MULTIQUIP Power Ultra-Silent DCA-45USI Parts Manual

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Page 1

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.

SERIES

Page 2

PAGE 2 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 3

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

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

Page 4

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

PAGE 4 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

NOTE

Specification and part number are subject to change without notice.

Page 5

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

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

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

Page 6

DCA-45USI — SPECIFICATIONS

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PAGE 6 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 7

DCA-45USI — DIMENSIONS (SIDE AND FRONT)

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 7

Figure 1. Dimensions

Page 8

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)

Page 9

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

Page 10

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

PAGE 10 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 11

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

DANGER

DANGERDANGER

per the

National Electrical Code

(NEC) and local

injury

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

■

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.

Page 12

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

Page 13

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

Page 14

DCA-45USI — INSTALLATION

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 15

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

Page 16

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.

Page 17

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

Page 18

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)

Page 19

DCA-45USI — GENERATOR DECALS

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 19

Page 20

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:

Tachometer

Water Temperature Gauge/ Alarm Lamp

Oil Pressure Gauge/ Alarm Lamp

Charging Ammeter Gauge

Pre-Heat Lamp

Panel Light

Panel Light Switch

Ignition/Preheat Switch

Fuel Gauge

Fuel Filter Water Level Alarm Lamp

Generator Control Panel

The “Generator Control Panel” is provided with the following:

Output Voltage Adjustment Knob

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

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

Three 120/240V output receptacles (CS-6369), 50 amps

Three auxilliary circuit breakers, @50 amps

Two 125 VAC output receptacles, (GFCI), 20 amps

Two GFCI circuit breakers @ 20amps

Five output terminal lugs (3Ø power)

Control Box

The “Control Box” is provided with the following:

Automatic Voltage Regulator

Current Transformer

Emergency Relay

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.

Page 21

DCA-45USI — MAJOR COMPONENTS

Figure 4. Major Components

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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 21

Page 22

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:

Over-Current Relay

Voltage Rectifer

Starter Relay

Engine Controller (Computer Controlled)

Current Transformer

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)

Page 23

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

Page 24

DCA-45USI — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The

Output Terminal Panel

(Figure 7) shown below is located

on the right-hand side (left from control panel) of the generator.

Output Terminal Familiarization

The “

Output Terminal Panel

following:

Lift up on the cover to gain access to receptacles and terminal

lugs.

NOTE

Terminal legs “O” and “Ground” are considered

bonded grounds

Three (3) 120/240V output receptacles, 50 amp

Three (3) Circuit Breakers 240V @50 amps

Two (2) 120V GFCI receptacles, 20 amp

Two (2) GFCI Circuit Breakers @ 20 amps

One Main Circuit Breaker @110 amps

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)

Page 25

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

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 UVWO terminals.

Pressing the being tripped. Pressing the "

reset

button resets the GFCI receptacle after

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

the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

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

Output Terminal Lugs

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-

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

Page 26

DCA-45USI — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by using the

Terminal Lugs

(See Figure 12). Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the

3-pole, 110 amp,

ALL

switch the engine.

circuit breakers to the OFF position prior to starting

or the convienience receptacles

Output Terminal Lugs

main

circuit breaker is provided. Make sure to

from overload, a

Output

Blower Fan

This unit has an intake fan located at the rear of the machine to draw outside air into the cabinet to cool the engine. The fan has a 10 amp AC fuse located beneath the

Selector Switch

DANGER:

Figure 12. Connecting Loads

Over Current Relay

over current relay

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 rent relay must be pressed. The over current relay is located in the control box.

(Figure 13) is connected to the main

reset button

on the over cur-

replace the fuse with the engine and/or generator operating could result in

electrocution

bodily harm

unit completely off before attempting to replace or handle

THIS fuse

Voltage

(Figure 14).

Figure 14. Blower Fan Fuse

This fuse has current running through it any time the engine is operating. IS NOT connected to the main circuit breaker OF the generator. Attempting to

and

severe

. ALWAYS turn the

THIS FUSE

Figure 13. Over Current Relay

PAGE 26 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 27

DCA-45USI — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage,

frequency

Three Phase Load

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

, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

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

NOTE

starting system of the equipment.

If wattage is not given on the equipment's

NOTE

The power factor of this generator is 0.8. See Table 4 below when connecting loads.

spmal

name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS l VOLTAGE x AMPERAGE

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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 5.

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 be used.

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

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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 27

CAUTION:

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Before connecting this generator to any building’s electrical system, a

electrician (transfer) switch

must install an

. Serious damage to the

licensed

isolation

building’s electrical system may occur without this transfer switch.

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

Page 28

DCA-45USI — GENERATOR OUTPUTS

Voltage Selector Switch

The

voltage selector

switch (Figure 15) is located above

the UVWO Hard Wire Hook-up Panel. It has been provided

Generator Amperage

Table 7 describes the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

for ease of voltage selection.

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminal lugs or the 3 twist lock auxilliary receptacles.

Tables 8 and 9 show what amount of current is available at the GFCI receptacles when the UVWO terminals and twist

Figure 15. Voltage Selector Switch

Voltage Selector Switch Locking Button

lock receptacles are in use. Be careful that your load does not to exceed the available current capability at the receptacles.

The voltage selector switch has a locking button to protect the generator and load from being switched while the engine is running. To lock the voltage selector switch,

hold

the

red button

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

located at the bottom of the switch.

NEVER change the position of the

selector switch

while the engine is running.

press

voltage

and

ALWAYS place circuit breaker in the open position before selecting voltage.

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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 14). To obtain some of the voltages as listed in Table 6 (see below) will require a fine adjustment using the

knob

located on the control panel.

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PAGE 28 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

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Page 29

DCA-45USI — GAUGE READING

How to Read the Output Terminal Gauges.

The gauges and selector switches on the control panel DO NOT effect the generator output. They are provided to help observe how much power is being supplied at the

put Terminal Lugs

Before taking a reading off either gauge, set the

Selector Switch

(Figure 16) to the position which produces

Out-

Voltage

the required voltage (For example, for 3Ø 240V, choose the center 3Ø 240/139V posi-

Reading Amperage

To determine the amperage at a terminal lug, set the

AC Ammeter Change-Over Switch

setting (Figure 19) to activate the (Figure 20) and read the available amperage at the terminal lug.

For example, to measure the amperage at the U terminal lug, set the U and read the AC Ammeter Gauge.

tion on the voltage selector switch.)

Figure 16. Voltage Selector

Switch 240/139V Three

Phase Position

Figure 19. AC Ammeter

Change-Over Switch

to the appropriate

AC Ammeter Gauge

AC Ammeter Change-Over Switch

Figure 20. AC Ammeter (Amp reading on U lug)

For 3Ø 208V/1Ø,120V, place

NOTE

the Voltage Selector Switch in the 3 Phase 340/139

NOTE

position.

Reading Voltage

To determine the voltage between two terminal lugs, set the

AC Voltmeter Change-Over Switch

setting (Figure 17) to activate the

to the appropriate

AC Voltmeter Gauge

(Figure 18) and read the available voltage between the two lugs.

For example, to measure the voltage between the W and U terminal lugs, set the to W-U and read the

AC Voltmeter Change-Over Switch

AC Voltmeter Gauge

The

ammeter

gauge will only

show a reading when the

Output Terminal Lugs

are

connected to a load and in use.

Figure 17. AC Voltmeter

Change-Over Switch

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 29

Figure 18. AC Voltmeter Gauge

(Volt reading on W-U Lug)

Page 30

DCA-45USI — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the using the

Output Terminal Lugs

dependent on the position of the and the adjustment of the

Remember the voltage selector switch determines the

. The voltages at the terminals are

Voltage Selector Switch

Voltage Regulator Control Knob

range

3Ø 208V/1Ø120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 24.

of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø 240/139 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 21.

2. Connect the load wires to the shown in Figure 25.

Use this position for 3Ø-208 or 1Ø120V.

Figure 24. Voltage Selector Switch 3Ø-208V/1Ø-120V Three-Phase Position

Output Terminal Lugs

Figure 21. Voltage Selector Switch 240/139V

Three-Phase Position

2. Connect the load wires to the

Output Terminal Lugs

shown in Figure 22.

Figure 22. Output Terminal Lugs

240/139V Three Phase Connections

3. Turn the voltage regulator knob (Figure 23) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Figure 23. Voltage Regulator Knob

Figure 25. Output Terminal Lugs

3Ø-208V/120V Connections

3. Turn the voltage regulator knob (Figure 23) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

To achieve a 3Ø 208V output, the voltage selector switch

NOTE

must be in the 3Ø 240/139V position and the voltage regulator must be adjusted to 208V.

PAGE 30 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 31

DCA-45USI — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø 480/277 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 26.

Figure 26. Voltage Selector Switch 480/277V

Three-Phase Position

2. Connect the load wires to the

Output Terminal Lugs

shown in Figure 27.

1Ø 240V/120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 28.

2. Connect the load wires to the shown in Figure 29.

Figure 28. Voltage Selector Switch 240/120V

Single-Phase Position

Output Terminal Lugs

Figure 27. Output Terminal Lugs

277/480V Three Phase Connections

3. Turn the voltage regulator knob (Figure 23) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 31

Figure 29. Output Terminal Lugs

1Ø-240V/120V Connections

3. Turn the voltage regulator knob (Figure 23) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Page 32

DCA-45USI — PRE-SETUP

Circuit Breakers

To protect the generator from an overload, a 3-pole, 110 amp,

main

circuit breaker is provided to protect the UVW output

Fuel Check

DANGER:DANGER:

DANGER:

DANGER:DANGER:

terminals from overload. In addition two single-pole, 20 amp

GFCI

circuit breakers are provided to protect the GFCI

load

receptacles from overload. Three 50 amp

circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level. and verify that the oil level is maintained between the two

Refilling the Fuel System

notches (Figure 30) on the dipstick. See Table 10 for proper selection of engine oil.

WARNING:WARNING:

WARNING:

WARNING:WARNING:

Fuel spillage on a

fire

explosion

hot!

engine can cause a

. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards.

NEVER!

smoke

around or near the generator.

ONLY properly trained personel who have read and understand this section should refill the fuel tank system.

The generator unit has an internal fuel tank located at the bottom of the cabinet (Figure 31).

Figure 30. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Isuzu Engine Owner's Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet

with clean and fresh tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel.The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

the following requirements:

API Service Classification CH-4

API Service Classification CG-4

API Service Classification CF-4

ACEA Specification E3

ACEA Specification E2

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ALWAYS

#2 diesel fuel.

DO NOT fill the fuel

fill the fuel tank

PAGE 32 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 33

DCA-45USI — PRE-SETUP

Refueling Procedure:

DANGER:DANGER:

DANGER:

DANGER:DANGER:

Diesel fuel

your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 32).

WARNING:WARNING:

WARNING:

WARNING:WARNING:

ALWAYS!

place trailer on firm level ground before refueling.

and its vapors are dangerous to

2. Open cabinet doors on the generator. Locate and remove the fuel tank cap and fill tank (Figure 33).

Figure 33. Fueling the Generator

3. NEVER overfill fuel tank – It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (See Figure 34).

Figure 32. Only Fill on Level Ground

NOTE

ONLY! use

when refueling.

#2 diesel fuel

Figure 34. Full Fuel Tank

WARNING:WARNING:

WARNING:

WARNING:WARNING:

DO NOT OVER-FILL fuel system. Leave room for fuel expansion . Fuel expands when heated (Figure 35).

Figure 35. Fuel Expansion

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 33

Page 34

Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)

DCA-45USI — PRE-SETUP

Use only drinkable tap water. If hard water or water with many impurities is used, the inside of the engine and radiator may become coated with deposits and cooling efficiency will be reduced.

An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system. See the engine manual for further details.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of

coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 12 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

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hot!

NOTE

Cleaning the Radiator

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

negative

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the Isusu Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the Isuzu

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 38) when depressed with the thumb as shown below.

When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

battery terminal disconnected.

less than 50%.

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Operation Freezing Weather

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

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PAGE 34 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

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Figure 36. Fan Belt Tension

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

NEVER!

near the belts or fan while the generator set is running.

place hands

Page 35

DCA-45USI — PRE-SETUP

Battery

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

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Battery Cable Installation ALWAYS be sure the battery cables (Figure 37) are properly

connected to the battery terminals as shown below. The

RED

cable is connected to the positive terminal of the battery, and the BLACK cable is connected to the negative terminal of the battery.

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the RUN position. ALWAYS make sure that the ignition switch is in the STOP position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTE

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

ignition

switch is in the PRE-HEAT/

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close

attention to the polarity of the battery when connecting the battery.

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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Figure 37. Battery Connections

ALWAYS

FIRST and reconnect negative terminal LAST.

disconnect the negative terminal

Alternator

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator leads an electrolyte corrosion causing an alternator failure.

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

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose ( immediately.

fuel

oil

) lines are defective replace them

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 35

Page 36

DCA-45USI — GENERATOR START-UP PROCEDURE

WARNING:WARNING:

WARNING:

WARNING:WARNING:

The engine's exhaust contains harmful

emissions.

ventilation when operating

away from nearby personnel.

Before Starting

ALWAYS have adequate

. Direct exhaust

CAUTION:

NEVER!

main, GFCI or auxiliary circuit breakers in the ON (closed) position.

1. Be sure and place the breakers (Figure 40) in the OFF position prior to starting the engine.

manually start the engine with the

main, G.F.C.I.

and

aux.

3. Close all engine enclosure doors (Figure 40).

Figure 40. Engine Enclosure Doors

4. Place the voltage selector switch in the desired voltage position (Figure 41).

circuit

Figure 38. Main, Aux. and GFCI

Circuit Breakers

2. Connect the load to the

auxiliary receptacles

connection points can be found on the output terminal panel.

Output Terminal Lugs

as shown in Figure 39. These load

Figure 41. Voltage Selector Switch

5. Preheat the engine

key (Figure 42) to the PRE-HEAT/RUN position. When the preheat lamp (Figure 43) turns off, proceed to step 6.

Figure 42. Ignition Switch

(Pre-Heat/Run Position)

Figure 43. Pre-Heat Indicator Lamp

glow plugs

by turning the ignition

Figure 39. Load Connections

PAGE 36 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 37

DCA-45USI — GENERATOR START-UP PROCEDURE

6. Turn the ignition key to the START position (Figure 44). Once the engine starts, release the ignition key and

9. The generator's voltage meter (Figure 46) displays the output voltage in VOLTS.

allow it to return to the PRE-HEAT/RUN position (Figure 42).

If the engine fails to start after 10 seconds, wait approximately 30 seconds and repeat steps 5-6.

10. If the voltage is not reading at the specified level, use the voltage adjustment control knob (Figure 47) to increase or decrease the voltage until you reach the

Figure 44. Ignition Switch

(Start Position)

desired voltage.

7. Let the engine run for 3-5 minutes and listen and check for any abnormal sounds or smells. Check for fuel leaks, and noises that would associate with a loose cover or hardware.

Check the electric motor fan cooling the radiator for abnormal speed, sound or vibration conditions.

If any of the above mentioned conditions exists, shutdown the engine and correct the problem before operating the generator.

11. The ammeter (Figure 48) will indicate zero amps with no load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator.

Figure 46. AC Voltmeter

Figure 47. Voltage Adjust Control Knob

8. The generator's frequency meter (Figure 45) displays the 60 cycle output frequency in HERTZ.

Figure 45. Frequency Meter (Hz)

Figure 48. Ammeter (No Load)

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 37

Page 38

DCA-45USI — GENERATOR START-UP PROCEDURE

12. The engine oil pressure gauge (Figure 49) will indicate the oil pressure of the engine. Under normal operating

15. Turn the ON position (Figure 52).

conditions the oil pressure is approximately

Figure 49. Oil Pressure Gauge

13. The coolant temperature gauge (Figure 50) will indicate the coolant temperature. Under normal operating conditions the coolant temperature is between 165 and 203° degrees Fahrenheit.

16. Observe the generator's ammeter (Figure 53) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if the load is in use.

main, GFCI

Figure 52. Main, AUX. and GFCI

Circuit Breakers (ON)

, and

aux

. circuit breakers to the

Figure 50. Coolant Temperature Gauge

14. The tachometer (Figure 51) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

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

Figure 51. Engine Tachometer

Figure 53. Ammeter (Load)

PAGE 38 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 39

DCA-45USI — GENERATOR SHUT-DOWN PROCEDURE

Normal Shut-down Procedure

To shutdown the generator, use the following procedure:

1. Switch the MAIN, AUX and GFCI circuit breakers (Figure 54) to the OFF position (no load).

Figure 54. Main, AUX. and GFCI

Circuit Breakers (OFF)

3. Let the engine cool by running it for 3-5 minutes with no load applied (circuit breakers in the OFF position).

4. Place the ignition switch (Figure 55) in the STOP position, remove the key and store in a safe place.

Emergency Shut-down Procedure

1. To shut-down the engine in the event of an emergency, switch the breakers to OFF position.

2. Turn the ignition switch key to the STOP position (Figure 55).

Automatic Shut-down SystemWN

This unit is equipped with safety devices to automatically stop the engine in the event of low oil pressure (approx. 14 PSI.), or high water temperature (approx. 221° F). The alarm lamps on the Engine Control Panel (Figure 5) illuminate to signify the reason for the shut-down.

CAUTION:

Before inspecting, turn the position, place all position and allow sufficient time for adequate cooling. When ready to restart, complete all steps in the Generator Startup Procedure section of this manual.

MAIN, GFCI

After automatic shut-down, the unit and eliminate any problems before attempting to restart. Failure to do so can damage the unit.

Generator Circuit Breakers

and

LOAD

(Figure 54) circuit

starter switch

ALWAYS

inspect

to the STOP

in the OFF

Figure 55. Ignition Switch (Off Position)

5. Remove

6. Allow for sufficient time for cooling and then inspect the complete unit for any damage or loosening that may have occured during operation.

7. Check the engine oil, coolant and fuel levels. Replenish as necessary.

all

loads from the generator.

Regularly maintain the unit as specified in the Maintenance section of this manual to prevent damage.

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 39

NOTE

Engine protection is furnished during operation, but cannot replace normal preventive maintenance.

Page 40

DCA-45USI — MAINTENANCE

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General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean the heavy duty paper element with light spray of compressed

Service Daily

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

frequently

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations). Always pour through the mesh filter.

air. Replace the air cleaner as needed.

Removing Water from the Fuel Tank

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing. After changing the air element, press the dust indicator button to reset the indicator.

PAGE 40 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

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

dusty

if these conditions exists.

dry grass

Page 41

Air Removal

DCA-45USI — MAINTENANCE

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

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

To restart after running out of fuel, turn the switch to the ON position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 33.

Replacing Oil Filter

Remove the old oil filter. Apply a film of oil to the gasket on the new oil filter. Install the new oil filter. After the oil cartridge has been replaced, the engine oil

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

Flushing Out Radiator and Replacing Coolant

Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.

Check hoses for softening and kinks. Check clamps for signs of leakage.

Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

Tighten both cocks and replace the overflow tank.

Replace with coolant (Table 12 for correct mixture).

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

cool

when flushing out

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 500 hours or so.

Loosen the drain plug at the lower top of the fuel filter. Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

Vent any air.

Close radiator cap tightly.

Generator Storage

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

Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.

Completely drain the oil from the crankcase and refill if necessary with fresh oil.

Clean the entire generator, internal and external.

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

Disconnect the battery.

Make sure engine coolant is at proper level.

If generator is mounted on a trailer, jack trailer up and place on blocks so tires do not touch the ground or block and completely remove the tires.

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 41

Page 42

DCA-45USI — TRAILER BRAKES MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles

. If driving over rough terrain, inspect the

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 56) should not require any

special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

brakes more frequently. Figure 74 displays the major hydraulic surge brake

components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 as listed below:

Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

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

Figure 56. Hydraulic Brake Components

Actuator

shoes.

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

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

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

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

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

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

surge

actuator

” to make

push

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PAGE 42 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

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Page 43

DCA-45USI — TRAILER MAINTENANCE

Tires/Wheels/Lug Nuts

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

Suspension

leaf suspension

The (Figure 57) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components

CAUTION:

as detailed in Table 17.

DO NOT attempt to repair or modify a wheel. DO NOT install in

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

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are

hot!

. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Figure 57. Major Suspension Components

springs and associated components

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

TABLE 16 TIRE WEAR TROUBLESHOOTING

WEAR PATTERN

Center Wear

Edge Wear

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

CAUSE

Over Inflation.

Under Inflation.

Loss of camber or overloading.

Wheel lockup & tire skidding.

SOLUTION

Adjust pressure to particular load per tire manufacturer.

Adjust pressure to particular load per tire

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

Check bearing adjustment

and balance tires.

Avoid sudden stops when possible and adjust brakes.

SHACKLE BOLT SPRING EYE BOLT

SHOULDER TYPE SHACKLE BOLT

CAUTION:

ALWAYS

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

wear safety glasses when removing or

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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 43

Page 44

DCA-45USI — TRAILER MAINTENANCE

Lug Nut Torque Requirements

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

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 58. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 18.

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

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gun to tighten wheel lug nuts.

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PAGE 44 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Figure 58. Wheel Lug Nuts Tightening Sequence

Page 45

DCA-45USI — TRAILER WIRING DIAGRAM

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 45

Figure 59. Trailer/Towing Vehicle Wiring Diagram

Page 46

DCA-45USI — ENGINE WIRING DIAGRAM

PAGE 46 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Figure 60. Engine Wiring Diagram

Page 47

DCA-45USI — ENGINE WIRING DIAGRAM

Figure 60. Engine Wiring Diagram(Continued)

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 47

Page 48

DCA-45USI — GENERATOR WIRING DIAGRAM

Figure 61. Generator Wiring Diagram

PAGE 48 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 49

DCA-45USI — TROUBLESHOOTING (GENERATOR)

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

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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 49

Page 50

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column, *, #, +,%, or <, belong to the same assembly or kit

If more than one of the same

NOTE

reference number is listed, the last one listed indicates newest (or latest) part available.

NOTE

The contents of this catalog are subject to change without notice

PAGE 50 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 51

DCA-45USI — SUGGESTED SPARE PARTS

DCA-45USI

w/ ISUZU BB-4JG1T

1 TO 3 UNITS

Qty. P/N Description

3 ......... 8970497081 .............. OIL FILTER

3 ......... 8943692993 .............. FUEL FILTER

3 ......... 0602046681 .............. AIR ELEMENT

1 ......... 0602122272 .............. UNIT, OIL PRESSURE

1 ......... 0602123260 .............. UNIT WATER TEMPERATURE

1 ......... 8972606490 .............. FAN BELT

3 ......... 8944024980 .............. KEY, STARTER SWITCH

1 ......... 0605505070 .............. CAP, FUEL TANK

1 ......... 9827200690 .............. SENDER, OIL PRESSURE (ENGINE SIDE)

1 ......... 8970785920 .............. SENDER, WATER TEMPERATURE (ENGINE SIDE)

2 ......... 0601802149 .............. FUSE, 10A

NOTE

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

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 51

Page 52

GENERATOR ASSY.

DCA-45USI — GENERATOR ASSY.

PAGE 52 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 53

DCA-45USI — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B3110100202 ROTOR ASSY. 1 1-1 FIELD ASSY. 1 1-2 8051070003 FAN 1 1-3 0010310035 HEX, HEAD BOLT 8 1-4 0042510000 SPRING WASHER 8 1-5 8041611004 COUPLING DISK 4

1-6 8041015003 BALANCING PLATE ............................................ 1 ............. PURCHASE SET OF 1-16

1-7 0010310025 HEX, HEAD BOLT 6 1-8 0042510000 SPRING WASHER 6

1-9 8001026013 SET PLATE, RECTIFIER BALANCING PLATE ...1 ............. PURCHASE SET OF 1-16

1-10 0601821349 RECTIFIER ......................................................... 2 ............. PT3610

1-11 0601822601 SURGE ABSORBER ...........................................1 ............. ERZ-M14JK621A

1-12 8001020004 INSULATOR WASHER 1 1-13 8001020504 INSULATOR WASHER 1 1-14 0010108020 HEX, HEAD BOLT 4 1-15 0040008000 SPRING WASHER 4 1-16 0601000209 BALANCING WEIGHT KIT 1

1-17 0071906310 BEARING ............................................................1 ............. 6310DDU C3

2 M1164400003 COUPLING RING 1 3 0012808030 HEX, HEAD BOLT 6 4 B3130100103 STATOR ASSY. 1 4-1 0845041904 GROMMET 2 5 M1164600003 COUPLING ADAPTER 1 6 0012810030 HEX, HEAD BOLT 8 7 8041315202 END BRACKET 1 8 8041350013 FIELD ASSY. EXCITER 1 9 0010308065 HEX, HEAD BOLT 4 10 0042608000 SPRING WASHER 4 11 0041208000 PLAIN WASHER 4 12 0017108030 HEX, HEAD BOLT 6 13 8041310024 COVER, BEARING 1 14 8041312014 GASKET, BEARING 1 15 0017106012 HEX, HEAD BOLT 4 16 8041331014 COVER, END BRACKET 1 17 0017106012 HEX, HEAD BOLT 4 18 8001333003 COVER, END BRACKET 1 19 0340406040 HEX, HEAD BOLT 2 20 0041206000 PLAIN WASHER 2 21 0012810030 HEX, HEAD BOLT 6 22 8051332014 COVER, FAN 1 23 0600815000 NUT 1 24 0605000055 RUBBER SUSPENSION 2 25 0030012000 HEX, NUT 2 25A 0040012000 SPRING WASHER 2 25B 0041212000 PLAIN WASHER 2

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 53

Page 54

CONTROL BOX ASSY.

DCA-45USI — CONTROL BOX ASSY.

PAGE 54 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 55

DCA-45USI — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1214000102 CONTROL BOX 1

2 0601808825 CIRCUIT BREAKER, 3-POLE, 110A ...................1 ............. KAF361101039

3 0021005080 MACHINE SCREW 4

4 0601823863 RELAY UNIT .......................................................2 ............. MSA9013A

5 0027104016 MACHINE SCREW 4

6 0601820671 AUTOMATIC VOLTAGE REGULATOR.................. 1 ............. NTA-5A-2DB

7 0027105016 MACHINE SCREW 4

8 0601806116 CURRENT TRANSFORMER ...............................3 ............. 812-943 75/5A

9 0027106016 MACHINE SCREW 6

10 0601820845 OVER CURRENT RELAY ....................................1 ............. LR2D1308

11 0601820846 OVER CURRENT RELAY ....................................1 ............. LA7D1064

12 0027104016 MACHINE SCREW 2 12A 0207004000 HEX, NUT 2 13 M1213500303 CONTROL BOX COVER 1 14 0016906016 HEX, HEAD BOLT 4

15 M1201000004 SELECTOR SWITCH ..........................................1 ............. VY-40

15A TBD KNOB, SELECTOR 1 16 M1215601204 SWITCH BRACKET 1 17 0027103010 MACHINE SCREW 4 18 0016906016 HEX, HEAD BOLT 4 19 0330000530 EDGING 1 20 M1215601104 SWITCH COVER 1 21 0016906016 HEX, HEAD BOLT 3 22 0016906016 HEX, HEAD BOLT 8 22A 0040506000 TOOTHED WASHER 1 23 M1224000003 CONTROL PANEL 1

24 0601807641 FREQUENCY METER ........................................1 ............. FCF-6 45~65Hz 240V

25 0601808986 AC AMMETER ....................................................1 ............. ACF-6 0~75A/150A:5A

26 0601801040 CHANGE-OVER SWITCH, AMMETER ...............1 ............. SL-2 AS

27 0601806859 AC VOLTMETER ................................................. 1 ............. SCF-6 0~600V

28 0601801041 CHANGE-OVER SWITCH, VOLTMETER ............1 ............. SL-2 VS

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 55

Page 56

CONTROL BOX ASSY.

DCA-45USI — CONTROL BOX ASSY.

PAGE 56 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 57

DCA-45USI — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

29 0601840073 RHEOSTAT(VOLTAGE REGULATOR) ..................1 ........ RA20A2SE102BJ 2W 1K OHM

30 0601840121 KNOB 1

31 0602100009 STARTER SWITCH ............................................. 1 ........ ISUZU 897044-4180

31A 8944024980 IGNITION KEY 1

32 0602103092 PREHEAT LAMP .................................................1 ........ PL-05

32A 0601810245 BULB, E-10 T-10 DC18V 1

33 0602120095 TACHOMETER ....................................................1 ........ 103680

34 0602122093 OIL PRESSURE GAUGE ....................................1 ........ 100174

35 0602123090 WATER TEMPERATURE GAUGE ....................... 1 ........ 100683

36 0602121080 CHARGING AMMETER ......................................1 ........ 100158

37 0602125090 FUEL GAUGE...................................................... 1 ........ 100176

38 0602103092 ALARM LAMP, PL-05 3

38 0602103092 ALARM LAMP, PL05 ........................................... 4 ........ S/N 8200081~

38A 0601810245 BULB, E-10 T-10 DC18V 3

38A 0601810245 BULB, E-10 T-10 DC18V ......................................4 ........ S/N 8200081~

39 0601810141 PANEL LIGHT ...................................................... 1 ........ 98268-O0370

40 0601831330 SWITCH, PANEL LIGHT 1 41 M1224100104 STOPPER 1 42 0027105010 MACHINE SCREW 2 43 0027105010 MACHINE SCREW 4 44 M9220100004 SET SCREW 2 45 0080200007 SNAP RING 2

46 0602200432 EMERGENCY RELAY .........................................1 ........ 897111-9621

47 0602202506 PREHEAT CONTROLLER ................................... 1 ........ 897246-5100

48 0016906020 HEX, HEAD BOLT ............................................... 3

49 0602200305 SAFETY RELAY .................................................1 ........ 182553-0430

50 0602201400 RELAY .................................................................1 ........ 582550-0290

51 0016906016 HEX, HEAD BOLT 3 52 0606503062 FUEL LEAK DETECTED SWITCH 1 53 M1414800104 BRACKET 1 54 0016908020 HEX, HEAD BOLT 2 55 M1247700114 WIRE HARNESS, GENERATOR 1 56 M1358200112 WIRE HARNESS, ENGINE 1

57 M3357200304 WIRE, HARNESS, FUEL LEAK ..........................1 ........ S/N 8200081~

58 0601823223 RECTIFIER ......................................................... 2 ........ S/N 8200001 TO 8200080

58 0601823245 RECTIFIER ......................................................... 2 ........ S/N 8200001 TO 8200080

59 0601802149 FUSE, 10A ..........................................................2 ........ S/N 8200081~

60 0602103092 ALARM LAMP, PL05 ........................................... 4 ........ S/N 8200081~

60A 0601810245 BULB, E-10 T-10 DC18V ......................................4 ........ S/N 8200081~

61 06021222272 UNIT, OIL PRESSURE ........................................1 ........ 108497

62 M9200100004 ADAPTER 1

63 0602123260 UNIT, WATER TEMPERATURE ........................... 1 ........ 02094-00

64 0602021109 PACKING ............................................................. 1 ........ 909572-0140

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 57

Page 58

ENGINE AND RADIATOR ASSY.

DCA-45USI — ENGINE AND RADIATOR ASSY.

PAGE 58 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 59

DCA-45USI — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1924200014 ENGINE ............................................................... 1 ........ ISUZU BB-4JG1T

1-1 897049-7081 CARTRIDGE, OIL FILTER ................................... 1 ........ REPLACES 0602041214

2 0605000048 RUBBER SUSPENSION 2 3 0030010000 HEX, NUT 2 4 0040010000 SPRING WASHER 2 5 0041210000 PLAIN WASHER 2

6 M1923200084 RADIATOR ........................................................... 1 ........ 2951-293-0000

6A 0602011079 CAP, RADIATOR .................................................. 1 ........ 6713-092-0901

7 M9312200104 MOUNT RUBBER 2 8 0016908040 HEX, HEAD BOLT 2 9 0207008000 HEX, NUT 2 10 M1311500003 RADIATOR HOSE 1 11 M1311500103 RADIATOR HOSE 1 12 0605515201 HOSE BAND 4 13 M1424700104 FAN GUARD 1 14 M1424700004 FAN GUARD 1 15 0016906016 HEX, HEAD BOLT 7

16 0602046582 AIR CLEANER ....................................................1 ........ FPG08-2527

16A 0602046681 ELEMENT, AIR CLEANER ..................................1 ........ P82-8889

17 0602040651 INDICATOR, AIR CLEANER ................................1 ........ RBX00-2352

18 M1374200104 BRACKET, AIR CLEANER 1 19 0602040556 BAND, AIR CLEANER 1 20 0016908020 HEX, HEAD BOLT 2 21 0207008000 HEX, NUT 2 22 0016910025 HEX, HEAD BOLT 2 23 M1374100003 HOSE, AIR CLEANER 1 24 M1374100103 HOSE, AIR CLEANER 1 25 0605515148 HOSE BAND 1 26 0605515200 HOSE BAND 2 27 0602022560 ADAPTER 1 28 M1320300304 PACKING 1 29 0602022561 90 DEG. ELBOW 1 30 0603306590 CONNECTOR 1

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 59

Page 60

ENGINE & RADIATOR ASSY.

DCA-45USI — ENGINE AND RADIATOR ASSY.

PAGE 60 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 61

DCA-45USI — ENGINE AND RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

31 0603300285 ROCKNUT 1 32 0605511395 VALVE 1 33 0603306395 HOSE JOINT 1 34 0602021070 CAP 1 35 0269200310 DRAIN HOSE 1 36 M2320300103 DRAIN JOINT 1 37 M920020004 PLUG 1 38 0150000018 O-RING 1 39 0016906016 HEX, HEAD BOLT 2 40 0199100850 DRAIN HOSE 1 41 0605515106 HOSE BAND 2 42 M9300000003 RESERVE TANK 1 43 M9300100003 CAP, RESERVE TANK 1 44 0199100215 HOSE 1 45 M1317100004 BRACKET, RESERVE TANK 1 46 0016908020 HEX, HEAD BOLT 1 47 0199101700 HOSE 1 48 0193601200 HOSE 1 49 0605515106 HOSE BAND 2 50 0199800730 HOSE 1 51 0269200480 BLOWBY HOSE 1 52 0605515198 HOSE BAND 2 53 0602120465 PICK UP, TACHOMETER 1 58 M1358300104 HARNESS CLAMP 1 59 M1358300004 HARNESS CLAMP 1 60 0016908020 HEX, HEAD BOLT 5 61 M1358300204 HARNESS CLAMP 1 62 0017110020 HEX, HEAD BOLT 2 63 M1924200004 MOTOR FAN 1 64 0016910025 HEX, HEAD BOLT 4

65 0602210810 ENGINE STOPPER.............................................1 ........ 181900-1902

66 0027106016 MACHINE SCREW 3 67 9827200690 SENDER, OIL PRESSURE 1 68 8970785920 SENDER, WATER TEMPERATURE 1 69 8971882810 V-BELT 1

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 61

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 62

OUTPUT TERMINAL ASSY.

DCA-45USI — OUTPUT TERMINAL ASSY.

PAGE 62 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 63

DCA-45USI — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1230700103 TERMINAL PANEL 1 2 M9220100204 OUTPUT TERMINAL BOLT 5 3 M9220100104 TIE SCREW 5 4 0039310000 HEX, NUT 10 5 0040010000 SPRING WASHER 15 6 0041410000 PLAIN WASHER 20 7 0016908025 HEX, HEAD BOLT 5 8 M1236100613 TERMINAL COVER 1 9 M1236100704 OUTPUT WINDOW 1 10 0605010040 HINGE 2 11 0027103010 MACHINE SCREW 4 11A 0030003000 HEX, NUT 8 11B 0041203000 PLAIN WASHER 4 12 0016906020 HEX, HEAD BOLT 2 13 0016906016 HEX, HEAD BOLT 4 14 M1236400004 CABLE OUTLET COVER 1 15 M1236300004 SUPPORTER, CABLE OUTLET COVER 1 16 0016906020 HEX, HEAD BOLT 6

17 0601808803 CIRCUIT BREAKER, 1-POLE, 20A.....................2 ................. QOU 120B

18 0601808804 CIRCUIT BREAKER, 2-POLE, 50A.....................3 ................. QOU 250B

19 M1260700304 BREAKER FITTING COVER 1 19A 0222100150 CUSHION RUBBER 1 20 0016906020 HEX, HEAD BOLT 2

21 0601812598 RECEPTACLE .....................................................2 ................. GF-530EM 125V 20A X 2

22 0601812538 RECEPTACLE .....................................................3 ................. CS6369 250V 50A

23 0027104016 MACHINE SCREW 10 23A 0207004000 HEX, NUT 10 24 M1236100803 TERMINAL COVER 1 25 0010112045 HEX, HEAD BOLT 2 26 0041212000 PLAIN WASHER 2 27 M9310200004 STAY RUBBER 2 28 0030012000 HEX, NUT 2 29 0027103010 MACHINE SCREW 4

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 63

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 64

BATTERY ASSY.

DCA-45USI — BATTERY ASSY.

PAGE 64 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 65

DCA-45USI — BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602220187 BATTERY 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 SPRING WASHER 2 6 M1347200004 BATTERY CABLE 1 7 M1347200104 BATTERY CABLE 1 8 0016910020 HEX, HEAD BOLT 2 9 0040510000 TOOTHED WASHER 2

10 CABLE, GROUND ............................................... 1 ..................... MAKE LOCALLY

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 65

Page 66

MUFFLER ASSY.

DCA-45USI — MUFFLER ASSY.

PAGE 66 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 67

DCA-45USI — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1331100102 MUFFLER 1 2 0017112030 HEX, HEAD BOLT 4 3 M1334000003 EXHAUST PIPE 1

4 0602320101 GASKET .............................................................1 ........ 894369-0210

5 0039308000 HEX, NUT 6 6 0602325088 SEAL CLAMP 1

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 67

Page 68

FUEL TANK ASSY.

DCA-45USI — FUEL TANK ASSY.

PAGE 68 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 69

DCA-45USI — FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1364000102 FUEL TANK 1 1A 0605505070 FUEL TANK CAP 1 1B 0605501072 FUEL SENDER UNIT 1 1C 0605516090 GASKET 1 2 M1364200004 TANK BAND 4 3 M9310500104 SUPPORTER SHEET 4 4 0016908020 HEX, HEAD BOLT 4 5 0016908065 HEX, HEAD BOLT 2 5A 0207008000 HEX, NUT 6 6 0191301300 VENT HOSE 1 7 0605515109 HOSE BAND 2

8 897211-2730 FUEL FILTER ...................................................... 1........ REPLACES 0602042203

8A 897213-4720 CARTRIDGE, FUEL FILTER ...............................1 ........ REPLACES 0602042701

9 M1367700004 BRACKET, FUEL FILTER 1 10 0016908020 HEX, HEAD BOLT 4 11 0191200550 SUCTION HOSE 1 12 0191201600 SUCTION HOSE 1 13 0605515108 HOSE BAND 4 14 0191300750 RETURN HOSE 1 15 0605515109 HOSE BAND 2 15 0222100700 TANK SHEET 5

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 69

Page 70

ENCLOSURE ASSY.

DCA-45USI — ENCLOSURE ASSY.

PAGE 70 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 71

DCA-45USI — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1414000202 BASE 1 1A M1494000004 ACOUSTIC SHEET 1 2 M1414800003 ENVIRONMENTAL TANK 1 3 0603306797 PLUG,1-1/2 1 4 0017110040 HEX, HEAD BOLT 8 5 M1424000012 FRONT FRAME 1

5A M1494100004 ACOUSTIC SHEET ............................................. 1 ........ S/N 8200001 TO 8200080

5A M1493104804 ACOUSTIC SHEET ............................................. 1 ........ S/N 8200081~

6 M1311600004 RADIATOR COVER 1 7 0016908020 HEX, HEAD BOLT 2

8 M1424000302 FRONT FRAME ...................................................1 ........ S/N 8200001 TO 8200080

8 M1424000402 FRONT FRAME ...................................................1 ........ S/N 8200081~

8A 0314502100 SEAL 1

8B M1494100004 ACOUSTIC SHEET ............................................. 1 ........ S/N 8200001 TO 8200080

8B M1493104804 ACOUSTIC SHEET ............................................. 1 ........ S/N 8200081~

9 0601851756 GROMMET, C30-SG-70A ....................................1 ........ S/N 8200001 TO 8200080

10 0601851736 GROMMET, C30-SG-60A 2 11 0601850266 GROMMET, C30-SG-28A 4 12 M1424500204 BLOWBY COVER 1 13 0016906016 HEX, HEAD BOLT 6 14 M1424500104 GUARD 1 15 0016906016 HEX, HEAD BOLT 4 16 0016908020 HEX, HEAD BOLT 8 17 0016908020 HEX, HEAD BOLT 4 18 M1424200504 DUCT COVER 2 19 0016906016 HEX, HEAD BOLT 16

20 M1311600104 HOSE COVER .....................................................1 ........ S/N 8200001 TO 8200080

20 M1484400004 HOSE COVER .....................................................1 ........ S/N 8200081~

20 M1484400103 HOSE COVER .....................................................1 ........ S/N 8200081~

21 0016906018 HEX, HEAD BOLT 4

22 M1424200303 COVER, FRONT FRAME ....................................1 ........ S/N 8200001 TO 8200080

22 M1424200313 COVER, FRONT FRAME ....................................1 ........ S/N 8200081~

22A M1494100104 ACOUSTIC SHEET 1 23 0016908020 HEX, HEAD BOLT 3 24 M1434300203 CENTER FRAME 1 25 M1434300303 CENTER FRAME 1 26 0010116040 HEX, HEAD BOLT 6

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 71

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 72

ENCLOSURE ASSY.

DCA-45USI — ENCLOSURE ASSY.

PAGE 72 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 73

DCA-45USI — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

26A 0040016000 SPRING WASHER 6 26B 0041216000 PLAIN WASHER 6 27 0010116040 HEX, HEAD BOLT 4 27A 0040016000 SPRING WASHER 4 27B 0041216000 PLAIN WASHER 4 28 M1444000102 REAR FRAME 1 28A M1494300003 ACOUSTIC SHEET 1 29 M1444800004 DUCT 2 29A M1494300204 ACOUSTIC SHEET 1 30 0207006000 HEX, NUT 12 31 0016908020 HEX, HEAD BOLT 4 32 M1444300003 REAR COVER 1 32A M1494300104 ACOUSTIC SHEET 1

33 0016908020 HEX, HEAD BOLT ...............................................6 ........ S/N 8200001 TO 8200080

33 0019208020 HEX, HEAD BOLT ...............................................6 ........ S/N 8200081~

34 M1444200003 REAR DOOR 1 35 M1444600004 WINDOW PLATE 1 36 0207306000 HEX, NUT 8 36A 0041206000 PLAIN WASHER 8 37 M9113000002 DOOR HANDLE ASSY. 1 38 0021806016 MACHINE SCREW 4 38A 0030006000 HEX, NUT 4 39 M9112100404 HINGE 2 40 M9112100604 HINGE 2 41 0016908020 HEX, HEAD BOLT 8 42 M1464000002 ROOF PANEL 1 42A M1494500004 ACOUSTIC SHEET 1

43 0016908020 HEX, HEAD BOLT ............................................. 18 ........ S/N 8200001 TO 8200080

43 0019208020 HEX, HEAD BOLT ............................................. 18 ........ S/N 8200081~

44 M1465400104 COVER 1

45 0016908020 HEX, HEAD BOLT ...............................................2 ........ S/N 8200001 TO 8200080

45 0019208020 HEX, HEAD BOLT ............................................... 2 ........ S/N 8200081~

46 M1454200002 SPLASHER PANEL 1 47 0016908020 HEX, HEAD BOLT 3

48 0016908065 HEX, HEAD BOLT ............................................... 1 ........ S/N 8200001 TO 8200080

48 0019208065 HEX, HEAD BOLT ............................................... 1 ........ S/N 8200081~

49 M1454000403 SIDE DOOR 1

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 73

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 74

ENCLOSURE ASSY.

DCA-45USI — ENCLOSURE ASSY.

PAGE 74 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 75

DCA-45USI — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

49A M1494400404 ACOUSTIC SHEET 1 50 M1454000103 SIDE DOOR 1 50A M1494400104 ACOUSTIC SHEET 1 51 M1454000503 SIDE DOOR 1 51A M1494400504 ACOUSTIC SHEET 1 52 M1454000303 SIDE DOOR 1 52A M1494400304 ACOUSTIC SHEET 1 53 M9113000002 DOOR HANDLE ASSY. 2 53A C9312500004 SEAL RUBBER 2 54 0021806016 MACHINE SCREW 8 54A 0030006000 HEX, NUT 8 55 M9112100404 HINGE 4 56 M9112100504 HINGE 4 57 M9112100604 HINGE 8 58 0016908020 HEX, HEAD BOLT 32 59 0016908020 HEX, HEAD BOLT 2 60 0601850097 STOPPER 5 61 0027208025 MACHINE SCREW 5

62 0605503062 FUEL LEAK DETECTION SWITCH .................... 1 ........ S/N 8200081~

63 M1414800104 BRACKET ........................................................... 1 ........ S/N 8200081~

64 0017108020 HEX HEAD BOLT ................................................ 2 ........ S/N 8200081~

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 75

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 76

RUBBER SEALS ASSY.

DCA-45USI — RUBBER SEALS ASSY.

PAGE 76 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 77

DCA-45USI — RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0229200950 SEAL RUBBER 1 2 0228901385 SEAL RUBBER 3 3 0228900900 SEAL RUBBER 3 4 0229400900 SEAL RUBBER 1 5 0228900795 SEAL RUBBER 1 6 0028900590 SEAL RUBBER 1 7 0229400445 SEAL RUBBER 1 8 0228800455 SEAL RUBBER 1 9 0228900445 SEAL RUBBER 1 10 0229200455 SEAL RUBBER 1 11 0228100870 SEAL RUBBER 2 12 0229200840 SEAL RUBBER 1 13 0229200560 SEAL RUBBER 2 14 0229200790 SEAL RUBBER 1

15 0228800800 SEAL RUBBER ...................................................1 ........ S/N 8200001 TO 8200080

15 0228800800 SEAL RUBBER ...................................................2 ........ S/N 8200081~

16 0228900475 SEAL RUBBER ...................................................1 ........ S/N 8200001 TO 8200080

16 0228900470 SEAL RUBBER ...................................................1 ........ S/N 8200081~

17 0228800475 SEAL RUBBER ...................................................1 ........ S/N 8200001 TO 8200080

17 0228800470 SEAL RUBBER ...................................................1 ........ S/N 8200081~

18 0228100420 SEAL RUBBER 2 19 0228100325 SEAL RUBBER 2 20 0314500700 SEAL 1 22 0330000460 EDGING 1 23 0330000180 EDGING 1

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 77

Page 78

NAME PLATE ASSY.

DCA-45USI — NAMEPLATE AND DECALS ASSY.

PAGE 78 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 79

DCA-45USI — NAMEPLATE AND DECALS ASSY.

NAME PLATE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1511400002 DECAL, GENERATOR CONTROL ................................ 1 ............. M11140000A

2 M1511400102 DECAL, ENGINE OPERATING .................................... 1 ............. M11140010A

3 M1550000204 DECAL, NOTE .............................................................. 1 ............. M15000020

4 M1550000703 DECAL, AUXILIARY OUTPUT ...................................... 1 ............. M15000070

5 M1550000804 DECAL, NOTE .............................................................. 1 ............. M15000080

6 M9500000004 DECAL, OIL DRAIN PLUG ........................................... 1 ............. M90000000

7 M9500100004 DECAL, WATER ............................................................ 1 ............. M90010000

8 M9500300004 DECAL, - ...................................................................... 1 ............. M90030000

9 M9500300104 DECAL, + ..................................................................... 1 .............M90030010

10 M9500500004 DECAL, DIESEL FUEL ................................................. 1 ............. M90050000

11 M9503000004 DECAL, WARNING MOVING PARTS ........................... 2 ............. M90300000

12 M9503000103 DECAL, WATER - OIL CHECK ..................................... 1 ............. M90300010

13 M9503100004 DECAL, WARNING HOT COOLANT ............................. 1 ............. M90310000

14 M9503200004 DECAL, WARNING ENGINE EXHAUST ....................... 1 ............. M90320000

15 M9510000004 DECAL, FLUID DRAIN ................................................. 1 ............. M91000000

16 M9510100004 DECAL, CAUTION HOT PARTS ................................... 1 ............. M91010000

17 M9512200004 DECAL, MQ .................................................................. 1 ............. M91220000

18 M9520000004 DECAL, GROUND ........................................................ 1 .............M92000000

19 M9520000104 DECAL, AMMETER CHANGE-OVER SW. ................... 1 ............. M92000010

20 M9520000204 DECAL, VOLTMETER CHANGE-OVER SW. ................ 1 ............. M92000020

21 M9520100004 DECAL, WARNING ELECTRIC SHOCK HAZARD ....... 2 ............. M92010000

22 M9520100204 DECAL, CAUTION ........................................................ 1 ............. M92010020A

23 M9520100304 DECAL, SAFETY INSTRUCTION................................. 1 ............. M92010030

24 M9520100404 DECAL, DANGER HIGH VOLTAGE ............................... 1 ............. M92010040

25 M9520100503 DECAL, WARNING ....................................................... 1 .............M92010050

26 M9520200003 DECAL, CONNECTION OF OUTPUT CABLE .............. 1 ............. M92020000

27 M9520200104 DECAL, OVER CURRENT RELAY ............................... 1 ............. C92020010

28 M1561000004 DECAL, MQ POWER ................................................... 3 ............. S/N 8200001 TO

...................................................................................................... 8200080

28 M1561000004 DECAL, MQ POWER ................................................... 2 ............. S/N 8200081~

29 M1561100004 STRIPE 2 30 M1561100103 STRIPE, WHISPERWATT 2 31 M1561100204 STRIPE, 45 1 32 M1561100304 STRIPE, 45 1 33 M1561100404 STRIPE 2

34 M9510100304 DECAL, ENVIRONMENTAL WARNING ........................ 1 .............S/N 8200081~

35 M9520000304 DECAL, FUEL LEAK DETECTED ................................ 1 ............. S/N 8200081~

36 0600500092 PLATE, MQ POWER .................................................... 1 .............S/N 8200081~

37 0021106016 MACHINE SCREW ....................................................... 4 ............. S/N 8200081~

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 79

Page 80

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

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

MINIMUM ORDER

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

RETURNED GOODS POLICY

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

1. A Returned Material Authorization must be approved by Multiquip prior to shipment.

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

a. The parts numbers and descriptions

must match the current parts price list.

b. The list must be typed or computer

generated.

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

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and

phone number of the person requesting the RMA.

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

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

5. Parts must be in new and resalable

6. The following items are not returnable:

7. The sender will be notified of any

8. Such material will be held for five

9. Credit on returned parts will be issued at

10. In cases where an item is accepted, for

11. Credit issued will be applied to future

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price.

Rebates for price declines and added charges condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

a. Obsolete parts. (If an item is in the

price book and shows as being replaced by another item, it is obsolete.)

b. Any parts with a limited shelf life

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

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items. e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

material received that is not acceptable.

working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

dealer net price at time of the original purchase, less a 15% restocking charge.

which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

purchases only.

for price increases will not be made for stock

on hand at the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade acces-

sories nor as to any engine not manufactured

by Multiquip. Such warranties made in connec-

tion with the sale of new, complete units are

made exclusively by a statement of warranty

packaged with such units, and Multiquip nei-

ther assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such written statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

PAGE 80 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)

Page 81

NOTE PAGE

DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 81

Page 82

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

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

Your Local Dealer is:

Manufactured for Multiquip Inc.

DENYO CO., LTD, JAPAN

MQ POWER

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

MULTIQUIP Power Ultra-Silent DCA-45USI Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual