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MULTIQUIP DCA-45USI Specifications

1. KH ON ISUZU 4 1 REPLACES 06020412113 REPLACES 1132400791 AND 0602042511 REPLACES 0010710025 REPLACES 0041212000 5 7200646 7200705 5 7200706 89 0115010 REPLACES 0016908020 FWG065295 P181052 RBX002252 007191 REPLACES 0016908020 REPLACES 0207008000 REPLACES 0602210810 REPLACES 0027106015 REPLACES 5136711320 AND 0602011403 DCA 45SSIU2 ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY PAGE 68 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY NO PARTNO ITEM QTY REMARKS 1 1354300304 SLIDE LEVER 2 0601840190 1 REPLACES M9320000004 3 020108060 REPLACES 0036003000 4 M1354200004 BRACKET 5 020108060 HEX NUT rarena REPLACES 0030008000 6 06054010550 SNAP PIN 7 1354300104 GOVERNOR ROD 8 0602180106 JOINT 9 020108060 HEX NUT S aaa REPLACES 0030008000 10 0207006000 NUT 10 0041206000 PLAIN WASHER 11 1823100080 STARTER SWITCH 1 REPLACES 0602100004 11 KEYISUZUF KEY STARTER SWITCH 12 8944626110 1 REPLACES 9825300410 AND 0602102066
2. DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 159 OPERATION AND PARTS MANUAL HERE S HOW GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING MQ Power 1800 Water Ridge Rd Tel 800 883 2551 Suite 500 600 Fax 972 315 1847 Lewisville TX 75057 Contact mqpower 0 multiquip com Web www mqpower com MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537 3700 Fax 310 637 3284 Service Tech Support Warranty 800 835 2551 Fax 310 638 8046 COPYRIGHT 2007 MULTIQUIP INC Power and the 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
3. 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 142 143 Misc Inj Pump Assembly 144 145 Coupling 5 146 147 Accelerator Pedal Assembly 148 149 Air Duct Assembly des indeed iv 150 151 Fuel Sedimenter Assembly 152 153 Clutch Assembly sias 154 155 Switch and Relay Assembly 156 157 Terms and Condition of Sale Parts 158 Specification and part number are subject to change without notice PAGE 4 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ORDERING PROCEDURES When ordering parts please supply the following information Dealer account number Dealer name and addres
4. 92020010 28 M1560100603 STRIPE WHISPERWATT 1 29 1560100703 STRIPE POWER 2 30 M1560101204 STRIPE 1 31 1560101104 STRIPE 2 32 M1560100904 STRIPE 45 2 33 M1560100804 STRIPE 1 34 M1560101004 STRIPE 1 35 19400110150 DECAL FUELING PROCEDURE 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 85 ISUZU 4861 CYLINDER HEAD COVER ASSY CYLINDER HEAD COVER ASSY PAGE 86 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 CYLINDER HEAD COVER ASSY CYLINDER HEAD COVER ASSY NO PARTNO PART NAME QTY REMARKS 1 8971334460 COVER 1 4 8941332075 1 5 8941236231 GASKET OIL FILLER 1 27 9111790300 GASKET HEAD COVER 3 68 9111791050 WASHER 3 69 8943109120 GASKET HEAD TO COVER pem REPLACES 8944625590 75 9111750120 3 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 87 ISUZU 4BG1 CYLINDER HEAD ASSY CYLINDER HEAD ASSY 168 B PAGE 88 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4861 CYLINDER HEAD ASSY CYLINDER HEAD ASSY PARTNO PART NAME QTY REMARKS 1 8971418211 CYLINDER HEAD ASSY mm INCLUDES ITEM W 2 8944189200 HEAD 1 3 8943674380 BOLT 4 M12X 115 3 8943674370 Gi id i i e ii auus M12X102 4 5117510010 GUIDE VALVE 8 5A 897
5. Table 10 GFCI Receptacle Load Capability U V W U KW in Use Available Load Current Twist Lock CS6369 AMPS OFF 10 240 120V GFCI Duplex NEMA 5 20R 120V Figure 17 AC Voltmeter Figure 18 AC Voltmeter Change Over Switch Gauge Volt reading on W U Lug 5 amps per receptacle 10 amps per receptacle 15 amps per receptacle V 55 2 20 amps per receptacle How to Read the Output Terminal Gauge U W 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 OFF UVWO terminals lugs When the Voltage selector switch is in the 30 240 139V Figure 19 AC Ammeter Figure 20 AC Ammeter position See Figure 16 place the AC Voltmeter Change Switch Amp reading on U lug Over Switch Figure 17 to the W U position and the AC Ammeter Change Over Switch Figure 19 to the U or W position to read the output on the selected leg The ammeter and voltmeter gauges are only active when the UVWO terminals are in use DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 33 DCA 45SSIU2 OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages 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 Regulat
6. 5 7201196 34 0027105015 MACHINE SCREW oss S N7200646 TO 7201195 34 0027105010 MACHINE SCREW ies 5 7201196 35 9220100004 SET SCREW 1 36 0080200007 SNAP RING 1 37 5825500422 EMERGENCY RELAY 12 VOLT pm REPLACES 0602200409 37 1825500732 EMERGENCY RELAY 24 VOLT 1 38 0601802132 FUSE 10A 1 39 011106015 HEX HEAD BOLT aetas 4 REPLACES 0016906015 40 0601821370 RECTIFIER dE B sand REPLACES 0601823240 41 0021004040 MACHINE SCREW 1 41 0040004000 LOCK WASHER 1 41 031104080 PLAIN WASHER a aa pert REPLACES 0041204000 42 0330000530 EDGING 1 43 1825530400 SAFETY RELAY REPLACES 0602200304 44 011106015 HEX HEAD BOLT B rione REPLACES 0016906015 45 M12467001004 WIRE HARNESS GENERATOR pe UP TO S N7106114 45 M1246700524 WIRE HARNESS GENERATOR 5 7106115 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 65 DCA 45SSIU2 ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY si En l J PAGE 66 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY NO PART NO ITEM 1 M19232000094 ENGINE 2 8943212191 CARTRIDGE OIL FILTER 3 X132400240 CARTRIDGE FUEL FILTER 4 M1303200103 ENGINE
7. QOU 120B 19 20A 18 0601808804 CIRCUIT 3 QOU 250B 2P 50A 19 M1260700304 BREAKER FITTING COVER 1 20 0222100150 CUSHION RUBBER 1 21 011206020 HEX HEAD BOLT ooi 2 REPLACES 0016906020 22 0601812597 RECEPTACLE GF 530EM 125V 20 2 2 REPLACES 0601812598 23 0601811034 RECEPTACLE CS6369 250V 50A 3 REPLACES 0601812538 24 0021304015 MACHINE SCREW 10 REPLACES 0027104015 24 0030004000 siai iii 10 REPLACES 0207004000 25 1236100803 TERMINAL COVER 1 26 012212045 HEX HEAD BOLT a iii ii 2 REPLACES 0010112045 27 031112230 PLAINWASHER 2 REPLACES 0041212000 28 9310200004 5 RUBBER 2 29 0030012000 NUT 2 30 0027103010 MACHINE SCREW 4 30 9207003900 HEX NUT piti 4 REPLACES 0030003000 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 71 DCA 45SSIU2 BATTERY ASSY BATTERY ASSY PAGE 72 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 BATTERY ASSY BATTERY ASSY NO PART REMARKS 1 551010280 BATTERY 627MFD REPLACES 0602220187 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040
8. 1 BRR REMARKS INCLUDES ITEMS W INCLUDES ITEMS W ISUZU 4BG1 OIL AND VACUUM PIPING ASSY OIL AND VACUUM PIPING ASSY See Oil Pump Assy See Governor Assy d Inj Pump Comp Assy t me Inj Pump Comp Assy V 116 P 1 See Cylinder Block AMO 142 See Oil Cooler Assy 47 40 B See Oylinder Block Assy e EA 277 See Pan Assy 44800 PAGE 126 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 OIL AND VACUUM PIPING ASSY OIL AND VACUUM PIPING ASSY NO PART PART NAME QTY REMARKS 1 8971242340 1 26 8941753012 1 28 9099211880 2 37 5133112561 1 40 0501408450 BOLT M8X45 W LOCK AND PLAIN WASHER 40 0500408350 BOLT T V M8X35 W LOCK WASHER 40 0500408320 BOLT ias M8X32 W LOCK WASHER 47 1096234620 GASKET 2 116 9095720100 GASKET 2 142 9098440220 NUT 1 279 8941625680 CLIP 2 33 1093600430 HOSE 1 434 0911501080 NUT 1 48 8941405812 FILLER 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 127 ISUZU 4861 ELECTRICAL CONTROL ASSY ELECTRICAL CONTROL ASSY PAGE 128 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4861 ELECTRICAL CONTROL ASSY
9. 1 60 SHIM S enas Asas asi T T 1 35 Ton sss sss T 1 45 SHIM 1 55 ISUZU 4BG1 GOVERNOR COMP ASSY GOVERNOR COMP ASSY 113 8 B S 12 111 A 110 105 D 105 105 B 87 Pj PAGE 138 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 GOVERNOR ASSY GOVERNOR COMP ASSY NO PARTNO PART NAME QTY REMARKS 1 8971621760 GOVERNOR ASSY INCLUDES ITEMS W 2 5157210040 HOUSING 3 5157290270 BOLT 6 44 8913253970 PLATE 1 74 5157210220 COVER 1 8 5157290330 BOLT 4 8 5157290540 BOLT 2 11 1157290010 1 12 1157220210 FLYWEIGHT ASSY 1 13 5196190490 1 15 5157290340 WASHER 1 16 9813250860 NUT 1 17 9813250880 cj me T Ilekas kada T 0 20 174 9813255510 su u nus 0 30 17 9813255520 jr 0 40 17 9813255530 1 00 17 5157292860 US 0 50 17 5157292870 cec p 1 50 17 1157298910 i eem pec 2 00 17 1157298920 3 00 17 1157298930 SHIM eT 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 98132
10. CONNECTER ARRANGEMENT WIRING VIEW 12 34 1234 LJ LI CN6 CNS PAGE 54 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 TROUBLESHOOTING ENGINE Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use the tables shown for diagnosis based on the Engine Troubleshooting Table 19 If the problem cannot be remedied consult our company s business office or service plant TABLE 19 ENGINE TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION Engine does not start No fuel Replenish fuel Air in the fuel system Bleed system Water in the fuel system Remove water from fuel tank Fuel pipe clogged Fuel filter clogged Clean fuel pipe Clean or change fuel filter Excessively high viscosity of fuel or engine oil at low temperature Use the specified fuel or engine oil Fuel with low cetane number Use the specified fuel Fuel leak due to loose injection pipe retaining nut Tighten nut Incorrect injection timing Adjust Fuel cam shaft worn Replace Injection nozzle clogged Clean injection nozzle Injection pump malfunctioning Repair or replace Seizure of crankshaft camshaft piston cylinder liner or bearing Repair or replace Compression leak from cylinder Replace head gasket tighten c
11. DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 69 DCA 45SSIU2 OUTPUT TERMINAL ASSY OUTPUT TERMINAL ASSY PAGE 70 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 OUTPUT TERMINAL ASSY OUTPUT TERMINAL ASSY NO PART ITEM QTY REMARKS 1 8111860908 TERMINAL PANEL Tis REPLACES M1230700103 2 08018317044 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 intcr aaa 1 5 7200646 7201195 8 M1236100613 TERMINAL COVER p S N7201196 9 1236100704 OUTPUT WINDOW 1 10 0605010040 HINGE 2 11 0027103010 MACHINE SCREW 4 11 0207003000 HEX 4 REPLACES 0030003000 11 58413 PLAINWASHER kawsasqa kaqqa 4 REPLACES 0041203000 12 016906020 HEX HEAD BOLT 2 13 011106015 HEX HEAD BOLT niat 4 REPLACES 0016906015 14 M1236400004 CABLE OUTLET COVER 1 15 M1236300004 SUPPORTER CABLE OUTLET COVER 1 16 011206020 HEX HEAD BOLT L sua 6 REPLACES 0016906020 17 0601808808 1 2
12. II DO NOT leave the generator running in the manual mode unattended NOT allow unauthorized people to operate this equipment ALWAYS read understand and follow procedures in Operator s Manual before attempting to operate equipment HI Refer to the Isuzu Engine Owner s Manual for engine technical questions or information DANGER Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area Generator Grounding To guard against electrical shock and possible damage to the equipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical ALWAYS be sure to use the ground terminal green wire when connecting a load to the UVWO output terminals 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
13. T REPLACES 0027104015 6 0601820671 AUTOMATIC VOLTAGE REGULATOR et NTA 5A 2DB 7 0027105010 MACHINE SCREW danau S N7200646 TO 7201105 7 0027105015 MACHINE SCREW 5 7201106 8 0601806116 CURRENT TRANSFORMER 812 943 75 5 9 011808015 MACHINE SCREW cacao pa Dances REPLACES 0027106015 10 0601820845 OVER CURRENT RELAY oett e LR2D1308 11 0601820846 OVER CURRENT pem LR7D1064 12 M1260600004 FITTING BRACKET a i piden poem S N7200646 TO 7200996 13 0021304015 MACHINE SCREW tr ttti REPLACES 0027104015 13 0030004000 HEX NUT REPLACES 0207004000 14 0021004010 MACHINE SCREW utres Un S N7200646 TO 7200996 15 M1213500303 CONTROL BOX COVER 1 16 011106015 HEX HEAD BOLT P LI REPLACES 0016906015 17 M1923100004 SELECTOR Ps VY 40 17A 47130106 KNOB SELECTOR SWITCH 1 18 M1213600104 SWITCH BRACKET a aaa 5 7200646 7200915 18 1213600114 SWITCH BRACKET sessies Pipan S N7200916 19 0027103010 MACHINE SCREW 4 20 011106015 HEX HEAD BOLT Hasan REPLACES 0016906015 21 M1213600004 SWITCH COVER tias asa sasa S N7200646 TO 7200915 21 M1213600014 SIRE GOVER uu sis eers BT S N7200916 22 011106015 HEX EAD BOLT 5 7200646 7200870 qaa REPLACES 0016906015 22 011106015 HE
14. PAGE 6 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 DIMENSIONS SIDE AND FRONT 825 mm 32 48 in 900 mm 35 43 in 800 mm 39 50 in 230 mm 230 mm 230 mm 9 05 in 9 05 in 9 05 in 2000 mm 78 74 in Figure 1 Dimensions DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 7 DCA 45SSIU2 DIMENSIONS AND REAR 7 1250 mm E 49 21 in 763 30 04 770 mm 30 31 Y d d E SERRE Sp 610 mm 24 02 N JA 30 04 in Figure 2 Dimensions LT PAGE 8 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 9 DCA 45SSIU2 SAFETY MESSAGE ALERT SYMBOLS FOR YOUR SAFETY ANDTHE SAFETY OF OTHERS Safety precautions should be followed at all times whe
15. QTY 1 1 1 1 1 4 2 1 2 1 1 REMARKS INCLUDES ITEM W ISUZU 4BG1 CAMSHAFT AND VALVE ASSY CAMSHAFT AND VALVE ASSY PAGE 94 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 CAMSHAFT AND VALVE ASSY CAMSHAFT AND VALVE ASSY NO PART NO 8944094120 1125510501 1125520251 5090002360 1125220161 9116810150 0500408250 9080107200 9098518503 8941295510 9126260050 5126280120 5096230600 5125650060 5125610090 8941145790 1125630351 1125690150 9098514300 5126110310 9126160420 9091115080 9126281050 1090005670 9098514300 1125750360 5125710032 1094001160 1095803350 5090300381 9125310300 5125350011 8941339372 9091800190 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 95 PART NAME CAMSHAFT INLET VALVE EXHAUST VALVE BOLT CAMSHAFT GEAR THRUST PLATE BOLT KEY WASHER ROCKER ARM SHAFT ROCKER ARM PLUG ROCKER ARM BRACKET ROCKER SHAFT GASKET SPLIT COLLAR OUTER VALVE SPRING SPRING SEAT UPPER SPRING SEAT LOWER VALVE GUIDE SEAT WASHER ROCKER ARM ADJ SCREW ADJ SCREW NUT ROCKER SHAFT BRACKET BOLT WASHER PUSH ROD VALVE TAPPET NUT ROCKER SHAFT SPRING BOLT IDLE GEAR SHAFT THRUST COLLAR IDLER GEAR SNAP RING TY O 4 OO 00 00 00 OO O gt REMARKS
16. 66 67 Engine Operating Panel Assembly 68 69 Output Terminal Assembly 70 71 Battery Assembly teri 72 73 Muffler Assembly 74 75 Fuel Tank 76 77 Enclosure Assembly 78 81 Rubber Seal Assembly 82 83 Plate And Decals 84 85 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 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 0
17. 7 06 13 07 PAGE 25 DCA 45SSIU2 GENERATOR CONTROL PANEL Figure 6 Generator Control Panel The definitions below describe the controls and functions of 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 AC Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch 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 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 Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 1 Hz 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 is equipped with the following major components
18. 9813250970 110 1157290980 111 8970242390 112 9813212050 113 9091854150 125 9813252100 150 9813150650 154 5157291120 156 1835794920 157 9019008180 161 1157290380 162 1157290150 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 141 PART NAME NUT SHIM SHIM SEAL BUSHING GASKET RING CAP ADAPTER BOLT WASHER BOLT PLUG WASHER QTY 1 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 ISUZU 4BG1 FEED PUMP ASSY FEED PUMP ASSY PAGE 142 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4861 FEED PUMP ASSY FEED PUMP ASSY QTY NO PART NO PART NAME 1 8971219100 PUMP 5 1 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 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 5 1 29 9813514030 ROLLER 1 30 9813514100 1 31 1157590020 GUIDE 2 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 143 REMARKS INCLUDES ITEMS W INCLUDES ITEMS W ISUZU 4BG1 MISC INJECTION PUMP ASSY MISC INJECTI
19. 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 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 CAUTION ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE BATTERY Figure 43 Battery Connections 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 H
20. particular load per tire WEAR PATTERN CAUSE Center Wear Over Inflation Edge Wear Under Inflation manufacturer Make sure load does not exceed axle rating Align wheels Loss of camber Side Wear B or overloading Toe Wear Incorrect toe in Align wheels Check bearing adjustment ut of balance and balance tires Cupping Wheel lockup amp tire skidding Avoid sudden stops when Flat Spots possible and adjust brakes CAUTION may result in serious injury ALWAYS wear safety glasses when removing or installing force fitted parts Failure to comply 7 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 SHACKLE SUPPORT BRACKET IS WELDED SHACKLE HANGER SUPPORT BRACKET IS WELDED SHACKLE TO FRAME BOLTS LEAF SUSPENSION FRONT U BOLT HANGER BOLT LOCKING TIE PLATE NUT Figure 66 Major Suspension Components Table 17 Suspension Torque Requirements mepa SHACKLE BOLT SNUG ONLY PARTS MUST ROTATE FREELY SPRING EYE BOLT LOCKING NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT BOLT ASSEMBLY SHOULDER TYPE MIN 30 MAX 50 SHACKLE BOLT n wi DCA 45SSIU2 OPERATIO
21. without notice and without incurring any obligations Manufactured for Multiquip Inc by Your Local Dealer is DENYO CO LTD JAPAN 44 21 POWER
22. 13 0602120095 1 103680 14 0602120480 PICKUP 1 7154400 15 0602122093 OIL PRESSURE GAUGE 1 100174 16 0602122272 UNIT OIL PRESSURE I REPLACES 0602122271 17 M9200100004 18 0602123090 WATER TEMPERATURE GAUGE 1 100683 19 0602123260 UNIT WATER TEMPERATURE 1 0209400 20 9075720140 PACKING ii siai asai ai lameness REPLACES 9095720140 AND 0602121109 21 0602121080 CHARGING AMMETER 1 100158 22 0602125090 FUEL 1 100176 23 0602103092 2 05 23 0601810245 BULB 10 10 DC18V 23 0601823223 RECTIFIER uasa 3004 24 0601810141 PANEL LIGHT a L l aaa 9826800370 25 0601831330 SWITCH PANEL LIGHT 1 900001 26 020108060 REPLACES 0207008000 27 M1354200204 GUIDE SLIDE LEVER 1 5 7200646 TO 7200675 28 0027105015 5 2 5 7200646 TO 7200675 i PM HH HSH H HSH HSH HSH HSK HSK SK SB SB HSB SB Ss po SK a See 29 1357200302 WIRE HARNESS ENGINE
23. 23 General Information iciatis 24 Major Components a 25 Generator Control 26 Engine Operating 27 Output Terminal Panel Familiarization 28 30 Load ADDNCSUOE 31 Generator Outputs sic o ob 32 33 Gauge Reading e ME 33 Output Terminal Panel Connections 34 35 Pressel uD 36 40 Generator Start up Procedure 41 43 Generator Shut down Procedure 44 Maintenance enne 45 47 Trailer Brakes 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 59 COMPONENT DRAWINGS Generator 60 61 Control Bax Assembly acies 62 65 Engine amp Radiator Assembly
24. 3 88 8941704860 NUT 4 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 105 ISUZU 4BG1 VENTILATION ASSY VENTILATION ASSY See Cylinder Head Assy PAGE 106 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 VENTILATION ASSY VENTILATION ASSY NO PART PART NAME QTY REMARKS 141 894110110 DIAPHRAGM ASSY 1 142 1143620020 PCV COVER 1 143 9934905100 SCREW 6 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 107 ISUZU 4BG1 WATER PUMP AND CORROSION RESISTOR ASSY WATER PUMP AND CORROSION RESISTOR ASSY See Water Piping Assy PAGE 108 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 WATER PUMP AND CORROSION RESISTOR ASSY WATER PUMP AND CORROSION RESISTOR ASSY NO PART PART NAME QTY REMARKS 2 8971250510 WATER PUMP ASSY Il INCLUDES ITEMS W 3f 8943706610 GASKET 1 4x 8943809470 REPAIR INCLUDES ITEMS W 7 8944161302 WATER PUMP PULLEY 1 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 3
25. 5811291420 5 5811291440 6 5811291450 8 1811130260 9 1811293860 10 1811230240 11A 5811291580 11B 5811291590 11C 5811291600 12 1811130730 15 1811160440 16 1811210370 17A 5811291550 17B 1811291960 18 5811291560 19 1811293960 20 1811160420 21 1811170140 22 1811180360 23 1811150620 27A 1811293870 278 5811292140 28 1811270310 29 1811291850 30 5811291470 31 5811510360 50 1811160430 54 5811220160 57 1811150610 59 5811291500 61 5811291480 62 9821161400 63 5811180190 64 9821161420 65 5811291490 ff 1811291140 78 1811293840 80 1811291840 86 1825530370 PART NAME SEAL KIT CASE METAL COVER CLIP STOPPER BRACKET BEARING SHAFT WASHER WASHER WASHER BRACKET WIRE ARMATURE BEARING BEARING WASHER COIL BRUSH SPRING HOLDER COVER BOLT BOLT LEVER PIN PLATE SWITCH BRUSH CLUTCH COVER ASS TERMINAL CONTACT BUSHING HOLDER WASHER RING WASHER TERMINAL NUT RELAY ISUZU 4BG1 STARTER COMP ASSY QTY cl cl c cl cl cl cl et 0 c B gt REMARKS INCLUDES ITEMS W SHOWN IN PICTURE INCLUDES ITEMS W INCL ITEM W INCL UDES ITEMS W rm INCLUDES ITEMS W DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 133 ISUZU 4BG1 INJECTION PUMP COMP ASSY CONT INJECT
26. Always complete the grounding e er i terminals when this path from the ground terminal an isolation transfer switch ine i ing on this genset to an external 4 m machine I operating source instruction e Serious injury or death may result without this Turn power off before manual for delta setup transfer switch servicing M9520100503 P N M9520100503 WARNING HOT COOLANT can cause A WARN severe burns ENGINE EXHAUST can cause Do not remove cap if severe injury or death radiator is hot Use only in open well ventilated areas or vent exhaust outside P N M9503100004 0320000 DANGER CAUTION P N M9503200004 A HIGH CAUTION cause P N M9520100404 90310000 9520100204 9520100204 J severe injury Do not operate with doors open Stop engine before servicing To use 50 amp receptacles adjust the voltage M90300000 selector switch to the single phase position and the main line circuit breaker to the on position PIN M1500020 P N M1550000204 P N M9503000004 A WARNING A CAUTION ELECTRIC SHOCK HAZARD HOT PARTS can burn skin e Do not touch output terminals while this M Do not touch until machine is operating EEE the machine has e Turn power off before sufficiently cooled 1491010000 servicing P N M9510100004 P N M9520100503 DCA 45SSIU
27. Brakes Dragging Brakes System lubricated Brake components correct Brake lining thickness incorrect or not adjusted correctly Enough brake fluid or correct fluid Lubricate Replace and correct Install new shoes and linings Replace rubber parts fill with dot 4 fluid PAGE 48 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 TRAILER MAINTENANCE Tires Wheels Lug Nuts Tires and wheels are a very important and critical components of the trailer When specifying or replacing the trailer wheels it is important the wheels tires and axle are properly matched CAUTION DO NOT attempt 2 to repair or modify d awheel install inner tube to correct a leak through the rim If the rim is cracked the air pressure in the inner tube may cause pieces of the rim to explode break off with great force and cause serious eye or bodily injury Tire Wear Inflation Tire inflation pressure is the most important factor in tire life Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot Check inflation pressure weekly during use to insure the maximum tire life and tread wear Table 16 Tire Wear Troubleshooting will help pinpoint the causes and solutions of tire wear problems TABLE 16 TIRE WEAR TROUBLESHOOTING SOLUTION Adjust pressure to particular load per tire manufacturer Adjust pressure to
28. ELECTRICAL CONTROL ASSY NO PARTNO PART NAME REMARKS 1 1811001911 STARTER ASSY Tiirinen 24V 4 5KW 2 8971433290 GENERATOR ASSY 24 30 4 0500512280 ern II 12 28 4 0287812350 chlorate locate M12X35 16 0501408350 BOLT asua amana qa aaa M8X35 W LOCK AND PLAIN WASHER 19 5197110620 BRACKET 1 26 050041000 BOLT 10 100 26 0500410450 pr M10X45 W LOCK WASHER 26 5090300101 BOLT M10X75 WILOCK WASHER 38 9825300460 RESISTOR 89 8970299880 SWITCH 1 252 8943717120 COVER 1 286 0911502080 NUT 1 288 9091606080 PLAINWASHER 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 129 ISUZU 4BG1 BATTERY RELAY ASSY BATTERY RELAY ASSY PAGE 130 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4861 BATTERY RELAY ASSY BATTERY RELAY ASSY NO PART NO PART NAME QTY REMARKS 68 1823200010 BATTERY RELAY 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 131 ISUZU 4BG1 STARTER COMP ASSY STARTER COMP ASSY PAGE 132 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 STARTER ASSY NO PART NO 1 1811293940 2 1811230250 3 1811293970 4
29. ISUZU 4BG1 CRANKSHAFT PISTON AND FLYWHEEL ASSY CRANKSHAFT PISTON AND FLYWHEEL ASSY PAGE 96 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 CRANKSHAFT PISTON AND FLYWHEEL ASSY CRANKSHAFT PISTON AND FLYWHEEL ASSY NO PARTNO PART NAME QTY REMARKS 1 8943398950 CRANKSHAFT 1 7 8970716610 CRANKSHAFT STD KIT 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 REPLACES 8941145652 44 5123780020 1 48 8941075970 2 56 8941004540 DAMPER PULLEY 1 59 5095030240 WASHER 1 63 8971766500 PISTON iunio tenes GRADE AX 63 8971766510 PISTON GRADE CX 68 8971238330 RING SET 4 73 9122716080 CONN ROD METAL SET 4 83 912211604 PISTON PIN 4 84 1122301041 CONNECTING ROD ASSY 4 INCLUDES ITEMS W 85 1122510270 BUSHING 4 86 1122350271 BOLT 8 126 8941075751 SNAP PIN RING 8 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 97 ISUZU 4BG1 TIMING GEAR AND FLYWHEEL HOUSING ASSY TIMING GEAR AND FLYWHEEL HOUSING ASSY See Oylinder Block Assy lt 2 Cylinder Block Assy EE C
30. J See Fuel Pump Assy e See Fuel Pump Assy 4 ee N d 54 x Fuel Pump 55 CEN a 27 See Fuel Inj Assy 5 See Fuel Inj Assy 6 me s A 79 Sedimenter Sedimenter ASSy FUEL SEDIMENTER PAGE 118 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4861 FUEL FILTER AND BRACKET ASSY FUEL FILTER AND BRACKET ASSY NO PART NO PART NAME REMARKS 1 1132007011 FUEL FILTER ASSY prem REPLACES 8944537371 AND 8941517451 INCLUDES ITEMS W 20 5154112231 JOINT 1 21 1132120870 jp REPLACES 5132120751 29 1132600470 OVERFLOW VALVE svsacateapas REPLACES 9132600562 30 1096300850 GASKET uisu REPLACES 9095720140 40 5197550010 BRACKET 1 45 0501410350 2 47 0501408250 2 54 1094680021 1 58 132400240 ELEMENT REPLACES 8944147963 1132400791 69 9099063251 2 88 0500410200 2 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 119 ISUZU 4BG1 FUEL PUMP AND PIPE ASSY FUEL PUMP AND PIPE ASSY See Fuel Filter Assy 150 d See Fuel Inj Assy 4 119 B See Fuel Filter Assy See Fuel Filter Assy 107 B KO C See Fuel Inj Assy Y 2 158 A PE PAGE 120 DCA 45SSIU
31. 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 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 PAGE 26 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 ENGINE OPERATING PANEL Figure 7 Engine Operating Panel The definitions below describe the controls and functions of the DCA 45SSIU2 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 Panel Light Switch When activated will turn on control panel light Water Temperature Lamp Indicates that the water temperature is outside of normal range and will shut down the engine Cil Pressure Lamp Indicates that the oil pressure is too low or high and will shut down the engine Pre heat Lamp This indicates when the engine is ready for starting during cold weather operating conditiions Engine Speed Handle This handle will change the speed of
32. Replace if necessary High Voltage Output Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary Circuit Breaker Tripped Short Circuit in load Check load and repair Over current Confirm load requirements and reduce Defective circuit breaker Check and replace Over current Relay actuated Confirm load requirement and replace DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 57 EXPLANATION OF CODE IN REMARKS COLUMN How to read the marks and remarks used in this parts book Items Found In the Remarks Column Serial Numbers Where indicated this indicates a serial number range inclusive where a particular part is used Model Number Where indicated this shows that the corresponding partis 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 PAGE 58 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 SUGGESTED SPARE PARTS DCA 45SSIU2 W ISUZU 4BG1 DIESEL ENGINE 1TO 3 UNITS Qty P N Descr
33. WASHER PLAIN WASHER HEX HEAD BOLT LOCK WASHER PLAIN WASHER COVER BEARING GASKET BEARING COVER END BRACKET HEX HEAD COVER END BRACKET HEX HEAD BOLT LOCK WASHER LOCK WASHER COVER FAN RUBBER SUSPENSION HEX NUT LOCK WASHER PLAIN WASHER wid nk 1 QTY REMARKS dein INCLUDES ITEMS W REPLACES 0042510000 4 1 ETE REPLACES 0010310025 6 1 pp PT 3610 ERZ M14JK621A 1 1 REPLACES 0010108020 4 1 murs 6310 DDU C3 REPLACES 1163400203 REPLACES 9200100204 7 MEAM REPLACES 0042510000 1 2 1 1 4 4 m REPLACES 0041208000 6 6 n REPLACES 0041208000 1 1 1 REPLACES 0017106012 1 2 2 REPLACES 0041206000 el REPLACES 0010310025 6 1 2 2 2 REPLACES 0041212000 DCA 45SSIU2 CONTROL BOX ASSY CONTROL BOX ASSY PAGE 62 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 CONTROL BOX ASSY CONTROL BOX ASSY NO PARTNO ITEM QTY REMARKS 1 M1213000402 CONTROL BOX P P c sya S N7500646 TO 7200915 1 M1213000412 CONTROL BOX c 5 7200916 7200995 1 1213000422 CONTROL S N7200996 2 0601808811 CIRCUIT BREAKER KAF3611010213P110A 1 3 0027105080 MACHINE SCREW 4 4 0601823863 e MSA9013A 5 0021304015 MACHINE SCREW unn aha
34. a Dg p 86 103 C 60 95 oe CYL BLOCK 2114 242 200 382 PAGE 98 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 TIMING GEAR AND FLYWHEEL HOUSING ASSY ISUZU 4BG1 TIMING GEAR AND FLYWHEEL HOUSING ASSY NO PART PART NAME 1 8944509752 TIMING GEAR CASE 2 8943213304 FLYWHEEL HOUSING 36 0500408200 36 0500408450 39 8943706710 GASKET 42 9112290581 DOWEL 49 8943706720 GASKET 54 8971298300 GEAR CASE COVER 57 5113210090 TIMING CHECK COVER 58 0500406140 BOLT 60 0500408250 BOM 60 0500408800 BOL I inci reas 60 5090000841 BOLT sssi 60 5090300381 BOLT tritis 65 8970276011 GASKET 86 8944533001 TACHO DRIVE ELBOW 93 1096234650 ELBOW GASKET 103 1096254380 OIL SEAL FRONT 175 1096253630 OIL SEAL REAR 211 0500408250 BOLT 242 9095714160 PLUG GASKET 252 0500408200 BOLT 290 8943218380 PLUG 382 9992023160 HOUSING PLUG DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 99 REMARKS M8X20 W LOCK WASHER M8X45 W LOCK WASHER MX45 W LOCK WASHER M8X80W LOCK WASHER M8X55 W LOCK WASHER M10X55 ISUZU 4BG1 ENGINE MOUNTING ASSY ENGINE MOUNTING ASSY See Cylinder Block Assy PAGE 100 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 ENGINE MOUNTING ASSY ENGI
35. accordance with national and local electrical codes ALWAYS have a qualified electrician perform the generator wiring installation NEVER power cables or cords lay in water NEVER stand in water while AC power from the generator is being transfer to a load NEVER use a defective or frayed power cable Check the cable for cuts in the insulation E NEVER use extension cord that is frayed or damaged where the insulation has been cut ALWAYS make certain that proper extension cord has been selected for the job See Table 5 The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits Turn all circuit breakers OFF before performing maintenance on the generator PAGE 12 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 RULES FOR SAFE OPERATION E ALWAYS make sure that electrical circuits are properly grounded per the National Electrical Code NEC and local codes before operating generator Severe injury or death by electrocution can result from operating an ungrounded generator lll 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
36. control panel before operating Moving parts and hot surfaces are contained within the enclosure 35200010 Close all doors and lock them before P N M3552000103 operating 92010030 9520100304 OIL U UW DRAIN PLUG Qu 2 P N M950000004 OFF OFF P N M9520000104 P N M9520000204 OVER CURRENT RELAY If itis Impossible to reset the CIRCUIT BREAKER open the control panel and push the RESET BUTTON as below pprox 60 0Hz 18 11 Adjust the Voltage Regulator to the specified voltage Zi amp i 29 P N M9500300104 P N M9510200002 DIESEL FUEL P N M9500300004 P N M9500500104 WATER OIL FILL DAILY M9503000103 PAGE 22 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 GENERATOR DECALS A WARNING FUELING ELECTRIC SHOCK HAZARD INSTRUCTIONS e Do not touch internal wiring EoPbest or connections while this 1 Elevate trailer tongue slightly 2 Fill trailer tank first e Turn power off before 3 Fill generator tank next servicing Optimum venting will be achieved as a result of 92010000 this procedure P N M9520100004 P N TBD A WARNING WARNING WARNING ELECTRIC SHOCK HAZARD ELECTRIC SHOCK HAZARD Before connecting this generator to any building s A lectrical system a licensed electrician must install Do not touch output
37. ft 600 ft 375 ft 250 ft 500 ft 300 ft 200 ft 125 ft 600 CAUTION Eguipment damage can result from low voltage Three Phase Load When calculating the power reguirements for 3 phase power use the following eguation VOLTAGE X AMPERAGE X 1 732 1000 KVA Motors and motor driven eguipment draw much greater current for starting than during operation An inadeguate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable See Table 5 When connecting a resistance load such as an incandescent lamp or electric heater a capacity of up to the generating set s rated output kW can be used When connecting a fluorescent or mercury lamp a capacity of up to the generating set s rated output KW multiplied by 0 6 can be used When connecting an electric drill or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generating set s rated output KW multiplied by 0 8 can be used CAUTION Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer Switch Serious injury or death may result without this transfer switch If 30 load kVA is not given on the equipment nameplate approximate 30 load out
38. in the control box Figure 14 Over Current Relay PAGE 30 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 LOAD APPLICATION Single Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage amperage and 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 WATTS I VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 4 below when connecting loads If wattage is not given on the eguipment s name plate approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage Table 4 Power Factor By Load Type Of Load Single phase induction motors Power Factor Electric heaters incandescent lamps Fluorescent lamps mercury lamps Electronic devices communication eguipment Common power tools Table 5 Cable Selection 60 Hz Single Phase Operation Load In Watts Maximum Allowable Cable Length Current in Amperes At 120 Volts At 240 Volts 10 Wire 12 Wire 14 Wire 16 Wire 300 600 1000
39. internal fuel tank This fuel will eventually drain into the primary trailer tank in order to return to the engine WARNING Itis recommended to only fill the internal secondary taketo 3 4 full in order to allow for fuel return fuel expansion and to avoid spillage See Figure 41 for fuel expansion Fuel EXPANDS When Heated Figure 41 Fuel Expansion PAGE 38 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 PRE SETUP Coolant Ethylane Glycol Green Water 50 50 mix Use only drinkable tap water If hard water or water with many impurities is used the inside of the engine and radiator may become coated with deposits and cooling efficiency will be reduced An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system See the engine manual for further details CAUTION If adding coolant antifreeze d 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 Table 12 Coolant
40. 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 priorto the return date c Anylineitemwithan extended dealer net price of less than 5 00 d Special order items e Electricalcomponents f Paint chemicals and lubricants g Decals andpaper products h Items purchased in kits 7 The sender will be notified of any material receivedthatis notacceptable 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 Crediton returned parts willbe issued at dealer net price at time of the original purchase lessa 15 restocking charge 10 Incases where anitemis accepted for which the original purchase document cannotbe determined the price willbe basedon the list price that was effective twelve months priorto 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 Rebatesfor price declines and added charges for price increases will not be made for stock on handatthe time of any price change Multiquip reserves the rightto quote and sell directto Go
41. pin to lock wheel stand in place while parked Avoid sudden stops and starts This can cause skidding or jackknifing Smooth gradual starts and stops will improve gas milage Avoid sharp turns to prevent rolling Remove wheel stand when transporting DO NOT transport generator with fuel in tank CHOCKED BLOCKS PREVENT ROLLING SUPPORT BLOCKS PAGE 18 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 TRAILER SPECIFICATIONS CAUTION ALWAYS make sure the trailer is in good operating condition Check the tires for proper inflation and wear Also check the wheel lug nuts for proper tightness Explanation of Chart This section is to provide the user with trailer service and maintenance information The service and maintenance guidelines referenced in this section apply a wide range of trailers Remember periodic inspection of the trailer will 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 B Brakes B Tires B LugNutTorguing Suspension m 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
42. result in high pressurized boiling water to gush out ofthe radiator causing severe scalding to any persons in the general area of the generator Coolant Drain Plug Removing the coolant drain plug while the engine is hot will result in hot coolant to gush out ofthe coolant drain plug therefore causing severe scalding to any persons in the general area of the generator Engine Oil Drain Plug Removing the engine oil drain plug while the engine is hot will result in hot oil to gush out of the oil drain plug therefore causing severe scalding to any persons in the general area of the generator Maintenance Safety NEVER lubricate components or attempt service on a running machine ALWAYS allow the machine a proper amount of time to cool before servicing i REM GENEVE Keepthe machinery in proper running condition Fix damage to the machine immediately and always replace broken parts DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 13 DCA 45SSIU2 RULES FOR SAFE OPERATION MNEVER 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 E ALWAYS store equipment properly when not in use
43. the engine from highto low Starter Switch Four position switch pre heat stop run and start Insert ignition key to start and stop engine Tachometer Indicates engine speed in RPM s for 60 Hz operation This meter should indicate 1800 RPM s when the rated load is applied In addition a built in hour meter will record the number of operational hours that the generator has been in use Fuel Gauge Indicates amount of diesel fuel available Charging Ammeter Gauge Indicates the current being supplied by the engine s alternator which provides current for generator s control circuits and battery charging system Water Temperature Gauge During normal operation this gauge be should read between 165 to 215 Oil Pressure Gauge Normal operation should be about 25 psi When starting the generator the oil pressure may read a bit higher but after the engine warms up the oil pressure should return to normal DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 27 DCA 45SSIU2 OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Familiarization Output Terminal Panel The Output Terminal Panel Figure 8 is provided with The OutputTerminal Panel Figure 8 shown below is located the following on the right hand side left from control panel of the generator Lift up on the cover to gain access to receptacles and terminal Three 3 240V output receptacles 50 a
44. water Button for aperon mately SO seconda SA engine is warm If the engine still does not start please operate as in using the Auto Off Reset Manual switch to the Manual position As soon as the engine starts release the button Emergency Stopping angine still does start watar hestar 1 Place the Generator Circuit Breakers in the OFF position Queue CAI WERT REIS 2 2 Turn the Auto Off Reset Manual switch to the OffiReset T After starting allow the engine to r or 2 minutes to nt to r1 warm up At temperatures below freezing this time period must be extended to 2 to 4 minutes 8 When the engine starts immediately check for abnormal noise vibration fluid leakage or any Indication of a problem Check the control panel gauges If all is normal let the engine remain at the Low position for a short time depending the ambient condition 9 After sufficient warm et the Engine speed switch to the High the unit is ready for operation 10 Check the NO Load speed as shown in the table below INSTRUCTIONS Improper operation of this machine can cause severe injury or death Read the instruction manual carefully before operating or servicing This machine should only be operated by a person with sufficient knowledge and skill to ensure safe operation High voltage circuits are located inside the output terminal cover and control panel Close the cover and
45. 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 diately Generator Internal Fuel Tank Trailer Fuel Tank Figure 34 Double Fuel Tank System WARNING ONLY properly trained personel who have read and understand this section should refill the double fuel tank system Use 2 diesel fuel PAGE 36 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 PRE SETUP CAUTION ALWAYS fill trailer tank first with 2 diesel fuel before filling secondary internal tank INTERNAL SECONDARY TANK INTERNAL FUEL TANK SIGHT GAUGE Figure 35 Skid Type Fuel Tank System Refueling Procedure DANGER TRAILER FUEL TANK Diesel fuel and its vapors are dangerous pee oe RG to your health and the surrounding INTERNAL FUEL TANK environment Avoid skin zz siue alina Sq contact and or inhaling ES P fumes ALWAYS FILL THE 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 TRAILER TANK WARNING ALWAYS place trailer on firm level ground before refueling CORRECT Figure 37 Fuel Tank Filling Order ONLY use 2 diesel fuel when refueling DO NOT fill on unlevel g
46. 00 Ibs meaning two axles with a total weight capacity of 6000 pounds Suspension Protects the trailer chassis from shocks transmitted through the wheels Types of suspension used are leaf Q flex and air ride Electrical Electrical connectors looms are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle Application Indicates which units can be employed on a particular trailer DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 19 DCA 45SSIU2 TRAILER SPECIFICATIONS Table 2 Trailer Specifications MODEL FUEL BRAKE GVWR FRAME FRAME JACK CELL SYSTEM LENGTH WIDTH STAND TRLR 10W SDW225 NO NO 1900LBS 50 800LB SGW250 TLW FULL TILT WHEEL 300 TRLR 10 DCA10 NO NO 1900LBS 50 800LB TLG12 DCA FULL TILT WHEEL 15 TRLR 10XF DCA10 TLG 52 GAL NO 1900LBS 50 800LB 12 DCA15 FULL TILT WHEEL TLW 300 TRLR 225W WELDERS NO NO 2200LBS 85 42 800LB DA7000SS FULL TILT WHEEL TRLR BLW400 BLW 400 NO ELECTRIC 2700LBS W MAST 55 800LB 154 78 FULL TILT WHEEL 124 TALL TRLR 50X DCA 25 NO NO 2700LBS 124 55 8001 FULL TILT WHEEL TRLR 50XF DCA 25 41 GAL NO 2700LBS 124 55 800LB FULL TILT WHEEL TRLR 70W DCA 45 60 NO SURGE 7000LBS 186 77 2000LB 70 FLAT PAD TRLR 70X DCA 45 60 OPT SURGE 7000LBS 138 2000LB 70 FLAT PAD TRLR 70XF DCA 45 60 53 GAL SURGE 7000LBS 138 2000LB 70 FLA
47. 006000 LOCK WASHER 2 6 M1346400204 BATTERY CABLE 1 7 M1346400404 BATTERY CABLE 1 8 0016910020 HEX HEAD BOLT 1 8 0040510000 TOOTHED WASHER 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 73 DCA 45SSIU2 MUFFLER ASSY MUFFLER ASSY PAGE 74 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 MUFFLER ASSY MUFFLER ASSY NO PART NO ITEM QTY REMARKS 1 0002300105 MUFFLER 27242N 2 0016910025 HEAD BOLT 4 3 M1333001303 EXHAUST PIPE 1 4 1141450690 GASKET ssis 1 asis REPLACES 0602320004 5 M1333200114 1 6 9098400850 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 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 75 DCA 45SSIU2 FUELTANK ASSY FUEL TANK ASSY PAGE 76 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 FUELTANK ASSY FUEL TANK ASSY NO PART NO ITEM QTY REMARKS 1 M1363000302 FUELTANK 2 0605505070 CAP FUEL TANK 3 M1363200104 TANK BAND 4 M9310500104 SUPPORTER SHEET 5 011008020 HEAD BOLT saskes REPLACES 0016908020 6 0207308000 NUT 7 0222100600 RUBB
48. 0376860 VALVE INSERT SEAT INLET 4 5 5117110280 VALVE INSERT SEAT EXHAUST 4 6 9096600340 PLUG PLATE 4 1096000051 SEALING CYL HEAD Jaa OD 45 7B 5112190150 SEALING CYL HEAD CUP D OD 32 7C 1096000160 SEALING CYL HEAD CUP 4 00 25 70 9111291280 SEALING CYL HEAD 00 20 7E 1096000160 SEALING CYL HEAD 00 25 7F 5096000130 SEALING CYL HEAD 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 M8X75 L 87 14 9098301770 STUD EX MANIFOLD Tas 8 85 L 97 53 1093000180 INJ NOZZLE STUD 8 54 5093000650 ROCKER ARM STUD 3 168 5117770640 FRONT ENG HANGER 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 89 ISUZU 4BG1 CYLINDER BLOCK ASSY 1 Front CYLINDER BLOCK ASSY See Crankshaft Assy PAGE 90 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 CYLINDER BLOCK ASSY CYLINDER BLOCK ASSY NO PARTNO 1 8971239542 2 5878133000 2 4878133010 2 4878133020 2 5878133030 4 1112612480 4 1112612490 4 1112612500 4 1112612520 4 1112612520 4
49. 08000 0016910020 0040510000 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 81 ITEM CHAIN ASSY SPLASHER PANEL SPLASHER PANEL ACOUSTIC SHEET HEX HEAD BOLT iiis HEX HEAD BOLL SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT DOOR HANDLE ASSY MACHINE SCREW HEX NUT aaa HINGE HINGE WASHER MACHINE SCREW DOOR STOPPER MACHINE SCREW BLIND PLUG EMBLEM MACHINE SCREW HEX HEAD BOLT enis TOOTHED WASHER HEX HEAD BOLT TOOTHED WASHER DCA 45SSIU2 ENCLOSURE ASSY QTY REMARKS co cO REPLACES M1483600204 m 5 7200646 7201195 5 7201196 REPLACES 0016908055 REPLACES 0016908020 REPLACES 9113000002 REPLACES 0021806015 REPLACES 0030006000 REPLACES 9310000004 re REPLACES 0016908020 DCA 45SSIU2 RUBBER SEAL ASSY RUBBER SEAL ASSY PAGE 82 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 RUBBER SEAL ASSY RUBBER SEAL ASSY NO PART NO ITEM 1 0228901400 RUBBER SEAL 2 0229200695 RUBBER SEAL 3 0228900620 RUBBER SEAL 4 0228900940 RUBBER SEAL 5 M1490300104 RUBBER SEAL 6 0228800515 RUB
50. 1112612530 4 1112612540 4 1112612550 8 1090004691 13 8941480790 15A 9992055170 15B 5096050180 23 5112190140 25A 9116110480 25B 9116130350 28 8941745290 29 8943706630 34 8970233390 35 5096230350 37 1096050681 38 1097400780 40 8943444620 45 9827200690 56 1133420742 70 1096000520 71 8943673681 72 8970285250 73 9112916051 74 8943675301 80 1096000121 83 9081510180 130 5112570011 132 1131610120 136 5112240040 137 5096800110 140 5096600330 141 0500408180 162 1093660330 179 9095720080 200 9992023140 218 9095720140 236 1093000790 267 5097070041 301 5111290030 CYLINDER BLOCK ASSY LINER e LINER eM t LINER SE e LINER aa LINER CYLINDER BLOCK csser LINER CYLINDER BLOCK LINER CYLINDER BLOCK sissen LINER CYLINDER BLOCK LINER CYLINDER BLOCK issen LINER CYLINDER BLOCK LINER CYLINDER BLOCK iesse LINER CYLINDER BLOCK eissis BOLT DOWEL OIL GALLERY OIL GALLERY PLUG cain decet ded CUP SEALING CAMSHAFT METAL CAMSHAFT METAL OIL PORT COVER OIL PORT COVER GASKET OIL RELIEF VALVE OIL RELIEF GASKET OIL GALLERY PLUG TIMING GEAR CASE PIN SEALING CUP OIL PRESSURE SWITCH PISTON COOLING OIL JET SEALING CUP GASKET TAPPET CHAMBER COVER TAPPET CHAMBER ASSY BOLT TAPPET CHAMBER SEALING CUP FLYWHEEL HOUSING PIN BRIDGE CAP DOWEL OIL CHECK VALVE OIL PUMP
51. 2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 23 DCA 45SSIU2 GENERAL INFORMATION 4595102 FAMILIARIZATION Generator The MQ Power Model DCA 45SSIU2 Figure 5 is a 26 kW generatorthat is designed as a high quality portable requires atrailerfortransport 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 20 amps Two circuit breakers 120V 20amps Five output terminal lugs 30 power Control Box The Control is provided with the following 3 Pole 250 VAC 110 amp Main Circuit Breaker Automatic Voltage Regulator Curre
52. 2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 FUEL PUMP AND PIPE ASSY FUEL PUMP AND PIPE ASSY NO PART NO PART NAME REMARKS 107 5154114570 rm TN REPLACES 8970209330 119 9154127311 1 REPLACES 8970209340 150 9095720140 2 158 5154190040 CLIP 1 158B 5154190051 CLIP 1 159 0501406160 BOLT 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 121 ISUZU 4BG1 OIL COOLER AND OIL FILTER ASSY OIL COOLER AND OIL FILTER ASSY 109 321 496 PAGE 122 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 48G1 OIL COOLER AND OIL FILTER ASSY OIL COOLER AND OIL FILTER ASSY NO 2 A 89 90 109 109 109 109 110 111 112A 112B 113A 113B 281 B 288 290 321 329 A 331 392 444 469 484 496 526 8943212191 5112890090 1217290430 0500408250 0500408450 0500408200 8942058961 8944496450 8970320250 8971281500 5112880020 8944706680 9095716200 8970261351 9132630100 9099211930 8943706700 5090000071 9091605100 9091505100 5112820110 8970196530 9099168190 8970209271 5112800111 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 123 PART NAME ELEMENT OIL FILTER BOLT ELEMENT TO CASE GASKET BOLT OIL COOLER BOLT M8X25 iii iii BOLT M8 NAS bai sb BOLT MBA n
53. 443600204 22 020106050 22 00412060000 23 9114000002 24 0027106016 24 020106050 25 9110100204 26 M9116100004 27 0021808020 28 0845031504 29 M1463000702 29 1493501503 30 011008020 31 1625165103 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 79 ITEM QTY REMARKS BASE 1 UNDER COVER 1 HEX HEADBOLT REPLACES 0016908020 FERONT FRAME 5 7200646 7200740 FRONT FRAME 5 7200741 ACOUSTIC 1 HEX HEAD REPLACES 0016908020 COVER FRONT FRAME 1 ACOUSTIC SHEET 1 HEX HEAD BOLT 12 REPLACES 0016908020 INNER COVER FRONT FRAME 1 5 7200646 TO 7200740 INNER COVER FRONT FRAME 1 5 7200741 HEX HEAD B ausus REPLACES 0016908020 CENTER FRAME 1 1 HEAD BOLT 8 LOCKWASHER NM REPLACES 0040014000 PLAIN WASHER REPLACES 0041214000 HEX HEAD 1 TU oues REPLACES 0010112030 SPRING WASHER 10 PLAIN WASHER asas REPLACES 0041212000 REAR FRAME 1 ACOUSTIC 1 HEX HEAD 1 Bina REPLACES 0016908020 TOOTHED WASHER 1 1 DUCT REAR COVER 2 ACOUSTIC SHEET 2 HEX NUT 12 HEX HEAD BOLT B notam R
54. 51820 SCREW 1 41 1157231860 SPRING CAPSULE 1 43 9008130230 NUT 1 45A 1157256680 LEVER ASSY 1 45 5157250330 LEVER ASSY 1 59 5157210210 COVER 1 60 5157290630 BOLT 60C 9019006160 BOLT 1 63 9813919070 GASKET 1 71 5157230880 SPRING 1 79 1157292940 SHIMI u u ppc m 0 20 79 1157292950 SHIM Wee pec 0 25 79 1157292960 SAIM e ai uapa T 0 30 79 1157292970 dicendis 0 35 79 1157292980 0 40 79 1157292990 LU ae annassa T 0 50 83 9813919060 SEAL 1 86 9813254290 BUSHING 1 87 9019006160 BOLT 1 90 9813251770 SCREW 1 91 1157230730 SPRING CAPSULE DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 139 ISUZU 4BG1 GOVERNOR COMP ASSY CONT GOVERNOR COMP ASSY CONT ioi 104 12 103 usse XA IB 60 0 25 110 105 D 105 A 105 B 87 Pj PAGE 140 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 GOVERNOR COMP ASSY GOVERNOR COMP ASSY CONT NO PART 93B 1157296890 930 9813261120 93E 9844100270 94 5157291230 96 5157290530 99 9813250620 101 8941445880 103 1157290920 105 1157250810 105D 8943444370 105D 8943444380 105F 8970874410 106 9813250300 107 9813254880 108 1157293010 109 1157290990 109
55. 6 0500410400 a aa M10X40 W LOCK WASHER 36 5090300101 M10X75 WILOCK WASHER 36 0500410500 s ie ii M10X50W LOCKWASHER 57 5096050050 HEATER PLUG 1 66 5096250780 SECONDARY SEAL 1 67 5136390070 SLINGER 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 109 ISUZU 4BG1 THERMOSTAT AND HOUSING ASSY THERMOSTAT AND HOUSING ASSY 558 8 so See Water Piping Assy 49 A R SS a 28 PAGE 110 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 THERMOSTAT AND HOUSING ASSY THERMOSTAT AND HOUSING ASSY NO PART NO 1 5137700301 2 8944033142 14 9096610050 27 9095713160 28 5096050050 44 0501410250 44 0501410300 49 8944017531 50 0500408250 58 5096050050 64 8941760310 66 8943706730 THERMOSTAT HOUSING SWITCH WATER OUTLET PIPE BOLT WATER OUTLET PLUG GASKET GASKET QTY REMARKS 1 1 1 n REPLACES 9095714160 1 M10X25 WILOCK AND PLAIN WASHER zie M10X30 W LOCK AND PLAIN WASHER DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 111 ISUZU 4BG1 ENGINE WATER PIPING ASSY ENGINE WATER PIPING ASSY 2 B 48 JU BP k See Thermostat Assy See Waterpump Assy PAGE 112 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 ENGINE WATER PIPING AS
56. 6 13 07 PAGE 153 ISUZU 4861 CLUTCH ASSY CLUTCH ASSY Bx 2 8 17 2 2 p 5 EE KN gt B 4 7 Bf amp PAGE 154 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 CLUTCH ASSY CLUTCH ASSY NO PART NO PART NAME QTY REMARKS 17 9910664500 BOLT 6 18 9091505140 LOCKWASHER 6 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 155 ISUZU 4861 SWITCH AND RELAY ASSY SWITCH AND RELAY ASSY PAGE 156 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 SWITCH AND RELAY ASSY SWITCH AND RELAY ASSY NO PART NO PART NAME 15 1819001372 ENG STOP ACTUATOR 58 1823100080 IGNITION SWITCH 417 1825500732 EMERGENCY RELAY 434 KEYISUZUF KEY DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 157 REMARKS INCLUDES ITEM W Effective October 1 2002 TERMS AND CONDITIONS OF SALE PARTS PAYMENT TERMS Terms of paymentfor parts are net 10 days FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges addedto the invoice All shipments are F O B point of origin Multiquip s responsibility ceases whenasigned manifest has been obtained from the carrier andany claim for shortage or damage mustbe settled betweenthe consignee and the carrier MI
57. ART Figure 63 Ignition Switch Off Position 5 Remove allloads from the generator PAGE 44 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 GENERATOR ENGINE MAINTENANCE TABLE 14 INSPECTION MAINTENANCE Drain Bottom of Fuel Tank Change Fuel Filter Clean Radiator and Check Coolant Protection Level 10 Hrs DAILY 250 Hrs 500 1000 Hrs Clean Unit Inside and Outside Test Fuel Injection Nozzle Check Injection Nozzle Clean Inside of Fuel Tank GENERATOR Measure Insulation Resistance Over 3M ohms 1 Replace engine oil anf filter at 100 hours first time only 2 Replace fuel filter at 250 Hours first time only General Inspection Priorto 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 th
58. BER SEAL 7 0228900420 RUBBER SEAL 8 0228900910 RUBBER SEAL 9 0229200900 RUBBER SEAL 10 0229200840 RUBBER SEAL 11 0228800780 RUBBER SEAL 12 0228800470 RUBBER SEAL 13 0228800510 RUBBER SEAL 14 0228100545 RUBBER SEAL 15 0228100370 RUBBER SEAL 16 0228100165 RUBBER SEAL 17 0228100340 RUBBER SEAL 18 0228100170 RUBBER SEAL 19 0228100200 RUBBER SEAL DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 83 QTY 3 1 1 1 1 1 1 3 1 1 2 1 1 1 1 1 1 1 1 REMARKS DCA 45SSIU2 NAMEPLATE AND DECALS NAMEPLATE AND DECALS C LL PAGE 84 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 NAMEPLATE AND DECALS NAMEPLATE AND DECALS NO PART REMARKS 1 1550060294 DECAL NOTE aaa 15000020 2 1550001003 DECAL GENERATOR CONTROL 1 15000100 3 M1550000603 DECAL ENGINE OPERATING 1 15000060 4 M1550000703 DECAL AUXILIARY OUTPUT 1 M15000070 5 141550000804 DECAL NOTE 1 M15000080 6 M9500000004 DECAL OIL DRAIN PLUG tte cs M9000000 7 M9500100004 DECAL 90010000 950030000 DECAL 90030000 9 9500300104 DECAL 90030010 sassa
59. Capacity Engine and Radiator 5 3 Gal 20 L Operation Freezing Weather When operating in freezing weather be certain the proper amount of antifreeze Table 13 has been added Table 13 Anti Freeze Operating Temperatures Freezing Point Boiling Point Vol Anti Freeze C 24 37 When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 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 10 15 MM DEFLECTION Figure 42 Fan Belt Tension CAUTION NEVER place hands near the belts or fan while the generator set is running DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 39 DCA 45SSIU2 PRE SETUP Battery
60. ECTION PUMP COMP ASSY CONT PART NAME QTY REMARKS ADAPTER 1 ADAPTER 1 SCREW 4 GASKET 2 BOLT 1 GASKET 1 RING 1 sj e S 0 10 SHIM M TE 0 12 SAIM Mee rere 0 14 SHIM 0 16 SHIM 0 18 LL T LTE 0 50 SHIM emere EE 1 00 SM ais ii ss 0 30 eiii 0 70 SHIM 1 40 Meme eee I T 2 40 PLATE 2 PINION 4 SCREW 4 EN 0 30 0 40 SHIM L a a aa aaa aaa aa n 0 50 0 60 E T 0 70 SHIM 0 80 SHIM aasan aaa aan 0 90 SHIM 1 00 1 10 SHIM A iek a as L 1 20 SAIM aan n Boon 1 30 US A 1 40 0 55 rm 0 65 RC Jus au T 0 75 a unas 0 85 amam qas pa ss 0 95 m M 1 05 SAM ass os 1 eost T 1 15 SHIN E TTT 1 25 SEN PRENNE Rr 0 20 0 25 asc 0 35 SHIM O I esi j 0 45 E T 1 50 al p
61. EMS W 4 4 4 4 1 1 2 3 3 4 4 2 1 1 Duet NSK Wed NTN ieee T 0 10 0 12 0 14 0 16 0 18 PITT 0 50 niin 1 00 DERE 0 30 PON 0 70 1 40 2 40 NSK 2 1 ISUZU 4861 INJECTION PUMP COMP ASSY CONT INJECTION PUMP COMP ASSY CONT A b lt ES X 43 A Sine 1 PAGE 136 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 NO PART 126 9812350170 127 5156190440 130 9019006140 148 9812151440 155 1156190240 157 8941445880 159 9812250470 162 5156290150 162 5156290160 162 5156290170 162 5156290180 162 5156290190 162 5156290200 162 5156290380 162 9812250330 162 5156190390 162 5156290900 162 1156390880 176 5156250010 177 9812250570 178 9812350030 181 5156190340 181 5156190350 181 5156190360 181 5156190010 181 5156190020 181 5156190030 181 5156190040 181 5156190050 181 5156190070 181 5156190080 181 5156190090 181 5156190100 181 5156190110 181 5156190120 181 5156190130 181 5156190150 181 9812350420 181 9812350430 181 9812350440 181 9812350450 181 5156190250 181 5156190260 181 5156190270 181 5156190370 181 5156191060 181 5156191070 181 5156191080 181 5156191090 181 5156191100 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 137 ISUZU 4BG1 INJECTION PUMP COMP ASSY CONT INJ
62. ENERATOR ASSY GENERATOR ASSY NO PARTNO 1 8051000042 1 1 1 2 8051070003 1 3 0012110035 1 4 030210250 1 5 8041611004 1 6 8041015003 1 7 0105091025 1 8 0042510000 1 9 8001026013 1 10 0601821349 1 11 0601822601 1 12 8001020004 1 13 8001020504 1 14 011008020 1 15 0040080000 1 16 0601000209 1 17 0071906310 2 8051614003 3 0801831704 4 0012810030 5 030210250 6 8051340503 7 0845041904 8 8041315202 9 8041350013 10 0010308065 11 0042608000 12 031108160 13 0010108030 14 0040008000 15 031108160 16 8041310024 17 8041312014 18 8041331014 19 0017106012 20 8001333003 21 0010106030 22 0040006000 23 952404470 24 0105091025 25 0042510000 26 8051332014 27 0605000010 28 0030012000 28 0040012000 28 031112230 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 61 ITEM ROTOR ASSY FIELD ASSY FAN HEX HEAD BOLT LOCK 5 COUPLING DISK BALANCING PLATE HEX HEAD LOCK WASHER SET PLATE RECTIFIER RECTIFIER SURGE ABSORBER INSULATOR WASHER INSULATOR WASHER HEX HEAD LOCK WASHER BALANCING WEIGHT KIT BEARING kain COUPLING RING REAMER BOLT HEX HEAD BOLT LOCK 5 STRATOR ASSY GROMMET END BRACKET FIELD ASSY EXCITER HEX HEAD BOLT LOCK
63. EPLACES 0016908020 REAR DOOR 1 WINDOW PLATE 1 HEX NUT 8 REPLACES 0207306000 PLAIN WASHER 8 DOOR HANDLE ASSY REPLACES 9113000002 MACHINE SCREW 4 REPLACES 0021806015 I REPLACES 0030006000 HINGE 2 WASHER 2 MACHINE SCREW 3 BLIND PLUG torre 2 REPLACES 9310000004 ROOF PANEL 1 ACOUSTIC 1 HEX HEAD 1 REPLACES 0016908020 BONNET OP Tissus REPLACES M9310000103 DCA 45SSIU2 ENCLOSURE ASSY CONT ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLARYELLOW 3 SPECTRUMGRAY 7 GOLD 4 SUNBELT GREEN THE SERIAL NUMBER MAY BE REQUIRED PAGE 80 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ENCLOSURE ASSY NO 32 33 33 33 34 35 36 36 37 37 38 38 39 39 40 40 41 42 PART NO 1625165204 M1453200002 M1453200012 M1493300204 011208060 011008020 M1453001503 M1493403104 M1453002003 M1493403003 M1453001303 M1493400404 M1453001203 M1493401404 M1453300603 M1493401304 0207006000 B9114000002 0027106016 020106050 M9110100204 M9110100304 M9116100004 0021808020 0601850097 0027208025 0845031504 0600500090 0021106015 011008020 00405
64. ER FLAT B78 13LRC 13 X4 50 3500 5 LUG 4 LEAF 4 POLE 2 3 8 RUBBER FLAT TRLR 70W 2 BALLCLASS 205 14C 14 X5 3500lbs 5 LUG 5 LEAF 4 POLE 3 ADJUSTABLE BIAS 4 gi RUBBER FLAT TRLR 70X 2 BALL CLASS 205 14 14 X5 3500s 5LUG 5 LEAF 4 POLE 3 ADJUSTABLE BIAS 4 3 RUBBER FLAT TRLR 70XF 2 BALL CLASS 205 14 14 X5 3500lbs 5 LUG 5 LEAF 4 POLE 3 ADJUSTABLE BIAS 4 3 RUBBER FLAT TRLR 100XF ADJUSTABLE 2 205 15C 14 X5 5 350005 5LUG 5 LEAF 4 WIRE LOOM 5 6 OPT 3 EYE BIAS 4 3 S TRLR 50XF 2 BALL CLASS TRLR 85 125 ADJUSTABLE 2 ST225 75R15D 14 x6 2 6000lbs 6 LUG 7 LEAF 4 WIRE LOOM 5 6 3 EYE RADIAL 4 TRLR 150XF 3 750 16 16 7 2 6000lbs 8 LUG 7 LEAF 4 WIRE LOOM BIAS 4 2 7 2 6 TRLR 220XF 3 EYE ST235 85R16E 16 7 2 7000 BLUG Q FLEX 4 WIRE LOOM ADJUSTABLE RADIAL 4 TRLR 300XF 3 EYE ST235 85R16E 16 7 2 6000 8LUG Q FLEX 4 WIRE LOOM ADJUSTABLE RADIAL 6 TRLR 400XF 3 EYE ST235 85R16E 16 7 3 7000lb 8LUG Q FLEX 4 WIRE LOOM ADJUSTABLE RADIAL 6 TRLR 600XF 5TH WHEEL ST215 75R17 5H 16 7 3 10000 8 LUG 7 LEAF 6 WIRE LOOM RADIAL 8 bs WHEEL ST215 75R17 5H 16 7 3 10000 8LUG AIR RIDE 6 WIRE LOOM RADIAL 8 bs TRLR 800AR o DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 21 DCA 45SSIU2 GENERATOR DECALS DCA 45SSIU2 generator is equipped with
65. ER SHEET 8 M9200000003 DRAIN JOINT 9 M9200200004 DRAIN BOLT 10 0150000018 O RING 11 011206020 HEAD BOLT ian REPLACES 0016906020 12 M1363400104 DRAIN HOSE 13 0605515198 HOSE BAND 14 0602042420 FUEL FILTER 15 0602220911 CLAMP 16 0191301200 SUCTION HOSE 17 0191300300 SUCTION HOSE 18 0191302000 RETURN HOSE 19 0605515109 HOSE BAND O apo Na NN DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 77 DCA 45SSIU2 ENCLOSURE ASSY ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUMGRAY GOLD 4 SUNBELT GREEN 8 THE SERIAL NUMBER MAY BE REQUIRED PAGE 78 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 ENCLOSURE ASSY ENCLOSURE ASSY NO PART NO 1 1413000402 2 1413400004 3 011008020 4 1423000902 4 1423000912 4 1493102703 5 011008020 6 1423200604 6 1493100804 7 011008020 8 1423200703 8 1423200713 9 011008020 10 1433000403 11 1433000003 12 0010114030 12 030214350 12 031114260 13 012012030 13 00400120000 13 031112230 14 1443000702 14 1493300504 15 011008020 15 0040508000 16 1443300613 17 1443300303 17 1493300604 18 0207006000 19 011008020 20 1443200803 21 1
66. FOOT 5 M1303200203 ENGINE FOOT 6 0105091025 HEAD BOLT 7 004251000 LOCKWASHER 8 003041000 HEX NUT 9 060500008 RUBBER SUSPENSION 10 00300120000 NUT 11 0040012000 LOCK WASHER 12 031112230 PLAIN WASHER 13 0602012740 RADIATOR C2810050000R2 13 0602012741 RADIATOR C2810050001 14 0602011065 RADIATOR 15 011008020 HEX HEAD BOLLI 16 M1310500403 RADIATOR HOSE UPPER 17 1310500303 RADIATOR HOSE LOWER 18 0605515147 HOSE BAND 19 0602046232 AIR 20 0602046368 ELEMENT AIR CLEANER 21 0602040650 INDICATOR AIR CLEANER 22 0602040595 BAND AIR CLEANER 23 011008020 HEX HEAD 1 24 020108060 HEX NUT 25 M1373100203 HOSE AIR CLEANER 26 060551548 HOSE BAND 27 0602022560 ADAPTER 28 M1320300304 PACKING OIL PAN SIDE 29 0602022561 90 ELBOW 30 0602022562 UNION 31 0602022792 SWIVEL 32 0602021070 33 0602021572 DRAIN HOSE 34 M9300000103 RESERVE TANK 35 M9300100003 CAP RESERVE TANK 36 0199100175 HOSE 37 M1316100404 BRACKET RESERVE TANK 38 1819001902 ENGINE STOPPER 38 0601802133 FUSE 39 011808015 MACHINE SCREW 40 8970208220 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 67 QTY REMARKS 1
67. Figure 26 clockwise to increase voltage output turn counterclockwise to decrease voltage output DECREASE INCREASE N Figure 26 Voltage Regulator Knob 208V To achieve 30 208V output the voltage selector switch must be in the 30 240 139 position and the voltage regulator must be adjusted to 208V PAGE 34 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 OUTPUT TERMINAL PANEL CONNECTIONS 30 480 277 UVWO Terminal Output Voltages 10 240V 120V UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 30 480 277 1 Place the voltage selector switch in the 10 240 120 position as shown in Figure 27 position as shown in Figure 30 3 PHASE 240 139 3 PHASE 240 139 3 480 277 PRESS LOCK Figure 27 Voltage Selector Switch 480 277V Three Phase Position Figure 30 Voltage Selector Switch 240 120V Single Phase Position 2 Connectthe load wires to the UVWO terminals as shown 2 Connect the load wires to the UVWO terminals as shown in Figure 28 in Figure 31 BLACK RED WHITE GREEN GROUND CONNECTION GROUND CONNECTION MUST BE USED K 480V 277 MUST BE USED AT ALL TIMES 277V Ww 277 WW 120v Figure 28 UVWO Terminal Lugs Figure 31 UVWO Terminal Lugs 240 139V Three Phase Connections 10 240V 120V Connect
68. HO PICKUP PANEL LIGHT P 20 G PANEL diis CONTINUED FROM LIGHT PREVIOUS PAGE SWITCH lt lt Figure 69 Engine Wiring Diagram Continued DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 53 DCA 45SSIU2 GENERATOR WIRING DIAGRAM RUD I R UT R U 2 9 ov x WO Pv 1 LDT O 7 CN8 TO CB1 Ww 14 mm vs oB y 865 T o9 CN12 O 98 97 1 vi TR 9 B gt gt 2 U2 TO CB1 v xi G m TO CN9 _ CN10 CN6 lt CT2 42 to G G sf k cal ENO OC CN1 CN12 L W2 L W2 R U2 R 02 R U2 cys w 2 L w2 w v2 Notice 1 No designation lead size 1 25 SYMBOL CODE TABLE BRUSHLESS AC GENERATOR DESIGNATION MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING EXCITER ARMATURE WINDING Figure 70 Generator Wiring Diagram EXCITER FIELD WINDING RECTIFIER AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR RHEOSTA CURRENT TRANSFORMER CHANGE OVER SWITCH AMMETER AC AMMETER CHANGE OVER SWITCH VOLTMETER AC VOLTMETER CIRCUIT BREAKER CIRCUIT BREAKER B BLlACK CIRCUIT BREAKER RECEPTACLE BR Brown RECEPTACLE IGHT BLUE OVER CURRENT RELAY SELECTOR SWITCH v O ORANGE RELAY UNIT SYMBOL Ar ExAr ExFg AVR 123 AS VS V Cb1 CB 2 3 4 CB 5 6 CON 1 2 3 CON 4 5 Q SW RY1 2
69. ION PUMP COMP ASSY CONT PAGE 134 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 INJECTION PUMP COMP ASSY CONT INJECTION PUMP COMP ASSY CONT NO PART NO 1 5156110590 6 5156440170 7 1096230520 8 5156290450 9 5156430010 10 1156490010 14 5156410030 19 8943771540 33 1096230130 46 1156192430 48 5156191560 49 9812250470 50 5156210190 51 5156190490 58 9812250580 62 9812350150 63 5156430090 64 9812350210 68 9812212230 69 5156190410 70 9812222200 71 1156290010 72 1156220030 73 8943865960 74 8941711090 75 1156190030 79 9812151150 80 8941711100 82 5156191360 88 9019006140 89 9095720100 102 1132600011 103 1157590010 105 9000906770 105 5098000380 107 5156290150 107 5156290160 107 5156290170 107 5156290180 107 5156290190 107 5156290200 107 5156290380 107 9812250330 107 5156190390 107 5156290900 107 1156390880 114 9000906770 114 5098000380 117 1157590010 118 1156190820 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 135 PART NAME HOUSING HOLDER GASKET STOPPER SPRING GASKET VALVE PLUNGER GASKET COVER GASKET RING CAMSHAFT KEY SLEEVE SEAT SPRING SEAT as GUIDE PIN BUSHING ROLLER GASKET SCREW STUD NUT PLUG BOLT GASKET VALVE GASKET BEARING GASKET BOLT QTY REMARKS 1 4 4 4 4 4 4 4 1 1 1 1 1 1 4 4 4 4 INCL IT
70. L INJECTION ASSY FUEL INJECTION ASSY NO PART NO PART NAME QTY REMARKS 1 8971612100 INJECTION PUMP ASSY pem INCLUDES ITEM W 15 8971230631 COUPLING ASSY 1 16 8970314671 INJ NO 1 1 17 8970314681 INJ PIPE NO 2 1 18 8970314691 INJ NO 3 1 19 8970314701 INJ PIPE NO 4 1 31 1153002912 NOZZLE ASSY 4 32 8970161471 NOZZLE HOLDER ASSY INCL ITEMS W 33 5153110270 NOZZLE ASSY u INCL ITEMS W 34 1153390090 4 35 1153320170 4 36 1153390100 8 37 5153320060 4 38 5153390600 4 39 8941695030 SCREW 4 41 8943203080 CONNECTOR 4 42 5513390030 4 45 8941695020 PUSH 4 46 9153470030 NOZZLE PIN 8 54 9153390510 COVER 4 62 0911501080 NUT 8 63 5154110420 LEAK OFF PIPE REPLACES 8970209371 65 9095720140 4 66 5153150030 4 75 9091605100 WASHER 1 80 5197510150 1 82 9091505100 WASHER 1 84 9091105100 1 87 0500410250 2 93 9095714080 2 113 5154190131 3 133 5154112231 NOZZLE PIPE 1 133 8970209350 NOZZLE PIPE 1 134 1096750371 BOLT 1 138 5153430050 SPRING 4 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 117 ISUZU 4BG1 FUEL FILTER AND BRACKET ASSY FUEL FILTER AND BRACKET ASSY See Fuel Inj Assy See Fuel Pump Assy
71. M90050000 90050010 90300000 sai M90310000 90320000 90320000 91010000 91020000 1 1 1 1 1 49500100004 DECAL WATER a iii 1 M9500300004 DECAL aan i dahil 1 M9500300104 is iii ii 1 10 M9500500004 DECAL DIESEL FUEL 1 11 M9500500104 DECAL FUEL DRAIN PLUG 1 12 M9503000004 DECAL WARNING a 2 13 M9503000103 DECAL WATER OIL 1 14 M9503100004 DECAL WARNING a 1 15 9503200004 DECAL 1 16 9510100004 DECAL CAUTION 1 17 49510200002 DECAL MQ 1 18 9520000004 DECAL GROUND nn 92000000 19 M9520000104 DECAL AMMETER CHANGE OVER SWITCH 1 M92000010 20 M9520000204 DECAL VOLTMETER CHANGE OVER SWITCH 1 M92000020 21 9520180004 DECAL WARNING l aaa 2 M92010000 22 M9520100204 DECAL CAUTION M92010020A 23 M9520100304 DECAL SAFETY INSTRUCTIONS 92010030 24 9520100404 DECAL DANGER lis M92010040 25 M9520100503 DECAL WARNING ttes cite 92010050 26 9520200003 DECAL CONNECTION OF OUTPUT CABLE as 92020000 27 9520200104 DECAL OVER CURRENT RELAY
72. N AND PARTS MANUAL STD REV 7 06 13 07 PAGE 49 DCA 45SSIU2 TRAILER MAINTENANCE Lug Nut Torque Requirements Itis 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 4 LUG NUTS 6 LUG NUTS 3 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically Table 18 Tire Torque Requirements First Pass Second Pass Third Pass FT LBS FT LBS FT LBS 20 25 35 40 50 65 2 9 NEVER use an pneumatic air gun to tighten wheel lug nuts PNEUMATIC AIR GUN TORQUE WRENCH Figure 67 Wheel Lug Nuts Tightening Sequence PAGE 50 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 TRAILER WIRING DIAGRAM TOWING TRAILER SIDE VEHICLE SIDE DOUBLE FILAMENT BULB CONNECT RIGHT TO CHASSIS TAILLIGHT E SINGLE eo YELLOW BROWN i GREEN STOP amp TURN LEFT LICENSE TAIL LIGHT 1 t DOUBLE BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT TAIL LIGH
73. NE MOUNTING ASSY NO PART NO PART NAME QTY REMARKS 2C 9117712470 ENGINE FOOT RIGHT 1 20 9117712480 ENGINE FOOT LEFT 1 20 8943134650 BOLT 7 125 9091105100 NUT 1 251 9091505100 LOCKWASHER 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 101 ISUZU 4BG1 INLET MANIFOLD ASSY INLET MANIFOLD ASSY 2 138 C 52 59 PAGE 102 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 INLET MANIFOLD ASSY INLET MANIFOLD ASSY NO PART NO PART NAME QTY REMARKS 1 8971333280 INLET MANIFOLD 1 7 8970241220 1 20 0911501080 2 52 8943216751 INLET PIPE 1 59 0500510300 BOLT TT 2 M10X30 W LOCK WASHER 59 0501510300 ze Rp 2 M10X30 W LOCK WASHER 60 8943706760 GASKET 1 60 8970225710 1 138 5141111970 INLET PIPE 1 144 0500408250 6 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 103 ISUZU 4BG1 EXHAUST MANIFOLD ASSY EXHAUST MANIFOLD ASSY PAGE 104 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 EXHAUST MANIFOLD ASSY EXHAUST MANIFOLD ASSY NO PART NO PART NAME QTY REMARKS 1 5141410360 EXHAUST MANIFOLD 1 2 8944046100 GASKET 2 15 8943185540 BOLT siais i i iai iii jp M8X63 W PLAIN WASHER 15 8943185550 BOLT doge M8X75 W PLAIN WASHER 16 9044110300 EXHAUST PIPE STUD
74. NIMUM 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 subjectto the following provi sions 1 A Returned Material Authorization must be approved by Multiquip prior to ship ment 2 ToobtainaReturn Material Authorization alistmustbe provided to Multiquip Parts Sales that defines item numbers quanti ties and descriptions of the items to be returned Theparts numbers and descriptions must match the current parts price list b The list must be typed or computer generated The list must state the reason s for the return d The list must reference the sales order s orinvoice s under which the items were originally purchased The list must include the name and phone number of the person request ing the RMA 3 Acopy ofthe Return Material Authoriza tion mustaccompany the return shipment 4 Freight is at the senders expense All parts mustbe returned freight prepaid to Multiquip s designated receiving point 5 Parts must be in new and resalable condition inthe original Multiquip pack age if any and with Multiquip part numbers clearly marked 6 Thefollowingitems are not returnable a Obsolete parts If an item is in the price book and shows as being replaced by another item it is
75. NUAL STD REV 7 06 13 07 PAGE 149 ISUZU 4BG1 AIR DUCT ASSY AIR DUCT ASSY See Cylinder Head Assy See Ventilation Assy 343 A E 345 A f EO 5 PAGE 150 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 AIR DUCT ASSY AIR DUCT ASSY NO PART PART NAME QTY REMARKS 343 8943216680 1 345 8942420340 CLIP 2 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 151 ISUZU 4861 FUEL SEDIMENTER ASSY FUEL SEDIMENTER ASSY See Fuel Filter Assy See Fuel Filter Assy FUEL SEDIMENTER PAGE 152 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 FUEL SEDIMENTER ASSY FUEL SEDIMENTER ASSY NO PART NO PART NAME QTY REMARKS 1 1132008410 FUEL SEDIMENTER 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 aaa naam per INCLUDES ITEMS W 35 8944163770 1 36 5132190221 RING 1 38 5132190210 FLOAT 1 46 9095720140 GASKET 4 47 894470470 1 50B 1097007590 CLIP 2 51B 9097161140 CLIP 3 50C 1097007600 CLIP 2 50C 9097161240 CLIP 3 51 0500406200 BOLT 62A 9099063251 1 62B 5157590270 BOLT 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 0
76. ON PUMP ASSY 19 A See Fuel Inj Assy 20 PAGE 144 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 MISC INJECTION PUMP ASSY MISC INJECTION PUMP ASSY NO PART NO 2 5197510500 3 9041010300 8 9091645100 9 9091506100 10 5156390020 19A 5090000841 19 5090002221 20 9095720080 2 8943706750 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 145 PART NAME BRACKET STUD WASHER WASHER NUT GASKET GASKET QTY REMARKS 1 4 4 4 4 m 6 M8X55 W LOCK WASHER 1 M8X22 ISUZU 4BG1 COUPLING ASSY COUPLING ASSY See Fuel Inj Assy PAGE 146 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 COUPLING ASSY COUPLING ASSY NO PART 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 6 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 147 ISUZU 48G1 ACCELERATOR PEDAL ASSY ACCELERATOR PEDAL ASSY PAGE 148 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4BG1 ACCELERATOR PEDAL ASSY ACCELERATOR PEDAL ASSY NO PART NO PART NAME QTY REMARKS 204A 5197890040 BRACKET 1 DCA 45SSIU2 OPERATION AND PARTS MA
77. OPERATION AND PARTS MANUAL A 4 POWER BRAND SERIES MODEL DCA 45SSIU2 WHISPERWATT GENERATOR STANDARD PARTS LIST NO M1870300034A Revision 7 06 13 07 To find the latest revision of this publication visit our website at www multiquip com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 3 TABLE CONTENTS MQ POWER DCA 45SSIU2 AC GENERATOR Here s How Get Help 3 Table CREER 4 Parts Ordering Procedures 5 DCA 45SSIU2 Specifications 6 E 7 8 Safety Message Alert Symbols 10 11 Rules for Safe Operation 12 15 Installati n u u 16 17 Towing Safety Precautions 18 Trailer Specifications 19 21 Generator 22
78. 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 e Tighten both cocks and replace the overflow tank e Replace with coolant Table 12 for correct mixture Close radiator cap tightly CAUTION Allow engine to cool when flushing out radiator Flushing the radiator while hot will damage radiator Generator Storage For longe term storage of the generator the following is recommended Fill the fuel tank completely Treat with a fuel stabilizer if necessary Completely drain the oil from the crankcase and refill if necessary with fresh oil Clean the entire generator internal and external Cover the generating set and store in a clean dry place Disconnect the battery Make sure engine coolant is at proper level If generator is mounted on a trailer jack trailer up and place on block so tires do touch the ground or remove tires PAGE 46 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 MAINTENANCE Jacket Water Heater and Internal Battery Charger 120 VAC Input Plu
79. SHAFT DRIVE BUSHING WATER DRAIN COCK INJ PUMP NIPPLE BOLT COVER CYL BLOCK WATER DRAIN GASKET OIL GALLERY PLUG GASKET PLUG ENGINE FOOT STUD DRAIN HOSE CLIP SEALING LEVEL GAUGE CUP QTY REMARKS a1 pop D SH KH po BR INCLUDES ITEM W GRADE 4 OD GRD 1 ID GRD AX OD GRD 1 ID GRD CX OD GRD 2 ID GRD AX OD GRD 2 ID GRD CX OD GRD 3 ID GRD AX OD GRD 3 ID GRD CX OD GRDz4 ID GRD AX OD GRD 4 ID GRD CX PT 3 8 PT 1 8 SQUARE HEAD REPLACES 9099135050 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 91 ISUZU 4BG1 OIL PAN AND LEVEL GAUGE ASSY OIL PAN AND LEVEL GAUGE ASSY 11 See and Oil and Vacuum Assy PAGE 92 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 48G1 OIL PAN AND LEVEL GAUGE ASSY OIL PAN AND LEVEL GAUGE ASSY NO 1 2 3x Ax 16 23 119A 119B 120A 120B 277 8941340361 5117601500 1096230570 9096620120 8943706660 0500408180 9992023160 9992023240 9095714160 9095714240 1117500120 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 93 PART NAME OIL PAN ASSEMBLY OIL LEVEL GAUGE DRAIN PLUG GASKET OIL DRAIN PLUG OIL PAN GASKET BOLT OIL HEATER BLIND PLUG OIL HEATER BLIND PLUG GASKET GASKET OIL FILLER CAP
80. SY ENGINE WATER PIPING ASSY NO PART PART NAME QTY REMARKS 2 8941324900 1 148 9099153151 CLIP 2 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 113 ISUZU 4861 FAN AND FAN BELT ASSY FAN AND FAN BELT ASSY See Waterpump Assy 38 PAGE 114 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4861 FAN AND FAN BELT ASSY FAN AND FAN BELT ASSY NO PART PART NAME QTY REMARKS 1 8970699020 COOLING 1 16 9098516490 WASHER 4 24 8942059861 8 65 36 8970208220 Jena sassa REPLACES 5136711320 38 1136420250 SPACER 1 77 9091647080 WASHER 1 80 5136740320 ADJUSTING PLATE 1 86 0500408220 BOLT 1 86B 0501410300 BOLT 1 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 115 ISUZU 4861 FUEL INJECTION ASSY FUEL INJECTION ASSY 31 e 62 oO d 2 32 B 31 22 389 39 B 9 42 17 18 19 113 oo o See Fuel Filter Assy 8 es 9 265 r NB 75 p 82 di N 84 D 133 A 137 EN 2e NOS 87 65 65 Gi amp Pump Assy Fuel Filter Assy See Fuel Filter Assy Fuel Pump Assy e PAGE 116 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4861 FUE
81. T i 1 1 1 1 1 1 DOUBLE i FILAMENT BULB CONNECT 1 RIGHT TO CHASSIS TAIL LIGHT ARSENE L 1 WHITE C WHITE COMMON GROUND SINGLE 1 BLUE TURN RIGHT FILAMENT gt GREEN TALL amp LICENSE BULB YELLOW STOP RED TURN LEFT LICENSE TAIL LIGHT 1 1 DOUBLE FILAMENT BULB FLAT 5 PIN ROUND FLAT 5 PIN ROUND CONNECTOR i CONNECTOR t LEFT TAIL LIGHT i 1 1 Figure 68 Trailer Towing Wiring Diagram DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 51 DCA 45SSIU2 ENGINE WIRING DIAGRAM DCAA5SSIU2 STANDARD ENGINE WIRE DIAGRAM LIR ENGINE STOPPER GAN CHARGING AMMETER STARTER SWITCH Figure 69 Engine Wiring Diagram CODE WIRE COLOR laac e Rep CHARGING pel per paure GENERATOR ER BROWN STARTER E 60 60 PP PINK CONTINUED ON NEXT PAGE D S COLOR CODE TABLE KEY CONNECTION DIAGRAM P m 1 Fe 14 PAGE 52 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 ENGINE WIRING DIAGRAM DCA45SSIU2 STANDARD WATER OIL ENGINE WIRE DIAGRAM TEMP PRESS ALARM ALARM D3 Ay LAMP D4 jy LAMP 02 URR LAN 3 GN re LY B OIL PRESS SWITCH SWITCH TO CONTROL BOX VY SW 41 G V TO TAC
82. T PAD TRLR 100XF DCA 100 125 150 GAL HYDRAULIC 7000LBS 190 76 2000LB SURGE FLAT PAD TRLR 85 125 DCA 85 100 145 GAL HYDRAULIC 10000LBS 186 77 2000LB 125 FLAT PAD TRLR 150XF DCA 150 180 200 GAL HYDRAULIC 11160LBS 204 84 5000 LB SURGE FLAT PAD TRLR 220XF DCA 220 250 GAL HYDRAULIC 14000LBS 222 83 5000 LB SURGE FLAT PAD TRLR 300XF DCA 300 250 GAL HYDRAULIC 18000LBS 238 83 5000 LB SURGE FLAT PAD TRLR 400XF DCA 400 350 GAL ELECTRIC 18000LBS 238 83 5000 LB FLAT PAD TRLR 600XF DCA 600 800 550 GAL 30000LBS 384 5000 LB FLAT PAD TRLR 800SX DCA 600 800 550 GAL 30000185 384 5000 LB PAGE 20 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 TRAILER SPECIFICATIONS Table 2 Specifications Con t MODEL COUPLER TIRES WHEELS AXLE HUBS SUSPENSION ELECTRICAL TRLR 10W 2 BALLCLASS 175 13C 13 X4 50 2200 2X2 5 LUG 3 LEAF 4 WIRE LOOM 2 ADJUSTABLE W 4 POLE FLAT TRLR 10 2 BALL CLASS 175 13C 13 4 5 2200 2 2 5 LUG 3 LEAF 4 POLE FLAT 2 ADJUSTABLE TRLR 10XF 2 BALL CLASS 175 13C 13 4 5 220082X2 5 LUG 3 LEAF 4 POLE FLAT 2 ADJUSTABLE TRLR 225W 2 BALLCLASS 175 13B 13X4 5 220082X2 5LUG 4 POLE FLAT 2 ADJUSTABLE TRLR BLW 2 BALL CLASS 175 13C 13 4 5 2200 2 2 5 LUG 3 LEAF 4 POLE FLAT 2 ADJUSTABLE TRLR 50X 2 BALLCLASS B78 13LRC 13 X4 50 3500lbs 5 LUG 4 LEAF 4 POLE 2 3 8 RUBB
83. X HEAD BODDI n a X pem 5 720871 REPLACES 0016906015 23 011106015 HEX HEAD BOL totns REPLACES 0016906015 23 0040506000 TOOTHED WASHER 1 24 M1223000303 CONTROL PANEL 1 25 0601807630 FREQUENCY METER 26425001019 S N7200646 TO 7202360 25 0601807641 FREQUENCY METER FCF6 45 65Hz 240V 1 5 7202361 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 63 DCA 45SSIU2 CONTROL BOX ASSY CONT CONTROL BOX ASSY CONT PAGE 64 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 CONTROL BOX ASSY CONTROL BOX ASSY CONT NO PARTNO ITEM QTY REMARKS 26 0601808950 AC AMMETER 260240LSPB1 pee S N7200646 TO 7202360 26 0601808986 AMMETER ACF60 75A 0 150A 5A 1 5 7202361 27 0601801040 CHANGE OVER SWITCH 1 SL 2AS 28 0601806813 VOLTMETER 260244SJSJ1 S N7200646 TO S N7202360 28 0601806859 VOLTMETER SCF6 0 600V 1 S N7202361 29 0601801041 CHANGE OVER SWITCH VOLTMETER 1 SL 2VS 30 0601840073 RHEOSTAT VOLTAGE REGULATOR 1 RA20A2SE102BJ 2W 1 31 0601840121 KNOB 1 32 M1223100004 STOPPER 1 33 0027105015 MACHINE SCREW CENE S N7200646 TO 7201195 33 0027105010 MACHINE SCREW ctt
84. 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 OPERATING PROCEDURES Manual Starting Manual Stopping 1 Cheek the engine oll coolant and fuel levels Place the Generator Circuit Breakers in the OFF position ry Set the Engine speed switch to the LOW position and allow ircuit Breakers in the OFF position the unitto cool for few minutes 3 Turn the Auto OffiReset Manual switch to the Off Reset 3 Check that the Voltage select switch or the Voltage change over position board is present at desired voltage In case of generator having multiple voltage ratings Auto Starting Stopping ose fe Engin ees P 1 With the AutoiManual switch in the Auto position the Auto i Starting Stopping controller monitors remote start contacts dee TEE Closure of the remote start contacts will begin engine cranking and the Auto OffiReset Manual switch must be returned When the contacts are opened cranking will stop or if running s Gb oss Qa the engine will stop funcitons fo the Automatic shutdown 6 When the engine is ready for starting during cold E Jai Weather operating conditions push the Intake heater 2 For cold weather conditions utilize the water heater until
85. accident while transporting the generator on public roads always make sure the trailer Figure 4 that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound The following list of suggestions should be used when towing your generator Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating GVWR ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure on both towing vehicle and trailer Also check the tire tread wear on both vehicles ALWAYS make sure the trailer is equipped with a Safety Chain HAND WINCH ADJUSTS TRAILER HEIGHT SAFETY CHAIN Figure 4 Generator with Trailer 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 trailers bumper to prevent tipping while parked Use the trailers hand winch to adjust the height of the trailer then insert locking
86. an or change Air cleaner clogged Clean or change Deficient nozzle injection Repair or replace the nozzle Deficient output Incorrect injection timing Adjust Engine s moving parts seem to be seizing Repair or replace Uneven fuel injection Repair or replace the injection pump Deficient nozzle injection Repair or replace the nozzle Compression leak Replace head gasket tighten cylinder head bolt glow plug and nozzle holder PAGE 56 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 TROUBLESHOOTING GENERATOR Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting Table 20 If the problem cannot be remedied consult our company s business office or service plant TABLE 20 GENERATOR TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION No Voltage Output AC Voltmeter defective Check output voltage using a voltmeter Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Low Voltage Output Is engine speed correct Turn engine throttle lever to High Is wiring connections loose Check wiring and repair Defective AVR
87. ately PAGE 40 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 GENERATOR START UP PROCEDURE WARNING TWISTLOCK RECEPTACLES The engine s exhaust contains harmful Cae emissions ALWAYS have adequate TERMINALS ventilation when operating Direct exhaust away from nearby personnel RECEPTACLE J GROUND Lu BEFORE STARTING Generator and Control Panel CAUTION wm OEIL NEVER manually start the engine with the Figure 45 Load Connections main GFCI or auailliary circuit breakers in the closed position 3 Close all engine enclosure doors Figure 46 1 Be sure and place the main G FC l and aux circuit breakers Figure 44 in the OFF position prior to starting the engine 9T MAIN GFCI AUXILIARY MN PI CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER LE i NM CORRECT INCORRECT KEE E E Figure 46 Engine Enclosure Doors 4 Place the voltage selector switch in the desired voltage Figure 44 Main Aux and GFCI position Figure 47 Circuit Breakers RE 2 Connect the load to the UVWO terminals or auxiliary 240 120 receptacles as shown 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
88. e center of the receptacle will check the GFCI function Both receptacles should be tested at least once a month 120 VAC RECEPTACLE RESET Figure 9 G F C l Receptacle Twist Lock Dual Voltage 120 240 VAC Receptacles There are three 240 VAC 50 amp auxilliary twist lock CS 6369 recepacles Figure 10 provided on the output terminal panel These receptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position 5 6369 TWIST LOCK RECEPTACLES SINGLE PHASE 240 VAC 50 AMP OUTPUT Figure 10 240 VAC Twist Lock Auxiliary Receptacles 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 increasethe voltage turning the knob counter clockwise will decrease the voltage DECREASE INCREASE Figure 11 Voltage Regulator Control Knob Removing the Plastic Face Plate UVWO Terminals The UVWO terminal lugs are protected by a plastic face plate cover Figure 12 Un lock the locking latch and lift the terminal cover to gain access to the plastic face plate Remove the screws securing the face plate t
89. e element needs changing After changing the air element press the dust indicator button to reset the indicator Service Daily If the engine is operating in very dustyor dry grass conditions a clogged air cleaner will result This can lead to a loss of power excessive carbon buildup in the combustion chamber and high fuel consumption Change air cleaner more frequently if these conditions exists Fuel Addition Add diesel fuel the grade may vary according to season and locations Always pour through the mesh filter Removing Water from the Fuel Tank After prolonged use water and other impurities accumulate in the bottom of the tank Occasionally remove the drain cock and drain the contents During cold weather the more empty volume inside the tank the easier it is for water to condense This can be reduced by keeping the tank full with diesel fuel DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 45 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 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 Rem
90. eat 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 If the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polarity of the battery when connecting the battery Inadequate battery connections may cause poor starting of the generator and create other malfunctions 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 or oil lines are defective replace them immedi
91. ecial attention with the exception of routine maintenance such as shoe and lining replacement Brake lines should be periodically checked for cracks kinks or blockage Anchor Post Retractor Sonna Cylinder Backing Actuating Pin Plate i Primary Shoe Adjuster Spring Adjuster Assembly Figure 65 Hydraulic Brake Components Actuator Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder supplying hydraulic pressure to the trailer brakes Periodically check and test the surge actuator to make sure that it is functioning correctly Never use an undersize actuator Table 15 Hydraulic Brake Troubleshooting Symptom No Brakes Possible Cause Brake line broken or kinked Brake lining glazed Solution Repair or replace Reburnish or replace Weak Brakes or Brakes Pull to One Side Trailer overloaded Brake drums scored or grooved Tire pressure correct Correct weight Machine or replace Inflate all tires egually Locking Brakes Tires unmatched on the same axle Brake components loose bent or broken Brake drums out of round Match tires Replace components Replace Noisy
92. eet every performance requirement for the generator Reference Table 1 for engine specifications In keeping with Multiquip s policy of constantly improving its products the specifications quoted herein are subject to change without prior notice The basic controls and indicators for the DCA 45SSIU2 generator are addressed on the following pages Mechanical Governor System The mechanical governor system control the RPM of the engine When the engine demands increase or decrease the mechanical governor system regulates the frequency variation to 5 The electronic governor option increases frequency variation to 0 25 Extension Cables When electric power is to be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to a minimum Use the cable selection chart Table 5 as a guide for selecting proper extension cable size PAGE 24 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 MAJOR COMPONENTS Figure 5 Major Components Muffler Assembly Engine Assembly Generator Assembly Output Terminal Assembly DESCRIPTION Fuel Tank Assembly Battery Assembly Generator Control Panel Assembly Engine Operating Panel Assembly DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV
93. 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 Frame Length Measurement is from fender to fender Jack Stand Trailer support device with maximum pound requirement from the tongue of the trailer Coupler Type of hitch used on the trailer for towing 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 Tire Ply The tire ply layers number is rated in letters 2 4 6 etc Wheel Hub The wheel hub is connected to the trailer s axle Tire Rim Tires mounted on a tire rim The tire rim must match the size of the tire 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 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 60
94. ent 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 Ibs ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure 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 trailers 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 to
95. er Power Connections DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 47 DCA 45SSIU2 TRAILER BRAKES MAINTENANCE Brakes Trailer brakes should be inspected the first 200 miles of operation This will allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes every 3 000 miles If driving over rough terrain inspect the brakes more frequently Figure 74 displays the major hydraulic surge brake components that will require inspection and maintenance Please inspect these components as required using steps 1 through 8 as listed below Brake Adjustment 1 Place the trailer on jack stands Make sure the jack stands are placed on secure level ground Check the wheel and drum for free rotation 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 Adjustthe brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn 6 Adjust rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag 7 Replace the adjusting hole cover and lower the trailer to the ground 8 Repeat steps 1 through 7 on the remaining brakes Hydraulic Surge Brakes Hydraulic surge brakes Figure 65 should not require any sp
96. erature Gauge 16 The tachometer Figure 58 will indicate the speed of the engine when the generator is operating Under normal operating conditions this speed is approximately 1800 RPM s Figure 60 Ammeter Load 19 The generator will run until manually stopped or an abnormal condition occurs TACH HOURS Figure 58 Engine Tachometer DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 43 DCA 45SSIU2 GENERATOR SHUT DOWN PROCEDURE NORMAL SHUT DOWN EMERGENCY SHUT DOWN To shutdown the generator use the following procedure 1 To shut down the engine in the event of an emergency 1 Switch the MAIN AUX and GFCl circuit breakers 9Witch the MAIN GFCI and LOAD Figure 61 circuit Figure 61 to the OFF position no load breakers to OFF position 2 Turn the ignition switch key to the STOP position MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKERS BREAKERS l Bum m m Figure 61 Main AUX and GFCI Circuit Breakers OFF 2 Push the engine throttle control lever inward Figure 62 to the LOW position START IDLE PULL TO RUN Figure 62 Engine Throttle Control Lever Low 3 Letthe 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 inthe STOP position remove the key and store in a safe place ST
97. ere Ratings 10 Table 8 Generator Ampere Ratings 30 kW 208V 240V 480V 20 59 60 30 25 87 75 38 30 104 90 45 35 121 105 53 40 139 120 60 45 156 136 68 50 174 152 76 60 208 181 99 Table 6 Voltages Available Three Phase Switchable Single Phase Switchable 208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 480 VOLT 277 VOLT PAGE 32 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 GENERATOR OUTPUTS GAUGE READING GFCI Receptacle Load Capability 3 PHASE The load capability of the GFCI receptacles is directly re 3401139 lated to the voltage being supplied at either the UVWO ter _ minals or the 3 twist lock auxilliary receptacles 480 277 240 120 Use this position for Tables 9 and 10 show what amount of current is available at 30 208V 10 120V 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 Table 9 GFCI Receptacle Load Capability KVA in Use Available Load Current UVWO Terminals AMPS 30 240 480V GFCI Duplex NEMA 5 20R 120V Figure 16 Voltage Selector Switch 240 139V Three Phase 5 amps per receptacle Position for 30 208V 120V voltage 10 amps per receptacle 15 amps per receptacle V W 65 4 20 amps per receptacle
98. 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 n case the battery liquid dilute sulfuric acid comes in contact with your eyes rinse eyes immediately with plenty of water then contact the nearest doctor or hospital and seek medical attention Transporting ALWAYS shutdown engine before transporting Tighten both fuel tank caps securely f generator is mounted on a trailer make sure trailer complies with all local and state safety transportation laws See next page Towing Safety Precautions for basic towing techniques PAGE 14 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 RULES FOR SAFE OPERATION Towing Safety Precautions CAUTION Conform to Department of Transportation DOT Safety Towing Regulations before towing generator To reduce the possibility of an accid
99. ey 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 mm or larger b Aluminum 8 AWG 8 4 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 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 17 DCA 45SSIU2 TOWING SAFETY PRECAUTIONS Towing Safety Precautions CAUTION Check with your local county or state safety towing regulations before towing your generator To reduce the possibility of an
100. follow o procedures in Operators Manual before attempting to equipment DANGER Never use damaged or worn cables when connecting equipment to the generator Make sure power connecting cables are securely connected to the generators output terminals insufficient tightening of the terminal connections may cause damage to the generator and electrical shock DANGER grab or touch a live R power cord with t wet hands the power possibility exists cower on of electrical shock electrocution and even death gt 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 DANGER lll Backfeed to a utility system can cause electrocution and or property damage DO NOT connectto any building s electrical System except through an approved device or after building main switch is opened ALWAYS have a licensed electrician perform the installation CAUTION 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 Removingthe radiator cap while the engine is hot will
101. gain access to the terminals Tighten terminal nuts securely to prevent load wires from slipping out ness ro Lock Figure 47 Voltage Selector Switch DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 41 DCA 45SSIU2 GENERATOR START UP PROCEDURE 5 Pushthe engine throttle control lever inward Figure 48 10 The generator s frequency meter Figure 52 displays to the LOW position the 60 cycle output frequency in HERTZ START IDLE PULL TO RUN Figure 48 Engine Throttle Control Lever Low Figure 52 Frequency Meter Hz 6 Preheat the engine glow plugs by turning the ignition key Figure 49 to the PRE HEAT position 11 The generator s voltage meter Figure 53 displays the 120 VAC in VOLTS If the voltage is not within the specified STOP OPERATION frequency tolerance PRE HEAT START Figure 49 Ignition Switch Pre Heat Position Figure 53 AC Voltmeter 7 When the preheat lamp luminates Figure 50 turn the ignition key to the START position Once the engine 12 Use the voltage adjustment control knob Figure 54 to starts release the ignition key and allow it to return to increase or decrease the desired voltage the OPERATION position Figure 49 DECREASE INCREASE Figure 50 Pre Heat Indicator Lamp Figure 54 Voltage Adjust Control Knob 8 Let the engine idle for 3 5 minutes listen and check for 13 The ammeter Figure 55 will indicate zero am
102. gs OPTIONAL This generator is equipped with two 120 VAC 20 amp input plugs located on the output terminal panel The purpose of these plugs is to provide power via commercial power to the jacket water heater and internal battery charger These plugs will ONLY function when commercial power has been supplied to them Figure 64 To apply commercial power to these plugs a power cord of adequate size will be required See Table 5 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 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 BATTERY CHARGER 120 VAC INPUT PLUG CONNECT TO EXTERNAL 120 VAC POWER SOURCE 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 JACKET WATER HEATER 120 VAC INPUT PLUG REFERENCE TABLE 6 FOR PROPER SIZE EXTENSION CORD Figure 64 DCA 45SIU2 Battery Charger amp Jacket Water Heat
103. hen you order 10 or more Warranty Department 800 421 1244 Ext 279 310 537 3700 Ext 279 Fax 310 537 1173 line items via Web or Fax FedEx Ground Service at no charge for freight Multiquip s Main Phone Numbers 800 421 1244 Fax 310 537 3927 310 537 3700 carrier No other allowances on freight shipped by any other NOTE DISCOUNTS ARE SUBJECTTO CHANGE MULTIQUIP INC Sa 18910 WILMINGTON AVENUE lt POST OFFICE BOX 6254 4 4 b CARSON CALIFORNIA 90749 310 537 3700 800 421 1244 MULTIAUIP 310 537 3927 MAIL mg multiquip com WWW multiquip com Direct TOLL FREE access to our Parts Department Toll free nationwide 800 427 1244 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 5 DCA 45SSIU2 SPECIFICATIONS Table 1 Generator Specifications DCA 45SSIU2 Revolving field self ventilated open protected type synchronous Type generator Armature Connection Star with Neutral Zig Zag Single Standby Output 47 7 KVA 38 2 KW 27 6 KW Prime Output 45 KVA 36 KW 26 KW 240V or 480V Voltage 240 120V Frequency 60 Hz Speed 1 800 rpm Power Factor Aux AC Power Single Phase 60 Hz 120 VAC Voltage 4 8 KW 2 4 KW x 2 Engine Specifications 2 7 gal 10 3L hr at full load 2 0 gal 7 6L hr at 3 4 load Fuel Consumption 1 5 gal 5 7L hr at 1 2 load 1 1 gal 4 2L hr at 1 4 load 12V 100AH 2 Diesel Fuel
104. hments 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 E 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 HOT DO NOT TOUCH LET COOL HNEVER touch the hot exhaust manifold muffler or cylinder Allow engine or generator E 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 E DO NOT place hands or fingers inside generator engine compartment when engine is running ALWAYS make sure generator installation is
105. iai etstra BOLT M8X65 BODY CASE OIL COOLER CORE OIL COOLER PLUG OIL COOLER CASE PLUG OIL COOLER CASE GASKET PLUG OIL COOLER CASE GASKET PLUG OIL COOLER CASE COVER OIL FILTER uu uu PLUG OIL DRAIN GASKET PLUG OIL DRAIN GASKET OIL FILTER TO C BL BOLT M10X135 WASHER LOCKWASHER GASKET ELEMENT TO BODY GASKET OIL COOLER TO C BL CLIP FILTER ASSY siai iii iii COVER WATER DUCT po 4 4 4 REMARKS W LOCKWASHER W LOCKWASHER W LOCKWASHER INCLUDES ITEMS W INCLUDES ITEMS W ISUZU 4861 OIL PUMP AND OIL STRAINER ASSY OIL PUMP AND OIL STRAINER ASSY YD PAGE 124 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 ISUZU 4861 OIL PUMP AND OIL STRAINER ASSY OIL PUMP AND OIL STRAINER ASSY NO PART NO 1 5131001373 2 5131650040 3 9081040300 5 5095800980 8 5131250020 19 5878102022 29 0500410250 329 1131280180 34 5131210140 35 5131130351 38 5131410171 38B 5131410180 40 1131230160 41 5098430030 42 5131190060 43 0108058000 67 9091505080 86 1131190010 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 125 PART NAME SPRING SEAT PIN COIL SPRING GEAR GEAR SET BOLT PINION SHAFT COVER CASE CASE COUPLING VALVE BALL STRAINER BOLT WASHER SPACER QTY OIL PUMP ASSY
106. ions 3 Turn the voltage regulator knob Figure 29 clockwise to 9 Turn the voltage regulator knob Figure 32 clockwise to increase voltage output turn counterclockwise to increase voltage output turn counterclockwise to decrease voltage output decrease voltage output DECREASE INCREASE DERREN INCREASE N Figure 32 Voltage Regulator Knob 10 240 120V Figure 29 Voltage Regulator Knob 139V 240V mue DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 35 DCA 45SSIU2 PRE SETUP Circuit Breakers To protect the generator from an overload a 3 pole 110 amp main circuit breaker is provided to protect the UVW output 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 Lubrication Oil Fill the engine crankcase with lubricating oil through the filler hole but DO NOT overfill Make sure the generator is level and verify that the oil level is maintained between the two notches Figure 33 on the dipstick See Table 11 for proper selection of engine oil Figure 33 Engine Oil Dipstick When checking the engine oil be sure to check if the oil is Clean If the oil is not clean drain the oil by removi
107. iption d ous 0601820671 AUTOMATIC VOLTAGE REGULATOR 0601840073 RHEOSTAT VOLTAGE REGULATOR luu 0601840121 KNOB RHEOSTAT 1310500403 RADIATOR HOSE 1310500303 RADIATOR HOSE 8943212191 OIL FILTER D senda 132400240 FUEL FILTER eames 0602046368 AIR ELEMENT 0602042420 FUEL TANK IN LINE FILTER pp 0602122272 UNIT OIL PRESSURE pm 0602123260 UNIT WATER TEMPERATURE P scans 0601810245 BULB ALARM LAMP d 8970208220 FAN BELT 1823100080 STARTER SWITCH P KEYISUZUF KEY STARTER SWITCH Z sassa 0601808803 CIRCUIT BREAKER GF 530EM 125V 20 0601808804 CIRCUIT BREAKER 6369 250V 50 9825199289 GLOW PLUG pm 47130106 KNOB SELECTOR SWITCH 5825500422 EMERGENCY RELAY pe 0605505070 FUEL Part number this Suggested Spare Parts list may supercede replace the P N shown in the text pages of this book DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 59 DCA 45SSIU2 GENERATOR ASSY GENERATOR ASSY PAGE 60 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 G
108. mp lugs Three 3 Circuit Breakers 240V 50 amps 2 120V receptacles 20 amp Terminal legs and Ground Two 2 GFCI Circuit Breakers 120V 20 amps are considered bonded grounds One Main Circuit Breaker 250V 9110 amps e Five 5 Output Terminal Lugs 18 AND 30 480 120 VAC NEUTRAL GROUND OUTPUT TERMINALS TERMINAL TERMINAL OUTPUT TERMINAL PANEL BLACK RED BLUE WHITE GREEN Figure 8 Output Terminal Panel CIRCUIT BREAKERS FOR RECEPTACLES CIRCUIT BREAKERS FOR CS 6369 TWIST LOCK RECEPTACLES 120 VAC 20 AMP CONN ACCESS DOOR LIFT TO OPEN RECEPTACLE AND CIRCUIT BREAKER PANEL CS 6369 TWIST LOCK AUX POWER RECEPTACLES 240V 50 AMPS PAGE 28 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles There are two 120 VAC 20 amp GFCI Duplex Nema 5 20R recepacles provided on the output terminal panel These receptacles can be accessed in any voltage selector switch position Each receptacle is protected by a 20 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current of both GFCI receptacles is dependent on the load requirements of the UVWO terminals Pressing the reset button resets the GFCI receptacle after being tripped Pressing the Test Button See Figure 9 in th
109. n operating this equipment Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others This Owner s Manual has been developed to provide complete instructions for the safe and efficient operation of the MQ Power Model DCA45SSIU2 WHISPERWATT GENERATOR Before using this GENERATOR ensure that the operating individual has read and understands all instructions in this manual SAFETY MESSAGE ALERT SYMBOLS The three 3 Safety Messages shown below will inform you about potential hazards that could injure you or others The Safety Messages specifically address the level of exposure to the operator and are preceded by one of three words DANGER WARNING or CAUTION DANGER vou WILL be KILLED or SERIOUSLY injured if you DO NOT follow directions WARNING vou CAN be KILLED or SERIOUSLY injured if you DO NOT follow directions CAUTION vou CAN be injured if you DO NOT follow directions 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 HAZARD SYMBOLS Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide This gas is colorless and odorless and can cause death if inhaled NEVER operate this equipment in a confined area or enclosed structure that does not pr
110. ng the oil drain plug and refill with the specified amount of oil as outlined in the Isuzu Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements API Service Classification CH 4 API Service Classification CG 4 API Service Classification CF 4 ACEA Specification E3 ACEA Specification E2 Table 11 Recommended Motor Oil Temperature Range Type Oil 77 F and greater 25 and greater SAE15W 40 or SAE40 SAE 10W 30 or SAE30 SAE10W 30 or SAE10 32 F to 77 F 0 C to 25 C 22 F to 32 F 30 0 Fuel Check DANGER Fuel spillage on a hot engine can cause a fire or explosion f fuel spillage occurs wipe up the spilled fuel completely to prevent fire hazards NEVER smoke around or near the Refilling the System The DCA45SSJU genset may if equipped with a trailer 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
111. nstall 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 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 Th
112. nt 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 Ato B Ato 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 m
113. o 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 TERMINAL ENCL RE PLASTIC lt gt TERMINAL LOCKING LATCH TERMINAL COVER Figure 12 Plastic Face Plate UVWO Terminals DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 29 DCA 45SSIU2 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Loads can be connected to the generator by the UVWO terminal lugs or the convienience receptacles See Figure 13 Make sure to read the operation manual before attempting to connect aload 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 VOLTAGE 4 OUTPUT TERMINALS LOAD NEUTRAL GFCI RECEPTACLE LOAD CS 6369 TWIST LOCK RECEPTACLES Figure 13 Connecting Loads Over Current Relay An over current relay Figure 14 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over cur rent relay must be pressed The over current relay is lo cated
114. onal injury and damage to the engine equipment gt 4 2 result if operating in speed ranges above maximum allowable A Equipment Damage Messages This generator other property or the surrounding environment could Other important messages provided throughout this manual be damaged if you do not follow 10 help prevent damage to your trowel other property or the instructions surrounding environment DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 11 DCA 45SSIU2 RULES FOR SAFE OPERATION 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 I 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 4 well due to fatigue illness or taking medicine 4 E NEVER operate this equipment under the influence or drugs or alcohol II NEVER use accessories or attac
115. or 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 30 240 139 UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 30 240 139 position as shown in Figure 21 3 PHASE 240 139 3 PHASE 1PHASE 480 277 240 120 lol Figure 21 Voltage Selector Switch 240 139V Three Phase Position 2 Connectthe load wires to the UVWO terminals as shown in Figure 22 BLUE GREEN WHITE GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 22 UVWO Terminal Lugs 240 139V Three Phase Connections 3 Turnthe voltage regulator knob Figure 23 clockwise to increase voltage output turn counterclockwise to decrease voltage output DECREASE INCREASE Figure 23 Voltage Regulator Knob 139V 240V 30 208V 10120V UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 30 240 139 position as shown in Figure 24 3 PHASE 240 139 Use this position for 30 208 or 10120V 1 PHASE 9 Figure 24 Selector Switch 30 208V 10 120V Three Phase Position PRESS TO LOCK 2 Connecttheload wires to the UVWO terminals as shown in Figure 25 BLACK RED BLUE WHITE GREEN GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 25 UVWO Terminal Lugs 30 208V 120V Connections Turn the voltage regulator knob
116. ove 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 e Detachthe oil filter by loosening center bolt and remove the element together with the filter body e Apply a film of oil to the gasket for the cartridge e Install the filter body together with the element and fix them by tightening the center bolt e 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 e 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 e Ventany 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 MAINTENANCE Flushing Out Radiator and
117. ovide ample free flow air A Explosive Fuel Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited DO while the engine is running hot DO 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 A Burn Hazards NOT start the engine near spilled fuel or 77 peru png combustible fluids DO NOT fill the fuel tank Rotating Parts 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 M NEVER operate equipment with covers or guards removed Keep fingers hands hair and clothing away from all moving parts to prevent injury x PAGE 10 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 A Respiratory Hazard DCA 45SSIU2 SAFETY MESSAGE ALERT SYMBOLS A Accidental Starting OFF ALWAYS place the engine ON OFF switch y in the OFF position when the trowel is not in use A Over Speed Conditions A Sight and Hearing hazard ALWAYS wear approved respiratory protection NEVER tamper with the factory settings of the engine governor or settings Pers
118. ps with no any abnormal sounds or smells Check for fuel leaks load applied When a load is applied this meter will harware If any of the above mentioned conditions exists from the generator shut down the engine and correct the problem 9 If the engine is running smoothly with no problems pull and place the engine throttle lever Figure 51 in the HIGH position START IDLE Figure 55 Ammeter No Load PULL TO RUN Figure 51 Engine Throttle Control Lever High PAGE 42 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 GENERATOR START UP PROCEDURE 14 The engine oil pressure gauge Figure 56 will indicate 17 Turn the main GFCI and aux circuit breakers to the the oil pressure kg cm of the engine Under normal ON position Figure 59 operating conditions the oil pressure is approximately MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Figure 56 Oil Pressure Gauge 15 The coolant temperature gauge Figure 57 will indicate the coolant temperature Under normal operating Figure 59 Main AUX and GFCI conditions the coolant temperature is between 165 and Circuit Breakers ON 215 degrees Fahrenheit 18 Observe the generator s ammeter Figure 60 and verify it reads the anticipated amount of current with respect to the load The ammeter will only display a current reading if the load is in use Figure 57 Coolant Temp
119. put maybe determined by multiplying voltage by amperage by 1 732 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 31 DCA 45SSIU2 GENERATOR OUTPUTS Generator Output Voltages A wide range of voltages are available to supply voltage for many different applications Voltages are selected by using the voltage selector switch Figure 15 To obtain some of 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 3 PHASE 240 139 1 PHASE 240 120 3 PHASE 480 277 PRESS TO LOCK Figure 15 Voltage Selector Switch Voltage Selector Switch Locking Button The voltage selector switch has a locking button to protect the generator and load from being switched while the engine is running To lock the voltage selector switch press and hold the red button located at the bottom of the switch 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 Generator Amperage Tables 7 and 8 describe the generator s current output capa bility for both 10 and 30 phase applications Table 7 Generator Amp
120. round ere Ground Fuel from the secondary inner tank will eventually drain into the Figure 36 Only Fill on Level Ground primary trailer tank 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 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 37 DCA 45SSIU2 PRE SETUP 3 NEVER overfill trailer fuel tank It is important to read the trailer fuel gauge when filling trailer fuel tank DO NOT wait for fuel to rise in filler neck See Figure 38 FUEL GAUGE LOCATED ON CONTROL PANEL H LAA 1111411158 Figure 38 Full Trailer Tank WARNING DO NOT OVER FILL fuel system Leave room for fuel expansion Fuel expands when heated 4 Once the trailer tank is the secondary inner tank can be filled See Figure 39 Notice how the trailer filler tube level rises when the internal tank is filled INTERNAL SECONDARY TANK SIGHT GAUGE ALWAYS FILL INTERNAL TANK LAST tall tl ll ah Ahi littl tt Figure 39 Filling Secondary Internal Fuel Tank 5 Figure 40 below reflects a full fuel system FILL 3 4 FULL DO NOT TOP OFF FUEL GAUGE LOCATED ON CONTROL PANEL ai TINA Figure 40 Full Fuel System 6 Fuelfrom the engine return line will drain into the secondary
121. s Shipping address if different than billing address Return fax number Applicable model number Quantity part number and description of each part Specify preferred method of shipment Note Unless otherwise indicated by customer all orders treated as Standard Orders will and wi Fedexorups second or Third Day ship within 24 hours We will make every effort to v FedEx or UPS Next Day ship Air Shipments the same day that the order is Federal Express Priority One received if prior to 2PM west coast time Stock DHL Orders must be so noted on fax or web forms Truck Here s how to get help Place Your Parts Order Via Web or Fax Please have the model and serial number on hand when calling For Even More Savings Parts Department 800 427 1244 Extra Discounts Fax 800 672 7877 All parts orders which include complete part numbers 310 537 3700 Fax 310 637 3284 and are received our automated web parts order Mayco Parts system or by fax qualify for the following extra 800 306 2926 Fax 800 672 7877 discounts 310 537 3700 Fax 310 637 3284 Ordered Standard Stock orders Service Department via orders 750 list and above 800 478 1244 Fax 310 537 4259 Fax 3 10 310 537 3700 Web 5 10 MQ Power Service Department 800 835 2551 Fax 310 638 8046 310 537 3700 Special freight allowances w
122. vernmentagencies andto Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 35 00 surcharge will be addedtothe invoice forspecial handling including bus shipments insured parcel post orincases where Multiguip must personally deliverthe parts to the carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable here under for damagesin excess ofthe purchase price of the itemwith respectto which damages are claimed andinnoeventshall Multiquip be liable forloss of profit or good will or for any other special consequential orincidental damages LIMITATION OF WARRANTIES No warranties express orimplied are made in connection withthe sale of parts ortrade acces sories noras to any engine not manufactured byMultiquip Such warranties madeinconnec 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 Apartfrom such written statement of warranty there are no warranties express impliedor statutory which extend beyondthe description ofthe products on the face hereof PAGE 158 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07
123. wing 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 Connect and test electric brake operation Secure portable power cables in cable tray with tie wraps Emergencies ALWAYS know the location of the nearest fire extinguisher P 2 gt T ALWAYS know the location of the nearest and first aid kit FIRSTAID 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 yam fimm DEPARTMENT DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 15 DCA 45SSIU2 INSTALLATION MZ GENERATOR GROUND LUG 2 GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING T GROUND GROUND CABLE 8 FT MINIMUM 1 250 83 C Figure 3 Typical Generator Grounding Application PAGE 16 DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 DCA 45SSIU2 INSTALLATION Outdoor Installation Install the generator in a clear area Make sure the generator is on secure level ground so that it cannot slide or shift around Also i
124. ylinder head bolt glow plug and nozzle holder Improper valve timing Correct or replace timing gear Piston ring and liner worn Replace Excessive valve clearance Adjust Starter does not run Starter malfunctioning Repair or replace Wiring disconnected Connect wiring DCA 45SSIU2 OPERATION AND PARTS MANUAL STD REV 7 06 13 07 PAGE 55 DCA 45SSIU2 TROUBLESHOOTING ENGINE TABLE 19 ENGINE TROUBLESHOOTING CONTINUED SYMPTOM POSSIBLE PROBLEM SOLUTION Engine revolution is not smooth Fuel filter clogged or dirty Clean or change Air cleaner clogged Clean or change Fuel leak due to loose injection pipe retaining nut Tighten nut Injection pump malfunctioning Repair or replace Incorrect nozzle opening pressure Adjust Injection nozzle stuck or clogged Repair or replace Fuel over flow pipe clogged Clean Governor malfunctioning Repair Either white or blue exhaust gas is observed Either black or dark gray exhaust gas is observed Excessive engine oil Reduce to the specified level Piston ring and liner worn or stuck Repair or replace Incorrect injection timing Adjust Deficient compression Overload Adjust top clearance Lessen the load Low grade fuel used Use the specified fuel Fuel filter clogged Cle

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