Multiquip DCA45SSIU2 User Manual

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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-45SSIU2MQ POWER DCA-45SSIU2

MQ POWER DCA-45SSIU2

MQ POWER DCA-45SSIU2MQ POWER DCA-45SSIU2 AC GENERAAC GENERA

AC GENERA

AC GENERAAC GENERA

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

TORTOR

TOR

TORTOR

ISUZU 4BG1 ENGINE

Cylinder Head Cover Assembly ......................... 86-87

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

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

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

PAGE 4 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

WINGSWINGS

WINGS

WINGSWINGS

Terms and Condition of Sale — Parts .................. 158

NOTE

Specification and part number are subject to change without notice.

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:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u ck

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

Parts Department

800-427-1244 Fax: 800-672-7877

310-537-3700 Fax: 310-637-3284

Mayco Parts

800-306-2926 Fax: 800-672-7877

310-537-3700 Fax: 310-637-3284

Service Department

800-478-1244 Fax: 310-537-4259

310-537-3700

MQ Power Service Department

800-835-2551 Fax: 310-638-8046

310-537-3700

Warranty Department

800-421-1244, Ext. 279 Fax: 310-537-1173

310-537-3700, Ext. 279

Multiquip’s Main Phone Numbers

800-421-1244 Fax: 310-537-3927

310-537-3700

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 Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other carrier.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

at no charge for freight

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

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

DCA-45SSIU2 — SPECIFICATIONS

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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.

This Owner's Manual has been

NOTE

Before using this GENERATOR, ensure that the operating individual has read and understands all instructions in this manual.

developed to provide complete instructions for the safe and efficient operation of the MQ Power

DCA45SSIU2 WHISPERWATT™ GENERATOR.

Model

HAZARD SYMBOLS

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.

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.

DANGER: You WILL be KILLED or

SERIOUSLY injured if you DO NOT follow directions.

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.

Potential hazards associated with trowel operation will be referenced with " this manual, and will be referenced in conjunction with Safety "

Message Alert Symbols

Hazard Symbols

" which appear throughout

Burn Hazards

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.

Rotating Parts

NEVER operate equipment with covers, or

guards removed. Keep and

clothing

prevent injury.

fingers, hands, hair

away from all moving parts to

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.

This

NOTE

the surrounding environment could be damaged if you do not follow instructions.

generator

, other property, or

Respiratory Hazard

ALWAYS wear approved respiratory protection.

Sight and Hearing hazard

ALWAYS wear approved eye and hearing

protection.

Equipment Damage Messages

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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

DCA-45SSIU2 — RULES FOR SAFE OPERATION

■

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

The following safety guidelines should always be used when operating the DCA-45SSIU2 Generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment before reading this entire manual.

■

High Temperatures – Allow the engine to cool before performing service and maintenance functions. Contact

hot!

with

■

The engine of this generator requires an adequate free flow of cooling air. operate the generator

■

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.

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 operate this equipment when not feeling well due to fatigue, illness or taking medicine.

NEVER use gas piping as an electrical ground.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

components can cause serious burns.

NEVER

■

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.

PAGE 12 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

■

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 NEVER

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. performing maintenance on the generator.

stand in water

while AC power from the generator

Turn all circuit breakers OFF before

lay in wate

DCA-45SSIU2 — RULES FOR SAFE OPERATION

■

ALWAYS make sure that electrical circuits are properly

grounded

codes before operating generator. Severe 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.

DANGERDANGER

DANGER

DANGERDANGER

securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator and electrical shock.

DANGERDANGER

DANGER

DANGERDANGER

DANGER

DANGERDANGER

per the

National Electrical Code

(NEC) and local

injury

death!

Never use damaged or worn cables when

connecting equipment to the generator.

Make sure power connecting cables are

WET

HANDS

NEVER grab or

touch a live power cord with

wet hands , the possibility exists

of electrical shock, electrocution, and even

death!

POWER

CORD

(POWER ON)

DANGERDANGER

DANGER

DANGERDANGER

■

Backfeed to a utility system can cause 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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the engine

2. Coolant Drain Plug - Removing the coolant drain plug

3. Engine Oil Drain Plug - Removing the engine oil drain

Maintenance Safety

■

electrocution

and or

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.

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.

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.

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.

NEVER lubricate components or attempt service on a running machine.

■

NEVER touch output terminals during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the “OFF” position when contact with the output terminals is required. There exists the possibility of

which can cause severe bodily harm or even death

electrocution, electrical shock or burn,

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 13

■

ALWAYS allow the machine a proper amount of time to cool before servicing.

Keep the machinery in proper running condition. Fix damage to the machine immediately and always replace

broken parts.

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 performing service on the generator.

■

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 unattended.

■

DO NOT allow unauthorized people to operate this equipment.

■

ALWAYS read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.

■

Refer to the technical questions or information.

DANGER:DANGER:

DANGER:

DANGER:DANGER:

Isuzu Engine Owner's Manual

negative battery terminal

manual mode

for engine

before

Battery

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

1. DO NOT drop the battery. There is the possibility of risk that the battery may explode.

2. DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.

3. ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

always

wear safety glasses.

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 (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.

National Electrical Code

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 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 “ basic towing techniques.

clothing or skin

Towing Safety Precautions

, rinse skin or clothing

” for

PAGE 14 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — RULES FOR SAFE OPERATION

■

Towing Safety Precautions

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Conform to

(DOT) 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.

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.

Department of Transportation

Safety Towing Regulations

before

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

DOT Requirements include the following:

z z

Emergencies

■

ALWAYS know the location of the nearest

■

ALWAYS know the location of the nearest and

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

fire extinguisher

first aid kit

■

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 chains to towing vehicle properly.

■

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 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.

Trailer tires should be inflated to 50 psi cold.

chock blocks

underneath wheel to prevent rolling,

■

In emergencies

nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

always

know the location of the

keep a phone on the job site

and

fire department

. This

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

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.

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.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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.

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.

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.

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.

NOTE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 17

DCA-45SSIU2 — TOWING SAFETY PRECAUTIONS

Towing Safety Precautions

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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".

Check with your local county or state safety towing regulations before towing your generator.

■

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 rolling, while parked.

■

Place 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.

chocked blocks

support blocks

underneath wheel to prevent

underneath the trailer’s bumper to

Figure 4. Generator with Trailer

PAGE 18 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — TRAILER SPECIFICATIONS

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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).

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.

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 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.

or lug nut tightening and

4. Frame Length - Measurement is from the ball hitch to the rear bumper (reflector).

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 19

DCA-45SSIU2 — TRAILER SPECIFICATIONS

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PAGE 20 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — TRAILER SPECIFICATIONS

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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:

Tachometer

Water Temperature Gauge/Lamp

Oil Pressure Gauge/Lamp

Charging Ammeter Gauge

Engine Speed Handle

Pre-Heat Lamp

Panel Light

Panel Light Switch

Ignition/Preheat Switch

Generator Control Panel

The “Generator Control Panel” is provided with the following:

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Voltage Regulator

Over-Current Relay

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

Three 250 VAC output receptacles (CS-6369), 50 amps

Three auxilliary circuit breakers, 250V @50 amps

Two 125 VAC output receptacles, (GFCI), 20 amps

Two GFCI circuit breakers, 120V@ 20amps

Five output terminal lugs (3Ø power)

Control Box

The “Control Box” is provided with the following:

3-Pole, 250 VAC, 110 amp Main Circuit Breaker

Automatic Voltage Regulator

Current Transformer

Emergency Relay

Open Delta Excitation System

The DCA-45SSIU2 generator is equipped with the state of the art

Open-Delta

" 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 " the required load.

Engine

The DCA-45SSIU2 is powered by a 4 cycle, water cooled, turbocharged Isuzu 4BG1 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.

" excitation system. The open delta system consist of

fixed ceiling

" and responds according the demands of

diesel

engine. This engine is designed

PAGE 24 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — MAJOR COMPONENTS

Figure 5. Major Components

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DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 25

Figure 6. Generator Control Panel

DCA-45SSIU2 — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions of the DCA-45SSIU2 "

1. Main Circuit Breaker – This three-pole, 110 amp main breaker is provided to protect the UVWO output terminals from overload.

2. AC Ammeter – Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

3. Ammeter Change-Over Switch – This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

4. Voltmeter Change-Over Switch – This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

5. Voltage Regulator Control – Allows ±15% manual adjustment of the generator’s output voltage.

6. Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz ±1 Hz .

7. AC Voltmeter – Indicates the output voltage present at the UVWO terminals.

Generator Control Panel

" (Figure 6).

Located behind the generator control panel is the

Control Box

electronic components required to make the genertator function.

The “Control Box” is equipped with the following major components:

Over-Current Relay

Voltage Rectifer

Starter Relay

Engine Controller (Computer Controlled)

Current Transformer

Voltage Selector Switch

NOTE

To restore power to the UWVO output terminals, press the

reset

button on the overcurrent relay and place the

circuit breaker in the

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current flowing from the UWVO output terminals to the load.

In the event of a short circuit or

over current condition, it will automatically trip the main 250 amp breaker.

overcurrent

main

closed

position (ON).

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 the DCA-45SSIU2 "

1. Panel Light - Normally used in dark places or at night. When activated, panel will luminate. When the generator is not in use, turn the panel light switch to the ‘OFF’ position.

2. Panel Light Switch- When activated, will turn on control panel light.

3. Water Temperature Lamp - Indicates that the water temperature is outside of normal range and will shut down the engine.

4. Oil Pressure Lamp - Indicates that the oil pressure is too low or high and will shut down the engine.

5. Pre-heat Lamp - This indicates when the engine is ready for starting during cold weather operating conditiions.

6. Engine Speed Handle- This handle will change the speed of the engine from

Engine Operating Panel

high

low

" (Figure 7).

7. Starter Switch – Four position switch, pre-heat, stop, run and start. Insert ignition key to start and stop engine.

8. 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.

9. Fuel Gauge - Indicates amount of diesel fuel available.

10. 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.

11. Water Temperature Gauge – During normal operation this gauge be should read between 165o F to 215o F.

12. Oil Pressure Gauge – Normal operation should be about 25 psi. When starting the generator the oil pressure may read a bit higher, but after the engine warms up the oil pressure should return to normal.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 27

DCA-45SSIU2 — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Familiarization

The “

Output Terminal Panel

the following:

Three (3) 240V output receptacles, 50 amp

Three (3) Circuit Breakers 240V @50 amps

Two (2) 120V GFCI receptacles, 20 amp

Two (2) GFCI Circuit Breakers 120V@ 20 amps

One Main Circuit Breaker 250V @110 amps

Five (5) Output Terminal Lugs

” (Figure 8) is provided with

Output Terminal Panel

The on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs.

NOTE

(Figure 8) shown below is located

Terminal legs “O” and “Ground” are considered

bonded grounds

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 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 being tripped. Pressing the " the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

" (See Figure 9) in

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 control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

Figure 11. Voltage Regulator Control Knob

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.

voltage regulator control knob

increase

decrease

the voltage, turning the knob counter-

the voltage.

(Figure 11) on the

After the load wires have been securely attached to the

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 (CS-

6369) recepacles (Figure 10) provided on the output terminal panel.These receptacles can voltage selector switch is placed in the

only

be accessed when the

single-phase 240/

UVWO terminals, reinstall the plastic face plate. Place the terminal cover in the down position and secure the locking latch.

120 position.

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, to switch starting the engine.

main

circuit breaker is provided. Make sure

ALL

circuit breakers to the "OFF" position prior to

Over Current Relay

over current relay

An 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 rent relay must be pressed. The over current relay is located in the control box.

(Figure 14) is connected to the main

reset button

Figure 14. Over Current Relay

on the over cur-

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

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and

Three Phase Load

When calculating the power requirements for 3-phase power

use the following equation: 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

NOTE

starting system of the equipment.

If wattage is not given on the equipment's

NOTE

The power factor of this generator is 0.8. See Table 4 below when connecting loads.

spmal

name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS l VOLTAGE x AMPERAGE

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An inadequate size connecting cable which cannot carry the

required load can cause a voltage drop which can burn out

the appliance or tool and overheat the cable. See Table 5.

When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

When connecting a fluorescent or mercury lamp, a capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

When connecting an electric drill or other power tools, pay close attention to the required starting current capacity.

When connecting ordinary power tools, a capacity of up to

the generating set’s rated output (kW) multiplied by 0.8 can

be used.

Motors and motor-driven equipment draw much greater current for starting than during operation.

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DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 31

CAUTION:

Before connecting this generator to any building’s electrical system, a

electrician switch

without this transfer switch.

NOTE

licensed

must install an

isolation (transfer)

. Serious injury or death may result

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.

DCA-45SSIU2 — GENERATOR OUTPUTS

Generator Output Voltages

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the

voltage selector

switch (Figure 15). To obtain some of

Generator Amperage

Tables 7 and 8 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

the voltages as listed in Table 6 (see below) will require a fine adjustment using the

knob

located on the control panel.

voltage regulator

(VR)

control

Voltage Selector Switch

voltage selector

The

switch (Figure 15) is located above the UVWO Hard Wire Hook-up Panel. It has been provided for ease of voltage selection.

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,

hold

the

red button

located at the bottom of the switch.

press

and

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CAUTION:

CAUTION:CAUTION:

NEVER change the position of the

selector switch

while the engine is running.

voltage

ALWAYS place circuit breaker in the open

position before selecting voltage.

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PAGE 32 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

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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.

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Figure 16. Voltage Selector Switch 240/139V Three Phase

Use this position for

3Ø, 208V/1Ø,120V

Position (for 3Ø, 208V, 120V voltage)

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Figure 17. AC Voltmeter

Change-Over Switch

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

Over Switch

(Figure 17) to the W-U position and the

Ammeter Change-Over Switch

AC Voltmeter Change-

(Figure 19) to the U or W

Figure 19. AC Ammeter

Change-Over Switch

position to read the output on the selected leg.

NOTE

Figure 18 AC Voltmeter

Gauge

(Volt reading on W-U Lug)

Figure 20. AC Ammeter (Amp reading on U lug)

The

ammeter

gauges are only active when the UVWO terminals are in use.

and

voltmeter

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 33

DCA-45SSIU2 — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the position of the the adjustment of the

Remember the voltage selector switch determines the of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø 240/139 UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139

position as shown in Figure 21.

Voltage Regulator Control Knob

Voltage Selector Switch

and

range

3Ø 208V/1Ø120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 24.

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

Use this position for 3Ø-208 or 1Ø120V.

Figure 24. Voltage Selector Switch 3Ø-208V/1Ø-120V Three-Phase Position

Figure 21. Voltage Selector Switch 240/139V

Three-Phase Position

2. Connect the load wires to the UVWO terminals as shown in Figure 22.

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

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)

Figure 25. UVWO Terminal Lugs

3Ø-208V/120V Connections

Figure 26. Voltage Regulator Knob (208V)

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

1. Place the voltage selector switch in the 3Ø 480/277

position as shown in Figure 27.

Figure 27. Voltage Selector Switch 480/277V

Three-Phase Position

2. Connect the load wires to the UVWO terminals as shown

in Figure 28.

1Ø 240V/120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 30.

2. Connect the load wires to the UVWO terminals as shown in Figure 31.

Figure 30. Voltage Selector Switch 240/120V

Single-Phase Position

Figure 28. UVWO Terminal Lugs

240/139V Three Phase Connections

3. Turn the voltage regulator knob (Figure 29) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Figure 29. Voltage Regulator Knob (139V/240V)

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 35

Figure 31. UVWO Terminal Lugs

1Ø-240V/120V Connections

3. Turn the voltage regulator knob (Figure 32) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Figure 32. Voltage Regulator Knob (1Ø-240/120V)

DCA-45SSIU2 — PRE-SETUP

Circuit Breakers

To protect the generator from an overload, a 3-pole, 110 amp,

main

circuit breaker is provided to protect the UVW output

Fuel Check

DANGER:DANGER:

DANGER:

DANGER:DANGER:

terminals from overload. In addition two single-pole, 20 amp

GFCI

circuit breakers are provided to protect the GFCI

load

receptacles from overload. Three 50 amp

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.

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

Refilling the Fuel System

notches (Figure 33) on the dipstick. See Table 11 for proper selection of engine oil.

The DCA45SSJU genset may (if equipped with a trailer or skid) have a consists of an

mounted

equipped with a skid type fuel system does not use the internal generator fuel tank.

Fuel spillage on a a

fire

explosion

hot!

engine can cause

. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards.

NEVER!

smoke

around or near the generator.

double fuel tank system

internal

generator fuel tank, and a

(Figure 34), which

trailer

fuel tank. It is also possible the genset can be

skid mounted

fuel tank (Figure 5). The

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:

API Service Classification CH-4

API Service Classification CG-4

API Service Classification CF-4

ACEA Specification E3

ACEA Specification E2

of fuel tank system.

ALWAYS 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.

liOrotoMdednemmoceR.11elbaT

Use the instructions in this section that applies to your type

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WARNING:WARNING:

WARNING:

WARNING:WARNING:

Figure 34. Double Fuel Tank System

fill the fuel tank with clean and fresh

#2 diesel

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:CAUTION:

CAUTION:

CAUTION:CAUTION:

Figure 35. Skid Type Fuel Tank System

Refueling Procedure:

DANGER:DANGER:

DANGER:

DANGER:DANGER:

Diesel fuel

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.

and its vapors are dangerous

ALWAYS! fuel

fill trailer tank

, before filling secondary internal tank.

first

with

#2 diesel

WARNING:WARNING:

WARNING:

WARNING:WARNING:

ALWAYS!

before refueling.

Figure 36. Only Fill on Level Ground

2. 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

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 37

place trailer on firm level ground

fill trailer fuel tank (Figure 37) first.

Figure 37. Fuel Tank Filling Order

NOTE

ONLY! use

refueling.

Fuel from the secondary inner tank will eventually drain into the primary trailer tank.

#2 diesel fuel

when

DCA-45SSIU2 — PRE-SETUP

3. NEVER overfill trailer fuel tank – It is important to 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:WARNING:

WARNING:

WARNING:WARNING:

DO NOT OVER-FILL fuel system. Leave room for fuel expansion . Fuel expands when heated.

4. Once the trailer tank is full, the can be filled (See Figure 39). Notice how the trailer filler tube level rises when the internal tank is filled.

secondary inner tank

5. Figure 40 below reflects a full fuel system.

Figure 40. Full Fuel System

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:WARNING:

WARNING:

WARNING: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 39. Filling Secondary Internal Fuel Tank

PAGE 38 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

Figure 41. Fuel Expansion

Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)

DCA-45SSIU2 — PRE-SETUP

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:CAUTION:

CAUTION:

CAUTION:CAUTION:

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator

cap until the unit has completely cooled. The possibility of burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 12 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

hot!

coolant exists which can cause severe

yticapaCtnalooC.21elbaT

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

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 insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the Isuzu

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 42) when depressed with the thumb as shown below.

When the antifreeze is mixed with

water, the antifreeze mixing ratio

must be

battery terminal disconnected.

less than 50%.

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Operation Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

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DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 39

tnioPgnizeerFtnioPgnilioB

1622

Figure 42. Fan Belt Tension

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

NEVER!

the belts or fan while the generator set is running.

place hands near

DCA-45SSIU2 — PRE-SETUP

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Battery Cable Installation 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.

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the Heat, RUN, or START position. ALWAYS make sure that the ignition switch is in the STOP position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTE

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

ignition

switch is in either the Pre-

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Figure 43. Battery Connections

ALWAYS

terminal FIRST and reconnect negative terminal LAST.

disconnect the negative

Alternator

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator leads an electrolyte corrosion causing an alternator failure.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose ( immediately.

fuel

oil

) lines are defective replace them

PAGE 40 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — GENERATOR START-UP PROCEDURE

WARNING:WARNING:

WARNING:

WARNING:WARNING:

The engine's exhaust contains harmful emissions.

ventilation when operating

away from nearby personnel.

BEFORE STARTING

Generator and Control Panel

ALWAYS have adequate

CAUTION:

. Direct exhaust

NEVER!

main, GFCI or auailliary circuit breakers in

the “ON“ (closed) position.

1. Be sure and place the breakers (Figure 44) in the “OFF” position prior to starting the engine.

Figure 44. Main, Aux. and GFCI

Circuit Breakers

2. Connect the load to the

receptacles

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.

manually start the engine with the

main, G.F.C.I.

UVWO

as shown in Figure 45. These load

and

aux.

terminals or

auxiliary

circuit

Figure 45. Load Connections

3. Close all engine enclosure doors (Figure 46).

Figure 46. Engine Enclosure Doors

4. Place the voltage selector switch in the desired voltage position (Figure 47).

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.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 41

Figure 47. Voltage Selector Switch

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)

6. Preheat the engine

glow plugs

by turning the ignition

key (Figure 49) to the “PRE-HEAT” position.

10. The generator's frequency meter (Figure 52) displays the 60 cycle output frequency in HERTZ.

11. The generator's voltage meter (Figure 53) displays the 120 VAC in VOLTS. If the voltage is not within the specified frequency tolerance,

Figure 49. Ignition Switch (Pre-Heat Position)

7. When the preheat lamp luminates (Figure 50), turn the ignition key to the “START” position. Once the engine starts, release the ignition key and allow it to return to

12. Use the voltage adjustment control knob (Figure 54) to increase or decrease the desired voltage.

the “OPERATION” position (Figure 49).

Figure 52. Frequency Meter (Hz)

Figure 53. AC Voltmeter

Figure 50. Pre-Heat Indicator Lamp

8. Let the engine idle for 3-5 minutes, listen and check for

13. The ammeter (Figure 55) will indicate zero amps with no

any abnormal sounds or smells. Check for fuel leaks, and noises that would associate with a loose cover or harware. If any of the above mentioned conditions exists,

Figure 54. Voltage Adjust Control Knob

load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator.

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 51. Engine Throttle Control Lever (High)

PAGE 42 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

Figure 55. Ammeter (No Load)

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

17. Turn the “ON” position (Figure 59).

operating conditions the oil pressure is approximately

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.

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.

main, GFCI

Figure 59. Main, AUX. and GFCI

Circuit Breakers (ON)

, and

aux

. circuit breakers to the

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.

19. The generator will run until manually stopped or an abnormal condition occurs.

Figure 58. Engine Tachometer

Figure 60. Ammeter (Load)

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).

Figure 61. Main, AUX. and GFCI

Circuit Breakers (OFF)

2. Push the engine throttle control lever inward (Figure 62) to the “

LOW

” position.

EMERGENCY SHUT-DOWN SHUTDOWN

1. To shut-down the engine in the event of an emergency, switch the breakers to “OFF” position.

2. Turn the ignition switch key to the “STOP” position.

MAIN, GFCI

and

LOAD

(Figure 61) circuit

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

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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.

Service Daily

If the engine is operating in very 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 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

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

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.

needs changing. After changing the air element, press the dust indicator button to reset the indicator.

dusty

dry grass

frequently

conditions, a

if these

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.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 33.

Flushing Out Radiator and Replacing Coolant

Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.

Check hoses for softening and kinks. Check clamps for signs of leakage.

Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

Tighten both cocks and replace the overflow tank.

Replace with coolant (Table 12 for correct mixture).

Close radiator cap tightly.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Allow engine to radiator. Flushing the radiator while will damage radiator.

cool

when flushing out

hot!

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.

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.

Generator Storage

For longe term storage of the generator the following is recommended:

Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.

Completely drain the oil from the crankcase and refill if necessary with fresh oil.

Clean the entire generator, internal and external.

Cover the generating set and store in a clean, dry place.

Disconnect the battery.

Make sure engine coolant is at proper level.

If generator is mounted on a trailer, jack trailer up and place on block so tires do touch the ground or remove tires.

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

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).

When using the generator in to apply power to jacket water heater. However, if the generator will be used in 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

an power cord of adequate size.

jacket water heate

hot

climates there is no reason

cold

climates it is always a good

via commercial power using

r and

internal

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

plug

via commercial power using an power cord of adequate

size.

NOTE

battery charger

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger

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

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

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.

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

Figure 65. Hydraulic Brake Components

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.

Actuator

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the 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 “ sure that it is functioning correctly. Never use an undersize actuator.

surge

actuator

” to make

push

gnitoohselbuorTekarBciluardyH.51elbaT

motpmyS esuaCelbissoP noituloS

sekarBoN?deknikronekorbenilekarB.ecalperroriapeR

?dezalggninilekarB.ecalpe

otlluPsekarBrosekarBkaeW

ediSenO

sekarBgnikcoL

sekarBysioN

sekarBgniggarD

eriT.yllauqeseritllaetalfnI

opmocekarB.stnenopmocecalpeR

?dedaolrevoreliarT.thgiewtcerroC

?devoorgroderocssmurdekarB.ecalperroenihcaM

?tcerrocerusserp

?elxaemasehtnodehctamnuseriT.serithctaM

?nekorbrotneb,esoolstnen

?dnuor-fo-tuosmurdekarB.ecalpeR

?detacirbulmetsyS.etacirbuL

?tcerro

cstnenopmocekarB.tcerrocdnaecalpeR

tonrotcerrocnissenkcihtgninilekarB

?yltcerrocdetsujda

?diulftcerrocrodiulfekarbhguonE

rrohsinrubeR

aseohswenllatsnI

.sgninil

straprebburecalpeR

.diulf4todhtiwllif

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.

Suspension

leaf suspension

The (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

CAUTION:

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.

Figure 66. Major Suspension Components

springs and associated components

Table 16 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

TABLE 16 TIRE WEAR TROUBLESHOOTING

WEAR PATTERN

Center Wear

Edge Wear

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

CAUSE

Over Inflation.

Under Inflation.

Loss of camber or overloading.

Wheel lockup & tire skidding.

SOLUTION

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.

Check bearing adjustment

and balance tires.

Avoid sudden stops when possible and adjust brakes.

SHACKLE BOLT SPRING EYE BOLT

SHOULDER TYPE SHACKLE BOLT

CAUTION:

ALWAYS

or installing force fitted parts. Failure to comply may result in serious injury.

wear safety glasses when removing

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SNUG FIT ONLY.PARTS MUST ROTATE FREELY LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT

BOLT ASSEMBLY

stnemeriuqeReuqroTnoisnepsuS.71elbaT

05-XAM03-NIM

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.

stnemeriuqeReuqroTeriT.81elbaT

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

NEVER

NOTE

gun to tighten wheel lug nuts.

ssaPdnoceS

SBL-TF

use an pneumatic air

ssaPdrihT

SBL-TF

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

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

woltalioenigneroleuf

?erutarepmet

?tungniniaterepip

diagnosis based on the Engine Troubleshooting (Table 19). If the problem cannot be remedied, consult our company's business office or service plant.

foytisocsivhgihylevissecxE

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

GNITOOHSELBUORTENIGNE.91ELBAT

.lioenigneroleufdeificepsehtesU

.tunnethgiT

.tratstonseodenignE

?rednilyc

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

morfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?gninoitcnuflamretratS .ecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

.nurtonseodretratS

?detcennocsidgniriW .gniriwtcennoC

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 55

DCA-45SSIU2 — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.91ELBAT

?tungniniaterepip

.htoomstonsinoituloverenignE

?erusserp

?deggolc

?lioenigneevissecxE .leveldeificepsehtotecudeR

.devresbosi

sagtsuahxeeulbroetihwrehtiE

?kcuts

?noisserpmoctneicifeD .ecnaraelcpottsujdA

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

.tunnethgiT

.tsujdA

.ecalperroriapeR

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?gnizieseb

?kaelnoisserpmoC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

.redlohelzzon

PAGE 56 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

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.

GNITOOHSELBUORTROTARENEG.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

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

If more than one of the same

NOTE

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

GENERATOR ASSY.

DCA-45SSIU2 — 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 QTY. REMARKS

1 8051000042 ROTOR ASSY. ..................................... 1 ............ INCLUDES ITEMS W/

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 8051614003 COUPLING RING ................................ 1 ............REPLACES M1163400203

3 0801831704A REAMER BOLT .................................... 2 ............REPLACES M9200100204

4 0012810030 HEX. HEAD BOLT 7

5 030210250 LOCK WASHER ................................... 2 ............REPLACES 0042510000

6 8051340503 STRATOR ASSY. 1 7 0845041904 GROMMET 2 8 8041315202 END BRACKET 1 9 8041350013 FIELD ASSY. EXCITER 1 10 0010308065 HEX. HEAD BOLT 4 11 0042608000 LOCK WASHER 4

12 031108160 PLAIN WASHER................................... 4 ............REPLACES 0041208000

13 0010108030 HEX. HEAD BOLT 6 14 0040008000 LOCK WASHER 6

15 031108160 PLAIN WASHER................................... 6 ............REPLACES 0041208000

16 8041310024 COVER, BEARING 1 17 8041312014 GASKET, BEARING 1 18 8041331014 COVER, END BRACKET 1

19 0017106012 HEX. HEAD BOLT ................................ 8 ............ REPLACES 0017106012

20 8001333003 COVER, END BRACKET 1 21 0010106030 HEX. HEAD BOLT 2 22 0040006000 LOCK WASHER 2

23 952404470 PLAIN WASHER................................... 2 ............REPLACES 0041206000

24 0105091025 HEX. HEAD BOLT ................................ 6 ............ REPLACES 0010310025

25 0042510000 LOCK WASHER 6 26 8051332014 COVER, FAN 1 27 0605000010 RUBBER SUSPENSION 2 28 0030012000 HEX. NUT 2 28 0040012000 LOCK WASHER 2

28 031112230 PLAIN WASHER................................... 2 ............REPLACES 0041212000

8051070003 FAN 1

0012110035 HEX. HEAD BOLT 8

030210250 LOCK WASHER ................................... 8 ............REPLACES 0042510000

8041611004 COUPLING DISK 4

8041015003 BALANCING PLATE 1

0105091025 HEX. HEAD BOLT ................................ 6 ............ REPLACES 0010310025

0042510000 LOCK WASHER 6

8001026013 SET PLATE, RECTIFIER 1

0601821349 RECTIFIER .......................................... 2 ............ PT 3610

0601822601 SURGE ABSORBER ........................... 1 ............ERZ-M14JK621A

8001020004 INSULATOR WASHER 1

8001020504 INSULATOR WASHER 1

011008020 HEX. HEAD BOLT ................................ 4 ............ REPLACES 0010108020

0040080000 LOCK WASHER 4

0601000209 BALANCING WEIGHT KIT 1

0071906310 BEARING ............................................. 1 ............ 6310 DDU C3

FIELD ASSY. 1

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 61

CONTROL BOX ASSY.

DCA-45SSIU2 — 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. ITEM QTY. REMARKS

1 M1213000402 CONTROL BOX ................................................... 1 ................. S/N7500646 TO 7200915

1 M1213000412 CONTROL BOX ................................................... 1 ................. S/N7200916 TO 7200995

1 M1213000422 CONTROL BOX ................................................... 1 ................. S/N7200996~

2 0601808811 CIRCUIT BREAKER, KAF3611010213P110A 1 3 0027105080 MACHINE SCREW 4

4 0601823863 RELAY UNIT ........................................................ 2 ................. MSA9013A

5 0021304015 MACHINE SCREW .............................................. 4 ................. REPLACES 0027104015

6 0601820671 AUTOMATIC VOLTAGE REGULATOR ................. 1 ................. NTA-5A-2DB

7 0027105010 MACHINE SCREW .............................................. 4 ................. S/N7200646 TO 7201105

7 0027105015 MACHINE SCREW .............................................. 4 ................. S/N7201106~

8 0601806116 CURRENT TRANSFORMER .............................. 3 ................. 812-943 75/5A

9 011808015 MACHINE SCREW .............................................. 6 ................. REPLACES 0027106015

10 0601820845 OVER CURRENT RELAY .................................... 1 ................. LR2D1308

11 0601820846 OVER CURRENT RELAY .................................... 1 ................. LR7D1064

12 M1260600004 FITTING BRACKET ............................................. 1 ................. S/N7200646 TO 7200996

13 0021304015 MACHINE SCREW .............................................. 2 ................. REPLACES 0027104015

13 0030004000 HEX. NUT .............................................................2 ................. REPLACES 0207004000

14 0021004010 MACHINE SCREW .............................................. 2 ................. S/N7200646 TO 7200996

15 M1213500303 CONTROL BOX COVER 1

16 011106015 HEX. HEAD BOLT ................................................ 4 ................. REPLACES 0016906015

17 M1923100004 SELECTOR SWITCH .......................................... 1 ................. VY-40

17A 47130106 KNOB, SELECTOR SWITCH 1

18 M1213600104 SWITCH BRACKET ............................................. 1 ................. S/N7200646 TO 7200915

18 M1213600114 SWITCH BRACKET ............................................. 1 ................. S/N7200916~

19 0027103010 MACHINE SCREW 4

20 011106015 HEX. HEAD BOLT ................................................ 4 ................. REPLACES 0016906015

21 M1213600004 SWITCH COVER ................................................. 1 ................. S/N7200646 TO 7200915

21 M1213600014 SWITCH COVER ................................................. 1 ................. S/N7200916~

22 011106015 HEX. HEAD BOLT ................................................ 4 ................. S/N7200646 TO 7200870;

................................................................................................... REPLACES 0016906015

22 011106015 HEX. HEAD BOLT ................................................ 3 ................. S/N720871~; REPLACES

................................................................................................... 0016906015

23 011106015 HEX. HEAD BOLT ................................................ 8 ................. REPLACES 0016906015

23 0040506000 TOOTHED WASHER 1 24 M1223000303 CONTROL PANEL 1

25 0601807630 FREQUENCY METER, 264250DJDJ9 ............... 1 ................. S/N7200646 TO 7202360

25 0601807641 FREQUENCY METER, FCF6 45-65Hz 240V .... 1 ................. S/N7202361~

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 63

CONTROL BOX ASSY. (CONT.)

DCA-45SSIU2 — 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 QTY. REMARKS

26 0601808950 AC AMMETER, 260240LSPB1 ................. 1 .......... S/N7200646 TO 7202360

26 0601808986 AC AMMETER, ACF60-75A,0-150A/5A ... 1 .......... S/N7202361~

27 0601801040 CHANGE-OVER SWITCH, AMMETER.... 1 .......... SL-2AS

28 0601806813 AC VOLTMETER, 260244SJSJ1 .............. 1 .......... S/N7200646 TO S/N7202360

28 0601806859 AC VOLTMETER, SCF6 0-600V .............. 1 .......... S/N7202361~

29 0601801041 CHANGE-OVER SWITCH, VOLTMETER 1 .......... SL-2VS

30 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ..... 1 .......... RA20A2SE102BJ 2W 1kOHM

31 0601840121 KNOB 1 32 M1223100004 STOPPER 1

33 0027105015 MACHINE SCREW ................................... 2 .......... S/N7200646 TO 7201195

33 0027105010 MACHINE SCREW ................................... 2 .......... S/N7201196~

34 0027105015 MACHINE SCREW ................................... 4 .......... S/N7200646 TO 7201195

34 0027105010 MACHINE SCREW ................................... 4 .......... S/N7201196~

35 M9220100004 SET SCREW 1 36 0080200007 SNAP RING 1

37 5825500422 EMERGENCY RELAY - 12 VOLT ............. 1 .......... REPLACES 0602200409

37 1825500732 EMERGENCY RELAY - 24 VOLT ............. 1

38 0601802132 FUSE, 10A 1

39 011106015 HEX. HEAD BOLT ..................................... 4 .......... REPLACES 0016906015

40 0601821370 RECTIFIER ............................................... 2 .......... REPLACES 0601823240

41 0021004040 MACHINE SCREW 1 41 0040004000 LOCK WASHER 1

41 031104080 PLAIN WASHER........................................ 1 .......... REPLACES 0041204000

42 0330000530 EDGING 1

43 1825530400 SAFETY RELAY ........................................ 1 .......... REPLACES 0602200304

44 011106015 HEX. HEAD BOLT ..................................... 2 .......... REPLACES 0016906015

45 M12467001004 WIRE HARNESS, GENERATOR .............. 1 .......... UP TO S/N7106114

45 M1246700524 WIRE HARNESS, GENERATOR .............. 1 .......... S/N7106115~

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 65

ENGINE AND RADIATOR ASSY.

DCA-45SSIU2 — 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. PART NO. ITEM QTY. REMARKS

1 M19232000034 ENGINE .......................................... 1 .......... ISUZU B-4BG1

2 8943212191 CARTRIDGE, OIL FILTER .............. 1 .......... REPLACES 06020412113

3 X132400240 CARTRIDGE, FUEL FILTER ........... 1 .......... REPLACES 1132400791 AND 0602042511

4 M1303200103 ENGINE FOOT 1 5 M1303200203 ENGINE FOOT 1

6 0105091025 HEX. HEAD BOLT ........................... 7 ........... REPLACES 0010710025

7 004251000 LOCK WASHER 8 8 003041000 HEX. NUT 1 9 060500008 RUBBER SUSPENSION 2 10 00300120000 HEX. NUT 2 11 0040012000 LOCK WASHER 2

12 031112230 PLAIN WASHER ............................. 2 ........... REPLACES 0041212000

13 0602012740 RADIATOR, C2810050000R2 .......... 1 ........... S/N7200646 TO 7200705

13 0602012741 RADIATOR, C2810050001 ............... 1 ........... S/N7200706~

14 0602011065 CAP, RADIATOR ............................. 1 ........... C89C0115010

15 011008020 HEX. HEAD BOLT ........................... 6 ........... REPLACES 0016908020

16 M1310500403 RADIATOR HOSE, UPPER 1 17 M1310500303 RADIATOR HOSE, LOWER 1 18 0605515147 HOSE BAND 4

19 0602046232 AIR CLEANER ................................ 1 .......... FWG065295

20 0602046368 ELEMENT. AIR CLEANER .............. 1 .......... P181052

21 0602040650 INDICATOR, AIR CLEANER ........... 1 .......... RBX002252

22 0602040595 BAND AIR CLEANER ..................... 2 .......... P007191

23 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0016908020

24 020108060 HEX. NUT ....................................... 4 .......... REPLACES 0207008000

25 M1373100203 HOSE, AIR CLEANER 1 26 060551548 HOSE BAND 2 27 0602022560 ADAPTER 1 28 M1320300304 PACKING, OIL PAN SIDE 1 29 0602022561 90O ELBOW 1 30 0602022562 UNION 1 31 0602022792 SWIVEL 1 32 0602021070 CAP 1 33 0602021572 DRAIN HOSE 1 34 M9300000103 RESERVE TANK 1 35 M9300100003 CAP, RESERVE TANK 1 36 0199100175 HOSE 1 37 M1316100404 BRACKET, RESERVE TANK 1

38 1819001902 ENGINE STOPPER ........................ 1 .......... REPLACES 0602210810

38 0601802133 FUSE, 5A 1

39 011808015 MACHINE SCREW .........................3 ........... REPLACES 0027106015

40 8970208220 FAN BELT ....................................... 1 .......... REPLACES 5136711320 AND 0602011403

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 67

ENGINE OPERATING PANEL ASSY.

DCA-45SSIU2 — 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

OUTPUT TERMINAL ASSY.

DCA-45SSIU2 — 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 30 0027103010 MACHINE SCREW 4

30 0207003000 HEX.NUT ................................................................ 4 ...... REPLACES 0030003000

HEX. NUT 2

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 71

BATTERY ASSY.

DCA-45SSIU2 — 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. ITEM QTY. REMARKS

1 551010280 BATTERY, 627MFD ......................... 1 .......... REPLACES 0602220187

2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 LOCK WASHER 2 6 M1346400204 BATTERY CABLE 1 7 M1346400404 BATTERY CABLE 1 8 0016910020 HEX. HEAD BOLT 1 8 0040510000 TOOTHED WASHER 1

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 73

MUFFLER ASSY.

DCA-45SSIU2 — 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. ITEM QTY. REMARKS

1 0602300165 MUFFLER ....................................... 1 .......... 27242N

2 0016910025 HEX. HEAD BOLT 4 3 M1333001303 EXHAUST PIPE 1

4 1141450690 GASKET ......................................... 1 .......... REPLACES 0602320004

5 M1333200114 GASKET 1

6 9098400850 HEX. NUT ....................................... 3 .......... REPLACES 0602323001

6 0040010000 LOCK WASHER 3 7 0016908035 HEX. HEAD BOLT 4 8 M1330400304 COVER 1 9 M1333300004 BRACKET 1 10 0016906015 HEX. HEAD BOLT 4 11 0602326090 U BOLT SET 1

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 75

FUEL TANK ASSY.

DCA-45SSIU2 — 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. ITEM QTY. REMARKS

1 M1363000302 FUEL TANK 1 2 0605505070 CAP, FUEL TANK 1 3 M1363200104 TANK BAND 2 4 M9310500104 SUPPORTER SHEET 4

5 011008020 HEX. HEAD BOLT ........................... 2 ........... REPLACES 0016908020

6 0207308000 HEX. NUT 2 7 0222100600 RUBBER SHEET 2 8 M9200000003 DRAIN JOINT 1 9 M9200200004 DRAIN BOLT 1 10 0150000018 O RING 1

11 011206020 HEX. HEAD BOLT ........................... 2 ........... REPLACES 0016906020

12 M1363400104 DRAIN HOSE 1 13 0605515198 HOSE BAND 2 14 0602042420 FUEL FILTER 1 15 0602220911 CLAMP 1 16 0191301200 SUCTION HOSE 1 17 0191300300 SUCTION HOSE 1 18 0191302000 RETURN HOSE 1 19 0605515109 HOSE BAND 6

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 77

ENCLOSURE ASSY.

DCA-45SSIU2 — ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 2-WHITE 3 -SPECTRUM GRAY 4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK 6 -CATERPILLAR YELLOW 7 -CATO GOLD 8 -RED

PAGE 78 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 M1413000402 BASE 1 2 M1413400004 UNDER COVER 1

3 011008020 HEX. HEAD BOLT ........................... 2 .......... REPLACES 0016908020

4 M1423000902 FRONT FRAME .............................. 1 .......... S/N7200646 TO 7200740

4 M1423000912 FRONT FRAME .............................. 1 .......... S/N7200741~

4 M1493102703 ACOUSTIC SHEET 1

5 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0016908020

6 M1423200604 COVER, FRONT FRAME 1 6 M1493100804 ACOUSTIC SHEET 1

7 011008020 HEX. HEAD BOLT ......................... 12 .......... REPLACES 0016908020

8 M1423200703 INNER COVER. FRONT FRAME .... 1 .......... S/N7200646 TO 7200740

8 M1423200713 INNER COVER, FRONT FRAME .... 1 .......... S/N7200741~

9 011008020 HEX. HEAD BOLT ........................... 6 .......... REPLACES 0016908020

10 M1433000403 CENTER FRAME 1 11 M1433000003 CENTER FRAME 1 12 0010114030 HEX. HEAD BOLT 8

12 030214350 LOCK WASHER .............................. 8 .......... REPLACES 0040014000

12 031114260 PLAIN WASHER ............................. 8 .......... REPLACES 0041214000

13 012012030 HEX. HEAD BOLT ......................... 10 .......... REPLACES 0010112030

13 00400120000 SPRING WASHER 10

13 031112230 PLAIN WASHER ........................... 10 .......... REPLACES 0041212000

14 M1443000702 REAR FRAME 1 14 M1493300504 ACOUSTIC SHEET 1

15 011008020 HEX. HEAD BOLT ............................ 4 .......... REPLACES 0016908020

15 0040508000 TOOTHED WASHER 1 16 M1443300613 REAR COVER 1 17 M1443300303 DUCT, REAR COVER 2 17 M1493300604 ACOUSTIC SHEET 2 18 0207006000 HEX. NUT 12

19 011008020 HEX. HEAD BOLT ........................... 9 .......... REPLACES 0016908020

20 M1443200803 REAR DOOR 1 21 M1443600204 WINDOW PLATE 1

22 020106050 HEX. NUT ....................................... 8 .......... REPLACES 0207306000

22 00412060000 PLAIN WASHER 8

23 B9114000002 DOOR HANDLE ASSY. ................... 1 .......... REPLACES M9113000002

24 0027106016 MACHINE SCREW ......................... 4 .......... REPLACES 0021806015

24 020106050 HEX. NUT ....................................... 4 .......... REPLACES 0030006000

25 M9110100204 HINGE 2 26 M9116100004 WASHER 2 27 0021808020 MACHINE SCREW 3

28 0845031504 BLIND PLUG ................................... 2 .......... REPLACES M9310000004

29 M1463000702 ROOF PANEL 1 29 M1493501503 ACOUSTIC SHEET 1

30 011008020 HEX. HEAD BOLT ......................... 19 .......... REPLACES 0016908020

31 1625165103 BONNET CAP ................................. 1 .......... REPLACES M9310000103

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 79

ENCLOSURE ASSY. (CONT.)

DCA-45SSIU2 — ENCLOSURE ASSY. (CONT.)

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 2-WHITE 3 -SPECTRUM GRAY 4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK 6 -CATERPILLAR YELLOW 7 -CATO GOLD 8 -RED

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

RUBBER SEAL ASSY.

DCA-45SSIU2 — 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. ITEM QTY. REMARKS

1 0228901400 RUBBER SEAL 3 2 0229200695 RUBBER SEAL 1 3 0228900620 RUBBER SEAL 1 4 0228900940 RUBBER SEAL 1 5 M1490300104 RUBBER SEAL 1 6 0228800515 RUBBER SEAL 1 7 0228900420 RUBBER SEAL 1 8 0228900910 RUBBER SEAL 3 9 0229200900 RUBBER SEAL 1 10 0229200840 RUBBER SEAL 1 11 0228800780 RUBBER SEAL 2 12 0228800470 RUBBER SEAL 1 13 0228800510 RUBBER SEAL 1 14 0228100545 RUBBER SEAL 1 15 0228100370 RUBBER SEAL 1 16 0228100165 RUBBER SEAL 1 17 0228100340 RUBBER SEAL 1 18 0228100170 RUBBER SEAL 1 19 0228100200 RUBBER SEAL 1

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 83

NAMEPLATE AND DECALS

DCA-45SSIU2 — 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

CYLINDER HEAD COVER ASSY.

ISUZU 4BG1 — 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

EA1013

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 87

CYLINDER HEAD ASSY.

ISUZU 4BG1 — 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 PART NAME QTY. REMARKS

1 8971418211 CYLINDER HEAD ASSY. .................. 1 ........ INCLUDES ITEM W/

2 8944189200 GASKET, HEAD 1

3 8943674380 BOLT ................................................. 4 ........ M12X 115

3 8943674370 BOLT ................................................. 4 ........ M12X102

5A 5B 6

7A 7B 7C 7D 7E 7F 8 9111296010 CUP, SEALING WATER JACKET 4 9 9041108250 INLET MANIFOLD STUD 2 10 9825139289 GLOW PLUG 4 11 5197320021 GLOW PLUG CONNECTOR 1 12 9117778050 REAR ENG. HANGER 1 13 0500410200 HANGER BOLT 4

14 9041108750 STUD, EX. MANIFOLD ...................... 3 ........ M8X75 L=87

14 9098301770 STUD, EX. MANIFOLD ...................... 1 ........ M8X85 L=97

53 1093000180 INJ. NOZZLE STUD 8 54 5093000650 ROCKER ARM STUD 3 168 5117770640 FRONT ENG. HANGER 1

5117510010 GUIDE, VALVE 8 8970376860 VALVE INSERT SEAT, INLET 4

5117110280 VALVE, INSERT SEAT, EXHAUST 4

9096600340 PLUG PLATE 4

1096000051 SEALING CYL. HEAD CUP .............. 1 ........ OD=45

5112190150 SEALING CYL. HEAD CUP .............. 2 ........ OD=32

1096000160 SEALING CYL. HEAD CUP .............. 4 ........ OD-25

9111291280 SEALING CYL. HEAD CUP .............. 2 ........ OD=20

1096000160 SEALING CYL. HEAD CUP .............. 3 ........ OD=25

5096000130 SEALING CYL. HEAD CUP .............. 4 ........ OD=12.3

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 89

CYLINDER BLOCK ASSY.

ISUZU 4BG1 — 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 QTY. REMARKS

1 8971239542 CYLINDER BLOCK ASSY. ..................................... 1 .......... INCLUDES ITEM W/

2 5878133000 LINER SET............................................................. 1 .......... GRADE 1

2 4878133010 LINER SET............................................................. 1 .......... GRADE 2

2 4878133020 LINER SET............................................................. 1 .......... GRADE 3

2 5878133030 LINER SET............................................................. 1 .......... GRADE 4

4 4 4 4 4 4 4 4 8 13 8941480790 DOWEL 2

15A 9992055170 OIL GALLERY PLUG ............................................. 1 .......... PT 3/8

15B 5096050180 OIL GALLERY PLUG ............................................. 7 .......... PT 1/8 (SQUARE HEAD)

23 25A 25B 28 8941745290 OIL PORT COVER 1 29 8943706630 OIL PORT COVER GASKET 1 34 8970233390 OIL RELIEF VALVE 1 35 5096230350 OIL RELIEF GASKET 1 37 1096050681 OIL GALLERY PLUG 2 38 1097400780 TIMING GEAR CASE PIN 1 40 8943444620 SEALING CUP 1 45 9827200690 OIL PRESSURE SWITCH 1 56 1133420742 PISTON COOLING OIL JET 4 70 71 8943673681 GASKET 2 72 8970285250 TAPPET CHAMBER COVER 1 73 9112916051 TAPPET CHAMBER ASSY. 1 74 8943675301 BOLT 80 83 9081510180 FLYWHEEL HOUSING PIN 2 130 132 1131610120 OIL CHECK VALVE 4 136 5112240040 OIL PUMP SHAFT DRIVE BUSHING 1 137 5096800110 WATER DRAIN COCK 1 140 5096600330 INJ. PUMP NIPPLE 1 141 0500408180 BOLT, COVER 2

162 1093660330 CYL. BLOCK WATER DRAIN HOSE ..................... 1 .......... REPLACES 9099135050

179 9095720080 GASKET 4 200 9992023140 OIL GALLERY PLUG 1 218 9095720140 GASKET PLUG 1 236 1093000790 ENGINE FOOT STUD 1 267 5097070041 DRAIN HOSE CLIP 1 301 5111290030 SEALING LEVEL GAUGE CUP 1

1112612480 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=1 ID GRD=AX

1112612490 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=1 ID GRD=CX

1112612500 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=2 ID GRD=AX

1112612520 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=2 ID GRD=CX

1112612520 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=3 ID GRD=AX

1112612530 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=3 ID GRD=CX

1112612540 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=4 ID GRD=AX

1112612550 LINER, CYLINDER BLOCK ................................... 4 .......... OD GRD=4 ID GRD=CX

1090004691 BOLT 2

5112190140 CUP, SEALING 1

9116110480 CAMSHAFT METAL 1

9116130350 CAMSHAFT METAL 2

1096000520 SEALING CUP 2

1096000121 TAPPET CHAMBER SEALING CUP 2

5112570011 BRIDGE CAP DOWEL 1

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 91

OIL PAN AND LEVEL GAUGE ASSY.

ISUZU 4BG1 — 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. PART NO. PART NAME QTY. REMARKS

1 8941340361 OIL PAN ASSEMBLY .................................. 1 ............... INCLUDES ITEM W/

2 5117601500 OIL LEVEL GAUGE 1 3

16 8943706660 OIL PAN GASKET 1 23 0500408180 BOLT 24 119A 119B 120A*9095714160 GASKET 2 120B*9095714240 GASKET 1 277 1117500120 OIL FILLER CAP 1

1096230570 DRAIN PLUG GASKET 1 9096620120 OIL DRAIN PLUG 1

9992023160 OIL HEATER BLIND PLUG 2

9992023240 OIL HEATER BLIND PLUG 1

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 93

CAMSHAFT AND VALVE ASSY.

ISUZU 4BG1 — 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. PART NO. PART NAME QTY. REMARKS

1 8944094120 CAMSHAFT 1 4 1125510501 INLET VALVE 4 5 1125520251 EXHAUST VALVE 4 7 5090002360 BOLT 1 9 1125220161 CAMSHAFT GEAR 1 10 9116810150 THRUST PLATE 1 11 0500408250 BOLT 2 12 9080107200 KEY 1 45 9098518503 WASHER 1 53 8941295510 ROCKER ARM SHAFT 1 55 9126260050 ROCKER ARM PLUG 2 58 5126280120 ROCKER ARM BRACKET 1 59 5096230600 ROCKER SHAFT GASKET 1 65 5125650060 SPLIT COLLAR 16 69 5125610090 OUTER VALVE SPRING 8 71A 8941145790 SPRING SEAT, UPPER 8 71B 1125630351 SPRING SEAT, LOWER 8 72 1125690150 VALVE GUIDE SEAT 8 76 9098514300 WASHER 3 78 5126110310 ROCKER ARM 8 81 9126160420 ADJ. SCREW 8 83 9091115080 ADJ. SCREW NUT 8 84 9126281050 ROCKER SHAFT BRACKET 4 85 1090005670 BOLT 6 86 9098514300 WASHER 6 88 1125750360 PUSH ROD 8 89 5125710032 VALVE TAPPET 8 93 1094001160 NUT 3 95 1095803350 ROCKER SHAFT SPRING 3 101 5090300381 BOLT 2 107 9125310300 IDLE GEAR SHAFT 1 111 5125350011 THRUST COLLAR 1 112 8941339372 IDLER GEAR 1 196 9091800190 SNAP RING 1

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 PART NO PART NAME QTY. REMARKS

1 8943398950 CRANKSHAFT 1

7 8970716610 CRANKSHAFT, STD KIT .......... 1 ........... INCLUDES ITEM W/# REPLACES 8941170322

12 8970461810 FLYWHEEL 1 28 8971379100 CRANKSHAFT GEAR 1 32 9081612200 FLYWHEEL PIN 1 33 5123190032 CRANKSHAFT RING 1 35 9123336070 GEAR RING 1 37 9000901570 PILOT BEARING 1 38 5123360030 WASHER 1 40 5123340060 BOLT 6

42# 8970713580 WASHER .................................. 2 ........... REPLACES 8941145652

44 5123780020 NUT 1 48 8941075970 KEY 2 56 8941004540 CRK DAMPER PULLEY 1 59 5095030240 WASHER 1

63 8971766500 PISTON, STD. .......................... 4 ........... GRADE=AX

63 8971766510 PISTON, STD. .......................... 4 ........... GRADE=CX

68 8971238330 RING SET 4 73 9122716080 CONN. ROD METAL SET 4 83 912211604 PISTON PIN 4

84 1122301041 CONNECTING ROD ASSY. ..... 4 ........... INCLUDES ITEMS W/$

85$ 1122510270 BUSHING 4 86$ 1122350271 BOLT 8 126 8941075751 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. PART NO. PART NAME QTY. REMARKS

1 8944509752 TIMING GEAR CASE 1 2 8943213304 FLYWHEEL HOUSING 1

36 0500408200 BOLT .............................................. 4 ........... M8X20 W/ LOCK WASHER

36 0500408450 BOLT .............................................. 2 ........... M8X45 W/ LOCK WASHER

39 8943706710 GASKET 1 42 9112290581 DOWEL 1 49 8943706720 GASKET 1 54 8971298300 GEAR CASE COVER 1 57 5113210090 TIMING CHECK COVER 2 58 0500406140 BOLT 4

60 0500408250 BOLT .............................................. 8 ........... MX45 W/ LOCK WASHER

60 0500408800 BOLT .............................................. 1 ........... M8X80W/ LOCK WASHER

60 5090000841 BOLT .............................................. 4 ........... M8X55 W/LOCK WASHER

60 5090300381 BOLT .............................................. 3 ........... M10X55

65 8970276011 GASKET 2 86 8944533001 TACHO DRIVE ELBOW 1 93 1096234650 ELBOW GASKET 1 103 1096254380 OIL SEAL, FRONT 1 175 1096253630 OIL SEAL, REAR 1 211 0500408250 BOLT 7 242 9095714160 PLUG GASKET 1 252 0500408200 BOLT 2 290 8943218380 PLUG 1 382 9992023160 HOUSING PLUG 1

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 99

ENGINE MOUNTING ASSY

ISUZU 4BG1 — ENGINE MOUNTING ASSY.

PAGE 100 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

Multiquip DCA45SSIU2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual