PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
DCA-45USI
ULTRA-SILENTTM SERIES
GENERATOR
PARTS LIST NO. M1871400004B
Revision #2 (04/22/05)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
Download from Www.Somanuals.com. All Manuals Search And Download.
PAGE 2 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-632-2656
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX:310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
WARRANTYDEPARTMENT
800-835-2551,EXT.279
310-537-3700,EXT.279
FAX:310-631-5032
FAX:310-638-8046
© COPYRIGHT 2004, MULTIQUIP INC.
Multiquip Inc, MQ Power Inc, Ultra-Silent series, the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc.and
may not be used, reproduced, or altered without written permission.All other trademarks are the property of thier respective owners
and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and
should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are
based on the DCA-45USI Ultra Silent Generator.Multiquip Inc.reserves the right to discontinue or change specifications, design or
the information published in this publication at any time without notice and without incurring any obligations.
To find the latest revision of this
publication, visit our website at:
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 3
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TABLE OF CONTENTS
MQ POWER DCA-45USI
AC GENERATOR
COMPONENT DRAWINGS
Generator Assembly ............................................ 52-53
Control Box Assembly .......................................... 54-57
Engine & Radiator Assembly ............................... 58-61
Output Terminal Assembly................................... 62-63
Battery Assembly .................................................64-65
Muffler Assembly .................................................66-67
Fuel Tank Assembly ............................................. 68-69
Enclosure Assembly ............................................ 70-75
Rubber Seal Assembly ........................................ 76-77
Nameplate and Decals ........................................ 78-79
Here's How To Get Help ............................................. 3
Table Of Contents ....................................................... 4
Parts Ordering Procedures ........................................ 5
DCA-45USI Specifications .......................................... 6
Dimensions.................................................................. 7
Safety Message Alert Symbols ............................... 8-9
Rules for Safe Operation .....................................10-13
Installation ............................................................14-15
Towing Safety Precautions ....................................... 16
Trailer Specifications ................................................. 17
Generator Decals.................................................18-19
General Information .................................................. 20
Major Components ................................................... 21
Generator Control Panel........................................... 22
Engine Operating Panel............................................ 23
Output Terminal Panel Familiarization.................24-26
Load Application........................................................ 27
Generator Outputs ...............................................28-29
Gauge Reading ......................................................... 30
Output Terminal Panel Connections....................30-31
Pre-setup ..............................................................32-35
Generator Start-up Procedure ............................36-38
Generator Shut-down Procedure............................. 39
Maintenance.........................................................40-41
Trailer Brakes Maintenance...................................... 42
Trailer Maintenance .............................................43-44
Trailer Wiring Diagram .............................................. 45
Engine Wiring Diagram ........................................46-47
Generator Wiring Diagram ....................................... 48
Generator Troubleshooting....................................... 49
Explanation of Codes in Remarks Column.............. 50
Suggested Spare Parts ............................................ 51
Terms and Condition of Sale — Parts...................... 80
Specification and part number
are subject to change without
notice.
NOTE
PAGE 4 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒
Dealeraccountnumber
❒
❒
❒
❒
❒
❒
Dealernameandaddress
Shipping address (if different than billing address)
Returnfaxnumber
Applicable model number
Quantity,part number and description of each part
Specifypreferredmethodofshipment:
✓
✓
✓
✓
✓
✓
FedEx or UPS Ground
FedEx or UPS Second Day or Third Day
FedEx or UPS Next Day
Federal Express Priority One
DHL
Note:Unlessotherwiseindicatedbycustomer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours.We will make every effort to
ship “Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
Truck
Place Your Parts Order Via Web or Fax
For Even More Savings!
Here’s how to get help...
Please have the model and serial number
on hand when calling.
(Domestic USA Dealers Only)
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
Email: [email protected]
800-421-1244
FAX: 310-632-2656
Extra Discounts!
All parts orders which include complete part numbers and
are received by our automated web parts order system, or
by fax qualify for the following extra discounts:
Ordered
via
Standard
orders
Stock orders
PARTS DEPARTMENT
800-427-1244
310-537-3700
SERVICE DEPARTMENT
800-835-2551
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
WARRANTY DEPARTMENT
800-835-2551, EXT. 279
310-537-3700, EXT. 279
($750 list and above)
FAX: 800-672-7877
FAX: 310-637-3284
Fax
3%
5%
10%
10%
Web
FAX: 310-638-8046
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other carrier.
FAX: 310-631-5032
FAX: 310-638-8046
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
NOTE:DISCOUNTSARESUBJECTTOCHANGE
MQPOWER
Direct TOLL-FREE access
to our Parts Department:
ADivisionofMultiquipInc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-632-2656
Toll-free nationwide — 800-427-1244
INTERNET:www.mqpower.com
Toll-free FAX — 800-6-PARTS-7 (800/672-7877)
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 5
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DCA-45USI — SPECIFICATIONS
Table 1. Generator Specifications
Model
Type
DCA-45USI
Revolving field, self ventilated, open protected type synchronous
generator
Star with Neutral
3
Zig Zag
Single
Armature Connection
Phase
47.3 KVA (37.8 KW)
45 KVA (36 KW)
240V or 480V
27.3 KW
26 KW
Standby Output
Prime Output
Voltage
240/120V
60 Hz
Frequency
Speed
1,800 rpm
0.8
1
Power Factor
Aux. AC Power
Voltage
Single Phase, 60 Hz
120 VAC
4.8 KW (2.4 KW x 2)
Output
Engine Specifications
Model
Type
ISUZU BB-4JG1T
4 Cycle, water-cooled, direct injection, turbocharged
4 cylinders
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
3.76 in. x 4.21 in. (95.4 mm x 107 mm)
55.3 HP/1,800 rpm
187 cu. in. (3,059 cc)
Electric
3.6 gal. (13.7 liters)
Coolant Capacity
Lube Oil Capacity
2.64 gal. (10.0 liters)
2.6 gal. (9.84 L)/hr at full load
1.43 gal. (5.42 L)/hr at 1/2 load
1.97 gal. (7.47 L)/hr at 3/4 load
0.87 gal. (3.3 L)/hr at 1/4 load
Fuel Consumption
12V - BCI Group 27
#2 Diesel Fuel
Battery
Fuel
PAGE 6 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — DIMENSIONS (SIDE AND FRONT)
Figure 1. Dimensions
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 7
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DCA-45USI — SAFETY MESSAGE ALERT SYMBOLS
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
HAZARD SYMBOLS
Lethal Exhaust Gases
Engine exhaust gases contain poisonous
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.
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined
area or enclosed structure that does not
provide ample free flow air.
This Owner's Manual has been
developed to provide complete
instructions for the safe and efficient
NOTE
operation of the MQ Power Model
DCA45USI ULTRA-SILENT™
GENERATOR.
Explosive Fuel
Before using this GENERATOR, ensure that the operating
individual has read and understands all instructions in this
manual.
Diesel fuel is extremely flammable, and its
vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use fuel as a cleaning agent.
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
the operator, and are preceded by one of three words: DANGER,
WARNING, or CAUTION.
Burn Hazards
DANGER: You WILL be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
Engine components can generate extreme heat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. NEVER operate the engine with
heat shields or heat guards removed.
WARNING: You CAN be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
Rotating Parts
NEVER operate equipment with covers, or
guards removed. Keep fingers, hands, hair
and clothing away from all moving parts to
prevent injury.
CAUTION: You CAN be injured if you
DO NOT follow directions.
Potential hazards associated with trowel operation will be
referenced with "Hazard Symbols" which appear throughout
this manual, and will be referenced in conjunction with Safety
"Message Alert Symbols".
PAGE 8 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — SAFETY MESSAGE ALERT SYMBOLS
Accidental Starting
Respiratory Hazard
ALWAYS place the engine ON/OFF switch
in the OFF position, when the trowel is not
in use.
ALWAYS wear approved respiratory protection.
Over Speed Conditions
Sight and Hearing hazard
NEVER tamper with the factory settings of the
engine governor or settings. Personal injury
and damage to the engine or equipment can
result if operating in speed ranges above
maximum allowable.
ALWAYS wear approved eye and hearing
protection.
Equipment Damage Messages
This generator, other property, or
the surrounding environment could
be damaged if you do not follow
instructions.
Other important messages are provided throughout this manual
to help prevent damage to your trowel, other property, or the
surrounding environment.
NOTE
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 9
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DCA-45USI — RULES FOR SAFE OPERATION
■
NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to
coolbeforeservicingengineorgenerator.
CAUTION
:
Failure to follow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is
for industrial use only.
The following safety guidelines should always be used when
operating the DCA-45USI Generator:
■
■
High Temperatures – Allow the engine to cool before
performing service and maintenance functions. Contact with
hot! components can cause serious burns.
GENERAL SAFETY
The engine of this
generator requires an
adequate free flow of
■
DO NOT operate or service this equipment befor
reading this entire manual.
cooling air. NEVER
operate the generator in
any enclosed or narrow
area where free flow of
the air is restricted. If the
air flow is restricted it will
cause serious damage
to the generator or
engine and may cause injury to people.The generator engine
gives off DEADLY carbon monoxide gas.
■
■
This equipment should not be operated by persons under 18
years of age.
NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel-
toed boots and other protective devices required
by the job.
■
■
■
ALWAYS make sure generator is properly grounded.
NEVER use gas piping as an electrical ground.
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■
■
ALWAYS make sure generator installation is accordance with
national and local electrical codes.
NEVER operate this equipment under the
influence or drugs or alcohol.
ALWAYS have a qualified electrician perform the generator
wiring installation.
■
■
NEVER power cables or cords lay in water.
NEVER stand in water while AC power from the generator
■
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage to
the equipment and/or injury to user may result.
is being transfer to a load.
■
■
■
■
NEVER use a defective or frayed power cable. Check the
cable for cuts in the insulation.
■
■
■
■
Manufacture does not assume responsibility for any accident
due to equipment modifications.
NEVER use a extension cord that is frayed or damaged where
the insulation has been cut.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
ALWAYS make certain that proper extension cord has been
selected for the job SeeTable 5.
ALWAYS check the machine for loosened threads or bolts
before starting.
The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits. Turn all circuit breakers OFF before
performing maintenance on the generator.
NEVER operate the generator in an explosive atmosphere or
near combustible materials. An explosion or fire could result
causing severe bodily harm or even death.
PAGE 10 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — RULES FOR SAFE OPERATION
.
■
ALWAYS make sure that electrical circuits are properly
grounded per the National Electrical Code (NEC) and local
codes before operating generator.Severe injury or death! by
electrocution can result from operating an ungrounded
generator.
DANGER
:
■
■
ALWAYS be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.
ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children.
■
Backfeed to a utility system can cause electrocution and or
property damage. DO NOT connect to any building's electrical
system except through an approved device or after building
main switch is opened. ALWAYS have a licensed electrician
perform the installation
■
ALWAYS read, understand, and follow
procedures in Operator’s Manual before
attempting to operate equipment.
DANGER
:
CAUTION
:
Never use damaged or worn cables when
connecting equipment to the generator.
Make sure power
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
c o n n e c t i n g
cables
are
securely connected to the
generator’s output terminals,
insufficient tightening of the
terminal connections may cause
damage to the generator and
electrical shock.
Radiator
1. Radiator Cap - Removing the radiator cap while the engine
is hot will result in high pressurized, boiling water to gush
out of the radiator, causing severe scalding to any persons
in the general area of the generator.
WET
HANDS
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush out
of the coolant drain plug, therefore causing severe scalding
to any persons in the general area of the generator.
DANGER
:
NEVER grab or
touch live
a
power cord with
wet hands , the
possibility exists
of electrical shock, electrocution, and even
death!
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush out
of the oil drain plug, therefore causing severe scalding to
any persons in the general area of the generator.
POWER
CORD
(POWER ON)
DANGER
:
Maintenance Safety
■
NEVER lubricate components or attempt
service on a running machine.
■
ALWAYS allow the machine a proper
amount of time to cool before servicing.
■
NEVER touch output terminals during operation. This is
extremely dangerous. ALWAYS stop the machine and
place the circuit breaker in the “OFF” position when contact
with the output terminals is required. There exists the
possibility of electrocution, electrical shock or burn,
which can cause severe bodily harm or even death!
■
■
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace
broken parts.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 11
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DCA-45USI — RULES FOR SAFE OPERATION
Battery
■
■
■
■
NEVER run engine without air filter.Severe engine damage
may occur.
The battery contains acids that can cause injury to the eyes
and skin.To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
ALWAYS service air cleaner frequently to prevent engine
malfunction.
ALWAYS disconnect the negative battery terminal before
performing service on the generator.
ALWAYS be sure the operator is familiar with proper safety
precautions when operating the generator set.
■
■
ALWAYS store equipment properly when not in use.
DO NOT leave the generator running in the manual mode
unattended.
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
■
■
■
DO NOT allow unauthorized people to operate this
equipment.
2. DO NOT expose the battery to
open flames, sparks, cigarettes
etc. The battery contains
combustible gases and liquids. If
these gases and liquids come in
contact with a flame or spark, an
explosion could occur.
ALWAYS read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
Refer to the Isuzu Engine Owner's Manual for engine
technical questions or information.
DANGER:
3. ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
Pay close attention to
ventilation when operating
the generator inside
tunnels and caves. The
4. ALWAYS keep battery charging and cables in good working
condition. Repair or replace all worn cables.
5. ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
engine exhaust contains noxious elements.
Engine exhaust must be routed to a
ventilated area.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with plenty
of water, then contact the nearest doctor or hospital, and
seek medical attention.
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.
Transporting
■
■
■
ALWAYS shutdown engine before transporting.
Tighten both fuel tank caps securely.
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the UVWO output terminals.
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See next page “Towing Safety Precautions” for
basic towing techniques.
PAGE 12 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — RULES FOR SAFE OPERATION
■
■
Avoid sharp turns.
Towing Safety Precautions
Trailer should be adjusted to a level position at all times
when towing.
CAUTION:
■
■
Raise and lock trailer wheel stand in up position when
transporting.
Conform to Department ofTransportation
(DOT) Safety Towing Regulations before
towing generator.
DOT Requirements include the following:
z
z
Connect and test electric brake operation.
Secure portable power cables in cable tray with
tie wraps.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
Emergencies
■
ALWAYS know the location of the nearest fire extinguisher.
The following list of suggestions should be used when towing
your generator:
■
■
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR) of 6,000 lbs.
■
■
ALWAYS know the location of the nearest and first aid kit.
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.
In emergencies always know the location of the
nearest phone or keep a phone on the job site.
Also know the phone numbers of the nearest
ambulance, doctor and fire department. This
information will be invaluable in the case of an
emergency.
■
■
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
ALWAYS attach trailer’s safety chains to towing vehicle
properly.
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
■
■
Place chock blocks underneath wheel to prevent rolling,
while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 13
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DCA-45USI — INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — INSTALLATION
Generator Grounding
Outdoor Installation
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Install the generator in a clear area. Make sure the generator
is on secure level ground so that it cannot slide or shift
around. Also install the generator in a manner so that the
exhaust will not be discharged in the direction of nearby
homes.
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.
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.
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.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
NOTE
Indoor Installation
electrician.
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside.The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 15
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DCA-45USI —TOWING SAFETY PRECAUTIONS
Towing Safety Precautions
■
■
ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
CAUTION
:
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
Check with your local county or state safety
towing regulations before towing your
generator.
■
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.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 3) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.
■
■
■
Place chocked blocks underneath wheel to prevent
rolling, while parked.
Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
The following list of suggestions should be used when towing
your generator:
Use the trailer’s hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■
Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■
ALWAYS inspect the hitch and coupling for wear.NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■
■
■
Avoid sharp turns to prevent rolling.
■
■
Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Generator w/trailer illustration is
for reference only.
NOTE
Figure 3. Generator with Trailer
PAGE 16 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI —TRAILER SPECIFICATIONS
5. Frame Width - Measurement is from fender to fender
6. Jack Stand - Trailer support device with maximum pound
CAUTION
:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
Explanation of Chart:
This section is to provide the user with trailer service and
maintenance information. The service and maintenance
guidelines referenced in this section apply a wide range of
trailers. Remember periodic inspection of the trailer will en-
sure safe towing of the equipment and will prevent damage
to the equipment and personal injury.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug nuts.
See Table 17 and Figure 67 or lug nut tightening and
sequence.
Brakes
Tires
Lug NutTorquing
Suspension
Electrical
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 2). Please note that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
BrakeTroubleshootingTables
Use the following definitions when reading Table 2.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels.Types of suspension used
are leaf, Q-flex, and air ride.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans-
porting equipment.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
16. Application - Indicates which units can be employed
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
on a particular trailer.
4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 17
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DCA-45USI — GENERATOR DECALS
The DCA-45USI generator is equipped with a number of safety decals. These decals are provided for operator safety and
maintenance information. The illustration below and on the preceding page show the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
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DCA-45USI — GENERATOR DECALS
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 19
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DCA-45USI — GENERAL INFORMATION
Open Delta Excitation System
DCA-45USI FAMILIARIZATION
Generator
The DCA-45USI 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.
The MQ Power Model DCA-45USI (Figure 4) is a 36 kW
generator that is designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.
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
fromtheparallelconnectionsofAtoB, AtoD, andCtoD.Thesethree
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:
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.
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Tachometer
WaterTemperature Gauge/ Alarm Lamp
Oil Pressure Gauge/ Alarm Lamp
Charging Ammeter Gauge
Pre-Heat Lamp
Panel Light
Panel Light Switch
Ignition/Preheat Switch
Fuel Gauge
Fuel Filter Water Level Alarm Lamp
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.
Generator Control Panel
The “Generator Control Panel”is provided with the following:
Engine
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Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
The DCA-45USIispoweredbya4cycle, watercooled, turbocharged
Isuzu BB-4JG1T diesel engine.This engine is designed to meet
every performance requirement for the generator.ReferenceTable 1
for engine specifications.
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
InkeepingwithMQPower'spolicyofconstantlyimprovingitsproducts,
the specifications quoted herein are subject to change without prior
notice.
3-Pole, 110 amp Main Circuit Breaker
Output Terminal Panel
The basic controls and indicators for the DCA-45USI generator are
addressed on the following pages.
The “Output Terminal Panel” is provided with the following:
Mechanical Governor System
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Three 120/240V output receptacles (CS-6369), 50 amps
Three auxilliary circuit breakers, @50 amps
Two 125 VAC output receptacles, (GFCI), 20 amps
Two GFCI circuit breakers @ 20amps
The mechanical governor system control the RPM of the engine.
When the engine demands increase or decrease, the mechanical
governor system regulates the frequency variation to within .5%.
The electronic governor option decreases the frequency variation
to within 0.25%.
Five output terminal lugs (3Ø power)
Control Box
Extension Cables
The “Control Box” is provided with the following:
When electric power is to be provided to various tools or loads at
some distance from the generator, extension cords are normally
used. Cables should be sized to allow for distance in length and
amperage so that the voltage drop between the generator and point
of use (load) is held to a minimum. Use the cable selection chart
(Table 5 ) as a guide for selecting proper extension cable size.
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Automatic Voltage Regulator
CurrentTransformer
Emergency Relay
Over-Current Relay
PAGE 20 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — MAJOR COMPONENTS
Major Components
ESCRIPTION
y
7
8
9
y
embly
mbly
Assembly
mbly
Battery Assembly
Figure 4. Major Components
Generator Control Panel Assembly
Engine Operating Panel Assembly
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 21
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DCA-45USI — GENERATOR CONTROL PANEL
Figure 5. Generator Control Panel
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the generator
function.
The definitions below describe the controls and functions of
the DCA-45USI "Generator Control Panel" (Figure 5).
1. Main Circuit Breaker – This three-pole, 110 amp main
breaker is provided to protect the U,V, and W Output
Terminal Lugs from overload.
The Control Box is equipped with the following major
components:
2. AC Ammeter – Indicates the amount of current the load
is drawing from the generator per leg selected by the
ammeter phase-selector switch.
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Over-Current Relay
Voltage Rectifer
Starter Relay
Engine Controller (Computer Controlled)
CurrentTransformer
3. 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.
Voltage Selector Switch
Remember the overcurrent
relay monitors the current
flowing from the U,V, and W
OutputTerminal Lugs to the
load.
NOTE
4. 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.
In the event of a short circuit or over current condition, it will
automatically trip the 60 amp main breaker.
5. Voltage Regulator Control – Allows 15% manual
adjustment of the generator’s output voltage.
To restore power to the Output Terminal Panel, press the
reset button on the overcurrent relay and place the main
circuit breaker in the closed position (ON).
6. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz 1 Hz .
7. ACVoltmeter – Indicates the output voltage present at
the U,V, and W Output Terminal Lugs.
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DCA-45USI — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-45USI "Engine Operating Panel" (Figure 6).
1. Panel Light - Normally used in dark places or at night.
When activated, panel will luminate. When the generator
is not in use, turn the panel light switch to the OFF
position.
2. Panel Light Switch-When activated, will turn on control
panel light.
3. Oil Pressure Lamp - Indicates that the oil pressure is
too low and will shut down the engine.
4. Water Temperature Lamp - Indicates that the water
temperature is too hot and will shut down the engine.
5. Fuel FilterWater Level Alarm Lamp - This lamp turns
on when water in the filter is detected. Drain the water
in the fuel filter strainer to correct the problem.
6. Pre-heat Lamp - This indicates when the engine has
been preheated and is ready for starting.In cold weather
conditions, it may be several minutes before the lamp
illuminates.
7. Fuel Leak Detected Alarm – This indicates that liquid
is present in the fuel tank containment basin. Drain the
containment basin and repair any leaks.
8. Tachometer – Indicates engine speed in RPM’s for
60 Hz operation.This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
9. Fuel Gauge - Indicates amount of diesel fuel available.
10. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
Figure 6. Engine Operating Panel
11. WaterTemperature Gauge – During normal operation
this gauge be should read between 165o F to 203o F.
12. Oil Pressure Gauge – Normal operation should be about
28 to 71 psi. When starting the generator the oil pressure
may read a bit higher, but after the engine warms up
the oil pressure should return to normal.
13. Starter Switch – Three position switch, stop,
preheat/run and start. Insert ignition key to start and
stop engine.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 23
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DCA-45USI — OUTPUT TERMINAL PANEL FAMILIARIZATION
OutputTerminal Panel
Output Terminal Familiarization
The OutputTerminal Panel (Figure 7) 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 “OutputTerminal Panel ” (Figure 7) is provided with the
following:
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Three (3) 120/240V output receptacles, 50 amp
Three (3) Circuit Breakers 240V @50 amps
Two (2) 120V GFCI receptacles, 20 amp
Two (2) GFCI Circuit Breakers @ 20 amps
One Main Circuit Breaker @110 amps
Terminal legs“O”and “Ground”are
NOTE
considered bonded grounds.
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
Figure 7. Output Terminal Panel
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DCA-45USI — OUTPUT TERMINAL PANEL FAMILIARIZATION
120VAC GFCI Receptacles
Each auxilliary receptacle is protected by a 50 amp circuit
breaker.These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
OutputTerminal Lugs.
There are two 120VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any voltage selector switch
position. Each receptacle is protected by a 20 amp circuit
breaker.These breakers are located directly above the GFCI Turn the voltage regulator control knob (Figure 10) on the
receptacles. Remember the load output (current) of both control panel to obtain the desired voltage.Turning the knob
GFCI receptacles is dependent on the load requirements of clockwise will increase the voltage, turning the knob counter-
the UVWO terminals.
clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the "Test Button" (See Figure 8) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 10. Voltage Regulator Control Knob
Removing the Plastic Face Plate (OutputTerminal Lugs
)
The Output Terminal Lugs are protected by a plastic face
plate cover (Figure 11). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
After the load wires have been securely attached to the
Output Terminal Lugs, reinstall the plastic face plate.
Figure 8. G.F.C.I. Receptacle
Twist Lock DualVoltage 120/240VAC Receptacles
There are three 120/240 VAC, 50 amp auxilliary twist-lock
(CS-6369) recepacles (Figure 9) 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 11. Plastic Face Plate (UVWO Terminals)
Figure 9. 240 VAC Twist-Lock
Auxiliary Receptacles
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 25
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DCA-45USI — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Blower Fan
Loads can be connected to the generator by using the Output This unit has an intake fan located at the rear of the machine
Terminal Lugs or the convienience receptacles to draw outside air into the cabinet to cool the engine. The
(See Figure 12). Make sure to read the operation manual fan has a 10 amp AC fuse located beneath the Voltage
before attempting to connect a load to the generator.
Selector Switch (Figure 14).
To protect the Output Terminal Lugs from overload, a
3-pole, 110 amp, main circuit breaker is provided. Make sure to
switch ALL circuit breakers to the OFF position prior to starting
the engine.
Figure 14. Blower Fan Fuse
DANGER:
This fuse has current running through it any
time the engine is operating. THIS FUSE
IS NOT connected to the main circuit
breaker OF the generator. Attempting to
Figure 12. Connecting Loads
Over Current Relay
replace the fuse with the engine
and/or generator operating could
result in electrocution and severe
bodily harm. ALWAYS turn the
unit completely off before
attempting to replace or handle
THIS fuse
An over current relay (Figure 13) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over cur-
rent relay must be pressed. The over current relay is lo-
cated in the control box.
Figure 13. Over Current Relay
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DCA-45USI — LOAD APPLICATION
Three Phase Load
Single Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency
,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
NOTE
If wattage is not given on the equipment's
name plate, approximate wattage may be
determined by multiplying nameplate
voltage by the nameplate amperage.
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 5.
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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.
WATTS l VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 4 below
when connecting loads.
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.
Table 4. Power Factor By Load
Type Of Load
Power Factor
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Fluorescent lamps, mercury lamps
Electronic devices, communication
equipment
Common power tools
0.8
CAUTION:
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.
Table 5. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts Maximum Allowable Cable Length
Current in
Amperes
At 120
Volts
At 240
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
5
300
600
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.
1200
1800
2400
3600
4800
7.5
10
15
20
900
1200
1800
2400
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
NOTE
50 ft.
maybe
determined
by
CAUTION: Equipment damage can result from low voltage.
multiplying voltage by amperage
by 1.732.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 27
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DCA-45USI — GENERATOR OUTPUTS
Voltage Selector Switch
Generator Amperage
The voltage selector switch (Figure 15) is located above Table 7 describes the generator’s current output capability
the UVWO Hard Wire Hook-up Panel. It has been provided for both 1Ø-phase and 3Ø phase applications.
for ease of voltage selection.
Table 7. Generator Ampere Ratings
DCA-45USJ
Single Phase
Three Phase*
kW
kVA
N/A
45
120V
108A x 2
N/A
208V
240V
108A
108A
480V
N/A
26
N/A
36
125A
54A
* Power Factor = 0.8
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly re-
lated to the voltage being supplied at either the output termi-
nal lugs or the 3 twist lock auxilliary receptacles.
Tables 8 and 9 show what amount of current is available at
the GFCI receptacles when the UVWO terminals and twist
lock receptacles are in use. Be careful that your load does
not to exceed the available current capability at the recep-
tacles.
Figure 15. Voltage Selector Switch
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and load from being switched while the engine
is running. To lock the voltage selector switch, press and
hold the red button located at the bottom of the switch.
Table 8. GFCI Receptacle Load Capability
KW in Use
Twist-Lock (CS6369)
Available Load Current
(AMPS)
GFCI Duplex NEMA
5-20R 120V
1Ø 240/120V
CAUTION:
60
0
NEVER change the position of the voltage
selector switch while the engine is running.
ALWAYS place circuit breaker in the open
position before selecting voltage.
58.8
57.6
56.4
55.2
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
Table 8. GFCI Receptacle Load Capability
Generator OutputVoltages
KVA in Use
Available Load Current
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 14). To obtain some of
the voltages as listed in Table 6 (see below) will require a
fine adjustment using the voltage regulator (VR) control
knob located on the control panel.
(UVWO Terminals)
(AMPS)
GFCI Duplex NEMA
5-20R 120V
3Ø 240/480V
82
0
77.8
73.7
69.5
65.4
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
Table 6. Voltages Available
Three Phase
208V
220V
240V
416V
440V
254V
480V
277V
(Switchable)
Single Phase
(Switchable)
120V
127V
139V
240V
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DCA-45USI — GAUGE READING
How to Read the OutputTerminal Gauges.
Reading Amperage
The gauges and selector switches on the control panel To determine the amperage at a terminal lug, set the
DO NOT effect the generator output. They are provided to AC Ammeter Change-Over Switch to the appropriate
setting (Figure 19) to activate the AC Ammeter Gauge
(Figure 20) and read the available amperage at the terminal
lug.
help observe how much power is being supplied at the Out-
putTerminal Lugs.
Before taking a reading off either gauge, set the Voltage
Selector Switch (Figure 16) to the position which produces
the required voltage (For example, for 3Ø 240V, choose the
center 3Ø 240/139V posi-
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.
tion on the voltage selector
switch.)
Figure 16. Voltage Selector
Switch 240/139V Three
Phase Position
Figure 20. AC Ammeter
(Amp reading on U lug)
Figure 19. AC Ammeter
Change-Over Switch
For 3Ø 208V/1Ø,120V, place
NOTE
the Voltage Selector Switch
in the 3 Phase 340/139
position.
The ammeter gauge will only
show a reading when the
Output Terminal Lugs are
connected to a load and in use.
NOTE
Reading Voltage
To determine the voltage between two terminal lugs, set the
AC Voltmeter Change-Over Switch to the appropriate
setting (Figure 17) to activate the AC Voltmeter Gauge
(Figure 18) and read the available voltage between the two
lugs.
For example, to measure the voltage between the W and U
terminal lugs, set the AC Voltmeter Change-Over Switch
to W-U and read the ACVoltmeter Gauge.
Figure 17. AC Voltmeter Figure 18. AC Voltmeter Gauge
Change-Over Switch
(Volt reading on W-U Lug)
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 29
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DCA-45USI — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 208V/1Ø120V OutputTerminal Lug Voltages
UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 24.
Various output voltages can be obtained using the using the
Output Terminal Lugs. The voltages at the terminals are
dependent on the position of the Voltage Selector Switch
and the adjustment of the Voltage Regulator Control Knob.
Use this position for
3Ø-208 or 1Ø120V.
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 24. Voltage Selector
Switch 3Ø-208V/1Ø-120V
Three-Phase Position
3Ø 240/139 OutputTerminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 21.
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 25.
Figure 21. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 22.
Figure 25 Output Terminal Lugs
.
3Ø-208V/120V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Figure 22. Output Terminal Lugs
240/139V Three Phase Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
To achieve a 3Ø 208V output,
the voltage selector switch
must be in the 3Ø 240/139V
position and the voltage
regulator must be adjusted to
208V.
NOTE
Figure 23. Voltage Regulator Knob
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DCA-45USI — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 OutputTerminal LugVoltages
1Ø 240V/120V OutputTerminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 26.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 28.
Figure 26. Voltage Selector Switch 480/277V
Three-Phase Position
Figure 28. Voltage Selector Switch 240/120V
Single-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as 2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 27. shown in Figure 29.
Figure 27 Output Terminal Lugs
277/480V Three Phase Connections
.
Figure 29 Output Terminal Lugs
.
1Ø-240V/120V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
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DCA-45USI — PRE-SETUP
Fuel Check
Circuit Breakers
To protect the generator from an overload, a 3-pole, 110 amp,
main circuit breaker is provided to protect the UVW output
terminals from overload. In addition two single-pole, 20 amp
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload.Three 50 amp load circuit breakers
have also been provided to protect the auxiliary receptacles
from overload. Make sure to switch ALL circuit breakers to
the OFF position prior to starting the engine.
DANGER:
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.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two
notches (Figure 30) on the dipstick. See Table 10 for proper
selection of engine oil.
Refilling the Fuel System
WARNING:
ONLY properly trained personel who have
read and understand this section should re-
fill the fuel tank system.
The generator unit has an internal fuel tank located at the
bottom of the cabinet (Figure 31). ALWAYS fill the fuel tank
with clean and fresh #2 diesel fuel. DO NOT fill the fuel
tanks beyond their capacities.
Figure 30. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the Isuzu Engine Owner's Manual. Oil should be warm
before draining.
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.
Other types of motor oils may be substituted if they meet
the following requirements:
z
z
z
z
z
API Service Classification CH-4
API Service Classification CG-4
API Service Classification CF-4
ACEA Specification E3
ACEA Specification E2
Table 11. Recommended Motor Oil
Temperature Range
Type Oil
77oF and greater
SAE15W-40 or SAE40
SAE 10W-30 or SAE30
SAE10W-30 or SAE10
(25oC and greater)
Figure 31. Internal Fuel Tank System
32oF to 77oF
(0oC to 25oC)
-22oF to -32oF
(-30oC0oC)
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DCA-45USI — PRE-SETUP
Refueling Procedure:
2. Open cabinet doors on the generator.Locate and remove
the fuel tank cap and fill tank (Figure 33).
DANGER:
Diesel fuel and its vapors are dangerous to
your health and the surrounding environment.
Avoid skin contact and/or
inhaling fumes.
1. Level Tanks – make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 32).
WARNING:
ALWAYS! place trailer on firm level ground before refueling.
Figure 33. 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 (See Figure 34).
Figure 32. Only Fill on Level Ground
ONLY! use #2 diesel fuel
when refueling.
NOTE
Figure 34. Full Fuel Tank
WARNING:
DO NOT OVER-FILL fuel system. Leave
room for fuel expansion . Fuel expands when
heated (Figure 35).
Figure 35. Fuel Expansion
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DCA-45USI — PRE-SETUP
Coolant (Ethylane Glycol [Green] /Water — 50/50 mix)
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be less than 50%.
NOTE
An anticorrosion additive added to the water will help prevent Cleaning the Radiator
deposits and corrosion in the cooling system. See the engine
manual for further details.
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.
CAUTION:
Ifaddingcoolant/antifreeze
mix to the radiator, DO
NOT remove the radiator
cap until the unit has
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Isusu Engine Owner's Manual.
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 38) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
Reserve Tank
5.3 Gal. (20 L)
0.26 Gal. (1L)
Figure 36. Fan Belt Tension
Operation FreezingWeather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
CAUTION
:
Table 13. Anti-Freeze Operating Temperatures
NEVER! place hands
near the belts or fan while
the generator set is
running.
Freezing Point
Boiling Point
Vol %
Anti-Freeze
°C
-24
-37
°F
°C
°F
40
50
-12
-34
106
108
222
226
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DCA-45USI — PRE-SETUP
Battery
When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
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.
terminals when the ignition switch is in the PRE-HEAT/
RUN position.ALWAYS make sure that the ignition switch
is in the STOP position when connecting the battery.
2. Place a small amount of battery terminal treatment
compound around both battery terminals.This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
DO NOT over fill. Check to see whether the battery cables
are loose. Poor contact may result in poor starting or
malfunctions. Always keep the terminals firmly tightened.
Coating the terminals with an approved battery terminal
treatment compound. Replace battery with only
recommended type battery. The battery type used in this
generator is BCI Group 27.
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.
NOTE
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Battery Cable Installation
CAUTION
:
ALWAYS be sure the battery cables (Figure 37) 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.
Inadequate battery connections may cause
poor starting of the generator, and create
other malfunctions.
Alternator
CAUTION
:
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.
ALWAYS disconnect the negative terminal
FIRST and reconnect negative terminal
LAST.
DO NOT put water directly on the alternator. Entry of water
into the alternator leads an electrolyte corrosion causing an
alternator failure.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness.Tighten all hose clamps and check hoses
for leaks.
Figure 37. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
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DCA-45USI — GENERATOR START-UP PROCEDURE
3. Close all engine enclosure doors (Figure 40).
WARNING:
The engine's exhaust contains harmful
emissions. ALWAYS have adequate
ventilation when operating. Direct exhaust
away from nearby personnel.
Before Starting
CAUTION:
Figure 40. Engine Enclosure Doors
NEVER! manually start the engine with the
main, GFCI or auxiliary circuit breakers in
the ON (closed) position.
4. Place the voltage selector switch in the desired voltage
position (Figure 41).
1. Be sure and place the main, G.F.C.I. and aux. circuit
breakers (Figure 40) in the OFF position prior to starting
the engine.
Figure 41. Voltage Selector Switch
5. Preheat the engine glow plugs by turning the ignition
key (Figure 42) to the PRE-HEAT/RUN position. When
the preheat lamp (Figure 43) turns off, proceed
to step 6.
Figure 38. Main, Aux. and GFCI
Circuit Breakers
2. Connect the load to the Output Terminal Lugs or
auxiliary receptacles as shown in Figure 39.These load
connection points can be found on the output terminal
panel.
Figure 42. Ignition Switch
(Pre-Heat/Run Position)
Figure 43. Pre-Heat Indicator Lamp
Figure 39. Load Connections
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DCA-45USI — GENERATOR START-UP PROCEDURE
6. Turn the ignition key to the START position (Figure 44). 9. The generator's voltage meter (Figure 46) displays the
Once the engine starts, release the ignition key and
allow it to return to the PRE-HEAT/RUN position
(Figure 42).
output voltage in VOLTS.
If the engine fails to start after 10 seconds, wait
approximately 30 seconds and repeat steps 5-6.
Figure 46. AC Voltmeter
10. If the voltage is not reading at the specified level, use
the voltage adjustment control knob (Figure 47) to
increase or decrease the voltage until you reach the
desired voltage.
Figure 44. Ignition Switch
(Start Position)
7. Let the engine run for 3-5 minutes and listen and check
for any abnormal sounds or smells. Check for fuel leaks,
and noises that would associate with a loose cover or
hardware.
Figure 47. Voltage Adjust Control Knob
Check the electric motor fan cooling the radiator for
abnormal speed, sound or vibration conditions.
11. The ammeter (Figure 48) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator.
If any of the above mentioned conditions exists, shut-
down the engine and correct the problem before operating
the generator.
8. The generator's frequency meter (Figure 45) displays
the 60 cycle output frequency in HERTZ.
Figure 48. Ammeter (No Load)
Figure 45. Frequency Meter (Hz)
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DCA-45USI — GENERATOR START-UP PROCEDURE
15. Turn the main, GFCI, and aux. circuit breakers to the
ON position (Figure 52).
12. The engine oil pressure gauge (Figure 49) will indicate
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately
Figure 49. Oil Pressure Gauge
13. The coolant temperature gauge (Figure 50) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature is between 165 and
203° degrees Fahrenheit.
Figure 52. Main, AUX. and GFCI
Circuit Breakers (ON)
16. Observe the generator's ammeter (Figure 53) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if the load is in use.
Figure 50. Coolant Temperature Gauge
14. The tachometer (Figure 51) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800
RPM’s.
Figure 53. Ammeter (Load)
17. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 51. Engine Tachometer
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DCA-45USI — GENERATOR SHUT-DOWN PROCEDURE
Emergency Shut-down Procedure
Normal Shut-down Procedure
1. To shut-down the engine in the event of an emergency,
switch the MAIN, GFCI and LOAD (Figure 54) circuit
breakers to OFF position.
To shutdown the generator, use the following procedure:
1. Switch the MAIN, AUX and GFCI circuit breakers
(Figure 54) to the OFF position (no load).
2. Turn the ignition switch key to the STOP position
(Figure 55).
Automatic Shut-down SystemWN
This unit is equipped with safety devices to automatically
stop the engine in the event of low oil pressure
(approx. 14 PSI.), or high water temperature
(approx. 221° F). The alarm lamps on the Engine Control
Panel (Figure 5) illuminate to signify the reason for the
shut-down.
Figure 54. Main, AUX. and GFCI
Circuit Breakers (OFF)
CAUTION:
After automatic shut-down, ALWAYS inspect
the unit and eliminate any problems before
attempting to restart. Failure to do so can
damage the unit.
3. Let the engine cool by running it for 3-5 minutes with no
load applied (circuit breakers in the OFF position).
4. Place the ignition switch (Figure 55) in the STOP position,
remove the key and store in a safe place.
Before inspecting, turn the starter switch to the STOP
position, place all Generator Circuit Breakers in the OFF
position and allow sufficient time for adequate cooling. When
ready to restart, complete all steps in the Generator Startup
Procedure section of this manual.
Engine protection is furnished
during operation, but cannot
replace normal preventive
maintenance.
NOTE
Figure 55. Ignition Switch (Off Position)
5. Remove all loads from the generator.
6. Allow for sufficient time for cooling and then inspect
the complete unit for any damage or loosening that
may have occured during operation.
Regularly maintain the unit as specified in the Maintenance
section of this manual to prevent damage.
7. Check the engine oil, coolant and fuel levels. Replenish
as necessary.
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DCA-45USI — MAINTENANCE
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
TABLE 14. INSPECTION/MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check Fluid Levels for Containment
Check for Loosening of Parts
1
Replace Engine Oil and Filter *
X
X
X
X
X
X
Drain Bottom of Fuel Tank
ENGINE
Check Fuel Filter/Water Seperator Bowl
Clean Unit, Inside and Outside
2
Check Blowby Hose *
Clean Air Filter
3
Replace Air Filter Element *
X
X
X
4
Change Fuel Filter *
Clean Radiator and Check Coolant Protection Level
Check all Hoses and Clamps
X
X
Clean Inside of Fuel Tank
Measure Insulation Resistance
GENERATOR
X
Check Rotor Rear Support Bearing
X
*1 Replace engine oil anf filter at 50 hours, first time only.
*2 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot, with
no sags or dips that could collect moisture and/or oil.
*3 Replace primary air filter element when restriction indicator shows a vaccumm of 625 mm. (25 in.) H2
*4 Push priming pump on fuel filter when air bleeding. It is not necessary to loosen any plugs.
0
General Inspection
Service Daily
Prior to each use, the generator should be cleaned and If the engine is operating in very dusty or dry grass
inspected for deficiencies. Check for loose, missing or conditions, a clogged air cleaner will result.This can lead to
damaged nuts, bolts or other fasteners. Also check for fuel, a loss of power, excessive carbon buildup in the combustion
oil, and coolant leaks.
chamber and high fuel consumption. Change air cleaner
more frequently if these conditions exists.
Engine Side (Refer to the Engine Instruction Manual)
Air Cleaner
Fuel Addition
Every 250 hours: Remove air cleaner element and clean the Add diesel fuel (the grade may vary according to season
heavy duty paper element with light spray of compressed and locations). Always pour through the mesh filter.
air. Replace the air cleaner as needed.
RemovingWater from the FuelTank
Air Cleaner with Dust Indicator
After prolonged use, water and other impurities accumulate
This indicator is attached to the air cleaner. When the air in the bottom of the tank. Occasionally inspect the fuel tank
cleaner element is clogged, air intake restriction becomes for water contamination and drain the contents if required.
greater and the dust indicator signal shows RED meaning
the element needs changing. After changing the air element,
press the dust indicator button to reset the indicator.
by keeping the tank full with diesel fuel.
During cold weather, the more empty volume inside the tank,
the easier it is for water to condense. This can be reduced
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DCA-45USI — MAINTENANCE
CAUTION:
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.
Allow engine to cool when flushing out
radiator.Flushing the radiator while hot could
cause serious burns
from water or steam.
To restart after running out of fuel, turn the switch to the ON
position for 15-30 seconds. Try again, if needed.This unit is
equipped with an automatic air bleeding system.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level.The oil level
must be between the two notches on the dipstick as shown
in Figure 33.
Flushing Out Radiator and Replacing Coolant
z
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant.Open the
radiator cap while draining. Remove the overflow tank
and drain.
Replacing Oil Filter
z
z
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
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.
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.
z
z
z
Tighten both cocks and replace the overflow tank.
Replace with coolant (Table 12 for correct mixture).
Close radiator cap tightly.
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 500 Generator Storage
hours or so.
For longe term storage of the generator the following is
Loosen the drain plug at the lower top of the fuel filter. recommended:
Drain the fuel in the fuel body together with the mixed
z
z
Fill the fuel tank completely.Treat with a fuel stabilizer if
water. DO NOT spill the fuel during disassembly.
necessary.
Vent any air.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
z
z
z
z
z
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Make sure engine coolant is at proper level.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
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DCA-45USI —TRAILER BRAKES MAINTENANCE
Brakes
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 56) should not require any
operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance
properly. After the first 200 mile interval, inspect the brakes such as shoe and lining replacement. Brake lines should be
every 3,000 miles. If driving over rough terrain, inspect the perio
brakes more frequently.
Figure 74 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 as listed below:
Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
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 56. 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.
Periodically check and test the surge “actuator ” to make
sure that it is functioning correctly. Never use an undersize
actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
Repair or replace.
Reburnish or replace.
Correct weight.
No Brakes
Brake line broken or kinked?
Brake lining glazed?
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?
Brake drums out-of-round?
System lubricated?
Replace components.
Replace.
Locking Brakes
Noisy Brakes
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness incorrect or not
adjusted correctly?
Install new shoes and
linings.
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
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DCA-45USI —TRAILER MAINTENANCE
Suspension
Tires/Wheels/Lug Nuts
The leaf suspension springs and associated components
(Figure 57) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 17.
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt
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.
TireWear/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.
Figure 57. Major Suspension Components
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Table 17. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-60
TABLE 16 TIRE WEARTROUBLESHOOTING
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
SOLUTION
CAUSE
WEAR PATTERN
Adjust pressure to
particular load per tire
manufacturer.
Over Inflation.
Center Wear
Adjust pressure to
particular load per tire
manufacturer.
Make sure load does
not exceed axle rating.
Align wheels.
Under Inflation.
Edge Wear
Side Wear
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.
Loss of camber
or overloading.
SPRING EYE BOLT
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
Check bearing adjustment
and balance tires.
Wheel lockup &
tire skidding.
Avoid sudden stops when
possible and adjust brakes.
Flat Spots
CAUTION:
ALWAYS wear safety glasses when removing or
installing force fitted parts.Failure to comply may
result in serious injury.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 43
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DCA-45USI —TRAILER MAINTENANCE
Lug NutTorque 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 58. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
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
NEVER use an pneumatic air
gun to tighten wheel lug nuts.
NOTE
Figure 58. Wheel Lug Nuts Tightening Sequence
PAGE 44 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI —TRAILERWIRING DIAGRAM
Figure 59. Trailer/Towing Vehicle Wiring Diagram
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 45
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DCA-45USI — ENGINEWIRING DIAGRAM
Figure 60. Engine Wiring Diagram
PAGE 46 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — ENGINEWIRING DIAGRAM
Figure 60. Engine Wiring Diagram(Continued)
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 47
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DCA-45USI — GENERATORWIRING DIAGRAM
PAGE 48 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI —TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use the table (Table 19) shown below for basic Generator Troubleshooting. If the problem cannot be remedied,
consult our company's business office or service plant.
TABLE 19. GENERATOR TROUBLESHOOTING
SYMPTOM
No Voltage Output
POSSIBLE PROBLEM
AC Voltmeter defective?
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
Is wiring connection loose?
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier?
Defective Exciter Field?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Check for 17.6 ohms across J and K on CN5
Check engine speed and adjust to the correct speed
Check wiring and repair.
Low Voltage Output
Replace if necessary.
High Voltage Output
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Circuit Breaker Tripped
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 49
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EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.
Items Found In the “Items Number” Column
All parts with same symbol in the number column, , #,
*
+,%, or <, belong to the same assembly or kit
If more than one of the same
reference number is listed, the last
one listed indicates newest (or
latest) part available.
The contents of this catalog are
subject to change without notice.
PAGE 50 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — SUGGESTED SPARE PARTS
DCA-45USI
w/ ISUZU BB-4JG1T
1TO 3 UNITS
Description
Qty.
P/N
3 ......... 8970497081 ..............OIL FILTER
3 ......... 8943692993 ..............FUEL FILTER
3 ......... 0602046681 ..............AIR ELEMENT
1 ......... 0602122272 ..............UNIT, OIL PRESSURE
1 ......... 0602123260 ..............UNIT WATERTEMPERATURE
1 ......... 8972606490 ..............FAN BELT
3 ......... 8944024980 ..............KEY, STARTER SWITCH
1 ......... 0605505070 ..............CAP, FUEL TANK
1 ......... 9827200690 ..............SENDER, OIL PRESSURE (ENGINE SIDE)
1 ......... 8970785920 ..............SENDER, WATER TEMPERATURE (ENGINE SIDE)
2 ......... 0601802149 ..............FUSE, 10A
Part number on this Suggested
NOTE
Spare Parts list may supercede/
replace the P/N shown in the text
pages of this book.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 51
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DCA-45USI — GENERATOR ASSY.
GENERATO
PAGE 52 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
PART NO.
PART NAME
ROTOR ASSY.
FIELD ASSY.
FAN
HEX, HEAD BOLT
SPRINGWASHER
COUPLING DISK
QTY.
REMARKS
B3110100202
1
1
1
8
8
4
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
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
8051070003
0010310035
0042510000
8041611004
8041015003
0010310025
0042510000
8001026013
0601821349
0601822601
8001020004
8001020504
0010108020
0040008000
0601000209
0071906310
M1164400003
0012808030
B3130100103
0845041904
M1164600003
0012810030
8041315202
8041350013
0010308065
0042608000
0041208000
0017108030
8041310024
8041312014
0017106012
8041331014
0017106012
8001333003
0340406040
0041206000
0012810030
8051332014
0600815000
0605000055
0030012000
0040012000
0041212000
BALANCING PLATE ............................................1 ............. PURCHASE SET OF 1-16
HEX, HEAD BOLT
SPRINGWASHER
SET PLATE, RECTIFIER BALANCING PLATE...1 ............. PURCHASE SET OF 1-16
RECTIFIER .........................................................2 ............. PT3610
SURGE ABSORBER...........................................1 ............. ERZ-M14JK621A
INSULATORWASHER
INSULATORWASHER
HEX, HEAD BOLT
SPRINGWASHER
BALANCING WEIGHT KIT
6
6
1
1
4
4
1
BEARING ............................................................1 ............. 6310DDU C3
COUPLING RING
HEX, HEAD BOLT
STATOR ASSY.
1
6
1
2
1
8
1
1
4
4
4
6
1
1
4
1
4
1
2
2
6
1
1
2
2
2
2
GROMMET
COUPLING ADAPTER
HEX, HEAD BOLT
END BRACKET
FIELD ASSY. EXCITER
HEX, HEAD BOLT
SPRINGWASHER
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
SPRINGWASHER
PLAIN WASHER
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 53
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DCA-45USI — CONTROL BOX ASSY.
PAGE 54 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
M1214000102
0601808825
0021005080
0601823863
0027104016
0601820671
0027105016
0601806116
0027106016
0601820845
0601820846
0027104016
0207004000
M1213500303
0016906016
M1201000004
TBD
CONTROL BOX
1
CIRCUIT BREAKER, 3-POLE, 110A...................1 ............. KAF361101039
MACHINE SCREW
RELAY UNIT .......................................................2 ............. MSA9013A
MACHINE SCREW
AUTOMATICVOLTAGE REGULATOR..................1 ............. NTA-5A-2DB
MACHINE SCREW
CURRENTTRANSFORMER ...............................3 ............. 812-943 75/5A
MACHINE SCREW
OVER CURRENT RELAY ....................................1 ............. LR2D1308
OVER CURRENT RELAY ....................................1 ............. LA7D1064
MACHINE SCREW
HEX, NUT
4
4
4
9
6
10
11
12
12A
13
14
15
15A
16
17
18
19
20
21
22
22A
23
24
25
26
27
28
2
2
1
4
CONTROL BOX COVER
HEX, HEAD BOLT
SELECTOR SWITCH ..........................................1 ............. VY-40
KNOB, SELECTOR
SWITCH BRACKET
MACHINE SCREW
HEX, HEAD BOLT
EDGING
SWITCH COVER
HEX, HEAD BOLT
HEX, HEAD BOLT
TOOTHEDWASHER
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
1
1
4
4
1
1
3
8
1
1
M1215601204
0027103010
0016906016
0330000530
M1215601104
0016906016
0016906016
0040506000
M1224000003
0601807641
0601808986
0601801040
0601806859
0601801041
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 55
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DCA-45USI — CONTROL BOX ASSY.
PAGE 56 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
29
30
31
31A
32
32A
33
34
35
36
37
38
38
38A
38A
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
58
59
60
60A
61
62
63
64
PART NO.
PART NAME
RHEOSTAT(VOLTAGE REGULATOR) ..................1 ........ RA20A2SE102BJ 2W 1K OHM
KNOB
STARTER SWITCH .............................................1 ........ ISUZU 897044-4180
IGNITION KEY
PREHEAT LAMP .................................................1 ........ PL-05
BULB, E-10 T-10 DC18V
TACHOMETER ....................................................1 ........ 103680
OIL PRESSURE GAUGE ....................................1 ........ 100174
WATERTEMPERATURE GAUGE .......................1 ........ 100683
CHARGING AMMETER ......................................1 ........ 100158
FUEL GAUGE......................................................1 ........ 100176
QTY.
REMARKS
0601840073
0601840121
0602100009
8944024980
0602103092
0601810245
0602120095
0602122093
0602123090
0602121080
0602125090
0602103092
0602103092
0601810245
0601810245
0601810141
0601831330
M1224100104
0027105010
0027105010
M9220100004
0080200007
0602200432
0602202506
0016906020
0602200305
0602201400
0016906016
0606503062
M1414800104
0016908020
M1247700114
M1358200112
M3357200304
0601823223
0601823245
0601802149
0602103092
0601810245
06021222272
M9200100004
0602123260
0602021109
1
1
1
ALARM LAMP, PL-05
ALARM LAMP, PL05 ...........................................4 ........ S/N 8200081~
BULB, E-10 T-10 DC18V
3
3
BULB, E-10 T-10 DC18V ......................................4 ........ S/N 8200081~
PANEL LIGHT......................................................1 ........ 98268-O0370
SWITCH, PANEL LIGHT
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
1
1
2
4
2
2
SNAP RING
EMERGENCY RELAY .........................................1 ........ 897111-9621
PREHEAT CONTROLLER ...................................1 ........ 897246-5100
HEX, HEAD BOLT ...............................................3
SAFETY RELAY .................................................1 ........ 182553-0430
RELAY .................................................................1 ........ 582550-0290
HEX, HEAD BOLT
FUEL LEAK DETECTED SWITCH
BRACKET
HEX, HEAD BOLT
WIRE HARNESS, GENERATOR
WIRE HARNESS, ENGINE
3
1
1
2
1
1
WIRE, HARNESS, FUEL LEAK ..........................1 ........ S/N 8200081~
RECTIFIER .........................................................2 ........ S/N 8200001TO 8200080
RECTIFIER .........................................................2 ........ S/N 8200001TO 8200080
FUSE, 10A ..........................................................2 ........ S/N 8200081~
ALARM LAMP, PL05 ...........................................4 ........ S/N 8200081~
BULB, E-10 T-10 DC18V ......................................4 ........ S/N 8200081~
UNIT, OIL PRESSURE ........................................1 ........ 108497
ADAPTER
1
UNIT, WATERTEMPERATURE ...........................1 ........ 02094-00
PACKING.............................................................1 ........ 909572-0140
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 57
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DCA-45USI — ENGINE AND RADIATOR ASSY.
ENGIN
PAGE 58 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
1
1-1
2
3
4
5
6
6A
7
8
PART NO.
PART NAME
QTY.
REMARKS
M1924200014
897049-7081
0605000048
0030010000
0040010000
0041210000
M1923200084
0602011079
M9312200104
0016908040
0207008000
M1311500003
M1311500103
0605515201
M1424700104
M1424700004
0016906016
0602046582
0602046681
0602040651
M1374200104
0602040556
0016908020
0207008000
0016910025
M1374100003
M1374100103
0605515148
0605515200
0602022560
M1320300304
0602022561
0603306590
ENGINE...............................................................1 ........ ISUZU BB-4JG1T
CARTRIDGE, OIL FILTER ...................................1 ........ REPLACES 0602041214
RUBBER SUSPENSION
HEX, NUT
SPRINGWASHER
PLAIN WASHER
RADIATOR ...........................................................1 ........ 2951-293-0000
CAP, RADIATOR ..................................................1 ........ 6713-092-0901
MOUNT RUBBER
HEX, HEAD BOLT
HEX, NUT
RADIATOR HOSE
RADIATOR HOSE
HOSE BAND
FAN GUARD
FAN GUARD
2
2
2
2
2
2
2
1
1
4
1
1
7
9
10
11
12
13
14
15
16
16A
17
18
19
20
21
22
23
24
25
26
27
28
29
30
HEX, HEAD BOLT
AIR CLEANER ....................................................1 ........ FPG08-2527
ELEMENT, AIR CLEANER ..................................1 ........ P82-8889
INDICATOR, AIR CLEANER ................................1 ........ RBX00-2352
BRACKET, AIR CLEANER
BAND, AIR CLEANER
HEX, HEAD BOLT
HEX, NUT
HEX, HEAD BOLT
HOSE, AIR CLEANER
HOSE, AIR CLEANER
HOSE BAND
HOSE BAND
ADAPTER
PACKING
90 DEG. ELBOW
CONNECTOR
1
1
2
2
2
1
1
1
2
1
1
1
1
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 59
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DCA-45USI — ENGINE AND RADIATOR ASSY.
ENGIN
PAGE 60 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — ENGINE AND RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
58
59
60
61
62
63
64
65
66
67
68
69
PART NO.
PART NAME
ROCKNUT
VALVE
HOSE JOINT
CAP
DRAIN HOSE
DRAIN JOINT
PLUG
QTY.
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
2
1
1
2
1
1
1
5
1
2
1
4
REMARKS
0603300285
0605511395
0603306395
0602021070
0269200310
M2320300103
M920020004
0150000018
0016906016
0199100850
0605515106
M9300000003
M9300100003
0199100215
M1317100004
0016908020
0199101700
0193601200
0605515106
0199800730
0269200480
0605515198
0602120465
M1358300104
M1358300004
0016908020
M1358300204
0017110020
M1924200004
0016910025
0602210810
0027106016
9827200690
8970785920
8971882810
O-RING
HEX, HEAD BOLT
DRAIN HOSE
HOSE BAND
RESERVE TANK
CAP, RESERVE TANK
HOSE
BRACKET, RESERVE TANK
HEX, HEAD BOLT
HOSE
HOSE
HOSE BAND
HOSE
BLOWBY HOSE
HOSE BAND
PICK UP, TACHOMETER
HARNESS CLAMP
HARNESS CLAMP
HEX, HEAD BOLT
HARNESS CLAMP
HEX, HEAD BOLT
MOTOR FAN
HEX, HEAD BOLT
ENGINE STOPPER.............................................1 ........ 181900-1902
MACHINE SCREW
SENDER, OIL PRESSURE
SENDER, WATERTEMPERATURE
V-BELT
3
1
1
1
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 61
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DCA-45USI — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
PAGE 62 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — OUTPUTTERMINAL ASSY.
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
0016906020
0016906016
M1236400004
M1236300004
0016906020
0601808803
0601808804
M1260700304
0222100150
0016906020
0601812598
0601812538
0027104016
0207004000
M1236100803
0010112045
0041212000
M9310200004
0030012000
0027103010
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE SCREW
5
HEX, NUT
SPRINGWASHER
PLAIN WASHER
HEX, HEAD BOLT
TERMINAL COVER
OUTPUTWINDOW
HINGE
MACHINE SCREW
HEX, NUT
10
15
20
5
1
1
2
4
8
4
2
4
1
1
9
10
11
11A
11B
12
13
14
15
16
17
18
19
19A
20
21
22
23
23A
24
25
26
27
28
29
PLAIN WASHER
HEX, HEAD BOLT
HEX, HEAD BOLT
CABLE OUTLET COVER
SUPPORTER, CABLE OUTLET COVER
HEX, HEAD BOLT
CIRCUIT BREAKER, 1-POLE, 20A.....................2 ................. QOU 120B
CIRCUIT BREAKER, 2-POLE, 50A.....................3 ................. QOU 250B
BREAKER FITTING COVER
CUSHION RUBBER
HEX, HEAD BOLT
RECEPTACLE .....................................................2 ................. GF-530EM 125V 20A X 2
RECEPTACLE .....................................................3 ................. CS6369 250V 50A
MACHINE SCREW
HEX, NUT
TERMINAL COVER
HEX, HEAD BOLT
PLAIN WASHER
STAY RUBBER
HEX, NUT
6
1
1
2
10
10
1
2
2
2
2
4
MACHINE SCREW
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 63
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DCA-45USI — BATTERY ASSY.
BATTERY ASSY.
PAGE 64 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — BATTERY ASSY.
BATTERY ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
0602220187
M9310500014
M9103000304
0602220920
0040006000
M1347200004
M1347200104
0016910020
0040510000
BATTERY
1
1
1
2
2
1
1
2
2
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET
SPRINGWASHER
BATTERY CABLE
BATTERY CABLE
HEX, HEAD BOLT
TOOTHEDWASHER
9
10
CABLE, GROUND ...............................................1 ..................... MAKE LOCALLY
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 65
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DCA-45USI — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 66 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
2
3
4
5
6
PART NO.
PART NAME
QTY.
REMARKS
M1331100102
0017112030
M1334000003
0602320101
0039308000
0602325088
MUFFLER
1
4
1
HEX, HEAD BOLT
EXHAUST PIPE
GASKET .............................................................1 ........ 894369-0210
HEX, NUT
SEAL CLAMP
6
1
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 67
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DCA-45USI — FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 68 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — FUELTANK ASSY.
FUEL TANK ASSY.
NO.
1
1A
1B
1C
2
3
4
5
5A
6
7
8
8A
9
10
11
12
13
14
15
15
PART NO.
PART NAME
QTY.
REMARKS
M1364000102
0605505070
0605501072
0605516090
M1364200004
M9310500104
0016908020
0016908065
0207008000
0191301300
0605515109
897211-2730
897213-4720
M1367700004
0016908020
0191200550
0191201600
0605515108
0191300750
0605515109
0222100700
FUELTANK
1
1
1
1
4
4
4
2
6
1
2
FUEL TANK CAP
FUEL SENDER UNIT
GASKET
TANK BAND
SUPPORTER SHEET
HEX, HEAD BOLT
HEX, HEAD BOLT
HEX, NUT
VENT HOSE
HOSE BAND
FUEL FILTER ......................................................1 ........ REPLACES 0602042203
CARTRIDGE, FUEL FILTER ...............................1 ........ REPLACES 0602042701
BRACKET, FUEL FILTER
HEX, HEAD BOLT
SUCTION HOSE
SUCTION HOSE
HOSE BAND
RETURN HOSE
HOSE BAND
TANK SHEET
1
4
1
1
4
1
2
5
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 69
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DCA-45USI — ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 70 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
1
1A
2
3
4
PART NO.
PART NAME
QTY.
REMARKS
M1414000202
M1494000004
M1414800003
0603306797
0017110040
M1424000012
M1494100004
M1493104804
M1311600004
0016908020
M1424000302
M1424000402
0314502100
M1494100004
M1493104804
0601851756
0601851736
0601850266
M1424500204
0016906016
M1424500104
0016906016
0016908020
0016908020
M1424200504
0016906016
M1311600104
M1484400004
M1484400103
0016906018
M1424200303
M1424200313
M1494100104
0016908020
M1434300203
M1434300303
0010116040
BASE
1
1
1
1
8
1
ACOUSTIC SHEET
ENVIRONMENTALTANK
PLUG,1-1/2
HEX, HEAD BOLT
FRONT FRAME
ACOUSTIC SHEET .............................................1 ........ S/N 8200001TO 8200080
ACOUSTIC SHEET .............................................1 ........ S/N 8200081~
RADIATOR COVER
HEX, HEAD BOLT
FRONT FRAME...................................................1 ........ S/N 8200001TO 8200080
FRONT FRAME...................................................1 ........ S/N 8200081~
SEAL
ACOUSTIC SHEET .............................................1 ........ S/N 8200001TO 8200080
ACOUSTIC SHEET .............................................1 ........ S/N 8200081~
GROMMET, C30-SG-70A ....................................1 ........ S/N 8200001TO 8200080
GROMMET, C30-SG-60A
GROMMET, C30-SG-28A
BLOWBY COVER
HEX, HEAD BOLT
GUARD
HEX, HEAD BOLT
HEX, HEAD BOLT
HEX, HEAD BOLT
DUCT COVER
5
5A
5A
6
7
8
1
2
8
8A
8B
8B
9
1
10
11
12
13
14
15
16
17
18
19
20
20
20
21
22
22
22A
23
24
25
26
2
4
1
6
1
4
8
4
2
HEX, HEAD BOLT
16
HOSE COVER .....................................................1 ........ S/N 8200001TO 8200080
HOSE COVER .....................................................1 ........ S/N 8200081~
HOSE COVER .....................................................1 ........ S/N 8200081~
HEX, HEAD BOLT
4
COVER, FRONT FRAME ....................................1 ........ S/N 8200001TO 8200080
COVER, FRONT FRAME ....................................1 ........ S/N 8200081~
ACOUSTIC SHEET
HEX, HEAD BOLT
CENTER FRAME
CENTER FRAME
HEX, HEAD BOLT
1
3
1
1
6
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 71
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DCA-45USI — ENCLOSURE ASSY.
ENCLOS
PAGE 72 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
26A
26B
27
27A
27B
28
28A
29
29A
30
31
32
32A
33
33
34
35
36
36A
37
38
38A
39
40
41
PART NO.
PART NAME
QTY.
6
6
4
4
4
1
1
2
1
12
4
1
1
REMARKS
0040016000
0041216000
0010116040
0040016000
0041216000
M1444000102
M1494300003
M1444800004
M1494300204
0207006000
0016908020
M1444300003
M1494300104
0016908020
0019208020
M1444200003
M1444600004
0207306000
0041206000
M9113000002
0021806016
0030006000
M9112100404
M9112100604
0016908020
M1464000002
M1494500004
0016908020
0019208020
M1465400104
0016908020
0019208020
M1454200002
0016908020
0016908065
0019208065
M1454000403
SPRINGWASHER
PLAIN WASHER
HEX, HEAD BOLT
SPRINGWASHER
PLAIN WASHER
REAR FRAME
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
HEX, NUT
HEX, HEAD BOLT
REAR COVER
ACOUSTIC SHEET
HEX, HEAD BOLT ...............................................6 ........ S/N 8200001TO 8200080
HEX, HEAD BOLT ...............................................6 ........ S/N 8200081~
REAR DOOR
WINDOW PLATE
HEX, NUT
PLAIN WASHER
DOOR HANDLE ASSY.
MACHINE SCREW
HEX, NUT
HINGE
HINGE
HEX, HEAD BOLT
ROOF PANEL
ACOUSTIC SHEET
HEX, HEAD BOLT .............................................18 ........ S/N 8200001TO 8200080
HEX, HEAD BOLT .............................................18 ........ S/N 8200081~
COVER
HEX, HEAD BOLT ...............................................2 ........ S/N 8200001TO 8200080
HEX, HEAD BOLT ...............................................2 ........ S/N 8200081~
SPLASHER PANEL
HEX, HEAD BOLT
HEX, HEAD BOLT ...............................................1 ........ S/N 8200001TO 8200080
HEX, HEAD BOLT ...............................................1 ........ S/N 8200081~
SIDE DOOR
1
1
8
8
1
4
4
2
2
8
1
1
42
42A
43
43
44
45
45
46
47
1
1
3
48
48
49
1
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 73
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DCA-45USI — ENCLOSURE ASSY.
ENCLOS
PAGE 74 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
49A
50
50A
51
51A
52
52A
53
53A
54
54A
55
56
57
58
59
60
61
62
63
64
PART NO.
PART NAME
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
DOOR HANDLE ASSY.
SEAL RUBBER
MACHINE SCREW
HEX, NUT
HINGE
HINGE
QTY.
1
1
1
1
1
1
1
2
2
8
8
4
4
8
32
2
5
REMARKS
M1494400404
M1454000103
M1494400104
M1454000503
M1494400504
M1454000303
M1494400304
M9113000002
C9312500004
0021806016
0030006000
M9112100404
M9112100504
M9112100604
0016908020
0016908020
0601850097
0027208025
0605503062
M1414800104
0017108020
HINGE
HEX, HEAD BOLT
HEX, HEAD BOLT
STOPPER
MACHINE SCREW
5
FUEL LEAK DETECTION SWITCH ....................1 ........ S/N 8200081~
BRACKET ...........................................................1 ........ S/N 8200081~
HEX HEAD BOLT ................................................2 ........ S/N 8200081~
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 75
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DCA-45USI — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
PAGE 76 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
3
3
1
1
1
1
1
1
1
2
1
2
1
REMARKS
0229200950
0228901385
0228900900
0229400900
0228900795
0028900590
0229400445
0228800455
0228900445
0229200455
0228100870
0229200840
0229200560
0229200790
0228800800
0228800800
0228900475
0228900470
0228800475
0228800470
0228100420
0228100325
0314500700
0330000460
0330000180
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
15
16
16
17
17
18
19
20
22
23
SEAL RUBBER ...................................................1 ........ S/N 8200001TO 8200080
SEAL RUBBER ...................................................2 ........ S/N 8200081~
SEAL RUBBER ...................................................1 ........ S/N 8200001TO 8200080
SEAL RUBBER ...................................................1 ........ S/N 8200081~
SEAL RUBBER ...................................................1 ........ S/N 8200001TO 8200080
SEAL RUBBER ...................................................1 ........ S/N 8200081~
SEAL RUBBER
SEAL RUBBER
SEAL
2
2
1
1
1
EDGING
EDGING
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 77
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DCA-45USI — NAMEPLATE AND DECALS ASSY.
NAME PLATE ASSY.
PAGE 78 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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DCA-45USI — NAMEPLATE AND DECALS ASSY.
NAME PLATE ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
M1511400002
M1511400102
M1550000204
M1550000703
M1550000804
M9500000004
M9500100004
M9500300004
M9500300104
M9500500004
M9503000004
M9503000103
M9503100004
M9503200004
M9510000004
M9510100004
M9512200004
M9520000004
M9520000104
M9520000204
M9520100004
M9520100204
M9520100304
M9520100404
M9520100503
M9520200003
M9520200104
M1561000004
DECAL, GENERATOR CONTROL ................................ 1 ............. M11140000A
DECAL, ENGINE OPERATING .................................... 1 ............. M11140010A
DECAL, NOTE .............................................................. 1 ............. M15000020
DECAL, AUXILIARY OUTPUT ...................................... 1 ............. M15000070
DECAL, NOTE .............................................................. 1 ............. M15000080
DECAL, OIL DRAIN PLUG ........................................... 1 ............. M90000000
DECAL, WATER ............................................................ 1 ............. M90010000
DECAL, - ...................................................................... 1 ............. M90030000
DECAL, + ..................................................................... 1 ............. M90030010
DECAL, DIESEL FUEL................................................. 1 ............. M90050000
DECAL, WARNING MOVING PARTS ........................... 2 ............. M90300000
DECAL, WATER - OIL CHECK ..................................... 1 ............. M90300010
DECAL, WARNING HOT COOLANT ............................. 1 ............. M90310000
DECAL, WARNING ENGINE EXHAUST ....................... 1 ............. M90320000
DECAL, FLUID DRAIN ................................................. 1 ............. M91000000
DECAL, CAUTION HOT PARTS ................................... 1 ............. M91010000
DECAL, MQ .................................................................. 1 ............. M91220000
DECAL, GROUND ........................................................ 1 ............. M92000000
DECAL, AMMETER CHANGE-OVER SW. ................... 1 ............. M92000010
DECAL, VOLTMETER CHANGE-OVER SW. ................ 1 ............. M92000020
DECAL, WARNING ELECTRIC SHOCK HAZARD ....... 2 ............. M92010000
DECAL, CAUTION ........................................................ 1 ............. M92010020A
DECAL, SAFETY INSTRUCTION................................. 1 ............. M92010030
DECAL, DANGER HIGHVOLTAGE............................... 1 ............. M92010040
DECAL,WARNING ....................................................... 1 ............. M92010050
DECAL, CONNECTION OF OUTPUT CABLE .............. 1 ............. M92020000
DECAL, OVER CURRENT RELAY ............................... 1 ............. C92020010
DECAL, MQ POWER ................................................... 3 ............. S/N 8200001TO
...................................................................................................... 8200080
DECAL, MQ POWER ................................................... 2 ............. S/N 8200081~
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
28
29
30
31
32
33
34
35
36
37
M1561000004
M1561100004
M1561100103
M1561100204
M1561100304
M1561100404
M9510100304
M9520000304
0600500092
STRIPE
STRIPE, WHISPERWATT
STRIPE, 45
STRIPE, 45
STRIPE
DECAL, ENVIRONMENTAL WARNING ........................ 1 ............. S/N 8200081~
DECAL, FUEL LEAK DETECTED ................................ 1 ............. S/N 8200081~
PLATE, MQ POWER .................................................... 1 ............. S/N 8200081~
MACHINE SCREW ....................................................... 4 ............. S/N 8200081~
2
2
1
1
2
0021106016
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 79
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Effective:October 1, 2002
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
5. Parts must be in new and resalable
condition,intheoriginalMultiquippack-
age (if any), and with Multiquip part
numbersclearlymarked.
Rebatesforpricedeclinesandaddedcharges
for price increases will not be made for stock
onhandatthetimeofanypricechange.
Terms of payment for parts are net 10 days.
FREIGHTPOLICY
Multiquip reserves the right to quote and sell
directtoGovernmentagencies,andtoOriginal
Equipment Manufacturer accounts who use
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:
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIALEXPEDITINGSERVICE
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
priortothereturndate.
A$35.00surchargewillbeaddedtotheinvoice
forspecialhandlingincludingbusshipments,
insuredparcelpostorincaseswhereMultiquip
mustpersonallydeliverthepartstothecarrier.
MINIMUMORDER
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
LIMITATIONSOFSELLER’SLIABILITY
c. Anylineitemwithanextendeddealer
netpriceoflessthan$5.00.
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
itemwithrespecttowhichdamagesareclaimed,
andinnoeventshallMultiquipbeliableforloss
of profit or good will or for any other special,
consequentialorincidentaldamages.
RETURNEDGOODSPOLICY
d. Special order items.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremadein
connectionwiththesaleofpartsortradeacces-
soriesnorastoanyenginenotmanufactured
byMultiquip.Suchwarrantiesmadeinconnec-
tion with the sale of new, complete units are
madeexclusivelybyastatementofwarranty
packagedwithsuchunits,andMultiquipnei-
ther assumes not authorizes any person to
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.
7. The sender will be notified of any
materialreceivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Such material will be held for five
workingdaysfromnotification,pending
instructions. If a reply is not received
within five days, the material will be
returnedtothesenderathisexpense.
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. Incaseswhereanitemisaccepted,for
which the original purchase document
cannotbedetermined,thepricewillbe
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
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-
cific date and all orders received on or after
that date will be billed at the revised price.
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
PAGE 80 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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NOTE PAGE
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 81
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PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-632-2656
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX:310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
WARRANTYDEPARTMENT
800-835-2551,EXT.279
310-537-3700,EXT.279
FAX:310-631-5032
FAX:310-638-8046
Manufactured for Multiquip Inc.
by
DENYO CO., LTD, JAPAN
Your Local Dealer is:
MQPOWER
ADivisionofMultiquipInc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-632-2656
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