PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
MQ POWER
DCA-25SSAI
TM
WHISPERWATT
GENERATOR
PARTS LIST NO. 3336000
Final Copy (06/30/01)
MULTIQUIPINC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
SERVICE DEPARTMENT:
800-835-2551
FAX:310-537-3927
FAX:310-638-8046
E-mail:mq@multiquip.com • www:multiquip.com
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HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
PAGE 3 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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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 andTransportation ............................................. 10
Trailer Safety Guidelines............................................11-15
TrailerWiring Diagram .................................................... 16
Operation Decals .......................................................17-18
DCA-25SSAI Specifications .......................................... 19
General Information ....................................................... 20
Major Components ........................................................ 21
Dimensions.................................................................... 22
Control Panel Descriptions ........................................24-25
Engine Operating Panel Descriptions ........................26-27
OutputTerminal Panel Descriptions ...........................28-29
Output Amerage Setup ..............................................30-31
Output Voltage Setup.................................................32-35
Installation .................................................................36-37
Pre Setup ..................................................................38-41
Load Application ............................................................ 42
Generator Start-up Procedure ...................................43-45
Generator Shutdown Procedure ..................................... 46
Maintenance ..............................................................47-48
GeneratorWiring Diagram .............................................. 50
EngineWiring Diagram .................................................. 51
EngineTroubleshooting ..............................................52-53
Generator/EngineTroubleshooting ................................. 54
Explanation of Codes in Remarks Column .................... 56
Suggested Spare Parts ................................................. 57
ISUZU C240 ENGINE
Cylinder Head and Cover Assembly ..........................86-87
Cylinder Block Assembly ..........................................88-89
Timing Gear Assembly ..............................................90-91
Flywheel Housing Assembly .....................................92-93
Oil Pan Assembly ......................................................94-95
Oil Pump Assembly ..................................................96-97
Crankshaft, Bridge and Flywheel Assembly ..............98-99
Oil and Fuel Filter Assembly ................................. 100-101
Oil Pipe Assembly................................................. 102-103
Water Pump and Fan Assembly ............................ 104-105
Intake and Exhaust Manifold Assembly ................ 106-107
Air Cleaner Assembly ............................................ 108-109
Engine Foot Assembly .......................................... 110-111
Injection Pump Assembly ..................................... 112-113
Electrical Parts Assembly ..................................... 114-115
Accessories .......................................................... 116-117
Injection Pump Comp. Assembly .......................... 118-121
Governor Comp. Assembly.................................... 122-127
Feed Pump Comp. Assembly ................................ 128-129
Auto Timer Assembly ............................................ 130-131
Nozzle Holder Comp. Assembly ............................ 132-133
Starter Comp. Assembly ....................................... 134-135
Alternator Comp. Assembly ................................... 136-139
Terms and Conditions of Sales ....................................140
MQ POWER DCA-25SSAI
AC GENERATOR
NOTE
Generator Assembly..................................................58-59
Control Box Assembly...............................................60-61
Engine & Radiator Assembly.....................................62-67
Engine Operating Panel Assembly ............................68-69
Output Terminal Assembly.........................................70-71
Battery Assembly ......................................................72-73
Muffler Assembly ......................................................74-75
Fuel Tank Assembly ..................................................76-77
Enclosure Assembly .................................................78-81
Rubber Seal Assembly ..............................................82-83
Name Plate And Decals ............................................84-85
Specification and part number
are subject to change without
notice.
PAGE 4 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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PARTS ORDERING PROCEDURES
I Dealer account number
I Dealer name and address
I Shipping address (if different than billing address)
I Return fax number
I Applicable model number
I Quantity, part number and description of each part
I Specify preferred method of shipment:
UPS Ground
•
UPS Second Day or Third Day*
•
UPS Next Day*
•
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
Airborne Express*
•
Truck or parcel post
•
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
Additional Discount
1-9 items
3%
10+ items**
5%
only
s
der
ed or
x
a
f
For
Get special freight allowances
when you order 10 or more
line items via FAX!**
Now! Direct TOLL-FREE access
to our Parts Department!
I
UPS Ground Service at no charge for freight
I
PS Third Day Service at one-half of actual freight cost
Toll-free nationwide:
800-421-1244
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.
Toll-free FAX:
*DISCOUNTS ARE SUBJECT TO CHANGE*
800/6-PARTS-7 • 800-672-7877
Fax order discount and UPS special programs revised June 1, 1995
PAGE 5 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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RULES FOR SAFE OPERATION
CAUTION:
I
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
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-25SSAI portable generator:
I
High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with hot components can cause serious
burns.
GENERAL SAFETY
I
I
I
DONOToperateorservicethisequipmentbefore
reading this entire manual.
I
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
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.
generator engine gives off DEADLY carbon monoxide gas.
I
I
I
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
CAUTION
:
NEVER operate this equipment under the
influence or drugs or alcohol.
I
Always refuel in a well-ventilated area,
away from sparks and open flames.
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.
I
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.
I
I
I
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.
I
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.
I
Topping-off to filler port is
dangerous, as it tends to spill fuel.
PAGE 6 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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RULES FOR SAFE OPERATION
CAUTION
:
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.
I
NEVER touch output terminals during operation. This is
extremely dangerous. Always stop the machine when
contact with the output terminals is required.
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.
CAUTION
:
I
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.
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.
CAUTION
:
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.
I
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.
PAGE 7 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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RULES FOR SAFE OPERATION
Battery
I
I
I
I
NEVER Run engine without air filter. Severe engine
damage may occur.
CAUTION
:
Always service air cleaner frequently to prevent carburetor
malfunction.
Never over fill the battery with water above
the upper limit.
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.
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:
I
Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.
I
I
I
I
DO NOT leave the generator running in the manual mode
unattended.
DO NOT allow unauthorized people to operate this
equipment.
1. DO NOT drop the battery. There is the possibility of risk
Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
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.
Refer to the Isuzu Engine Owner's Manual for engine
technical questions or information.
Loading and Unloading (Crane)
I
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.
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.
I
I
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.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
I
I
NEVER lift the machine while the engine is running.
Use adequate lifting cable (wire or rope) of sufficient
strength.
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.
I
I
I
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.
PAGE 8 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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RULES FOR SAFE OPERATION
Transporting
I
I
I
Always shutdown engine before transporting.
Tighten fuel tank cap securely.
Drain fuel when transporting generator over long distances
or bad roads.
I
I
Keep the machinery in proper running condition.
I
I
Always tie-down the generator during transportation by
securing the generator.
Fix damage to the machine immediately and always
replace broken parts.
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.
I
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
Emergencies
I
I
DO NOT use plastic containers to dispose of hazardous
waste.
I
Always know the location of the nearest fire extinguisher
and first aid kit. Know the location of the nearest telephone.
Also know the phone numbers of the nearest ambulance,
doctor and fire department.
DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source.
PAGE 9 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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DCA-25SSAI —TOWING RULES FOR SAFE OPERATION
Towing Safety Precautions
I
I
ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
CAUTION :
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
Check with your county or state safety
towing regulations department before
towing your generator.
I
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.
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.
I
I
I
Place chocked blocks underneath wheel to prevent
rolling, while parked.
Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
The following list of suggestions should be used when towing
your generator:
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.
I
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
I
Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve gas milage.
I
ALWAYS inspect the hitch and coupling for wear.NEVER
tow a trailer with defective hitches, couplings, chains
etc.
I
I
I
Avoid sharp turns to prevent rolling.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
I
I
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".
Figure 1. Generator with Trailer
PAGE 10 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI — TRAILER-SAFETY GUIDELINES
5.
6.
Frame Width - This measurement is from fender to
fender.
Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the 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.
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.
Explanation of Chart:
This section is intended to provide the user with trailer ser-
vice and maintenance information. The service and mainte-
nance guidelines referenced in this section apply a wide range
of trailers. Remember periodic inspection of the trailer will
ensure safe towing of the equipment and will prevent dam-
age to the equipment and personal injury.
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. SeeTable 4 and Figure 5 or lug nut tightening and
sequence.
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:
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 3). Please note that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
„
„
„
„
Tires
Lug NutTorquing
Suspension
Electrical
Use the following definitions with reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans-
porting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
4.
Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
PAGE 11 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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DCA-25SSAI —TRAILER-SPECIFICATIONS
Table 1. Specifications
MODEL
APPLICATION
FUEL
CELL
BRAKE
SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
TRLR-10W
TRLR-10
SDW225,
SGW250,TLW300
NO
NO
1900LBS
1900LBS
1900LBS
2200LBS
2700LBS
2700LBS
2700LBS
7000LBS
7000LBS
7000LBS
7000LBS
10000LBS
11160LBS
14000LBS
18000LBS
18000LBS
30000LBS
30000LBS
96"
96"
96"
85"
50"
50"
50"
42"
800LB.
FULL TILT WHEEL
DCA10, TLG12,
DCA-15
NO
NO
800LB.
FULL TILT WHEEL
TRLR-10XF
TRLR-225W
TRLR-BLW400
TRLR-50X
DCA10, TLG-12,
DCA15, TLW-300
52 GAL
NO
NO
NO
800LB.
FULL TILT WHEEL
WELDERS,
DA7000SS
800LB.
FULL TILT WHEEL
BLW-400
NO
ELECTRIC
NO
W/MAST 154"
W/O 124"
55"
(78" TALL)
800LB.
FULL TILT WHEEL
DCA-25
NO
124"
124"
186"
138"
138"
190"
186"
204"
222"
238"
238"
384"
384"
55"
55"
77"
66"
66"
76"
77"
84"
83"
83"
83"
96"
96"
800LB.
FULL TILT WHEEL
TRLR-50XF
TRLR-70W
DCA-25
41 GAL
NO
NO
800LB.
FULL TILT WHEEL
DCA-45, -60, 70
DCA-45, -60, 70
DCA-45, -60, 70
DCA-100, 125
SURGE
2000LB.
FLAT PAD
TRLR-70X
OPT
SURGE
2000LB.
FLAT PAD
TRLR-70XF
TRLR-100XF
TRLR-85/125
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800SX
53 GAL
150 GAL
145 GAL
200 GAL
250 GAL
250 GAL
350 GAL
550 GAL
550 GAL
SURGE
2000LB.
FLAT PAD
HYDRAULIC SURGE
HYDRAULIC
HYDRAULIC SURGE
HYDRAULIC SURGE
HYDRAULIC SURGE
ELECTRIC
AIR
2000LB.
FLAT PAD
DCA-85, 100,
125
2000LB.
FLAT PAD
DCA-150, 180
5000 LB.
FLAT PAD
DCA-220
5000 LB.
FLAT PAD
DCA-300
5000 LB.
FLAT PAD
DCA-400
5000 LB.
FLAT PAD
DCA-600, 800
DCA-600, 800
5000 LB.
FLAT PAD
AIR
5000 LB.
FLAT PAD
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DCA-25SSAI —TRAILER-SPECIFICATIONS
Table 1. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS SUSPENSION
ELECTRICAL
TRLR-10W
2" BALL CLASS
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X2
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
6 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
3 LEAF
3 LEAF
3 LEAF
Q FLEX
3 LEAF
4 LEAF
4 LEAF
5 LEAF
5 LEAF
5 LEAF
5 LEAF
7 LEAF
7 LEAF
Q FLEX
Q FLEX
Q FLEX
7 LEAF
AIR-RIDE
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10
TRLR-10XF
TRLR-225W
2"BALL CLASS
2 ADJUSTABLE
175-13C
175-13C
13"X4.5"
13"X4.5"
13X4.5"
13 X 4.5"
13"X4.50"
13"X4.50"
14"X5"
2200#2X2
2200#2X2
2200#2X2
2200#2X2
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
2"BALL CLASS
2 ADJUSTABLE
2"BALL CLASS
2 ADJUSTABLE
175-13B
TRLR-BLW
400
2"BALL CLASS
2 ADJUSTABLE
175-13C
TRLR-50X
TRLR-50XF
TRLR-70W
TRLR-70X
TRLR-70XF
2" BALL CLASS
B78-13LRC
B78-13LRC
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
2" BALL CLASS
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
3500lbs.
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs.
3"
4 POLE RUBBER
FLAT
TRLR-100XF ADJUSTABLE 2-5/6
205-15C
BIAS (4)
14"X5.5"
14"x6"
3500lbs
3"
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
6 WIRE LOOM
6 WIRE LOOM
OPT 3" EYE
TRLR-85/125 ADJUSTABLE 2-5/6
ST225/75R15D
RADIAL (4)
(2)-6000lbs
(2)-6000lbs
(2)-7000lbs
(2)-6000lbs
(3)-7000lbs.
(3)-10000lbs
(3)-10000lbs
OPT 3" EYE
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800AR
3" BALL EYE
750-16 E
BIAS (4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
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DCA-25SSAI —TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked, the
air pressure in
the inner tube
may cause pieces of the rim to
explode (break off) with great force
and cause serious eye or bodily
injury.
Suspension
The leaf suspension springs and associated components
(Figure 2) should be visually inspected every 6,000 miles for
signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 3.
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:
Figure 2. Major Suspension Components
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to
comply may result in serious injury.
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DCA-25SSAI —TRAILER SAFETY GUIDELINES
Table 3. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-60
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAIN NUT-BOLT ASSEMBLY.
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
Lug NutTorque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 3. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined byTable 4.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 4. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 3. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
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DCA-25SSAI —TRAILER-WIRING DIAGRAM
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
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DCA-25SSAI — GENERATOR DECALS
The DCA-25SSAI generator is equipped with a number of safety decals. These decals are provided for operator safety
and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
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DCA-25SSAI — GENERATOR DECALS
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DCA-25SSAI — SPECIFICATIONS
Table 5. Specifications
Generator Specifications
Model
Type
DCA-25SSAI
Revolving field, self ventilated, open protected type synchronous
Armature Connection
Phase
Star with Neutral
3
Zig Zag
Single
Standby Output
Prime Output
Voltage
26.5 KVA (21.2 KW)
25 KVA (20 KW)
240V or 480V
15.3KW
14.4KW
240/120V
Frequency
Speed
60 Hz
1800 rpm
Power Factor
Aux. AC Power
Voltage
0.8
1
Single Phase, 60 Hz
120 V
Output
4.8 KW (2.4 KW x 2)
Engine Specifications
Model
Type
Isuzu C240
4 Cycle, water-cooled, swirl combustion chamber
4 cylinders
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
3.38 in. x 4 in. (86 mm x 102 mm)
30.6HP/1800 rpm
144 cu. in. (2369cc)
Electric
Coolant Capacity
Lube Oil Capacity
2.9 gal. (11 liters)
1.45 gal. (5.5 liters)
1.65 gal. (6.3L)/hr at full load
0.9 gal. (3.4L)/hr at 1/2 load
1.3 gal. (5.0L)/hr at 3/4 load
Fuel Consumption
0.6 gal. (2.3L)/hr at 1/4 load
Battery
Fuel
12V- 70AH
#2 Diesel Fuel
PAGE 19 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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DCA-25SSAI — GENERAL INFORMATION
DCA-25SSAI FAMILIARIZATION
Generator
Open Delta Excitation System
The DCA-25SSAI generator is equipped with the state of
the art "Open-Delta" excitation system. The open delta
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
The MQ Power Model DCA-25SSAI is a 20 kW generator
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 There are four leads: A, B, C and D. During light loads, the
industrial and construction machinery.
power to the Automatic Voltage 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.
Engine Operating Panel
The “Engine Operating Panel”is provided with the following:
z
z
z
z
z
z
z
z
z
z
z
Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel level gauge
Engine Throttle Lever
Pre-Heat Light
Alarm Lights
Panel Light
Panel Light Switch
Starter Switch
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 ceiling" and responds
according the demands of the required load.
Engine
The DCA-25SSAI is powered by a 4 cycle, water cooled,
turbocharged Isuzu QD60(C640) diesel engine.This engine
is designed to meet every performance requirement for the
generator. Reference Table 5, page 19 for engine
specifications.
Generator Control Panel
The “Generator Control Panel”is provided with the following:
z
z
z
z
z
z
Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
The basic controls and indicators for the DCA-25SSAI
generator are addressed on the following pages.
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
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%.
z
z
z
z
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:
z
z
Main Circuit Breaker 60 amps
Over-Current Relay
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DCA-25SSAI — MAJOR COMPONENTS
Figure 4. Major Components
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DCA-25SSAI — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 5. Dimensions
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NOTE PAGE
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DCA-25SSAI — CONTROL PANEL
Figure 6. Control Panel
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DCA-25SSAI — CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-25SSAI " Control Panel " (Figure 6).
1. Main Circuit Breaker – This three-pole, 60 amp main
breaker is provided to protect the UVW voltage output
terminals from overload.
2. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz 1 Hz .
3. AC Ammeter – Indicates the amount of current the
load is drawing from the generator.
4. AC Voltmeter – Indicates the single phase output
voltage present at the UVW terminals.
5. Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage.
6. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off.
7.
Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
8. Pilot Lamp- This will light if the oil pressure or water
temperature is not within normal limits. If the lamp does
not illuminate when the lamp switch is turned on, the
bulb should be replaced.
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DCA-25SSAI — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
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DCA-25SSAI — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-25SSAI " Engine Operating Panel " (Figure 7).
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. WaterTemperature Gauge – During normal operation
this gauge be should read between 165o to 215o.
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. Oil Pressure Indicator - This light will luminate if the
oil pressure exceeds 35 psi and will shut off the engine.
6. WaterTemperature Indicator - This light will luminate
if the water temperature exceeds 2150 and will shut off
the engine.
7. Lamp Check Switch (see Control Panel)-Test switch
for the lamp indicator on the control panel that the oil
pressure and water temperature warning system is
working properly.
8. Panel light switch-When activated, will turn on control
panel light.
9. Speed Control Handle- To change the speed of the
engine from idle to high, pull and turn the handle.
10. Pre-Heat Indicator - This light will luminate once the
engine is warmed to an operating temperature.
11. Ignition Switch - This switch is used with a key to
start, preheat, and stop the engine..
12. Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
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DCA-25SSAI — OUTPUTTERMINAL PANEL
Output Terminal Panel
Connecting Load
Loads can be connected to the generator by the UVW Lugs or
The output control panel is located on the rear (control panel)
end of the generator. The UVW lugs are protected by a face
plate cover that can be secured in the close position by a
pad lock.
the duplex receptacle. (See Figure 9). Make sure to read the
operation manual before attempting to connect a load to the
generator.
120Volt Receptacle
One GFCI Duplex NEMA 5-20R (120V, 20 Amp) receptacle
is located on the output terminal. This receptacle can be
used anytime the generator is in operation. The receptacle
is controlled by the circuit breaker located on the control
panel.
The reset button will reset the receptacle after being tripped.
Pressing the "Test Button" (See Figure 8) in the center of
this receptacle will check the GFCI function. The receptacle
should be tested at least once a month.
Figure 9. Connecting Loads
Circuit Breakers
To protect the generator from an overload, a 3-pole, 60 amp,
main circuit breaker is provided to protect the UVWO output
terminals from overload. In addition two single-pole, 20 amp
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload. Three 50 amp load circuit
breakers have also been provided to protect the load side of
the generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
Figure 8. GFCI Test Button
Maximum Output
The entire load connected to the UVW l ugs and all four slots in
the duplex receptacle must not exceed 22 kW in standby or 20
kW in prime output.
120V Receptacles - These receptacles can be used
anytime the generator is in operation. They are controlled
by the circuit breakers above them.
Twist Lock Dual Voltage Receptacles - To use these
receptacles, place the voltage selector switch in the single
phase 240/120 voltage position and adjust the output
voltage to 240 volts with the voltage regulator on the
control panel (see Figure 6, page 24). Place the voltmeter
change-over switch to the U-W position and the ammeter
change-over switch to the U or W to read the output.
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DCA-25SSAI — OUTPUTTERMINAL PANEL
NOTE
Legs “O” and Ground are
considered Bonded Grounds.
Figure 10. Output Terminal Description
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DCA-25SSAI — OUTPUT AMPERAGE SETUP
Over Current Relay
Output Terminal Panel Available Voltages
An over current relay is connected to the circuit breaker.
During an over current situation, both the circuit breaker
and the over current relay may trip. If the circuit breaker
can not be reset, the reset button on the over current relay
must be pressed. The over current relay is located inside
the control box.
A wide range of voltages are available to supply load to
many different applications. Voltages may be selected by
using the voltage selector switch and depending how you
hookup your hard wire connection to the generator. To
obtain voltages listed, fine adjustment with the voltage
regulator on the control panel is necessary. See the table
below (Table 6) for a list of available voltages the generator
is able to supply.
Table 6. Voltage Available
3 Phase
(Switchable)
208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 480 VOLT
120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 277 VOLT
Single Phase
(Switchable)
CAUTION :
Maximum Amps
NEVER switch the voltage selector switch
position while the engine is engaged.
The following table show the maximum amps the entire
generator can provide. Do not exceed the maximum amps
listed. (See Table 7)
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and generator load from being switched while
the engine is running. To lock the voltage selector switch,
press in the red button located on the lower part of the
voltage selector switch, and use a pad lock to hold it into
this position.
Table 7. Maximum Amps
Rated Voltage
Maximum Amps
55.5 amps (4 wire)
27.8 amps (4 wire)
60 amps
Single Phase
120 Volt
Single Phase
240 Volt
Three Phase
240 Volt
Three Phase
480 Volt
30 amps
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DCA-25SSAI — OUTPUT AMPERAGE SETUP
Receptacle Use
When the UVWO terminals are providing power, the
receptacle power available decrease. Do not exceed
receptacle power available listed on Table 8.
Table 8. Receptacle Use
Receptacle
Power
Available
Power in Use
Figure 11. Voltage Selector Switch 240/120V
Single Phase Position
240/120V
Single Phase
or Twist Lock
CS6369
240/480V
3-Phase
Duplex NEMA
5-20R 120V
25
14.4
13.2
12
0
20.8
16.7
12.5
8.4
1.2
2.4
3.6
4.8
Figure 12. AC Voltmeter
Figure 13. AC Voltmeter
Change-over switch
Gauge
10.8
9.6
(Reading the W-U leg on
(Volt reading on W-U Lug)
the output terminal panel)
How To ReadThe OutputTerminal Gauges
The gauges (Figures 13 and 15) and change-over switches
on the control panel DO NOT effect the generator output.
They are to help observe how much power is being
supplied produced at the UVWO legs.
When the voltage selector switch is in the 240/120V
position (see Figure 11), place the AC voltmeter change-
over switch to the W-U position (Figure 12) and the AC
ammeter change-over switch to the U or W position (Figure
14) to read the output on the selected leg.
Figure 15. AC Ammeter
(Amp reading on U lug)
Figure 14. AC Ammeter
Change-over Switch
(Reading the U leg on the
output terminal panel)
NOTE
When using plural single phase
voltages, make sure to balance
the load on each of the single
phase legs.
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DCA-25SSAI — OUTPUT VOLTAGE SETUP
480/240V Hard Wire Hookup
240/120V HardWire Hookup
With the voltage selector set and locked at ‘3 phase 480/
277’ (Figure 17) and using the 3-phase 240 volt hookup, it
will provide one circuit available at 108 amps with any two
wires plus the ground (Figure 18).
With the voltage selector set and locked at ‘single phase
240/120’ and using single phase 120 volts, it will provide
three legs available with 100 amps each on three different
circuits (Figure 16).
When using the 3-phase 480 volts hookup, it will provide
one circuit available at 50 amps available with all three wires
plus ground (Figure 18).
When using single phase 240 volts, it will provide one leg
with 50 amps available (Figure 16).
FIGURE 17. Voltage Selector Switch 480/277V Three Phase
Position
FIGURE 16. Hard Wire Hookup at 240/120V Position
FIGURE 18. Hard Wire Hookup For 240V or 480V
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DCA-25SSAI — OUTPUT VOLTAGE SETUP
Voltage Selector Switch- 3 Phase 480/277V Position
Single Phase: 480V, 440V, or 416 Volt
The following are additional voltages available when the
voltage selector switch is in the 3 phase 480/277V
position.
This setting can provide single phase power at 480, 440,
or 416 volts. After hooking up the hard wires to the lugs
as shown in Figure 21, 480 volts can be obtained the
voltage regulator knob turned toward maximum; 440 volts
can be obtained with the voltage regulator knob is turned
down; and 416 volts can be obtained with the voltage
regulator knob is at lowest setting.
Figure 19. Voltage Regulator Knob
3 Phase, 480V, 440V, or 416 Volt
This setting can provide 3-phase power at 480, 440, or
416 volts. After hooking up the hard wires to the lugs as
shown in Figure 20, 480 volts can be obtained the
voltage regulator knob turned toward maximum; 440 volts
can be obtained with the voltage regulator knob is turned
down; and 416 volts can be obtained with the voltage
regulator knob is at lowest setting.
Figure 21. Hard Wire Hookup for Single Phase 480V, 440V,
or 416V
Single Phase: 277V, 254V, or 240V
This setting can provide single phase power at 277, 254
or 240 volts. After hooking up the hard wires to the lugs
as shown in Figure 22, 277 volts can be obtained the
voltage regulator knob turned toward maximum; 254 volts
can be obtained with the voltage regulator knob is turned
down; and 240 volts can be obtained with the voltage
regulator knob is at lowest setting.
Figure 20. Hard Wire Hookup for Three Phase
480V, 440V, or 416V
Figure 22. Hard Wire Hookup for Single Phase 277V, 254V,
or 240V
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DCA-25SSAI — OUTPUTVOLTAGE SETUP
Single Phase: 240V, 220V, or 208 Volt
Voltage Selector Switch- 3 Phase 240/139V Position
The following are additional voltages available when the
voltage selector switch is in the 3 phase 240/139V
position.
This setting can provide single phase power at 240, 220,
or 208 volts. After hooking up the hard wires to the lugs
as shown in Figure 25, 240 volts can be obtained the
voltage regulator knob turned toward maximum; 220 volts
can be obtained with the voltage regulator knob is turned
down; and 208 volts can be obtained with the voltage
regulator knob is at lowest setting.
Figure 25. Hard Wire Hookup for Single Phase 240V, 220V,
or 208V
FIGURE 23. Voltage Selector Switch 240/139V Three Phase
Position
Single Phase: 139V, 127V, or 120V
3 Phase, 240V, 220V, or 208 Volt
This setting can provide single phase power at 139, 127,
or 120 volts. After hooking up the hard wires to the lugs
as shown in Figure 26, 139 volts can be obtained the
voltage regulator knob turned toward maximum; 127 volts
can be obtained with the voltage regulator knob is turned
down; and 120 volts can be obtained with the voltage
regulator knob is at lowest setting.
This setting can provide 3-phase power at 240, 220, or
208 volts. After hooking up the hard wires to the lugs as
shown in Figure 24, 240 volts can be obtained the
voltage regulator knob turned toward maximum; 220 volts
can be obtained with the voltage regulator knob is turned
down; and 208 volts can be obtained with the voltage
regulator knob is at lowest setting.
Figure 26. Hard Wire Hookup for Single Phase 139V, 127V,
or 120V
Figure 24. Hard Wire Hookup for Three Phase 240V, 220V, or
208V
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DCA-25SSAI — OUTPUTVOLTAGE SETUP
Single Phase: 120 Volt
This setting can provide single phase power at 120 volts.
Voltage Selector Switch- Single Phase 240/120V
Position
After hooking up the hard wires to the lugs as shown in
Figure 29, 120 volts can be obtained by using the voltage
regulator to fine tune.
The following are additional voltages available when the
240/120V position.
Figure 29. Hard Wire Hookup for Single Phase, 120 volt
Figure 27. Voltage Selector Switch 240/120V Single Phase
Position
Single Phase, 240 Volt
This setting can provide single phase power at 240 volts.
After hooking up the hard wires to the lugs as shown in
Figure 28, 240 volts can be obtained and using the
voltage regulator to fine tune.
Figure 28. Hard Wire Hookup for Single Phase 240 volt
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DCA-25SSAI — INSTALLATION
Outdoor Installation
CAUTION
:
Install the generator in a location where it will not be exposed
to rain or sunshine. Make sure the generator is on secure
level ground so that it cannot slide or shift around. Also
install the generator in a manner so that the exhaust will not
be discharged in the direction of nearby homes.
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
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.
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.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
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.
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 30) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully.Connect the other
end of the ground cable to earth ground.
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.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
NOTE
Mounting
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
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DCA-25SSAI — INSTALLATION
Figure 30. Typical Generator Grounding Application
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DCA-25SSAI — PRE-SETUP
General Inspection Prior to Operation
Circuit Breakers
The DCA-25SSAI generator has been thoroughly inspected To protect the generator from an overload, a 3-pole, 60 amp,
and accepted prior to shipment from the factory. However, main circuit breaker is provided to protect the UVW output
be sure to check for damaged parts or components, or loose terminals from overload. In addition two single-pole, 20 amp
nuts and bolts, which could have occurred in transit.
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload.Three 50 amp load circuit breakers
have also been provided to protect the load side of the
generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
Extension Cable
When electric power is to be provided to various tools or
loads at some distance from the generator, extension
cords are normally used. Cables should be sized to allow
for distance in length and amperage so that the voltage
drop between the generator and point of use (load) is held
to a minimum. Use the Cable Selection Guide (Table 9)
as a guide for selecting proper cable size.
NOTE
ALWAYS consult with a licensed
electrician for correct extension
cord wire size.
Table 9. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Maximum Allowable Cable Length
Current in
Amperes
At 120 At 240
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
Volts
2.5
5
300
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
600
900
1200
1800
2400
3600
4800
7.5
10
15
20
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage.
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DCA-25SSAI — PRE-SETUP
Fuel
Lubrication Oil
Fill the fuel tank with clean and fresh diesel fuel. DO NOT
fill the tank beyond capacity.
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way, but without being screw
into the filler hole, verify that the oil level is maintained
between the two notches (Figure 31) on the dipstick. See
Table 10 for proper selection of engine oil.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 19
Specification Table 5.
The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel. Wipe up any spilled fuel immediately.
CAUTION :
Never fill the fuel tank while the engine is
running or in the dark. Gasoline spillage
on a hot engine can cause a fire or
explosion. If gasoline spillage occurs, wipe
up the spilled gasoline completely to
prevent fire hazards.
Coolant
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced. See maintenance section on page 42 and
43 on instructions to flush out radiator.
Figure 31. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean and viscous. If the oil is not clean, drain the oil by An anticorrosion additive added to the water will help prevent
removing the oil drain plug, and refill with the specified amount deposits and corrosion in the cooling system.
of oil as outlined in the Isuzu Engine Operator’s Manual.
Table 10. Recommended Motor Oil
Temperature Range
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
SAE 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
SAE 10W or SAE 10W-30
Below 5° C (-15°)
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DCA-25SSAI — PRE-SETUP
Cleaning the Outer Radiator
CAUTION :
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.
When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.
Air Cleaner
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.SeeTable11.
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.
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Kubota Engine Owner's Manual.
Fan BeltTension
The slack on the fan belt may contribute to overheating, or
to insufficient charging of the battery. Inspect the fan belt
for damage and wear and adjust it in accordance with the
Kubota Engine Owner's Manual.
Table 11. Coolant Capacity
The fan belt tension is proper if the fan beltdeflects 10 to 15
mm (Figure 32) when depressed with the thumb as shown
below. Never place hands near the belts or fan while the
generator is running.
Engine and Radiator
Reserve Tank
2.9 Gal. (11 Liters)
0.27 Gal. (1 Liter)
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 12) has been added.
Table 12. Anti-Freeze Operating Temperatures
Figure 32. Fan Belt Tension
Freezing Point
Boiling Point
CAUTION :
Vol %
Anti-Freeze
°C
-24
-37
°F
°C
°F
Never place hands near the belts or fan
while the generator set is running.
40
50
-12
-34
106
108
222
226
Adjusting Fan Belt
If the fan belt does not have the 10 to 15mm defection
follow the procedure below to adjust:
y
y
y
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.
NOTE
When the antifreeze is mixed with
water, the antifreeze mixing ratio must
be less than 50%.
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DCA-25SSAI — PRE-SETUP
Battery
CAUTION :
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.
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.
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.
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.
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.
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.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 33) are properly
connected to the battery terminals as shown below.The 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 :
Inadequate battery connections may
cause poor starting of the generator, and
create other malfunctions.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness.Tighten all hose clamps and check hoses
for leaks.
If any hose (fuel or oil) lines are defective replace them
immediately.
Figure 33. Battery Connections
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DCA-25SSAI — LOAD APPLICATION
Single Phase Load
CAUTION
:
Motors and motor-driven equipment draw
much greater current for starting than
during operation.
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.
An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can burn
out the appliance or tool and overheat the cable.
z
z
z
When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.
When the voltage selector switch is in single phase (240/
120V position), place the AC voltmeter change-over switch
to the U-W position and the AC ammeter change over-switch
to the U or W position to read the output.
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.
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.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
WATTS = VOLTAGE x AMPERAGE
If wattage is not available on the equipment, approximate
wattage may be determined by multiplying the nameplate
voltage by the nameplate amperage for three-phase:
WATTS =1.732 x VOLTAGE x AMPERAGE
The power factor of this generator is 1.0. See Table 13.
below when connecting loads.
CAUTION:
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.
Table 13. Power Factor By Load
Type Of Load
Power Factor
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
NOTE
Fluorescent lamps, mercury lamps
If output (kVA) is not given on the
equipment nameplate, approximate
output may be determined by
multiplying voltage by amperage by
Electronic devices, communication
equipment
Common power tools
0.8
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
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DCA-25SSAI — GENERATOR START-UP PROCEDURE
WARNING:
2. Connect the load to the UVW terminals as shown in
The engine's exhaust contains harmful
Figure 35. These terminals can be found on the output
terminal panel, (see page 29 Figure10).To gain access
to the output terminals lift the UVW cover. Tighten
terminal nuts securely to prevent load wires from slipping
out.
emissions. ALWAYS ventilate the
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.
Before Starting
Engine
1. Check the lubricating oil level prior to starting the engine.
Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.
2. When there is not enough lubricating oil, fill the crankcase
with high grade motor oil. Use a high quality detergent
oil classified CC or higher (See Table 8 on page 33).
3. Check the coolant level in the radiator and subtank.
Replenish with antifreeze as necessary.Always maintain
the coolant level between the FULL and LOW markings
on the coolant container.Be sure that the radiator cap is
fastened securely.
Figure 35. UVW Terminal Lugs (Load)
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.
3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 36).
Before Starting
Generator and Control Panel
CAUTION:
NEVER start the engine with the
main, GFCI or load circuit breakers
in the ON position.
1. Be sure to disconnect the electrical load and switch the
main, load and G.F.C.I. circuit breakers (Figure 34) to
the “OFF” position prior to starting the engine.
Y
TTER
BA
Figure 36. Battery Connections
Figure 34. Main, GFCI and
Load Circuit Breakers
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DCA-25SSAI — GENERATOR START-UP PROCEDURE
4. Close all engine enclosure doors (Figure 37).
8. Once the preheat indicator lights, turn the ignition
key to ‘START’ until the engine starts (Figure 41).
Then release the key to ‘RUN’.
Figure 41. Ignition Switch ‘START’
Figure 37. Engine Enclosure Doors
9. Pull the engine throttle and turn to the right until the
metal stop rests against the control panel (Figure 42).
5. Check the voltage selection switch (Figure 38) is at
the desired voltage.
Figure 42. Engine Throttle Lever (high)
10. The generator's frequency meter (Figure 43) displays
Figure 38. Voltage Selection Switch
the 60 cycle output frequency in HERTZ.
6. Make sure the engine throttle (Figure 39) is in
’start/idle’.
Figure 43. Frequency Meter (Hz)
Figure 39. Engine Throttle Lever (low)
11. The generator's voltage meter (Figure 44) displays the
120 VAC in VOLTS. If the voltage is not within the
specified frequency tolerance, use the voltage
adjustment control knob (Figure 45) to increase or
decrease the desired voltage.
7. Turn the ignition key to preheat (Figure 40), until the
preheat indicator turns on.
Figure 40. Ignition Switch ‘PREHEAT’
Figure 44. Voltage Meter (Volts)
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DCA-25SSAI — GENERATOR START-UP PROCEDURE
15. The tachometer (Figure 49) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800
RPM’s.
Figure 45. Voltage Adjust Control Knob
12. The ammeter (Figure 46) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator’s alternator.
Figure 49. Engine Tachometer
40
20
60
0
75
16. Turn the MAIN, GFCI and LOAD circuit breakers to
their ON position (Figure 50).
A
Figure 46. Ammeter (No Load)
13. The engine oil pressure gauge (Figure 47) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure is approximately
25 psi.
Figure 50. Main and GFCI Circuit Breakers
17. Observe the generator's ammeter (Figure 51) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if the load is in use.
Figure 47. Oil Pressure Gauge
40
20
60
0
75
14. The coolant temperature gauge (Figure 48) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature is between 165 and
215 degrees Fahrenheit.
A
Figure 51. Ammeter (Load)
18. The generator will run until manually stopped or an
abnormal condition occurs.
WATER TEMP
Figure 48. Coolant Temperature Gauge
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DCA-25SSAI — GENERATOR SHUTDOWN PROCEDURE
ENGINE SHUTDOWN
To shutdown the generator, use the following procedure:
1. Switch both the MAIN, GFCI and LOAD circuit breakers
(Figure 52) to the “OFF” position.
Figure 52. Main, GFCI and Load
circuit breakers
2. Set the engine throttle lever to (low) position.
3. Let the engine cool by running it for 3-5 minutes with no
load applied.
4. Turn the ignition key to ‘STOP’ (Figure 53).
Figure 53. Ignition Switch ‘STOP’
5. Remove the load from the UVW terminal strip.
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NOTE PAGE
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DCA-25SSAI — MAINTENANCE
General Inspection
Check Oil Level
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.
Check the crankcase oil level prior to each use, or when
the fuel tank is filled. Insufficient oil may cause severe
damage to the engine. Make sure the generator is level.
The oil level must be between the two notches on the dipstick
as shown in Figure 31, page 39.
Engine Side (Refer to the Engine Instruction Manual)
Replacing Oil Filter
Air Cleaner
Detach the oil filter cartridge with a filter wrench.
Apply a film of oil to the gasket for the cartridge.
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.
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.
Fuel Addition
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.
Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.
Removing Water from the FuelTank
Replacing Fuel Filter
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.
Replace the fuel filter cartridge with new one every 400
hours or so.
Apply fuel oil thinly over the gasket and hand-tighten
the cartridge into position.
Vent any air.
Flushing Out Radiator and Replacing Coolant
Air Removal
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.
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.
Check hoses for softening and kinks. Check clamps
for signs of leakage.
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.
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.
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.
Tighten both cocks and replace the overflow tank.
Replace with coolant (see page 40,Table 12 for mixture).
Close radiator cap tightly.
CAUTION :
Cleaning the Fuel Strainer
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
will damage radiator.
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.
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DCA-25SSAI — MAINTENANCE
Generator Storage
For storage of the generator for over 30 days, the following
is required:
z
z
Drain the fuel tank completely.
Completely drain the oil from the crankcase and refill
with fresh oil.
z
z
Clean all external parts of the generator with a cloth.
Cover the generating set and store in a clean, dry place.
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
INSPECTION / MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Replace Engine Oil and Filter *1
Clean Air Filter
X
X
X
X
ENGINE
Drain Bottom of Fuel Tank
Clean Unit, Inside and Outside
Change Fuel Filter *2
X
X
Clean Radiator and Check Coolant Protection
Level
Replace Air Filter Element
Change Corrosion Resistor
Check all Hoses and Clamps
Clean Inside of Fuel Tank
X
X
X
X
X
Measure Insulation Resistance Over 3M ohms
GENERATOR
1
*
*
Replace engine oil anf filter at 100 hours, first time only.
Replace fuel filter at 250 Hours, first time only.
2
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DCA-25SSAI — GENERATORWIRING DIAGRAM
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DCA-25SSAI — ENGINEWIRING DIAGRAM
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DCA-25SSAI —TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper diagnosis based on the EngineTroubleshooting (Table 14).If
handling and maintenance inspections, but in the event of a the problem cannot be remedied, consult our company's
breakdown, use the tables shown for
business office or service plant.
TABLE 14. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Replenish fuel.
No fuel?
Air in the fuel system?
Water in the fuel system?
Fuel pipe clogged?
Bleed system.
Remove water from fuel tank.
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity of fuel
or engine oil at low temperature?
Use the specified fuel or engine oil.
Use the specified fuel.
Tighten nut.
Fuel with low cetane number?
Fuel leak due to loose injection
pipe retaining nut?
Incorrect injection timing?
Fuel cam shaft worn?
Adjust.
Engine does not start.
Replace.
Injection nozzle clogged?
Injection pump malfunctioning?
Clean injection nozzle.
Repair or replace.
Seizure of crankshaft, camshaft,
piston, cylinder liner or bearing?
Repair or replace.
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Compression leak from cylinder?
Improper valve timing?
Correct or replace timing gear.
Piston ring and liner worn?
Excessive valve clearance?
Replace.
Adjust.
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DCA-25SSAI —TROUBLESHOOTING (ENGINE)
TABLE 14. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
POSSIBLE PROBLEM
Fuel filter clogged or dirty?
Air cleaner clogged?
SOLUTION
Clean or change.
Clean or change.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Repair or replace.
Adjust.
Injection pump malfunctioning?
Engine revolution is not smooth.
Incorrect nozzle opening
pressure?
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe clogged?
Governor malfunctioning?
Excessive engine oil?
Clean.
Repair.
Reduce to the specified level.
Piston ring and liner worn or
stuck?
Repair or replace.
Either white or blue exhaust gas
is observed.
Incorrect injection timing?
Deficient compression?
Overload?
Adjust.
Adjust top clearance.
Lessen the load.
Use the specified fuel.
Clean or change.
Clean or change.
Repair or replace the nozzle.
Adjust.
Low grade fuel used?
Fuel filter clogged?
Either black or dark gray exhaust
gas is observed.
Air cleaner clogged?
Deficient nozzle injection?
Incorrect injection timing?
Engine's moving parts seem to
be seizing?
Repair or replace.
Deficient output.
Uneven fuel injection?
Repair or replace the injection pump.
Repair or replace the nozzle.
Deficient nozzle injection?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Compression leak?
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DCA-25SSAI —TROUBLESHOOTING (GENERATOR)
TABLE 17. GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
No Voltage Output
AC Voltmeter defective?
Is wiring connection loose?
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Low Voltage Output
Turn engine throttle lever to "High".
Check wiring and repair.
Replace if necessary.
High Voltage Output
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Circuit Breaker Tripped
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
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NOTE PAGE
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EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.
Items Found In the “Items Number” Column
All parts with same symbol in the number column, , #,
*
+, or %, belong to the same assembly or kit.
Note: If more than one of the same reference number is
listed, the last one listed indicates newest (or latest)
part available.
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DCA-25SSAI — SUGGESTED SPARE PARTS
DCA-25SSAIW/ISUZU C240 DIESEL ENGINE
1 TO 3 UNITS
Qty.
P/N
Description
10 ............ 0601804971 ............ CIRCUIT BREAKER
20 ............ X132400150 ........... FUEL FILTER
20 ............ 5873103370 ............ OIL FILTER
5 .............. 5136710400 ............ FAN BELT
1 .............. 8943768300 ............ WATER PUMP
2 .............. 9136140430 ............ WATER PUMP GASKET
2 .............. 1823100080 ............ STARTER SWITCH
5 .............. KEYISUZUF ........... STARTER SWITCH KEY
3 .............. 0602122272 ............ OIL SENDING UNIT
2 .............. 5137700221 ............ THERMOSTAT
2 .............. X137130020 ........... THERMOSTAT GASKET
2 .............. 9214311960 ............ RADIATOR HOSE (UPPER)
2 .............. 9214311980 ............ RADIATOR HOSE (LOWER)
1 .............. 0810105004 ............ FUEL CAP
8 .............. 9825119783 ............ GLOW PLUGS
2 .............. 5153110060 ............ INJECTOR NOZZLES
1 .............. 5825500191 ............ EMERGENCY RELAY
1 .............. 5819000200 ............ STOPPER ENGINE
1 .............. 5812003411 ............ ALTERNATOR
1 .............. 8944532120 ............ STARTER
1 .............. 0800225200 ............ AUTOMATICVOLTAGE REGULATOR
1 .............. 0601808810 ............ MAIN CIRCUIT BREAKER
1 .............. 0601840031 ............ VOLTAGE REGULATOR (RHEOSTAT)
1 .............. M1923100004 ......... SELECTOR SWITCH
1 .............. 47130106 ................ SELECTOR SWITCH KNOB
2 .............. 5814200330 ............ PREHEAT LAMP BULB
NOTE
Part number on this Suggested Spare
Parts list may supercede/replace the
P/N shown in the text pages of this
book.
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DCA-25SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
PAGE 58 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
PART NO.
ITEM
QTY.
REMARKS
3331040400
3331010112
3331042303
3331080013
7511032103
7511085103
3331610003
7511025103
3361026003
0601820067
0010004020
0041604000
0040004000
OEMAA8
FIELD ASSY.
1
1
1
1
1
1
1
1
1
1-1
1-2
1-3
1-4
1-5
1-6
2
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
3
4
5
6
7
8
9
10
11
12
13
14
15
15-1
15-2
15-3
16
17
18
SHAFT
FIELD CORE
FIELD COIL
ARMATURE CORE, EXCITER
ARMATURE COIL, EXCITER
COUPLING HUB
RECTIFIER ASSY.
SET PLATE, RECTIFIER
RECTIFIER ........................................... 2 ........... PB2510
HEX. HEAD BOLT
PLAIN WASHER
LOCK WASHER
HEX. NUT ............................................. 2 ........... REPLACES 0030004000
SURGE ABSORBER ............................ 1 ........... ERZ,14JK621A
INSULATOR WASHER
INSULATOR WASHER
HEX. HEAD BOLT ................................ 1 ........... REPLACES 0010005020
PLAIN WASHER ................................... 2 ........... REPLACES 0041605000
LOCK WASHER.................................... 1 ........... REPLACES 0040005000
2
4
2
0601822601
0801841004
0801841104
0017105020
58151
1
1
0032005000
0030005000
0011305100
042006309
0080000045
3331070002
3331611002
3331612004
0040008000
014208020
3331614002
0040008000
011208025
004000800
011008040
3331341600
3331320502
7511342114
3331366013
0801350104
0601850264
7511315103
7511350000
7511352103
7511362103
HEX. NUT
1
HEX. HEAD BOLT ................................ 4 ........... REPLACES 0017105012
BEARING .............................................. 1 ........... 6309ZZ; REPLACES 0070506309
SNAP RING
FAN
COUPLING DISK
WASHER, COUPLING HUB
LOCK WASHER
HEX. HEAD BOLT ................................ 6 ........... REPLACES 0010308020
COUPLING RING
LOCK WASHER
1
1
1(4)
1
6
1
6
HEX. HEAD BOLT ................................ 6 ........... REPLACES 0010308025
LOCK WASHER
HEX.HEAD BOLT ................................. 6 ........... REPLACES 0010308040
6
STATOR ASSY.
1
1
1
1
1
2
1
1
1
1
GENERATOR FRAME
ARMATURE CORE
ARMATURE COIL
GROMMET
GROMMET
END BRACKET
FIELD ASSY. EXCITER
FIELD CORE, EXCITER
FIELD COIL, EXCITER
19
19-1
19-2
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DCA-25SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
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DCA-25SSAI --- GENERATOR ASSY.
GENERATOR ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
20
21
22
23
24
25
26
27
28
31
32
33
34
35
36
37
38
39
40
41
42
031108160
0040008000
0010008055
0040008000
011208030
3331310104
0105050616
7511331104
0105050616
012010040
031110160
0040010000
0030310000
7511332103
0041606000
952404470
0010006030
0605000008
031110160
0040010000
020310080
PLAIN WASHER ................................... 4 ........... REPLACES 0041608000
LOCK WASHER
HEX. HEAD BOLT
LOCK WASHER
4
4
6
HEX. HEAD BOLT ................................ 6 ........... REPLACES 0010008030
COVER, BEARING
HEX. HEAD BOLT ................................ 4 ........... REPLACES 0010006012
COVER, END BRACKET
1
1
HEX. HEAD BOLT ................................ 4 ........... REPLACES 0017106012
HEX.HEAD BOLT ................................. 6 ........... REPLACES 0010310040
PLAIN WASHER ................................... 6 ........... REPLACES 0041610000
LOCK WASHER
HEX. NUT
COVER, FAN
PLAIN WASHER
6
6
1
1
LOCK WASHER.................................... 1 ........... REPLACES 0040006000
HEX. HEAD BOLT
RUBBER SUSPENSION
1
2
PLAIN WASHER ................................... 4 ........... REPLACES 0041610000
LOCK WASHER
HEX. NUT ............................................. 4 ........... REPLACES 0030110000
4
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DCA-25SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 62 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
3331813502
3331813512
7511870103
0017106016
0601801192
0027104010
0800225200
0027106010
0601820042
0027103010
0601842057
0027105010
0601820851
0027104016
0601804971
0041604000
0040004000
0021004060
0601830625
0021104016
0020004010
0020004020
3331823513
0601800460
0601800783
0601801040
0601800217
0601801041
0601810072
0601810261
0601840031
0601840120
CONTROL BOX ......................................... 1 ......... UP TO S/N3311929
CONTROL BOX ......................................... 1 ......... S/N3311930~
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
CURRENT TRANSOFRMER
HEX. HEA DBOLT
1
4
CURRENT TRANSFORMER, AMMETER . 2 ......... CT3.5MR 50/5A
MACHINE SCREW
AUTOMATIC VOLTAGE REGULATOR ..... 1 ......... AE2206A
MACHINE SCRE
RECTIFIER ................................................ 1 ......... 16T60
4
6
MACHINE SCREW
RESITOR
MACHINE SCREW
OVER CURRENT RELAY
MACHINE SCREW
4
1
2
1
2
CIRCUIT BREAKER .................................. 1 ......... TO100CC500V 60AT
PLAIN WASHER
LOCK WASHER
MACHINE SCREW
2
2
2
CHANGE-OVER SWITCH, VOLTAGE....... 1 ......... VY40
MACHINE SCREW
4
MACHINE SCREW .................................... 2 ......... UP TO S/N331929
MACHINE SCREW .................................... 2 ......... S/N331930~
21
22
23
24
25
26
27
CONTROL PANEL
1
FREQUENCY METER ............................... 1 ......... PAK60 220V 45~65Hz
AC AMMETER ........................................... 1 ......... PSK60 0~50A 0~100A
CHANGE-OVER SWITCH, AMMETER ..... 1 ......... SL2AS
AC VOLTMETER ....................................... 1 ......... PCK60 0~600V
CHANGE-OVER SW., VOLTMETER ......... 1 ......... SL2VS
PILOT LAMP.............................................. 1 ......... LP132DC 220V
BULB
VOLTAGE REGULATOR ........................... 1 ......... RA30A2FE202BJ
KNOB
1
28
29
1
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DCA-25SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
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DCA-25SSAI --- CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
30
31
32
33
34
35
36
37
3901824004
0027105016
0030005000
0805001304
031108160
020108060
0027105010
3331814703
3331814713
0017106016
3331826713
3331826723
3331826804
0017106016
0017106016
011008020
020108060
5825500422
9822531070
0027106016
0601830614
STOPPER, CONTROL PANEL
MACHINE SCREW
HEX. NUT
SET SCREW, CONTROL PANEL
PLAIN WSHER .......................................... 2 ......... REPLACES 0041608000
HEX. NUT .................................................. 2 ......... REPLACES 0030008000
MACHINE SCREW
COVER, CONTROL BOX .......................... 1 ......... UP TO S/N3311929
COVER, CONTROL BOX .......................... 1 ......... S/N3311930~
HEX. HEAD BOLT
SIDE PANEL, CONTROL BOX .................. 1 ......... UP TO S/N3311929
SIDE PANEL, CONTROL BOX .................. 1 ......... S/N3311930~
COVER, SIDE PANEL ............................... 1 ......... UP TO S/N3311929
HEX. HEAD BOLT ..................................... 6 ......... UP TO S/N3311929
HEX. HEAD BOLT ..................................... 4 ......... S/N3311930~
HEX. HEAD BOLT ..................................... 4 ......... REPLACES 0017108020
HEX. NUT .................................................. 4 ......... REPLACES 0030008000
EMERGENCY RELAY ............................... 1 ......... REPLACES 0602200406 AND 5825500191
REGULATOR ............................................. 1 ......... REPLACES 0602201305
1
2
2
2
4
38
39
5
40
41
42
43
44
45
46
47
MACHINE SCREW
SWITCH CAP
6
1
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DCA-25SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIA
PAGE 66 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
C240PR12
0602010067
9214311960
9214311980
9214311970
3332011504
3332012504
0602014000
0602014004
8941521130
5142150140
0602040690
0602040593
3332031103
011008020
020108060
0017110025
1322036004
0605515010
8970246071
8971725490
3335112204
012210035
031110160
0040010000
020310080
0605000008
0041610000
0040010000
020310080
011008020
0802020403
0805006304
0602021100
0805006204
011206020
020106050
0802081403
0802081104
8012082103
011606025
0199500550
0199500220
0193600970
0605515013
ENGINE .......................................... 1........... REPLACES 0602000008; ISUZU C240
RADIATOR......................................1........... TCR38253
3
4
5
6
7
8
9
10
RADIATOR HOSE ..........................1........... REPLACES 0602013008
RADIATOR HOSE ..........................1........... REPLACES 0602013109
RADIATOR HOSE ..........................1........... REPLACES 0602013108
RADIATOR PIPE
CLAMPER
HOSE BAND
HOSE BAND
1
1
5
1
AIR CLEANER ................................ 1........... REPLACES 0602040069;FWG058036
ELEMENT, AIR CLEANER .............1........... REPLACES 0602040175;P105629
DUST INDICATOR ..........................1........... RPX002252
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
BAND, AIR CLEANER .................... 2........... 9002348
BRACKET, AIR CLEANER
1
HEX. HEAD BOLT ..........................4........... REPLACES 0017108020
HEX. NUT .......................................4........... REPLACES 0030008000
HEX. HEAD BOLT
HOSE,AIR CLEANER
HOSE BAND
2
1
2
CARTRIDGE, OIL FILTER ..............1........... REPLACES 0602041175 AND 8941564550
CARTRIDGE, FUEL FILTER...........1........... REPLACES 0602042102 AND 8941434790
ENGINE FOOT
2
HEX. HEAD BOLT ..........................4........... REPLACES 0010010035
PLAIN WASHER .............................4........... REPLACES 0041610000
LOCK WASHER
HEX. NUT .......................................4........... REPLACES 0030010000
RUBBER SUSPENSION
PLAIN WASHER .............................4........... REPLACES 0041610000
LOCK WASHER
4
2
4
HEX. NUT .......................................4........... REPLACES 0030110000
HEX. HEAD BOLT ..........................8........... REPLACES 0017108020
DRAIN PIPE
PACKING, OIL PAN SIDE
1
1
PACKING ........................................1........... 9099209590
JOINT BOLT
1
HEX. HEAD BOLT ..........................2........... REPLACES 0017106020
HEX. NUT .......................................2........... REPLACES 0030006000
RESERVE TANK
CAP, RESERVE TANK
1
1
BRACKET, RESERVE TANK ......... 1........... REPLACES 3335182123
HEX. HEAD BOLT ..........................1........... REPLACES 0017106025
HOSE
HOSE
HOSE
HOSE BAND
1
1
1
4
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DCA-25SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
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DCA-25SSAI ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
45
46
47
48
49
50
51
0194500600
0605515022
0193000500
0605515005
0193100200
0605515000
9829315110
BREATHER HOSE
HOSE BAND
HOSE
HOSE BAND
HOSE
1
2
1
1
1
1
HOSE BAND
EARTH CABLE ...............................1........... REPLACES 0602220000
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DCA-25SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
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DCA-25SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
3
4
5
6
7
8
3332111603
3332142004
0601840190
0080200006
3332140504
020108060
0605010503
1823100080
5814200330
0602120053
0602120167
0602122050
0602122200
0602123060
0602123201
0602121052
0602103061
0601810245
0601830420
0601810141
0040520000
0601830710
031108160
0040008000
011008040
3335312402
012010030
020310080
5819000200
3332159204
0027106016
011008020
3332152704
0602180101
OPERATING PANEL
SLIDE BAR
KNOB .................................................... 1 ........... REPLACES 0805012904
SNAP RING
BRACKET, GOVERNOR ROD
HEX. NUT ............................................. 2 ........... REPLACES 0030008000
SNAP PIN
STARTER SWITCH ............................... 1 ........... REPLACES 0602100004
PREHEAT LAMP................................... 1 ........... REPLACES 0602102002 AND 9825301090
TACHOMETER...................................... 1 ........... REPLACES 0602120052;25000KX3710
CABLE, TACHOMETER ........................ 1 ........... 62100KB3900L=1000
OIL PRESSURE GAUGE ...................... 1 ........... 42000KX1412
UNIT, OIL PRESSURE.......................... 1 ........... 53000AC0101
WATER TEMPERATURE GAUGE ......... 1 ........... 40000KB5111
UNIT, WATER TEMPERATURE ............. 1 ........... 51400KV0200
CHARGING AMMETER ........................ 1 ........... 43000KV0300
ALARM LAMP
BULB
SWITCH, LAMP CHECK....................... 1 ........... SB61A
PANEL LIGHT ....................................... 1 ........... 9826800370
TOOTHED LOCKWASHER
SWITCH, PANEL LIGHT
PLAIN WASHER ................................... 4 ........... REPLACES 0041608000
LOCKWASHER
HEX. HEAD BOLT................................. 4 ........... REPLACES 0010008040
SUPPORT LEG
HEX. HEAD BOLT................................. 5 ........... REPLACES 0017110030
HEX. NUT ............................................. 2 ........... REPLACES 0030010000
ENGINE STOPPER .............................. 1 ........... REPLACES 0602210802
BRACKET, ENGINE STOPPER
MACHINE SCREW
HEX. HEAD BOLT................................. 2 ........... REPLACES 0017108020
GOVERNOR ROD
BALL JOINT
1
1
1
1
1
9
10
11
12
13
14
15
16
17
2
2
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
1
1
4
1
1
3
1
2
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DCA-25SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 72 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI --- ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
34
35
36
37
38
39
40
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
PART NO.
020108060
3331860803
ITEM
HEX. NUT ............................................. 2 ........... REPLACES 0030008000
SET BOARD, OUTPUT TERMINAL
QTY
REMARKS
1
0801830104A OUTPUTTERMINAL............................. 4 ........... REPLACES 0801830104
0801830604
0041408000
0040008000
0039308000
952404470
HEX. HEAD BOLT
PLAIN WASHER
LOCKWASHER
HEX. NUT
4
16
12
8
PLAIN WASHER ................................... 4 ........... REPLACES 0041606000
0040006000
0010006030
0601811030
0601811031
0601811032
0601811037
0027103010
0041603000
0207003000
0601804887
0601805315
7451816004
0027106016
3331867503
3331866513
0805012304
031112230
LOCKWASHER
HEX. HEAD BOLT
4
4
RECEPTACLE, 5-20R ........................... 1 ........... 125V 20Ax2
RECEPTACLE, L5-30R ......................... 1 ........... 125V 30A
RECEPTACLE, L6-20R ......................... 1 ........... 250V 20A
RECEPTACLE, CS8269 ........................ 1 ........... 250V 50A
MACHINE SCREW
PLAIN WASHER
8
8
HEX. NUT ............................................. 8 ........... REPLACES 0030003000
CIRCUIT BREAKER ............................. 2 ........... KM51 265V 20A; REPLACES 0601805313
CIRCUIT BREAKER ............................. 2 ........... KM51 265V 30A
BRACKET, CIRCUIT BREAKER
MACHINE SCREW
1
2
COVER, OUTPUT TERMINAL .............. 1 ........... UPTO S/N3311929;REPLACES 3331866503
COVER, OUTPUT TERMINAL .............. 1 ........... S/N3311930~
57
58
59
60
61
62
63
64
65
66
67
68
69
70
HEX.HEAD BOLT
2
PLAIN WASHER ................................... 4 ........... REPLACES 0041612000
0805009804
0030012000
0605010505
0601802132
0601820015
3331867503
RUBBERWASHER
HEX. NUT
SNAP PIN
2
2
2
1
FUSE, 10A
RECTIFIER ........................................... 4 ........... 1S2762
COVER, OUTPUT TERMINAL .............. 1 ........... S/N3312316~
3331855503A HINGE ................................................... 1 ........... S/N3312316~
3331855703
0021304015
0040004000
031104080
OEMAA8
HINGE ................................................... 1 ........... S/N3312316~
MACHINE SCREW ............................... 4 ........... S/N3312316~
LOCKWASHER .................................... 4 ........... S/N3312316~
PLAIN WASHER ................................... 8 ........... S/N3312316~; REPLACES 0041204000
HEX. NUT ............................................. 4 ........... S/N3312316~; REPLACES 0030104000
PAGE 73 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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DCA-25SSAI --- BATTERY ASSY.
BATTERY ASSY.
PAGE 74 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI --- BATTERY ASSY.
BATTERY ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
3
4
5
6
7
8
9
10
0160012070
3312251004
3332250004
0805002404
031108160
0040008000
0037808000
0215260160
0215860110
0602220310
0037808000
0602220311
0037808000
BATTERY ...................................... 1 ........... N70 12V 70Ah
BATTERY SHEET
BATTERY BAND
BATTERY BOLT
1
1
2
PLAIN WASHER ............................ 2 ........... REPLACES 0041608000
LOCK WASHER
WING NUT
BATTERY CABLE
BATTERY CABLE
2
2
1
1
TERMINAL ASSY. (+) ................... 1 ........... NO. 9N
WING NUT ..................................... 1 ........... REPLACES 0208008000
TERMINAL ASSY. (-) .................... 1 ........... NO. 9N
11
WING NUT ..................................... 1 ........... REPLACES 0208008000
PAGE 75 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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DCA-25SSAI --- MUFFLER ASSY.
MUFFLER ASSY.
PAGE 76 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI --- MUFFLER ASSY.
MUFFLER ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
3
4
3332350503
9141450760
0040010000
9098400850
EXHAUST PIPE
1
GASKET ........................................ 1 ........... REPLACES 0602320001
LOCK WASHER
HEX. NUT ...................................... 3 ........... REPLACES 0602323001
3
5
6
7
8
7342311002A MUFFLER
1
01008020
HEX.HEAD BOLT .......................... 4 ........... REPLACES 0017108020
GASKET
7342356004
011008035
031108160
0040008000
020108060
7342354004
011008020
1
HEX. HEAD BOLT ......................... 4 ........... REPLACES 0010108035
PLAIN WASHER ............................ 4 ........... REPLACES 0041608000
9
10
11
12
13
LOCK WASHER
HEX. NUT ...................................... 4 ........... REPLACES 0030008000
COVER
HEX. HEAD BOLT ......................... 4 ........... REPLACES 0017108020
4
2
PAGE 77 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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DCA-25SSAI --- FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 78 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI --- FUELTANK ASSY.
FUEL TANK ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
3335510413
0810105004
0810105400
3335523104
0805003404
011008020
031108160
0040008000
020108060
3805522004
0191300620
0191300970
0605515014
0845032204
0150000018
0802011104
0193100255
0605515079
FUEL TANK
1
1
1
2
4
1-1
1-2
2
3
4
5
6
7
8
CAP, FUEL TANK
FUEL FILTER
TANK BAND
PAD, TANK BAND
HEX. HEAD BOLT ......................... 2 ........... REPLACES 0017108020
PLAIN WASHER ............................ 2 ........... REPLACES 0041608000
LOCK WASHER
2
HEX. NUT ...................................... 2 ........... REPLACES 0030008000
TANK SHEET
SUCTION HOSE
RETURN HOSE
HOSE BAND
2
1
1
4
1
9
10
11
12
13
14
15
16
DRAIN JOINT
O RING .......................................... 1 ........... REPLACES 0150000018
PLUG
FUEL GAUGE HOSE
HOSE BAND
1
1
2
PAGE 79 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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DCA-25SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 80 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
3335110102
3335109104
3335116014
011008020
3335121904
3335109203
3330630103
3330630303
B1561100603
0600500090
0021106020
011008020
3335162804
011206020
7345125104
011008020
3335125224
011008020
3335131503
7345131103
012214035
0041614000
030214350
020114110
3335140102
3335140112
3330630704
011008020
7345181013
335109304
7345181704
3335109404
011008020
011008020
3335142203
3335142213
0840625902
7345147004
0021006020
952404470
0040006000
020106050
0845028303
011208025
3335161902
BASE
1
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
LINING
FLOOR PANEL
HEX. HEAD BOLT............................... 8 .............REPLACES 0017108020
FRONT FRAME
LINING
1
1
1
STRIPE
STRIPE................................................ 1 .............LT. SIDE
STRIPE................................................ 1 .............RT. SIDE; REPLACES 3330630503
EMBLEM.............................................. 1 .............REPLACES 6360510003
MACHINE SCREW
HEX. HEAD BOLT............................... 8 .............REPLACES 0017108020
RUBBER SEAL
HEX. HEAD BOLT............................... 4 .............REPLACES 0017106020
COVER, FRONT FRAME
HEX. HEAD BOLT............................. 12 .............REPLACES 0017108020
COVER, FRONT FRAME
HEX. HEAD BOLT............................. 10 .............REPLACES 0017108020
2
1
1
1
CENTER FRAME
CENTER FRAME
1
1
HEX. HEAD BOLT............................... 8 .............REPLACES 0010014035
PLAIN WASHER 16
LOCK WASHER.................................. 8 .............REPLACES 0040014000
HEX. NUT ............................................ 4 .............REPLACES 0030014000
REAR FRAME ..................................... 1 .............UP TO S/N3311929
REAR FRAME ..................................... 1 .............S/N3311930~
26
27
28
29
30
31
32
33
34
STRIPE
2
HEX. HEAD BOLT............................... 4 .............REPLACES 0017108020
COVER, REAR FRAME
LINING
GUIDE PANEL, AIR
LINING
HEX. HEAD BOLT............................... 4 .............REPLACES 0017108020
HEX. HEAD BOLT............................... 8 .............REPLACES 0017108020
DOOR, REAR FRAME........................ 1 .............UP TO S/N3311929
DOOR, REAR FRAME........................ 1 .............S/N3311930~
STICKER ............................................. 1 .............REPLACES 1320632003
WINDOW PLATE
MACHINE SCREW
PLAIN WASHER ................................. 6 .............REPLACES 0041606000
LOCK WASHER
HEX. NUT ............................................ 6 .............REPLACES 0030006000
HINGE
HEX.HEAD BOLT ............................... 4 .............REPLACES 0017108025
ROOF PANEL
1
1
1
1
35
36
37
38
39
40
41
42
43
1
6
6
2
1
PAGE 81 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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DCA-25SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 82 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI --- ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
44
45
46
47
48
49
50
PART NO.
ITEM
QTY.
REMARKS
3335109503
3335132204
0010020070
0401450200
0030020000
011008020
3335181902
3335181912
0010008055
0040008000
031108160
3335124203
3335124213
3335109604
3335124303
3335124313
3335109704
B1561100804
3335175004
7345175104
011008020
3335124003
3335124013
3335109804
B1561100804
3335124103
3335124113
3335109904
B1561100903
0845028203
0845028303
011208025
LINING
1
1
2
HANGER
HEX. HEAD BOLT
PLAIN WASHER ................................. 4 .............REPLACES 0041620000
HEX. NUT
HEX. HEAD BOLT............................. 14 .............REPLACES 0017108020
SPLASHER PANEL ............................ 1 .............UP TO S/N3311929
SPLASHER PANEL ............................ 1 .............S/N3311930~
HEX. HEAD BOLT
LOCK WASHER
2
52
53
54
55
4
4
PLAIN WASHER ................................. 4 .............REPLACES 0041608000
SIDE DOOR, LEFT SIDE .................... 1 .............UP TO S/N3311929
SIDE DOOR, LEFT SIDE .................... 1 .............S/N3311930~
56
57
LINING
1
SIDE DOOR, RIGHT SIDE ................. 1 .............UP TO S/N3311929
SIDE DOOR, RIGHT SIDE ................. 1 .............S/N3311930~
LINING
STRIPE................................................ 2 .............REPLACES 3330630904
GUIDE PANEL, AIR
GUIDE PANEL, AIR
HEX. HEAD BOLT............................... 8 .............REPLACES 0017108020
SIDE DOOR, LEFT SIDE .................... 1 .............UP TO S/N3311929
SIDE DOOR, LEFT SIDE .................... 1 .............S/N3311930~
58
59
60
61
62
63
1
1
1
64
65
66
LINING
1
STRIPE................................................ 1 .............REPLACES 3330631304
SIDE DOOR, RIGHT SIDE ................. 1 .............UP TO S/N3311929
SIDE DOOR, RIGHT SIDE ................. 1 .............S/N3311930~
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
LINING
1
STRIPE................................................ 1 .............REPLACES 3330631104
HINGE
HINGE
HEX. HEAD BOLT............................. 16 .............REPLACES 0017108025
CAP 10
LATCH................................................. 1 .............UP TO S/N3311929
MACHINE SCREW ............................. 7 .............UP TO S/N3311929
LATCH................................................. 2 .............UP TO S/N3311929
MACHINE SCREW ........................... 14 .............UP TO S/N3311929
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
4
4
0845031504
0605010910
0027103010
0605010911
0027104010
3335104104
3335104204
3335104304
3335104404
3335104504
3335104604
3335104704
3335104804
3335104904
3335103004
3335103104
2
2
3
1
1
1
1
2
2
2
2
PAGE 83 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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DCA-25SSAI --- DECALS
DECAL ASSY.
PAGE 84 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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DCA-25SSAI --- DECALS
DECAL ASSY.
NO.
PART NO.
ITEM
QTY. REMARKS
1
2
3
4
5
6
7
8
M1550000003 DECAL; ENGINE OPERATING ..............................1..... M15000000
M1550000104 DECAL; NOTE ........................................................1..... M15000010
M1550000204 DECAL; NOTE ........................................................1..... M15000020
M1550000303 DECAL; AUXILLARY OUTPUT...............................1..... M15000030
M1550000403 DECAL;GENERATOR CONTROL..........................1..... M15000040
M9500000004 DECAL; OIL DRAIN PLUG .....................................1..... M90000000
M9500100004 DECAL;WATER .....................................................1..... M90010000
M9500300004 DECAL; - ................................................................1..... M90030000
M9500300104 DECAL; + ...............................................................1..... M90030010
M9500500004 DECAL; DIESEL FUEL ..........................................1..... M90050000
M9500500104 DECAL; FUEL DRAIN PLUG..................................1..... M90050010
M9503000004 DECAL;WARNING .................................................2 ..... M90300000
M9503000103 DECAL;WATER, OIL CHECK ................................1..... M90300000
M9503100004 DECAL;WARNING .................................................1 ..... M90310000
M9503200004 DECAL;WARNING .................................................1 ..... M90320000
M9510100004 DECAL;CAUTION..................................................1..... M91010000
M9520100503 DECAL;WARNING .................................................1 ..... REPLACES M9510100104
M9520100503 DECAL;WARNING .................................................1 ..... REPLACES M9510100204
M9510200002 DECAL; MQ ...........................................................1..... M91020000
M9520000004 DECAL; GROUND ..................................................1..... M92000000
M9520000104 DECAL; AMMETER CHANGE OVER SWITCH .....1..... M92000010
M9520000204 DECAL;VOLTMETER CHANGE OVER SWITCH ..1..... M92000020
M9520100004 DECAL;WARNING .................................................2 ..... M92010000
M9520100503 DECAL;WARNING .................................................1 ..... REPLACES M9520100104
M9520100503 DECAL;WARNING .................................................1 ..... M92010050 M9100601~
M9520100204 DECAL;CAUTION..................................................1..... M92010020A
M9520100304 DECAL; SAFETY INSTRUCTIONS ........................1..... M92010030
M9520100404 DECAL;DANGER ..................................................1..... M92010040
M9520200003 DECAL; CONNECTION OF OUTPUT CABLE .......1..... M92020000
M9520200104 DECAL; OVER CURRENT RELAY .........................1..... M92020010
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
M1560100403 STRIPE;WHISPERWATT
M1560100303 STRIPE;MQ POWER
M1560100004 STRIPE;
1
2
3
2
1
1
M1560100504 STRIPE; 25
M1560100104 STRIPE
M1560100204 STRIPE
PAGE 85 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- CYLINDER HEAD AND COVER ASSY.
CYLINDER HEAD AND COVER ASSY.
PAGE 86 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- CYLINDER HEAD AND COVER ASSY.
CYLINDER HEAD AND COVER ASSY.
NO.
1
3
3-1
3-2
3-3
4
7
8
9
9-1
11
14
16
16-1
16-2
21
22
29
30
31
49
51
52
54
60
PART NO.
ITEM
QTY.
1
1
4
5
4
4
4
4
4
4
4
8
3
3
1
1
19
1
1
1
1
2
2
2
1
REMARKS
5111102070
1096000051
5111290060
5112190080
5096000130
9098605220
5117150230
5117110260
5117210160
5117210160
5111501080
5125690060
9041108350
9041108400
9041108450
5111410690
5090090530
5111702400
9117510381
5111790520
5111730170
9111798080
9111791320
5090000960
5096050050
CYLINDER HEAD ASSY.
SEALING CUP, RR FACE D=44
SEALING CUP, LOWER D=16
SEALING CUP, UPPER D=18
SEALING CUP, DRILLED D=12
PLUG; LOWER CYLINDER HEAD PLATE
VALVE SEAT INLET INSERT
VALVE SEAT EXHAUST INSERT
VALVE INLET HEAD GUIDE
VALVE EXHAUST HEAD GUIDE
HOT PLUG ASSY.
INLET AND EXHAUST VALVE SEAL
MANIFOLD STUD
MAINFOLD STUD
MANIFOLD STUD
CYLINDER HEAD GASKET
BOLT
CYLINDER HEAD COVER ASSY.
OIL FILLER CAP
BREATHER NIPPLE
HEAD COVER PACKING
HEAD COVER FIX. PACKING
WAHER
BOLT
CYLINDER HEAD OIL COOLER PLUG
PAGE 87 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
PAGE 88 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
4
4-1
5
5112101771
9098025910
9096640340
5112190080
5116100010
5112190180
5112190170
5112190150
5096000130
1096000051
9112612300
8942505140
5111290060
5112210020
5096050161
9992023160
9095714160
5096500210
9112976500
9113111530
5113120110
9081510240
9019008220
9099022990
9081610320
9019008180
9019008220
9099168160
5112920110
9097040380
9098785970
8942008311
9099138340
9112290490
5117400211
9099210990
9097130870
9099152380
9019008180
9091645080
9123631120
5096250360
9113411940
5090002270
9112581080
5117490340
9019008180
9019608180
9092023080
9095714080
CYLINDER BLOCK ASSY.
BOLT
1
10
2
2
1
1
1
2
1
3
4
1
2
1
1
1
1
1
1
1
1
2
3
1
1
12
2
2
PLUG; 1/2 TAPPET CHAMBER
SEALING CUP CHAMBER D=18
BEARING KIT; CAM. STANDARD
SEALING CUP RR FACE D=36
SEALING CUP RR FACE D=38
SEALING CUP LH SIDE D=32
SEALING CUP RR FACE D=12
SEALING CUP LH SIDE D=45
CYLINDER LINER
PLUG; CAMSHAFT BRIDGE PLATE
PLUG; OIL GALLERY PLATE
DUCT; CYL. BLOCK WATER
PLUG; OIL GALLERY 1/8
PLUG; OIL GALLERY SCREW
PLUG PACKING
INJ. PUMP OIL FEED NIPPLE
TAPPET CHAMBER COVER ASSY.
FRONT CYL. BLOCK PLATE
FRONT PLATE PACKING
FRONT PLATE STRAIGHT PIN
BOLT
ROCKER OIL FEED NIPPLE
REAR PLATE STRAIGHT PIN
BOLT
6
6-1
6-2
6-3
6-4
7
8
9
10
11-1
12-1
13-1
26
27-1
28
29
31
32
36
37
42-1
42-2
43
46
47-1
52
54-2
55
56
58-2
59
64-1
66
67
69
77
78
81
84
99
BOLT
TAPPET CHAMBER COVER CLIP
CHAMBER COVER PACKING ......................... 1 .......... REPLACES 5112920150
WATER DRAIN COCK
CRANK CASE PIN
BOLT
PIPE; VINYL WATER DRAIN
CYLINDER BLOCK DOWEL
BREATHER AIR ASSY.
BREATHER PACKING
PIPE; VINYL BREATHER
CLIP
1
2
1
1
2
1
1
1
1
1
1
1
1
1
3
2
1
2
1
1
1
BOLT
WASHER
SPACER; OIL SEAL
CRANK SHAFT REAR SEAL
REAR CYLINDER BLOCK PLATE
BOLT
OIL PAN BRIDGE CAP PACKING
BREATHER HEAD PACKING
BOLT
117
120
121
130
131
BOLT
PLUG; OIL GALLERY SCREW
SCREW PLUG PACKING
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ISUZU C240 ---TIMING GEAR ASSY.
TIMING GEAR ASSY.
PAGE 90 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 ---TIMING GEAR ASSY.
TIMING GEAR ASSY.
NO.
1
PART NO.
ITEM
QTY.
REMARKS
5113110282
9113211480
9099206010
901906140
9113120460
5096250790
9113270450
9113120340
9019108320
TIMING GEAR CASE
GEAR CASE COVER
PACKING
1
1
1
4
2
1
1
1
9
2
3
4
8
BOLT
PACKING
OIL SEAL
POINTER
PACKING
9
12
14
17
BOLT
PAGE 91 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 FLYWHEEL HOUSING ASSY.
FLYWHEEL HOUSING ASSY.
PAGE 92 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 FLYWHEEL HOUSING ASSY.
FLYWHEEL HOUSING ASSY.
NO.
1-5
11
PART NO.
ITEM
QTY.
REMARKS
5113410191
9113430391
9019006120
5113490380
5113490370
9019110200
9019110180
9019310450
9019110350
9010560400
9091104100
9091505100
FLYWHEEL HOUSING
1
1
6
1
1
2
2
4
3
1
2
2
COVER
BOLT
12
21
STIFFENER; RIGHT SIDE
22
23
STIFFENER; LEFT SIDE
BOLT
23-1
31
41
BOLT
BOLT
BOLT
41
42
BOLT
NUT
46
LOCKWASHER
PAGE 93 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 OIL PAN ASSY.
OIL PAN ASSY.
PAGE 94 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 OIL PAN ASSY.
OIL PAN ASSY.
NO.
1-2
3*
PART NO.
ITEM
QTY.
REMARKS
5113601832
5096050050
9992023200
9097205600
9112150810
5113670040
9992023160
9095714160
9019106160
9112193160
9030906160
9117606090
9019008220
9019708450
5117400870
5117410100
5117500021
9099207080
9019008200
OIL PAN ASSY. ................................ 1 ................ INCL. ITEMS W/*
OIL DRAIN PLUG, 3/8
OIL DRAIN PLUG
O RING PACKING
CRANK CASE
OIL CASE PACKING
OIL THERMO PLUG
PLUG PACKING
BOLT
DISTRIBUTION PLATE
SCREW
OIL LEVEL GAUGE
BOLT
1
1
1
1
1
1
1
30
1
4
3-1
4-1*
6
17
24
26
29
31
32
36
42
42-1
51
1
16
4
BOLT
OIL FILLER ASSY............................ 1 ................ INCL. ITEMS W/#
52#
53#
56
OIL FILLER
OIL FILLER CAP
PACKING
1
1
1
2
57
BOLT
PAGE 95 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 ---OIL PUMP ASSY.
OIL PUMP ASSY.
PAGE 96 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 ---OIL PUMP ASSY.
OIL PUMP ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
6*
9131008010
5131200040
9131290170
9098780840
9131280790
9131130771
9020408250
9091505080
9091505080
9131401200
OIL PUMP ASSY. ................................. 1 ........... INCL. ITEMS W/*
ROTOR SET .......................................... 1 ........... INCL. ITEMS W/#
8*#
11*#
12*
13*
14*
15*
16*
21*
PIN
PIN
PINION
COVER
BOLT
LOCKWASHER
LOCKWASHER
1
1
1
1
4
4
4
OIL STRAINER ASSY........................... 1 ........... INCL. ITEM W/%
22*% 9131430100
41 9019708250
OIL STRAINER GAUZE
BOLT
1
2
PAGE 97 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.
CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.
PAGE 98 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.
CRANKSHAFT, BRIDGE AND FLYWHEEL ASSY.
NO.
PART NO.
ITEM
QTY
REMARKS
1
5115100211
5115300211
5115400211
9115810570
5121112020
5121210070
5122110090
5095870010
5122300390
CRANK BEARING KIT;STD
CRANK BEARING KIT;-0.25
CRANK BEARING KIT;-0.50
THRUST BEARING
PISTON;STD
1
1
1
2
4
4
4
8
1-1
1-2
2
3
4
6
7
8-1
PISTON RING SET;STD
PISTON PIN
SNAP RING
CONNECTING ROD ASSY. .................... 4 ..................... INCL. ITEMS W/@
9-1@ 5122510050
11-1@ 512350090
SMALL END BUSHING
BOLT
NUT
CONN. ROD BEARING SET;STD........... 4 .................... REPLACES 5122710050
BEARING SET;-0.25
BEARING SET;-0.50
CRANKSHAFT ASSY. ............................ 1 .................... INCL. ITEM W/#
STRAIGHT PIN
RADIAL BALL BEARING
FLYWHEEL ASSY. .................................. 1 .................... INCL. ITEM W/%
RING GEAR ............................................ 1 .................... Z=108
STRAIGHT PIN
BOLT
WASHER
FEATHER KEY
CRANKSHAFT GEAR............................. 1 .................... Z=21
THROWER
CRANKSHAFT PULLEY
BOLT
THROWER
WASHER
4
8
8
12@
13
5094090160
8941422080
8941631740
8941631750
8941396690
9081612200
5098010010
5123301100
9123330361
9098785320
5090001461
5123360100
9080307430
9125210420
9123620390
9123736051
9098026060
9123736060
9123790160
13-1
13-2
14
4
4
15#
17
1
1
25-1
27%
31
2
6
1
1
33
34
36
37
38
1
1
1
1
1
60-1
64-1
67
69
PAGE 99 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- OIL AND FUEL FILTER ASSY.
OIL AND FUEL FILTER ASSY.
PAGE 100 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- OIL AND FUEL FILTER ASSY.
OIL AND FUEL FILTER ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
2
9885131071
9132130350
9099211920
9099209780
9099221100
9132121240
9099410540
9132390330
9132316030
9098621170
9132110950
9132390320
9099522170
9132260130
9099208410
9098640150
5132600080
1096231630
5131600030
9099209750
8941434770
8941434790
9095720140
5132120750
9132600561
9197518010
9020608180
9091506080
9091645080
9019110320
9132190570
OIL FILTER ELEMENT KIT ........ 1 .............. INCL. ITEMS W/*
3*
4
5-1
6*
7
8
9
O RING PACKING COVER
CENTER PIPE PACKING
DRAIN PIPE PACKING
FELT RING
1
1
1
1
1
OIL FILTER COVER
COIL COMPRESSION SPRING 1
SPRING SEAT
CENTER PIPE
DRAIN PLUG
OIL FILTER BODY
ELEMENT HOLDER
SNAP RING
ADAPTER
PLUG PACKING
SCREW PLUG
SAFETY VALVE ASSY. .............. 1 .............. INCL. ITEM W/%
O RING PACKING
RELIEF VALVE ASSY. ................ 1 .............. INCL. ITEM W/#
RELIEF VALE PACKING
FUEL CART. FILTER ASSY. ....... 1 .............. INCL. ITEMS W/$
1
1
1
1
1
1
1
1
1
10
11
12
13
14
23
24
25
26
27%
28
29#
70
72$
77$
80$
86$
91
92
93
94
96
100
1
1
FUEL ELEMENT
1
2
1
1
1
2
OVERFLOW VALVE PACKING
FUEL FILTER COVER
OVERFLOW VALVE ASSY.
FUEL FILTER BRACKET
BOLT
LOCKWASHER .......................... 2 .............. REPLACES 9091508080
PLAIN WASHER
BOLT
2
2
1
4
OIL FILTER PACKING
BOLT
101-1 9019008350
110 8941208540
OIL FILTER ASSY....................... 1 .............. INCL. ITEMS W/@
111@ 8941564550
112@ 8941564540
113@ 9132260090
114@ 5131600030
115@ 9099206200
OIL FILTER CARTRIDGE
OIL FILTER BODY
ADAPTER
RELIEF VALVE ASSY.
PACKING ADAPTER
1
1
1
1
1
PAGE 101 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- OIL PIPE ASSY.
OIL PIPE ASSY.
PAGE 102 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- OIL PIPE ASSY.
OIL PIPE ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
9133119810
5133111141
9099061051
9099209000
5133111740
5096750220
9095720080
901906120
OIL PUMP ASSY.
ROCKER OIL FEED PIPE
BOLT
1
1
1
2
1
1
2
1
2
3
4
9
10
11
13
PACKING
OIL INJECTION PIPE
ADAPTER
PACKING
BOLT
PAGE 103 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 ---WATER PUMP AND FAN ASSY.
WATER PUMP AND FAN ASSY.
PAGE 104 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 ---WATER PUMP AND FAN ASSY.
WATER PUMP AND FAN ASSY.
NO.
1
PART NO.
ITEM
QTY.
REMARKS
5136101673
5878101391
5136310080
9136210760
9136136070
8942366870
WATER PUMP ASSY. ................... 1 ............ INCL. ITEMS W/*
3*
WATER PUMP REPAIR KIT.......... 1 ............ INCL. ITEMS W.#
6*#
BEARING UNIT
IMPELLER
PACKING
SEAL UNIT ASSY.
SCREW HEATER PLUG
SCREW
LOCKWASHER
FAN CENTER
WATER PUMP COVER
SCREW
1
1
1
1
1
1
1
1
1
1
1
1
2
4
1
1
1
1
4
1
1
1
1
1
2
1
1
1
2
2
1
2
78**##
9*#
10*# 5096050050
11*# 5098140010
12*# 9091505080
13*# 5136420640
16*# 9136120530
18*# 9030408160
24*# 9136390010
BRIDGE UNITTHROWER
PACKING
31
33
33-1
41
50
51
54
59
64
71
72
73
76
77
78
90
91
92
92
93
94
9136140430
5090000890
5090000880
5136750390
9136416160
9136420770
9136608090
9019108450
5136710400
9137130380
5137700221
5096050050
5096370130
9019708300
9099168190
9137168042
5137430050
9019708200
9019108220
9137211322
9099156441
BOLT
BOLT
ADJUSTING FAN BELT PLATE
FAN PULLEY
FAN SPACER
FAN ASSY.
BOLT
COOLING FAN BELT
OUTLET PIPE
THERMOSTAT
HEATER PLUG
PACKING
BOLT
CLIP
THERMOSTAT HOUSING
HOUSING PACKING
BOLT
BOLT
RUBBER BYPASS HOSE
HOSE CLIP
PAGE 105 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY.
INTAKE AND EXHAUST MAINIFOLD ASSY.
PAGE 106 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- INTAKE AND EXHAUST MANIFOLD ASSY.
INTAKE AND EXHAUST MANIFOLD ASSY.
NO.
1
3
PART NO.
ITEM
QTY.
REMARKS
9141126954
9041108500
9141416142
5093020020
5141111290
5141460180
9091646080
9091505080
9091104080
5090000870
5143101961
5096370150
9091104080
9091505080
5093600530
5143340780
INLET MANIFOLD
INTAKE STUD
EXHAUST MANIFOLD
EXHAUST STUD
INLET PIPE
1
2
1
1
2
1
7
7
7
2
1
3
3
2
1
1
20
21
30
46
48
49
51
52
66
76
77
78
83
97
GASKET
PLAIN WASHER
LOCK WASHER
NUT
BOLT
INTAKE SHUTTER ASSY.
THROTTLE VALVE PACKING
NUT
LOCK WASHER
HOSE
WIRE CONTROL BRACKET
PAGE 107 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- AIR CLEANER ASSY.
AIR CLEANER ASSY.
PAGE 108 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- AIR CLEANER ASSY.
AIR CLEANER ASSY.
NO.
3
PART NO.
ITEM
QTY.
REMARKS
5142102130
5142150140
5142110670
9142191410
5142120560
5142170040
9142170620
AIR CLEANER ASSY.................... 1 ............ INCL. ITEMS W/*
5*
ELEMENT
COVER
1
1
1
1
1
27*
38*
59*
76*
81*
INDICATOR
DUST W/BAFFLE PAN
CLAMP
BOLT W/GASKET WASHER ......... 1 ............ INCL. ITEMS W/#
GASKET WASHER
82*# 9142191770
3
2
200
9142176020
BAND ASSY. W/BOLT
PAGE 109 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- ENGINE FOOT ASSY.
ENGINE FOOT ASSY.
PAGE 110 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- ENGINE FOOT ASSY.
ENGINE FOOT ASSY.
NO.
PART NO.
ITEM
QTY. REMARKS
1
1-1
6
6-1
6-2
8
9117712070
5117710501
9029510250
9029510250
9029560400
9098518660
5197110010
9091505080
9091114080
9091605120
9829315110
9019312450
9010558320
9019108400
9091647080
9091505080
9091605080
9117770750
9117771360
9141491730
9091105080
5197190060
9091104080
9091505080
5113190570
8942059870
9019108320
ENGINE FOOT, RIGHT SIDE
ENGINE FOOT, LEFT SIDE
FOOT BOLT, RIGHT SIDE
BOLT FOOT, LEFT SIDE
BOLT FOOT, LEFT SIDE
PLAIN WASHER
ALTERNATOR BRACKET
LOCKWASHER
NUT
PLAIN WASHER
CABLE ASSY.
BOLT
BOLT
BOLT
PLAIN WASHER
LOCKWASHER
PLAIN WASHER
FRONT LIFTING HANGER
REAR LIFTING HANGER
REAR HANGER PIECE
NUT
ALTERNATOR FAN COVER
NUT
LOCKWASHER
FRONT PLATE PACKING
BOLT
1
1
4
1
3
8
1
1
1
1
1
2
2
1
1
2
2
1
1
2
2
1
1
1
1
2
4
11
30
31
32
33
34
36
37
38
39
40
41
41-1
42
43
44
46
47
51
52
52-1
BOLT
PAGE 111 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- INJECTION PUMP ASSY.
INJECTION PUMP ASSY.
PAGE 112 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- INJECTION PUMP ASSY.
INJECTION PUMP ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
5
8943864440
INJECTION PUMP ASSY. .................... 1 ..................... REPLACES 5156010252
INCL. ITEMS W/*
15*
20*
35*
38*
40*
42*
5157201400
8941415340
5157400720
9197510790
9099205760
5125240660
GOVERNOR ASSY.
FEED PUMP ASSY.
AUTOMATIC TIMER
INJ. PUMP SPACER BRACKET
O RING PACKING
1
1
1
1
1
1
INJ. PUMP GEAR
PAGE 113 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- ELECTRICAL PARTS
ELECTRICAL PARTS
PAGE 114 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- ELECTRICAL PARTS
ELECTRICAL PARTS
NO.
PART NO.
ITEM
QTY.
REMARKS
1
2
5811000801
5812003410
9822007640
9822531070
9829317430
9825119780
9825301090
9829513240
9829513250
9829513320
9197326100
5824500140
5825500190
1823100080
1823170070
9091114080
9091505080
STARTER
1
ALTERNATOR ....................................1......................... UP TO OCT. 1992
ALTERNATOR ....................................1......................... OCT.1992~
REGULATOR
CABLE ASSY.
GLOW PLUG
CONTROL
INSULATOR CAP
INSULATOR CAP
CABLE CAP
CONNECTOR
SWITCH
EMERGENCY RELAY
STARTER SWITCH
KEY
4
8
1
1
4
1
2
2
1
1
1
1
1
1
1
1
12
14
19
20
21
23
30
34
36
38-1
50
51
NUT
LOCKWASHER
PAGE 115 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- ACCESSORIES
ACCESSORIES
PAGE 116 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- ACCESSORIES
ACCESSORIES
NO.
PART NO.
ITEM
QTY.
REMARKS
50
5193100060
9193110240
9193110200
9193120060
9193160270
9193160170
9019006160
9090310100
9099243550
9019008220
9099211070
5819000020
5828480360
DRIVE ASSY. ....................................... 1 ..................... INCL. ITEMS W/*
51*
52*
53*
54*
56*
58*
59*
61*
66
CASE
1
1
1
1
1
4
1
1
2
1
1
1
COVER
PACKING
GEAR
GEAR
BOLT
NIPPLE
OIL SEAL
BOLT
PACKING
STOPPER ASSY.
CABLE ASSY.
67
91
91-1
PAGE 117 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 ---INJECTION PUMP COMP. ASSY.
INJECTIO
PAGE 118 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- INJECTION PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
5
5156110460
9812151150
9812350170
1156190240
1156390080
1156390080
5156120080
1156190030
9812151440
9091505060
9091104060
1096230130
5156310090
9812411030
5156430020
9812450140
5156440050
5156490160
9812212230
HOUSING ASSY. .................................. 1 ..................... INCL. ITEMS W/*
15*
16*
18*
20*
21*
22*
23*
24*
27*
28*
29*
31*
32*
34*
35*
36*
40*
43*
STUD
3
1
2
1
1
1
2
2
3
3
1
4
4
4
4
4
2
ADAPTER
BOLT
GASKET
GASKET
COVER
SCREW
GASKET
LOCKWASHER
NUT
PACKING
PLUNGER ASSY.
DELIVERY VALVE
DELIVERY VALVE SPRING
GASKET
HOLDER
PLATE ASSY.
TAPPET ASSY. ..................................... 4 ..................... INCL. ITEMS W/#
45*# 9812212200
47*# 1156220030
48*# 1156290010
49*# 5156190410
PIN TAPPET
4
4
4
4
TAPPET ROLLER
TAPPET BUSHING
TAPPET GUIDE
55*
5156190340
TAPPET SHIM .................................. A/R ..................... T=0.30
TAPPET SHIM .................................. A/R ..................... T=0.40
TAPPET SHIM .................................. A/R ..................... T=0.50
TAPPET SHIM .................................. A/R ..................... T=0.60
TAPPET SHIM .................................. A/R ..................... T=0.70
TAPPET SHIM .................................. A/R ..................... T=0.80
TAPPET SHIM .................................. A/R ..................... T=0.90
TAPPET SHIM .................................. A/R ..................... T=1.00
TAPPET SHIM .................................. A/R ..................... T=1.10
TAPPET SHIM .................................. A/R ..................... T=1.20
TAPPET SHIM .................................. A/R ..................... T=1.30
TAPPET SHIM .................................. A/R ..................... T=1.40
TAPPET SHIM .................................. A/R ..................... T=0.55
TAPPET SHIM .................................. A/R ..................... T=0.65
TAPPET SHIM .................................. A/R ..................... T=0.75
TAPPET SHIM .................................. A/R ..................... T=0.85
TAPPET SHIM .................................. A/R ..................... T=0.95
TAPPET SHIM .................................. A/R ..................... T=1.05
TAPPET SHIM .................................. A/R ..................... T=1.15
TAPPET SHIM .................................. A/R ..................... T=1.25
TAPPET SHIM .................................. A/R ..................... T=0.25
55-1* 5156190350
55-2* 5156190360
55-3* 5156190010
55-4* 5156190020
55-5* 5156190030
55-6* 5156190040
55-7* 5156190050
55-8* 5156190070
55-9* 5156190080
55-10* 5156190090
55-11* 5156190100
55-12* 5156190110
55-13* 5156190120
55-14* 5156190130
55-15* 5156190150
55-16* 9812350420
55-17* 9812350430
55-18* 9812350440
55-19* 9812350450
55-20* 5156190250
PAGE 119 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- INJECTION PUMP COMP. ASSY.
INJECTIO
PAGE 120 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- INJECTION PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
NO. PART NO. ITEM
QTY.
REMARKS
55-21* 5156190260
55-22* 5156190270
55-23* 5156190370
55-24* 5156191060
55-25* 5156191070
55-26* 5156191080
55-27* 5156191090
55-28* 5156191100
TAPPET SHIM ................................ A/R ....................... T=0.26
TAPPET SHIM ................................ A/R ....................... T=0.35
TAPPET SHIM ................................ A/R ....................... T=0.45
TAPPET SHIM ................................ A/R ....................... T=1.50
TAPPET SHIM ................................ A/R ....................... T=1.60
TAPPET SHIM ................................ A/R ....................... T=1.35
TAPPET SHIM ................................ A/R ....................... T=1.45
TAPPET SHIM ................................ A/R ....................... T=1.55
57*
58*
59*
60*
61*
62*
66*
67*
75*
73*
9812314070
9812350150
9812350210
9812250580
9812250570
9812350030
5156370020
1156390030
5156210170
9812232010
PLUNGER SPRING
PLUNGER SEAT
PLUNGER SEAT
SLEEVE
PINION
SCREW
CONTROL RACK
SCREW
CAM SHAFT
BALL BEARING, CAMSHAFT
BALL BEARING, CAMSHAFT
BALL BEARING, GOV. SIDE
BALL BEARING, GOV. SIDE
CAMSHAFT RING
CAM RING, GOV. SIDE
4
4
4
4
4
4
1
1
1
1
1
1
1
1
1
76-2* 9000906770
77*
9812232010
77-2* 9000906770
82*
83*
84*
9812250470
9812250470
5156290150
CAMSHAFT SHIM .......................... A/R ....................... T=0.10
CAMSHAFT SHIM .......................... A/R ....................... T=0.12
CAMSHAFT SHIM .......................... A/R ....................... T=0.14
CAMSHAFT SHIM .......................... A/R ....................... T=0.16
CAMSHAFT SHIM .......................... A/R ....................... T=0.18
CAMSHAFT SHIM .......................... A/R ....................... T=0.50
CAMSHAFT SHIM .......................... A/R ....................... T=1.00
CAMSHAFT SHIM .......................... A/R ....................... T=0.30
CAMSHAFT SHIM .......................... A/R ....................... T=0.70
CAMSHAFT SHIM .......................... A/R ....................... T=1.40
CAMSHAFT SHIM .......................... A/R ....................... T=0.10
CAMSHAFT SHIM .......................... A/R ....................... T=0.30
CAMSHAFT SHIM .......................... A/R ....................... T=0.14
CAMSHAFT SHIM .......................... A/R ....................... T=0.16
CAMSHAFT SHIM .......................... A/R ....................... T=0.18
CAMSHAFT SHIM .......................... A/R ....................... T=0.50
CAMSHAFT SHIM .......................... A/R ....................... T=1.00
CAMSHAFT SHIM .......................... A/R ....................... T=0.30
CAMSHAFT SHIM .......................... A/R ....................... T=0.70
CAMSHAFT SHIM .......................... A/R ....................... T=1.40
84-1* 5156290160
84-2* 5156290170
84-3* 5156290180
84-4* 5156290190
84-5* 5156290200
84-6* 5156190380
84-7* 5156290210
84-8* 5156190390
84-9* 1156190900
85*
5156290150
85-1* 5156290160
85-2* 5156290170
85-3* 5156290180
85-4* 5156290190
85-5* 5156290200
85-6* 5156190380
85-7* 5156290210
85-8* 5156190390
85-9* 1156190900
93*
5156290050
9019006140
HOUSING COVER
BOLT
1
4
95*
PAGE 121 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- INJECTION PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
PAGE 122 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- INJECTION PUMP COMP. ASSY.
INJECTION PUMP COMP. ASSY.
NO.
PART NO.
ITEM
QTY. REMARKS
108* 9812214110
111* 1156190820
113* 1157590010
137* 9097060370
138* 1096350070
150* 9812150780
162* 9091606100
163* 9091505100
164* 5156390020
180* 9197510790
181* 9099205760
KEY
BOLT
1
1
2
1
2
4
4
4
4
1
1
PACKING
BOLT
PACKING
TAPPET PLUG
PLAIN WASHER
LOCKWASHER
NUT
BRACKET
O RING PACKING
PAGE 123 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 ---GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
PAGE 124 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- GOVERNOR COMP. ASSY.
COVERNOR COMP. ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
5
1157210040
1157290150
9813150650
9019008180
9813253970
901906140
HOUSING ............................................. 1 ..................... INCL. ITEMS W/*
12*
13*
14*
15*
16*
18*
19*
20*
26*
27*
30*
32*
34*
35*
36*
40*
42*
43*
44*
47*
50*
52*
53*
54*
57*
O RING PACKING
ADAPTER
BOLT
1
1
1
1
6
1
2
1
1
1
1
2
2
2
1
1
1
2
2
1
1
1
1
1
HOUSING PLATE
BOLT
SCREW
NUT
HOUSING PLUG
SCREW
NUT
COVER
PLUG
BOLT
BOLT
SCREW
COVER
O RING PACKING
BOLT
BOLT
CAP
FLYWEIGHT ASSY.
KEY
LOCKWASHER
NUT
5157291230
9813252370
1157290380
9813251820
9813261120
5157210080
5157290530
5157290540
5157290330
5157291230
9813211860
9813919070
5157290630
9019006160
9812350340
9813213230
5156190490
5157290340
9813250860
5157190080
SLEEVE................................................ 1 ..................... INCL. ITEM W/#
BEARING
58*# 9000902290
1
60*
9813250880
SHIM ................................................. A/R ..................... T=0.20
SHIM ................................................. A/R ..................... T=0.30
SHIM ................................................. A/R ..................... T=0.40
SHIM ................................................. A/R ..................... T=1.00
60-1* 9813255510
60-2* 9813255520
60-3* 9813255530
63*
64*
67*
68*
69*
73*
74*
77*
80*
81*
82*
9813222100
5157230820
1157230200
9813932040
1156390080
9813216360
9008130230
9813217210
9813250990
9813212050
9091854150
GOVERNOR SPRING
LINK SPRING
CAPSULE SPRING
NUT
GASKET
CAPSULE SPRING
NUT
LEVER
BUSHING
O RING PACKING
SNAP RING
1
1
1
1
2
1
1
1
2
2
2
PAGE 125 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
PAGE 126 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
NO.
PART NO.
ITEM
OIL SEAL
QTY.
REMARKS
83*
84*
85*
9813212200
9813251730
9813250970
9813253180
9813250300
9813913070
9813254880
5157250160
9813217130
1157290230
5157250170
9813250620
5157250490
1157290010
1157290020
5157291120
5157230880
1
SHIM ..................................................... 1 ..................... T=0.50
SHIM ................................................. A/R ..................... T=0.30
86*
88*
PLUG
KEY
1
1
1
89*
90*
93*
COLLAR
WASHER
GUIDE LEVER ASSY.
LINK
SNAP RING
TENSION LEVER
PIN
A/R
1
100*
101*
102*
103*
104*
116*
117*
148*
150*
1
1
1
1
1
1
1
1
LEVER
GASKET
GASKET
BOLT
SPRING
1
PAGE 127 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- FEED PUMP COMP. ASSY.
FEED PUMP COMP. ASSY.
PAGE 128 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- FEED PUMP COMP. ASSY.
FEED PUMP COMP. ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
5
9*
5157510120
9813512050
9813513030
9813550230
9813550350
5157540010
9813514030
9813514100
1157590020
9813516020
1096230160
9813517020
9099063260
1156190820
1157590010
1157590030
1096230160
9813550250
9813521040
9813550330
HOUSING ........................................... 1 ....................... INCL. ITEMS W/*
PISTON
SPRING
PLUG
1
1
1
1
10*
11*
12*
15*
16*#
17*#
18*#
26*
27*
28*
31*
32*
33*
35*
40*
42*
44*
45*
GASKET
TAPPET ASSY. ................................... 1 ....................... INCL. ITEMS W/*
ROLLER
PIN
GUIDE
CHECK VALVE
GASKET
SPRING
BOLT
1
1
2
2
1
2
1
1
4
1
1
1
BOLT
PACKING
ADAPTER
PACKING
RING
PUMP ................................................. 1 ....................... REPLACES 5157610050
COVER
1
PAGE 129 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- AUTOTIMER COMP. ASSY.
AUTO TIMER COMP. ASSY.
PAGE 130 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- AUTOTIMER COMP. ASSY.
AUTO TIMER COMP. ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
5
6*
9813435050
9813450430
9813450440
9813450450
5157490090
5157490100
5157490110
5157490680
5157490690
5157490700
5157490710
9813450720
9813453380
9813453250
FLYWEIGHT.................................. 2.............................. INCL. ITEMS W/*
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
TIMER SPRING
WASHER
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
WASHER
PLATE
NUT
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
2
6-1*
6-2*
6-3*
6-4*
6-5*
6-6*
6-7*
6-8*
6-9*
7*
11*
12*
1
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
1
12-1* 9813453260
12-2* 9813453400
12-3* 9813453270
12-4* 9813453280
12-5* 9813453290
12-6* 9813453300
12-7* 9813453310
12-8* 9813453320
13*
14*
15*
17*
5157490070
9813450520
9813453060
5125240660
1
1
GEAR
LOCKWASHER
NUT
1
1
1
6
20-1* 5156190480
21*
26*
27*
28*
1156190010
5157490080
9813433050
5157490280
BOLT
FLANGE
HOLDER
1
1
PAGE 131 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- NOZZLE HOLDER COMP. ASSY.
NOZZLE HOLDER COMP. ASSY.
PAGE 132 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- NOZZLE HOLDER COMP. ASSY.
NOZZLE HOLDER COMP. ASSY.
NO.
5
PART NO.
ITEM
QTY.
REMARKS
5153410020
5153430020
9153396010
5153340030
9153390560
9153390570
9153326030
9153520050
9153510070
5153490010
9095714080
9153596010
PUSH ROD ......................................... 4 ....................... INCL. ITEMS W/*
7*
9*
SPRING
SCREW
NUT
4
4
4
4
4
4
4
4
4
8
4
11*
12*
13*
21*
22*
23*
31*
32*
38*
GASKET
WASHER
NUT
GASKET
CONNECTOR
BOLT
GASKET
SCREW
PAGE 133 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 ---STARTER COMP. ASSY.
STARTER COMP. ASSY.
PAGE 134 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- STARTER COMP. ASSY.
STARTER COMP. ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
6
5811210160
5811291050
5811290030
5811120100
5811160480
5811150130
ARMATURE ASSY. .................................... 1 ................ INCL. ITEMS W/*
13*
14*
22*
25*>
30*
PINION STOPPER
WASHER SET
1
1
FIELD COIL ASSY. .................................... 1 ................ INCL. ITEM W/>
BRUSH, +
REAR COVER ASSY. ................................ 1 ................ INCL. ITEM W/%
REAR METAL
BRUSH HOLDER ....................................... 1 ................ INCL. ITEMS W/@
1
32*% 5811190120
33* 5811160180
1
35*@ 5811170060
37*@ 5811160490
BRUSH SPRING
BRUSH, -
4
2
50*
52*&
55*
65*
66*#
67*
75*
80*
85*
86*
5811190130
9821121340
5811230070
5811130170
5811190260
5811290680
5811270130
5811510290
5811290710
5811290730
BRACKET ASSY. ...................................... 1 ................ INCL. ITEM W/&
CENTER METAL
CLUTCH ASSY.
GEAR CASE ASSY. .................................. 1 ................ INCL. ITEM W/#
FRONT METAL
DUST COVER
SHIFT LEVER ASSY.
MAGNETIC SWITCH ASSY.
BOLT
1
1
1
1
1
1
2
2
WASHER
PAGE 135 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 --- ALTERNATOR COMP. ASSY.
ALTERNATOR COMP. ASSY. (OCT. 1992~)
PAGE 136 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- ALTERNATOR COMP. ASSY.
ALTERNATOR COMP. ASSY. (OCT. 1992~)
NO.
PART NO.
ITEM
QTY. REMARKS
3
4*>
5*
7*
8*#
9*#
5812210630
9000901810
5812110580
5812141310
5812141320
5812190360
ROTOR ASSY.........................................................1..... INCL. ITEMS W/* AND W/>
BALL BEARING
STRATOR ASSY.
1
1
REAR COVER ASSY. ............................................1..... INCL. ITEMS W/#
REAR COVER
BRUSH REGULATOR .............................................1..... INCL. ITEMS W/%
1
10*#% 5812150460
11*#% 5812291660
12*#% 5812150400
13*#% 5812700040
BRUSH ASSY.
BOLT
BRUSH
1
2
2
1
1
REGULATOR ASSY.
RECTIFIER
FRONT COVER ASSY. ..........................................1..... INCL. ITEMS W/&
RETAINER
BALL BEARING
SCREW KIT
PULLEY ASSY.
NUT
14*#
17*
5812620050
5812130430
5812290290
5098000870
5812291650
5812220760
9822350150
5812291820
5812291830
18*&
19*&
22*&
23*
1
1
1
1
1
2
1
24*
26*
BOLT
BOLT
27*
PAGE 137 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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ISUZU C240 ---ALTERNATOR COMP. ASSY.
ALTERNATOR COMP. ASSY. (BEFORE OCT. 1992)
PAGE 138 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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ISUZU C240 --- ALTERNATOR COMP. ASSY.
ALTERNATOR COMP. ASSY. (BEFORE OCT. 1992)
NO.
PART NO.
ITEM
QTY. REMARKS
5
8*
18*
20*
5812210100
9000901810
9822250270
5812110090
5812140010
9822316190
5812150010
9822316170
9822316180
9822350700
9822319040
9822313080
9822158230
9822158240
9822159170
9000901820
5812220140
9822350740
9822350720
9822350730
ROTOR ASSY. .......................................................1..... INCL. ITEMS W/*
BALL BEARING
KEY
STRATOR ASSY.
1
1
1
25*
COVER ASSY. .......................................................1..... INCL. ITEMS W/#
27*#
30*#
33*#
34*#
35*#
39*#
50*
52*&
53*&
54*&
55*&
75*
RECTIFIER ASSY.
HOLDER ASSY.
BRUSH
BRUSH
BOLT ASSY.
RECTIFIER COVER
1
1
1
1
1
1
FRONT COVER ASSY. ..........................................1..... INCL. ITEMS W/&
PACKING
RETAINER
RETAINER BRIDGE
FRONT BALL BEARING
PULLEY ASSY.
NUT
1
1
1
1
1
1
80*
90*
91*
BOLT ......................................................................2..... L=85
BOLT ......................................................................2..... L=95
PAGE 139 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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TERMS AND CONDITIONS OF SALE — PARTS
Effective: July 1, 2000
PAYMENT TERMS
4. Freight is at the sender’s expense. All PRICINGANDREBATES
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
Terms of payment for parts are net 10 days.
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspecific
5. Parts must be in new and resalable dateandallordersreceivedonorafterthatdate
condition,intheoriginalMultiquippackage willbebilledattherevisedprice.Rebatesfor
(ifany),andwithMuiltiquippartnumbers price declines and added charges for price
FREIGHTPOLICY
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signedmanifesthasbeenobtainedfromthe
carrier,andanyclaimforshortageordamage
mustbesettledbetweentheconsigneeandthe
carrier.
clearly marked.
increaseswillnotbemadeforstockonhand
atthetimeofanypricechange.
6. Thefollowingitemsarenotreturnable:
Multiquipreservestherighttoquoteandsell
directtoGovernmentagencies,andtoOriginal
EquipmentManufactureraccountswhouse
our products as integral parts of their own
products.
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,
andotherrubberparts)thatwere
purchasedmorethansixmonths
priortothereturndate.
MINIMUMORDER
SPECIALEXPEDITINGSERVICE
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
A$20.00to$50.00surchargewillbeaddedto
theinvoiceforspecialhandlingincludingbus
c. Anylineitemwithanextendeddealer shipments, insured parcel post or in cases
netpriceoflessthan$5.00.
where Multiquip must personally deliver the
partstothecarrier.
d. Special order items.
RETURNEDGOODSPOLICY
e. Electricalcomponents.
LIMITATIONSOFSELLER’SLIABILITY
Returnshipmentswillbeacceptedandcredit
will be allowed, subject to the following
provisions:
f.
Paint,chemicals,andlubricants.
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
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.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
beapprovedbyMultiquippriortoshipment.
7. Thesenderwillbenotifiedofanymaterial
receivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Sales that defines item numbers,
quantities,anddescriptionsoftheitems
tobereturned.
8. Such material will be held for 5 working
days from notification, pending
instructions. If a reply is not received
within5days,thematerialwillbereturned
tothesenderathisexpense.
LIMITATIONOFWARRANTIES
a. Thepartsnumbersanddescriptions
mustmatchthecurrentpartsprice
list.
Nowarranties,expressorimplied,aremade
in connection with the sale of parts or trade
accessories nor as to any engine not
manufacturedbyMultiquip.Suchwarranties
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
connectionwiththesaleofitsproducts.Apart
fromsuchwrittenstatementofwarranty,there
arenowarranties,express,impliedorstatutory,
which extend beyond the description of the
productsonthefacehereof.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. Thelistmustbetypedorcomputer
generated.
10. In cases where an item is accepted for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. Thelistmuststatethereason(s)for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhich
theitemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. Thelistmustincludethenameand
phonenumberoftheperson
requestingtheRMA.
3. A copy of the Return Material
Authorizationmustaccompanythereturn
shipment.
PAGE 140 — DCA-25SSAI — PARTS AND OPERATION MANUAL—FINAL COPY (06/30/01)
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NOTE PAGE
PAGE 141 — DCA-25SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (06/29/01)
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PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
MULTIQUIPINC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
SERVICE DEPARTMENT:
800-835-2551
FAX:310-537-3927
FAX:310-638-8046
E-mail:mq@multiquip.com • www:multiquip.com
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