Multiquip DCA45SSKU3, DCA45SSKU User Manual

0 (0)

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)

www.multiquip.com

Parts Ordering Procedures

Ordering parts has never been easier!

Choose from three easy options:

Effective: January 1st, 2006

Best Deal! Order via Internet (Dealers Only):

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

View Parts Diagrams

Order Parts

Print Specification Information

Goto www.multiquip.com and click on

Order Parts to log in and save!

If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip. com.

To obtain an MQ Account, contact your District Sales Manager for more information.

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

Note: Discounts Are Subject To Change

 

 

 

 

Order via Fax (Dealers Only):

 

Fax your order in and qualify for a 2% Discount

 

 

 

 

 

 

 

 

 

 

 

 

All customers are welcome to order parts via Fax.

 

on Standard orders for all orders which include

 

 

 

 

 

 

 

 

 

Domestic (US) Customers dial:

 

complete part numbers.*

 

 

 

 

1-800-6-PARTS-7 (800-672-7877)

 

 

 

 

 

Note: Discounts Are Subject To Change

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Order via Phone:

Domestic (US) Dealers Call:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1-800-427-1244

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Non-Dealer Customers:

 

 

 

 

 

 

 

 

 

 

International Customers should contact

 

 

 

Contact your local Multiquip Dealer for

 

 

 

their local Multiquip Representatives for

 

 

 

parts or call 800-427-1244 for help in

 

 

 

Parts Ordering information.

 

 

 

locating a dealer near you.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

Specify Preferred Method of Shipment:

UPS/Fed Ex

DHL

Priority One

Truck

Ground

Next Day

Second/Third Day

NOTICE

All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST.

WE ACCEPT ALL MAJOR CREDIT CARDS!

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 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

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.

Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

page 6 — DCA45ssk/ku3 60 hz Generator • operation and parts manual — rev. #0 (12/15/11)

Safety Information

general saFeTY

CauTion

never operate this equipment without proper protective clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.

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.

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 use accessories or attachments that are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

alWaYs know the location of the nearest fire extinguisher.

alWaYs know the location of the nearest first aid kit.

alWaYs know the location of the nearest

phone or keep a phone on the job site. Also, know the phone numbers of the nearest ambulance, doctor and fire department. This information will be invaluable in the case of an emergency.

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

never disconnect any emergency or safety devices.

These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these devices will void all warranties.

CauTion

never lubricate components or attempt service on a running machine.

NOTICE

alWaYs ensure generator is on level ground before use.

alWaYs keep the machine in proper running condition.

Fix damage to machine and replace any broken parts immediately.

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

DCA45ssk/ku3 60 hz Generator • operation and parts manual — rev. #0 (12/15/11) — page 7

Safety Information

engine saFeTY

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 hands or fingers inside engine 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.

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.

NOTICE

never run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter 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.

Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied. When a diesel engine operates without suffi cient load (less than 40% of the rated output), it will not operate at its optimum temperature. This will allow unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce the operating performance.

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 to completely burn all of the fuel.

Wet stacking does not usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition. It can reduce the system performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several hours to burn off the accumulated unburned fuel.

State Health Safety Codes and Public Resources Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or fl ames from the engine exhaust. Spark arresters are qualifi ed 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.

page 8 — DCA45ssk/ku3 60 hz Generator • operation and parts manual — rev. #0 (12/15/11)

Safety Information

Fuel saFeTY

Danger

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 flammable 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 near the equipment. Fire or explosion could result

from fuel vapors or if fuel is spilled on a hot engine.

ToWing saFeTY

CauTion

Check with your local county or state safety towing regulations, in addition to meeting

Department of Transportation (DOT) SafetyTowing 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

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer “gross vehicle weight rating.”

alWaYs inspect the hitch and coupling for wear. never tow a trailer with defective hitches, couplings, chains, etc.

Check the tire air pressure on both towing vehicle and trailer. Trailer tires should be inflated to 50 psi cold.

Also check the tire tread wear on both vehicles.

alWaYs make sure the trailer is equipped with a safety chain.

alWaYs properly attach trailer’s safety chains to towing 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 unless posted otherwise.Recommended off-road towing is not to exceed 15 mph or less depending on type of terrain.

Avoid sudden stops and starts.This can cause skidding, or jack-knifi ng. Smooth, gradual starts and stops will improve towing.

Avoid sharp turns to prevent rolling.

Trailer should be adjusted to a level position at all times when towing.

Raise and lock trailer wheel stand in up position when towing.

Place chock blocks underneath wheel to prevent rolling while parked.

Place support blocks underneath the trailer’s bumper to prevent tipping while parked.

Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

DCA45ssk/ku3 60 hz Generator • operation and parts manual — rev. #0 (12/15/11) — page 9

Safety Information

eleCTriCal saFeTY

Danger

Do noT touch output terminals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or burn.

The electrical voltage required 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 operation. 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.

power Cord/Cable safety

Danger

Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections may cause electrical shock and damage to the generator.

NOTICE

alWaYs make certain that proper power or extension cord has been selected for the job. See Cable Selection Chart in this manual.

grounding safety

Danger

alWaYs make sure that electrical circuits are properly grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator. severe injury or death by electrocution can result from operating an ungrounded generator.

never use gas piping as an electrical ground.

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

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.

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.

environmenTal saFeTY

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 pour waste, oil or fuel directly onto the ground, down a drain or into any water source.

DCA45ssk/ku3 60 hz Generator • operation and parts manual — rev. #0 (12/15/11) — page 11

 

 

 

Specifications

 

 

 

 

 

 

 

 

 

 

Table 1. Generator Specifications

 

 

 

Model

DCA-45SSKU/KU3

 

 

Type

Revolving field, self ventilated,

 

 

open protected type synchronous generator

 

 

 

 

 

Armature Connection

Star with Neutral

Zigzag

 

 

Phase

3

Single

 

 

Standby Output

39.6 KW (49.5 kVA)

28.6 KW

 

 

Prime Output

36 KW (45 kVA)

26 KW

 

 

3Ø Voltage (L-L/L-N)

208Y/120, 220Y/127,

N/A

 

 

Voltage Selector Switch at 3Ø 240/139

240Y/139

 

 

 

 

 

3Ø Voltage (L-L/L-N)

416Y/240, 440Y/254,

N/A

 

 

Voltage Selector Switch at 3Ø 480/277

480Y/277

 

 

 

 

 

1Ø Voltage (L-L/L-N)

N/A

240/120

 

 

Voltage Selector Switch at 1Ø 240/120

 

 

 

 

 

 

Power Factor

0.8

1.0

 

 

Frequency

60 Hz

 

 

Speed

1800 rpm

 

 

Aux. AC Power

Single Phase, 60 Hz

 

 

Aux. Voltage/Output

4.8 Kw (2.4 kW x 2)

 

 

Dry Weight

2,072 lbs. (940 kg.)

 

 

Wet Weight

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

 

 

Table 2. Engine Specifications

 

 

 

Model

Kubota V3800-DI-T-E3B EPA Tier 3

 

 

Type

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

 

 

cooled EGR

 

 

 

 

 

No. of Cylinders

4 cylinders

 

 

Bore x Stroke

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

 

 

Displacement

230 cu. in. (3.769 liters)

 

 

Rated Output

61.1 HP at 1800 rpm

 

 

Starting

Electric

 

 

Coolant Capacity

2.91 gal. (11.0 liters)

 

 

Lube Oil Capacity

3.49 gal. (13.2 liters)

 

 

Fuel Type

#2 Diesel Fuel

 

 

Fuel Tank Capacity

26.4 gal. (100 liters)

 

 

Fuel Consumption

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

 

 

 

 

 

Battery

27 (CCA 0° 800A) x 1

 

page 12 — DCA45ssk/ku3 60 hz Generator • operation and parts manual — rev. #0 (12/15/11)

Dimensions

B C

D

TOP VIEW

A E

45

SIDE VIEW

F

FRONT VIEW

Figure 1. Dimensions

 

 

Table 3. Dimensions

 

 

Reference

Dimension in. (mm)

Reference Letter

Dimension in. (mm)

G H

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.)

 

 

I

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.

Indoor Installation

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

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.

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.

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 SwitchIgnition 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 SwitchVoltage 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 ampsTwo auxiliary circuit breakers, 250V @50 ampsTwo 125 VAC output receptacles, (GFCI), 20 ampsTwo GFCI circuit breakers, 125V@ 20 amps

Five output terminal lugs (3Ø power)

Options

Battery Charger

Water Heater

Low Coolant Level Switch/IndicatorCamlock 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)

Multiquip DCA45SSKU3, DCA45SSKU User Manual

Major Components

45

2

3

 

 

PRESS TO LOCK

U V W O

1

5 4

Figure 3. Major Components

8

7

6

45

9

 

 

12

11

10

Table 4. Generator Major Components

 

 

 

 

 

13

 

14

 

 

ITEM NO.

DESCRIPTION

 

 

 

 

 

1

Output Terminal Panel Assembly

 

 

 

 

 

2

Terminal Panel Assembly

 

 

 

 

 

3

Voltage Selector Switch Assembly

 

 

OFF

 

 

4

Coolant Drain Plug

 

 

V-W

 

 

 

 

 

U-V

W-U

 

 

 

 

STOP

START

 

 

 

5

Fuel Drain Plug

RUN

 

 

 

 

 

 

 

 

 

 

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

1

2

3

4

V-W

U-V W-U

INCREASE DECREASE

OFF

STOP RUN

START

5

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 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 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.

d.Pre-Heat Lamp — The pre-heat lamp will be ON during the pre-heating cycle (cold weather conditions).When the pre-heat cycle is completed the lamp will turn OFF and the engine can be started.

In addition 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.

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.

page 18 — DCA45ssk/ku3 60 hz Generator • operation and parts manual — rev. #0 (12/15/11)

generator control PANEL

1 2 3

4

 

V-W

U-V

W-U

INCREASE DECREASE

OFF

5 6

STOP RUN

START

Figure 5. Generator Control Panel

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.

Output Terminal Familiarization

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

Two 120/240V output receptacles @ 50 ampTwo 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)

1Ø AND 3Ø,

 

 

NEUTRAL

GROUND

480 -120 VAC

 

 

 

 

TERMINAL

TERMINAL

OUTPUT TERMINALS

 

 

 

 

 

 

 

 

HARD WIRE

 

 

 

 

HOOKUP PANEL

U

V

W

O

 

BLACK RED BLUE WHITE GREEN

MQ POW

ER

CIRCUIT BREAKERS

FOR CS-6369 TWIST

LOCK RECEPTACLES CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

120 VAC, 20 AMP GFCI RECEPTACLES

ACCESS DOOR

LIFT TO OPEN

RECEPTACLE

 

 

AND

 

 

CIRCUIT BREAKER

 

 

PANEL

 

Y

 

 

 

W

X

 

 

CS-6369

TWIST-LOCK

AUX. POWER RECEPTACLES

240/139V, 50 AMPS

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.

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 (CS6369) receptacles (Figure 8) provided on the output terminal panel. These receptacles can only be accessed when the voltage selector switch is placed in the singlephase 240/120 position.

Figure 8. 120/240V Twist-Lock Auxiliary

Receptacles

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.

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 12. Over Current Relay

Figure 11. Connecting Loads

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.

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

 

1.0

 

equipment

 

 

 

 

 

 

 

 

 

 

 

 

Common power tools

 

 

 

0.8

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

Current

Load in Watts

Maximum Allowable Cable Length

 

 

 

 

 

 

 

 

in

At 100

At 200

#10 Wire

#12 Wire

#14 Wire

 

#16 Wire

Amperes

 

Volts

Volts

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION: Equipment damage can result from low voltage

 

 

 

 

 

 

 

 

 

 

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.

When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

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

.

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

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

Voltage Selector Switch

Voltage Selector Switch

Terminal Lugs

3-Phase 240/139V Position

3-Phase 480/270V Position

 

 

 

 

 

 

 

Line-Line

208V

220V

240V

416V

440V

480V

 

 

 

 

 

 

 

Line-Neutral

120V

127V

139V

240V

254V

277V

 

 

 

 

 

 

 

Voltage Selector Switch Single-Phase 240/120V Position

 

 

 

 

 

 

 

 

Line-Neutral/

120V

N/A

N/A

240V

N/A

N/A

Line-Line

Line-Neutral

Line-Line

 

 

 

 

 

 

 

 

 

 

 

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

100 amps (4 wire)

108A x 2 (Zigzag)

 

1Ø 240 Volt

50 amps (4 wire)

108A (Zigzag)

 

3Ø 240 Volt

108 amps

 

 

3Ø 480 Volt

54 amps

 

 

GFCI Receptacle Load Capability

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

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

Table 9. 1Ø GFCI Receptacle Load Capacity

KW in Use

Available Load

Twist Lock (C6369)

Current (Amps)

1Ø 240/120V

GFCI Duplex

5-20R 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

Available Load

(UVWO Terminals)

Current (Amps)

3Ø 240/480V

GFCI Duplex

5-20R 120V

 

45

0 amps/receptacle

 

 

40.9

5 amps/receptacle

 

 

36.7

10 amps/receptacle

 

 

32.6

15 amps/receptacle

 

 

28.4

20 amps/receptacle

 

 

page 24 — DCA45ssk/ku3 60 hz Generator • operation and parts manual — rev. #0 (12/15/11)

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