OPERATION AND PARTS MANUAL
®
MODEL DCA45USI2
60HZ WHISPERWATT™ GENERATOR
(ISUZU BU-4JJ1T DIESEL ENGINE)
PARTS LIST NO. M1870400004
Revision #0 (01/12/11)
To find the latest revision of this
publication, visit our website at:
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
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PROPOSITION 65 WARNING
Diesel engine exhaust and some of
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REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at
write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
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TABLE OF CONTENTS
Component Drawings
DCA45USI2 Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects......................................... 3
Table Of Contents.................................................... 4
Parts Ordering Procedures...................................... 5
Safety Information .............................................. 6-11
Specifications ........................................................ 12
Dimensions............................................................ 13
Installation ............................................................. 14
Installation ............................................................. 15
General Information............................................... 16
Major Components ................................................ 17
Generator Control Panel........................................ 18
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization .............. 22-24
Load Application.................................................... 25
Generator Outputs................................................. 26
How To Read AC Ammeter/AC Voltmeter Gauges 27
Output Terminal Panel Connections ................. 28-29
Inspection/Setup............................................... 30-33
Generator Start-Up Procedure ........................ 34-35
Generator Shut-Down Procedures ........................ 36
Maintenance..................................................... 37-39
Trailer Maintenance .......................................... 40-43
Trailer Wiring Diagram ........................................... 44
Generator Wiring Diagram..................................... 45
Engine Wiring Diagram.......................................... 46
Troubleshooting (Generator).................................. 47
Troubleshooting (Diagnostic Lamp)....................... 48
Generator Assembly......................................... 52-53
Control Box Assembly ...................................... 54-59
Engine and Radiator Assembly ........................ 60-63
Output Terminal Assembly................................ 64-65
Battery Assembly.............................................. 66-67
Muffler Assembly.............................................. 68-69
Fuel Tank Assembly.......................................... 70-71
Enclosure Assembly......................................... 72-75
Rubber Seals Assembly ................................... 76-77
Nameplate and Decals Assembly .................... 78-79
Terms And Conditions Of Sale — Parts ................ 80
Explanation Of Code In Remarks Column............. 50
Suggested Spare Parts ......................................... 51
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PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Effective:
January 1st, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
to log in and save!
Order Parts
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
Order via Phone:
1-800-427-1244
Non-Dealer Customers:
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
❒
Dealer Account Number
❒
Specify Preferred Method of Shipment:
❒
❒
❒
❒
❒
Dealer Name and Address
✓ UPS/Fed Ex
✓ DHL
✓ Truck
■
■
Priority One
Ground
Shipping Address (if different than billing address)
Return Fax Number
■ Next Day
Second/Third Day
Applicable Model Number
■
Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
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SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others.The
safety messages specifically address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
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SAFETY INFORMATION
NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment.Damage
to the equipment and/or injury to user may result.
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
ALWAYS know the location of the nearest
fire extinguisher.
ALWAYS know the location of the nearest
first aid kit.
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.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the influence of
drugs or alcohol.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials.An
explosion or fire could result causing severe
bodily harm or even death.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
WARNING
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death.Disconnection of any of these
devices will void all warranties.
NOTICE
This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
CAUTION
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
ALWAYS store equipment properly when it is not being
used.Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel
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SAFETY INFORMATION
ENGINE SAFETY
DANGER
NOTICE
NEVER run engine without an air filter or with a dirty air
filter.Severe engine damage may occur.Service air filter
frequently to prevent engine malfunction.
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
The engine of this equipment
requires an adequate free
flow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied.When a diesel engine operates without
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
NEVER operate the engine with heat shields or
guards removed.
Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition.It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels.A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffler or cylinder.Allow these parts to cool
before servicing equipment.
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SAFETY INFORMATION
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains, etc.
Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.
ALWAYS use extreme caution when working with
flammable liquids.
ALWAYS make sure the trailer is equipped with a safety
chain.
DO NOT fill the fuel tank while the engine is running
or hot.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.
DOT Requirements include the following:
• Connect and test electric brake operation.
NEVER use fuel as a cleaning agent.
• Secure portable power cables in cable tray with tie
wraps.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
The maximum speed for highway towing is 55 MPH unless
posted otherwise.Recommended off-road towing is not to
exceed 15 MPH or less depending on type of terrain.
TOWING SAFETY
CAUTION
Avoid sudden stops and starts.This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
SafetyTowing Regulations, before towing
your generator.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Refer to MQ Power trailer manual for additional safety
information.
Place chock blocks underneath wheel to prevent rolling
while parked.
In order to reduce the possibility of an accident while
transporting the generator on public roads, ALWAYS
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
ALWAYS shutdown engine before transporting
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SAFETY INFORMATION
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
duringoperationcancauseelectrocution,
electrical shock or burn.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
The electrical voltage required to
operate the generator can cause severe
Grounding Safety
DANGER
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous.The possibility exists
of electrical shock, electrocution or
death.
NEVER use gas piping as an electrical ground.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
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SAFETY INFORMATION
BATTERY SAFETY
DANGER
ENVIRONMENTAL SAFETY
NOTICE
DO NOT drop the battery. There is a possibility that the
battery will explode.
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel filters.
DO NOT expose the battery to open flames,
sparks, cigarettes, etc.The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
DO NOT use food or plastic containers to
dispose of hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
WARNING
ALWAYSwearsafetyglasseswhenhandling
the battery to avoid eye irritation.The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ALWAYS recharge the battery in a well-ventilated
environmenttoavoidtheriskofadangerousconcentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 11
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SPECIFICATIONS
Table 1. Generator Specifications
DCA-45USI2
Model
Type
Revolving field, self ventilated,
open protected type synchronous generator
Armature Connection
Phase
Star with Neutral
3
Zigzag
Single
Standby Output
Prime Output
Voltage
49.5 kVA (39.6 kW)
45 kVA (36 KW)
240 or 480V
28.6 KW
26 KW
240 or 120V
Frequency
60 Hz
Speed
1800 rpm
Power Factor
Aux. AC Power
Voltage
0.8
1.0
Single Phase, 60 Hz
120V
Output
4.8 Kw (2.4 kW x 2)
2,889 lbs. (1,310 kg)
6,960 lbs. (3,157 kg)
Dry Weight
Maximum Lifting Capacity
Table 2. Engine Specifications
ISUZU BU-4JJ1T Tier 4
Model
Type
4 cycle, water-cooled, direct injection, turbo-charged
4 cylinders
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
3.76 in. x 4.13 in. (95.4 mm x 105 mm)
183 cu. in. (3,000 cc)
57.1 HP/1800 RPM
Electric
Coolant Capacity
Lube Oil Capacity
Fuel Type
3.17 gal. (12 liters)
3.83 gal. (14.5 liters)
#2 Diesel Fuel
Fuel Tank Capacity
78 gal. (300 liters)
2.7 gal. (10.4 L)/hr at full load
1.5 gal. (5.6 L)/hr at 1/2 load
2.1 gal. (8.0 L)/hr at 3/4 load
0.9 gal. (3.4 L)/hr at 1/4 load
Fuel Consumption
Battery
12V 72Ah x 1
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DIMENSIONS
C
B
A
TOP VIEW
E
D
45
SIDE VIEW
F
FRONT VIEW
Figure 1. Dimensions
Table 3. Dimensions
G
Reference
Letter
Dimension in. (mm)
Reference Letter
Dimension in. (mm)
A
B
C
D
30.55 in. (776 mm.)
24.37 in. (619 mm.)
30.16 in. (766 mm.)
30.16 in. (766 mm.)
F
G
H
83.07 in. (2,130 mm.)
61.00 in. (1,550 mm.)
37.40 in. (950 mm.)
H
E
24.37 in. (619 mm.)
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 13
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INSTALLATION
Figure 2. Typical Generator Grounding Application
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INSTALLATION
OUTDOOR INSTALLATION
GENERATOR GROUNDING
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide
or shift around. Also install the generator in a manner so
that the exhaust will not be discharged in the direction of
nearby homes.
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifies that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
The installation site must be relatively free from moisture
and dust.All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
a. Copper - 8 AWG (5.3 mm2)
b. Aluminum - 6 AWG (8.4 mm2)
CAUTION
Pay close attention to ventilation when operating the
generator inside tunnels and caves.The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
INDOOR INSTALLATION
Exhaust gases from diesel engines are extremely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
MOUNTING
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running.The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1).DO NOT remove
the metal skids on the bottom of the generator. They are
to resist damage to the bottom of the generator and to
maintain alignment.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 15
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GENERAL INFORMATION
GENERATOR
OPEN DELTA EXCITATION SYSTEM
This generator (Figure 3) is a high quality portable (requires
a trailer for transport) power source for telecom sites,
lighting facilities, power tools, submersible pumps and other
industrial and construction machinery.
This generator is equipped with the state of the art “Open-
Delta” excitation system. The open delta system consist
of an electrically independent winding wound among
stationary windings of the AC output section.
There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to D, and C to D. These three phases of the voltage
input to the voltage regulator are then rectified and are the
excitation current for the exciter section.
ENGINE OPERATING PANEL
The “Engine Operating Panel” is provided with the following:
Tachometer
Water Temperature Gauge
Warning Lamp
Fuel Leak Detected Alam Lamp
Pre-Heat Lamp
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Panel Light/Panel Light Switch
ECU Controller
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.
Engine Speed Switch
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:
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
3-Pole, 110 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
• Automatic Voltage Regulator
• Current Transformer
ENGINE
This generator unit incorporates an ISUZU BU-4JJ1T diesel
engine.This engine is designed to meet every performance
requirement for the generator.ReferenceTable 2 for engine
specifications.
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
ELECTRIC GOVERNOR SYSTEM
• Over-Current Relay
• Starter Relay
• Voltage Selector Switch
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to .25%.
EXTENSION CABLES
OUTPUT TERMINAL PANEL
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
The “Output Terminal Panel” is provided with the following:
Three 120/240V output receptacles (CS-6369), 50A
Three auxiliary circuit breakers, 50A
Two 120V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Five output terminal lugs (3Ø power)
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MAJOR COMPONENTS
1
45
4
2
3
45
5
6
Table 4. Generator Major Components
ITEM NO.
DESCRIPTION
Muffler Assembly
1
2
3
4
5
6
7
8
7
AUTO
MANUAL
OFF/RESET
LOW OIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
OVERSPEED
ENGINE RUNNING
Fuel Tank Assembly
MOOOOO-20001Q
1000
2000
0
3000
R
P
M
Engine and Radiator Assembly
Generator Assembly
Output Terminal Assembly
Engine Operating Panel Assembly
Generator Control Panel Assembly
Battery Assembly
8
Figure 3. Major Components
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 17
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GENERATOR CONTROL PANEL
1
INCREASE
DECREASE
7
6
5
2
V
U
W
3
OFF
AUTO
MANUAL
OFF/RESET
LOW OIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
V-W
U-V
W-U
OVERSPEED
ENGINE RUNNING
OFF
MOOOOO-20001Q
4
1000
2000
0
3000
R
P
M
Figure 4. Generator Control Panel
The definitions below describe the controls and functions
of the Generator Control Panel (Figure 4).
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the generator
function.
1. Voltage Regulator Control — Allows 15% manual
adjustment of the generator’s output voltage.
The Control Box is equipped with the following major
components:
2. Main Circuit Breaker—This three-pole, 110A main
breaker is provided to protect the the U,V, and W
Output Terminal Lugs from overload.
Over-Current Relay
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.
Automatic Voltage Regulator (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
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.
NOTICE
Remember the overcurrent relay monitors the current
flowing from the U,V, and W Output Terminal Lugs
to the load.
5. ACVoltmeter — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
In the event of a short circuit or over current condition,
it will automatically trip the 110 amp main breaker.
6. AC Ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
To restore power to the OutputTerminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
7. Frequency Meter — Indicates the output frequency
in hertz (Hz). Normally 60 Hz.
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NOTES
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 19
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ENGINE OPERATING PANEL
1
3
4
8
9
2
INCREASE
DECREASE
10
V
U
W
12
OFF
5
6
AUTO
MANUAL
OFF/RESET
V-W
LOW OIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
W-U
U-V
OVERSPEED
OFF
ENGINE RUNNING
MOOOOO-20001Q
1000
2000
7
0
3000
R P
M
11
Figure 5. Engine Operating Panel
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ENGINE OPERATING PANEL
If the engine does not engage (start) by the third
attempt, the engine will be shutdown by the engine
controller’s Over Crank Protection mode. If the engine
engages at a speed (RPM's) that is not safe, the
controller will shutdown the engine by initializing the
Over Speed Protection mode.
The definitions below describe the controls and functions
of the Engine Operating Panel (Figure 5).
1. Panel Light — Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel light
switch to the OFF position.
Also the engine controller will shut down the engine in
the event of low oil pressure, high coolant temperature,
low coolant level, and loss of magnetic pickup.
These conditions can be observed by monitoring the
LED status indicators on the front of the controller
module.
2. Panel Light Switch —When activated will turn on control
panel light.
3. Oil Pressure Gauge — During normal operation this
gauge should read between 42 ~71 psi. (290~490 kPa).
When starting the generator the oil pressure may read a
little higher, but after the engine warms up the oil pressure
should return to the correct pressure range.
A. MPEC Control Switch — This switch controls the
running of the unit. If this switch is set to the OFF/
RESET position, the unit will not run. When this switch
is set to the manual position, the generator will start
immediately.
4. WaterTemperature Gauge — During normal operation this
gauge be should read between 167°~203°F (75° ~95°C
5. 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.
If the generator is to be connected to a building’s
AC power source via an automatic transfer switch
(isolation), place the switch in the AUTO position.In this
position, should an outage occur, the automatic transfer
switch (ATS) will start the generator automatically
via the generator’s auto-start contacts connected to
the ATS’s start contacts. Please refer to your ATS
installation manual for further instructions for the
correct installation of the auto-start contacts of the
generator to the ATS.
6. Fuel Gauge — Indicates amount of diesel fuel available.
7. 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.
8. Preheat Lamp — As the engine cranks, this lamp will
illuminate to indicate automatic preheating of the engine
glow plugs. When the lamp turns off, this indicates that
the preheat cycle is complte and the engine will start
automatically.
B. Low Oil Pressure — Indicates the engine pressure
has fallen below 15 psi (103 kPa). The oil pressure
is detected using variable resistive values from the
oil pressure sending unit. This is considered a major
fault.
9. Warning Lamp —This lamp will illuminate when a critical
engine fault has occured.
C. High Coolant Temperature — Indicates the engine
temperature has exceeded 230°F (110°C).The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
10. Fuel Leak Detected Alarm Lamp — This lamp will
illuminate when fluids in the containment have reached
high levels
11. Engine Speed Switch —This switch controls the speed
of the engine (low/high).
D. Overcrank Shutdown — Indicates the unit has
attempted to start a pre- programmed number of
times, and has failed to start. The number of cycles
and duration are programmable. It is pre-set at 3
cycles with a 10 second duration. This is considered
a major fault.
12. Auto START/STOP Engine Controller (ECU) —This
controller has a vertical row of status LED's (inset), that
when lit, indicate that an engine
malfunction (fault) has been
detected. When a fault has been
detected the engine controller will
evaluate the fault and all major
faults will shutdown the generator.
During cranking cycle, the ECU
will attempt to crank the engine for
10 seconds before disengaging.
E. Overspeed Shutdown — Indicates the engine is
running at an unsafe speed. This is considered a
major fault.
F. Engine Running — Indicates that engine is running
at a safe operating speed.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 21
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OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
OUTPUT TERMINAL FAMILIARIZATION
The Output Terminal Panel (Figure 6) shown below is
located on the right-hand side (left from control panel) of
the generator. Lift up on the cover to gain access to
receptacles and terminal lugs.
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
Three 120/240V output receptacles @ 50 amp
Three Circuit Breakers @ 50 amps
NOTICE
Two 120V GFCI receptacles @ 20 amp
Two GFCI Circuit Breakers @ 20 amps
Five Output Terminal Lugs ( U, V, W, O, Ground)
Terminal legs “O”and “Ground”are considered bonded
grounds.
Figure 6. Output Terminal Panel
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OUTPUT TERMINAL PANEL FAMILIARIZATION
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
GFCI receptacles. Remember the load output (current) on
all three receptacles is dependent on the load requirements
of the output terminal lugs.
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles provided on the output terminal panel.
These receptacles can be accessed in any voltage
selector switch position.Each receptacle is protected by a
20 amp circuit breaker.These breakers are located directly
above the GFCI receptacles. Remember the load output
(current) of both GFCI receptacles is dependent on the load
requirements of the U, V, and W output terminal lugs.
Turn the voltage regulator control knob (Figure 9) on the
control panel to obtain the desired voltage.Turning the knob
clockwise will increase the voltage, turning the knob
counter-clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 7) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 9. Voltage Regulator Control Knob
Removing the Plastic Face Plate (Hard Wire
Hookup Panel)
The output terminal lugs are protected by a plastic face
plate cover (Figure 10). Un-screw the securing bolts and
lift the plastic terminal cover to gain access to the terminal
enclosure.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 7. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 8) provided on the output
terminal panel. These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.
Figure 10. Plastic Face Plate
(Output Terminal Lugs)
Figure 8. 120/240V Twist-Lock Auxiliary
Receptacles
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 23
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OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Over Current Relay
Loads can be connected to the generator by the output
terminal lugs or the convenience receptacles (Figure 11).
Make sure to read the operation manual before attempting
to connect a load to the generator.
An over current relay (Figure 12) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over
current relay must be pressed. The over current relay is
located in the control box.
To protect the output terminals from overload, a 3-pole, 110
amp main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Figure 12. Over Current Relay
Figure 11. Connecting Loads
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LOAD APPLICATION
SINGLE PHASE LOAD
THREE PHASE LOAD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
When calculating the power requirements for 3-phase
power use the following equation:
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require
130—150% more wattage than the rating on the nameplate,
as the wattage is influenced by the efficiency, power factor
and starting system of the equipment.
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
WATTS = VOLTAGE x AMPERAGE
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. SeeTable 6.
The power factor of this generator is 0.8.SeeTable 5 below
when connecting loads.
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.
Table 5. Power Factor By Load
Type of Load
Power Factor
Single-phase induction motors
0.4-0.75
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.
Electric heaters, incandescent lamps
Fluorescent lamps, mercury lamps
1.0
0.4-0.9
Electronic devices, communication
equipment
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
1.0
0.8
Common power tools
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Table 6. Cable Selection (60 Hz, Single Phase Operation)
Load in Watts
Maximum Allowable Cable Length
Current
in
Amperes
At 100
Volts
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
DANGER
2.5
5
300
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
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.
600
1200
1800
2400
3600
4800
7.5
10
15
20
900
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 25
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GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES
Generator Amperage
A wide range of voltages are available to supply voltage for
many different applications.Voltages are selected by using
the voltage selector switch (Figure 13).To obtain some of
the voltages as listed in Table 7 (see below) will require a
fine adjustment using the voltage regulator (VR) control
knob located on the control panel.
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed..
Table 8. Generator Maximum Amps
Rated Voltage
Maximum Amps
100 amps (4 wire)
108A x 2 (Zigzag)
1Ø 120 Volt
Voltage Selector Switch
50 amps (4 wire)
108A (Zigzag)
1Ø 240 Volt
The voltage selector switch (Figure 13) is located above
the output terminal panel’s Hard Wire Hook-up Panel. It
has been provided for ease of voltage selection.
3Ø 240 Volt
3Ø 480 Volt
108 amps
54 amps
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly
related to the voltage being supplied at either the output
terminals or the 2 twist lock auxiliary receptacles.
Table 9 and Table 10 show what amount of current is
available at the GFCI receptacles when the output terminals
and twist lock receptacles are in use. Be careful that your
load does not to exceed the available current capability at
the receptacles.
Figure 13. Voltage Selector Switch
Voltage Selector Switch Locking Button
Table 9. 1Ø GFCI Receptacle Load Capacity
To lock the voltage selector switch, press and hold the
red button located at the bottom of the switch. While
holding the red button down, insert a pad lock into the hole
next to the button to retain it in the inward locked position.
When the lock is removed, the red button is spring loaded
and will return to its normal outward unlocked position.
KW in Use
Twist Lock (C6369)
Available Load
Current (Amps)
GFCI Duplex
5-20R 120V
1Ø 240/120V
26.0
24.8
0 amps/receptacle
5 amps/receptacle
23.6
22.4
21.2
10 amps/receptacle
15 amps/receptacle
20 amps/receptacle
CAUTION
NEVER change the position of the voltage selector
switch while the engine is running. ALWAYS place
circuit breaker in the OFF position before selecting
voltage.
Table 10. 3Ø Generator Maximum Amps
KVA in Use
(UVWO Terminals)
Available Load
Current (Amps)
GFCI Duplex
5-20R 120V
Table 7. Voltages Available
3Ø 240/480V
UVWO Output
Terminal Lugs
Voltage Selector Switch
3-Phase 240/139V Position
Voltage Selector Switch
3-Phase 480/270V Position
0 amps/receptacle
5 amps/receptacle
45.0
40.9
208V
120V
220V
127V
240V
139V
416V
240V
440V
254V
480V
277V
3Ø Line-Line
10 amps/receptacle
15 amps/receptacle
20 amps/receptacle
36.7
32.6
28.4
1Ø Line-Neutral
Voltage Selector Switch Single-Phase 240/120V Position
1Ø Line-Neutral/
Line-Line
120V
Line-Neutral
240V
Line-Line
N/A
N/A
N/A
N/A
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GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE AC AMMETER AND AC
VOLTAGE GAUGES
AC Ammeter Gauge Reading
Place the AC Ammeter Change-Over Switch (Figure 17)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 18). This process can be repeated for
terminals V and W.
The AC ammeter and AC voltmeter gauges are controlled
by the AC ammeter and AC voltmeter change-over
switches.
Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.
Before taking a reading from either gauge, set the Voltage
Selector Switch (Figure 14) to the position which produces
the required voltage (For example, for 3Ø 240V, choose
the center 3Ø 240/139V position on the voltage selector
switch).
Figure 17. AC Ammeter
Change-Over Switch
Figure 18. AC Ammeter
(Amp Reading on U Lug)
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
Figure 14. Voltage Selector Switch
240/139V 3Ø Position
NOTICE
For 3Ø 208V/1Ø,120V, place the Voltage Selector
Switch in the 3 Phase 240/139 position.
AC Voltmeter Gauge Reading
Place the ACVoltmeter Change-Over Switch (Figure 15)
in theW-U position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 16)
Figure 15. AC Voltmeter
Change-Over Switch
Figure 16. AC Voltmeter
Gauge
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 27
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OUTPUT TERMINAL PANEL CONNECTIONS
3. Turn the voltage regulator knob (Figure 21) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
UVWO TERMINAL OUTPUT VOLTAGES
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the position of the Voltage Selector Switch
and the adjustment of the Voltage Regulator Control
Knob.
Remember the voltage selector switch determines the
range of the output voltage. The voltage regulator (VR)
allows the user to increase or decrease the selected
voltage.
Figure 21. Voltage Regulator Knob
3Ø-208V/1Ø-120V UVWO Terminal Output Voltages
3Ø-240/139 UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure Figure 22.
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 19.
Figure 22. Voltage Selector Switch
3Ø-240/139V Position
Figure 19. Voltage Selector Switch
3Ø-240/139V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 23.
2. Connect the load wires to the UVWO terminals as
shown in Figure Figure 20.
Figure 23. UVWO Terminal Lugs
3Ø-208/1Ø-120V Connections Connections
NOTICE
To achieve a 3Ø 208V output the voltage selector switch
must be in the 3Ø-240/139 position and the voltage
regulator must be adjusted to 208V..
Figure 20. UVWO Terminal Lugs
3Ø-240/139V Connections
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OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480/277V UVWO Terminal Output Voltages
1Ø-240/120V UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 24.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 26.
Figure 24. Voltage Selector Switch
3Ø-480/277V Position
Figure 26. Voltage Selector Switch
1Ø-240/120V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 25.
2. Connect the load wires to the UVWO terminals as
shown in Figure 27.
Figure 25. UVWO Terminal Lugs
3Ø-440/254V Connections
Figure 27. UVWO Terminal Lugs
1Ø-240/120V Connections
3. Turn the voltage regulator knob (Figure 21) clockwise
to increase voltage output, turn counterclockwise
to decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
3. Turn the voltage regulator knob (Figure 27) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
NOTICE
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight.The possibility of arcing
exists, that could cause a fire.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 29
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INSPECTION/SETUP
CIRCUIT BREAKERS
FUEL CHECK
DANGER
To protect the generator from an overload, a 3-pole, 110
amp, main circuit breaker is provided to protect the U,V,
and W Output Terminals from overload. In addition two
single-pole, 20 amp GFCI circuit breakers are provided to
protect the GFCI receptacles from overload.Three 50 amp
load circuit breakers have also been provided to protect the
auxiliary receptacles from overload. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Fuel spillage on a hot engine can cause
a fire or explosion.If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.
Refilling the Fuel System
LUBRICATION OIL
CAUTION
Fill the engine crankcase with lubricating oil through the
filler hole, but DO NOT overfill. Make sure the generator is
level and verify that the oil level is maintained between the
two notches (Figure 28) on the dipstick. See Table 11 for
proper selection of engine oil.
ONLY properly trained personnel who have read
and understand this section should refill the fuel tank
system.
This generator has an internal fuel tank (Figure 29) located
inside the generator enclosure and may also be equipped
with an environmental fuel tank (located inside trailer
frame).ALWAYS fill the fuel tanks with clean fresh #2 diesel
fuel. DO NOT fill the fuel tanks beyond their capacities.
Figure 28. Engine Oil Dipstick
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the
oil drain plug, and refill with the specified amount of oil as
outlined in the ISUZU Engine Owner’s Manual.Oil should
be warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
45
API Service Classification CC/SC
API Service Classification CC/SD
API Service Classification CC/SE
API Service Classification CC/SF
FUEL TANK
Table 11. Recommended Motor Oil
Figure 29. Internal Fuel Tank System
PAGE 30 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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INSPECTION/SETUP
2. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel
cap and fill tank (Figure 31).
Refueling Procedure:
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. LevelTanks — Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 30).
CAUTION
ALWAYS place trailer on firm level ground before
refueling to prevent spilling and maximize the amount
of fuel that can be pumped into the tank.
Figure 31. Fueling the Generator
3. NEVER overfill fuel tank — It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait
for fuel to rise in filler neck (Figure 32).
Figure 30. Only Fill on Level Ground
Figure 32. Full Fuel Tank
NOTICE
CAUTION
ONLY use #2 diesel fuel when refueling.
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 33).
Figure 33. Fuel Expansion
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 31
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INSPECTION/SETUP
COOLANT (ANTIFREEZE/SUMMER COOLANT/
WATER)
CLEANING THE RADIATOR
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the
radiator fins with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
ISUZU recommends ISUZU antifreeze/summer coolant for
use in their engines, which can be purchased in concentrate
(and mixed with 50% demineralized water) or pre-diluted.See
the ISUZU Engine Owner’s Manual for further details.
AIR CLEANER
WARNING
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the ISUZU Engine Owner’s Manual.
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which can
cause severe burns.
FAN BELT TENSION
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
ISUZU Engine Owner’s Manual.
Day-to-day addition of coolant is done from the recovery
tank.When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 12 for engine, radiator, and recovery tank coolant
capacities.Make sure the coolant level in the recovery tank
is always between the “H” and the “L” markings.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 34) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
Reserve Tank
3.15 gal (12 liters)
2 quarts (1.9 liters)
Operation in Freezing Weather
When operating in freezing weather, be certain
the proper amount of antifreeze (Table 13) has been added.
Figure 34. Fan Belt Tension
CAUTION
Table 13. Anti-Freeze Operating Temperatures
NEVER place hands near the belts or fan
while the generator set is running.
Vol %
Anti-
Freeze
Freezing Point
Boiling Point
°C
°F
°C
°F
50
-37
-34
108
226
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
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INSPECTION/SETUP
When connecting battery do the following:
BATTERY
1. NEVER connect the battery cables to the battery
terminals when the MPEC Control Switch is in either
the MANUAL position. ALWAYS make sure that the
MPEC Control Switch is in the OFF/RESET position
when connecting the battery.
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are
not properly maintained. Add only distilled water when
replenishment is necessary.
2. Place a small amount of battery terminal treatment
compound around both battery terminals. This will
ensure a good connection and will help prevent
corrosion around the battery terminals.
DO NOT over fill. Check to see whether the battery
cables are loose. Poor contact may result in poor starting
or malfunctions. Always keep the terminals firmly
tightened. Coating the terminals with an approved battery
terminal treatment compound. Replace battery with only
recommended type battery.
NOTICE
If the battery cable is connected incorrectly, electrical
damage to the generator will occur.Pay close attention to
the polarity of the battery when connecting the battery.
The battery is sufficiently charged if the specific gravity
of the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
CAUTION
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Inadequate battery connections may cause poor
starting of the generator, and create other malfunctions.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 35) are
properly connected to the battery terminals as shown below.
The red cable is connected to the positive terminal of the
battery, and the black cable is connected to the negative
terminal of the battery.
ALTERNATOR
The polarity of the alternator is negative grounding type.
When an inverted circuit connection takes place, the
circuit will be in short circuit instantaneously resulting the
alternator failure.
CAUTION
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrosion and damage the
alternator.
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
WIRING
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
PIPING AND HOSE CONNECTION
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check
hoses for leaks.
Figure 35. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
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GENERATOR START-UP PROCEDURE
BEFORE STARTING
CAUTION
STARTING
1. Place the voltage selector switch in the desired
voltage position (Figure 38).
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING
NEVER manually start the engine with the main,GFCI or
auxiliary circuit breakers in the ON (closed) position.
1. Place the main,G.F.C.I.,and aux. circuit breakers (Figure
36) in the OFF position prior to starting the engine.
Figure 38. Voltage Selector Switch
STARTING (MANUAL)
1. Place the engine speed switch (Figure 39) in the LOW
(down) position.
Figure 36. Main, Aux. and GFCI
Circuit Breakers (OFF)
Figure 39. Engine Speed Switch (Low)
2. Place the MPEC control switch in the MANUAL
position to start the engine (Figure 40).
2. Make sure the voltage change-over board has been
configured for the desired output voltage.
3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 11. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
Figure 40. MPEC Control Switch
(Manual Position)
3. Depending on the temperature of the coolant (cold
weather conditions), the pre-heat lamp (Figure 41) will
light (ON) and remain on until the pre-heating cycle has
been completed. After completion of the pre-heating
cycle, the light will go OFF and the engine will start up
automatically.
4. Tighten terminal nuts securely to prevent load wires
from slipping out.
5. Close all engine enclosure doors (Figure 37).
CORRECT
Figure 41. Pre-Heat Lamp
Figure 37. Engine Enclosure Doors
4. Once the engine starts, let the engine run for 1-2
minutes. Listen for any abnormal noises. If any
abnormalities exist, shut down the engine and correct
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GENERATOR START-UP PROCEDURE
the problem. If the engine is running smoothly, place
the engine speed switch (Figure 42) in the HIGH (up)
position.
9. The ammeter (Figure 47) will indicate zero amps with
no load applied. When a load is applied, the ammeter
will indicate the amount of current that the load is
drawing from the generator.
Figure 42. Engine Speed Switch (High)
5. Verify that the engine running status LED on the
MPEC module (Figure 43) is lit (ON) after the engine
has started.
Figure 47. Ammeter (No Load)
10. The engine oil pressure gauge (Figure 48) will indicate
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 42 to 71
psi. (290~490 kPa).
Figure 43. Engine Running (LED ON)
6. The generator’s frequency meter (Figure 44) should be
displaying the 50 cycle output frequency in HERTZ.
Figure 48. Oil Pressure Gauge
11. The coolant temperature gauge (Figure 49) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 167°~203°F (75°~95°C) (Green Zone).
Figure 44. Frequency Meter
7. The generator’s AC-voltmeter (Figure 45) will display
the generator’s output in VOLTS.
Figure 49. Coolant Temperature Gauge
12. The tachometer gauge (Figure 50) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Figure 45. Voltmeter Meter
8. If the voltage is not within the specified tolerance use
the voltage adjustment control knob (Figure 46) to
increase or decrease the desired voltage.
Figure 46. Voltage Adjust Control Knob
Figure 50. Engine Tachometer Gauge
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GENERATOR SHUT-DOWN PROCEDURES
13. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 51).
2. Place the engine speed switch (Figure 54) in the “LOW”
(down) position.
Figure 54. Engine Speed Switch (Low)
3. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
4. Place the MPEC Control Switch (Figure 55) to the
OFF/RESET position.
Figure 51. Main, Aux. and GFCI
Circuit Breakers (ON)
14. Observe the generator’s ammeter (Figure 52) and
verify it reads the anticipated amount of current with
respect to the load. The ammeter will only display a
current reading if a load is in use.
Figure 55. MPEC Control Switch (Off/Reset)
5. Verify that all status LEDs on the MPEC display are
OFF (not lit).
6. Remove all loads from the generator.
Figure 52. 9Ammeter (Load)
7. Inspect entire generator for any damage or loosening of
components that may have occurred during operation.
15. The generator will run until manually stopped or an
abnormal condition occurs.
EMERGENCY SHUTDOWN PROCEDURE
WARNING
1. Place the MPEC Control Switch (Figure 55) in the
OFF/RESET position.
NEVER stop the engine suddenly except in an
emergency.
AUTOMATIC SHUT-DOWN SYSTEM
NORMAL SHUTDOWN PROCEDURE
This unit is equipped with safety devices to automatically
stop the engine in the event of low oil pressure, approximately
14 psi (97 kPa), or high water temperature, approximately
230° F (110° C), overspeed approximately +15%.The alarm
lamps on the ECU illuminate to signify the reason for the
shutdown.
To shutdown the generator, use the following procedure:
1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 53 to the OFF position.
NOTICE
Before inspecting generator, check that the Auto/
Manual switch is in the OFF/RESET position, and place
all circuit breakers in the OFF position. Allow sufficient
time for adequate cooling. When ready to restart,
complete all steps in the Generator Startup Procedure
section of this manual.
Figure 53. Main, GFCI and Load
Circuit Breakers (OFF)
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MAINTENANCE
10 Hrs
DAILY
1000
Hrs
Table 14. Inspection/Maintenance
250 Hrs 500 Hrs
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Replace Engine Oil and Filter * 1
Clean Air Filter
X
X
Engine
Check Fuel Filter/Water Separator Bowl
Clean Unit, Inside and Outside
Change Fuel Filter
Clean Radiator and Check Coolant Protection Level*2
Replace Air Filter Element * 3
Check all Hoses and Clamps * 4
Clean Inside of Fuel Tank
X
X
X
X
X
X
X
Measure Insulation Resistance Over 3M ohms
X
Generator
Check Rotor Rear Support Bearing
Replace engine oil and filter at 100 hours, first time only.
X
1
*
2
*
Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
3
*
4
*
with no sags or dips that could collect moisture and/or oil.
GENERAL INSPECTION
Prior to each use, the generator should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for
fuel, oil, and coolant leaks. Use Table 14 as a general
maintenance guideline Engine Side (Refer to the Engine
Instruction Manual)
AIR CLEANER
Every 250 hours: Remove air cleaner element (Figure 56)
and clean the heavy duty paper element with light spray of
compressed air. Replace the air cleaner as needed.
Figure 56. Air Cleaner/Indicator
NOTICE
Air Cleaner with Dust Indicator
The air filter should not be changed until the indicator
reads “RED”. Dispose of old air filter. It may not be
cleaned or reused.
This indicator (Figure 56) is attached to the air cleaner.
When the air cleaner element is clogged, air intake
restriction becomes greater and the dust indicator signal
shows RED meaning the element needs changing or
service. After changing the air element, press the dust
indicator button to reset the indicator.
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MAINTENANCE
If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result.This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber and high fuel consumption. Change air cleaner
more frequently if these conditions exists.
FUEL TANK INSPECTION
In addition to cleaning the fuel tank, the following
components should be inspected for wear:
Rubber Suspension — look for signs of wear or
deformity due to contact with oil. Replace the rubber
suspension if necessary.
FUEL ADDITION
Add diesel fuel (the grade may vary according to season
and locations).
Fuel Hoses — inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
Removing Water from the Fuel Tank
FuelTank Lining — inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally inspect the fuel
tank for water contamination and drain the contents if
required.
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 500
hours or so.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Cleaning Inside the Fuel Tank
Vent any air
If necessary, drain the fuel inside the fuel tank completely.
Using a spray washer (Figure 57) wash out any deposits
or debris that have accumulated inside the fuel tank.
AIR REMOVAL
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel,
or after disassembling the fuel system, bleed the system
according to the following procedure. See the ISUZU
Engine Manual for details.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed.
Figure 57. Fuel Tank Cleaning
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MAINTENANCE
CHECK OIL LEVEL
RADIATOR CLEANING
Check the crankcase oil level prior to each use, or when the
fuel tank is filled.Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil
level must be between the two notches on the dipstick as
shown in Figure 28.
The radiator (Figure 58) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fins or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fins and tube.
Replacing Oil Filter
Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
After the oil cartridge has been replaced, the engine oil
will drop slightly.Run the engine for a while and check for
leaks before adding more oil if needed. Clean excessive
oil from engine.
FLUSHING OUT RADIATOR AND REPLACING
COOLANT
Figure 58. Radiator Cleaning
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overflow
tank and drain.
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Drain the fuel tank completely.Treat with a fuel stabilizer
if necessary.
Tighten both cocks and replace the overflow tank.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Replace with coolant as recommended by the engine
manufacturer.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Close radiator cap tightly.
Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.
Make sure engine coolant is at proper level.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
WARNING
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
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TRAILER MAINTENANCE
8. Tire Size — Indicates the diameter of the tire in
inches (10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
TRAILER MAINTENANCE
This section is intended to provide the user with generic
trailer service and maintenance information. The service
and maintenance guidelines referenced in this section refer
to a wide range of trailers.
9. Tire Ply — The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
10. Wheel Hub — The wheel hub is connected to the
trailer’s axle.
11. Tire Rim — Tires mounted on a tire rim. The tire rim
must match the size of the tire.
The definitions below describe some of the major
components of a typical trailer that would be used with
generator.
12. Lug Nuts — Used to secure the wheel to the wheel
hub. Always use a torque wrench to tighten down the
lug nuts. See Table 18 and FigureFigure 61 for lug nut
tightening and sequence.
1. Fuel Cell — Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
13. Axle — Indicates the maximum weight the axle can
support in pounds, and the diameter of the axle
expressed in inches. Please note that some trailers
have a double axle.This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
2. Braking System — System employed in stopping
the trailer.Typical braking systems are electric, surge,
hydraulic, hydraulic-surge and air.
3. GVWR — Gross Vehicle Weight Rating (GVWR) is
the maximum number of pounds the trailer can carry,
including the fuel cell (empty).
14. Suspension — Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
4. Frame Length — Measurement is from the ball hitch
to the rear bumper (reflector).
5. Frame Width — Measurement is from fender to
fender
15. Electrical — Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
6. Jack Stand — Trailer support device with maximum
pound requirement from the tongue of the trailer.
16. Application — Indicates which units can be employed
on a particular trailer.
7. Coupler — Type of hitch used on the trailer for
towing.
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TRAILER MAINTENANCE
BRAKES
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of
operation.This will allow the brake shoes and drums to seat
properly.After the first 200 mile interval, inspect the brakes
every 3,000 miles. If driving over rough terrain, inspect the
brakes more frequently.
Hydraulic surge brakes (Figure 59) should not require any
special attention with the exception of routine maintenance
such as shoe and lining replacement. Brake lines should
be periodically checked for cracks, kinks, or blockage.
Figure 59 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 and Table 15 as 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 59. Hydraulic Brake Components
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
Actuator
Hydraulic surge braking requires the installation of an
actuator at the tongue of the trailer. Remember the surge
or push of the trailer toward the tow vehicle automatically
synchronizes the trailer brakes with the tow vehicle brakes.
As the trailer pushes against the tow vehicle the actuator
telescopes together and applies force to the master cylinder,
supplying hydraulic pressure to the trailer brakes.
5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer
to the ground.
Periodicallycheckandtestthesurge“actuator”tomakesurethat
it is functioning correctly. Never use an undersize actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Repair or replace.
Reburnish or replace.
Correct weight.
Trailer overloaded?
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or
broken?
Replace components.
Locking Brakes
Noisy Brakes
Brake drums out-of-round?
System lubricated?
Replace.
Lubricate.
Brake components correct?
Replace and correct.
Install new shoes and
linings.
Brake lining thickness incorrect or
not adjusted correctly?
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
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TRAILER MAINTENANCE
TIRES/WHEELS/LUG NUTS
Suspension
Tires and wheels are a very important and critical
components of the trailer.When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
The leaf suspension springs and associated components
(Figure 60) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately.Torqued suspension components
as detailed in Table 17.
CAUTION
ALWAYS wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim is
cracked, the air pressure in the inner tube
may cause pieces of the rim to explode (break off) with
great force and cause serious eye or bodily injury.
Figure 60. Major Suspension Components
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire
life. Pressure should be checked cold before operation DO
NOT bleed air from tires when they are hot!.Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 17. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
Min-30 Max-35
Min-45 Max-60
Min-45 Max-60
3/8" U-Bolt
7/16" U-Bolt
1/2" U-Bolt
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Snug fit only. Parts must rotate freely.
Locking nuts or cotter pins are
Shackle Bolt
Spring Eye Bolt
Table 16. Tire Wear Troubleshooting
provided to retain nut-bolt assembly.
Wear Pattern
Cause
Solution
Shoulder Type
Shackle Bolt
Min-30 Max-50
Adjust pressure to particular
load per tire manufacturer.
Center Wear Over inflation.
Edge Wear Under inflation.
Adjust pressure to particular
load per tire manufacturer.
Make sure load does not
exceed axle rating.
Align wheels.
Loss of camber
Side Wear
or overloading.
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
Check bearing adjustment
and balance tires.
Wheel lockup and Avoid sudden stops when
tire skidding. possible and adjust brakes.
Flat Spots
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TRAILER MAINTENANCE
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (see Figure 61). 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
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
Wheel Size
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 61. Wheel Lug Nuts
Tightening Sequence
NOTICE
NEVER use an pneumatic air gun to tighten wheel
lug nuts.
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TRAILER WIRING DIAGRAM
Figure 62. Trailer/Towing Vehicle Wiring Diagram
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GENERATOR WIRING DIAGRAM
Figure 63. Generator Wiring Diagram
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ENGINE WIRING DIAGRAM
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CONTROLLER WIRING DIAGRAM
Figure 65. Engine Controller
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 47
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TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business office or service plant.
Table 19. Generator Troubleshooting
Symptom
Possible Problem
AC Voltmeter defective?
Is wiring connection loose?
Is AVR defective?
Solution
Check output voltage using a voltmeter.
Check wiring and repair.
No Voltage Output
Replace if necessary.
Defective Rotating Rectifier? Check and replace.
Defective Exciter Field?
Is engine speed correct?
Check for approximately 17.3 ohms across J & K on CN1
Turn engine throttle lever to “High”.
Low Voltage Output
High Voltage Output
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
Defective AVR?
Replace if necessary.
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Circuit Breaker Tripped
Defective circuit breaker?
Over current Relay actuated? Confirm load requirement and replace.
PAGE 48 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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TROUBLESHOOTING (DIAGNOSTIC LAMP)
The engine controller of this generator diagnoses problems
that arise from the engine control system and the engine
itself. Press the diagnostic button (Figure 66) on the
diagnostic panel to determine if an engine malfunction has
occurred.
Figure 66. Diagnostic Panel
METHOD OF OPERATION
1. Normally, the diagnostic lamp will be dimly lit when
the MPEC Control Switch is placed in the MANUAL
position.
2. If engine trouble occurs, the diagnostic lamp will be
brightly lit as long as the control switch is left in the
manual position.
3. The diagnostic lamp will indicate that an engine
malfunction has occurred.
NOTICE
For a complete understanding of error codes and
troubleshooting procedures, refer to the enclosed
engine instruction manual.
NOTICE
If the engine is cranked while the diagnostic switch is in
the “ON”position, the engine will not be stopped even if
the starter switch is turned to the “OFF”position.In such
case, turn the diagnostic switch to the “OFF” position.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 49
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EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
QTY. Column
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice.Multiquip
does not guarantee the availability of the parts listed.
A blank entry generally indicates that the item is not sold
separately.Other entries will be clarified in the“Remarks”
Column.
SAMPLE PARTS LIST
REMARKS Column
NO. PART NO. PART NAME
QTY. REMARKS
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
1
2%
12345
BOLT......................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN............NOT SOLD SEPARATELY
WASHER, 3/8 IN....1 .....MQ-45T ONLY
2% 12347
3
4
12348
12349
HOSE ..................A/R ...MAKE LOCALLY
BEARING ..............1 .....S/N 2345B AND ABOVE
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
NO. Column
Indicated by:
Unique Symbols — All items with same unique
symbol
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model number
variant.
NOTICE
When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items.Examples include battery cables, shims,
and certain washers and nuts.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
“Not Sold Separately”— Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
PAGE 50 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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SUGGESTED SPARE PARTS
DCA45USI2 WHISPERWATT GENERATOR WITH
ISUZU BU-4JJ1T DIESEL ENGINE
1 to 3 units
QTY. P/N
DESCRIPTION
5............8980188580..........CARTRIDGE , OIL FILTER
5............8980088400..........FILTER, FUEL, ELEMENT, MAIN
5............8980742880..........FILTER, FUEL, ELEMENT, PRE
5............8980714010..........FILTER, FUEL, FEED PUMP
3............0602046365..........ELEMENT, AIR
1............8980388550..........BELT, FAN
1............M1310501203.......RADIATOR HOSE, UPPER
1............M1310501303.......RADIATOR HOSE, LOWER
1............8121468300..........SENSOR, WATER TEMP. (ENGINE SIDE)
1............8971256001..........SWITCH, WARNING, OVERHEAT (ENGINE SIDE)
1............8980274560..........SENSOR, OIL PRESSURE (ENGINE SIDE)
1............1096300850..........GASKET, SENSOR OIL PRESSURE (ENGINE SIDE)
1............0601808803..........CIRCUIT BREAKER, 1P, 20 AMP
1............0601808804..........CIRCUIT BREAKER, 2P, 50 AMP
1............0601806644..........FUSE, 30 AMP
1............0601806640..........FUSE, 65 AMP
3............0601806671..........FUSE, 15 AMP
1............0601820602..........AUTOMATIC VOLTAGE REGULATOR
1............0602122272..........UNIT, OIL PRESSURE
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 51
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GENERATOR ASSY.
PAGE 52 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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GENERATOR ASSY.
NO.
1
PART NO.
B3110001102
PART NAME
ROTOR ASSY.
FIELD ASSY.
RECTIFIER
QTY. REMARKS
1
1
3
1
1
3
5
1
1- 1
1- 2
1- 3
1- 4
1- 5
1- 6
1- 7
1- 8
1- 9
0601820083
0601822664
B3120100804
B3120100604
B3120100704
B3111100603
B2163100004
0010304016
ZNR
HOLDER, ZNR
INSULATOR WASHER
INSULATOR WASHER
FAN
COUPLING DISK ........................................3 ......... PURCHASE ITEM 1-8 AS A SET
HEX. HEAD BOLT
BALANCING WEIGHT
U-NUT
COUPLING WASHER
HEX. SOCKET HEAD CAP SCREW
WASHER, FLAT
1
1
1
2
6
6
1
8
8
1
2
1
4
4
1-9A B2163700004
1-9B 0204004000
1-10 B3163200104
1-11 0342612030
1-12 0046512000
1-13 0071906309
2
3
4
4-1
5
BEARING
0010310020
0042510000
3130000903
0845041904
B3137000803
0016008060
0042508000
B3153000513
0017108035
B3153400504
B3153400404
0017106016
0010310025
0042510000
B5131300004
0340406040
0600815000
0041206000
B3131300804
0029205012
0041205000
0605000455
0030012000
0040012000
0041212000
HEX. HEAD BOLT
WASHER, LOCK
STATOR ASSY.
GROMMET
FIELD ASSY., EXCITER
HEX. SOCKET HEAD CAP SCREW
WASHER, LOCK
END BRACKET
HEX. HEAD BOLT
PACKING
COVER, BEARING
HEX. HEAD BOLT
HEX. HEAD BOLT
WASHER, LOCK
COVER, END BRACKET
HEX. HEAD BOLT
NUT
6
7
8
9
6
1
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
23A
23B
3
12
12
1
1
1
1
1
4
4
2
2
2
2
WASHER, FLAT
COVER, END BRACKET
MACHINE SCREW
WASHER, FLAT
RUBBER SUSPENSION
HEX. NUT
WASHER, LOCK
WASHER, FLAT
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 53
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CONTROL BOX ASSY.
PAGE 54 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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CONTROL BOX ASSY.
NO.
1
1- 1
1- 2
1- 3
2
3
4
5
6
PART NO.
PART NAME
CONTROL BOX
EDGING
EDGING
EDGING
CIRCUIT BREAKER,3P
MACHINE SCREW
RELAY UNIT
MACHINE SCREW
AUTOMATIC VOLTAGE REGULATOR
MACHINE SCREW
CURRENT TRANSFORMER,150/5A
MACHINE SCREW
OVER CURRENT RELAY
OVER CURRENT RELAY
MACHINE SCREW
HEX. NUT
SET PANEL, ELECTRIC PARTS
HEX. HEAD BOLT
HOLDER, FUSE
USE,15A
MACHINE SCREW
QTY.
REMARKS
M1213001212
0330000180
0330000615
0330000245
0601808825
0021005080
0601823863
0027104016
0601820602
0027105016
0601801123
0027106020
0601820847
0601820848
0027104016
0207004000
2260500204
0016906016
0601802218
0601806671
0027103020
LY-2DDC12V
PTF08A
1
2
1
2
1
4
2
4
1
4
3
6
1
1
2
2
1
4
1
3
1
7
8
9
10
11
12
12A
13
14
15
15A
16
17
17A
17B
18
19
20
21
22
23
24
25
26
27
28
29
30
RELAY.........................................................2 ................REPLACES P/N 0601827656
BASE...........................................................2 ................REPLACES P/N 0601823109
CLIP ............................................................4 ................REPLACES P/N 0601824400
MACHINE SCREW
TERMINAL
MACHINE SCREW
SENSOR, INLET AIR TEMP.
CONTROLLER
PYCA1
002710402C
0601815153
0027104016
0603250240
0602202688
M3260500604
0016906016
0601831205
0601831330
0016906016
0601823240
0027105020
8972177780
4
1
2
1
1
1
4
1
1
4
1
1
BRACKET
HEX. HEAD BOLT
PUSH BUTTON SWITCH
DIAGNOSTIC SWITCH
HEX. HEAD BOLT
RECTIFIER
MACHINE SCREW
SENSOR, BAROMETRIC PRESSURE ......1 ................REPLACES P/N 0602130220
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 55
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CONTROL BOX ASSY.
PAGE 56 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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CONTROL BOX ASSY.
NO.
31
32
33
34
35
36
37
38
39
40
41
42A
42B
42
43
44
44A
45
45A
46
47
48
49
PART NO.
PART NAME
QTY.
REMARKS
M2260600104
0027105016
0027105016
8942481610
8970119490
0027105016
5825500290
0027105016
M121350060
0016906016
M1270100304
M1550002904
M1550003004
M1213602204
M1213602304
0021104030
0207004000
0027104016
0207004000
0016906016
M1213602404
0016906016
1213602504
BRACKET, SENSOR
MACHINE SCREW
MACHINE SCREW
1
2
2
RELAY, STARTER .......................................1 ...............REPLACES P/N 0602202502
RELAY, GLOW PLUG..................................1 ................REPLACES P/N 0602202685
MACHINE SCREW
RELAY.........................................................3 ................REPLACES P/N 0602201400
MACHINE SCREW
CONTROL BOX COVER
HEX. HEAD BOLT
SELECTOR SWITCH
DECAL;SELECTOR SWITCH NUMBER
DECAL;SELECTOR SWITCH NUMBER
SWITCH BRACKET
SWITCH BRACKET
MACHINE SCREW
HEX. NUT
MACHINE SCREW
HEX. NUT
HEX. HEAD BOLT
SWI TCH COVER
HEX. HEAD BOLT
SWITCH COVER
SEAL RUBBER
HEX. HEAD BOLT
HEX. HEAD BOLT
TOOTHED WASHER
CONTROL PANEL
FREQUENCY METER, 45~65HZ 240V
AC AMMETER, 0~75A/150A:5A
CHANGE-OVER SW, AMMETER
AC VOLTMETER, 0-600V
CHANGE-OVER SW, VOLTMETER
RHEOSTAT (VR) 2W 1K OHM
KNOB
4
3
1
4
1
1
1
1
1
4
4
4
4
4
1
6
1
1
4
12
1
1
1
1
1
1
1
1
I
49- 1 0317700180
50
51
51A
52
53
54
55
56
57
58
59
60
0016906016
0016906016
0040506000
M1223000803
0601807641
0601803986
0601801040
0601806859
0601801041
0601840073
0601840121
0602202641
CONTROLLER ECU(CAN77)
1
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 57
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CONTROL BOX ASSY.
PAGE 58 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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CONTROL BOX ASSY.
NO.
61
61A
62
63
63A
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
82A
83
84
85
86
PART NO.
PART NAME
QTY.
REMARKS
0021004040
0207004000
0601831340
0602103092
0601810245
0602120095
0602122093
0602123090
0602121081
0602125090
0601810141
0601831330
0601831395
1224100104
0027105010
0027105010
M9220100004
0080200007
0602122272
M9200100004
0130000000
0304300050
0602120465
M2357202104
0601806644
0601806640
M1246703314
M1357201702
M2357201802
MACHINE SCREW
HEX. NUT
SWITCH
ALARM LAMP
BULB, DC18V
TACHOMETER
OIL PRESSURE GAUGE
WATER TEMP GAUGE
CHARGING AMMETER
FUEL GAUGE
2
2
1
3
3
1
1
1
1
1
1
1
1
1
2
4
2
2
1
1
1
1
1
1
1
1
1
1
1
PANEL LIGHT
SWITCH, PANEL LIGHT
SWITCH, ENGINE SPEED
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
SNAP RING
UNIT, OIL PRESSURE
ADAPTER
ELBOW 1/8"
LONG NIPPLE
PICKUP TACHOMETER
FUSE HOLDER UNIT
FUSE, 30A
FUSE, 65A
WIRE HARNESS, GENERATOR
WIRE HARNESS, ENGINE
WIRE HARNESS, CONTROLLER
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 59
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ENGINE AND RADIATOR ASSY.
PAGE 60 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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ENGINE AND RADIATOR ASSY.
NO.
1
1A
1-1
2
3
4
5
6
PART NO.
PART NAME
ENGINE, ISUZU BU- 4JJ1T
FAN BELT....................................................1 ................REPLACES P/N 0602015255
CARTRIDGE, OIL FILTER ..........................1 ................REPLACES P/N 0602041222
RUBBER SUSPENSION
HEX. NUT
WASHER, LOCK
WASHER, FLAT
RADIATOR
CAP, RADIATOR
PLUG
O-RING
MOUNT RUBBER
HEX. HEAD BOLT
HEX. NUT
RADIATOR HOSE
RADIATOR HOSE
HOSE BAND
FAN GUARD
FAN GUARD
QTY.
REMARKS
M1923200114
8980388550
8980188580
060500455
2
2
2
2
1
1
1
1
2
2
2
1
1
4
1
1
7
1
4
1
1
1
1
0030012000
0040012000
0041212000
M1923200084
0602011079
M9200100904
0150000016
M9312200104
0016908040
0207008000
M1310501203
M1310501303
0605515201
M1423700004
M1423700114
0016906016
M1924200004
0016910025
0602046582
0602046385
0602040651
M1373200204
0602040556
0016908030
0207008000
0019210025
M1373101003
M1373101103
M1326100104
M1374100103
0605515199
0605515225
0269200570
0605515198
M9602000003
M9200200004
0150000018
0016906016
0199100700
0199100800
0605515106
0602022581
6-1
7
8
9
10
11
12
13
14
15
16
17
18
19
20
20A
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
HEX. HEAD BOLT
MOTOR FAN
HEX. HEAD BOLT
AIR CLEANER
ELEMENT, AIR CLEANER
INDICATOR, AIR CLEANER
BRACKET, AIR CLEANER
BAND, AIR CLEANER
HEX. HEAD BOLT
HEX. NUT
HEX. HEAD BOLT
HOSE, AIR CLEANER
HOSE, AIR CLEANER
BLOWBY PIPE
HOSE, AIR CLEANER
HOSE BAND
2
2
2
1
1
1
1
1
4
1
2
1
1
1
2
1
HOSE BAND
BLOWBY HOSE
HOSE BAND
DRAIN JOINT
PLUG
O-RING
HEX. HEAD BOLT
DRAIN HOSE
DRAIN HOSE
HOSE BAND
ADAPTER
4
1
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 61
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ENGINE AND RADIATOR ASSY. (CONTINUED)
PAGE 62 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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ENGINE AND RADIATOR ASSY. (CONTINUED)
NO.
41
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
60A
60B
61
62
63
64
65
66
PART NO.
PART NAME
PLUG
90° ELBOW
CONNECTOR
LOCKNUT
VALVE
HOSE JOINT
CAP
DRAIN HOSE
RESERVE TANK
CAP. RESERVE TANK
HOSE
BRACKET, RESERVE TANK
HEX. HEAD BOLT
HOSE
HOSE
HOSE BAND
HARNESS CLAMP
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. NUT
QTY.
1
1
REMARKS
M9200200004
0602022561
0603306590
0603300285
0605511395
0603306395
0602021070
0269200310
M9300000003
M9300100003
0199100215
M1317100004
0016908020
0199101700
0193601200
0605515106
M1357300204
0017110020
0017110040
0030010000
0041210000
M1357300004
00171 10020
8121468300
8971256001
1096300850
1096300850
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
WASHER, FLAT
HARNESS CLAMP
HEX. HEAD BOLT
SENSOR, WATER TEMPERATURE
SWITCH, WARNING, OVERHEAT
SENSOR,OIL PRESSURE
GASKET, SENSOR OIL PRESSURE
1
1
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 63
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OUTPUT TERMINAL ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
3-SPECTRUM GREY
4-SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 64 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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OUTPUT TERMINAL ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
5
REMARKS
M1230700103
M9220100204
M9220100104
0039310000
0040010000
0041410000
0016908025
M1236101203
M1236100704
0605010040
0027103010
0030003000
0041203000
0027103010
0030003000
9220100804
0040006000
0041206000
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE SCREW
5
HEX. NUT
10
15
20
5
1
1
2
4
4
4
4
4
2
2
2
2
4
1
WASHER, LOCK
WASHER, FLAT
HEX. HEAD BOLT
TERMINAL COVER
OUTPUT WINDOW
HINGE
MACHINE SCREW
HEX. NUT
WASHER, FLAT
MACHINE SCREW
HEX. NUT
9
10
11
11A
11B
12
12A
13
13A
13B
SET SCREW
WASHER, LOCK
WASHER, FLAT
RETAINING RING
HEX. HEAD BOLT
CABLE OUTLET COVER
SUPPORTER, CABLE OUTLET COVER 1
HEX. HEAD BOLT
TERMINAL
MACHINE SCREW
CIRCUIT BREAKER IP 20A
CIRCUIT BREAKER 2P 50 A
BREAKER FITTING COVER
CUSHION RUBBER
HEX. HEAD BOLT
RECEPTACLE GF-530EM, 125V 20A
RECEPTACLE CS6369, 250V, 50A
MACHINE SCREW
HEX. NUT
13C 0080200005
14
15
16
17
18
19
20
21
22
0016906016
1236400004
1236300004
0016906020
0601815194
0027104016
0601808803
0601808804
M1260700304
6
1
2
2
3
1
1
2
2
22-1 0222100150
23
24
25
26
26A
27
28
29
30
31
32
33
0016906020
0601812598
0601812538
0027104016
0207004000
M1236400104
0016906016
M1236100803
0010112045
0041212000
9310200004
0030012000
3
10
10
1
4
1
2
2
2
2
COVER
HEX. HEAD BOLT
TERMINAL COVER
HEX. HEAD BOLT
WASHER, FLAT
STAY RUBBER
HEX. NUT
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 65
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BATTERY ASSY.
PAGE 66 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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BATTERY ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
BATTERY
QTY.
REMARKS
0602220187
M9310500014
M9103000304
06022 20920
0040006000
M1347200004
M1347200104
0016910020
0040510000
1
1
1
2
2
1
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET
WASHER, LOCK
BATTERY CABLE
BATTERY CABLE........................................1 ................MAKE LOCALLY
HEX. HEAD BOLT
TOOTHED WASHER
2
2
9
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 67
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MUFFLER ASSY.
PAGE 68 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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MUFFLER ASSY.
NO.
1
2
3
4
PART NO.
PART NAME
MUFFLER
HEX HEAD BOLT
EXHAUST PIPE
QTY.
REMARKS
M1331100102
0017112030
M1333002903
8943690210
0039308000
0602325088
1
4
1
GASKET......................................................1 ................REPLACES P/N 0602320101
HEX. NUT
SEAL CLAMP
5
6
6
1
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 69
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FUEL TANK ASSY.
PAGE 70 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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FUEL TANK ASSY.
NO.
1
1- 1
1- 2
PART NO.
PART NAME
FUEL TANK
FUEL TANK CAP
FUEL SENDER UNIT
GASKET
QTY.
1
1
1
1
REMARKS
M2363000102
0605505070
0605501072
1-2A 0605516090
2
3
4
5
6
7
8
9
10
11
12
13
14
14A
15
15A
16
17
18
M1364200004
M1363200404
M9310500104
0016908020
0207008000
0222100700
0191301300
0605515109
M1366700214
0016910025
M1366700304
0016908025
8980139861
8980088400
8980758550
8980758540
8973834270
1096750951
1096300860
TANK BAND
TANK BAND
SUPPORTER SHEET
HEX. HEAD BOLT
HEX. NUT
TANK SHEET
VENT HOSE
HOSE BAND
FUEL FILTER BRACKET
HEX. HEAD BOLT
FUEL PUMP BRACKET
HEX. HEAD BOLT
FUEL FILTER (MAIN) .................................1 ................REPLACES P/N 0602042426
ELEMENT, FUEL FILTER............................1 ................REPLACES P/N 0602042515
FUEL FILTER (PRE.) ..................................1 ................REPLACES P/N 0602042405
ELEMENT, FUEL FILTER............................1 ................REPLACES P/N 0602042516
JOINT PIPE.................................................4 ................REPLACES P/N 0602042661
JOINT BOLT................................................4 ................REPLACES P/N 0602042621
PACKING.....................................................8 ................REPLACES P/N 0602042641
2
2
4
4
4
5
1
2
1
4
1
2
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 71
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ENCLOSURE ASSY.
PAGE 72 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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ENCLOSURE ASSY.
NO.
1
1A
2
PART NO.
PART NAME
BASE
ACOUSTIC SHEET
ENVIRONMENTAL TANK
PLUG, 1-1/2"
QTY.
1
1
1
1
REMARKS
M1413003102
M1493000404
M1414800003
0603306797
3
4
5
5A
6
7
0017110040
HEX. HEAD BOLT
FRONT FRAME
ACOUSTIC SHEET
RADIATOR COVER
HEX. HEAD BOLT
FRONT FRAME
SEAL
8
1
1
1
2
1
1
M1423002002
M1493107604
M13116000041
00169080201
M14230021021
03145021001
8
8-1
8-1A 14931076041
ACOUSTIC SHEET
GROMMET
GROMMET
GROMMET
GROMMET
GUARD
1
1
2
5
1
1
4
8
4
2
16
1
1
12
1
1
1
4
3
1
1
6
6
6
4
4
4
1
1
2
2
12
4
1
1
9
10
11
12
13
14
15
16
17
18
19
20
21
22
22A
23
06018517561
06018517361
06018502661
0601850263
1423500004
0016906016
0016908020
0016908020
1423202404
00169 06016
1310600103
M1310600004
0016906020
M1423202203
M1493107704
M1423202303
0019206016
0019208020
M1433300113
M1433300203
0010116040
0040016000
004121600
0010116040
0040016000
0041216000
1443001702
1493303703
1443800004
1493303904
0207006000
0016908020
1443301903
1493303804
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. HEAD BOLT
DUCT COVER
HEX. HEAD BOLT
HOSE COVER
HOSE COVER
HEX. HEAD BOLT
COVER, FRONT FRAME
ACOUSTIC SHEET
FRONT LOUVER
HEX. HEAD BOLT
HEX. HEAD BOLT
CENTER FRAME
CENTER FRAME
HEX. HEAD BOLT
WASHER, LOCK
WASHER, FLAT
HEX. HEAD BOLT
WASHER, LOCK
WASHER, FLAT
REAR FRAME
24
25
26
27
28
28A
29B
29
29A
29B
30
30A
31
31A
32
33
34
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
HEX. NUT
HEX. HEAD BOLT
REAR COVER
ACOUSTIC SHEET
34A
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 73
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ENCLOSURE ASSY. (CONTINUED)
PAGE 74 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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ENCLOSURE ASSY. (CONTINUED)
NO.
35
36
37
38
38A
39
40
40A
41
42
43
44
44A
45
46
47
46
49
50
50A
50B
51
51A
52
52A
53
53A
54
54A
55
55A
56
56A
57
58
59
60
61
62
63
64
65
66
67
PART NO.
PART NAME
HEX. HEAD BOLT
REAR DOOR
WINDOW PLATE
HEX. NUT
WASHER, FLAT
DOOR HANDLE ASS' Y
MACHINE SCREW
HEX. NUT
HINGE
HINGE
HEX. HEAD BOLT
ROOF PANEL
ACOUSTIC SHEET
HEX. HEAD BOLT
COVER
HEX. HEAD BOLT
SPLASHER PANEL
HEX. HEAD BOLT
HEX. HEAD BOLT
WASHER, LOCK
WASHER, FLAT
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
DOOR HANDLE ASS' Y
SEAL RUBBER
MACHINE SCREW
HEX. NUT
HINGE
HINGE
HINGE
HEX. HEAD BOLT
HEX. HEAD BOLT
STOPPER
MACHINE SCREW
FUEL LEAK DETECTED SWITCH
BRACKET
QTY.
6
1
1
8
8
1
4
4
2
2
8
1
1
18
1
4
1
3
1
1
1
1
1
1
1
1
1
1
1
2
2
8
8
REMARKS
0019208020
M1444200003
M1444600004
020730600C
004120600C
M9113000002
0021806016
0030006000
M9112100404
M9112100604
0016908020
M1463002002
M1493504504
0019208020
M3310600004
0019208020
M1453201002
0016908020
0019108065
0042308000
0042408000
1454000403
1493408404
M1454000103
M1493408604
M1453004203
M1493408504
M1453004303
M14934 08704
M9113000002
C9312500004
M0021806016
0030006000
M9112100404
M9112100504
M9112100604
0016908020
0016908020
0601850097
0027208025
0605503062
1413800304
0017108020
0600800321
1483600804
0016906016
4
4
8
32
2
5
5
1
1
2
1
2
4
HEX. HEAD BOLT
MANUAL-PAK
HEX CLAMPER
HEX. HEAD BOLT
68
69
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 75
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RUBBER SEALS ASSY.
PAGE 76 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL
QTY.
1
1
1
1
1
1
1
1
1
1
2
1
2
1
2
1
1
2
2
1
1
1
1
REMARKS
0229200950
0228901425
0228900900
0229400900
0228900795
0228900630
0229400445
0228800455
0228900445
0229200455
0228100870
0229200840
0229200540
0229200790
0228800800
0228900470
02288 00470
0228100420
0228100325
0314500750
0330000180
0330000615
0330000180
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
EDGING
EDGING
EDGING
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 77
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NAMEPLATE AND DECALS ASSY.
PAGE 78 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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NAMEPLATE AND DECALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
M1550000204
M1550000703
M1550000804
M1550001504
M1550003603
M2550002203
M2550002303
M9500000004
M9500100004
M9500300004
M9500300104
M9500500304
M9503000004
M9503000103
M9503100004
M9503200104
M9510000004
M9510000104
M9510100004
M9510100304
M9510100403
M9512200004
M9520000004
M952000010
M9520000204
M9520000504
M9520000904
M9520001104
M9520100004
M9520100204
M9520100304
M9520100404
M9520100503
M9520100603
M9520200003
M9520200404
M1561000004
M1561100004
M1561100103
M1560102204
M1560102304
M1561100404
0600500092
DECAL; NOTE...........................................................1 ........... M15000020
DECAL; AUXILIARY OUTPUT ..................................1 ........... M15000070
DECAL; NOTE...........................................................1 ........... M15000080
DECAL ; CAUTION....................................................1 ........... M15000150
DECAL; GENERATOR CONTROL............................1 ........... M15000360
DECAL; ENGINE OPERATING.................................1 ........... M25000220
DECAL; OPERATING PROCEDURES......................1 ........... M25000230
DECAL; OIL DRAIN PLUG........................................1 ........... M90000000
DECAL; WATER ........................................................1 ........... M90010000
DECAL; - (NEGATIVE) ..............................................1 ........... M90030000
DECAL; + (POSITIVE)...............................................1 ........... M90030010
DECAL; DIESEL FUEL..............................................1 ........... M90050030
DECAL; WARNING MOVING PARTS........................2 ........... M90300000
DECAL; WATER OIL CHECK....................................1 ........... M90300010
DECAL; WARNING HOT COOLANT.........................1 ........... M90310000
DECAL; WARNING ENGINE EXHAUST...................1 ........... M90320010
DECAL; FLUID DRAIN..............................................1 ........... M91000000
DECAL; DOCUMENT BOX LOCATED......................1 ........... M91000010
DECAL; CAUTION HOT PARTS................................1 ........... M91010000
OECAL; ENVIRONMENTAL WARNING....................1 ........... M91010030
DECAL; CAUTION.....................................................1 ........... M91010040
DECAL; MQ...............................................................1 ........... M91220000
DECAL; GROUND.....................................................1 ........... M92000000
DECAL; AMMETER CHANGE-OVER SW. .............1 ........... M92000010
DECAL: VOLTMETER CHANGE-OVER SW. ...........1 ........... M92000020
DECAL; START CONTACT........................................1 ........... M92000050
DECAL; DIAGNOSTIC SWITCH ...............................1 ........... M92000090
DECAL; DIAGNOSTIC BUTTON...............................1 ........... M92000110
DECAL; WARNING ELECTRIC SHOCK HAZARD ...2 ........... M92010000
DECAL; CAUTION.....................................................1 ........... M92010020A
DECAL; SAFETY INSTRUCTIONS...........................1 ........... M92010030
DECAL; DANGER HIGH VOLTAGE...........................1 ........... M92010040
DECAL; WARNING....................................................1 ........... M92010050
DECAL; CAUTION.....................................................2 ........... M92010060
DECAL; CONNECTION OF OUTPUT CABLE..........1 ........... M92020000
DECAL; OVER CURRENT RELAY............................1 ........... M92020040
DECAL; MQ POWER ................................................2
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
STRIPE .....................................................................2
STRIPE; WHISPERWATT..........................................2
STRIPE; 45................................................................1
STRIPE; 45................................................................1
STRIPE .....................................................................2
PLATE; MO POWER .................................................1
MACHINE SCREW....................................................4
DECAL; AC................................................................1
DECAL; DANGER ENGINE EXHAUST.....................1 ........... M90320010
0021106016
M9520000804
M9503200104
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 79
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TERMS AND CONDITIONS OF SALE — PARTS
5. Parts must be in new and resalable
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
Multiquip reserves the right to quote and
sell direct to Government agencies, and to
Original Equipment Manufacturer accounts
who use our products as integral parts of their
own products.
PAYMENT TERMS
Terms of payment for parts are net 30 days.
FREIGHT POLICY
6. The following items are not returnable:
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIAL EXPEDITING SERVICE
A $35.00 surcharge will be added to the
invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
LIMITATIONS OF SELLER’S LIABILITY
MINIMUM ORDER
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of
the item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
c. Any line item with an extended
dealer net price of less than
$5.00.
d. Special order items.
RETURNED GOODS POLICY
e. Electrical components.
f. Paint, chemicals, and lubricants.
g. Decals and paper products.
h. Items purchased in kits.
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
LIMITATION OF WARRANTIES
No warranties, express or implied, are
made in connection with the sale of parts or
trade accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes nor
authorizes any person to assume for it
any other obligation or liability whatever in
connection with the sale of its products. Apart
from such written statement of warranty,
there are no warranties, express, implied or
statutory, which extend beyond the description
of the products on the face hereof.
1. A Returned Material Authorization
must be approved by Multiquip prior to
shipment.
7. The sender will be notified of any material
received that is not acceptable.
8. Such material will be held for five
working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.
2. To obtain a Return Material Authorization,
a list must be provided to Multiquip
Parts Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
9. Credit on returned parts will be issued
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
a. The parts numbers and descriptions
must match the current parts price
list.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
c. The list must state the reason(s)
for the return.
Effective: February 22, 2006
d. The list must reference the sales
order(s) or invoice(s) under
which the items were originally
purchased.
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
e. The list must include the name
and phone number of the person
requesting the RMA.
Prices are subject to change without prior
notice. Price changes are effective on a
specific date and all orders received on or
after that date will be billed at the revised price.
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
3. AcopyoftheReturnMaterialAuthorization
must accompany the return shipment.
4. Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
PAGE 80 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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NOTES
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 81
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OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office
MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: [email protected]
Tel. (800) 421-1244
Fax (800) 537-3927
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department
Warranty Department
800-421-1244
310-537-3700
Fax: 310-537-4259
Fax: 310-943-2238
800-421-1244
310-537-3700
Fax: 310-537-1173
Technical Assistance
800-478-1244
MEXICO
UNITED KINGDOM
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [email protected]
Tel: (52) 222-225-9900
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223
Fax: (52) 222-285-0420 Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: [email protected]
Fax: 0161 339 3226
CANADA
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [email protected]
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2011, MULTIQUIP INC.
Multiquip Inc, 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 their respective owners and used with permission.
This manual MUST accompany the equipment at all times.This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
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