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MULTIQUIP Power WHISPERWATT DCA-45SSIU2, Parts And Operation Manual

The MULTIQUIP Power WHISPERWATT DCA-45SSIU2 is a top-notch generator for industrial use. To ensure seamless operation, it is crucial to have the correct Parts And Operation Manual. You can easily download the manual for free from our website, making troubleshooting and maintenance hassle-free. Get yours now at manualshive.com.

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

TABLE OF CONTENTS

MQ POWER DCA-45SSIU2

MQ POWER DCA-45SSIU2

MQ POWER DCA-45SSIU2

MQ POWER DCA-45SSIU2

MQ POWER DCA-45SSIU2

AC GENERA

AC GENERA

AC GENERA

AC GENERA

AC GENERATOR

TOR

TOR

TOR

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 DRA

COMPONENT DRA

COMPONENT DRA

COMPONENT DRA

COMPONENT DRAWINGS

WINGS

WINGS

WINGS

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

Summary of Contents for Power WHISPERWATT DCA-45SSIU2

Page 1: ...UAL PARTS LIST NO M1870300034A Revision 7 06 13 07 BRAND SERIES MODEL DCA 45SSIU2 WHISPERWAT T GENERATOR STANDARD THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES To find the latest revision of this publication visit our website at www multiquip com ...

Page 2: ...PAGE 2 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 Diesel engine exhaust and some of ...

Page 3: ...DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 3 NOTE PAGE ...

Page 4: ...an 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...

Page 5: ...t 279 Multiquip s Main Phone Numbers 800 421 1244 Fax 310 537 3927 310 537 3700 Note Unlessotherwiseindicatedbycustomer all orders are treated as Standard Orders and will ship within 24 hours We will make every effort to ship AirShipments thesamedaythattheorderis received ifpriorto2PMwestcoasttime Stock Orders must be so noted on fax or web forms Extra Discounts All parts orders which include comp...

Page 6: ... 0 1 r e w o P C A x u A z H 0 6 e s a h P e l g n i S e g a t l o V C A V 0 2 1 t u p t u O 2 x W K 4 2 W K 8 4 s n o i t a c i f i c e p S e n i g n E l e d o M 1 G B 4 B U Z U S I e p y T n o i t c e j n i t c e r i d d e l o o c r e t a w e l c y C 4 s r e d n i l y C f o o N s r e d n i l y c 4 e k o r t S x e r o B m m 5 2 1 x m m 5 0 1 n i 2 9 4 x n i 3 1 4 t u p t u O d e t a R m p r 0 0 8...

Page 7: ...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: ...PAGE 8 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 DIMENSIONS TOP AND REAR Figure 2 Dimensions ...

Page 9: ...DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 9 NOTE PAGE ...

Page 10: ...ons 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...

Page 11: ...an 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 ...

Page 12: ...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 narrowareawherefree flow of the air is restricted If the air flow is ...

Page 13: ...hine and place the circuit breaker in the OFF positionwhencontact 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 Makesurepower c o n n e c t i n g cables are securely connected to the generator s output terminals ...

Page 14: ...not charged a buildup of combustible gas will occur 4 ALWAYSkeepbatterychargingandcablesingoodworking 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 pl...

Page 15: ...r 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 oth...

Page 16: ...PAGE 16 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 Figure 3 Typical Generator Grounding Application DCA 45SSIU2 INSTALLATION ...

Page 17: ...vely 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...

Page 18: ...ailer 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 unlesspostedoth...

Page 19: ...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...

Page 20: ... 8 L E E H W T L I T L L U F W 0 7 R L R T 0 6 5 4 A C D 0 7 O N E G R U S S B L 0 0 0 7 6 8 1 7 7 B L 0 0 0 2 D A P T A L F X 0 7 R L R T 0 6 5 4 A C D 0 7 T P O E G R U S S B L 0 0 0 7 8 3 1 6 6 B L 0 0 0 2 D A P T A L F F X 0 7 R L R T 0 6 5 4 A C D 0 7 L A G 3 5 E G R U S S B L 0 0 0 7 8 3 1 6 6 B L 0 0 0 2 D A P T A L F F X 0 0 1 R L R T 5 2 1 0 0 1 A C D L A G 0 5 1 C I L U A R D Y H E G R U...

Page 21: ...b l 0 0 5 3 3 G U L 5 F A E L 5 E L O P 4 T A L F R E B B U R X 0 7 R L R T S S A L C L L A B 2 E L B A T S U J D A 3 C 4 1 5 0 2 4 S A I B 5 X 4 1 s b l 0 0 5 3 3 G U L 5 F A E L 5 E L O P 4 T A L F R E B B U R F X 0 7 R L R T S S A L C L L A B 2 E L B A T S U J D A 3 C 4 1 5 0 2 4 S A I B 5 X 4 1 s b l 0 0 5 3 3 G U L 5 F A E L 5 E L O P 4 T A L F R E B B U R F X 0 0 1 R L R T 2 E L B A T S U J ...

Page 22: ...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 ...

Page 23: ...DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 23 DCA 45SSIU2 GENERATOR DECALS ...

Page 24: ...steadystateloads thepowerfromthevoltageregulatorissupplied fromtheparallelconnectionsofAtoB AtoD andCtoD Thesethree phasesofthevoltageinputtothevoltageregulatorarethenrectified andaretheexcitationcurrentfortheexcitersection Whenaheavyload suchasamotorstartingorashortcircuitoccurs theautomaticvoltageregulator AVR switchestheconfigurationof theopendeltatotheseriesconnectionofBtoC Thishastheeffect of...

Page 25: ... r e n e G O N M E T I N O I T P I R C S E D 1 y l b m e s s A r e l f f u M 2 y l b m e s s A e n i g n E 3 y l b m e s s A r o t a r e n e G 4 y l b m e s s A l a n i m r e T t u p t u O 5 y l b m e s s A k n a T l e u F 6 y l b m e s s A y r e t t a B 7 y l b m e s s A l e n a P l o r t n o C r o t a r e n e G 8 y l b m e s s A l e n a P g n i t a r e p O e n i g n E ...

Page 26: ...he 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 e...

Page 27: ...e Speed Handle This handle will change the speed of the engine from high to low Figure 7 Engine Operating Panel 7 Starter Switch Four position switch pre heat stop runandstart Insertignitionkeytostartandstopengine 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 nu...

Page 28: ...ptacles 20 amp z Two 2 GFCI Circuit Breakers 120V 20 amps z One Main Circuit Breaker 250V 110 amps z Five 5 Output Terminal Lugs Output Terminal Panel TheOutputTerminalPanel Figure8 shownbelowislocated ontheright handside leftfromcontrolpanel ofthegenerator 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 Ou...

Page 29: ...inals Turn the voltage regulator control knob Figure 11 on the control panel to obtain the desired voltage Turning the knob clockwise will increasethe 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 DualVoltage 120 240VAC Receptacles There are three 240 VAC 50 amp au...

Page 30: ...rload 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 An over current relay Figure 14 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker ...

Page 31: ...rated output kW can be used z When connecting a fluorescent or mercury lamp a capacity of up to the generating set s rated output kW multiplied by 0 6 can be used z When connecting an electric drill or other power tools pay close attention to the required starting current capacity NOTE WATTS l VOLTAGE x AMPERAGE Three Phase Load When calculating the power requirements for 3 phase power use the fol...

Page 32: ... 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 e l b a l i a v A s e g a t l o V 6 e l b a T e s ...

Page 33: ...he 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 A 0 40 60 75 20 Figure 20 AC Ammeter Amp reading on U lug Figure 19 AC Ammeter Change Over Switch The ammeter and voltmeter gauges areonlyactivewhenthe UVWO termi...

Page 34: ...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 UVWOTerminal OutputVoltages 1 Place the voltage selector switch in the 3Ø 240 139 position as shown in Figure 24 Figure 23 Voltage Regulator Knob 139V 24...

Page 35: ...rease voltage output turn counterclockwise to decrease voltage output 1Ø 240V 120V UVWOTerminal OutputVoltages 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 counte...

Page 36: ...WARNING WARNING 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 a fire or explosion If fuel spillage occurs wipe up the spilled fuel completely to prevent fire hazards NEVER smoke around or near the generator Fuel Che...

Page 37: ...r fuel tank Figure 37 first Figure 37 Fuel Tank Filling Order CAUTION CAUTION CAUTION CAUTION CAUTION DANGER DANGER DANGER DANGER DANGER WARNING WARNING 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 ...

Page 38: ...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 Fuelfromtheenginereturnlinewilldrainintothesecondary internal fuel tank This fuel will eventually drain into the primary trailer tank in order to return...

Page 39: ... CAUTION CAUTION CAUTION CAUTION 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...

Page 40: ...nections 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 or oil lines are defective replace them immediately If the battery cable is connected incorrectly electricaldamagetothe generator will occur Pay close attention t...

Page 41: ...rting 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 protec...

Page 42: ...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 ...

Page 43: ...r 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 ...

Page 44: ...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 Placetheignitionswitch Figure63 inthe STOP position remove the key and store in a safe place...

Page 45: ...vice Daily Iftheengineisoperatinginverydustyor drygrass 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...

Page 46: ...el 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 i...

Page 47: ... 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 ...

Page 48: ...urgebrakingrequirestheinstallationofanactuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder supplying hydraulic pressure to the trailer brakes Periodically c...

Page 49: ...lt 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 CenterWe...

Page 50: ...g nuts all the way down Tighten each lug nut in 3 separate passes as defined byTable 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 s t n e m e r i u q e R e u q r o T e r i T 8 1 e l b a T e z i S l e e h W s s a P...

Page 51: ...DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 51 DCA 45SSIU2 TRAILERWIRING DIAGRAM Figure 68 Trailer Towing Vehicle Wiring Diagram ...

Page 52: ...PAGE 52 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 ENGINEWIRING DIAGRAM Figure 69 Engine Wiring Diagram ...

Page 53: ...DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 53 DCA 45SSIU2 ENGINEWIRING DIAGRAM Figure 69 Engine Wiring Diagram Continued ...

Page 54: ...PAGE 54 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 GENERATORWIRING DIAGRAM Figure 70 Generator Wiring Diagram ...

Page 55: ...o l e u f d e i f i c e p s e h t e s U r e b m u n e n a t e c w o l h t i w l e u F l e u f d e i f i c e p s e h t e s U n o i t c e j n i e s o o l o t e u d k a e l l e u F t u n g n i n i a t e r e p i p t u n n e t h g i T g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n r o w t f a h s m a c l e u F e c a l p e R d e g g o l c e l z z o n n o i t c e j n I e l z z o n n o i t ...

Page 56: ...e i f i c e p s e h t o t e c u d e R r o n r o w r e n i l d n a g n i r n o t s i P k c u t s e c a l p e r r o r i a p e R g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n o i s s e r p m o c t n e i c i f e D e c n a r a e l c p o t t s u j d A y a r g k r a d r o k c a l b r e h t i E d e v r e s b o s i s a g t s u a h x e d a o l r e v O d a o l e h t n e s s e L d e s u l e u ...

Page 57: ... V A s I y r a s s e c e n f i e c a l p e R r e i f i t c e R g n i t a t o R e v i t c e f e D e c a l p e r d n a k c e h C t u p t u O e g a t l o V w o L t c e r r o c d e e p s e n i g n e s I h g i H o t r e v e l e l t t o r h t e n i g n e n r u T e s o o l s n o i t c e n n o c g n i r i w s I r i a p e r d n a g n i r i w k c e h C R V A e v i t c e f e D y r a s s e c e n f i e c a l p...

Page 58: ...re a particular part is used Model Number Where indicated this shows that the correspondingpartisutilizedonlywiththisspecificmodelnumber 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 availa...

Page 59: ...MENT 3 0602042420 FUEL TANK IN LINE FILTER 1 0602122272 UNIT OIL PRESSURE 1 0602123260 UNITWATERTEMPERATURE 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 0605...

Page 60: ...PAGE 60 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 GENERATOR ASSY GENERATOR ASSY ...

Page 61: ...UPLING 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 ...

Page 62: ...PAGE 62 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 CONTROL BOX ASSY CONTROL BOX ASSY ...

Page 63: ...646 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 BRAC...

Page 64: ...PAGE 64 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 CONTROL BOX ASSY CONT CONTROL BOX ASSY CONT ...

Page 65: ...R 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 REP...

Page 66: ...PAGE 66 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY ...

Page 67: ...5 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 ...

Page 68: ...PAGE 68 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ENGINE OPERATING PANEL ASSY DCA 45SSIU2 ENGINE OPERATING PANEL ASSY ...

Page 69: ...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 WATERTEMPERATURE GAUGE 1 100683 19 0602123260 UNIT WATERTEMPERATURE 1 0209400 20 9075720140 PACKING 1 REPLACES 9095720140 AND 0602121109 21 0602121080 CHARGING AMMETER 1 100158 22 0602125090 F...

Page 70: ...PAGE 70 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 OUTPUT TERMINAL ASSY DCA 45SSIU2 OUTPUTTERMINAL ASSY ...

Page 71: ... 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 001...

Page 72: ...PAGE 72 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 BATTERY ASSY BATTERY ASSY ...

Page 73: ...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 LOCKWASHER 2 6 M1346400204 BATTERY CABLE 1 7 M1346400404 BATTERY CABLE 1 8 0016910020 HEX HEAD BOLT 1 8 0040510000 TOOTHEDWASHER 1 ...

Page 74: ...PAGE 74 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 MUFFLER ASSY MUFFLER ASSY ...

Page 75: ...65 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 LOCKWASHER 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: ...PAGE 76 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 FUELTANK ASSY FUEL TANK ASSY ...

Page 77: ...T 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 01913...

Page 78: ...OSURE 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 CATERPILLARYELLOW 7 CATO GOLD 8 RED THE SERIAL NUMBER MAY BE REQUIRED ...

Page 79: ...4000 13 012012030 HEX HEAD BOLT 10 REPLACES 0010112030 13 00400120000 SPRINGWASHER 10 13 031112230 PLAINWASHER 10 REPLACES 0041212000 14 M1443000702 REAR FRAME 1 14 M1493300504 ACOUSTIC SHEET 1 15 011008020 HEX HEAD BOLT 4 REPLACES 0016908020 15 0040508000 TOOTHEDWASHER 1 16 M1443300613 REAR COVER 1 17 M1443300303 DUCT REAR COVER 2 17 M1493300604 ACOUSTIC SHEET 2 18 0207006000 HEX NUT 12 19 011008...

Page 80: ...OLLOWING 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 CATERPILLARYELLOW 7 CATO GOLD 8 RED THE SERIAL NUMBER MAY BE REQUIRED ENCLOSURE ASSY CONT DCA 45SSIU2 ENCLOSURE ASSY CONT ...

Page 81: ...3400404 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 MACH...

Page 82: ...PAGE 82 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 RUBBER SEAL ASSY RUBBER SEAL ASSY ...

Page 83: ...40 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 SE...

Page 84: ...PAGE 84 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 NAMEPLATE AND DECALS NAMEPLATE AND DECALS ...

Page 85: ...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...

Page 86: ...PAGE 86 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 CYLINDER HEAD COVER ASSY ISUZU 4BG1 CYLINDER HEAD COVER ASSY ...

Page 87: ...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: ...PAGE 88 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 CYLINDER HEAD ASSY CYLINDER HEAD ASSY ...

Page 89: ...1 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 R...

Page 90: ...PAGE 90 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 CYLINDER BLOCK ASSY CYLINDER BLOCK ASSY ...

Page 91: ...UARE 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...

Page 92: ...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 ...

Page 93: ...EMARKS 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: ...PAGE 94 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 CAMSHAFT ANDVALVE ASSY CAMSHAFT AND VALVE ASSY ...

Page 95: ...OCKER 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 909851430...

Page 96: ...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 ...

Page 97: ...N 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 META...

Page 98: ...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 ...

Page 99: ... 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 LOCKWASHER 60 5090000841 BOLT 4 M8X55W LOCKWASHER 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 17...

Page 100: ...PAGE 100 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 ENGINE MOUNTING ASSY ENGINE MOUNTING ASSY ...

Page 101: ...EV 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 LOCKWASHER 1 ...

Page 102: ...PAGE 102 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 INLET MANIFOLD ASSY INLET MANIFOLD ASSY ...

Page 103: ... 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 M10X30W LOCKWASHER 59 0501510300 BOLT 2 M10X30W LOCKWASHER 60 8943706760 GASKET 1 60 8970225710 GASKET 1 138 5141111970 INLET PIPE 1 144 0500408250 BOLT 6 ...

Page 104: ...PAGE 104 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 EXHAUST MANIFOLD ASSY EXHAUST MANIFOLD ASSY ...

Page 105: ... 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: ...PAGE 106 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 VENTILATION ASSY VENTILATION ASSY ...

Page 107: ...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: ...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 ...

Page 109: ...02 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 M10X40W LOCKWASHER 36 5090300101 BOLT 2 M10X75W LOCKWASHER 36 05004...

Page 110: ...PAGE 110 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 THERMOSTAT AND HOUSING ASSY ISUZU 4BG1 THERMOSTAT AND HOUSING ASSY ...

Page 111: ...700301 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: ...PAGE 112 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 ENGINEWATER PIPING ASSY ENGINE WATER PIPING ASSY ...

Page 113: ...DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 113 ISUZU 4BG1 ENGINEWATER PIPING ASSY ENGINE WATER PIPING ASSY NO PART NO PART NAME QTY REMARKS 2 8941324900 HOSE 1 148 9099153151 CLIP 2 ...

Page 114: ...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 ...

Page 115: ...SSY 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: ...PAGE 116 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 FUEL INJECTION ASSY FUEL INJECTION ASSY ...

Page 117: ...E 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 9091605...

Page 118: ...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 ...

Page 119: ... 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: ...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 ...

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: ...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 ...

Page 123: ...ASE 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 509...

Page 124: ...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 ...

Page 125: ...MS 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 1131...

Page 126: ...PAGE 126 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 OIL ANDVACUUM PIPING ASSY OIL AND VACUUM PIPING ASSY ...

Page 127: ...971242340 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 M8X35W LOCK WASHER 40 0500408320 BOLT 2 M8X32W LOCKWASHER 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: ...PAGE 128 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 ELECTRICAL CONTROL ASSY ELECTRICAL CONTROL ASSY ...

Page 129: ...KW 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 M10X45W LOCKWASHER 26 5090300101 BOLT 1 M10X75W LOCKWASHER 38 9825300460 RESISTOR 89 8970299880 SWITCH 1 252 8943717120 COVER 1 286 0911502080 NUT 1 288 9091606080 PLAINWASHER 1 ...

Page 130: ...PAGE 130 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 BATTERY RELAY ASSY BATTERY RELAY ASSY ...

Page 131: ...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: ...PAGE 132 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 STARTER COMP ASSY STARTER COMP ASSY ...

Page 133: ...T 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 BRU...

Page 134: ...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 ...

Page 135: ...CL 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 ...

Page 136: ...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 ...

Page 137: ...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 51561...

Page 138: ...PAGE 138 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 GOVERNOR COMP ASSY GOVERNOR COMP ASSY ...

Page 139: ...292870 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 5157...

Page 140: ...PAGE 140 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 GOVERNOR COMP ASSY CONT GOVERNOR COMP ASSY CONT ...

Page 141: ...5880 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 BO...

Page 142: ...PAGE 142 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 FEED PUMP ASSY FEED PUMP ASSY ...

Page 143: ...P 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: ...PAGE 144 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 MISC INJECTION PUMP ASSY MISC INJECTION PUMP ASSY ...

Page 145: ...ON 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 M8X55W LOCKWASHER 19 B 5090002221 BOLT 1 M8X22 20 9095720080 GASKET 1 2 8943706750 GASKET 1 ...

Page 146: ...PAGE 146 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 COUPLING ASSY COUPLING ASSY ...

Page 147: ...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: ...PAGE 148 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 ACCELERATOR PEDAL ASSY ACCELERATOR PEDAL ASSY ...

Page 149: ...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: ...PAGE 150 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 AIR DUCT ASSY AIR DUCT ASSY ...

Page 151: ...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: ...PAGE 152 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 FUEL SEDIMENTER ASSY FUEL SEDIMENTER ASSY ...

Page 153: ...132112110 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 ...

Page 154: ...PAGE 154 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 CLUTCH ASSY CLUTCH ASSY ...

Page 155: ...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 LOCKWASHER 6 ...

Page 156: ...PAGE 156 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 SWITCH AND RELAY ASSY SWITCH AND RELAY ASSY ...

Page 157: ...EV 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: ...s andlubricants g Decalsandpaperproducts h Itemspurchasedinkits 7 The sender will be notified of any materialreceivedthatisnotacceptable 8 Such material will be held for five workingdaysfromnotification pending instructions If a reply is not received within five days the material will be returnedtothesenderathisexpense 9 Creditonreturnedpartswillbeissuedat dealer net price at time of the original ...

Page 159: ...DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 159 NOTE PAGE ...

Page 160: ...ded 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 p...

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