Multiquip DCA45USI2 User Manual
OPERATION AND PARTS MANUAL
®
MODEL DCA45USI2
60HZ WHISPERWATT™ GENERATOR
(ISUZU BU-4JJ1T DIESEL ENGINE)
PARTS LIST NO. M1870400004
Revision #0 (01/12/11)
To fi nd the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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
Traffi c 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
fi nds 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.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 3
TABLE OF CONTENTS
DCA45USI2 Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information .............................................. 6-11
Specifi cations ........................................................ 12
Dimensions ............................................................ 13
Installation ............................................................. 14
Installation ............................................................. 15
General Information ............................................... 16
Major Components ................................................ 17
Generator Control Panel ........................................ 18
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization .............. 22-24
Load Application .................................................... 25
Generator Outputs ................................................. 26
How To Read AC Ammeter/AC Voltmeter Gauges 27
Output Terminal Panel Connections ................. 28-29
Inspection/Setup ............................................... 30-33
Generator Start-Up Procedure ........................ 34-35
Generator Shut-Down Procedures ........................ 36
Maintenance ..................................................... 37-39
Trailer Maintenance .......................................... 40-43
Trailer Wiring Diagram ........................................... 44
Generator Wiring Diagram ..................................... 45
Engine Wiring Diagram .......................................... 46
Troubleshooting (Generator) .................................. 47
Troubleshooting (Diagnostic Lamp) ....................... 48
Component Drawings
Generator Assembly ......................................... 52-53
Control Box Assembly ...................................... 54-59
Engine and Radiator Assembly ........................ 60-63
Output Terminal Assembly ................................ 64-65
Battery Assembly.............................................. 66-67
Muffl er Assembly .............................................. 68-69
Fuel Tank Assembly .......................................... 70-71
Enclosure Assembly ......................................... 72-75
Rubber Seals Assembly ................................... 76-77
Nameplate and Decals Assembly .................... 78-79
Terms And Conditions Of Sale — Parts ................ 80
Explanation Of Code In Remarks Column............. 50
Suggested Spare Parts ......................................... 51
PAGE 4 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
PARTS ORDERING PROCEDURES
r
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 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
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)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
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 you
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
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 ✓ Tr uck
■ Ground
■ Next Day
■ Second/Third Day
www.multiquip.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — 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
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.
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 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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.
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
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. Also, know the
phone numbers of the nearest ambulance, doctor and
fi re 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
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 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
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — 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 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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
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 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)
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
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 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 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.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — 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.
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.
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 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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.
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.
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.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 11
SPECIFICATIONS
Table 1. Generator Specifi cations
Model
Type
Armature Connection Star with Neutral Zigzag
Phase
Standby Output
Prime Output
49.5 kVA (39.6 kW) 28.6 KW
45 kVA (36 KW) 26 KW
Revolving fi eld, self ventilated,
open protected type synchronous generator
3 Single
DCA-45USI2
Voltage
Frequency
Speed
Power Factor
Aux. AC Power
Voltage
Output
Dry Weight
Maximum Lifting Capacity
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
240 or 480V 240 or 120V
60 Hz
1800 rpm
0.8 1.0
Single Phase, 60 Hz
120V
4.8 Kw (2.4 kW x 2)
2,889 lbs. (1,310 kg)
6,960 lbs. (3,157 kg)
Table 2. Engine Specifi cations
ISUZU BU-4JJ1T Tier 4
4 cycle, water-cooled, direct injection, turbo-charged
4 cylinders
3.76 in. x 4.13 in. (95.4 mm x 105 mm)
183 cu. in. (3,000 cc)
57.1 HP/1800 RPM
Electric
3.17 gal. (12 liters)
3.83 gal. (14.5 liters)
#2 Diesel Fuel
78 gal. (300 liters)
2.7 gal. (10.4 L)/hr at full load 2.1 gal. (8.0 L)/hr at 3/4 load
1.5 gal. (5.6 L)/hr at 1/2 load 0.9 gal. (3.4 L)/hr at 1/4 load
12V 72Ah x 1
PAGE 12 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
DIMENSIONS
A
SIDE VIEW
45
B
E
C
TOP VIEW
D
F
FRONT VIEW
Figure 1. Dimensions
Table 3. Dimensions
G
H
Reference
Letter
A 30.55 in. (776 mm.) F 83.07 in. (2,130 mm.)
B 24.37 in. (619 mm.) G 61.00 in. (1,550 mm.)
C 30.16 in. (766 mm.) H 37.40 in. (950 mm.)
D 30.16 in. (766 mm.)
E 24.37 in. (619 mm.)
Dimension in. (mm) Reference Letter Dimension in. (mm)
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 13
INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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
specifi es 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 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 fi rmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the fl oor 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(c) specifi es 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.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 15
GENERAL INFORMATION
GENERATOR
This generator (Figure 3) is a high quality portable (requires
a trailer for transport) power source for telecom sites,
lighting facilities, power tools, submersible pumps and other
industrial and construction machinery.
ENGINE OPERATING PANEL
The “Engine Operating Panel” is provided with the following:
Tachometer
Water Temperature Gauge
Warning Lamp
Fuel Leak Detected Alam Lamp
Pre-Heat Lamp
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Panel Light/Panel Light Switch
ECU Controller
Engine Speed 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
Voltmeter Change-Over Switch
Voltage Regulator
3-Pole, 110 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
• Automatic Voltage Regulator
• Current Transformer
• Over-Current Relay
• Starter Relay
• Voltage Selector Switch
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
Three 120/240V output receptacles (CS-6369), 50A
Three auxiliary circuit breakers, 50A
Two 120V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Five output terminal lugs (3Ø power)
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 rectifi ed 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 confi guration 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 “fi xed ceiling” and responds
according the demands of the required load.
ENGINE
This generator unit incorporates an ISUZU BU-4JJ1T diesel
engine. This engine is designed to meet every performance
requirement for the generator. Reference Table 2 for engine
specifi cations.
In keeping with MQ Power’s policy of constantly improving
its products, the specifi cations quoted herein are subject
to change without prior notice.
ELECTRIC GOVERNOR SYSTEM
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 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
MAJOR COMPONENTS
1000
2000
3000
0
RPM
1
45
4
2
3
MOOOOO-20001Q
6
AUTO
LOWOILPRESSURE
HIGHCOOLANTTEMPERATURE
OVERCRANK
OVERSPEED
ENGINERUNNING
45
5
Table 4. Generator Major Components
ITEM NO. DESCRIPTION
MANUAL
OFF/RESET
3000
7
1 Muffl er Assembly
2 Fuel Tank Assembly
3 Engine and Radiator Assembly
4 Generator Assembly
5 Output Terminal Assembly
6 Engine Operating Panel Assembly
8
Figure 3. Major Components
7 Generator Control Panel Assembly
8 Battery Assembly
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 17
GENERATOR CONTROL PANEL
1
AUTO
MANUAL
OFF/RESET
LOW OILPRESSURE
HIGH COOLANTTEMPERATURE
OVERCRANK
OVERSPEED
ENGINE RUNNING
MOOOOO-20001Q
1000
2000
0
3000
RPM
Figure 4. Generator Control Panel
The defi nitions below describe the controls and functions
of the Generator Control Panel (Figure 4).
1. Voltage Regulator Control — Allows ±15% manual
adjustment of the generator’s output voltage.
2. Main Circuit Breaker—This three-pole, 110A main
breaker is provided to protect the the U,V, and W
Output Terminal Lugs from overload.
7
6
INCREASE
DECREASE
2
V
U
W
3
OFF
V-W
W-U
U-V
OFF
5
4
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the generator
function.
The Control Box is equipped with the following major
components:
Over-Current Relay
3. Ammeter Change-Over Switch — This switch allows
the AC ammeter to indicate the current fl owing 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. AC Voltmeter — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
6. AC Ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
7. Frequency Meter — Indicates the output frequency
in hertz (Hz). Normally 60 Hz.
Automatic Voltage Regulator (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
NOTICE
Remember the overcurrent relay monitors the current
fl owing 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 110 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).
PAGE 18 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
NOTES
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 19
ENGINE OPERATING PANEL
1
8
9
10
12
AUTO
MANUAL
OFF/RESET
LOW OIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
OVERSPEED
ENGINE RUNNING
MOOOOO-20001Q
11
3
2
INCREASE
DECREASE
4
V
U
W
5
6
1000
2000
7
0
3000
RPM
Figure 5. Engine Operating Panel
OFF
V-W
W-U
U-V
OFF
PAGE 20 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
ENGINE OPERATING PANEL
The defi nitions below describe the controls and functions
of the Engine Operating Panel (Figure 5).
1.
Panel Light — Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel light
switch to the OFF position.
2. Panel Light Switch — When activated will turn on control
panel light.
3. Oil Pressure Gauge — During normal operation this
gauge should read between 42 ~71 psi. (290~490 kPa).
When starting the generator the oil pressure may read a
little higher, but after the engine warms up the oil pressure
should return to the correct pressure range.
4. Water Temperature Gaug e — During normal operation this
gauge be should read between 167°~203°F (75° ~95°C
5. Charging Ammeter Gauge — Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
6. Fuel Gauge — Indicates amount of diesel fuel available.
7. Tachometer — Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
8. Preheat Lamp — As the engine cranks, this lamp will
illuminate to indicate automatic preheating of the engine
glow plugs. When the lamp turns off, this indicates that
the preheat cycle is complte and the engine will start
automatically.
9. Warning Lamp — This lamp will illuminate when a critical
engine fault has occured.
10. Fuel Leak Detected Alarm Lamp — This lamp will
illuminate when fl uids in the containment have reached
high levels
11. Engine Speed Switch — This switch controls the speed
of the engine (low/high).
12. Auto START/STOP Engine Controller (ECU) — This
controller has a vertical row of status LED's (inset), that
when lit, indicate that an engine
malfunction (fault) has been
detected. When a fault has been
detected the engine controller will
evaluate the fault and all major
faults will shutdown the generator.
During cranking cycle, the ECU
will attempt to crank the engine for
10 seconds before disengaging.
If the engine does not engage (start) by the third
attempt, the engine will be shutdown by the engine
controller’s Over Crank Protection mode. If the engine
engages at a speed (RPM's) that is not safe, the
controller will shutdown the engine by initializing the
Over Speed Protection mode.
Also the engine controller will shut down the engine in
the event of low oil pressure, high coolant temperature,
low coolant level, and loss of magnetic pickup.
These conditions can be observed by monitoring the
LED status indicators on the front of the controller
module.
A. MPEC Control Switch — This switch controls the
running of the unit. If this switch is set to the OFF/
RESET position, the unit will not run. When this switch
is set to the manual position, the generator will start
immediately.
If the generator is to be connected to a building’s
AC power source via an automatic transfer switch
(isolation), place the switch in the AUTO position. In this
position, should an outage occur, the automatic transfer
switch (ATS) will start the generator automatically
via the generator’s auto-start contacts connected to
the ATS’s start contacts. Please refer to your ATS
installation manual for further instructions for the
correct installation of the auto-start contacts of the
generator to the ATS.
B. Low Oil Pressure — Indicates the engine pressure
has fallen below 15 psi (103 kPa). The oil pressure
is detected using variable resistive values from the
oil pressure sending unit. This is considered a major
fault.
C. High Coolant Temperature — Indicates the engine
temperature has exceeded 230°F (110°C). The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
D. Overcrank Shutdown — Indicates the unit has
attempted to start a pre- programmed number of
times, and has failed to start. The number of cycles
and duration are programmable. It is pre-set at 3
cycles with a 10 second duration. This is considered
a major fault.
E. Overspeed Shutdown — Indicates the engine is
running at an unsafe speed. This is considered a
major fault.
F. Engine Running — Indicates that engine is running
at a safe operating speed.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 21
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:
Three 120/240V output receptacles @ 50 amp
Three 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)
Figure 6. Output Terminal Panel
PAGE 22 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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
all three 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 and
lift the plastic terminal cover to gain access to the terminal
enclosure.
Figure 7. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 8) provided on the output
terminal panel. These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.
Figure 8. 120/240V Twist-Lock Auxiliary
Receptacles
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 10. Plastic Face Plate
(Output Terminal Lugs)
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 23
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, 110
amp 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 24 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)
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 infl uenced by the effi ciency, 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. See Table 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. SeeTable 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
in
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 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 fl uorescent 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.
DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 25
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