PARTS AND OPERATION MANUAL PARTS AND OPERATION MANUAL © COPYRIGHT 2001, MULTIQUIP INC. MQ POWER DCA-40SSAI TM WHISPERWATT GENERATOR PARTS LIST NO.M3340163804 FINAL COPY MULTIQUIP INC. PARTS DEPARTMENT: 18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 SERVICE DEPARTMENT: 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046 E-mail:mq@multiquip.com • www:multiquip.
PAGE 2 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING PAR TS DEP AR TMENT ARTS DEPAR ARTMENT 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284 VICE DEP AR TMENT SER ARTMENT SERVICE DEPAR 800/835-2551 or 310/537-3700 FAX: 310/638-8046 WARRANTY DEP AR TMENT DEPAR ARTMENT 800/835-2551 or 310/537-3700 FAX: 310/638-8046 MAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927 DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 3
TABLE OF CONTENTS Here's How To Get Help ................................................... 3 Table Of Contents ............................................................ 4 Parts Ordering Procedures .............................................. 5 Rules for Safe Operation .............................................. 6-9 Towing and Transportation ............................................. 10 Trailer Safety Guidelines ........................................... 11-17 Trailer Wiring Diagram ...........
PARTS ORDERING PROCEDURES ■ ■ ■ ■ ■ ■ ■ Dealer account number Dealer name and address Shipping address (if different than billing address) Return fax number Applicable model number Quantity, part number and description of each part Specify preferred method of shipment: • • • • UPS Ground UPS Second Day or Third Day* UPS Next Day* Federal Express Priority One (please provide us with your Federal Express account number)* • • Airborne Express* Truck or parcel post *Normally shipped the same day the order
RULES FOR SAFE OPERATION CAUTION: Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only. ■ NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.
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. ■ NEVER touch output terminals during operation. This is extremely dangerous. Always stop the machine when contact with the output terminals is required. CAUTION: ■ Backfeed to a utility system can cause electrocution and.or property damage.
RULES FOR SAFE OPERATION ■ NEVER Run engine without air filter. Severe engine damage may occur. Battery CAUTION: Never over fill the battery with water above the upper limit. 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: ■ Always service air cleaner frequently to prevent carburetor malfunction.
RULES FOR SAFE OPERATION Transporting ■ Always shutdown engine before transporting. ■ Tighten fuel tank cap securely. ■ Drain fuel when transporting generator over long distances or bad roads. ■ Always tie-down the generator during transportation by securing the generator. ■ If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. See page 10 for basic towing procedures.
DCA-40SSAI — TOWING AND TRANSPORTATION Towing Safety Precautions CAUTION : Check with your county or state safety towing regulations department before towing your generator. 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.
DCA-40SSAI — TRAILER-SAFETY GUIDELINES 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. Explanation of Chart: This section is to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers.
DCA-40SSAI —TRAILER-SPECIFICATIONS Table 1. Specifications MODEL APPLICATION FU E L C E LL BRAKE SYSTEM GVWR FRAME LENGTH FRAME WIDTH JACK STAND TRLR-10W SDW225, SGW250,TLW300 NO NO 1900LB S 96" 50" 800LB . FULL TILT WHEEL TRLR-10 DCA10, TLG12, DCA-15 NO NO 1900LB S 96" 50" 800LB . FULL TILT WHEEL TRLR-10XF DCA10, TLG-12, DCA15, TLW-300 52 GAL NO 1900LB S 96" 50" 800LB . FULL TILT WHEEL TRLR-225W WELDERS, D A 7000S S NO NO 2200LB S 85" 42" 800LB .
DCA-40SSAI —TRAILER-SPECIFICATIONS Table 1. Specifications (Con't) MODEL COUPLER TIRES WHEELS AXLE HUBS SUSPENSION ELECTRICAL TRLR-10W 2" B A LL C LA S S 2 ADJUSTABLE 175-13C 13"X4.50" 2200# 2X 2 5 LUG 3 LE A F 4 WIRE LOOM W/ 4 POLE FLAT TRLR-10 2" B A LL C LA S S 2 ADJUSTABLE 175-13C 13"X4.5" 2200#2X 2 5 LUG 3 LE A F 4 POLE FLAT TRLR-10XF 2" B A LL C LA S S 2 ADJUSTABLE 175-13C 13"X4.
DCA-40SSAI —TRAILER SAFETY GUIDELINES Brakes If your trailer has a braking system, the brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently. Electric Brakes Electrically actuated brakes (Figure 2) are similar to hydraulic brakes.
DCA-40SSAI — TRAILER SAFETY GUIDELINES Figure 2. Electrical Brake Components Hydraulic/Air/Surge Brakes Hydraulic brakes (Figure 3) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. These brakes can be adjusted in the same manner as electric brakes. Brake lines should be periodically checked for cracks, kinks, or blockage.
DCA-40SSAI — 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.
DCA-40SSAI —TRAILER SAFETY GUIDELINES Table 3. Suspension Torque Requirements Item Torque (Ft.-Lbs.) 3/8" U-BOLT MIN-30 MAX-35 7/16" U-BOLT MIN-45 MAX-60 1/2" U-BOLT MIN-45 MAX-60 SHACKLE BOLT SNUG FIT ONLY. PARTS MUST ROTATE FREELY. SPRING EYE BOLT LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT-BOLT ASSEMBLY. MIN-30 MAX-50 SHOULDER TYPE SHACKLE BOLT Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer.
DCA-40SSAI —TRAILER-WIRING DIAGRAM NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT PAGE 18 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
DCA-40SSAI —TRAILER-BRAKE TROUBLESHOOTING Table 5. Electric Brake Troubleshooting Symptom Possible Cause Solution No Brakes or Intermittent Brakes Any open circuits or broken wires? Find and correct. Any shor t circuits? Find and correct. Faulty controller? Test and correct. Any loose connections? Find and repair. Ground wire secure? Find and secure. Grease or oil on magnets or linings? Clean or replace. Connections corroded? Clean and correct cause of corrosion.
DCA-40SSAI —TRAILER-BRAKE TROUBLESHOOTING Table 6. Hydraulic Brake Troubleshooting Symptom Possible Cause Solution No Brakes Brake line broken or kinked? Repair or replace. Weak Brakes or Brakes Pull to One Side Brake lining glazed? Reburnish or replace. Trailer overloaded? Correct weight. Brake drums scored or grooved? Machine or replace. Tire pressure correct? Inflate all tires equally. Tires unmatched on the same axle? Match tires.
DCA-40SSAI — GENERATOR DECALS The DCA-40SSAI 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 page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-40SSAI — GENERATOR DECALS PAGE 22 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
DCA-40SSAI — SPECIFICATIONS Table 7. Specifications Generator Specifications Model DCA-40SSAI Type Revolving field, self ventilated, open protected type synchronous generator Armature Connection Star with Neutral Phase 3 Standby Output 46.8 KVA (37.4 KW) Prime Output 40 KVA (32 KW) Voltage 240V or 480V Frequency 60 Hz Speed 1800 rpm Power Factor 0.8 Aux. AC Power Single Phase, 60 Hz Voltage 120/240 V Output 11.5 KW (13.
DCA-40SSAI — GENERAL INFORMATION DCA-40SSAI FAMILIARIZATION Open Delta Excitation System Generator The DCA-40SSAI generator is equipped with the state of ator the art "Open-Delta" excitation system. The open delta The MQ Power Model DCA-40SSAI is a 26 kW gener generator that is designed as a high quality portable (requires a trailer system consist of an electrically independent winding wound for transport) power source for telecom sites, lighting among stationary windings of the AC output section.
NOTE PAGE DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 25
DCA-40SSAI — MAJOR COMPONENTS Figure 6.
DCA-40SSAI — DIMENSIONS Figure 7.
DCA-40SSAI — CONTROL PANEL DESCRIPTION Figure 8.
DCA-40SSAI — CONTROL PANEL DESCRIPTION The definitions below describe the controls and functions of the DCA-40SSAI " Control Panel " (Figure 8). 1. Main Circuit Breaker – This three-pole, 110 amp main breaker is provided to protect the UNV voltage output terminals from overload. 2. AC Ammeter – Indicates the amount of current the load is drawing from the generator. 3. Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz ±1 Hz . 4.
DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION Figure 9.
DCA-40SSAI — ENGINE OPERATING PANEL DESCRIPTION The definitions below describe the controls and functions of the DCA-40SSAI " Engine Operating Panel " (Figure 9). 1. Fuel Gauge - Indicates amount of diesel fuel available. 2. 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. 3.
DCA-40SSAI — OUTPUT TERMINAL PANEL Output Terminal Panel The output control panel is located on the rear (control panel) end of the generator. The UNV lugs are protected by a face plate cover that can be secured in the close position by a pad lock. 120 Volt Receptacle One GFCI Duplex NEMA 5-20R (120V, 20 Amp) receptacle is located on the output terminal. This receptacle can be used anytime the generator is in operation. The receptacle is controlled by the circuit breaker located on the control panel.
DCA-40SSAI — OUTPUT TERMINAL VOLTAGE SELECTION DCA-40SSAI NOTE Legs O and Ground are considered Bonded Grounds. Figure 12.
DCA-40SSAI — OUTPUT AMPERAGE SETUP Output Terminal Panel Available Voltages A wide range of voltages are available to supply load to many different applications. Voltages may be selected by using the voltage selector switch and depending how you hookup your hard wire connection to the generator. To obtain some of the voltages listed, fine adjustment with the voltage regulator on the control panel is necessary. See Table 8 for available voltages the generator will supply.
DCA-40SSAI — OUTPUT AMPERAGE SETUP Receptacle Use When the UVWO terminals are providing power, the receptacle power availability will decrease. Do not exceed receptacle power as listed on Table 10. Table 10. Receptacle Use Pow er in U se R eceptacle P o w er Available 240/480V 3-Phase 240/120V Single Phase or Tw ist L o ck C S 6369 D uplex N EMA 5-20R 120V K VA KW KW 45 26 0 40.9 24.8 1.2 36.7 23.6 2.4 32.6 22.4 3.6 28.4 21.2 4.8 Figure 13.
DCA-40SSAI — OUTPUT VOLTAGE SETUP 240/120V Hard Wire Hookup 480/240V Hard Wire Hookup With the voltage selector set and locked at ‘single phase 240/120’ and using single phase 120 volts, the generator will provide three legs available with 100 amps each on three different circuits (Figure 18). With the voltage selector set and locked at ‘3 phase 480/ 277’ (Figure 19) and using the 3-phase 240 hookup, it will provide one circuit available at 108 amps with any two wires plus the ground (Figure 20).
DCA-40SSAI — OUTPUT VOLTAGE SETUP Voltage Selector Switch- 3 Phase 480/277V Position The following are additional voltages available when the voltage selector switch is in the ‘3 phase 480/277V’ position. Single Phase: 480V, 440V, or 416 Volt This setting can provide single phase power at 480, 440, or 416 volts.
DCA-40SSAI — OUTPUT VOLTAGE SETUP 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. Figure 25. Voltage Selector Switch 240/139V Three Phase Position 3 Phase, 240V, 220V, or 208 Volt This setting can provide 3-phase power at 240, 220, or 208 volts.
DCA-40SSAI — OUTPUT VOLTAGE SETUP Voltage Selector Switch- Single Phase 240/120V Position The following are additional voltages available when the voltage selector switch is in the ‘single phase 240/120V’ position. Single Phase: 120 Volt This setting can provide single phase power at 120 volts. After hooking up the hard wires to the lugs as shown in Figure 31, 120 volts can be obtained with the voltage regulator knob turned to fine tune. Figure 31. Hard Wire Hookup for Single Phase, 120 volt Figure 29.
DCA-40SSAI — INSTALLATION Outdoor Installation Install the generator in a location where it will not be exposed to rain or sunshine. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes. The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture.
DCA-40SSAI — INSTALLATION Figure 31.
DCA-40SSAI — PRE-SETUP General Inspection Prior to Operation Circuit Breakers The DCA-40SSAI generator has been thoroughly inspected and accepted prior to shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts, which could have occurred in transit. Extension Cable To protect the generator from an overload, a 3-pole, 100 amp, main circuit breaker is provided to protect the UNV output terminals from overload.
DCA-40SSAI — PRE-SETUP Lubrication Oil Fuel 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 32) on the dipstick. See Table 12 for proper selection of engine oil. Fill the fuel tank with clean and fresh diesel fuel. DO NOT fill the tank beyond capacity.
DCA-40SSAI — PRE-SETUP CAUTION : When adding coolant or antifreeze to the radiator, do not remove the radiator cap until the unit has completely cooled. Day-to-day addition of coolant is done from the reserve tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 13. 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. Table 13.
DCA-40SSAI — PRE-SETUP Battery This unit is of negative ground. DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level is not properly maintained. Add only distilled water when replenishment is necessary. DO NOT over fill. The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.
DCA-40SSAI — LOAD APPLICATION Single Phase Load CAUTION: 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. Motors and motor-driven equipment draw much greater current for starting than during operation. Generally, the wattage listed on the nameplate of the equipment is its rated output.
DCA-40SSAI — GENERATOR START-UP PROCEDURE WARNING: The engine's exhaust contains harmful W AY S ventilate the emissions. A LLW exhaust when operating inside tunnels, excavations or buildings. Direct exhaust away from nearby personnel. 2. Connect the load to the UNV terminals as shown in Figure 36. These terminals can be found on the output terminal panel, (see page 33 Figure 12). To gain access to the output terminals lift the UNV cover.
DCA-40SSAI — GENERATOR START-UP PROCEDURE 4. Close all engine enclosure doors (Figure 38). 8. Once the engine is warm and the engine is running properly, pull and turn the engine throttle control lever to ‘High’ (Figure 42). Figure 42. Engine Speed Switch (high) Figure 38. Engine Enclosure Doors 5. Check the voltage selection switch (Figure 39) is at the desired voltage. Figure 39. Voltage Selection Switch 6. 9.
DCA-40SSAI — GENERATOR START-UP PROCEDURE 11. 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. 20 40 0 14. 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. 60 75 A Figure 46. Ammeter (No Load) 12.
DCA-40SSAI — 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. EMERGENCY STOP 1. To stop the engine in the event of an emergency, switch the MAIN, GFCI and LOAD circuit breakers to ‘OFF’ position. 2. Turn the starter switch key to ‘Stop’ position. Figure 52. Main, GFCI and Load circuit breakers 2.
NOTE PAGE DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 51
DCA-40SSAI — MAINTENANCE General Inspection Cleaning the Fuel Strainer Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Engine Side (Refer to the Engine Instruction Manual) 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.
DCA-40SSAI — MAINTENANCE Feed Pump Strainer Cleaning The strainer is incorporated in the feed pump inlet side joint bolt. Clean the strainer with compressed air and rinse it in the fuel oil. Flushing Out Radiator and Replacing Coolant Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain. Check hoses for softening and kinks. Check clamps for signs of leakage.
DCA-40SSAI — MAINTENANCE Valve Clearance Check 1. In order to bring No. 1 or No. 4 cylinder to top dead center in the compression stroke, align the notched line on the crank pulley with TDC mark on the timing gear case cover. 3. Remove the timing check hole cover at the front of injection pump to check the alignment between the pointer “a” on the injection pump gear lock plate and the projected area mark “b” on the timing gear case. 4. If “a” and “b” are in alignment, the timing is set correctly.
DCA-40SSAI — MAINTENANCE 10 Hrs DAILY INSPECTION / MAINTENANCE ENGINE Check Engine Fluid Levels X Check Air Cleaner X Check Battery Acid Level X Check Fan Belt Condition X Check for Leaks X Check for Loosening of Parts X 250 Hrs Replace Engine Oil and Filter *1 X Clean Air Filter X Drain Bottom of Fuel Tank X Clean Unit, Inside and Outside X 500 Hrs Change Fuel Filter *2 X Clean Radiator and Check Coolant Protection Level X Test Fuel Injection Nozzle X Replace Air Filter Eleme
DCA-40SSAI — ENGINE WIRING DIAGRAM PAGE 56 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
DCA-40SSAI — GENERATOR WIRING DIAGRAM DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 57
DCA-40SSAI — TROUBLESHOOTING (ENGINE) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use the tables shown for diagnosis based on the Engine Troubleshooting (Table 1 7). If the problem cannot be remedied, consult our company's business office or service plant. TABLE 17. ENGINE TROUBLESHOOTING (PART 1) SYMPTOM Engine does not start. POSSIBLE PROBLEM SOLUTION No fuel? Replenish fuel. Air in the fuel system? Bleed system.
DCA-40SSAI — TROUBLESHOOTING (ENGINE) TABLE 17. ENGINE TROUBLESHOOTING (PART 2) SYMPTOM Engine revolution is not smooth. POSSIBLE PROBLEM Fuel filter clogged or dirty? Clean or change. Air cleaner clogged? Clean or change. Fuel leak due to loose injection pipe retaining nut? Tighten nut. Injection pump malfunctioning? Repair or replace. Incorrect nozzle opening pressure? Adjust. Injection nozzle stuck or clogged? Repair or replace. Fuel over flow pipe clogged? Clean.
DCA-40SSAI — TROUBLESHOOTING (GENERATOR/ENGINE) TABLE 17. GENERATOR TROUBLESHOOTING SYMPTOM No Voltage Output Low Voltage Output High Voltage Output Circuit Breaker Tripped POSSIBLE PROBLEM SOLUTION AC Voltmeter defective? Check output voltage using a voltmeter. Is wiring connection loose? Check wiring and repair. Is AVR defective? Replace if necessary. Defective Rotating Rectifier? Check and replace. Is engine speed correct? Turn engine throttle lever to "High".
NOTE PAGE DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 61
EXPLANATION OF CODE IN REMARKS COLUMN How to read the marks and remarks used in this parts book. Items Found In the “Remarks” Column Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used. Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.
DCA-40SSAI — SUGGESTED SPARE PARTS DCA-40SSAI W/ISUZU 4BD1 DIESEL ENGINE 1 TO 3 UNITS Qty. P/N Description 1 ......... 0601808811 .............. CIRCUIT BREAKER 1 ......... 0601820671 .............. AUTOMATIC VOLTAGE REGULATOR 1 ......... 0601840073 .............. RHEOSTAT VOLTAGE REGULATOR 1 ......... 0601840121 .............. KNOB RHEOSTAT 1 ......... M1310500403 ........... RADIATOR HOSE 1 ......... M1310500303 ........... RADIATOR HOSE 1 ......... 8941324900 .............. RADIATOR HOSE 5 .........
DCA-40SSAI --- GENERATOR ASSY. GENERATOR ASSY.
DCA-40SSAI --- GENERATOR ASSY. GENERATOR ASSY. NO. PART NO. ITEM 1 1-1 1-2 1-3 1-4 1-5 1-6 2 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16-1 16-2 16-3 17 18 19 19-1 19-2 FIELD ASSY. 1 SHAFT 1 FIELD CORE 1 FIELD COIL 1 ARMATURE CORE, EXCITER 1 ARMATURE COIL, EXCITER 1 COUPLING HUB 1 RECTIFIER ASSY. 1 SET PLATE, RECTIFIER 1 RECTIFIER .......................................... 3 ............PB2510 HEX. HEAD BOLT 3 PLAIN WASHER 6 LOCK WASHER 3 HEX. NUT ...
DCA-40SSAI --- GENERATOR ASSY. GENERATOR ASSY.
DCA-40SSAI --- GENERATOR ASSY. GENERATOR ASSY. NO. PART NO. ITEM 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 PLAIN WASHER .................................. 4 ............REPLACES LOCK WASHER 4 HEX. HEAD BOLT 4 LOCK WASHER 6 HEX. HEAD BOLT ................................ 6 ............REPLACES GASKET, BEARING 1 COVER, BEARING 1 LOCK WASHER 4 HEX. HEAD BOLT 4 COVER, END BRACKET 1 HEX. HEAD BOLT ................................ 8 ............REPLACES LOCK WASHER 6 HEX. HEAD BOLT ..........
DCA-40SSAI --- CONTROL BOX ASSY. CONTROL BOX ASSY.
DCA-40SSAI --- CONTROL BOX ASSY. CONTROL BOX ASSY. NO. PART NO.
DCA-40SSAI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY.
DCA-40SSAI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. NO. PART NO. ITEM QTY. REMARKS 1 4B01PD02 ENGINE .......................................... 1 .......... ISUZU 4BD1; REPLACES 0602000078 2 0602010800 RADIATOR ...................................... 1 .......... B961110002 3 0602011303 RADIATOR NECK ........................... 1 .......... 4079111300 4 0602011102 HOSE .............................................. 1 .......... B9611111910 5 0602014062 HOSE BAND ...................................
DCA-40SSAI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY.
DCA-40SSAI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. NO. PART NO. ITEM QTY. REMARKS 34 3342054104 DRAIN JOINT 1 35 0805013704 PACKING, OIL PAN SIDE 1 36 0805014204 PACKING 1 37 3362054104 JOINT BOLT 1 38 3342051104 DRAIN JOINT 1 39 0802024004 PACKING 1 40 0802010204 PLUG 1 41 3342022104 DRAIN HOSE 1 42 0605515003 HOSE BAND 2 43 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0017108020 44 020108060 HEX. NUT ....................................... 2 ..........
DCA-40SSAI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY.
DCA-40SSAI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY. NO. PART NO. ITEM QTY. REMARKS 1 3342101003 OPERATING PANEL 1 2 7452142004 SLIDE BAR 1 3 0601840190 KNOB .............................................. 1 .......... REPLACES 0805012904 4 0080200006 SNAP RING 1 5 7452140504 BRACKET, GOVERNOR ROD 1 6 020108060 HEX. NUT ....................................... 2 .......... REPLACES 0030008000 7 0605010503 SNAP PIN 1 8 1823100080 STARTER SWITCH ........................ 1 ...........
DCA-40SSAI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY.
DCA-40SSAI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY. NO. PART NO.
DCA-40SSAI --- BATTERY ASSY. BATTERY ASSY.
DCA-40SSAI --- BATTERY ASSY. BATTERY ASSY. NO. PART NO. 1 0160012100 2 0805003904 3 0805004004 4 3802252004 5 0041608000 6 031108160 7 0037808000 8 0215260050 9 0211160160 10 0215860045 11 0602220310 0037808000 12 0602220311 0037808000 ITEM QTY. REMARKS BATTERY ......................................... 2 ......... N100 12V 100Ah BATTERY SHEET 2 BATTERY BAND 2 BATTERY BOLT 4 PLAIN WASHER 4 LOCK WASHER ............................... 4 .........
DCA-40SSAI --- MUFFLER ASSY. MUFFLER ASSY.
DCA-40SSAI --- MUFFLER ASSY. MUFFLER ASSY. NO. PART NO. 1 3342350103 2 1141450690 3 9091103100 4 3342311102 5 3342359104 6 011208025 7 012210020 8 3342356104 9 011008035 10 031108160 11 0040008000 12 020108060 13 3342354104 14 3342354004 15 3342328104 16 020108060 17 3342359004 18 0112508025 ITEM QTY. REMARKS EXHAUST PIPE 1 GASKET ......................................... 1 .......... REPLACES 0602320000 AND 9221160010 HEX. NUT ....................................... 6 ..........
DCA-40SSAI --- FUEL TANK ASSY. FUEL TANK ASSY.
DCA-40SSAI --- FUEL TANK ASSY. FUEL TANK ASSY. NO. PART NO. 1 3345510323 1-1 0810105004 1-2 0810105400 2 0802010304 3 0602021042 4 3345523304 5 0805003404 6 011008020 7 031108160 8 0040008000 9 020108060 10 3805522004 11 0191300600 12 0191300700 13 0605515014 14 0845032204 15 0150000018 16 0802011104 17 0193100225 18 0605515079 ITEM QTY. REMARKS FUEL TANK 1 CAP, FUEL TANK 1 FUEL FILTER 1 PACKING 1 PLUG .............................................. 1 ........... 960922101 TANK BAND 2 PAD, TANK BAND 4 HEX.
DCA-40SSAI --- ENCLOSURE ASSY. ENCLOSURE ASSY.
DCA-40SSAI --- ENCLOSURE ASSY. ENCLOSURE ASSY. NO. PART NO.
DCA-40SSAI --- ENCLOSURE ASSY. ENCLOSURE ASSY.
DCA-40SSAI --- ENCLOSURE ASSY. ENCLOSURE ASSY. NO. PART NO.
DCA-40SSAI --- ENCLOSURE ASSY. ENCLOSURE ASSY.
DCA-40SSAI --- ENCLOSURE ASSY. ENCLOSURE ASSY. NO. PART NO. 82 0605010910 83 0027103010 84 0605010910 85 0027104010 86 3345104104 87 3345104204 88 3345104304 89 3345104404 90 3345104504 91 3345104604 92 3345104704 93 3345104804 94 3345104904 ITEM QTY. REMARKS LATCH ............................................. 1 .......... UP TO S/N3311949; REPLACES 0605010910 MACHINE SCREW ......................... 7 .......... UP TO S/N3311949 LATCH ............................................. 2 ..........
DCA-40SSAI --- DECALS DECAL ASSY.
DCA-40SSAI --- DECALS DECAL ASSY. NO. PART NO. 1 M1550000204 2 M1550001003 3 M1550000603 4 M1550000703 5 M1550000804 6 M9500000004 7 M9500100004 8 M9500300004 9 M9500300104 10 M9500500004 11 M9500500104 12 M9503000004 13 M9503000103 14 M9503100004 15 M9503200004 16 M9510100004 17 M9510200002 18 M9520000004 19 M9520000104 20 M9520000204 21 M9520100004 22 M9520100204 23 M9520100304 24 M9520100404 25 M9520100503 26 M9520200003 27 M9520200104 ITEM QTY. REMARKS DECAL; NOTE ......................................
ISUZU 4BD1 — CYLINDER HEAD COVER ASSY. CYLINDER HEAD COVER ASSY.
ISUZU 4BD1 — CYLINDER HEAD COVER ASSY. CYLINDER HEAD COVER ASSY. NO PART NO PART NAME QTY. REMARKS 1 5111101680 CYLINDER HEAD ASSY. .................1 .......... INCL. ITEMS W/# 2# 9117156070 VALVE SEAT, INTAKE 4 3# 9117118030 VALVE SEAT, EXHAUST 4 5# 1096000580 SEALING CUP, REAR FACE ...........1 .......... REPLACES 1096000051 5-1# 1096000121 SEALING CUP, EXHAUST MAN. ....2 ..........
ISUZU 4BD1 — CYLINDER BLOCK ASSY. CYLINDER BLOCK ASSY.
ISUZU 4BD1 — CYLINDER BLOCK ASSY. CYLINDER BLOCK ASSY.
ISUZU 4BD1 — CYLINDER BLOCK ASSY. CYLINDER BLOCK ASSY.
ISUZU 4BD1 — CYLINDER BLOCK ASSY. CYLINDER BLOCK ASSY. NO PART NO 70 0500408160 71 9091606080 80 8941405811 81 1117500120 82 1094400401 83 1099851770 85 9099129760 86 9099155531 92 8970233390 93@ 5096230350 PART NAME QTY. REMARKS BOLT 1 PLAIN WASHER 1 OIL FILLER ASSY. 1 OIL FILLER CAP 1 NUT ................................................... 1 ........ REPLACES 9091104080 LOCK WASHER ................................. 1 ........ REPLACES 9091505080 HOSE 1 CLIP 2 VALVE RELIEF ASSY. ...................... 1 .
ISUZU 4BD1 — TIMING GEAR ASSY. TIMING GEAR ASSY.
ISUZU 4BD1 — TIMING GEAR ASSY. TIMING GEAR ASSY. NO. 1 2 3 4 6 7 8 9 10 10 12 13 14 PART NO. 5113110113 9081510180 8943706710 0500408450 1113210790 8943632690 1096254380 9113276020 0500408250 8941500451 5113210090 8971186980 0500406140 PART NAME QTY. REMARKS CASE 1 STRAIGHT PIN 1 PACKING ........................................................ 1 .......... REPLACES 1113120140 BOLT ............................................................... 6 .......... REPLACES 0500408200 COVER 1 PACKING 1 SEAL ......
ISUZU 4BD1 — FLYWHEEL HOUSING ASSY. FLYWHEEL HOUSING ASSY.
ISUZU 4BD1 — FLYWHEEL HOUSING ASSY. FLYWHEEL HOUSING ASSY. NO. 1 3 4 5 9 9-1 11 PART NO. 8943213303 8943218380 5096000090 9095714160 9910664500 0500408250 9096510690 PART NAME QTY. REMARKS HOUSING 1 PLUG, PICK UP HOSE 1 DRAIN PLUG .................................................. 1 ..........
ISUZU 4BD1 — OIL PAN ASSY. OIL PAN ASSY.
ISUZU 4BD1 — OIL PAN ASSY. OIL PAN ASSY. NO 1 3# 3-1# 3-2# 4# 4-1# 4-2# 7 9 15 PART NO 8941340361 9096620120 5096000090 1096040230 1096231830 9095714160 9095714240 8943708360 8943706660 0500408180 5117601501 PART NAME QTY. REMARKS OIL PAN ...................................... 1 ........ INCL. ITEMS W/# PLUG 1 PLUG, THERMO SWITCH .......... 2 ........ REPLACES 9992023160 HEATER PLUG ........................... 1 ........ REPLACES 9992023240 O RING ....................................... 1 ........
ISUZU 4BD1 — OIL PUMP ASSY. OIL PUMP ASSY.
ISUZU 4BD1 — OIL PUMP ASSY. OIL PUMP ASSY. NO. 1 2# 3# 4# 5#& 7# 9# 15# 16# 17# 19# 21# 22# 23# 24# 27#& 28#& 32 PART NO. 5131001373 5878102022 5131130351 5131210140 5131250020 5131190060 5131410171 1131190010 0108058000 1099851770 5098430030 5095800980 5131650040 9081040300 1131230160 1131280180 0500410250 PART NAME QTY. REMARKS OIL PUMP ASSY. .......................... 1 ........... INCL. ITEMS W/# GEAR SET ..................................... 1 ........... INCL. ITEMS W/& COVER ASSY. 1 DOWEL .........
ISUZU 4BD1 — CRANKSHAFT. PISTON, FLYWHEEL ASSY.
ISUZU 4BD1 — CRANKSHAFT. PISTON, FLYWHEEL ASSY. CRANKSHAFT, PISTON, FLYWHEEL ASSY. NO. 1 1-1 1-2 1-3 1-4 2# 3 4 5 6 7 8& 9& 11 11-1 11-2 11-3 11-4 14 15$ 17 18 20 23 24 25 30 31% 33 34 PART NO.
ISUZU 4BD1 — CAMSHAFT, IDLE GEAR, ROCKER ASSY. CAMSHAFT, IDLE GEAR, ROCKER ASSY.
ISUZU 4BD1 — CAMSHAFT, IDLE GEAR, ROCKER ASSY. CAMSHAFT, IDLE GEAR, ROCKER ASSY. NO. 1 2 3 4 5 6 7 10 11 13 14 17 18 19 21 22 23 24 25 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PART NO.
ISUZU 4BD1 — OIL AND FUEL FILTER ASSY. OIL AND FUEL FILTER ASSY.
ISUZU 4BD1 — OIL AND FUEL FILTER ASSY. OIL AND FUEL FILTER ASSY. NO. 1 PART NO. 5132002262 2# 10 1878102201 8943706700 11 13 14 15 50# 52#& 60 8943706700 5132190261 5090000071 030210250 9091645100 9132004193 5878100500 0501510350 PART NAME QTY. REMARKS OIL FILTER ASSY. ............................. 1 ............. INCL. ITEMS W/#; REPLACES 5132002262 OIL FILTER ELEMENT KIT 1 PACKING ............................................ 2 ............. UP TO MAR. 94; REPLACES 1132191940 PACKING ................
ISUZU 4BD1 — OIL PIPING ASSY. OIL PIPING ASSY.
ISUZU 4BD1 — OIL PIPING ASSY. OIL PIPING ASSY. NO. 1 2 3 5 6 7 7-1 10 12 13 PART NO. 8941753012 9099211880 0501408450 5133112561 1096234620 0500408350 0500408320 8944284630 9095720100 909840220 PART NAME OIL PUMP ASSY. PACKING BOLT FILTER PIPE ASSY. PACKING BOLT BOLT OIL INJECTION PIPE ASSY. PACKING NUT QTY.
ISUZU 4BD1 — COOLING ASSY. COOLING ASSY.
ISUZU 4BD1 — COOLING ASSY. COOLING ASSY. NO. 1 2# 3& 4& 5& 6& 7& 8& 9%& 11%& 13& 14% 15%& 17%& 19& 21& 23%& 27 28%& 29 31 32 35 37 38 40 41 43 48 49 50 52 53 60 62 63 65 80 81 83 PART NO.
ISUZU 4BD1 — INTAKE AND EXHAUST ASSY. INTAKE AND EXHAUST ASSY.
ISUZU 4BD1 — INTAKE AND EXHAUST ASSY. INTAKE AND EXHAUST ASSY. NO. 1 3 4 5 8 39 50 50-1 51 51-1 60 61 62 66 67 69 PART NO. 5141112070 8970241220 1094400401 1099851770 0500408250 8970225710 5141111160 5141112360 0501510300 0500510300 5141410360 5093020020 8944046100 1094400401 1099851770 8942059871 0500408600 PART NAME QTY. REMARKS INTAKE MANIFOLD 1 GASKET, INTAKE ..................... 1 ................ REPLACES 8943632700 NUT ........................................... 2 ................
ISUZU 4BD1 — FUEL INJECTION ASSY. FUEL INJECTION ASSY.
ISUZU 4BD1 — FUEL INJECTION ASSY. FUEL INJECTION ASSY. NO. 1 3 5 8 9 11 12 13 14 15 15-1# 15-2# 15-3# 16 16-1 16-2 18 20 27 29 29-1 30 31 32 33 34 42 49 49-1 49-2 PART NO. 5153001032 1153150131 9153390510 1094400401 1099851770 8944636740 8944636750 8944636760 8944636770 5154190131 9154196130 9154196140 5154190040 5154190051 0501406160 5154112290 5132600101 5154115730 5154118580 5154115680 5154116030 9099063141 9095714080 9095720140 1095751460 9095720140 5097091030 9097161240 0500406250 PART NAME QTY.
ISUZU 4BD1 — ENGINE FOOT ASSY. ENGINE FOOT ASSY.
ISUZU 4BD1 — ENGINE FOOT ASSY. ENGINE FOOT ASSY. NO. 1 2 3 4 5 17 18 19 20 22 27 27 28 29 30 31 35 39 42 PART NO. 9117712470 9117712480 8943134650 9091105100 030210250 5117770080 9117778050 0500410200 5197110620 0501408350 0501408400 0500410000 0500410450 5090300101 8943717120 8942790500 1099851770 9091606080 5136740320 0500408400 9091647080 PART NAME QTY. REMARKS FOOT, FRONT RIGHT 1 FOOT, FRONT LEFT 1 BOLT 7 NUT 1 LOCK WASHER ...................... 1 ...................
ISUZU 4BD1 — ENGINE CONTROL ASSY. ENGINE CONTROL ASSY.
ISUZU 4BD1 — ENGINE CONTROL ASSY. ENGINE CONTROL ASSY. NO. 2 PART NO. 5197890041 PART NAME QTY. REMARKS BRACKET ................................. 1 ................
ISUZU 4BD1 — INJECTION PUMP ASSY. INJECTION PUMP ASSY.
ISUZU 4BD1 — INJECTION PUMP ASSY. INJECTION PUMP ASSY. NO. 1 3# 5# 14# 15# 16# 17# 18# 19# 20# 32 33 35 36 38 39 40 PART NO. 8943440260 8943440280 8941327042 5125240890 1156192450 9096620070 5157810030 8944575170 9884105020 5156190480 1113190090 8941500451 5197510150 0500410250 9091105100 9091645100 030210250 PART NAME QTY. REMARKS INJECTION PUMP ASSY. ......... 1 ................ INCL. ITEMS W/# GOVERNOR ASSY. 1 FEED PUMP ASSY. .................. 1 ................ REPLACES 8941327040 GEAR ..............
ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY. ELECTRICAL COMPONENTS ASSY.
ISUZU 4BD1 — ELECTRICAL COMPONENTS ASSY. ELECTRICAL COMPONENTS ASSY. NO. PART NO. 1 1811001910 6 0500512280 6 0500512350 7 9091605120 8 9829315110 10 5812002121 16 9827200690 16-1 5824100160 19 1825130430 20 5197320021 23 9825300460 35 5824500141 35-1 8970299880 78 1819001931 1819000161 79% 1828490430 PART NAME QTY. REMARKS STARTER ASSY 1 BOLT 1 BOLT 2 PLAIN WASHER 1 CABLE ASSY. 1 ALTERNATOR ASSY. 1 OIL PRESS. WARNING SW. 1 OIL PRESS. WARNING SW. 1 GLOW PLUG (24V) ........................ 4 ...............
ISUZU 4BD1 — FEED PUMP COMP. ASSY. FEED PUMP COMP. ASSY.
ISUZU 4BD1 — FEED PUMP COMP. ASSY. FEED PUMP COMP. ASSY. NO. 1 5# 9# 10# 11# 12# 15# 16#% 17#% 18#% 20# 26# 27# 31# 32# 33# 35# 37# 40# 42# 44# PART NO. 8941327042 5157510120 9813512050 9813513020 9813550230 9813550350 5157540010 9813514030 9813514100 1157590020 9813517020 9813516020 1156290650 5157590270 1156190820 1157590010 1157590030 5157590120 1156290650 9813550250 1157610060 PART NAME QTY. REMARKS FEED PUMP ASSY. .................. 1 ........... INCL.
ISUZU 4BD1 — NOZZLE ASSY. NOZZLE ASSY.
ISUZU 4BD1 — NOZZLE ASSY. NOZZLE ASSY. NO. 1 2 4# 6# 8# 10# 11# 12# 20# 21# 22# 30# 31# 32# PART NO. 5153110191 1153300941 5153410010 9153430130 5153450010 5153320100 9153390560 9153390570 1153320170 5153390030 5153510010 1096750371 1153390100 9153470030 PART NAME QTY. REMARKS INJ. NOZZLE ............................. 4 ................ REPLACES 5153110190 HOLDER ASSY. ........................ 4 ................ INCL. ITEMS W/# PUSH ROD 4 SPRING 4 ADJ.
ISUZU 4BD1 — OIL FILTER ASSY. OIL FILTER ASSY.
ISUZU 4BD1 — OIL FILTER ASSY. OIL FILTER ASSY. NO. 1 2# 4#& 5#& 6#& 7#& 8# 9# 10# 11# 12# 15# 16# 17# 18# 20# 21# 22# PART NO. 5132002262 1878102201 9097205550 5096230670 9099211950 9132490090 5132120681 9132316020 9099410980 9132390310 9098621170 9000975270 9099408600 8941326650 9099208410 9132260110 9099208410 5132110201 PART NAME QTY. REMARKS OIL FILTER ASSY. .................... 1 ................ INCL. ITEMS W/# OIL FILTER ELEMENT KIT ....... 1 ................ INCL. ITEMS W/& PACKING ...............
ISUZU 4BD1 — FUEL FILTER ASSY. FUEL FILTER ASSY.
ISUZU 4BD1 — FUEL FILTER ASSY. FUEL FILTER ASSY. NO. 1 2# 3#% 4#% 5# 6#% 7# 8# 9# 10#% 11# 12# 13# 14# 15# PART NO. 9132004193 5878100500 9099203270 9132136010 9099208410 5096230241 9095720140 1132600470 9099203260 9098518100 9099409010 9132310660 9098620680 9132111071 9132128040 PART NAME QTY. REMARKS FUEL FILTER ASSY. ................. 1 ................ INCL. ITEMS W/# ELEMENT KIT ........................... 1 ................ INCL.
ISUZU 4BD1 — ENGINE ACCESSORIES ENGINE ACCESSORIES PAGE 136 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
ISUZU 4BD1 — ENGINE ACCESSORIES ENGINE ACCESSORIES NO. 1 3 4 PART NO. 8944533001 1096234650 0500408200 PART NAME QTY. REMARKS TACHOMETER DRIVE ASSY. ... 1 ................
TERMS AND CONDITIONS OF SALE — PARTS Effective: July 1, 2000 PAYMENT TERMS 4. Terms of payment for parts are net 10 days. FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier. Freight is at the sender’s expense.
NOTE PAGE DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 139
PARTS AND OPERATION MANUAL PARTS AND OPERATION MANUAL HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING © COPYRIGHT 2001, MULTIQUIP INC.
