OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA45SSIU3
50HZ GENERATOR
(ISUZU BB-4JG1T DIESEL ENGINE)
PARTS LIST NO. M1870300904
Revision #2 (12/19/08)
To find the latest revision of this
publication, visit our website at:
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
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PROPOSITION 65 WARNING
Diesel engine exhaust and some of
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REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at
write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 3
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TABLE OF CONTENTS
DCA45SSIU3 Generator
Component Drawings
Proposition 65 Warning ........................................... 2
Reporting Safety Defects......................................... 3
Table of Contents..................................................... 4
Parts Ordering Procedures...................................... 5
Safety Information .............................................. 6-11
Specifications ........................................................ 12
Dimensions............................................................ 13
Installation ........................................................ 14-15
General Information............................................... 16
Major Components ................................................ 17
Generator Control Panel........................................ 18
Engine Operating Panel......................................... 20
Output Terminal Panel Familiarization .............. 22-24
Load Application.................................................... 25
Generator Outputs............................................ 26-27
Gauge Reading ..................................................... 27
Output Terminal Panel Connections ................. 28-29
Inspection/Setup............................................... 30-33
Generator Start-Up Procedure ......................... 34-35
Generator Shut-Down Procedures ........................ 36
Maintenance..................................................... 37-39
Trailer Maintenance .......................................... 40-43
Trailer Wiring Diagram ........................................... 44
Generator Wiring Diagram..................................... 45
Engine Wiring Diagram.......................................... 46
Troubleshooting (Generator).................................. 47
Explanation of Code in Remarks Column.............. 48
Suggested Spare Parts ......................................... 49
Generator Assy................................................. 50-51
Control Box Assy............................................... 52-53
Engine And Radiator Assy................................ 54-57
Output Terminal Assy........................................ 58-59
Engine Operating Panel Assy........................... 60-61
Battery Assy...................................................... 62-63
Muffler Assy...................................................... 64-65
Fuel Tank Assy. ................................................ 66-67
Enclosure Assy................................................. 68-71
Rubber Seals Assy............................................ 72-73
Nameplate and Decals Assy. ........................... 74-75
Terms and Conditions of Sale — Parts ................. 76
PAGE 4 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Effective:
January 1st, 2006
Order via Internet (Dealers Only)
Orderpartson-lineusingMultiquip’sSmartEquipwebsite!
:
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
Best Deal!
■
■
■
View Parts Diagrams
Order Parts
PrintSpecificationInformation
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Gotowww.multiquip.comandclickon
to log in and save!
Order Parts
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Order via Fax (Dealers Only)
:
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
1-800-427-1244
Order via Phone:
Non-Dealer Customers:
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
❒
Dealer Account Number
❒
Specify Preferred Method of Shipment:
✓
UPS/Fed Ex
✓ DHL
❒
Dealer Name and Address
■
■
Priority One
Ground
✓
Truck
❒
❒
❒
❒
Shipping Address (if different than billing address)
Return Fax Number
■ Next Day
Applicable Model Number
■
Second/ThirdDay
Quantity, Part Number and Description of Each Part
All orders are treated as Standard Orders
andwillshipthesamedayifreceivedprior
to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 5
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SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
SAFETY MESSAGES
The four 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 four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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SAFETY INFORMATION
GENERAL SAFETY
CAUTION
GENERATOR SAFETY
DANGER
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment requires an adequate free
flow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air
is restricted. If the air flow
is restricted it will cause
injury to people and property
and serious damage to the
equipment or engine.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the influence of
drugs or alcohol.
NEVER operate the equipment in an explosive
atmosphere or near combustible materials.An
explosion or fire could result causing severe
bodily harm or even death.
NOTICE
WARNING
This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death.Disconnection of any of these
devices will void all warranties.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NEVER use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
ALWAYS know the location of the nearest
fire extinguisher.
ALWAYS know the location of the nearest
first aid kit.
Fix damage to machine and replace any broken parts
immediately.
ALWAYS know the location of the nearest phone or
keep a phone on the job site. Also, know the phone
numbers of the nearest ambulance, doctor and fire
department. This information will be invaluable in the
case of an emergency.
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 and unauthorized personnel.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 7
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SAFETY INFORMATION
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied.When a diesel engine operates without
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
ENGINE SAFETY
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water will gush out
of the radiator and severely scald any persons in the
general area of the generator.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition.It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
DO NOT remove the coolant drain plug
while the engine is hot. Hot coolant will
gush out of the coolant tank and severely
scald any persons in the general area of
the generator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels.A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
CAUTION
NEVER touch the hot exhaust manifold,
muffler or cylinder.Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air filter or with a dirty air
filter.Severe engine damage may occur.Service air filter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
PAGE 8 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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SAFETY INFORMATION
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
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 refuel in a well-ventilated area, away from
sparks and open flames.
ALWAYS use extreme caution when working with
flammable liquids.
ALWAYS make sure the trailer is equipped with a safety
chain.
DO NOT fill the fuel tank while the engine is running
or hot.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.
DOT Requirements include the following:
• Connect and test electric brake operation.
NEVER use fuel as a cleaning agent.
• Secure portable power cables in cable tray with tie
wraps.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
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.
TOWING SAFETY
CAUTION
Avoid sudden stops and starts.This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
Check with your local county or state safety towing
regulations, in addition to meeting
Department of Transportation (DOT)
SafetyTowing Regulations, before towing
your generator.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Refer to MQ Power trailer manual for additional safety
information.
Place chock blocks underneath wheel to prevent rolling
while parked.
In order 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 mechanically sound and in good
operating condition.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
ALWAYS shutdown engine before transporting
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 9
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SAFETY INFORMATION
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
duringoperationcancauseelectrocution,
electrical shock or burn.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
The electrical voltage required to
operate the generator can cause severe injury or even
death through physical contact with live circuits. Turn
generator and all circuit breakers OFF before performing
maintenance on the generator or making contact with
output terminals.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) 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.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility
exists of electrical shock, electrocution
or death.
NEVER use gas piping as an electrical ground.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be performed by a
licensed electrician in accordance with all applicable
laws and electrical codes. Failure to do so could result
in electrical shock or burn, causing serious injury or
even death.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 10 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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SAFETY INFORMATION
BATTERY SAFETY
DANGER
ENVIRONMENTAL SAFETY
NOTICE
DO NOT drop the battery. There is a possibility that the
battery will explode.
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, fuel
and fuel filters.
DO NOT expose the battery to open flames,
sparks, cigarettes, etc.The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
DO NOT use food or plastic containers to dispose of
hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
WARNING
ALWAYS wear safety glasses when
handling the battery to avoid eye irritation.
The battery contains acids that can cause
injury to the eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ALWAYS recharge the battery in a well-ventilated
environmenttoavoidtheriskofadangerousconcentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 11
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SPECIFICATIONS
Table 1. Generator Specifications
DCA-45SSIU3
Model
Type
Revolving field, self ventilated,
open protected type synchronous generator
Armature Connection
Phase
Star with Neutral
3
Zigzag
Single
Standby Output
Prime Output
Voltage
37.8 KVA (30.0 kW)
36.1 kVA (28.8KW)
200 or 400V
23.1 KW
21 KW
100 or 200V
Frequency
50 Hz
Speed
1500 rpm
Aux. AC Power
Aux. Voltage/Output
Single Phase, 50 Hz
4.8 Kw (2.4 kW x 2)
Table 2. Engine Specifications
ISUZU BB-4JG1T
Model
Type
4 cycle, water-cooled, direct injection, turbo-charged
4 cylinders
No. of Cylinders
Bore x Stroke
Displacement
Starting
3.76 in. x 4.21 in. (95.4 mm x 107 mm)
187 cu. in. (3,059 cc)
Electric
Coolant Capacity
Lube Oil Capacity
Fuel Type
3.60 gal. (13.7 liters)
2.64 gal. (10.0 liters)
#2 Diesel Fuel
Fuel Tank Capacity
Fuel Consumption
Battery
26.4 gal. (100 liters)
2.8 gal. (10.6 L)/hr at full load
27V-(CCA 0° F 700A) x 1
PAGE 12 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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DIMENSIONS
Figure 1. Dimensions
Table 3. Dimensions
Reference
Letter
Dimension in. (mm)
Reference Letter
Dimension in. (mm)
A
B
C
D
30.31 in. (770 mm.)
25.00 in. (635 mm.)
29.05 in. (738 mm.)
24.21 in. (615 mm.)
F
G
H
74.80 in. (1,900 mm.)
49.21 in. (1,250 mm.)
35.43 in. (900 mm.)
E
29.05 in. (945 mm.)
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 13
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INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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INSTALLATION
OUTDOOR INSTALLATION
GENERATOR GROUNDING
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.
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 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.
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.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
CAUTION
Pay close attention to ventilation when operating the
generator inside tunnels and caves.The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.
2. When grounding the generator (Figure 2) 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 a minimum of 8 ft. into the ground.
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.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
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.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 15
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GENERAL INFORMATION
GENERATOR
OPEN DELTA EXCITATION SYSTEM
The MQ Power Model DCA45SSIU3 generator (Figure 3) is
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.
The DCA45SSIU3 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.
ENGINE OPERATING PANEL
The “Engine Operating Panel” is provided with the following:
Tachometer
Water Temperature Gauge
Water Temperature Alarm Lamp
Oil Pressure Gauge
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.
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)
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.
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
ENGINE
The DCA45SSIU3 is powered by a 4 cylinder, water cooled,
direct injection, turbocharged ISUZU BB4JG1T diesel
engine.This engine is designed to meet every performance
requirement for the generator.ReferenceTable 2 for engine
specifications.
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
• Over-Current Relay
• Starter Relay
• Voltage Selector Switch
ELECTRIC GOVERNOR SYSTEM
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
Three 100/200V output receptacles (CS-6369), 50A
Three auxiliary circuit breakers, 50A
Two 100V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Five output terminal lugs (3Ø power)
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to .25%.
EXTENSION CABLES
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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MAJOR COMPONENTS
Table 4. Generator Major Components
ITEM NO.
DESCRIPTION
Output Terminal Panel Assembly
Output Receptacles Assembly
Air Filter Assembly
1
2
3
4
Muffler Assembly
5
Fuel Tank Assembly
6
Engine Assembly
7
Battery Assembly
8
Generator Assembly
9
Engine Operating Panel Assembly
Generator Control Panel Assembly
10
Figure 3. Major Components
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 17
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GENERATOR CONTROL PANEL
Figure 4. Generator Control Panel
The definitions below describe the controls and functions
of the DCA45SSIU3 Generator Control Panel (Figure 4).
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.
1. Main Circuit Breaker—This three-pole, 110A main
breaker is provided to protect the the U,V, and W
Output Terminal Lugs from overload.
The Control Box is equipped with the following major
components:
2. Voltage Regulator Control — Allows 15% manual
adjustment of the generator’s output voltage.
Over-Current Relay
3. Frequency Meter — Indicates the output frequency
in hertz (Hz). Normally 50 Hz.
Automatic Voltage Regulator (AVR)
Starter Relay
4. AC Ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected
by the ammeter phase-selector switch.
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
5. ACVoltmeter — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
NOTICE
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.
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 110 amp main breaker.
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.
To restore power to the OutputTerminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
PAGE 18 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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NOTES
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 19
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ENGINE OPERATING PANEL
Figure 5. Engine Operating Panel
The definitions below describe the controls and functions of
the DCA-45SSIU3 Engine Operating Panel (Figure 5).
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.
1. Panel Light — Normally used in dark areas or at night
time.When activated, panel lights will illuminate.When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
9. Fuel Gauge — Indicates amount of diesel fuel
available.
2. Panel Light Switch — When activated will turn on
control panel light.
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.
3. Oil Pressure Alarm Lamp — Indicates that the oil
pressure is too low or high. Engine will shut down.
4. WaterTemperature Alarm Lamp — Indicates that the
water temperature is outside of the normal operating
range. Engine will shut down.
11. WaterTemperature Gauge — During normal operation
this gauge be should read between 167°~203°F (75°
~95°C
5. WaterTemperature Alarm Lamp — Indicates that the
water level in the fuel has risen. Drain the water in the
fuel filter strainer when this condition occurs.
12. Oil Pressure Gauge — During normal operation this
gauge should read between 42 ~71 psi.(290~490 kPa).
When starting the generator the oil pressure may read
a little higher, but after the engine warms up the oil
pressure should return to the correct pressure range.
6. Ignition Switch — Three position switch, stop,
operation and start. Insert key to start and stop
engine.
7. Pre-Heat Lamp — As the engine cranks, this lamp
will illuminate to indicate automatic preheating of
the engine glow plugs. When the lamp turns off, this
indicates that the preheat cycle is complte and the
engine will start automatically.
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NOTES
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 21
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OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
OUTPUT TERMINAL FAMILIARIZATION
The Output Terminal Panel (Figure 6) 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.
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
Three 100/200V output receptacles @ 50 amp
Three Circuit Breakers @ 50 amps
NOTICE
Two 100V GFCI receptacles @ 20 amp
Two GFCI Circuit Breakers @ 20 amps
Five Output Terminal Lugs ( U, V, W, O, Ground)
Terminal legs “O”and “Ground”are considered bonded
grounds.
Figure 6. Output Terminal Panel
PAGE 22 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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OUTPUT TERMINAL PANEL FAMILIARIZATION
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.
100 VAC GFCI Receptacles
There are two 100 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.
Turn the voltage regulator control knob (Figure 9) on the
control panel to obtain the desired voltage.Turning the knob
clockwise will increase the voltage, turning the knob
counter-clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 7) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 9. Voltage Regulator Control Knob
Figure 7. G.F.C.I. Receptacle
Twist Lock Dual Voltage 100/200 VAC Receptacles
There are three 100/200V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 8) provided on the output
terminal panel. These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.
Figure 8. 100/200V Twist-Lock Auxiliary
Receptacles
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 23
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OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Over Current Relay
Loads can be connected to the generator by the Output
Terminal Lugs or the convenience receptacles (Figure 10).
Make sure to read the operation manual before attempting
to connect a load to the generator.
An over current relay (Figure 11) 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.
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.
Figure 11. Over Current Relay
Figure 10. Connecting Loads
PAGE 24 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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LOAD APPLICATION
SINGLE PHASE LOAD
THREE 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.
When calculating the power requirements for 3-phase
power use the following equation:
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.
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
WATTS = VOLTAGE x AMPERAGE
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.
The power factor of this generator is 0.8.SeeTable 5 below
when connecting loads.
Table 5. Power Factor By Load
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.
Type of Load
Power Factor
Single-phase induction motors
0.4-0.75
Electric heaters, incandescent lamps
Fluorescent lamps, mercury lamps
1.0
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.
0.4-0.9
Electronic devices, communication
equipment
1.0
0.8
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Common power tools
Table 6. Cable Selection (60 Hz, Single Phase Operation)
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Load in Watts
Maximum Allowable Cable Length
Current
in
Amperes
At 100
Volts
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
DANGER
2.5
5
300
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
600
1200
1800
2400
3600
4800
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.
7.5
10
15
20
900
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 25
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GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES
Maximum Amps
A wide range of voltages are available to supply voltage for
many different applications.Voltages are selected by using
the voltage selector switch (Figure 12).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.
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed..
Table 8. Generator Maximum Amps
Rated Voltage
Maximum Amps
98 amps (4 wire)
48 amps (4 wire)
104 amps
Single Phase 100 Volt
Single Phase 200 Volt
Three Phase 200 Volt
Three Phase 400 Volt
Voltage Selector Switch
The voltage selector switch (Figure 12) is located above
the output terminal panel’s Hard Wire Hook-up Panel. It
has been provided for ease of voltage selection.
52 amps
Figure 12. Voltage Change-Over Board
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and load from being switched while the
engine is running.To lock the voltage selector switch, press
and hold the red button located at the bottom of the switch.
CAUTION
NEVER change the position of the voltage selector
switch while the engine is running. ALWAYS place
circuit breaker in the OFF position before selecting
voltage.
Table 7. Voltages Available
Three Phase
(Switchable)
200V
220V
416V
440V
254V
Single Phase
(Switchable)
115V
127V
240V
PAGE 26 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE OUTPUT TERMINAL GAUGE
Reading Amperage
To determine the amperage at a terminal lug, set the AC
Ammeter Change-Over Switch to the appropriate setting
(Figure 16) to activate the AC Ammeter Gauge (Figure 17)
and read the available amperage at the terminal lug.
The AC ammeter and AC voltmeter change-over switches
on the control panel DO NOT effect the generator output.
They are provided to help observe how much power is being
supplied, produced at the UVWO terminals lugs.
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.
Before taking a reading from either gauge, set the Voltage
Selector Switch (Figure 13) to the position which produces
the required voltage (For example, for 3Ø 200V, choose
the center 3Ø 240/139V position on the voltage selector
switch.)
Figure 17. AC Ammeter
(Amp Reading on U Lug)
Figure 16. AC Ammeter
Change-Over Switch
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
Figure 13. Voltage Selector Switch
240/139V 3Ø Positio
NOTICE
For 3Ø 200V/1Ø,115V, place the Voltage Selector
Switch in the 3 Phase 340/139 position.
Reading Voltage
To determine the voltage between two terminal lugs, set
the ACVoltmeter Change-Over Switch to the appropriate
setting (Figure 14) to activate the AC Voltmeter Gauge
(Figure 15) and read the available voltage between the
two lugs.
For example, to measure the voltage between the W and U
terminal lugs, set the ACVoltmeter Change-Over Switch
to W-U and read the AC Voltmeter Gauge.
Figure 14. AC Voltmeter
Change-Over Switch
Figure 15. AC Voltmeter
Gauge
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 27
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OUTPUT TERMINAL PANEL CONNECTIONS
3. Turn the voltage regulator knob (Figure 20) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
UVWO TERMINAL OUTPUT VOLTAGES
Various output voltages can be obtained using the UVWO
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.
Figure 20. Voltage Regulator Knob
3Ø-200V/1Ø-115V UVWO Terminal Output Voltages
3Ø-220/127 UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 21.
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 18..
Figure 21. Voltage Selector Switch
3Ø-240/139V Position
Figure 18. Voltage Selector Switch
3Ø-240/139V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 22.
2. Connect the load wires to the UVWO terminals as
shown in Figure 19.
Figure 22. UVWO Terminal Lugs
3Ø-200/1Ø-115V Connections Connections
NOTICE
To achieve a 3Ø 200V output the voltage selector switch
must be in the 3Ø-240/139 position and the voltage
regulator must be adjusted to 200V..
Figure 19. UVWO Terminal Lugs
3Ø-220/127V Connections
PAGE 28 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-440/254V UVWO Terminal Output Voltages
1Ø-200/100V UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 23.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 25.
Figure 23. Voltage Selector Switch
3Ø-480/277V Position
Figure 25. Voltage Selector Switch
1Ø-240/120V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 24.
2. Connect the load wires to the UVWO terminals as
shown in Figure 26.
Figure 24. UVWO Terminal Lugs
3Ø-440/254V Connections
Figure 26. UVWO Terminal Lugs
1Ø-200/100V Connections
3. Turn the voltage regulator knob (Figure 20) clockwise
to increase voltage output, turn counterclockwise
to decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
3. Turn the voltage regulator knob (Figure 20) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
NOTICE
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight.The possibility of arcing
exists, that could cause a fire.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 29
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INSPECTION/SETUP
CIRCUIT BREAKERS
FUEL CHECK
DANGER
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.Three 50 amp
load circuit breakers have also been provided to protect the
auxiliary receptacles from overload. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
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
LUBRICATION OIL
CAUTION
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 27) on the dipstick. See Table 11 for
proper selection of engine oil.
ONLY properly trained personnel who have read
and understand this section should refill the fuel tank
system.
This generator has an internal fuel tank located inside
the trailer frame and may also be equipped with an
environmental fuel tank (Figure 28). ALWAYS fill the fuel
tanks with clean fresh #2 diesel fuel. DO NOT fill the fuel
tanks beyond their capacities.
Figure 27. Engine Oil Dipstick
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.
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
Table 9. Recommended Motor Oil
Figure 28. Internal Fuel Tank System
PAGE 30 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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INSPECTION/SETUP
2. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel
cap and fill tank (Figure 30).
Refueling Procedure:
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. LevelTanks — 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 29).
CAUTION
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 30. 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 31).
Figure 29. Only Fill on Level Ground
Figure 31. Full Fuel Tank
NOTICE
CAUTION
ONLY use #2 diesel fuel when refueling.
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 32).
Figure 32. Fuel Expansion
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 31
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INSPECTION/SETUP
COOLANT (ANTIFREEZE/SUMMER COOLANT/
WATER)
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.
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.
AIR CLEANER
WARNING
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.
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.
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.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 33) when depressed with the thumb as shown
below.
Table 10. Coolant Capacity
Engine and Radiator
Reserve Tank
2.88 gal (10.9 liters)
2 quarts (1.9 liters)
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Figure 33. Fan Belt Tension
CAUTION
Table 11. Anti-Freeze
Operating Temperatures
NEVER place hands near the belts or fan
while the generator set is running.
Freezing Point
Vol %
Anti-Freeze
°C
°F
50
-37
-34
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
PAGE 32 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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INSPECTION/SETUP
When connecting battery do the following:
BATTERY
1. NEVER connect the battery cables to the battery
terminals when the MPEC Control Switch is in either
the MANUAL position. ALWAYS make sure that the
MPEC Control Switch is in the OFF/RESET position
when connecting the 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.
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.
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.
NOTICE
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.
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.
CAUTION
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 34) 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.
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.
CAUTION
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrosion and damage the
alternator.
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
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.
Figure 34. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 33
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GENERATOR START-UP PROCEDURE
BEFORE STARTING
CAUTION
STARTING
1. Place the voltage selector switch in the desired
voltage position (Figure 37)..
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING
NEVER manually start the engine with the main,GFCI or
auxiliary circuit breakers in the ON (closed) position.
1. Place the main,G.F.C.I.,and aux. circuit breakers (Figure
35) in the OFF position prior to starting the engine.
Figure 37. Voltage Selector Switch
2. Preheat the engine glow plugs by turning the ignition
key (Figure 38) to the “OPERATION” position.
Figure 35. Main, Aux. and GFCI
Circuit Breakers (OFF)
Figure 38. Ignition Switch
(Operation/PreHeat Position)
2. Make sure the voltage change-over board has been
configured for the desired output voltage.
3. When the preheat lamp illuminates (Figure 39), 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 38).
3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 10. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
4. Tighten terminal nuts securely to prevent load wires
from slipping out.
5. Close all engine enclosure doors (Figure 36).
Figure 39. Pre-Heat Lamp
4. 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.
CORRECT
Figure 36. Engine Enclosure Doors
PAGE 34 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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GENERATOR START-UP PROCEDURE
5. he generator’s frequency meter (Figure 40) should be
displaying the 50 cycle output frequency in HERTZ.
9. The coolant temperature gauge (Figure 45) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 167°~203°F (75°~95°C) (Green Zone).
Figure 40. Frequency Meter
6. The generator’s AC-voltmeter (Figure 41) will display
the generator’s output in VOLTS. If the voltage is not
within the specified tolerance, use the voltage
adjustment control knob (Figure 42) to increase or
decrease the desired voltage.
Figure 45. Coolant Temperature Gauge
10. The tachometer gauge (Figure 46) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1500 RPM’s.
Figure 41. Voltmeter
Figure 46. Engine Tachometer Gauge
11. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 47).
Figure 42. Voltage Adjust Control Knob
7. The ammeter (Figure 43) will indicate zero amps with
no load applied. When a load is applied, the ammeter
will indicate the amount of current that the load is
drawing from the generator.
Figure 47. Main, Aux. and GFCI
Circuit Breakers (ON)
12. Observe the generator’s ammeter (Figure 48) and
verify it reads the anticipated amount of current with
respect to the load. The ammeter will only display a
current reading if a load is in use.
Figure 43. Ammeter (No Load)
8. The engine oil pressure gauge (Figure 44) will indicate
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 42 to 71
psi. (290~490 kPa).
Figure 48. Ammeter (Load)
13. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 44. Oil Pressure Gauge
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 35
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GENERATOR SHUT-DOWN PROCEDURES
EMERGENCY SHUTDOWN PROCEDURE
WARNING
1. Place the MAIN, GFCI and LOAD (Figure 51) circuit
breakers to “OFF” position.
NEVER stop the engine suddenly except in an
emergency.
2. Turn the ignition switch key to the “STOP” position.
NORMAL SHUTDOWN PROCEDURE
To shutdown the generator, use the following procedure:
1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 49 to the OFF position..
Figure 51. Ignition Switch (Emergency)
Figure 49. Main, GFCI and Load
Circuit Breakers Off
2. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
3. Place the ignition switch (Figure 50) in the “STOP”
position, remove the key and store in a safe place.
Figure 50. Ignition Switch (Normal)
4. Remove all loads from the generator.
5. Inspect entire generator for any damage or loosening
of components that may have occurred during
operation.
PAGE 36 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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MAINTENANCE
10 Hrs
DAILY
1000
Hrs
Table 12. Inspection/Maintenance
250 Hrs 500 Hrs
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Replace Engine Oil and Filter * 1
Clean Air Filter
X
X
Engine
Check Fuel Filter/Water Separator Bowl
Clean Unit, Inside and Outside
Change Fuel Filter
Clean Radiator and Check Coolant Protection Level*2
Replace Air Filter Element * 3
Check all Hoses and Clamps * 4
Clean Inside of Fuel Tank
X
X
X
X
X
X
X
Measure Insulation Resistance Over 3M ohms
X
Generator
Check Rotor Rear Support Bearing
Replace engine oil and filter at 100 hours, first time only.
X
1
*
2
*
Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
3
*
4
*
with no sags or dips that could collect moisture and/or oil.
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 12 as a general
maintenance guideline Engine Side (Refer to the Engine
Instruction Manual)
AIR CLEANER
Every 250 hours: Remove air cleaner element (Figure 52)
and clean the heavy duty paper element with light spray of
compressed air. Replace the air cleaner as needed.
Figure 52. Air Cleaner/Indicator
NOTICE
Air Cleaner with Dust Indicator
The air filter should not be changed until the indicator
reads “RED”. Dispose of old air filter. It may not be
cleaned or reused.
This indicator (Figure 52) 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.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 37
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MAINTENANCE
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 TANK INSPECTION
In addition to cleaning the fuel tank, the following
components should be inspected for wear:
Rubber Suspension — look for signs of wear or
deformity due to contact with oil. Replace the rubber
suspension if necessary.
FUEL ADDITION
Add diesel fuel (the grade may vary according to season
and locations).
Fuel Hoses — inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
Removing Water from the Fuel Tank
FuelTank Lining — inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
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.
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 500
hours or so.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
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.
Cleaning Inside the Fuel Tank
Vent any air
If necessary, drain the fuel inside the fuel tank completely.
Using a spray washer (Figure 53) wash out any deposits
or debris that have accumulated inside the fuel tank.
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. See the ISUZU
Engine Manual for details.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed.
Figure 53. Fuel Tank Cleaning
PAGE 38 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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MAINTENANCE
CHECK OIL LEVEL
RADIATOR CLEANING
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 27.
The radiator (Figure 54) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fins or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fins and tube.
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 check for
leaks before adding more oil if needed. Clean excessive
oil from engine.
FLUSHING OUT RADIATOR AND REPLACING
COOLANT
Figure 54. Radiator Cleaning
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.
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Drain the fuel tank completely.Treat with a fuel stabilizer
if necessary.
Tighten both cocks and replace the overflow tank.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Replace with coolant as recommended by the engine
manufacturer.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Close radiator cap tightly.
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.
Make sure engine coolant is at proper level.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
WARNING
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 39
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TRAILER MAINTENANCE
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.
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.
9. Tire Ply — The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
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.
The definitions below describe some of the major
components of a typical trailer that would be used with
generator.
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 16 and Figure 57 for lug nut
tightening and sequence.
1. Fuel Cell — Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
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.
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).
14. Suspension — Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
4. Frame Length — Measurement is from the ball hitch
to the rear bumper (reflector).
5. Frame Width — Measurement is from fender to
fender
15. Electrical — Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
6. Jack Stand — Trailer support device with maximum
pound requirement from the tongue of the trailer.
16. Application — Indicates which units can be employed
on a particular trailer.
7. Coupler — Type of hitch used on the trailer for
towing.
PAGE 40 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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TRAILER MAINTENANCE
BRAKES
Hydraulic Surge 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.
Hydraulic surge brakes (Figure 55) 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 55 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 13 as listed 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.
Figure 55. Hydraulic Brake Components
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
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.
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.
Periodicallycheckandtestthesurge“actuator”tomakesurethat
it is functioning correctly. Never use an undersize actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 13. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Repair or replace.
Reburnish or replace.
Correct weight.
Trailer overloaded?
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or
broken?
Replace components.
Locking Brakes
Noisy Brakes
Brake drums out-of-round?
System lubricated?
Replace.
Lubricate.
Brake components correct?
Replace and correct.
Install new shoes and
linings.
Brake lining thickness incorrect or
not adjusted correctly?
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 41
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TRAILER MAINTENANCE
TIRES/WHEELS/LUG NUTS
Suspension
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.
The leaf suspension springs and associated components
(Figure 56) 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 13.
CAUTION
ALWAYS wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim is
cracked, the air pressure in the inner tube
may cause pieces of the rim to explode (break off) with
great force and cause serious eye or bodily injury.
Figure 56. Major Suspension Components
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 15. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
Min-30 Max-35
Min-45 Max-60
Min-45 Max-60
3/8" U-Bolt
7/16" U-Bolt
1/2" U-Bolt
Table 14 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Snug fit only. Parts must rotate freely.
Locking nuts or cotter pins are
Shackle Bolt
Spring Eye Bolt
Table 14. Tire Wear Troubleshooting
provided to retain nut-bolt assembly.
Wear Pattern
Cause
Solution
Shoulder Type
Shackle Bolt
Min-30 Max-50
Adjust pressure to particular
load per tire manufacturer.
Center Wear Over inflation.
Edge Wear Under inflation.
Adjust pressure to particular
load per tire manufacturer.
Make sure load does not
exceed axle rating.
Align wheels.
Loss of camber
Side Wear
or overloading.
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
Check bearing adjustment
and balance tires.
Wheel lockup and Avoid sudden stops when
tire skidding. possible and adjust brakes.
Flat Spots
PAGE 42 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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TRAILER MAINTENANCE
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 57). DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defined
by Table 16.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 16. Tire Torque Requirements
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
Wheel Size
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 57. Wheel Lug Nuts
Tightening Sequence
NOTICE
NEVER use an pneumatic air gun to tighten wheel
lug nuts.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 43
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TRAILER WIRING DIAGRAM
Figure 58. Trailer/Towing Vehicle Wiring Diagram
PAGE 44 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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GENERATOR WIRING DIAGRAM
Figure 59. Generator Wiring Diagram
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 45
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ENGINE WIRING DIAGRAM
Figure 60. Engine Wiring Diagram
PAGE 46 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 17 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business office or service plant.
Table 17. Generator Troubleshooting
Symptom
Possible Problem
AC Voltmeter defective?
Is wiring connection loose?
Is AVR defective?
Solution
Check output voltage using a voltmeter.
Check wiring and repair.
No Voltage Output
Replace if necessary.
Defective Rotating Rectifier? Check and replace.
Defective Exciter Field?
Is engine speed correct?
Check for approximately 17.3 ohms across J & K on CN1
Turn engine throttle lever to “High”.
Low Voltage Output
High Voltage Output
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
Defective AVR?
Replace if necessary.
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Circuit Breaker Tripped
Defective circuit breaker?
Over current Relay actuated? Confirm load requirement and replace.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 47
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EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
QTY. Column
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.
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.
The contents and part numbers listed in the parts section are
subject to change without notice. Multiquip does not
guarantee the availability of the parts listed.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Sample Parts List:
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.
NO. PART NO. PART NAME
QTY. REMARKS
1
2
2
3
4
12345
BOLT ...................... 1 ......INCLUDES ITEMS W/
WASHER, 1/4 IN. .............NOT SOLD SEPARATELY
WASHER, 3/8 IN. ... 1 ......MQ-45T ONLY
HOSE ................... A/R ....MAKE LOCALLY
BEARING ............... 1 ......S/N2345B AND ABOVE
*
*
*
12347
12348
12349
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)”
NO. Column
Unique Symbols - All items with same unique symbol
Serial Number Break - Used to list an effective serial
number range where a particular part is used.
( , #,
+
, %, or >) in the number column belong to the same
*
assembly or kit, which is indicated by a note in the “Remarks”
column.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXXTO S/N XXX”
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.
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.
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.
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.
PART NO. Column
Numbers Used - Part numbers can be indicated by a
number, a blank entry, orTBD.
“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.
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.
PAGE 48 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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SUGGESTED SPARE PARTS
DCA45SSIU3 WHISPERWATT GENERATOR WITH
ISUZU BB-4JG1T DIESEL 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)
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 49
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GENERATOR ASSY.
PAGE 50 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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GENERATOR ASSY.
NO.
1
1-1*
PART NO.
B3110100202
PART NAME
ROTOR ASSY
FIELD ASSY
FAN
HEX, HEAD BOLT
WASHER, LOCK
COUPLING DISK
QTY.
REMARKS
1
1
1
8
8
4
1-2* 8051070003
1-3* 0010310035
1-4* 0042510000
1-5* 8041611004
1-6* 8041015003
1-7* 0010310025
1-8* 0042510000
1-9* 8001026013
1-10* 0601821349
1-11* 0601822601
1-12* 8001020004
1-13* 8001020504
1-14* 0010108020
1-15* 0040008000
1-16* 0601000209
1-17* 0071906310
BALANCING PLATE....................................1 ................PURCHASE SET OF 1-16
HEX, HEAD BOLT
WASHER, LOCK
SET PLATE, RECTIFIER BAL. PLATE........1 ................PURCHASE SET OF 1-16
RECTIFIER .................................................2 ................PT3610
SURGE ABSORBER...................................1 ................ERZ-M14JK621A
INSULATOR WASHER
INSULATOR WASHER
HEX, HEAD BOLT
6
6
1
1
4
4
1
WASHER, LOCK
BALANCING WEIGHT KIT
BEARING ....................................................1 ................6310DDU C3
2
3
4
4-1
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
25A
25B
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
COUPLING RING
HEX, HEAD BOLT
STATOR ASSY ............................................1 ................B3135100104
1
6
GROMMET
2
1
8
1
1
4
4
4
6
1
1
4
1
4
1
2
2
6
1
1
2
2
2
2
COUPLING ADAPTER
HEX, HEAD BOLT
END BRACKET
FIELD ASSY EXCITER
HEX, HEAD BOLT
WASHER, LOCK
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
WASHER, LOCK
WASHER, FLAT
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 51
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CONTROL BOX ASSY.
PAGE 52 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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CONTROL BOX ASSY.
NO.
1
2
2-1
3
4
5
6
7
8
PART NO.
PART NAME
CONTROL BOX
QTY.
REMARKS
M1213000802
0601870431
0601870490
0021004040
0601823863
0027104016
0601820671
0027105016
0601806116
0027106016
0601820847
0027120848
0027104016
0207004000
0330000200
M1213500303
0016906016
M1923100004
47130106
M1213600114
0330000160
0027103010
0016906016
M1213600014
0016906016
0016906016
0040506000
M1223000503
0601807641
0601808986
0601801040
0601806859
0601801041
0601840073
0601840121
M1223100004
0027105010
0027105010
M9220100004
0080200007
8971119621
8972465100
0016906020
1825530401
5825500290
0016906016
M1246702604
1
CIRCUIT BREAKER....................................1 ................FG3110WS02 3P 110A
COVER, CIRCUIT BREAKER
MACHINE SCREW
2
4
RELAY UNIT................................................2 ................MSA9013A
MACHINE SCREW
AUTOMATIC VOLTAGE REGULATOR ........1 ................NTA-5A-2DB
MACHINE SCREW
CURRENT TRANSFORMER ......................3 ................812-943 75/5A
MACHINE SCREW
OVER CURRENT RELAY ...........................1 ................TA25DU 4.0
OVER CURRENT RELAY ...........................1 ................DB25/25A
MACHINE SCREW
HEX NUT
EDGING
4
4
9
6
10
11
12
12A
13
14
15
16
16A
17
18
19
20
21
22
23
23A
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
2
2
1
1
4
CONTROL BOX COVER
HEX HEAD BOLT
SELECTOR SWITCH..................................1 ................VY-40
KNOB. SELECTOR SWITCH
SWITCH BRACKET
EDGING
MACHINE SCREW
HEX HEAD BOLT
SWITCH COVER
HEX HEAD BOLT
HEX HEAD BOLT
TOOTHED WASHER
CONTROL PANEL
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 W
1
1
2
4
4
1
4
8
1
1
KNOB
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
SNAP RING
1
1
2
4
1
1
EMERGENCY RELAY.................................1 ................REPLACES P/N 0602200432
PREHEAT CONTROLLER ..........................1 ................REPLACES P/N 0602202506
HEX HEAD BOLT
SAFETY RELAY..........................................1 ................REPLACES P/N 0602200304
RELAY.........................................................1 ................REPLACES P/N 0602201400
HEX HEAD BOLT
WIRE HARNESS, GENERATOR
3
3
1
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 53
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ENGINE AND RADIATOR ASSY.
PAGE 54 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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ENGINE AND RADIATOR ASSY.
NO.
1
1-1
2
3
4
5
6
6-1
6-2
7
PART NO.
PART NAME
QTY.
REMARKS
M1923200054
8970497081
0605000048
0030010000
0040010000
0041210000
M1923200064
0602011053
M1493105204
0016908040
M1310501003
M1310501103
0605515147
M1310300903
0016908020
M1310300504
M1310300604
0016908020
0602046585
0602046366
0602040651
0602040557
0016908030
M1373100703
M1373100603
0605515148
0605515200
0602022560
M1320300304
0602022561
0603306590
0603300285
0605511395
0603306395
0602021070
0269200450
M2320300103
M9200200004
ENGINE.......................................................1 ................ISUZU BB-4JG1T PD-04
CARTRIDGE, OIL FILTER ..........................1 ................REPLACES P/N 0602041214
RUBBER SUSPENSION
HEX NUT
SPRING WASHER
PLAIN WASHER
RADIATOR ..................................................1 ................232000-2620
CAP, RADIATOR..........................................1 ................16401-1450A
ACOUSTIC SHEET
HEX HEAD BOLT
RADIATOR HOSE
RADIATOR HOSE
HOSE BAND
2
2
2
2
2
6
1
1
4
1
4
1
1
6
8
9
10
11
12
13
14
15
16
16A
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
FAN SHROUD
HEX HEAD BOLT
FAN GUARD
FAN GUARD
HEX HEAD BOLT
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
HOSE, AIR CLEANER
HOSE, AIR CLEANER
HOSE BAND
HOSE BAND
ADAPTER
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
PACKING
90 DEGREE ELBOW
CONNECTOR
ROCKNUT
VALVE
HOSE JOINT
CAP
DRAIN HOSE
DRAIN JOINT
PLUG
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 55
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ENGINE AND RADIATOR ASSY. (CONTINUED)
PAGE 56 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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ENGINE AND RADIATOR ASSY. (CONTINUED)
NO.
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
PART NO.
PART NAME
O RING
QTY.
1
2
1
2
1
1
1
1
1
1
1
2
2
2
1
1
REMARKS
0150000018
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
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
DRAIN HOSE
BLOWBY HOSE
HOSE BAND
CLAMP
HEX HEAD BOLT
PICK UP, TACHOMETER
SENDER, OIL SWITCH ..............................1 ................REPLACES P/N 0602122281
ADAPTER
UNIT, WATER TEMPERATURE...................1 ................02094-00
PACKING.....................................................1 ................REPLACES P/N 0602021109
ENGINE STOPPER.....................................1 ................REPLACES P/N 0602210810
BRACKET, ENGINE STOPPER
MACHINE SCREW
HEX HEAD BOLT
1
1
1
1
1
1
3
2
FAN BELT....................................................1 ................REPLACES P/N 0602011432
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 57
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OUTPUT TERMINAL ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
3-SPECTRUM GREY
4-SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 58 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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OUTPUT TERMINAL ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
5
REMARKS
M1230700103
M9220100204
M9220100104
0039310000
0040010000
0041410000
0016908025
M1236100613
M1236100704
0605010040
0027103010
0030003000
0041203000
0027103010
0030003000
0016906020
0016906016
M1236400004
M1236300004
0016906020
0601870440
0601870441
M1260700504
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE BOLT
5
HEX NUT
10
15
20
5
1
1
2
4
4
4
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 1
HEX HEAD BOLT
CIRCUIT BREAKER....................................2 ................QCF 1020 1P 20A
CIRCUIT BREAKER....................................3 ................QCF 2050 2P 50A
BREAKER FITTING COVER
CUSHION RUBBER
HEX HEAD BOLT
RECEPTACLE.............................................2 ................GF-530EM 125V 20AX2
RECEPTACLE.............................................2 ................CS6369 250V 50A
MACHINE SCREW
HEX NUT
TERMINAL COVER
HEX HEAD BOLT
PLAIN WASHER
STAY RUBBER
HEX NUT
9
10
11
11A
11B
12
12A
13
14
15
16
17
18
19
20
4
4
2
4
1
6
1
2
2
20-1 0222100100
21
22
23
24
2A
25
26
27
28
29
0016906020
0601812598
0601812538
0027104016
0207004000
M1236100803
0010112045
0041212000
M9310200004
0030012000
10
10
1
2
2
2
2
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 59
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ENGINE OPERATING PANEL ASSY.
PAGE 60 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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ENGINE OPERATING PANEL ASSY.
NO.
1
PART NO.
8970444180
PART NAME
QTY.
REMARKS
STARTER SWITCH.....................................1 ................REPLACES P/N 0602100009
.......................................................................................INCLUDES ITEM W/*
1A*
2
2A#
3
4
5
6
7
8
8A+
9
8944024980
0602103092
0601810245
0602120095
0602122093
0602123090
0602121080
0602125090
0602103092
0601810245
9826800370
0601831330
M1357201302
0602122272
1518183040
KEYS, IGNITION SWITCH
PREHEAT LAMP.........................................1 ................INCLUDES ITEM W/#
1
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
PANEL LIGHT .............................................1 ................REPLACES P/N 0601810141
3
10
11
12
13
SWITCH, PANEL LIGHT
WIRE HARNESS, ENGINE
UNIT, OIL PRESSURE
1
1
1
SENDER, OVERHEAT SWITCH.................1 ................REPLACES P/N 0602123282
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 61
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BATTERY ASSY.
PAGE 62 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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BATTERY ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
BATTERY ....................................................1 ................627MFD
QTY.
REMARKS
0602220187
M9310500014
M9103000304
0602220920
0040006000
M1347200004
M1347200104
0016910020
0040510000
BATTERY SHEET
BATTERY BAND
1
1
BATTERY BOLT SET ..................................2 ................BHL-10J
SPRING WASHER
BATTERY CABLE
BATTERY CABLE
HEX HEAD BOLT
TOOTHED WASHER
2
1
1
2
2
9
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 63
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MUFFLER ASSY.
PAGE 64 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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MUFFLER ASSY.
NO.
1
1
2
3
4
5
6
7
8
9
10
11
PART NO.
PART NAME
MUFFLER
MUFFLER
HEX HEAD BOLT
EXHAUST PIPE
QTY.
REMARKS
M3330100902
M1330100703
0016910025
M1333001903
8943690210
M1333200114
0039308000
0016908035
M1330400304
M1333300004
0016906016
0602326090
1
1
4
1
GASKET......................................................1 ................ REPLACES P/N 0602320101
GASKET
HEX NUT
HEX HEAD BOLT
COVER
BRACKET
1
6
4
1
1
4
HEX HEAD BOLT
U BOLT SET................................................1 ................89542K
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 65
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FUEL TANK ASSY.
PAGE 66 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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FUEL TANK ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
FUEL TANK
CAP, FUEL TANK
TANK BAND
SUPPORTER SHEET
HEX HEAD BOLT
HEX NUT
RUBBER SHEET
DRAIN JOINT
DRAIN BOLT
O-RING
QTY.
1
1
2
4
2
2
2
1
1
1
2
1
REMARKS
M1363001602
0605505070
M1363200104
M9310500104
0016908020
0207308000
0222100600
M9200000003
M9200200004
0150000018
0016906020
M1363400104
0605515198
8943672922
8943692993
0016908020
0602220911
0016908020
0191201150
0191201500
0191301100
0605515108
0605515109
9
10
11
12
13
14
14A
15
16
17
18
19
20
21
22
HEX HEAD BOLT
DRAIN HOSE
HOSE BAND
2
FUEL FILTER ..............................................1 ................REPLACES P/N 0602042202
CARTRIDGE, FUEL FILTER.......................1 ................REPLACES P/N 0602042700
HEX HEAD BOLT
CLAMP
HEX HEAD BOLT
SUCTION HOSE
SUCTION HOSE
RETURN HOSE
HOSE BAND
2
2
2
1
1
1
4
2
HOSE BAND
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 67
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ENCLOSURE ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
3-SPECTRUM GREY
4-SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 68 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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ENCLOSURE ASSY.
NO.
1
2
3
4
4A
5
6
6A
7
8
PART NO.
PART NAME
BASE
QTY.
1
1
2
1
1
4
1
1
12
1
4
1
1
8
8
8
8
8
8
1
1
4
1
1
1
12
9
1
1
8
8
1
4
4
REMARKS
M1413002902
M1413400004
0016908020
M1423001902
M1493106703
0016908020
M1423200604
M1493100804
0016908020
M1423201403
0016908020
M1433000803
M1433001003
0010114030
0040014000
0041214000
0010114030
0040014000
0041214000
M1443001302
M1493300504
0016908020
M1443300613
M1443301603
M1493303004
0207006000
0016908020
M1443200803
M1443600204
0037906000
0041206000
M9113000002
0021806016
0030006000
M9110100204
M9116100004
0016908020
M9310000004
M1463001802
M1493503403
0016908020
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
9
10
11
12
12A
12B
13
13A
13B
14
14A
15
16
17
17A
18
19
20
21
22
22A
23
24
24A
25
26
27
28
29
29A
30
PLAIN WASHER
DOOR HANDLE ASSY
MACHINE SCREW
HEX NUT
HINGE
WASHER
HEX HEAD BOLT
BLIND PLUG
ROOF PANEL
ACOUSTIC SHEET
HEX HEAD BOLT
2
2
3
2
1
1
19
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 69
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ENCLOSURE ASSY. (CONTINUED)
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
3-SPECTRUM GREY
4-SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 70 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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ENCLOSURE ASSY. (CONTINUED)
NO.
31
32
PART NO.
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
QTY.
1
1
1
1
1
4
2
1
1
1
1
1
1
1
1
2
2
1
1
15
3
12
12
4
4
8
9
8
8
8
1
2
1
1
REMARKS
M9310000103
M1483600204
32-1 0016908020
33
33A
34
35
36
36A
37
37A
38
38A
39
39A
40
40A
41
41A
42
43
44
44A
45
46
47
48
49
50
51
52
53
54
M1453200602
M1493300204
0016908055
0016908020
M1453003403
M1493406304
M1453003503
M1493406404
M1453001303
M1493400404
M1453003603
M1493406504
M1453301104
M1493405504
M1453301304
M1493407904
0207006000
M9113000002
0021806016
0030006000
M9110100204
M9110100304
M9116100004
0016908020
0601850097
0027208025
M9310000004
0600500090
0021106016
0016908020
0040508000
0017110020
0040510000
EMBLEM
MACHINE SCREW
HEX HEAD BOLT
TOOTHED WASHER
HEX HEAD BOLT
TOOTHED WASHER
54A
55
55A
1
1
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 71
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RUBBER SEALS ASSY.
PAGE 72 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
3
1
1
1
1
1
1
3
2
1
2
1
1
1
1
1
REMARKS
0228901370
0229200660
0228900620
0228900940
M1490300104
0228900515
0228900425
0228900910
0229200900
0229200740
0228800770
0228800470
0228800510
0228100545
0228100370
0228100165
0228100340
0228100170
0228100200
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
9
10
11
12
13
14
15
16
17
18
19
1
1
1
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 73
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NAMEPLATE AND DECALS ASSY.
PAGE 74 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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NAMEPLATE AND DECALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
M1550000204
M1550001304
M1550002003
M1550002103
M1550002203
M1550000804
M9500000004
M9500100004
M9500100104
M9500300004
M9500300104
M9500500004
M9500500104
M9503000004
M9503000103
M9503100004
M9503200004
M9510100004
M9510200002
M9520000004
M9520000104
M9520000204
M9520100004
M9520100204
M9520100304
M9520100404
M9520100503
M9520200003
M9520200404
M1560100603
M1560101904
M1560102003
M1560101104
M1560100904
M1560102103
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
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
DECAL; MQ POWER ................................................2
STRIPE .....................................................................1
STRIPE .....................................................................2
STRIPE; 45................................................................2
STRIPE .....................................................................1
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 75
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TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
5. Partsmustbeinnewandresalablecon- Multiquipreservestherighttoquoteandsell
dition,intheoriginalMultiquippackage(if directtoGovernmentagencies,andtoOriginal
Terms of payment for parts are net 30 days.
any), and with Multiquip part numbers Equipment Manufacturer accounts who use
FREIGHTPOLICY
clearlymarked.
our products as integral parts of their own
products.
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifesthasbeenobtainedfromthecarrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
SPECIALEXPEDITINGSERVICE
a. Obsolete parts. (If an item is in the
price book and shows as being re- A$35.00surchargewillbeaddedtotheinvoice
placedbyanotheritem,itisobsolete.) forspecialhandlingincludingbusshipments,
insuredparcelpostorincaseswhereMultiquip
mustpersonallydeliverthepartstothecarrier.
(such as gaskets, seals, “O” rings,
b. Any parts with a limited shelf life
andotherrubberparts)thatwerepur- LIMITATIONSOFSELLER’SLIABILITY
MINIMUMORDER
chasedmorethansixmonthspriorto
thereturndate.
Multiquip shall not be liable hereunder for
damagesinexcessofthepurchasepriceofthe
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
c. Anylineitemwithanextendeddealer item with respect to which damages are
netpriceoflessthan$5.00.
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
otherspecial,consequentialorincidentaldam-
ages.
d. Special order items.
RETURNEDGOODSPOLICY
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremade
in connection with the sale of parts or trade
accessoriesnorastoanyenginenotmanufac-
tured by Multiquip. Such warranties made in
connectionwiththesaleofnew,completeunits
are made exclusively by a statement of war-
rantypackagedwithsuchunits,andMultiquip
neitherassumesnorauthorizesanypersonto
assume for it any other obligation or liability
whatever in connection with the sale of its
products.Apartfromsuchwrittenstatementof
warranty, there are no warranties, express,
impliedorstatutory,whichextendbeyondthe
descriptionoftheproductsonthefacehereof.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
7. Thesenderwillbenotifiedofanymaterial
receivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Suchmaterialwillbeheldforfiveworking
days from notification, pending instruc-
tions.Ifareplyisnotreceivedwithinfive
days,thematerialwillbereturnedtothe
senderathisexpense.
a. Thepartsnumbersanddescriptions
must match the current parts price
list.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
Effective: February 22, 2006
d. The list must reference the sales
order(s)orinvoice(s)underwhichthe
itemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. The list must include the name and
phonenumberofthepersonrequest-
ingtheRMA.
PRICINGANDREBATES
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspe-
cificdateandallordersreceivedonorafterthat
datewillbebilledattherevisedprice.Rebates
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All forpricedeclinesandaddedchargesforprice
partsmustbereturnedfreightprepaidto increaseswillnotbemadeforstockonhand
Multiquip’sdesignatedreceivingpoint.
atthetimeofanypricechange.
PAGE 76 — DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08)
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NOTES
DCA45SSIU3 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #2 (12/19/08) — PAGE 77
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OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MQ Power
1800 Water Ridge Rd. Tel. (800) 883-2551
Suite 500/600
Lewisville, TX 75057
Fax (972) 315-1847
Contact: [email protected]
MQ Parts Department
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service/Tech Support/Warranty
800-835-2551 Fax: 310-638-8046
© COPYRIGHT 2008, MULTIQUIP INC.
MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the
property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
Manufactured for
Multiquip Inc.
by
Your Local Dealer is:
DENYO CO., LTD, JAPAN
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