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MQ Power WHISPERWATT DCA-60SSAI Parts And Operation Manual

Mq power whisperwatt generator (standard)
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PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
DCA-60SSAI
WHISPERWATT
GENERATOR
MQ POWER
(Standard)
PARTS LIST NO. 7451201B
FINAL COPY
MULTIQUIP INC.
18910 WILMINGTON AVE.
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
FAX: 310-537-3927
E-mail:mq@multiquip.com
TM
PARTS DEPARTMENT:
800-427-1244
SERVICE DEPARTMENT:
800-835-2551
FAX: 310-638-8046
•
www:multiquip.com

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Summary of Contents for MQ Power WHISPERWATT DCA-60SSAI

  • Page 1 PARTS AND OPERATION MANUAL PARTS AND OPERATION MANUAL MQ POWER DCA-60SSAI WHISPERWATT GENERATOR (Standard) PARTS LIST NO. 7451201B 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 •...

  • Page 2: Dca-60Ssai — Parts And Operation Manual— Final Copy (09/15/01)

    PAGE 2 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 3 ARRANTY DEP ARRANTY DEP TMENT TMENT ARRANTY DEP ARRANTY DEPAR ARTMENT TMENT TMENT 800/835-2551 or 310/537-3700 FAX: 310/638-8046 MAIN MAIN MAIN MAIN MAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 3...

  • Page 4: Table Of Contents

    Fuel Tank Assembly ..........80-81 notice notice notice notice notice ..Enclosure Assembly ..........82-85 Rubber Seal Assembly ..........86-87 Name Plate And Decals .......... 88-89 PAGE 4 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 5: Parts Ordering Procedures

    10+ line items. Toll-free FAX: 800/6-PARTS-7 • 800-672-7877 *DISCOUNTS ARE SUBJECT TO CHANGE* Fax order discount and UPS special programs revised June 1, 1995 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 5...

  • Page 6: Rules For Safe Operation

    An explosion or fire could result causing severe bodily harm or even death. Topping-off to filler por t is dangerous, as it tends to spill fuel. PAGE 6 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 7: Rules For Safe Operation

    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. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 7...
  • Page 8 I 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 9 , doctor doctor doctor and fire department doctor doctor fire department fire department fire department fire department . ground, down a drain or into any water source. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 9...
  • Page 10 Also check the tire tread wear on both vehicles. I DO NOT transport generator with fuel in tank. I ALWAYS make sure the trailer is equipped with a "Safety Chain". Figure 1. Generator with Trailer PAGE 10 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 11 3. GVWR- Gross Vehicle Weight Rating (GVWR), is the 16. Application - Indicates which units can be employed maximum number of pounds the trailer can carry, in- on a particular trailer. cluding the fuel cell (empty). DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 11...
  • Page 12 " 6 " 7 " 4 " 4 " 2 " 3 " 8 " 3 " 8 " 3 " 4 " 6 " 4 " 6 PAGE 12 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 13 " 7 7 - ) " 3 X " " 7 6 - ) " 3 X " " 7 X " " 7 X " " 7 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 13...

  • Page 14: Trailer Safety Guidelines

    8. Repeat steps 1 through 6 on the remaining brakes. and the trailer being towed or under-adjusted brakes. PAGE 14 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 15: Trailer Safety Guidelines

    1 through 6 as referenced in the electric brake adjustments adjusted in the same manner as electric brakes. Brake section. lines should be periodically checked for cracks, kinks, or blockage. Figure 3. Hydraulic Brake Components DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 15...
  • Page 16 CAUTION: NOTE ALWAYS wear safety glasses when removing Figure 4. Major Suspension Components or installing force fitted parts. Failure to comply may result in serious injury. PAGE 16 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 17 " 2 " 3 " 4 " 5 Figure 5. Wheel Lug Nuts Tightening Sequence " 6 NOTE NEVER use an pneumatic air gun to tighten wheel lug nuts. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 17...
  • Page 18 DCA-60SSAI —TRAILER-WIRING DIAGRAM NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT PAGE 18 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 19 . r i l l u l i o n i l o i t . t c . s t c i r . t c . t s DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 19...
  • Page 20 . y l . s t n i l l l a t i s n i l l l i f i u l PAGE 20 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 21 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. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 21...
  • Page 22 DCA-60SSAI — GENERATOR DECALS PAGE 22 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 23 ( . l r h / i t p . l a r h / . l a r h / e t t l e s DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 23...

  • Page 24: General Information

    The “Control Box” is provided with the following: the mechanical governor system regulates the frequency Main Circuit Breaker 150 amps variation to ±1.5%. The electronic governor option in- Over-Current Relay creases frequency variation to ±.25%. PAGE 24 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 25: Major Components

    DCA-60SSAI — MAJOR COMPONENTS Figure 6. Major Components DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 25...

  • Page 26: Dimensions

    DCA-60SSAI — DIMENSIONS (TOP, SIDE AND FRONT) Figure 7. Dimensions PAGE 26 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 27 NOTE PAGE DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 27...
  • Page 28 DCA-60SSAI — CONTROL PANEL Figure 8. Control Panel PAGE 28 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 29 AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. Voltage Regulator Control – Allows manual adjustment of the generator’s output voltage. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 29...
  • Page 30 DCA-60SSAI — ENGINE OPERATING PANEL Figure 9. Engine Operating Panel PAGE 30 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 31 In addition, a built in hour meter will record the number of operational hours that the generator has been in use. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 31...
  • Page 32 Make sure to ground the generator in EVERY application prior to connecting a load. Generators are NOT grounded just because they are mounted on trailers or other vehicles that are on rubber tires. PAGE 32 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 33 DCA-60SSAI — OUTPUT TERMINAL VOLTAGE SELECTION DCA-60SSAI NOTE Legs O and Ground are considered Bonded Grounds. Figure 12. Output Panel Location DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 33...

  • Page 34: Output Amperage Setup

    PAGE 34 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 35: Output Amperage Setup

    When using plural single phase voltages, make sure to balance the load on each of the single Figure 13. Voltage Selector Switch 240/120V Single phase legs. Phase Position DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 35...

  • Page 36: Output Voltage Setup

    50 amps with all three wires plus ground. Figure 19. Voltage Selector Switch 480/277V Three Phase Position Figure 18. Hard Wire Hookup at 240/120V Position Figure 20. Hard Wire Hookup at 480/240V Position PAGE 36 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 37: Output Voltage Setup

    Figure 22. Hard Wire Hookup for Three Phase 480V, 440V, or 416V Figure 24. Hard Wire Hookup for Single Phase 277V, 254V, or 240V DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 37...
  • Page 38 Figure 28. Hard Wire Hookup for Single Phase 139V, 127V, Figure 26. Hard Wire Hookup for Three Phase 240V, 220V, or or 120V 208V PAGE 38 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 39 After hooking up the hard wires to the lugs as shown in Figure 30, 240 volts can be obtained with the voltage regula- tor knob turned to fine tune. Figure 30. Hard Wire Hookup for Single Phase 240 volt DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 39...

  • Page 40: Installation

    8 ft. into the ground. NOTE When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician. PAGE 40 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 41: Installation

    DCA-60SSAI — INSTALLATION Figure 32. Typical Generator Grounding Application DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 41...
  • Page 42 . t f . t f . t f . t f . t f . t f . t f t l u o r f t l o PAGE 42 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 43 Isuzu Engine Owner's Manual. ° 4 ° 3 ° 0 ° 5 - ° 3 ° 5 ° 5 - ° 5 ° 5 1 - ( ) ° 5 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 43...
  • Page 44 50%. be less than 50%. be less than 50%. be less than 50%. be less than 50%. PAGE 44 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 45 Do not put water directly on the alternator. Entry of water into the alternator leads an electrolyte corrosion causing an alternator failure. Before charging the battery with an external electric source, be sure to disconnect the battery cables. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 45...

  • Page 46: Load Application

    Three Phase Load When calculating the power requirements for 3-phase power use the following equation: PAGE 46 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 47: Generator Start-Up Procedure

    G.F circuit breakers (Figure 12) to the “OFF” position prior to starting the engine. Figure 38. Battery Connections Figure 36. Main, GFCI and Load Circuit Breakers DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 47...

  • Page 48: Generator Start-Up Procedure

    Figure 42. Key Switch (Preheat) Figure 46. Voltage Meter (Volts) PAGE 48 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 49 165 and 215 degrees fahrenheit. WATER TEMP Figure 54. Ammeter (Load) 19. The generator will run until manually stopped or an abnormal condition occurs. Figure 50. Coolant Temperature Gauge DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 49...

  • Page 50: Generator Shut-Down Procedure

    3. Let the engine cool by running it for 3-5 minutes with no load applied. Turn the key switch to ‘STOP’’ (Figure 57). Figure 57. Key Switch (OFF) Remove the load from the UVW terminal strip. PAGE 50 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 51 NOTE PAGE DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 51...

  • Page 52: Maintenance

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

  • Page 53: Maintenance

    5. Replace with coolant (see page 44, Table 14 for mixture). 6. Close radiator cap tightly. CAUTION : Allow engine to cool when flushing out radiator. Flushing the radiator while hot will damage radiator. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 53...
  • Page 54 12. The injection starting crank angle should be at the 14 timing mark. Figure 58. Valve Adjustment NOTE: Take necessary precautions to prevent dust and foreign particles in the pump interior when timing adjustments are made. PAGE 54 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 55: Generator Storage

    Completely drain the oil from the crankcase and refill with fresh oil. Clean all external parts of the generator with a cloth. Cover the generating set and store in a clean, dry place. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 55...

  • Page 56: Generator Wiring Diagram

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

  • Page 57: Engine Wiring Diagram

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

  • Page 58: Engine Troubleshooting

    PAGE 58 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 59 . e l , t e g i t i l y , t l o i s e l z . r e DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 59...
  • Page 60 Engine and Radiator Troubleshooting (Table 7). If the problem cannot be remedied, consult our company's business office or service plant. PAGE 60 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 61 NOTE PAGE DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 61...

  • Page 62: Explanation Of Codes In Remarks 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. PAGE 62 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

  • Page 63: Suggested Spare Parts

    3 ..KEYISUZUF ..KEY, STARTER SWITCH NOTE Part number on this Suggested Spare Parts list may supercede/replace the P/N shown in the text pages of this book. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 63...
  • Page 64 DCA-60SSAI --- GENERATOR ASSY. GENERATOR ASSY. PAGE 64 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 65 BOLT SET 0040010000 LOCK WASHER 0010310030 HEX. HEAD BOLT 7451340000 STATOR ASSY. 16-1 3361320122 GENERATOR FRAME 16-2 3361342024 ARMATURE CORE 16-3 7451361113 ARMATURE COIL 0801350104 GROMMET 3361315013 END BRACKET DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 65...
  • Page 66 DCA-60SSAI --- GENERATOR ASSY. GENERATOR ASSY. PAGE 66 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 67 LOCK WASHER 0010310025 HEX. HEAD BOLT 3341332103 COVER, FAN 0041606000 PLAIN WASHER 0040006000 LOCK WASHER 0010006030 HEX. HEAD BOLT 0605000011 RUBBER SUSPENSION 0040016000 LOCK WASHER 0030116000 HEX. NUT DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 67...
  • Page 68 DCA-60SSAI --- CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 68 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 69 1 ..PSK60 0~100A 0~200a 0601801040 CHANGE-OVER SW., AMMETER 1 ..SL2AS 0601800217 AC VOLTMETER 1 ..PCK60 0~600V 0601801041 CHANGE OVER SW., VOLTMETER 1 ..SL2VS 0601810072 PILOT LAMP 0601810261 BULB DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 69...
  • Page 70 DCA-60SSAI --- CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 70 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 71 HEX. HEAD BOLT 0017108020 HEX. HEAD BOLT 0030008000 HEX., NUT 0601815933 TERMINAL 1 ..S/N3312673~; AYBS0431 0601815934 TERMINAL 1 ..S/N3312673~; AYBS0441 0027105020 MACHINE SCREW 4 ..S/N3312673~ DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 71...
  • Page 72 DCA-60SSAI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PAGE 72 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 73 0602210803 ENGINE STOPPER ......1 ..1819000161 7452215104 BRACKET, ENGINE STOPPER 0027106016 MACHINE SCREW 0017108020 HEX. HEAD BOLT 7452051104 DRAIN JOINT 0805013704 PACKING, OIL PAN SIDE 0805014204 PACKING DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 73...
  • Page 74 DCA-60SSAI ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PAGE 74 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 75 HE. HEAD BOLT 0017106025 HEX. HEAD BOLT 0199500470 HOSE 0199500175 HOSE 0193602000 HOSE 0605515013 HOSE BAND 0193100950 HOSE 0605515007 HOSE BAND 0193800850 HOSE 0605515019 HOSE BAND 7452220404 EARTH CABLE DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 75...
  • Page 76 DCA-60SSAI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY. PAGE 76 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 77 HEX. NUT 0041606000 PLAIN WASHER 7455188103 SET PANEL, ELECTRIC PARTS 0017108020 HEX. HEAD BOLT 0602200405 EMERGENCY RELAY 1 ..1825500730 0027106016 MACHINE SCREW 0601823706 RELAY 1 ..JH1A DC24V DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 77...
  • Page 78 DCA-60SSAI --- ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY. PAGE 78 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 79 4 ..FROM S/N3312331 0040004000 LOCK WASHER 4 ..FROM S/N3312331 0041204000 PLAIN WASHER 8 ..FROM S/N3312331 0030104000 HEX. NUT 4 ..FROM S/N3312331 0030104000 HEX. NUT 4 ..SN3312672~ DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 79...
  • Page 80 DCA-60SSAI --- BATTERY ASSY. BATTERY ASSY. PAGE 80 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 81 0215860100 BATTERY CABLE 0602220310 TERMINAL ASSY. (+) ...... 2 ..NO.9P 0208008000 WING NUT ........2 0602220311 TERMINAL ASSY.(-) ......2 ..NO.9N 0208008000 WING NUT ........2 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 81...
  • Page 82 DCA-60SSAI --- MUFFLER ASSY. MUFFLER ASSY. PAGE 82 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 83 PIPE BAND 0010008030 HEX. HEAD BOLT 0041608000 PLAIN WASHER 0030008000 HEX. NUT 3342354104 COVER 3342354004 COVER 3342328104 PIPE CLAMPER 0030008000 HEX. NUT 3342359004 COVER SHEET 0017108025 HEX. HEAD BOLT DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 83...
  • Page 84 DCA-60SSAI --- FUEL TANK ASSY. FUEL TANK ASSY. PAGE 84 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 85 0191300530 SUCTION HOSR 0191300650 RETURN HOSE 0605515014 HOSE BAND 0845032204 DRAIN JOINT 0150000018 O RING 0802011104 PLUG 0193100255 FUEL GAUGE HOSE 0605515079 HOSE BAND 0131906000 1 ..S/N3312673~ DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 85...
  • Page 86 DCA-60SSAI --- ENCLOSURE ASSY. ENCLOSURE ASSY. PAGE 86 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 87 INDICATE COLOR OF UNIT: 1-ORANGE 5 -BLACK 2-WHITE 6 -CATERPILLAR YELLOW 3 -SPECTRUM GRAY 7 -CATO GOLD 4 -SUNBELT GREEN 8 -RED THE SERIAL NUMBER MAY BE REQUIRED. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 87...
  • Page 88 DCA-60SSAI --- ENCLOSURE ASSY. ENCLOSURE ASSY. PAGE 88 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 89 INDICATE COLOR OF UNIT: 1-ORANGE 5 -BLACK 2-WHITE 6 -CATERPILLAR YELLOW 3 -SPECTRUM GRAY 7 -CATO GOLD 4 -SUNBELT GREEN 8 -RED THE SERIAL NUMBER MAY BE REQUIRED. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 89...
  • Page 90 DCA-60SSAI --- RUBBER SEAL ASSY. RUBBER SEAL ASSY. PAGE 90 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 91 7455104404 RUBBER SEAL 7455104504 RUBBER SEAL 7455104604 RUBBER SEAL 7455104704 RUBBER SEAL 7455104804 RUBBER SEAL 7455104904 RUBBER SEAL 7455116504 COVER 1 ....S/N3312673~ 0017108020 HEX. HEAD BOLT 2 ....S/N3312673~ DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 91...
  • Page 92 DCA-60SSAI --- DECALS DECAL ASSY. PAGE 92 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 93 DECAL; WARNING HOT COOLANT ......1 ..B90410010 B9504000304 DECAL; CAUTION HOT PARTS ......... 1 ..B90400030 7450630703 STRIPE ................ 1 ..REPLACES B4561100103 B4561100403 STRIPE B4561100503 STRIPE B4561100604 STRIPE B4561100304 STRIPE B4561100003 STRIPE DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 93...
  • Page 94 ISUZU 6BD1 — CYLINDER HEAD COVER ASSY. CYLINDER HEAD COVER ASSY. PAGE 94 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 95 1111801531 CYL. HEAD COVER ASSY. 9117510381 OIL FILLER CAP 5111790520 BREATHER HOSE NIPPLE 1 ..REPLACES 9143193681 1111730590 CYL. HEAD COVER PACKING 9111790300 COVER PACKING 9111791050 WASHER 9111750110 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 95...
  • Page 96 ISUZU 6BD1 — CYLINDER BLOCK ASSY. CYLINDER BLOCK ASSY. PAGE 96 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 97 WATER DRAIN COCK PACKING ......1 ..REPLACES 9099212420 9099148600 VINYL PIPE WITH DRAIN, L=510 8970157540 RUBBER HOSE CLIP 9112298010 CYLINDER HEAD DOWEL 5117401220 AIR BREATHER ASSY. 9091105080 NUT ................ 2 ..REPLACES 9091104080 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 97...
  • Page 98 ISUZU 6BD1 — CYLINDER BLOCK ASSY. CYLINDER BLOCK ASSY. PAGE 98 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 99 OIL PORT COVER ..........1 ..AUG. 90~ 9019708180 BOLT ..............2 ..UP TO JUL. 90; REPLACES 0501408180 0501408200 BOLT ..............2 ..AUG. 90~ 8942351570 DISTANCE CLIP PIECE ........2 ..NOT SHOWN DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 99...
  • Page 100 ISUZU 6BD1 — TIMING GEAR CASE ASSY. TIMING GEAR CASE ASSY. PAGE 100 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 101 BOLT ............... 5 ..REPLACES 9010558550 9091605080 PLAIN WASHER 9091505080 LOCK WASHER 5113210090 TIMING CHECK COVER 1112820130 COVER PACKING ........... 2 ..REPLACES 1112820090 0500406140 BOLT ............... 4 ..REPLACES 9019006140 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 101...
  • Page 102 ISUZU 6BD1 — FLYWHEEL HOUSING ASSY. FLYWHEEL HOUSING ASSY. PAGE 102 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 103 BOLT ............... 5 ..REPLACES 9910664500 999104140 9096510690 PLAIN WASHER 5096250141 OIL SEAL ............1 ..UP TO MAR. 84 1096253620 OIL SEAL ............1 ..APR. 84~ 9123631460 OIL SEAL SPACER DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 103...
  • Page 104 ISUZU 6BD1 —OIL PAN ASSY. OIL PAN ASSY. PAGE 104 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 105 CAP ..........1 ..REPLACES 1117500120; UP TO APR. 89 53-2 1117500241 OIL FILLER CAP ......1 ..MAY 89~ 9099129760 RUBBER HOSE 9099155531 CLIP 9091104080 9091505080 LOCK WASHER DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 105...
  • Page 106 ISUZU 6BD1 — OIL PUMP ASSY. OIL PUMP ASSY. PAGE 106 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 107 VALVE SEAT 22#& 9081040300 VALVE PIN 23#& 1131230160 COUPLING 24#& 1131280180 PINION 26#& 9131190100 COLLAR 36#& 1131400860 STRAINER ASSY. 0500410250 BOLT ..........2 ... REPLACES 9019110250 9131190100 COLLER DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 107...
  • Page 108 ISUZU 6BD1 — CRANKSHAFT ASSY. CRANKSHAFT ASSY. PAGE 108 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 109 RING GEAR, Z=129 T=22 9920616380 BOLT ..........6 ... REPLACES 9098013340 5123360081 WASHER, ID=48 5097380010 FEATHER KEY 9125210430 CRANKSHAFT GEAR 1123620031 THROWER 5123712072 PULLEY 5123620031 THROWER 9098401071 CLAW 9098514310 WASHER DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 109...
  • Page 110 ISUZU 6BD1 — CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY. CAMSHAFT, IDLE GEAR, ROCKER ARM ASSY. PAGE 110 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 111 BOLT, FRONT BRACKET 9098514300 PLAIN WASHER ........10 ..... UP TO AUG. 87 9098514300 PLAIN WASHER ......... 9 ..... SEPT. 87~ 1094001160 NUT ............. 4 ..... REPLACES 9091123080 9098514300 PLAIN WASHER DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 111...
  • Page 112 ISUZU 6BD1 — OIL AND FUEL FILTER ASSY. OIL AND FUEL FILTER ASSY. PAGE 112 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 113 BOLT .............. 2 ..UP TO OCT. 87 0501410350 BOLT .............. 2 ..NOV. 87~ 101-1 9098009281 BOLT, L=145 9091505100 LOCK WSAHER 9091605100 PLAIN WASHER 9091104100 9095720100 OIL FILTER PACKING DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 113...
  • Page 114 ISUZU 6BD1 — OIL AND AIR PIPE ASSY. OIL AND AIR PIPE ASSY. PAGE 114 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 115 O RING ......... 2 ..... NOV. 87~ 0500408400 BOLT ........4 ..... REPLACES 9019108400 5133112050 OIL PIPE ASSY....1 ..... INCL. ITEM W/# 9099171050 CLIP 1096308830 PACKING 9098440220 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 115...
  • Page 116 ISUZU 6BD1 — COOLING SYSTEM ASSY. COOLING SYSTEM ASSY. PAGE 116 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 117 THERMOSTAT JOINT ....1 ....REPLACES 5137130161 5137700310 THERMOSTAT, 82-95C ....1 ....UP TO APR. 85 1137700700 THERMOSTAT, 85-95C ....1 ....MAY 85~ 9096640050 COCK PLUG 9096620340 HEATER PLUG 5137210152 WATER PIPE DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 117...
  • Page 118 ISUZU 6BD1 — COOLING SYSTEM ASSY. COOLING SYSTEM ASSY. PAGE 118 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 119 BOLT ........15 ....REPLACES 9019708280 0501408200 BOLT ......... 2 ....UP TO APR. 91;REPLACES 9019708200 1090300910 BOLT ......... 2 ....MAY 91~ 0501408450 BOLT ........12 ....REPLACES 9019708450 9091605080 PLAIN WASHER DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 119...
  • Page 120 ISUZU 6BD1 — INTAKE AND EXHAUST ASSY. INTAKE AND EXHAUST ASSY. PAGE 120 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 121 INLET PACKING ..... 1 ....UP TO OCT. 87 1141150540 INLET PACKING ..... 1 ....NOV. 87~ 76-1 1096370560 SHUTTER PIPE PACKING ..1 ....REPLACES 1096370470 9091104100 9091505100 LOCK WASHER 5093603200 RUBBER HOSE 109700870 CLIP DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 121...
  • Page 122 ISUZU 6BD1 — FUEL SYSTEM ASSY. FUEL SYSTEM ASSY. PAGE 122 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 123 1154129180 FILTER LEAK OFF PIPE ASSY. 1096300850 PACKING 5197890030 BRACKET 9091505100 LOCK WASHER 0208010200 BOLT ..........2 ..REPLACES 9020510200 5132600101 OVER FLOW VALVE 1096300850 VALVE FIXTURE PACKING DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 123...
  • Page 124 ISUZU 6BD1 — ENGINE FOOT AND HANGER ASSY. ENGINE FOOT AND HANGER ASSY. PAGE 124 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 125 9091505100 LOCK WASHER 9091607100 PLAIN WASHER 9091646100 PLAIN WASHER ......1 ....UP TO SEP. 87 9091607100 PLAIN WASHER ......1 ....OCT. 87~ 9091505100 LOCK WASHER 9091104100 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 125...
  • Page 126 ISUZU 6BD1 — INJECTION PUMP ASSY. INJECTION PUMP ASSY. PAGE 126 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 127 FEED PUMP ASSY....1 ....REPLACES 1157500280 5157810030 INJ. PUMP COUPLING 1197510400 BRACKET 9884105020 5156190480 WASHER 9096620070 BOLT 1095390070 PLATE ........1 ....REPLACES 5095390060 41-2# 1156192450 PLATE 5125240570 GEAR 9019006140 BOLT DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 127...
  • Page 128 ISUZU 6BD1 — ELECTRICAL ASSY. ELECTRICAL ASSY. PAGE 128 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 129 9825300430 RESISTANCE CONTROL, 24V 1819000161 ENGINE STOPPER ASSY....1 ....INCL. ITEM W/% 82-1 1819001931 ENGINE STOPPER ASSY. W/COVER 1 1828490430 CABLE ASSY., L=460 9829322110 STARTER-FRAME CABLE ASSY. DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 129...
  • Page 130 ISUZU 6BD1 — INJ. PUMP COMP. ASSY. INJECTION PUMP COMP. ASSY. PAGE 130 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 131 SHIM, T=+1.45 5156191060 SHIM, T=+1.50 5156191100 SHIM, T=+1.55 5156191070 SHIM, T=+1.60 5156190110 SHIM, T=+0.55 5156190120 SHIM, T=+0.65 5156190130 SHIM, T=+0.75 5156190150 SHIM, T=+0.85 5156190250 SHIM, T=+0.20 5156190260 SHIM, T=+0.25 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 131...
  • Page 132 ISUZU 6BD1 — INJ. PUMP COMP. ASSY. INJECTION PUMP COMP. ASSY. PAGE 132 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 133 SHIM, T=1.00 5156190390 SHIM, T=+0.70 1156190900 SHIM, T=+1.40 5156290150 SHIM, T=+0.10 5156290160 SHIM, T=+0.12 5156290170 SHIM, T=+0.14 5156290180 SHIM, T=+0.16 51562901190 SHIM, T=+0.18 5156290200 SHIM, T=+0.50 5156290210 SHIM, T=+0.30 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 133...
  • Page 134 ISUZU 6BD1 — INJ. PUMP COMP. ASSY. INJECTION PUMP COMP. ASSY. PAGE 134 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 135 1156190330 BEARING 9884100660 SCREW 9812250430 WASHER 1156290470 COVER 1156192820 BOLT 5835390240 WOODRUFF KEY 5156191360 PLUB 9091606100 WASHER 9091506100 WASHER 5156390020 1156192660 BRACKET 1156290490 PACKING 9041010300 STUD 1156290480 GASKET DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 135...
  • Page 136 ISUZU 6BD1 — GOVERNOR COMP. ASSY. GOVERNOR COMP. ASSY. PAGE 136 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 137 5157292860 SHIM, T=+0.50 5157292870 SHIM, T=+0.50 9008121300 SPRING 9813222350 SPRING 5157231240 CAPSULE 5157292090 1156390080 GASKET 5157230990 CAPSULE 9008130230 9813217210 LEVER 1157292930 BUSH 9813212050 O RING 9091854150 SNAP RING DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 137...
  • Page 138 ISUZU 6BD1 — GOVERNOR COMP. ASSY. GOVERNOR COMP. ASSY. PAGE 138 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 139 1157292940 SHIM, T=+0.20 111# 9813252100 112# 5157230640 SPRING 116# 1157290010 GASKET 117# 1157290020 GASKET 120# 5157250420 LEVER ASSY. 148# 5157291120 BOLT 149# 9091505080 LOCK WASHER 150# 5157230880 SPRING DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 139...
  • Page 140 ISUZU 6BD1 —FEED PUMP ASSY. FEED PUMP ASSY. PAGE 140 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 141 O RING ........... 1 ....REPLACES 1096230160 9813517020 SPRING 1096750630 BOLT 1157590110 BOLT 1157590120 PACKING 1157590030 ADAPTER 1196230160 O RING ........... 1 ....REPLACES 1096230160 9813550250 SNAP RING 8941311300 PUMP DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 141...
  • Page 142 ISUZU 6BD1 — NOZZLE ASSY. NOZZLE ASSY. PAGE 142 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 143 HOLDER ASSY......6 ....REPLACES 5153300190; INCL. ITEMS W/# 5153410010 PUSH ROD 9153470030 9153430130 SPRING 5153450010 SCREW 9153390570 WASHE 5153340010 9153390560 GASKET 5153320020 5153390030 GASKET 5153490020 CONNECTOR 5153490010 BOLT 9095714080 PAKCING, T=1.0 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 143...
  • Page 144 ISUZU 6BD1 — STARTER ASSY, STARTER ASSY. PAGE 144 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 145 9821161400 INSULATE BUSING 5811291480 CONNECTOR 5811180190 HOLDER 5811291510 WASHER 5811291520 BOLT 5811291500 TERMINAL ASSY 9821161420 WASHER 5811291490 CLI RING 1811291140 WASHER 5811292140 BOLT 100# 1811293940 STARTER SEAL KIT DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 145...
  • Page 146 ISUZU 6BD1 — ALTERNATOR ASSY. ALTERNATOR ASSY. PAGE 146 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 147 1812292330 PACKING 1812291350 WASHER 1812170230 HOLDER ASSY. 1812292260 PACKING 1812292320 PACKIG 1812220340 PULLEY ASSY. 1812290970 BOLT 1812510240 VOLTAGE REGULATOR .... 1 ....NOT SHOWN 1812295960 9822190270 LOCK WASHER DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 147...
  • Page 148 ISUZU 6BD1 — ACCESSORIES ACCESSORIES PAGE 148 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 149 TACHO DRIVE ELBOW ASSY. . 1 1096231800 PACKING ........1 ....UP TO OCT. 87 1096234650 PACKING ........1 ....NOV. 87~ 0500408200 BOLT ......... 2 ....REPLACES 9019108200 DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 149...

  • Page 150: Terms And Condition Of Sale — Parts

    RMA. products on the face hereof. A copy of the Return Material Authorization must accompany the return shipment. PAGE 150 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)
  • Page 151 NOTE PAGE DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 151...
  • Page 152 TMENT TMENT 800/835-2551 or 310/537-3700 FAX: 310/638-8046 MAIN MAIN MAIN MAIN MAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927 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 •...

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