Generators Portable Ultrasilent DCA45USI Rev 2 Manual DataId 19073 Version 1

PARTS AND OPERATION MANUALOPERATION AND PARTS MANUAL

PARTS LIST NO. M1871400004B

Revision #2 (04/22/05)

DCA-45USIULTRA-SILENTTM SERIES

GENERATOR

THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALL TIMES.

DCA-45USI OPERATION AND PARTS MANUAL (STD) REV. #2 (04/22/05)

DCA-45USI OPERATION AND PARTS MANUAL (STD) REV. #2 (04/22/05) PAGE 3

COPYRIGHT 2004, MULTIQUIP INC.Multiquip Inc, MQ Power Inc, Ultra-Silent series, the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. andmay not be used, reproduced, or altered without written permission. All other trademarks are the property of thier respective ownersand used with permission.This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment andshould 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 arebased on the DCA-45USI Ultra Silent Generator. Multiquip Inc. reserves the right to discontinue or change specifications, design orthe information published in this publication at any time without notice and without incurring any obligations.

To find the latest revision of thispublication, visit our website at:

www.mqpower.com

HERE'S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLINGMQ POWER CORPORATE OFFICE18910 Wilmington Ave. 800-421-1244Carson, CA 90746 FAX: 310-632-2656Email: [email protected]: www.mqpower.comPARTS DEPARTMENT800-427-1244 FAX: 800-672-7877310-537-3700 FAX: 310-637-3284SERVICE DEPARTMENT800-835-2551 FAX: 310-638-8046310-537-3700TECHNICAL ASSISTANCE800-478-1244 FAX: 310-631-5032WARRANTY DEPARTMENT800-835-2551, EXT. 279 FAX: 310-638-8046310-537-3700, EXT. 279


TABLE OF CONTENTS

MQ POWER DCA-45USIMQ POWER DCA-45USIMQ POWER DCA-45USIMQ POWER DCA-45USIMQ POWER DCA-45USIAC GENERAAC GENERAAC GENERAAC GENERAAC GENERATORTORTORTORTORHere's How To Get Help ............................................. 3Table Of Contents ....................................................... 4Parts Ordering Procedures ........................................ 5DCA-45USI Specifications .......................................... 6Dimensions .................................................................. 7Safety Message Alert Symbols ............................... 8-9Rules for Safe Operation ..................................... 10-13Installation ............................................................ 14-15Towing Safety Precautions ....................................... 16Trailer Specifications ................................................. 17Generator Decals ................................................. 18-19General Information .................................................. 20Major Components ................................................... 21Generator Control Panel ........................................... 22Engine Operating Panel ............................................ 23Output Terminal Panel Familiarization ................. 24-26Load Application........................................................ 27Generator Outputs ............................................... 28-29Gauge Reading ......................................................... 30Output Terminal Panel Connections .................... 30-31Pre-setup .............................................................. 32-35Generator Start-up Procedure ............................ 36-38Generator Shut-down Procedure ............................. 39Maintenance ......................................................... 40-41Trailer Brakes Maintenance ...................................... 42Trailer Maintenance ............................................. 43-44Trailer Wiring Diagram .............................................. 45Engine Wiring Diagram ........................................ 46-47Generator Wiring Diagram ....................................... 48Generator Troubleshooting ....................................... 49Explanation of Codes in Remarks Column .............. 50Suggested Spare Parts ............................................ 51

Specification and part numberare subject to change withoutnotice.

NOTE

COMPONENT DRACOMPONENT DRACOMPONENT DRACOMPONENT DRACOMPONENT DRAWINGSWINGSWINGSWINGSWINGSGenerator Assembly ............................................ 52-53Control Box Assembly .......................................... 54-57Engine & Radiator Assembly ............................... 58-61Output Terminal Assembly ................................... 62-63Battery Assembly ................................................. 64-65Muffler Assembly ................................................. 66-67Fuel Tank Assembly ............................................. 68-69Enclosure Assembly ............................................ 70-75Rubber Seal Assembly ........................................ 76-77Nameplate and Decals ........................................ 78-79

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


PARTS ORDERING PROCEDURES

MQPOWERA Division of Multiquip Inc.POST OFFICE BOX 6254CARSON, CA 90749310-537-3700 800-421-1244FAX: 310-632-2656E-MAIL: [email protected]: www.mqpower.com

When ordering parts,please supply the following information: Dealer account number Dealer name and address Shipping address (if different than billing address) Return fax number Applicable model number Quantity, part number and description of each part Specify preferred method of shipment:

FedEx or UPS Ground FedEx or UPS Second Day or Third Day FedEx or UPS Next Day Federal Express Priority One DHL Truck

Note: Unless otherwise indicated by customer, allorders are treated as Standard Orders, and willship within 24 hours. We will make every effort toship Air Shipments the same day that the order isreceived, if prior to 2PM west coast time. StockOrders must be so noted on fax or web forms.

Extra Discounts!All parts orders which include complete part numbers andare received by our automated web parts order system, orby fax qualify for the following extra discounts:

Ordered Standard Stock ordersvia orders ($750 list and above)Fax 3% 10%Web 5% 10%

Special freight allowanceswhen you order 10 or moreline items via Web or Fax!**FedEx Ground Service at no charge for freightNo other allowances on freight shipped by any other carrier.**Common nuts, bolts and washers (all items under $1.00list price) do not count towards the 10+ line items.

Place Your Parts Order Via Web or FaxFor Even More Savings!

(Domestic USA Dealers Only)

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

Heres how to get help...Please have the model and serial numberon hand when calling.MQ POWER CORPORATE OFFICE18910 Wilmington Ave. 800-421-1244Carson, CA 90746 FAX: 310-632-2656Email: [email protected]: www.mqpower.comPARTS DEPARTMENT800-427-1244 FAX: 800-672-7877310-537-3700 FAX: 310-637-3284SERVICE DEPARTMENT800-835-2551 FAX: 310-638-8046310-537-3700TECHNICAL ASSISTANCE800-478-1244 FAX: 310-631-5032WARRANTY DEPARTMENT800-835-2551, EXT. 279 FAX: 310-638-8046310-537-3700, EXT. 279

Direct TOLL-FREE accessto our Parts Department:

Toll-free nationwide 800-427-1244Toll-free FAX 800-6-PARTS-7 (800/672-7877)


DCA-45USI SPECIFICATIONS

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DCA-45USI DIMENSIONS (SIDE AND FRONT)

Figure 1. Dimensions


DCA-45USI SAFETY MESSAGE ALERT SYMBOLS

This Owner's Manual has beendeveloped to provide completeinstructions for the safe and efficientoperation of the MQ Power ModelDCA45USI ULTRA-SILENTGENERATOR.

Before using this GENERATOR, ensure that the operatingindividual has read and understands all instructions in thismanual.

Safety precautions should be followed at all times when operatingthis equipment. Failure to read and understand the SafetyMessages and Operating Instructions could result in injury toyourself and others.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform youabout potential hazards that could injure you or others. TheSafety Messages specifically address the level of exposure tothe operator, and are preceded by one of three words: DANGER,WARNING, or CAUTION.

DANGER: You WILL be KILLED orSERIOUSLY injured if you DO NOT followdirections.

WARNING: You CAN be KILLED orSERIOUSLY injured if you DO NOT followdirections.

CAUTION: You CAN be injured if youDO NOT follow directions.

HAZARD SYMBOLS

Engine exhaust gases contain poisonouscarbon monoxide. This gas is colorless andodorless, and can cause death if inhaled.NEVER operate this equipment in a confinedarea or enclosed structure that does notprovide ample free flow air.

Potential hazards associated with trowel operation will bereferenced with "Hazard Symbols" which appear throughoutthis manual, and will be referenced in conjunction with Safety"Message Alert Symbols".

Diesel fuel is extremely flammable, and itsvapors can cause an explosion if ignited. DONOT start the engine near spilled fuel orcombustible fluids. DO NOT fill the fuel tankwhile the engine is running or hot. DO NOToverfill tank, since spilled fuel could ignite if itcomes into contact with hot engine parts orsparks from the ignition system. Store fuel inapproved containers, in well-ventilated areasand away from sparks and flames. NEVERuse fuel as a cleaning agent.

Burn Hazards

Engine components can generate extreme heat.To prevent burns, DO NOT touch these areaswhile the engine is running or immediately afteroperations. NEVER operate the engine withheat shields or heat guards removed.

Rotating Parts

NEVER operate equipment with covers, orguards removed. Keep fingers, hands, hairand clothing away from all moving parts toprevent injury.

Explosive Fuel

Lethal Exhaust Gases

NOTE


Accidental Starting

ALWAYS place the engine ON/OFF switchin the OFF position, when the trowel is notin use.

Over Speed Conditions

NEVER tamper with the factory settings of theengine governor or settings. Personal injuryand damage to the engine or equipment canresult if operating in speed ranges abovemaximum allowable.

Respiratory Hazard

ALWAYS wear approved respiratory protection.

ALWAYS wear approved eye and hearingprotection.

Sight and Hearing hazard

Equipment Damage Messages

Other important messages are provided throughout this manualto help prevent damage to your trowel, other property, or thesurrounding environment.

This generator, other property, orthe surrounding environment couldbe damaged if you do not followinstructions.

NOTE

DCA-45USI SAFETY MESSAGE ALERT SYMBOLS


DCA-45USI RULES FOR SAFE OPERATION

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:Failure to follow instructions in this manual maylead to serious injury or even death! Thisequipment is to be operated by trained andqualified personnel only! This equipment isfor industrial use only.

The following safety guidelines should always be used whenoperating the DCA-45USI Generator:GENERAL SAFETY DO NOT operate or service this equipment before

reading this entire manual.

This equipment should not be operated by persons under 18years of age.

NEVER operate this equipment without properprotective clothing, shatterproof glasses, steel-toed boots and other protective devices requiredby the job.

NEVER operate this equipment when notfeeling well due to fatigue, illness or takingmedicine.

NEVER operate this equipment under theinfluence or drugs or alcohol.

NEVER use accessories or attachments, which are notrecommended by MQ Power for this equipment. Damage tothe equipment and/or injury to user may result.

Manufacture does not assume responsibility for any accidentdue to equipment modifications.

Whenever necessary, replace nameplate, operation andsafety decals when they become difficult read.

ALWAYS check the machine for loosened threads or boltsbefore starting.

NEVER operate the generator in an explosive atmosphere ornear combustible materials. An explosion or fire could resultcausing severe bodily harm or even death.

High Temperatures Allow the engine to cool beforeperforming service and maintenance functions. Contact withhot! components can cause serious burns.

The engine of thisgenerator requires anadequate free flow ofcooling air. NEVERoperate the generator inany enclosed or narrowarea where free flow ofthe air is restricted. If theair flow is restricted it willcause serious damageto the generator orengine and may cause injury to people. The generator enginegives off DEADLY carbon monoxide gas.

ALWAYS make sure generator is properly grounded. NEVER use gas piping as an electrical ground. DO NOT place hands or fingers inside generator engine

compartment when engine is running. ALWAYS make sure generator installation is accordance with

national and local electrical codes. ALWAYS have a qualified electrician perform the generator

wiring installation. NEVER power cables or cords lay in water. NEVER stand in water while AC power from the generator

is being transfer to a load. NEVER use a defective or frayed power cable. Check the

cable for cuts in the insulation. NEVER use a extension cord that is frayed or damaged where

the insulation has been cut. ALWAYS make certain that proper extension cord has been

selected for the job See Table 5. The electrical voltage required to operate the generator can

cause severe injury or even death through physical contactwith live circuits. Turn all circuit breakers OFF beforeperforming maintenance on the generator.

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



Backfeed to a utility system can cause electrocution and orproperty damage. DO NOT connect to any building's electricalsystem except through an approved device or after buildingmain switch is opened. ALWAYS have a licensed electricianperform the installation

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:DO NOT touch or open any of the belowmentioned components while thegenerator is running. Always allowsufficient time for the engine and generatorto cool before performing maintenance.

Radiator1. Radiator Cap - Removing the radiator cap while the engine

is hot will result in high pressurized, boiling water to gushout of the radiator, causing severe scalding to any personsin the general area of the generator.

2. Coolant Drain Plug - Removing the coolant drain plugwhile the engine is hot will result in hot coolant to gush outof the coolant drain plug, therefore causing severe scaldingto any persons in the general area of the generator.

3. Engine Oil Drain Plug - Removing the engine oil drainplug while the engine is hot will result in hot oil to gush outof the oil drain plug, therefore causing severe scalding toany persons in the general area of the generator.

DANGERDANGERDANGERDANGERDANGER:


NEVER touch output terminals during operation. This isextremely dangerous. ALWAYS stop the machine andplace the circuit breaker in the OFF position when contactwith the output terminals is required. There exists thepossibility of electrocution, electrical shock or burn,which can cause severe bodily harm or even death!

Never use damaged or worn cables whenconnecting equipment to the generator.Make sure powerc o n n e c t i n gcables are

securely connected to thegenerators output terminals,insufficient tightening of theterminal connections may causedamage to the generator andelectrical shock.

.

Maintenance Safety NEVER lubricate components or attempt

service on a running machine.

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

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

broken parts.

ALWAYS make sure that electrical circuits are properlygrounded per the National Electrical Code (NEC) and localcodes before operating generator. Severe injury or death! byelectrocution can result from operating an ungroundedgenerator.

ALWAYS be sure the operator is familiar with proper safetyprecautions and operations techniques before using generator.

ALWAYS store equipment properly when it is not being used.Equipment should be stored in a clean, dry location out of thereach of children.

ALWAYS read, understand, and followprocedures in Operators Manual beforeattempting to operate equipment.



POWERCORD

(POWER ON)

WETHANDS

NEVER grab ortouch a livepower cord withwet hands , thepossibility existsof electrical shock, electrocution, and evendeath!



NEVER run engine without air filter. Severe engine damagemay occur.

ALWAYS service air cleaner frequently to prevent enginemalfunction.

ALWAYS disconnect the negative battery terminal beforeperforming service on the generator.

ALWAYS be sure the operator is familiar with proper safetyprecautions when operating the generator set.

ALWAYS store equipment properly when not in use.DO NOT leave the generator running in the manual mode

unattended.DO NOT allow unauthorized people to operate this

equipment.ALWAYS read, understand, and follow procedures in

Operators Manual before attempting to operate equipment.Refer to the Isuzu Engine Owner's Manual for engine

technical questions or information.

BatteryThe battery contains acids that can cause injury to the eyesand skin. To avoid eye irritation, always wear safety glasses.Use well insulated gloves when picking up the battery. Usethe following guidelines when handling the battery:

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

2. DO NOT expose the battery toopen flames, sparks, cigarettesetc. The battery containscombustible gases and liquids. Ifthese gases and liquids come incontact with a flame or spark, anexplosion could occur.

3. ALWAYS keep the battery charged. If the battery is notcharged a buildup of combustible gas will occur.

4. ALWAYS keep battery charging and cables in good workingcondition. Repair or replace all worn cables.

5. ALWAYS recharge the battery in an vented airenvironment, to avoid risk of a dangerous concentrationof combustible gases.

6. In case the battery liquid (dilute sulfuric acid) comes incontact with clothing or skin, rinse skin or clothingimmediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes incontact with your eyes, rinse eyes immediately with plentyof water, then contact the nearest doctor or hospital, andseek medical attention.

Pay close attention toventilation when operatingthe generator insidetunnels and caves. The

engine exhaust contains noxious elements.Engine exhaust must be routed to aventilated area.

DANGER:DANGER:DANGER:DANGER:DANGER:

Generator GroundingTo guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground.Article 250 (Grounding) of the National Electrical Code(NEC) provides guide lines for proper grounding and specifiesthat the cable ground shall be connected to the groundingsystem of the building as close to the point of cable entryas practical.ALWAYS be sure to use the ground terminal (green wire)when connecting a load to the UVWO output terminals.

Transporting ALWAYS shutdown engine before transporting. Tighten both fuel tank caps securely. If generator is mounted on a trailer, make sure trailer

complies with all local and state safety transportationlaws. See next page Towing Safety Precautions forbasic towing techniques.


Emergencies ALWAYS know the location of the nearest fire extinguisher.

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

In emergencies always know the location of thenearest phone or keep a phone on the job site.Also know the phone numbers of the nearestambulance, doctor and fire department. Thisinformation will be invaluable in the case of anemergency.

To reduce the possibility of an accident while transportingthe generator on public roads, always make sure the trailerthat supports the generator and the towing vehicle are ingood operating condition and both units are mechanicallysound.The following list of suggestions should be used when towingyour generator: Make sure the hitch and coupling of the towing vehicle

are rated equal to, or greater than the trailer "gross vehicleweight rating" (GVWR) of 6,000 lbs.

ALWAYS inspect the hitch and coupling for wear. NEVERtow a trailer with defective hitches, couplings, chainsetc.

Check the tire air pressure on both towing vehicle andtrailer. 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 "SafetyChain".

ALWAYS attach trailers safety chains to towing vehicleproperly.

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

The maximum speed for highway towing is 55 MPHunless posted otherwise. Recommended off-road towingis not to exceed 15 MPH or less depending on type ofterrain.

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

Use the trailers swivel jack to adjust the trailer height toa level position while parked.

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

Towing Safety Precautions

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:Conform to Department of Transportation(DOT) Safety Towing Regulations beforetowing generator.

Avoid sharp turns. Trailer should be adjusted to a level position at all times

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

transporting. DOT Requirements include the following:


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

tie wraps.


Figure 2. Typical Generator Grounding Application

DCA-45USI INSTALLATION


Outdoor InstallationInstall the generator in a clear area. Make sure the generatoris on secure level ground so that it cannot slide or shiftaround. Also install the generator in a manner so that theexhaust will not be discharged in the direction of nearbyhomes.

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

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

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:Pay close attention to ventilation whenoperating the generator inside tunnels andcaves. The engine exhaust containsnoxious elements. Engine exhaust mustbe routed to a ventilated area.

Indoor InstallationExhaust gases from diesel engines are extremely poisonous.Whenever an engine is installed indoors the exhaust fumesmust be vented to the outside. The engine should be installedat least two feet from any outside wall. Using an exhaustpipe which is too long or too small can cause excessiveback pressure which will cause the engine to heatexcessively and possibly burn the valves.MountingThe generator must be mounted on a solid foundation (suchas concrete) and set firmly on the foundation to isolatevibration of the generator when it is running. The generatormust set at least 6 inches above the floor or grade level (inaccordance to NFPA 110, Chapter 5-4.1). DO NOT removethe metal skids on the bottom of the generator. They are toresist damage to the bottom of the generator and to maintainalignment.

Generator GroundingTo guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground.Article 250 (Grounding) of the National Electrical Code (NEC)provides guide lines for proper grounding and specifies thatthe cable ground shall be connected to the grounding systemof the building as close to the point of cable entry aspractical.NEC articles 250-64(b) and 250-66 set the followinggrounding requirements:1. Use one of the following wire types to connect the

generator to earth ground.a. Copper - 10 AWG (5.3 mm2) or larger.b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 2) connect theground cable between the lock washer and the nut onthe generator and tighten the nut fully. Connect the otherend of the ground cable to earth ground.

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

When connecting the generator toany buildings electrical systemALWAYS consult with a licensedelectrician.

DCA-45USI INSTALLATION

NOTE


To reduce the possibility of an accident while transportingthe generator on public roads, always make sure the trailer(Figure 3) that supports the generator and the towing vehicleare in good operating condition and both units aremechanically sound.The following list of suggestions should be used when towingyour generator:

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:Towing Safety Precautions

Check with your local county or state safetytowing regulations before towing yourgenerator.

Make sure the hitch and coupling of the towing vehicleare rated equal to, or greater than the trailer "gross vehicleweight rating" (GVWR).

ALWAYS inspect the hitch and coupling for wear. NEVERtow a trailer with defective hitches, couplings, chainsetc.

Check the tire air pressure on both towing vehicle andtrailer. Also check the tire tread wear on both vehicles.

ALWAYS make sure the trailer is equipped with a "SafetyChain".

DCA-45USI TOWING SAFETY PRECAUTIONS ALWAYS attach trailers safety chain to bumper of towing

vehicle. ALWAYS make sure the vehicle and trailer directional,

backup, brake, and trailer lights are connected andworking properly.

The maximum speed for highway towing is 55 MPHunless posted otherwise. Recommended off-road towingis not to exceed 15 MPH or less depending on type ofterrain.

Place chocked blocks underneath wheel to preventrolling, while parked.

Place support blocks underneath the trailers bumper toprevent tipping, while parked.

Use the trailers hand winch to adjust the height of thetrailer, then insert locking pin to lock wheel stand in place,while parked.

Avoid sudden stops and starts. This can cause skidding,or jackknifing. Smooth, gradual starts and stops willimprove gas milage.

Avoid sharp turns to prevent rolling. Remove wheel stand when transporting. DO NOT transport generator with fuel in tank.

Figure 3. Generator with Trailer

Generator w/trailer illustration isfor reference only.

NOTE


Explanation of Chart:This section is to provide the user with trailer service andmaintenance information. The service and maintenanceguidelines referenced in this section apply a wide range oftrailers. Remember periodic inspection of the trailer will en-sure safe towing of the equipment and will prevent damageto the equipment and personal injury.It is the purpose of this section to cover the major mainte-nance components of the trailer. The following trailer com-ponents will be discussed in this section:

Brakes Tires Lug Nut Torquing Suspension Electrical Brake Troubleshooting TablesUse the following definitions when reading Table 2.1. Fuel Cell - Provides an adequate amount of fuel for the

equipment in use. Fuel cells must be empty when trans-porting equipment.

2. Braking System - System employed in stopping thetrailer. Typical braking systems are electric, surge, hy-draulic, hydraulic-surge and air.

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

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

DCA-45USI TRAILER SPECIFICATIONS

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:ALWAYS make sure the trailer is in goodoperating condition. Check the tires forproper inflation and wear. Also check thewheel lug nuts for proper tightness.

5. Frame Width - Measurement is from fender to fender6. 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 thediameter 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 trailersaxle.

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

12. Lug Nuts - Used to secure the wheel to the wheel hub.Always use a torque wrench to tighten down the lug nuts.See Table 17 and Figure 67 or lug nut tightening andsequence.

13. Axle - Indicates the maximum weight the axle can sup-port in pounds, and the diameter of the axle expressedin inches (see Table 2). Please note that some trailershave a double axle. This will be shown as 2-6000 lbs.,meaning two axles with a total weight capacity of 6000pounds.

14. Suspension - Protects the trailer chassis from shockstransmitted through the wheels. Types of suspension usedare leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are providedwith the trailer so the brake lights and turn signals canbe connected to the towing vehicle.

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


The DCA-45USI generator is equipped with a number of safety decals. These decals are provided for operator safety andmaintenance information. The illustration below and on the preceding page show the decals as they appear on themachine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-45USI GENERATOR DECALS


DCA-45USI GENERATOR DECALS


DCA-45USI GENERAL INFORMATION

DCA-45USI FAMILIARIZATIONGeneratorThe MQ Power Model DCA-45USI (Figure 4) is a 36 kWgenerator that is designed as a high quality portable (requiresa trailer for transport) power source for telecom sites, lightingfacilities, power tools, submersible pumps and otherindustrial and construction machinery.Engine Operating PanelThe Engine Operating Panel is provided with the following:z Tachometerz Water Temperature Gauge/ Alarm Lampz Oil Pressure Gauge/ Alarm Lampz Charging Ammeter Gaugez Pre-Heat Lampz Panel Lightz Panel Light Switchz Ignition/Preheat Switchz Fuel Gaugez Fuel Filter Water Level Alarm LampGenerator Control PanelThe Generator Control Panel is provided with the following:z Output Voltage Adjustment Knobz Frequency Meter (Hz)z AC Ammeter (Amps)z AC Voltmeter (Volts)z Ammeter Change-Over Switchz Voltmeter Change-Over Switchz Voltage Regulatorz 3-Pole, 110 amp Main Circuit BreakerOutput Terminal PanelThe Output Terminal Panel is provided with the following:z Three 120/240V output receptacles (CS-6369), 50 ampsz Three auxilliary circuit breakers, @50 ampsz Two 125 VAC output receptacles, (GFCI), 20 ampsz Two GFCI circuit breakers @ 20ampsz Five output terminal lugs (3 power)Control BoxThe Control Box is provided with the following:z Automatic Voltage Regulatorz Current Transformerz Emergency Relayz Over-Current Relay

Open Delta Excitation SystemThe DCA-45USI generator is equipped with the state of the art"Open-Delta" excitation system. The open delta system consist ofan electrically independent winding wound among stationarywindings of the AC output section.There are four connections of the open delta A, B, C and D. Duringsteady state loads, the power from the voltage regulator is suppliedfrom the parallel connections of A to B, A to D, and C to D. These threephases of the voltage input to the voltage regulator are then rectifiedand 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 ofthe open delta to the series connection of B to C. This has the effectof adding the voltages of each phase to provide higher excitation tothe exciter section and thus better voltage response during theapplication of heavy loads.The connections of the AVR to the AC output windings are forsensing only. No power is required from these windings.The open-delta design provides virtually unlimited excitation current,offering maximum motor starting capabilities. The excitation doesnot have a "fixed ceiling" and responds according the demands ofthe required load.EngineThe DCA-45USI is powered by a 4 cycle, water cooled, turbochargedIsuzu BB-4JG1T diesel engine. This engine is designed to meetevery performance requirement for the generator. Reference Table 1for engine specifications.In keeping with MQ Power's policy of constantly improving its products,the specifications quoted herein are subject to change without priornotice.The basic controls and indicators for the DCA-45USI generator areaddressed on the following pages.Mechanical Governor SystemThe mechanical governor system control the RPM of the engine.When the engine demands increase or decrease, the mechanicalgovernor system regulates the frequency variation to within .5%.The electronic governor option decreases the frequency variationto within 0.25%.Extension CablesWhen electric power is to be provided to various tools or loads atsome distance from the generator, extension cords are normallyused. Cables should be sized to allow for distance in length andamperage so that the voltage drop between the generator and pointof use (load) is held to a minimum. Use the cable selection chart(Table 5 ) as a guide for selecting proper extension cable size.


DCA-45USI MAJOR COMPONENTS

Figure 4. Major Components

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DCA-45USI GENERATOR CONTROL PANEL

The definitions below describe the controls and functions ofthe DCA-45USI "Generator Control Panel" (Figure 5).1. Main Circuit Breaker This three-pole, 110 amp main

breaker is provided to protect the U,V, and W OutputTerminal Lugs from overload.

2. AC Ammeter Indicates the amount of current the loadis drawing from the generator per leg selected by theammeter phase-selector switch.

3. Ammeter Change-Over Switch This switch allowsthe AC ammeter to indicate the current flowing to theload connected to any phase of the output terminals, orto be switched off. This switch does not effect thegenerator output in any fashion, it is for current readingonly.

4. Voltmeter Change-Over Switch This switch allowsthe AC voltmeter to indicate phase to phase voltagebetween any two phases of the output terminals or tobe switched off.

5. Voltage Regulator Control Allows 15% manualadjustment of the generators output voltage.

6. Frequency Meter Indicates the output frequency inhertz (Hz). Normally 60 Hz 1 Hz .

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

Located behind the generator control panel is the GeneratorControl Box. This box contains some of the necessaryelectronic components required to make the generatorfunction.The Control Box is equipped with the following majorcomponents:z Over-Current Relayz Voltage Rectiferz Starter Relayz Engine Controller (Computer Controlled)z Current Transformerz Voltage Selector Switch

Remember the overcurrentrelay monitors the currentflowing from the U,V, and WOutput Terminal Lugs to theload.

In the event of a short circuit or over current condition, it willautomatically trip the 60 amp main breaker.To restore power to the Output Terminal Panel, press thereset button on the overcurrent relay and place the maincircuit breaker in the closed position (ON).

Figure 5. Generator Control Panel

NOTE


DCA-45USI ENGINE OPERATING PANELThe definitions below describe the controls and functions ofthe DCA-45USI "Engine Operating Panel" (Figure 6).1. Panel Light - Normally used in dark places or at night.

When activated, panel will luminate. When the generatoris not in use, turn the panel light switch to the OFFposition.

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

3. Oil Pressure Lamp - Indicates that the oil pressure istoo low and will shut down the engine.

4. Water Temperature Lamp - Indicates that the watertemperature is too hot and will shut down the engine.

5. Fuel Filter Water Level Alarm Lamp - This lamp turnson when water in the filter is detected. Drain the waterin the fuel filter strainer to correct the problem.

6. Pre-heat Lamp - This indicates when the engine hasbeen preheated and is ready for starting. In cold weatherconditions, it may be several minutes before the lampilluminates.

7. Fuel Leak Detected Alarm This indicates that liquidis present in the fuel tank containment basin. Drain thecontainment basin and repair any leaks.

8. Tachometer Indicates engine speed in RPMs for60 Hz operation. This meter should indicate 1800 RPMswhen the rated load is applied. In addition a built in hourmeter will record the number of operational hours thatthe 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 engines alternator which providescurrent for generators control circuits and batterycharging system.

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

12. Oil Pressure Gauge Normal operation should be about28 to 71 psi. When starting the generator the oil pressuremay read a bit higher, but after the engine warms upthe oil pressure should return to normal.

13. Starter Switch Three position switch, stop,preheat/run and start. Insert ignition key to start andstop engine.

Figure 6. Engine Operating Panel


Output Terminal FamiliarizationThe Output Terminal Panel (Figure 7) is provided with thefollowing:z Three (3) 120/240V output receptacles, 50 ampz Three (3) Circuit Breakers 240V @50 ampsz Two (2) 120V GFCI receptacles, 20 ampz Two (2) GFCI Circuit Breakers @ 20 ampsz One Main Circuit Breaker @110 ampsz Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

Output Terminal PanelThe Output Terminal Panel (Figure 7) shown below is locatedon the right-hand side (left from control panel) of the generator.Lift up on the cover to gain access to receptacles and terminallugs.

Terminal legs O and Ground areconsidered bonded grounds.

Figure 7. Output Terminal Panel

DCA-45USI OUTPUT TERMINAL PANEL FAMILIARIZATION

NOTE


120 VAC GFCI ReceptaclesThere are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)recepacles provided on the output terminal panel. Thesereceptacles can be accessed in any voltage selector switchposition. Each receptacle is protected by a 20 amp circuitbreaker. These breakers are located directly above the GFCIreceptacles. Remember the load output (current) of bothGFCI receptacles is dependent on the load requirements ofthe UVWO terminals.Pressing the reset button resets the GFCI receptacle afterbeing tripped. Pressing the "Test Button" (See Figure 8) inthe center of the receptacle will check the GFCI function.Both receptacles should be tested at least once a month.

Figure 8. G.F.C.I. Receptacle

Each auxilliary receptacle is protected by a 50 amp circuitbreaker. These breakers are located directly above the GFCIreceptacles. Remember the load output (current) on all threereceptacles is dependent on the load requirements of theOutput Terminal Lugs.Turn the voltage regulator control knob (Figure 10) on thecontrol panel to obtain the desired voltage. Turning the knobclockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 9. 240 VAC Twist-LockAuxiliary Receptacles


Twist Lock Dual Voltage 120/240 VAC ReceptaclesThere are three 120/240 VAC, 50 amp auxilliary twist-lock(CS-6369) recepacles (Figure 9) provided on the outputterminal panel.These receptacles can only be accessedwhen the voltage selector switch is placed in the single-phase 240/120 position.

Figure 10. Voltage Regulator Control Knob

Figure 11. Plastic Face Plate (UVWO Terminals)

Removing the Plastic Face Plate (Output Terminal Lugs)The Output Terminal Lugs are protected by a plastic faceplate cover (Figure 11). Un-screw the securing bolts and liftthe plastic terminal cover to gain access to the terminalenclosure.After the load wires have been securely attached to theOutput Terminal Lugs, reinstall the plastic face plate.


Figure 12. Connecting Loads

Connecting LoadsLoads can be connected to the generator by using the OutputTerminal Lugs or the convienience receptacles(See Figure 12). Make sure to read the operation manualbefore attempting to connect a load to the generator.To protect the Output Terminal Lugs from overload, a3-pole, 110 amp, main circuit breaker is provided. Make sure toswitch ALL circuit breakers to the OFF position prior to startingthe engine.


Over Current RelayAn over current relay (Figure 13) is connected to the maincircuit breaker. In the event of an overload, both the circuitbreaker and the over current relay may trip. If the circuitbreaker can not be reset, the reset button on the over cur-rent relay must be pressed. The over current relay is lo-cated in the control box.

Figure 13. Over Current Relay

Blower FanThis unit has an intake fan located at the rear of the machineto draw outside air into the cabinet to cool the engine. Thefan has a 10 amp AC fuse located beneath the VoltageSelector Switch (Figure 14).

This fuse has current running through it anytime the engine is operating. THIS FUSEIS NOT connected to the main circuitbreaker OF the generator. Attempting to

replace the fuse with the engineand/or generator operating couldresult in electrocution and severebodily harm. ALWAYS turn theunit completely off beforeattempting to replace or handleTHIS fuse

DANGER:

Figure 14. Blower Fan Fuse


DCA-45USI LOAD APPLICATIONSingle Phase LoadAlways be sure to check the nameplate on the generatorand equipment to insure the wattage, amperage, frequency,and voltage requirements are satisfactorily supplied by thegenerator for operating the equipment.Generally, the wattage listed on the nameplate of theequipment is its rated output. Equipment may require 130150% more wattage than the rating on the nameplate, asthe wattage is influenced by the efficiency, power factor andstarting system of the equipment.

Motors and motor-drivenequipment draw much greatercurrent for starting than duringoperation.

When connecting ordinary power tools, a capacity of up tothe generating sets rated output (kW) multiplied by 0.8 canbe used.

If wattage is not given on the equipment'sname plate, approximate wattage may bedetermined by multiplying nameplatevoltage by the nameplate amperage.

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

CAUTION:

If 3 load (kVA) is not given onthe equipment nameplate,approximate 3 load outputmaybe determined bymultiplying voltage by amperageby 1.732.

z When connecting a resistance load such as anincandescent lamp or electric heater, a capacity of up tothe generating sets rated output (kW) can be used.

z When connecting a fluorescent or mercury lamp, acapacity of up to the generating sets rated output (kW)multiplied by 0.6 can be used.

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

NOTE

WATTS l VOLTAGE x AMPERAGE

Three Phase LoadWhen calculating the power requirements for 3-phase poweruse the following equation:

NOTE

An inadequate size connecting cable which cannot carry therequired load can cause a voltage drop which can burn outthe appliance or tool and overheat the cable. See Table 5.

NOTE

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Before connecting this generator to anybuildings electrical system, a licensedelectrician must install an isolation(transfer) switch. Serious damage to thebuildings electrical system may occurwithout this transfer switch.


DCA-45USI GENERATOR OUTPUTS

GFCI Receptacle Load CapabilityThe load capability of the GFCI receptacles is directly re-lated to the voltage being supplied at either the output termi-nal lugs or the 3 twist lock auxilliary receptacles.Tables 8 and 9 show what amount of current is available atthe GFCI receptacles when the UVWO terminals and twistlock receptacles are in use. Be careful that your load doesnot to exceed the available current capability at the recep-tacles.

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Voltage Selector SwitchThe voltage selector switch (Figure 15) is located abovethe UVWO Hard Wire Hook-up Panel. It has been providedfor ease of voltage selection.

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:NEVER change the position of the voltageselector switch while the engine is running.ALWAYS place circuit breaker in the openposition before selecting voltage.

Voltage Selector Switch Locking ButtonThe voltage selector switch has a locking button to protectthe generator and load from being switched while the engineis running. To lock the voltage selector switch, press andhold the red button located at the bottom of the switch.

Figure 15. Voltage Selector Switch

Generator AmperageTable 7 describes the generators current output capabilityfor both 1-phase and 3 phase applications.

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Generator Output VoltagesA wide range of voltages are available to supply voltage formany different applications. Voltages are selected by usingthe voltage selector switch (Figure 14). To obtain some ofthe voltages as listed in Table 6 (see below) will require afine adjustment using the voltage regulator (VR) controlknob located on the control panel.


DCA-45USI GAUGE READINGHow to Read the Output Terminal Gauges.The gauges and selector switches on the control panelDO NOT effect the generator output. They are provided tohelp observe how much power is being supplied at the Out-put Terminal Lugs.Before taking a reading off either gauge, set the VoltageSelector Switch (Figure 16) to the position which producesthe required voltage (For example, for 3 240V, choose thecenter 3 240/139V posi-tion on the voltage selectorswitch.)

Figure 16. Voltage SelectorSwitch 240/139V Three

Phase Position

Figure 17. AC VoltmeterChange-Over Switch

Figure 18. AC Voltmeter Gauge(Volt reading on W-U Lug)

For 3 208V/1,120V, placethe Voltage Selector Switchin the 3 Phase 340/139position.

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

Figure 19. AC AmmeterChange-Over Switch

The ammeter gauge will onlyshow a reading when theOutput Terminal Lugs areconnected to a load and in use.

NOTE

Reading VoltageTo determine the voltage between two terminal lugs, set theAC Voltmeter Change-Over Switch to the appropriatesetting (Figure 17) to activate the AC Voltmeter Gauge(Figure 18) and read the available voltage between the twolugs.For example, to measure the voltage between the W and Uterminal lugs, set the AC Voltmeter Change-Over Switchto W-U and read the AC Voltmeter Gauge.

NOTE

Reading AmperageTo determine the amperage at a terminal lug, set theAC Ammeter Change-Over Switch to the appropriatesetting (Figure 19) to activate the AC Ammeter Gauge(Figure 20) and read the available amperage at the terminallug.For example, to measure the amperage at the Uterminal lug, set the AC Ammeter Change-Over Switch toU and read the AC Ammeter Gauge.


Figure 21. Voltage Selector Switch 240/139VThree-Phase Position

DCA-45USI OUTPUT TERMINAL PANEL CONNECTIONSUVWO Terminal Output VoltagesVarious output voltages can be obtained using the using theOutput Terminal Lugs. The voltages at the terminals aredependent on the position of the Voltage Selector Switchand the adjustment of the Voltage Regulator Control Knob.Remember the voltage selector switch determines the rangeof the output voltage. The voltage regulator (VR) allows theuser to increase or decrease the selected voltage.3 240/139 Output Terminal Lug Voltages1. Place the voltage selector switch in the 3 240/139

position as shown in Figure 21.

Figure 22. Output Terminal Lugs240/139V Three Phase Connections

2. Connect the load wires to the Output Terminal Lugs asshown in Figure 22.

3. Turn the voltage regulator knob (Figure 23) clockwise toincrease voltage output, turn counterclockwise todecrease voltage output.

3 208V/1120V Output Terminal Lug Voltages1. Place the voltage selector switch in the 3 240/139


Figure 23. Voltage Regulator Knob

Use this position for3-208 or 1120V.



NOTE

To achieve a 3 208V output,the voltage selector switchmust be in the 3 240/139Vposition and the voltageregulator must be adjusted to208V.

Figure 25. Output Terminal Lugs3-208V/120V Connections

Figure 24. Voltage SelectorSwitch 3-208V/1-120VThree-Phase Position


Figure 26. Voltage Selector Switch 480/277V Three-Phase Position

3 480/277 Output Terminal Lug Voltages1. Place the voltage selector switch in the 3 480/277


Figure 27. Output Terminal Lugs277/480V Three Phase Connections



1 240V/120V Output Terminal Lug Voltages1. Place the voltage selector switch in the 1 240/120




Figure 29. Output Terminal Lugs1-240V/120V Connections

DCA-45USI OUTPUT TERMINAL PANEL CONNECTIONS

Figure 28. Voltage Selector Switch 240/120V Single-Phase Position


Lubrication OilFill the engine crankcase with lubricating oil through the fillerhole, but DO NOT overfill. Make sure the generator is level.and verify that the oil level is maintained between the twonotches (Figure 30) on the dipstick. See Table 10 for properselection of engine oil.

DCA-45USI PRE-SETUP

Figure 30. Engine Oil Dipstick

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

Circuit BreakersTo protect the generator from an overload, a 3-pole, 110 amp,main circuit breaker is provided to protect the UVW outputterminals from overload. In addition two single-pole, 20 ampGFCI circuit breakers are provided to protect the GFCIreceptacles from overload. Three 50 amp load circuit breakershave also been provided to protect the auxiliary receptaclesfrom overload. Make sure to switch ALL circuit breakers tothe OFF position prior to starting the engine.

z API Service Classification CH-4z API Service Classification CG-4z API Service Classification CF-4z ACEA Specification E3z ACEA Specification E2

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

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ONLY properly trained personel who haveread and understand this section should re-fill the fuel tank system.

Figure 31. Internal Fuel Tank System

Fuel spillage on a hot! engine can cause afire or explosion. If fuel spillage occurs,wipe up the spilled fuel completely toprevent fire hazards. NEVER! smokearound or near the generator.


Refilling the Fuel System

Fuel Check

WARNING:WARNING:WARNING:WARNING:WARNING:

The generator unit has an internal fuel tank located at thebottom of the cabinet (Figure 31). ALWAYS fill the fuel tankwith clean and fresh #2 diesel fuel. DO NOT fill the fueltanks beyond their capacities.Pay attention to the fuel tank capacity when replenishingfuel.The fuel tank cap must be closed tightly after filling.Handle fuel in a safety container. If the container does nothave a spout, use a funnel. Wipe up any spilled fuelimmediately.


DCA-45USI PRE-SETUPRefueling Procedure:

1. Level Tanks make sure fuel cells are level with theground. Failure to do so will cause fuel to spill from thetank before reaching full capacity (Figure 32).


WARNING:WARNING:WARNING:WARNING:WARNING:

Figure 32. Only Fill on Level Ground

ONLY! use #2 diesel fuelwhen refueling.

Diesel fuel and its vapors are dangerous toyour health and the surrounding environment.Avoid skin contact and/orinhaling fumes.

ALWAYS! place trailer on firm level ground before refueling.

NOTE

3. NEVER overfill fuel tank It is important to read thefuel gauge when filling trailer fuel tank. DO NOT wait forfuel to rise in filler neck (See Figure 34).

Figure 34. Full Fuel Tank

Figure 35. Fuel Expansion

WARNING:WARNING:WARNING:WARNING:WARNING:DO NOT OVER-FILL fuel system. Leaveroom for fuel expansion . Fuel expands whenheated (Figure 35).

2. Open cabinet doors on the generator. Locate and removethe fuel tank cap and fill tank (Figure 33).

Figure 33. Fueling the Generator


Coolant (Ethylane Glycol [Green] / Water 50/50 mix)Use only drinkable tap water. If hard water or water withmany impurities is used, the inside of the engine and radiatormay become coated with deposits and cooling efficiencywill be reduced.An anticorrosion additive added to the water will help preventdeposits and corrosion in the cooling system. See the enginemanual for further details.

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:If adding coolant/antifreezemix to the radiator, DONOT remove the radiatorcap until the unit hascompletely cooled. The possibility of hot!

coolant exists which can cause severe burns.Day-to-day addition of coolant is done from the recoverytank. When adding coolant to the radiator, DO NOT removethe radiator cap until the unit has completely cooled. SeeTable 12 for engine, radiator, and recovery tank coolantcapacities. Make sure the coolant level in the recovery tankis always between the "H" and the "L" markings.

Operation Freezing WeatherWhen operating in freezing weather, be certain the properamount of antifreeze (Table 13) has been added. CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:

Cleaning the RadiatorThe engine may overheat if the radiator fins becomeoverloaded with dust or debris. Periodically clean the radiatorfins with compressed air. Cleaning inside the machine isdangerous, so clean only with the engine turned off and thenegative battery terminal disconnected.Air CleanerPeriodic cleaning/replacement is necessary. Inspect it inaccordance with the Isusu Engine Owner's Manual.Fan Belt TensionA slack fan belt may contribute to overheating, or toinsufficient charging of the battery. Inspect the fan belt fordamage and wear and adjust it in accordance with the IsuzuEngine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15mm (Figure 38) when depressed with the thumb as shownbelow.

Figure 36. Fan Belt Tension

DCA-45USI PRE-SETUP

When the antifreeze is mixed withwater, the antifreeze mixing ratiomust be less than 50%.

NOTE

NEVER! place handsnear the belts or fan whilethe generator set isrunning.

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DCA-45USI PRE-SETUPWhen connecting battery do the following:1. NEVER connect the battery cables to the battery

terminals when the ignition switch is in the PRE-HEAT/RUN position. ALWAYS make sure that the ignition switchis in the STOP position when connecting the battery.

2. Place a small amount of battery terminal treatmentcompound around both battery terminals. This will ensurea good connection and will help prevent corrosion aroundthe battery terminals.

Figure 37. Battery Connections

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:

ALWAYS disconnect the negative terminalFIRST and reconnect negative terminalLAST.

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:Inadequate battery connections may causepoor starting of the generator, and createother malfunctions.

AlternatorThe polarity of the alternator is negative grounding type. Whenan inverted circuit connection takes place, the circuit will bein short circuit instantaneously resulting the alternator failure.DO NOT put water directly on the alternator. Entry of waterinto the alternator leads an electrolyte corrosion causing analternator failure.Before charging the battery with an external electric source,be sure to disconnect the battery cables.WiringInspect the entire generator for bad or worn electrical wiringor connections. If any wiring or connections are exposed(insulation missing) replace wiring immediately.Piping and Hose ConnectionInspect all piping, oil hose, and fuel hose connections forwear and tightness. Tighten all hose clamps and check hosesfor leaks.If any hose (fuel or oil) lines are defective replace themimmediately.

If the battery cable is connectedincorrectly, electrical damage tothe generator will occur. Pay closeattention to the polarity of thebattery when connecting thebattery.

NOTE

BatteryThis unit is of negative ground DO NOT connect in reverse.Always maintain battery fluid level between the specifiedmarks. Battery life will be shortened, if the fluid level are notproperly maintained. Add only distilled water whenreplenishment is necessary.DO NOT over fill. Check to see whether the battery cablesare loose. Poor contact may result in poor starting ormalfunctions. Always keep the terminals firmly tightened.Coating the terminals with an approved battery terminaltreatment compound. Replace battery with onlyrecommended type battery. The battery type used in thisgenerator is BCI Group 27.The battery is sufficiently charged if the specific gravity ofthe battery fluid is 1.28 (at 68 F). If the specific gravityshould fall to 1.245 or lower, it indicates that the battery isdead and needs to be recharged or replaced.Battery Cable InstallationALWAYS be sure the battery cables (Figure 37) are properlyconnected to the battery terminals as shown below. TheRED cable is connected to the positive terminal of the battery,and the BLACK cable is connected to the negative terminalof the battery.


5. Preheat the engine glow plugs by turning the ignitionkey (Figure 42) to the PRE-HEAT/RUN position. Whenthe preheat lamp (Figure 43) turns off, proceedto step 6.

Figure 43. Pre-Heat Indicator Lamp

WARNING:WARNING:WARNING:WARNING:WARNING:The engine's exhaust contains harmful

emissions. ALWAYS have adequateventilation when operating. Direct exhaustaway from nearby personnel.

DCA-45USI GENERATOR START-UP PROCEDURE

Figure 39. Load Connections

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

CAUTION:

1. Be sure and place the main, G.F.C.I. and aux. circuitbreakers (Figure 40) in the OFF position prior to startingthe engine.

Before Starting

Figure 38. Main, Aux. and GFCI Circuit Breakers

2. Connect the load to the Output Terminal Lugs orauxiliary receptacles as shown in Figure 39. These loadconnection points can be found on the output terminalpanel.

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

Figure 40. Engine Enclosure Doors

4. Place the voltage selector switch in the desired voltageposition (Figure 41).

Figure 41. Voltage Selector Switch

Figure 42. Ignition Switch(Pre-Heat/Run Position)


Figure 47. Voltage Adjust Control Knob

Figure 48. Ammeter (No Load)

11. The ammeter (Figure 48) will indicate zero amps with noload applied. When a load is applied, this meter willindicate the amount of current that the load is drawingfrom the generator.


8. The generator's frequency meter (Figure 45) displaysthe 60 cycle output frequency in HERTZ.

9. The generator's voltage meter (Figure 46) displays theoutput voltage in VOLTS.

Figure 46. AC Voltmeter

Figure 45. Frequency Meter (Hz)

10. If the voltage is not reading at the specified level, usethe voltage adjustment control knob (Figure 47) toincrease or decrease the voltage until you reach thedesired voltage.

7. Let the engine run for 3-5 minutes and listen and checkfor any abnormal sounds or smells. Check for fuel leaks,and noises that would associate with a loose cover orhardware.Check the electric motor fan cooling the radiator forabnormal speed, sound or vibration conditions.If any of the above mentioned conditions exists, shut-down the engine and correct the problem before operatingthe generator.

6. Turn the ignition key to the START position (Figure 44).Once the engine starts, release the ignition key andallow it to return to the PRE-HEAT/RUN position(Figure 42).If the engine fails to start after 10 seconds, waitapproximately 30 seconds and repeat steps 5-6.

Figure 44. Ignition Switch(Start Position)



Figure 51. Engine Tachometer

14. The tachometer (Figure 51) will indicate the speed ofthe engine when the generator is operating. Under normaloperating conditions this speed is approximately 1800RPMs.

15. Turn the main, GFCI, and aux. circuit breakers to theON position (Figure 52).

13. The coolant temperature gauge (Figure 50) will indicatethe coolant temperature. Under normal operatingconditions the coolant temperature is between 165 and203 degrees Fahrenheit.

Figure 50. Coolant Temperature Gauge

16. Observe the generator's ammeter (Figure 53) and verifyit reads the anticipated amount of current with respectto the load. The ammeter will only display a currentreading if the load is in use.

Figure 53. Ammeter (Load)

Figure 52. Main, AUX. and GFCI Circuit Breakers (ON)

12. The engine oil pressure gauge (Figure 49) will indicatethe oil pressure of the engine. Under normal operatingconditions the oil pressure is approximately

Figure 49. Oil Pressure Gauge

17. The generator will run until manually stopped or anabnormal condition occurs.


Normal Shut-down ProcedureTo shutdown the generator, use the following procedure:1. Switch the MAIN, AUX and GFCI circuit breakers

(Figure 54) to the OFF position (no load).

Figure 54. Main, AUX. and GFCI Circuit Breakers (OFF)

Emergency Shut-down Procedure1. To shut-down the engine in the event of an emergency,

switch the MAIN, GFCI and LOAD (Figure 54) circuitbreakers to OFF position.

2. Turn the ignition switch key to the STOP position(Figure 55).

3. Let the engine cool by running it for 3-5 minutes with noload applied (circuit breakers in the OFF position).

4. Place the ignition switch (Figure 55) in the STOP position,remove the key and store in a safe place.

Figure 55. Ignition Switch (Off Position)5. Remove all loads from the generator.6. Allow for sufficient time for cooling and then inspect

the complete unit for any damage or loosening thatmay have occured during operation.

7. Check the engine oil, coolant and fuel levels. Replenishas necessary.

DCA-45USI GENERATOR SHUT-DOWN PROCEDURE

Automatic Shut-down SystemWNThis unit is equipped with safety devices to automaticallystop the engine in the event of low oil pressure(approx. 14 PSI.), or high water temperature(approx. 221 F). The alarm lamps on the Engine ControlPanel (Figure 5) illuminate to signify the reason for theshut-down.

Engine protection is furnishedduring operation, but cannotreplace normal preventivemaintenance.

Regularly maintain the unit as specified in the Maintenancesection of this manual to prevent damage.

NOTE

CAUTION:After automatic shut-down, ALWAYS inspectthe unit and eliminate any problems beforeattempting to restart. Failure to do so candamage the unit.

Before inspecting, turn the starter switch to the STOPposition, place all Generator Circuit Breakers in the OFFposition and allow sufficient time for adequate cooling. Whenready to restart, complete all steps in the Generator StartupProcedure section of this manual.


DCA-45USI MAINTENANCEECNANETNIAM/NOITCEPSNI.41ELBAT srH01 YLIAD srH052 srH005 srH0001

ENIGNE

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Service DailyIf the engine is operating in very dusty or dry grassconditions, a clogged air cleaner will result. This can lead toa loss of power, excessive carbon buildup in the combustionchamber and high fuel consumption. Change air cleanermore frequently if these conditions exists.Fuel AdditionAdd diesel fuel (the grade may vary according to seasonand locations). Always pour through the mesh filter.Removing Water from the Fuel TankAfter prolonged use, water and other impurities accumulatein the bottom of the tank. Occasionally inspect the fuel tankfor 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 reducedby keeping the tank full with diesel fuel.

General InspectionPrior to each use, the generator should be cleaned andinspected for deficiencies. Check for loose, missing ordamaged nuts, bolts or other fasteners. Also check for fuel,oil, and coolant leaks.Engine Side (Refer to the Engine Instruction Manual)Air CleanerEvery 250 hours: Remove air cleaner element and clean theheavy duty paper element with light spray of compressedair. Replace the air cleaner as needed.

Air Cleaner with Dust IndicatorThis indicator is attached to the air cleaner. When the aircleaner element is clogged, air intake restriction becomesgreater and the dust indicator signal shows RED meaningthe element needs changing. After changing the air element,press the dust indicator button to reset the indicator.


DCA-45USI MAINTENANCE

Flushing Out Radiator and Replacing Coolantz Open both cocks located at the crankcase side and at

the lower part of the radiator and drain coolant. Open theradiator cap while draining. Remove the overflow tankand drain.

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

z Flush the radiator by running clean tap water throughradiator until signs of rust and dirt are removed. DO NOTclean radiator core with any objects, such as ascrewdriver.

z Tighten both cocks and replace the overflow tank.z Replace with coolant (Table 12 for correct mixture).z Close radiator cap tightly.Generator StorageFor longe term storage of the generator the following isrecommended: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 blocks so tires do not touch the ground or blockand completely remove the tires.

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:Allow engine to cool when flushing outradiator. Flushing the radiator while hot couldcause serious burnsfrom water or steam.

Air RemovalIf air enters the fuel injection system of a diesel engine,starting becomes impossible. After running out of fuel, orafter disassembling the fuel system, bleed the systemaccording to the following procedure.To restart after running out of fuel, turn the switch to the ONposition for 15-30 seconds. Try again, if needed. This unit isequipped with an automatic air bleeding system.Check Oil LevelCheck the crankcase oil level prior to each use, or when thefuel tank is filled. Insufficient oil may cause severe damageto the engine. Make sure the generator is level. The oil levelmust be between the two notches on the dipstick as shownin Figure 33.Replacing Oil Filter Remove the old oil filter. Apply a film of oil to the gasket on the new oil filter. Install the new oil filter. After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and checkfor leaks before adding more oil if needed. Cleanexcessive 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 mixedwater. DO NOT spill the fuel during disassembly.

Vent any air.


DCA-45USI TRAILER BRAKES MAINTENANCEHydraulic Surge BrakesHydraulic surge brakes (Figure 56) should not require anyspecial attention with the exception of routine maintenancesuch as shoe and lining replacement. Brake lines should beperiodically checked for cracks, kinks, or blockage.

Figure 56. Hydraulic Brake Components

Brake Adjustment1. 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 brakeshoes.

5. Adjust the brake shoes outward until the pressure of thelining against the wheel drum makes the wheel difficultto turn.

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

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

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

BrakesTrailer brakes should be inspected the first 200 miles ofoperation. This will allow the brake shoes and drums to seatproperly. After the first 200 mile interval, inspect the brakesevery 3,000 miles. If driving over rough terrain, inspect thebrakes more frequently.Figure 74 displays the major hydraulic surge brakecomponents that will require inspection and maintenance.Please inspect these components as required using steps1 through 8 as listed below:

ActuatorHydraulic surge braking requires the installation of an actuatorat the tongue of the trailer. Remember the surge or push ofthe trailer toward the tow vehicle automatically synchronizesthe trailer brakes with the tow vehicle brakes. As the trailerpushes against the tow vehicle the actuator telescopestogether and applies force to the master cylinder, supplyinghydraulic pressure to the trailer brakes.Periodically check and test the surge actuator to makesure that it is functioning correctly. Never use an undersizeactuator.

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DCA-45USI TRAILER MAINTENANCE

Tires/Wheels/Lug NutsTires and wheels are a very important and criticalcomponents of the trailer. When specifying or replacing thetrailer wheels it is important the wheels, tires, and axle areproperly matched.

CAUTION:DO NOT attemptto repair ormodify a wheel.DO NOT install ininner tube to correct a leak through the rim.

If the rim is cracked, the air pressure in the inner tube maycause pieces of the rim to explode (break off) with greatforce and cause serious eye or bodily injury.Tire Wear/InflationTire inflation pressure is the most important factor in tire life.Pressure should be checked cold before operation DO NOTbleed air from tires when they are hot!. Check inflationpressure weekly during use to insure the maximum tire lifeand tread wear.Table 16 (Tire Wear Troubleshooting) will help pinpoint thecauses and solutions of tire wear problems.

CAUTION:ALWAYS wear safety glasses when removing orinstalling force fitted parts. Failure to comply mayresult in serious injury.

SuspensionThe leaf suspension springs and associated components(Figure 57) should be visually inspected every 6,000 milesfor signs of excessive wear, elongation of bolt holes, andloosening of fasteners. Replace all damaged parts(suspension) immediately. Torqued suspension componentsas detailed in Table 17.

Figure 57. Major Suspension Components

WEAR PATTERN CAUSE SOLUTION

Center Wear Over Inflation.Adjust pressure toparticular load per tiremanufacturer.

Edge Wear Under Inflation.Adjust pressure toparticular load per tiremanufacturer.

Side Wear Loss of camberor overloading.

Make sure load doesnot exceed axle rating.Align wheels.

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance. Check bearing adjustmentand balance tires.

Flat Spots Wheel lockup &tire skidding.Avoid sudden stops whenpossible and adjust brakes.

TABLE 16 TIRE WEAR TROUBLESHOOTING

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SHACKLE BOLTSPRING EYE BOLT

SNUG FIT ONLY. PARTS MUST ROTATE FREELY.LOCKING NUTS OR COTTER PINS ARE PROVIDEDTO RETAIN NUT-BOLT ASSEMBLY.

SHOULDER TYPESHACKLE BOLT

05-XAM03-NIM


Lug Nut Torque RequirementsIt is extremely important to apply and maintain proper wheelmounting torque on the trailer. Be sure to use only thefasteners matched to the cone angle of the wheel. Properprocedure 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 58. DO NOT

torque the wheel lug nuts all the way down. Tighteneach lug nut in 3 separate passes as defined by Table 18.

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

NEVER use an pneumatic airgun to tighten wheel lug nuts.

Figure 58. Wheel Lug Nuts Tightening Sequence

DCA-45USI TRAILER MAINTENANCE

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NOTE


DCA-45USI TRAILER WIRING DIAGRAM

Figure 59. Trailer/Towing Vehicle Wiring Diagram


DCA-45USI ENGINE WIRING DIAGRAM

Figure 60. Engine Wiring Diagram


DCA-45USI ENGINE WIRING DIAGRAM

Figure 60. Engine Wiring Diagram(Continued)


DCA-45USI GENERATOR WIRING DIAGRAM

Figure 61. Generator Wiring Diagram


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

DCA-45USI TROUBLESHOOTING (GENERATOR)

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EXPLANATION OF CODE IN REMARKS COLUMNHow to read the marks and remarks used in this partsbook.

Items Found In the Remarks ColumnSerial Numbers-Where indicated, this indicates a serialnumber range (inclusive) where a particular part is used.Model Number-Where indicated, this shows that thecorresponding part is utilized only with this specific modelnumber or model number variant.

Items Found In the Items Number ColumnAll parts with same symbol in the number column,

*, #,

+,%, or


DCA-45USIw/ ISUZU BB-4JG1T

1 TO 3 UNITS

DCA-45USI SUGGESTED SPARE PARTS

Part number on this SuggestedSpare Parts list may supercede/replace the P/N shown in the textpages of this book.

NOTE

Qty. P/N Description3 ......... 8970497081 ..............OIL FILTER3 ......... 8943692993 ..............FUEL FILTER3 ......... 0602046681 ..............AIR ELEMENT1 ......... 0602122272 ..............UNIT, OIL PRESSURE1 ......... 0602123260 ..............UNIT WATER TEMPERATURE1 ......... 8972606490 ..............FAN BELT3 ......... 8944024980 ..............KEY, STARTER SWITCH1 ......... 0605505070 ..............CAP, FUEL TANK1 ......... 9827200690 ..............SENDER, OIL PRESSURE (ENGINE SIDE)1 ......... 8970785920 ..............SENDER, WATER TEMPERATURE (ENGINE SIDE)2 ......... 0601802149 ..............FUSE, 10A


DCA-45USI GENERATOR ASSY.GENERATOR ASSY.


GENERATOR ASSY.NO. PART NO. PART NAME QTY. REMARKS1 B3110100202 ROTOR ASSY. 11-1 FIELD ASSY. 11-2 8051070003 FAN 11-3 0010310035 HEX, HEAD BOLT 81-4 0042510000 SPRING WASHER 81-5 8041611004 COUPLING DISK 41-6 8041015003 BALANCING PLATE ............................................1 ............. PURCHASE SET OF 1-161-7 0010310025 HEX, HEAD BOLT 61-8 0042510000 SPRING WASHER 61-9 8001026013 SET PLATE, RECTIFIER BALANCING PLATE...1 ............. PURCHASE SET OF 1-161-10 0601821349 RECTIFIER .........................................................2 ............. PT36101-11 0601822601 SURGE ABSORBER ...........................................1 ............. ERZ-M14JK621A1-12 8001020004 INSULATOR WASHER 11-13 8001020504 INSULATOR WASHER 11-14 0010108020 HEX, HEAD BOLT 41-15 0040008000 SPRING WASHER 41-16 0601000209 BALANCING WEIGHT KIT 11-17 0071906310 BEARING ............................................................1 .......

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Generators Portable Ultrasilent DCA45USI Rev 2 Manual DataId 19073 Version 1

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