Multiquip Portable Generator Dca 60Ssai Users Manual

Multiquip Portable Generator dca-60ssai Generators_portable_supersilent_DCA60SSAI_rev_0__manual_DataId_19055_Version_1

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PARTS AND OPERATION MANUAL

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

SERVICE DEPARTMENT:

800-421-1244 800-835-2551

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

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

PARTS AND OPERATION MANUAL

MQ POWER

DCA-60SSAI

WHISPERWATT

GENERATOR

(Standard)

PARTS LIST NO. 7451201B

FINAL COPY

PAGE 2 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI

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 6BD1 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

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DCA-60SSAI —TRAILER-SPECIFICATIONS

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 13

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DCA-60SSAI —TRAILER-SPECIFICATIONS

PAGE 14 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI —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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 15

DCA-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — TRAILER SAFETY GUIDELINES

Figure 4. Major Suspension Components

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI —TRAILER SAFETY GUIDELINES

Figure 5. Wheel Lug Nuts Tightening Sequence

PAGE 18 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

NOTE:

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

DCA-60SSAI —TRAILER-WIRING DIAGRAM

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 19

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DCA-60SSAI —TRAILER-BRAKE TROUBLESHOOTING

PAGE 20 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

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DCA-60SSAI —TRAILER-BRAKE TROUBLESHOOTING

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 21

DCA-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — GENERATOR DECALS

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 23

DCA-60SSAI — SPECIFICATIONS

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PAGE 24 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — GENERAL INFORMATION

DCA-60SSAI FAMILIARIZATION

Generator

The MQ Power Model DCA-60SSAI 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-60SSAI 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-60SSAI

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-60SSAI 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 25

DCA-60SSAI — MAJOR COMPONENTS

Figure 6. Major Components

PAGE 26 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

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

Figure 7. Dimensions

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 27

NOTE PAGE

PAGE 28 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — CONTROL PANEL

Figure 8. Control Panel

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 29

DCA-60SSAI — CONTROL PANEL

The definitions below describe the controls and functions of

the DCA-60SSAI "

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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — ENGINE OPERATING PANEL

Figure 9. Engine Operating Panel

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 31

The definitions below describe the controls and functions of

the DCA-60SSAI "

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-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 33

DCA-60SSAI — OUTPUT TERMINAL VOLTAGE SELECTION

DCA-60SSAI

Legs O and Ground are

considered Bonded Grounds.

NOTE

Figure 12. Output Panel Location

PAGE 34 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — OUTPUT AMPERAGE SETUP

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — OUTPUT AMPERAGE SETUP

PAGE 36 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — OUTPUT VOLTAGE SETUP

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — OUTPUT VOLTAGE SETUP

PAGE 38 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — OUTPUT VOLTAGE SETUP

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — OUTPUT VOLTAGE SETUP

PAGE 40 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

Outdoor Installation

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

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

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

the generator so the exhaust will not be discharged in the

direction of nearby homes.

The installation site must be relatively free from moisture

and dust. All electrical equipment should be protected from

excessive moisture. Failure to do will result in deterioration

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

Foreign materials such as dust, sand, lint and abrasive

materials have a tendency to cause excessive wear to the

engine and alternator parts.

CAUTION :

Pay close attention to ventilation when

operating the generator inside tunnels and

caves. The engine exhaust contains

noxious elements. Engine exhaust must

be routed to a ventilated area.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.

Whenever an engine is installed indoors the exhaust fumes

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

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

pipe which is too long or too small can cause excessive

back pressure which will cause the engine to heat

excessively and possibly burn the valves.

CAUTION

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-60SSAI — INSTALLATION

NOTE

When connecting the generator to any buildings

electrical system ALWAYS consult with a licensed

electrician.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 41

Figure 32. Typical Generator Grounding Application

DCA-60SSAI — INSTALLATION

PAGE 42 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

General Inspection Prior to Operation

The DCA-60SSAI 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-60SSAI — PRE-SETUP

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ALWAYS consult with a licensed

electrician for correct extension

cord wire size.

NOTE

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 45

DCA-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — 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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NOTE

If wattage is not given on the

equipment's name plate, approximate

wattage may be determined by

multiplying nameplate voltage by the

nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 1.0. See Table 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — GENERATOR SHUT-DOWN PROCEDURE

Figure 57. Key Switch (OFF)

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 51

NOTE PAGE

PAGE 52 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 53

DCA-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — 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.

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OO OO

NOTE:

Take necessary precautions to prevent dust and

foreign particles in the pump interior when timing

adjustments are made.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — MAINTENANCE

ECNANETNIAM/NOITCEPSNI

srH01

YLIAD srH052 srH005 srH0001

ENIGNE

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

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.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

.ylnoemittsrif,sruoH052taretlifleufecalpeR

PAGE 56 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — GENERATOR WIRING DIAGRAM

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 57

DCA-60SSAI — ENGINE WIRING DIAGRAM

PAGE 58 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — 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

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?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

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?tungniniaterepip .tunnethgiT

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip .ecalperroriapeR

?rednilycmorfkaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

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?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.nurtonseodretratS

?gninoitcnuflamretratS .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 59

DCA-60SSAI — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.61ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

.htoomstonsinoituloverenignE

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.devresbosi

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ronrowrenildnagnirnotsiP

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.devresbosisag

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.tuptuotneicifeD

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?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

PAGE 60 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

GNITOOHSELBUORTROTARENEG&ENIGNE.71ELBAT

MOTPMYSMELBORPELBISSOPNOITULOS

retratsdnatratsotsliafenignE

.detatortonseod

?yrettabdaeD.yrettabecalpeR

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?tuodenrub5FesuF.esufecalpeR

retratsdnatratsotsliafenignE

.setator

?tiucrictaeh-erpnekorB.tiucrictaeh-erpkcehC

?leufoN.leufddA

?gniriwevitcefeD.gniriwkcehC

woltasniamerdnastratsenignE

.deeps

?reniartsleufdeggolC.ecalperronaelC

?renaelcriadeggolC.ecalperronaelC

?gniriwdetcennocsiD.gniriwriaperdnakcehC

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niseriwnekorb,tiucric-trohsreyaL

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yrettabdnasesirdeepsenignE

.noosootsegrahcsid

?rotalugerenigneevitcefeD.rotalugerecalpeR

?gniriwevitcefeD.gniriwecalperroriapeR

enignednasesirdeepsenignE

.dedaolrevosmees

?rotanretlaevitcefeD.rotanretlaecalperroriapeR

?gniraebrotanretladegamaD.sgniraebrotanretlaecalpeR

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-60SSAI — TROUBLESHOOTING (GENERATOR/ENGINE)

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 61

NOTE PAGE

PAGE 62 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 63

DCA-60SSAI DCA-60SSAI

DCA-60SSAI W/ISUZU 6BD1 DIESEL ENGINEW/ISUZU 6BD1 DIESEL ENGINE

W/ISUZU 6BD1 DIESEL ENGINEW/ISUZU 6BD1 DIESEL ENGINE

W/ISUZU 6BD1 DIESEL ENGINE

1 1

1 TT

TO 3 UNITSO 3 UNITS

O 3 UNITSO 3 UNITS

O 3 UNITS

DCA-60SSAI — 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 65

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

1 7451040000 FIELD ASSY. 1

1-1 3361010112 SHAFT 1

1-2 7461042003 FIELD CORE 1

1-3 3361080003 FIELD COIL 1

1-4 3361032003 ARMATURE CORE, EXCITER 1

1-5 3361085003 ARMATURE COIL, EXCITER 1

1-6 3341610003 COUPLING HUB 1

2 3361025003 RECTIFIER ASSY. 1

2-1 3361026003 SET PLATE, RECTIFIER 1

2-2 0601820067 RECTIFIER 3 ........... PB2510

2-3 0010004020 HEX. HEAD BOLT 3

2-4 0041604000 PLAIN WASHER 6

2-5 0040004000 LOCK WASHER 3

2-6 0030004000 HEX. NUT 3

2-7 0601822601 SURGE ABSORBER 1 ........... ERZM14JK621A

2-8 0801841004 INSULATOR WASHER 1

2-9 0801841104 INSULATOR WASHER 1

2-10 0010005020 HEX. HEAD BOLT 1

2-11 0041605000 PLAIN WASHER 2

2-12 0040005000 LOCK WASHER 1

2-13 0030005000 HE. NUT 1

2-14 0017105012 HE.HEAD BOLT 4

3 3331014004 BEARING FLANGE 1

4 0070206310 BEARING 1 ........... 6310RS

5 008000050 SNAP RING 1

6 3361070003 FAB 1

7 3341611003 COUPLING DISC 1 ........... (80 0

8 3341613004 LOCK WASHER 5

10 0010312030 HEX. HEAD BOLT 10

11 060160000 COUPLING RING 1 ........... 92612590050

12 0601610700 LOCK WASHER 9 ........... 9091505100

13 0601610511 BOLT SET 1

14 0040010000 LOCK WASHER 9

15 0010310030 HEX. HEAD BOLT 9

16 7451340000 STATOR ASSY. 1

16-1 3361320122 GENERATOR FRAME 1

16-2 3361342024 ARMATURE CORE 1

16-3 7451361113 ARMATURE COIL 1

17 0801350104 GROMMET 1

18 3361315013 END BRACKET 1

PAGE 66 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 67

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSAI --- GENERATOR ASSY.

GENERATOR ASSY.

19 3361350030 FIELD ASSY., EXCITER 1

19-1 3361352023 FIELD CORE, EXCITER 1

19-2 3361362303 FIELD COIL, EXCITER 1

20 0041608000 PLAIN WASHER 4

21 0040008000 LOCK WASHER 4

22 0010008060 HEX. HEAD BOLT 4

23 0040010000 LOCK WASHER 6

24 0010010030 HEX. HEAD BOLT 6

25 3801312004 GASKET, BERAING 1

26 3331310104 COVER, BEARING 1

27 0040006000 LOCK WASHER 4

28 0010006055 HEX. HEAD BOLT 4

29 3361331003 COVER, END BRACKET 1

30 0017106010 HEX. HEAD BOLT 8

31 0040010000 LOCK WASHER 6

32 0010310025 HEX. HEAD BOLT 6

33 3341332103 COVER, FAN 1

34 0041606000 PLAIN WASHER 1

35 0040006000 LOCK WASHER 1

36 0010006030 HEX. HEAD BOLT 1

37 0605000011 RUBBER SUSPENSION 2

38 0040016000 LOCK WASHER 4

39 0030116000 HEX. NUT 4

PAGE 68 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 69

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSAI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

1 7451810002 CONTROL BOX 1 ....... UP TO S/N3311616

7451810012 CONTROL BOX 1 ....... S/N3311617 TO 3312672

7451810022 CONTROL BOX 1 ....... S/N3312673~

2 3361870603 CURRENT TRANSORMER 3

3 0017106016 HEX. HEAD BOLT 6

4 0601801143 CURRENT TRANSORMER, AMMETER 2 ....... CT3.5MR 100/5A

5 0027104010 MACHINE SCREW 4

6 0800225201 AUTOMATIC VOLTAGE REGULATOR 1 ....... AE2206A

7 0027106010 MACHINE SCREW 6

8 0601820042 RECTIFIE 1 ....... 16T60

9 0027103010 MACHINE SCREW 4

10 0601842058 RESISTOR 1 ....... RWH80V 200KOHMS

11 0027105010 MACHINE SCREW 2

12 0601820851 OVER CURENT RELAY 1 ....... THK20

13 0027104016 MACHINE SCREW 2

14 0601805352 CIRCUIT BREAKER 1 ....... KM203 550V 150AT

15 0041604000 PLAIN WASHER 4

16 0040004000 LOCK WASHER 4

17 0021004020 MACHINE SCREW 4

18 0601830625 CHANGE-OVER SW. VOLTAGE 1

0601840191 SWITCH CAP 1

0601830614 PLATE 1

19 0021104016 MACHINE SCREW 4

20 0021104014 MACHINE SCREW 2

21 7451822503 CONTROL PANEL 1

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

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

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

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

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

27 0601810072 PILOT LAMP 1

0601810261 BULB 1

PAGE 70 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 71

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSAI --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

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

29 0601840120 KNOB 1

30 3331824003 STOPPER, CONTROL PANEL 1

31 0027105016 MACHINE SCREW 2

32 0030005000 HEX. NUT 2

33 0805001304 SET SCREW, CONTROL PANEL 2

34 0041608000 PLAIN WASHER 2

35 0030008000 HEX. NUT 2

36 0027105010 MACHINE SCREW 4

37 7451826504 SIDE PANEL, CONTROL BOX 1 ....... UP TO S/N3311616

7451826514 SIDE PANEL, CONTROL BOX 1 ....... S/N3312178~

38 0017106016 HEX. HEAD BOLT 2

39 0017108020 HEX. HEAD BOLT 4

40 0030008000 HEX., NUT 4

41 0601815933 TERMINAL 1 ....... S/N3312673~; AYBS0431

42 0601815934 TERMINAL 1 ....... S/N3312673~; AYBS0441

43 0027105020 MACHINE SCREW 4 ....... S/N3312673~

PAGE 72 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 73

DCA-60SSAI ENGINE AND RADIATOR ASSY.

NO. PART NO.ITEM QTY.REMARKS

ENGINE AND RADIATOR ASSY.

1 0602000100 ENGINE ........................................... 1 ......... ISUZU 6BD1

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

3 0602013901 RADIATOR HOSE ........................... 1 ......... B400008

4 0602013160 RADIATOR HOSE ........................... 1 ......... B400007

5 0602014302 HOSE BAND 3

6 0602014303 HOSE BAND 1

7 0602040090 AIR CLEANER ................................. 1 ......... FWG088006

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

8 0602040690 DUST INDICATOR ........................... 1 ......... RBX002252

9 0602040598 BAND, AIR CLEANER ..................... 2 ......... AAH008263

10 0017108020 HEX. HEAD BOLT 4

11 0030008000 HEX. NUT 4

12 7452032303 HOSE, AIR CLEANER 1

13 0605515008 HOSE BAND 2

14 0602041106 ELEMENT, OIL FILTER ................... 1 ......... 1878100750

15 0602042106 ELEMENT, FUEL FILTER ............... 1 ......... 9885111911

16 3345112403 ENGIEN FOOT 1

17 3345112503 ENGIEN FOOT 1

18 0040010000 LOCK WASHER 8

19 0010710025 HEX.HEAD BOLT 8

20 0605000009 RUBBER SUSPENSION 2

21 0040012000 LOCK WASHER 4

22 0030112000HEX. NUT 4

23 0017108020 HEX. HEAD BOLT 6

24 0602210803 ENGINE STOPPER ......................... 1 ......... 1819000161

25 7452215104 BRACKET, ENGINE STOPPER 1

26 0027106016 MACHINE SCREW 3

27 0017108020 HEX. HEAD BOLT 2

28 7452051104 DRAIN JOINT 1

29 0805013704 PACKING, OIL PAN SIDE 1

30 0805014204 PACKING 1

PAGE 74 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 75

DCA-60SSAI ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO.ITEM QTY.REMARKS

31 3362054104 JOINT BOLT 1

32 3362051003 DRIAN JOINT 1

33 0802024004 PACKING 1

34 0802010204 PLUG 1

35 7452052104 DRAIN HOSE 1

36 0605515003 HOSE BAND 2

37 0017108020 HEX. HEAD BOLT 2

38 0030008000 HEX. NUT 2

39 0845031303 RESERVE TANK 1

41 7452082504 BRAKET, RESERVE TANK 1

42 0017108020 HE. 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

PAGE 76 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ENGINE OPERATING PANEL ASSY.

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

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 77

ENGINE OPERATING PANEL ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

1 7452111103 OPERATING PANEL 1

2 7452142004 SLIDE BAR 1 ......... UP TO S/N3313037

7452142014 SLIDE BAR 1 ......... S/N3313038~

3 0805012904 KNOB 1

4 0080200006 SNAP RING 1 ......... UP TO S/N3313037

0036003000 HEX. NUT 1 ......... S/N3313038~

5 7452140504 BRACKET, GOVERNOR ROD 1

6 0030008000 HEX., NUT 2

7 0605010503 SNAP PIN 1

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

9 0602102005 PREHEAT LAMP 1 ......... 9825300430

10 0602120052 TACHOMETER 1 ......... 25000KX3710

11 0602120161 CABLE, TACHOMETER 1 ......... 62100KA0910 L=1700

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

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

14 0131300000 STREET SOCKET 1

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

16 0602123204 UNIT, WATER TEMPERATURE 1 ......... 51400KA1200

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

18 0602103060 ALARM LAMP 2

0601810244 BULB 2

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

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

21 0040520000 TOITHED LOCK WASHER 1

22 0601830710 SWITCH, PANEL LIGHT 1

23 0041608000 PLAIN WASHER 2

24 0040008000 LOCK WASHER 2

25 0010008040 HEX. HEAD BOLT 2

26 0017108020 HEX. HEAE BOLT 2

30 0030008000 HEX. NUT 2

31 7452183004 LINK, GOBERNOR ROD 1

32 0010010025 HEX. HEAD BOLT 1

33 0041610000 PLAIN WASHER2

34 0030010000 HE.X NUT 1

35 7452182004 GOVERNOR ROD 1

36 7452152004 GOBERNOR ROD 1

37 0602180101 BALL JOINT 2

38 0030008000 HEX. NUT 2

39 0602180100 BALL JOINT 2

40 0030006000 HEX. NUT 3

41 0041606000 PLAIN WASHER 1

42 7455188103 SET PANEL, ELECTRIC PARTS 1

43 0017108020 HEX. HEAD BOLT 5

44 0602200405 EMERGENCY RELAY 1 ......... 1825500730

45 0027106016 MACHINE SCREW 4

46 0601823706 RELAY 1 ......... JH1A DC24V

PAGE 78 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ENGINE OPERATING PANEL ASSY.

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

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 79

47 0027104016 MACHINE SCREW 2

48 7451860203 SET BOARD, OUTPUT TERMINAL 1

49 0801830204 OUTPUT TERMINAL 4

50 0801830704 HEX. HEAD BOLT 4

51 0041412000 PLAIN WASHER 16

52 0040012000 LOCK WASHER 12

53 0039312000 HEX, .NUT 8

54 0601805318 CIRCUIT BREAKER 1 ......... S/N3312673~;KM52 265V 20A

55 0041608000 PLAIN WSHER 5

56 0040008000 LOCK WASHER 5

57 0010008030 HEX. HEAD BOLT 5

58 0601811032 RECEPTACLE 2 ......... UP TO S/N3312672; L6-20R 250V 20A

0601811032 RECEPTACLE 1 ......... S/N3312673~; L620R 250V 20A

59 0601811037 RECEPTACLE 2 ......... UP TO S/N3312672; CS8269 250V 20A

0601811034 RECEPTACLE 2 ......... S/N3312672~; CS6369 250V 50A

60 0601811031 RECEPTACLE 2 ......... UP TO S/N3312672; L530R 125V 30A

0601811092 RECEPTACLE 2 ......... S/N3312673~; L520R 125V 20A

61 0601811030 RECEPTACLE 2 ......... 5-20R 125V 20Ax2

62 0027103010 MACHINE SCREW 16

63 0041603000 PLAIN WASHER 16

64 0030003000 HEX. NUT 16

65 0601805353 CIRCUIT BREAKER 2 ......... UP TO S/N3312672; KM101 265V 75A

0601805319 CIRCUIT BREAKER 2 ......... S/N3312673~; KM52 265V 40A

66 0601805306 CIRCUIT BREAKER 2 ......... UP TO S/N3312672; KM51 265V 40A

0601805311 CIRCUIT BREAKER 2 ......... S/N3312673~; KM51 265V 50A

67 7451816004 BRACKET, CIRCUIT BREAKER 1 ......... UP TO S/N3312672

7451816014 BRACKET, CIRCUIT BREAKER 1 ......... S/N3312673~

68 0027106016 MACHINE SCREW 2

69 7451865503 COVER, OUTPUT TERMINAL 1

70 0805012304 HEX. HEAD BOLT 2

71 0041612000 PLAIN WASHER 4

72 0805019704 RUBBER WASHER 2

73 0030012000 HEX. NUT 2

74 0605010505 SNAP PIN 2

75 0601850091 RUBBER CUSHION 2 ......... SK156

76 0021003010 MACHINE SCREW 2

77 0601802133 FUSE 1 ......... F5 5A

78 0601820015 RECTIFIER 4 ......... 1S2762

79 7451865603 COVER, OUTPUT TERMINAL 1 ......... FROM S/N3312331

80 7451855503 HINGE 1 ......... FROM S/N3312331

81 7451855703 HINGE 1 ......... FROM S/N3312331

82 0021304015 MACHINE SCREW 4 ......... FROM S/N3312331

83 0040004000 LOCK WASHER 4 ......... FROM S/N3312331

84 0041204000 PLAIN WASHER 8 ......... FROM S/N3312331

85 0030104000 HEX. NUT 4 ......... FROM S/N3312331

0030104000 HEX. NUT 4 ......... SN3312672~

ENGINE OPERATING PANEL ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

PAGE 80 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI --- BATTERY ASSY.

BATTERY ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 81

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSAI --- BATTERY ASSY.

BATTERY ASSY.

1 0160012100 BATTERY ......................................... 2 ......... N1000 12V 100Ah

2 0805003904 BATTERY SHEET 2

3 0805004004 BATTERY BAND 2

4 0805002904 BATTERY BOLT 4

5 0041608000 PLAIN WASHER 4

6 0040008000 LOCK WASHER 4

7 0037808000 WING NUT 4

8 0215260065 BATTERY CABLE 1

9 02511160180 BATTERY CABLE 1

10 0215860100 BATTERY CABLE 1

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

0208008000 WING NUT ....................................... 2

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

0208008000 WING NUT ....................................... 2

PAGE 82 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI --- MUFFLER ASSY.

MUFFLER ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 83

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSAI --- MUFFLER ASSY.

MUFFLER ASSY.

1 7452330103 EXHAUST PIPE 1

2 0602320000 GASKET 1 ......... 9221160010

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

4 3802311122 MUFFLER 1

5 0017110020 HEX. HEAD BOLT 4

6 7452330303 EXHAUST PIPE 1

7 3342356104 GASKET 1

8 0010108035 HEX. HEAD BOLT 4

9 0041608000 PLAIN WASHER 4

10 0040008000 LOCK WASHER 4

11 0030008000 HEX. NUT 4

12 1382320003 PIPE BAND 1

13 0010008030 HEX. HEAD BOLT 1

14 0041608000 PLAIN WASHER 1

15 0030008000 HEX. NUT 1

16 3342354104 COVER 1

17 3342354004 COVER 1

18 3342328104 PIPE CLAMPER 1

19 0030008000 HEX. NUT 4

20 3342359004 COVER SHEET 2

21 0017108025 HEX. HEAD BOLT 4

PAGE 84 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI --- FUEL TANK ASSY.

FUEL TANK ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 85

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSAI --- FUEL TANK ASSY.

FUEL TANK ASSY.

1 7455510123 FUEL TANK 1 ......... UP TO S/N3312672

7455510303 FUEL TANK 1 ......... S/N3312673~

1-1 0810105004 CAP, FUEL TANK 1

1-2 0810105400 FUEL FILTER 1

2 0802010304 PACKING 1 ......... UP TO S/N3312672

3 0602021042 PLUG 1 ......... UP TO S/N3312672; 960922101

4 7455523104 TANK BAND 2 ......... UP TO S/N3312672

7455523304 TANK BAND 2 ......... S/N3312673~

5 0805003404 PAD, TANK BAND 4

6 0017108020 HEX. HEAD BOLT 2

7 0041608000 PLAIN WASHER 2

8 0040008000 LOCK WASHER 2

9 0030008000 HEX. NUT 2

10 3805522004 TANK SHEET 4

11 0191300530 SUCTION HOSR 1

12 0191300650 RETURN HOSE 1

13 0605515014 HOSE BAND 4

14 0845032204 DRAIN JOINT 1

15 0150000018 O RING 1

16 0802011104 PLUG 1

17 0193100255 FUEL GAUGE HOSE 1

18 0605515079 HOSE BAND 2

19 0131906000 CAP 1 ......... S/N3312673~

PAGE 86 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ENCLOSURE ASSY.

DCA-60SSAI --- ENCLOSURE ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 87

NO. PART NO.ITEM QTY.REMARKS

ENCLOSURE ASSY.

DCA-60SSAI --- ENCLOSURE ASSY.

1 7455111012 BASE 1 ............ UP TO S/N3312672

7455111102 BASE 1 ............ S/N3312673~

2 7455109104 ACOUSTIC SHEET 1

3 7455116004 FLOOR PANEL 1

0017108020 HEX. HEAD BOLT 12

5 7455121012 FRONT FRAME 1

6 7455109203 ACOUSTIC SHEET 1

7 7450630503 STRIPE, LEFT SIDE 1

8 7450630703 STRIPE, RIGHT SIDE 1

9 6360510003 EMBLEM 2

10 0021106020 MACHINE SCREW 4

11 0017108020 HEX. HEAD BOLT 6

12 0800251201 FILTER COVER 1

13 0027106016 MACHINE SCREW 2

14 7455125003 COVER, FRONT FRAME 1 ............ UP TO S/N3312672

7455125503

15 7455109304 ACOUSTIC SHEET 1

16 7450630303 STRIPE 1

17 0017108020 HEX., HEAD BOLT 16

18 7455125303 COVER, FRONT FRAME 1

19 0017108020 HEX.HEAD BOLT 12

20 3385155104 COVER 2

21 0017106020 HEX. HEAD BOLT 8

22 7455125104 COVER, FROT FRAME 1

23 7455109404 ACOUSTIC SHEET 1

24 0017108020 HEX. HEAD BOLT 6

25 7455125204 COVER, FRONT FRAME 1 ............ UP TO S/N3312672

7455125704 COVER, FRONT FRAME 1 ............S/N3312673~

26 7455109504 ACOUSTIC SHEET 1

27 0017108020 HEX. HEAD BOLT 4

28 7455132013 CENTER FRAME 1

29 7455132203 CENTER FRAME 1

30 00101141040 HEX. HEAD BOLT 8

31 0041614000 PLAIN WASHER 16

32 0040014000 LOCK WASHER 8

33 0030014000 HEX. NUT 8

34 0010012030 HEX. HEAD BOLT 10

35 0040012000 LOCK WASHER 10

36 0041612000 PLAIN WASHER 10

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

PAGE 88 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ENCLOSURE ASSY.

DCA-60SSAI --- ENCLOSURE ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 89

ENCLOSURE ASSY.

DCA-60SSAI --- ENCLOSURE ASSY.

NO. PART NO.ITEM QTY.REMARKS

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

37 7455141102 REAR FRAME 1 ............UP TO S/N3311616

7455141112 REAR FRAME 1 ............S/N3312178~

38 7455109603 ACOUSTIC SHEET 1

39 7450630904 STRIPE 2

40 0017108020 HEX. HEAD BOLT 4

41 7455155003 COVER, REAR FRAME 1

42 7455109703 ACOUSTIC SHEET 1

43 0041608000 PLAIN WASHER 8

44 0040008000 LOCK WASHER 8

45 0010008040 HEX. HEAD BOLT 8

46 7455143103 DOOR, REAR FRAME 1 ............UP TO S/N3311616

7455143113 DOOR, REAR FRAME 1 ............S/N3312178~

47 1320632003 STICKER 1

48 3805147104 WINDOW PLATE 1

49 0021006020 MACHINE SCREW 6

50 0041606000 PLAIN WASHER 6

51 0040006000 LOCK WASHER 6

52 0030006000 HEX. NUT 6

53 0845028303 HINGE 2

54 0017108025 HEX. HEAD BOLT 4

55 7455161012 ROOF PANEL 1

56 7455109803 ACOUSTIC SHEET 1

57 0017108020 HEX. HEAD BOLT 16

58 7455165004 GUIDE PANEL, AIR 2

59 7455109904 ACOUSTIC SHEET 2

60 0017108020 HEX. HEAD BOLT 8

61 7455181202 SPLASHER PANEL 1 ............UP TO S/N3312672

7455181212 SPLASHER PANEL 1 ............S/N3312673~

62 7455105004 ACOUSTIC SHEET 1

63 0010008055 HEX. HEAD BOLT 6

64 0040008000 LOCK WASHER 6

65 001608000 PLAIN WASHER 6

PAGE 90 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI --- RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 91

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSAI --- RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

66 7455171403 SIDE DOOR, LEFT SIDE 1 ............ UP TO S/N3311616

7455171413 SIDE DOOR, LEFT SIDE 1 ............S/N3312178~

67 7455105104 ACOUSTIC SHEET 1

68 7455171503 SIDE DOOR, RIGHT SIDE 1 ............UP TO S/N3311616

7455171513 SIDE DOOR, RIGHT SIDE 1 ............S/N3312178~

69 7455105204 ACOUSTIC SHEET 1

70 7450631104 STRIPE 2

71 7455171603 SIDE DOOR, LEFT SIDE 1 ............ UP TO S/N3311616

7455171613 SIDE DOR, LEFT SIDE 1 ............S/N3312178~

72 7455105304 ACOUSTIC SHEET 1

73 7450631304 STRIPE 1

74 7455171703 SIDE DOOR, RIGHT SIDE 1 ............UP TO S/N3311616

7455171713 SIDE DOOR, RIGHT SIDE 1 ............S/N3312178~

75 7455105404 ACOUSTIC SHEET 1 ............

76 7450631504 STRIPE 1

77 0845028203 HINGE 4

78 0845028303 HINGE 4

79 0017108025 HEX. HEAD BOLT 16

80 0845031504 CAP 10

81 0605010910 LATCH 1 ............UP TO S/N3311616

82 0027103010 MACHIEN SCREW 7 ............UP TO S/N3311616

83 0605010911 LATCH 2 ............UP TO S/N3311616

84 0027104010 MACHIEN SCREW 14 .......... UP TO S/N3311616

85 7455104104 RUBBER SEAL 2

86 7455104204 RUBBER SEAL 2

87 7455104304 RUBBER SEAL 3

88 7455104404 RUBBER SEAL 1

89 7455104504 RUBBER SEAL 1

90 7455104604 RUBBER SEAL 1

91 7455104704 RUBBER SEAL 1

92 7455104804 RUBBER SEAL 2

93 7455104904 RUBBER SEAL 2

94 7455116504 COVER 1 ............S/N3312673~

95 0017108020 HEX. HEAD BOLT 2 ............ S/N3312673~

PAGE 92 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI --- DECALS

DECAL ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 93

NO. PART NO.ITEM QTY.REMARKS

DCA-60SSAI --- 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 B4561100403 STRIPE 2

35 B4561100503 STRIPE 1

36 B4561100604 STRIPE 1

37 B4561100304 STRIPE 2

38 B4561100003 STRIPE 1

PAGE 94 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

CYLINDER HEAD COVER ASSY.

ISUZU 6BD1 — CYLINDER HEAD COVER ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 95

ISUZU 6BD1 — CYLINDER HEAD COVER ASSY.

EA1013

CYLINDER HEAD COVER ASSY.

NO PART NO PART NAME QTY.REMARKS

1 1111105271 CYLINDER HEAD 1 .......... UP TO AUG. 85; REPLACES 1111105270

1111106141 CYLINDER HEAD 1 .......... AUG. 85~; INCL. ITEMS W/#

3# 1096000051 REAR SEALING CUP, D=44.5 1

3-1# 9111291280 LOWER SEALING CUP, D=20 3

3-2# 5112190150 EXH. SEALING CUP, D=31.75 3

3-3# 5096000130 DRILLED SEALING CUP, D=12 6 .......... REPLACES 9111296010

3-4# 1096000160 TOP FACE SEALING CUP, D=25 5

3-5# 1096000160 INL. MAN. SEALING CUP 6

4# 9096600340 PLUG 6

7# 9117156070 INLET VALVE SEAT INSERT 6 .......... UP TO APR. 85

1117150540 INLET VALVE SEAT INSERT 6 .......... MAY 85~

8# 1117110260 EXH. VALVE SEAT INSERT 6 .......... UP TO JUL. 85

1117110430 EXH. VALVE SEAT INSERT 6 .......... AUG. 85~

9# 5117210010 VALVE GUIDE, EXH. & INL. 12

10 9111296010 SEALING CUP, DRILLED D=12 5

15 9041108250 INLET MANIFOLD STUD 3

16 9041108750 EXH. MANIFOLD STUD 9

9098301790 EXH. MANIFOLD STUD, L1=88 2

9096300260 EXH. MANIFOLD STUD, L1=86 12

17 1093000180 NOZZLE HOLDER STUD, L1-40 12

18 9098301630 ROCKER ARM NUT STUD, L1=83 4

20 5125690010 VALVE GUIDE, INL & EXH. SEAL 12 ........ UP TO JUL. 85

1125690150 VALVE GUIDE, INL & EXH. SEAL 12 ........ AUG. 85~

21 1111410902 CYLINDER HEAD GASKET 1 .......... AUG. 84. TO AUG. 85

1111411950 CYLINDER HEAD GASKET 1 .......... AUG. 85~; REPLACES 1111411710

22 5090090180 BOLT, L=115 20 ........ UP TO SEPT. 88

1090701010 BOLT, L=113 20 ........ OCT. 88~;REPLACES 1090700630

22-1 5090090170 BOLT, L=102 6 .......... UP TO JUL. 84

1090390030 BOLT, L=106 6 .......... AUG. 84~JUL. 86

1090701000 BOLT, L=100 6 .......... JUL. 86~; REPLACES 1090700620

29-1 1111709281 CYL. HEAD COVER ASSY. 1

29-2 1111801531 CYL. HEAD COVER ASSY. 1

30 9117510381 OIL FILLER CAP 1

36 5111790520 BREATHER HOSE NIPPLE 1 .......... REPLACES 9143193681

49 1111730590 CYL. HEAD COVER PACKING 1

51 9111790300 COVER PACKING 4

52 9111791050 WASHER 4

53 9111750110 NUT 4

PAGE 96 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 97

ISUZU 6BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1112102790 CYLINDER BLOCK ASSY. ..................................... 1 .......... UP TO S/NE518004;

INCL. ITEMS W/#

1112103324 CYLINDER BLOCK ASSY. ..................................... 1 .......... REPLACES 1112103320

2# 1090004691 BOLT ...................................................................... 14 ........ REPLACES 5090001330

4# 8943706360 BRIDGE CAP NO.4 DOWEL ................................. 1 .......... REPLACES 5112570010;

UP TO MAY 89

5112570010 BRIDGE CAP NO. 4 DOWEL ................................ 1 .......... JUNE 89~

5# 9116110480 FRONT CAM METAL ............................................ 1 .......... REPLACES 911690480

5-1# 9116130350 INNER AND REAR CAM METAL .......................... 5 .......... REPLACES 9116930350

6# 1096000520 SEALING FACE CUP, D=60 2

6-1# 5112190140 LEFT SEALING CUP, D=28 2

6-2# 1096000121 TAPPET CHAMBER SEALING CUP 3

7# 1112611180 CYLINDER LINER ................................................. 6 .......... REPLACES 5112610040

8# 9098600190 REAR END CAMSHAFT PLUG 1

11 1096050660 OIL GALLERY PLUG, PT 3/8 1

11-1 5096050180 OIL GALLERY PLUG, PT 1/8 10

11-2 1096050681 FRONT OIL GALLERY PLUG, PT 1/2 1

11-3 1096050681 REAR OIL GALLERY PLUG, PT 1/2 1

11-4 1096050791 TURBO FEEDING PLUG 1

12 9992023140 CYL. BLOCK PLUG, LEFT SIDE 1

12-1 9992023120 CYL. BLOCK PLUG, RIGHT SIDE 1

13 9095714140 PLUG PACKING, LEFT SIDE 1

13-1 9095714120 PLUG PACKING 1

26 5096540130 NIPPLE, INJ. PUMP, PT 1/8 1

27 9112916050 TAPPET CHAMBER COVER 1

27-1 1112910441 TAPPET CHAMBER COVER 1

27-2 5112901450 TAPPET CHAMBER COVER ASSY. 1

32 1097400780 TIMING GEAR CASE PIN ..................................... 1 .......... REPLACES 9081510500

33 9112246021 OIL PUMP DRIVE SHAFT BUSHING 1

35 5093000231 FLYWHEEL HOUSING STUD 1

37 9081510180 FLYWHEEL HOUSING PIN 2

42 1090520211 CHAMBER COVER FIXTURE ............................... 2 .......... REPLACES 1090520221

44 9095720080 CHAMBER COVER PACKING 6

46 1112920200 CYLINDER BLOCK COVER PACKING 3

47 1096800240 WATER DRAIN COCK ASSY. 1

48 1096660360 DRAIN COCK JOINT 1

49 1096301150 WATER DRAIN COCK PACKING ......................... 1 .......... REPLACES 9099212420

50 9099148600 VINYL PIPE WITH DRAIN, L=510 1

54 8970157540 RUBBER HOSE CLIP 1

56 9112298010 CYLINDER HEAD DOWEL 2

58 5117401220 AIR BREATHER ASSY. 1

60 9091105080 NUT ........................................................................ 2 .......... REPLACES 9091104080

PAGE 98 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 99

ISUZU 6BD1 — CYLINDER BLOCK ASSY.

NO. PART NO. PART NAME QTY.REMARKS

CYLINDER BLOCK ASSY.

61 9091505080 LOCK WASHER 2

63 1093604390 BREATHER COVER HOSE 1

64 9117426140 DRAIN PIPE, H=32 ................................................ 1 .......... UP TO MAR. 84

1117420211 DRAIN PIPE, H=26 ................................................ 1 .......... APR. 84~

61-1 5093609780 RUBBER 1

65 9097130740 HOSE 1

66 9097150670 CLIP 1

66-1 9099156661 CLIP 1

66-3 1097040570 CLIP 2

67 0208006250 BOLT ...................................................................... 2 .......... REPLACES 9020406250

68 0208008140 BOLT ...................................................................... 2 .......... REPLACE 9020508140

69 9091505080 LOCK WASHER 2

96 8970233390 OIL RELIEF VALVE ASSY. ..................................... 1 .......... REPLACES 9131606062;

INCL. ITEMS W/&

97& 5096230350 VALVE PACKING 1

98 5111290030 SEALING CUP 1

110 1112190983 OIL PORT COVER ................................................ 1 .......... UP TO JUL. 90

1112191630 OIL PORT COVER ................................................ 1 .......... AUG. 90~

111 9019708180 BOLT ...................................................................... 2 .......... UP TO JUL. 90;

REPLACES 0501408180

0501408200 BOLT ...................................................................... 2 .......... AUG. 90~

120 8942351570 DISTANCE CLIP PIECE ........................................ 2 .......... NOT SHOWN

PAGE 100 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — TIMING GEAR CASE ASSY.

TIMING GEAR CASE ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 101

ISUZU 6BD1 — TIMING GEAR CASE ASSY.

TIMING GEAR CASE ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5113110113 TIMING GEAR CASE 1

2 9081510180 STRAIGHT PIN 1

3 1113120140 GEAR PACKING ............................................. 1 .......... REPLACES 1113120100

4 0500408450 BOLT ............................................................... 2 .......... REPLACES 9019108450

0500408200 BOLT ............................................................... 4 .......... REPLACES 9019108200

7 1113210790 GEAR CASE COVER 1

8 1113220360 GEAR CASE PACKING .................................. 1 .......... UP TO JUN. 90

8943632690 GEAR CASE PACKING .................................. 1 .......... JUL. 90~

9 5096250540 CRANKSHAFT OIL SEAL ............................... 1 .......... UP TO OCT. 87

1096254380 CRANKSHAFT OIL SEAL ............................... 1 .......... NOV. 87~; REPLACES 1096253190

12 5113270090 TIMER POINTER; L1=33 1

13 0501408250 BOLT ............................................................... 7 .......... REPLACES 9019708250

5090000841 BOLT ............................................................... 5 .......... REPLACES 9010558550

14 9091605080 PLAIN WASHER 5

17 9091505080 LOCK WASHER 5

18 5113210090 TIMING CHECK COVER 2

19 1112820130 COVER PACKING ........................................... 2 .......... REPLACES 1112820090

22 0500406140 BOLT ............................................................... 4 .......... REPLACES 9019006140

PAGE 102 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — FLYWHEEL HOUSING ASSY.

FLYWHEEL HOUSING ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 103

ISUZU 6BD1 — FLYWHEEL HOUSING ASSY.

FLYWHEEL HOUSING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 9113416098 FLYWHEEL HOUSING 1

6 9992023160 DRAIN PLUG 1

7 9095714160 DRAIN PLUG PACKING 1

8 9944112350 NUT ................................................................. 3 .......... REPLACES 9944112280

15 992023160 PLUG 1

41 0500408250 BOLT ............................................................... 7 .......... REPLACE 9019108250

45 9910664500 BOLT ............................................................... 5 .......... REPLACES 9910664500

46 999104140 NUT 1

47 9096510690 PLAIN WASHER 8

48 5096250141 OIL SEAL ........................................................ 1 .......... UP TO MAR. 84

1096253620 OIL SEAL ........................................................ 1 .......... APR. 84~

49 9123631460 OIL SEAL SPACER 1

PAGE 104 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 —OIL PAN ASSY.

OIL PAN ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 105

ISUZU 6BD1 — OIL PAN ASSY.

OIL PAN ASSY.

NO PART NO PART NAME QTY.REMARKS

1 1113604421 OIL PAN ...................................... 1 ........ INCL. ITEMS W/#

3# 9096620120 PLUG, M=20 1

4# 1096230570 PACKING, ID=24 ........................ 1 ........ REPLACES 1096231830

6 9992023160 OIL PAN PLUG 1

7 9095714160 OIL PAN PACKING 1

17 1113670961 CYL. BLOCK PACKING .............. 1 ........ REPLACES 1113670720

20 9992023240 OIL PAN PLUG 1

21 9095714240 OIL PAN PACKING 1

29 0500408180 BOLT ......................................... 32 ........ REPLACES 9019108180

32 9112290700 CLIP 1

36 1117602000 OIL LEVEL GAUGE 1

51-2 5117401102 OIL FILLER ASSY. ..................... 1 ........ INCL. ITEMS W/&; UP TO APR. 89

51-5 1117402011 OIL FILLER ASSY. ..................... 1 ........ INCL. ITEMS W/&; MAY 89~

52& 5117410131 OIL FILLER 1

53& 1117500060 CAP ............................................ 1 ........ REPLACES 1117500120; UP TO APR. 89

53-2 1117500241 OIL FILLER CAP ........................ 1 ........ MAY 89~

58 9099129760 RUBBER HOSE 1

59 9099155531 CLIP 2

62 9091104080 NUT 1

63 9091505080 LOCK WASHER 1

PAGE 106 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — OIL PUMP ASSY.

OIL PUMP ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 107

ISUZU 6BD1 — OIL PUMP ASSY.

OIL PUMP ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5131000913 OIL PUMP ...................................... 1 ........... UP TO AUG. 88; INCL. ITEMS W/#

1-2 1131002330 OIL PUMP ...................................... 1 ........... SEP. 88~; INCL. ITEMS W/&

2#& 1131130470 COVER ........................................... 1 ........... INCL. ITEMS W/$

4#&$ 1131190030 DOWEL 1

6#& 5131210050 GEAR ASSY. 1

8#& 5131250010 GEAR 1

9# 5131190020 PIPE 1

11# 9095612230 O RING 1

12# 1131410210 TOP CASE 1

13# 1131190020 OIL SPACER 1

14# 5131410020 BOTTOM CASE 1

16# 9098010741 BOLT, L=115 4

16-2# 1090440470 BOLT, L=60 4

17# 9091505080 LOCK WASHER 4

18#& 5098430030 BALL 1

19#& 5095800980 SPRING 1

21#& 5131650040 VALVE SEAT 1

22#& 9081040300 VALVE PIN 1

23#& 1131230160 COUPLING 1

24#& 1131280180 PINION 1

26#& 9131190100 COLLAR 1

36#& 1131400860 STRAINER ASSY. 1

41 0500410250 BOLT .............................................. 2 ........... REPLACES 9019110250

43 9131190100 COLLER 1

PAGE 108 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — CRANKSHAFT ASSY.

CRANKSHAFT ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 109

ISUZU 6BD1 — CRANKSHAFT ASSY.

CRANKSHAFT ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1115100400 METAL KIT ..................................... 1 ........... UP TO S//N E518727; INCL. ITEMS W/#

1115100742 METAL KIT ..................................... 1 ........... S/N E518728~

1-1 1115300400 METAL KIT, -.025MM ..................... 1 ........... UP TO S/N E518727

1115300742 METAL KIT, -0.25MM ..................... 1 ........... S/N E518728~

1-2 1115400400 METAL KIT, -0.50MM ..................... 1 ........... UP TO S/N E518727

1115400742 METAL KIT, -0.50MM ..................... 1 ........... S/N E518728~

2# 1116800012 METAL SET, THRUST 2

3 5121110682 PISTON .......................................... 6 ........... UP TO MAR. 90

1121110690 PISTON .......................................... 6 ........... APR. 90~

4 5121210050 RING SET 6

6 912216040 PISTON PIN 6

7 8941075750 SNAP RING .................................. 12 ........... REPLACES 1095870480

8 5122300361 ROD ASSY. .................................... 6 ........... UP TO JUL. 85

1122301041 ROD ASSY. .................................... 6 ........... AUG. 85~; INCL. ITEMS W/&

9& 5122510060 BUSHING ....................................... 6 ........... UP TO JUL 85

1122510270 BUSHING ....................................... 6 ........... AUG. 85~

11& 5122350051 BOLT ............................................ 12 ........... UP TO JUL. 85

1122350271 BOLT ............................................ 12 ........... AUG. 85~

13 9122716080 METAL SET, STD. 6

13-1 9122736080 METAL SET, -0.25MM 6

13-2 9122746080 METAL SET, -0.50MM 6

14 1123104370 CRANKSHAFT ASSY. .................... 1 ........... INCL. ITEMS W/$

17$ 9081512200 STRAIGHT PIN 1

19 1098001560 PILOT BEARING ............................ 1 ........... REPLACES 9000901570; UP TO DEC. 87

1098002140 PILOT BEARING ............................ 1 ........... JAN. 87~

26 5123310641 FLYWHEEL 1

27 9123336070 RING GEAR, Z=129 T=22 1

33 9920616380 BOLT .............................................. 6 ........... REPLACES 9098013340

34 5123360081 WASHER, ID=48 1

36 5097380010 FEATHER KEY 1

37 9125210430 CRANKSHAFT GEAR 1

38 1123620031 THROWER 1

60 5123712072 PULLEY 1

67 5123620031 THROWER 1

81 9098401071 CLAW 1

83 9098514310 WASHER 1

PAGE 110 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.

CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 111

ISUZU 6BD1 — CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.

CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 9125148030 TIMING CAMSHAFT 1

6 9125221471 GEAR, FC25 1

7 9080307130 FEATHER KEY 1

8 9920614280 BOLT 1

9 9098518502 WASHER 1

11 9116810150 THRUST PLATE 1

12 0500408250 BOLT ................................................... 2 ............. REPLACES 9019108250

21 9125310300 IDLE GEAR SHAFT 1

22 9125238013 GEAR 1

24 5125350011 THRUST COLLAR 1

26 9010510550 BOLT ................................................... 2 ............. REPLACES 9010510550

27 9091505100 LOCK WASHER 2

31 1125510830 INLET VALVE ...................................... 6 ............. UP TO APR. 85

1125511390 INLET VALVE ...................................... 6 ............. MAY 85~

32 1125520520 EXHAUST VALVE ............................... 6 ............. REPLACES 1125520250

33 112561080 VALVE SPRING .................................12 ............. REPLACES 5125610090

35 1125630300 UPPER VALVE SEAT ........................12 ............. UP TO APR. 85

8941145790 UPPER VALVE SEAT ........................ 12 ............. MAY 85~

36 1125630351 LOWER VALVE SEAT ........................ 12 ............. UP TO AUG. 88

5125630010 LOWER VALVE SEAT ........................ 12 ............. SEP. 88~

38 5125650060 COLLAR 24

43 5125710032 TAPPET 12

44 1125750360 PUSH ROD 12

51 5126110310 ROCKER ARM 12

53 9126160420 SCREW 12

54 9091115080 NUT 12

56-1 9126211301 REAR ROCKER ARM SHAFT 1

56-2 5126200210 ROCKER ARM SHAFT ....................... 1 ............. UP TO AUG. 87

1126210621 ROCKER ARM SHAFT ....................... 1 ............. SEP. 87~

57 9126260050 ROCKER ARM PLUG 2

58 5126280112 FRONT ROCKER ARM BRACKET ..... 1 ............. UP TO AUG. 87

5126280120 FRONT ROCKER ARM BRACKET ..... 1 ............. SEP. 87~

58-1 5126280060 REAR ROCKER ARM BRACKET 1

58-2 9126281050 INTER ROCKER ARM BRACKET 6

59 1095803350 ROCKER ARM SPRING 5

60 5126230011 CONNECTOR 1

61 9091800190 SNAP RING 1

62 5096230600 PACKING 1

64 9029508650 BOLT ................................................... 9 ............. UP TO AUG. 87

1090005670 BOLT ................................................... 8 ............. SEP. 87~

64-1 9096021480 BOLT, FRONT BRACKET 1

66 9098514300 PLAIN WASHER ................................10 ............. UP TO AUG. 87

9098514300 PLAIN WASHER ................................. 9 ............. SEPT. 87~

67 1094001160 NUT ..................................................... 4 ............. REPLACES 9091123080

68 9098514300 PLAIN WASHER 4

PAGE 112 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — OIL AND FUEL FILTER ASSY.

OIL AND FUEL FILTER ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 113

ISUZU 6BD1 — OIL AND FUEL FILTER ASSY.

OIL AND FUEL FILTER ASSY.

NO. PART NO. PART NAME QTY.REMARKS

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

2# 1878100752 ELEMENT KIT ............................................... 1 ........ INCL. ITEMS W/&

3#& 9099203110 COVER PACKING 1

4# 9099206940 CENTER BOLT PACKING 1

5# 1096230550 O RING PACKING 1

6# 5132120212 OIL FILTER COVER 1

8# 1132310420 BOLT 1

9# 9098621610 PLUG 1

12# 5132110100 OIL FILTER CASE 1

16# 9099412830 SPRING 1

17# 9132390250 SPRING SEAT 1

21# 1090001050 DRAIN PLUG 1

28# 5132600061 OVER FLOW VALVE ASSY. .......................... 1 ........ INCL. ITEMS W/$

29#$ 1096231630 O RING PACKING 1

70 1132003322 FUEL FILTER ASSY. ..................................... 1 ........ INCL. ITEMS W/@

72 1878105650 ELEMENT KIT ............................................... 1 ........ REPLACES 988511911;

INCL. ITEMS W/?

73@? 9097205420 PACKING 2

71@? 9132136010 COVER BODY PACKING 1

75@? 9097205410 O RING 1

76@? 9099202550 DRAIN PLUG O RING 1

78@ 5132110151 FUEL FILTER CASE 1

80@ 9132128040 UPPER COVER 1

81@ 1132310330 BOLT 1

82@ 9096510680 ELEMENT SPRING SEAT 1

83@ 9097421090 ELEMENT SET SPRING 1

84@ 9098620680 DRAIN PLUG 1

86@ 1132600470 VALVE ASSY. 1

87@ 1096300850 PACKING 1

100 1132191000 PACKING ....................................................... 1 ........ UP TO OCT. 87

1132191940 PACKING ....................................................... 1 ........ NOV. 87~

101 9019710350 BOLT .............................................................. 2 ........ UP TO OCT. 87

0501410350 BOLT .............................................................. 2 ........ NOV. 87~

101-1 9098009281 BOLT, L=145 2

102 9091505100 LOCK WSAHER 2

103 9091605100 PLAIN WASHER 2

104 9091104100 NUT 2

106 9095720100 OIL FILTER PACKING 2

PAGE 114 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — OIL AND AIR PIPE ASSY.

OIL AND AIR PIPE ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 115

ISUZU 6BD1 — OIL AND AIR PIPE ASSY.

OIL AND AIR PIPE ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5133110890 OIL PUMP ASSY. ................. 1 ..................... UP TO MAR. 84

133115322 OIL PUMP ASSY. ................. 1 ..................... APR. 4~

2 9099211880 PACKING 2

3 0500408400 BOLT .................................... 4 ..................... REPLACES 9019108400

4 5133111190 COOLER PIPE ASSY. 1

6 1096232820 O RING ................................. 2 ..................... UP TO OCT. 87

1096234620 O RING ................................. 2 ..................... NOV. 87~

7 0500408400 BOLT .................................... 4 ..................... REPLACES 9019108400

9 5133112050 OIL PIPE ASSY. ................... 1 ..................... INCL. ITEM W/#

10# 9099171050 CLIP 1

11 1096308830 PACKING 2

12 9098440220 NUT 1

PAGE 116 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

COOLING SYSTEM ASSY.

ISUZU 6BD1 — COOLING SYSTEM ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 117

ISUZU 6BD1 — COOLING SYSTEM ASSY.

COOLING SYSTEM ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5136101452 WATER PUMP ASSY ................ 1 ................ INCL. ITEMS W/#

2# 1136108770 PUMP KIT W/ GASKET ............ 1 ................ INCL. ITEMS W/%

3#% 1878102772 REPAIR KIT ............................... 1 ................ REPLACES 5878100983

4#% 5136310090 WATER PUMP SHAFT 1

6#% 5098000510 BALL BEARING, FRONT 1

6-1#% 5098000500 BALL BEARING, REAR 1

7#% 5136340020 BALL SPACKER 1

8#% 9099521430 SNAP RING 1

9#% 9091801520 C RING 1

11#% 5136200061 SEAL UNIT 1

12#% 9136218020 IMPELLER 1

13#% 5136420072 FAN AND PULLEY CENTER 1

16#% 9136128020 WATER PUMP COVER 1

17#% 9136136130 PACKING 1

18#% 9030908200 SCREW 3

20#% 5096250550 SECONDARY SEAL 1

21#% 1095030700 WASHER 1

22#% 5136390010 DUST THROWER 1

31% 1136140100 PACKING ................................... 1 ................ UP TO OCT. 87

1136140131 PACKING ................................... 1 ................ NOV. 87~

33 5090300101 BOLT 1

0500410500 BOLT ......................................... 2 ................ REPLACES 5090000880

0500410350 BOLT ......................................... 1 ................ REPLACES 9019110350

33-1 0500410250 BOLT ......................................... 1 ................ REPLACES 9019110250

41 9136756330 PLATE 1

50 5136410171 PULLEY 1

51 9136428032 SPACER .................................... 1 ................ UP TO MAR. 87

1136420250 SPACER .................................... 1 ................ APR. 87~

52 9034406100 SCREW 2

53 9019108160 BOLT 4

54 1136600870 FAN ASSY., D=550,6,BLOWER 1

59 1090440720 BOLT, L=65 4

61 9091505080 LOCK WASHER 4

62 9091647080 PLAIN WASHER 4

64 5136710910 BELT ASSY., L=997 .................. 1 ................ UP TO APR. 85

5136710160 BELT ASSY., L1225 .................. 1 ................ MAY 85 TO MAR. 87

1136711430 BELT ASSY., L=1226 ................ 1 ................ APR 87~

68 5137160260 THERMOSTAT HOUSING 1

71 1137130371 THERMOSTAT JOINT ............... 1 ................ REPLACES 5137130161

72 5137700310 THERMOSTAT, 82-95C .............. 1 ................ UP TO APR. 85

1137700700 THERMOSTAT, 85-95C .............. 1 ................ MAY 85~

73 9096640050 COCK PLUG 1

74 9096620340 HEATER PLUG 1

75 5137210152 WATER PIPE 1

PAGE 118 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — COOLING SYSTEM ASSY.

COOLING SYSTEM ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 119

ISUZU 6BD1 — COOLING SYSTEM ASSY.

COOLING SYSTEM ASSY.

NO. PART NO. PART NAME QTY.REMARKS

76 9137436030 PACKING ................................... 1 ................ UP TO APR. 86

1137430160 PACKING ................................... 1 ................ MAY 86~

77 0501408250 BOLT ......................................... 3 ................ REPLACES 9019708250

79 9096610050 PLUG 1

80 9095714160 PAKING 1

91 1137410100 PACKING ................................... 1 ................ REPLACES 1137410080

92 0108060950 BOLT ......................................... 3 ................ REPLACES 9010560950

92-1 0501410350 BOLT ......................................... 3 ................ REPLACES 9019710350

93 5137210141 HOSE 1

94 5097040460 CLIP 2

106 9091505100 LOCK WASHER 3

107 9091605100 PLAIN WASHER 3

119 1112800051 WATER DUCT COVER .............. 1 ................ REPLACES 9112808016

120 5112800053 OIL COOLER ASSY. ................. 1 ................ INCL. ITEMS W/@

121@ 5112820070 OIL COOLER ELEMENT ASSY 1

122@ 5112820060 GASKET .................................... 2 ................ UP TO SEP. 88

1112820140 GASKET .................................... 2 ................ OCT. 88~

123@ 9132630100 BY PASS PLUG VALVE ............ 1 ................ REPLACES 5096040100

124@ 9095622150 PACKING 1

125@ 5095800920 SPRING 1

126@ 5112880010 BY PASS VALVE 1

127@ 5096050170 TAPER PLUG 2

128@ 9091114100 NUT ........................................... 4 ................ REPLACES 50904000280

129@ 9091645100 PLAIN WASHER ........................ 4 ................ REPLACES 5095030720

130@ 5112810081 COOLER BODY 1

141 1112820080 PACKING, COVER .................... 1 ................ UP TO AUG. 88

1112820120 PACKING, COVER .................... 1 ................ SEP. 88~

142 8942059861 BOLT 1

142-1 0501408280 BOLT ....................................... 15 ................ REPLACES 9019708280

0501408200 BOLT ......................................... 2 ................ UP TO APR. 91;REPLACES 9019708200

1090300910 BOLT ......................................... 2 ................ MAY 91~

0501408450 BOLT ....................................... 12 ................ REPLACES 9019708450

144 9091605080 PLAIN WASHER 1

PAGE 120 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — INTAKE AND EXHAUST ASSY.

INTAKE AND EXHAUST ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 121

ISUZU 6BD1 — INTAKE AND EXHAUST ASSY.

INTAKE AND EXHAUST ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5141112434 INLET MANIFOLD W/O STUD 1

3 9040108280 STUD 3

4 9044110280 FUEL FILTER STUD 2

20 9141406130 MAINFOLD ASSY. .................. 1 ................... INCL. ITEM W/#

20-1# 9141418030 MANIFOLD ASSY. 1

21 9141496530 SEALING EXHAUST RING 3

22 9044110300 EXHAUST STUD 3

24 5141450040 EXHAUST GASKET 3

27 9098445650 BUT 12

30 5141112511 INLET PIPE ............................ 1 ................... UP TO NOV. 88

1141123150 INLET PIPE, H=57 ................. 1 ................... DEC. 88~

30-1 5141111100 INLET PIPE 1

31 9044110250 INTAKE PIPE STUD 2

32 9091104080 NUT 3

32-1 9091104100 NUT 2

33 9091505080 LOCK WASHER 3

33-1 9091505100 LOCK WASHER 2

34 9091605080 PLAIN WASHER 3

34-1 9091605100 PLAIN WASHER 2

46 1141150360 INLET HEAD PACKING .......... 1 ................... UP TO AUG. 88

1141150520 INLET HEAD PACKING .......... 1 ................... SEP. 88~

48 9091605080 PLAIN WASHER 3

49 9091505080 LOCK WASHER 3

50 9091104080 NUT 3

51 9019708280 BOLT ...................................... 9 ................... UP TO APR. 90;REPLACES 9019708250

0501408280 BOLT ...................................... 9 ................... MAY 90~

76 1141150370 INLET PACKING..................... 1 ................... UP TO OCT. 87

1141150540 INLET PACKING ..................... 1 ................... NOV. 87~

76-1 1096370560 SHUTTER PIPE PACKING .... 1 ................... REPLACES 1096370470

77 9091104100 NUT 2

78 9091505100 LOCK WASHER 2

83 5093603200 RUBBER HOSE 1

86 109700870 CLIP 1

PAGE 122 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — FUEL SYSTEM ASSY.

FUEL SYSTEM ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 123

ISUZU 6BD1 — FUEL SYSTEM ASSY.

FUEL SYSTEM ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5153001031 NOZZLE ASSY. 6

11 5153150030 PACKING 6

12 9153390510 COVER 6

13 9091104080 NUT 12

14 9091505080 LOCK WASHER 12

15 5154116952 PIPE ASSY., INJ. NO. 1 1

16 5154116962 PIPE ASSY., INJ. NO. 2 1

17 5154116971 PIPE ASSY., INJ. NO. 3 .................... 1 ........ UP TO MAR. 89

1154148131 PIPE ASSY., INJ. NO. 3 .................... 1 ........ APR. 89~

18 5154116982 PIPE ASSY., INJ. NO. 4 1

19 5154116992 PIPE ASSY., INJ. NO. 5 1

20 5154117002 PIPE ASSY., INJ. NO. 6 1

21 5154115060 PIPE ASSY., FUEL PUMP FILTER 1

22 5154115070 PIPE ASSY., INJECTION FILTER 1

23 1096750860 BOLT 2

24 1096300850 FUEL PIPE PACKING 6

31 1154124711 INJECTION LEAK OFF PIPE ASSY. 1

32 1096750371 BOLT 1

33 9095714080 LEAK OFF PIPE PACKING 2

34 9154196120 CLIP 6

35 9095245550 CLIP 1

36 5154112231 SUCTION FEED PUMP PIPE 1

37 5097091030 CLIP 2

38 509709104 CLIP 2

39 9019006250 BOLT 2

39-1 0500406300 BOLT ................................................. 2 ........ REPLACES 9019006300

41-5 5154112231 FILTER LEAK OFF PIPE ASSY. 1

41-6 1154129180 FILTER LEAK OFF PIPE ASSY. 1

43 1096300850 PACKING 2

47 5197890030 BRACKET 1

48 9091505100 LOCK WASHER 2

49 0208010200 BOLT ................................................. 2 ........ REPLACES 9020510200

54 5132600101 OVER FLOW VALVE 1

56 1096300850 VALVE FIXTURE PACKING 1

PAGE 124 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — ENGINE FOOT AND HANGER ASSY.

ENGINE FOOT AND HANGER ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 125

ISUZU 6BD1 — ENGINE FOOT AND HANGER ASSY.

ENGINE FOOT AND HANGER ASSY.

NO. PART NO. PART NAME QTY.REMARKS

8 1093000530 RIGHT FOOT STUD, L1=18.5 1

11 5197110312 ALTERNATOR BRACKET 1

13 0500410250 BOLT ......................................... 1 ................ REPLACES 9019110250

13-1 0500410350 BOLT ......................................... 2 ................ REPLACES 9019110350

15 1090001331 BOLT 1

16 9091605140 PLAIN WASHER 1

17 9091505140 LOCK WASHER 1

18 9991104140 NUT 1

19 1197190362 COVER 1

31 9991104120 NUT 3

32 9091505120 LOCK WASHER 3

35 0208012400 BOLT ......................................... 1 ................ REPLACES 9910562400

36 9091607120 PLAIN WSAHER 1

37 9091505120 LOCK WASHER 1

38 9991104120 ADJUSTING NUT 1

41 9117776221 RR. ENGINE LIFTING HANGER 1

42 9019110200 BOLT ......................................... 2 ................ UP TO APR. 90

9019110220 BOLT ......................................... 2 ................ MAY 90~

42-1 9019110220 BOLT ......................................... 1 ................ UP TO APR. 90

0500410220 BOLT ......................................... 1 ................ MAY 90~

42-2 0208014250 BOLT ......................................... 1 ................ REPLACES 9920514250

43 9091504140 LOCK WASHER 1

51 1113190080 INJECTION PUMP BRACKET .. 1 ................ UP TO OCT. 87

1113190090 INJECTION PUMP BRACKET .. 1 ................ NOV. 87~

52 0108058600 BOLT ......................................... 7 ................ REPLACES 9010558600

55 9091505080 LOCK WASHER 7

56 9091605080 PLAIN WASHER 7

62 9099167550 CLIP 1

63 9098008790 BOLT ......................................... 1 ................ UP TO APR. 92

0208006100 BOLT ......................................... 1 ................ MAY 92~; REPLACES 9020406100

64 9091505060 LOCK WASHER 1

80 5197510042 BRACKET 1

81 9020510200 BOLT ......................................... 2 ................ UP TO SEP. 87

0500410200 BOLT ......................................... 2 ................ OCT. 87~; REPLACES 9019110200

82 9091505100 LOCK WASHER 2

83 9091607100 PLAIN WASHER 2

84 9091646100 PLAIN WASHER ........................ 1 ................ UP TO SEP. 87

9091607100 PLAIN WASHER ........................ 1 ................ OCT. 87~

85 9091505100 LOCK WASHER 1

87 9091104100 NUT 1

PAGE 126 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — INJECTION PUMP ASSY.

INJECTION PUMP ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 127

ISUZU 6BD1 — INJECTION PUMP ASSY.

INJECTION PUMP ASSY.

NO. PART NO. PART NAME QTY.REMARKS

5 1156020451 INJECTION PUMP ASSY. ......... 1 ................ UP TO NOV. 89; REPLACES 1156010605

INCL. ITEMS W/#

1156026800 INJECTION PUMP ASSY. ......... 1 ................ DEC. 89~

15# 1157203470 GOVERNOR ASSY. ................... 1 ................ UP TO NOV. 89

1157704760 GOVERNOR ASSY. ................... 1 ................ DEC. 89~

20# 1157500480 FEED PUMP ASSY. .................. 1 ................ REPLACES 1157500280

36# 5157810030 INJ. PUMP COUPLING 1

37# 1197510400 BRACKET 1

38# 9884105020 NUT 1

39# 5156190480 WASHER 1

40# 9096620070 BOLT 1

41# 1095390070 PLATE ....................................... 1 ................ REPLACES 5095390060

41-2# 1156192450 PLATE 1

42# 5125240570 GEAR 1

43# 9019006140 BOLT 6

PAGE 128 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — ELECTRICAL ASSY.

ELECTRICAL ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 129

ISUZU 6BD1 — ELECTRICAL ASSY.

ELECTRICAL ASSY.

NO. PART NO. PART NAME QTY.REMARKS

3 1811001910 STARTER 1

7 1812002050 ALTERNATOR 1

22 5831510030 OIL PRESSURE SWITCH ADAPTER ...1 ............... INCL. ITEMS W/#

23# 9827200690 OIL PRESSURE WARNING SW. 1

24# 9099022380 ADAPTER 1

29 9831514320 THERMOMETER, OIL 1

30 1823200010 BATTERY SW. ASSY. ............................1 ............... REPLACES 9827300090

31 1823100080 STARTER SWITCH ASSY. ....................1 ............... INCL. ITEMS W/&

32& 1823130030 STARTER SWITCH 1

33& 1823170070 LOCK WITH KEY BARREL 1

37 5824500141 OVER HEAT SW. 1

40 1825500732 EMERGENCY RELAY 1

64 9825139288 GLOW PLUG, 20.5V 6

65 5197320010 GLOW PLUG CONNECTOR 1

65-1 5197320020 GLOW PLUG CONNECTOR 1

67 9825300430 RESISTANCE CONTROL, 24V 1

82 1819000161 ENGINE STOPPER ASSY. ...................1 ............... INCL. ITEM W/%

82-1 1819001931 ENGINE STOPPER ASSY. W/COVER 1

83% 1828490430 CABLE ASSY., L=460 1

109 9829322110 STARTER-FRAME CABLE ASSY. 1

PAGE 130 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — INJ. PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 131

ISUZU 6BD1 — INJ. PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

5 1156110750 HOUSING ASSY. 1

14 5156190440 ADAPTER 1

15 9812151150 STUD 3

16 9812350170 ADAPTER 1

18 1156190240 BOLT 3

20 8941445880 GASKET 1

22 1156290500 COVER 1

23 1156190030 SCREW 2

24 9812151440 GASEKT 2

27 9091505060 WAWSHER 3

28 1157290060 NUT 3

29 1096230130 O RING 1

31 5156310070 PLUNGER ASSY. 6

32 1156410160 DELIVERY VALVE ASSY. 6

34 515630010 SPRING 6

35 1156490010 GASKET 6

36 5156440100 HOLDER 6

40 5156250010 PLATE ASSY 3

41 1096230520 O RING 3

43 9812212230 TAPPET ASSY. ......................... 6 ................. INCL. ITEMS W/#

45# 9812212200 PIN 6

47# 1156220030 ROLLER 6

48# 1156290010 BUSHING 6

49# 5156190410 GUIDE 6

55 5156190010 SHIM, T=+0.60

5156190020 SHIM, T=+0.70

5156190030 SHIM, T=+0.80

5156190040 SHIM, T=+0.90

5156190050 SHIM, T=+1.00

5156190070 SHIM, T=+1.10

5156190080 SHIM, T=+1.20

5156190090 SHIM, T=+1.30

5156191080 SHIM, T=+1.35

5156190100 SHIM, T=+1.40

5156191090 SHIM, T=+1.45

5156191060 SHIM, T=+1.50

5156191100 SHIM, T=+1.55

5156191070 SHIM, T=+1.60

5156190110 SHIM, T=+0.55

5156190120 SHIM, T=+0.65

5156190130 SHIM, T=+0.75

5156190150 SHIM, T=+0.85

5156190250 SHIM, T=+0.20

5156190260 SHIM, T=+0.25

PAGE 132 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — INJ. PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 133

ISUZU 6BD1 — INJ. PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

5156190270 SHIM, T=+0.35

5156190340 SHIM, T=+0.30

5156190350 SHIM, T=+0.40

5156190360 SHIM, T=+0.50

5156190370 SHIM, T=+0.45

9812350420 SHIM, T=+0.95

9812350430 SHIM, T=+1.05

9812350440 SHIM, T=+1.15

9812350450 SHIM, T=+1.25

5156430090 SPRING 6

58 9812350150 SEAT 6

59 9812350210 SEAT 6

60 9812250580 SLEEVE 6

61 9812250570 PINION 6

62 9812350030 SCREW 6

66 5156370030 RACK 1

67 1156390030 SCREW 1

75-3 1156210630 CAMSHAFT 1

75-4 1156210630 CAMSHAFT 1

76 1156290020 BALL BEARING, OVERSIZE AR

1156290030 BALL BEARING, STD AR

77 5098000380 BALL BEARING, OVERSIZE AR

9000906770 BALL BEARING, STD AR

82 5156290240 RING 1

83 9812250470 RING 1

84 9812250490 SHIM, T=+0.10

9812250500 SHIM, T=+0.12

9812250510 SHIM, T=+0.14

9812250520 SHIM, T=+0.16

9812250530 SHIM, T=+0.18

9812250540 SHIM, T=+0.50

1156290070 SHIM, T=+1.00

5156190380 SHIM, T=1.00

5156190390 SHIM, T=+0.70

1156190900 SHIM, T=+1.40

5156290150 SHIM, T=+0.10

5156290160 SHIM, T=+0.12

5156290170 SHIM, T=+0.14

5156290180 SHIM, T=+0.16

51562901190 SHIM, T=+0.18

5156290200 SHIM, T=+0.50

5156290210 SHIM, T=+0.30

PAGE 134 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — INJ. PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 135

ISUZU 6BD1 — INJ. PUMP COMP. ASSY.

INJECTION PUMP COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

87 1156190330 BEARING 1

88 9884100660 SCREW 2

89 9812250430 WASHER 2

93 1156290470 COVER 1

95 1156192820 BOLT 4

108 5835390240 WOODRUFF KEY 1

150 5156191360 PLUB 6

162 9091606100 WASHER 4

163 9091506100 WASHER 4

164 5156390020 NUT 4

180 1156192660 BRACKET 1

181 1156290490 PACKING 1

182 9041010300 STUD 4

183 1156290480 GASKET 1

PAGE 136 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — GOVERNOR COMP. ASSY.

GOVERNOR COMP. ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 137

ISUZU 6BD1 — GOVERNOR COMP. ASSY.

GOVERNOR COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

5 5157210040 HOUSING ...................................1 ...................... INCL. ITEMS W/#

12# 1157290150 O RING 1

13# 9813150650 ADAPTER 1

14# 9019008180 BOLT 1

15# 9813253970 PLATE 1

16# 9019006140 BOLT 6

18# 5157291230 SCREW 1

19# 9813252370 NUT 2

50# 1157290380 PLUG 1

26# 9813251820 SCREW 1

27# 9813261120 NUT 1

30# 5157210200 COVER 1

31# 9813254290 BUSHING 1

32# 5157290530 PLUG 2

34# 5157290540 BOLT 2

35# 5157290330 BOLT 4

36# 9813251770 SCRWE 1

37# 5157291020 BLT 1

38# 9884100270 NUT 1

40# 5157210210 COVER 1

42# 9813919070 O RING 1

44# 9019006160 BOLT 3

46# 1157290280 BOLT 1

47# 9812350340 CAP 1

48# 9091505060 LOCK WASHER 1

50# 5157220080 FLYWEIGHT ASSY. 1

52# 5156190490 KEY 1

53# 5157290340 LOCK WASHER 1

54# 9813250860 NUT 1

57# 5157190080 SLEEVE 1

58# 9000902290 BEARING 1

60# 9813250880 SHIM, T=0.20

9813255510 SHIM, T=+0.30

9813255520 SHIM, T=+0.40

9813255530 SHIM, T=+1.00

5157292860 SHIM, T=+0.50

5157292870 SHIM, T=+0.50

63# 9008121300 SPRING 1

64# 9813222350 SPRING 1

67# 5157231240 CAPSULE 1

68# 5157292090 NUT 1

69# 1156390080 GASKET 2

73# 5157230990 CAPSULE 1

74# 9008130230 NUT 1

77# 9813217210 LEVER 1

80# 1157292930 BUSH 2

81# 9813212050 O RING 2

82# 9091854150 SNAP RING 2

PAGE 138 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — GOVERNOR COMP. ASSY.

GOVERNOR COMP. ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 139

ISUZU 6BD1 — GOVERNOR COMP. ASSY.

GOVERNOR COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

83# 1157290980 OIL SEAL 1

84# 1157290990 SHIM 1

85# 9813250970 SHIM, T=0.30

86# 9813253180 PLUG 1

89# 1157293010 COLLAR 1

90# 9813254880 WASHER

93# 5157250570 LEVER 1

100# 1157250110 LINK 1

101# 9091854040 SNAP RING 1

102# 5157250170 LEVER 1

103# 9813250620 PIN 1

104# 5157250410 LEVER 1

107# 5157250810 LEVER 1

108# 9019006160 BOLT 1

109# 9813919060 O RING 1

110# 1157292990 SHIM, T=0.50

1157292980 SHIM, T=+0.50

1157292980 SHIM, T=+0.40

1157292970 SHIM, T=+3.35

1157292960 SHIM, T=+0.30

1157292950 SHIM, T=+0.25

1157292940 SHIM, T=+0.20

111# 9813252100 CAP 1

112# 5157230640 SPRING 1

116# 1157290010 GASKET 1

117# 1157290020 GASKET 1

120# 5157250420 LEVER ASSY. 1

148# 5157291120 BOLT 1

149# 9091505080 LOCK WASHER 1

150# 5157230880 SPRING 1

PAGE 140 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 —FEED PUMP ASSY.

FEED PUMP ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 141

ISUZU 6BD1 — FEED PUMP ASSY.

FEED PUMP ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1157500480 FEED PUMP ASSY. ....................... 1 .................. INCL. ITEMS W#

5# 5157510120 HOUSING 1

9# 9813512050 PISTON 1

10# 9813513020 SPRING 1

11# 9813550230 PLUG 1

12# 9813550350 GASKET 1

15# 5157540010 TAPPET ASSY. ............................... 1 .................. INCL. ITEMS W/%

16#% 9813514030 ROLLER 1

17#% 9813514100 PIN 1

18#% 1157590020 GUIDE 2

26# 9813516020 VALVE 2

27# 1196230160 O RING ........................................... 1 .................. REPLACES 1096230160

28# 9813517020 SPRING 2

31# 1096750630 BOLT 1

32# 1157590110 BOLT 1

33# 1157590120 PACKING 4

35# 1157590030 ADAPTER 1

40# 1196230160 O RING ........................................... 1 .................. REPLACES 1096230160

42# 9813550250 SNAP RING 1

44# 8941311300 PUMP 1

PAGE 142 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — NOZZLE ASSY.

NOZZLE ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 143

ISUZU 6BD1 — NOZZLE ASSY.

NOZZLE ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5153110191 NOZZLE ASSY. ......................... 6 ................ REPLACES 5153110190

2 5153300191 HOLDER ASSY. ........................ 6 ................ REPLACES 5153300190;

INCL. ITEMS W/#

5# 5153410010 PUSH ROD 6

6# 9153470030 PIN 12

7# 9153430130 SPRING 6

8# 5153450010 SCREW 6

9# 9153390570 WASHE 6

10# 5153340010 NUT 6

12# 9153390560 GASKET 6

21# 5153320020 NUT 6

22# 5153390030 GASKET 6

23# 5153490020 CONNECTOR 6

31# 5153490010 BOLT 6

32# 9095714080 PAKCING, T=1.0 12

PAGE 144 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — STARTER ASSY,

STARTER ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 145

ISUZU 6BD1 — STARTER ASSY.

STARTER ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1811001910 STARTER ASSY. ..................................1 ............. INCL. ITEMS W/#

6# 1811210370 ARMATURE ASSY. 1

7# 1811293950 BALL BEARING 1

8# 1811293850 BALL BEARING 1

18# 5811291560 WASHER 2

21# 1811160440 LEAD WIRE 1

22# 1811293840 TERMINAL 1

23# 1811293960 FIELD COIL 1

24# 5811292210 SCREW 4

30# 1811150610 COVER .................................................1 ............. INCL.. ITEMS W/@

31#@ 1811150620 REAR COVER 1

34#@ 1811180360 BRUSH HOLDER 1

35#@ 1811170140 BRUSH SPRNG 4

37#@ 1811160430 BRUSH, (-) 2

38#@ 1811160420 BRUSH, (+) 2

40# 1825530230 RELAY SAFETY SWITCH 1

41# 1811180390 HOLDER 1

42# 1811294010 BOLT 1

50# 1811230250 FRONT COVER ...................................1 ............. INCL. ITEMS W/$

52#& 1811293970 METAL COVER 1

53# 5811291420 DISH LUG 1

55# 5811220160 CLUTCH 1

56# 5811291440 CLIP RIG 2

57# 5811291450 PINION STOPPER 1

58# 1811130260 CENTER BRACKET 1

59# 1811293870 BOLT 3

60# 1811230240 SHAFT ASSY. .......................................1 ............. INCL. ITEMS W/&

61#& 1811293860 BALL BEARING 1

64# 5811291600 SHAFT WASHER 1

65# 5811291590 SHAFT WASHER 2

66# 5811291580 INSULATE WASHER 1

67# 1811130730 CENTER COVER 1

76# 1811270310 SHIFT LEVER 1

77# 1811291850 LEVER PIN 1

78# 1811291840 NUT 1

79# 5811291470 PLATE 1

80# 5811510360 MAGNETIC SWITCH ASSY. 1

84# 5811291460 PLUNGER 1

87# 9821161400 INSULATE BUSING 1

88# 5811291480 CONNECTOR 1

89# 5811180190 HOLDER 1

91# 5811291510 WASHER 2

92# 5811291520 BOLT 2

93# 5811291500 TERMINAL ASSY 1

94# 9821161420 WASHER 1

97# 5811291490 CLI RING 2

98# 1811291140 WASHER 2

99# 5811292140 BOLT 2

100# 1811293940 STARTER SEAL KIT 1

PAGE 146 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — ALTERNATOR ASSY.

ALTERNATOR ASSY.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 147

ISUZU 6BD1 — ALTERNATOR ASSY.

ALTERNATOR ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1812002050 ALTERNATOR ASSY. ................ 1 ................. INCL. ITEMS W/#

5# 1812210300 ROTOR ASSY. 1

7# 1812292250 BEARING 1

8# 1812292240 BALL BEARING 1

9# 1812292310 ROTOR PACKING 1

10# 1812240090 SLIP RING 1

11# 1812291610 ROTOR RETAINER 1

12# 1812291620 ROTOR PACKING 1

13# 9822160600 ROTOR RETAINER 1

14# 1812291630 ROTOR RETAINER 1

15# 1812291640 ROTOR RETAINER 1

16# 1812291950 ROTOR CLIP 1

16-1# 1812292300 ROTOR CLIP 1

17# 1812291600 COLLAR 1

18# 1812291650 PACKING 1

19# 1812291230 PLATE 1

20# 1812110310 STATOR 1

25# 1812140810 REAR COVER ASSY. ................ 1 ................. INCL. ITEMS W/@

26#@ 1812140820 REAR COVER 1

27#@ 1812190330 RECTIFIER ASSY. 1

33#@ 1812292270 WASHER 2

40#@ 1812293100 BOLT 1

41#@ 1812292350 BUSH 1

43#@ 1812292340 TUBE 1

45#@ 1811180110 CLIP 1

51# 1812130240 COVER 1

52# 1812291670 BUSHING 1

55# 181240830 COVER 1

56# 1812292330 PACKING 1

60# 1812291350 WASHER 1

61# 1812170230 HOLDER ASSY. 1

62# 1812292260 PACKING 1

63# 1812292320 PACKIG 1

75# 1812220340 PULLEY ASSY. 1

90# 1812290970 BOLT 3

95# 1812510240 VOLTAGE REGULATOR ............ 1 ................. NOT SHOWN

97# 1812295960 NUT 1

99# 9822190270 LOCK WASHER 1

PAGE 148 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

ISUZU 6BD1 — ACCESSORIES

ACCESSORIES

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 149

ISUZU 6BD1 — ACCESSORIES

ACCESSORIES

NO. PART NO. PART NAME QTY.REMARKS

50 9839101011 TACHO DRIVE ELBOW ASSY. . 1

55 1096231800 PACKING ................................... 1 ................. UP TO OCT. 87

1096234650 PACKING ................................... 1 ................. NOV. 87~

60 0500408200 BOLT ......................................... 2 ................. REPLACES 9019108200

PAGE 150 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or

prepaid with the charges added to the invoice.

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

Multiquip’s responsibility ceases when a

signed manifest has been obtained from the

carrier, and any claim for shortage or damage

must be settled between the consignee and the

carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip

is $15.00 net. Customers will be asked for

instructions regarding handling of orders not

meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit

will be allowed, subject to the following

provisions:

1. A Returned Material Authorization must

be approved by Multiquip prior to shipment.

2. To obtain a Return Material Authorization,

a list must be provided to Multiquip Parts

Sales that defines item numbers,

quantities, and descriptions of the items

to be returned.

a. The parts numbers and descriptions

must match the current parts price

list.

b. The list must be typed or computer

generated.

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

the return.

d. The list must reference the sales

order(s) or invoice(s) under which

the items were originally purchased.

e. The list must include the name and

phone number of the person

requesting the RMA.

3. A copy of the Return Material

Authorization must accompany the return

shipment.

PRICING AND REBATES

Prices are subject to change without prior

notice. Price changes are effective on a specific

date and all orders received on or after that date

will be billed at the revised price. Rebates for

price declines and added charges for price

increases will not be made for stock on hand

at the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $20.00 to $50.00 surcharge will be added to

the invoice for special handling including bus

shipments, insured parcel post or in cases

where Multiquip must personally deliver the

parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are

claimed, and in no event shall Multiquip be

liable for loss of profit or good will or for any

other special, consequential or incidental

damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made

in connection with the sale of parts or trade

accessories nor as to any engine not

manufactured by Multiquip. Such warranties

made in connection with the sale of new,

complete units are made exclusively by a

statement of warranty packaged with such

units, and Multiquip neither assumes not

authorizes any person to assume for it any

other obligation or liability whatever in

connection with the sale of its products. A part

from such written statement of warranty, there

are no warranties, express, implied or statutory,

which extend beyond the description of the

products on the face hereof.

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

parts must be returned freight prepaid to

Multiquip’s designated receiving point.

5. Parts must be in new and resalable

condition, in the original Multiquip package

(if any), and with Muiltiquip part numbers

clearly marked.

6. The following items are not returnable:

a. Obsolete parts. (If an item is listed

in the parts price book as being

replaced by another item, it is

obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings,

and other rubber parts) that were

purchased more than six months

prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7. The sender will be notified of any material

received that is not acceptable.

8. Such material will be held for 5 working

days from notification, pending

instructions. If a reply is not received

within 5 days, the material will be returned

to the sender at his expense.

9. Credit on returned parts will be issued at

dealer net price at time of the original

purchase, less a 15% restocking charge.

10. In cases where an item is accepted for

which the original purchase document

can not be determined, the price will be

based on the list price that was effective

twelve months prior to the RMA date.

11. Credit issued will be applied to future

purchases only.

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

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 151

NOTE PAGE

PARTS AND OPERATION MANUAL

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

SERVICE DEPARTMENT:

800-421-1244 800-835-2551

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

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

PARTS AND OPERATION MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HAND WHEN CALLING

PARAR

ARAR

ARTS DEPTS DEP

TS DEPTS DEP

TS DEP

ARAR

ARTMENTTMENT

TMENTTMENT

TMENT

800/427-1244 or 310/537-3700

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

SERSER

SERVICE DEPVICE DEP

VICE DEPVICE DEP

VICE DEPARAR

ARAR

ARTMENTTMENT

TMENTTMENT

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

WARRANTY DEPARRANTY DEP

ARRANTY DEPARRANTY DEP

ARRANTY DEPARAR

ARAR

ARTMENTTMENT

TMENTTMENT

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

MAINMAIN

MAIN

800/421-1244 or 310/537-3700

FAX: 310/537-3927

Multiquip Portable Generator Dca 60Ssai Users Manual

Multiquip Portable Generator dca-60ssai Generators_portable_supersilent_DCA60SSAI_rev_0__manual_DataId_19055_Version_1

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