MULTIQUIP DCA-45USI Specifications

PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
BRAND SERIES
MODEL DCA-45SSIU2
WHISPERWATT™
GENERATOR
(STANDARD)
PARTS LIST NO. M1870300034A
Revision #7 (06/13/07)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
Diesel engine exhaust and some of
PAGE 2 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
NOTE PAGE
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 3
TABLE OF CONTENTS
MQ POWER DCA-45SSIU2 ISUZU 4BG1 ENGINE
Cylinder Head Cover Assembly ......................... 86-87
AC GENERA
TOR
GENERATOR
Here's How To Get Help ............................................. 3
Table Of Contents ....................................................... 4
Parts Ordering Procedures ........................................ 5
DCA-45SSIU2 Specifications...................................... 6
Dimensions ............................................................... 7-8
Safety Message Alert Symbols ........................... 10-11
Rules for Safe Operation ..................................... 12-15
Installation ............................................................ 16-17
Towing Safety Precautions ....................................... 18
Trailer Specifications ............................................ 19-21
Generator Decals ................................................. 22-23
General Information .................................................. 24
Major Components ................................................... 25
Generator Control Panel ........................................... 26
Engine Operating Panel ............................................ 27
Output Terminal Panel Familiarization................. 28-30
Load Application........................................................ 31
Generator Outputs ............................................... 32-33
Gauge Reading ......................................................... 33
Output Terminal Panel Connections .................... 34-35
Pre-setup .............................................................. 36-40
Generator Start-up Procedure ............................ 41-43
Generator Shut-down Procedure ............................. 44
Maintenance ......................................................... 45-47
Trailer Brakes Maintenance ...................................... 48
Trailer Maintenance ............................................. 49-50
Trailer Wiring Diagram .............................................. 51
Engine Wiring Diagram ........................................ 52-53
Generator Wiring Diagram ....................................... 54
Engine Troubleshooting ....................................... 55-56
Generator Troubleshooting ....................................... 57
Explanation of Codes in Remarks Column .............. 58
Suggested Spare Parts ............................................ 59
COMPONENT DRA
WINGS
DRAWINGS
Generator Assembly ........................................... 60-61
Control Box Assembly ......................................... 62-65
Engine & Radiator Assembly .............................. 66-67
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
Cylinder Head Assembly .................................... 88-89
Cylinder Block Assembly .................................... 90-91
Oil Pan and Level Gauge Assembly ................... 92-93
Camshaft and Valve Assembly ........................... 94-95
Crankshaft, Piston and Flywheel Assembly ...... 96-97
Timing Gear and Flywheel Housing Assembly ........ 98-99
Engine Mounting Assembly ............................ 100-101
Inlet Manifold Assembly .................................. 102-103
Exhaust Manifold Assembly ............................ 104-105
Ventilation Assembly ....................................... 106-107
Water Pump and Corrosion Resistor Assembly ... 108-109
Thermostat and Housing Assembly ............... 110-111
Engine Water Piping Assembly ....................... 112-113
Fan and Fan Belt Assembly ............................ 114-115
Fuel Injection Assembly .................................. 116-117
Fuel Filter and Bracket Assembly .................. 118-119
Fuel Pump and Piping Assembly ................... 120-121
Oil Cooler and Oil Filter Assembly ................. 122-123
Oil Pump and Oil Strainer Assembly .............. 124-125
Oil and Vacuum Piping Assembly ................... 126-127
Electrical Control Assembly ............................ 128-129
Battery Relay Assembly .................................. 130-131
Starter Component Assembly ........................ 132-133
Inj. Pump Component Assembly .................... 134-137
Governor Component Assembly .................... 138-141
Feed Pump Assembly ..................................... 142-143
Misc. Inj. Pump Assembly ............................... 144-145
Coupling Assembly ......................................... 146-147
Accelerator Pedal Assembly ........................... 148-149
Air Duct Assembly ........................................... 150-151
Fuel Sedimenter Assembly ............................ 152-153
Clutch Assembly.............................................. 154-155
Switch and Relay Assembly ............................ 156-157
Terms and Condition of Sale — Parts .................. 158
NOTE
Specification and part
number are subject to
change without notice.
PAGE 4 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒
❒
❒
❒
❒
❒
❒
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:
Note: Unless otherwise indicated by customer, all
✓ FedEx or UPS Ground
orders are treated as “Standard Orders”, and will
✓ FedEx or UPS Second Day or Third Day
ship within 24 hours. We will make every effort to
✓ FedEx or UPS Next Day
ship “Air Shipments” the same day that the order is
✓ Federal Express Priority One
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
✓ DHL
✓
Truck
Here’s how to get help...
Please have the model and serial number on
hand when calling.
Parts Department
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Mayco Parts
800-306-2926
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department
800-478-1244
310-537-3700
Fax: 310-537-4259
MQ Power Service Department
800-835-2551
Fax: 310-638-8046
310-537-3700
Warranty Department
800-421-1244, Ext. 279
310-537-3700, Ext. 279
Fax: 310-537-1173
Multiquip’s Main Phone Numbers
800-421-1244
Fax: 310-537-3927
310-537-3700
MULTIQUIP INC.
18910 WILMINGTON AVENUE
POST OFFICE BOX 6254
CARSON, CALIFORNIA 90749
310-537-3700 • 800-421-1244
FAX: 310-537-3927
E-MAIL: mq@multiquip.com
WWW: multiquip.com
Place Your Parts Order Via Web or Fax
For Even More Savings!
Extra Discounts!
All parts orders which include complete part numbers
and are received by our automated web parts order
system, or by fax qualify for the following extra
discounts:
Ordered
via
Fax
Standard
orders
3%
Web
5%
Stock orders
($750 list and above)
10%
10%
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other
carrier.
NOTE: DISCOUNTS ARE SUBJECT TO CHANGE
Direct TOLL-FREE access
to our Parts Department:
Toll-free nationwide — 800-427-1244
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 5
DCA-45SSIU2 — SPECIFICATIONS
Table 1. Generator Specifications
Model
DCA-45SSIU2
Type
Revolving field, self ventilated, open protected type synchronous
generator
Armature Connection
Star with Neutral
Zig Zag
P ha s e
3
S in g le
Standby Output
47.7 KVA (38.2 KW)
27.6 KW
Prime Output
45 KVA (36 KW)
2 6 KW
Voltage
240V or 48 0V
240/120V
Frequency
60 Hz
Speed
1,800 rpm
Power Factor
0.8
1
Aux. AC Power
Single Phase, 60 Hz
Voltage
120 VAC
Output
4.8 KW (2.4 KW x 2)
Engine Specifications
Model
ISUZU B-4BG1
Type
4 Cycle, water-cooled, direct injection
No. of Cylinders
4 cylinders
Bore x Stroke
4.13 in. x 4.92 in. (105 mm x 125 mm)
Rated Output
55.2 HP/1,800 rpm
Displacement
268 cu. in. (4,392 cc)
Starting
Electric
Coolant Capacity
5.3 gal. (20 liters)
Lube Oil Capacity
3.4 gal. (12.9 liters)
2.7 gal. (10.3L)/hr at full load
2.0 gal. (7.6L)/hr at 3/4 load
1.5 gal. (5.7L)/hr at 1/2 load
1.1 gal. (4.2L)/hr at 1/4 load
Fuel Consumption
Battery
12V- 100AH
Fue l
#2 Diesel Fuel
PAGE 6 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — DIMENSIONS (SIDE AND FRONT)
Figure 1. Dimensions
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 7
DCA-45SSIU2 — DIMENSIONS (TOP AND REAR)
Figure 2. Dimensions
PAGE 8 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
NOTE PAGE
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 9
DCA-45SSIU2 — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
Safety precautions should be followed at all times when operating
this equipment. Failure to read and understand the Safety
Messages and Operating Instructions could result in injury to
yourself and others.
NOTE
This Owner's Manual has been
developed to provide complete
instructions for the safe and efficient
operation of the MQ Power Model
DCA45SSIU2 WHISPERWATT™
GENERATOR.
Before using this GENERATOR, ensure that the operating
individual has read and understands all instructions in this
manual.
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
the operator, and are preceded by one of three words: DANGER,
WARNING, or CAUTION.
HAZARD SYMBOLS
Lethal Exhaust Gases
Engine exhaust gases contain poisonous
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined
area or enclosed structure that does not
provide ample free flow air.
Explosive Fuel
Diesel fuel is extremely flammable, and its
vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use fuel as a cleaning agent.
Burn Hazards
DANGER:
You WILL be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
Engine components can generate extreme heat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. NEVER operate the engine with
heat shields or heat guards removed.
WARNING:
You CAN be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
CAUTION: You CAN be injured if you
DO NOT follow directions.
Rotating Parts
NEVER operate equipment with covers, or
guards removed. Keep fingers, hands, hair
and clothing away from all moving parts to
prevent injury.
Potential hazards associated with trowel operation will be
referenced with "Hazard Symbols" which appear throughout
this manual, and will be referenced in conjunction with Safety
"Message Alert Symbols".
PAGE 10 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — SAFETY MESSAGE ALERT SYMBOLS
Accidental Starting
ALWAYS place the engine ON/OFF switch
in the OFF position, when the trowel is not
in use.
Over Speed Conditions
NEVER tamper with the factory settings of the
engine governor or settings. Personal injury
and damage to the engine or equipment can
result if operating in speed ranges above
maximum allowable.
Respiratory Hazard
ALWAYS wear approved respiratory protection.
Sight and Hearing hazard
ALWAYS wear approved eye and hearing
protection.
Equipment Damage Messages
This generator, other property, or
NOTE
the surrounding environment could
be damaged if you do not follow
instructions.
Other important messages are provided throughout this manual
to help prevent damage to your trowel, other property, or the
surrounding environment.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 11
DCA-45SSIU2 — RULES FOR SAFE OPERATION
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
Failure to follow instructions in this manual may
these parts to cool before servicing
lead to serious injury or even death! This
engine or generator.
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 ■ High Temperatures – Allow the engine to cool before
operating the DCA-45SSIU2 Generator:
performing service and maintenance functions. Contact
with hot! components can cause serious burns.
GENERAL SAFETY
CAUTION
CAUTION:
■ DO NOT operate or service this equipment
before reading this entire manual.
■ This equipment should not be operated by persons under 18
years of age.
■ NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steeltoed boots and other protective devices required
by the job.
■ NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage to
the equipment and/or injury to user may result.
■ Manufacture 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.
■ 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.
■ The engine of this
generator requires an
adequate free flow of
cooling air. NEVER
operate the generator
in any enclosed or
narrow area where free
flow of the air is
restricted. If the air flow
is restricted it will
cause serious damage to the generator or engine and
may cause injury to people. The generator engine gives
off DEADLY carbon monoxide gas.
■ ALWAYS make sure generator is properly grounded.
■ NEVER use gas piping as an electrical ground.
■ DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■ ALWAYS make sure generator installation is accordance with
national and local electrical codes.
■ ALWAYS have a qualified electrician perform the generator
wiring installation.
■ NEVER power cables or cords lay in water.
■ NEVER stand in water while AC power from the generator
is being transfer to a load.
■ NEVER use a defective or frayed power cable. Check the
cable for cuts in the insulation.
■ NEVER use a extension cord that is frayed or damaged where
the insulation has been cut.
■ ALWAYS make certain that proper extension cord has been
selected for the job See Table 5.
■ The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits. Turn all circuit breakers OFF before
performing maintenance on the generator.
PAGE 12 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — RULES FOR SAFE OPERATION
■ ALWAYS make sure that electrical circuits are properly
grounded per the National Electrical Code (NEC) and local
codes before operating generator. Severe injury or death! by
electrocution can result from operating an ungrounded
generator.
■ ALWAYS be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.
■ ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children.
■ ALWAYS read, understand, and follow
procedures in Operator’s Manual before
attempting to operate equipment.
DANGER
DANGER:
Never use damaged or worn cables when
connecting 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.
WET
DANGER
DANGER:
DANGER
DANGER:
HANDS
NEVER grab or
touch a live
power cord with
wet hands , the POWER
CORD
possibility exists (POWER
ON)
of electrical shock, electrocution, and even
death!
.
DANGER
DANGER:
■ 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. ALWAYS have a licensed electrician
perform the installation
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.
Radiator
1. Radiator Cap - Removing the radiator cap while the engine
is hot will result in high pressurized, boiling water to gush
out of the radiator, causing severe scalding to any persons
in the general area of the generator.
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush out
of the coolant drain plug, therefore causing severe scalding
to any persons in the general area of the generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush out
of the oil drain plug, therefore causing severe scalding to
any persons in the general area of the generator.
Maintenance Safety
■ NEVER lubricate components or attempt service on a running
machine.
■ ALWAYS allow the machine a proper
amount of time to cool before servicing.
■ NEVER touch output terminals during operation. This is
extremely dangerous. ALWAYS stop the machine and ■ Keep the machinery in proper running condition.
place the circuit breaker in the “OFF” position when contact ■ Fix damage to the machine immediately and always replace
with the output terminals is required. There exists the
broken parts.
possibility of electrocution, electrical shock or burn,
which can cause severe bodily harm or even death!
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 13
DCA-45SSIU2 — RULES FOR SAFE OPERATION
■ NEVER Run engine without air filter. Severe engine
damage may occur.
■ ALWAYSservice air cleaner frequently to prevent engine
malfunction.
■ ALWAYS disconnect the negative battery terminal before
performing service on the generator.
Battery
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 be sure the operator is familiar with proper safety
precautions when operating the generator set.
■ ALWAYS store equipment properly when not in use.
■ DO NOT leave the generator running in the manual mode
unattended.
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
■ DO NOT allow unauthorized people to operate this
equipment.
2. DO NOT expose the battery to
open flames, sparks, cigarettes
etc. The battery contains
■ ALWAYS read, understand, and follow procedures in
combustible gases and liquids. If
Operator’s Manual before attempting to operate equipment.
these gases and liquids come in
■ Refer to the Isuzu Engine Owner's Manual for engine
contact with a flame or spark, an
technical questions or information.
explosion could occur.
3. ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
DANGER:
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.
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and specifies
that the cable ground shall be connected to the grounding
system of the building as close to the point of cable entry
as practical.
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the UVWO output terminals.
4. ALWAYS keep battery charging and cables in good working
condition. Repair or replace all worn cables.
5. ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with plenty
of water, then contact the nearest doctor or hospital, and
seek medical attention.
Transporting
■ ALWAYS shutdown engine before transporting.
■ Tighten both fuel tank caps securely.
■ If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See next page “Towing Safety Precautions” for
basic towing techniques.
PAGE 14 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — RULES FOR SAFE OPERATION
Towing Safety Precautions
■ Avoid sharp turns.
CAUTION:
■ Trailer should be adjusted to a level position at all times
when towing.
Conform to Department of Transportation
(DOT) Safety Towing Regulations before
towing generator.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
■ Raise and lock trailer wheel stand in up position when
transporting.
■ DOT Requirements include the following:
z Connect and test electric brake operation.
z Secure portable power cables in cable tray with
tie wraps.
Emergencies
■ ALWAYS know the location of the nearest fire extinguisher.
The following list of suggestions should be used when towing
your generator:
■ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR) of 6,000 lbs.
■ ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■ Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■ ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■ ALWAYS know the location of the nearest and first aid kit.
■ In emergencies always know the location of the
nearest phone or keep a phone on the job site.
Also know the phone numbers of the nearest
ambulance, doctor and fire department. This
information will be invaluable in the case of an
emergency.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ The maximum speed for highway towing is 45 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of
terrain.
■ Place chock blocks underneath wheel to prevent rolling,
while parked.
■ Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
■ Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 15
DCA-45SSIU2 — INSTALLATION
Figure 3.
Typical Generator Grounding Application
PAGE 16 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — INSTALLATION
Outdoor Installation
Generator Grounding
Install the generator in a clear area. 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.
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTION
CAUTION:
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements. Engine exhaust must be
routed to a ventilated area.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 3) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
NOTE
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 17
DCA-45SSIU2 — TOWING SAFETY PRECAUTIONS
Towing Safety Precautions
CAUTION
CAUTION:
Check with your local county or state safety
towing regulations before towing your
generator.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 4) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.
The following list of suggestions should be used when towing
your generator:
■ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■ ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■ Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■ ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■ Place chocked blocks underneath wheel to prevent
rolling, while parked.
■ Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
■ Use the trailer’s hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.
■ Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■ Avoid sharp turns to prevent rolling.
■ Remove wheel stand when transporting.
■ DO NOT transport generator with fuel in tank.
Figure 4. Generator with Trailer
PAGE 18 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — TRAILER SPECIFICATIONS
CAUTION
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. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage
to the equipment and personal injury.
It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:
„ Brakes
„ Tires
„ Lug Nut Torquing
„ Suspension
„ Electrical
„ Brake Troubleshooting Tables
Use the following definitions when reading Table 2.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when transporting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, including the fuel cell (empty).
4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).
5. Frame Length - Measurement is from fender to fender
6. Jack Stand - Trailer support device with maximum pound
requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug nuts.
See Table 17 and Figure 67 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed
in inches (see Table 2). 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.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 19
DCA-45SSIU2 — TRAILER SPECIFICATIONS
Table 2. Trailer 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
D C A 10,
TLG12, DCA15
NO
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-10XF
DCA10, TLG12, D C A 15,
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 .
FULL TILT WHEEL
TRLR-BLW400
BLW-400
NO
ELECTRIC
2700LB S
W/MAST
154"
W/O 124"
55"
(78"
TALL)
800LB .
FULL TILT WHEEL
TRLR-50X
DCA-25
NO
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TRLR-50XF
DCA-25
41 GAL
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TRLR-70W
DCA-45, -60,
70
NO
SURGE
7000LB S
186"
77"
2000LB .
FLAT PAD
TRLR-70X
DCA-45, -60,
70
OPT
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TRLR-70XF
DCA-45, -60,
70
53 GAL
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TRLR-100XF
DCA-100, 125
150 GAL
HYDRAULIC
SURGE
7000LB S
190"
76"
2000LB .
FLAT PAD
TRLR-85/125
DCA-85, 100,
125
145 GAL
HYDRAULIC
10000LB S
186"
77"
2000LB .
FLAT PAD
TRLR-150XF
DCA-150, 180
200 GAL
HYDRAULIC
SURGE
11160LBS
204"
84"
5000 LB .
FLAT PAD
TRLR-220XF
DCA-220
250 GAL
HYDRAULIC
SURGE
14000LB S
222"
83"
5000 LB .
FLAT PAD
TRLR-300XF
DCA-300
250 GAL
HYDRAULIC
SURGE
18000LB S
238"
83"
5000 LB .
FLAT PAD
TRLR-400XF
DCA-400
350 GAL
ELECTRIC
18000LB S
238"
83"
5000 LB .
FLAT PAD
TRLR-600XF
DCA-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
TRLR-800SX
DCA-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
PAGE 20 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — TRAILER SPECIFICATIONS
Table 2. 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"X4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-225W
2" B A LL C LA S S
2 ADJUSTABLE
175-13B
13X4.5"
2200#2X 2
5 LUG
Q F LE X
4 POLE FLAT
TRLR-BLW
400
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13 X 4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-50X
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE
RUBBER FLAT
TRLR-50XF
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE
RUBBER FLAT
TRLR-70W
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE
RUBBER FLAT
TRLR-70X
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs
3"
5 LUG
5 LE A F
4 POLE
RUBBER FLAT
TRLR-70XF
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE
RUBBER FLAT
TRLR-100XF
ADJUSTABLE 25/6 OPT 3" EYE
205-15C
BIAS (4)
14"X5.5"
3500lbs
3"
5 LUG
5 LE A F
4 WIRE LOOM
TRLR-85/125
ADJUSTABLE 25/6 OPT 3" EYE
ST225/75R15D
RADIAL (4)
14"x6"
(2)-6000lbs
6 LUG
7 LE A F
4 WIRE LOOM
TRLR-150XF
3" BALL EYE
750-16 E
BIAS (4)
16" X 7"
(2)-6000lbs
8 LUG
7 LE A F
4 WIRE LOOM
TRLR-220XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16" X 7"
(2)-7000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-300XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(2)-6000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-400XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(3)-7000lbs.
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-600XF
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
7 LE A F
6 WIRE LOOM
TRLR-800AR
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
AIR-RIDE
6 WIRE LOOM
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 21
DCA-45SSIU2 — GENERATOR DECALS
The DCA-45SSIU2 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.
PAGE 22 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — GENERATOR DECALS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 23
DCA-45SSIU2 — GENERAL INFORMATION
DCA-45SSIU2 FAMILIARIZATION
Generator
The MQ Power Model DCA-45SSIU2 (Figure 5) is a 26 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
industrial and construction machinery.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
z Tachometer
z Water Temperature Gauge/Lamp
z Oil Pressure Gauge/Lamp
z Charging Ammeter Gauge
z Engine Speed Handle
z Pre-Heat Lamp
z Panel Light
z Panel Light Switch
z Ignition/Preheat Switch
Generator Control Panel
The “Generator Control Panel” is provided with the following:
z Output Voltage Adjustment Knob
z Frequency Meter (Hz)
z AC Ammeter (Amps)
z AC Voltmeter (Volts)
z Ammeter Change-Over Switch
z Voltmeter Change-Over Switch
z Voltage Regulator
z Over-Current Relay
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
z Three 250 VAC output receptacles (CS-6369), 50 amps
z Three auxilliary circuit breakers, 250V @50 amps
z Two 125 VAC output receptacles, (GFCI), 20 amps
z Two GFCI circuit breakers, 120V@ 20amps
z Five output terminal lugs (3Ø power)
Control Box
The “Control Box” is provided with the following:
z 3-Pole, 250 VAC, 110 amp Main Circuit Breaker
z Automatic Voltage Regulator
z Current Transformer
z Emergency Relay
Open Delta Excitation System
The DCA-45SSIU2 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.
There are four connections of the open delta A, B, C and D. During
steady state loads, the power from the voltage regulator is supplied
from the parallel connections of A to B, A to D, and C to D.These three
phases of the voltage input to the voltage regulator are then rectified
and are the excitation current for the exciter section.
When a heavy load, such as a motor starting or a short circuit occurs,
the automatic voltage regulator (AVR) switches the configuration of
the open delta to the series connection of B to C. This has the effect
of adding the voltages of each phase ot provide higher excitation to
the exciter section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are for
sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation current,
offering maximum motor starting capabilities. The excitation does
not have a "fixed ceiling" and responds according the demands of
the required load.
Engine
The DCA-45SSIU2 is powered by a 4 cycle, water cooled,
turbocharged Isuzu 4BG1 diesel engine. This engine is designed
to meet every performance requirement for the generator. Reference
Table 1 for engine specifications.
In keeping with Multiquip's policy of constantly improving its products,
the specifications quoted herein are subject to change without prior
notice.
The basic controls and indicators for the DCA-45SSIU2 generator
are addressed on the following pages.
Mechanical Governor System
The mechanical governor system control the RPM of the engine.
When the engine demands increase or decrease, the mechanical
governor system regulates the frequency variation to ±.5%. The
electronic governor option increases frequency variation to
±0.25%.
Extension Cables
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 chart
(Table 5 ) as a guide for selecting proper extension cable size.
PAGE 24 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — MAJOR COMPONENTS
Figure 5. Major Components
Table 3. Generator Major Components
ITEM NO.
DESCRIPTION
1
Muffler Assembly
2
Engine Assembly
3
Generator Assembly
4
Output Terminal Assembly
5
Fuel Tank Assembly
6
Batter y Assembly
7
Generator Control Panel Assembly
8
Engine Operating Panel Assembly
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 25
DCA-45SSIU2 — GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
The definitions below describe the controls and functions of Located behind the generator control panel is the Generator
the DCA-45SSIU2 "Generator Control Panel " (Figure 6). Control Box. This box contains some of the necessary
1. Main Circuit Breaker – This three-pole, 110 amp main electronic components required to make the genertator
breaker is provided to protect the UVWO output function.
2.
3.
4.
5.
6.
7.
The “Control Box” is equipped with the following major
components:
z Over-Current Relay
z Voltage Rectifer
z Starter Relay
Ammeter Change-Over Switch – This switch allows z Engine Controller (Computer Controlled)
the AC ammeter to indicate the current flowing to the z Current Transformer
load connected to any phase of the output terminals, or z Voltage Selector Switch
to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.
Remember the overcurrent
Voltmeter Change-Over Switch – This switch allows
relay monitors the current
the AC voltmeter to indicate phase to phase voltage
flowing from the UWVO output
between any two phases of the output terminals or to
terminals to the load.
NOTE
be switched off.
In the event of a short circuit or
Voltage Regulator Control – Allows ±15% manual
over current condition, it will
adjustment of the generator’s output voltage.
automatically trip the main 250
amp breaker.
Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
To restore power to the UWVO output terminals, press the
AC Voltmeter – Indicates the output voltage present reset button on the overcurrent relay and place the main
circuit breaker in the closed position (ON).
at the UVWO terminals.
terminals from overload.
AC Ammeter – Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
PAGE 26 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
The definitions below describe the controls and functions of 7.
the DCA-45SSIU2 "Engine Operating Panel " (Figure 7).
1. Panel Light - Normally used in dark places or at night. 8.
When activated, panel will luminate. When the generator
is not in use, turn the panel light switch to the ‘OFF’
position.
2.
3.
4.
5.
6.
Panel Light Switch- When activated, will turn on control
9.
panel light.
Water Temperature Lamp - Indicates that the water 10.
temperature is outside of normal range and will shut
down the engine.
Starter Switch – Four position switch, pre-heat, stop,
run and start. Insert ignition key to start and stop engine.
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.
Fuel Gauge - Indicates amount of diesel fuel available.
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.
Oil Pressure Lamp - Indicates that the oil pressure is
11. Water Temperature Gauge – During normal operation
too low or high and will shut down the engine.
this gauge be should read between 165o F to 215o F.
Pre-heat Lamp - This indicates when the engine is
ready for starting during cold weather operating 12. Oil Pressure Gauge – Normal operation should be about
25 psi. When starting the generator the oil pressure
conditiions.
may read a bit higher, but after the engine warms up
Engine Speed Handle- This handle will change the
the oil pressure should return to normal.
speed of the engine from high to low.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 27
DCA-45SSIU2 — OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel
Output Terminal Familiarization
The “Output Terminal Panel ” (Figure 8) is provided with The Output Terminal Panel (Figure 8) shown below is located
on the right-hand side (left from control panel) of the generator.
the following:
Lift up on the cover to gain access to receptacles and terminal
z Three (3) 240V output receptacles, 50 amp
lugs.
z Three (3) Circuit Breakers 240V @50 amps
z Two (2) 120V GFCI receptacles, 20 amp
z Two (2) GFCI Circuit Breakers 120V@ 20 amps
NOTE
Terminal legs “O” and “Ground”
are considered bonded grounds.
z One Main Circuit Breaker 250V @110 amps
z Five (5) Output Terminal Lugs
Figure 8. Output Terminal Panel
PAGE 28 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any voltage selector switch
position. Each receptacle is protected by a 20 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) of both
GFCI receptacles is dependent on the load requirements of
the UVWO terminals.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the "Test Button" (See Figure 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Each auxilliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
UVWO terminals.
Turn the voltage regulator control knob (Figure 11) on the
control panel to obtain the desired voltage. Turning the knob
clockwise will increase the voltage, turning the knob counterclockwise will decrease the voltage.
Figure 11. Voltage Regulator Control Knob
Figure 9. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 240 VAC, 50 amp auxilliary twist-lock (CS6369) recepacles (Figure 10) provided on the output terminal
panel.These receptacles can only be accessed when the
voltage selector switch is placed in the single-phase 240/
120 position.
Removing the Plastic Face Plate (UVWO Terminals)
The UVWO terminal lugs are protected by a plastic face
plate cover (Figure 12). Un-lock the locking latch, and lift the
terminal cover to gain access to the plastic face plate.
Remove the screws securing the face plate to the terminal
enclosure, then lift the plastic hinged face plate.
After the load wires have been securely attached to the
UVWO terminals, reinstall the plastic face plate. Place the
terminal cover in the down position and secure the locking
latch.
Figure 12. Plastic Face Plate (UVWO Terminals)
Figure 10. 240 VAC Twist-Lock
Auxiliary Receptacles
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 29
DCA-45SSIU2 — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the UVWO terminal
lugs or the convienience receptacles. (See Figure 13). Make
sure to read the operation manual before attempting to connect
a load to the generator.
To protect the UVWO output terminals from overload, a 3pole, 250 amp, main circuit breaker is provided. Make sure
to switch ALL circuit breakers to the "OFF" position prior to
starting the engine.
Over Current Relay
An over current relay (Figure 14) is connected to the main
circuit breaker. In the event of an overload, 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 in the control box.
Figure 14. Over Current Relay
Figure 13. Connecting Loads
PAGE 30 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — LOAD APPLICATION
Single Phase Load
Three Phase Load
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
When calculating the power requirements for 3-phase power
use the following equation:
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
NOTE
If wattage is not given on the equipment's
name plate, approximate wattage may be
An inadequate size connecting cable which cannot carry the
determined by multiplying nameplate
required load can cause a voltage drop which can burn out
voltage by the nameplate amperage.
the appliance or tool and overheat the cable. See Table 5.
NOTE
WATTS l VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 4 below
when connecting loads.
Table 4. Power Factor By Load
Type Of Load
Power Factor
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1 .0
Fluorescent lamps, mercury lamps
0.4 - 0.9
Electronic devices, communication
equipment
1.0
Common power tools
0.8
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.
z 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.
z When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
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 5. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Current in
Amperes At 120 At 240
Volts
Volts
Maximum Allowable Cable Length
#10 Wire
#12 Wire
#14 Wire
#16 Wire
6 0 0 ft .
375 ft.
250 ft.
2.5
30 0
600
1000 ft.
5
600
1200
500 ft.
300 ft.
200 ft.
1 2 5 ft .
7.5
900
1800
350 ft.
200 ft.
125 ft.
1 0 0 ft .
10
1200
2400
250 ft.
1 5 0 ft .
100 ft.
15
1800
3600
150 ft.
100 ft.
65 ft.
20
2400
4800
125 ft.
75 ft.
50 ft.
NOTE
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
maybe determined by multiplying
voltage by amperage by 1.732.
CAUTION: Equipment damage can result from low voltage.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 31
DCA-45SSIU2 — GENERATOR OUTPUTS
Generator Output Voltages
Generator Amperage
A wide range of voltages are available to supply voltage for Tables 7 and 8 describe the generator’s current output capamany different applications. Voltages are selected by using bility for both 1Ø-phase and 3Ø phase applications.
the voltage selector switch (Figure 15). To obtain some of
the voltages as listed in Table 6 (see below) will require a
Table 7. Generator Ampere
fine adjustment using the voltage regulator (VR) control
Ratings — 1Ø
knob located on the control panel.
kW
240V
120V
Voltage Selector Switch
20
83
166
25
104
208
The voltage selector switch (Figure 15) is located above
the UVWO Hard Wire Hook-up Panel. It has been provided
30
225
250
for ease of voltage selection.
35
145
291
40
166
333
45
187
375
50
208
417
60 (Max)
250
500
Table 8. Generator Ampere Ratings — 3Ø
Figure 15. Voltage Selector Switch
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and load from being switched while the engine
is running. To lock the voltage selector switch, press and
hold the red button located at the bottom of the switch.
kW
208V
240V
480V
20
59
60
30
25
87
75
38
30
104
90
45
35
121
105
53
40
139
120
60
45
156
136
68
50
174
152
76
60
208
181
99
CAUTION:
NEVER change the position of the voltage
selector switch while the engine is running.
ALWAYS place circuit breaker in the open
position before selecting voltage.
Table 6. Voltages Available
Three Phase
(Sw itchable)
208 VOLT
220 VOLT
240 VOLT
416 VOLT
440 VOLT
480 VOLT
Single Phase
(Sw itchable)
120 VOLT
127 VOLT
139 VOLT
240 VOLT
254 VOLT
277 VOLT
PAGE 32 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — GENERATOR OUTPUTS/GAUGE READING
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the UVWO terminals or the 3 twist lock auxilliary receptacles.
Tables 9 and 10 show what amount of current is available at
the GFCI receptacles when the UVWO terminals and twist
lock receptacles are in use. Be careful that your load does
not to exceed the available current capability at the receptacles.
Use this position for
3Ø, 208V/1Ø,120V
Table 9. GFCI Receptacle Load Capability
KVA in Use
(UVWO Terminals)
3Ø 240/480V
82
77.8
73.7
69.5
65.4
Available Load Current
(AMPS)
GFCI Duplex NEMA
5-20R 120V
0
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
Figure 16. Voltage Selector Switch 240/139V Three Phase
Position (for 3Ø, 208V, 120V voltage)
Table 10. GFCI Receptacle Load Capability
KW in Use
Twist-Lock (CS6369)
1Ø 240/120V
60
58.8
57.6
56.4
55.2
Available Load Current
(AMPS)
GFCI Duplex NEMA
5-20R 120V
0
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
Figure 17. AC Voltmeter
Change-Over Switch
Figure 18 AC Voltmeter
Gauge
(Volt reading on W-U Lug)
20
40
0
How to Read the Output Terminal Gauge.
The gauge and selector switch on the control panel DO NOT
effect the generator output. They are provided to help observe how much power is being supplied, produced at the
UVWO terminals lugs.
When the Voltage selector switch is in the 3Ø,240/139V
position (See Figure 16), place the AC Voltmeter ChangeOver Switch (Figure 17) to the W-U position and the AC
Ammeter Change-Over Switch (Figure 19) to the U or W
position to read the output on the selected leg.
60
75
A
Figure 19. AC Ammeter
Change-Over Switch
NOTE
Figure 20. AC Ammeter
(Amp reading on U lug)
The ammeter and voltmeter
gauges are only active when the
UVWO terminals are in use.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 33
DCA-45SSIU2 — OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø 208V/1Ø120V UVWO Terminal Output Voltages
Various output voltages can be obtained using the UVWO 1. Place the voltage selector switch in the 3Ø 240/139
output terminal lugs. The voltages at the terminals are deposition as shown in Figure 24.
pendent on the position of the Voltage Selector Switch and
Use this position for
the adjustment of the Voltage Regulator Control Knob.
3Ø-208 or 1Ø120V.
Remember the voltage selector switch determines the range
of the output voltage. The voltage regulator (VR) allows the
user to increase or decrease the selected voltage.
Figure 24. Voltage Selector
Switch 3Ø-208V/1Ø-120V
Three-Phase Position
3Ø 240/139 UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 21.
2. Connect the load wires to the UVWO terminals as shown
in Figure 25.
Figure 21. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the UVWO terminals as shown
in Figure 22.
Figure 25. UVWO Terminal Lugs
3Ø-208V/120V Connections
3. Turn the voltage regulator knob (Figure 26) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Figure 22. UVWO Terminal Lugs
240/139V Three Phase Connections
Figure 26. Voltage Regulator Knob (208V)
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
NOTE
Figure 23. Voltage Regulator Knob (139V/240V)
To achieve a 3Ø 208V
output the voltage selector
switch must be in the 3Ø240/139 position and the
voltage regulator must be
adjusted to 208V.
PAGE 34 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 UVWO Terminal Output Voltages
1Ø 240V/120V UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 480/277 1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 27.
position as shown in Figure 30.
Figure 27. Voltage Selector Switch 480/277V
Three-Phase Position
Figure 30. Voltage Selector Switch 240/120V
Single-Phase Position
2. Connect the load wires to the UVWO terminals as shown
in Figure 28.
2. Connect the load wires to the UVWO terminals as shown
in Figure 31.
Figure 28. UVWO Terminal Lugs
240/139V Three Phase Connections
Figure 31. UVWO Terminal Lugs
1Ø-240V/120V Connections
3. Turn the voltage regulator knob (Figure 29) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
3. Turn the voltage regulator knob (Figure 32) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Figure 29. Voltage Regulator Knob (139V/240V)
Figure 32. Voltage Regulator Knob (1Ø-240/120V)
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 35
DCA-45SSIU2 — PRE-SETUP
Circuit Breakers
Fuel Check
To protect the generator from an overload, a 3-pole, 110 amp,
main circuit breaker is provided to protect the UVW 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 auxiliary receptacles
from overload. Make sure to switch ALL circuit breakers to
the "OFF" position prior to starting the engine.
DANGER:
Fuel spillage on a hot! engine can cause
a fire or explosion. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER! smoke
around or near the generator.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two
notches (Figure 33) on the dipstick. See Table 11 for proper
selection of engine oil.
Figure 33. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the Isuzu Engine Owner's Manual. Oil should be warm
before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
z
z
z
z
z
Refilling the Fuel System
The DCA45SSJU genset may (if equipped with a trailer or
skid) have a double fuel tank system (Figure 34), which
consists of an internal generator fuel tank, and a trailer
mounted fuel tank. It is also possible the genset can be
equipped with a skid mounted fuel tank (Figure 5). The
skid type fuel system does not use the internal generator
fuel tank.
Use the instructions in this section that applies to your type
of fuel tank system.
ALWAYS fill the fuel tank with clean and fresh #2 diesel
fuel. DO NOT fill the fuel tanks beyond their capacities.
Pay attention to the fuel tank capacity when replenishing
fuel.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.
API Service Classification CH-4
API Service Classification CG-4
API Service Classification CF-4
ACEA Specification E3
ACEA Specification E2
Table 11. Recommended Motor Oil
Temperature Range
Type Oil
77oF and greater
(25oC and greater)
SAE15W-40 or SAE40
32oF to 77oF
(0oC to 25oC)
SAE 10W-30 or SAE30
-22oF to -32oF
(-30oC0oC)
SAE10W-30 or SAE10
Figure 34. Double Fuel Tank System
WARNING:
ONLY properly trained personel who have
read and understand this section should refill
the double fuel tank system.
Use #2 diesel fuel.
PAGE 36 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — PRE-SETUP
CAUTION:
ALWAYS! fill trailer tank first with #2 diesel
fuel, before filling secondary internal tank.
Figure 35. Skid Type Fuel Tank System
Refueling Procedure:
DANGER:
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin
contact and/or inhaling
fumes.
1.
Level Tanks – make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity. See Figure 36.
WARNING:
Figure 37. Fuel Tank Filling Order
ALWAYS! place trailer on firm level ground
before refueling.
Figure 36. Only Fill on Level Ground
2.
NOTE
ONLY! use #2 diesel fuel when
refueling.
NOTE
Fuel from the secondary inner
tank will eventually drain into the
primary trailer tank.
Trailer Fuel Tank First – The trailer fuel tank is the
primary fuel tank and holds a larger capacity of fuel.
The fuel in the trailer will be filtered and sent to the
engine. ALWAYS fill trailer fuel tank (Figure 37) first.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 37
DCA-45SSIU2 — PRE-SETUP
3.
NEVER overfill trailer fuel tank – It is important to 5.
read the trailer fuel gauge when filling trailer fuel tank.
DO NOT wait for fuel to rise in filler neck. See Figure 38.
Figure 38. Full Trailer Tank
WARNING:
DO NOT OVER-FILL fuel system. Leave room
for fuel expansion . Fuel expands when heated.
4.
Once the trailer tank is full, the secondary inner tank
can be filled (See Figure 39). Notice how the trailer
filler tube level rises when the internal tank is filled.
Figure 40 below reflects a full fuel system.
Figure 40. Full Fuel System
6.
Fuel from the engine return line will drain into the secondary
internal fuel tank. This fuel will eventually drain into the
primary trailer tank in order to return to the engine.
WARNING:
It is recommended to only fill the internal secondary
take to 3/4 full in order to allow for fuel return, fuel
expansion, and to avoid spillage. See Figure 41
for fuel expansion.
Figure 41. Fuel Expansion
Figure 39. Filling Secondary Internal Fuel Tank
PAGE 38 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — PRE-SETUP
Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
CAUTION:
If adding coolant/antifreeze
mix to the radiator, DO
NOT remove the radiator
cap until the unit has completely cooled. The
possibility of hot! coolant exists which can cause severe
burns.
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be less than 50%.
NOTE
Cleaning the Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the
negative battery terminal disconnected.
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Isusu Engine Owner's Manual.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
Day-to-day addition of coolant is done from the recovery insufficient charging of the battery. Inspect the fan belt for
tank. When adding coolant to the radiator, DO NOT remove damage and wear and adjust it in accordance with the Isuzu
the radiator cap until the unit has completely cooled. See Engine Owner's Manual.
Table 12 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
The fan belt tension is proper if the fan belt bends 10 to 15
is always between the "H" and the "L" markings.
mm (Figure 42) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
5.3 Gal. (20 L)
Reserve Tank
0.26 Gal. (1L)
Figure 42. Fan Belt Tension
Operation Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Table 13. Anti-Freeze Operating Temperatures
Freezing Point
Boiling Point
°C
°F
°C
°F
40
-24
-12
106
222
50
-37
-34
10 8
226
Vol %
Anti-Freeze
CAUTION
CAUTION:
NEVER! place hands near
the belts or fan while the
generator set is running.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 39
DCA-45SSIU2 — PRE-SETUP
Battery
When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
Always maintain battery fluid level between the specified
terminals when the ignition switch is in either the Premarks. Battery life will be shortened, if the fluid level are not
Heat, RUN, or START position. ALWAYS make sure
properly maintained. Add only distilled water when
that the ignition switch is in the STOP position when
connecting the battery.
replenishment is necessary.
DO NOT over fill. Check to see whether the battery cables 2. Place a small amount of battery terminal treatment
are loose. Poor contact may result in poor starting or
compound around both battery terminals. This will ensure
malfunctions. Always keep the terminals firmly tightened.
a good connection and will help prevent corrosion around
Coating the terminals with an approved battery terminal
the battery terminals.
treatment compound. Replace battery with only
If the battery cable is connected
recommended type battery. The battery type used in this
incorrectly, electrical damage to the
generator is BCI Group 27.
generator
will occur. Pay close
NOTE
The battery is sufficiently charged if the specific gravity of
attention to the polarity of the
the battery fluid is 1.28 (at 68° F). If the specific gravity
battery when connecting the
should fall to 1.245 or lower, it indicates that the battery is
battery.
dead and needs to be recharged or replaced.
Battery Cable Installation
CAUTION
CAUTION:
ALWAYS be sure the battery cables (Figure 43) 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
CAUTION:
Inadequate battery connections may cause
poor starting of the generator, and create
other malfunctions.
Alternator
The polarity of the alternator is negative grounding type. When
ALWAYS disconnect the negative an inverted circuit connection takes place, the circuit will be
terminal FIRST and reconnect in short circuit instantaneously resulting the alternator failure.
DO NOT put water directly on the alternator. Entry of water
negative terminal LAST.
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.
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
Figure 43. Battery Connections
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.
PAGE 40 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — GENERATOR START-UP PROCEDURE
WARNING:
The engine's exhaust contains harmful
emissions. ALWAYS have adequate
ventilation when operating. Direct exhaust
away from nearby personnel.
BEFORE STARTING
Generator and Control Panel
CAUTION:
NEVER! manually start the engine with the
Figure 45. Load Connections
main, GFCI or auailliary circuit breakers in
3. Close all engine enclosure doors (Figure 46).
the “ON“ (closed) position.
1. Be sure and place the main, G.F.C.I. and aux. circuit
breakers (Figure 44) in the “OFF” position prior to starting
the engine.
Figure 46. Engine Enclosure Doors
Figure 44. Main, Aux. and GFCI
Circuit Breakers
2. Connect the load to the UVWO terminals or auxiliary
receptacles as shown in Figure 45. These load
connection points can be found on the output terminal
panel. To gain access to the UVWO terminals or other
power receptacles, unlock the access cover and lift the
door.
The UVWO terminals are protected by a plastic cover,
remove this cover to gain access to the terminals.
Tighten terminal nuts securely to prevent load wires from
slipping out.
4. Place the voltage selector switch in the desired voltage
position (Figure 47).
Figure 47. Voltage Selector Switch
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 41
DCA-45SSIU2 — GENERATOR START-UP PROCEDURE
5. Push the engine throttle control lever inward (Figure 48)
to the “LOW ” position.
Figure 48. Engine Throttle Control Lever (Low)
10. The generator's frequency meter (Figure 52) displays
the 60 cycle output frequency in HERTZ.
Figure 52. Frequency Meter (Hz)
6. Preheat the engine glow plugs by turning the ignition
11. The generator's voltage meter (Figure 53) displays the
key (Figure 49) to the “PRE-HEAT” position.
120 VAC in VOLTS. If the voltage is not within the specified
frequency tolerance,
Figure 49. Ignition Switch (Pre-Heat Position)
Figure 53. AC Voltmeter
7. When the preheat lamp luminates (Figure 50), turn the
ignition key to the “START” position. Once the engine 12. Use the voltage adjustment control knob (Figure 54) to
increase or decrease the desired voltage.
starts, release the ignition key and allow it to return to
the “OPERATION” position (Figure 49).
Figure 50. Pre-Heat Indicator Lamp
Figure 54. Voltage Adjust Control Knob
8. Let the engine idle for 3-5 minutes, listen and check for 13. The ammeter (Figure 55) will indicate zero amps with no
load applied. When a load is applied, this meter will
any abnormal sounds or smells. Check for fuel leaks,
indicate the amount of current that the load is drawing
and noises that would associate with a loose cover or
from the generator.
harware. If any of the above mentioned conditions exists,
shut-down the engine and correct the problem.
9. If the engine is running smoothly with no problems, pull
and place the engine throttle lever (Figure 51) in the
“HIGH ” position”.
Figure 55. Ammeter (No Load)
Figure 51. Engine Throttle Control Lever (High)
PAGE 42 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — GENERATOR START-UP PROCEDURE
14. The engine oil pressure gauge (Figure 56) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure is approximately
17. Turn the main, GFCI, and aux. circuit breakers to the
“ON” position (Figure 59).
Figure 56. Oil Pressure Gauge
15. The coolant temperature gauge (Figure 57) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature is between 165 and
215 degrees Fahrenheit.
Figure 59. Main, AUX. and GFCI
Circuit Breakers (ON)
18. Observe the generator's ammeter (Figure 60) 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 57. Coolant Temperature Gauge
16. The tachometer (Figure 58) will indicate the speed of the
engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800
RPM’s.
Figure 60. Ammeter (Load)
19. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 58. Engine Tachometer
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 43
DCA-45SSIU2 — GENERATOR SHUT-DOWN PROCEDURE
NORMAL SHUT-DOWN
To shutdown the generator, use the following procedure:
1. Switch the MAIN, AUX and GFCI circuit breakers
(Figure 61) to the “OFF” position (no load).
EMERGENCY SHUT-DOWN SHUTDOWN
1. To shut-down the engine in the event of an emergency,
switch the MAIN, GFCI and LOAD (Figure 61) circuit
breakers to “OFF” position.
2. Turn the ignition switch key to the “STOP” position.
Figure 61. Main, AUX. and GFCI
Circuit Breakers (OFF)
2. Push the engine throttle control lever inward (Figure 62)
to the “LOW ” position.
Figure 62. Engine Throttle Control Lever (Low)
3. Let the engine cool by running it for 3-5 minutes with no
load applied (circuit breakers in the off position).
4. Place the ignition switch (Figure 63) in the “STOP” position,
remove the key and store in a safe place.
Figure 63. Ignition Switch (Off Position)
5.
Remove all loads from the generator.
PAGE 44 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — GENERATOR/ENGINE MAINTENANCE
TABLE 14. INSPECTION/MAINTENANCE
10 Hrs
DAILY
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 Par ts
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
1000 Hrs
ENGINE
Change Fuel Filter *2
X
Clean Radiator and Check Coolant Protection Level
X
Test Fuel Injection Nozzle
X
Replace Air Filter Element
X
Check all Hoses and Clamps
X
Check Valve Clearance
X
Check Injection Nozzle
X
Clean Inside of Fuel Tank
GENERATOR
X
X
Measure Insulation Resistance Over 3M ohms
X
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Replace fuel filter at 250 Hours, first time only.
General Inspection
Prior to each use, the generator should be cleaned and inspected
for deficiencies. Check for loose, missing or damaged nuts, bolts
or other fasteners. Also check for fuel, oil, and coolant leaks.
Engine Side (Refer to the Engine Instruction Manual)
Air Cleaner
Every 50 hours: Remove air cleaner element and clean the 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.
Air Cleaner with Dust Indicator
This indicator is attached to the air cleaner. When the air cleaner
element is clogged, air intake restriction becomes greater and
the dust indicator signal shows “RED” meaning the element
needs changing. After changing the air element, press the dust
indicator button to reset the indicator.
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 and high
fuel consumption. Change air cleaner more frequently if these
conditions exists.
Fuel Addition
Add diesel fuel (the grade may vary according to season and
locations). Always pour through the mesh filter.
Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate in
the bottom of the tank. Occasionally remove the drain cock and
drain the contents. During cold weather, the more empty volume
inside the tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 45
DCA-45SSIU2 — MAINTENANCE
Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system.
Flushing Out Radiator and Replacing Coolant
z 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.
z Check hoses for softening and kinks. Check clamps for
signs of leakage.
z Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO NOT
Cleaning the Fuel Strainer
clean radiator core with any objects, such as a
Clean the fuel strainer if it contains dust or water. Remove
screwdriver.
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not z Tighten both cocks and replace the overflow tank.
leak. Check the fuel strainer every 200 hours of operation or z Replace with coolant (Table 12 for correct mixture).
once a month.
z Close radiator cap tightly.
Check Oil Level
CAUTION:
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
Allow engine to cool when flushing out
to the engine. Make sure the generator is level. The oil level
radiator. Flushing the radiator while hot!
must be between the two notches on the dipstick as shown
will damage radiator.
in Figure 33.
Replacing Oil Filter
Detach the oil filter by loosening center bolt and remove
the element together with the filter body.
Apply a film of oil to the gasket for the cartridge.
Install the filter body together with the element and fix
them by tightening the center bolt.
After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check
for leaks before adding more oil if needed. Clean
excessive oil from engine.
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 400
hours or so.
Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Vent any air.
Generator Storage
For longe term storage of the generator the following is
recommended:
z Fill the fuel tank completely. Treat with a fuel stabilizer
if necessary.
z Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
z Clean the entire generator, internal and external.
z Cover the generating set and store in a clean, dry place.
z Disconnect the battery.
z Make sure engine coolant is at proper level.
z If generator is mounted on a trailer, jack trailer up and
place on block so tires do touch the ground or remove
tires.
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.
PAGE 46 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — MAINTENANCE
Jacket Water Heater and Internal Battery Charger
120 VAC Input Plugs (OPTIONAL)
This generator is equipped with two 120 VAC, 20 amp input
plugs located on the output terminal panel.
The purpose of these plugs is to provide power via
commercial power to the jacket water heater and internal
battery charger.
These plugs will ONLY function when commercial power has
been supplied to them (Figure 64). To apply commercial power
to these plugs, a power cord of adequate size will be required
(See Table 5).
If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
plug via commercial power using an power cord of adequate
size.
NOTE
To ensure adequate starting
capability, always have power
applied to the generator's
internal battery charger.
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times. To
apply power to the jacket water heater, simply apply power
to the jacket water heater plug via commercial power using
an power cord of adequate size.
Figure 64. DCA-45SIU2 Battery Charger &
Jacket Water Heater Power Connections
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 47
DCA-45SSIU2 — TRAILER BRAKES MAINTENANCE
Brakes
Trailer 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.
Figure 74 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 as listed below:
Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate the
star wheel of the adjuster assembly to expand the brake
shoes.
5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer to
the ground.
8. Repeat steps 1 through 7 on the remaining brakes.
Hydraulic Surge Brakes
Hydraulic surge brakes (Figure 65) should not require any
special attention with the exception of routine maintenance
such as shoe and lining replacement. Brake lines should be
periodically checked for cracks, kinks, or blockage.
Figure 65. Hydraulic Brake Components
Actuator
Hydraulic surge braking requires the installation of an actuator
at the tongue of the trailer. Remember the surge or push of
the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer
pushes against the tow vehicle the actuator telescopes
together and applies force to the master cylinder, supplying
hydraulic pressure to the trailer brakes.
Periodically check and test the surge “actuator ” to make
sure that it is functioning correctly. Never use an undersize
actuator.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Repair or replace.
Brake lining glazed?
Reburnish or replace.
Trailer overloaded?
Correct weight.
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Machine or replace.
Tire pressure correct?
Inflate all tires equally.
Tires unmatched on the same axle?
Match tires.
Brake components loose, bent or broken?
Replace components.
Brake drums out-of-round?
Replace.
Locking Brakes
System lubricated?
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness incorrect or not
adjusted correctly?
Install new shoes and
linings.
Enough brake fluid or correct fluid?
Replace rubber par ts
fill with dot 4 fluid.
Noisy Brakes
Dragging Brakes
PAGE 48 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — TRAILER MAINTENANCE
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:
Suspension
The leaf suspension springs and associated components
(Figure 66) 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 17.
DO NOT attempt
to repair or modify
a wheel. DO NOT
install in inner
tube to correct a leak through the rim. If the
rim is cracked, the air pressure in the inner tube may cause
pieces of the rim to explode (break off) with great force and
cause serious eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot!. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
TABLE 16 TIRE WEAR TROUBLESHOOTING
WEAR PATTERN
SOLUTION
CAUSE
Adjust pressure to
particular load per tire
manufacturer.
Adjust pressure to
particular load per tire
manufacturer.
Make sure load does
not exceed axle rating.
Align wheels.
Center Wear
Over Inflation.
Edge Wear
Under Inflation.
Side Wear
Loss of camber
or overloading.
Toe Wear
Incorrect toe-in.
Align wheels.
Cupping
Out-of-balance.
Check bearing adjustment
and balance tires.
Flat Spots
Wheel lockup &
tire skidding.
Avoid sudden stops when
possible and adjust brakes.
Figure 66. Major Suspension Components
Table 17. 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
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.
MIN-30 MAX-50
CAUTION:
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 49
DCA-45SSIU2 — TRAILER MAINTENANCE
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 67. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
20-25
35-40
50-65
13"
20-25
35-40
50-65
14"
20-25
50-60
90-120
15"
20-25
50-60
90-120
16"
20-25
50-60
90-120
NOTE
NEVER use an pneumatic air
gun to tighten wheel lug nuts.
Figure 67. Wheel Lug Nuts Tightening Sequence
PAGE 50 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — TRAILER WIRING DIAGRAM
Figure 68. Trailer/Towing Vehicle Wiring Diagram
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 51
DCA-45SSIU2 — ENGINE WIRING DIAGRAM
Figure 69. Engine Wiring Diagram
PAGE 52 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — ENGINE WIRING DIAGRAM
Figure 69. Engine Wiring Diagram(Continued)
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 53
DCA-45SSIU2 — GENERATOR WIRING DIAGRAM
Figure 70. Generator Wiring Diagram
PAGE 54 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — 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 19). If
the problem cannot be remedied, consult our company's
business office or service plant.
TABLE 19. ENGINE TROUBLESHOOTING
SYMPTOM
Engine does not star t.
POSSIBLE PROBLEM
SOLUTION
No fuel?
Replenish fuel.
Air in the fuel system?
Bleed system.
Water in the fuel system?
Remove water from fuel tank.
Fuel pipe clogged?
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.
Fuel with low cetane number?
Use the specified fuel.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Incorrect injection timing?
Adjust.
Fuel cam shaft worn?
Replace.
Injection nozzle clogged?
Clean injection nozzle.
Injection pump malfunctioning?
Repair or replace.
Seizure of crankshaft, camshaft,
piston, cylinder liner or bearing?
Repair or replace.
Compression leak from
cylinder?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Improper valve timing?
Correct or replace timing gear.
Piston ring and liner worn?
Replace.
Excessive valve clearance?
Adjust.
Star ter malfunctioning?
Repair or replace.
Wiring disconnected?
Connect wiring.
Star ter does not run.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 55
DCA-45SSIU2 — TROUBLESHOOTING (ENGINE)
TABLE 19. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
Engine revolution is not smooth.
Either white or blue exhaust gas
is observed.
Either black or dark gray
exhaust gas is observed.
Deficient output.
POSSIBLE PROBLEM
SOLUTION
Fuel filter clogged or dir ty?
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.
Governor malfunctioning?
Repair.
Excessive engine oil?
Reduce to the specified level.
Piston ring and liner worn or
stuck?
Repair or replace.
Incorrect injection timing?
Adjust.
Deficient compression?
Adjust top clearance.
Overload?
Lessen the load.
Low grade fuel used?
Use the specified fuel.
Fuel filter clogged?
Clean or change.
Air cleaner clogged?
Clean or change.
Deficient nozzle injection?
Repair or replace the nozzle.
Incorrect injection timing?
Adjust.
Engine's moving par ts seem to
be seizing?
Repair or replace.
Uneven fuel injection?
Repair or replace the injection pump.
Deficient nozzle injection?
Repair or replace the nozzle.
Compression leak?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
PAGE 56 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table 20) . If the
problem cannot be remedied, consult our company's business office or service plant.
TABLE 20. 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".
Is wiring connections loose?
Check wiring and repair.
Defective AVR?
Replace if necessary.
Is wiring connections loose?
Check wiring and repair.
Defective AVR?
Replace if necessary.
Shor t Circuit in load?
Check load and repair.
Over current?
Confirm load requirements and reduce.
Defective circuit breaker?
Check and replace.
Over current Relay actuated?
Confirm load requirement and replace.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 57
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
NOTE
If more than one of the same
reference number is listed, the last
one listed indicates newest (or
latest) part available.
The contents of this catalog are
subject to change without notice.
PAGE 58 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — SUGGESTED SPARE PARTS
DCA-45SSIU2 W/ISUZU 4BG1 DIESEL ENGINE
1 TO 3 UNITS
Qty.
P/N
Description
1 ......... 0601820671 .............. AUTOMATIC VOLTAGE REGULATOR
1 ......... 0601840073 .............. RHEOSTAT VOLTAGE REGULATOR
1 ......... 0601840121 .............. KNOB RHEOSTAT
1 ......... M1310500403 ........... RADIATOR HOSE
1 ......... M1310500303 ........... RADIATOR HOSE
5 ......... 8943212191 .............. OIL FILTER
5 ......... X132400240 ............. FUEL FILTER
5 ......... 0602046368 .............. AIR ELEMENT
3 ......... 0602042420 .............. FUEL TANK, IN-LINE FILTER
1 ......... 0602122272 .............. UNIT, OIL PRESSURE
1 ......... 0602123260 .............. UNIT WATER TEMPERATURE
2 ......... 0601810245 .............. BULB, ALARM LAMP
1 ......... 8970208220 .............. FAN BELT
1 ......... 1823100080 .............. STARTER SWITCH
3 ......... KEYISUZUF ............. KEY, STARTER SWITCH
2 ......... 0601808803 .............. CIRCUIT BREAKER, GF-530EM 125V 20A
3 ......... 0601808804 .............. CIRCUIT BREAKER, CS6369 250V 50A
4 ......... 9825139289 .............GLOW PLUG
1 ......... 47130106 .................. KNOB, SELECTOR SWITCH
1 ......... 5825500422 .............. EMERGENCY RELAY
1 ......... 0605505070 .............. FUEL CAP
NOTE
Part number on this Suggested Spare
Parts list may supercede/replace the
P/N shown in the text pages of this book.
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 59
DCA-45SSIU2 — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 60 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — GENERATOR ASSY.
GENERATOR ASSY.
NO.
PART NO.
ITEM
1
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
28
28
ROTOR ASSY. ..................................... 1 ............INCLUDES ITEMS W/
FIELD ASSY.
1
FAN
1
HEX. HEAD BOLT
8
LOCK WASHER ................................... 8 ............REPLACES 0042510000
COUPLING DISK
4
BALANCING PLATE
1
HEX. HEAD BOLT ................................ 6 ............REPLACES 0010310025
LOCK WASHER
6
SET PLATE, RECTIFIER
1
RECTIFIER .......................................... 2 ............PT 3610
SURGE ABSORBER ........................... 1 ............ERZ-M14JK621A
INSULATOR WASHER
1
INSULATOR WASHER
1
HEX. HEAD BOLT ................................ 4 ............REPLACES 0010108020
LOCK WASHER
4
BALANCING WEIGHT KIT
1
BEARING ............................................. 1 ............6310 DDU C3
COUPLING RING ................................ 1 ............REPLACES M1163400203
REAMER BOLT .................................... 2 ............REPLACES M9200100204
HEX. HEAD BOLT
7
LOCK WASHER ................................... 2 ............REPLACES 0042510000
STRATOR ASSY.
1
GROMMET
2
END BRACKET
1
FIELD ASSY. EXCITER
1
HEX. HEAD BOLT
4
LOCK WASHER
4
PLAIN WASHER ................................... 4 ............REPLACES 0041208000
HEX. HEAD BOLT
6
LOCK WASHER
6
PLAIN WASHER ................................... 6 ............REPLACES 0041208000
COVER, BEARING
1
GASKET, BEARING
1
COVER, END BRACKET
1
HEX. HEAD BOLT ................................ 8 ............REPLACES 0017106012
COVER, END BRACKET
1
HEX. HEAD BOLT
2
LOCK WASHER
2
PLAIN WASHER ................................... 2 ............REPLACES 0041206000
HEX. HEAD BOLT ................................ 6 ............REPLACES 0010310025
LOCK WASHER
6
COVER, FAN
1
RUBBER SUSPENSION
2
HEX. NUT
2
LOCK WASHER
2
PLAIN WASHER ................................... 2 ............REPLACES 0041212000
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
8051000042
8051070003
0012110035
030210250
8041611004
8041015003
0105091025
0042510000
8001026013
0601821349
0601822601
8001020004
8001020504
011008020
0040080000
0601000209
0071906310
8051614003
0801831704A
0012810030
030210250
8051340503
0845041904
8041315202
8041350013
0010308065
0042608000
031108160
0010108030
0040008000
031108160
8041310024
8041312014
8041331014
0017106012
8001333003
0010106030
0040006000
952404470
0105091025
0042510000
8051332014
0605000010
0030012000
0040012000
031112230
QTY.
REMARKS
*
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 61
DCA-45SSIU2 — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 62 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
1
1
1
2
3
4
5
6
7
7
8
9
10
11
12
13
13
14
15
16
17
17A
18
18
19
20
21
21
22
M1213000402
M1213000412
M1213000422
0601808811
0027105080
0601823863
0021304015
0601820671
0027105010
0027105015
0601806116
011808015
0601820845
0601820846
M1260600004
0021304015
0030004000
0021004010
M1213500303
011106015
M1923100004
47130106
M1213600104
M1213600114
0027103010
011106015
M1213600004
M1213600014
011106015
22
011106015
23
23
24
25
25
011106015
0040506000
M1223000303
0601807630
0601807641
ITEM
QTY.
REMARKS
CONTROL BOX ................................................... 1 ................. S/N7500646 TO 7200915
CONTROL BOX ................................................... 1 ................. S/N7200916 TO 7200995
CONTROL BOX ................................................... 1 ................. S/N7200996~
CIRCUIT BREAKER, KAF3611010213P110A 1
MACHINE SCREW
4
RELAY UNIT ........................................................ 2 ................. MSA9013A
MACHINE SCREW .............................................. 4 ................. REPLACES 0027104015
AUTOMATIC VOLTAGE REGULATOR ................. 1 ................. NTA-5A-2DB
MACHINE SCREW .............................................. 4 ................. S/N7200646 TO 7201105
MACHINE SCREW .............................................. 4 ................. S/N7201106~
CURRENT TRANSFORMER .............................. 3 ................. 812-943 75/5A
MACHINE SCREW .............................................. 6 ................. REPLACES 0027106015
OVER CURRENT RELAY .................................... 1 ................. LR2D1308
OVER CURRENT RELAY .................................... 1 ................. LR7D1064
FITTING BRACKET ............................................. 1 ................. S/N7200646 TO 7200996
MACHINE SCREW .............................................. 2 ................. REPLACES 0027104015
HEX. NUT ............................................................. 2 ................. REPLACES 0207004000
MACHINE SCREW .............................................. 2 ................. S/N7200646 TO 7200996
CONTROL BOX COVER
1
HEX. HEAD BOLT ................................................ 4 ................. REPLACES 0016906015
SELECTOR SWITCH .......................................... 1 ................. VY-40
KNOB, SELECTOR SWITCH
1
SWITCH BRACKET ............................................. 1 ................. S/N7200646 TO 7200915
SWITCH BRACKET ............................................. 1 ................. S/N7200916~
MACHINE SCREW
4
HEX. HEAD BOLT ................................................ 4 ................. REPLACES 0016906015
SWITCH COVER ................................................. 1 ................. S/N7200646 TO 7200915
SWITCH COVER ................................................. 1 ................. S/N7200916~
HEX. HEAD BOLT ................................................ 4 ................. S/N7200646 TO 7200870;
................................................................................................... REPLACES 0016906015
HEX. HEAD BOLT ................................................ 3 ................. S/N720871~; REPLACES
................................................................................................... 0016906015
HEX. HEAD BOLT ................................................ 8 ................. REPLACES 0016906015
TOOTHED WASHER
1
CONTROL PANEL
1
FREQUENCY METER, 264250DJDJ9 ............... 1 ................. S/N7200646 TO 7202360
FREQUENCY METER, FCF6 45-65Hz 240V .... 1 ................. S/N7202361~
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 63
DCA-45SSIU2 — CONTROL BOX ASSY. (CONT.)
CONTROL BOX ASSY. (CONT.)
PAGE 64 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — CONTROL BOX ASSY. (CONT.)
CONTROL BOX ASSY. (CONT.)
NO.
PART NO.
ITEM
26
26
27
28
28
29
30
31
32
33
33
34
34
35
36
37
37
38
39
40
41
41
41
42
43
44
45
45
0601808950
0601808986
0601801040
0601806813
0601806859
0601801041
0601840073
0601840121
M1223100004
0027105015
0027105010
0027105015
0027105010
M9220100004
0080200007
5825500422
1825500732
0601802132
011106015
0601821370
0021004040
0040004000
031104080
0330000530
1825530400
011106015
M12467001004
M1246700524
QTY.
REMARKS
AC AMMETER, 260240LSPB1 ................. 1 .......... S/N7200646 TO 7202360
AC AMMETER, ACF60-75A,0-150A/5A ... 1 .......... S/N7202361~
CHANGE-OVER SWITCH, AMMETER .... 1 .......... SL-2AS
AC VOLTMETER, 260244SJSJ1 .............. 1 .......... S/N7200646 TO S/N7202360
AC VOLTMETER, SCF6 0-600V .............. 1 .......... S/N7202361~
CHANGE-OVER SWITCH, VOLTMETER 1 .......... SL-2VS
RHEOSTAT (VOLTAGE REGULATOR) ..... 1 .......... RA20A2SE102BJ 2W 1kOHM
KNOB
1
STOPPER
1
MACHINE SCREW ................................... 2 .......... S/N7200646 TO 7201195
MACHINE SCREW ................................... 2 .......... S/N7201196~
MACHINE SCREW ................................... 4 .......... S/N7200646 TO 7201195
MACHINE SCREW ................................... 4 .......... S/N7201196~
SET SCREW
1
SNAP RING
1
EMERGENCY RELAY - 12 VOLT ............. 1 .......... REPLACES 0602200409
EMERGENCY RELAY - 24 VOLT ............. 1
FUSE, 10A
1
HEX. HEAD BOLT ..................................... 4 .......... REPLACES 0016906015
RECTIFIER ............................................... 2 .......... REPLACES 0601823240
MACHINE SCREW
1
LOCK WASHER
1
PLAIN WASHER ........................................ 1 .......... REPLACES 0041204000
EDGING
1
SAFETY RELAY ........................................ 1 .......... REPLACES 0602200304
HEX. HEAD BOLT ..................................... 2 .......... REPLACES 0016906015
WIRE HARNESS, GENERATOR .............. 1 .......... UP TO S/N7106114
WIRE HARNESS, GENERATOR .............. 1 .......... S/N7106115~
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 65
DCA-45SSIU2 — ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 66 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
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
38
39
40
PART NO.
M19232000034
8943212191
X132400240
M1303200103
M1303200203
0105091025
004251000
003041000
060500008
00300120000
0040012000
031112230
0602012740
0602012741
0602011065
011008020
M1310500403
M1310500303
0605515147
0602046232
0602046368
0602040650
0602040595
011008020
020108060
M1373100203
060551548
0602022560
M1320300304
0602022561
0602022562
0602022792
0602021070
0602021572
M9300000103
M9300100003
0199100175
M1316100404
1819001902
0601802133
011808015
8970208220
ITEM
QTY.
REMARKS
ENGINE .......................................... 1 .......... ISUZU B-4BG1
CARTRIDGE, OIL FILTER .............. 1 .......... REPLACES 06020412113
CARTRIDGE, FUEL FILTER ........... 1 .......... REPLACES 1132400791 AND 0602042511
ENGINE FOOT
1
ENGINE FOOT
1
HEX. HEAD BOLT ........................... 7 ........... REPLACES 0010710025
LOCK WASHER
8
HEX. NUT
1
RUBBER SUSPENSION
2
HEX. NUT
2
LOCK WASHER
2
PLAIN WASHER ............................. 2 ........... REPLACES 0041212000
RADIATOR, C2810050000R2 .......... 1 ........... S/N7200646 TO 7200705
RADIATOR, C2810050001 ............... 1 ........... S/N7200706~
CAP, RADIATOR ............................. 1 ........... C89C0115010
HEX. HEAD BOLT ........................... 6 ........... REPLACES 0016908020
RADIATOR HOSE, UPPER
1
RADIATOR HOSE, LOWER
1
HOSE BAND
4
AIR CLEANER ................................ 1 .......... FWG065295
ELEMENT. AIR CLEANER .............. 1 .......... P181052
INDICATOR, AIR CLEANER ........... 1 .......... RBX002252
BAND AIR CLEANER ..................... 2 .......... P007191
HEX. HEAD BOLT ........................... 4 .......... REPLACES 0016908020
HEX. NUT ....................................... 4 .......... REPLACES 0207008000
HOSE, AIR CLEANER
1
HOSE BAND
2
ADAPTER
1
PACKING, OIL PAN SIDE
1
1
90O ELBOW
UNION
1
SWIVEL
1
CAP
1
DRAIN HOSE
1
RESERVE TANK
1
CAP, RESERVE TANK
1
HOSE
1
BRACKET, RESERVE TANK
1
ENGINE STOPPER ........................ 1 .......... REPLACES 0602210810
FUSE, 5A
1
MACHINE SCREW ......................... 3 ........... REPLACES 0027106015
FAN BELT ....................................... 1 .......... REPLACES 5136711320 AND 0602011403
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 67
DCA-45SSIU2 — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 68 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
PART NO.
ITEM
QTY.
REMARKS
1
M1354300304 SLIDE LEVER
1
2
0601840190
KNOB .............................................. 1 ........... REPLACES M9320000004
3
020108060
HEX. NUT ....................................... 1 ........... REPLACES 0036003000
4
M1354200004 BRACKET
1
5
020108060
HEX. NUT ....................................... 1 ........... REPLACES 0030008000
6
06054010550 SNAP PIN
1
7
M1354300104 GOVERNOR ROD
1
8
0602180106
BALL JOINT
1
9
020108060
HEX. NUT ....................................... 2 ........... REPLACES 0030008000
10
0207006000
HEX. NUT
2
10
0041206000
PLAIN WASHER
2
11
1823100080
STARTER SWITCH ......................... 1 ........... REPLACES 0602100004
11
KEYISUZUF KEY, STARTER SWITCH
1
12
8944626110
PREHEAT LAMP ............................. 1 ........... REPLACES 9825300410 AND 0602102066
13
0602120095
TACHOMETER ................................ 1 ........... 103680
14
0602120480
PICKUP, TACHOMETER ................. 1 ........... 7154400
15
0602122093
OIL PRESSURE GAUGE ................ 1 ........... 100174
16
0602122272
UNIT, OIL PRESSURE .................... 1 ........... REPLACES 0602122271
17
M9200100004 ADAPTER ....................................... 1
18
0602123090
WATER TEMPERATURE GAUGE ... 1 ........... 100683
19
0602123260
UNIT, WATER TEMPERATURE ....... 1 ........... 0209400
20
9075720140
PACKING ........................................ 1 ........... REPLACES 9095720140 AND 0602121109
21
0602121080
CHARGING AMMETER .................. 1 ........... 100158
22
0602125090
FUEL GAUGE ................................. 1 ........... 100176
23
0602103092
ALARM LAMP ................................. 2 ........... PL-05
23
0601810245
BULB ............................................... 2 ........... E-10 T-10 DC18V
23
0601823223
RECTIFIER ..................................... 2 ........... 30D4
24
0601810141
PANEL LIGHT ................................. 1 ........... 9826800370
25
0601831330
SWITCH, PANEL LIGHT ................. 1 ........... 900001
26
020108060
HEX. NUT ....................................... 1 ........... REPLACES 0207008000
27
M1354200204 GUIDE, SLIDE LEVER ................... 1 ........... S/N7200646 TO 7200675
28
0027105015
MACHINE SCREW ......................... 2 ........... S/N7200646 TO 7200675
29
M1357200302 WIRE HARNESS. ENGINE
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 69
DCA-45SSIU2 — OUTPUT TERMINAL ASSY.
OUTPUT TERMINAL ASSY.
PAGE 70 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — OUTPUT TERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO.
PART NO.
ITEM
QTY REMARKS
1
8111860303
TERMINAL PANEL .................................................. 1 ...... REPLACES M1230700103
2
0801831704A OUTPUT TERMINAL BOLT .................................... 5 ...... REPLACES M9220100204
3
012210020
TIE BOLT ................................................................ 5 ...... REPLACES M9220100104
4
0039310000
HEX. NUT
10
5
0040010000
LOCK WASHER
15
6
0041410000
PLAIN WASHER
20
7
0016908025
HEX. HEAD BOLT
5
8
M1236100603 TERMINAL COVER ................................................ 1 ...... S/N7200646 TO 7201195
8
M1236100613 TERMINAL COVER ................................................ 1 ...... S/N7201196~
9
M1236100704 OUTPUT WINDOW
1
10
0605010040
HINGE
2
11
0027103010
MACHINE SCREW
4
11
0207003000
HEX. NUT ............................................................... 4 ...... REPLACES 0030003000
11
58413
PLAIN WASHER ..................................................... 4 ...... REPLACES 0041203000
12
016906020
HEX. HEAD BOLT
2
13
011106015
HEX. HEAD BOLT ................................................... 4 ...... REPLACES 0016906015
14
M1236400004 CABLE OUTLET COVER
1
15
M1236300004 SUPPORTER, CABLE OUTLET COVER
1
16
011206020
HEX. HEAD BOLT ................................................... 6 ...... REPLACES 0016906020
17
0601808803
CIRCUIT BREAKER ............................................... 2 ...... QOU 120B 19 20A
18
0601808804
CIRCUIT BREAKER ............................................... 3 ...... QOU 250B 2P 50A
19
M1260700304 BREAKER FITTING COVER
1
20
0222100150
CUSHION RUBBER
1
21
011206020
HEX. HEAD BOLT ................................................... 2 ...... REPLACES 0016906020
22
0601812597
RECEPTACLE, GF-530EM 125V 20Ax2 ................. 2 ...... REPLACES 0601812598
23
0601811034
RECEPTACLE, CS6369 250V 50A ......................... 3 ...... REPLACES 0601812538
24
0021304015
MACHINE SCREW ................................................10 ...... REPLACES 0027104015
24
0030004000
HEX.NUT ............................................................... 10 ...... REPLACES 0207004000
25
M1236100803 TERMINAL COVER
1
26
012212045
HEX. HEAD BOLT ................................................... 2 ...... REPLACES 0010112045
27
031112230
PLAIN WASHER ..................................................... 2 ...... REPLACES 0041212000
28
M9310200004 STAY RUBBER
2
29
0030012000
HEX. NUT
2
30
0027103010
MACHINE SCREW
4
30
0207003000
HEX.NUT ................................................................ 4 ...... REPLACES 0030003000
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 71
DCA-45SSIU2 — BATTERY ASSY.
BATTERY ASSY.
PAGE 72 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — BATTERY ASSY.
BATTERY ASSY.
NO.
PART NO.
1
551010280
2
M9310500014
3
M9103000304
4
0602220920
5
0040006000
6
M1346400204
7
M1346400404
8
0016910020
8
0040510000
ITEM
QTY.
REMARKS
BATTERY, 627MFD ......................... 1 .......... REPLACES 0602220187
BATTERY SHEET
1
BATTERY BAND
1
BATTERY BOLT SET
2
LOCK WASHER
2
BATTERY CABLE
1
BATTERY CABLE
1
HEX. HEAD BOLT
1
TOOTHED WASHER
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 73
DCA-45SSIU2 — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 74 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — MUFFLER ASSY.
MUFFLER ASSY.
NO.
PART NO.
1
0602300165
2
0016910025
3
M1333001303
4
1141450690
5
M1333200114
6
9098400850
6
0040010000
7
0016908035
8
M1330400304
9
M1333300004
10
0016906015
11
0602326090
ITEM
QTY.
REMARKS
MUFFLER ....................................... 1 .......... 27242N
HEX. HEAD BOLT
4
EXHAUST PIPE
1
GASKET ......................................... 1 .......... REPLACES 0602320004
GASKET
1
HEX. NUT ....................................... 3 .......... REPLACES 0602323001
LOCK WASHER
3
HEX. HEAD BOLT
4
COVER
1
BRACKET
1
HEX. HEAD BOLT
4
U BOLT SET
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 75
DCA-45SSIU2 — FUEL TANK ASSY.
FUEL TANK ASSY.
PAGE 76 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — FUEL TANK ASSY.
FUEL TANK ASSY.
NO.
PART NO.
1
M1363000302
2
0605505070
3
M1363200104
4
M9310500104
5
011008020
6
0207308000
7
0222100600
8
M9200000003
9
M9200200004
10
0150000018
11
011206020
12
M1363400104
13
0605515198
14
0602042420
15
0602220911
16
0191301200
17
0191300300
18
0191302000
19
0605515109
ITEM
QTY.
REMARKS
FUEL TANK
1
CAP, FUEL TANK
1
TANK BAND
2
SUPPORTER SHEET
4
HEX. HEAD BOLT ........................... 2 ........... REPLACES 0016908020
HEX. NUT
2
RUBBER SHEET
2
DRAIN JOINT
1
DRAIN BOLT
1
O RING
1
HEX. HEAD BOLT ........................... 2 ........... REPLACES 0016906020
DRAIN HOSE
1
HOSE BAND
2
FUEL FILTER
1
CLAMP
1
SUCTION HOSE
1
SUCTION HOSE
1
RETURN HOSE
1
HOSE BAND
6
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 77
DCA-45SSIU2 — ENCLOSURE ASSY.
ENCLOSURE ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 78 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
PART NO.
1
M1413000402
2
M1413400004
3
011008020
4
M1423000902
4
M1423000912
4
M1493102703
5
011008020
6
M1423200604
6
M1493100804
7
011008020
8
M1423200703
8
M1423200713
9
011008020
10
M1433000403
11
M1433000003
12
0010114030
12
030214350
12
031114260
13
012012030
13
00400120000
13
031112230
14
M1443000702
14
M1493300504
15
011008020
15
0040508000
16
M1443300613
17
M1443300303
17
M1493300604
18
0207006000
19
011008020
20
M1443200803
21
M1443600204
22
020106050
22
00412060000
23
B9114000002
24
0027106016
24
020106050
25
M9110100204
26
M9116100004
27
0021808020
28
0845031504
29
M1463000702
29
M1493501503
30
011008020
31
1625165103
ITEM
QTY.
REMARKS
BASE
1
UNDER COVER
1
HEX. HEAD BOLT ........................... 2 .......... REPLACES 0016908020
FRONT FRAME .............................. 1 .......... S/N7200646 TO 7200740
FRONT FRAME .............................. 1 .......... S/N7200741~
ACOUSTIC SHEET
1
HEX. HEAD BOLT ........................... 4 .......... REPLACES 0016908020
COVER, FRONT FRAME
1
ACOUSTIC SHEET
1
HEX. HEAD BOLT ......................... 12 .......... REPLACES 0016908020
INNER COVER. FRONT FRAME .... 1 .......... S/N7200646 TO 7200740
INNER COVER, FRONT FRAME .... 1 .......... S/N7200741~
HEX. HEAD BOLT ........................... 6 .......... REPLACES 0016908020
CENTER FRAME
1
CENTER FRAME
1
HEX. HEAD BOLT
8
LOCK WASHER .............................. 8 .......... REPLACES 0040014000
PLAIN WASHER ............................. 8 .......... REPLACES 0041214000
HEX. HEAD BOLT ......................... 10 .......... REPLACES 0010112030
SPRING WASHER
10
PLAIN WASHER ........................... 10 .......... REPLACES 0041212000
REAR FRAME
1
ACOUSTIC SHEET
1
HEX. HEAD BOLT ............................4 .......... REPLACES 0016908020
TOOTHED WASHER
1
REAR COVER
1
DUCT, REAR COVER
2
ACOUSTIC SHEET
2
HEX. NUT
12
HEX. HEAD BOLT ........................... 9 .......... REPLACES 0016908020
REAR DOOR
1
WINDOW PLATE
1
HEX. NUT ....................................... 8 .......... REPLACES 0207306000
PLAIN WASHER
8
DOOR HANDLE ASSY. ................... 1 .......... REPLACES M9113000002
MACHINE SCREW ......................... 4 .......... REPLACES 0021806015
HEX. NUT ....................................... 4 .......... REPLACES 0030006000
HINGE
2
WASHER
2
MACHINE SCREW
3
BLIND PLUG ................................... 2 .......... REPLACES M9310000004
ROOF PANEL
1
ACOUSTIC SHEET
1
HEX. HEAD BOLT ......................... 19 .......... REPLACES 0016908020
BONNET CAP ................................. 1 .......... REPLACES M9310000103
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 79
DCA-45SSIU2 — ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 80 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
NO.
PART NO.
ITEM
QTY.
REMARKS
32
1625165204
CHAIN ASSY. ................................. 1 ........... REPLACES M1483600204
33
M1453200002 SPLASHER PANEL ........................ 1 ........... S/N7200646 TO 7201195
33
M1453200012 SPLASHER PANEL ........................ 1 ........... S/N7201196~
33
M1493300204 ACOUSTIC SHEET
1
34
011208060
HEX. HEAD BOLT ........................... 4 ........... REPLACES 0016908055
35
011008020
HEX. HEAD BOLT ........................... 2 ........... REPLACES 0016908020
36
M1453001503 SIDE DOOR
1
36
M1493403104 ACOUSTIC SHEET
1
37
M1453002003 SIDE DOOR
1
37
M1493403003 ACOUSTIC SHEET
1
38
M1453001303 SIDE DOOR
1
38
M1493400404 ACOUSTIC SHEET
1
39
M1453001203 SIDE DOOR
1
39
M1493401404 ACOUSTIC SHEET
1
40
M1453300603 DUCT
1
40
M1493401304 ACOUSTIC SHEET
1
41
0207006000
HEX. NUT
5
42
B9114000002 DOOR HANDLE ASSY. ................... 3 ........... REPLACES M9113000002
43
0027106016
MACHINE SCREW ....................... 12 ........... REPLACES 0021806015
43
020106050
HEX. NUT ..................................... 12 ........... REPLACES 0030006000
44
M9110100204 HINGE
4
45
M9110100304 HINGE
4
46
M9116100004 WASHER
8
47
0021808020
MACHINE SCREW
9
48
0601850097
DOOR STOPPER
8
49
0027208025
MACHINE SCREW
8
50
0845031504
BLIND PLUG ................................... 8 ........... REPLACES M9310000004
51
0600500090
EMBLEM
1
52
0021106015
MACHINE SCREW
2
53
011008020
HEX. HEAD BOLT ........................... 1 ........... REPLACES 0016908020
53
0040508000
TOOTHED WASHER
1
54
0016910020
HEX. HEAD BOLT
1
54
0040510000
TOOTHED WASHER
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 81
DCA-45SSIU2 — RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
PAGE 82 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
NO.
PART NO.
1
0228901400
2
0229200695
3
0228900620
4
0228900940
5
M1490300104
6
0228800515
7
0228900420
8
0228900910
9
0229200900
10
0229200840
11
0228800780
12
0228800470
13
0228800510
14
0228100545
15
0228100370
16
0228100165
17
0228100340
18
0228100170
19
0228100200
ITEM
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
QTY.
3
1
1
1
1
1
1
3
1
1
2
1
1
1
1
1
1
1
1
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 83
DCA-45SSIU2 — NAMEPLATE AND DECALS
NAMEPLATE AND DECALS
PAGE 84 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
DCA-45SSIU2 — NAMEPLATE AND DECALS
NAMEPLATE AND DECALS
NO.
PART NO.
ITEM
QTY. REMARKS
1
M1550000204 DECAL, NOTE ....................................................... 1 ...... M15000020
2
M1550001003 DECAL, GENERATOR CONTROL ......................... 1 ...... M15000100
3
M1550000603 DECAL, ENGINE OPERATING .............................. 1 ...... M15000060
4
M1550000703 DECAL, AUXILIARY OUTPUT ...............................1 ...... M15000070
5
M1550000804 DECAL, NOTE ....................................................... 1 ...... M15000080
6
M9500000004 DECAL, OIL DRAIN PLUG .....................................1 ...... M9000000
7
M9500100004 DECAL, WATER .....................................................1 ...... M90010000
8
M9500300004 DECAL, - ................................................................1 ...... M90030000
9
M9500300104 DECAL, + ............................................................... 1 ...... M90030010
10
M9500500004 DECAL, DIESEL FUEL .......................................... 1 ...... M90050000
11
M9500500104 DECAL, FUEL DRAIN PLUG ................................. 1 ...... M90050010
12
M9503000004 DECAL, WARNING ................................................. 2 ...... M90300000
13
M9503000103 DECAL, WATER, OIL CHECK ................................1 ...... M90310000
14
M9503100004 DECAL, WARNING ................................................. 1 ...... M90320000
15
M9503200004 DECAL, WARNING ................................................. 1 ...... M90320000
16
M9510100004 DECAL, CAUTION ................................................. 1 ...... M91010000
17
M9510200002 DECAL, MQ ...........................................................1 ...... M91020000
18
M9520000004 DECAL, GROUND ..................................................1 ...... M92000000
19
M9520000104 DECAL, AMMETER CHANGE-OVER SWITCH ..... 1 ...... M92000010
20
M9520000204 DECAL, VOLTMETER CHANGE-OVER SWITCH .. 1 ...... M92000020
21
M9520100004 DECAL, WARNING ................................................. 2 ...... M92010000
22
M9520100204 DECAL, CAUTION ................................................. 1 ...... M92010020A
23
M9520100304 DECAL, SAFETY INSTRUCTIONS ....................... 1 ...... M92010030
24
M9520100404 DECAL, DANGER ..................................................1 ...... M92010040
25
M9520100503 DECAL, WARNING ................................................. 1 ...... M92010050
26
M9520200003 DECAL, CONNECTION OF OUTPUT CABLE ....... 1 ...... M92020000
27
M9520200104 DECAL, OVER CURRENT RELAY ......................... 1 ...... M92020010
28
M1560100603 STRIPE, WHISPERWATT
1
29
M1560100703 STRIPE, MQ POWER
2
30
M1560101204 STRIPE
1
31
M1560101104 STRIPE
2
32
M1560100904 STRIPE, 45
2
33
M1560100804 STRIPE
1
34
M1560101004 STRIPE
1
35
M1940011015Q DECAL, FUELING PROCEDURE
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 85
ISUZU 4BG1 — CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.
PAGE 86 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — CYLINDER HEAD COVER ASSY.
CYLINDER HEAD COVER ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
1
8971334460
COVER
1
4
8941332075
CAP
1
5
8941236231
GASKET, OIL FILLER
1
27
9111790300
GASKET, HEAD COVER
3
68
9111791050
WASHER
3
69
8943109120
GASKET, HEAD TO COVER ........... 1 .......... REPLACES 8944625590
75
9111750120
NUT
3
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 87
EA1013
ISUZU 4BG1 — CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
PAGE 88 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
NO
PART NO
1
8971418211
2
8944189200
3
8943674380
3
8943674370
5117510010
4
*
5A
* 8970376860
5B
* 5117110280
6
9096600340
*
7A
* 1096000051
7B
5112190150
*
7C
* 1096000160
7D
* 9111291280
1096000160
7E
*
5096000130
7F
* 9111296010
8
9
9041108250
10
9825139289
11
5197320021
12
9117778050
13
0500410200
14
9041108750
14
9098301770
53
1093000180
54
5093000650
168
5117770640
PART NAME
QTY.
REMARKS
CYLINDER HEAD ASSY. .................. 1 ........ INCLUDES ITEM W/
*
GASKET, HEAD
1
BOLT ................................................. 4 ........ M12X 115
BOLT ................................................. 4 ........ M12X102
GUIDE, VALVE
8
VALVE INSERT SEAT, INLET
4
VALVE, INSERT SEAT, EXHAUST 4
PLUG PLATE
4
SEALING CYL. HEAD CUP .............. 1 ........ OD=45
SEALING CYL. HEAD CUP .............. 2 ........ OD=32
SEALING CYL. HEAD CUP .............. 4 ........ OD-25
SEALING CYL. HEAD CUP .............. 2 ........ OD=20
SEALING CYL. HEAD CUP .............. 3 ........ OD=25
SEALING CYL. HEAD CUP .............. 4 ........ OD=12.3
CUP, SEALING WATER JACKET
4
INLET MANIFOLD STUD
2
GLOW PLUG
4
GLOW PLUG CONNECTOR
1
REAR ENG. HANGER
1
HANGER BOLT
4
STUD, EX. MANIFOLD ...................... 3 ........ M8X75 L=87
STUD, EX. MANIFOLD ...................... 1 ........ M8X85 L=97
INJ. NOZZLE STUD
8
ROCKER ARM STUD
3
FRONT ENG. HANGER
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 89
ISUZU 4BG1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
PAGE 90 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — CYLINDER BLOCK ASSY.
CYLINDER BLOCK ASSY.
NO.
PART NO.
PART NAME
1
2
2
2
2
4
4
4
4
4
4
4
4
8
13
15A
15B
23
25A
25B
28
29
34
35
37
38
40
45
56
70
71
72
73
74
80
83
130
132
136
137
140
141
162
179
200
218
236
267
301
8971239542
5878133000
4878133010
4878133020
5878133030
1112612480
1112612490
1112612500
1112612520
1112612520
1112612530
1112612540
1112612550
1090004691
8941480790
9992055170
5096050180
5112190140
9116110480
9116130350
8941745290
8943706630
8970233390
5096230350
1096050681
1097400780
8943444620
9827200690
1133420742
1096000520
8943673681
8970285250
9112916051
8943675301
1096000121
9081510180
5112570011
1131610120
5112240040
5096800110
5096600330
0500408180
1093660330
9095720080
9992023140
9095720140
1093000790
5097070041
5111290030
CYLINDER BLOCK ASSY. ..................................... 1
LINER SET ............................................................. 1
LINER SET ............................................................. 1
LINER SET ............................................................. 1
LINER SET ............................................................. 1
LINER, CYLINDER BLOCK ................................... 4
LINER, CYLINDER BLOCK ................................... 4
LINER, CYLINDER BLOCK ................................... 4
LINER, CYLINDER BLOCK ................................... 4
LINER, CYLINDER BLOCK ................................... 4
LINER, CYLINDER BLOCK ................................... 4
LINER, CYLINDER BLOCK ................................... 4
LINER, CYLINDER BLOCK ................................... 4
BOLT
2
DOWEL
2
OIL GALLERY PLUG ............................................. 1
OIL GALLERY PLUG ............................................. 7
CUP, SEALING
1
CAMSHAFT METAL
1
CAMSHAFT METAL
2
OIL PORT COVER
1
OIL PORT COVER GASKET
1
OIL RELIEF VALVE
1
OIL RELIEF GASKET
1
OIL GALLERY PLUG
2
TIMING GEAR CASE PIN
1
SEALING CUP
1
OIL PRESSURE SWITCH
1
PISTON COOLING OIL JET
4
SEALING CUP
2
GASKET
2
TAPPET CHAMBER COVER
1
TAPPET CHAMBER ASSY.
1
BOLT
TAPPET CHAMBER SEALING CUP
2
FLYWHEEL HOUSING PIN
2
BRIDGE CAP DOWEL
1
OIL CHECK VALVE
4
OIL PUMP SHAFT DRIVE BUSHING
1
WATER DRAIN COCK
1
INJ. PUMP NIPPLE
1
BOLT, COVER
2
CYL. BLOCK WATER DRAIN HOSE ..................... 1
GASKET
4
OIL GALLERY PLUG
1
GASKET PLUG
1
ENGINE FOOT STUD
1
DRAIN HOSE CLIP
1
SEALING LEVEL GAUGE CUP
1
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
QTY.
REMARKS
.......... INCLUDES ITEM W/
.......... GRADE 1
.......... GRADE 2
.......... GRADE 3
.......... GRADE 4
.......... OD GRD=1 ID GRD=AX
.......... OD GRD=1 ID GRD=CX
.......... OD GRD=2 ID GRD=AX
.......... OD GRD=2 ID GRD=CX
.......... OD GRD=3 ID GRD=AX
.......... OD GRD=3 ID GRD=CX
.......... OD GRD=4 ID GRD=AX
.......... OD GRD=4 ID GRD=CX
*
.......... PT 3/8
.......... PT 1/8 (SQUARE HEAD)
.......... REPLACES 9099135050
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 91
ISUZU 4BG1 — OIL PAN AND LEVEL GAUGE ASSY.
OIL PAN AND LEVEL GAUGE ASSY.
PAGE 92 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — OIL PAN AND LEVEL GAUGE ASSY.
OIL PAN AND LEVEL GAUGE ASSY.
NO.
1
2
3
*
4
*
16
23
119A
*
119B
*
120A
*
120B
*
277
PART NO.
8941340361
5117601500
1096230570
9096620120
8943706660
0500408180
9992023160
9992023240
9095714160
9095714240
1117500120
PART NAME
QTY.
REMARKS
OIL PAN ASSEMBLY .................................. 1 ............... INCLUDES ITEM W/
*
OIL LEVEL GAUGE
1
DRAIN PLUG GASKET
1
OIL DRAIN PLUG
1
OIL PAN GASKET
1
BOLT
24
OIL HEATER BLIND PLUG
2
OIL HEATER BLIND PLUG
1
GASKET
2
GASKET
1
OIL FILLER CAP
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 93
ISUZU 4BG1 — CAMSHAFT AND VALVE ASSY.
CAMSHAFT AND VALVE ASSY.
PAGE 94 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — CAMSHAFT AND VALVE ASSY.
CAMSHAFT AND VALVE ASSY.
NO.
1
4
5
7
9
10
11
12
45
53
55
58
59
65
69
71A
71B
72
76
78
81
83
84
85
86
88
89
93
95
101
107
111
112
196
PART NO.
8944094120
1125510501
1125520251
5090002360
1125220161
9116810150
0500408250
9080107200
9098518503
8941295510
9126260050
5126280120
5096230600
5125650060
5125610090
8941145790
1125630351
1125690150
9098514300
5126110310
9126160420
9091115080
9126281050
1090005670
9098514300
1125750360
5125710032
1094001160
1095803350
5090300381
9125310300
5125350011
8941339372
9091800190
PART NAME
CAMSHAFT
INLET VALVE
EXHAUST VALVE
BOLT
CAMSHAFT GEAR
THRUST PLATE
BOLT
KEY
WASHER
ROCKER ARM SHAFT
ROCKER ARM PLUG
ROCKER ARM BRACKET
ROCKER SHAFT GASKET
SPLIT COLLAR
OUTER VALVE SPRING
SPRING SEAT, UPPER
SPRING SEAT, LOWER
VALVE GUIDE SEAT
WASHER
ROCKER ARM
ADJ. SCREW
ADJ. SCREW NUT
ROCKER SHAFT BRACKET
BOLT
WASHER
PUSH ROD
VALVE TAPPET
NUT
ROCKER SHAFT SPRING
BOLT
IDLE GEAR SHAFT
THRUST COLLAR
IDLER GEAR
SNAP RING
QTY.
1
4
4
1
1
1
2
1
1
1
2
1
1
16
8
8
8
8
3
8
8
8
4
6
6
8
8
3
3
2
1
1
1
1
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 95
ISUZU 4BG1 — CRANKSHAFT, PISTON AND FLYWHEEL ASSY.
CRANKSHAFT, PISTON AND FLYWHEEL ASSY.
PAGE 96 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — CRANKSHAFT, PISTON AND FLYWHEEL ASSY.
CRANKSHAFT, PISTON AND FLYWHEEL ASSY.
NO
1
7
12
28
32
33
35
37
38
40
42#
44
48
56
59
63
63
68
73
83
84
85$
86$
126
PART NO
8943398950
8970716610
8970461810
8971379100
9081612200
5123190032
9123336070
9000901570
5123360030
5123340060
8970713580
5123780020
8941075970
8941004540
5095030240
8971766500
8971766510
8971238330
9122716080
912211604
1122301041
1122510270
1122350271
8941075751
PART NAME
QTY.
REMARKS
CRANKSHAFT
1
CRANKSHAFT, STD KIT .......... 1 ........... INCLUDES ITEM W/# REPLACES 8941170322
FLYWHEEL
1
CRANKSHAFT GEAR
1
FLYWHEEL PIN
1
CRANKSHAFT RING
1
GEAR RING
1
PILOT BEARING
1
WASHER
1
BOLT
6
WASHER .................................. 2 ........... REPLACES 8941145652
NUT
1
KEY
2
CRK DAMPER PULLEY
1
WASHER
1
PISTON, STD. .......................... 4 ........... GRADE=AX
PISTON, STD. .......................... 4 ........... GRADE=CX
RING SET
4
CONN. ROD METAL SET
4
PISTON PIN
4
CONNECTING ROD ASSY. ..... 4 ........... INCLUDES ITEMS W/$
BUSHING
4
BOLT
8
SNAP PIN RING
8
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 97
ISUZU 4BG1 — TIMING GEAR AND FLYWHEEL HOUSING ASSY.
TIMING GEAR AND FLYWHEEL HOUSING ASSY.
PAGE 98 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — TIMING GEAR AND FLYWHEEL HOUSING ASSY.
TIMING GEAR AND FLYWHEEL HOUSING ASSY.
NO.
1
2
36
36
39
42
49
54
57
58
60
60
60
60
65
86
93
103
175
211
242
252
290
382
PART NO.
8944509752
8943213304
0500408200
0500408450
8943706710
9112290581
8943706720
8971298300
5113210090
0500406140
0500408250
0500408800
5090000841
5090300381
8970276011
8944533001
1096234650
1096254380
1096253630
0500408250
9095714160
0500408200
8943218380
9992023160
PART NAME
QTY.
REMARKS
TIMING GEAR CASE
1
FLYWHEEL HOUSING
1
BOLT .............................................. 4 ........... M8X20 W/ LOCK WASHER
BOLT .............................................. 2 ........... M8X45 W/ LOCK WASHER
GASKET
1
DOWEL
1
GASKET
1
GEAR CASE COVER
1
TIMING CHECK COVER
2
BOLT
4
BOLT .............................................. 8 ........... MX45 W/ LOCK WASHER
BOLT .............................................. 1 ........... M8X80W/ LOCK WASHER
BOLT .............................................. 4 ........... M8X55 W/LOCK WASHER
BOLT .............................................. 3 ........... M10X55
GASKET
2
TACHO DRIVE ELBOW
1
ELBOW GASKET
1
OIL SEAL, FRONT
1
OIL SEAL, REAR
1
BOLT
7
PLUG GASKET
1
BOLT
2
PLUG
1
HOUSING PLUG
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 99
ISUZU 4BG1 — ENGINE MOUNTING ASSY.
ENGINE MOUNTING ASSY
PAGE 100 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — ENGINE MOUNTING ASSY.
ENGINE MOUNTING ASSY.
NO.
2C
2D
20
125
251
PART NO.
9117712470
9117712480
8943134650
9091105100
9091505100
PART NAME
ENGINE FOOT, RIGHT
ENGINE FOOT, LEFT
BOLT
NUT
LOCK WASHER
QTY.
1
1
7
1
1
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 101
ISUZU 4BG1 — INLET MANIFOLD ASSY.
INLET MANIFOLD ASSY.
PAGE 102 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — INLET MANIFOLD ASSY.
INLET MANIFOLD ASSY.
NO.
1
7
20
52
59
59
60
60
138
144
PART NO.
8971333280
8970241220
0911501080
8943216751
0500510300
0501510300
8943706760
8970225710
5141111970
0500408250
PART NAME
QTY.
REMARKS
INLET MANIFOLD
1
GASKET
1
NUT
2
INLET PIPE
1
BOLT .............................................. 2 ........... M10X30 W/ LOCK WASHER
BOLT .............................................. 2 ........... M10X30 W/ LOCK WASHER
GASKET
1
GASKET
1
INLET PIPE
1
BOLT
6
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 103
ISUZU 4BG1 — EXHAUST MANIFOLD ASSY.
EXHAUST MANIFOLD ASSY.
PAGE 104 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — EXHAUST MANIFOLD ASSY.
EXHAUST MANIFOLD ASSY.
NO.
1
2
15
15
16
88
PART NO.
5141410360
8944046100
8943185540
8943185550
9044110300
8941704860
PART NAME
QTY.
REMARKS
EXHAUST MANIFOLD
1
GASKET
2
BOLT ................................................... 1 ............. M8X63 W/PLAIN WASHER
BOLT ................................................... 3 ............. M8X75 W/ PLAIN WASHER
EXHAUST PIPE STUD
3
NUT
4
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 105
ISUZU 4BG1 — VENTILATION ASSY.
VENTILATION ASSY.
PAGE 106 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — VENTILATION ASSY.
VENTILATION ASSY.
NO.
141
142
143
PART NO.
894110110
1143620020
9934905100
PART NAME
DIAPHRAGM ASSY.
PCV COVER
SCREW
QTY.
1
1
6
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 107
ISUZU 4BG1 — WATER PUMP AND CORROSION RESISTOR ASSY.
WATER PUMP AND CORROSION RESISTOR ASSY.
PAGE 108 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — WATER PUMP AND CORROSION RESISTOR ASSY.
WATER PUMP AND CORROSION RESISTOR ASSY.
NO.
2
3#
4
*
7
9 #
*
18 #
*
19 #
*
20 #
*
25 #
*
26 #
*
27 #
*
28 #
*
29 #
*
30 #
*
32 #
*
34 #
*
36
36
36
57
66 #
*
67 #
*
PART NO.
8971250510
8943706610
8943809470
8944161302
9091801470
5136210110
5136130070
5136120100
5136420530
5136390020
5098000520
5095030990
8943777860
9099521030
5136200061
9090908200
0500410400
5090300101
0500410500
5096050050
5096250780
5136390070
PART NAME
QTY.
REMARKS
WATER PUMP ASSY. .......... 1 ..................... INCLUDES ITEMS W/
*
GASKET
1
REPAIR KIT .......................... 1 ..................... INCLUDES ITEMS W/#
WATER PUMP PULLEY
1
RING
1
WATER PUMP IMPELLER 1
GASKET
1
COVER
1
CENTER
1
DUST COVER
1
BEARING
2
WASHER
1
SHAFT
1
SNAP RING
1
SEAL
1
SCREW
3
BOLT .................................... 1 ..................... M10X40 W/LOCK WASHER
BOLT .................................... 2 ..................... M10X75 W/LOCK WASHER
BOLT .................................... 1 ..................... M10X50 W/ LOCK WASHER
HEATER PLUG
1
SECONDARY SEAL
1
SLINGER
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 109
ISUZU 4BG1 — THERMOSTAT AND HOUSING ASSY.
THERMOSTAT AND HOUSING ASSY.
PAGE 110 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — THERMOSTAT AND HOUSING ASSY.
THERMOSTAT AND HOUSING ASSY.
NO.
1
2
14
27
28
44
44
49
50
58
64
66
PART NO.
5137700301
8944033142
9096610050
9095713160
5096050050
0501410250
0501410300
8944017531
0500408250
5096050050
8941760310
8943706730
PART NAME
QTY.
REMARKS
THERMOSTAT
1
HOUSING
1
SWITCH
1
GASKET .................................... 1 ................ REPLACES 9095714160
HEATER PLUG
1
BOLT ......................................... 4 ................ M10X25 W/LOCK AND PLAIN WASHER
BOLT ......................................... 2 ................ M10X30 W/LOCK AND PLAIN WASHER
WATER OUTLET PIPE
1
BOLT
3
WATER OUTLET PLUG
1
GASKET
1
GASKET
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 111
ISUZU 4BG1 — ENGINE WATER PIPING ASSY.
ENGINE WATER PIPING ASSY.
PAGE 112 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — ENGINE WATER PIPING ASSY.
ENGINE WATER PIPING ASSY.
NO.
2
148
PART NO.
8941324900
9099153151
PART NAME
HOSE
CLIP
QTY.
1
2
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 113
ISUZU 4BG1 — FAN AND FAN BELT ASSY.
FAN AND FAN BELT ASSY.
PAGE 114 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — FAN AND FAN BELT ASSY.
FAN AND FAN BELT ASSY.
NO.
1
16
24
36
38
77
80
86A
86B
PART NO.
8970699020
9098516490
8942059861
8970208220
1136420250
9091647080
5136740320
0500408220
0501410300
PART NAME
QTY.
REMARKS
COOLING FAN
1
WASHER
4
BOLT ...................................... 4 ................... M8X65
BELT....................................... 1 ................... REPLACES 5136711320
SPACER
1
WASHER
1
ADJUSTING PLATE
1
BOLT
1
BOLT
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 115
ISUZU 4BG1 — FUEL INJECTION ASSY.
FUEL INJECTION ASSY.
PAGE 116 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — FUEL INJECTION ASSY.
FUEL INJECTION ASSY.
NO.
1
*
15
16
17
18
19
31
32#
33#
34%#
35%#
36%#
37%#
38%#
39%#
41%#
42%#
45%#
46%#
54
62
63
65
66
75
80
82
84
87
93
113
133
133
134
138%#
PART NO.
8971612100
8971230631
8970314671
8970314681
8970314691
8970314701
1153002912
8970161471
5153110270
1153390090
1153320170
1153390100
5153320060
5153390600
8941695030
8943203080
5513390030
8941695020
9153470030
9153390510
0911501080
5154110420
9095720140
5153150030
9091605100
5197510150
9091505100
9091105100
0500410250
9095714080
5154190131
5154112231
8970209350
1096750371
5153430050
PART NAME
QTY.
REMARKS
INJECTION PUMP ASSY. ......... 1 ................ INCLUDES ITEM W/
*
COUPLING ASSY.
1
INJ. PIPE, NO. 1
1
INJ. PIPE, NO. 2
1
INJ. PIPE, NO. 3
1
INJ. PIPE, NO. 4
1
NOZZLE ASSY.
4
NOZZLE HOLDER ASSY. ......... 4 ................ INCL. ITEMS W/%
NOZZLE ASSY. ......................... 4 ................ INCL. ITEMS W/#
BOLT
4
NUT
4
GASKET
8
NUT
4
GASKET
4
SCREW
4
CONNECTOR
4
GASKET
4
PUSH ROD
4
NOZZLE PIN
8
COVER
4
NUT
8
LEAK OFF PIPE ....................... 1 ................ REPLACES 8970209371
GASKET
4
GASKET
4
WASHER
1
BRACKET
1
WASHER
1
NUT
1
BOLT
2
GASKET
2
CLIP
3
NOZZLE PIPE
1
NOZZLE PIPE
1
BOLT
1
SPRING
4
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 117
ISUZU 4BG1 — FUEL FILTER AND BRACKET ASSY.
FUEL FILTER AND BRACKET ASSY.
PAGE 118 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — FUEL FILTER AND BRACKET ASSY.
FUEL FILTER AND BRACKET ASSY.
NO.
1
PART NO.
1132007011
20
21
*
29
*
30
*
40
45
47
54
58
*
69
88
5154112231
1132120870
1132600470
1096300850
5197550010
0501410350
0501408250
1094680021
X132400240
9099063251
0500410200
*
PART NAME
QTY.
REMARKS
FUEL FILTER ASSY. ................. 1 ................ REPLACES 8944537371 AND 8941517451
...................................................................... INCLUDES ITEMS W/
*
EYE JOINT
1
COVER ...................................... 1 ................ REPLACES 5132120751
OVERFLOW VALVE .................. 1 ................ REPLACES 9132600562
GASKET .................................... 2 ................ REPLACES 9095720140
BRACKET
1
BOLT
2
BOLT
2
NUT
1
ELEMENT ................................. 1 ................ REPLACES 8944147963, 1132400791
BOLT
2
BOLT
2
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 119
ISUZU 4BG1 — FUEL PUMP AND PIPE ASSY.
FUEL PUMP AND PIPE ASSY.
PAGE 120 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — FUEL PUMP AND PIPE ASSY.
FUEL PUMP AND PIPE ASSY.
NO.
107
119
150
158A
158B
159
PART NO.
5154114570
9154127311
9095720140
5154190040
5154190051
0501406160
PART NAME
QTY.
REMARKS
PIPE .......................................... 1 ................ REPLACES 8970209330
PIPE .......................................... 1 ................ REPLACES 8970209340
GASKET
2
CLIP
1
CLIP
1
BOLT
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 121
ISUZU 4BG1 — OIL COOLER AND OIL FILTER ASSY.
OIL COOLER AND OIL FILTER ASSY.
PAGE 122 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — OIL COOLER AND OIL FILTER ASSY.
OIL COOLER AND OIL FILTER ASSY.
NO.
2 A$
89
90
109
109
109
109
110
111
112 A
112 B
113 A
113 B
281 B$
288 $
*
290 $
*
321
329 A
331
392
444
469
484
496 B
526
PART NO.
8943212191
5112890090
1217290430
0500408250
0500408450
0500408200
8942058961
8944496450
8970320250
8971281500
5112880020
8944706680
9095716200
8970261351
9132630100
9099211930
8943706700
5090000071
9091605100
9091505100
5112820110
8970196530
9099168190
8970209271
5112800111
PART NAME
QTY.
REMARKS
ELEMENT, OIL FILTER
1
BOLT, ELEMENT TO CASE
1
GASKET, BOLT, OIL COOLER
1
BOLT, M8X25 ............................................ 11 ........... W/LOCK WASHER
BOLT, M8 X45 ............................................. 8 ........... W/LOCK WASHER
BOLT, M8X20 .............................................. 2 ........... W/LOCK WASHER
BOLT, M8X65
1
BODY; CASE, OIL COOLER
1
CORE; OIL COOLER
1
PLUG; OIL COOLER CASE
1
PLUG; OIL COOLER CASE
1
GASKET; PLUG; OIL COOLER CASE
1
GASKET; PLUG; OIL COOLER CASE
1
COVER, OIL FILTER ................................... 1 ........... INCLUDES ITEMS W/
*
PLUG; OIL DRAIN
1
GASKET; PLUG OIL DRAIN
1
GASKET; OIL FILTER TO C/BL
1
BOLT, M10X135
4
WASHER
4
LOCK WASHER
4
GASKET;ELEMENT TO BODY
1
GASKET; OIL COOLER TO C/BL
1
CLIP
2
FILTER ASSY. ............................................. 1 ........... INCLUDES ITEMS W/$
COVER; WATER DUCT
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 123
ISUZU 4BG1 — OIL PUMP AND OIL STRAINER ASSY.
OIL PUMP AND OIL STRAINER ASSY.
PAGE 124 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — OIL PUMP AND OIL STRAINER ASSY.
OIL PUMP AND OIL STRAINER ASSY.
NO.
1
2$
3$
5$
8$
19$
29
32$#
34$#
35$
38A$
38B$
40$#
41$
42$
43$
67$
86$
PART NO.
5131001373
5131650040
9081040300
5095800980
5131250020
5878102022
0500410250
1131280180
5131210140
5131130351
5131410171
5131410180
1131230160
5098430030
5131190060
0108058000
9091505080
1131190010
PART NAME
QTY.
REMARKS
OIL PUMP ASSY. ...................... 1 ................ INCLUDES ITEMS W/$
SPRING SEAT
1
PIN
1
COIL SPRING
1
GEAR
1
GEAR SET ................................ 1 ................ INCLUDES ITEMS W/#
BOLT
2
PINION
1
SHAFT
1
COVER
1
CASE
1
CASE
1
COUPLING
1
VALVE BALL
1
STRAINER
1
BOLT
4
WASHER
4
SPACER
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 125
ISUZU 4BG1 — OIL AND VACUUM PIPING ASSY.
OIL AND VACUUM PIPING ASSY.
PAGE 126 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — OIL AND VACUUM PIPING ASSY.
OIL AND VACUUM PIPING ASSY.
NO.
1
26
28
37
40
40
40
47
116
142
279
343
434
448
PART NO.
8971242340
8941753012
9099211880
5133112561
0501408450
0500408350
0500408320
1096234620
9095720100
9098440220
8941625680
1093600430
0911501080
8941405812
PART NAME
QTY.
REMARKS
PIPE
1
PIPE
1
GASKET
2
PIPE
1
BOLT ...................................... 4 ................... M8X45 W/LOCK AND PLAIN WASHER
BOLT ...................................... 2 ................... M8X35 W/LOCK WASHER
BOLT ...................................... 2 ................... M8X32 W/LOCK WASHER
GASKET
2
GASKET
2
NUT
1
CLIP
2
HOSE
1
NUT
1
FILLER
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 127
ISUZU 4BG1 — ELECTRICAL CONTROL ASSY.
ELECTRICAL CONTROL ASSY.
PAGE 128 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — ELECTRICAL CONTROL ASSY.
ELECTRICAL CONTROL ASSY.
NO.
1
2
4
4
16
19
26
26
26
38
89
252
286
288
PART NO.
1811001911
8971433290
0500512280
0287812350
0501408350
5197110620
050041000
0500410450
5090300101
9825300460
8970299880
8943717120
0911502080
9091606080
PART NAME
QTY.
REMARKS
STARTER ASSY. ....................... 1 ................ 24V 4.5KW
GENERATOR ASSY. ................. 1 ................ 24V 30A
BOLT ......................................... 1 ................ M12X28
BOLT ......................................... 2 ................ M12X35
BOLT ......................................... 2 ................ M8X35 W/LOCK AND PLAIN WASHER
BRACKET
1
BOLT ......................................... 1 ................ M10X100
BOLT ......................................... 1 ................ M10X45 W/LOCK WASHER
BOLT ......................................... 1 ................ M10X75 W/LOCK WASHER
RESISTOR
SWITCH
1
COVER
1
NUT
1
PLAIN WASHER
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 129
ISUZU 4BG1 — BATTERY RELAY ASSY.
BATTERY RELAY ASSY.
PAGE 130 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — BATTERY RELAY ASSY.
BATTERY RELAY ASSY.
NO.
68
PART NO.
1823200010
PART NAME
BATTERY RELAY
QTY.
1
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 131
ISUZU 4BG1 — STARTER COMP. ASSY.
STARTER COMP. ASSY.
PAGE 132 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — STARTER COMP. ASSY.
STARTER COMP. ASSY.
NO.
1
2
3#
4
5
6
8
9%
10
11A
11B
11C
12
15
16
17A$
17B$
18$
19
20@
21@
22@
23@
27A
27B
28
29
30
31
50@
54
57
59
61
62
63
64
65
77
78
80
86
PART NO.
1811293940
1811230250
1811293970
5811291420
5811291440
5811291450
1811130260
1811293860
1811230240
5811291580
5811291590
5811291600
1811130730
1811160440
1811210370
5811291550
1811291960
5811291560
1811293960
1811160420
1811170140
1811180360
1811150620
1811293870
5811292140
1811270310
1811291850
5811291470
5811510360
1811160430
5811220160
1811150610
5811291500
5811291480
9821161400
5811180190
9821161420
5811291490
1811291140
1811293840
1811291840
1825530370
PART NAME
QTY.
REMARKS
SEAL KIT ........................... 1 ................. INCLUDES ITEMS W/ SHOWN IN PICTURE
*
CASE ................................. 1 ................. INCLUDES ITEMS W/#
METAL
1
COVER
1
CLIP
1
STOPPER
1
BRACKET
1
BEARING
1
SHAFT ............................... 1 ................. INCL. ITEM W%
WASHER
1
WASHER
2
WASHER
1
BRACKET
1
WIRE
1
ARMATURE ....................... 1 ................. INCL.UDES ITEMS W/$
BEARING
1
BEARING
1
WASHER
1
COIL
1
BRUSH
1
SPRING
1
HOLDER
1
COVER
1
BOLT
3
BOLT
2
LEVER
1
PIN
1
PLATE
1
SWITCH
1
BRUSH
1
CLUTCH
1
COVER ASSY. ................... 1 ................. INCLUDES ITEMS W/@
TERMINAL
1
CONTACT
1
BUSHING
1
HOLDER
1
WASHER
1
RING
2
WASHER
2
TERMINAL
1
NUT
1
RELAY
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 133
ISUZU 4BG1 — INJECTION PUMP COMP. ASSY. (CONT.)
INJECTION PUMP COMP. ASSY. (CONT.)
PAGE 134 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — INJECTION PUMP COMP. ASSY. (CONT.)
INJECTION PUMP COMP. ASSY. (CONT.)
NO.
PART NO.
PART NAME
1
6
7
8
9
10
14
19
33
46
48
49
50
51
58
62
63
64
68
69
70
71
72
73
74
75
79
80
82
88
89
102
103
105
105
107
107
107
107
107
107
107
107
107
107
107
114
114
117
118
5156110590
5156440170
1096230520
5156290450
5156430010
1156490010
5156410030
8943771540
1096230130
1156192430
5156191560
9812250470
5156210190
5156190490
9812250580
9812350150
5156430090
9812350210
9812212230
5156190410
9812222200
1156290010
1156220030
8943865960
8941711090
1156190030
9812151150
8941711100
5156191360
9019006140
9095720100
1132600011
1157590010
9000906770
5098000380
5156290150
5156290160
5156290170
5156290180
5156290190
5156290200
5156290380
9812250330
5156190390
5156290900
1156390880
9000906770
5098000380
1157590010
1156190820
HOUSING
1
HOLDER
4
GASKET
4
STOPPER
4
SPRING
4
GASKET
4
VALVE
4
PLUNGER
4
GASKET
1
COVER
1
GASKET
1
RING
1
CAMSHAFT
1
KEY
1
SLEEVE
4
SEAT
4
SPRING
4
SEAT
4
TAPPET .......................................... 4 .................. INCL. ITEMS W/
GUIDE
4
PIN
4
BUSHING
4
ROLLER
4
GASKET
1
COVER
1
SCREW
2
STUD
3
NUT
3
PLUG
4
BOLT
4
GASKET
2
VALVE
1
GASKET
1
BEARING ....................................... 1 .................. NSK
BEARING ....................................... 1 .................. NTN
SHIM ............................................... 1 .................. T=0.10
SHIM ............................................... 1 .................. T=0.12
SHIM ............................................... 1 .................. T=0.14
SHIM ............................................... 1 .................. T=0.16
SHIM ............................................... 1 .................. T=0.18
SHIM ............................................... 1 .................. T=0.50
SHIM ............................................... 1 .................. T=1.00
SHIM ............................................... 1 .................. T=0.30
SHIM ............................................... 1 .................. T=0.70
SHIM ............................................... 1 .................. T=1.40
SHIM ............................................... 1 .................. T=2.40
BEARING ....................................... 1 .................. NSK
BEARING ....................................... 1 .................. NTN
GASKET
2
BOLT
1
*
*
*
QTY.
REMARKS
*
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 135
ISUZU 4BG1 — INJECTION PUMP COMP. ASSY. (CONT.)
INJECTION PUMP COMP. ASSY. (CONT.)
PAGE 136 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — INJECTION PUMP COMP. ASSY. (CONT.)
INJECTION PUMP COMP. ASSY. (CONT.)
NO.
PART NO.
PART NAME
126
127
130
148
155
157
159
162
162
162
162
162
162
162
162
162
162
162
176
177
178
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
181
9812350170
5156190440
9019006140
9812151440
1156190240
8941445880
9812250470
5156290150
5156290160
5156290170
5156290180
5156290190
5156290200
5156290380
9812250330
5156190390
5156290900
1156390880
5156250010
9812250570
9812350030
5156190340
5156190350
5156190360
5156190010
5156190020
5156190030
5156190040
5156190050
5156190070
5156190080
5156190090
5156190100
5156190110
5156190120
5156190130
5156190150
9812350420
9812350430
9812350440
9812350450
5156190250
5156190260
5156190270
5156190370
5156191060
5156191070
5156191080
5156191090
5156191100
ADAPTER
1
ADAPTER
1
SCREW
4
GASKET
2
BOLT
1
GASKET
1
RING
1
SHIM ............................................... 1 .................. T=0.10
SHIM ............................................... 1 .................. T=0.12
SHIM ............................................... 1 .................. T=0.14
SHIM ............................................... 1 .................. T=0.16
SHIM ............................................... 1 .................. T=0.18
SHIM ............................................... 1 .................. T=0.50
SHIM ............................................... 1 .................. T=1.00
SHIM ............................................... 1 .................. T=0.30
SHIM ............................................... 1 .................. T=0.70
SHIM ............................................... 1 .................. T=1.40
SHIM ............................................... 1 .................. T=2.40
PLATE
2
PINION
4
SCREW
4
SHIM ............................................... 1 .................. T=0.30
SHIM ............................................... 1 .................. T=0.40
SHIM ............................................... 1 .................. T=0.50
SHIM ............................................... 1 .................. T=0.60
SHIM ............................................... 1 .................. T=0.70
SHIM ............................................... 1 .................. T=0.80
SHIM ............................................... 1 .................. T=0.90
SHIM ............................................... 1 .................. T=1.00
SHIM ............................................... 1 .................. T=1.10
SHIM ............................................... 1 .................. T=1.20
SHIM ............................................... 1 .................. T=1.30
SHIM ............................................... 1 .................. T=1.40
SHIM ............................................... 1 .................. T=0.55
SHIM ............................................... 1 .................. T=0.65
SHIM ............................................... 1 .................. T=0.75
SHIM ............................................... 1 .................. T=0.85
SHIM ............................................... 1 .................. T=0.95
SHIM ............................................... 1 .................. T=1.05
SHIM ............................................... 1 .................. T=1.15
SHIM ............................................... 1 .................. T=1.25
SHIM ............................................... 1 .................. T=0.20
SHIM ............................................... 1 .................. T=0.25
SHIM ............................................... 1 .................. T=0.35
SHIM ............................................... 1 .................. T=0.45
SHIM ............................................... 1 .................. T=1.50
SHIM ............................................... 1 .................. T=1.60
SHIM ............................................... 1 .................. T=1.35
SHIM ............................................... 1 .................. T=1.45
SHIM ............................................... 1 .................. T=1.55
QTY.
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 137
ISUZU 4BG1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
PAGE 138 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — GOVERNOR COMP. ASSY.
GOVERNOR COMP. ASSY.
NO.
PART NO.
PART NAME
1
2#
3#
4#
7#
8A#
8B#
11 #
12 #
13 #
15 #
16 #
17 #
17 #
17 #
17 #
17 #
17 #
17 #
17 #
17 #
18 #
23 #
24 #
25 #
28 #
34 #
37 #
40 #
41 #
43 #
45A#
45B#
59 #
60B#
60C #
63 #
71 #
79 #
79 #
79 #
79 #
79 #
79 #
83 #
86 #
87 #
90 #
91 #
8971621760
5157210040
5157290270
8913253970
5157210220
5157290330
5157290540
1157290010
1157220210
5196190490
5157290340
9813250860
9813250880
9813255510
9813255520
9813255530
5157292860
5157292870
1157298910
1157298920
1157298930
5157190080
1157250110
9813222350
9091854040
5157250420
1157232120
5157250170
9813251820
1157231860
9008130230
1157256680
5157250330
5157210210
5157290630
9019006160
9813919070
5157230880
1157292940
1157292950
1157292960
1157292970
1157292980
1157292990
9813919060
9813254290
9019006160
9813251770
1157230730
GOVERNOR ASSY. ....................1 ...................... INCLUDES. ITEMS W/#
HOUSING
1
BOLT
6
PLATE
1
COVER
1
BOLT
4
BOLT
2
GASKET
1
FLYWEIGHT ASSY.
1
KEY
1
WASHER
1
NUT
1
SHIM ............................................1 ...................... T=0.20
SHIM ............................................1 ...................... T=0.30
SHIM ............................................1 ...................... T=0.40
SHIM ............................................1 ...................... T=1.00
SHIM ............................................1 ...................... T=0.50
SHIM ............................................1 ...................... T=1.50
SHIM ............................................1 ...................... T=2.00
SHIM ............................................1 ...................... T=3.00
SHIM ............................................1 ...................... T=4.00
SCREW
1
LINK
1
SPRING
1
RING
1
LEVER
1
SPRING
1
LEVER ASSY.
1
SCREW
1
SPRING CAPSULE
1
NUT
1
LEVER ASSY.
1
LEVER ASSY.
1
COVER
1
BOLT
BOLT
1
GASKET
1
SPRING
1
SHIM ............................................1 ...................... T=0.20
SHIM ............................................1 ...................... T=0.25
SHIM ............................................1 ...................... T=0.30
SHIM ............................................1 ...................... T=0.35
SHIM ............................................1 ...................... T=0.40
SHIM ............................................1 ...................... T=0.50
SEAL
1
BUSHING
1
BOLT
1
SCREW
1
SPRING CAPSULE
QTY.
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 139
ISUZU 4BG1 — GOVERNOR COMP. ASSY. (CONT.)
GOVERNOR COMP. ASSY. (CONT.)
PAGE 140 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — GOVERNOR COMP. ASSY. (CONT.)
GOVERNOR COMP. ASSY. (CONT.)
NO.
PART NO.
PART NAME
93B#
93D#
93E#
94#
96#
99#
101#
103#
105A#
105D#
105D#
105F #
106#
107#
108#
109#
109#
110#
111#
112#
113#
125#
150#
154#
156#
157#
161#
162#
1157296890
9813261120
9844100270
5157291230
5157290530
9813250620
8941445880
1157290920
1157250810
8943444370
8943444380
8970874410
9813250300
9813254880
1157293010
1157290990
9813250970
1157290980
8970242390
9813212050
9091854150
9813252100
9813150650
5157291120
1835794920
9019008180
1157290380
1157290150
NUT
NUT
NUT
SCREW
PLUG
PIN
GASKET
NUT
LEVER
LEVER
LEVER
LEVER
KEY
WASHER
COLLAR
SHIM
SHIM
SEAL
BUSHING
GASKET
RING
CAP
ADAPTER
BOLT
WASHER
BOLT
PLUG
WASHER
QTY.
REMARKS
1
1
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 141
ISUZU 4BG1 — FEED PUMP ASSY.
FEED PUMP ASSY.
PAGE 142 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — FEED PUMP ASSY.
FEED PUMP ASSY.
NO.
1
2
*
3
*
4
*
5
*
8
*
9
*
10
*
11
*
13
*
15
*
16
*
17
*
18
*
19
*
28*
29 #
*
30 #
*
31 #
*
PART NO.
8971219100
1157610060
1196230160
9813517020
1157550020
1156190820
1157590010
1157590030
5157590270
9813550250
5157510120
9813512050
9813513020
9813550350
8941711850
5157540010
9813514030
9813514100
1157590020
PART NAME
QTY.
REMARKS
PUMP ASSY. .................................. 1 ................. INCLUDES ITEMS W/
*
PUMP
1
GASKET
1
SPRING
2
VALVE
2
BOLT
1
GASKET
4
ADAPTER
1
BOLT
1
RING
1
HOUSING
1
PISTON
1
SPRING
1
GASKET
1
PLUG
1
TAPPET ASSY. ............................... 1 ................. INCLUDES ITEMS W/#
ROLLER
1
PIN
1
GUIDE
2
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 143
ISUZU 4BG1 — MISC. INJECTION PUMP ASSY.
MISC. INJECTION PUMP ASSY.
PAGE 144 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — MISC. INJECTION PUMP ASSY.
MISC. INJECTION PUMP ASSY.
NO.
2
3
8
9
10
19 A
19 B
20
2
PART NO.
5197510500
9041010300
9091645100
9091506100
5156390020
5090000841
5090002221
9095720080
8943706750
PART NAME
QTY.
REMARKS
BRACKET
1
STUD
4
WASHER
4
WASHER
4
NUT
4
BOLT ......................................... 6 ........... M8X55 W/LOCK WASHER
BOLT ......................................... 1 ........... M8X22
GASKET
1
GASKET
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 145
ISUZU 4BG1 — COUPLING ASSY.
COUPLING ASSY.
PAGE 146 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — COUPLING ASSY.
COUPLING ASSY.
NO.
1
4
9
10
11
27
30
PART NO.
5157810030
1156192470
9096620070
9884105020
5156190480
5125240210
8944575170
PART NAME
COUPLING
PLATE
BOLT
NUT
WASHER
GEAR
BOLT
QTY.
1
1
1
1
1
1
6
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 147
ISUZU 4BG1 — ACCELERATOR PEDAL ASSY.
ACCELERATOR PEDAL ASSY.
PAGE 148 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — ACCELERATOR PEDAL ASSY.
ACCELERATOR PEDAL ASSY.
NO.
PART NO.
204 A 5197890040
PART NAME
BRACKET
QTY.
1
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 149
ISUZU 4BG1 — AIR DUCT ASSY.
AIR DUCT ASSY.
PAGE 150 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — AIR DUCT ASSY.
AIR DUCT ASSY.
NO.
343
345
PART NO.
8943216680
8942420340
PART NAME
HOSE
CLIP
QTY.
1
2
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 151
ISUZU 4BG1 — FUEL SEDIMENTER ASSY.
FUEL SEDIMENTER ASSY.
PAGE 152 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — FUEL SEDIMENTER ASSY.
FUEL SEDIMENTER ASSY.
NO.
1
3%
4%
5%
7%
9%
34%
35%#
36%
38%
46%
47
50B
51B
50C
50C
51
62A
62B
PART NO.
1132008410
1132112110
5132120591
5096230700
5132190200
5096300240
8944537460
8944163770
5132190221
5132190210
9095720140
894470470
1097007590
9097161140
1097007600
9097161240
0500406200
9099063251
5157590270
PART NAME
QTY.
REMARKS
FUEL SEDIMENTER ................. 1 ................ INCLUDES ITEMS W/%
BODY ASSY.
1
COVER
1
GASKET
1
PLUG
1
GASKET
1
PLUG ......................................... 1 ................ INCLUDES ITEMS W/#
GASKET
1
RING
1
FLOAT
1
GASKET
4
PIPE
1
CLIP
2
CLIP
3
CLIP
2
CLIP
3
BOLT
7
BOLT
1
BOLT
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 153
ISUZU 4BG1 — CLUTCH ASSY.
CLUTCH ASSY.
PAGE 154 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — CLUTCH ASSY.
CLUTCH ASSY.
NO.
17
18
PART NO.
9910664500
9091505140
PART NAME
BOLT
LOCK WASHER
QTY.
6
6
REMARKS
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 155
ISUZU 4BG1 — SWITCH AND RELAY ASSY.
SWITCH AND RELAY ASSY.
PAGE 156 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
ISUZU 4BG1 — SWITCH AND RELAY ASSY.
SWITCH AND RELAY ASSY.
NO.
15
58
417
434%
PART NO.
1819001372
1823100080
1825500732
KEYISUZUF
PART NAME
QTY.
REMARKS
ENG. STOP ACTUATOR
1
IGNITION SWITCH ................... 1 ................ INCLUDES ITEM W/%
EMERGENCY RELAY
1
KEY
1
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 157
Effective: October 1, 2002
PAYMENT TERMS
TERMS AND CONDITIONS OF SALE — PARTS
5.
Parts must be in new and resalable
condition, in the original Multiquip package (if any), and with Multiquip part
numbers clearly marked.
6.
The following items are not returnable:
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.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
MINIMUM ORDER
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
RETURNED GOODS POLICY
1.
2.
A Returned Material Authorization must
be approved by Multiquip prior to shipment.
To obtain a Return Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers, quantities, and descriptions of the items to be
returned.
a. The parts numbers and descriptions
must match the current parts price
list.
b. The list must be typed or computer
generated.
c. The list must state the reason(s) for
the return.
d. The list must reference the sales
order(s) or invoice(s) under which the
items were originally purchased.
e. The list must include the name and
phone number of the person requesting the RMA.
3.
A copy of the Return Material Authorization must accompany the return shipment.
4.
Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
Multiquip reserves the right to quote and sell
direct to Government agencies, and to Original
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
SPECIAL EXPEDITING SERVICE
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
A $35.00 surcharge will be added to the invoice
for special handling including bus shipments,
insured parcel post or in cases where Multiquip
must personally deliver the parts to the carrier.
c. Any line item with an extended dealer
net price of less than $5.00.
f. Paint, chemicals, and lubricants.
Multiquip shall not be liable here under for
damages in excess of the purchase price of the
item with respect to which damages are claimed,
and in no event shall Multiquip be liable for loss
of profit or good will or for any other special,
consequential or incidental damages.
g. Decals and paper products.
LIMITATION OF WARRANTIES
h. Items purchased in kits.
No warranties, express or implied, are made in
connection with the sale of parts or trade accessories nor as to any engine not manufactured
by Multiquip. Such warranties made in connection with the sale of new, complete units are
made exclusively by a statement of warranty
packaged with such units, and Multiquip neither assumes not authorizes any person to
assume for it any other obligation or liability
whatever in connection with the sale of its
products. Apart from such written statement of
warranty, there are no warranties, express,
implied or statutory, which extend beyond the
description of the products on the face hereof.
d. Special order items.
Return shipments will be accepted and credit
will be allowed, subject to the following provisions:
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
e. Electrical components.
7.
The sender will be notified of any
material received that is not acceptable.
8.
Such material will be held for five
working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.
9.
Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
LIMITATIONS OF SELLER’S LIABILITY
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a specific date and all orders received on or after
that date will be billed at the revised price.
PAGE 158 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)
NOTE PAGE
DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 159
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MQ Power
1800 Water Ridge Rd. Tel. (800) 883-2551
Suite 500/600
Fax (972) 315-1847
Lewisville, TX 75057
Contact: mqpower@multiquip.com
Web: www.mqpower.com
MQ Parts Department
800-427-1244
Fax: 800-672-7877
310-537-3700
Fax: 310-637-3284
Service/Tech Support/Warranty
800-835-2551
Fax: 310-638-8046
© COPYRIGHT 2007, MULTIQUIP INC.
MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other
trademarks are the property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if
resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the DCA-45SSIU2
WHISPERWATT™ GENERATOR. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be
considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time
without notice and without incurring any obligations.
Your Local Dealer is:
Manufactured for
Multiquip Inc.
by
DENYO CO., LTD, JAPAN