Multiquip Portable Generator DCA 45US1 User Manual

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.  
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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  
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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