MQ Power DCA45SSIU3 Generator Operation Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

TM

SERIES

MODEL DCA-45SSIU3

60 Hz GENERATOR

PARTS LIST NO. M1870300904

Revision #0 (11/30/05)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave.

Carson, CA 90746

800-421-1244

FAX: 310-632-2656

Email: [email protected]

Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244

310-537-3700

SERVICE DEPARTMENT

800-835-2551

310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, EXT. 279

310-537-3700, EXT. 279

FAX: 800-672-7877

FAX: 310-637-3284

FAX: 310-638-8046

FAX: 310-638-8046

FAX: 310-638-8046

© COPYRIGHT 2005, MULTIQUIP INC.

MQ Power Inc, Ultra-Silent series, and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the DCA-45SSIU3 (60 Hz)Whisperwatt™ Generator. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time without notice and without incurring any obligations.

To find the latest revision of this publication, visit our website at: www.mqpower.com

1

DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 3

DCA-45SSIU3 (60 Hz)

—

TABLE OF CONTENTS

WHISPER W A TT™ GENERA TOR

California Proposition 65 Warning ..................................... 2

Here's How To Get Help .................................................... 3

Table Of Contents ............................................................. 4

Parts Ordering Procedures ............................................... 5

Specifications ................................................................... 6

Dimensions ( Side, Front) ................................................. 7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals ....................................................... 14-15

Installation ................................................................. 16-17

General Information ........................................................ 18

Major Components ......................................................... 19

Generator Control Panel ................................................. 20

Engine Operating Panel .................................................. 21

Output Terminal Panel Familiarization ........................ 22-24

Load Application ............................................................. 25

Generator Outputs .......................................................... 26

Gauge Reading ............................................................... 27

Output Terminal Panel Connections ........................... 28-29

Pre Setup .................................................................. 30-33

Generator Start-up Procedure ................................... 34-36

Generator Shut-Down Procedure .................................... 36

Maintenance .............................................................. 37-38

Trailer Maintenance .................................................... 39-42

Trailer Wiring Diagram ..................................................... 43

Generator Wiring Diagram ............................................... 44

Engine Wiring Diagram ................................................... 45

Generator Troubleshooting .............................................. 46

Engine Troubleshooting ............................................. 47-48

Explanation of Code in Remarks Column ....................... 50

Suggested Spare Parts .................................................. 51

ISUZU BB4JG1T ENGINE

Generator Assembly ............................................ 52-53

Control Box Assembly .......................................... 54-55

Engine & Radiator Assembly ............................... 56-59

Output Terminal Assy. .......................................... 60-61

Engine Operating Panel Assembly ...................... 62-63

Battery Assembly ................................................. 64-65

Muffler Assembly ................................................. 66-67

Fuel Tank Assembly ............................................. 68-69

Enclosure Assembly ............................................ 70-73

Rubber Seal Assembly ........................................ 74-75

Nameplate and Decals ........................................ 76-77

Terms and Condition of Sale — Parts ...................... 80

NOTE

Specification and part number are subject to change without notice .


DCA-45SSIU3 (60 Hz)

—

PARTS ORDERING PROCEDURES

❒

❒

When ordering parts, please supply the following information:

❒

❒ ❒ Quantity, part number and description of each part

❒

✓ FedEx or UPS Ground

✓ FedEx or UPS Second Day or Third Day

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will

✓ FedEx or UPS Next Day

✓ Federal Express Priority One ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock ✓ DHL

✓ Truck

Orders” must be so noted on fax or web forms.

Here’s how to get help...

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



800-421-1244

Carson, CA 90746


FAX: 310-632-2656



800-427-1244

310-537-3700


800-835-2551

310-537-3700

FAX: 800-672-7877

FAX: 310-637-3284

FAX: 310-638-8046


800-835-2551


800-835-2551, EXT. 279

310-537-3700, EXT. 279

FAX: 310-638-8046

FAX: 310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered via

Fax

Standard orders

3%

Web 5%

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

Stock orders

($750 list and above)

10%

10%

FedEx Ground Service at no charge for freight

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00

list price) do not count towards the 10+ line items.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254

CARSON, CA 90749

310-537-3700 • 800-421-1244

FAX: 310-632-2656

E-MAIL: [email protected]

INTERNET: www.mqpower.com

Direct TOLL-FREE access to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

1


DCA-45SSIU3 (60 Hz) — SPECIFICATIONS

M o d e l

T y p e

A r m a t u r e C o n n e c t i o n

P h a s e

S t a n d b y O u t p u t

P r i m e O u t p u t

V o l t a g e

F r e q u e n c y

S p e e d

P o w e r F a c t o r

A u x .

A C P o w e r

V o l t a g e

O u t p u t

T a b l e 1 .

G e n e r a t o r S p e c i f i c a t i o n s

S t a r w ti h N e u t r a l

D C A 4 5 S S I U 3

R e v o l v i n g if e l d , s e fl v e n t li a t e g d , e n o e p r a e n t o r p r o t e c t e d t y p e s y n c h r o n o u s

Z i g Z a g

3

4 7 .

3 K V A ( 3 7 .

8 K W )

4 5 K V A ( 3 6 K W )

2 4 0 V o r 4 8 0 V

S i n g l e

2 7 .

3 K W

2 6 K W

2 4 0 / 1 2 0 V

6 0 H z

1 , 8 0 0 r p m

0 .

8 1

S i n g l e P h a s e , 6 0 H z

1 2 0 V A C

4 .

8 K W ( 2 .

4 K W x 2 )

M o d e l

T y p e

N o .

o f C y il n d e r s

B o r e x S t r o k e

D i s p l a c e m e n t

S t a r t i n g

C o o l a n t C a p a c i t y

L u b e O li C a p a c i t y

F u e l T a n k C a p a c i t y

F u e l C o n s u m p t i o n

B a t t e r y

F u e l

T a b l e 2 .

E n g i n e S p e c i f i c a t i o n s

I S U Z U B B 4 J G 1 T

4 C y c l e , w a t e r c o o l e d , d ri e c t i n j e c it o n , t u r b o c h a r g e d

4 c y il n d e r s

3 .

7 6 i n .

x 4 .

2 1 i n .

( 9 5 .

4 m m x 1 0 7 m m )

1 8 7 c u .

i n .

( 3 , 0 5 9 c c )

E l e c t r i c

3 .

6 g a .l

( 1 3 .

7 l ti e r s )

2 .

6 4 g a .l

( 1 0 .

0 l ti e r s )

2 6 .

4 g a .l

( 1 0 0 l ti e r s )

2 .

6 g a .l

( 9 .

8 4 L ) / h r a t f u ll l o a d

2 7 ( C C A 0 ° F 7 0 0 A ) X 1

# 2 D i e s e l F u e l


DCA-45SSIU3 (60 Hz) — DIMENSIONS (TOP, SIDE AND FRONT)

R e f e r e n c e

L e t t e r

A

B

C

D

E

T A B L E 3 .

D I M E N S I O N S

D i m e n s i o n f t .

( m m .

) R e f e r e n c e L e t t e r D i m e n s i o n f t .

( m m .

)

3 0 .

3 1 i n .

( 7 7 0 m m .

)

2 5 .

0 0 i n .

( 6 3 5 m m .

)

2 9 .

0 5 i n .

( 7 3 8 m m .

)

2 4 .

2 1 i n .

( 6 1 5 m m .

)

2 9 .

0 5 i n .

( 7 3 8 m m .

)

F

G

H

7 4 .

8 0 i n .

( 1 , 9 0 0 m m .

)

4 9 .

2 1 i n .

( 1 , 2 5 0 m m .

)

3 5 .

4 3 i n .

( 9 0 0 m m .

)

Figure 1. Dimensions

1


DCA-45SSIU3 (60 Hz) — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the

Safety Messages and Operating Instructions could result in injury to yourself and others.

NOTE

This Operation and Parts Manual has been developed to provide complete instructions for the safe and efficient operation of the MQ

Power Model DCA-45SSIU3

(60Hz) UltraSilent™ Generator.

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

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " Hazard Symbols" which appear throughout this manual, and will be referenced in conjunction with Safety " Message Alert Symbols".

WARNING - LETHAL EXHAUST GASES

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH if inhaled. NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The

Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

WARNING - EXPLOSIVE FUEL

Gasoline is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids.

DO NOT fill the fuel tank while the engine is running or hot.

DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of electrocution,

electrical shock or burn, which can cause

severe bodily harm or even DEATH!


DCA-45SSIU3 (60 Hz) — SAFETY MESSAGE ALERT SYMBOLS

CAUTION - RESPIRATORY HAZARDS WARNING - ROTATING PARTS

NEVER operate equipment with covers, or guards removed. Keep fingers, hands,

hair and clothing away from all moving parts to prevent injury.

ALWAYS wear approved respiratory protection.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the Engine ON/OFF switch in the OFF position and remove the ignition key when the pump is not in use.

CAUTION - SIGHT AND HEARING HAZARDS

ALWAYS wear approved

hearing protection.

eye and

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings of the engine governor or settings.

Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

NOTE

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.

1


DCA-45SSIU3 (60 Hz) — RULES FOR SAFE OPERATION

DANGER - READ THIS MANUAL!

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-45SSIU3 (60 Hz) Whisperwatt ™

Generator

General Safety:

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

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■ This equipment should not be operated by persons under

18 years of age.

■ NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

■ NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■ NEVER operate this equipment under the influence or

■ 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.

■ NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

■ 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.

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

■ NEVER run engine without air filter. Severe engine damage may occur.

■ DO NOT leave the generator running in the manual mode unattended.

■ Refer to the Isuzu Engine Owner's Manual for engine technical questions or information.

■ 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.

drugs or alcohol.

■ NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■ Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.

■ Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.



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.

The following safety recommendations should also be followed:

■ ALWAYS make sure generator is properly grounded.

■ NEVER use gas piping as an electrical ground.

■ ALWAYS make sure that electrical circuits are properly

grounded per the National Electrical Code (NEC) and local codes before operating generator. Severe injury or

DEATH! by electrocution can result from operating an ungrounded generator.

■ ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

Electrical Safety

■ ALWAYS have a qualified electrician perform the generator wiring installation.

■ ALWAYS make sure generator installation is accordance with the National Electrical Code (NEC) and local codes before operating generator.

■ NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■ NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■ ALWAYS make certain that proper extension cord has been selected for the job. See Table 6.

■ NEVER power cables or cords lay in water.

■ NEVER stand in water while AC power from the generator is being transfer to a load.


During operation of this generator, there exists the possibility of electrocution,

electrical shock or burn, which can cause

severe bodily harm or even DEATH!

To avoid these hazards:

NEVER use damaged or worn cables when connecting equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator WET

HANDS and electrical shock.

NEVER grab or touch a live power cord with wet hands.

POWER

CORD

(POWER ON)

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.

Backfeed to a utility system can cause electrocution and or property damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened.

ALWAYS have a licensed electrician perform the installation

1



Maintenance Safety

■ The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits.

Turn all circuit breakers OFF before performing maintenance on the generator.

■ NEVER lubricate components or attempt service on a running machine.

■ ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator.

■ Follow all Battery Safety Guidelines listed in this manual when handling or servicing the generator.

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

■ Keep the machinery in proper running condition.

■ Fix damage to the machine immediately and always replace broken parts.

■ ALWAYS service air cleaner frequently to prevent engine malfunction.

Battery Safety

Use the following guidelines when handling the 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.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid severe injury or DEATH: is the possibility of risk that the battery may explode.

open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids.

If these gases and liquids come in contact with a flame or spark, an explosion could occur.


To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations.

Always allow sufficient time for the engine and generator to cool before performing maintenance.

■ Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

■ Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the 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 gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

charged a buildup of combustible gas will occur.

condition. Repair or replace all worn cables.

environment, to avoid risk of a dangerous concentration of combustible gases.

contact with clothing or skin, rinse skin or clothing immediately with plenty of water.

contact with your EYES, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.



Towing & Transporting Safety

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting Department of

Transportation (DOT) Safety Towing Regulations, before towing your generator.

■ ALWAYS shutdown engine before transporting.

■ Tighten both fuel tank caps securely.

■ If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed Towing & Transporting Safety guidelines for basic towing techniques.

■ Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”

■ ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

■ Check the tire air pressure on both towing vehicle and trailer. Trailer tires should be inflated to 50 psi cold.

Also check the tire tread wear on both vehicles.

■ ALWAYS make sure the trailer is equipped with a "Safety

Chain".

■ ALWAYS attach trailer’s safety chains to towing vehicle properly.

■ ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■ DOT Requirements include the following: z Connect and test electric brake operation.

z Secure portable power cables in cable tray with tie wraps.

■ 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 chock blocks underneath wheel to prevent rolling, while parked.

■ Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■ Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

■ 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.

■ 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 support blocks underneath the trailer’s bumper to prevent tipping, while parked.

■ Avoid sharp turns to prevent rolling.

■ DO NOT transport generator with fuel in tank.

Emergencies

■ ALWAYS know the location of the nearest fire extinguisher.

■ ALWAYS know the location of the nearest and first aid kit.

■ ALWAYS know the location of the nearest phone or keep a phone on

the job site, in case of emergencies.

■ ALWAYS have easy access to the phone numbers of the nearest Ambulance, Doctor and Fire Department. This information will be invaluable in the case of an emergency.

1


DCA-45SSIU3 (60 Hz) — GENERATOR DECALS

The DCA-45SSIU3 (60 Hz) Whisperwatt ™ Generator is equipped with a number of safety decals (Figures 2 and 3).

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.

Figure 2. Generator Decals


DCA-45SSIU3 (60 Hz) — GENERATOR DECALS

Figure 3. Generator Decals (Continued)

1


DCA-45SSIU3 (60 Hz) — INSTALLATION

Figure 4. Typical Generator Grounding Application


DCA-45SSIU3 (60 Hz) — INSTALLATION

Outdoor Installation

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION - EXHAUST HAZARD

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.

Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground. See Figure 4 for a typical grounding configuration.

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 2 ) or larger.

b. Aluminum - 8 AWG (8.4 mm 2 ) or larger.

2. When grounding the generator (Figure 4) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground rod should be buried aminimum of 8 ft. into the ground.

NOTE

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

1


DCA-45SSIU3 (60 Hz) — GENERAL INFORMATION

DCA-45SSIU3 Whisperwatt™ Generator Familiarization

The MQ Power Model DCA-45SSIU3 is a 36 kW, 60 Hz generator (Figure 5) that is designed as a high quality portable

(requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:

■

■

■

■

■

■

■

■

■

■

■

■

■

■

■

Tachometer

Water Temperature Gauge

Water Temperature Alarm Lamp

Oil Pressure Gauge

Oil Pressure Alarm Lamp

Charging Ammeter Gauge

Fuel Level Gauge

Pre-heat Lamp

Panel Light/Panel Light Switch

Ignition Switch

Fuel Filter Water Level Alarm Lamp

Generator Control Panel

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

■

■

■

■

■

■

■

■

■

■

■

■

■

■

■

■

■

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Voltage Regulator

3-Pole, 110 amp Main Circuit Breaker

“Control Box” (located behind the Gen. Control Panel)

Automatic Voltage Regulator

Current Transformer

Over-Current Relay

Voltage Rectifier

Starter Relay

Voltage Selector Switch

Output Terminal Panel

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

■

■

■

■

■

■

■

■

■

Three 120/240V output receptacles (CS-6369), 50A

Three auxiliary circuit breakers, 50A

Two 120V output receptacles (GFCI), 20A

Two GFCI circuit breakers, 20A

Five output terminal lugs (3Ø power)

Battery Charger (Optional)

Water Heater (Optional)

Open Delta Excitation System

The DCA-45SSIU3 (60 Hz)generator is equipped with the state of the art " Open-Delta" excitation system. The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section.

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

During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to 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.


DCA-45SSIU3 (60 Hz) — MAJOR COMPONENTS

T a b l e 4 .

G e n e r a t o r M a j o r C o m p o n e n t s

I T E M N O .

1

2

5

6

3

4

9

1 0

7

8

D E S C R I P T I O N

O u t p u t T e r m i n a l P a n e l A s s e m b l y

O u t p u t R e c e p t a c l e s A s s e m b l y

A ri F i tl e r A s s e m b l y

M u f lf e r A s s e m b l y

F u e l T a n k A s s e m b l y

E n g i n e A s s e m b l y

B a tt e r y A s s e m b l y

G e n e r a t o r A s s e m b l y

E n g i n e O p e r a it n g P a n e l A s s e m b l y

G e n e r a t o r C o n t r o l P a n e l A s s e m b l y

Figure 5. Major Components

1


DCA-45SSIU3 (60 Hz) — GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel

The definitions below describe the controls and functions of the DCA-45SSIU3 (60 Hz) Whisperwatt™ Generator Control

Panel (Figure 6).

1.

Main Circuit Breaker – This three-pole, 110A main breaker is provided to protect the U,V, and W Output

Terminal Lugs from overload.

2.

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

3.

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

4.

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

5.

AC Voltmeter – Indicates the output voltage present at the U,V, and W Output Terminal Lugs.

6.

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.

7.

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.

Located behind the generator control panel is the Generator

Control Box. This box contains some of the necessary electronic components required to make the generator function.

The Control Box is equipped with the following major components:

■

■

■

■

■

■

Over-Current Relay

Voltage Rectifier (AVR)

Starter Relay

Current Transformer

Voltage Selector Switch

NOTE

Remember the overcurrent

relay monitors the current flowing from the U,V, and W

Output Terminal Lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the 60 amp main breaker.

To restore power to the Output Terminal Panel, press the

reset button on the overcurrent relay and place the main circuit breaker in the closed position (ON).


DCA-45SSIU3 (60 Hz) — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

The definitions below describe the controls and functions of the

DCA-45SSIU3 (60 Hz) " Engine Operating Panel " (Figure 7).

1.

Panel Light - Normally used in dark places or at night.

When activated, panel will illuminate. When the generator is not in use, turn the panel light switch to the ‘OFF’ position.

2.

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

3.

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

4.

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

5.

Fuel Filter Water Lever Alarm Lamp - Indicates that water level in the fuel level has risen. Drain the water in the fuel filter strainer when this condition occurs.

6.

Ignition Switch – Three position switch, stop, operation and start. Insert ignition key to start and stop engine.

7.

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

8.

Tachometer – Indicates engine speed in RPM’s for 50

Hz operation. This meter should indicate 1500 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

9.

Fuel Gauge - Indicates amount of diesel fuel available.

10. Charging Ammeter Gauge – Indicates the current being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

11. Water Temperature Gauge – During normal operation this gauge be should read between 165 o F to 203 o F.

12. Oil Pressure Gauge – Normal operation should be between 28 ~71 psi (193 ~490 kPa). 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.

1


DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The Output Terminal Panel (Figure 8) shown below is located on the right-hand side (left from control panel) of the generator.

Lift up on the cover to gain access to receptacles and terminal lugs.

NOTE

Terminal legs “O” and “Ground” are considered bonded grounds.

Output Terminal Familiarization

The “ Output Terminal Panel ” (Figure 9) is provided with the following:

120/240V output receptacles (3) @ 50 amp

Circuit Breakers (3) @ 50 amps, 2-pole

120V GFCI receptacles (2) @ 20 amp

GFCI Circuit Breaker (2) @ 20 amps, 1-pole

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

Figure 8. Output Terminal Panel



Figure 11. Voltage Regulator Control Knob

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

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles 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 U, V, and W output terminal lugs.

Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the Test Button (See Figure 9) in the center of the receptacle will check the GFCI function.

Both receptacles should be tested at least once a month.

Each auxiliary 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

Output Terminal Lugs.

Turn the voltage regulator control knob (Figure 11) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counterclockwise will decrease the voltage.

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The Output Terminal Lugs are protected by a plastic face plate cover (Figure 12). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxiliary twist-lock

(CS-6369) receptacles (Figure 10) provided on the output terminal panel. These receptacles can only be accessed when the voltage selector switch is placed in the singlephase 240/120 position.

1



Connecting Loads

Loads can be connected to the generator by the Output

Terminal Lugs or the convenience receptacles (Figure 13).

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a

3-pole, 110A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Blower Fan

This unit has an intake fan located at the rear of the machine to draw outside air into the cabinet to cool the engine. The fan has a 10 amp AC fuse located beneath the Voltage

Selector Switch (Figure 15).

Figure 13. Connecting Loads

Figure 15. Blower Fan Fuse


This fuse has current running through it any time the engine is running. This fuse is NOT connected to the main circuit breaker of the generator. Attempting to replace the fuse with the engine and/or generator operating could result in electrocution and severe

bodily harm. ALWAYS turn the unit completely off before attempting to replace or handle this fuse.

Figure 14. Over Current Relay

Over Current Relay

An over current relay (Figure 14) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.


DCA-45SSIU3 (60 Hz) — LOAD APPLICATION

Single Phase Load

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

Three Phase Load

When calculating the power requirements for 3-phase power use the following equation:

NOTE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

NOTE

If wattage is not given on the equipment's name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

NOTE

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

The power factor of this generator is 0.8. See Table 5 below when connecting loads.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 6.

T a b l e 5 .

P o w e r F a c t o r B y L o a d

T y p e O f L o a d

S i n g l e p h a s e i n d u c it o n m o t o r s

E l e c t r i c l a m p s h e a t e r s , i n c a n d e s c e n t

F l u o r e s c e n t l a m p s , m e r c u r y l a m p s

E l e c t r o n i c e q u i p m e n t d e v i c e s , c o m m u n i c a it o n

C o m m o n p o w e r t o o l s

P o w e r F a c t o r

0 .

4 0 .

7 5

1 .

0

0 .

4 0 .

9

1 .

0

0 .

8

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.

T a b l e 5 .

C a b l e S e l e c t i o n ( 6 0 H z , S i n g l e P h a s e O p e r a t i o n )

L o a d I n W a t t s

C u r r e n t i n

A m p e r e s A t

V o l

1 t s

2 0 A

V t o l t

2 4 s

0

2 .

5 3 0 0 6 0 0

# 1 0 W i r e

1 0 0 0 f .t

M a x i m u m A ll o w a b l e C a b l e L e n g t h

# 1 2 W i r e

6 0 0 f .t

# 1 4 W i r e

3 7 5 f .t

# 1 6 W i r e

2 5 0 f .t

5

7 .

5

1 0

6

9

1 2

0 0

0 0

0 0

1

1

2

2

8

4

0

0

0

0

0

0

5

3

2

0 0

5 0

5 0 f f f

.t

.t

.t

3

2

1

0 0

0 0

5 0 f f f

1 5

2 0

1

2

8

4

0

0

0

0

3

4

6

8

0

0

0

0

1

1

5

2

0

5 f f

.t

.t

1

7

0

5

0

C A U T I O N : E q u i p m e n t d a m a g e c a n r e s u tl f r o m l o w v o tl a g e .

f .t

f .t

.t

.t

.t

2 0 0 f .t

1 2 5 f .t

1 0 0 f .t

6 5 f .t

5 0 f .t

1 2 5 f .t

1 0 0 f .t

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation

(transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

1


DCA-45SSIU3 (60 Hz) — GENERATOR OUTPUTS

Voltage Selector Switch

The voltage selector switch (Figure 16) is located above the output terminal panel’s Hard Wire Hook-up Panel. It has been provided for ease of voltage selection.

Generator Amperage

Table 8 describes the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

D C A 4 5 S S I U 3

S i n g l e P h a s e

T h r e e P h a s e

K W

2 6 .

0

3 6 .

0

T a b l e 8 .

G e n e r a t o r A m p e r e R a it n g s

K V A

N / A

4 5

1 2 0 V

1 0 8 A x 2

N / A

2

N

0 8

/ A

V

1 2 4 A

* P o w e r F a c t o r = 0 .

8

2 4 0 V

1 0 8 A

1 0 8 A

4 8 0 V

N / A

5 4 A

Figure 16. 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 - CHANGING VOLTAGES

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.

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles.

Tables 9 and 10 show what amount of current is available at the GFCI receptacles when the output terminals and twist lock receptacles are in use. Be careful that your load does not to exceed the available current capability at the receptacles.

T a b l e 9 .

G F C I

K W

T w i s t L o c k i n U s e

( C S 6 3 6 9 )

1 Ø 2 4 0 / 1 2 0 V

2 6

2 4 .

8

2 3 .

6

2 2 .

4

2 1 .

2

R e c e p t a c l e L o a d C a p a b i il t y

A v

C u r a r e li a b l e n t

L o a d

( A m p s )

G F C I

5 -

D u p

2 0 R l e x N E M A

1 2 0 V

0

5 a m p s p e r r e c e p t a c l e

1 0 a m p s p e r r e c e p t a c l e



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 16). To obtain some of the voltages as listed in Table 7 (see below) will require a fine adjustment using the voltage regulator (VR) control

knob located on the control panel.

T h r e e P h a s e

( S w i t c h a b l e )

S i n g l e P h a s e

( S w i t c h a b l e )

T a b l e 7 .

V o l t a g e s A v a li a b l e

2 0 8 V 2 2 0 V 2 4 0 V 4 1 6 V 4 4 0 V 4 8 0 V

1 2 0 V 1 2 7 V 1 3 9 V 2 4 0 V 2 5 4 V 2 7 7 V

T a b l e 1 0 .

G F C I

K V A

( U V W O i n U s e

T e r m i n a l s )

3 Ø 2 4 0 / 4 8 0 V

R e c e p t a c l e L o a d C a p a b i

A v a

C u r r e li a b l e n t

L o a d

( A m p s )

G F C I

5

D

2 0 u p l e x

R 1 2

N E M A

0 V il t y

4 5

4 0 .

9

3 6 .

7

3 2 .

6

2 8 .

4

0

5 a m p s p e r r e c e p t a c l e





DCA-45SSIU3 (60 Hz) — GAUGE READING

How to Read the Output Terminal Gauges.

The gauges and selector switches on the control panel

DO NOT effect the generator output. They are provided to help observe how much power is being supplied at the

Output terminals lugs.

Before taking a reading off either gauge, set the Voltage

Selector Switch (Figure 17) to the position which produces the required voltage (For example, for 3Ø 240V, choose the center 3Ø 240/

139V position on the voltage selector switch.)

Reading Amperage

To determine the amperage at a terminal lug, set the

AC Ammeter Change-Over Switch to the appropriate setting (Figure 20) to activate the AC Ammeter Gauge

(Figure 21) and read the available amperage at the terminal lug.

For example, to measure the amperage at the U terminal lug, set the AC Ammeter Change-Over Switch to

U and read the AC Ammeter Gauge.

Figure 17. Voltage

Selector Switch 240/

139V Three Phase

Position

NOTE

For 3Ø 208V/1Ø,120V, place the Voltage Selector Switch in the 3 Phase 240/139 position.

Reading Voltage

To determine the voltage between two terminal lugs, set the

AC Voltmeter Change-Over Switch to the appropriate setting (Figure 18) to activate the AC Voltmeter Gauge

(Figure 19) and read the available voltage between the two lugs.

For example, to measure the voltage between the W and U terminal lugs, set the AC Voltmeter Change-Over Switch to W-U and read the AC Voltmeter Gauge.

Figure 20. AC Ammeter

Change-Over Switch

Figure 21. AC Ammeter

(Amp reading on U lug)

NOTE

The ammeter gauge will only show a reading when the

Output Terminal Lugs are connected to a load and in use.

Figure 18. AC Voltmeter

Change-Over Switch

Figure 19. AC Voltmeter Gauge

1


DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the Output

Terminal Lugs.. The voltages at the terminals are dependent on the position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob.

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

3Ø 240/139 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in (Figure 22).

3Ø 208V/1Ø120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 25.

Use this position for

3Ø-208 or 1Ø120V.

Figure 25. Voltage Selector

Switch 240/139V

Three-Phase Position

2. Connect the load wires to the Output Terminal Lugs as shown in Figure 26.

Figure 22. Voltage Selector Switch 240/139V


2. Connect the load wires to the Output Terminal Lugs as shown in (Figure 23).

Figure 26. Output Terminal Lugs

3Ø-208V/1Ø120V Connections


3Ø 240/139V Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.


NOTE

To achieve a 3Ø 208V output the voltage selector switch must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to

208V.

Figure 24. Voltage Regulator Knob (139V/240V)


DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø 480/277 Output Terminal Lug Voltages


1Ø 240V/120V Output Terminal Lug Voltages





Single-Phase Position

2. Connect the load wires to the Output Terminal Lugs as shown in Figure 28.

2. Connect the load wires to the Output Terminal Lugs as shown in (Figure 30).


3Ø 480/277V Connections


1Ø-240V/120V Connections



1


DCA-45SSIU3 (60 Hz) — PRE-SETUP

Circuit Breakers

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

main circuit breaker is provided to protect the U,V, and W

Output Terminals from overload. In addition two single-pole,

20 amp GFCI circuit breakers are provided to protect the

GFCI receptacles from overload. Two 50 amp, 2-pole 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 31) on the dipstick. See Table 11 for proper selection of engine oil.

Fuel Check

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a hot engine can cause a fire or explosion.

If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

Refilling the Fuel System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personnel who have read and understand this section should refill the fuel tank system.

Figure 31. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Isuzu Engine Owner's Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements:

■

■

■

■

■

■

■

API Service Classification CC/SC

API Service Classification CC/SD

API Service Classification CC/SE

API Service Classification CC/SF

Located at the bottom-front of the cabinet (Figure 32) is the internal fuel tank. Some generators may be equipped with a trailer mounted fuel tank (option). ALWAYS fill the either fuel tank with clean and fresh #2 diesel fuel. DO NOT fill the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after filling.

Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

Figure 32. Internal Fuel Tank System


Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.


2.

Remove fuel cap and fill fuel tank as shown in Figure 34.

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 (Figure 33).


ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

Figure 34. Fueling the Generator

3.

NEVER overfill fuel tank – It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 35).

Figure 33. Only Fill on Level Ground

NOTE

ONLY! use #2 diesel fuel when refueling.

Figure 35. Full Fuel Tank


DO NOT OVERFILL fuel system. Leave room for fuel expansion. Fuel expands when heated (Figure 36).

Figure 36. Fuel Expansion

1



Coolant (Isuzu Antifreeze/Summer Coolant/Water)

Isuzu recommends Isuzu Antifreeze/Summer Coolant for use in their engines, which can be purchased in concentrate

(and mixed with 50% demineralized water) or pre-diluted.

See the Isuzu Engine Owner's Manual for further details.

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 Isuzu Engine Owner's Manual.


If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See

Table 12 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

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 37) when depressed with the thumb as shown below.

T a b l e 1 2 .

C o o l a n t C a p a c i t y

E n g i n e a n d R a d i a t o r

R e s e r v e T a n k

2 .

8 8 G a .l

( 1 0 .

9 l ti e r s )

2 Q u a r t s ( 1 .

9 l ti e r s )

Operation Freezing Weather

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

A n t

V o l %

-i F r e e z e

5

T a b l e 1 3

O p e r a t i n g

.

A n t i F r e e z e

T e m p e r a t u r e s

0

F r e e z i n g P o i n t

° C

3 7

° F

3 4

Figure 37. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near the belts or fan while the generator set is running.

NOTE

When the antifreeze is mixed with water, the antifreeze mixing ratio

must be less than 50%.



Battery

This unit is of negative ground DO NOT connect in reverse.

Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always keep the terminals firmly tightened.

Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

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

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

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 38) 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 - BATTERY SERVICING SAFETY

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the ignition is in the operate or start position.

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

NOTE

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.

CAUTION - BATTERY SERVICING SAFETY

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 can cause corrosion and damage the alternator.

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 immediately.

Figure 38. Battery Connections

1


Before Starting

DCA-45SSIU3 (60 Hz) — GENERATOR START-UP PROCEDURE

5. Place the voltage selector switch in the desired voltage position (Figure 41).

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating.

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER! manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position.

Figure 41. Voltage

Selector Switch

1. Place the main, G.F.C.I., and aux. circuit breakers

(Figure 39) in the OFF position prior to starting the engine.

6. Preheat the engine glow plugs by turning the ignition key (Figure 42) to the “OPERATION” position.

Figure 39. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Connect the load to the receptacles or the Output

Terminal Lugs as shown in Figure 13. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

3. The output terminal lugs are protected by a plastic cover.

Remove this cover to gain access to the terminals.

Tighten terminal nuts securely to prevent load wires from slipping out.

4. Close all engine enclosure doors (Figure 40).

Figure 42. Ignition Switch (Operation

Pre-Heat Position)

7. When the preheat lamp illuminates (Figure 43), turn the ignition key to the “START” position. Once the engine starts, release the ignition key and allow it to return to the “OPERATION” position (Figure 42).

Figure 43. Pre-Heat Indicator Lamp

8. Let the engine run for 3-5 minutes, listen and check for any abnormal sounds or smells. Check for fuel leaks, and noises that would associate with a loose cover or hardware. If any of the above mentioned conditions exists, shut-down the engine and correct the problem.

Figure 40. Engine Enclosure Doors


DCA-45SSIU3 (60 Hz) — GENERATOR START-UP PROCEDURE

9. The generator's frequency meter (Figure 44) displays the 50 cycle output frequency in HERTZ.

13. The engine oil pressure gauge (Figure 48) will indicate the oil pressure (kg/cm 2 ) of the engine. Under normal operating conditions the oil pressure is between 28 ~71 psi (193 ~490 kPa).

Figure 44. Frequency Meter (Hz)

10. The generator's voltage meter (Figure 45) displays the

120 VAC in VOLTS. If the voltage is not within the specified frequency tolerance,

Figure 48. Oil Pressure Gauge

14. The coolant temperature gauge (Figure 49) will indicate the coolant temperature. Under normal operating conditions the coolant temperature is between 165 and

203 degrees Fahrenheit (74 ~ 95 degrees Celsius).

Figure 45. AC Voltmeter

11. Use the voltage adjustment control knob (Figure 46) to increase or decrease the desired voltage.

Figure 49. Coolant Temperature Gauge

15. The tachometer (Figure 50) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800

RPM’s.

Figure 46. Voltage Adjusted Control Knob

12. The ammeter (Figure 47) will indicate zero amps with no load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator.

Figure 50. Engine Tachometer

Figure 47. Ammeter (No Load)

1


DCA-45SSIU3 (60 Hz) — GEN. START-UP PROCEDURE/SHUTDOWN

16. Turn the main, GFCI, and aux. circuit breakers to the

“ON” position (Figure 51).

Figure 53. Main, AUX. and GFCI

Circuit Breakers (OFF)

Figure 51. Main, AUX. and GFCI

Circuit Breakers (ON)

17. Observe the generator's ammeter (Figure 52) 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.

2. Let the engine cool by running it for 3-5 minutes with no load applied (circuit breakers in the off position).

3. Place the ignition switch (Figure 54) in the “STOP” position, remove the key and store in a safe place.

Figure 54. Ignition Switch (Stop Position)

4. Remove all loads from the generator.

Figure 52. Ammeter (Load)

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

EMERGENCY SHUT-DOWN SHUTDOWN

1. To shut-down the engine in the event of an emergency, switch the MAIN, GFCI and LOAD (Figure 55) circuit breakers to “OFF” position.

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

NORMAL SHUT-DOWN

To shutdown the generator, use the following procedure:

1. Switch the MAIN, AUX and GFCI circuit breakers

(Figure 53) to the “OFF” position (no load).

Figure 55. Ignition Switch (Off Position)


DCA-45SSIU3 (60 Hz) — MAINTENANCE

T A B L E

E N G I N E

G E N E R A T O R

1 4 .

I N S P E C T I O N / M A I N T E N A N C E

1 0 H r s

D A I L Y

X

2 5 0 H r s 5 0 0 H r s 1 0 0 0 H r s

C h e c k E n g i n e F l u i d L e v e l s

C h e c k A ri C l e a n e r

C h e c k B a tt e r y A c i d L e v e l

C h e c k F a n B e tl C o n d i it o n

C h e c k f o r L e a k s

C h e c k f o r L o o s e n i n g o f P a r t s

R e p l a c e E n g i n e O li a n d F i tl e r * 1

C l e a n A ri F i tl e r

C l e a n U n i ,t I n s i d e a n d O u t s i d e

C h a n g e F u e l F i tl e r

X

X

X

X

X

X

X

X

C l e a n R a d i a t o r a n d C h e c k C o o l a n t P r o t e c it o n L e v e l * 2

R e p l a c e A ri F i tl e r E l e m e n t * 3

C h e c k a ll H o s e s a n d C l a m p s * 4

C l e a n I n s i d e o f F u e l T a n k

M e a s u r e I n s u l a it o n R e s i s t a n c e O v e r 3 M o h m s X

X

X

X

X

X

C h e c k R o t o r R e a r S u p p o r t B e a r i n g

* 1 R e p l a c e e n g i n e o li a n d if tl e r a t 1 0 0 h o u r s , f ri s t it m e o n l y .

X

* 2 A d d " S u p p l e m e n t a l C o o l a n t A d d i it v e s ( S C A ' S ) " t o r e c h a r g e t h e e n g i n e c o o l a n .t

* 3 R e p l a c e p r i m a r y a ri if tl e r e l e m e n t w h e n r e s t r i c it o n i n d i c a t o r s h o w s a v a c c u m o f 6 2 5 m m ( 2 5 i n .

H

2

0 ) .

* 4 fI n o b l o w b y s a g s o r h o s d i e p s n e e d s t h a t c t o o u l d b e c o r e p l ll e c a c e d , t m o i s e n s t u r e u r e t h a t a n d / o r t h e o i .l

s l o p e o f t h e b l o w b y h o s e i s a t l e a s t a 1 / 2 i n c h p e r f o o ,t w ti h

General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction

Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

Service Daily

If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exists.

Fuel Addition

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

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be



Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure.

To restart after running out of fuel, turn the switch to the

“ON” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline.

Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in (Figure 31).

Replacing Oil Filter

To remove the oil filter, grip the filter body and turn counter-clockwise

Apply a film of oil to the rubber seal gasket.

Place the oil filter body onto the oil filter spindle by turning clockwise. DO NOT over tighten.

After the oil filter has been replaced, the engine oil will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

.

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 500 hours or so.

Loosen the drain plug at the lower top of the fuel filter.

Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

Vent any air.

Flushing Out Radiator and Replacing Coolant z Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.

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

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

z Tighten both cocks and replace the overflow tank.

z Replace with coolant (Table 13 for correct mixture).

z Close radiator cap tightly.


Allow engine to steam.

cool when flushing out radiator. Flushing the radiator while hot could cause serious burns from water

Generator Storage o r

For longe term storage of the generator the following is recommended: z Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.

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

z Clean the entire generator, internal and external.

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

z Disconnect the battery.

z Make sure engine coolant is at proper level.

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



Jacket Water Heater and Internal Battery Charger

120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC,

20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal

battery charger.

These receptacles will ONLY function when commercial power has been supplied to them (Figure 56). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

When using the generator in hot climates there is no reason to apply power to jacket water heater. However, if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using an power cord of adequate size.

NOTE

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

battery charger.

internal

Figure 56. DCA-45SIU2 Battery Charger &

Jacket Water Heater Power Connections

1


DCA-45SSIU3 (60 Hz) — TRAILER MAINTENANCE

Trailer Maintenance

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with the DCA-45SSIU3

Whisperwatt ™ Generator.

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

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

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

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

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

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

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

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

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

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

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

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

Always use a torque wrench to tighten down the lug nuts. See Table 18 and Figure 58 for lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed on a particular trailer.



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 57 displays the major hydraulic surge brake components that will require inspection and maintenance.

Please inspect these components as required using steps 1 through 8 and Table 15 as shown below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

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

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

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 56) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 57. 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.

T a b l e 1 5 .

H y d r a u l i c B r a k e T r o u b l e s h o o t i n g

S y m p t o m

N o B r a k e s

W e a k B r a k e s o

O n e r B r a k e s

S i d e

P u ll t o

L o c k i n g B r a k e s

N o i s y B r a k e s

D r a g g i n g B r a k e s

P o s s i b l e C a u s e

B r a k e il n e b r o k e n o r k i n k e d ?

B r a k e il n i n g g l a z e d ?

T r a li e r o v e r l o a d e d ?

B r a k e d r u m s s c o r e d o r g r o o v e d ?

T ri e p r e s s u r e c o r r e c t ?

T ri e s u n m a t c h e d o n t h e s a m e a x l e ?

B r a k e c o m p o n e n t s l o o s e , b e n t o r b r o k e n ?

B r a k e d r u m s o u t o f r o u n d ?

S y s t e m l u b r i c a t e d ?

B r a k e c o m p o n e n t s c o r r e c t ?

B r a k e il n i n g a d j t h i c k n e u s t e d s s i n c o r r e c t c o r r e c lt y ?

o r n o t

E n o u g h b r a k e lf u i d o r c o r r e c t lf u i d ?

S o l u t i o n

R e p a ri o r r e p l a c e .

R e b u r n i s h o r r e p l a c e .

C o r r e c t w e i g h .t

M a c h i n e o r r e p l a c e .

I n lf a t e a ll t ri e s e q u a ll y .

M a t c h t ri e s .

R e p l a c e c o m p o n e n t s .

R e p l a c e .

L u b r i c a t e .

R e p l a c e a n d c o r r e c .t

I n s t a ll n e w s h o e s il n i n g s .

a n d

R e p l a c e if ll w ti h r u b b e r d o t 4 p a r t s lf u i d .

1



Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

Suspension

The leaf suspension springs and associated components

(Figure 58) 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.

CAUTION - EYESIGHT HAZARD

ALWAYS wear safety glasses when removing or installing force fitted parts.

Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

DO NOT attempt to repair or modify a wheel. DO NOT install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

Tire Wear/Inflation

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

Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot!. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

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

Figure 58. Major Suspension Components

T a b l e 1 7 .

S u s p e n s i o n T o r q u e R e q u i r e m e n t s

I t e m

3 / 8 " U B O L T

7 / 1 6 " U B O L T

1 / 2 " U B O L T

SHACKLE BOLT

SPRING EYE BOLT

T o

M

M I r

I q

N

N -

u

3

4 e

0

5

( F

M

M t .

A

A

L

X

X -

b

3

6 s

5

0

.

)

M I N 4 5 M A X 6 0

SNUG FIT ONLY

.

PARTS MUST ROTATE FREELY

.

LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

-

BOLT ASSEMBLY

.

SHOULDER TYPE

SHACKLE BOLT

M I N 3 0 M A X 5 0



Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 59). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 18.

3. After first road use, retorque all lug nuts in sequence.

Check all wheel lug nuts periodically.

W h e e l S i z e

1 2 "

T a b l e 1 8 .

T i r e T o r q u e R e q u i r e m e n t s

F i

F r s

T t

L

P a s s

B

2 0 2 5

S

S e c o n d P a s s

F T L B S

3 5 4 0

T h i r d P a

F T L B S s s

5 0 6 5

1 3 "

1 4 "

1 5 "

1 6 "

2

2

2

2

0

0

0

0

-

-

-

-

2

2

2

2

5

5

5

5

3

5

5

5

5

0

0

0

-

-

-

-

4

6

6

6

0

0

0

0

9

9

9

5 0

0 -

0 -

0 -

6

1 2

1 2

1 2

5

0

0

0

NOTE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

Figure 59. Wheel Lug Nuts

Tightening Sequence

1


DCA-45SSIU3 (60 Hz) — TRAILER WIRING DIAGRAM

Figure 60. Trailer/Towing Vehicle Wiring Diagram


DCA-45SSIU3 (60 Hz) — GENERATOR WIRING DIAGRAM

Figure 61. Generator Wiring Diagram

1


DCA-45SSIU3 (60 Hz) — ENGINE WIRING DIAGRAM

Figure 62. Engine Wiring Diagram


DCA-45SSIU3 (60 Hz) — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company's business office or service plant.

S Y M P T O M

N o V o tl a g e O u t p u t

L o w V o tl a g e O u t p u t

H i g h V o tl a g e O u t p u t

C ri c u ti B r e a k e r T r i p p e d

T A B L E 1 9 .

G E N E R A T O R T R O U B L E S H O O T I N G

P O S S I B L E P R O B L E M

A C V o tl m e t e r d e f e c it v e ?

I s w ri i n g c o n n e c it o n l o o s e ?

I s A V R d e f e c it v e ?

D e f e c it v e R o t a it n g R e c it if e r ?

D e f e c it v e E x c ti e r F i e l d ?

I s e n g i n e s p e e d c o r r e c t ?

I s w ri i n g c o n n e c it o n s l o o s e ?

D e f e c it v e A V R ?

I s w ri i n g c o n n e c it o n s l o o s e ?

D e f e c it v e A V R ?

S h o r t C ri c u ti i n l o a d ?

O v e r c u r r e n t ?

D e f e c it v e c ri c u ti b r e a k e r ?

O v e r c u r r e n t R e l a y a c t u a t e d ?

S O L U T I O N

C h e c k o u t p u t v o tl a g e u s i n g a v o tl m e t e .r

C h e c k w ri i n g a n d r e p a i .r

R e p l a c e fi n e c e s s a r y .

C h e c k a n d r e p l a c e .

C h e c k f o r 1 7 .

3 o h m s a c r o s s J & K o n C N 1

T u r n e n g i n e t h r o t lt e l e v e r t o " H i g h " .





C h e c k l o a d a n d r e p a i .r

C o n f ri m l o a d r e q u ri e m e n t s a n d r e d u c e .

C h e c k a n d r e p l a c e .

C o n f ri m l o a d r e q u ri e m e n t a n d r e p l a c e .

1


DCA-45SSIU3 (60 Hz) — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 20 (Engine Troubleshooting) as a basic guideline for troubleshooting the Engine. If the problem cannot be remedied, consult our company's business office or service plant.

S Y M P T O M

E n g i n e d o e s n o t s t a r .t

S t a r t e r d o e s n o t r u n .

T A B L E 2 0 .

E N G I N E T R O U B L E S H O O T I N G

P O S S I B L E P R O B L E M

N o f u e l ?

A ri i n t h e f u e l s y s t e m ?

W a t e r i n t h e f u e l s y s t e m ?

F u e l p i p e c l o g g e d ?

F u e l if tl e r c l o g g e d ?

S O L U T I O N

R e p l e n i s h f u e .l

B l e e d s y s t e m .

R e m o v e w a t e r f r o m f u e l t a n k .

C l e a n f u e l p i p e .

C l e a n o r c h a n g e f u e l if tl e .r

t f

E x c u e l e s s i o r e v e l y n g i n e h i g h o li e m p e r a t u r e ?

v i s c o s a t l o w ti y o f

F u e l w ti h l o w c e t a n e n u m b e r ?

F u e l p i p e l e a k r e t a i d u e n i n g t o l o o s e n u t ?

i n j e c it o n

I n j e c it o n n o z z l e c l o g g e d ?

U

U

T i s s g e e h t t t e h h n e e n s s p e p e u .t

c i c i if if e d e d f f u e l u e .l

o r e n g i n e o i .l

C l e a n i n j e c it o n n o z z l e .

I n j e c it o n p u m p m a fl u n c it o n i n g ?


S e i z u r e p i s t o n , c o f y c r a il n d e r n k il s h a f n e r

,t o r c a m s b e a r h a f i n g ?

,t


C o m p r e s s i o n c y il n d e r ?

l e a k f r o m

P i s t o n r i n g a n d il n e r w o r n ?

R e p l a c e n o z z l e h o h e a d l d e .r

g a s k e ,t it g h t e n c y il n d e r h e a d b o l ,t g l o w p l u g a n d

R e p l a c e .

E x c e s s i v e v a l v e c l e a r a n c e ?

S t a r t e r m a fl u n c it o n i n g ?

W ri i n g d i s c o n n e c t e d ?

A d j u s .t


C o n n e c t w ri i n g .


DCA-45SSIU3 (60 Hz) — TROUBLESHOOTING (ENGINE)

T A B L E 2 0 .

E N G I N E T R O U B L E S H O O T I N G ( C O N T I N U E D )

S O L U T I O N S Y M P T O M P O S S I B L E P R O B L E M

F u e l if tl e r c l o g g e d o r d ri t y ?

A ri c l e a n e r c l o g g e d ?

F u e l p i p e l e a k r e t a i d u e n i n g t o l o o s e n u t ?

i n j e c it o n

I n j e c it o n p u m p m a fl u n c it o n i n g ?

E n g i n e r e v o l u it o n i s n o t s m o o t h .

I n p r c o e s r r e c t s u r e ?

n o z z l e o p e n i n g

I n j e c it o n c l o g g e d ?

n o z z l e s t u c k o r

F u e l o v e r lf o w p i p e c l o g g e d ?

G o v e r n o r m a fl u n c it o n i n g ?

E x c e s s i v e e n g i n e o li ?

E i s ti h o e r b s e w h r ti e v e d .

o r b l u e e x h a u s t g a s

P s t i s t u c o n k ?

r i n g a n d il n e r w o r n o r

I n c o r r e c t i n j e c it o n it m i n g ?

E e x h a u s

D ti e h if e c r i e b l a c k t g a s n t o u t o r p i s u .t

d a r k g r a y o b s e r v e d .

D e if c i e n t c o m p r e s s i o n ?

O v e r l o a d ?

L o w g r a d e f u e l u s e d ?

F u e l if tl e r c l o g g e d ?

A ri c l e a n e r c l o g g e d ?

D e if c i e n t n o z z l e i n j e c it o n ?

I n c o r r e c t i n j e c it o n it m i n g ?

E n b e g i s n e ' s e i z i n m g ?

o v i n g p a r t s s e e m t o

U n e v e n f u e l i n j e c it o n ?

D e if c i e n t n o z z l e i n j e c it o n ?

C o m p r e s s i o n l e a k ?

C l e a n o r c h a n g e .


T i g h t e n n u .t


A d j u s .t


C l e a n .

R e p a i .r

R e d u c e t o t h e s p e c i if e d l e v e .l


A d j u s .t

A d j u s t t o p c l e a r a n c e .

L e s s e n t h e l o a d .

U s e t h e s p e c i if e d f u e .l



R e p a ri o r r e p l a c e t h e n o z z l e .

A d j u s .t


R e p a ri o r r e p l a c e t h e i n j e c it o n p u m p .

R e p a ri o r r e p l a c e t h e n o z z l e .

R e p n o z z l a l e c e h h e a d o l d e .r

g a s k e ,t it g h t e n c y il n d e r h e a d b o l ,t g l o w p l u g a n d

1


DCA-45SSIU3 (60 Hz) — EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

4

NO.

PART NO. PART NAME

1 12345

QTY. REMARKS

BOLT ....................... 1 .... INCLUDES ITEMS W/

WASHER, 1/4 IN. ........... NOT SOLD SEPARATELY

*

3

2 *

2 * 12347

12348

WASHER, 3/8 IN. .... 1 .... MQ-45T ONLY

HOSE .................... A/R .. MAKE LOCALLY

12349 BEARING ................ 1 .... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same unique symbol

( * , #, + , %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers - Duplicate numbers indicate multiple part numbers are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTE

PART NO. Column

without notice. Multiquip does not

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

Numbers Used - Part numbers can be indicated by a number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clarified in the “Remarks” Column.

QTY. Column

Numbers Used - Item quantity can be indicated by a number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold separately. Other entries will be clarified in the “Remarks”

Column.

REMARKS Column

Some of the most common notes found in the “Remarks”

Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit - All items on the parts list with the same unique symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break - Used to list an effective serial number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW”

“S/N XXXX AND ABOVE”

“S/N XXXX TO S/N XXX”

Specific Model Number Use - Indicates that the part is used only with the specific model number or model number variant listed. It can also be used to show a part is NOT used on a specific model or model number variant.

Indicated by:

“XXXXX ONLY”

“NOT USED ON XXXX”

“Make/Obtain Locally” - Indicates that the part can be purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately” - Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.


DCA-45SSIU3 (60 Hz) — SUGGESTED SPARE PARTS

DCA-45SSIU3 (60 HZ) ULTRA-SILENT GENRATOR

W/ISUZU BB-4JG1T ENGINE

1 TO 3 UNITS

Qty.

P/N Description

5 ......... 8943672922 ........ FILTER, OIL

5 ......... 8943692993 ........ FILTER, FUEL, CARTRIDGE

3 ......... 0602046366 ........ ELEMENT, AIR

1 ......... 8941618410 ........ BELT, FAN

1 ......... 0605505070 ........ CAP. FUEL TANK

1 ......... 0602122272 ........ UNIT, OIL PRESSURE

1 ......... 0602123261 ........ UNIT, WATER TEMPERATURE

1 ......... 1518183040 ........ SENDER, WATER SWITCH (ENGINE SIDE)

1 ......... 1718939010 ........ SENDER, OIL SWITCH (ENGINE SIDE)

NOTE

Part number on this Suggested Spare Parts list may supercede/replace the P/N shown in the text pages of this book.

1


GENERATOR ASSY.

DCA-45SSIU3 (60 Hz) — GENERATOR ASSY.


DCA-45SSIU3 (60 Hz) — GENERATOR ASSY.

GENERATOR ASSY.

NO.

15

16

17

18

11

12

13

14

7

8

9

10

5

6

4

4-1

19

20

21

22

23

24

25

25A

25B

1

3

1-9 *

1-10 *

1-11 *

1-12 *

1-13 *

1-14 *

1-15 *

1-16 *

2

1-17 *

1-1 *

1-2 *

1-3 *

1-4 *

1-5 *

1-6 *

1-7 *

1-8 *

PART NO.

B3110100202

8051070003

0010310035

0042510000

8041611004

8041015003

0010310025

0042510000

8001026013

0601821349

0601822601

8001020004

8001020504

0010108020

0040008000

0601000209

0071906310

M1164400003

0012808030

B3130100103

0845041904

M1164600003

0012810030

8041315202

8041350013

0010308065

0042608000

0041208000

0017108030

8041310024

8041312014

0017106012

8041331014

0017106012

8001333003

0340406040

0041206000

0012810030

8051332014

0600815000

0605000055

0030012000

0040012000

0041212000

PART NAME

ROTOR ASSY

FIELD ASSY

FAN

HEX, HEAD BOLT

QTY.

REMARKS

1

8

1

1

SPRING WASHER

COUPLING DISK

8

4

BALANCING PLATE ................................................. 1 ........ PURCHASE SET OF 1-16

HEX, HEAD BOLT 6

SPRING WASHER 6

SET PLATE, RECTIFIER BALANCING PLATE ........ 1 ........ PURCHASE SET OF 1-16

RECTIFIER .............................................................. 2 ........ PT3610

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

INSULATOR WASHER

INSULATOR WASHER

HEX, HEAD BOLT

SPRING WASHER

4

4

1

1

BALANCING WEIGHT KIT 1

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

COUPLING RING

HEX, HEAD BOLT

1

6

STATOR ASSY ......................................................... 1 ........ B3135100104

GROMMET 2

COUPLING ADAPTER

HEX, HEAD BOLT

1

8

END BRACKET

FIELD ASSY EXCITER

HEX, HEAD BOLT

SPRING WASHER

1

1

4

4

PLAIN WASHER

HEX, HEAD BOLT

COVER, BEARING

GASKET, BEARING

HEX, HEAD BOLT

COVER, END BRACKET

HEX HEAD BOLT

COVER, END BRACKET

HEX HEAD BOLT

PLAIN WASHER

HEX HEAD BOLT

COVER, FAN

NUT

RUBBER SUSPENSION

HEX NUT

SPRING WASHER

PLAIN WASHER

2

2

1

2

6

1

2

2

2

4

1

4

1

1

1

4

6

1


CONTROL BOX ASSY.

DCA-45SSIU3 (60 Hz) — CONTROL BOX ASSY.


DCA-45SSIU3 (60 Hz) — CONTROL BOX ASSY.

CONTROL BOX ASSY.

38

39

40

41

34

35

36

37

42

43

30

31

32

33

26

27

28

29

9

10

11

12

7

8

5

6

NO.

PART NO.

1 M1213000802

3

4

2 0601870431

2-1 0601870490

0021004040

0601823863

0027104016

0601820671

0027105016

0601806116

0027106016

0601820847

0027120848

0027104016

12A 0207004000

13 0330000200

14

15

M1213500303

0016906016

16 M1923100004

16A 47130106

17

18

M1213600114

0330000160

19

20

21

22

0027103010

0016906016

M1213600014

0016906016

23 0016906016

23A 0040506000

24

25

M1223000503

0601807641

0601808986

0601801040

0601806859

0601801041

0601840073

0601840121

M1223100004

0027105010

0027105010

M9220100004

0080200007

8971119621

8972465100

0016906020

1825530401

5825500290

0016906016

M1246702604

PART NAME

CONTROL BOX

QTY.

1

REMARKS

CIRCUIT BREAKER ............................................1 ............. FG3110WS02 3P 110A

COVER, CIRCUIT BREAKER 2

MACHINE SCREW 4

RELAY UNIT ....................................................... 2 ............. MSA9013A

MACHINE SCREW 4

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

MACHINE SCREW 4

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

MACHINE SCREW 6

OVER CURRENT RELAY ....................................1 ............. TA25DU 4.0

OVER CURRENT RELAY ....................................1 ............. DB25/25A

MACHINE SCREW 2

HEX NUT

EDGING

CONTROL BOX COVER

HEX HEAD BOLT

1

4

2

1

SELECTOR SWITCH ..........................................1 ............. VY-40

KNOB. SELECTOR SWITCH 1

SWITCH BRACKET

EDGING

1

2

MACHINE SCREW

HEX HEAD BOLT

SWITCH COVER

HEX HEAD BOLT

1

4

4

4

HEX HEAD BOLT

TOOTHED WASHER

8

1

CONTROL PANEL 1

FREQUENCY METER ........................................1 ............. FCF-6 45~65Hz 240V

AC AMMETER ....................................................1 ............. ACF-6 0~75A/150A:5A

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

AC VOLTMETER .................................................1 ............. SCF-6 0~600V

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

RHEOSTAT (VOLTAGE REGULATOR) .................1 ............. RA20A2SE102BJ 2W 1K Ω

KNOB 1

STOPPER

MACHINE SCREW

MACHINE SCREW

SET SCREW

4

1

1

2

SNAP RING 1

EMERGENCY RELAY .........................................1 ........ REPLACES P/N 0602200432

PREHEAT CONTROLLER ...................................1 ........ REPLACES P/N 0602202506

HEX HEAD BOLT 3

SAFETY RELAY .................................................1 ........ REPLACES P/N 0602200304

RELAY .................................................................1 ........ REPLACES P/N 0602201400

HEX HEAD BOLT

WIRE HARNESS, GENERATOR

3

1

1


ENGINE & RADIATOR ASSY.

DCA-45SSIU3 (60 Hz) — ENGINE & RADIATOR ASSY.



29

30

31

32

25

26

27

28

33

34


NO.

PART NO.

1 M1923200054

1-1 8970497081

2 0605000048

5

6

3

4

0030010000

0040010000

0041210000

M1923200064

7

8

6-1 0602011053

6-2 M1493105204

0016908040

M1310501003

13

14

15

16

9

10

11

12

M1310501103

0605515147

M1310300903

0016908020

M1310300504

M1310300604

0016908020

0602046585

21

22

23

24

16A 0602046366

17 0602040651

18

19

20

0602040557

0016908030

M1373100703

M1373100603

0605515148

0605515200

0602022560

M1320300304

0602022561

0603306590

0603300285

0605511395

0603306395

0602021070

0269200450

M2320300103

M9200200004

PART NAME QTY.

REMARKS

ENGINE ...............................................................1 ........ ISUZU BB-4JG1T PD-04

CARTRIDGE, OIL FILTER ..................................1 ........ REPLACES P/N 0602041214

RUBBER SUSPENSION 2

HEX NUT

SPRING WASHER

2

2

PLAIN WASHER 2

RADIATOR ...........................................................1 ........ 232000-2620

CAP, RADIATOR ..................................................1 ........ 16401-1450A

ACOUSTIC SHEET 2

HEX HEAD BOLT

RADIATOR HOSE

6

1

RADIATOR HOSE

HOSE BAND

FAN SHROUD

HEX HEAD BOLT

1

4

1

4

FAN GUARD

FAN GUARD

1

1

HEX HEAD BOLT 6

AIR CLEANER ....................................................1 ........ FPG07-0019

ELEMENT, AIR CLEANER ..................................1 ........ P827653

INDICATOR, AIR CLEANER ................................1 ........ RBX00-2352

BRACKET, AIR CLEANER ..................................1 ........ P77-7731

HEX HEAD BOLT 2

HOSE, AIR CLEANER 1

HOSE, AIR CLEANER

HOSE BAND

HOSE BAND

ADAPTER

PACKING

90 DEGREE ELBOW

CONNECTOR

ROCKNUT

1

1

2

1

1

1

1

1

VALVE

HOSE JOINT

CAP

DRAIN HOSE

DRAIN JOINT

PLUG

1

1

1

1

1

1

1







61

62

63

57

58

59

60

53

54

55

56

49

50

51

52

45

46

47

48

41

42

43

44

37

38

39

40

NO.

PART NO.

35 0150000018

36 0016906020

0199900700

0605515106

M9300000003

M9300100003

0199100215

M1317100004

0016908020

0199100800

0193601200

0605515106

0602220910

0016908020

0199800700

0269200900

0605515198

0602220911

0016908020

0602120465

1718939010

M9200100004

0602123260

9095720140

1819001902

M1354200404

0027106016

0016908025

8941618410

PART NAME

O RING

HEX HEAD BOLT

DRAIN HOSE

HOSE BAND

RESERVE TANK

CAP, RESERVE TANK

HOSE

BRACKET, RESERVE TANK

HEX HEAD BOLT

HOSE

HOSE

HOSE BAND

CLAMP

HEX HEAD BOLT

2

2

1

2

1

1

1

1

QTY.

REMARKS

1

2

1

1

1

2

DRAIN HOSE

BLOWBY HOSE

HOSE BAND

CLAMP

1

1

1

1

HEX HEAD BOLT

PICK UP, TACHOMETER

1

1

SENDER, OIL SWITCH .......................................1 ........ REPLACES P/N 0602122281

ADAPTER 1

UNIT, WATER TEMPERATURE ...........................1 ........ 02094-00

PACKING .............................................................1 ........ REPLACES P/N 0602021109

ENGINE STOPPER ............................................. 1 ........ REPLACES P/N 0602210810

BRACKET, ENGINE STOPPER 1

MACHINE SCREW

HEX HEAD BOLT

3

2

FAN BELT ............................................................1 ........ REPLACES P/N 0602011432

1


OUTPUT TERMINAL ASSY.

DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN

5-BLACK

6-CATERPILLAR YELLOW

7-CATO GOLD

8-RED

THE SERIAL NUMBER MAY BE REQUIRED.


DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

2A

25

26

27

28

29

NO.

PART NO.

3

4

1

2

M1230700103

M9220100204

M9220100104

0039310000

7

8

5

6

0040010000

0041410000

0016908025

M1236100613

9

10

M1236100704

0605010040

11 0027103010

11A 0030003000

14

15

16

17

11B 0041203000

12 0027103010

12A 0030003000

13 0016906020

0016906016

M1236400004

M1236300004

0016906020

21

22

23

24

18

19

0601870440

0601870441

20 M1260700504

20-1 0222100100

0016906020

0601812598

0601812538

0027104016

0207004000

M1236100803

0010112045

0041212000

M9310200004

0030012000

PART NAME

TERMINAL PANEL

OUTPUT TERMINAL BOLT

TIE BOLT

HEX NUT

SPRING WASHER

PLAIN WASHER

HEX HEAD BOLT

TERMINAL COVER

OUTPUT WINDOW

HINGE

MACHINE SCREW

HEX NUT

PLAIN WASHER

MACHINE SCREW

HEX NUT

HEX HEAD BOLT

HEX HEAD BOLT

CABLE OUTLET COVER

SUPPORTER, CABLE OUTLET COVER

HEX HEAD BOLT

1

6

4

1

4

2

4

4

CIRCUIT BREAKER ............................................2 ........ QCF 1020 1P 20A

CIRCUIT BREAKER ............................................3 ........ QCF 2050 2P 50A

BREAKER FITTING COVER

CUSHION RUBBER

1

2

HEX HEAD BOLT 2

RECEPTACLE .....................................................2 ........ GF-530EM 125V 20AX2

RECEPTACLE .....................................................2 ........ CS6369 250V 50A

MACHINE SCREW 10

HEX NUT

TERMINAL COVER

HEX HEAD BOLT

PLAIN WASHER

STAY RUBBER

HEX NUT

10

1

2

2

2

2

4

4

1

2

15

20

5

1

QTY.

REMARKS

5

10

1

5

1


DCA-45SSIU3 (60 Hz) — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.


DCA-45SSIU3 (60 Hz) — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO.

PART NO.

1 8970444180

2

1A * 8944024980

0602103092

2A# 0601810245

3 0602120095

6

7

4

5

8

0602122093

0602123090

0602121080

0602125090

0602103092

8A+ 0601810245

9 9826800370

10

11

0601831330

M1357201302

12

13

0602122272

1518183040

PART NAME QTY.

REMARKS

STARTER SWITCH .............................................1 ........ REPLACES P/N 0602100009

....................................................................................... INCLUDES ITEM W/ *

KEYS, IGNITION SWITCH 1

PREHEAT LAMP .................................................1 ........ INCLUDES ITEM W/#

BULB

TACHOMETER

OIL PRESSURE GAUGE

WATER TEMPERATURE GAUGE

CHARGING AMMETER

FUEL GAUGE

1

1

1

1

1

1

ALARM LAMP .....................................................3 ........ INCLUDES ITEM W/+

BULB 3

PANEL LIGHT ......................................................1 ........ REPLACES P/N 0601810141

SWITCH, PANEL LIGHT

WIRE HARNESS, ENGINE

1

1

UNIT, OIL PRESSURE 1

SENDER, OVERHEAT SWITCH .........................1 ........ REPLACES P/N 0602123282

1


BATTERY ASSY.

DCA-45SSIU3 (60 Hz) — BATTERY ASSY.


8

9

6

7

4

5

2

3

BATTERY ASSY.

NO.

PART NO.

1 0602220187

M9310500014

M9103000304

0602220920

0040006000

M1347200004

M1347200104

0016910020

0040510000

DCA-45SSIU3 (60 Hz) — BATTERY ASSY.

PART NAME QTY.

REMARKS

BATTERY ............................................................1 ........ 627MFD

BATTERY SHEET

BATTERY BAND

1

1

BATTERY BOLT SET ..........................................2 ........ BHL-10J

SPRING WASHER 2

BATTERY CABLE

BATTERY CABLE

HEX HEAD BOLT

TOOTHED WASHER

2

2

1

1

1


MUFFLER ASSY.

DCA-45SSIU3 (60 Hz) — MUFFLER ASSY.


8

9

6

7

10

11

4

5

2

3

MUFFLER ASSY.

NO.

PART NO.

1 M1330100703

0016910025

M1333001903

8943690210

M1333200114

0039308000

0016908035

M1330400304

M1333300004

0016906016

0602326090

DCA-45SSIU3 (60 Hz) — MUFFLER ASSY.

PART NAME

MUFFLER

QTY.

REMARKS

1

HEX HEAD BOLT

EXHAUST PIPE

4

1

GASKET .............................................................1 ........ REPLACES P/N 0602320101

GASKET 1

HEX NUT

HEX HEAD BOLT

COVER

BRACKET

6

4

1

1

HEX HEAD BOLT 4

U BOLT SET .......................................................1 ........ 89542K

1


FUEL TANK ASSY.

DCA-45SSIU3 (60 Hz) — FUEL TANK ASSY.


10

11

12

13

8

9

6

7

4

5

2

3

FUEL TANK ASSY.

NO.

PART NO.

1 M1363001602

0605505070

M1363200104

M9310500104

0016908020

0207308000

0222100600

M9200000003

M9200200004

0150000018

0016906020

M1363400104

0605515198

17

18

19

20

14 8943672922

14A 8943692993

15

16

0016908020

0602220911

21

22

0016908020

0191201150

0191201500

0191301100

0605515108

0605515109

DCA-45SSIU3 (60 Hz) — FUEL TANK ASSY.

PART NAME

FUEL TANK

CAP, FUEL TANK

TANK BAND

SUPPORTER SHEET

HEX HEAD BOLT

HEX NUT

RUBBER SHEET

DRAIN JOINT

DRAIN BOLT

O-RING

HEX HEAD BOLT

DRAIN HOSE

HOSE BAND

QTY.

1

1

2

4

2

2

2

1

1

1

2

1

2

REMARKS

FUEL FILTER ......................................................1 ........ REPLACES P/N 0602042202

CARTRIDGE, FUEL FILTER ...............................1 ........ REPLACES P/N 0602042700

HEX HEAD BOLT

CLAMP

2

2

HEX HEAD BOLT

SUCTION HOSE

SUCTION HOSE

RETURN HOSE

HOSE BAND

HOSE BAND

2

1

1

1

4

2

1


ENCLOSURE ASSY.

DCA-45SSIU3 (60 Hz) — ENCLOSURE ASSY.




1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN

5-BLACK


7-CATO GOLD

8-RED



3

4

1

2

ENCLOSURE ASSY.

NO.

PART NO.

M1413002902

M1413400004

0016908020

M1423001902

5

6

7

8

9

10

M1493106703

0016908020

M1423200604

M1493100804

0016908020

M1423201403

0016908020

M1433000803

11

12

M1433001003

0010114030

12A 0040014000

12B 0041214000

13 0010114030

13A 0040014000

13B 0041214000

14 M1443001302

14A M1493300504

15 0016908020

16

17

M1443300613

M1443301603

17A M1493303004

18

19

20

21

0207006000

0016908020

M1443200803

M1443600204

22 0037906000

22A 0041206000

23

24

M9113000002

0021806016

24A 0030006000

25 M9110100204

26

27

M9116100004

0016908020

28

29

M9310000004

M1463001802

29A M1493503403

30 0016908020


PART NAME

BASE

UNDER COVER

HEX HEAD BOLT

FRONT FRAME

ACOUSTIC SHEET

HEX HEAD BOLT

COVER, FRONT FRAME

ACOUSTIC SHEET

HEX HEAD BOLT

INNER COVER, FRONT FRAME

HEX HEAD BOLT

CENTER FRAME

CENTER FRAME

HEX HEAD BOLT

SPRING WASHER

PLAIN WASHER

HEX HEAD BOLT

SPRING WASHER

PLAIN WASHER

REAR FRAME

ACOUSTIC SHEET

HEX HEAD BOLT

REAR COVER

DUCT, REAR COVER

ACOUSTIC SHEET

HEX NUT

HEX HEAD BOLT

REAR DOOR

WINDOW PLATE

U-NUT

PLAIN WASHER

DOOR HANDLE ASSY

MACHINE SCREW

HEX NUT

HINGE

WASHER

HEX HEAD BOLT

BLIND PLUG

ROOF PANEL

ACOUSTIC SHEET

HEX HEAD BOLT

2

3

4

2

1

4

8

8

1

19

2

1

12

9

1

1

1

1

1

4

1

8

1

8

8

8

8

1

8

12

1

4

1

1

1

1

4

QTY.

REMARKS

2

1

1

1

1


ENCLOSURE ASSY.





1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN

5-BLACK


7-CATO GOLD

8-RED



ENCLOSURE ASSY.

NO.

PART NO.

31 M9310000103

32 M1483600204

32-1 0016908020

33 M1453200602

33A M1493300204

34

35

0016908055

0016908020

36 M1453003403

36A M1493406304

37 M1453003503

37A M1493406404

38 M1453001303

38A M1493400404

39 M1453003603

39A M1493406504

40 M1453301104

40A M1493405504

41 M1453301304

41A M1493407904

42

43

0207006000

M9113000002

47

48

49

50

44 0021806016

44A 0030006000

45

46

M9110100204

M9110100304

M9116100004

0016908020

0601850097

0027208025

51

52

53

54

M9310000004

0600500090

0021106016

0016908020

54A 0040508000

55 0017110020

55A 0040510000


PART NAME

BONNET CAP

CHAIN ASSY

HEX HEAD BOLT

SPLASHER PANEL

ACOUSTIC SHEET

HEX HEAD BOLT

HEX HEAD BOLT

SIDE DOOR

ACOUSTIC SHEET

SIDE DOOR

ACOUSTIC SHEET

SIDE DOOR

ACOUSTIC SHEET

SIDE DOOR

ACOUSTIC SHEET

DUCT

ACOUSTIC SHEET

DUCT

ACOUSTIC SHEET

HEX NUT

DOOR HANDLE ASSY

MACHINE SCREW

HEX NUT

HINGE

HINGE

WASHER

HEX HEAD BOLT

DOOR STOPPER

MACHINE SCREW

BLIND PLUG

EMBLEM

MACHINE SCREW

HEX HEAD BOLT

TOOTHED WASHER

HEX HEAD BOLT

TOOTHED WASHER

8

8

8

9

12

12

4

4

15

3

1

1

2

2

1

1

1

1

1

2

1

8

1

1

1

1

1

1

1

4

2

QTY.

REMARKS

1

1

1

1

1

1


RUBBER SEALS ASSY.

DCA-45SSIU3 (60 Hz) — RUBBER SEALS ASSY.


RUBBER SEALS ASSY.

17

18

19

13

14

15

16

9

10

11

12

7

8

5

6

NO.

PART NO.

3

4

1

2

0228901370

0229200660

0228900620

0228900940

M1490300104

0228900515

0228900425

0228900910

0229200900

0229200740

0228800770

0228800470

0228800510

0228100545

0228100370

0228100165

0228100340

0228100170

0228100200

DCA-45SSIU3 (60 Hz) — RUBBER SEALS ASSY.

PART NAME

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

1

1

1

1

1

1

1

2

1

2

1

1

3

1

1

QTY.

REMARKS

1

1

3

1

1


DCA-45SSIU3 (60 Hz) — NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.


DCA-45SSIU3 (60 Hz) — NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

25

26

27

28

21

22

23

24

17

18

19

20

13

14

15

16

33

34

35

29

30

31

32

9

10

11

12

7

8

5

6

NO.

PART NO.

3

4

1

2

M1550000204

M1550001304

M1550002003

M1550002103

M1550002203

M1550000804

M9500000004

M9500100004

M9500100104

M9500300004

M9500300104

M9500500004

M9520200404

M1560100603

M1560101904

M1560102003

M1560101104

M1560100904

M1560102103

M9500500104

M9503000004

M9503000103

M9503100004

M9503200004

M9510100004

M9510200002

M9520000004

M9520000104

M9520000204

M9520100004

M9520100204

M9520100304

M9520100404

M9520100503

M9520200003

PART NAME QTY.

REMARKS

DECAL; NOTE .....................................................1 ........ M150O0020

DECAL; CAUTION ...............................................1 ........ M150O0130

DECAL; GENERATOR CONTROL .......................1 ........ M150O0200

DECAL; ENGINE OPERATING ...........................1 ........ M150O0210

DECAL; AUXILLARY OUTPUT ............................1 ........ M150O0220

DECAL; NOTE .....................................................1 ........ M150O0080

DECAL; OIL DRAIN PLUG ..................................1 ........ M900O0000

DECAL; WATER ...................................................1 ........ M90010000

DECAL; WATER DRAIN .......................................1 ........ M90010010

DECAL;- ..............................................................1 ........ M90030000

DECAL;+ .............................................................1 ........ M90030010

DECAL; DIESEL FUEL ........................................1 ........ M90050000

DECAL; FUEL DRAIN PLUG ...............................1 ........ M90050010

DECAL; WARNING ..............................................2 ........ M90300000

DECAL; WATER - OIL CHECK ............................1 ........ M90300010

DECAL; WARNING ..............................................1 ........ M90310000

DECAL; WARNING ..............................................1 ........ M90320000

DECAL; CAUTION ...............................................1 ........ M91010000

DECAL; MQ .........................................................1 ........ M91020000

DECAL; GROUND ...............................................1 ........ M92000000

DECAL; AMMETER CHANGE-OVER SW. ..........1 ........ M92000010

DECAL; VOLTMETER CHANGE-OVER SW. .......1 ........ M92000020

DECAL; WARNING ..............................................2 ........ M92010000

DECAL; CAUTION ...............................................1 ........ M92010020A

DECAL; SAFETY INSTRUCTIONS .....................1 ........ M92010030

DECAL; DANGER ................................................1 ........ M92010040

DECAL; WARNING ..............................................1 ........ M92010050

DECAL; CONNECTION OF OUTPUT CABLE .....1 ........ M92020000

DECAL; OVER CURRENT RELAY ......................1 ........ M92020040

STRIPE; WHISPERWATT 1

DECAL; MQ POWER

STRIPE

2

1

STRIPE

STRIPE; 45

STRIPE

2

2

1

1


Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice.

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

Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1.

A Returned Material Authorization must be approved by Multiquip prior to shipment.

2.

To obtain a Return Material Authorization, a list must be provided to Multiquip Parts

Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions must match the current parts price list.

b. The list must be typed or computer generated.

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

d. The list must reference the sales order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and phone number of the person requesting the RMA.

3.

A copy of the Return Material Authorization must accompany the return shipment.

4.

Freight is at the sender’s expense. All parts must be returned freight prepaid to

Multiquip’s designated receiving point.

5.

Parts must be in new and resalable condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

6.

The following items are not returnable: a. Obsolete parts. (If an item is in the price book and shows as being replaced by another item, it is obsolete.) b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer net price of less than $5.00.

d. Special order items.

e. Electrical components.

f.

Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7.

The sender will be notified of any material received that is not acceptable.

8.

Such material will be held for five working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

9.

Credit on returned parts will be issued at dealer net price at time of the original purchase, less a 15% restocking charge.

10. In cases where an item is accepted, for which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

11. Credit issued will be applied to future purchases only.

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

Multiquip reserves the right to quote and sell direct to Government agencies, and to Original

Equipment Manufacturer accounts who use our products as integral parts of their own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of profit or good will or for any other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes not authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. Apart from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof.


NOTE PAGE

1


PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING



800-421-1244

FAX: 310-632-2656 Carson, CA 90746




800-427-1244

310-537-3700


800-835-2551

310-537-3700

FAX: 800-672-7877

FAX: 310-637-3284

FAX: 310-638-8046


800-835-2551


800-835-2551, EXT. 279

310-537-3700, EXT. 279

FAX: 310-638-8046

FAX: 310-638-8046

Your Local Dealer is:

Manufactured for Multiquip Inc.

by

DENYO CO., LTD, JAPAN

MQ POWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254

CARSON, CA 90749

310-537-3700 • 800-421-1244

FAX: 310-632-2656

E-mail: [email protected]


MQ Power DCA45SSIU3 Generator Operation Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

60 Hz GENERATOR

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

To find the latest revision of this publication, visit our website at: www.mqpower.com

—

ISUZU BB4JG1T ENGINE

—

When ordering parts, please supply the following information:

Here’s how to get help...

Place Your Parts Order Via Web or Fax

For Even More Savings!

Extra Discounts!

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

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

DCA-45SSIU3 (60 HZ) ULTRA-SILENT GENRATOR

W/ISUZU BB-4JG1T ENGINE

1 TO 3 UNITS

Effective: October 1, 2002

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

Related manuals

Table of contents

MQ Power DCA45SSIU3 Generator Operation Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

60 Hz GENERATOR

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

To find the latest revision of this publication, visit our website at: www.mqpower.com

—

ISUZU BB4JG1T ENGINE

—

When ordering parts, please supply the following information:

Here’s how to get help...

Place Your Parts Order Via Web or Fax

For Even More Savings!

Extra Discounts!

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

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

DCA-45SSIU3 (60 HZ) ULTRA-SILENT GENRATOR

W/ISUZU BB-4JG1T ENGINE

1 TO 3 UNITS

Effective: October 1, 2002

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

Related manuals

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M2870300504

MQ Power

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MULTIQUIP

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MULTIQUIP

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SDG400S-8E1

MULTIQUIP

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MULTIQUIP

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Table of contents