PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
WHISPERWATTTM SERIES
MODEL DCA-45SSIU3
60 Hz GENERATOR
PARTS LIST NO. M1870300904
Revision #0 (11/30/05)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
Download from Www.Somanuals.com. All Manuals Search And Download.
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-632-2656
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX:310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
WARRANTYDEPARTMENT
800-835-2551,EXT.279
310-537-3700,EXT.279
FAX:310-638-8046
FAX:310-638-8046
© COPYRIGHT 2005, MULTIQUIP INC.
MQ Power Inc, Ultra-Silent series, 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 are
based on the DCA-45SSIU3 (60 Hz)Whisperwatt™ Generator.Multiquip Inc.reserves the right to discontinue or change specifications,
design or the information published in this publication at any time without notice and without incurring any obligations.
To find the latest revision of this
publication, visit our website at:
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 3
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DCA-45SSIU3 (60 Hz) — TABLE OF CONTENTS
MQ POWER DCA-45SSIU3 (60 HZ) ISUZU BB4JG1T ENGINE
WHISPERWATT™ GENERATOR
Generator Assembly ............................................ 52-53
Control Box Assembly.......................................... 54-55
Engine & Radiator Assembly ............................... 56-59
Output Terminal Assy. .......................................... 60-61
Engine Operating Panel Assembly...................... 62-63
Battery Assembly ................................................. 64-65
Muffler Assembly ................................................. 66-67
Fuel Tank Assembly ............................................. 68-69
Enclosure Assembly ............................................ 70-73
Rubber Seal Assembly ........................................ 74-75
Nameplate and Decals ........................................ 76-77
California Proposition 65 Warning .....................................2
Here's How To Get Help ....................................................3
Table Of Contents .............................................................4
Parts Ordering Procedures ...............................................5
Specifications ................................................................... 6
Dimensions ( Side, Front) .................................................7
Safety Message Alert Symbols ....................................8-9
Rules for Safe Operation ........................................... 10-13
Generator Decals....................................................... 14-15
Installation ................................................................. 16-17
General Information ........................................................ 18
Major Components ......................................................... 19
Generator Control Panel ................................................. 20
Engine Operating Panel .................................................. 21
OutputTerminal Panel Familiarization ........................ 22-24
Load Application ............................................................. 25
Generator Outputs .......................................................... 26
Gauge Reading ............................................................... 27
OutputTerminal Panel Connections ........................... 28-29
Pre Setup .................................................................. 30-33
Generator Start-up Procedure ................................... 34-36
Generator Shut-Down Procedure .................................... 36
Maintenance .............................................................. 37-38
Trailer Maintenance.................................................... 39-42
TrailerWiring Diagram ..................................................... 43
Generator Wiring Diagram ............................................... 44
Engine Wiring Diagram ................................................... 45
GeneratorTroubleshooting .............................................. 46
Engine Troubleshooting ............................................. 47-48
Explanation of Code in Remarks Column ....................... 50
Suggested Spare Parts .................................................. 51
Terms and Condition of Sale — Parts...................... 80
Specification and part
NOTE
number are subject to
change without notice.
PAGE 4 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒
Dealeraccountnumber
❒
❒
❒
❒
❒
❒
Dealernameandaddress
Shipping address (if different than billing address)
Returnfaxnumber
Applicable model number
Quantity,part number and description of each part
Specifypreferredmethodofshipment:
✓
✓
✓
✓
✓
✓
FedEx or UPS Ground
FedEx or UPS Second Day or Third Day
FedEx or UPS Next Day
Federal Express Priority One
DHL
Note:Unlessotherwiseindicatedbycustomer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours.We will make every effort to
ship “Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
Truck
Place Your Parts Order Via Web or Fax
For Even More Savings!
Here’s how to get help...
Please have the model and serial number
on hand when calling.
(Domestic USA Dealers Only)
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
Email: [email protected]
800-421-1244
FAX: 310-632-2656
Extra Discounts!
All parts orders which include complete part numbers and
are received by our automated web parts order system, or
by fax qualify for the following extra discounts:
Ordered
via
Standard
orders
Stock orders
PARTS DEPARTMENT
800-427-1244
310-537-3700
SERVICE DEPARTMENT
800-835-2551
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
WARRANTY DEPARTMENT
800-835-2551, EXT. 279
310-537-3700, EXT. 279
($750 list and above)
FAX: 800-672-7877
FAX: 310-637-3284
Fax
3%
5%
10%
10%
Web
FAX: 310-638-8046
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other carrier.
FAX: 310-638-8046
FAX: 310-638-8046
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
NOTE:DISCOUNTSARESUBJECTTOCHANGE
MQPOWER
Direct TOLL-FREE access
to our Parts Department:
Toll-free nationwide — 800-427-1244
ADivisionofMultiquipInc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-632-2656
INTERNET:www.mqpower.com
Toll-free FAX — 800-6-PARTS-7 (800/672-7877)
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 5
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DCA-45SSIU3 (60 Hz) — SPECIFICATIONS
Table 1. Generator Specifications
DCA-45SSIU3
Model
Type
Revolving field, self ventilated, open protected type synchronous
generator
Star with Neutral
3
Zig Zag
Single
Armature Connection
Phase
47.3 KVA (37.8 KW)
45 KVA (36 KW)
240V or 480V
27.3 KW
26 KW
Standby Output
Prime Output
Voltage
240/120V
60 Hz
Frequency
Speed
1,800 rpm
0.8
1
Power Factor
Aux. AC Power
Voltage
Single Phase, 60 Hz
120 VAC
4.8 KW (2.4 KW x 2)
Output
Table 2. Engine Specifications
ISUZU BB-4JG1T
Model
Type
4 Cycle, water-cooled, direct injection, turbocharged
4 cylinders
No. of Cylinders
Bore x Stroke
Displacement
Starting
3.76 in. x 4.21 in. (95.4 mm x 107 mm)
187 cu. in. (3,059 cc)
Electric
3.6 gal. (13.7 liters)
Coolant Capacity
Lube Oil Capacity
Fuel Tank Capacity
Fuel Consumption
Battery
2.64 gal. (10.0 liters)
26.4 gal. (100 liters)
2.6 gal. (9.84 L)/hr at full load
27 (CCA 0° F 700A) X1
#2 Diesel Fuel
Fuel
PAGE 6 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — DIMENSIONS (TOP, SIDE AND FRONT)
TABLE 3. DIMENSIONS
Reference
Dimension ft. (mm.)
Reference Letter
Dimension ft. (mm.)
Letter
A
B
C
D
E
30.31 in. (770 mm.)
25.00 in. (635 mm.)
29.05 in. (738 mm.)
24.21 in. (615 mm.)
29.05 in. (738 mm.)
F
G
H
74.80 in. (1,900 mm.)
49.21 in. (1,250 mm.)
35.43 in. (900 mm.)
Figure 1. Dimensions
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DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 7
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DCA-45SSIU3 (60 Hz) — SAFETY MESSAGE ALERT SYMBOLS
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "Hazard Symbols" which
appear throughout this manual, and will be referenced in
conjunction with Safety "Message Alert Symbols".
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.
This Operation and Parts Manual
has been developed to provide
WARNING - LETHAL EXHAUST GASES
NOTE
complete instructions for the safe
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
and efficient operation of the MQ
Power Model DCA-45SSIU3
(60Hz) UltraSilent™ Generator.
DEATH if inhaled. NEVER operate this
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
Before using this generator, ensure that the operating
individual has read and understands all instructions in
this manual.
WARNING - EXPLOSIVE FUEL
SAFETY MESSAGE ALERT SYMBOLS
Gasoline is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
DO NOT fill the fuel tank while the engine
is running or hot.
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
WARNING
WARNING - BURN HAZARDS
Engine components can generate extreme
heat.To prevent burns, DO NOT touch these
areas while the engine is running or
immediately after operations. NEVER
operate the engine with heat shields or heat
guards removed.
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
PAGE 8 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - RESPIRATORY HAZARDS
NEVER operate equipment with covers,
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
ALWAYS wear approved respiratory
protection.
CAUTION - ACCIDENTAL STARTING
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS place the Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump is not in
use.
ALWAYS wear approved eye and
hearing protection.
CAUTION - OVER-SPEED CONDITIONS
CAUTION - EQUIPMENT DAMAGE MESSAGES
NEVER tamper with the factory settings
of the engine governor or settings.
Personal injury and damage to the engine
or equipment can result if operating in
speed ranges above maximum allowable.
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
This generator, other property, or
the surrounding environment
could be damaged if you do not
follow instructions.
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DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 9
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DCA-45SSIU3 (60 Hz) — RULES FOR SAFE OPERATION
■
ALWAYS check the machine for loosened threads or bolts
before starting.
DANGER - READTHIS MANUAL!
Failure to follow instructions in this manual may lead to
serious injury or even DEATH! This equipment is to be
operated by trained and qualified personnel only! This
equipment is for industrial use only.
■
NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe bodily harm or even death.
■
■
NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or generator.
The following safety guidelines should always be used when
operating the DCA-45SSIU3 (60 Hz) Whisperwatt
™
Generator
HighTemperatures – Allow the engine
to cool before performing service and
maintenance functions. Contact with
hot! components can cause serious
burns.
General Safety:
■
DO NOT operate or service this
equipment before reading this entire
manual.
■
The engine of this generator requires an adequate free
flow of cooling air. NEVER operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is
restricted it will cause serious
damage to the generator or
engine and may cause injury
to people. The generator
engine gives off DEADLY
The operator MUST BE familiar with proper safety
precautions and operations techniques before using
generator.
■
■
This equipment should not be operated by persons under
18 years of age.
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, steel-toed boots and other
carbon monoxide gas.
■
■
■
■
■
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
protective devices required by the job.
NEVER run engine without air filter.Severe engine damage
may occur.
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
DO NOT leave the generator running in the manual mode
unattended.
NEVER operate this equipment under the influence or
Refer to the Isuzu Engine Owner's Manual for engine
technical questions or information.
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.
drugs or alcohol.
■
■
■
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment.Damage
to the equipment and/or injury to user may result.
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
PAGE 10 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
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.
To avoid these hazards:
NEVER use damaged or worn cables when connecting
equipment to the generator. Make sure power connecting
cables are securely connected to the generator’s output
The following safety recommendations should also be
followed:
terminals, insufficient tightening of the terminal connections
WET
HANDS
may cause damage to the generator
■
■
■
ALWAYS make sure generator is properly grounded.
and electrical shock.
NEVER use gas piping as an electrical ground.
NEVER grab or touch a live power
ALWAYS make sure that electrical circuits are properly
grounded per the National Electrical Code (NEC) and
local codes before operating generator. Severe injury or
DEATH! by electrocution can result from operating an
ungrounded generator.
cord with wet hands.
POWER
CORD
(POWER ON)
NEVER touch output terminals
during operation. This is extremely
dangerous. ALWAYS stop the
machine and place the circuit
breaker in the OFF position when
contact with the output terminals is
required.
■
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the U,V, and W output
terminal lugs.
Electrical Safety
Backfeed to a utility system can
cause electrocution and or property
damage. DO NOT connect to any
building's electrical system except
through an approved device or after
building main switch is opened.
ALWAYS have a licensed electrician
perform the installation
■
ALWAYS have a qualified electrician perform the
generator wiring installation.
■
ALWAYS make sure generator installation is accordance
with the National Electrical Code (NEC) and local codes
before operating generator.
■
■
■
NEVER use a defective or frayed power cable. Check
the cable for cuts in the insulation.
NEVER use a extension cord that is frayed or damaged
where the insulation has been cut.
ALWAYS make certain that proper extension cord has
been selected for the job. See Table 6.
■
■
NEVER power cables or cords lay in water.
NEVER stand in water while AC power from the generator
is being transfer to a load.
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 11
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DCA-45SSIU3 (60 Hz) — RULES FOR SAFE OPERATION
Maintenance Safety
Battery Safety
■
The electrical voltage required to operate the generator Use the following guidelines when handling the battery:
can cause severe injury or even death through physical
contact with live circuits. Turn all circuit breakers OFF
■
The battery contains acids that can
cause injury to the eyes and skin. To
avoid eye irritation, always wear safety
glasses.
before performing maintenance on the generator.
■
■
■
■
NEVER lubricate components or attempt service on a
running machine.
■
Use well insulated gloves when picking up the battery.
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
DANGER - EXPLOSION HAZARDS
Follow all Battery Safety Guidelines listed in this manual
when handling or servicing the generator.
The risk of an explosion exists when performing service
on the battery.To avoid severe injury or DEATH:
ALWAYS allow the machine a proper amount of time to
cool before servicing.
■
DO NOT drop the battery.There
is the possibility of risk that the
battery may explode.
■
■
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always
replace broken parts.
■
DO NOT expose the battery to
open flames, sparks, cigarettes
etc.The battery contains combustible gases and liquids.
If these gases and liquids come in contact with a flame
or spark, an explosion could occur.
■
ALWAYS service air cleaner frequently to prevent engine
malfunction.
WARNING - BURN HAZARDS
■
ALWAYS keep the battery charged. If the battery is not
To prevent burns, DO NOT touch or open any of the below
mentioned components while the engine is
running or immediately after operations.
Always allow sufficient time for the engine
and generator to cool before performing
maintenance.
charged a buildup of combustible gas will occur.
■
■
ALWAYS keep battery charging and cables in good working
condition. Repair or replace all worn cables.
ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
■
Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
■
■
In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
In case the battery liquid (dilute sulfuric acid) comes in
contact with your EYES, rinse eyes immediately with
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
■
Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant gushing
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
■
Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil gushing
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
PAGE 12 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — RULES FOR SAFE OPERATION
Towing &Transporting Safety
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
■
■
■
Place chock blocks underneath wheel to prevent rolling,
while parked.
The following list of safety precautions should be followed
when towing your generator:
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
Avoid sudden stops and starts.This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
CAUTION - FOLLOWTOWING REGULATIONS
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.
Trailer should be adjusted to a level position at all times
when towing.
■
■
Raise and lock trailer wheel stand in up position when
transporting.
■
■
■
ALWAYS shutdown engine before transporting.
Tighten both fuel tank caps securely.
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.
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. Follow the listed Towing & Transporting Safety
guidelines for basic towing techniques.
■
Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating.”
■
■
Avoid sharp turns to prevent rolling.
DO NOT transport generator with fuel in tank.
■
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
Emergencies
■
■
■
ALWAYS know the location of the
nearest fire extinguisher.
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 know the location of the
nearest and first aid kit.
■
■
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
ALWAYS know the location of the
nearest phone or keep a phone on
the job site, in case of emergencies.
ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■
ALWAYS have easy access to the phone
numbers of the nearest Ambulance, Doctor
and Fire Department. This information will
be invaluable in the case of an emergency.
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
DOT Requirements include the following:
z
z
Connect and test electric brake operation.
Secure portable power cables in cable tray with tie
wraps.
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 13
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DCA-45SSIU3 (60 Hz) — GENERATOR DECALS
The DCA-45SSIU3 (60 Hz) Whisperwatt
™
Generator is equipped with a number of safety decals (Figures 2 and 3).
These decals are provided for operator safety and maintenance information. The illustration below and on the preceding
page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements
can be obtained from your dealer.
Figure 2. Generator Decals
PAGE 14 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — GENERATOR DECALS
Figure 3. Generator Decals (Continued)
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 15
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DCA-45SSIU3 (60 Hz) — INSTALLATION
Figure 4.Typical Generator Grounding Application
PAGE 16 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — INSTALLATION
Outdoor Installation
Generator Grounding
Install the generator in a area that is free of debris, To guard against electrical shock and possible damage to
bystanders, and overhead obstructions. Make sure the the equipment, it is important to provide a good EARTH
generator is on secure level ground so that it cannot slide or ground. See Figure 4 for a typical grounding configuration.
shift around. Also install the generator in a manner so that
Article 250 (Grounding) of the National Electrical Code (NEC)
the exhaust will not be discharged in the direction of nearby
provides guide lines for proper grounding and specifies that
homes.
the cable ground shall be connected to the grounding system
The installation site must be relatively free from moisture of the building as close to the point of cable entry as
and dust. All electrical equipment should be protected from practical.
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
grounding requirements:
NEC articles 250-64(b) and 250-66 set the following
Foreign materials such as dust, sand, lint and abrasive
1. Use one of the following wire types to connect the
materials have a tendency to cause excessive wear to
generator to earth ground.
engine and alternator parts.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
CAUTION - EXHAUST HAZARD
2. When grounding the generator (Figure 4) 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.
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be routed
to a ventilated area.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
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.
When connecting the generator
to any buildings electrical
system ALWAYS consult with
a licensed electrician.
NOTE
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.
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DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 17
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DCA-45SSIU3 (60 Hz) — GENERAL INFORMATION
DCA-45SSIU3 Whisperwatt™ Generator Familiarization
Open Delta Excitation System
The MQ Power Model DCA-45SSIU3 is a 36 kW, 60 Hz
The DCA-45SSIU3 (60 Hz)generator is equipped with the
generator (Figure 5) that is designed as a high quality portable 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.
(requires a trailer for transport) power source for telecom
sites, lighting facilities, power tools, submersible pumps and
other industrial and construction machinery.
There are four connections of the open delta A, B, C and D.
During steady state loads, the power from the voltage regulator
is supplied 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
WaterTemperature Gauge
WaterTemperature Alarm Lamp
Oil Pressure Gauge
Oil Pressure Alarm Lamp
Charging Ammeter Gauge
Fuel Level Gauge
Pre-heat Lamp
Panel Light/Panel Light Switch
Ignition Switch
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.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
Fuel Filter Water Level Alarm Lamp
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
CurrentTransformer
Over-Current Relay
Voltage Rectifier
Starter Relay
Voltage Selector Switch
OutputTerminal Panel
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)
Battery Charger (Optional)
Water Heater (Optional)
PAGE 18 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — MAJOR COMPONENTS
mponents
N
embly
bly
sembly
Generator Control Panel Assembly
10
Figure 5. Major Components
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DCA-45SSIU3 (60 Hz) — GENERATOR CONTROL PANEL
Figure 6. Generator Control Pane
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the generator
function.
The definitions below describe the controls and functions of
the DCA-45SSIU3 (60 Hz) Whisperwatt™ Generator Control
Panel (Figure 6).
1. Main Circuit Breaker – This three-pole, 110A main
breaker is provided to protect the U,V, and W Output
Terminal Lugs from overload.
The Control Box is equipped with the following major
components:
■
■
■
■
■
Over-Current Relay
Voltage Rectifier (AVR)
Starter Relay
CurrentTransformer
Voltage Selector Switch
2. Voltage Regulator Control – Allows 15% manual
adjustment of the generator’s output voltage
3. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz.
4. AC Ammeter – Indicates the amount of current the load
is drawing from the generator per leg selected by the
ammeter phase-selector switch.
Remember the overcurrent
relay monitors the current
flowing from the U,V, and W
OutputTerminal Lugs to the
load.
NOTE
5. ACVoltmeter – Indicates the output voltage present at
the U,V, and W Output Terminal Lugs.
6. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.
In the event of a short circuit or over current condition, it will
automatically trip the 60 amp main breaker.
To restore power to the Output Terminal Panel, press the
reset button on the overcurrent relay and place the main
circuit breaker in the closed position (ON).
7. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
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DCA-45SSIU3 (60 Hz) — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
7. Pre-heat Lamp - This indicates when the engine is
ready for starting during cold weather operating
conditions.
The definitions below describe the controls and functions of the
DCA-45SSIU3 (60 Hz) "Engine Operating Panel " (Figure 7).
1. Panel Light - Normally used in dark places or at night.
When activated, panel will illuminate. When the generator
is not in use, turn the panel light switch to the ‘OFF’
position.
8. Tachometer – Indicates engine speed in RPM’s for 50
Hz operation. This meter should indicate 1500 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
2. Panel Light Switch-When activated, will turn on control
panel light.
9. Fuel Gauge - Indicates amount of diesel fuel available.
3. Oil Pressure Alarm Lamp - Indicates that the oil
10. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
pressure is too low or high and will shut down the engine.
4. Water Temperature Alarm Lamp - Indicates that the
water temperature is outside of normal range and will
shut down the engine.
11. WaterTemperature Gauge – During normal operation
5. Fuel Filter Water Lever Alarm Lamp - Indicates that
water level in the fuel level has risen. Drain the water in
the fuel filter strainer when this condition occurs.
this gauge be should read between 165o F to 203o F.
12. Oil Pressure Gauge – Normal operation should be
between 28 ~71 psi (193 ~490 kPa). When starting the
generator the oil pressure may read a bit higher, but
after the engine warms up the oil pressure should return
6. Ignition Switch –Three position switch, stop, operation
and start. Insert ignition key to start and stop engine.
to normal.
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DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL FAMILIARIZATION
OutputTerminal Panel
Output Terminal Familiarization
The OutputTerminal Panel (Figure 8) shown below is located The “OutputTerminal Panel ” (Figure 9) is provided with the
on the right-hand side (left from control panel) of the generator. following:
Lift up on the cover to gain access to receptacles and terminal
lugs.
■
■
■
■
■
120/240V output receptacles (3) @ 50 amp
Circuit Breakers (3) @ 50 amps, 2-pole
120V GFCI receptacles (2) @ 20 amp
Terminal legs “O” and “Ground”
are considered bonded grounds.
NOTE
GFCI Circuit Breaker (2) @ 20 amps, 1-pole
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
Figure 8. Output Terminal Panel
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DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL FAMILIARIZATION
Figure 11. Voltage Regulator Control Knob
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
OutputTerminal Lugs.
Figure 9. G.F.C.I. Receptacle
120VAC GFCI Receptacles
Turn the voltage regulator control knob (Figure 11) 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.
There are two 120VAC, 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.
Removing the Plastic Face Plate (HardWire Hookup Panel)
The Output Terminal Lugs are protected by a plastic face
plate cover (Figure 12). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the Test Button (See Figure 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 10. 120/240VTwist-Lock
Auxiliary Receptacles
Figure 12. Plastic Face Plate (Output Terminal Lugs)
Twist Lock DualVoltage 120/240VAC Receptacles
There are three 120/240V, 50 amp auxiliary twist-lock
(CS-6369) receptacles (Figure 10) 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.
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DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Blower Fan
Loads can be connected to the generator by the Output This unit has an intake fan located at the rear of the machine
Terminal Lugs or the convenience receptacles (Figure 13). to draw outside air into the cabinet to cool the engine. The
Make sure to read the operation manual before attempting fan has a 10 amp AC fuse located beneath the Voltage
to connect a load to the generator.
Selector Switch (Figure 15).
To protect the output terminals from overload, a
3-pole, 110A main circuit breaker is provided. Make sure to
switch ALL circuit breakers to the OFF position prior to
starting the engine.
Figure 15. Blower Fan Fuse
DANGER - ELECTROCUTION HAZARDS
Figure 13. Connecting Loads
This fuse has current running through it any time the engine
is running. This fuse is NOT connected to the main circuit
breaker of the generator. Attempting to replace the fuse
with the engine and/or generator operating
could result in electrocution and severe
bodily harm. ALWAYS turn the unit
completely off before attempting to replace
or handle this fuse.
Figure 14. Over Current Relay
Over Current Relay
An over current relay (Figure 14) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over cur-
rent relay must be pressed. The over current relay is lo-
cated in the control box.
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DCA-45SSIU3 (60 Hz) — LOAD APPLICATION
Single Phase Load
Three Phase Load
Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase power
and equipment to insure the wattage, amperage, frequency
,
use the following equation:
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
maybedeterminedbymultiplying
voltage by amperage by 1.732.
NOTE
If wattage is not given on the
equipment's
name
plate,
approximate wattage may be
determined by multiplying
nameplate voltage by the
nameplate amperage.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
NOTE
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.
Table 5. Power Factor By Load
Type Of Load
Power Factor
■
■
■
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.
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
Fluorescent lamps, mercury lamps
Electronic devices, communication
equipment
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Common power tools
0.8
Table 5. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts Maximum Allowable Cable Length
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Current in
Amperes
At 120
Volts
At 240
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
5
300
600
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
DANGER - ELECTRICAL SYSTEM HAZARDS
1200
1800
2400
3600
4800
7.5
10
15
20
900
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.
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage.
1
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DCA-45SSIU3 (60 Hz) — GENERATOR OUTPUTS
Voltage Selector Switch
Generator Amperage
The voltage selector switch (Figure 16) is located above Table 8 describes the generator’s current output capability
the output terminal panel’s Hard Wire Hook-up Panel. It for both 1Ø-phase and 3Ø phase applications.
has been provided for ease of voltage selection.
Table 8. Generator Ampere Ratings
DCA- 45SSIU3
Single Phase
Three Phase
KW
26.0
36.0
KVA
N/A
45
120V
108A x 2
N/A
208V
N/A
240V
108A
108A
480V
N/A
124A
54A
*Power Factor = 0.8
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly re-
lated to the voltage being supplied at either the output termi-
nals or the 2 twist lock auxiliary receptacles.
Tables 9 and 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 recep-
tacles.
Figure 16. Voltage Selector Switch
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and load from being switched while the engine
is running. To lock the voltage selector switch, press and
hold the red button located at the bottom of the switch.
Table 9. GFCI Receptacle Load Capability
KW in Use
Twist-Lock (CS6369)
Available Load
Current (Amps)
GFCI Duplex NEMA
5-20R 120V
1Ø 240/120V
CAUTION - CHANGINGVOLTAGES
26
0
24.8
23.6
22.4
21.2
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
NEVER change the position of the voltage selector switch
while the engine is running. ALWAYS place circuit breaker
in the open position before selecting voltage.
Generator OutputVoltages
Table 10. GFCI Receptacle Load Capability
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 16). 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.
KVA in Use
Available Load
(UVWO Terminals)
Current (Amps)
GFCI Duplex NEMA
5-20R 120V
3Ø 240/480V
45
0
40.9
36.7
32.6
28.4
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
Table 7. Voltages Available
Three Phase
208V
220V
240V
416V
440V
254V
480V
277V
(Switchable)
Single Phase
(Switchable)
120V
127V
139V
240V
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DCA-45SSIU3 (60 Hz) — GAUGE READING
How to Read the OutputTerminal Gauges.
Reading Amperage
The gauges and selector switches on the control panel To determine the amperage at a terminal lug, set the
DO NOT effect the generator output. They are provided to AC Ammeter Change-Over Switch to the appropriate
help observe how much power is being supplied at the setting (Figure 20) to activate the AC Ammeter Gauge
Output terminals lugs.
(Figure 21) and read the available amperage at the terminal
lug.
Before taking a reading off either gauge, set the Voltage
Selector Switch (Figure 17) to the position which produces For example, to measure the amperage at the U
the required voltage (For example, for 3Ø 240V,
choose the center 3Ø 240/
139V position on the volt-
terminal lug, set the AC Ammeter Change-Over Switch to
U and read the AC Ammeter Gauge.
age selector switch.)
Figure 17. Voltage
Selector Switch 240/
139VThree Phase
Position
Figure 21. AC Ammeter
(Amp reading on U lug)
Figure 20. AC Ammeter
Change-Over Switch
For 3Ø 208V/1Ø,120V, place
NOTE
the Voltage Selector Switch
in the 3 Phase 240/139
position.
The ammeter gauge will only
show a reading when the
Output Terminal Lugs are
connected to a load and in use.
NOTE
Reading Voltage
To determine the voltage between two terminal lugs, set the
AC Voltmeter Change-Over Switch to the appropriate
setting (Figure 18) to activate the AC Voltmeter Gauge
(Figure 19) and read the available voltage between the two
lugs.
For example, to measure the voltage between the W and U
terminal lugs, set the AC Voltmeter Change-Over Switch
to W-U and read the ACVoltmeter Gauge.
Figure 18. AC Voltmeter
Change-Over Switch
Figure 19. ACVoltmeter Gauge
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DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL CONNECTIONS
UVWOTerminal OutputVoltages
3Ø 208V/1Ø120V Output Terminal Lug Voltages
Various output voltages can be obtained using the Output
Terminal Lugs.. The voltages at the terminals are depen-
dent on the position of the Voltage Selector Switch and the
adjustment of the Voltage Regulator Control Knob.
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 25.
Use this position for
3Ø-208 or 1Ø120V.
Remember the voltage selector switch determines the range
of the output voltage. The voltage regulator (VR) allows the
user to increase or decrease the selected voltage.
3Ø 240/139 Output Terminal Lug Voltages
Figure 25. Voltage Selector
Switch 240/139V
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in (Figure 22).
Three-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 26.
Figure 22. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
shown in (Figure 23).
Figure 26. Output Terminal Lugs
3Ø-208V/1Ø120V Connections
3. Turn the voltage regulator knob (Figure 25) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
To achieve a 3Ø 208V output
the voltage selector switch
must be in the 3Ø-240/139
position and the voltage
regulator must be adjusted to
208V.
Figure 23. Output Terminal Lugs
3Ø 240/139V Connections
NOTE
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Figure 24. Voltage Regulator Knob (139V/240V)
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DCA-45SSIU3 (60 Hz) — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 OutputTerminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 27.
1Ø 240V/120V Output Terminal Lug Voltages
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 29.
Figure 27. Voltage Selector Switch 480/277V
Three-Phase Position
Figure 29. Voltage Selector Switch 240/120V
Single-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 28.
shown in (Figure 30).
Figure 30. Output Terminal Lugs
1Ø-240V/120V Connections
Figure 28. Output Terminal Lugs
3Ø 480/277V Connections
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
1
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DCA-45SSIU3 (60 Hz) — PRE-SETUP
Fuel Check
Circuit Breakers
To protect the generator from an overload, a 3-pole, 110 amp,
main circuit breaker is provided to protect the U,V, and W
OutputTerminals from overload.In addition two single-pole,
20 amp GFCI circuit breakers are provided to protect the
GFCI receptacles from overload.Two 50 amp, 2-pole circuit
breakers have also been provided to protect the auxiliary
receptacles from overload. Make sure to switch ALL circuit
breakers to the OFF position prior to starting the engine.
DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a hot engine can cause a fire or explosion.
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level,
and verify that the oil level is maintained between the two
notches (Figure 31) on the dipstick. See Table 11 for proper
selection of engine oil.
Refilling the Fuel System
CAUTION - REFUELINGTHE GENERATOR
ONLY properly trained personnel who have read and
understand this section should refill the fuel tank system.
Located at the bottom-front of the cabinet (Figure 32) is the
internal fuel tank. Some generators may be equipped with a
trailer mounted fuel tank (option). ALWAYS fill the either fuel
tank with clean and fresh #2 diesel fuel. DO NOT fill the fuel
tanks beyond their capacities.
Figure 31. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the Isuzu Engine Owner's Manual. Oil should be warm
before draining.
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
Other types of motor oils may be substituted if they meet
the following requirements:
■
■
■
■
API Service Classification CC/SC
API Service Classification CC/SD
API Service Classification CC/SE
API Service Classification CC/SF
Figure 32. Internal Fuel Tank System
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DCA-45SSIU3 (60 Hz) — PRE-SETUP
Refueling Procedure:
WARNING - RESPIRATORY HAZARDS
2. Remove fuel cap and fill fuel tank as shown in Figure 34.
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. Level Tanks – Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 33).
CAUTION - REFUELINGTHE GENERATOR
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 34. 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 35).
Figure 33. Only Fill on Level Ground
NOTE
ONLY! use #2 diesel fuel when
refueling.
Figure 35. Full Fuel Tank
CAUTION - REFUELINGTHE GENERATOR
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 36).
Figure 36. Fuel Expansion
1
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DCA-45SSIU3 (60 Hz) — PRE-SETUP
Coolant (Isuzu Antifreeze/Summer Coolant/Water)
Cleaning the Radiator
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.
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.
Air Cleaner
WARNING - BURN HAZARDS
Periodic cleaning/replacement is necessary. Inspect it in
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.
accordance with the Isuzu Engine Owner's Manual.
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 37) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
Reserve Tank
2.88 Gal. (10.9 liters)
2 Quarts (1.9 liters)
Figure 37. Fan Belt Tension
CAUTION - ROTATING PARTS
Operation FreezingWeather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Table 13. Anti-Freeze
Operating Temperatures
NEVER place hands near the belts or fan while the
generator set is running.
Freezing Point
Vol %
Anti-Freeze
°C
°F
50
-37
-34
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be less than 50%.
NOTE
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DCA-45SSIU3 (60 Hz) — PRE-SETUP
Battery
When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are not
properly maintained. Add only distilled water when
replenishment is necessary.
terminals when the ignition is in the operate or start
position.
2. Place a small amount of battery terminal treatment
compound around both battery terminals.This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
DO NOT over fill. Check to see whether the battery cables
are loose. Poor contact may result in poor starting or
malfunctions. Always keep the terminals firmly tightened.
Coating the terminals with an approved battery terminal
treatment compound. Replace battery with only
recommended type battery. The battery type used in this
generator is BCI Group 27.
If the battery cable is connected
incorrectly, electrical damage to the
NOTE
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 - BATTERY SERVICING SAFETY
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 38) 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.
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrosion and damage the
alternator.
CAUTION - BATTERY SERVICING SAFETY
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.
If any hose (fuel or oil) lines are defective replace them
immediately.
Figure 38. Battery Connections
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DCA-45SSIU3 (60 Hz) — GENERATOR START-UP PROCEDURE
5. Place the voltage selector switch in the desired voltage
Before Starting
position (Figure 41).
CAUTION - LETHAL EXHAUST HAZARD
The engine's exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING - STARTINGTHE GENERATOR
NEVER! manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.
Figure 41.Voltage
Selector Switch
1. Place the main, G.F.C.I., and aux. circuit breakers
6. Preheat the engine glow plugs by turning the ignition
(Figure 39) in the OFF position prior to starting the engine.
key (Figure 42) to the “OPERATION” position.
Figure 42. Ignition Switch (Operation
Pre-Heat Position)
Figure 39. Main, Aux. and GFCI
Circuit Breakers (OFF)
7. When the preheat lamp illuminates (Figure 43), turn the
ignition key to the “START” position. Once the engine
starts, release the ignition key and allow it to return to
the “OPERATION” position (Figure 42).
2. Connect the load to the receptacles or the Output
Terminal Lugs as shown in Figure 13. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
3. The output terminal lugs are protected by a plastic cover.
Remove this cover to gain access to the terminals.
Tighten terminal nuts securely to prevent load wires from
slipping out.
Figure 43. Pre-Heat Indicator Lamp
4. Close all engine enclosure doors (Figure 40).
8. Let the engine run for 3-5 minutes, listen and check for
any abnormal sounds or smells. Check for fuel leaks,
and noises that would associate with a loose cover or
hardware. If any of the above mentioned conditions
exists, shut-down the engine and correct the problem.
Figure 40. Engine Enclosure Doors
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DCA-45SSIU3 (60 Hz) — GENERATOR START-UP PROCEDURE
9. The generator's frequency meter (Figure 44) displays 13. The engine oil pressure gauge (Figure 48) will indicate
the 50 cycle output frequency in HERTZ.
the oil pressure (kg/cm2) of the engine. Under normal
operating conditions the oil pressure is between 28 ~71
psi (193 ~490 kPa).
Figure 44. Frequency Meter (Hz)
Figure 48. Oil Pressure Gauge
14. The coolant temperature gauge (Figure 49) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature is between 165 and
203 degrees Fahrenheit (74 ~ 95 degrees Celsius).
10. The generator's voltage meter (Figure 45) displays the
120VAC in VOLTS.If the voltage is not within the specified
frequency tolerance,
Figure 45. AC Voltmeter
Figure 49. CoolantTemperature Gauge
11. Use the voltage adjustment control knob (Figure 46) to
increase or decrease the desired voltage.
15. The tachometer (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 46.Voltage Adjusted Control Knob
12. The ammeter (Figure 47) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator.
Figure 50. Engine Tachometer
Figure 47. Ammeter (No Load)
1
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DCA-45SSIU3 (60 Hz) — GEN. START-UP PROCEDURE/SHUTDOWN
16. Turn the main, GFCI, and aux. circuit breakers to the
“ON” position (Figure 51).
Figure 53. Main, AUX. and GFCI
Circuit Breakers (OFF)
2. Let the engine cool by running it for 3-5 minutes with no
load applied (circuit breakers in the off position).
Figure 51. Main, AUX. and GFCI
Circuit Breakers (ON)
3. Place the ignition switch (Figure 54) in the “STOP”position,
remove the key and store in a safe place.
17. 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 the load is in use.
Figure 54. Ignition Switch (Stop Position)
4. Remove all loads from the generator.
Figure 52. Ammeter (Load)
EMERGENCY SHUT-DOWN SHUTDOWN
18. The generator will run until manually stopped or an
abnormal condition occurs.
1. To shut-down the engine in the event of an emergency,
switch the MAIN, GFCI and LOAD (Figure 55) circuit
breakers to “OFF” position.
2. Turn the ignition switch key to the “STOP” position.
NORMAL SHUT-DOWN
To shutdown the generator, use the following procedure:
1. Switch the MAIN, AUX and GFCI circuit breakers
(Figure 53) to the “OFF” position (no load).
Figure 55. Ignition Switch (Off Position)
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DCA-45SSIU3 (60 Hz) — MAINTENANCE
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
TABLE 14. INSPECTION/MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
1
Replace Engine Oil and Filter *
X
X
X
ENGINE
Clean Air Filter
Clean Unit, Inside and Outside
Change Fuel Filter
X
X
Clean Radiator and Check Coolant Protection Level*2
3
Replace Air Filter Element *
X
4
Check all Hoses and Clamps *
X
X
Clean Inside of Fuel Tank
Measure Insulation Resistance Over 3M ohms
GENERATOR
X
Check Rotor Rear Support Bearing
X
*1 Replace engine oil and filter at 100 hours, first time only.
*2 Add "Supplemental Coolant Additives (SCA'S)" to recharge the engine coolant.
*3 Replace primary air filter element when restriction indicator shows a vaccum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot, with
no sags or dips that could collect moisture and/or oil.
General Inspection
Service Daily
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.UseTable 14 as a general maintenance
guideline Engine Side (Refer to the Engine Instruction
Manual)
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 Addition
Air Cleaner
Add diesel fuel (the grade may vary according to season
and locations).
Every 250 hours: Remove air cleaner element and clean the
heavy duty paper element with light spray of compressed
air. Replace the air cleaner as needed.
RemovingWater from the FuelTank
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.
Air Cleaner with Dust Indicator
This indicator 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.
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 dies1el fuel.
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 37
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DCA-45SSIU3 (60 Hz) — MAINTENANCE
Air Removal
Flushing Out Radiator and Replacing Coolant
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.
z
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant.Open the
radiator cap while draining. Remove the overflow tank
and drain.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system.
z
z
Check hoses for softening and kinks. Check clamps for
signs of leakage.
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.
Cleaning the Fuel Strainer
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation or
once a month.
z
z
z
Tighten both cocks and replace the overflow tank.
Replace with coolant (Table 13 for correct mixture).
Close radiator cap tightly.
Check Oil Level
WARNING - BURN HAZARDS
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 31).
Allow engine to cool when flushing out
radiator.Flushing the radiator while hot
could cause serious burns from water
steam.
o r
Replacing Oil Filter
To remove the oil filter, grip the filter body and turn
counter-clockwise
Generator Storage
For longe term storage of the generator the following is
recommended:
Apply a film of oil to the rubber seal gasket.
Place the oil filter body onto the oil filter spindle by turning
clockwise. DO NOT over tighten.
z
Fill the fuel tank completely. Treat with a fuel stabilizer
if necessary.
After the oil filter has been replaced, the engine oil will
drop slightly. Run the engine for a while and check for
leaks before adding more oil if needed. Clean excessive
oil from engine.
z
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
z
z
z
z
z
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 500
hours or so.
Make sure engine coolant is at proper level.
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.
If generator is mounted on a trailer, jack trailer up and
place on block so tires do touch the ground or remove
tires.
Vent any air.
.
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DCA-45SSIU3 (60 Hz) — MAINTENANCE
If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
receptacle via commercial power using an power cord of
adequate size.
Jacket Water Heater and Internal Battery Charger
120VAC Input Receptacles (OPTIONAL)
This generator can be optionally equipped with two 120VAC,
20 amp input receptacles located on the output terminal
panel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
To ensure adequate starting
capability, always have power
applied to the generator's internal
battery charger.
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 56). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).
NOTE
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times.To
apply power to the jacket water heater simply apply power to
the jacket water heater receptacle via commercial power
using an power cord of adequate size.
Figure 56. DCA-45SIU2 Battery Charger &
Jacket Water Heater Power Connections
1
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DCA-45SSIU3 (60 Hz) —TRAILER MAINTENANCE
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.
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.
The definitions below describe some of the major components
of a typical trailer that would be used with the DCA-45SSIU3
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
Whisperwatt
™
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 Figure 58 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 trans-
porting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
13. Axle - Indicates the maximum weight the axle can sup-
port 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.
3. GVWR- Gross Vehicle Weight Rating (GVWR) is the
maximum number of pounds the trailer can carry, in-
cluding 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
7. Coupler - Type of hitch used on the trailer for towing.
on a particular trailer.
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DCA-45SSIU3 (60 Hz) —TRAILER MAINTENANCE
Brakes
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 56) should not require any
operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance
properly. After the first 200 mile interval, inspect the brakes such as shoe and lining replacement. Brake lines should be
every 3,000 miles. If driving over rough terrain, inspect the periodically checked for cracks, kinks, or blockage.
brakes more frequently.
Figure 57 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 shown 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.
4. With a screwdriver or standard adjusting tool, rotate the
Figure 57. Hydraulic Brake Components
star wheel of the adjuster assembly to expand the brake
shoes.
Actuator
5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
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.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer to
the ground.
Periodically check and test the surge “actuator” to make
sure that it is functioning correctly. Never use an undersize
actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
Repair or replace.
Reburnish or replace.
Correct weight.
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Trailer overloaded?
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or broken?
Brake drums out-of-round?
System lubricated?
Replace components.
Replace.
Locking Brakes
Noisy Brakes
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness incorrect or not
adjusted correctly?
Install new shoes and
linings.
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
1
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DCA-45SSIU3 (60 Hz) —TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
Suspension
Tires and wheels are a very important and critical The leaf suspension springs and associated components
components of the trailer. When specifying or replacing the (Figure 58) should be visually inspected every 6,000 miles
trailer wheels it is important the wheels, tires, and axle are for signs of excessive wear, elongation of bolt holes, and
properly matched.
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 17.
CAUTION - EYESIGHT HAZARD
ALWAYS wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION - REPAIRINGTRAILERWHEELS
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 58. Major Suspension Components
Table 17. Suspension Torque Requirements
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.
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 PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.
SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
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DCA-45SSIU3 (60 Hz) —TRAILER MAINTENANCE
Lug NutTorque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (see Figure 59). DO NOT
torque the wheel lug nuts all the way down.Tighten each
lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
NEVER use an pneumatic air
gun to tighten wheel lug nuts.
NOTE
Figure 59. Wheel Lug Nuts
Tightening Sequence
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 43
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DCA-45SSIU3 (60 Hz) —TRAILERWIRING DIAGRAM
Figure 60. Trailer/Towing Vehicle Wiring Diagram
PAGE 44 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — GENERATORWIRING DIAGRAM
Figure 61. Generator Wiring Diagram
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 45
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DCA-45SSIU3 (60 Hz) — ENGINEWIRING DIAGRAM
Figure 62. Engine Wiring Diagram
PAGE 46 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) —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
No Voltage Output
POSSIBLE PROBLEM
AC Voltmeter defective?
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
Is wiring connection loose?
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier?
Defective Exciter Field?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Check for 17.3 ohms across J & K on CN1
Turn engine throttle lever to "High".
Check wiring and repair.
Low Voltage Output
Replace if necessary.
High Voltage Output
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Circuit Breaker Tripped
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 47
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DCA-45SSIU3 (60 Hz) —TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 20 (Engine Troubleshooting) as a basic guideline for troubleshooting the Engine. If the problem
cannot be remedied, consult our company's business office or service plant.
TABLE 20. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
No fuel?
SOLUTION
Replenish fuel.
Bleed system.
Air in the fuel system?
Water in the fuel system?
Fuel pipe clogged?
Remove water from fuel tank.
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity of
fuel or engine oil at low
temperature?
Use the specified fuel or engine oil.
Fuel with low cetane number?
Use the specified fuel.
Tighten nut.
Engine does not start.
Fuel leak due to loose injection
pipe retaining nut?
Injection nozzle clogged?
Clean injection nozzle.
Repair or replace.
Injection pump malfunctioning?
Seizure of crankshaft, camshaft,
piston, cylinder liner or bearing?
Repair or replace.
Compression leak from
cylinder?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Piston ring and liner worn?
Excessive valve clearance?
Starter malfunctioning?
Wiring disconnected?
Replace.
Adjust.
Repair or replace.
Connect wiring.
Starter does not run.
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DCA-45SSIU3 (60 Hz) —TROUBLESHOOTING (ENGINE)
TABLE 20. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
POSSIBLE PROBLEM
Fuel filter clogged or dirty?
Air cleaner clogged?
SOLUTION
Clean or change.
Clean or change.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Repair or replace.
Adjust.
Injection pump malfunctioning?
Engine revolution is not smooth.
Incorrect nozzle opening
pressure?
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe clogged?
Governor malfunctioning?
Excessive engine oil?
Clean.
Repair.
Reduce to the specified level.
Repair or replace.
Piston ring and liner worn or
stuck?
Either white or blue exhaust gas
is observed.
Incorrect injection timing?
Deficient compression?
Overload?
Adjust.
Adjust top clearance.
Lessen the load.
Use the specified fuel.
Clean or change.
Clean or change.
Repair or replace the nozzle.
Adjust.
Low grade fuel used?
Fuel filter clogged?
Either black or dark gray
exhaust gas is observed.
Air cleaner clogged?
Deficient nozzle injection?
Incorrect injection timing?
Engine's moving parts seem to
be seizing?
Repair or replace.
Deficient output.
Uneven fuel injection?
Repair or replace the injection pump.
Repair or replace the nozzle.
Deficient nozzle injection?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Compression leak?
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 49
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DCA-45SSIU3 (60 Hz) — EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and remarks QTY. Column
used in the Parts section of this manual. Use the help numbers
found on the back page of the manual if there are any questions.
Numbers Used - Item quantity can be indicated by a number,
a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other parts
that are sold in bulk and cut to length.
The contents and part numbers listed in the parts section are
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
subject to change without notice. Multiquip does not
guarantee the availibility of the parts listed.
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
2
3
4
12345
BOLT ....................... 1.... INCLUDES ITEMS W/
WASHER, 1/4 IN. ........... NOT SOLD SEPARATELY
WASHER, 3/8 IN. .... 1.... MQ-45TONLY
HOSE .................... A/R.. MAKE LOCALLY
BEARING ................ 1.... S/N2345B AND ABOVE
*
*
*
12347
12348
12349
Assembly/Kit - All items on the parts list with the same unique
symbol will be included when this item is purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
NO. Column
Unique Symbols - All items with same unique symbol
Serial Number Break - Used to list an effective serial number
range where a particular part is used.
( , #,
+
, %, or >) in the number column belong to the same
*
assembly or kit, which is indicated by a note in the “Remarks”
column.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Duplicate Item Numbers - Duplicate numbers indicate
multiple part numbers are in effect for the same general item,
such as different size saw blade guards in use or a part that
has been updated on newer versions of the same machine.
Specific Model Number Use - Indicates that the part is used
only with the specific model number or model number variant
listed. It can also be used to show a part is NOT used on a
specific model or model number variant.
When ordering a part that has more
than one item number listed, check
the remarks column for help in
determining the proper part to order.
NOTE
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“Make/Obtain Locally” - Indicates that the part can be
purchased at any hardware shop or made out of available
items. Examples include battery cables, shims, and certain
washers and nuts.
PART NO. Column
Numbers Used - Part numbers can be indicated by a number,
a blank entry, orTBD.
TBD (To Be Determined) is generally used to show a part that
has not been assigned a formal part number at 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 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — SUGGESTED SPARE PARTS
DCA-45SSIU3 (60 HZ) ULTRA-SILENT GENRATOR
W/ISUZU BB-4JG1T ENGINE
1TO 3 UNITS
Qty.
P/N
Description
5 ......... 8943672922 ........ FILTER, OIL
5 ......... 8943692993 ........ FILTER, FUEL, CARTRIDGE
3 ......... 0602046366 ........ ELEMENT, AIR
1 ......... 8941618410 ........ BELT, FAN
1 ......... 0605505070 ........ CAP. FUEL TANK
1 ......... 0602122272 ........ UNIT, OIL PRESSURE
1 ......... 0602123261 ........ UNIT, WATER TEMPERATURE
1 ......... 1518183040 ........ SENDER, WATER SWITCH (ENGINE SIDE)
1 ......... 1718939010 ........ SENDER, OIL SWITCH (ENGINE SIDE)
Part number on this Suggested Spare Parts list
may supercede/replace the P/N shown in the text
pages of this book.
NOTE
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 51
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DCA-45SSIU3 (60 Hz) — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 52 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
PART NO.
PART NAME
ROTOR ASSY
FIELD ASSY
FAN
HEX, HEAD BOLT
SPRINGWASHER
COUPLING DISK
QTY.
REMARKS
B3110100202
1
1
1
8
8
4
1-1
*
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
8051070003
0010310035
0042510000
8041611004
8041015003
0010310025
0042510000
8001026013
0601821349
0601822601
8001020004
8001020504
0010108020
0040008000
0601000209
0071906310
M1164400003
0012808030
B3130100103
0845041904
M1164600003
0012810030
8041315202
8041350013
0010308065
0042608000
0041208000
0017108030
8041310024
8041312014
0017106012
8041331014
0017106012
8001333003
0340406040
0041206000
0012810030
8051332014
0600815000
0605000055
0030012000
0040012000
0041212000
*
*
*
*
*
*
*
*
BALANCING PLATE .................................................1........ PURCHASE SET OF 1-16
HEX, HEAD BOLT
SPRINGWASHER
SET PLATE, RECTIFIER BALANCING PLATE........ 1........ PURCHASE SET OF 1-16
RECTIFIER ..............................................................2........ PT3610
SURGE ABSORBER................................................1........ ERZ-M14JK621A
INSULATORWASHER
INSULATORWASHER
HEX, HEAD BOLT
SPRINGWASHER
BALANCING WEIGHT KIT
BEARING .................................................................1........ 6310DDU C3
COUPLING RING
HEX, HEAD BOLT
STATOR ASSY .........................................................1........ B3135100104
GROMMET
COUPLING ADAPTER
HEX, HEAD BOLT
END BRACKET
FIELD ASSY EXCITER
HEX, HEAD BOLT
SPRINGWASHER
PLAINWASHER
HEX, HEAD BOLT
COVER, BEARING
GASKET, BEARING
HEX, HEAD BOLT
COVER, END BRACKET
HEX HEAD BOLT
COVER, END BRACKET
HEX HEAD BOLT
PLAINWASHER
HEX HEAD BOLT
COVER, FAN
6
6
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
2
*
*
*
*
*
*
*
*
1
1
4
4
1
1
6
3
4
4-1
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
25A
25B
2
1
8
1
1
4
4
4
6
1
1
4
1
4
1
2
2
6
1
1
2
2
2
2
NUT
RUBBER SUSPENSION
HEX NUT
SPRINGWASHER
PLAINWASHER
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 53
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DCA-45SSIU3 (60 Hz) — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 54 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
PART NO.
PART NAME
QTY.
REMARKS
M1213000802
0601870431
0601870490
0021004040
0601823863
0027104016
0601820671
0027105016
0601806116
0027106016
0601820847
0027120848
0027104016
0207004000
0330000200
M1213500303
0016906016
M1923100004
47130106
CONTROL BOX
1
2
CIRCUIT BREAKER ............................................1 ............. FG3110WS02 3P 110A
COVER, CIRCUIT BREAKER
MACHINE SCREW
RELAY UNIT .......................................................2 ............. MSA9013A
MACHINE SCREW
AUTOMATICVOLTAGE REGULATOR..................1 ............. NTA-5A-2DB
MACHINE SCREW
CURRENTTRANSFORMER ...............................3 ............. 812-943 75/5A
MACHINE SCREW
OVER CURRENT RELAY ....................................1 ............. TA25DU 4.0
OVER CURRENT RELAY ....................................1 ............. DB25/25A
MACHINE SCREW
HEX NUT
EDGING
2-1
3
2
4
4
5
4
6
7
4
8
9
6
10
11
12
12A
13
14
15
16
16A
17
18
19
20
21
22
23
23A
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
2
2
1
1
4
CONTROL BOX COVER
HEX HEAD BOLT
SELECTOR SWITCH ..........................................1 ............. VY-40
KNOB. SELECTOR SWITCH
SWITCH BRACKET
EDGING
MACHINE SCREW
HEX HEAD BOLT
SWITCH COVER
HEX HEAD BOLT
HEX HEAD BOLT
TOOTHEDWASHER
CONTROL PANEL
FREQUENCY METER ........................................1 ............. FCF-6 45~65Hz 240V
AC AMMETER ....................................................1 ............. ACF-6 0~75A/150A:5A
CHANGE-OVER SWITCH, AMMETER ...............1 ............. SL-2 AS
AC VOLTMETER .................................................1 ............. SCF-6 0~600V
CHANGE-OVER SWITCH,VOLTMETER ............1 ............. SL-2 VS
RHEOSTAT (VOLTAGE REGULATOR) .................1 ............. RA20A2SE102BJ 2W 1K
1
1
2
4
4
1
4
8
1
1
M1213600114
0330000160
0027103010
0016906016
M1213600014
0016906016
0016906016
0040506000
M1223000503
0601807641
0601808986
0601801040
0601806859
0601801041
0601840073
0601840121
M1223100004
0027105010
0027105010
M9220100004
0080200007
8971119621
8972465100
0016906020
1825530401
5825500290
0016906016
M1246702604
Ω
KNOB
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
SNAP RING
1
1
2
4
1
1
EMERGENCY RELAY .........................................1 ........ REPLACES P/N 0602200432
PREHEAT CONTROLLER ...................................1 ........ REPLACES P/N 0602202506
HEX HEAD BOLT
SAFETY RELAY .................................................1 ........ REPLACES P/N 0602200304
RELAY .................................................................1 ........ REPLACES P/N 0602201400
HEX HEAD BOLT
3
3
1
WIRE HARNESS, GENERATOR
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 55
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DCA-45SSIU3 (60 Hz) — ENGINE & RADIATOR ASSY.
ENGINE &
PAGE 56 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
1-1
2
3
4
5
6
6-1
6-2
7
M1923200054
8970497081
0605000048
0030010000
0040010000
0041210000
M1923200064
0602011053
M1493105204
0016908040
M1310501003
M1310501103
0605515147
M1310300903
0016908020
M1310300504
M1310300604
0016908020
0602046585
0602046366
0602040651
0602040557
0016908030
M1373100703
M1373100603
0605515148
0605515200
0602022560
M1320300304
0602022561
0603306590
0603300285
0605511395
0603306395
0602021070
0269200450
M2320300103
M9200200004
ENGINE...............................................................1 ........ ISUZU BB-4JG1T PD-04
CARTRIDGE, OIL FILTER ..................................1 ........ REPLACES P/N 0602041214
RUBBER SUSPENSION
HEX NUT
SPRINGWASHER
PLAIN WASHER
RADIATOR ...........................................................1 ........ 232000-2620
CAP, RADIATOR ..................................................1 ........ 16401-1450A
ACOUSTIC SHEET
HEX HEAD BOLT
RADIATOR HOSE
RADIATOR HOSE
HOSE BAND
FAN SHROUD
HEX HEAD BOLT
FAN GUARD
FAN GUARD
HEX HEAD BOLT
AIR CLEANER ....................................................1 ........ FPG07-0019
ELEMENT, AIR CLEANER ..................................1 ........ P827653
INDICATOR, AIR CLEANER ................................1 ........ RBX00-2352
BRACKET, AIR CLEANER ..................................1 ........ P77-7731
HEX HEAD BOLT
HOSE, AIR CLEANER
HOSE, AIR CLEANER
HOSE BAND
HOSE BAND
ADAPTER
2
2
2
2
2
6
1
1
4
1
4
1
1
6
8
9
10
11
12
13
14
15
16
16A
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
PACKING
90 DEGREE ELBOW
CONNECTOR
ROCKNUT
VALVE
HOSE JOINT
CAP
DRAIN HOSE
DRAIN JOINT
PLUG
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 57
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DCA-45SSIU3 (60 Hz) — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 58 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
PART NO.
PART NAME
QTY.
1
2
1
2
1
1
1
1
1
1
1
2
2
2
1
1
REMARKS
0150000018
0016906020
0199900700
0605515106
M9300000003
M9300100003
0199100215
M1317100004
0016908020
0199100800
0193601200
0605515106
0602220910
0016908020
0199800700
0269200900
0605515198
0602220911
0016908020
0602120465
1718939010
M9200100004
0602123260
9095720140
1819001902
M1354200404
0027106016
0016908025
8941618410
O RING
HEX HEAD BOLT
DRAIN HOSE
HOSE BAND
RESERVE TANK
CAP, RESERVE TANK
HOSE
BRACKET, RESERVE TANK
HEX HEAD BOLT
HOSE
HOSE
HOSE BAND
CLAMP
HEX HEAD BOLT
DRAIN HOSE
BLOWBY HOSE
HOSE BAND
CLAMP
HEX HEAD BOLT
PICK UP, TACHOMETER
1
1
1
1
SENDER, OIL SWITCH.......................................1 ........ REPLACES P/N 0602122281
ADAPTER
UNIT, WATERTEMPERATURE ...........................1 ........ 02094-00
PACKING.............................................................1 ........ REPLACES P/N 0602021109
ENGINE STOPPER.............................................1 ........ REPLACES P/N 0602210810
BRACKET, ENGINE STOPPER
MACHINE SCREW
1
1
3
2
HEX HEAD BOLT
FAN BELT............................................................1 ........ REPLACES P/N 0602011432
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 59
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DCA-45SSIU3 (60 Hz) — OUTPUTTERMINAL ASSY.
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
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 60 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
5
REMARKS
M1230700103
M9220100204
M9220100104
0039310000
0040010000
0041410000
0016908025
M1236100613
M1236100704
0605010040
0027103010
0030003000
0041203000
0027103010
0030003000
0016906020
0016906016
M1236400004
M1236300004
0016906020
0601870440
0601870441
M1260700504
0222100100
0016906020
0601812598
0601812538
0027104016
0207004000
M1236100803
0010112045
0041212000
M9310200004
0030012000
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE BOLT
5
HEX NUT
10
15
20
5
1
1
2
4
4
4
4
4
2
4
1
1
6
SPRINGWASHER
PLAINWASHER
HEX HEAD BOLT
TERMINAL COVER
OUTPUTWINDOW
HINGE
MACHINE SCREW
HEX NUT
PLAINWASHER
MACHINE SCREW
HEX NUT
HEX HEAD BOLT
HEX HEAD BOLT
CABLE OUTLET COVER
SUPPORTER, CABLE OUTLET COVER
HEX HEAD BOLT
CIRCUIT BREAKER ............................................2 ........ QCF 1020 1P 20A
CIRCUIT BREAKER ............................................3 ........ QCF 2050 2P 50A
BREAKER FITTING COVER
CUSHION RUBBER
HEX HEAD BOLT
RECEPTACLE .....................................................2 ........ GF-530EM 125V 20AX2
RECEPTACLE .....................................................2 ........ CS6369 250V 50A
MACHINE SCREW
HEX NUT
TERMINAL COVER
HEX HEAD BOLT
PLAINWASHER
STAY RUBBER
HEX NUT
9
10
11
11A
11B
12
12A
13
14
15
16
17
18
19
20
20-1
21
22
23
24
2A
25
26
27
28
29
1
2
2
10
10
1
2
2
2
2
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 61
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DCA-45SSIU3 (60 Hz) — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 62 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
1
PART NO.
8970444180
PART NAME
QTY.
REMARKS
STARTER SWITCH .............................................1 ........ REPLACES P/N 0602100009
....................................................................................... INCLUDES ITEM W/
*
1A
2
2A#
3
4
5
6
7
8
8A+
9
10
11
12
13
8944024980
0602103092
0601810245
0602120095
0602122093
0602123090
0602121080
0602125090
0602103092
0601810245
9826800370
0601831330
M1357201302
0602122272
1518183040
KEYS, IGNITION SWITCH
1
*
PREHEAT LAMP .................................................1 ........ INCLUDES ITEM W/#
BULB
TACHOMETER
OIL PRESSURE GAUGE
WATERTEMPERATURE GAUGE
CHARGING AMMETER
FUEL GAUGE
1
1
1
1
1
1
ALARM LAMP .....................................................3 ........ INCLUDES ITEM W/+
BULB
PANEL LIGHT......................................................1 ........ REPLACES P/N 0601810141
3
SWITCH, PANEL LIGHT
WIRE HARNESS, ENGINE
UNIT, OIL PRESSURE
1
1
1
SENDER, OVERHEAT SWITCH .........................1 ........ REPLACES P/N 0602123282
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 63
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DCA-45SSIU3 (60 Hz) — BATTERY ASSY.
BATTERY ASSY.
PAGE 64 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — BATTERY ASSY.
BATTERY ASSY.
NO.
1
PART NO.
PART NAME
QTY.
REMARKS
0602220187
M9310500014
M9103000304
0602220920
0040006000
M1347200004
M1347200104
0016910020
0040510000
BATTERY ............................................................1 ........ 627MFD
2
3
4
5
6
7
8
9
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET ..........................................2 ........ BHL-10J
SPRINGWASHER
BATTERY CABLE
BATTERY CABLE
HEX HEAD BOLT
TOOTHEDWASHER
1
1
2
1
1
2
2
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 65
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DCA-45SSIU3 (60 Hz) — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 66 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
PART NO.
PART NAME
QTY.
REMARKS
M1330100703
0016910025
M1333001903
8943690210
M1333200114
0039308000
0016908035
M1330400304
M1333300004
0016906016
0602326090
MUFFLER
1
4
1
2
3
4
5
6
7
8
9
HEX HEAD BOLT
EXHAUST PIPE
GASKET .............................................................1 ........ REPLACES P/N 0602320101
GASKET
HEX NUT
HEX HEAD BOLT
COVER
BRACKET
HEX HEAD BOLT
U BOLT SET .......................................................1 ........ 89542K
1
6
4
1
1
4
10
11
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 67
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DCA-45SSIU3 (60 Hz) — FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 68 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — FUELTANK ASSY.
FUEL TANK ASSY.
NO.
1
PART NO.
PART NAME
QTY.
REMARKS
M1363001602
0605505070
M1363200104
M9310500104
0016908020
0207308000
0222100600
M9200000003
M9200200004
0150000018
0016906020
M1363400104
0605515198
8943672922
8943692993
0016908020
0602220911
0016908020
0191201150
0191201500
0191301100
0605515108
0605515109
FUELTANK
1
1
2
4
2
2
2
1
1
1
2
1
2
2
3
4
5
6
7
8
9
CAP, FUEL TANK
TANK BAND
SUPPORTER SHEET
HEX HEAD BOLT
HEX NUT
RUBBER SHEET
DRAIN JOINT
DRAIN BOLT
O-RING
HEX HEAD BOLT
DRAIN HOSE
HOSE BAND
FUEL FILTER ......................................................1 ........ REPLACES P/N 0602042202
CARTRIDGE, FUEL FILTER ...............................1 ........ REPLACES P/N 0602042700
HEX HEAD BOLT
CLAMP
HEX HEAD BOLT
SUCTION HOSE
SUCTION HOSE
RETURN HOSE
HOSE BAND
10
11
12
13
14
14A
15
16
17
18
19
20
21
22
2
2
2
1
1
1
4
2
HOSE BAND
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 69
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DCA-45SSIU3 (60 Hz) — ENCLOSURE ASSY.
ENCLOSURE AS
ADD THE FOLLO
NUMBER WHEN
INDICATE COLO
1-ORANGE
2-WHITE
3-SPECTRUM G
4-SUNBELT GRE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 70 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
1
PART NO.
PART NAME
BASE
QTY.
1
REMARKS
M1413002902
M1413400004
0016908020
M1423001902
M1493106703
0016908020
M1423200604
M1493100804
0016908020
M1423201403
0016908020
M1433000803
M1433001003
0010114030
0040014000
0041214000
0010114030
0040014000
0041214000
M1443001302
M1493300504
0016908020
M1443300613
M1443301603
M1493303004
0207006000
0016908020
M1443200803
M1443600204
0037906000
0041206000
M9113000002
0021806016
0030006000
M9110100204
M9116100004
0016908020
M9310000004
M1463001802
M1493503403
0016908020
2
3
4
UNDER COVER
HEX HEAD BOLT
FRONT FRAME
ACOUSTIC SHEET
HEX HEAD BOLT
COVER, FRONT FRAME
ACOUSTIC SHEET
HEX HEAD BOLT
INNER COVER, FRONT FRAME
HEX HEAD BOLT
CENTER FRAME
CENTER FRAME
HEX HEAD BOLT
SPRINGWASHER
PLAIN WASHER
HEX HEAD BOLT
SPRINGWASHER
PLAIN WASHER
REAR FRAME
ACOUSTIC SHEET
HEX HEAD BOLT
REAR COVER
DUCT, REAR COVER
ACOUSTIC SHEET
HEX NUT
HEX HEAD BOLT
REAR DOOR
WINDOW PLATE
U-NUT
1
2
1
1
4
1
1
12
1
4
1
1
8
8
8
8
8
8
1
1
4
1
1
1
12
9
1
1
8
8
1
4
4
2
5
6
7
8
9
10
11
12
12A
12B
13
13A
13B
14
14A
15
16
17
17A
18
19
20
21
22
22A
23
24
24A
25
26
27
28
PLAIN WASHER
DOOR HANDLE ASSY
MACHINE SCREW
HEX NUT
HINGE
WASHER
HEX HEAD BOLT
BLIND PLUG
ROOF PANEL
ACOUSTIC SHEET
HEX HEAD BOLT
2
3
2
1
1
19
29
29A
30
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 71
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DCA-45SSIU3 (60 Hz) — ENCLOSURE ASSY.
ENCLOSURE AS
ADD THE FOLLOWIN
NUMBER WHEN ORD
INDICATE COLOR OF
1-ORANGE
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 72 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
31
PART NO.
PART NAME
BONNET CAP
CHAIN ASSY
HEX HEAD BOLT
SPLASHER PANEL
ACOUSTIC SHEET
HEX HEAD BOLT
HEX HEAD BOLT
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
HEX NUT
DOOR HANDLE ASSY
MACHINE SCREW
HEX NUT
HINGE
HINGE
WASHER
QTY.
1
1
1
1
1
4
2
1
1
1
1
1
1
1
1
2
2
1
1
15
3
12
12
4
4
8
9
8
8
8
1
2
1
1
REMARKS
M9310000103
M1483600204
0016908020
M1453200602
M1493300204
0016908055
0016908020
M1453003403
M1493406304
M1453003503
M1493406404
M1453001303
M1493400404
M1453003603
M1493406504
M1453301104
M1493405504
M1453301304
M1493407904
0207006000
M9113000002
0021806016
0030006000
M9110100204
M9110100304
M9116100004
0016908020
0601850097
0027208025
M9310000004
0600500090
0021106016
0016908020
0040508000
0017110020
0040510000
32
32-1
33
33A
34
35
36
36A
37
37A
38
38A
39
39A
40
40A
41
41A
42
43
44
44A
45
46
47
48
49
50
51
HEX HEAD BOLT
DOOR STOPPER
MACHINE SCREW
BLIND PLUG
52
53
54
54A
55
EMBLEM
MACHINE SCREW
HEX HEAD BOLT
TOOTHEDWASHER
HEX HEAD BOLT
TOOTHEDWASHER
1
1
55A
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 73
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DCA-45SSIU3 (60 Hz) — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
PAGE 74 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
3
1
1
1
1
1
1
3
2
1
2
1
1
1
1
1
REMARKS
0228901370
0229200660
0228900620
0228900940
M1490300104
0228900515
0228900425
0228900910
0229200900
0229200740
0228800770
0228800470
0228800510
0228100545
0228100370
0228100165
0228100340
0228100170
0228100200
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
9
10
11
12
13
14
15
16
17
18
19
1
1
1
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 75
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DCA-45SSIU3 (60 Hz) — NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
PAGE 76 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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DCA-45SSIU3 (60 Hz) — NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
M1550000204
M1550001304
M1550002003
M1550002103
M1550002203
M1550000804
M9500000004
M9500100004
M9500100104
M9500300004
M9500300104
M9500500004
M9500500104
M9503000004
M9503000103
M9503100004
M9503200004
M9510100004
M9510200002
M9520000004
M9520000104
M9520000204
M9520100004
M9520100204
M9520100304
M9520100404
M9520100503
M9520200003
M9520200404
M1560100603
M1560101904
M1560102003
M1560101104
M1560100904
M1560102103
DECAL;NOTE .....................................................1 ........ M150O0020
DECAL;CAUTION ...............................................1 ........ M150O0130
DECAL;GENERATOR CONTROL .......................1 ........ M150O0200
DECAL; ENGINE OPERATING ...........................1 ........ M150O0210
DECAL; AUXILLARY OUTPUT ............................1 ........ M150O0220
DECAL;NOTE .....................................................1 ........ M150O0080
DECAL; OIL DRAIN PLUG ..................................1 ........ M900O0000
DECAL;WATER ...................................................1 ........ M90010000
DECAL;WATER DRAIN .......................................1 ........ M90010010
DECAL;- ..............................................................1 ........ M90030000
DECAL;+ .............................................................1 ........ M90030010
DECAL; DIESEL FUEL........................................1 ........ M90050000
DECAL; FUEL DRAIN PLUG ...............................1 ........ M90050010
DECAL;WARNING ..............................................2 ........ M90300000
DECAL;WATER - OIL CHECK ............................1 ........ M90300010
DECAL;WARNING ..............................................1 ........ M90310000
DECAL;WARNING ..............................................1 ........ M90320000
DECAL;CAUTION ...............................................1 ........ M91010000
DECAL; MQ .........................................................1 ........ M91020000
DECAL; GROUND ...............................................1 ........ M92000000
DECAL; AMMETER CHANGE-OVER SW. ..........1 ........ M92000010
DECAL;VOLTMETER CHANGE-OVER SW. .......1 ........ M92000020
DECAL;WARNING ..............................................2 ........ M92010000
DECAL;CAUTION ...............................................1 ........ M92010020A
DECAL; SAFETY INSTRUCTIONS .....................1 ........ M92010030
DECAL;DANGER ................................................1 ........ M92010040
DECAL;WARNING ..............................................1 ........ M92010050
DECAL; CONNECTION OF OUTPUT CABLE .....1 ........ M92020000
DECAL; OVER CURRENT RELAY ......................1 ........ M92020040
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
STRIPE; WHISPERWATT
DECAL; MQ POWER
STRIPE
STRIPE
STRIPE; 45
1
2
1
2
2
1
STRIPE
1
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 77
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Effective:October 1, 2002
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENTTERMS
5. Partsmustbeinnewandresalablecon- forpricedeclinesandaddedchargesforprice
dition,intheoriginalMultiquippackage(if increaseswillnotbemadeforstockonhandat
any), and with Multiquip part numbers thetimeofanypricechange.
Terms of payment for parts are net 10 days.
FREIGHTPOLICY
clearlymarked.
Multiquip reserves the right to quote and sell
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifesthasbeenobtainedfromthecarrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
directtoGovernmentagencies,andtoOriginal
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIALEXPEDITINGSERVICE
b. Any parts with a limited shelf life A$35.00surchargewillbeaddedtotheinvoice
(such as gaskets, seals, “O” rings, forspecialhandlingincludingbusshipments,
andotherrubberparts)thatwerepur- insuredparcelpostorincaseswhereMultiquip
chasedmorethansixmonthspriorto mustpersonallydeliverthepartstothecarrier.
MINIMUMORDER
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
thereturndate.
LIMITATIONSOFSELLER’SLIABILITY
c. Anylineitemwithanextendeddealer
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
itemwithrespecttowhichdamagesareclaimed,
andinnoeventshallMultiquipbeliableforloss
of profit or good will or for any other special,
consequentialorincidentaldamages.
netpriceoflessthan$5.00.
RETURNEDGOODSPOLICY
d. Special order items.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremadein
connection with the sale of parts or trade
accessoriesnorastoanyenginenotmanufac-
tured by Multiquip. Such warranties made in
connectionwiththesaleofnew,completeunits
are made exclusively by a statement of war-
rantypackagedwithsuchunits,andMultiquip
neitherassumesnotauthorizesanypersonto
assume for it any other obligation or liability
whatever in connection with the sale of its
products.Apartfromsuchwrittenstatementof
warranty, there are no warranties, express,
impliedorstatutory,whichextendbeyondthe
descriptionoftheproductsonthefacehereof.
7. The sender will be notified of any
materialreceivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Such material will be held for five
workingdaysfromnotification, pending
instructions. If a reply is not received
within five days, the material will be re-
turnedtothesenderathisexpense.
a. Thepartsnumbersanddescriptions
must match the current parts price
list.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhichthe
itemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. The list must include the name and
phonenumberofthepersonrequest-
ingtheRMA.
PRICINGANDREBATES
Prices are subject to change without prior
notice. Pricechangesareeffectiveonaspe-
cificdateandallordersreceivedonorafterthat
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All datewillbebilledattherevisedprice.Rebates
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
PAGE 78 — DCA-45SSIU3 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05)
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NOTE PAGE
DCA-45SSIU3 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (11/30/05) — PAGE 79
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PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-632-2656
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX:310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
WARRANTYDEPARTMENT
800-835-2551,EXT.279
310-537-3700,EXT.279
FAX:310-638-8046
FAX:310-638-8046
Manufactured for Multiquip Inc.
by
DENYO CO., LTD, JAPAN
Your Local Dealer is:
MQPOWER
ADivisionofMultiquipInc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-632-2656
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