated



Brake system can provide an independent emergency

brake system

Remember in order to properly synchronize the tow vehicle’s

braking to the trailer’s braking, can only be accomplished

by road testing. Brake lockup, grabbiness or harshness is

due to lack of synchronization between the tow vehicle

and the trailer being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be

made, the trailer brakes should be burnished-in by applying

the brakes 20-30 times with approximately a 20 m.p.h.

decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample

time for brakes to cool between application. This allows

the brake shoes to slightly be seated into the brake drum

surface.

Figure 2 displays the major electric brake components that

will require inspection and maintenance. Please inspect

these components as required.

Electric Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack

stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting

slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate

the star wheel of the adjuster assembly to expand the

brake shoes.

5. Adjust the brake shoes outward until the pressure of

the lining against the wheel drum makes the wheel

difficult to turn.

6. Rotate the star wheel in the opposite direction until the

wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer

to the ground.

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

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 15

DCA-60SSIU — TRAILER SAFETY GUIDELINES

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special

attention with the exception of routine maintenance such

as shoe and lining replacement. These brakes can be

adjusted in the same manner as electric brakes. Brake

lines should be periodically checked for cracks, kinks, or

blockage.

Figure 3 below displays the major hydraulic/air/surge brake

components that will require inspection and maintenance.

Please inspect these components as required using steps

1 through 6 as referenced in the electric brake adjustments

section.

Figure 2. Electrical Brake Components

Figure 3. Hydraulic Brake Components

PAGE 16 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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 4) should be visually inspected every 6,000 miles for

signs of excessive wear, elongation of bolt holes, and

loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components

as detailed in Table 3.

DCA-60SSIU — TRAILER SAFETY GUIDELINES

Figure 4. Major Suspension Components

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 17

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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 5. DO NOT

torque the wheel lug nuts all the way down. Tighten

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

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

Check all wheel lug nuts periodically.

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-60SSIU —TRAILER SAFETY GUIDELINES

Figure 5. Wheel Lug Nuts Tightening Sequence

PAGE 18 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

NOTE:

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

DCA-60SSIU —TRAILER-WIRING DIAGRAM

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 19

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DCA-60SSIU —TRAILER-BRAKE TROUBLESHOOTING

PAGE 20 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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DCA-60SSIU —TRAILER-BRAKE TROUBLESHOOTING

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 21

DCA-60SSI2 — GENERATOR DECALS

The DCA -100SSJU generator is wquipped 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 22 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 — GENERATOR DECALS

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 23

DCA-60SSI2 — SPECIFICATIONS

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PAGE 24 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 — GENERAL INFORMATION

DCA-60SSI2 FAMILIARIZATION

Generator

The MQ Power Model DCA-60SSI2 is a 48 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

Engine Throttle Lever

Panel Light

Panel Light Switch

Oil Pressure and WaterTemp. Indicator lights

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 150 amps

Over-Current Relay

Engine

The DCA-60SSI2 is powered by a 4 cycle, water cooled,

Isuzu A-6BG1

diesel diesel

diesel

engine. This engine is designed to

meet every performance requirement for the generator.

Reference Table 1, page13 for engine specifications.

In keeping with Multiquip's policy of constantly improving

its products, the specifications quoted herein are subject to

change without prior notice.

The basic controls and indicators for the DCA-60SSI2

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-60SSI2 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.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 25

DCA-60SSI2 — MAJOR COMPONENTS

Figure 6. Major Components

PAGE 26 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 7. Dimensions

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 27

NOTE PAGE

PAGE 28 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 — CONTROL PANEL

Figure 8. Control Panel

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 29

DCA-60SSI2 — CONTROL PANEL

The definitions below describe the controls and functions of

the DCA-60SSI2 "

Control Panel Control Panel

Control Panel

" (Figure 8).

1. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz ±1 Hz .

2. AC Ammeter – Indicates the amount of current the

load is drawing from the generator.

3. ACVoltmeter – Indicates the single phase output

voltage present at the UNV terminals.

4. Pilot Lamp - This lamp indicates the load is not properly

set. Readjust the load, or use the voltmeter change-

over switch to adjust phase position.

5. Main Circuit Breaker – This three-pole, 150 amp main

breaker is provided to protect the UNV voltage output

terminals from overload.

6. 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.

7. 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.

8. Voltage Regulator Control – Allows manual

adjustment of the generator’s output voltage.

PAGE 30 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 — ENGINE OPERATING PANEL

Figure 9. Engine Operating Panel

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 31

The definitions below describe the controls and functions of

the DCA-60SSI2 "

Engine Operating Panel Engine Operating Panel

Engine Operating Panel

" (Figure 9).

1. Oil Pressure Gauge – Normal operation should be about

25 psi. When starting the generator the oil pressure

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

the oil pressure should return to normal.

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

When activated, panel will luminate. When the generator

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

position.

3. Water Temperature Gauge – During normal operation

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

DCA-60SSI2 — ENGINE OPERATING PANEL

4. Charging Ammeter Gauge – Indicates the current

being supplied by the engine’s alternator which provides

current for generator’s control circuits and battery

charging system.

5. Indicator Lights - These lights indicate if the oil

pressure or water temperature is at dangerous levels

and will shut off the engine. The oil pressure indicator

will initially light at start-up, but will go off once the

pressure rises.

6. Panel light switch- When activiated, will turn on control

panel light.

7. Lamp Check Switch - This is used to check the

indicator lights. Turn on the engine, then press this to

check the bulbs. If they don’t light, replace the bulbs.

8. Engine Throttle Lever - Pull or push this lever to change

the speed of the engine when a load is applied.

9. Pre-Heat Indicator – Under cold conditions, turn the

starter key to preheat. Once the indicator lights, the

engine is ready to start.

10. Starter Switch - Turn this to start, stop, and preheat

the engine.

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

Hz operation. This meter should indicate 1800 RPM’s

when the engine is at full speed and a 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 32 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSIU — OUTPUT TERMINAL PANEL

Output Terminal Panel

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

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

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

pad lock.

120 Volt Receptacle

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

is located on the output terminal. This receptacle can be

used anytime the generator is in operation. The receptacle

is controlled by the circuit breaker located on the control

panel.

The reset button will reset the receptacle after being tripped.

Pressing the :Test Button” (Figure 8) in the center of this

receptacle will check the GFCI function. The receptacle

should be tested at least once a month.

Figure 10. GFCI Test Button

Connecting Load

Loads can be connected to the generator by the UVWO lugs or

the duplex receptacles. (See figure 3). Make sure to read the

operation manual before attempting to connect a load to the

generator.

Maximum Output

The entire load connected to the UVWO lugs, all four slots in

the duplex receptacles, and the must not exceed 52.8 kW in

standby or 48 kW in prime output.

Generator Grounding

Make sure to ground the generator in EVERY application

prior to connecting a load. Generators are NOT grounded

just because they are mounted on trailers or other vehicles

that are on rubber tires.

Twist Lock Dual Voltage Receptacles - To use these

receptacles, place the voltage selector switch in the single

phase 240/120 voltage position and adjust the output

voltage to 240 volts with the voltage regulator on the

Control Panel (Figure 8, page 28). Place the voltmeter

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

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

Circuit Breakers

To protect the generator from an overload, a 3-pole, 150 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.

Generator Grounding

Make sure the generator is properly grounded before

applying load. Generators are NOT considered grounded

when mounted on a trailer.

Figure 11. Load Application

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 33

DCA-60SSIU — OUTPUT TERMINAL VOLTAGE SELECTION

DCA-60SSIU

Legs O and Ground are

considered Bonded Grounds.

NOTE

Figure 12. Output Panel Location

PAGE 34 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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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

some of the voltages listed, fine adjustment with the voltage

regulator on the control panel is necessary. See Table 8 for

available voltages the generator will supply.

CAUTION :

NEVER switch Voltage Selector Switch

position while the engine is engaged.

Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect

the generator and generator load from being switched while

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

press in the red button located on the voltage selector switch,

and use a pad lock to hold it into this position.

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Maximum Amps

Table 9 shows the maximum amps the generator will pro-

vide. Do not exceed the maximum amps listed.

Over Current Relay

An over current relay is connected to the circuit breaker.

During an over current situation, both the circuit breaker and

the over current relay will trip. If the circuit breaker can not

be reset, the reset button on the over current relay must be

pressed. The over current relay is located inside the control

box.

DCA-60SSIU — OUTPUT AMPERAGE SETUP

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 35

Receptacle Use

When the UVWO terminals are providing power, the recep-

tacle power availability will decrease.

How To Read The Output Terminal Gauges.

The gauges (Figure 15 and 17) and change-over switches

on the control panel DO NOT effect the generator output.

They are to help observe how much power is being supplied

at the UVWO legs.

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

tion (Figure 13), place the AC voltmeter change-over switch

to the W-U position (Figure 14) and the AC ammeter change-

over switch to the U or W position (Figure 16) to read the

output on the selected leg.

Figure 13. Voltage Selector Switch 240/120V Single

Phase Position

Figure 14 and 15. AC Voltmeter Change-over switch

and Voltmeter Gauge

Figure 16 and 17. AC Ammeter Change-over Switch

and Ammeter Gauge

When using plural single phase

voltages, make sure to balance

the load on each of the single

phase legs.

NOTE

DCA-60SSIU — OUTPUT AMPERAGE SETUP

PAGE 36 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

240/120V Hard Wire Hookup

With the voltage selector set and locked at ‘single phase

240/120’ and using single phase 120 volts, the generator

will provide three legs available with 100 amps each on three

different circuits (Figure 18).

480/240V Hard Wire Hookup

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

277’ (Figure 19) and using the 3-phase 240 hookup, it will

provide one circuit available at 108 amps with any two wires

plus the ground (Figure 20).

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

one circuit available at 50 amps with all three wires plus

ground.

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

Position

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

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

DCA-60SSIU — OUTPUT VOLTAGE SETUP

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 37

Voltage Selector Switch- 3 Phase 480/277V Position

The following are additional voltages available when the volt-

age 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 22, 480 volts can be obtained with the voltage

regulator knob turned toward maximum; 440 volts can be

obtained with the voltage regulator knob is turned down; and

416 volts can be obtained with the voltage regulator knob is

at the lowest setting.

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

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

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

shown in Figure 23, 480 volts can be obtained with the volt-

age regulator knob turned toward maximum; 440 volts can

be obtained with the voltage regulator knob is turned down;

and 416 volts can be obtained with the voltage regulator

knob is at the lowest setting.

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

This setting can provide single phase power at 277, 254, or

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

shown in Figure 24, 277 volts can be obtained with the volt-

age regulator knob turned toward maximum; 254 volts can

be obtained with the voltage regulator knob is turned down;

and 240 volts can be obtained with the voltage regulator

knob is at the lowest setting.

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

416V

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

or 240V

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

or 416V

Figure 21. Voltage Regulator Knob

DCA-60SSIU — OUTPUT VOLTAGE SETUP

PAGE 38 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

Voltage Selector Switch- 3 Phase 240/139V Position

The following are additional voltages available when the volt-

age 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 26, 240 volts can be obtained with the voltage

regulator knob turned toward maximum; 220 volts can be

obtained with the voltage regulator knob is turned down; and

208 volts can be obtained with the voltage regulator knob is

at the 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 27, 240 volts can be obtained with the volt-

age regulator knob turned toward maximum; 220 volts can

be obtained with the voltage regulator knob is turned down;

and 208 volts can be obtained with the voltage regulator

knob is at the lowest setting.

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 28, 139 volts can be obtained with the volt-

age regulator knob turned toward maximum; 127 volts can

be obtained with the voltage regulator knob is turned down;

and 120 volts can be obtained with the voltage regulator

knob is at the lowest setting.

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

Position

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

208V

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

or 208V

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

or 120V

DCA-60SSIU — OUTPUT VOLTAGE SETUP

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 39

Voltage Selector Switch- Single Phase 240/120V

Position

The following are additional voltages available when the volt-

age selector switch is in the ‘single phase 240/120V’ posi-

tion.

Single Phase, 240 Volt

This setting can provide single phase power at 240 volts.

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

Figure 30, 240 volts can be obtained with the voltage regula-

tor knob turned 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 31, 120 volts can be obtained with the voltage regula-

tor knob turned to fine tune.

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

Position

Figure 30. Hard Wire Hookup for Single Phase 240 volt

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

DCA-60SSIU — OUTPUT VOLTAGE SETUP

PAGE 40 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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 25064(b) a 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 32) 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-60SSI2 — 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.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 41

Figure 32. Typical Generator Grounding Application

DCA-60SSI2 — INSTALLATION

PAGE 42 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

General Inspection Prior to Operation

The DCA-60SSI2 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 10)

as a guide for selecting proper cable size.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 150 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-60SSI2 — PRE-SETUP

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ALWAYS consult with a licensed

electrician for correct extension

cord wire size.

NOTE

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 43

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 33) on the dipstick. See

Table 11 for proper selection of engine oil.

Fuel

Fill the fuel tank with clean and fresh

diesel fuel.diesel 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 23,

Specification Table 7.

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

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

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

DCA-60SSI2 — PRE-SETUP

Figure 33. Engine Oil Dipstick

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

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

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

of oil as outlined in the Isuzu Engine Owner's Manual.

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CAUTION

Never fill the fuel tank while the engine is

running or in the dark. Diesel spillage on

a hot engine can cause a fire or

explosion. If diesel spillage occurs, wipe

up the spilled diesel 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.

An anticorrosion additive added to the water will help prevent

deposits and corrosion in the cooling system. See the engine

manual for further details.

PAGE 44 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSIU — 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 Table

12. 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 13) 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 Isuzu Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to

insufficient charging of the battery. Inspect the fan belt for

damage and wear and adjust it in accordance with the Isuzu

Engine Owner's Manual.

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

mm (Figure 34) when depressed with the thumb as shown

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

generator is running.

Figure 34. 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 15 mm defection

follow the procedure below to adjust:

Loosen the alternator adjusting plate and alternator mounding

bolt.

Pivot the alternator at the mounting bolt toward the engine

left or right until the belt reflects the proper tension.

Tighten the mounting bolt and the adjusting bolt.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 45

DCA-60SSIU — PRE-SETUP

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 35) 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 35. 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.

Alternator

The polarity of the alternator is negative grounding type.

When an inverted circuit connection takes place, the circuit

will be in short circuit instantaneously resulting the alternator

failure.

Do not put water directly on the alternator. Entry of water

into the alternator leads an electrolyte corrosion causing an

alternator failure.

Before charging the battery with an external electric source,

be sure to disconnect the battery cables.

PAGE 46 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 — 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 ouput.

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 mulitplying the nameplate

voltage by the nameplate amperage for three-phase:

WATTS =1.732 x VOLTAGE x AMPERAGE

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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 14.

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

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 47

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 11 on page 43).

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

Replenish with antifreeze as necessary. Always maintain

the coolant level between the FULL and LOW markings

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

fastened securely.

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 12) 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 36. Main, GFCI and

Load Circuit Breakers

DCA-60SSI2 — GENERATOR START-UP PROCEDURE

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

Figure 37. These terminals can be found on the output

terminal panel, (see page 22 Figure 6). To gain access

to the output terminals lift the UVW cover. Tighten

terminal nuts securely to prevent load wires from slipping

out.

Figure 37. UVW Terminal Lugs (Load)

NEGATIVE

POSTIVE

BATTERY

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

negative post on the battery (Figure 38).

Figure 38. Battery Connections

PAGE 48 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

10. The generator's frequency meter (Figure 45) displays

the 60 cycle output frequency in HERTZ.

Figure 46. Voltage Meter (Volts)

11. The generator's voltage meter (Figure 46) displays the

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

specified frequency tolerance, use the voltage

adjustment control knob (Figure 47) to increase or

decrease the desired voltage.

Figure 40. Voltage Selection Switch

4. Close all engine enclosure doors (Figure 39).

Figure 39. Engine Enclosure Doors

DCA-60SSI2 — GENERATOR START-UP PROCEDURE

5. Check the voltage selection switch (Figure 40) is

at the desired voltage.

6. Check to see if the engine throttle lever (Figure

41) is pushed in.

7. Turn the starter switch to ‘PREHEAT’ (Figure 42)

until the indicator light turns on. The oil pressure

indicator light will initially turn on, but should turn off

once the pressure rises.

8. Once the preheat indicator lights, turn the key to

‘START’ (Figure 43). After the engine cranks,

release the key to ‘RUN’.

Figure 41. Engine Throttle Lever

Figure 42. Key Switch (Preheat)

Figure 43. Starter Switch (Start)

Figure 45. Frequency Meter (Hz)

9. Pull the engine throttle lever and turn left until the

lever sets on the knob (Figure 44).

Figure 44. Engine Throttle Lever (Up)

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 49

Figure 48. Ammeter (No Load)

Figure 47. Voltage Adjust Control

Knob

12. The ammeter (Figure 48) 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 52. Engine Tachometer

DCA-60SSI2 — GENERATOR START-UP PROCEDURE

13. The engine oil pressure gauge (Figure 49) 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 50) will indicate

the coolant temperature. Under normal operating

conditions the coolant temperature is between 165 and

215 degrees fahrenheit.

WATER TEMP

Figure 50. Coolant Temperature Gauge

Figure 49. Oil Pressure Gauge

16. The tachometer (Figure 52) will indicate the speed of

the engine when the generator is operating. Under normal

operating conditions this speed is approximately 1800

RPM’s.

18. Observe the generator's ammeter (Figure 54) 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.

19. The generator will run until manually stopped or an

abnormal condition occurs.

Figure 53. Main and GFCI Circuit Breakers

Figure 54. Ammeter (Load)

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

their ON position (Figure 53).

15. The charging ammeter (Figure 51) will indicate if the

battery is properly charged.

Figure 51. Charging Ammeter

PAGE 50 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

1. To stop the engine in the event of an emergency, switch

the MAIN, GFCI and LOAD circuit breakers to ‘OFF’

position.

2. Turn the key switch to ‘STOP’.

EMERGENCY STOP

ENGINE SHUTDOWN

To shutdown the generator, use the following procedure:

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

(Figure 55)to the “OFF” position.

2. Turn to the right and press in the engine throttle lever

(Figure 56).

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

load applied.

4. Turn the key switch to ‘STOP’’ (Figure 57).

5. Remove the load from the UVW terminal strip.

Figure 55. Main, GFCI and Load

circuit breakers

Figure 56. Engine Throttle Lever

DCA-60SSI2 — GENERATOR SHUT-DOWN PROCEDURE

Figure 57. Key Switch (OFF)

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 51

NOTE PAGE

PAGE 52 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSIU — MAINTENANCE

General Inspection

Prior to each use, the generator should be cleaned and

inspected for deficiencies. Check for loose, missing or

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

oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 50 hours: Remove air cleaner element and clean heavy

duty paper element with kerosene, or foam element with

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

and squeeze dry. For heavy duty paper element, wipe

excess kerosene with towel.

The air cleaner is equipped with an indicator. After the dirty

air cleaner has been replaced, press the dust indicator button

to reset the indicator.

Fuel Addition

Add diesel fuel (the grade may vary according to season

and locations). Always pour through the mesh filter.

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate

in the bottom of the tank. Occasionally remove the drain

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

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

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

much as possible.

Air Removal

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

starting becomes impossible. After running out of fuel, or

after disassembling the fuel system, bleed the system

according to the following procedure.

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

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

unit is equipped with an automatic air bleeding system.

Service Daily

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 32, page 43.

Replacing Oil Filter

1. Detach the oil filter cartridge with a filter wrench.

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

3. 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.

4. 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

1. Replace the fuel filter cartridge with new one every 400

hours or so.

2. Apply fuel oil thinly over the gasket and hand-tighten

the cartridge into position.

3. Vent any air.

4. Fuel Injection Nozzle

5. Use an injection nozzle tester to check the static injection

starting pressure and the fuel spray conditions.

6. Abnormal fuel consumption will lead to a lowered output

and blackish exhaust smoke. The required injection

starting pressure should be 14.7MPa (150kg/cm2,

2130psi).

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 53

DCA-60SSIU — MAINTENANCE

CAUTION :

Allow engine to cool when flushing out

radiator. Flushing the radiator while hot will

damage radiator.

Feed Pump Strainer Cleaning

The strainer is incorporated in the feed pump inlet side joint

bolt. Clean the strainer with compressed air and rinse it in

the fuel oil.

Flushing Out Radiator and Replacing Coolant

1. 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.

2. Check hoses for softening and kinks. Check clamps for

signs of leakage.

3. 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.

4. Tighten both cocks and replace the overflow tank.

5. Replace with coolant (see page 44, Table 14 for mixture).

6. Close radiator cap tightly.

PAGE 54 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSIU — MAINTENANCE

Figure 58. Valve Adjustment

Valve Clearance Check

1. In order to bring No. 1 or No. 4 cylinder to top dead center

in the compression stroke, align the notched line on the

crank pulley with TDC mark on the timing gear case

cover.

2. Do the adjustment on the circle marked valves in the

below table where No. 1 cylinder is at the center in the

compression stroke.

3. After adjustment started from either piston top center,

turn the crankshaft 360o to align the notched line with

the TDC mark to do the adjustment again on the

remaining valve. See Table 16 and Figure 55 for valve

arrangement.

Injection Timing Check and Adjustment

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

compression stroke.

2. Turn the crankshaft pulley clockwise (viewed at engine

front) and align the notched line on the crank pulley with

the TDC mark on the timing gear case cover.

3. Remove the timing check hole cover at the front of

injection pump to check the alignment between the

pointer “a” on the injection pump gear lock plate and the

projected area mark “b” on the timing gear case.

4. If “a” and “b” are in alignment, the timing is set correctly.

If not, follow nos. 1-3 until the “a” and “b” are aligned.

5. Reversely turn the crankshaft pulley counterclockwise

viewed at the engine front about 30o crank angle.

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

7. Remove the injection pump No. 1 delivery valve holder,

delivery valve and spring and reinstall the delivery valve

holder on the original place.

8. Delivery valve holder tightening torque:

39~44Nm(29~33lbft.)

9. Slowly turn the crankshaft pulley clockwise and at the

same time continue to feed the fuel with pumping the

Feed pump. When the fuel stop to flow out from No. 1

delivery valve holder, stop pumping.

10. Observe and make sure which mark (injection starting

angle line) on the timing gear case cover is aligning with

the notched line on the crank pulley.

11. The timing line shows the injection starting crank angle

of the engine.

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

timing mark.

tnemtsudAevlaV.51elbaT

)tsuahxE=E;telnI=I(

.oNrednilyC1234

tnemegnarrAevlaV IEIEIEIE

pottasi1.oNnehW

ehtniretnecdaed

ekotsnoisserpmoc

XXX X

pottasi4.oNnehW

ehtniretnecdaed

ekortsnoisserpmoc

OO OO

NOTE:

Take necessary precautions to prevent dust and

foreign particles in the pump interior when timing

adjustments are made.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 55

Generator Storage

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

is required:

Fill 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.

DCA-60SSIU — MAINTENANCE

ECNANETNIAM/NOITCEPSNI

srH01

YLIAD srH052 srH005 srH0001

ENIGNE

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

retliFriAnaelC X

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC

noitcetorPtnalooCkcehCdnarotaidaRnaelC

leveL

tnemelEretliFriAecalpeR X

rotsiseRnoisorroCegnahC X

spmalCdnasesoHllakcehC X

knaTleuFfoedisnInaelC X

ROTARENEG

smhoM3revOecnatsiseRnoitalusnIerusaeM X

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

.ylnoemittsrif,sruoH052taretlifleufecalpeR

PAGE 56 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 — GENERATOR WIRING DIAGRAM

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 57

DCA-60SSI2 — ENGINE WIRING DIAGRAM

PAGE 58 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 — 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 16). If

the problem cannot be remedied, consult our company's

business office or service plant.

GNITOOHSELBUORTENIGNE.61ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

.tratstonseodenignE

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

leuffoytisocsivhgihylevissecxE

?erutarepmetwoltalioenignero .lioenigneroleufdeificepsehtesU

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

?tungniniaterepip .tunnethgiT

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip .ecalperroriapeR

?rednilycmorfkaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.nurtonseodretratS

?gninoitcnuflamretratS .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 59

DCA-60SSI2 — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.61ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

.htoomstonsinoituloverenignE

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

noitcejniesooloteudkaelleuF

?tungniniaterepip .tunnethgiT

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

?erusserp .tsujdA

rokcutselzzonnoitcejnI

?deggolc .ecalperroriapeR

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

sagtsuahxeeulbroetihwrehtiE

.devresbosi

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP

?kcuts .ecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

tsuahxeyargkradrokcalbrehtiE

.devresbosisag

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.tuptuotneicifeD

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?gnizieseb .ecalperroriapeR

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

PAGE 60 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

GNITOOHSELBUORTROTARENEG.71ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a

breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table 7). If the problem

cannot be remedied, consult our company's business office or service plant.

DCA-60SSI2 — TROUBLESHOOTING (GENERATOR/ENGINE)

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 61

NOTE PAGE

PAGE 62 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

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

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 63

DCA-60SSI2 DCA-60SSI2

DCA-60SSI2 W/ISUZU 6BG1 DIESEL ENGINEW/ISUZU 6BG1 DIESEL ENGINE

W/ISUZU 6BG1 DIESEL ENGINEW/ISUZU 6BG1 DIESEL ENGINE

W/ISUZU 6BG1 DIESEL ENGINE

1 1

1 TT

TO 3 UNITSO 3 UNITS

O 3 UNITSO 3 UNITS

O 3 UNITS

DCA-60SSI2 — 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

1 ......... 0601805869 ......... CIRCUIT BREAKER

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

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

1 ......... 0601840121 ......... KNOB REHOSTAT

1 ......... 0602013901 ......... RADIATOR HOSE, UPPER

1 ......... 0602013160 ......... RADIATOR HOSE, LOWER

5 ......... 1878100753 ......... OIL FILTER

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

5 ......... 0602040193 ......... ELEMENT, AIR

1 ......... 0602122200 ......... UNIT OIL PRESSURE

1 ......... 0602123204 ......... UNIT WATER PRESSURE

1 ......... 0601810244 ......... BULB, ALARM LAMP

1 ......... 0601808507 ......... TRANSDUCER WATT METER

1 ......... 8972322520 ......... FAN BELT

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

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

PAGE 64 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 --- GENERATOR ASSY.

GENERATOR ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 65

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSI2 --- GENERATOR ASSY.

GENERATOR ASSY.

1 8081000302 ROTOR ASSY. ................................ 1 ........... UP TO S/N3621172

1 8081000312 ROTOR ASSY. ................................ 1 ........... FROM S/N3621173~

1-1 FIELD ASSY. 1

1-2 8051070003 FAN 1

1-3 0010310030 HEX. HEAD BOLT ........................... 8 ........... UP TO S/N3621172

0012110035 HEX. HEAD BOLT ........................... 8 ........... S/N3621173~

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

1-5 8041611004 COUPLING DISK 4

1-6 8041015003 BALANCING PLATE 1

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

1-8 0042610000 LOCK WASHER 6

1-6 8001026013 SET PLATE RECTUFER 1

1-10 0601821349 RECTIFIER ..................................... 2 ............ PT3610

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

1-12 8001020004 INSULATOR WASHER 1

1-13 8001020504 INSULATOR WASHER 1

1-14 0010108020 LOCK WASHER 4

1-15 0040008000 LOCK WASHER 4

1-16 0601000209 BALANCING WEIGHT KIT 1

1-17 0070806309 BEARING ........................................ 1 ........... 6309DU;UP TO S/N3621172

1-17 0071906310 BEARING ........................................ 1 ........... 6310DDU; S/N3621173~

2 8051614003 COUPLING RING 1

3 8051653004 REAMER BOLT 2

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

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

6 8081340503 STRATOR ASSY. 1

7 0845041904 GROMMET 2

8 8041315202 END BRACKET .............................. 1 ........... UP TO S/N362172

8 8041315202 END BRACKET .............................. 1 ........... S/N362173~

9 8041350013 FIELD ASSY. EXCITER 1

10 0010308065 HEX. HEAD BOLT 4

11 0042608000 LOCK WASHER 4

12 031108160 PLAIN WASHER ............................. 6 ........... REPLACES 0041208000

13 0010108025 HEX. HEAD BOLT 6

14 0040008000 LOCK WASHER 6

15 0041208000 PLAIN WASHER 6

16 0601000003 WAVE WASHER .............................. 1 ........... BWW6309; UP TO S/N3621172

17 8041310014 COVER, BEARING ......................... 1 ........... UP TO S/N3621172

8041310024 COVER, BEARING ......................... 1 ........... S/N3621173~

18 8041312004 GASKET, BEARING ....................... 1 ........... UP TO S/N3621173

8041310014 GASKET, BEARING ....................... 1 ........... S/N3621173~

PAGE 66 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 --- GENERATOR ASSY.

GENERATOR ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 67

19 8041331014 COVER, END BRACKET 1

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

21 8001333003 COVER, END BRACKET 1

22 0010106030 HEX. HEAD BOLT 2

23 0040006000 LOCK WASHER 2

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

25 015091025 HEX. HEAD BOLT ........................... 6 ........... REPLACES 0010310025

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

27 8051332003 COVER, FAN................................... 1 ........... UP TO S/N3621172

8051332014 COVER, FAN................................... 1 ........... S/N3621173~

28 0605000010 RUBBER SUSPENSION

29 0030012000 HEX. NUT 4

0040012000 LOCK WASHER 4

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSI2 --- GENERATOR ASSY.

GENERATOR ASSY.

PAGE 68 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 69

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSI2 --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

1 8081812502 CONTROL BOX ............................................ 1 ....... UP TO S/N3646800

B4214000002 CONTROL BOX ............................................ 1 ....... S/N3646801~

2 0601801143 CURRENT TRANSFORMER, AMMETER ..... 3 ....... CT-3.5MR 100/5A

3 0027104010 MACHINE SCREW 6

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

5 0027104016 MACHINE SCREW 4

6 0601820628 AUTOMATIC VOLTAGE REGULATOR ........... 1 ....... NTA5A2D; UP TO S/N3656070

0601820671 AUTOMATIC VOLTAGE REGULATOR ........... 1 ....... NTA5A2DB; S/N3656071~

7 0027105012 MACHINE SCREW 4

8 0601820853 OVER CURRENT RELAY ............................. 1 ....... THK20KP; UP TO S/N3656070

0601820892 OVER CURRENT RELAY ............................. 1 ....... THN20HZKP; S/N3656071~

9 0027104016 MACHINE SCREW 4

10 0602200405 EMERGENCY RELAY .................................. 1 ....... ISUZU 1825500730

11 0027106016 MACHINE SCREW 4

12 0601823706 RELAY .......................................................... 1 ....... HE1AAHE1112 DC24V

13 0027104016 MACHINE SCREW 2

14 0601805352 CIRCUIT BREAKER ..................................... 1 ....... KM203150AT; UP TO S/N3646800

14 0601805869 CIRCUIT BREAKER ..................................... 1 ....... NY203A 150AT; S/N3646801~

15 0021004020 MACHINE SCREW 4

0040004000 LOCK WASHER 4

031104080 PLAIN WASHER ........................................... 4 ....... REPLACES 0041204000

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

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

18 8051839504 BRACKET, SELECTOR SWITCH 1

19 0021003010 MACHINE SCREW 4

20 0017106016 HEX. HEAD BOLT 2

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

21 7451822503 CONTROL PANEL ......................................... 1 ....... UP TO /SN3646800

7451822513 CONTROL PANEL ......................................... 1 ....... S/N36463801~

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

23 0601800784 AC AMMETER .............................................. 1 ....... PSK60 0~100A -~200A

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

25 0601800212 AC VOLTMETER ........................................... 1 ....... REPLACES 0601800217 PCK60 0~600V

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

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

0601810261 BULB ............................................................. 1 ....... T13

28 0601840073 VOLTAGE REGULATOR ................................ 1 ....... RA20A2SE102BJ 2W 1k OHM

29 0601840121 KNOB 1

PAGE 70 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 71

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSI2 --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

30 3331824003 STOPPER, CONTROL PANEL 1

31 0027105016 MACHINE SCREW 2

0030005000 HEX. NUT 2

32 0805001304 SET SCREW ................................................. 2 ....... UP TO S/N3655377

0845056404 SET SCREW ................................................. 2 ....... S/N3655378~

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

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

35 0027105010 MACHINE SCREW 4

36 8081814503 COVER 1

37 0017106016 HEX. HEAD BOLT 11

38 8081814604 SIDE PANEL 1

39 0017106016 HEX. HEAD BOLT 4

40 011208025 HEX. HEAD BOLT ......................................... 4 ....... REPLACES 0017108025

PAGE 72 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 73

DCA-60SSI2 ENGINE AND RADIATOR ASSY.

NO. PART NO.ITEM QTY.REMARKS

ENGINE AND RADIATOR ASSY.

1 0602000100 ENGINE ........................................... 1 ......... ISUZU 6BD1; UP TO S/N3656070

B4924200114 ENGINE ........................................... 1 ......... ISUZU A6BD1; S/N3656071~

2 0602010802 RADIATOR ....................................... 1 ......... H190110000

3 0017108020 HEX. HEAD BOLT 6

4 0602013901 RADIATOR HOSE ............................ 1 ......... B400008

5 0602013160 RADIATOR HOSE ............................ 1 ......... B400007

6 0602014302 HOSE BAND 3

7 06020143303 HOSE BAND 1

8 0602040090 AIR CLEANER ................................. 1 ......... FWG088006

0602040193 ELEMENT, AIR CLEANER ............... 1 ......... P104972

9 0602040690 DUST INDICATOR ............................ 1 ......... RBX002252

10 0602040598 BAND, AIR CLEANER ..................... 2 ......... AAH008263

11 0017108020 HEX. HEAD BOLT 4

12 7452032303 HOSE, AIR CLEANER 1

13 0605515008 HOSE BAND 2

14 0602041106 ELEMENT, OIL FILTER ................... 1 ......... 1878100751

15 0602042106 ELEMENT, FUEL FILTER ................ 1 ......... 988511911;UP TO S/N3656070

X132400240 ELEMENT, FUEL FILTER ................ 1 ......... S/N3656071~; REPLACES 1132400791

16 3345112403 ENGINE FOOT 1

17 3345112503 ENGINE FOT 1

18 0010710025 HEX. HEAD BOLT 7

19 0030610000 HEX. NUT 1

20 0040010000 LOCK WASHER 8

21 060500009 RUBBER SUSPENSON 4

22 0040012000 LOCK WASHER 4

23 0030112000 HEX. NUT 4

24 1819001931 ENGINE STEOPPER ...................... 1 ......... REPLACES 0602210803 & 1819000161

25 7452215104 BRACKET, ENGINE STOPPER 1

26 0027106016 MACHIEN SCREW 3

27 00171080220 HEX. HEA BOLT 2

PAGE 74 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 75

DCA-60SSI2 ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

28 74522051104 DRIAN JOINT 1

29 0805013704 PACKING, OIL PAN SIDE 1

30 0805014204 PACKING 1

31 3362054104 JOINT BOLT 1

32 3362051003 DRIAN GOINT 1

33 0802024004 PACKING 1

34 0802010204 PLUG1

35 7452053104 DRINAG HOSE 1

36 0605515158 HOSE BAND 2

37 0017108020 HEX. HEAD BOLT 2

38 0030008000 HEX. NUT 2

39 0845031303 RESERVE TANK 1

40 0802081104 CAP, RESERVE TANK 1

41 7452082504 BRAKET, RESERVE TANK 1

42 0017108020 HEX. HEAD BOLT 2

43 0017106025 HEX. HEAD BOLT 1

44 0199500470 HOSE 1

45 0199500175 HOSE 1

46 0193602000 HOSE 1

47 0605515013 HOSE BAND 4

48 0193100950 HOSE 1

49 0605515007 HOSE BAND 1

50 0193800850 HOSE 1

51 0605515019 HOSE BAND 1

52 7452220404 EARTH CABLE 1

53 8970209410 FILTER ............................................. 1 ......... REPLACES 9581541441

NO. PART NO.ITEM QTY.REMARKS

PAGE 76 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ENGINE OPERATING PANEL ASSY.

DCA-60SSI2 --- ENGINE OPERATING PANEL ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 77

ENGINE OPERATING PANEL ASSY.

DCA-60SSI2 --- ENGINE OPERATING PANEL ASSY.

NO. PART NO.ITEM QTY.REMARKS

1 7452111103 OPERATING PANEL 1

2 7452142014 SLIDE BAR 1

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

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

5 7452140504 BRACKET, GOVERNOR ROD 1

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

7 0605010503 SNAP PIN 1

8 1823100080 STARTER SWITCH .......................... 1 ......... REPLACES 06021000004

KEYISUZUF KEY, STARTER SWITCH 1

9 1814020031 PREHEAT LAMP .............................. 1 ......... REPLACES 9825300430

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

11 0602120154 CABLE, TACHOMETER ................... 1 ......... 621000KA6710L=1150

12 0602122060 OIL PRESSURE GAUGE ................. 1 ......... 4200KX1410

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

14 0131300000 STREET SOCKET ........................... 1 ......... UP TO S/N3623457

14 9099022380 STREET SOCKET ........................... 1 ......... S/N3623458~; REPLACES 0603306350

15 0602123061 WATER TEMPERATURE GAUGE .... 1 ......... 51400KA1200

16 0602123204 UNIT, WATER TEMPERATURE ........ 1 ......... 41400KA1200

17 0602121052 CHARGING AMMETER GAUGE ..... 1 ......... 43000KV0300

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

0601810244 BULB 2

19 0601830420 SWITCH, LAMP CHECK .................. 1 ......... SB61A

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

0601810214 BULB ................................................ 1 ......... REPLACES 0601810201

21 0040520000 TOOTHED LOCK WASHER 1

22 0601830710 SWITCH, PANEL LIGHT .................. 1 ......... S301T

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

0040008000 LOCK WASHER 2

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

24 011008020 HEX. HEAD BOLT ............................. 2......... REPLACES 0017108020

25 8085312103 SUPPORT LEG 1

26 0017110025 HEX.HEAD BOLT 2

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

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

28 7452183004 LINK, GOVERNOR ROD 1

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

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

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

32 7452182014 GOVERNOR ROD 1

33 7452152004 GOVERNOR ROD 1

34 0602180106 BALL JOINT 2

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

PAGE 78 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ENGINE OPERATING PANEL ASSY.

DCA-60SSI2 --- ENGINE OPERATING PANEL ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 79

36 0602180108 BALL JOINT 1

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

38 952404470 PLAIN WASHER .............................. 1 ......... REPLACES 0041206000

39 8111860103 SET BOARD, OUPUT TERMINAL 1

40 0801830204 OUTPUT TERMINAL 5

41 0801830704 HEX. HEAD BOLT 5

42 0039312000 HEX. NUT 10

43 0040012000 LOCK WASHER 15

44 0041412000 PLAIN WASHER 20

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

46 8081865504 COVER, OUTPUT TERMINAL 1

47 0605010051 HINGE 2

48 0027103016 MACHINE SCREW 12

0207003000 HEX. NUT 6

49 0017106016 HEX. HEAD BOLT 2

50 0601811034 RECEPTACLE .................................. 2 ......... REPLACES 0601812565; CS6369 250V 50A;

51 0601811030 RECEPTACLE .................................. 2 ......... UP TO S/N3627236; 5-20R 125V0 20A

0601812598 RECEPTACLE .................................. 1 ......... S/N3627237~;GF53 OEM 125V 20A

52 0027103010 MACHINE SCREW 10

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

S8413 PLAIN WASHER ............................ 10 ......... REPLACES 0041203000

53 0601805306 CIRCUIT BREAKER ........................ 2 ......... UP TO S/N3627236; KM51 265V 40A

0601804887 CIRCUIT BREAKER ........................ 2 ......... S/N3627237~;REPLACES 0601805313

KM51 265V 20A

54 0601805840 CIRCUIT BREAKER ........................ 3 ......... KM52 265V 50A

55 8081816303 BRACKET, CIRCUIT BREAKER 1

0222100200 RUBBER SHEET 1

56 0017106016 HEX. HEAD BOLT 2

57 8085182004 RUBBER COVER 1

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

60 8081865303 COVER, RECEPTACLE 1

61 12212045 HEX. HEAD BOLT ............................ 2 ......... REPLACES 0010012045

62 031112230 PLAIN WASHER .............................. 4 ......... REPLACES 0041612000

63 0805009804 RUBBER WASHER 2

64 0030012000 HEX. NUT 2

65 0601820015 RECTIFER ....................................... 4 ......... IS2762

66 0601802133 FUSE ............................................... 1 ......... 5A

67 0601851780 GROMMET ...................................... 2 ......... S/N3700638~

ENGINE OPERATING PANEL ASSY.

DCA-60SSI2 --- ENGINE OPERATING PANEL ASSY.

NO. PART NO.ITEM QTY.REMARKS

PAGE 80 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 --- BATTERY ASSY.

BATTERY ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 81

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSI2 --- BATTERY ASSY.

BATTERY ASSY.

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

2 0805003904 BATTERY SHEET 2

3 0805004004 BATTERY BAND 2

4 0805002904 BATTERY BOLT 4

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

6 0040008000 LOCK WASHER 4

7 0037808000 WING NUT 4

8 0215260065 BATTERY CABLE 1

9 0211160180 BATTERY CABLE 1

10 0215860100 BATTERY CABLE 1

11 0602220310 TERMINAL ASSY (+) 2

020800800 WING NUT 2

12 0602220311 TERMINAL ASSY (-) 2

0208008000 WING NUT 2

13 0845040414 TERMINAL CAP 2

14 0845041304 TERMINAL CAP 2

PAGE 82 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 --- MUFFLER ASSY.

MUFFLER ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 83

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSI2 --- MUFFLER ASSY.

MUFFLER ASSY.

1 8082330303 EXHAUST PIPE 1

2 1141450690 GASKET .......................................... 1 ......... REPLACES 9221160010

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

4 3802311122 MUFFLER 1

5 012210020 HEX. HEAD BOLT ............................ 4 ......... REPLACES 0017110020

6 7452330303 EXHAUST PIPE 1

7 B4334200404 GASKET 1

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

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

10 0040008000 LOCK WASHER 4

11 0030008000 HEX. NUT 4

12 1382320003 PIPE BAND 1

13 011208030 HEX. HEAD BOLT ............................ 1 ......... REPLACES 0010008030

14 031108160 PLAIN WASHER .............................. 1 ......... REPLACES 0041208000

15 020108060 HEX. NUT ........................................ 1 ......... REPLACES 0030008000

16 3342354104 COVER 1

17 3342354004 COVER 2

18 3342328104 PIPE CLAMPER 1

19 031108160 PLAIN WASHER .............................. 2 ......... REPLACES 0041208000

20 020108060 HEX. NUT ........................................ 4 ......... REPLACES 0030008000

21 3342359004 COVER SHEET 2

22 011208025 HEX. HEAD BOLT ............................ 4 ......... REPLACES 0017108025

PAGE 84 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 --- FUEL TANK ASSY.

FUEL TANK ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 85

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSI2 --- FUEL TANK ASSY.

FUEL TANK ASSY.

1 7455510303 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 7455523304 TANK BAND 2

3 0805003414 PAD, TANK BAND 4

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

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

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

7 0222100200 TANK SHEET 4

8 0131906000 CAP 1

9 0191301150 SUCTION HOSE 1

10 0191300670 RETURN HOSE 1

11 0605515109 HOSE BAND 4

12 0845032204 DRAIN JOINT .................................. 1 ......... UP TO S/N3653118

0845047504 DRAIN JOINT .................................. 1 ......... S/N3653119~

13 0150000018 O RING 1

14 0802011104 PLUG 1

PAGE 86 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ENCLOSURE ASSY.

DCA-60SSI2 --- ENCLOSURE ASSY.

5 -BLACK

6 -CATERPILLAR YELLOW

7 -CATO GOLD

8 -RED

THE SERIAL NUMBER MAY BE REQUIRED.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE

2-WHITE

3 -SPECTRUM GRAY

4 -SUNBELT GREEN

UP TO S/N3656070

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 87

NO. PART NO.ITEM QTY.REMARKS

ENCLOSURE ASSY.

DCA-60SSI2 --- ENCLOSURE ASSY.

1 7455111112 BASE 1

2 7455116004 FLOOR PANLE 1

3 0017108020 HEX. HEAD BOLT 12

4 7455116504 COVER 1

5 0017108020 HEX.HEAD BOLT 2

6 7455121012 FRONT FRAME ................................... 1 ............ UP TO S/N3656070

7455121022 FRONT FRAME ................................... 1 ............ S/N3656071~

7455109203 ACOUSTIC SHEET 1

7 0017108020 HEX. HEAD BOLT 6

8 0800251201 FILLER COVER 1

9 0027106016 MACHINE SCREW 2

10 7455125503 COVER, FRONT FRAME 1

7455109304 ACOUSTIC SHET 1

11 0017108020 HEX. HEAD BOLT 16

12 7455125304 COVER, FRONT FRAME 1

13 00171080220 HEX. HEAD BOLT 12

14 3385155104 COVER ................................................. 2 ............ UP TO S/N3656070

15 0017106020 HEX. HEAD BOLT ................................ 8 ............ UP TO S/N3656070

16 7455125104 COVER, FRONT FRAME 1

7455109404 ACOUSTIC SHEET 1

17 0017108020 HEX. HEAD BOLT 4

18 7455125704 COVER, FRONT FRAME 1

7455109504 ACOUSTIC SHEET 1

19 0017108020 HEX. HEAD BOLT 4

20 7455132013 CENTER FRAME ................................. 1 ............UP TO S/N3656070

B4434300003 CENTER FRAME ................................. 1 ............S/N3656071~

21 7455132213 CENTER FRAME ................................. 1 ............UP TO S/N3656070

B4434300103 CENTER FRAME ................................. 1 ............S/N3656071~

22 0010114040 HEX. HEAD BOLT ................................ 8 ............ UP TO S/N3656070

0030014000 HEX. NUT ............................................. 8 ............ UP TO S/N3656070

0040014000 LOCK WASHER ................................... 8 ............UP TO S/N3656070

0041214000 PLAIN WASHER ................................... 16 ..........UP TO S/N3656070

22 0010124040 HEX. HEAD BOLT ................................ 8 ............ S/N3656071~

0030014000 HEX. NUT ............................................. 1 ............ S/N3656071~

0040014000 LOCK WASHER ................................... 8 ............S/N3656071~

0041214000 PLAIN WASHER ................................... 9 ............ S/N3656071~

23 0010112030 HEX. HEAD BOLT 10

0040012000 LOCK WASHER 10

0041212000 PLAIN WASHER 10

24 7455141122 REAR FRAME ...................................... 1 ............UP TO S/N3656070

B4444000102 REAR FRAME ...................................... 1 ............S/N3656071 TO 3700637

B4444000112 REAR FRAME ...................................... 1 ............S/N3700638~

7455109603 ACOUSTIC SHEET 1

25 0017108020 HEX. HEAD BOLT 4

26 7455155003 COVER, REAR FRAME ....................... 1 ............ UP TO S/N3656070

B4444300203 COVER, REAR FRAME ....................... 1 ............ S/N3656071~

7455109713 ACOUSTIC SHEET 1

PAGE 88 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ENCLOSURE ASSY.

DCA-60SSI2 --- ENCLOSURE ASSY.

5 -BLACK

6 -CATERPILLAR YELLOW

7 -CATO GOLD

8 -RED

THE SERIAL NUMBER MAY BE REQUIRED.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE

2-WHITE

3 -SPECTRUM GRAY

4 -SUNBELT GREEN

UP TO S/N3656070

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 89

ENCLOSURE ASSY.

DCA-60SSI2 --- ENCLOSURE ASSY.

NO. PART NO.ITEM QTY.REMARKS

27 0010108040 HEX. HEAD BOLT 8

0040008000 LOCK WASHER 8

0041208000 PLAIN WASHER 8

28 7455143113 DOOR, REAR FRAME ......................... 1 ............UP TO S/N3656070

B4444200203 DOOR, REAR FRAME ......................... 1 ............S/N3656071 TO 3700637

B4444200213 DOOR, REAR FRAME ......................... 1 ............S/N3700638~

29 3805147104 WINDOW PLATE 1

30 0021006020 MACHINE SCREW 6

0030006000 HEX. NUT 6

0040006000 LOCK WASHER 6

0041206000 PLAIN WASHER 6

31 0845028303 HINGE .................................................. 2 ............ UP TO S/N3656070

0845047204 HINGE .................................................. 2 ............S/N656071~

32 0017108025 HEX. HEAD BOLT 4

33 7455161012 ROOF PANEL 1

7455109803 ACOUSTIC SHEET 1

34 0017108020 HEX. HEAD BOLT 16

35 7455165004 GUIDE PANEL, AIR 2

7455109904 ACOUSTIC SHEET 2

36 0017108020 HEX. HEAD BOLT 8

37 8085181202 SPLASHER PANEL .............................. 1 ............UP TO S/N3627236

8085181212 SPLASHER PANEL .............................. 1 ............S/N3627237 TO 3700637

8085181222 SPLASHER PANEL .............................. 1 ............S/N3700638~

38 0010108055 HEX. HEAD BOLT 6

0040008000 LOCK WASHER 6

0041208000 PLAIN WASHER 6

39 7455171413 SIDE DOOR ......................................... 1 ............ UP TO S/N3656070

B4454000703 SIDE DOOR ......................................... 1 ............S/N3656071 TO 3700637

B4454000713 SIDE DOOR ......................................... 1 ............ S/N3700638~

7455105104 ACOUSTIC SHEET ............................. 1 ............UP TO S/N3656070

B4494100104 ACOUSTIC SHEET ............................. 1 ............S/N3656071~

40 7455171513 SIDE DOOR ......................................... 1 ............ UP TO S/N3656070

B4454000803 SIDE DOOR ......................................... 1 ............S/N3656071 TO 3700637

B4454000813 SIDE DOOR ......................................... 1 ............ S/N3700638~

7455105204 ACOUSTIC SHEET ............................. 1 ............UP TO S/N3656070

B4494100204 ACOUSTIC SHEET ............................. 1 ............S/N3656071~

41 7455171613 SIDE DOOR ......................................... 1 ............ UP TO S/N3656070

B4454000903 SIDE DOOR ......................................... 1 ............S/N3656071 TO 3700637

B4454000913 SIDE DOOR ......................................... 1 ............ S/N3700638~

7455105304 ACOUSTIC SHEET ............................. 1 ............UP TO S/N3656070

B4494300204 ACOUSTIC SHEET ............................. 1 ............S/N3656071~

42 7455171723 SIDE DOOR ......................................... 1 ............ UP TO S/N3656070

B4454001003 SIDE DOOR ......................................... 1 ............S/N3656071 TO 3700637

B4454001013 SIDE DOOR ......................................... 1 ............ S/N3700638~

7455105414 ACOUSTIC SHEET ............................. 1 ............UP TO S/N3656070

B4494300304 ACOUSTIC SHEET ............................. 1 ............S/N3656071~

PAGE 90 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ENCLOSURE ASSY.

DCA-60SSI2 --- ENCLOSURE ASSY.

UP TO S/N3656070

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 91

ENCLOSURE ASSY.

DCA-60SSI2 --- ENCLOSURE ASSY.

NO. PART NO.ITEM QTY.REMARKS

43 0845028203 HINGE .................................................. 4 ............ UP TO S/N3656070

0845046904 HINGE .................................................. 4 ............S/N3656071~

44 0845028304 HINGE .................................................. 4 ............ UP TO S/N3656070

0845047004 HINGE .................................................. 4 ............S/N3656071~

45 0017108025 HEX. HEAD BOLT 16

0601850097 RUBBER CUSHION 8

47 0845031504 CAP 10

48 6360510003 EMBLEM ............................................... 2 ............UP TO S/N3660480

0600500090 EMBLEM ............................................... 2 ............ S/N3660481~

49 0021106020 MACHINE SCREW 4

69 0825007362 DOOR HANDLE................................... 5 ............S/N3656071~

70 0221806015 MACHINE SCREW .............................. 20 ..........S/N3656071~

71 B4444800004 DUCT ................................................... 1 ............S/N3656071~

7455109713 ACOUSTIC SHEET 1

72 B4444800104 DUCT ................................................... 1 ............S/N3656071~

7455109713 ACOUSTIC SHEET 1

73 0207006000 HEX. NUT ............................................. 10 ..........S/N3656071~

PAGE 92 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 --- RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 93

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSI2 --- RUBBER SEAL ASSY.

RUBBER SEAL ASSY. UP TO S/N3656070

57 7455104104 RUBBER SEAL 2

58 7455104204 RUBBER SEAL 2

59 7455104304 RUBBER SEAL 3

60 7455104404 RUBBER SEAL 1

61 7455104514 RUBBER SEAL 1

62 7455104614 RUBBER SEAL 1

63 7455104714 RUBBER SEAL 1

64 7455104804 RUBBER SEAL 2

65 7455104904 RUBBER SEAL 2

66 0225100365 RUBBER SEAL 1

67 0220100365 RUBBER SEAL 1

68 0220200750 RUBBER SEAL 2

57 0229200668 RUBBER SEAL 2

58 0228900665 RUBBER SEAL 1

59 0228900890 RUBBER SEAL 3

60 0228900890 RUBBER SEAL 1

61 0228900555 RUBBER SEAL 1

62 0228800335 RUBBER SEAL 1

63 0228900555 RUBBER SEAL 1

64 0228901465 RUBBER SEAL 1

65 0229200900 RUBBER SEAL 2

66 0228800365 RUBBER SEAL 1

67 0228800325 RUBBER SEAL 1

68 0228800780 RUBBER SEAL 2

74 0278100120 RUBBER SEAL .................................... 2 ............ SN3700638~

75 0228100560 RUBBER SEAL .................................... 1 ............ S/N3700638~

76 0228900670 RUBBER SEAL .................................... 2 ............ S/N3700638~

NO. PART NO.ITEM QTY.REMARKS

RUBBER SEAL ASSY. S/N3656071~

PAGE 94 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

DCA-60SSI2 --- DECALS

DECAL ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 95

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSI2 --- DECALS

DECAL ASSY.

1 B9521100504 DECAL; CAUTION ....................................................... 1 ....... B92110050

2 B4551005902 DECAL; CONTROL PANEL ........................................ 1 ....... B45100590

3 0800520904 PLATE; AMMETER CHANGE-OVER SWITCH .......... 1 ....... N2438

4 0800520804 PLATE; VOLTAGE CHANGE-OVER SWITCH ........... 1 ....... N2439

5 B9521100404 DECAL; SAFETY INSTRUCTION .............................. 1 ....... B92110040

6 B9531100604 DECAL; WARNING ..................................................... 1 ....... B93110060

7 3340670002 DECAL; OPERATING PANEL ..................................... 1 ....... S2361A

8 8050670113 DECAL; RECEPTABLE & CIRCUIT BREAKER .......... 1 ....... S3349A

9 B1551001604 DECAL; NOTE ............................................................. 1 ....... B15100160

10 0840614104 DECAL; GROUND MARK ........................................... 1 ....... S2635

11 0840619904 DECAL; CAUTION ....................................................... 1 ....... S2731

12 0840627103 DECAL; CABLE JOINING ........................................... 1 ....... S3245

13 8080670514 DECAL; CAUTION ....................................................... 1 ....... S3696B

14 B9531100604 DECAL; WARNING ELECTRIC SHOCK HAZARD .... 1 ....... B93110060

15 B9511100404 DECAL; WARNING ELECTRIC SHOCK HAZARD .... 1 ....... B91110040

16 B9531100504 DECAL; WARNING ELECTRIC SHOCK HAZARD .... 1 ....... B93110050

17 B9511100304 DECAL; WARNING ..................................................... 1 ....... B91110030

18 0800689404 DECAL; + ..................................................................... 1 ....... S2090

19 0800689504 DECAL; - ...................................................................... 1 ....... S2091

20 1320620904 DECAL; DIESEL FUEL ................................................ 1 ....... S1756

21 1320610603 DECAL; WATER, OIL .................................................. 1 ....... S1760

22 6360610304 DECAL; WATER .......................................................... 1 ....... S1880

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

24 6360620204 DECAL; OIL DRAIN PLUG .......................................... 1 ....... S1885

25 0840627304 DECAL; WARNING ..................................................... 1 ....... S3247

26 1320621504 DECAL; SUPPORT HOOK ......................................... 2 ....... S2257

27 0840625902 DECAL; MQ ................................................................. 1 ....... S3057

28 B9504200004 DECAL; WARNING ENGINE EXHAUST .................... 1 ....... B90420000

29 B9504000404 DECAL; WARNING MOVING PARTS ......................... 2 ....... M90400040

30 B9504500004 DECAL; WARNING DIESEL FUEL ............................. 1 ....... B90450000

31 B9504100104 DECAL; WARNING HOT COOLANT ......................... 1 ....... B90410010

32 B9504000304 DECAL; CAUTION HOT PARTS ................................. 1 ....... B90400030

33 7450630703 STRIPE ........................................................................ 1 ....... REPLACES B4561100103

34 7450631104 STRIPE ........................................................................ 2 ....... UP TO S/N3656070

B4561100403 STRIPE ........................................................................ 2 ....... S/N3656071~

35 7450631304 STRIPE, LEFT SIDE ................................................... 1 ....... UP TO S/N3656070

B4561100503 STRIPE ........................................................................ 1 ....... S/N3656071~

36 7450631504 STRIPE, RIGHT SIDE ................................................. 1 ....... UP TO SN3656070

B4561100604 STRIPE ........................................................................ 1 ....... S/N3656071~

37 7450630904 STRIPE ........................................................................ 2 ....... UP TO S/N3656070

B4561100304 STRIPE ........................................................................ 2 ....... S/N3656071~

38 7450630303 STRIPE ........................................................................ 1 ....... UP TO S/N3656070

B4561100003 STRIPE ........................................................................ 1 ....... S/N3656071~

50 7450630303 STRIPE ........................................................................ 1 ....... UP TO S/N3656070

PAGE 96 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

CYLINDER HEAD COVER ASSY.

ISUZU 6BG1 — CYLINDER HEAD COVER ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 97

ISUZU 6BG1 — CYLINDER HEAD COVER ASSY.

EA1013

CYLINDER HEAD COVER ASSY.

NO PART NO PART NAME QTY.REMARKS

1 1111803500 CYLINDER HEAD COVER 1

27 9111790300 GASKET 4

68 9111791050 CAP NUT WASHER 4

69 1111730550 GASKET 1

75 8943401920 NUT 4

PAGE 98 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — CYLINDER HEAD ASSY.

CYLINDER HEAD ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 99

ISUZU 6BG1 — CYLINDER HEAD ASSY.

CYLINDER HEAD ASSY.

NO PART NO PART NAME QTY.REMARKS

1 1111106142 CYLINDER HEAD ASSY. .................. 1 ........ INCL. ITEMS W/*

2 1111411960 GASKET 1

4* 5117210010 VALVE GUIDE 12

5A* 1117150540 INLET SEAT 6

5B* 1117110430 EXHAUST SEAT 6

7A* 1096000051 SEALING CUP, OD=45 1

7B* 9111291280 SEALING CUP, OD=20 3

7C* 5112190150 SEALING CUP, OD=32 3

7D* 5096000130 SEALING CUP, OD=12.3 6

7E* 1096000160 SEALING CUP, OD=25 5

7F 9111296010 SEALING CUP, OD=12.5 5

9 9041108250 STUD, M8X25 L=37 3

10 1825130430 GLOW PLUG ..................................... 6 ........ REPLACES 9825139289

11A 5197320011 CONNECTOR, L=236 1

11B 5197320021 CONNECTOR, L=354 1

12 9117776221 HANGER 1

14 9096300260 STUD, M8X86 L=99 12

41A 0286810200 BOLT, M10X20 FLANGE 3

41B 0208014250 BOLT, M14X25 1

54 9098301630 STUD, M8X83 L=96 4

56 1093000180 STUD, M8X40 L=58 12

81* 9096600340 PLUG, OD=11.9 6

112 9099167550 CLIP 1

113 0280806100 BOLT, M6X10 FLANGE 1

117 9091505140 WASHER 1

120A 1090701010 BOLT, M12X113 20

120B 1090701000 BOLT, M12X100 6

168 5117770551 HANGER 1

PAGE 100 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 101

ISUZU 6BG1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1112103408 CYLINDER BLOCK 1 .......... INCL. ITEMS W/*

2 1878116900 LINER, GRADE=1 ................................................. 6 .......... UP TO DEC. 98; INCL. ITEMS W/#

1878119420 LINER, GRADE=1 ................................................. 6 .......... FROM JAN. 99~

1878116910 LINER, GRADE=2 ................................................. 6 .......... UP TO DEC. 98

1878119430 LINER, GRADE=2 ................................................. 6 .......... FROM JAN. 99~

1878116920 LINER, GRADE=3 ................................................. 6 .......... UP TO DEC. 98

1878119440 LINER, GRADE=3 ................................................. 6 .......... FROM JAN. 99~

1878116930 LINER, GRADE=4 ................................................. 6 .......... UP TO DEC. 98

1878119450 LINER, GRADE=4 ................................................. 6 .......... FROM JAN. 99~

4*# 1112612480 LINER, OD GRD=1 ID GRD=AX ........................... 6 .......... UP TO DEC. 98

1112613820 LINER, OD GRD=1 ID GRD=AX ........................... 6 .......... FROM JAN. 99~

1112612490 LINER, OD GRD=1 ID GRD=CX ........................... 6 .......... UP TO DEC. 98

1112613830 LINER, OD GRD=1 ID GRD=CX ........................... 6 .......... FROM JAN. 99~

1112612500 LINER, OD GRD=2 ID GRD=AX ........................... 6 .......... UP TO DEC. 98

1112613840 LINER, OD GRD=2 ID GRD=AX ........................... 6 .......... FROM JAN. 99~

1112612510 LINER, OD GRD=2 ID GRD=CX ........................... 6 .......... UP TO DEC. 98

1112613850 LINER, OD GRD=2 ID GRD=CX ........................... 6 .......... FROM JAN. 99~

1112612520 LINER, OD GRD=3 ID GRD=AX ........................... 6 .......... UP TO DEC. 98

1112613860 LINER, OD GRD=3 ID GRD=AX ........................... 6 .......... FROM JAN. 99~

1112612530 LINER, OD GRD=3 ID GRD=CX ........................... 6 .......... UP TO DEC. 98

1112613870 LINER, OD GRD=3 ID GRD=CX ........................... 6 .......... FROM JAN. 99~

1112612540 LINER, OD GRD=4 ID GRD=AX ........................... 6 .......... UP TO DEC. 98

1112613880 LINER, OD GRD=4 ID GRD=AX ........................... 6 .......... FROM JAN. 99~

1112612550 LINER, OD GRD=4 ID GRD=CX ........................... 6 .......... UP TO DEC. 98

1112613890 LINER, OD GRD=4 ID GRD=CX ........................... 6 .......... FROM JAN. 99~

8* 1090004691 BOLT, M16X119 14

12 1096660360 CONNECTOR 1

28 1112191630 COVER 1

30 8941480790 PIN, OD=16 2

34 8970233390 VALVE 1

35 5096230350 GASKET 1

37 1096050681 PLUG 2

38 1097400780 PIN, OD=10 L=50 1

55 1096050660 PLUG, PT 3/8 T=8.0 1

70* 1096000520 SEALING CUP, OD=60 2

71 8943673681 GASKET 3

72C 8970285250 COVER 2

72D 9112916051 COVER 1

74 8943675301 BOLT, M8X56 FLANGE 6

80* 1096000121 CUP, OD=32 3

82 5093000231 STUD, M14X44 L=65 1

83 9081510180 PIN, OD=10 L=18 2

PAGE 102 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 103

ISUZU 6BG1 — CYLINDER BLOCK ASSY.

NO. PART NO. PART NAME QTY.REMARKS

CYLINDER BLOCK ASSY.

113* 5112190140 CUP, OD=28 2

130* 5112570011 DOWEL 1

136 9112246021 BUSHING 1

137 1096800240 DRAIN COCK 1

162 9099147010 HOSE, L=900 S.B. L=10000 1

179 9095720080 GASKET 6

218 9095714120 GASKET ................................................................ 1 .......... UP TO MAR. 98

9095720140 GASKET ................................................................ 1 .......... FROM APR. 98~

219 5096540130 NIPPLE 1

220 9098600190 PLUG 1

236 1093000530 STUD, M10X18.5 L=33 1

242 0286808200 BOLT, M8X20 FLANGE 2

267 8970157540 CLIP 1

269 1096301150 GASKET 1

279 0286810200 BOLT, M10X20 FLANGE 2

281 5197890030 BRACKET 1

335A 5096050180 PLUG, RIGHT SIDE 8

335B 1096050791 PLUG, LEFT SIDE 1

335C 9992023140 PLUG, LEFT SIDE 1

335D 9992023120 PLUG, RIGHT SIDE 1

338 5111290030 SEALING CUP, OD=15.6 1

PAGE 104 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — OIL PAN AND LEVEL GAUGE ASSY.

OIL PAN AND LEVEL GAUGE ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 105

ISUZU 6BG1 — OIL PAN AND LEVEL GAUGE ASSY.

OIL PAN AND LEVEL GAUGE ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1113604421 OIL PAN ASSY. ............................................... 1 .......... INCL. ITEMS W/*

2 1117602000 GAUGE 1

5* 1096230570 GASKET 1

6* 9096620120 PLUG 1

16 1113671000 GASKET 1

23 0500408180 BOLT, M8X12 W/LOCK WASHER 32

119C 9992023240 PLUG, M24X12 1

9992023160 PLUG; M16X12 1

120 9095714240 GASKET, ID=24.5 1

9095714160 GASKET, ID=16.5 1

151 9112290700 CLIP 1

153 9831514320 THERMOMETER 1

PAGE 106 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — CAMSHAFT AND VALVE ASSY.

CAMSHAFT AND VALVE ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 107

ISUZU 6BG1 — CAMSHAFT AND VALVE ASSY.

CAMSHAFT AND VALVE ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1125140050 CAMSHAFT 1

4 1125510830 VALVE, INLET 6

5 1125520251 VALVE, EXHAUST 6

7 9920614280 BOLT, M14X28 1

8 9098518503 WASHER, ID=14.5 1

9 1125220162 GEAR, Z=50 1

10 9116810150 THRUST PLATE 1

11 0500408250 BOLT, M8X25 W/LOCK WASHER 2

14 9080307130 KEY 1

37A 9116110480 METAL 1

37B 9116130350 METAL 5

51 9091800190 SNAP RING 1

53 1126210621 ROCKER ARM SHAFT 1

55 9126260050 PLUG 2

58 5126280120 BRACKET 1

65 5126560060 SPLIT COLLAR 24

68 1125610990 VALVE SPRING 12

71A 8941145790 SPRING SEAT 12

71B 5125630010 SPRING SEAT 12

72 1125690150 SEAL 12

75A 1090005670 BOLT, M8X65 8

75B 9096021480 BOLT, M8X65 1

76 9098514300 WASHER 9

78 1126111180 ROCKER ARM 12

81 9126160420 SCREW 12

83 9091115080 ADJ. SCREW LOCK NUT 12

84 9126281050 BRACKET 6

88 1125750360 PUSH ROD 12

89 5125710032 TAPPET VALVE 12

93 1094001160 NUT 4

94 9095814300 WASHER 4

95 1095803350 SPRING 5

100 5096230600 GASKET 1

103 9091505100 WASHER 2

107 9125310300 SHAFT 1

111 5125350011 COLLAR 1

112 8941339373 GEAR 1

207 0108110550 BOLT, M10X55 2

PAGE 108 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — CRANKSHAFT, PISTON AND FLYWHEEL ASSY.

CRANKSHAFT, PISTON AND FLYWHEEL ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 109

ISUZU 6BG1 — CRANKSHAFT, PISTON AND FLYWHEEL ASSY.

CRANKSHAFT, PISTON AND FLYWHEEL ASSY.

NO PART NO PART NAME QTY.REMARKS

1 1123104480 CRANKSHAFT ............................ 1 ........ INCL. ITEMS W/*

7 1115100742 METAL KIT ................................. 1 ........ INCL. ITEMS W/#

12 5123310642 FLYWHEEL 1

13 9098401071 NUT 1

14 9098514310 WASHER 1

15 9123790450 BUSHING 1

28 8971379101 GEAR, Z=25 1

31 5097380010 FEATHER KEY 1

32* 9081512200 PIN 1

33 5123190032 RING 1

35 9123336070 GEAR, Z=129 1

37 1098002140 BEARING 1

38 5123360081 WASHER 1

40 9098013340 BOLT 6

42# 1116800012 WASHER 2

56 5123712092 PULLEY, 2-GROOVE 1

63 1121117690 PISTON, STD. GRD=AX 6

1121117700 PISTON, STD. GRD=CX 6

68 1121211011 RING SET 6

73 9122716080 METAL SET 6

83 9122116040 PISTON PIN 6

84 1122301041 CONNECTOR ARM ASSY. ......... 6 ........ INCL. ITEMS W/%

85% 1122510270 BUSHING 6

86% 1122350271 BOLT, M20X49.5 12

93 1123620031 THROWER 1

96 5123620031 DUST THROWER 1

126 8941075751 SNAP RING 12

PAGE 110 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — TIMING GEAR AND FLYWHEEL HOUSING ASSY.

TIMING GEAR AND FLYWHEEL HOUSING ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 111

ISUZU 6BG1 — TIMING GEAR AND FLYWHEEL HOUSING ASSY.

TIMING GEAR AND FLYWHEEL HOUSING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5113110113 TIMING GEAR CASE 1

2 8943213304 FLYWHEEL HOUSING 1

32 8943706710 GASKET 1

35 1096254380 SEAL 1

36 0280808450 BOLT, M8X45 FLANGE 2

0286808200 BOLT, M8X20 FLANGE 4

38 9081510180 PIN, OD=10 L=18 1

49 8970222160 GASKET 1

54 1113210790 COVER 1

57 5113210090 TIMING COVER 2

58 0280806120 BOLT, M6X12 FLANGE 4

62A 0286808250 BOLT, M8X25 FLANGE 7

62B 0280808500 BOLT, M8X50 FLANGE 5

65 8970276011 GASKET 2

86 9839101012 ELBOW 1

93 1096234650 GASKET 1

175 1096254391 SEAL 1

178 8943218380 PLUG 1

205 0911602140 NUT 1

211 0500408250 BOLT, M8X25 W/LOCK WASHER .. 7 ........... REPLACES 0288914450

224 9944112350 STUD, M12X35 L=53 3

252 0286808200 BOLT, M8X20 FLANGE 2

275 5113270090 POINTER 1

297 9095714160 GASKET 1

298 9992023160 PLUG 1

PAGE 112 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — INLET MANIFOLD ASSY.

INLET MANIFOLD ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 113

ISUZU 6BG1 — INLET MANIFOLD ASSY.

INLET MANIFOLD ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1141121842 INLET MANIFOLD 1

7 1141150610 GASKET 1

10A 1141150590 GASKET 1

10B 1096370610 GASKET 1

13 0501408280 BOLT, M8X28 ................................. 9 ........... W/LOCK AND PLAIN WASHER

20A 9091104080 NUT. M8 3

20B 0911501080 NUT, M8 FLANGE 3

22 9091505080 LOCK WASHER 3

23 9091605080 PLAIN WASHER 3

27 9040108200 STUD, M8X20 L=36 3

27A 9040108450 STUD, M8X45 L=61 3

32 9044110250 STUD, M10X25 L=40 2

50G 1141123150 PIPE 1

50I 1141126310 PIPE 1

54 9091505100 LOCK WASHER 2

55 9091104100 NUT 2

94 0500406300 BOLT, M6X30 ................................. 1 ........... W/LOCK WASHER

159 8941640270 PIPE 1

168 1154192151 CLIP 1

225A 9044110280 STUD, M10X28 L=43 2

225B 5093000290 STUD, M10X18 L=33 2

231 1154192162 STAY 1

PAGE 114 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — EXHAUST MANIFOLD ASSY.

EXHAUST MANIFOLD ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 115

ISUZU 6BG1 — EXHAUST MANIFOLD ASSY.

EXHAUST MANIFOLD ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1A 9141412761 EXHAUST MANIFOLD 1

1B 9141418030 EXHAUST MANIFOLD 1

2C 1141451140 GASKET ............................................. 6 ............. UP TO MAR. 99

2A 8944046100 GASKET ............................................. 3 ............. FROM APR. 99~

16 9044110300 STUD, M10X30 L=45 3

18 9098445650 NUT 12

155 9141496530 RING 3

PAGE 116 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — VENTILATION ASSY.

VENTILATION ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 117

ISUZU 6BG1 — VENTILATION ASSY.

VENTILATION ASSY.

NO. PART NO. PART NAME QTY.REMARKS

23 1093607520 HOSE, L=240 1

24 1097070841 CLIP, ID=20 2

141 8941101110 DIAPHRAGM ASSY. 1

142 1143620020 COVER 1

143 9934905100 SCREW, M5X10 PANHEAD 6

PAGE 118 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — WATER PUMP AND CORROSION RESISTOR ASSY.

WATER PUMP AND CORROSION RESISTOR ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 119

ISUZU 6BG1 — WATER PUMP AND CORROSION RESISTOR ASSY.

WATER PUMP AND CORROSION RESISTOR ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1136500180 PUMP ASSY ........................ 1 ..................... INCL. ITEMS W/*

3 8943706610 GASKET 1

4* 1878112530 REPAIR KIT .......................... 1 ..................... INCL. ITEMS W/#

7 5136410381 PULLEY, 2-GROOVE, D=173 1 ..................... UP TO MAR. 99

1136411870 PULLEY, 2-GROOVE, D=173 1 ..................... FROM APR. 99~

8*# 5136390010 THROWER 1

9A*# 9099521430 SNAP RING 1

9B* 9091801520 SNAP RING 1

10A* 5098000510 BEARING 1

10B* 5098000500 BEARING 1

11* 5136340020 SPACER 1

17*# 5136200062 SEAL UNIT 1

18*# 9136218020 IMPELLER 1

19*# 9136136130 GASKET 1

20* 9136128020 COVER 1

24* 0280810700 BOLT, M10X70 FLANGE 1

0280810500 BOLT, M10X50 2

0286810350 BOLT, M10X35 1

25* 5136420072 CENTER 1

28*# 1095030700 WASHER 1

29*# 1136310740 SHAFT 1

65* 9030908200 SCREW 3

66*# 5096250550 SEAL 1

117* 1096601192 CONNECTOR 1

PAGE 120 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

THERMOSTAT AND HOUSING ASSY.

ISUZU 6BG1 — THERMOSTAT AND HOUSING ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 121

ISUZU 6BG1 — THERMOSTAT AND HOUSING ASSY.

THERMOSTAT AND HOUSING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1137700700 THERMOSTAT 1

2 5137160260 HOUSING 1

14 9096640050 PLUG, PT 3/4 1

17 5097040460 CLIP 2

28 9096620340 HEATER PLUG, M25 1

44A 0286810350 BOLT, M10X35 3

44B 0108060950 BOLT, M10X95 3

47 9091505100 LOCK WASHER 3

48 9091605100 PLAIN WASHER 3

49 1137130370 PIPE 1

50 0501408250 BOLT, M8X25 ............................ 3 ................ W/LOCK AND PLAIN WASHER

64 1137430160 GASKET 1

65 113740130 GASKET 1

107 5137210152 PIPE 1

PAGE 122 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — ENGINE WATER PIPING ASSY.

ENGINE WATER PIPING ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 123

ISUZU 6BG1 — ENGINE WATER PIPING ASSY.

ENGINE WATER PIPING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

132 8971380860 HOSE 1

PAGE 124 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — FAN AND FAN BELT ASSY.

FAN AND FAN BELT ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 125

ISUZU 6BG1 — FAN AND FAN BELT ASSY.

FAN AND FAN BELT ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 8944838971 FAN, D=550-7 BLOW 1

16 9091647080 PLAIN WASHER 4

24 1090440730 BOLT 4

36 1136712260 BELT, L=1246 2 PIECE SET 1

38A 8944340750 SPACER, T=51.7 1

38G 1136420470 SPACER, T=61 1

68 9091505120 LOCK WASHER 1

69 9091607120 PLAIN WASHER 2

70 9991104120 NUT 1

71 1090091141 BOLT, M10X155 1

80 1136741181 ADJ. PLATE 1

81 1136741610 SLIDING PIECE 1

86 0286810250 ADJ. BOLT, M10X25 FLANGE 1

110 9034906100 SCREW, M6X10 2

122 9091505080 LOCK WASHER 4

PAGE 126 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — FUEL INJECTION ASSY.

FUEL INJECTION ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 127

ISUZU 6BG1 — FUEL INJECTION ASSY.

FUEL INJECTION ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1156032880 FUEL INJ. PUMP ASSY. ........... 1 ................ INCL. ITEMS W/*

2 0108108750 BOLT, M8X75 4

3 9091505080 LOCK WASHER 7

4A 9098519340 WASHER 4

4B 9091605080 WASHER 7

7C 0108108600 BOLT, M8X60 ............................ 7 ................ REPLACES 0108058600

7D 0500410250 BOLT, M10X25 ........................... 1 ................ W/LOCK WASHER

15* 1157801720 COUPLING ASSY. 1

16 1154151831 PIPE, INJ. NO. 1 1

17 1154151841 PIPE, INJ. NO. 2 1

18 1154151851 PIPE, INJ. NO. 3 1

19 1154151861 PIPE, INJ. NO. 4 1

20 1154151871 PIPE, INJ. NO. 5 1

21 1154151881 PIPE, INJ. NO. 6 1

31 1153002912 NOZZLE ASSY. 6

32 8970161471 HOLDER ASSY. ........................ 6 ................ INCL. ITEMS W/#

33 5153110270 NOZZLE 6

34# 1096750371 BOLT 6

35# 1153320170 NUT 6

36# 1096300820 GASKET, ID=8 OD=13.2 12

37# 5153320060 NUT 6

38# 5153390600 GASKET 6

39# 8941695030 SCREW 6

41# 8943203080 CONNECTOR 6

42# 5153390030 GASKET 6

44# 5153430050 SPRING 6

45# 8941695020 PUSH ROD 6

46# 9153470030 PIN 12

54 9153390510 COVER 6

60 9091505080 LOCK WASHER 12

62 9091104080 NUT 12

66 5153150030 GASKET 6

75 9091607100 PLAIN WASHER 3

78 0500410200 BOLT, M10X20 ........................... 2 ................ W/PLAIN WASHER

80 1197511200 BRACKET 1

85 8943706750 GASKET 1

114 9154196120 CLIP 6

133 1154124711 PIPE 1

134 1096750371 BOLT 1

135 1096300820 GASKET, ID=8.2 OD=13.2 2

PAGE 128 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — FUEL FILTER AND BRACKET ASSY.

FUEL FILTER AND BRACKET ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 129

ISUZU 6BG1 — FUEL FILTER AND BRACKET ASSY.

FUEL FILTER AND BRACKET ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1132007011 FUEL FILTER ASSY. ................. 1 ................ INiICL. ITEMS W/*

21* 1132121080 COVER 1

29* 1132600470 VALVE 1

30* 1096300850 GASKET 2

58* 1132400691 ELEMENT 1

62 9091104100 NUT 2

63 9091505100 LOCK WASHER 2

64 9091605100 PLAIN WASHER 2

72 9091105100 NUT, M10 2

99 9091505100 LOCK WASHER 2

PAGE 130 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — FUEL PUMP AND PIPE ASSY.

FUEL PUMP AND PIPE ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 131

ISUZU 6BG1 — FUEL PUMP AND PIPE ASSY.

FUEL PUMP AND PIPE ASSY.

NO. PART NO. PART NAME QTY.REMARKS

107 1154142940 PIPE 1

108 1096750860 BOLT 1

110 1096300850 GASKET 2

111A 5097091030 CLIP, W/TUBE L=48 3

111C 5097091040 CLIP, W/OUT TUBE L=45 3

112 1096750860 BOLTM14X27 1

115 1096300850 GASKET, ID=14.2 OD=19.2 2

119 1154142950 PIPE 1

123 1154142962 PIPE 1

124 1094680021 NUT 1

126 0500406300 BOLT M6X30 ............................. 2 ................ W/LOCK WASHER

145 9095245550 CLIP, ID=6 1

150 1096300850 GASKET, ID=14.2 OD=19.2 2

212 1132600011 OVERFLOW VALVE 1

216 0500406300 BOLT, M6X30 ............................ 1 ................ W/ LOCK WASHER

217 1096300850 GASKET, ID=14.2 OD=19.2 1

PAGE 132 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — OIL COOLER AND OIL FILTER ASSY.

OIL COOLER AND OIL FILTER ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 133

ISUZU 6BG1 — OIL COOLER AND OIL FILTER ASSY.

OIL COOLER AND OIL FILTER ASSY.

NO. PART NO. PART NAME QTY.REMARKS

2 1878100752 OIL FILTER ELEMENT ............. 1 ................ INCL. ITEMS W/%

76A 9098009281 BOLTM10X145 2

76B 0286810350 BOLT, M10X35 2

102 1217002491 OIL COOLER ASSY. ................. 1 ................ INCL. ITEMS W/*

103A 8942059861 BOLT, M8X65 1

103B 0501408450 BOLT, M8X65 .......................... 10 ................ W/LOCK AND PLAIN WASHER

103C 0501408280 BOLT. M8X28 ........................... 15 ................ W/LOCK AND PLAIN WASHER

103D 1090300910 BOLT, M8X20 ............................ 2 ................ W/PLAIN WASHER

107 9091605080 PLAIN WASHER 3

110* 1112810281 BODY 1

111* 1112820180 CORE 1

115* 9091114100 NUT 4

116* 9091645100 PLAIN WASHER 4

189* 9132630100 PLUG 1

190* 9095622150 GASKET 1

191* 5095800920 BYPASS SPRING 1

192* 5112880010 BYPASS VALVE 1

196 5096050170 PLUG 2

265# 5132110100 BODY 1

281# 5132120212 COVER 1

284# 1132310420 BOLT 1

288# 109000105 PLUG, M10 1

290A%# 9099203110 GASKET 1

290B%# 9099206940 GASKET, ID=15.5 1

290C%# 1096230550 GASKET, ID=9.8 1

292 9099412830 SPRING 1

293 9132390250 SEAT 1

297 9098621610 PLUG 1

307 5132600061 VALVE 1

309 1096231630 GASKET 1

321 8943706700 GASKET 1

328 8941486171 BOLT 1

331 9091605100 PLAIN WASHER 2

333 9095720100 GASKET, ID=10.2 OD=19 2

410 1096231630 GASKET 1

444* 1112820140 GASKET 2

469 112820200 GASKET 1

496 5132000726 OIL FILTER ASSY. .................... 1 ................ INCL. ITEMS W/#

PAGE 134 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — OIL PUMP AND OIL STRAINER ASSY.

OIL PUMP AND OIL STRAINER ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 135

ISUZU 6BG1 — OIL PUMP AND OIL STRAINER ASSY.

OIL PUMP AND OIL STRAINER ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1131002770 OIL PUMP ASSY. ...................... 1 ................. INCL. ITEMS W/*

2* 5131650040 SEAT 1

3* 9081140300 PIN 1

5* 5095800980 SPRING 1

8* 5131250010 GEAR 1

11* 1131130470 COVER ASSY. 1

20* 5131210050 GEAR 1

29 0286810250 BOLT, M10X25 FLANGE 2

32* 1131280180 PINION 1

37* 1131190030 DOWEL 1

39* 9131190100 COLLAR 1

40* 1131230160 COUPLING 1

41* 5098430030 BALL 1

42* 1131401160 STRAINER 1

65 9131190100 COLLAR 1

97* 1090440470 BOLT, M8X60 4

PAGE 136 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — OIL AND VACUUM PIPING ASSY.

OIL AND VACUUM PIPING ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 137

ISUZU 6BG1 — OIL AND VACUUM PIPING ASSY.

OIL AND VACUUM PIPING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5133112050 PIPE ....................................... 1 ................... INCL. ITEMS W/*

2 1096750770 BOLT, M10X21 1

37 5133111190 PIPE 1

40 0286808400 BOLT, M8X40 FLANGE 4

47A 9099211880 GASKET, ID=18 2

47B 1096234620 GASKET, ID=22.8 2

62 1133115322 PIPE 1

110 9098440220 NUT 1

117 1096300830 GASKET, ID=10.2 2

134* 9099171051 CLIP 1

143 0280808400 BOLT, M8X40 FLANGE 4

277# 1117500241 CAP 1

278 9099129760 HOSE 1

279 9099155531 CLIP 2

430 9091505080 LOCK WASHER 1

434 9091104080 NUT 1

448 1117402011 FILLER ................................... 1 ................... INCL. ITEMS W/#

PAGE 138 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — ELECTRICAL CONTROL ASSY.

ELECTRICAL CONTROL ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 139

ISUZU 6BG1 — ELECTRICAL CONTROL ASSY.

ELECTRICAL CONTROL ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1811001911 STARTER ASSY. 1

2 1812003650 GENERATOR ASSY. 1

7 9991104120 NUT 3

16 1090001331 BOLT, M14X135 1

17 9091605140 PLAIN WASHER 1

18 9091505140 LOCK WASHER 1

23 9991104140 NUT 1

26A 0280810250 BOLT, M10X25 FLANGE 1

26C 0286810350 BOLT, M10X35 2

38 9825300430 RESISTOR 1

56A 5831510030 SWITCH ................................... 1 .................. INCL. ITEMS W/*

56D* 9827200690 SWITCH 1

88* 9099022380 ADAPTER 1

89 8971256010 SWITCH 1

252 1197190362 COVER 1

292 9091505120 LOCK WASHER 3

293 9829322110 CABLE 1

488 1819001931 STOPPER 1

PAGE 140 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — STARTER COMP. ASSY.

STARTER COMP. ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 141

ISUZU 6BG1 — STARTER COMP. ASSY.

STARTER COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1811293640 SEAL KIT ........................................ 1 .................. INCL. ITEMS W/1

2 1811230250 CASE .............................................. 1 .................. INCL. ITEMS W/%

3% 1811293970 METAL 1

4 5811291420 COVER 1

5 5811291440 CLIP 2

6 5811291450 STOPPER 1

8 1811130260 BRACKET 1

9& 1811293860 BEARING 1

10 1811230240 SHAFT ........................................... 1 .................. INCL. ITEMS W/&

11A 5811291600 WASHER 1

11B 5811291590 WASHER 2

11C 5811291580 WASHER 1

12 1811130730 BRACKET 1

15 1811160440 WIRE 1

16 1811210370 ARMATURE ................................... 1 .................. INCL. ITEMS W/#

17A# 1811293950 BEARING ....................................... 1 .................. UP TO MAR. 95

5811291550 BEARING ....................................... 1 .................. FROM APR. 95~

17B# 1811293850 BEARING ....................................... 1 .................. UP TO MAR. 95

1811291960 BEARING ....................................... 1 .................. FROM APR. 95~

18 5811291560 WASHER 2

19 1811293960 COIL 1

20* 1811160420 BRUSH, + 2

21* 1811170140 SPRING 2

22* 1811180360 HOLDER 1

23* 1811150620 COVER 1

27A 1811293870 BOLT 3

27B 5811292140 BOLT 2

28 1811270310 LEVER 1

29 1811291850 PIN 1

30 5811291470 PLATE 1

31 5811510360 SWITCH 1

50* 1811160430 BRUSH, - 2

54 5811220160 CLUTCH 1

57 1811150610 COVER ASSY. ................................ 1 .................. INCL. ITEMS W/*

59 5811291500 TERMINAL 1

60 5811291460 PLUNGER 1

61 5811291480 CONTACT 1

62 9821161400 BUSHING 1

63 5811180190 HOLDER 1

64A 9821161420 WASHER 1

64B 5811291510 WASHER 2

65 5811291490 RING 2

77 1812291140 WASHER 2

78 1811293840 TERMINAL 1

80 1811291840 NUT 1

86 1825530230 RELAY ............................................ 1 .................. UP TO MAR. 95

1825530370 RELAY ............................................ 1 .................. FROM APR. 95~

PAGE 142 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — ALTERNATOR COMP. ASSY.

ALTERNATOR COMP. ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 143

ISUZU 6BG1 — ALTERNATOR COMP. ASSY.

ALTERNATOR COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1812142290 REAR COVER 1 .................. INCL. ITEMS W/#

2 1812210720 ROTOR 1

3T 1812292250 BEARING 1

3U 8941730540 BEARING 1

5 1812170620 HOLDER 1

6# 1812700070 REGULATOR ASSY. 1

10# 1812170690 RECTIFIER 1

11# 1812142240 COVER 1

12 9822158670 KEY 1

13 1812293830 GASKET 2

14B 1812295270 COLLAR 1

14C 1812295430 COLLAR 1

15H 1812295130 RETAINER 1

15F 1812293760 RETAINER 1

15I 1812295260 RETAINER 1

15L 8941730600 RETAINER 1

17 1812130670 FRONT COVER 1

19 1812220550 PULLEY 1

20 1812230090 FAN 1

22 1812110900 STATOR 1

33# 1812295560 WIRE 1

49# 8941730610 BUSHING 1

57 1812295440 COVER 1

62 1812291220 CLIP 1

69 1812295160 CLIP 1

PAGE 144 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — INJ. PUMP COMP. ASSY.

INJ. PUMP COMP. ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 145

ISUZU 6BG1 — INJ. PUMP COMP. ASSY.

INJ. PUMP COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5156110250 HOUSING ............................................ 1 .................... INCL. ITEMS W/*

6* 5156440170 HOLDER 6

7* 1096230520 GASKET 6

8* 5156290450 STOPPER 6

9* 5156430010 SPRING 6

10* 1156490010 GASKET 6

14* 5156410010 VALVE 6

19* 1156310690 PLUNGER ASSY. 6

33 1096230130 GASKET 1

46 1156192430 COVER 1

48 5156191560 GASKET 14

49 9812250470 RING 1

50* 5156210250 CAMSHAFT 1

51 5196190490 KEY 1

62 9812350150 SEAT 6

63 5156430090 SPRING 6

64 9812350210 SET 6

68 9812212230 TAPPET ............................................... 6 .................... INCL. ITEMS W/#

69# 5156190410 GUIDE 6

70# 9812222200 PIN 6

71# 1156290010 BUSHING 6

72# 1156220030 ROLLER 6

73*% 1157299600 GASKET 1

74 1156120500 COVER ................................................ 1 .................... INCL. ITEMS W/%

75* 1156190030 SCREW 2

77 1156190330 BEARING 1

79* 9812151150 STUD 3

80 8941711100 NUT 3

82 5156191360 PLUG 6

88 1156190920 BOLT 1

89 1157190930 GASKET 2

105 9000906770 BEARING, NSK 1

5098000380 BEARING, NTN 1

107 5156290150 SHIM ................................................. AR .................... T=0.10

5156290160 SHIM ................................................. AR .................... T=0.12

5156290170 SHIM ................................................. AR .................... T=0.14

5156290180 SHIM ................................................. AR .................... T=0.16

5156290190 SHIM ................................................. AR .................... T=0.18

5156290200 SHIM ................................................. AR .................... T=0.50

5156290380 SHIM ................................................. AR .................... T=1.00

9812250330 SHIM ................................................. AR .................... T=0.30

5156190390 SHIM ................................................. AR .................... T=0.70

5156290900 SHIM ................................................. AR .................... T=1.40

1156390880 SHIM ................................................. AR .................... T=2.40

109* 5156370030 RACK 1

114 5098000380 BEARING, NTN 1

9000906770 BEARING, NSK 1

117 1096300850 GASKET, ID=14.2 OD=19.2 2

118 1157590110 BOLT 1

126* 9812350170 ADAPTER 1

127* 5156190440 ADAPTER 1

130 9019006140 SCREW, M6X14 ................................... 4 .................... W/LOCK WASHER

148* 9812151440 GASKET 2

115 1156190240 BOLT 1

PAGE 146 — DCA-60SSI2 — PARTS AND OPERATION MANUAL — REV. #3 (09/15/01)

ISUZU 6BG1 — INJ. PUMP COMP. ASSY.

INJ. PUMP COMP. ASSY.

DCA-60SSI2 — PARTS AND OPERATION MANUAL— REV. #3 (09/15/01) — PAGE 147

ISUZU 6BG1 — INJ. PUMP COMP. ASSY.

NJ. PUMP COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

157* 8941445880 GASKET 1

159 9812250470 RING 1

160 9884100660 SCREW 2

161 9812250430 GASKET 2

162 5156290150 SHIM ................................................. AR .................... T=0.10