Multiquip DCA-45US1 User Manual
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
DCA-45USI
ULTRA-SILENT
GENERATOR
PARTS LIST NO. M1871400004B
Revision #2 (04/22/05)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALL TIMES.
TM
SERIES
PAGE 2 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave. 800-421-1244
Carson, CA 90746
Email: mqpower@multiquip.com
Internet: www.mqpower.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
SERVICE DEPARTMENT
800-835-2551
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
WARRANTY DEPARTMENT
800-835-2551,
310-537-3700,
ON-HAND
EXT.
279
EXT.
279
WHEN CALLING
FAX:
310-632-2656
FAX:
800-672-7877
FAX:
310-637-3284
FAX:
310-638-8046
FAX:
310-631-5032
FAX:
310-638-8046
© COPYRIGHT 2004, MULTIQUIP INC.
Multiquip Inc, MQ Power Inc, Ultra-Silent series, the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and
may not be used, reproduced, or altered without written permission. All other trademarks are the property of thier respective owners
and used with permission.
This manual
should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are
based on the
the information published in this publication at any time without notice and without incurring any obligations.
MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and
DCA-45USI Ultra Silent Generator
. Multiquip Inc. reserves the right to discontinue or change specifications, design or
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 3
TABLE OF CONTENTS
MQ POWER DCA-45USIMQ POWER DCA-45USI
MQ POWER DCA-45USI
MQ POWER DCA-45USIMQ POWER DCA-45USI
AC GENERAAC GENERA
AC GENERA
AC GENERAAC GENERA
Here's How To Get Help ............................................. 3
Table Of Contents ....................................................... 4
Parts Ordering Procedures ........................................ 5
DCA-45USI Specifications .......................................... 6
Dimensions .................................................................. 7
Safety Message Alert Symbols ............................... 8-9
Rules for Safe Operation ..................................... 10-13
Installation ............................................................ 14-15
Towing Safety Precautions ....................................... 16
Trailer Specifications ................................................. 17
Generator Decals ................................................. 18-19
General Information .................................................. 20
Major Components ................................................... 21
Generator Control Panel........................................... 22
Engine Operating Panel............................................ 23
Output Terminal Panel Familiarization................. 24-26
Load Application........................................................ 27
Generator Outputs ............................................... 28-29
Gauge Reading ......................................................... 30
Output Terminal Panel Connections .................... 30-31
Pre-setup .............................................................. 32-35
Generator Start-up Procedure ............................36-38
Generator Shut-down Procedure ............................. 39
Maintenance......................................................... 40-41
Trailer Brakes Maintenance...................................... 42
Trailer Maintenance ............................................. 43-44
Trailer Wiring Diagram .............................................. 45
Engine Wiring Diagram ........................................ 46-47
Generator Wiring Diagram ....................................... 48
Generator Troubleshooting....................................... 49
Explanation of Codes in Remarks Column .............. 50
Suggested Spare Parts ............................................ 51
TORTOR
TOR
TORTOR
COMPONENT DRACOMPONENT DRA
COMPONENT DRA
COMPONENT DRACOMPONENT DRA
Generator Assembly ............................................ 52-53
Control Box Assembly .......................................... 54-57
Engine & Radiator Assembly ............................... 58-61
Output Terminal Assembly ................................... 62-63
Battery Assembly ................................................. 64-65
Muffler Assembly ................................................. 66-67
Fuel Tank Assembly ............................................. 68-69
Enclosure Assembly ............................................ 70-75
Rubber Seal Assembly ........................................ 76-77
Nameplate and Decals ........................................ 78-79
Terms and Condition of Sale — Parts ...................... 80
WINGSWINGS
WINGS
WINGSWINGS
NOTE
PAGE 4 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
Specification and part number
are subject to change without
notice.
PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒❒
❒ 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:
❒❒
✓ FedEx or UPS Ground
✓ FedEx or UPS Second Day or Third Day
✓ FedEx or UPS Next Day
✓ Federal Express Priority One
✓ DHL
✓ Tr u c k
Note: Unless otherwise indicated by customer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours. We will make every effort to
ship “Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
Here’s how to get help...
Please have the model and serial number
on hand when calling.
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave. 800-421-1244
FAX:
Carson, CA 90746
Email: mqpower@multiquip.com
Internet: www.mqpower.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
SERVICE DEPARTMENT
800-835-2551
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
WARRANTY DEPARTMENT
800-835-2551,
310-537-3700,
EXT.
EXT.
279
279
310-632-2656
FAX:
800-672-7877
FAX:
310-637-3284
FAX:
310-638-8046
FAX:
310-631-5032
FAX:
310-638-8046
Place Your Parts Order Via Web or Fax
For Even More Savings!
(Domestic USA Dealers Only)
Extra Discounts!
All parts orders which include complete part numbers and
are received by our automated web parts order system, or
by fax qualify for the following extra discounts:
Ordered Standard Stock orders
via orders ($750 list and above)
Fax 3% 10%
Web 5% 10%
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
at no charge for freight
NOTE: DISCOUNTS ARE SUBJECT TO CHANGE
MQPOWER
A Division of Multiquip Inc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: 310-632-2656
E-MAIL: mqpower@multiquip.com
INTERNET: www.mqpower.com
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 5
Direct TOLL-FREE access
to our Parts Department:
Toll-free nationwide — 800-427-1244
Toll-free FAX — 800-6-PARTS-7
(800/672-7877)
DCA-45USI — SPECIFICATIONS
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PAGE 6 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — DIMENSIONS (SIDE AND FRONT)
Figure 1. Dimensions
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 7
DCA-45USI — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
Safety precautions should be followed at all times when operating
this equipment. Failure to read and understand the Safety
Messages and Operating Instructions could result in injury to
yourself and others.
This Owner's Manual has been
NOTE
Before using this GENERATOR, ensure that the operating
individual has read and understands all instructions in this
manual.
developed to provide complete
instructions for the safe and efficient
operation of the MQ Power
DCA45USI ULTRA-SILENT™
GENERATOR.
Model
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
the operator, and are preceded by one of three words: DANGER,
WARNING, or CAUTION.
Lethal Exhaust Gases
Engine exhaust gases contain poisonous
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined
area or enclosed structure that does not
provide ample free flow air.
Explosive Fuel
Diesel fuel is extremely flammable, and its
vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use fuel as a cleaning agent.
DANGER: You WILL be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
WARNING: You CAN be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
CAUTION: You CAN be injured if you
DO NOT follow directions.
Potential hazards associated with trowel operation will be
referenced with "
this manual, and will be referenced in conjunction with Safety
"
Message Alert Symbols
Hazard Symbols
".
" which appear throughout
Burn Hazards
Engine components can generate extreme heat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. NEVER operate the engine with
heat shields or heat guards removed.
Rotating Parts
NEVER operate equipment with covers, or
guards removed. Keep
and
clothing
prevent injury.
fingers, hands, hair
away from all moving parts to
PAGE 8 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — SAFETY MESSAGE ALERT SYMBOLS
Accidental Starting
ALWAYS place the engine ON/OFF switch
in the OFF position, when the trowel is not
in use.
Over Speed Conditions
NEVER tamper with the factory settings of the
engine governor or settings. Personal injury
and damage to the engine or equipment can
result if operating in speed ranges above
maximum allowable.
This
NOTE
the surrounding environment could
be damaged if you do not follow
instructions.
generator
, other property, or
Respiratory Hazard
ALWAYS wear approved respiratory protection.
Sight and Hearing hazard
ALWAYS wear approved eye and hearing
protection.
Equipment Damage Messages
Other important messages are provided throughout this manual
to help prevent damage to your trowel, other property, or the
surrounding environment.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 9
DCA-45USI — RULES FOR SAFE OPERATION
■
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
The following safety guidelines should always be used when
operating the DCA-45USI Generator:
GENERAL SAFETY
■
DO NOT operate or service this equipment before
reading this entire manual.
■
This equipment should not be operated by persons under 18
years of age.
■
NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steeltoed boots and other protective devices required
by the job.
:
Failure to follow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is
for industrial use only.
NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to
cool before servicing engine or generator.
■
High Temperatures – Allow the engine to cool before
performing service and maintenance functions. Contact with
hot!
components can cause serious burns.
■
The engine of this
generator requires an
adequate free flow of
cooling air.
operate the generator in
any enclosed or narrow
area where free flow of
the air is restricted. If the
air flow is restricted it will
cause serious damage
to the generator or
engine and may cause injury to people. The generator engine
gives off DEADLY carbon monoxide gas.
NEVER
■
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■
NEVER operate this equipment under the
influence or drugs or alcohol.
■
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage to
the equipment and/or injury to user may result.
■
Manufacture does not assume responsibility for any accident
due to equipment modifications.
■
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■
ALWAYS check the machine for loosened threads or bolts
before starting.
■
NEVER operate the generator in an explosive atmosphere or
near combustible materials. An explosion or fire could result
causing severe
bodily harm or even death.
■
■
■
■
■
■
■
■
■
ALWAYS make sure generator is properly grounded.
NEVER use gas piping as an electrical ground.
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
ALWAYS make sure generator installation is accordance with
national and local electrical codes
ALWAYS have a qualified electrician perform the generator
wiring installation.
NEVER power cables or cords
NEVER
is being transfer to a load.
NEVER use a defective or frayed power cable. Check the
cable for cuts in the insulation.
NEVER use a extension cord that is frayed or damaged where
the insulation has been cut.
ALWAYS make certain that proper extension cord has been
selected for the job See Table 5.
The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits.
performing maintenance on the generator.
stand in water
while AC power from the generator
Turn all circuit breakers OFF before
.
lay in wate
r.
PAGE 10 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — RULES FOR SAFE OPERATION
■
ALWAYS make sure that electrical circuits are properly
grounded
codes before operating generator. Severe
electrocution can result from operating an ungrounded
generator.
■
ALWAYS be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.
■
ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children.
■
ALWAYS read, understand, and follow
procedures in Operator’s Manual before
attempting to operate equipment.
DANGERDANGER
DANGER
DANGERDANGER
securely connected to the
generator’s output terminals,
insufficient tightening of the
terminal connections may cause
damage to the generator and
electrical shock.
DANGERDANGER
DANGER
DANGERDANGER
DANGERDANGER
DANGER
DANGERDANGER
per the
National Electrical Code
(NEC) and local
injury
or
death!
:
Never use damaged or worn cables when
connecting equipment to the generator.
Make sure power
connecting
cables are
WET
HANDS
:
NEVER grab or
touch a live
power cord with
wet hands , the
possibility exists
of electrical shock, electrocution, and even
death!
POWER
CORD
(POWER ON)
:
.
DANGERDANGER
DANGER
DANGERDANGER
by
■
Backfeed to a utility system can cause
property damage. DO NOT connect to any building's electrical
system except through an approved device or after building
main switch is opened. ALWAYS have a licensed electrician
perform the installation
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
Radiator
1. Radiator Cap - Removing the radiator cap while the engine
2. Coolant Drain Plug - Removing the coolant drain plug
3. Engine Oil Drain Plug - Removing the engine oil drain
Maintenance Safety
■
:
electrocution
and or
:
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
is hot will result in high pressurized, boiling water to gush
out of the radiator, causing severe scalding to any persons
in the general area of the generator.
while the engine is hot will result in hot coolant to gush out
of the coolant drain plug, therefore causing severe scalding
to any persons in the general area of the generator.
plug while the engine is hot will result in hot oil to gush out
of the oil drain plug, therefore causing severe scalding to
any persons in the general area of the generator.
NEVER lubricate components or attempt
service on a running machine.
■
■
NEVER touch output terminals during operation. This is
extremely dangerous. ALWAYS stop the machine and
place the circuit breaker in the “OFF” position when contact
with the output terminals is required. There exists the
possibility of
which can cause severe bodily harm or even death
electrocution, electrical shock or burn,
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 11
■
■
!
ALWAYS allow the machine a proper
amount of time to cool before servicing.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace
broken parts.
DCA-45USI — RULES FOR SAFE OPERATION
■
NEVER run engine without air filter. Severe engine damage
may occur.
■
ALWAYS service air cleaner frequently to prevent engine
malfunction.
■
ALWAYS disconnect the
performing service on the generator.
■
ALWAYS be sure the operator is familiar with proper safety
precautions when operating the generator set.
■
ALWAYS store equipment properly when not in use.
■
DO NOT leave the generator running in the
unattended.
■
DO NOT allow unauthorized people to operate this
equipment.
■
ALWAYS read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
■
Refer to the
technical questions or information.
DANGER:DANGER:
DANGER:
DANGER:DANGER:
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
(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.
Isuzu Engine Owner's Manual
Pay close attention to
ventilation when operating
the generator inside
tunnels and caves. The
negative battery terminal
manual mode
for engine
National Electrical Code
before
Battery
The battery contains acids that can cause injury to the eyes
and skin. To avoid eye irritation,
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
2. DO NOT expose the battery to
open flames, sparks, cigarettes
etc. The battery contains
combustible gases and liquids. If
these gases and liquids come in
contact with a flame or spark, an
explosion could occur.
3. ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. ALWAYS keep battery charging and cables in good working
condition. Repair or replace all worn cables.
5. ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with plenty
of water, then contact the nearest doctor or hospital, and
seek medical attention.
Transporting
■
ALWAYS shutdown engine before transporting.
■
Tighten both fuel tank caps securely.
always
clothing or skin
, rinse skin or clothing
wear safety glasses.
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the UVWO output terminals.
PAGE 12 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
■
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See next page “
basic towing techniques.
Towing Safety Precautions
” for
DCA-45USI — RULES FOR SAFE OPERATION
■
Towing Safety Precautions
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
Conform to
(DOT)
towing generator.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
The following list of suggestions should be used when towing
your generator:
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR) of 6,000 lbs.
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
Department of Transportation
Safety Towing Regulations
before
Avoid sharp turns.
■
Trailer should be adjusted to a level position at all times
when towing.
■
Raise and lock trailer wheel stand in up position when
transporting.
■
DOT Requirements include the following:
z
z
Emergencies
■
ALWAYS know the location of the nearest
■
ALWAYS know the location of the nearest and
Connect and test electric brake operation.
Secure portable power cables in cable tray with
tie wraps.
fire extinguisher
first aid kit
.
.
■
Check the tire air pressure on both towing vehicle and
trailer.
Also check the tire tread wear on both vehicles.
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■
ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
Place
while parked.
■
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
■
Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
Trailer tires should be inflated to 50 psi cold.
chock blocks
underneath wheel to prevent rolling,
■
In emergencies
nearest phone or
Also know the phone numbers of the nearest
ambulance, doctor
information will be invaluable in the case of an
emergency.
always
know the location of the
keep a phone on the job site
and
fire department
.
. This
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 13
DCA-45USI — INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — INSTALLATION
Outdoor Installation
Install the generator in a clear area. 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.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
:
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 - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
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.
NOTE
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 15
DCA-45USI — TOWING SAFETY PRECAUTIONS
Towing Safety Precautions
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 3) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.
The following list of suggestions should be used when towing
your generator:
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■
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. Also check the tire tread wear on both vehicles.
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
:
Check with your local county or state safety
towing regulations before towing your
generator.
■
ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
■
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
Place
rolling, while parked.
■
Place
prevent tipping, while parked.
■
Use the trailer’s hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.
■
Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■
Avoid sharp turns to prevent rolling.
■
Remove wheel stand when transporting.
■
DO NOT transport generator with fuel in tank.
chocked blocks
support blocks
underneath wheel to prevent
underneath the trailer’s bumper to
NOTE
Figure 3. Generator with Trailer
PAGE 16 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
Generator w/trailer illustration is
for reference only.
DCA-45USI — TRAILER SPECIFICATIONS
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
Explanation of Chart:
This section is to provide the user with trailer service and
maintenance information. The service and maintenance
guidelines referenced in this section apply a wide range of
trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage
to the equipment and personal injury.
It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:
Brakes
Tires
Lug Nut Torquing
Suspension
Electrical
Brake Troubleshooting Tables
Use the following definitions when reading Table 2.
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).
:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
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.
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 17 and Figure 67
sequence.
13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed
in inches (see Table 2). 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.
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.
or lug nut tightening and
4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 17
DCA-45USI — GENERATOR DECALS
The DCA-45USI generator is equipped with a number of safety decals. These decals are provided for operator safety and
maintenance information. The illustration below and on the preceding page show the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
PAGE 18 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — GENERATOR DECALS
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 19
DCA-45USI — GENERAL INFORMATION
DCA-45USI FAMILIARIZATION
Generator
The MQ Power Model DCA-45USI (Figure 4) is a 36 kW
generator
that is designed as 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 Operating Panel
The “Engine Operating Panel” is provided with the following:
z
Tachometer
z
Water Temperature Gauge/ Alarm Lamp
z
Oil Pressure Gauge/ Alarm Lamp
z
Charging Ammeter Gauge
z
Pre-Heat Lamp
z
Panel Light
z
Panel Light Switch
z
Ignition/Preheat Switch
z
Fuel Gauge
z
Fuel Filter Water Level Alarm Lamp
Generator Control Panel
The “Generator Control Panel” is provided with the following:
z
Output Voltage Adjustment Knob
z
Frequency Meter (Hz)
z
AC Ammeter (Amps)
z
AC Voltmeter (Volts)
z
Ammeter Change-Over Switch
z
Voltmeter Change-Over Switch
z
Voltage Regulator
z
3-Pole, 110 amp Main Circuit Breaker
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
Open Delta Excitation System
The DCA-45USI generator is equipped with the state of the art
Open-Delta
"
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 "
the required load.
Engine
The DCA-45USI is powered by a 4 cycle, water cooled, turbocharged
Isuzu BB-4JG1T
every performance requirement for the generator. Reference Table 1
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.
The basic controls and indicators for the DCA-45USI generator are
addressed on the following pages.
" excitation system. The open delta system consist of
fixed ceiling
" and responds according the demands of
diesel
engine. This engine is designed to meet
z
Three 120/240V output receptacles (CS-6369), 50 amps
z
Three auxilliary circuit breakers, @50 amps
z
Two 125 VAC output receptacles, (GFCI), 20 amps
z
Two GFCI circuit breakers @ 20amps
z
Five output terminal lugs (3Ø power)
Control Box
The “Control Box” is provided with the following:
z
Automatic Voltage Regulator
z
Current Transformer
z
Emergency Relay
z
Over-Current Relay
PAGE 20 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
Mechanical Governor System
The mechanical governor system control the RPM of the engine.
When the engine demands increase or decrease, the mechanical
governor system regulates the frequency variation to within ±.5%.
The electronic governor option decreases the frequency variation
to within ±0.25%.
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 5 ) as a guide for selecting proper extension cable size.
DCA-45USI — MAJOR COMPONENTS
Figure 4. Major Components
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uO
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 21
Figure 5. Generator Control Panel
DCA-45USI — GENERATOR CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-45USI "
1. Main Circuit Breaker – This three-pole, 110 amp main
breaker is provided to protect the
Terminal Lugs
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. 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.
4. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
5. Voltage Regulator Control – Allows ±15% manual
adjustment of the generator’s output voltage.
6. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
7. AC Voltmeter – Indicates the output voltage present at
the
U,V, and W Output Terminal Lugs
Generator Control Panel
" (Figure 5).
U,V, and W Output
from overload.
.
Located behind the generator control panel is the
Control Box
electronic components required to make the generator
function.
The Control Box is equipped with the following major
components:
z
Over-Current Relay
z
Voltage Rectifer
z
Starter Relay
z
Engine Controller (Computer Controlled)
z
Current Transformer
z
Voltage Selector Switch
NOTE
In the event of a short circuit or over current condition, it will
automatically trip the 60 amp main breaker.
To restore power to the
reset
button on the overcurrent relay and place the
circuit breaker in the
Generator
. This box contains some of the necessary
Remember the
relay
monitors the current
flowing from the
Output Terminal Lugs
load.
Output Terminal Panel
overcurrent
U,V, and W
to the
, press the
main
closed
position (ON).
PAGE 22 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-45USI "
1. Panel Light - Normally used in dark places or at night.
When activated, panel will luminate. When the generator
is not in use, turn the panel light switch to the OFF
position.
2. Panel Light Switch- When activated, will turn on control
panel light.
3. Oil Pressure Lamp - Indicates that the oil pressure is
too low and will shut down the engine.
4. Water Temperature Lamp - Indicates that the water
temperature is too hot and will shut down the engine.
5. Fuel Filter Water Level Alarm Lamp - This lamp turns
on when water in the filter is detected. Drain the water
in the fuel filter strainer to correct the problem.
6. Pre-heat Lamp - This indicates when the engine has
been preheated and is ready for starting. In cold weather
conditions, it may be several minutes before the lamp
illuminates.
Engine Operating Panel
" (Figure 6).
7. Fuel Leak Detected Alarm – This indicates that liquid
is present in the fuel tank containment basin. Drain the
containment basin and repair any leaks.
8. Tachometer – Indicates engine speed in RPM’s for
60 Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
9. Fuel Gauge - Indicates amount of diesel fuel available.
10. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
11. Water Temperature Gauge – During normal operation
this gauge be should read between 165o F to 203o F.
12. Oil Pressure Gauge – Normal operation should be about
28 to 71 psi. When starting the generator the oil pressure
may read a bit higher, but after the engine warms up
the oil pressure should return to normal.
13. Starter Switch – Three position switch, stop,
preheat/run and start. Insert ignition key to start and
stop engine.
Figure 6. Engine Operating Panel
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 23
DCA-45USI — OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel
The
Output Terminal Panel
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.
NOTE
(Figure 7) shown below is located
Terminal legs “O” and “Ground” are
considered
bonded grounds
Output Terminal Familiarization
The “
Output Terminal Panel
following:
z
Three (3) 120/240V output receptacles, 50 amp
z
Three (3) Circuit Breakers 240V @50 amps
z
Two (2) 120V GFCI receptacles, 20 amp
z
.
Two (2) GFCI Circuit Breakers @ 20 amps
z
One Main Circuit Breaker @110 amps
z
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
” (Figure 7) is provided with the
Figure 7. Output Terminal Panel
PAGE 24 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any
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 UVWO terminals.
Pressing the
being tripped. Pressing the "
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
reset
button resets the GFCI receptacle after
voltage selector switch
Test Button
" (See Figure 8) in
Each auxilliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
Output Terminal Lugs
Turn the
control panel to obtain the desired voltage. Turning the knob
clockwise will
clockwise will
Figure 10. Voltage Regulator Control Knob
Removing the Plastic Face Plate (
The
Output Terminal Lugs
plate cover (Figure 11). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
.
voltage regulator control knob
increase
decrease
the voltage, turning the knob counter-
the voltage.
(Figure 10) on the
Output Terminal Lugs
are protected by a plastic face
)
After the load wires have been securely attached to the
Figure 8. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240 VAC, 50 amp auxilliary twist-lock
(CS-6369) recepacles (Figure 9) provided on the output
terminal panel.These receptacles can
when the voltage selector switch is placed in the
only
be accessed
single-
Output Terminal Lugs
phase 240/120 position.
Figure 11. Plastic Face Plate (UVWO Terminals)
, reinstall the plastic face plate.
Figure 9. 240 VAC Twist-Lock
Auxiliary Receptacles
DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 25
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