Multiquip DCA45SSKU3, DCA45SSKU User Manual

Download

OPERATION AND PARTS MANUAL

MODEL DCA45SSKU

MODEL DCA45SSKU3

60HZ WHISPERWATT™ GENERATOR

(KUBOTA V3800-DI-T DIESEL ENGINE)

PARTS LIST NO. M1870301504

Revision #0 (12/15/11)

To ﬁnd the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

REPORTING SAFETY DEFECTS

If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Trafﬁc Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.

If NHTSA receives similar complaints, it may open an investigation, and if it ﬁnds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Multiquip.

To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:

Administrator

NHTSA

1200 New Jersey Avenue S.E.

Washington, DC 20590

You can also obtain information about motor vehicle safety from http://www.safecar.gov.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 3

TABLE OF CONTENTS

DCA45SSKU/SSKU3 60 Hz Generator

Proposition 65 Warning ........................................... 2

Reporting Safety Defects ......................................... 3

Table Of Contents .................................................... 4

Parts Ordering Procedures ...................................... 5

Safety Information ..............................................6-11

Speciﬁcations ........................................................ 12

Dimensions ............................................................ 13

Installation ........................................................14-15

General Information ............................................... 16

Major Components ................................................ 17

Generator Control Panel ........................................ 18

Engine Operating Panel......................................... 19

Output Terminal Panel Familiarization .............. 20-22

Load Application .................................................... 23

Generator Outputs ................................................. 24

Generator Outputs/Gauge Reading ....................... 25

Output Terminal Panel Connections ................. 26-27

Inspection/Setup ............................................... 28-31

Generator Start-Up Procedure ........................ 32-33

Generator Shut-Down Procedures ........................ 34

Maintenance ..................................................... 35-38

Trailer Maintenance .......................................... 39-42

Trailer Wiring Diagram ........................................... 43

Generator Wiring Diagram ..................................... 44

Engine Wiring Diagram .......................................... 45

Troubleshooting (Generator) .................................. 46

Explanation Of Code In Remarks Column............. 48

Suggested Spare Parts ......................................... 49

Component Drawings

Generator Assembly ......................................... 50-51

Control Box Assembly ...................................... 52-55

Engine and Radiator Assembly ........................ 56-59

Output Terminal Assembly ................................ 60-61

Battery Assembly.............................................. 62-63

Mufﬂer Assembly .............................................. 64-65

Fuel Tank Assembly .......................................... 66-67

Enclosure Assembly ......................................... 68-71

Rubber Seals Assembly ................................... 72-73

Nameplate and Decals Assembly ..................... 74-75

Terms And Conditions Of Sale — Parts ................ 76

PAGE 4 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

If you have an MQ Account, to obtain a Username

Effective:

Choose from three easy options:

January 1st, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■ View Parts Diagrams

■ Order Parts

■ Print Speciﬁcation Information

Goto www.multiquip.com and click on

Order Parts

to log in and save!

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax. Domestic (US) Customers dial: 1-800-6-PARTS-7 (800-672-7877)

Order via Phone:

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

and Password, E-mail us at: parts@multiquip.

com.

To ob ta i n an MQ Acc oun t, con ta ct yo ur District Sales Manager for more information.

Use the internet and qualify for a 5% Discount on Standard orders for all orders which include complete part numbers.*

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

Note: Discounts Are Subject To Change

When ordering parts, please supply:

❒ Dealer Account Number ❒ Dealer Name and Address ❒ Shipping Address (if different than billing address) ❒ Return Fax Number ❒ Applicable Model Number ❒ Quantity, Part Number and Description of Each Part

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

❒ Specify Preferred Method of Shipment: ✓ UPS/Fed Ex ✓ DHL

■ Priority One ✓ Truck

■ Ground

■ Next Day

■ Second/Third Day

www.multiquip.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 5

SAFETY INFORMATION

Do not operate or service the equipment before reading the

Potential hazards associated with the operation of this

entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.

SAFETY MESSAGES

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages speciﬁ cally address the level of exposure to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION or NOTICE.

SAFETY SYMBOLS

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

WARNING

equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

Indicates a hazardous situation which, if not avoided,

COULD result in DEATH or SERIOUS INJURY.

CAUTION

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

PAGE 6 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

SAFETY INFORMATION

GENERAL SAFETY



 NEVER use accessories or attachments that are not

recommended by MQ Power for this equipment. Damage

Also, know the

and

This information will be invaluable in

emergency or safety devices.

Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these

ensure generator is on level ground before use.

keep the machine in proper running condition.

store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel

CAUTION

 NEVER operate this equipment without proper protective

clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.

NEVER operate this equipment when not feeling well due to fatigue, illness or when under medication.

NEVER operate this equipment under the inﬂ uence of

drugs or alcohol.

ALWAYS check the equipment for loosened threads or bolts before starting.

DO NOT use the equipment for any purpose other than

its intended purposes or applications.

to the equipment and/or injury to user may result.

 ALWAYS know the location of the nearest

ﬁ re extinguisher.

 ALWAYS know the location of the nearest

ﬁ rst aid kit.

 ALWAYS know the location of the nearest

phone or keep a phone on the job site. phone numbers of the nearest ambulance, doctor

ﬁ re department.

the case of an emergency.

GENERATOR SAFETY

DANGER

 NEVER operate the equipment in an explosive

atmosphere or near combustible materials. An explosion or ﬁ re could result causing severe

bodily harm or even death.

WARNING

NOTICE

This equipment should only be operated by trained and qualiﬁ ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and

safety decals when they become difﬁ cult read.

Manufacturer does not assume responsibility for any

accident due to equipment modiﬁ cations. Unauthorized equipment modiﬁ cation will void all warranties.

 NEVER disconnect any

These devices are intended for operator safety.

devices will void all warranties.

CAUTION

 NEVER lubricate components or attempt service on a

running machine.

NOTICE

 ALWAYS

 Fix damage to machine and replace any broken parts

immediately.

 ALWAYS

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 7

ENGINE SAFETY

NOTICE

run engine without an air ﬁ lter or with a dirty air

ﬁ lter. Severe engine damage may occur. Service air ﬁ lter

Wet stacking is a common problem with diesel engines

no load applied. When a diesel engine operates without sufﬁ cient load (less than 40% of the rated output), it will

In order for a diesel engine to operate at peak efﬁ ciency,

it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine

applied to relieve the condition. It can reduce the system

Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed

from the engine exhaust. Spark arresters are qualiﬁ ed

SAFETY INFORMATION

DANGER

 The engine fuel exhaust gases contain poisonous carbon

monoxide. This gas is colorless and odorless, and can cause death if inhaled.

 The engine of this equipment

requires an adequate free ﬂ ow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free ﬂ ow of the air is restricted. If the air ﬂ ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.

WARNING

 DO NOT place han d s or fingers inside en g ine

compartment when engine is running.

 NEVER operate the engine with heat shields or

guards removed.

 Keep ﬁ ngers, hands hair and clothing away

from all moving parts to prevent injury.

 DO NOT remove the radiator cap while the

engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator.

 DO NOT remove the coolant drain plug while the engine

is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator.

 NEVER

frequently to prevent engine malfunction.

 NEVER tamper with the factory settings

of the engine or engine governor. Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable.



which are operated for extended periods with light or

not operate at its optimum temperature. This will allow unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce the operating performance.

to completely burn all of the fuel.

Wet stacking does not usually cause any permanent

damage and can be alleviated if additional load is

performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several hours to burn off the accumulated unburned fuel.

 State Health Safety Codes and Public Resources

 DO NOT remove the engine oil drain plug while the

engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator.

CAUTION

 NEVER touch the hot exhaust manifold,

mufﬂ er or cylinder. Allow these parts to cool before servicing equipment.

PAGE 8 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

to prevent accidental discharge of sparks or ﬂ ames

and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.

FUEL SAFETY

DANGER

 Make sure the hitch and coupling of the towing vehicle

tow a trailer with defective hitches, couplings, chains, etc.

attach trailer’s safety chains to towing

unless

posted otherwise. Recommended off-road towing is not to

Avoid sudden stops and starts. This can cause skidding,

Trailer should be adjusted to a level position at all times

underneath the trailer’s bumper

Use the trailer’s swivel jack to adjust the trailer height to

SAFETY INFORMATION

are rated equal to, or greater than the trailer “gross vehicle weight rating.”

 DO NOT start the engine near spilled fuel or combustible

ﬂ uids. Diesel fuel is extremely ﬂ ammable and its vapors can cause an explosion if ignited.

 ALWAYS refuel in a well-ventilated area, away from

sparks and open ﬂ ames.

 ALWAYS use extreme caution when working with

ﬂ ammable liquids.

 DO NOT ﬁ ll the fuel tank while the engine is running

or hot.

 DO NOT overﬁ ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system.

 Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and ﬂ ames.

 NEVER use fuel as a cleaning agent.

 DO NOT smoke around or ne a r the

equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

TOWING SAFETY

 Check with your local county or state safety

towing regulations, in addition to meeting

Depar tment of Transpor tation (DOT) Safety Towing Regulations, before towing

your generator.

 Refer to MQ Power trailer manual for additional safety

information.

 In order to reduce the possibility of an accident while

transporting the generator on public roads, ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition.

 ALWAYS shutdown engine before transporting

CAUTION

 ALWAYS inspect the hitch and coupling for wear. NEVER

 Check the tire air pressure on both towing vehicle and

trailer. Trailer tires should be inﬂ ated to 50 psi cold. Also check the tire tread wear on both vehicles.

 ALWAYS make sure the trailer is equipped with a safety

chain.

 ALWAYS properly

vehicle.

 ALWAYS make sure the vehicle and trailer directional,

backup, brake and trailer lights are connected and working properly.

 DOT Requirements include the following:

• Connect and test electric brake operation.

• Secure portable power cables in cable tray with tie wraps.

 The maximum speed for highway towing is 55 MPH

exceed 15 MPH or less depending on type of terrain.



or jack-kniﬁ ng. Smooth, gradual starts and stops will improve towing.

 Avoid sharp turns to prevent rolling.



when towing.

 Raise and lock trailer wheel stand in up position when

towing.

 Place chock blocks underneath wheel to prevent rolling

while parked.

 Place support blocks

to prevent tipping while parked.



a level position while parked.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 9

ELECTRICAL SAFETY

DANGER



 Make sure power cables are securely connected to the

cord has been selected for the job. See Cable Selection

make sure that electrical circuits are properly

Severe injury or death by

can result from operating an ungrounded

DO NOT touch output terminals during operation. Contact with output terminals during operation can cause electrocution,

electrical shock or burn.

SAFETY INFORMATION

generator’s output receptacles. Incorrect connections may cause electri cal sh ock and damage to the generator.

NOTICE

 ALWAYS make certain that proper power or extension

The electr ical vol tage require d to

operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.

NEVER insert any objects into the output

receptacles during op era tion. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death.

Backfeed to a utility system can cause

electrocution and/or property damage. NEVER connect the generator to a

building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious

injury or even death.

Chart in this manual.

Grounding Safety

DANGER

 ALWAYS

grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator.

electrocution

generator.

 NEVER use gas piping as an electrical ground.

Power Cord/Cable Safety

DANGER

 NEVER let power cords or cables lay in water.

 NEVER stand in water while AC power from the

generator is being transferred to a load.

 NEVER use damaged or worn cables or cords when

connecting equipment to generator. Inspect for cuts in the insulation.

NEVER grab or touch a live power

cord or cable with wet hands. The possibility exists of electrical shock,

electrocution or death.

PAGE 10 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

SAFETY INFORMATION

BATTERY SAFETY

ENVIRONMENTAL SAFETY

pour waste, oil or fuel directly onto the ground,

DANGER

 DO NOT drop the battery. There is a possibility that the

battery will explode.

 DO NOT expose the battery to open ﬂ ames,

sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a ﬂ ame or spark, an explosion could occur.

WARNING

 ALWAYS wear safety glasses when handling

the battery to avoid eye irritation. The battery contains acids that can cause injury to the eyes and skin.

 Use well-insulated gloves when picking up the battery.

 ALWAYS keep the battery charged. If the battery is not

charged, combustible gas will build up.

 ALWAYS recharge the battery in a well-ventilated

environment to avoid the risk of a dangerous concentration of combustible gasses.

NOTICE

 Dispose of hazardous waste properly.

Examples of potentially hazardous waste are used motor oil, fuel and fuel ﬁ lters.

 DO NOT use food or plastic containers to

dispose of hazardous waste.

 DO NOT

down a drain or into any water source.

 If the battery liquid (dilute sulfuric acid) comes into

contact with clothing or skin, rinse skin or clothing immediately with plenty of water.

 If the battery liquid (dilute sulfuric acid) comes into

contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

CAUTION

 ALWAYS disconnect the NEGATIVE battery terminal

before performing service on the generator.

 ALWAYS keep battery cables in good working condition.

Repair or replace all worn cables.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 11

Table 1. Generator Speciﬁcations

Model

Type

Armature Connection Star with Neutral Zigzag

Phase

Standby Output

Prime Output

3Ø Voltage (L-L/L-N)

Voltage Selector Switch at 3Ø 240/139

3Ø Voltage (L-L/L-N)

Voltage Selector Switch at 3Ø 480/277

1Ø Voltage (L-L/L-N)

Voltage Selector Switch at 1Ø 240/120

Power Factor

Frequency

Speed

Aux. AC Power

Aux. Voltage/Output

Dry Weight

Wet Weight

Table 2. Engine Speciﬁcations

Model

Type

No. of Cylinders

Bore x Stroke

Displacement

Rated Output

Starting

Coolant Capacity

Lube Oil Capacity

Fuel Type

Fuel Tank Capacity

Fuel Consumption

Battery

SPECIFICATIONS

DCA-45SSKU/KU3

Revolving ﬁeld, self ventilated,

open protected type synchronous generator

3 Single

39.6 KW (49.5 kVA) 28.6 KW

36 KW (45 kVA) 26 KW

208Y/120, 220Y/127,

240Y/139

416Y/240, 440Y/254,

480Y/277

N/A 240/120

0.8 1.0

60 Hz

1800 rpm

Single Phase, 60 Hz

4.8 Kw (2.4 kW x 2)

2,072 lbs. (940 kg.)

2,314 lbs. (1,050 kg.)

Kubota V3800-DI-T-E3B EPA Tier 3

4 cycle, water-cooled, direct injection, turbo-charged

cooled EGR

4 cylinders

3.94 in. x 4.72 in. (100 mm x 120 mm)

230 cu. in. (3.769 liters)

61.1 HP at 1800 rpm

Electric

2.91 gal. (11.0 liters)

3.49 gal. (13.2 liters)

#2 Diesel Fuel

26.4 gal. (100 liters)

3.1 gal. (11.8 L)/hr at full load 2.2 gal. (8.5 L)/hr at 3/4 load

1.6 gal. (6.0 L)/hr at 1/2 load 1.1 gal. (4.0 L)/hr at 1/4 load

27 (CCA 0° 800A) x 1

N/A

PAGE 12 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

DIMENSIONS

TOP VIEW

A E

SIDE VIEW

FRONT VIEW

M91020000

Figure 1. Dimensions

Table 3. Dimensions

Reference

Letter

A 25.19 in. (640 mm.) F 76.37 in. (1,940 mm.)

B 25.19 in. (640 mm.) G 49.21 in. (1,250 mm.)

C 24.60 in. (625mm.) H 52.91 in. (1,344 mm.)

D 32.28 in. (820 mm.) I 37.40 in. (950 mm.)

E 24.60 in. (625 mm.)

Dimension in. (mm) Reference Letter Dimension in. (mm)

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 13

INSTALLATION

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

INSTALLATION

OUTDOOR INSTALLATION

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

GENERATOR GROUNDING

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and speciﬁes that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 8 AWG (5.3 mm2)

b. Aluminum - 6 AWG (8.4 mm2)

2. When grounding the generator ( Figure 2) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

INDOOR INSTALLATION

Exhaust gases from diesel engines are extremel y poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

MOUNTING

The generator must be mounted on a solid foundation (such as concrete) and set ﬁrmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the ﬂoor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

3. NEC article 250-52 (5) speciﬁes that the earth ground rod should be buried a minimum of 8 ft. into the ground.

NOTICE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

NOTICE

This generator has a permanent bonding conductor between the generator stator windings and the frame.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 15

GENERAL INFORMATION

GENERATOR

This MQ Power generator (Figure 3) is a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

ENGINE CONTROL PANEL

The “Engine Operating Panel” is provided with the following:

 Engine Warning Lamp Module

• Oil Pressure Alarm Lamp

• Water Temperature Lamp

• Charging Alarm Lamp

• Pre-Heat Lamp

 Fuel Gauge  Hour Meter  Speed Control Switch  Ignition Switch

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  Voltage Regulator  3-Pole, 125 amp Main Circuit Breaker  “Control Box” (located behind the Gen. Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Starter Relay

• Voltage Selector Switch

OUTPUT TERMINAL PANEL

The “Output Terminal Panel” is provided with the following:

 Two 250 VAC output receptacles (CS-6369), 50 amps  Two auxiliary circuit breakers, 250V @50 amps  Two 125 VAC output receptacles, (GFCI), 20 amps  Two GFCI circuit breakers, 125V@ 20 amps  Five output terminal lugs (3Ø power)

OPTIONS

 Battery Charger  Water Heater  Low Coolant Level Switch/Indicator  Camlock Connectors

OPEN DELTA EXCITATION SYSTEM

This generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist

of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectiﬁed and are the excitation current for the exciter section.

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.

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.

ENGINE

This generator unit incorporates an Kubota V3800-DI-T-E3B diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 2 for engine speciﬁcations.

In keeping with MQ Power’s policy of constantly improving its products, the speciﬁcations quoted herein are subject to change without prior notice.

ELECTRIC GOVERNOR SYSTEM (OPTION)

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

EXTENSION CABLES

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size.

PAGE 16 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

678

M91020000

OFF

W-U

V-W

U-V

START

STOP

RUN

DECREASE

INCREASE

3 PHASE 240/139

3 PHASE

1 PHASE

480/277

240/120

PRESSTO LOCK

U V W O

Figure 3. Major Components

MAJOR COMPONENTS

Table 4. Generator Major Components

ITEM NO. DESCRIPTION

1 Output Terminal Panel Assembly

2 Terminal Panel Assembly

3 Voltage Selector Switch Assembly

4 Coolant Drain Plug

5 Fuel Drain Plug

6 Air Cleaner Assembly

7 Lifting Hook

8 Mufﬂer Assembly

9 Generator Assembly

10 Engine/Radiator Assembly

11 Battery

12 Fuel Tank Assembly

13 Engine Control Panel Assembly

14 Generator Control Panel Assembly

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 17

ENGINE CONTROL PANEL

OFF

W-U

V-W

U-V

START

STOP

RUN

DECREASE

INCREASE

Figure 4. Engine Control Panel

The deﬁnitions below describe the controls and functions of the Engine Control Panel (Figure 4).

1. Engine Warning Lamps — There are four engine

warning lamps, they are deﬁned as follows:

a. Low Oil Pressure Alarm Lamp — During normal

operation of the generator this lamp will remain OFF. When the ignition switch is placed in the RUN position to start the engine, the lamp will be ON. When the oil pressure rises after start-up the lamp will go OFF. If this lamp is ever lit (ON) during normal operation of the generator, the emergency shutdown system

d. Pre-Heat Lamp — The pre-heat lamp will be ON

during the pre-heating cycle (cold wea ther conditions). When the pre-heat cycle is completed the lamp will turn OFF and the engine can be started.

In add ition this lamp displays engine trouble shooting faults via flashes (blinking). See engine trouble codes in the maintenance section of this manual.

2. Fuel Gauge – Indicates amount of diesel fuel available

3. Hour Meter – Indicates amount of time generator has

been in use.

will stop the engine automatically.

b. Water Temperature Alarm Lamp — This lamp

goes ON when the cooling water temperature rises abnormally. If the lamp goes ON during normal

4. Engine Speed Switch – This switch controls the speed

of the engine (low/high).

5. Ignition Switch – Three position switch, stop, run and

start. Insert ignition key to start and stop engine.

operation of the generator, the emergency shutdown system will stop the engine automatically.

c. Battery Charge Alarm Lamp — This lamp is

ON when the output voltage of the alternator drops below a set value. If this lamp is ON during normal operation, the emergency shutdown system will immediately stop the engine.

PAGE 18 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

GENERATOR CONTROL PANEL

1 2 3

V-W

OFF

W-U

INCREASE

U-V

STOP

RUN

START

Figure 5. Generator Control Panel

DECREASE

5 6

The deﬁnitions below describe the controls and functions of the Generator Control Panel (Figure 5).

1. Frequency Meter — Indicates the output frequency

in hertz (Hz). Normally 60 Hz.

2. AC Ammeter — Indicates the amount of current the

load is drawing from the generator per leg selected by the ammeter phase-selector switch.

3. AC Voltmeter — Indicates the output voltage present

at the U,V, and W output terminal lugs.

4. 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.

5. Voltage Regulator Control — Allows ±15% manual

adjustment of the generator’s output voltage.

6. Main Circuit Breaker—This three-pole, 125A main breaker is provided to protect the the U,V, and W Output Terminal Lugs from overload.

NOTICE

Remember the overcurrent relay monitors the current ﬂowing from the U,V, and W output terminal lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the 125 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).

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 19

OUTPUT TERMINAL PANEL FAMILIARIZATION

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 6) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs.

NOTICE

Terminal legs “O” and “Ground” are considered bonded grounds.

1Ø AND 3Ø,

480 -120 VAC

OUTPUT TERMINALS

BLACK RED BLUE WHITE GREEN

NEUTRAL

TERMINAL

OUTPUT TERMINAL FAMILIARIZATION

The “Output Terminal Panel ” (Figure 6) is provided with the following:

 Two 120/240V output receptacles @ 50 amp

 Two Circuit Breakers @ 50 amps

 Two 120V GFCI receptacles @ 20 amp

 Two GFCI Circuit Breakers @ 20 amps

 Five Output Terminal Lugs ( U, V, W, O, Ground)

GROUND

TERMINAL

HARD WIRE

HOOKUP PANEL

120 VAC, 20 AMP

GFCI RECEPTACLES

RECEPTACLE

AND

CIRCUIT BREAKER

PANEL

CIRCUIT BREAKERS FOR CS-6369 TWIST

LOCK RECEPTACLES

CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

AUX. POWER RECEPTACLES

240/139V, 50 AMPS

TWIST-LOCK

MQ POWER

CS-6369

ACCESS DOOR

LIFT TO OPEN

Figure 6. Output Terminal Panel

PAGE 20 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage selector switch position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the test button (See Figure 7) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

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 both auxiliary receptacles is dependent on the load requirements of the Output Terminal Lugs.

Turn the voltage regulator control knob (Figure 9) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 9. Voltage Regulator Control Knob

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The Output Terminal Lugs are protected by a plastic face plate cover (Figure 10). Un-screw the securing bolts (2) and raise the plastic face plate to gain access to the output terminal lugs.

Figure 7. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are two 120/240V, 50 amp auxiliary twist-lock (CS-

6369) receptacles (Figure 8) provided on the output terminal panel. These receptacles can only be accessed when the voltage selector switch is placed in the single-

phase 240/120 position.

Figure 8. 120/240V Twist-Lock Auxiliary

Receptacles

After the load wires have been securely attached to the output terminal lugs, lower the plastic face plate, and reinstall the retaining bolts.

TERMINAL

ENCLOSURE

RETAINING

BOLT

PLASTIC

TERMINAL

COVER

Figure 10. Plastic Face Plate

(Output Terminal Lugs)

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 21

OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 11).

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 125A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Over Current Relay

An over current relay (Figure 12) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

Figure 11. Connecting Loads

Figure 12. Over Current Relay

PAGE 22 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

LOAD APPLICATION

SINGLE PHASE LOAD

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, as the wattage is inﬂuenced by the efﬁciency, power factor and starting system of the equipment.

NOTICE

If wattage is not given on the equipment’s name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. SeeTable 5 below when connecting loads.

THREE PHASE LOAD

When calculating the power requirements for 3-phase power use the following equation:

NOTICE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load may be determined by multiplying voltage by amperage by 1.732.

NOTICE

Motors and motor-driven equipment draw much greater current for starting than during operation.

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

Single-phase induction motors 0.4-0.75

Electric heaters, incandescent lamps 1.0

Fluorescent lamps, mercury lamps 0.4-0.9

Electronic devices, communication equipment

1.0

Common power tools 0.8

Table 6. Cable Selection (60 Hz, Single Phase Operation)

Current

Amperes

2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.

5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.

7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.

10 1200 2400 250 ft. 150 ft. 100 ft.

15 1800 3600 150 ft. 100 ft. 65 ft.

20 2400 4800 125 ft. 75 ft. 50 ft.

Load in Watts Maximum Allowable Cable Length

At 100

Volts

CAUTION: Equipment damage can result from low voltage

At 200

Volts

#10 Wire #12 Wire #14 Wire #16 Wire

 When connecti ng 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.

 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.

 When connecting an electric drill or other power tools,

pay close attention to the required starting current capacity.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER

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.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 23

GENERATOR OUTPUTS

GENERATOR OUTPUT VOLTAGES

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the voltage selector switch (Figure 13). To obtain some of the voltages as listed in Table 7 (see below) will require a ﬁne adjustment using the voltage regulator (VR) control

knob located on the control panel.

Voltage Selector Switch

The voltage selector switch (Figure 13) is located above the output terminal panel’s Hard Wire Hook-up Panel. It has been provided for ease of voltage selection.

Figure 13. Voltage Selector Switch

Voltage Selector Switch Locking Button

To lock the voltage selector switch, press and hold the red button located at the bottom of the switch. While

holding the red button down, insert a pad lock into the hole next to the button to retain it in the inward locked position. When the lock is removed, the red button is spring loaded and will return to its normal outward unlocked position.

CAUTION

NEVER change the position of the voltage selector switch while the engine is running. ALWAYS place

circuit breaker in the OFF position before selecting voltage.

Table 7. Voltages Available

UVWO Output

Terminal Lugs

Line-Line

3Ø

1Ø Line-Neutral 120V 127V 139V 240V 254V 277V

1Ø Line-Neutral/

Line-Line

Voltage Selector Switch

3-Phase 240/139V Position

208V 220V 240V 416V 440V 480V

Voltage Selector Switch Single-Phase 240/120V Position

120V

Line-Neutral

N/A N/A

Voltage Selector Switch

3-Phase 480/270V Position

240V

Line-Line

N/A N/A

Generator Amperage

Table 8 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed..

Table 8. Generator Maximum Amps

Rated Voltage Maximum Amps

1Ø 120 Volt

1Ø 240 Volt

3Ø 240 Volt 108 amps

3Ø 480 Volt 54 amps

100 amps (4 wire) 108A x 2 (Zigzag)

50 amps (4 wire)

108A (Zigzag)

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles.

Table 9 and Table 10 show what amount of current is available at the GFCI receptacles when the output terminals and twist lock receptacles are in use. Be careful that your load does not to exceed the available current capability at the receptacles.

Table 9. 1Ø GFCI Receptacle Load Capacity

KW in Use

Twist Lock (C6369)

1Ø 240/120V

26 0

24.8 5 amps/receptacle

23.6 10 amps/receptacle

22.4 15 amps/receptacle

21.2 20 amps/receptacle

Table 10. 3Ø Generator Maximum Amps

KVA in Use

(UVWO Terminals)

3Ø 240/480V

40.9

36.7

32.6

28.4

Available Load

Current (Amps)

GFCI Duplex

5-20R 120V

Available Load

Current (Amps)

GFCI Duplex

5-20R 120V

0 amps/receptacle

5 amps/receptacle

10 amps/receptacle

15 amps/receptacle

20 amps/receptacle

PAGE 24 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

GENERATOR OUTPUTS/GAUGE READING

HOW TO READ THE AC AMMETER AND AC VOLTAGE GAUGES

The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches.

Both of these switches are located on the control panel and DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

Before taking a reading from either gauge, set the Voltage Selector Switch (Figure 14) to the position which produces the required voltage (For example, for 3Ø 240V, choose the center 3Ø 240/139V position on the voltage selector switch).

AC Ammeter Gauge Reading

Place the AC Ammeter Change-Over Switch (Figure 17) in the U position and observe the current reading (load drain) on the U terminal as indicated on the AC Ammeter Gauge (Figure 18). This process can be repeated for terminals V and W.

Figure 17. AC Ammeter

Change-Over Switch

NOTICE

The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use.

Figure 18. AC Ammeter

(Amp Reading on U Lug)

Figure 14. Voltage Selector Switch

240/139V 3

Ø Position

NOTICE

For 3Ø 208V/1Ø,120V, place the Voltage Selector Switch in the 3 Phase 240/139 position.

AC Voltmeter Gauge Reading

Place the AC Voltmeter Change-Over Switch (Figure 15) in the W-U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge (Figure 16)

Figure 15. AC Voltmeter

Change-Over Switch

Figure 16. AC Voltmeter

Gauge

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 25

OUTPUT TERMINAL PANEL CONNECTIONS

UVWO TERMINAL OUTPUT VOLTAGES

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob.

Remember the voltage selector switch determines the range of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240/139 UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 19..

3. Turn the voltage regulator knob (Figure 21) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever ﬁne tuning of the output voltage is required.

Figure 21. Voltage Regulator Knob

3Ø-208V/1Ø-120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 22.

Figure 19. Voltage Selector Switch

3Ø-240/139V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 20.

Figure 20. UVWO Terminal Lugs

3Ø-240/139V Connections

Figure 22. Voltage Selector Switch

3Ø-240/139V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 23.

Figure 23. UVWO Terminal Lugs

3Ø-208/1Ø-120V Connections Connections

NOTICE

To achieve a 3Ø 208V output the voltage selector switch must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to 208V..

PAGE 26 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480/277V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 24.

Figure 24. Voltage Selector Switch

3Ø-480/277V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

1Ø-240/120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 26.

Figure 26. Voltage Selector Switch

1Ø-240/120V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

Figure 25. UVWO Terminal Lugs

3Ø-440/254V Connections

3. Turn the voltage regulator knob (Figure 21) clockwise

Figure 27. UVWO Terminal Lugs

1Ø-200/100V Connections

to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever ﬁne tuning of the output voltage is required.

NOTICE

ALWAYS make sure that the connections to the UVWO terminals are secure and tight. The possibility of arcing exists, that could cause a ﬁre.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 27

INSPECTION/SETUP

TRAILER

FUEL TANK

(OPTION)

FUEL

TANK

INTERNAL

CIRCUIT BREAKERS

To protect the generator from an overload, a 3-pole, 125 amp, main circuit breaker is provided to protect the U,V, and W output terminals from overload. In addition two single- pole, 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Two 50 amp 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.

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 28) on the dipstick. See Table 11 for proper selection of engine oil.

Figure 28. 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 KUBOTA Engine Owner’s Manual. Oil should be warm before draining.

FUEL CHECK

DANGER

Fuel spillage on a hot engine can cause a ﬁre or explosion. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

Reﬁlling the Fuel System

CAUTION

ONLY properly trained personnel who have read

and understand this section should reﬁll the fuel tank system.

This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank (Figure 29). ALWAYS ﬁll the fuel tanks with clean fresh #2 diesel fuel. DO NOT ﬁll the fuel tanks beyond their capacities.

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

Table 11. Recommended Motor Oil

Figure 29. Internal Fuel Tank System

PAGE 28 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

INSPECTION/SETUP

Refueling Procedure:

WARNING

Diesel fuel and its vapors are dangerous

to your hea l th and th e surro unding 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 30).

CAUTION

ALWAYS place trailer on ﬁrm level ground before

refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

150

Unlevel Ground

Level Ground

DO NOT fill on unlevel ground

Unlevel Ground

Level Ground

2. Remove fuel cap and ﬁll tank as shown in Figure 31.

Figure 31. Fueling the Generator

3. NEVER overﬁll fuel tank — It is important to read the fuel gauge when ﬁlling trailer fuel tank. DO NOT wait for fuel to rise in ﬁller neck (Figure 32).

Figure 30. Only Fill on Level Ground

NOTICE

ONLY use low sulfur or ultra low sulfur diesel fuel when refueling.

Figure 32. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 33).

Figure 33. Fuel Expansion

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 29

INSPECTION/SETUP

COOLANT (ANTIFREEZE/SUMMER COOLANT/ WATER)

KUBOTA recommends 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

KUBOTA Engine Owner’s Manual for further details.

WARNING

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.

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.

CLEANING THE RADIATOR

The engine may overheat if the radiator ﬁns become overloaded with dust or debris. Periodically clean the radiator ﬁns with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the negative battery terminal disconnected.

AIR CLEANER

Periodic cleaning/replacement is necessary. Inspect it in accordance with the KUBOTA 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

KUBOTA Engine Owner’s Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 34) when depressed with the thumb as shown below.

Table 12. Coolant Capacity

Engine and Radiator 2.91 gal (11 liters)

Reserve Tank 1 quart (0.9 liters)

Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

Table 13. Anti-Freeze Operating Temperatures

Vol %

Anti-

Freeze

50 -37 -34 108 226

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.

Freezing Point Boiling Point

°C °F °C °F

Figure 34. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan

while the generator set is running.

PAGE 30 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

INSPECTION/SETUP

BATTERY

This unit is of negative ground DO NOT connect in reverse. Always maintain battery ﬂuid level between the speciﬁed marks. Battery life will be shortened, if the ﬂuid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always kee p the ter minals fir mly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type 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.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position. ALWAYS make sure that the MPEC Control Switch is in the OFF/RESET position when connecting the battery.

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.

NOTICE

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

ALWAYS be sure the battery cables (Figure 35) are properly connected to the battery terminals as shown below. The red cable is connected to the positive terminal of the battery, and the black cable is connected to the negative terminal of the battery.

CAUTION

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

Figure 35. Battery Connections

ALTERNATOR

The polarity of the alternator is negative grounding type. When an inver ted 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.

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.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 31

GENERATOR START-UP PROCEDURE

INCORRECT

BEFORE STARTING

CAUTION

The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel.

WARNING

NEVER manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position.

1. Place the main, G.F.C.I., and aux. circuit breakers (Figure 36) in the OFF position prior to starting the engine.

STARTING

1. Place the voltage selector switch in the desired voltage position (Figure 38)..

Figure 38. Voltage Selector Switch

STARTING

1. Place the engine speed control switch (Figure 39) in the Start/Idle position (down)..

Figure 36. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been

conﬁgured for the desired output voltage.

3. Connect the load to the receptacles or the output terminal lugs as shown in Figure 11. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

4. Tighten terminal nuts securely to prevent load wires from slipping out.

5. Close all engine enclosure doors (Figure 37).

CORRECT

START/IDLE

Figure 39. Engine Speed Control Switch

Start Idle Position

1. In warm weather conditions, skip to step 3. In cold weather conditions, preheat the engine glow plugs by turning the ignition key (Figure 40) to the RUN position

Figure 40. Ignition Switch Pre-Heat

(Run Position)

Figure 37. Engine Enclosure Doors

PAGE 32 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

GENERATOR START-UP PROCEDURE

2. Depending on the temperature of the coolant (cold weather conditions), the pre-heat lamp (Figure 41) will light (ON) and remain on until the pre-heating cycle has been completed. After completion of the pre-heating cycle, the light will go OFF and the engine can be started

Figure 41. Pre-Heat Lamp

3. Turn the ignition key to the start position (Figure 42). Once the engine starts, release the ignition key and allow it to return to the RUN position (Figure 40).

If the engine fails to start after 10 seconds, wait approximately 30 seconds and repeat steps 3-4.

6. The generator’s frequency meter (Figure 44) should be displaying the 60 cycle output frequency in HERTZ.

Figure 44. Frequency Meter

7. The generator’s AC-voltmeter (Figure 45) will display the generator’s output in VOLTS..

Figure 45. Voltmeter Meter

8. If the voltage is not within the speciﬁed tolerance use the voltage adjustment control knob (Figure 46) to increase or decrease the desired voltage.

Figure 42. Ignition Switch (Start Position)

4. Let the engine run for 1-2 minutes. Listen for any abnormal noises. If any abnormalities exist, shut down the engine and correct the problem.

5. Place the engine speed control switch (Figure 43) in the RUN position (up).

RUN

Figure 43. Engine Speed Control Switch

Run Position

Figure 46. Voltage Adjust Control Knob

9. The ammeter (Figure 47) will indicate zero amps with

no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 47. Ammeter (No Load)

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 33

GENERATOR SHUT-DOWN PROCEDURES

10. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 48).

Figure 48. Main, Aux. and GFCI

Circuit Breakers (ON)

11. Observe the generator’s ammeter (Figure 49) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

Figure 49. Ammeter (Load)

12. The generator will run until manually stopped or an abnormal condition occurs.

NORMAL SHUTDOWN PROCEDURE

WARNING

NEVER stop the engine suddenly except in an

emergency.

To shutdown the generator, use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 50 to the OFF position..

2. Place the engine speed control switch (Figure 51) in the Start/Idle position (down).

START/IDLE

Figure 51. Engine Speed Control Switch

Start Idle Position

3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

4. Place the ignition switch (Figure 52) in the “STOP” position, remove the key and store in a safe place.

Figure 52. Ignition Switch (Stop Position)

5. Remove all loads from the generator.

6. Inspect entire generator for any damage or loosening of components that may have occurred during operation.

EMERGENCY SHUTDOWN PROCEDURE

1. Turn ignition switch key to the STOP position.

2. To shut-down the engine in the event of an emergency, switch the MAIN, GFCI and LOAD (Figure 50) circuit breakers to OFF position.

AUTOMATIC SHUT-DOWN SYSTEM

This unit is equipped with safety devices to automatically stop the engine in the event of low oil pressure, approximately 7 psi (49 kPa), or high water temperature, approximately 230° F (110° C). The alarm lamps on the Engine Control Panel illuminate to signify the reason for the shutdown.

NOTICE

Before inspecting, turn the ignition switch to the STOP position, place all circuit breakers in the OFF position and allow sufﬁcient time for adequate cooling. When

Figure 50. Main, GFCI and Load

Circuit Breakers Off

ready to restart, complete all steps in the Generator Startup Procedure section of this manual.

PAGE 34 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

MAINTENANCE

Engine

Generator

10 Hrs

DAILY

250 Hrs 500 Hrs

Table 14. Inspection/Maintenance

Check Engine Fluid Levels X

Check Air Cleaner X

Check Battery Acid Level X

Check Fan Belt Condition X

Check for Leaks X

Check for Loosening of Parts X

Replace Engine Oil and Filter *

Clean Air Filter X

Check Fuel Filter/Water Separator Bowl X

Clean Unit, Inside and Outside X

Change Fuel Filter X

Clean Radiator and Check Coolant Protection Level*

Replace Air Filter Element *

Check all Hoses and Clamps *

Clean Inside of Fuel Tank X

Measure Insulation Resistance Over 3M ohms 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 vacuum 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.

1000

Hrs

GENERAL INSPECTION

Prior to each use, the generator should be cleaned and inspected for deﬁciencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

AIR CLEANER

Every 250 hours: Remove air cleaner element (Figure 53) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator (Figure 53) is attached to the air cleaner. When the air cleaner element is clogged, air intake

NOTICE

The air ﬁlter should not be changed until the indicator reads “RED”. Dispose of old air ﬁlter. It may not be cleaned or reused.

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.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 35

Figure 53. Air Cleaner/Indicator

MAINTENANCE

If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exists.

FUEL ADDITION

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

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.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

Cleaning Inside the Fuel Tank

FUEL TANK INSPECTION

In addition to cleaning the fuel tank, the following components should be inspected for wear:

 Rubber Suspension — look for signs of wear or

deformity due to contact with oil. Replace the rubber suspension if necessary.

 Fuel Hoses — inspect nylon and rubber hoses for signs

of wear, deterioration and hardening.

 Fuel Tank Lining — inspect the fuel tank lining for signs

of excessive amounts of oil or other foreign matter.

Replacing Fuel Filter

 Replace the fuel ﬁlter cartridge with new one every 500

hours or so.

 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.

 Vent any air

If necessary, drain the fuel inside the fuel tank completely. Using a spray washer (Figure 54) wash out any deposits or debris that have accumulated inside the fuel tank.

Figure 54. Fuel Tank Cleaning

FUEL FILTER/WATER SEPARATOR

Inspect the fuel ﬁlter water separator daily. If the fuel ﬁlter/ water separator (Figure 55) has collected a signiﬁcant amount of water and sediment at the bottom of the cup, it should be drained off. Refer to your engine manual for speciﬁc details to perform this operation.

FUEL

COCK

RETAINING

RING

SEDIMENT

Figure 55. Fuel Filter/Water Separator

CUP

PAGE 36 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

MAINTENANCE

AIR REMOVAL

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the KUBOTA Engine Manual for details.

To restart after running out of fuel, turn the switch to the “ON” position for 15-30 seconds. Try again, if needed.

CHECK OIL LEVEL

Check the crankcase oil level prior to each use, or when the fuel tank is ﬁlled. Insufﬁcient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 28.

Replacing Oil Filter

 Remove the old oil ﬁlter.

 Apply a ﬁlm of oil to the gasket on the new oil ﬁlter.

 Install the new oil ﬁlter.

WARNING

Allow engine to cool when ﬂushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.

RADIATOR CLEANING

The radiator (Figure 56) should be sprayed (cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling ﬁns or tube. When using a high pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the ﬁns and tube.

 After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

FLUSHING OUT RADIATOR AND REPLACING COOLANT

 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.

 Check hoses for softening and kinks. Check clamps for

signs of leakage.

 Tighten both cocks and replace the overﬂow tank.

 Replace with coolant as recommended by the engine

manufacturer.

 Close radiator cap tightly.

 Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

Figure 56. Radiator Cleaning

GENERATOR STORAGE

For long term storage of the generator the following is recommended:

 Drain the fuel tank completely. Treat with a fuel stabilizer

if necessary.

 Completely drain the oil from the crankcase and reﬁll if

necessary with fresh oil.

 Clean the entire generator, internal and external.

 Cover the generating set and store in a clean, dry place.

 Disconnect the battery.

 Make sure engine coolant is at proper level.

 If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block and completely remove the tires.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 37

MAINTENANCE

JACKET WATER HEATER AND INTERNAL BATTERY (OPTIONAL)

This generator can be equipped as an option with a jacket water heater and an internal battery charger. They are provided with electric cords to connect to a commercial power source.

These units will ONLY function when commercial power has been supplied to them (Figure 57). When using extension cords, refer to Table 6 for the correct size and length.

The battery charger should always be connected to a commercial power source to ensure that the battery does not get discharged.

When using the generator in hot climates there is no need to apply power to jacket water heater. However, if the generator will be used in cold climates, it is best to apply power to the jacket water heater at all times.

JACKET

WATER

HEATER

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 a power cord of adequate size.

NOTICE

To ensure adequate starting capability, always have power applied to the generator's inter nal battery charger.

CONNECT TO EXTERNAL

120 VAC POWER SOURCE

Figure 57. Battery Charger and Jacket Water

Heater (option)

PAGE 38 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

TRAILER MAINTENANCE

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below des cribe some of th e major components of a typical trailer that would be used with generator.

1. Fuel Cell — Provides an adequate amount of fuel for

the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System — System employed in stopping

the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR — Gross Vehicle Weight Rating (GVWR) is

the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length — Measurement is from the ball hitch

to the rear bumper (reﬂector).

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.

9. Tire Ply — The tire ply (layers) number is rated in

letters; 2-ply,4-ply,6-ply, etc.

10. Wheel Hub — The wheel hub is connected to the

trailer’s axle.

11. Tire Rim — Tires mounted on a tire rim. The tire rim

must match the size of the tire.

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 60 for lug nut tightening and sequence.

13. Axle — Indicates the maximum weight the axle can

suppor t 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.

14. Suspension — Protects the trailer chassis from shocks

transmitted through the wheels. Types of suspension used are leaf, Q-ﬂex, and air ride.

5. Frame Width — Measurement is from fender to fender

6. Jack Stand — Trailer support device with maximum

pound requirement from the tongue of the trailer.

7. Coupler — Type of hitch used on the trailer for

towing.

15. Electrical — Electrical connectors (looms) are provided

with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application — Indicates which units can be employed

on a particular trailer.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 39

TRAILER MAINTENANCE

BRAKES

Trailer brakes should be inspected the ﬁrst 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the ﬁrst 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Figure 58 displays the major hydraulic surge brake components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 15 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difﬁcult to turn.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer to the ground.

8. Repeat steps 1 through 7 on the remaining brakes.

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 58) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 58. Hydraulic Brake Components

Actuator

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying hydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator” to make sure that it is functioning correctly. Never use an undersize actuator.

Table 15. Hydraulic Brake Troubleshooting

Symptom Possible Cause Solution

No Brakes Brake line broken or kinked? Repair or replace.

Brake lining glazed? Reburnish or replace.

Weak Brakes or Brakes Pull to

One Side

Locking Brakes

Noisy Brakes

Dragging Brakes

Trailer overloaded? Correct weight.

Brake drums scored or grooved? Machine or replace.

Tire pressure correct? Inﬂate all tires equally.

Tires unmatched on the same axle? Match tires.

Brake components loose, bent or

broken?

Brake drums out-of-round? Replace.

System lubricated? Lubricate.

Brake components correct? Replace and correct.

Brake lining thickness incorrect or

not adjusted correctly?

Enough brake ﬂuid or correct ﬂuid?

Replace components.

Install new shoes and

linings.

Replace rubber parts

ﬁll with dot 4 ﬂuid.

PAGE 40 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

TRAILER MAINTENANCE

TIRES/WHEELS/LUG NUTS

Tires and wheels are a very impor tant and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

CAUTION

ALWAYS wear safet y glasses whe n

removing or installing force ﬁtted parts. Failure to comply may result in serious injury.

CAUTION

DO NOT attempt to repair or modify a

wheel. DO NOT install in inner tube to correct a leak through the rim. If the rim

is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

Tire Wear/Inﬂation

Suspension

The leaf suspension springs and associated components (Figure 59) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components as detailed in Table 17.

Figure 59. Major Suspension Components

Tire inﬂation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot!. Check inﬂation pressure weekly during use to insure the maximum tire life and tread wear.

Table 16 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Table 16. Tire Wear Troubleshooting

Wear Pattern Cause Solution

Center Wear Over inﬂation.

Edge Wear Under inﬂation.

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

Loss of camber or overloading.

Wheel lockup and tire skidding.

Adjust pressure to particular load per tire manufacturer.

Make sure load does not exceed axle rating. Align wheels.

Check bearing adjustment and balance tires.

Avoid sudden stops when possible and adjust brakes.

Table 17. Suspension Torque Requirements

Item Torque (Ft.-Lbs.)

3/8" U-Bolt Min-30 Max-35

7/16" U-Bolt Min-45 Max-60

1/2" U-Bolt Min-45 Max-60

Shackle Bolt

Spring Eye Bolt

Shoulder Type

Shackle Bolt

Snug ﬁt only. Parts must rotate freely.

Locking nuts or cotter pins are

provided to retain nut-bolt assembly.

Min-30 Max-50

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 41

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 60). 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

12" 20-25 35-40 50-65

13" 20-25 35-40 50-65

14" 20-25 50-60 90-120

15" 20-25 50-60 90-120

16" 20-25 50-60 90-120

First Pass

FT-LBS

Second Pass

FT-LBS

Third Pass

FT-LBS

TRAILER MAINTENANCE

Figure 60. Wheel Lug Nuts

Tightening Sequence

NOTICE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

PAGE 42 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

TRAILER WIRING DIAGRAM

Figure 61. Trailer/Towing Vehicle Wiring Diagram

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 43

GENERATOR WIRING DIAGRAM

Figure 62. Generator Wiring Diagram

PAGE 44 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

ENGINE WIRING DIAGRAM

Figure 63. Engine Wiring Diagram

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 45

TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business ofﬁce or service plant.

Table 19. Generator Troubleshooting

Symptom Possible Problem Solution

AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Is AVR defective? Replace if necessary.

Defective Rotating Rectiﬁer? Check and replace.

Defective Exciter Field? Check and replace.

Is engine speed correct? Turn engine throttle lever to “High”.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Short Circuit in load? Check load and repair.

Over current? Conﬁrm load requirements and reduce.

Defective circuit breaker? Check and replace.

Over current Relay actuated? Conﬁrm load requirement and replace.

When the Emergency/Malfunction shutdown system has been activated, the engine will be stopped and the pre-heat lamp will indicate the malfunction by a series of ﬂashing patterns. The ﬂashing patterns and corrective action are shown below in Table 20. The ﬂashing patterns consist of combinations of one or more long ﬂashes and one or more short ﬂashes.

Table 20. Engine/Generator Troubleshooting (Pre-heat Lamp)

Type of Fault Possible Fault

Engine Overspeed 115% or more rated RPM speed? Long 1 Short 1 Check electronic governor

Low Oil Pressure

Insufﬁcient Charge No Voltage of Charging Genset? Long 1 Short 3 Check wiring and repair.

High Water Temperature

Emergency Stop Emergency Stop signal detected? Long 1 Short 5 Check and repair fault

Starter Motor Protection

Rotation Sensor Defective sensor, short circuit? Long 2 Short 1 Check wiring and repair.

Solenoid Defective solenoid, short circuit? Long 2 Short 2 Check wiring and repair.

Water Temperature Sensor

Charging Gen. Terminal Disconnection Long 2 Short 6 Check connections.

Over Voltage VCC 18 volts or greater Long 3 Short 1 Check overcurrent relay.

Oil pressure 7 psi (49 kPa) or greater?

Engine Overheat, 230° F (110° C)? Long 1 Short 4 Check cooling system.

Engine Overheat, 248° F (120° C)? Long 1 Short 6 Check cooling system.

Starter motor run for 12 seconds or more?

Disconnection Long 2 Short 4 Check connection.

Short Circuit Long 2 Short 5 Check sensor. Replace.

Pre-Heat Lamp

Indication

Long 1 Short 2 Check oil level.

Long 1 Short 7 Check wiring and repair.

Solution

PAGE 46 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

NOTES

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 47

EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and

QTY. Column

— Item quantity can be indicated by a

A/R (As Required) is generally used for hoses or other

A blank entry generally indicates that the item is not sold separately. Other entries will be clariﬁed in the “Remarks”

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed

same unique symbol will be included when this item is

— Used to list an effective serial

— Indicates that the part

part is NOT used on a speciﬁc model or model number

available items. Examples include battery cables, shims,

— 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

remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

Numbers Used

number, a blank entry, or A/R.

NOTICE

The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTICE

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

PART NO. Column

Numbers Used — Part numbers can be indicated by a

number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

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.

parts that are sold in bulk and cut to length.

Column.

REMARKS Column

to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the

purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Speciﬁc Model Number Use

is used only with the speciﬁc model number or model number variant listed. It can also be used to show a

variant.

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

and certain washers and nuts.

“Not Sold Separately”

for sale through Multiquip.

PAGE 48 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

SUGGESTED SPARE PARTS

DCA45SSKU/KU3 WHISPERWATT GENERATOR WITH KUBOTA V3800-DI-T-E3CB DIESEL ENGINE

1 to 3 units

QTY. P/N DESCRIPTION

5............1C02032433 ......... CARTRIDGE , OIL FILTER

5............1663143562 .......... FILTER, FUEL, MAIN

5............RB10151281 ......... FILTER, FUEL, ELEMENT, PRE

2............1J41905810 ..........KIT, ELEMENT, SEPARATOR

3............0602046366 .......... ELEMENT, AIR

1............1G54197011 .........BELT, FAN

1............B3311501503 ....... RADIATOR HOSE, UPPER

1............B3311501603 ....... RADIATOR HOSE, LOWER

1............T106365660 .........SENSOR, WATER TEMP, (ENGINE SIDE)

1............5160137670 .......... SWITCH, WARNING, OVERHEAT (ENGINE SIDE)

1............1584139010 .......... SWITCH, OIL PRESSURE (ENGINE SIDE)

1............3824032830 .......... SWITCH, THERMOMETER

1............0601870440 .......... CIRCUIT BREAKER, 1P, 20 AMP

1............0601870441 .......... CIRCUIT BREAKER, 2P, 50 AMP

3............0601806642 .......... FUSE, 5 AMP

1............0601806645 .......... FUSE, 10 AMP

1............0601806640 .......... FUSE, 65 AMP

1............0601820602 .......... AUTOMATIC VOLTAGE REGULATOR

2............1742263720 .......... KEY, STARTER SWITCH

1............5671342930 .......... ELECTRIC/MAG/TIC, PICKUP

NOTICE

Part number on this Suggested Spare Parts list may supersede/replace the P/N shown in the text pages of this book.

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 49

GENERATOR ASSY.

PAGE 50 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B3110001302 ROTOR ASSY. ..........................................1 ............. INCLUDES ITEMS W/#

1-1# FIELD ASSY. 1 1-2# 0601820083 RECTIFIER 3 1-3# 06018 22664 ZNR 1 1-4# B3120100804 HOLDER, ZNR 1 1-5# B3120100604 INSULATOR WASHER 3 1-6# B3120100704 INSULATOR WASHER 5 1-7# B3111100603 FAN 1

1-8# B2163100004 COUPLING DISK. ....................................3 ............. PURCHASE ITEM 1-9A AS A SET

.......................................................................................................WHEN REPLACING COUPLING DISK

1-9# Y0010304016 HEX. HEAD BOLT 12 1-9A# B2163700004 BALANCING WEIGHT KIT 1 1-9B# 0204004000 U-NUT 12 1-10# B3163200104 COUPLING WASHER 2 1-11# 0342612030 HEX. SOCKET HEAD CAP SCREW 6 1-12# 0046512000 WASHER, FLAT 6 1-13# 0071906309 BEARING 1 2 0010310020 HEX. HEAD BOLT 8 3 0042510000 WASHER, LOCK 8 4 B3130000903 STATOR ASSY. 1 4-1 0845041904 GROMMET 2 5 B3137000803 FIELD ASSY., EXCITER 1 6 0016008060 HEX. SOCKET HEAD CAP SCREW 4 7 0042508000 WASHER, LOCK 4 8 B3153000513 END BRACKET 1 9 0017108035 HEX. HEAD BOLT 6 10 B3153400504 PACKING 1 11 B3153400404 COVER, BEARING 1 12 0017106016 HEX. HEAD BOLT 3 13 0010310025 HEX. HEAD BOLT 6 14 0042510000 WASHER, LOCK 6 15 B5131300004 COVER, END BRACKET 1 16 0340406040 HEX. HEAD BOLT 1 17 0600815000 NUT 1 18 0041206000 WASHER, FLAT 1 19 B3131300804 COVER, END BRACKET 1 20 0029205012 MACHINE SCREW 4 21 0041205000 WASHER, FLAT 4 22 0605000455 RUBBER SUSPENSION 2 23 0030012000 HEX. NUT 2 23A 0040012000 WASHER, LOCK 2 23B 0041212000 WASHER, FLAT 2

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 51

CONTROL BOX ASSY.

PAGE 52 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1213002012 CONTROL BOX 1 1- 1 Y0330000555 EDGING 1 1- 2 Y0330000255 EDGING 1 1- 3 Y0330000190 EDGING 1 2 0016906016 HEX. HEAD BOLT 10 3 0601807521 CIRCUIT BREAKER, 3P 125A 1 3A INSULATING PLATE 1 4 0601823863 RELAY UNIT 1

5 0027104016 MACHINE SCREW 2 6 0601820602 AUTOMATIC VOLTAGE REGULATOR 1 7 0027105016 MACHINE SCREW 4 8 0601801123 CURRENT TRANSFORMER, 150/5A 3 9 0027106020 MACHINE SCREW 6 10 0601820847 OVER CURRENT RELAY 1 11 0601820848 OVER CURRENT RELAY 1 12 0027104020 MACHINE SCREW 2 12A 0207004000 HEX. NUT 2 13 1270100604 SELECTOR SWITCH 1 14 1213602814 SWITCH BRACKET 1 15 0027105020 MACHINE SCREW 4

15A 0030005000 HEX. NUT ....................................................4 ................REPLACES P/N 0207005000

16 0016906016 HEX. HEAD BOLT 2 17 1E31560601 ENGINE CONTROL UNIT 1 18 Y0021005050 MACHINE SCREW 2 18A 0032005000 WASHER, LOCK 2 18B 0401450050 WASHER, FLAT 2 19 3N30075211 RELAY 1 20 6888153542 RELAY 2 21 0027105016 MACHINE SCREW 4 22 3F24075551 FUSE, 100A 1 23 1G37765831 HOLDER, FUSE 1 24 0027106010 MACHINE SCREW 2 25 M1260600104 FUSE BRACKET 1

26 7538070 MACHINE SCREW .....................................2 ................REPLACES P/N 0027104016

27 M0261200004 FUSE BOX 1 27A 0601806642 FUSE, 5A (F1~3) 5 27B 0601806645 FUSE, 10A (F4~6) 4 28 0027105016 MACHINE SCREW 2 29 0601806640 FUSE, 65A 1 30 M1213501004 CONTROL BOX COVER 1 31 0016906016 HEX. HEAD BOLT 4 32 M1213400014 CONTROL BOX COVER 1 33 0016906016 HEX. HEAD BOLT 4 34 M1223001513 CONTROL PANEL 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 53

CONTROL BOX ASSY.

PAGE 54 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS 35 0027105010 MACHINE SCREW 4 36 M9220100004 SET SCREW 2 37 Y0080200007 SNAP RING 2 38 M1224100104 STOPPER 1 39 0027105010 MACHINE SCREW 2 40 0601806859 AC VOLTMETER, 0-600V 1 41 0601808986 AC AMMETER, 0~75/150A:5A 1 42 0601807641 FREQUENCY METER, 6 45~65HZ 240V 1

43 0601801040 CHANGE— OVER SWITCH, 1 44 0601840073 VOITAGE REGUIATOR 2W 1K OHM 1 45 0601840121 KNOB 1 46 0601810523 INDICATOR WARNING 1 46A 0601810830 BULB 4 47 0601800682 HOUR METER 1 48 0021004016 MACHINE SCREW 2 49 OEMAA8 SELF-LOCKING NUT 2 50 0602125090 FUEL GAUGE 1 51 0601830710 TOGGLE SWITCH 1 52 1742263591 IGNITION SWITCH 1 52A 1742263720 KEY, IGNITION SWITCH 1 53 Y0601851754 GROMMET 1 54 Y0601851725 GRORNNET 2 55 0016906016 HEX. HEAD BOLT 1 55A 0040506000 TOOTHED WASHER 1 56 M1246705904 WIRE HARNESS, GENERATOR 1 57 M1357201402 WIRE HARNESS, ENGINE 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 55

ENGINE AND RADIATOR ASSY.

PAGE 56 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1923200154 ENGINE, KUBOTA V3800-DI-T 1 1A 1G54197011 FAN BELT 1 1-1 1663143562 ELEMENT, FUEL FILTER 1 1-2 1C02032433 CARTRIDGE, OIL FILTER 1 1-3 1J41905811 ELEMENT, BROWBY GAS SEPARATOR 1 2 0605000451 RUBBER SUSPENSION 2 3 020310080 HEX. HEAD NUT 2 4 0040010000 WASHER, LOCK 2

5 031110160 WASHER, FLAT 2 6 B3924200324 RADIATOR 1 6-1 0602011079 CAP. RADIATOR 1 7 Y0220300550 RUBBER SEAL 2 8 M1310302204 FAN SHROUD 1 9 M1310302304 FAN SHROUD 1 10 011008020 HEX. HEAD BOLT 6 11 M1310302404 FAN GUARD 1 12 M1310302504 FAN GUARD 1 13 011008020 HEX. HEAD BOLT 6 14 B3311501503 RADIATOR HOSE 1 15 B3311501603 RADIATOR HOSE 1 16 0605515147 HOSE BAND 4 17 0602046585 AIR CLEANER 1 17A 0602046366 ELEMENT, AIR CLEANER 1 18 0602040651 AIR CLEANER INDICATOR 1 19 0602040557 AIR CLEANER BAND 1 20 011208030 HEX. HEAD BOLT 2 21 M1373200704 BRACKET, AIR CLEANER 1 22 011008020 HEX. HEAD BOLT 2 23 M1373102003 HOSE, AIR CLEANER 1 24 M1373100603 HOSE, AIR CLEANER 1 25 0605515230 HOSE BAND 1 26 0605515146 HOSE BAND 2 27 M1373200804 HOSE CLAMP 1 28 011008020 HEX. HEAD BOLT 1 29 Y0602022588 ADAPTER 1 30 Y0602022579 90° ELBOW 1 31 Y0379500800 DRAIN HOSE 1 32 Y0603306399 HOSE JOINT 1 33 Y0605511399 VALVE 1 34 Y0603306597 CONNECTOR 1 35 Y0603300286 LOCKNUT 1 36 Y0602021071 CAP 1

37 0802081403D RESERVE TANK .........................................1 ................REPLACES P/N M9300000003

38 0802081104 CAP, RESERVE TANK .................................1 ................REPLACES P/N M9300100003

39 0199100215 HOSE 1 40 M1317100004 BRACKET, RESERVE TANK 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 57

ENGINE AND RADIATOR ASSY. (CONTINUED)

PAGE 58 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

ENGINE AND RADIATOR ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 41 011008020 HEX. HEAD BOLT 1 42 Y0199101000 HOSE 1 43 0193601300 HOSE 1 44 0605515170 HOSE BAND 2 45 M1310200904 BRACKET, RADIATOR 1 46 M1310201004 BRACKET, RADIATOR 1 47 M1310201104 BRACKET, RADIATOR 2 48 011008020 HEX. HEAD BOLT 8 49 M9312200104 MOUNT RUBBER 4

50 1502025103C DRAIN JOINT ..............................................1 ................REPLACES P/N M9200000003

51 011008020 HEX. HEAD BOLT 2

52 0802011104 DRAIN BOLT ...............................................1 ................REPLACES P/N M9200200004

53 0150000018 O-RING 1 54 Y0379501000 DRAIN HOSE 1 55 0605515198 HOSE BAND 2 56 0193601000 DRAIN HOSE 1 57 Y0602220910 CLAMP 2 58 011008020 HEX. HEAD BOLT 1 59 0601850239 GROMMET 1 60 M1303200604 ENGINE FOOT 1 61 M1303200704 ENGINE FOOT 1 62 Y0013512025 HEX. HEAD BOLT 8 63 0040012000 WASHER, LOCK 8 64 031112230 PLAIN HASHER 8 65 M1357301004 HARNESS CLAMP 1 66 M1357300804 HARNESS CLAMP 1 67 Y0013512025 HEX. HEAD BOLT 3 68 0040012000 WASHER, LOCK 3 69 031112230 WASHER, FLAT 3 70 M1357300904 HARNESS CLAMP 1 71 0010510020 HEX. HEAD BOLT 2 72 0040010000 WASHER, LOCK 2 73 031110160 WASHER, FLAT 2 74 1J41905810 KIT, ELEMENT 1 75 1584139010 SWITCH, OIL PRESSURE 1 76 5160137670 SWITCH, THERMOMETER 1 77 T106365660 SENSOR, WATER TEMP 1 78 3824032830 SWITCH, THERMOMETER 1 79 5671342930 ELECT/MAG/TIC. PICKUP 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 59

OUTPUT TERMINAL ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK

2-WHITE 6-CATERPILLAR YELLOW

3-SPECTRUM GREY 7-CATO GOLD

4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 60 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1230700103 TERMINAL PANEL 1 2 M9220100204 OUTPUT TERMINAL BOLT 5 3 M9220100104 TIE SCREW 5 4 0039310000 HEX. NUT 10 5 0040010000 WASHER, LOCK 15 6 0041410000 WASHER, FLAT 20 7 0016908025 HEX. HEAD BOLT 5 8 M1236102013 TERMINAL COVER 1

9 011106015 HEX. HEAD BOLT 4 10 M1236102114 OUTPUT WINDOW 1 11 Y0605012028 HINGE 1 12 0027103010 MACHINE SCREW 4 12A 0030003000 HEX. NUT 4 12B 0041203000 WASHER, FLAT 4 13 011206020 HEX. HEAD BOLT 2 14 M1236101814 COVER 1 15 0016906016 HEX. HEAD BOLT 7 16 0601870440 CIRCUIT BREAKER, 1P 20A 2 17 0601870441 CIRCUIT BREAKER, 2P 50A 2 18 M1260700404 BREAKER FITTING COVER 1 18-1 0222100080 CUSHION RUBBER 2 19 0016906020 HEX. HEAD BOLT 2 20 Y0601814014 RECEPTACLE, CS6369LM2, 250V 50A 2 21 0601814013 RECEPTACLE, GF20LA, (125V 20AX2) 2 22 0027104016 MACHINE SCREW 8 23 0207004000 SELF-LOCKING NUT 8 24 Y0317700480 CUSHION RUBBER 1 25 M1236400104 COVER 1 26 0016906016 HEX. HEAD BOLT 4 27 M1236101904 TERMINAL COVER 1 28 0010112045 HEX. HEAD BOLT 2 29 0041212000 WASHER, FLAT 4

30 0805009804 STAY RUBBER ............................................2 ................REPLACES P/N M9310200004

31 0030012000 HEX. NUT 2 32 0019208020 HEX. HEAD BOLT 1 33 0019208020 HEX. HEAD BOLT 1 33A 0040508000 TOOTHED WASHER 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 61

BATTERY ASSY.

PAGE 62 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 0602220199 BATTERY, 727MF 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 M1346400104 BATTERY CABLE 1 6 M0348200104 BATTERY CABLE 1

7 CABLE, GROUND .......................................1 ................MAKE LOCALLY

8 Y0013512025 HEX. HEAD BOLT 1

8A 0040012000 WASHER, LOCK 1 8B 031112230 WASHER, FLAT 1 8C 0040512000 TOOTHED WASHER 1 9 0016910020 HEX. HEAD BOLT 1 9A 0040510000 TOOTHED WASHER 1 10 020108060 HEX. NUT 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 63

MUFFLER ASSY.

PAGE 64 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 B3331102203 MUFFLER 1 2 011008020 HEX. HEAD BOLT 4 3 B3334001403 EXHAUST PIPE 1 4 1925812231 GASKET 1 5 0030410000 HEX. NUT 8 6 0602325097 SEAL CLAMP 1 7 M1333300504 BRACKET, EXHAUST PIPE 1 8 011008020 HEX. HEAD BOLT 2

9 Y0602326066 U-BOLT 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 65

FUEL TANK ASSY.

PAGE 66 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1363002602 FUEL TANK 1 1-1 0605505070 FUEL TANK CAP 1 1- 2 0605501072 FUEL SENDER UNIT 1 1-2A 0605516090 GASKET 1 2 M1363200104 TANK BAND 2 3 M9310500104 SUPPORTER SHEET 4 4 0016908020 HEX. HEAD BOLT 2 5 0207308000 HEX. NUT 2

6 0222100600 RUBBER SHEET 1 7 0222100085 RUBBER SHEET 2

8 1502025103C DRAIN JOINT ..............................................1 ................REPLACES P/N M9200000003

9 0802011104 DRAIN BOLT ...............................................1 ................REPLACES P/N M9200200004

10 0150000018 O-RING 1 11 011206020 HEX. HEAD BOLT 2 12 M1363400104 DRAIN HOSE 1 13 0605515198 HOSE BAND 2 14 M1366701204 FUEL FI ITER BRACKET 1 15 011206020 HEX. HEAD BOLT 4 16 0016908065 HEX. HEAD BOLT 1 17 RB10151261 FUEL FILTER 1 17A RB10151281 ELEMENT, FUEL FIITER 1 18 R140151351 FUEL PUMP 1 19 0191201500 SUCTION HOSE 1 20 Y0191200500 SUCTION HOSE 1 21 Y0191200500 SUCTION HOSE 1 22 Y0191202500 RETURN HOSE 1 23 0605515189 HOSE BAND 8

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 67

ENCLOSURE ASSY.

PAGE 68 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1413004202 BASE 1 2 M1413400004 UNDER COVER 1 3 011008020 HEX. HEAD BOLT 2 4 M1423003102 FRONT FRAME 1 4A M1493110203 ACOUSTIC SHEET 1 5 011008020 HEX. HEAD BOLT 4 6 M1423200604 COVER, FRONT FRAME 1 6A M1493100804 ACOUSTIC SHEET 1

7 0019208020 HEX. HEAD BOLT 12 8 M1423203303 INNER COVER, FRONT FRAME 1 9 011008020 HEX. HEAD BOLT 4 10 M1423203214 OVER COVER, FRONT FRAME 1 11 011008020 HEX. HEAD BOLT 10 12 M3310600004 COVER, RADIATOR CAP 1 13 0019208020 HEX. HEAD BOLT 4 14 M1433001703 CENTER FRAME 1 15 M1433001803 CENTER FRAME 1 16 0013616040 HEX. HEAD BOLT 4 16A 0040016000 WASHER, LOCK 4 16B 0041216000 WASHER, FLAT 4 17 M1443002412 REAR FRAME 1 17A M1493300504 ACOUSTIC SHEET 1 18 011008020 HEX. HEAD BOLT 4 19 M1443302613 REAR COVER 1 20 M1443302713 DUCT, REAR COVER 1 20A M1493307114 ACOUSTIC SHEET 1 21 0176060030 SELF-LOCKING NUT 14 22 0019208020 HEX. HEAD BOLT 10 23 M1443201303 REAR DOOR 1 24 M1444600004 WINDOW PLATE 1 25 020106050 SELF-LOCKING NUT 8 25A 952404470 WASHER, FLAT 8 26 B9114000002 DOOR HANDLE ASS' Y 1 27 0021806016 MACHINE SCREW 4 27A 020106050 HEX. HEAD NUT 4 28 M9110100204 HINGE 2 29 M9116100004 WASHER 2 30 0019208020 HEX. HEAD BOLT 3

31 0845031504 BLIND PLUG ...............................................2 ................REPLACES P/N M9310000004

32 M1463002712 ROOF PANEL 1 32A M1493506113 ACOUSTIC SHEET 1 33 0019208020 HEX. HEAD BOLT 10 34 0013616040 HEX. HEAD BOLT 4 34A 0040016000 WASHER, LOCK 4 34B 0041216000 WASHER, FLAT 4 35 M1453201422 SPLASHER PANEL 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 69

ENCLOSURE ASSY. (CONTINUED)

PAGE 70 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

ENCLOSURE ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 36 0019108055 HEX. HEAD BOLT 2 36A 0042308000 WASHER, LOCK, STAINLESS 2 36B 031108160 WASHER, FLAT 2 37 011008020 HEX. HEAD BOLT 2 38 0019208020 HEX. HEAD BOLT 2 39 M1453006213 SIDE DOOR 1 39A M1493414814 ACOUSTIC SHEET 1 40 M1453006313 SIDE DOOR 1

40A M1493414914 ACOUSTIC SHEET 1 41 M1453006403 SIDE DOOR 1 41A M1493415004 ACOUSTIC SHEET 1 42 M1453006523 SIDE DOOR 1 42A M1493415114 ACOUSTIC SHEET 1 43 M1453302904 DUCT 2 43A M1493415204 ACOUSTIC SHEET 2 44 M1453303104 DUCT 1 44A M1493415404 ACOUSTIC SHEET 1 45 0176060030 SELF-LOCKING NUT 14

46 B9114000002 DOOR HANDLE ASS' Y ..............................2 ................REPLACES P/N M9113000002

47 0021806016 MACHINE SCREW 8 47A 020106050 HEX. HEAD NUT 8 48 M9110100204 HINGE 4 49 M9110100304 HINGE 4 50 M9116100004 WASHER 8 51 0019208020 HEX. HEAD BOLT 9 52 0601850097 DOOR STOPPER 8 53 0027208025 MACHINE SCREW 8

54 0845031504 BLIND PLUG ...............................................8 ................REPLACES P/N M9310000004

55 0600800320 MANUAL PAK 1 56 0021806016 MACHINE SCREW 4 57 0600500090 EMBLEM 1 58 0021106016 MACHINE SCREW 2 59 0016910025 HEX. HEAD BOLT 1 59A 0040510000 TOOTHED WASHER 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 71

RUBBER SEALS ASSY.

PAGE 72 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 Y0228901240 SEAL RUBBER 3 2 Y0228900625 SEAL RUBBER 1 3 Y0228900595 SEAL RUBBER 1 4 0229400970 SEAL RUBBER 3 5 0229400485 SEAL RUBBER 1 6 Y0229400910 SEAL RUBBER 1 7 Y0229400425 SEAL RUBBER 1 8 0228800515 SEAL RUBBER 1 9 Y0228800820 SEAL RUBBER 2 10 0228800510 SEAL RUBBER 1 11 0228800470 SEAL RUBBER 1 12 0228100420 SEAL RUBBER 2 13 0228100325 SEAL RUBBER 2 14 0229200950 SEAL RUBBER 2 15 Y0229200890 SEAL RUBBER 1

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 73

NAMEPLATE AND DECALS ASSY.

PAGE 74 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

NAMEPLATE AND DECALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M9522000504 DECAL; CIRCUIT BREAKER ......................1 ................M92200050

2 M9520000104 DECAL; AMMETER CHANGE-OVER SW. ..1 ................M92000010

3 M9522000604 DECAL; VOLTAGE REGULATOR ................1 ................M92200060

4 M9500400204 DECAL; STARTER SWITCH .......................1 ................M90040020

5 M9501400004 DECAL; SPEED CONTROL ........................1 ................M90140000

6 M9521000204 DECAL; FUSE BOX 1

7 M1550003503 DECAL; OPERATING PROCEDURES ......1 ................M15000350

8 M9520100304 DECAL; GENERAL CAUTIONS ...............1 ................M92010030

9 M9520200404 DECAL; O.C.R. RESET ...............................1 ................M92020040

10 M9520100204 DECAL; CAUTION.......................................1 ................M92010020A

11 M9500500304 DECAL; DIESEL FUEL ................................1 ................M90050030

12 M9500500104 DECAL; FUEL DRAIN PLUG ......................1 ................M90050010

13 M9500000004 DECAL; OIL DRAIN PLUG ..........................1 ................M90000000

14 M9500100004 DECAL; WATER ..........................................1 ................M90010000

15 M9503000103 DECAL; WATER OII CHECK ....................1 ................M90300010

16 M9500300104 DECAL; + ....................................................1 ................M90030010

17 M9500300004 DECAL; - .....................................................1 ................M90030000

18 M9510200002 DECAL; MQ .................................................1 ................M91020000

19 M1560100603 STRIPE; WHISPERWATT 1 20 M1560102804 STRIPE 2 21 M1560102903 STRIPE; MQ POWER 2 22 M1560100904 STRIPE; 45 2 23 M1560103004 STRIPE 2

24 M9520000004 DECAL; GROUNDING ................................2 ................M92000000

25 M1550001803 DECAL; AUXIIIARY OUTPUT ..................1 ................M15000180

26 M1550000804 DECAL; NOTE .............................................1 ................M15000080

27 M1550000204 DECAL; NOTE .............................................1 ................M15000020

28 M9520100503 DECAL; WARNING .....................................1 ................M92010050

29 M9520200003 DECAL; CONNECT OF OUTPUT CABLE ..1 ................M92020000

30 M9520100004 DECAL; WARNING .....................................1 ................M92010000

31 M9520100704 DECAL; WARNING .....................................1 ................M92010070

32 M9520100404 DECAL; DANGER .......................................1 ................M92010040

33 M9510100004 DECAL; CAUTION.......................................1 ................M91010000

34 M9503000004 DECAL; WARNING .....................................2 ................M90300000

35 M9503100004 DECAL; WARNING .....................................1 ................M90310000

36 M9503200004 DECAL; WARNING .....................................1 ................M90320000

37 M9503200104 DECAL; DANGER .......................................1 ................M90320010

38 920214100 DECAL; WARNING .....................................1 ................M90420000

.......................................................................................REPLACES P/N M9504200004

39 M1550002304 DECAL; CAUTION.......................................1 ................M15000230

40 M9510000104 DECAL; DOCUMENT BOX LOCATED ........1 ................M91000010

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 75

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Parts must be in new and resalable 5.

Multiquip reserves the right to quote and

who use our products as integral parts of their

LIMITATIONS OF SELLER’S LIABILITY

connection with the sale of its products. Apart

statutory, which extend beyond the description

Terms of payment for parts are net 30 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be acc epted and credit will be allowed, subject to the following provisions:

A Retur ned Mate ria l Aut horizat ion 1. must be approved by Multiquip prior to shipment.

To obtain a Return Material Authorization, 2. a list must be provided to Multiquip Parts Sales that deﬁnes item numbers, quantities, and descriptions of the items to be returned.

A copy of the Return Material Authorization 3. must accompany the return shipment.

Freight is at the sender’s expense. All 4. parts must be returned freight prepaid to Multiquip’s designated receiving point.

The parts numbers and descriptions a. must match the current parts price list.

The list must be typed or computer b. generated.

The list must state the reason (s) c. for the return.

The list must reference the sales d. order ( s ) o r i n v o i c e (s ) u n d e r which the items were originally purchased.

The list must include the name e. and phone number of the person requesting the RMA.

co ndi tio n, in the ori gin al Mult iqu ip package (if any), and with Multiquip part numbers clearly marked.

The following items are not returnable:6.

Obsolete parts. (If an item is in the a. price book and shows as being repl aced by another item, it is obsolete.)

Any parts with a limited shelf life b. (such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

Any line item with an extended c. dea l e r ne t pr i c e of le s s th a n $5.00.

Special order items.d.

Electrical components.e.

Paint, chemicals, and lubricants.f.

Decals and paper products.g.

Items purchased in kits.h.

The sender will be notiﬁed of any material 7. received that is not acceptable.

Su ch mate ria l will be hel d for five 8. working days from notiﬁcation, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

Credit on returned parts will be issued 9. at dealer net price at time of the original pur c h a s e, le s s a 15 % rest o c k i ng charge.

In cases where an item is accepted, for 10. which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

Credit issued will be applied to future 11. purchases only.

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a speciﬁc date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

sell direct to Government agencies, and to Original Equipment Manufacturer accounts

own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of proﬁt or good will or for any other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warra nti es, expre ss or impli ed, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes nor author izes any person to assum e for it any other obligation or liability whatever in

from such writ ten statement of warranty, there are no warranties, express, implied or

of the products on the face hereof.

Effective: February 22, 2006

PAGE 76 — DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11)

NOTES

DCA45SSK/KU3 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/15/11) — PAGE 77

OPERATION AND PARTS MANUAL

HERE’S HOW TO GET HELP

Multiquip Inc trademarks are the property of their respective owners and used with permission.

This manual

The information and speciﬁcations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change speciﬁcations, design or the information published in this publication at any time without notice and without incurring any obligations.

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

United StateS

Multiquip Corporate Ofﬁce MQ Parts Department

18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com

Service Department Warranty Department

800-421-1244 310-537-3700

Technical Assistance

800-478-1244 Fax: 310-943-2238

Tel. (800) 421-1244 Fax (800) 537-3927

Fax: 310-537-4259 800-421-1244

800-427-1244 310-537-3700

310-537-3700

Fax: 800-672-7877 Fax: 310-637-3284

Fax: 310-943-2249

mexico United Kingdom

MQ Cipsa Multiquip (UK) Limited Head Ofﬁce

Carr. Fed. Mexico-Puebla KM 126.5 Momoxpan, Cholula, Puebla 72760 Mexico Contact: pmastretta@cipsa.com.mx

Tel: (52) 222-225-9900 Fax: (52) 222-285-0420

Unit 2, Northpoint Industrial Estate, Globe Lane, Dukinﬁeld, Cheshire SK16 4UJ Contact: sales@multiquip.co.uk

Canada

Multiquip

4110 Industriel Boul. Laval, Quebec, Canada H7L 6V3 Contact: jmartin@multiquip.com

Tel: (450) 625-2244 Tel: (877) 963-4411 Fax: (450) 625-8664

Tel: 0161 339 2223 Fax: 0161 339 3226

, the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other

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.

Your Local Dealer is:

Multiquip DCA45SSKU3, DCA45SSKU User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual