DCA45SSIU2 STD REV7.PMD MQ Power Series Generator DCA45SSI Generators Portable Supersilent Rev 7 Manual Data Id 19051 Version 1

User Manual: MQ Power Series Generator DCA45SSI

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

PARTS LIST NO. M1870300034A

Revision #7 (06/13/07)

BRAND SERIES

MODEL DCA-45SSIU2

WHISPERWATT™

GENERATOR

(STANDARD)

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

PAGE 2 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

Diesel engine exhaust and some of

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 3

NOTE PAGE

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

TABLE OF CONTENTS

MQ POWER DCA-45SSIU2MQ POWER DCA-45SSIU2

MQ POWER DCA-45SSIU2

AC GENERAAC GENERA

AC GENERATORTOR

TORTOR

TOR

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

Specification and part

number are subject to

change without notice.

NOTE

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

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

COMPONENT DRACOMPONENT DRA

COMPONENT DRAWINGSWINGS

WINGSWINGS

WINGS

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

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

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

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

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.

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

at no charge for freight

No other allowances on freight shipped by any other

carrier.

Place Your Parts Order Via Web or Fax

For Even More Savings!

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

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

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

PAGE 6 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — SPECIFICATIONS

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

DCA-45SSIU2 — DIMENSIONS (SIDE AND FRONT)

Figure 1. Dimensions

PAGE 8 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — DIMENSIONS (TOP AND REAR)

Figure 2. Dimensions

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 9

NOTE PAGE

PAGE 10 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — SAFETY MESSAGE ALERT SYMBOLS

This Owner's Manual has been

developed to provide complete

instructions for the safe and efficient

operation of the MQ Power

Model

DCA45SSIU2 WHISPERWATT™

GENERATOR.

Before using this GENERATOR, ensure that the operating

individual has read and understands all instructions in this

manual.

Safety 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.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

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.

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.

HAZARD SYMBOLS

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.

Potential hazards associated with trowel operation will be

referenced with "

Hazard Symbols

" which appear throughout

this manual, and will be referenced in conjunction with Safety

Message Alert Symbols

Diesel fuel is extremely flammable, and its

vapors can cause an explosion if ignited. DO

NOT start the engine near spilled fuel or

combustible fluids. DO NOT fill the fuel tank

while the engine is running or hot. DO NOT

overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or

sparks from the ignition system. Store fuel in

approved containers, in well-ventilated areas

and away from sparks and flames. NEVER

use fuel as a cleaning agent.

Burn Hazards

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

fingers

hands

hair

and

clothing

away from all moving parts to

prevent injury.

Explosive Fuel

Lethal Exhaust Gases

NOTE

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 11

Accidental Starting

ALWAYS place the engine ON/OFF switch

in the OFF position, when the trowel is not

in use.

Over Speed Conditions

NEVER tamper with the factory settings of the

engine governor or settings. Personal injury

and damage to the engine or equipment can

result if operating in speed ranges above

maximum allowable.

Respiratory Hazard

ALWAYS wear approved respiratory protection.

ALWAYS wear approved eye and hearing

protection.

Sight and Hearing hazard

Equipment Damage Messages

Other important messages are provided throughout this manual

to help prevent damage to your trowel, other property, or the

surrounding environment.

This

generator

, other property, or

the surrounding environment could

be damaged if you do not follow

instructions.

NOTE

DCA-45SSIU2 — SAFETY MESSAGE ALERT SYMBOLS

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

DCA-45SSIU2 — RULES FOR SAFE OPERATION

CAUTIONCAUTION

CAUTION

Failure to follow instructions in this manual may

lead to serious injury or even death! This

equipment is to be operated by trained and

qualified personnel only! This equipment is for

industrial use only.

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.

■

This equipment should not be operated by persons under 18

years of age.

■

NEVER operate this equipment without proper

protective clothing, shatterproof glasses, steel-

toed boots and other protective devices required

by the job.

■

NEVER operate this equipment when not feeling

well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the

influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not

recommended by MQ Power for this equipment. Damage to

the equipment and/or injury to user may result.

■

Manufacture does not assume responsibility for any accident

due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and

safety decals when they become difficult read.

■

ALWAYS check the machine for loosened threads or bolts

before starting.

■

NEVER operate the generator in an explosive atmosphere or

near combustible materials. An explosion or fire could result

causing severe

bodily harm or even death.

■

High Temperatures – Allow the engine to cool before

performing service and maintenance functions. Contact

with

hot!

components can cause serious burns.

■

The engine of this

generator requires an

adequate free flow of

cooling air.

NEVER

operate the generator

in any enclosed or

narrow area where free

flow of the air is

restricted. If the air flow

is restricted it will

cause serious damage to the generator or engine and

may cause injury to people. The generator engine gives

off DEADLY carbon monoxide gas.

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

DO NOT place hands or fingers inside generator engine

compartment when engine is running.

■

ALWAYS make sure generator installation is accordance with

national and local electrical codes

■

ALWAYS have a qualified electrician perform the generator

wiring installation.

■

NEVER power cables or cords

lay in wate

■

NEVER

stand in water

while AC power from the generator

is being transfer to a load.

■

NEVER use a defective or frayed power cable. Check the

cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where

the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been

selected for the job See Table 5.

■

The electrical voltage required to operate the generator can

cause severe injury or even death through physical contact

with live circuits.

Turn all circuit breakers OFF before

performing maintenance on the generator.

■

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow

these parts to cool before servicing

engine or generator.

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

DCA-45SSIU2 — RULES FOR SAFE OPERATION

■

Backfeed to a utility system can cause

electrocution

and or

property damage. DO NOT connect to any building's electrical

system except through an approved device or after building

main switch is opened. ALWAYS have a licensed electrician

perform the installation

CAUTIONCAUTION

CAUTION

DO NOT touch or open any of the below

mentioned components while the

generator is running. Always allow

sufficient time for the engine and generator

to cool before performing maintenance.

Radiator

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

is hot will result in high pressurized, boiling water to gush

out of the radiator, causing severe scalding to any persons

in the general area of the generator.

2. Coolant Drain Plug - Removing the coolant drain plug

while the engine is hot will result in hot coolant to gush out

of the coolant drain plug, therefore causing severe scalding

to any persons in the general area of the generator.

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

plug while the engine is hot will result in hot oil to gush out

of the oil drain plug, therefore causing severe scalding to

any persons in the general area of the generator.

DANGERDANGER

DANGER

DANGERDANGER

DANGER

■

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

electrocution, electrical shock or burn,

which can cause severe bodily harm or even death

Never use damaged or worn cables when

connecting equipment to the generator.

Make sure power

connecting

cables are

securely connected to the

generator’s output terminals,

insufficient tightening of the

terminal connections may cause

damage to the generator and

electrical shock.

Maintenance Safety

■

NEVER lubricate components or attempt service on a running

machine.

■

ALWAYS allow the machine a proper

amount of time to cool before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace

broken parts.

■

ALWAYS make sure that electrical circuits are properly

grounded

per the

National Electrical Code

(NEC) and local

codes before operating generator. Severe

injury

death!

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

DANGER

POWER

CORD

(POWER ON)

WET

HANDS

NEVER grab or

touch a live

power cord with

wet hands , the

possibility exists

of electrical shock, electrocution, and even

death!

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

DCA-45SSIU2 — RULES FOR SAFE OPERATION

■

NEVER Run engine without air filter. Severe engine

damage may occur.

■

ALWAYSservice air cleaner frequently to prevent engine

malfunction.

■

ALWAYS disconnect the

negative battery terminal

before

performing service on the generator.

■

ALWAYS be sure the operator is familiar with proper safety

precautions when operating the generator set.

■

ALWAYS store equipment properly when not in use.

■

DO NOT leave the generator running in the

manual mode

unattended.

■

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

Isuzu Engine Owner's Manual

for engine

technical questions or information.

Battery

The battery contains acids that can cause injury to the eyes

and skin. To avoid eye irritation,

always

wear safety glasses.

Use well insulated gloves when picking up the battery. Use

the following guidelines when handling the battery:

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.

4. ALWAYS keep battery charging and cables in good working

condition. Repair or replace all worn cables.

5. ALWAYS recharge the battery in an vented air

environment, to avoid risk of a dangerous concentration

of combustible gases.

6. In case the battery liquid (dilute sulfuric acid) comes in

contact with

clothing or skin

, rinse skin or clothing

immediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes in

contact with your eyes, rinse eyes immediately with plenty

of water, then contact the nearest doctor or hospital, and

seek medical attention.

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.

DANGER:DANGER:

DANGER:

Generator Grounding

To guard against electrical shock and possible damage to

the equipment, it is important to provide a good EARTH

ground.

Article 250 (Grounding) of the

National Electrical Code

(NEC) provides guide lines for proper grounding and specifies

that the cable ground shall be connected to the grounding

system of the building as close to the point of cable entry

as practical.

ALWAYS be sure to use the ground terminal (green wire)

when connecting a load to the UVWO output terminals.

Transporting

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer

complies with all local and state safety transportation

laws. See next page “

Towing Safety Precautions

” for

basic towing techniques.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 15

Emergencies

■

ALWAYS know the location of the nearest

fire extinguisher

■

ALWAYS know the location of the nearest and

first aid kit

■

In emergencies

always

know the location of the

nearest phone or

keep a phone on the job site

Also know the phone numbers of the nearest

ambulance

doctor

and

fire department

. This

information will be invaluable in the case of an

emergency.

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.

■

Check the tire air pressure on both towing vehicle and

trailer.

Trailer tires should be inflated to 50 psi cold.

Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety

Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle

properly.

■

ALWAYS make sure the vehicle and trailer directional,

backup, brake, and trailer lights are connected and

working properly.

■

The maximum speed for highway towing is 45 MPH

unless posted otherwise. Recommended off-road towing

is not to exceed 10 MPH or less depending on type of

terrain.

■

Place

chock blocks

underneath wheel to prevent rolling,

while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to

a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding,

or jack-knifing. Smooth, gradual starts and stops will

improve towing.

Towing Safety Precautions

CAUTION:CAUTION:

CAUTION:

Conform to

Department of Transportation

(DOT)

Safety Towing Regulations

before

towing generator.

■

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:

DCA-45SSIU2 — RULES FOR SAFE OPERATION

Connect and test electric brake operation.

Secure portable power cables in cable tray with

tie wraps.

PAGE 16 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

Figure 3. Typical Generator Grounding Application

DCA-45SSIU2 — INSTALLATION

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

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

Pay close attention to ventilation when

operating the generator inside tunnels and

caves. The engine exhaust contains

noxious elements. Engine exhaust must be

routed to a ventilated area.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.

Whenever an engine is installed indoors the exhaust fumes

must be vented to the outside. The engine should be installed

at least two feet from any outside wall. Using an exhaust

pipe which is too long or too small can cause excessive

back pressure which will cause the engine to heat

excessively and possibly burn the valves.

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.

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.

When connecting the generator to

any buildings electrical system

ALWAYS consult with a licensed

electrician.

DCA-45SSIU2 — INSTALLATION

NOTE

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

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:

CAUTIONCAUTION

CAUTION

Towing Safety Precautions

Check with your local county or state safety

towing regulations before 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".

DCA-45SSIU2 — TOWING SAFETY PRECAUTIONS

■

ALWAYS attach trailer’s safety chain to bumper of towing

vehicle.

■

ALWAYS make sure the vehicle and trailer directional,

backup, brake, and trailer lights are connected and

working properly.

■

The maximum speed for highway towing is 55 MPH

unless posted otherwise. Recommended off-road towing

is not to exceed 15 MPH or less depending on type of

terrain.

■

Place

chocked blocks

underneath wheel to prevent

rolling, while parked.

■

Place

support blocks

underneath the trailer’s bumper to

prevent tipping, while parked.

■

Use the trailer’s hand winch to adjust the height of the

trailer, then insert locking pin to lock wheel stand in place,

while parked.

■

Avoid sudden stops and starts. This can cause skidding,

or jackknifing. Smooth, gradual starts and stops will

improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

Figure 4. Generator with Trailer

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

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 en-

sure 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 mainte-

nance components of the trailer. The following trailer com-

ponents 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 trans-

porting equipment.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hy-

draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the

maximum number of pounds the trailer can carry, in-

cluding the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch to

the rear bumper (reflector).

DCA-45SSIU2 — TRAILER SPECIFICATIONS

CAUTIONCAUTION

CAUTION

ALWAYS make sure the trailer is in good

operating condition. Check the tires for

proper inflation and wear. Also check the

wheel lug nuts for proper tightness.

5. Frame Length - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound

requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches

(10,12,14, etc.), and the width in millimeters

(175,185,205, etc.). The tire diameter must match the

diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;

2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s

axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must

match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.

Always use a torque wrench to tighten down the lug nuts.

See Table 17 and Figure 67 or lug nut tightening and

sequence.

13. Axle - Indicates the maximum weight the axle can sup-

port 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.

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 — TRAILER SPECIFICATIONS

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PAGE 22 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

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.

DCA-45SSIU2 — GENERATOR DECALS

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 23

DCA-45SSIU2 — GENERATOR DECALS

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

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

" excitation system. The open delta system consist of

an electrically independent winding wound among stationary

windings of the AC output section.

There are four connections of the open delta A, B, C and D. During

steady state loads, the power from the voltage regulator is supplied

from the parallel connections of A to B, A to D, and C to D. These three

phases of the voltage input to the voltage regulator are then rectified

and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs,

the automatic voltage regulator (AVR) switches the configuration of

the open delta to the series connection of B to C. This has the effect

of adding the voltages of each phase ot provide higher excitation to

the exciter section and thus better voltage response during the

application of heavy loads.

The connections of the AVR to the AC output windings are for

sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current,

offering maximum motor starting capabilities. The excitation does

not have a "

fixed ceiling

" and responds according the demands of

the required load.

Engine

The DCA-45SSIU2 is powered by a 4 cycle, water cooled,

turbocharged Isuzu 4BG1

diesel

engine. This engine is designed

to meet every performance requirement for the generator. Reference

Table 1 for engine specifications.

In keeping with Multiquip's policy of constantly improving its products,

the specifications quoted herein are subject to change without prior

notice.

The basic controls and indicators for the DCA-45SSIU2 generator

are addressed on the following pages.

Mechanical Governor System

The mechanical governor system control the RPM of the engine.

When the engine demands increase or decrease, the mechanical

governor system regulates the frequency variation to ±.5%. The

electronic governor option increases frequency variation to

±0.25%.

Extension Cables

When electric power is to be provided to various tools or loads at

some distance from the generator, extension cords are normally

used. Cables should be sized to allow for distance in length and

amperage so that the voltage drop between the generator and point

of use (load) is held to a minimum. Use the cable selection chart

(Table 5 ) as a guide for selecting proper extension cable size.

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

DCA-45SSIU2 — MAJOR COMPONENTS

Figure 5. Major Components

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PAGE 26 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions of

the DCA-45SSIU2 "

Generator Control Panel

" (Figure 6).

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.

Located behind the generator control panel is the

Generator

Control Box

. This box contains some of the necessary

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

Remember the

overcurrent

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.

NOTE

To restore power to the UWVO output terminals, press the

reset

button on the overcurrent relay and place the

main

circuit breaker in the

closed

position (ON).

Figure 6. Generator Control Panel

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

DCA-45SSIU2 — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of

the DCA-45SSIU2 "

Engine Operating Panel

" (Figure 7).

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

high

low

Figure 7. Engine Operating Panel

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.

PAGE 28 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

Output Terminal Familiarization

The “

Output Terminal Panel

” (Figure 8) is provided with

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

Output Terminal Panel

The

Output Terminal Panel

(Figure 8) shown below is located

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 Terminal legs “O” and “Ground”

are considered

bonded grounds

Figure 8. Output Terminal Panel

DCA-45SSIU2 — OUTPUT TERMINAL PANEL FAMILIARIZATION

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 29

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)

recepacles provided on the output terminal panel. These

receptacles can be accessed in any

voltage selector switch

position. Each receptacle is protected by a 20 amp circuit

breaker. These breakers are located directly above the GFCI

receptacles. Remember the load output (current) of both

GFCI receptacles is dependent on the load requirements of

the UVWO terminals.

Pressing the

reset

button resets the GFCI receptacle after

being tripped. Pressing the "

Test Button

" (See Figure 9) in

the center of the receptacle will check the GFCI function.

Both receptacles should be tested at least once a month.

Figure 9. G.F.C.I. Receptacle

Each auxilliary receptacle is protected by a 50 amp circuit

breaker. These breakers are located directly above the GFCI

receptacles. Remember the load output (current) on all three

receptacles is dependent on the load requirements of the

UVWO terminals.

Turn the

voltage regulator control knob

(Figure 11) on the

control panel to obtain the desired voltage. Turning the knob

clockwise will

increase

the voltage, turning the knob counter-

clockwise will

decrease

the voltage.

Figure 10. 240 VAC Twist-Lock

Auxiliary Receptacles

DCA-45SSIU2 — OUTPUT TERMINAL PANEL FAMILIARIZATION

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

only

be accessed when the

voltage selector switch is placed in the

single-phase 240/

120 position.

Removing the Plastic Face Plate (UVWO Terminals)

The UVWO terminal lugs are protected by a plastic face

plate cover (Figure 12). Un-lock the locking latch, and lift the

terminal cover to gain access to the plastic face plate.

Remove the screws securing the face plate to the terminal

enclosure, then lift the plastic hinged face plate.

After the load wires have been securely attached to the

UVWO terminals, reinstall the plastic face plate. Place the

terminal cover in the down position and secure the locking

latch.

Figure 11. Voltage Regulator Control Knob

Figure 12. Plastic Face Plate (UVWO Terminals)

PAGE 30 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

Figure 13. Connecting Loads

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 3-

pole, 250 amp,

main

circuit breaker is provided. Make sure

to switch

ALL

circuit breakers to the "OFF" position prior to

starting the engine.

DCA-45SSIU2 — OUTPUT TERMINAL PANEL FAMILIARIZATION

Over Current Relay

over current relay

(Figure 14) is connected to the main

circuit breaker. In the event of an overload, both the circuit

breaker and the over current relay may trip. If the circuit

breaker can not be reset, the

reset button

on the over cur-

rent relay must be pressed. The over current relay is lo-

cated in the control box.

Figure 14. Over Current Relay

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

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

frequency requirements are satisfactorily supplied by the

generator for operating the equipment.

Generally, the wattage listed on the nameplate of the

equipment is its rated output. Equipment may require 130—

150% more wattage than the rating on the nameplate, as

the wattage is influenced by the efficiency, power factor and

starting system of the equipment.

Motors and motor-driven

equipment draw much greater

current for starting than during

operation.

When connecting ordinary power tools, a capacity of up to

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

be used.

If wattage is not given on the equipment's

name plate, approximate wattage may be

determined by multiplying nameplate

voltage by the nameplate amperage.

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

when connecting loads.

Before connecting this generator to any

building’s electrical system, a

licensed

electrician

must install an

isolation (transfer)

switch

. Serious injury or death may result

without this transfer switch.

CAUTION:

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.

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.

NOTE

WATTS l VOLTAGE x AMPERAGE

Three Phase Load

When calculating the power requirements for 3-phase power

use the following equation:

NOTE

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.

NOTE

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

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

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

fine adjustment using the

voltage regulator

(VR)

control

knob

located on the control panel.

Voltage Selector Switch

The

voltage selector

switch (Figure 15) is located above

the UVWO Hard Wire Hook-up Panel. It has been provided

for ease of voltage selection.

CAUTION:CAUTION:

CAUTION:

NEVER change the position of the

voltage

selector switch

while the engine is running.

ALWAYS place circuit breaker in the open

position before selecting voltage.

Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect

the generator and load from being switched while the engine

is running. To lock the voltage selector switch,

press

and

hold

the

red button

located at the bottom of the switch.

Figure 15. Voltage Selector Switch

DCA-45SSIU2 — GENERATOR OUTPUTS

Generator Amperage

Tables 7 and 8 describe the generator’s current output capa-

bility for both 1Ø-phase and 3Ø phase applications.

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

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly re-

lated to the voltage being supplied at either the UVWO ter-

minals 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 recep-

tacles.

DCA-45SSIU2 — GENERATOR OUTPUTS/GAUGE READING

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 ob-

serve how much power is being supplied, produced at the

UVWO terminals lugs.

When the Voltage selector switch is in the 3Ø,240/139V

position (See Figure 16), place the

AC Voltmeter Change-

Over

Switch

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

Ammeter Change-Over Switch

(Figure 19) to the U or W

position to read the output on the selected leg.

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

Position (for 3Ø, 208V, 120V voltage)

Figure 17. AC Voltmeter

Change-Over Switch

Figure 18 AC Voltmeter

Gauge

(Volt reading on W-U Lug)

Use this position for

3Ø, 208V/1Ø,120V

40 60

Figure 20. AC Ammeter

(Amp reading on U lug)

Figure 19. AC Ammeter

Change-Over Switch

The

ammeter

and

voltmeter

gauges are only active when the

UVWO terminals are in use.

NOTE

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PAGE 34 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

Figure 21. Voltage Selector Switch 240/139V

Three-Phase Position

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 de-

pendent on the position of the

Voltage Selector Switch

and

the adjustment of the

Voltage Regulator Control Knob

Remember the voltage selector switch determines the

range

of the output voltage. The voltage regulator (VR) allows the

user to increase or decrease the selected voltage.

3Ø 240/139 UVWO Terminal Output Voltages

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

position as shown in Figure 21.

Figure 22. UVWO Terminal Lugs

240/139V Three Phase Connections

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

in Figure 22.

3. Turn the voltage regulator knob (Figure 23) clockwise to

increase voltage output, turn counterclockwise to

decrease voltage output.

3Ø 208V/1Ø120V UVWO Terminal Output Voltages

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

position as shown in Figure 24.

Figure 23. Voltage Regulator Knob (139V/240V)

Use this position for

3Ø-208 or 1Ø120V.

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

in Figure 25.

3. Turn the voltage regulator knob (Figure 26) clockwise to

increase voltage output, turn counterclockwise to

decrease voltage output.

Figure 26. Voltage Regulator Knob (208V)

NOTE

To achieve a 3Ø 208V

output the voltage selector

switch must be in the 3Ø-

240/139 position and the

voltage regulator must be

adjusted to 208V.

Figure 25. UVWO Terminal Lugs

3Ø-208V/120V Connections

Figure 24. Voltage Selector

Switch 3Ø-208V/1Ø-120V

Three-Phase Position

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

Figure 27. Voltage Selector Switch 480/277V

Three-Phase Position

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 28. UVWO Terminal Lugs

240/139V Three Phase Connections

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

in Figure 28.

3. Turn the voltage regulator knob (Figure 29) clockwise to

increase voltage output, turn counterclockwise to

decrease voltage output.

1Ø 240V/120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 1Ø 240/120

position as shown in Figure 30.

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

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

in Figure 31.

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)

Figure 31. UVWO Terminal Lugs

1Ø-240V/120V Connections

DCA-45SSIU2 — OUTPUT TERMINAL PANEL CONNECTIONS

Figure 30. Voltage Selector Switch 240/120V

Single-Phase Position

PAGE 36 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler

hole, but DO NOT overfill. Make sure the generator is level.

and verify that the oil level is maintained between the two

notches (Figure 33) on the dipstick. See Table 11 for proper

selection of engine oil.

DCA-45SSIU2 — PRE-SETUP

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.

Circuit Breakers

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

main

circuit breaker is provided to protect the UVW output

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

GFCI

circuit breakers are provided to protect the GFCI

receptacles from overload. Three 50 amp

load

circuit breakers

have also been provided to protect the auxiliary receptacles

from overload. Make sure to switch

ALL

circuit breakers to

the "OFF" position prior to starting the engine.

API Service Classification CH-4

API Service Classification CG-4

API Service Classification CF-4

ACEA Specification E3

ACEA Specification E2

Other types of motor oils may be substituted if they meet

the following requirements:

WARNING:WARNING:

WARNING:

ONLY properly trained personel who have

read and understand this section should refill

the double fuel tank system.

Use

#2 diesel fuel

Figure 34. Double Fuel Tank System

Fuel spillage on a

hot!

engine can cause

fire

explosion

. If fuel spillage occurs,

wipe up the spilled fuel completely to

prevent fire hazards.

NEVER!

smoke

around or near the generator.

Fuel Check

DANGER:DANGER:

DANGER:

Refilling the Fuel System

The DCA45SSJU genset may (if equipped with a trailer or

skid) have a

double fuel tank system

(Figure 34), which

consists of an

internal

generator fuel tank, and a

trailer

mounted

fuel tank. It is also possible the genset can be

equipped with a

skid mounted

fuel tank (Figure 5). The

skid type fuel system does not use the internal generator

fuel tank.

Use the instructions in this section that applies to your type

of fuel tank system.

ALWAYS

fill the fuel tank with clean and fresh

#2 diesel

fuel.

DO NOT fill the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing

fuel.The fuel tank cap must be closed tightly after filling.

Handle fuel in a safety container. If the container does not

have a spout, use a funnel. Wipe up any spilled fuel

immediately.

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

DCA-45SSIU2 — PRE-SETUP

Refueling Procedure:

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.

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

fill trailer fuel tank (Figure 37) first.

Figure 37. Fuel Tank Filling Order

CAUTION:CAUTION:

CAUTION:

DANGER:DANGER:

DANGER:

WARNING:WARNING:

WARNING:

Figure 36. Only Fill on Level Ground

ONLY! use

#2 diesel fuel

when

refueling.

Diesel fuel

and its vapors are dangerous

to your health and the surrounding

environment. Avoid skin

contact and/or inhaling

fumes.

ALWAYS!

fill trailer tank

first

with

#2 diesel

fuel

, before filling secondary internal tank.

ALWAYS!

place trailer on firm level ground

before refueling.

NOTE

Fuel from the secondary inner

tank will eventually drain into the

primary trailer tank.

Figure 35. Skid Type Fuel Tank System

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

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

Figure 39. Filling Secondary Internal Fuel Tank

Figure 41. Fuel Expansion

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

secondary inner tank

can be filled (See Figure 39). Notice how the trailer

filler tube level rises when the internal tank is filled.

5. Figure 40 below reflects a full fuel system.

6. Fuel from the engine return line will drain into the secondary

internal fuel tank. This fuel will eventually drain into the

primary trailer tank in order to return to the engine.

Figure 40. Full Fuel System

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.

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

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

Use only drinkable tap water. If hard water or water with

many impurities is used, the inside of the engine and radiator

may become coated with deposits and cooling efficiency

will be reduced.

An anticorrosion additive added to the water will help prevent

deposits and corrosion in the cooling system. See the engine

manual for further details.

CAUTION: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

hot!

coolant exists which can cause severe

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.

Operation Freezing Weather

When operating in freezing weather, be certain the proper

amount of antifreeze (Table 13) has been added.

CAUTIONCAUTION

CAUTION

Cleaning the Radiator

The engine may overheat if the radiator fins become

overloaded with dust or debris. Periodically clean the radiator

fins with compressed air. Cleaning inside the machine is

dangerous, so clean only with the engine turned off and the

negative

battery terminal disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in

accordance with the Isusu Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to

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.

Figure 42. Fan Belt Tension

DCA-45SSIU2 — PRE-SETUP

When the antifreeze is mixed with

water, the antifreeze mixing ratio

must be

less than 50%.

NOTE

NEVER!

place hands near

the belts or fan while the

generator set is running.

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

DCA-45SSIU2 — PRE-SETUP

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the

ignition

switch is in either the Pre-

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.

Figure 43. Battery Connections

CAUTIONCAUTION

CAUTION

ALWAYS

disconnect the negative

terminal FIRST and reconnect

negative terminal LAST.

CAUTIONCAUTION

CAUTION

Inadequate battery connections may cause

poor starting of the generator, and create

other malfunctions.

Alternator

The polarity of the alternator is negative grounding type. When

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 (

fuel

oil

) lines are defective replace them

immediately.

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.

NOTE

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.

Always

keep the terminals firmly tightened.

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.

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

WARNING:WARNING:

WARNING:

The engine's exhaust contains harmful

emissions.

ALWAYS have adequate

ventilation when operating

. Direct exhaust

away from nearby personnel.

DCA-45SSIU2 — GENERATOR START-UP PROCEDURE

Figure 45. Load Connections

NEVER!

manually start the engine with the

main, GFCI or auailliary circuit breakers in

the “ON“ (closed) position.

CAUTION:

1. Be sure and place the

main, G.F.C.I.

and

aux.

circuit

breakers (Figure 44) in the “OFF” position prior to starting

the engine.

BEFORE STARTING

Generator and Control Panel

Figure 44. Main, Aux. and GFCI

Circuit Breakers

2. Connect the load to the

UVWO

terminals or

auxiliary

receptacles

as shown in Figure 45. These load

connection points can be found on the output terminal

panel. To gain access to the UVWO terminals or other

power receptacles, unlock the access cover and lift the

door.

The UVWO terminals are protected by a plastic cover,

remove this cover to gain access to the terminals.

Tighten terminal nuts securely to prevent load wires from

slipping out.

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).

Figure 47. Voltage Selector Switch

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

Figure 54. Voltage Adjust Control Knob

Figure 55. Ammeter (No Load)

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

load applied. When a load is applied, this meter will

indicate the amount of current that the load is drawing

from the generator.

DCA-45SSIU2 — GENERATOR START-UP PROCEDURE

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 53. AC Voltmeter

Figure 52. Frequency Meter (Hz)

12. Use the voltage adjustment control knob (Figure 54) to

increase or decrease the desired voltage.

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.

Figure 50. Pre-Heat Indicator Lamp

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

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,

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”.

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

the “OPERATION” position (Figure 49).

Figure 51. Engine Throttle Control Lever (High)

Figure 49. Ignition Switch (Pre-Heat Position)

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 43

DCA-45SSIU2 — GENERATOR START-UP PROCEDURE

Figure 58. Engine Tachometer

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.

17. Turn the

main

GFCI

, and

aux

. circuit breakers to the

“ON” position (Figure 59).

15. The coolant temperature gauge (Figure 57) will indicate

the coolant temperature. Under normal operating

conditions the coolant temperature is between 165 and

215 degrees Fahrenheit.

Figure 57. Coolant Temperature Gauge

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.

19. The generator will run until manually stopped or an

abnormal condition occurs.

Figure 60. Ammeter (Load)

Figure 59. Main, AUX. and GFCI

Circuit Breakers (ON)

14. The engine oil pressure gauge (Figure 56) will indicate

the oil pressure (kg/ cm2) of the engine. Under normal

operating conditions the oil pressure is approximately

Figure 56. Oil Pressure Gauge

PAGE 44 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

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)

EMERGENCY SHUT-DOWN SHUTDOWN

1. To shut-down the engine in the event of an emergency,

switch the

MAIN

GFCI

and

LOAD

(Figure 61) circuit

breakers to “OFF” position.

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

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

to the “

LOW

” position.

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 62. Engine Throttle Control Lever (Low)

Figure 63. Ignition Switch (Off Position)

5. Remove

all

loads from the generator.

DCA-45SSIU2 — GENERATOR SHUT-DOWN PROCEDURE

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

DCA-45SSIU2 — GENERATOR/ENGINE MAINTENANCE

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Service Daily

If the engine is operating in very

dusty

dry grass

conditions, a

clogged air cleaner will result. This can lead to a loss of power,

excessive carbon buildup in the combustion chamber and high

fuel consumption. Change air cleaner more

frequently

if these

conditions exists.

Fuel Addition

Add diesel fuel (the grade may vary according to season and

locations). Always pour through the mesh filter.

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in

the bottom of the tank. Occasionally remove the drain cock and

drain the contents. During cold weather, the more empty volume

inside the tank, the easier it is for water to condense. This can be

reduced by keeping the tank full with diesel fuel.

General Inspection

Prior to each use, the generator should be cleaned and inspected

for deficiencies. Check for loose, missing or damaged nuts, bolts

or other fasteners. Also check for fuel, oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 50 hours: Remove air cleaner element and clean the heavy

duty paper element with kerosene, or foam element with liquid

detergent and hot water. Wrap foam element in a cloth and

squeeze dry. For heavy duty paper element, wipe excess

kerosene with towel.

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner

element is clogged, air intake restriction becomes greater and

the dust indicator signal shows “RED” meaning the element

needs changing. After changing the air element, press the dust

indicator button to reset the indicator.

PAGE 46 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — MAINTENANCE

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.

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:

Allow engine to

cool

when flushing out

radiator. Flushing the radiator while

hot!

will damage radiator.

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.

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.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 47

DCA-45SSIU2 — MAINTENANCE

Jacket Water Heater and Internal Battery Charger

120 VAC Input Plugs (OPTIONAL)

This generator is equipped with two 120 VAC, 20 amp input

plugs located on the output terminal panel.

The purpose of these plugs is to provide power via

commercial power to the

jacket water heate

r and

internal

battery charger

These plugs will ONLY function when commercial power has

been supplied to them (Figure 64). To apply commercial power

to these plugs, a power cord of adequate size will be required

(See Table 5).

When using the generator in

hot

climates there is no reason

to apply power to jacket water heater. However, if the

generator will be used in

cold

climates it is always a good

idea to apply power to the jacket water heater at all times. To

apply power to the jacket water heater, simply apply power

to the

jacket water heater plug

via commercial power using

an power cord of adequate size.

If the generator will be used daily, the battery should normally

not require charging. If the generator will be idle (not used)

for long periods of time, apply power to the

battery charger

plug

via commercial power using an power cord of adequate

size.

To ensure adequate starting

capability, always have power

applied to the generator's

internal battery charger

NOTE

Figure 64. DCA-45SIU2 Battery Charger &

Jacket Water Heater Power Connections

PAGE 48 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — TRAILER BRAKES MAINTENANCE

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 65) should not require any

special attention with the exception of routine maintenance

such as shoe and lining replacement. Brake lines should be

periodically checked for cracks, kinks, or blockage.

Figure 65. Hydraulic Brake Components

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack

stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot

at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the

star wheel of the adjuster assembly to expand the brake

shoes.

5. Adjust the brake shoes outward until the pressure of the

lining against the wheel drum makes the wheel difficult

to turn.

6. Adjust, rotate the star wheel in the opposite direction

until the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer to

the ground.

8. Repeat steps 1 through 7 on the remaining brakes.

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

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:

Actuator

Hydraulic surge braking requires the installation of an actuator

at the tongue of the trailer. Remember the

surge

push

the trailer toward the tow vehicle automatically synchronizes

the trailer brakes with the tow vehicle brakes. As the trailer

pushes against the tow vehicle the actuator telescopes

together and applies force to the master cylinder, supplying

hydraulic pressure to the trailer brakes.

Periodically check and test the surge “

actuator

” to make

sure that it is functioning correctly. Never use an undersize

actuator.

gnitoohselbuorTekarBciluardyH.51elbaT

motpmyS esuaCelbissoP noituloS

sekarBoN?deknikronekorbenilekarB.ecalperroriapeR

otlluPsekarBrosekarBkaeW

ediSenO

?dezalggninilekarB.ecalpe

rrohsinrubeR

?dedaolrevoreliarT.thgiewtcerroC

?devoorgroderocssmurdekarB.ecalperroenihcaM

?tcerrocerusserp

eriT.yllauqeseritllaetalfnI

?elxaemasehtnodehctamnuseriT.serithctaM

sekarBgnikcoL ?nekorbrotneb,esoolstnen

opmocekarB.stnenopmocecalpeR

?dnuor-fo-tuosmurdekarB.ecalpeR

sekarBysioN ?detacirbulmetsyS.etacirbuL

?tcerro

cstnenopmocekarB.tcerrocdnaecalpeR

sekarBgniggarD

tonrotcerrocnissenkcihtgninilekarB

?yltcerrocdetsujda

aseohswenllatsnI

.sgninil

?diulftcerrocrodiulfekarbhguonE straprebburecalpeR

.diulf4todhtiwllif

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 49

DCA-45SSIU2 — TRAILER MAINTENANCE

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical

components of the trailer. When specifying or replacing the

trailer wheels it is important the wheels, tires, and axle are

properly matched.

CAUTION:

DO NOT attempt

to repair or modify

a wheel. DO NOT

install in inner

tube to correct a leak through the rim. If the

rim is cracked, the air pressure in the inner tube may cause

pieces of the rim to explode (break off) with great force and

cause serious eye or bodily injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life.

Pressure should be checked cold before operation DO NOT

bleed air from tires when they are

hot!

. Check inflation

pressure weekly during use to insure the maximum tire life

and tread wear.

Table 16 (Tire Wear Troubleshooting) will help pinpoint the

causes and solutions of tire wear problems.

CAUTION:

ALWAYS

wear safety glasses when removing

or installing force fitted parts. Failure to comply

may result in serious injury.

Suspension

The

leaf suspension

springs and associated components

(Figure 66) should be visually inspected every 6,000 miles

for signs of excessive wear, elongation of bolt holes, and

loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components

as detailed in Table 17.

Figure 66. Major Suspension Components

WEAR PATTERN CAUSE SOLUTION

Center Wear Over Inflation.

Adjust pressure to

particular load per tire

manufacturer.

Edge Wear Under Inflation.

Adjust pressure to

particular load per tire

manufacturer.

Side Wear Loss of camber

or overloading.

Make sure load does

not exceed axle rating.

Align wheels.

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance. Check bearing adjustment

and balance tires.

Flat Spots Wheel lockup &

tire skidding.

Avoid sudden stops when

possible and adjust brakes.

TABLE 16 TIRE WEAR TROUBLESHOOTING

stnemeriuqeReuqroTnoisnepsuS.71elbaT

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SHACKLE BOLT

SPRING EYE BOLT

SNUG FIT ONLY

PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

BOLT ASSEMBLY

SHOULDER TYPE

SHACKLE BOLT

05-XAM03-NIM

PAGE 50 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

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.

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

Figure 67. Wheel Lug Nuts Tightening Sequence

DCA-45SSIU2 — TRAILER MAINTENANCE

stnemeriuqeReuqroTeriT.81elbaT

eziSleehWssaPtsriF

SBL-TF

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

NOTE

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 51

DCA-45SSIU2 — TRAILER WIRING DIAGRAM

Figure 68. Trailer/Towing Vehicle 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

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 53

DCA-45SSIU2 — ENGINE WIRING DIAGRAM

Figure 69. Engine Wiring Diagram(Continued)

PAGE 54 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — GENERATOR WIRING DIAGRAM

Figure 70. Generator Wiring Diagram

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

DCA-45SSIU2 — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper

handling and maintenance inspections, but in the event of a

breakdown, use the tables shown for

diagnosis based on the Engine Troubleshooting (Table 19). If

the problem cannot be remedied, consult our company's

business office or service plant.

GNITOOHSELBUORTENIGNE.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

.tratstonseodenignE

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

foytisocsivhgihylevissecxE

woltalioenigneroleuf

?erutarepmet

.lioenigneroleufdeificepsehtesU

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

?tungniniaterepip .tunnethgiT

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip .ecalperroriapeR

morfkaelnoisserpmoC

?rednilyc

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.nurtonseodretratS

?gninoitcnuflamretratS .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

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

DCA-45SSIU2 — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

.htoomstonsinoituloverenignE

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

noitcejniesooloteudkaelleuF

?tungniniaterepip .tunnethgiT

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

?erusserp .tsujdA

rokcutselzzonnoitcejnI

?deggolc .ecalperroriapeR

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

sagtsuahxeeulbroetihwrehtiE

.devresbosi

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP

?kcuts .ecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.tuptuotneicifeD

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?gnizieseb .ecalperroriapeR

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 57

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.

DCA-45SSIU2 — TROUBLESHOOTING (GENERATOR)

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

PAGE 58 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

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

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

NOTE

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 59

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

DCA-45SSIU2 — SUGGESTED SPARE PARTS

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this book.

NOTE

PAGE 60 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — GENERATOR ASSY.

GENERATOR ASSY.

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

NO. PART NO.ITEM QTY.REMARKS

DCA-45SSIU2 — GENERATOR ASSY.

GENERATOR ASSY.

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

1-1*FIELD ASSY. 1

1-2*8051070003 FAN 1

1-3*0012110035 HEX. HEAD BOLT 8

1-4*030210250 LOCK WASHER ................................... 8 ............REPLACES 0042510000

1-5*8041611004 COUPLING DISK 4

1-6*8041015003 BALANCING PLATE 1

1-7*0105091025 HEX. HEAD BOLT ................................ 6 ............REPLACES 0010310025

1-8*0042510000 LOCK WASHER 6

1-9*8001026013 SET PLATE, RECTIFIER 1

1-10*0601821349 RECTIFIER .......................................... 2 ............PT 3610

1-11*0601822601 SURGE ABSORBER ........................... 1 ............ERZ-M14JK621A

1-12*8001020004 INSULATOR WASHER 1

1-13*8001020504 INSULATOR WASHER 1

1-14*011008020 HEX. HEAD BOLT ................................ 4 ............REPLACES 0010108020

1-15*0040080000 LOCK WASHER 4

1-16*0601000209 BALANCING WEIGHT KIT 1

1-17*0071906310 BEARING ............................................. 1 ............6310 DDU C3

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

PAGE 62 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — CONTROL BOX ASSY.

CONTROL BOX ASSY.

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

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 — CONTROL BOX ASSY.

PAGE 64 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — CONTROL BOX ASSY. (CONT.)

CONTROL BOX ASSY. (CONT.)

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

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~

PAGE 66 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

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

DCA-45SSIU2 — ENGINE AND RADIATOR ASSY.

NO. PART NO.ITEM QTY.REMARKS

ENGINE AND RADIATOR ASSY.

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

PAGE 68 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ENGINE OPERATING PANEL ASSY.

DCA-45SSIU2 — ENGINE OPERATING PANEL ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 69

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 — ENGINE OPERATING PANEL ASSY.

PAGE 70 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

OUTPUT TERMINAL ASSY.

DCA-45SSIU2 — OUTPUT TERMINAL ASSY.

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

DCA-45SSIU2 — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO.ITEM QTY REMARKS

1 8111860303 TERMINAL PANEL .................................................. 1 ...... REPLACES M1230700103

2 0801831704A OUTPUT TERMINAL BOLT .................................... 5 ...... REPLACES M9220100204

3 012210020 TIE BOLT ................................................................ 5 ...... REPLACES M9220100104

4 0039310000 HEX. NUT 10

5 0040010000 LOCK WASHER 15

6 0041410000 PLAIN WASHER 20

7 0016908025 HEX. HEAD BOLT 5

8 M1236100603 TERMINAL COVER ................................................ 1 ...... S/N7200646 TO 7201195

8 M1236100613 TERMINAL COVER ................................................ 1 ...... S/N7201196~

9 M1236100704 OUTPUT WINDOW 1

10 0605010040 HINGE 2

11 0027103010 MACHINE SCREW 4

11 0207003000 HEX. NUT ............................................................... 4 ...... REPLACES 0030003000

11 58413 PLAIN WASHER ..................................................... 4 ...... REPLACES 0041203000

12 016906020 HEX. HEAD BOLT 2

13 011106015 HEX. HEAD BOLT ................................................... 4 ...... REPLACES 0016906015

14 M1236400004 CABLE OUTLET COVER 1

15 M1236300004 SUPPORTER, CABLE OUTLET COVER 1

16 011206020 HEX. HEAD BOLT ................................................... 6 ...... REPLACES 0016906020

17 0601808803 CIRCUIT BREAKER ............................................... 2 ...... QOU 120B 19 20A

18 0601808804 CIRCUIT BREAKER ............................................... 3 ...... QOU 250B 2P 50A

19 M1260700304 BREAKER FITTING COVER 1

20 0222100150 CUSHION RUBBER 1

21 011206020 HEX. HEAD BOLT ................................................... 2 ...... REPLACES 0016906020

22 0601812597 RECEPTACLE, GF-530EM 125V 20Ax2 ................. 2 ...... REPLACES 0601812598

23 0601811034 RECEPTACLE, CS6369 250V 50A ......................... 3 ...... REPLACES 0601812538

24 0021304015 MACHINE SCREW ................................................10 ...... REPLACES 0027104015

24 0030004000 HEX.NUT ...............................................................10 ...... REPLACES 0207004000

25 M1236100803 TERMINAL COVER 1

26 012212045 HEX. HEAD BOLT ................................................... 2 ...... REPLACES 0010112045

27 031112230 PLAIN WASHER ..................................................... 2 ...... REPLACES 0041212000

28 M9310200004 STAY RUBBER 2

29 0030012000 HEX. NUT 2

30 0027103010 MACHINE SCREW 4

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

PAGE 72 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — BATTERY ASSY.

BATTERY ASSY.

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

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

PAGE 74 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — MUFFLER ASSY.

MUFFLER ASSY.

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

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

PAGE 76 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — FUEL TANK ASSY.

FUEL TANK ASSY.

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

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

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

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

5 -BLACK

6 -CATERPILLAR YELLOW

7 -CATO GOLD

8 -RED

THE SERIAL NUMBER MAY BE REQUIRED.

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

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 — ENCLOSURE ASSY.

PAGE 80 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

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

5 -BLACK

6 -CATERPILLAR YELLOW

7 -CATO GOLD

8 -RED

THE SERIAL NUMBER MAY BE REQUIRED.

ENCLOSURE ASSY. (CONT.)

DCA-45SSIU2 — ENCLOSURE ASSY. (CONT.)

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 81

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 — ENCLOSURE ASSY. (CONT.)

PAGE 82 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

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

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

PAGE 84 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

DCA-45SSIU2 — NAMEPLATE AND DECALS

NAMEPLATE AND DECALS

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 85

NO. PART NO.ITEM QTY.REMARKS

DCA-45SSIU2 — NAMEPLATE AND DECALS

NAMEPLATE AND DECALS

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

PAGE 86 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

CYLINDER HEAD COVER ASSY.

ISUZU 4BG1 — CYLINDER HEAD COVER ASSY.

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

ISUZU 4BG1 — CYLINDER HEAD COVER ASSY.

EA1013

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

PAGE 88 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — CYLINDER HEAD ASSY.

CYLINDER HEAD ASSY.

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

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

4*5117510010 GUIDE, VALVE 8

5A*8970376860 VALVE INSERT SEAT, INLET 4

5B*5117110280 VALVE, INSERT SEAT, EXHAUST 4

6*9096600340 PLUG PLATE 4

7A*1096000051 SEALING CYL. HEAD CUP .............. 1 ........ OD=45

7B*5112190150 SEALING CYL. HEAD CUP .............. 2 ........ OD=32

7C*1096000160 SEALING CYL. HEAD CUP .............. 4 ........ OD-25

7D*9111291280 SEALING CYL. HEAD CUP .............. 2 ........ OD=20

7E*1096000160 SEALING CYL. HEAD CUP .............. 3 ........ OD=25

7F*5096000130 SEALING CYL. HEAD CUP .............. 4 ........ OD=12.3

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

PAGE 90 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — CYLINDER BLOCK ASSY.

CYLINDER BLOCK ASSY.

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

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

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

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

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

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

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

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

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

8*1090004691 BOLT 2

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*5112190140 CUP, SEALING 1

25A*9116110480 CAMSHAFT METAL 1

25B*9116130350 CAMSHAFT METAL 2

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*1096000520 SEALING CUP 2

71 8943673681 GASKET 2

72 8970285250 TAPPET CHAMBER COVER 1

73 9112916051 TAPPET CHAMBER ASSY. 1

74 8943675301 BOLT

80*1096000121 TAPPET CHAMBER SEALING CUP 2

83 9081510180 FLYWHEEL HOUSING PIN 2

130*5112570011 BRIDGE CAP DOWEL 1

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

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.

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

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*1096230570 DRAIN PLUG GASKET 1

4*9096620120 OIL DRAIN PLUG 1

16 8943706660 OIL PAN GASKET 1

23 0500408180 BOLT 24

119A*9992023160 OIL HEATER BLIND PLUG 2

119B*9992023240 OIL HEATER BLIND PLUG 1

120A*9095714160 GASKET 2

120B*9095714240 GASKET 1

277 1117500120 OIL FILLER CAP 1

PAGE 94 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — CAMSHAFT AND VALVE ASSY.

CAMSHAFT AND VALVE ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 95

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

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.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 97

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

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.

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

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

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

ISUZU 4BG1 — ENGINE MOUNTING ASSY.

ENGINE MOUNTING ASSY

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 101

ISUZU 4BG1 — ENGINE MOUNTING ASSY.

ENGINE MOUNTING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

2C 9117712470 ENGINE FOOT, RIGHT 1

2D 9117712480 ENGINE FOOT, LEFT 1

20 8943134650 BOLT 7

125 9091105100 NUT 1

251 9091505100 LOCK WASHER 1

PAGE 102 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — INLET MANIFOLD ASSY.

INLET MANIFOLD ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 103

ISUZU 4BG1 — INLET MANIFOLD ASSY.

INLET MANIFOLD ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 8971333280 INLET MANIFOLD 1

7 8970241220 GASKET 1

20 0911501080 NUT 2

52 8943216751 INLET PIPE 1

59 0500510300 BOLT .............................................. 2 ........... M10X30 W/ LOCK WASHER

59 0501510300 BOLT .............................................. 2 ........... M10X30 W/ LOCK WASHER

60 8943706760 GASKET 1

60 8970225710 GASKET 1

138 5141111970 INLET PIPE 1

144 0500408250 BOLT 6

PAGE 104 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — EXHAUST MANIFOLD ASSY.

EXHAUST MANIFOLD ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 105

ISUZU 4BG1 — EXHAUST MANIFOLD ASSY.

EXHAUST MANIFOLD ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5141410360 EXHAUST MANIFOLD 1

2 8944046100 GASKET 2

15 8943185540 BOLT ................................................... 1 ............. M8X63 W/PLAIN WASHER

15 8943185550 BOLT ................................................... 3 ............. M8X75 W/ PLAIN WASHER

16 9044110300 EXHAUST PIPE STUD 3

88 8941704860 NUT 4

PAGE 106 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — VENTILATION ASSY.

VENTILATION ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 107

ISUZU 4BG1 — VENTILATION ASSY.

VENTILATION ASSY.

NO. PART NO. PART NAME QTY.REMARKS

141 894110110 DIAPHRAGM ASSY. 1

142 1143620020 PCV COVER 1

143 9934905100 SCREW 6

PAGE 108 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — WATER PUMP AND CORROSION RESISTOR ASSY.

WATER PUMP AND CORROSION RESISTOR ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 109

ISUZU 4BG1 — WATER PUMP AND CORROSION RESISTOR ASSY.

WATER PUMP AND CORROSION RESISTOR ASSY.

NO. PART NO. PART NAME QTY.REMARKS

2 8971250510 WATER PUMP ASSY. .......... 1 ..................... INCLUDES ITEMS W/*

3# 8943706610 GASKET 1

4*8943809470 REPAIR KIT .......................... 1 ..................... INCLUDES ITEMS W/#

7 8944161302 WATER PUMP PULLEY 1

9*# 9091801470 RING 1

18*# 5136210110 WATER PUMP IMPELLER 1

19*# 5136130070 GASKET 1

20*# 5136120100 COVER 1

25*# 5136420530 CENTER 1

26*# 5136390020 DUST COVER 1

27*# 5098000520 BEARING 2

28*# 5095030990 WASHER 1

29*# 8943777860 SHAFT 1

30*# 9099521030 SNAP RING 1

32*# 5136200061 SEAL 1

34*# 9090908200 SCREW 3

36 0500410400 BOLT .................................... 1 ..................... M10X40 W/LOCK WASHER

36 5090300101 BOLT .................................... 2 ..................... M10X75 W/LOCK WASHER

36 0500410500 BOLT .................................... 1 ..................... M10X50 W/ LOCK WASHER

57 5096050050 HEATER PLUG 1

66*# 5096250780 SECONDARY SEAL 1

67*# 5136390070 SLINGER 1

PAGE 110 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

THERMOSTAT AND HOUSING ASSY.

ISUZU 4BG1 — THERMOSTAT AND HOUSING ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 111

ISUZU 4BG1 — THERMOSTAT AND HOUSING ASSY.

THERMOSTAT AND HOUSING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5137700301 THERMOSTAT 1

2 8944033142 HOUSING 1

14 9096610050 SWITCH 1

27 9095713160 GASKET .................................... 1 ................ REPLACES 9095714160

28 5096050050 HEATER PLUG 1

44 0501410250 BOLT ......................................... 4 ................ M10X25 W/LOCK AND PLAIN WASHER

44 0501410300 BOLT ......................................... 2 ................ M10X30 W/LOCK AND PLAIN WASHER

49 8944017531 WATER OUTLET PIPE 1

50 0500408250 BOLT 3

58 5096050050 WATER OUTLET PLUG 1

64 8941760310 GASKET 1

66 8943706730 GASKET 1

PAGE 112 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — ENGINE WATER PIPING ASSY.

ENGINE WATER PIPING ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 113

ISUZU 4BG1 — ENGINE WATER PIPING ASSY.

ENGINE WATER PIPING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

2 8941324900 HOSE 1

148 9099153151 CLIP 2

PAGE 114 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — FAN AND FAN BELT ASSY.

FAN AND FAN BELT ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 115

ISUZU 4BG1 — FAN AND FAN BELT ASSY.

FAN AND FAN BELT ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 8970699020 COOLING FAN 1

16 9098516490 WASHER 4

24 8942059861 BOLT ...................................... 4 ................... M8X65

36 8970208220 BELT ....................................... 1 ................... REPLACES 5136711320

38 1136420250 SPACER 1

77 9091647080 WASHER 1

80 5136740320 ADJUSTING PLATE 1

86A 0500408220 BOLT 1

86B 0501410300 BOLT 1

PAGE 116 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — FUEL INJECTION ASSY.

FUEL INJECTION ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 117

ISUZU 4BG1 — FUEL INJECTION ASSY.

FUEL INJECTION ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1*8971612100 INJECTION PUMP ASSY. ......... 1 ................ INCLUDES ITEM W/*

15 8971230631 COUPLING ASSY. 1

16 8970314671 INJ. PIPE, NO. 1 1

17 8970314681 INJ. PIPE, NO. 2 1

18 8970314691 INJ. PIPE, NO. 3 1

19 8970314701 INJ. PIPE, NO. 4 1

31 1153002912 NOZZLE ASSY. 4

32# 8970161471 NOZZLE HOLDER ASSY. ......... 4 ................ INCL. ITEMS W/%

33# 5153110270 NOZZLE ASSY. ......................... 4 ................ INCL. ITEMS W/#

34%# 1153390090 BOLT 4

35%# 1153320170 NUT 4

36%# 1153390100 GASKET 8

37%# 5153320060 NUT 4

38%# 5153390600 GASKET 4

39%# 8941695030 SCREW 4

41%# 8943203080 CONNECTOR 4

42%# 5513390030 GASKET 4

45%# 8941695020 PUSH ROD 4

46%# 9153470030 NOZZLE PIN 8

54 9153390510 COVER 4

62 0911501080 NUT 8

63 5154110420 LEAK OFF PIPE ....................... 1 ................ REPLACES 8970209371

65 9095720140 GASKET 4

66 5153150030 GASKET 4

75 9091605100 WASHER 1

80 5197510150 BRACKET 1

82 9091505100 WASHER 1

84 9091105100 NUT 1

87 0500410250 BOLT 2

93 9095714080 GASKET 2

113 5154190131 CLIP 3

133 5154112231 NOZZLE PIPE 1

133 8970209350 NOZZLE PIPE 1

134 1096750371 BOLT 1

138%# 5153430050 SPRING 4

PAGE 118 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — FUEL FILTER AND BRACKET ASSY.

FUEL FILTER AND BRACKET ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 119

ISUZU 4BG1 — FUEL FILTER AND BRACKET ASSY.

FUEL FILTER AND BRACKET ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1*1132007011 FUEL FILTER ASSY. ................. 1 ................ REPLACES 8944537371 AND 8941517451

...................................................................... INCLUDES ITEMS W/*

20 5154112231 EYE JOINT 1

21*1132120870 COVER ...................................... 1 ................ REPLACES 5132120751

29*1132600470 OVERFLOW VALVE .................. 1 ................ REPLACES 9132600562

30*1096300850 GASKET .................................... 2 ................ REPLACES 9095720140

40 5197550010 BRACKET 1

45 0501410350 BOLT 2

47 0501408250 BOLT 2

54 1094680021 NUT 1

58*X132400240 ELEMENT ................................. 1 ................ REPLACES 8944147963, 1132400791

69 9099063251 BOLT 2

88 0500410200 BOLT 2

PAGE 120 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — FUEL PUMP AND PIPE ASSY.

FUEL PUMP AND PIPE ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 121

ISUZU 4BG1 — FUEL PUMP AND PIPE ASSY.

FUEL PUMP AND PIPE ASSY.

NO. PART NO. PART NAME QTY.REMARKS

107 5154114570 PIPE .......................................... 1 ................ REPLACES 8970209330

119 9154127311 PIPE .......................................... 1 ................ REPLACES 8970209340

150 9095720140 GASKET 2

158A 5154190040 CLIP 1

158B 5154190051 CLIP 1

159 0501406160 BOLT 1

PAGE 122 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — OIL COOLER AND OIL FILTER ASSY.

OIL COOLER AND OIL FILTER ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 123

ISUZU 4BG1 — OIL COOLER AND OIL FILTER ASSY.

OIL COOLER AND OIL FILTER ASSY.

NO. PART NO. PART NAME QTY.REMARKS

2 A$ 8943212191 ELEMENT, OIL FILTER 1

89 5112890090 BOLT, ELEMENT TO CASE 1

90 1217290430 GASKET, BOLT, OIL COOLER 1

109 0500408250 BOLT, M8X25 ............................................ 11 ........... W/LOCK WASHER

109 0500408450 BOLT, M8 X45 ............................................. 8 ........... W/LOCK WASHER

109 0500408200 BOLT, M8X20 .............................................. 2 ........... W/LOCK WASHER

109 8942058961 BOLT, M8X65 1

110 8944496450 BODY; CASE, OIL COOLER 1

111 8970320250 CORE; OIL COOLER 1

112 A 8971281500 PLUG; OIL COOLER CASE 1

112 B 5112880020 PLUG; OIL COOLER CASE 1

113 A 8944706680 GASKET; PLUG; OIL COOLER CASE 1

113 B 9095716200 GASKET; PLUG; OIL COOLER CASE 1

281 B$ 8970261351 COVER, OIL FILTER ................................... 1 ........... INCLUDES ITEMS W/*

288*$ 9132630100 PLUG; OIL DRAIN 1

290*$ 9099211930 GASKET; PLUG OIL DRAIN 1

321 8943706700 GASKET; OIL FILTER TO C/BL 1

329 A 5090000071 BOLT, M10X135 4

331 9091605100 WASHER 4

392 9091505100 LOCK WASHER 4

444 5112820110 GASKET;ELEMENT TO BODY 1

469 8970196530 GASKET; OIL COOLER TO C/BL 1

484 9099168190 CLIP 2

496 B 8970209271 FILTER ASSY. ............................................. 1 ........... INCLUDES ITEMS W/$

526 5112800111 COVER; WATER DUCT 1

PAGE 124 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — OIL PUMP AND OIL STRAINER ASSY.

OIL PUMP AND OIL STRAINER ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 125

ISUZU 4BG1 — OIL PUMP AND OIL STRAINER ASSY.

OIL PUMP AND OIL STRAINER ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5131001373 OIL PUMP ASSY. ...................... 1 ................ INCLUDES ITEMS W/$

2$ 5131650040 SPRING SEAT 1

3$ 9081040300 PIN 1

5$ 5095800980 COIL SPRING 1

8$ 5131250020 GEAR 1

19$ 5878102022 GEAR SET ................................ 1 ................ INCLUDES ITEMS W/#

29 0500410250 BOLT 2

32$# 1131280180 PINION 1

34$# 5131210140 SHAFT 1

35$ 5131130351 COVER 1

38A$ 5131410171 CASE 1

38B$ 5131410180 CASE 1

40$# 1131230160 COUPLING 1

41$ 5098430030 VALVE BALL 1

42$ 5131190060 STRAINER 1

43$ 0108058000 BOLT 4

67$ 9091505080 WASHER 4

86$ 1131190010 SPACER 1

PAGE 126 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — OIL AND VACUUM PIPING ASSY.

OIL AND VACUUM PIPING ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 127

ISUZU 4BG1 — OIL AND VACUUM PIPING ASSY.

OIL AND VACUUM PIPING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 8971242340 PIPE 1

26 8941753012 PIPE 1

28 9099211880 GASKET 2

37 5133112561 PIPE 1

40 0501408450 BOLT ...................................... 4 ................... M8X45 W/LOCK AND PLAIN WASHER

40 0500408350 BOLT ...................................... 2 ................... M8X35 W/LOCK WASHER

40 0500408320 BOLT ...................................... 2 ................... M8X32 W/LOCK WASHER

47 1096234620 GASKET 2

116 9095720100 GASKET 2

142 9098440220 NUT 1

279 8941625680 CLIP 2

343 1093600430 HOSE 1

434 0911501080 NUT 1

448 8941405812 FILLER 1

PAGE 128 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — ELECTRICAL CONTROL ASSY.

ELECTRICAL CONTROL ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 129

ISUZU 4BG1 — ELECTRICAL CONTROL ASSY.

ELECTRICAL CONTROL ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1811001911 STARTER ASSY. ....................... 1 ................ 24V 4.5KW

2 8971433290 GENERATOR ASSY. ................. 1 ................ 24V 30A

4 0500512280 BOLT ......................................... 1 ................ M12X28

4 0287812350 BOLT ......................................... 2 ................ M12X35

16 0501408350 BOLT ......................................... 2 ................ M8X35 W/LOCK AND PLAIN WASHER

19 5197110620 BRACKET 1

26 050041000 BOLT ......................................... 1 ................ M10X100

26 0500410450 BOLT ......................................... 1 ................ M10X45 W/LOCK WASHER

26 5090300101 BOLT ......................................... 1 ................ M10X75 W/LOCK WASHER

38 9825300460 RESISTOR

89 8970299880 SWITCH 1

252 8943717120 COVER 1

286 0911502080 NUT 1

288 9091606080 PLAIN WASHER 1

PAGE 130 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — BATTERY RELAY ASSY.

BATTERY RELAY ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 131

ISUZU 4BG1 — BATTERY RELAY ASSY.

BATTERY RELAY ASSY.

NO. PART NO. PART NAME QTY.REMARKS

68 1823200010 BATTERY RELAY 1

PAGE 132 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — STARTER COMP. ASSY.

STARTER COMP. ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 133

ISUZU 4BG1 — STARTER COMP. ASSY.

STARTER COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1811293940 SEAL KIT ........................... 1 ................. INCLUDES ITEMS W/* SHOWN IN PICTURE

2 1811230250 CASE ................................. 1 ................. INCLUDES ITEMS W/#

3# 1811293970 METAL 1

4 5811291420 COVER 1

5 5811291440 CLIP 1

6 5811291450 STOPPER 1

8 1811130260 BRACKET 1

9% 1811293860 BEARING 1

10 1811230240 SHAFT ............................... 1................. INCL. ITEM W%

11A 5811291580 WASHER 1

11B 5811291590 WASHER 2

11C 5811291600 WASHER 1

12 1811130730 BRACKET 1

15 1811160440 WIRE 1

16 1811210370 ARMATURE ....................... 1................. INCL.UDES ITEMS W/$

17A$ 5811291550 BEARING 1

17B$ 1811291960 BEARING 1

18$ 5811291560 WASHER 1

19 1811293960 COIL 1

20@ 1811160420 BRUSH 1

21@ 1811170140 SPRING 1

22@ 1811180360 HOLDER 1

23@ 1811150620 COVER 1

27A 1811293870 BOLT 3

27B 5811292140 BOLT 2

28 1811270310 LEVER 1

29 1811291850 PIN 1

30 5811291470 PLATE 1

31 5811510360 SWITCH 1

50@ 1811160430 BRUSH 1

54 5811220160 CLUTCH 1

57 1811150610 COVER ASSY. ................... 1 ................. INCLUDES ITEMS W/@

59 5811291500 TERMINAL 1

61 5811291480 CONTACT 1

62 9821161400 BUSHING 1

63 5811180190 HOLDER 1

64 9821161420 WASHER 1

65 5811291490 RING 2

77 1811291140 WASHER 2

78 1811293840 TERMINAL 1

80 1811291840 NUT 1

86 1825530370 RELAY 1

PAGE 134 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — INJECTION PUMP COMP. ASSY. (CONT.)

INJECTION PUMP COMP. ASSY. (CONT.)

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 135

ISUZU 4BG1 — INJECTION PUMP COMP. ASSY. (CONT.)

INJECTION PUMP COMP. ASSY. (CONT.)

NO. PART NO. PART NAME QTY.REMARKS

1 5156110590 HOUSING 1

6 5156440170 HOLDER 4

7 1096230520 GASKET 4

8 5156290450 STOPPER 4

9 5156430010 SPRING 4

10 1156490010 GASKET 4

14 5156410030 VALVE 4

19 8943771540 PLUNGER 4

33 1096230130 GASKET 1

46 1156192430 COVER 1

48 5156191560 GASKET 1

49 9812250470 RING 1

50 5156210190 CAMSHAFT 1

51 5156190490 KEY 1

58 9812250580 SLEEVE 4

62 9812350150 SEAT 4

63 5156430090 SPRING 4

64 9812350210 SEAT 4

68 9812212230 TAPPET.......................................... 4 .................. INCL. ITEMS W/*

69 5156190410 GUIDE 4

70*9812222200 PIN 4

71*1156290010 BUSHING 4

72*1156220030 ROLLER 4

73 8943865960 GASKET 1

74 8941711090 COVER 1

75 1156190030 SCREW 2

79 9812151150 STUD 3

80 8941711100 NUT 3

82 5156191360 PLUG 4

88 9019006140 BOLT 4

89 9095720100 GASKET 2

102 1132600011 VALVE 1

103 1157590010 GASKET 1

105 9000906770 BEARING ....................................... 1 .................. NSK

105 5098000380 BEARING ....................................... 1 .................. NTN

107 5156290150 SHIM ............................................... 1 .................. T=0.10

107 5156290160 SHIM ............................................... 1 .................. T=0.12

107 5156290170 SHIM ............................................... 1 .................. T=0.14

107 5156290180 SHIM ............................................... 1 .................. T=0.16

107 5156290190 SHIM ............................................... 1 .................. T=0.18

107 5156290200 SHIM ............................................... 1 .................. T=0.50

107 5156290380 SHIM ............................................... 1 .................. T=1.00

107 9812250330 SHIM ............................................... 1 .................. T=0.30

107 5156190390 SHIM ............................................... 1 .................. T=0.70

107 5156290900 SHIM ............................................... 1 .................. T=1.40

107 1156390880 SHIM ............................................... 1 .................. T=2.40

114 9000906770 BEARING ....................................... 1 .................. NSK

114 5098000380 BEARING ....................................... 1 .................. NTN

117 1157590010 GASKET 2

118 1156190820 BOLT 1

PAGE 136 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — INJECTION PUMP COMP. ASSY. (CONT.)

INJECTION PUMP COMP. ASSY. (CONT.)

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 137

ISUZU 4BG1 — INJECTION PUMP COMP. ASSY. (CONT.)

INJECTION PUMP COMP. ASSY. (CONT.)

NO. PART NO. PART NAME QTY.REMARKS

126 9812350170 ADAPTER 1

127 5156190440 ADAPTER 1

130 9019006140 SCREW 4

148 9812151440 GASKET 2

155 1156190240 BOLT 1

157 8941445880 GASKET 1

159 9812250470 RING 1

162 5156290150 SHIM ............................................... 1 .................. T=0.10

162 5156290160 SHIM ............................................... 1 .................. T=0.12

162 5156290170 SHIM ............................................... 1 .................. T=0.14

162 5156290180 SHIM ............................................... 1 .................. T=0.16

162 5156290190 SHIM ............................................... 1 .................. T=0.18

162 5156290200 SHIM ............................................... 1 .................. T=0.50

162 5156290380 SHIM ............................................... 1 .................. T=1.00

162 9812250330 SHIM ............................................... 1 .................. T=0.30

162 5156190390 SHIM ............................................... 1 .................. T=0.70

162 5156290900 SHIM ............................................... 1 .................. T=1.40

162 1156390880 SHIM ............................................... 1 .................. T=2.40

176 5156250010 PLATE 2

177 9812250570 PINION 4

178 9812350030 SCREW 4

181 5156190340 SHIM ............................................... 1 .................. T=0.30

181 5156190350 SHIM ............................................... 1 .................. T=0.40

181 5156190360 SHIM ............................................... 1 .................. T=0.50

181 5156190010 SHIM ............................................... 1 .................. T=0.60

181 5156190020 SHIM ............................................... 1 .................. T=0.70

181 5156190030 SHIM ............................................... 1 .................. T=0.80

181 5156190040 SHIM ............................................... 1 .................. T=0.90

181 5156190050 SHIM ............................................... 1 .................. T=1.00

181 5156190070 SHIM ............................................... 1 .................. T=1.10

181 5156190080 SHIM ............................................... 1 .................. T=1.20

181 5156190090 SHIM ............................................... 1 .................. T=1.30

181 5156190100 SHIM ............................................... 1 .................. T=1.40

181 5156190110 SHIM ............................................... 1 .................. T=0.55

181 5156190120 SHIM ............................................... 1 .................. T=0.65

181 5156190130 SHIM ............................................... 1 .................. T=0.75

181 5156190150 SHIM ............................................... 1 .................. T=0.85

181 9812350420 SHIM ............................................... 1 .................. T=0.95

181 9812350430 SHIM ............................................... 1 .................. T=1.05

181 9812350440 SHIM ............................................... 1 .................. T=1.15

181 9812350450 SHIM ............................................... 1 .................. T=1.25

181 5156190250 SHIM ............................................... 1 .................. T=0.20

181 5156190260 SHIM ............................................... 1 .................. T=0.25

181 5156190270 SHIM ............................................... 1 .................. T=0.35

181 5156190370 SHIM ............................................... 1 .................. T=0.45

181 5156191060 SHIM ............................................... 1 .................. T=1.50

181 5156191070 SHIM ............................................... 1 .................. T=1.60

181 5156191080 SHIM ............................................... 1 .................. T=1.35

181 5156191090 SHIM ............................................... 1 .................. T=1.45

181 5156191100 SHIM ............................................... 1 .................. T=1.55

PAGE 138 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — GOVERNOR COMP. ASSY.

GOVERNOR COMP. ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 139

ISUZU 4BG1 — GOVERNOR COMP. ASSY.

GOVERNOR COMP. ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 8971621760 GOVERNOR ASSY. ....................1 ...................... INCLUDES. ITEMS W/#

2#5157210040 HOUSING 1

3#5157290270 BOLT 6

4#8913253970 PLATE 1

7#5157210220 COVER 1

8A#5157290330 BOLT 4

8B#5157290540 BOLT 2

11#1157290010 GASKET 1

12#1157220210 FLYWEIGHT ASSY. 1

13#5196190490 KEY 1

15#5157290340 WASHER 1

16#9813250860 NUT 1

17#9813250880 SHIM ............................................1 ...................... T=0.20

17#9813255510 SHIM ............................................1 ...................... T=0.30

17#9813255520 SHIM ............................................1 ...................... T=0.40

17#9813255530 SHIM ............................................1 ...................... T=1.00

17#5157292860 SHIM ............................................1 ...................... T=0.50

17#5157292870 SHIM ............................................1 ...................... T=1.50

17#1157298910 SHIM ............................................1 ...................... T=2.00

17#1157298920 SHIM ............................................1 ...................... T=3.00

17#1157298930 SHIM ............................................1 ...................... T=4.00

18#5157190080 SCREW 1

23#1157250110 LINK 1

24#9813222350 SPRING 1

25#9091854040 RING 1

28#5157250420 LEVER 1

34#1157232120 SPRING 1

37#5157250170 LEVER ASSY. 1

40#9813251820 SCREW 1

41#1157231860 SPRING CAPSULE 1

43#9008130230 NUT 1

45A#1157256680 LEVER ASSY. 1

45B#5157250330 LEVER ASSY. 1

59#5157210210 COVER 1

60B#5157290630 BOLT

60C#9019006160 BOLT 1

63#9813919070 GASKET 1

71#5157230880 SPRING 1

79#1157292940 SHIM ............................................1 ...................... T=0.20

79#1157292950 SHIM ............................................1 ...................... T=0.25

79#1157292960 SHIM ............................................1 ...................... T=0.30

79#1157292970 SHIM ............................................1 ...................... T=0.35

79#1157292980 SHIM ............................................1 ...................... T=0.40

79#1157292990 SHIM ............................................1 ...................... T=0.50

83#9813919060 SEAL 1

86#9813254290 BUSHING 1

87#9019006160 BOLT 1

90#9813251770 SCREW 1

91#1157230730 SPRING CAPSULE

PAGE 140 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — GOVERNOR COMP. ASSY. (CONT.)

GOVERNOR COMP. ASSY. (CONT.)

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 141

ISUZU 4BG1 — GOVERNOR COMP. ASSY. (CONT.)

GOVERNOR COMP. ASSY. (CONT.)

NO. PART NO. PART NAME QTY.REMARKS

93B#1157296890 NUT 1

93D#9813261120 NUT 1

93E#9844100270 NUT 2

94#5157291230 SCREW 1

96#5157290530 PLUG 2

99#9813250620 PIN 1

101#8941445880 GASKET 2

103#1157290920 NUT 1

105A#1157250810 LEVER 1

105D#8943444370 LEVER 1

105D#8943444380 LEVER 1

105F#8970874410 LEVER 1

106#9813250300 KEY 1

107#9813254880 WASHER 1

108#1157293010 COLLAR 1

109#1157290990 SHIM 1

109#9813250970 SHIM 1

110#1157290980 SEAL 1

111#8970242390 BUSHING 2

112#9813212050 GASKET 2

113#9091854150 RING 2

125#9813252100 CAP 1

150#9813150650 ADAPTER 1

154#5157291120 BOLT 1

156#1835794920 WASHER 1

157#9019008180 BOLT 1

161#1157290380 PLUG 1

162#1157290150 WASHER 1

PAGE 142 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — FEED PUMP ASSY.

FEED PUMP ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 143

ISUZU 4BG1 — FEED PUMP ASSY.

FEED PUMP ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 8971219100 PUMP ASSY. .................................. 1 ................. INCLUDES ITEMS W/*

2*1157610060 PUMP 1

3*1196230160 GASKET 1

4*9813517020 SPRING 2

5*1157550020 VALVE 2

8*1156190820 BOLT 1

9*1157590010 GASKET 4

10*1157590030 ADAPTER 1

11*5157590270 BOLT 1

13*9813550250 RING 1

15*5157510120 HOUSING 1

16*9813512050 PISTON 1

17*9813513020 SPRING 1

18*9813550350 GASKET 1

19*8941711850 PLUG 1

28*5157540010 TAPPET ASSY. ............................... 1 ................. INCLUDES ITEMS W/#

29*# 9813514030 ROLLER 1

30*# 9813514100 PIN 1

31*# 1157590020 GUIDE 2

PAGE 144 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — MISC. INJECTION PUMP ASSY.

MISC. INJECTION PUMP ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 145

ISUZU 4BG1 — MISC. INJECTION PUMP ASSY.

MISC. INJECTION PUMP ASSY.

NO. PART NO. PART NAME QTY.REMARKS

2 5197510500 BRACKET 1

3 9041010300 STUD 4

8 9091645100 WASHER 4

9 9091506100 WASHER 4

10 5156390020 NUT 4

19 A 5090000841 BOLT ......................................... 6 ........... M8X55 W/LOCK WASHER

19 B 5090002221 BOLT ......................................... 1 ........... M8X22

20 9095720080 GASKET 1

2 8943706750 GASKET 1

PAGE 146 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — COUPLING ASSY.

COUPLING ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 147

ISUZU 4BG1 — COUPLING ASSY.

COUPLING ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 5157810030 COUPLING 1

4 1156192470 PLATE 1

9 9096620070 BOLT 1

10 9884105020 NUT 1

11 5156190480 WASHER 1

27 5125240210 GEAR 1

30 8944575170 BOLT 6

PAGE 148 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — ACCELERATOR PEDAL ASSY.

ACCELERATOR PEDAL ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 149

ISUZU 4BG1 — ACCELERATOR PEDAL ASSY.

ACCELERATOR PEDAL ASSY.

NO. PART NO. PART NAME QTY.REMARKS

204 A 5197890040 BRACKET 1

PAGE 150 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — AIR DUCT ASSY.

AIR DUCT ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 151

ISUZU 4BG1 — AIR DUCT ASSY.

AIR DUCT ASSY.

NO. PART NO. PART NAME QTY.REMARKS

343 8943216680 HOSE 1

345 8942420340 CLIP 2

PAGE 152 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — FUEL SEDIMENTER ASSY.

FUEL SEDIMENTER ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 153

ISUZU 4BG1 — FUEL SEDIMENTER ASSY.

FUEL SEDIMENTER ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 1132008410 FUEL SEDIMENTER ................. 1 ................ INCLUDES ITEMS W/%

3% 1132112110 BODY ASSY. 1

4% 5132120591 COVER 1

5% 5096230700 GASKET 1

7% 5132190200 PLUG 1

9% 5096300240 GASKET 1

34% 8944537460 PLUG ......................................... 1 ................ INCLUDES ITEMS W/#

35%# 8944163770 GASKET 1

36% 5132190221 RING 1

38% 5132190210 FLOAT 1

46% 9095720140 GASKET 4

47 894470470 PIPE 1

50B 1097007590 CLIP 2

51B 9097161140 CLIP 3

50C 1097007600 CLIP 2

50C 9097161240 CLIP 3

51 0500406200 BOLT 7

62A 9099063251 BOLT 1

62B 5157590270 BOLT 1

PAGE 154 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — CLUTCH ASSY.

CLUTCH ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 155

ISUZU 4BG1 — CLUTCH ASSY.

CLUTCH ASSY.

NO. PART NO. PART NAME QTY.REMARKS

17 9910664500 BOLT 6

18 9091505140 LOCK WASHER 6

PAGE 156 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

ISUZU 4BG1 — SWITCH AND RELAY ASSY.

SWITCH AND RELAY ASSY.

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 157

ISUZU 4BG1 — SWITCH AND RELAY ASSY.

SWITCH AND RELAY ASSY.

NO. PART NO. PART NAME QTY.REMARKS

15 1819001372 ENG. STOP ACTUATOR 1

58 1823100080 IGNITION SWITCH ................... 1 ................ INCLUDES ITEM W/%

417 1825500732 EMERGENCY RELAY 1

434% KEYISUZUF KEY 1

PAGE 158 — DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07)

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or

prepaid with the charges added to the invoice.

All shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a signed

manifest has been obtained from the carrier,

and any claim for shortage or damage must be

settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip

is $15.00 net. Customers will be asked for

instructions regarding handling of orders not

meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit

will be allowed, subject to the following provi-

sions:

1. A Returned Material Authorization must

be approved by Multiquip prior to ship-

ment.

2. To obtain a Return Material Authorization,

a list must be provided to Multiquip Parts

Sales that defines item numbers, quanti-

ties, and descriptions of the items to be

returned.

a. The parts numbers and descriptions

must match the current parts price

list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the

items were originally purchased.

e. The list must include the name and

phone number of the person request-

ing the RMA.

3. A copy of the Return Material Authoriza-

tion must accompany the return shipment.

4. Freight is at the sender’s expense. All

parts must be returned freight prepaid to

Multiquip’s designated receiving point.

5. Parts must be in new and resalable

condition, in the original Multiquip pack-

age (if any), and with Multiquip part

numbers clearly marked.

6. The following items are not returnable:

a. Obsolete parts. (If an item is in the

price book and shows as being

replaced by another item, it is

obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings,

and other rubber parts) that were

purchased more than six months

prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7. The sender will be notified of any

material received that is not acceptable.

8. Such material will be held for five

working days from notification, pending

instructions. If a reply is not received

within five days, the material will be

returned to the sender at his expense.

9. Credit on returned parts will be issued at

dealer net price at time of the original

purchase, less a 15% restocking charge.

10. In cases where an item is accepted, for

which the original purchase document

can not be determined, the price will be

based on the list price that was effective

twelve months prior to the RMA date.

11. Credit issued will be applied to future

purchases only.

PRICING AND REBATES

Prices are subject to change without prior

notice. Price changes are effective on a spe-

cific date and all orders received on or after

that date will be billed at the revised price.

Rebates for price declines and added charges

for price increases will not be made for stock

on hand at the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade acces-

sories nor as to any engine not manufactured

by Multiquip. Such warranties made in connec-

tion with the sale of new, complete units are

made exclusively by a statement of warranty

packaged with such units, and Multiquip nei-

ther assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such written statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

Effective: October 1, 2002

DCA-45SSIU2 — OPERATION AND PARTS MANUAL (STD) — REV. #7 (06/13/07) — PAGE 159

NOTE PAGE

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

Your Local Dealer is:

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

ON-HAND

WHEN CALLING

MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other

trademarks are the property of their respective owners and used with permission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if

resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the

DCA-45SSIU2

WHISPERWATT™ GENERATOR.

Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be

considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time

without notice and without incurring any obligations.

MQ Power

1800 Water Ridge Rd. Tel. (800) 883-2551

Suite 500/600 Fax (972) 315-1847

Lewisville, TX 75057

Contact: mqpower@multiquip.com

Web: www.mqpower.com

MQ Parts Department

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

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

Service/Tech Support/Warranty

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

Manufactured for

Multiquip Inc.

DENYO CO., LTD, JAPAN

DCA45SSIU2 STD REV7.PMD MQ Power Series Generator DCA45SSI Generators Portable Supersilent Rev 7 Manual Data Id 19051 Version 1

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