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Multiquip DCA45USI2 Portable Generator User Manual

1. po Aa PO REMARKS _ REPLACES P N 0602015255 REPLACES P N 0602041222 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 61 ENGINE AND RADIATOR ASSY CONTINUED 10 4 D 11 A9 34 63 64 48 464749 VIEW Z 65 PAGE 62 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NO PART NO 41 M9200200004 43 0602022561 44 0603306590 45 0603300285 46 0605511395 47 0603306395 48 0602021070 49 0269200310 50 M9300000003 51 M9300100003 52 0199100215 53 M1317100004 54 0016908020 55 0199101700 56 0193601200 57 0605515106 58 M1357300204 59 0017110020 60 0017110040 60A 0030010000 60B 0041210000 61 1357300004 62 00171 10020 63 8121468300 64 8971256001 65 1096300850 66 1096300850 PLUG 90 ELBOW CONNECTOR LOCKNUT VALVE HOSE JOINT CAP DRAIN HOSE RESERVE TANK CAP RESERVE TANK HOSE BRACKET RESERVE TANK HEX HEAD BOLT HOSE HOSE HOSE BAND HARNESS CLAMP HEX HEAD BOLT HEX HEAD BOLT HEX NUT WASHER FLAT HARNESS CLAMP HEX HEAD BOLT SENSOR WATER TEMPERATURE SWITCH WARNING OVERHEAT SENSOR OIL PRESSURE GASKET SENSOR OIL PRESSURE QTY 1 1 1 1 1 TD
2. 46 Troubleshooting Generator 47 Troubleshooting Diagnostic Lamp 48 Explanation Of Code In Remarks Column 50 Suggested Spare Parts 51 TABLE OF CONTENTS Component Drawings Generator 52 53 Control Box Assembly 54 59 Engine and Radiator Assembly 60 63 Output Terminal Assembly 64 65 Battery 66 67 Muffler Assembly aiebant t tp amen 68 69 Fuel Tank Assembly 70 71 Enclosure 72 75 Rubber Seals Assembly 76 77 Nameplate and Decals Assembly 78 79 Terms And Conditions Of Sale Parts 80 PAGE 4 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options January 1s 2006 Order via Internet Dealers Only If you have MQ Account to obtain Username Order parts on line using Multiquip s SmartEquip website and Password E mail us at parts multiquip View Part
3. M25000220 7 M2550002303 DECAL OPERATING PROCEDURES M25000230 8 M9500000004 DECAL OIL DRAIN L sa ss M90000000 9 M9500100004 DECAL WATER nal 90010000 10 9500300004 DECAL NEGATIVE A M90030000 11 M9500300104 DECAL M90030010 12 M9500500304 I een M90050030 13 M9503000004 DECAL WARNING MOVING PARTS 90300000 14 9503000103 DECAL WATER OIL M90300010 15 9503100004 DECAL WARNING gt M90310000 16 M9503200104 DECAL WARNING ENGINE EXHAUST Ternes M90320010 17 M9510000004 DECAL FLUID A M91000000 18 M9510000104 DECAL DOCUMENT BOX LOCATED M91000010 19 M9510100004 DECAL CAUTION HOT M 8 II M91010000 20 M9510100304 OECAL ENVIRONMENTAL WARNING M91010030 21 M9510100403 T a aaa M91010040 22 M9512200004 pz b ppm M insit M91220000 23 M9520000004 DECAL GROUND s texit La uu eem M92000000 24 M952000010 DECAL AMMETER CHANGE OVER SW Tasas M92000010 25 M9520000204 DECAL
4. 0 01 12 11 PAGE 71 ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 6 CATERPILLAR YELLOW 5 BLACK 7 CATO GOLD 8 RED THE SERIAL NUMBER MAY BE REQUIRED 1 ORANGE 2 WHITE 3 SPECTRUM GREY 4 SUNBELT GREEN VIEW 2 PAGE 72 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL 0 01 12 11 NO PART NO 1 M1413003102 1A M1493000404 2 M1414800003 3 0603306797 4 0017110040 5 M1423002002 5A M1493107604 6 M13116000041 7 00169080201 8 M14230021021 8 1 03145021001 8 1A 14931076041 9 06018517561 10 06018517361 11 06018502661 12 0601850263 13 1423500004 14 0016906016 15 0016908020 16 0016908020 17 1423202404 18 00169 06016 19 1310600103 20 1310600004 21 0016906020 22 1423202203 22A 1493107704 23 1423202303 24 0019206016 25 0019208020 26 M1433300113 27 M1433300203 28 0010116040 28A 0040016000 29B 004121600 29 0010116040 29A 0040016000 29B 0041216000 30 1443001702 30A 1493303703 31 1443800004 31A 1493303904 32 0207006000 33 0016908020 34 1443301903 34A 1493303804 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 73 PART NAME BASE ACOUSTIC SHEET ENVIRONMENTAL TANK PLUG 1 1 2 HEX HEAD BOLT FRONT FRAME ACOUSTIC SHEET RADIATOR COVER HEX HEAD BOLT FRONT FRAME SEAL AC
5. Safety Hazard Lethal exhaust gas hazards W Explosive fuel hazards aS E Burn hazards Overspeed hazards Rotating parts hazards Pressurized fluid hazards Electric shock hazards PAGE 6 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 SAFETY INFORMATION GENERAL SAFETY NEVER operate this equipment without proper protective clothing shatterproof glasses respiratory protection hearing protection steel toed boots and other protective devices required by the job or city and state regulations NEVER operate this equipment when not feeling well due to fatigue illness or when under medication NEVER operate this equipment under the influence of drugs or alcohol Ii ALWAYS check the equipment for loosened threads or bolts before starting DO NOT use the equipment for any purpose other than its intended purposes or applications NOTICE B This equipment should only be operated by trained and qualified personnel 18 years of age and older E Whenever necessary replace nameplate operation and safety decals when they become difficult read i Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties m NEVER use accessories or attachments that are not recommended by MQ Power for this equipment Damage to the equipment and or injury to us
6. Figure 9 Voltage Regulator Control Knob Removing the Plastic Face Plate Hard Wire Hookup Panel The output terminal lugs are protected by a plastic face plate cover Figure 10 Un screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure After the load wires have been securely attached to the terminal lugs reinstall the plastic face plate HARD WIRE ae HOOKUP PANEL TERMINAL COVER SECURING BOLTS Figure 10 Plastic Face Plate Output Terminal Lugs DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 23 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Loads can be connected to the generator by the output terminal lugs or the convenience receptacles Figure 11 Make sure to read the operation manual before attempting to connect a load to the generator To protect the output terminals from overload a 3 pole 110 amp main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine CS 6369 TWIST LOCK RECEPTACLES HARD WIRE HOOKUP PANEL LOAD Ee GFC RECEPTACLE NEUTRAL GROUND LOAD AS Y Figure 11 Connecting Loads Over Current Relay An over current relay Figure 12 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can n
7. NO PART NO 1 M1923200114 1A 8980388550 1 1 8980188580 2 060500455 3 0030012000 4 0040012000 5 0041212000 6 M1923200084 6 1 0602011079 7 M9200100904 8 0150000016 9 M9312200104 10 0016908040 11 0207008000 12 1310501203 13 M1310501303 14 0605515201 15 M1423700004 16 M1423700114 17 0016906016 18 M1924200004 19 0016910025 20 0602046582 20 0602046385 21 0602040651 22 1373200204 23 0602040556 24 0016908030 25 0207008000 26 0019210025 27 M1373101003 28 M1373101103 29 M1326100104 30 M1374100103 31 0605515199 32 0605515225 33 0269200570 34 0605515198 35 M9602000003 36 M9200200004 37 0150000018 38 0016906016 39 0199100700 40 0199100800 41 0605515106 42 0602022581 ENGINE AND RADIATOR ASSY PART NAME QTY ENGINE ISUZU BU 4JJ1T CARTRIDGE OIL FILTER RUBBER SUSPENSION HEX NUT WASHER LOCK WASHER FLAT RADIATOR CAP RADIATOR PLUG O RING MOUNT RUBBER HEX HEAD BOLT HEX NUT RADIATOR HOSE RADIATOR HOSE HOSE BAND FAN GUARD FAN GUARD HEX HEAD BOLT MOTOR FAN HEX HEAD BOLT AIR CLEANER ELEMENT AIR CLEANER INDICATOR AIR CLEANER BRACKET AIR CLEANER BAND AIR CLEANER HEX HEAD BOLT HEX NUT HEX HEAD BOLT HOSE AIR CLEANER HOSE AIR CLEANER BLOWBY PIPE HOSE AIR CLEANER HOSE BAND HOSE BAND BLOWBY HOSE HOSE BAND DRAIN JOINT PLUG O RING HEX HEAD BOLT DRAIN HOSE DRAIN HOSE HOSE BAND ADAPTER P SOB O
8. k ENGINE AND RADIATOR ASSY CONTINUED REMARKS DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 63 OUTPUT TERMINAL ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 64 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 OUTPUT TERMINAL ASSY NO PART NO PART NAME QTY REMARKS 1 M1230700103 TERMINAL PANEL 1 2 M9220100204 OUTPUT TERMINAL BOLT 5 3 M9220100104 TIE SCREW 5 4 0039310000 HEX NUT 10 5 0040010000 WASHER LOCK 15 6 0041410000 WASHER FLAT 20 7 0016908025 HEX HEAD BOLT 5 8 1236101203 TERMINAL COVER 1 9 M1236100704 OUTPUT WINDOW 1 10 0605010040 HINGE 2 11 0027103010 MACHINE SCREW 4 11A 0030003000 HEX NUT 4 11B 0041203000 WASHER FLAT 4 12 0027103010 MACHINE SCREW 4 12A 0030003000 HEX NUT 4 13 9220100804 SET SCREW 2 13A 0040006000 WASHER LOCK 2 138 0041206000 WASHER FLAT 2 13C 0080200005 RETAINING RING 2 14 0016906016 HEX HEAD BOLT 4 15 1236400004 CABLE OUTLET COVER 1 16 1236300004 SUPPORTER CABLE OUTLET COVER 1 17 0016906020 HEX HEAD BOLT 6 18 0601815194 TERMINAL 1 19 0027104016 MACHINE SCREW 2 20 0601808803 CIRCUIT BREAKER IP 20A 2 21 0601808804 CIRCUIT BREAKER 2P 50 3 22 1260700304 BREAKER FITTING COVER 1 22 1
9. 0 01 12 11 SAFETY INFORMATION BATTERY SAFETY DANGER DO NOT drop the battery There is a possibility that the battery will explode DO NOT expose the battery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come into contact with a flame or spark an explosion could occur ALWAYS wear safety glasses when handling the battery to avoid eye irritation The battery 2 contains acids that can cause injury to the eyes and skin E Use well insulated gloves when picking up the battery ALWAYS keep the battery charged If the battery is not charged combustible gas will build up ALWAYS recharge the battery a well ventilated environment to avoid the risk of a dangerous concentration of combustible gasses E f the battery liquid dilute sulfuric acid comes into contact with clothing or skin rinse skin or clothing immediately with plenty of water W f the battery liquid dilute sulfuric acid comes into contact with eyes rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention M ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator MI ALWAYS keep battery cables in good working condition Repair or replace all worn cables ENVIRONMENTAL SAFETY NOTICE B Dispose of hazardous waste properly QY Examples of potentially h
10. DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 GENERATOR OUTPUTS GAUGE READING HOW TO READ THE AC AMMETER AND AC VOLTAGE GAUGES The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change over switches Both of these switches are located on the control panel and DO NOT effect the generator output They are provided to help observe how much power is being supplied produced at the UVWO terminals lugs Before taking a reading from either gauge set the Voltage Selector Switch Figure 14 to the position which produces the required voltage For example for 30 240V choose the center 30 240 139V position on the voltage selector switch 3 PHASE 240 139 1PHASE PRESS TO LOCK Figure 14 Voltage Selector Switch 240 139V 30 Position NOTICE For 30 208V 10 120V place the Voltage Selector Switch in the 3 Phase 240 139 position AC Voltmeter Gauge Reading Place the AC Voltmeter Change Over Switch Figure 15 inthe W U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge Figure 16 V W U V W U OFF Figure 15 AC Voltmeter Change Over Switch Figure 16 AC Voltmeter Gauge AC Ammeter Gauge Reading Place the AC Ammeter Change Over Switch Figure 17 in the U position and observe the current reading load drain on the U terminal as indicated on the AC Ammeter Ga
11. This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing Avoid sharp turns to prevent rolling E Trailer should be adjusted to a level position at all times when towing Ii Raise and lock trailer wheel stand in up position when towing E Place chock blocks underneath wheel to prevent rolling while parked E Place support blocks underneath the trailers bumper to prevent tipping while parked E Use the trailer s swivel jack to adjust the trailer height to a level position while parked DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 9 SAFETY INFORMATION ELECTRICAL SAFETY m DO NOT touch output terminals during operation Contact with output terminals during operation can cause electrocution electrical shock or burn B The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals NEVER insert any objects into the output receptacles during operation This is SN extremely dangerous The possibility exists of electrical shock electrocution or death M Backfeed to a utility system can cause electrocution and or property damage NEVER connect the generator to a building s electrical system without a transfer switch or
12. Using an exhaust pipe which is too long or too small can Cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves MOUNTING The generator must be mounted on a solid foundation such as concrete and set firmly on the foundation to isolate vibration of the generator when it is running The generator must set at least 6 inches above the floor or grade level in accordance to NFPA 110 Chapter 5 4 1 DO NOT remove the metal skids on the bottom of the generator They are to resist damage to the bottom of the generator and to maintain alignment GENERATOR GROUNDING To guard against electrical shock and possible damage to the equipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical NEC articles 250 64 b and 250 66 set the following grounding requirements 1 Use one of the following wire types to connect the generator to earth ground a Copper 8 AWG 5 3 mm2 b Aluminum 6 AWG 8 4 mm2 2 When grounding the generator Figure 2 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect the other end of the ground cable to earth ground 3 NEC article 250 52 c specifies th
13. 0222100150 CUSHION RUBBER 1 23 0016906020 HEX HEAD BOLT 2 24 0601812598 RECEPTACLE GF 530EM 125V 20A 2 25 0601812538 RECEPTACLE CS6369 250V 50A 3 26 0027104016 MACHINE SCREW 10 26A 0207004000 HEX NUT 10 27 M1236400104 COVER 1 28 0016906016 HEX HEAD BOLT 4 29 M1236100803 TERMINAL COVER 1 30 0010112045 HEX HEAD BOLT 2 31 0041212000 WASHER FLAT 2 32 9310200004 STAY RUBBER 2 33 0030012000 HEX NUT 2 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 65 BATTERY ASSY PAGE 66 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PART NO Y O N 2 0602220187 M9310500014 M9103000304 06022 20920 0040006000 M1347200004 M1347200104 0016910020 0040510000 PART NAME BATTERY BATTERY SHEET BATTERY BAND BATTERY BOLT SET WASHER LOCK BATTERY CABLE BATTERY GABLE sucias HEX HEAD BOLT TOOTHED WASHER BATTERY ASSY QTY REMARKS 1 1 1 2 2 1 MAKE LOCALLY 2 2 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL 0 01 12 11 PAGE 67 MUFFLER ASSY PAGE 68 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PART NO gt M1331100102 0017112030 M1333002903 8943690210 0039308000 0602325088 MUFFLER ASSY PART NAME QTY REMARKS MUFFLER 1 HEX HEAD BOLT 4 EXHAUST PIPE 1 OE sisi aroma AA REPLACES P N 0602320101 HE
14. 7 Voltages Available UVWO Output Voltage Selector Switch Voltage Selector Switch Terminal Lugs 3 Phase 240 139V Position 3 Phase 480 270V Position 30 Line Line 208V 220V 240V 416V 440V 480V 10 Line Neutral 120V 127V 139V 240V 254V 277V Voltage Selector Switch Single Phase 240 120V Position 10 Line Neutral 420V 240V Generator Amperage Table 8 shows the maximum amps the generator can provide DO NOT exceed the maximum amps as listed Table 8 Generator Maximum Amps Rated Voltage Maximum Amps 19 120 Volt 100 amps 4 wire 108A x 2 Zigzag 50 amps 4 wire 10 240 Volt 108A Zigzag 30 240 Volt 108 amps Receptacle Load Capability The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles Table 9 and Table 10 show what amount of current is available at the GFCI receptacles when the output terminals and twist lock receptacles are in use Be careful that your load does not to exceed the available current capability at the receptacles Table 9 10 GFCI Receptacle Load Capacity KW in Use Available Load Twist Lock C6369 Current Amps 10 240 120 801 Duplex 5 20R 120V 0 amps receptacle 5 amps receptacle 10 amps receptacle 15 amps receptacle 20 amps receptacle Table 10 30 Generator Maximum Amps UVWO Terminals Current Amps 15 amps receptacle 20 amps receptacle PAGE 26
15. 76 o icon toon ow vase oon CAUTION Equipment damage can result from low voltage THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation VOLTAGE X AMPERAGE X 1 732 1000 KVA NOTICE If 30 load kVA is not given on the equipment nameplate approximate 30 load may be determined by multiplying voltage by amperage by 1 732 NOTICE Motors and motor driven equipment draw much greater current for starting than during operation An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable SeeTable 6 m When connecting a resistance load such as incandescent lamp or electric heater a capacity of up to the generating set s rated output KW can be used i 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 i When connecting an electric drill or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generating set s rated output KW multiplied by 0 8 can be used DANGER Before connecting this generator to any building s electrical system a li
16. BODY SIDD ENGINE CONTROL UNIT QN En 5008 CONTROLER SIDO O TO Wa TSS ei n AES LL IEELEEERAm E lt FU ra a 1 SEIRLD foo T Je i _ Hum en d aminorar REDOZXORERR SEHE ENGINE WIRING CH sv N D EN ON F 731 DIAGRAM SERVICE HOND 70 ENGINE HARNESS D HARKI 3 G ENGINE HARNLISQ 70 ENGINE EAPNES Rh nii CN B CN B CN G CN SY CN X p 1 XX me EER ess CE AIT 2245265 2651 XIII PANAH CN B KXK ECM CONNECTOR ARANGEMENT WIRING VIEW a WIRING VIEW Figure 65 Engine Controller DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL 0 01 12 11 PAGE 47 TROUBLESHOOTING GENERATOR Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 19 shown below for diagnosis of the Generator If the problem cannot be remedied consult our company s business office or service plant Table 19 Generator Troubleshooting Check output voltage using a voltmeter Check wiring and repair No Voltage Output Replace if necessary Chec
17. MOLDED 1 FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT TAIL LIGHT i 1 1 1 DOUBLE FILAMENT BULB Eus RIGHT HASSIS TAIL LIGHT aa WHITE E SINGLE FILAMENT BULB RED TURN LEFT LICENSE TAIL LIGHT 1 1 DOUBLE i FILAMENT BULB FLAT 5 PIN ROUND FLAT 5 PIN ROUND 1 1 I I 1 Figure 62 Trailer Towing Vehicle Wiring Diagram PAGE 44 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 GENERATOR WIRING DIAGRAM CNT CNB TO CI T ES 9 CM12 Mi R 0 AF R 98 RY sm L FUSE 104 CN M VR I S WIRING VIEW BRUSHLESS AC GENERATOR 12 34 CM CN5 CN8 Notice 1 No designation lead size 1 25 1 2 3 4 SYMBOL DESIGNATION Ar MAIN GENERATOR ARMATURE WINDING Fg MAIN GENERATOR FIELD WINDING ER 12 3 123 CN9 CN3 MMI mu s Re RECTIFIERS VOLTAGE REGULATOR IRHEOSTAT Ar Fg VR AS CHANGE OVER SWTCH AMMETER A AC AMMETER VS CHANGE OVER SWITCH VOLTMETER F OC SW M AS vs VT ACVOLTMETER F C81 COLOR CODE B BLACK R RED BROWN Y YELLOW GRAY LIGHT GREEN VIOLET O ORANGE OC sw SELEC
18. MPEC display are OFF not lit 6 Remove all loads from the generator 7 Inspect entire generator for any damage or loosening of components that may have occurred during operation EMERGENCY SHUTDOWN PROCEDURE 1 Place the MPEC Control Switch Figure 55 in the OFF RESET position AUTOMATIC SHUT DOWN SYSTEM This unit is equipped with safety devices to automatically stop the engine in the event of low oil pressure approximately 14 psi 97 kPa or high water temperature approximately 230 F 110 C overspeed approximately 15 The alarm lamps on the ECU illuminate to signify the reason for the shutdown NOTICE Before inspecting generator check that the Auto Manual switch is in the OFF RESET position and place all circuit breakers in the OFF position Allow sufficient time for adequate cooling When ready to restart complete all steps in the Generator Startup Procedure section of this manual PAGE 36 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 Table 14 Inspection Maintenance MAINTENANCE 10 Hrs 1000 DAILY 250 Hrs 500Hrs Hrs Check Fan Belt Condition Check forLeaks EX Check for Looseningof Parts X Replace Engine Oil and Fiter L X Clean airFiter Check Fuel FiterWater Separator Bow X Clean Unit Inside and Outside ChangeFuelFiter X Clean Radiator and Check Coolant Protection Level X
19. Number and Description of Each Part NOTICE All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST WWW WE ACCEPT ALL MAJOR CREDIT CARDS DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 5 SAFETY INFORMATION Do not operate or service the equipment before reading the entire manual Safety precautions should be followed at all times when operating this equipment Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others SAFETY MESSAGES The four safety messages shown below will inform you about potential hazards that could injure you or others The safety messages specifically address the level of exposure to the operator and are preceded by one of four words DANGER WARNING CAUTION or NOTICE SAFETY SYMBOLS DANGER Indicates a hazardous situation which if not avoided WILL result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in MINOR or MODERATE INJURY NOTICE Addresses practices not related to personal injury Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages
20. Safety Towing Regulations before towing your generator E Refer to MQ Power trailer manual for additional safety information order to reduce the possibility of an accident while transporting the generator on public roads ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition ALWAYS shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating M ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure on both towing vehicle and trailer Trailer tires should be inflated to 50 psi cold Also check the tire tread wear on both vehicles M ALWAYS make sure the trailer is equipped with a safety chain ALWAYS properly attach trailer s safety chains to towing vehicle B ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly DOT Requirements include the following Connect and test electric brake operation Secure portable power cables in cable tray with tie wraps E The maximum speed for highway towing is 55 MPH unless posted otherwise Recommended off road towing is not to exceed 15 MPH or less depending on type of terrain Avoid sudden stops and starts
21. Unit 2 Northpoint Industrial Estate Globe Lane Dukinfield Cheshire SK16 4UJ Contact sales multiquip co uk CANADA Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact martin multiquip com Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 COPYRIGHT 2011 MULTIQUIP INC Multiquip Inc the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc and may not be used reproduced or altered without written permission All other trademarks are the property of their respective owners and used with permission This manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Your Local Dealer is 3 MULTIQUIP
22. air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service After changing the air element press the dust indicator button to reset the indicator AIR CLEANER INDICATOR AIR CLEANER ELEMENT Figure 56 Air Cleaner Indicator NOTICE The air filter should not be changed until the indicator reads RED Dispose of old air filter It may not be cleaned or reused DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 37 MAINTENANCE If the engine is operating in very dusty or dry grass conditions a clogged air cleaner will result This can lead to aloss of power excessive carbon buildup in the combustion chamber and high fuel consumption Change air cleaner more frequently if these conditions exists FUEL ADDITION Add diesel fuel the grade may vary according to season and locations Removing Water from the Fuel Tank After prolonged use water and other impurities accumulate in the bottom of the tank Occasionally inspect the fuel tank for water contamination and drain the contents if required During cold weather the more empty volume inside the tank the easier it is for water to condense This can be reduced by keeping the tank full with diesel fuel Cleaning Inside the Fuel Tank If necessary drain the fuel inside the fuel tank completely Using a spray washer Figure 57 wash out any deposits or debris
23. that have accumulated inside the fuel tank Figure 57 Fuel Tank Cleaning FUEL TANK INSPECTION In addition to cleaning the fuel tank the following components should be inspected for wear B Rubber Suspension look for signs of wear or deformity due to contact with oil Replace the rubber suspension if necessary B Fuel Hoses inspect nylon and rubber hoses for signs of wear deterioration and hardening B Fuel Tank Lining inspect the fuel tank lining for signs of excessive amounts of oil or other foreign matter Replacing Fuel Filter Replace the fuel filter cartridge with new one every 500 hours or so Loosen the drain plug at the lower top of the fuel filter Drain the fuel in the fuel body together with the mixed water DO NOT spill the fuel during disassembly Vent any air AIR REMOVAL If air enters the fuel injection system of a diesel engine starting becomes impossible After running out of fuel or after disassembling the fuel system bleed the system according to the following procedure See the ISUZU Engine Manual for details To restart after running out of fuel turn the switch to the ON position for 15 30 seconds Try again if needed PAGE 38 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 MAINTENANCE 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
24. 001 SWITCH WARNING OVERHEAT ENGINE SIDE 8980274560 SENSOR OIL PRESSURE ENGINE SIDE 1096300850 GASKET SENSOR OIL PRESSURE ENGINE SIDE eren 0601808803 CIRCUIT BREAKER 1P 20 AMP 0601808804 CIRCUIT BREAKER 2P 50 AMP 0601806644 FUSE 30 AMP 0601806640 FUSE 65 AMP e 0601806671 FUSE 15 AMP 0601820602 AUTOMATIC VOLTAGE REGULATOR 0602122272 UNIT OIL PRESSURE NOTICE Part number on this Suggested Spare Parts list may supersede replace the P N shown in the text pages of this book DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 51 GENERATOR ASSY PAGE 52 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 oo m 01 gt AON Su 1 Li 1 B3110001102 0601820083 0601822664 B3120100804 B3120100604 B3120100704 B3111100603 B2163100004 0010304016 B2163700004 0204004000 B3163200104 0342612030 0046512000 0071906309 0010310020 0042510000 3130000903 0845041904 B3137000803 0016008060 0042508000 B3153000513 0017108035 B3153400504 B3153400404 0017106016 0010310025 0042510000 B5131300004 0340406040 0600815000 0041206000 B31
25. 00290 38 0027105016 39 M121350060 40 0016906016 41 M1270100304 42A 1550002904 428 1550003004 42 1213602204 43 1213602304 44 0021104030 44A 0207004000 45 0027104016 45A 0207004000 46 0016906016 47 1213602404 48 0016906016 49 1213602504 49 1 0317700180 50 0016906016 51 0016906016 51A 0040506000 52 M1223000803 53 0601807641 54 0601803986 55 0601801040 56 0601806859 57 0601801041 58 0601840073 59 0601840121 60 0602202641 CONTROL BOX ASSY PART NAME QTY REMARKS BRACKET SENSOR Eg MACHINE SCREW 2 2 MACHINE SCREW RELAY STARTER RELAY GLOW PLUG aaa MACHINE SCREW DY MACHINE SCREW CONTROL BOX COVER HEX HEAD BOLT SELECTOR SWITCH DECAL SELECTOR SWITCH NUMBER DECAL SELECTOR SWITCH NUMBER SWITCH BRACKET SWITCH BRACKET MACHINE SCREW HEX NUT MACHINE SCREW HEX NUT HEX HEAD BOLT SWITCH COVER HEX HEAD BOLT SWITCH COVER SEAL RUBBER HEX HEAD BOLT HEX HEAD BOLT TOOTHED WASHER CONTROL PANEL FREQUENCY METER 45 65HZ 240V AC AMMETER 0 75 150 5 CHANGE OVER SW AMMETER AC VOLTMETER 0 600V CHANGE OVER SW VOLTMETER RHEOSTAT VR 2W 1K OHM KNOB CONTROLLER ECU CAN77 O BKB HB LC HSH PE WW HS PO k i i de REPLACES P N 0602202502 T REPLACES P N 0602202685 t REPLACES P N 0602201400 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL 0 01 12 11 PAGE 57 CONTRO
26. 0228900900 4 0229400900 5 0228900795 6 0228900630 7 0229400445 8 0228800455 9 0228900445 10 0229200455 11 0228100870 12 0229200840 13 0229200540 14 0229200790 15 0228800800 16 0228900470 17 02288 00470 18 0228100420 19 0228100325 20 0314500750 21 0330000180 22 0330000615 23 0330000180 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL 0 01 12 11 PAGE 77 PART NAME SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL EDGING EDGING EDGING QTY 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 2 2 1 1 1 1 RUBBER SEALS ASSY REMARKS NAMEPLATE AND DECALS ASSY PAGE 78 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NAMEPLATE AND DECALS ASSY NO PART NO PART NAME QTY REMARKS 1 M1550000204 M15000020 2 M1550000703 DECAL AUXILIARY OUTPUT 15000070 1550000804 DEGAL NOT M15000080 4 M1550001504 PA M15000150 5 M1550003603 DECAL GENERATOR CONTROL 15000360 6 2550002203 DECAL ENGINE 0 LMIIMC
27. 0500204 14 0016906016 15 0601802218 15A 0601806671 16 0027103020 17 LY 2DDC12V 17A 178 18 002710402C 19 0601815153 20 0027104016 21 0603250240 22 0602202688 23 M3260500604 24 0016906016 25 0601831205 26 0601831330 27 0016906016 28 0601823240 29 0027105020 30 8972177780 PART NAME CONTROL BOX EDGING EDGING EDGING CIRCUIT BREAKER 3P MACHINE SCREW RELAY UNIT MACHINE SCREW AUTOMATIC VOLTAGE REGULATOR MACHINE SCREW CURRENT TRANSFORMER 150 5A MACHINE SCREW OVER CURRENT RELAY OVER CURRENT RELAY MACHINE SCREW HEX NUT SET PANEL ELECTRIC PARTS HEX HEAD BOLT HOLDER FUSE USE 15A MACHINE SCREW M en m MACHINE SCREW TERMINAL MACHINE SCREW SENSOR INLET AIR TEMP CONTROLLER BRACKET HEX HEAD BOLT PUSH BUTTON SWITCH DIAGNOSTIC SWITCH HEX HEAD BOLT RECTIFIER MACHINE SCREW SENSOR BAROMETRIC PRESSURE CONTROL BOX ASSY TY REMARKS ___ REPLACES P N 0601827656 _ REPLACES P N 0601823109 _ REPLACES P N 0601824400 AA REPLACES P N 0602130220 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 55 CONTROL BOX ASSY PAGE 56 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NO PART 31 M2260600104 32 0027105016 33 0027105016 34 8942481610 35 8970119490 36 0027105016 37 58255
28. 11 PAGE 79 TERMS AND CONDITIONS OF SALE PARTS PAYMENT TERMS Terms of payment for parts are net 30 days FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice All shipments are F O B point of origin Multiquip s responsibility ceases when a signed manifest has been obtained from the carrier and any claim for shortage or damage must be settled between the consignee and the carrier MINIMUM ORDER The minimum charge for orders from Multiquip is 15 00 net Customers will be asked for instructions regarding handling of orders not meeting this requirement RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed subject to the following provisions 1 Returned Material Authorization must be approved by Multiquip prior to shipment 2 Toobtain 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 Theparts 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 Acopyofthe Return Material Authori
29. 1453004203 53 1493408504 54 1453004303 54 14934 08704 55 9113000002 55 9312500004 56 0021806016 56A 0030006000 57 M9112100404 58 M9112100504 59 M9112100604 60 0016908020 61 0016908020 62 0601850097 63 0027208025 64 0605503062 65 1413800304 66 0017108020 67 0600800321 68 1483600804 69 0016906016 ENCLOSURE ASSY CONTINUED PART NAME HEX HEAD BOLT REAR DOOR WINDOW PLATE HEX NUT WASHER FLAT DOOR HANDLE ASS Y MACHINE SCREW HEX NUT HINGE HINGE HEX HEAD BOLT ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT COVER HEX HEAD BOLT SPLASHER PANEL HEX HEAD BOLT HEX HEAD BOLT WASHER LOCK WASHER FLAT SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET DOOR HANDLE ASS Y SEAL RUBBER MACHINE SCREW HEX NUT HINGE HINGE HINGE HEX HEAD BOLT HEX HEAD BOLT STOPPER MACHINE SCREW FUEL LEAK DETECTED SWITCH BRACKET HEX HEAD BOLT MANUAL PAK HEX CLAMPER HEX HEAD BOLT QTY 69 00 400 E REMARKS DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 75 RUBBER SEALS ASSY PAGE 76 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL 0 01 12 11 NO PART NO 1 0229200950 2 0228901425 3
30. 31300804 0029205012 0041205000 0605000455 0030012000 0040012000 0041212000 PART NAME ROTOR ASSY FIELD ASSY RECTIFIER ZNR HOLDER ZNR INSULATOR WASHER INSULATOR WASHER FAN COUPLING DISK HEX HEAD BOLT BALANCING WEIGHT U NUT COUPLING WASHER HEX SOCKET HEAD CAP SCREW WASHER FLAT BEARING HEX HEAD BOLT WASHER LOCK STATOR ASSY GROMMET FIELD ASSY EXCITER HEX SOCKET HEAD CAP SCREW WASHER LOCK END BRACKET HEX HEAD BOLT PACKING COVER BEARING HEX HEAD BOLT HEX HEAD BOLT WASHER LOCK COVER END BRACKET HEX HEAD BOLT NUT WASHER FLAT COVER END BRACKET MACHINE SCREW WASHER FLAT RUBBER SUSPENSION HEX NUT WASHER LOCK WASHER FLAT GENERATOR ASSY QTY REMARKS BRAM lt A iudi PURCHASE ITEM 1 8 AS A SET DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 53 CONTROL BOX ASSY PAGE 54 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NO PART 1 M1213001212 1 1 0330000180 1 2 0330000615 1 3 0330000245 2 0601808825 3 0021005080 4 0601823863 5 0027104016 6 0601820602 T 0027105016 8 0601801123 9 0027106020 10 0601820847 11 0601820848 12 0027104016 12A 0207004000 13 226
31. 8 3 PHASE 240 139 PRESS TO LOCK Figure 38 Voltage Selector Switch STARTING MANUAL 1 Placethe engine speed switch Figure 39 in the LOW down position LOW DOWN Figure 39 Engine Speed Switch Low 2 Place the MPEC control switch in the MANUAL position to start the engine Figure 40 p AUTO gt MANUAL OFF RESET Figure 40 MPEC Control Switch Manual Position 3 Depending on the temperature of the coolant cold weather conditions the pre heat lamp Figure 41 will light ON and remain on until the pre heating cycle has been completed After completion of the pre heating cycle the light will go OFF and the engine will start up automatically Figure 41 Pre Heat Lamp 4 Once the engine starts let the engine run for 1 2 minutes Listen for any abnormal noises If any abnormalities exist shut down the engine and correct PAGE 34 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 GENERATOR START UP PROCEDURE the problem If the engine is running smoothly place the engine speed switch Figure 42 in the HIGH up position 4 1 HIGH UP Figure 42 Engine Speed Switch High Verify that the engine running status LED on the MPEC module Figure 43 is lit ON after the engine has started AUTO MANUAL OFF RESET LOWOIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING Figure 43 Engine Run
32. ECTION Figure 34 Fan Belt Tension NEVER place hands near the belts or fan while the generator set is running PAGE 32 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 INSPECTION SETUP BATTERY This unit is of negative ground DO NOT connect in reverse Always maintain battery fluid level between the specified marks Battery life will be shortened if the fluid level are not properly maintained Add only distilled water when replenishment is necessary DO NOT over fill Check to see whether the battery cables are loose Poor contact may result in poor starting or malfunctions Always keep the terminals firmly tightened Coating the terminals with an approved battery terminal treatment compound Replace battery with only recommended type battery The battery is sufficiently charged if the specific gravity of the battery fluid is 1 28 at 68 F If the specific gravity should fall to 1 245 or lower it indicates that the battery is dead and needs to be recharged or replaced Before charging the battery with an external electric source be sure to disconnect the battery cables Battery Cable Installation ALWAYS be sure the battery cables Figure 35 are properly connected to the battery terminals as shown below The red cable is connected to the positive terminal of the battery and the black cable is connected to the negative terminal of the battery ALWAYS disconnect th
33. ECU This controller has a vertical row of status LED s inset that when lit indicate that an engine malfunction fault has been detected When a fault has been detected the engine controller will evaluate the fault and all major 2 HIGH COOLANT TEMPERATURE faults will shutdown the generator During cranking cycle the ECU ENGINE RUNNING will attempt to crank the engine for 10 seconds before disengaging AUTO MANUAL OFF RESET If the engine does not engage start by the third attempt the engine will be shutdown by the engine controller s Over Crank Protection mode If the engine engages at a speed RPM s that is not safe the controller will shutdown the engine by initializing the Over Speed Protection mode Also the engine controller will shut down the engine in the event of low oil pressure high coolant temperature low coolant level and loss of magnetic pickup These conditions can be observed by monitoring the LED status indicators on the front of the controller module MPEC Control Switch This switch controls the running of the unit If this switch is set to the OFF RESET position the unit will not run When this switch is set to the manual position the generator will start immediately If the generator is to be connected to a building s AC power source via an automatic transfer switch isolation place the switch in the AUTO position In this position shoul
34. GE 17 GENERATOR CONTROL PANEL Figure 4 Generator Control Panel The definitions below describe the controls and functions of the Generator Control Panel Figure 4 1 Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage Main Circuit Breaker This three pole 110A main breaker is provided to protect the the U V and W Output Terminal Lugs from overload 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 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 AC Voltmeter Indicates the output voltage present at the U V and W Output Terminal Lugs AC Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz Located behind the generator control panel is the Generator Control Box This box contains some of the necessary electronic components required to make the generator f
35. L BOX ASSY PAGE 58 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NO PART NO 61 0021004040 61A 0207004000 62 0601831340 63 0602103092 63A 0601810245 64 0602120095 65 0602122093 66 0602123090 67 0602121081 68 0602125090 69 0601810141 70 0601831330 71 0601831395 72 1224100104 73 0027105010 74 0027105010 75 M9220100004 76 0080200007 77 0602122272 78 M9200100004 79 0130000000 80 0304300050 81 0602120465 82 M2357202104 82A 0601806644 83 0601806640 84 1246703314 85 1357201702 86 M2357201802 PART NAME MACHINE SCREW HEX NUT SWITCH ALARM LAMP BULB DC18V TACHOMETER OIL PRESSURE GAUGE WATER TEMP GAUGE CHARGING AMMETER FUEL GAUGE PANEL LIGHT SWITCH PANEL LIGHT SWITCH ENGINE SPEED STOPPER MACHINE SCREW MACHINE SCREW SET SCREW SNAP RING UNIT OIL PRESSURE ADAPTER ELBOW 1 8 LONG NIPPLE PICKUP TACHOMETER FUSE HOLDER UNIT FUSE 30A FUSE 65A WIRE HARNESS GENERATOR WIRE HARNESS ENGINE WIRE HARNESS CONTROLLER CONTROL BOX ASSY QTY 2 2 1 3 3 1 1 1 1 1 1 1 1 1 2 4 2 2 1 1 1 1 1 1 1 1 1 1 1 REMARKS DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 59 ENGINE AND RADIATOR ASSY i 11 48 464749 VIEW Z PAGE 60 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11
36. OD FOR EARTH GROUND WE AC CONNECT TO BUILDING gt GROUND GROUND CABLE 8 FT MINIMUM REFERENCE 250 83 6 Figure 2 Typical Generator Grounding Application PAGE 14 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 INSTALLATION OUTDOOR INSTALLATION Install the generator in a area that is free of debris bystanders and overhead obstructions Make sure the generator is on secure level ground so that it cannot slide or shift around Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes The installation site must be relatively free from moisture and dust All electrical equipment should be protected from excessive moisture Failure to do will result in deterioration of the insulation and will result in short circuits and grounding Foreign materials such as dust sand lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area INDOOR INSTALLATION Exhaust gases from diesel engines are extremely poisonous Whenever an engine is installed indoors the exhaust fumes must be vented to the outside The engine should be installed at least two feet from any outside wall
37. OPERATION AND PARTS MANUAL MULTIQUIP 1 POWER MODEL DCA45USI2 60HZ WHISPERWATT GENERATOR ISUZU BU 4JJ1T DIESEL ENGINE PARTS LIST NO M1870400004 Revision 0 01 12 11 To find the latest revision of this publication visit our website at www multiquip com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect that could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Multiquip at 1 800 421 1244 If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Multiquip To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator NHTSA 1200 New Jersey Avenue S E Washington DC 20590 You can also
38. OUSTIC SHEET GROMMET GROMMET GROMMET GROMMET GUARD HEX HEAD BOLT HEX HEAD BOLT HEX HEAD BOLT DUCT COVER HEX HEAD BOLT HOSE COVER HOSE COVER HEX HEAD BOLT COVER FRONT FRAME ACOUSTIC SHEET FRONT LOUVER HEX HEAD BOLT HEX HEAD BOLT CENTER FRAME CENTER FRAME HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX HEAD BOLT WASHER LOCK WASHER FLAT REAR FRAME ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT HEX HEAD BOLT REAR COVER ACOUSTIC SHEET QTY 1 1 1 1 8 1 1 1 2 1 1 1 1 2 5 1 1 4 8 4 2 ENCLOSURE ASSY REMARKS ENCLOSURE ASSY CONTINUED 777 E e Gi x o NUMBER WHEN ORDERING ANY PAINTED PANEL TO 5 BLACK 6 CATERPILLAR YELLOW 7 CATO GOLD 8 RED ADD THE FOLLOWING DIGITS AFTER THE PART INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GREY 4 SUNBELT GREEN THE SERIAL NUMBER MAY BE REQUIRED VIEW 2 PAGE 74 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NO PART NO 35 0019208020 36 M1444200003 37 M1444600004 38 020730600C 38A 004120600C 39 M91 13000002 40 0021806016 40A 0030006000 41 9112100404 42 9112100604 43 0016908020 44 M1463002002 44 M1493504504 45 0019208020 46 M3310600004 47 0019208020 46 M1453201002 49 0016908020 50 0019108065 50A 0042308000 50B 0042408000 51 1454000403 51 1493408404 52 1454000103 52 1493408604 53
39. Replace Air Fiter Eleme X Check all Hoses and Clamps X Check Engine Fluid Leves xo 1 Check AirCleaner X Check Battery AcidLevel YX Clean Inside ofFuelTank X Measure Insulation Resistance Over Mohms X Measure Insulation Resistance Over ohms Generator Check Rotor Rear Support Bearing o PX Replace engine oil and filter at 100 hours first time only Add Supplemental Coolant Additives SCA S to recharge the engine coolant 3 Replace primary air filter element when restriction indicator shows a vacuum of 625 mm 25 in H20 4 f blowby hose needs to be replaced ensure that the slope of the blowby hose is at least 1 2 inch per foot with no sags or dips that could collect moisture and or oil GENERAL INSPECTION Prior to each use the generator should be cleaned and inspected for deficiencies Check for loose missing or damaged nuts bolts or other fasteners Also check for fuel oil and coolant leaks Use Table 14 as a general maintenance guideline Engine Side Refer to the Engine Instruction Manual AIR CLEANER Every 250 hours Remove air cleaner element Figure 56 and clean the heavy duty paper element with light spray of compressed air Replace the air cleaner as needed Air Cleaner with Dust Indicator This indicator Figure 56 is attached to the air cleaner When the air cleaner element is clogged
40. TOR SWITCH RY12 RELAY UNIT Re RECTIFIER FM F FAN MOTOR FUSE 10AMP Figure 63 Generator Wiring Diagram DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 45 ENGINE WIRING DIAGRAM TO CONTROLLER Cut CONTROLLER WIZING DIAGRAM CHI DIAGRAM s d x at E E 5 de Me 3333 EE 3832 jt 5 TO mic lt x CM lt TO CH C E lt Tz e r EA Y peo E pm STARTER COT RELAY vo A sour 1 TO FL 3 TO CN 974 714 3 MI TACHO METER I CNE a m STARTER Cr 4 j 70 2 SELRCTOR SW i E T CN Q TB2 CM21 5 e ex LM Ez ar acc merece CN72 bres Re Li ee dl TO Vio CN E BATTERY 112 TO 132 ACCT SBLECTOR 3 5 TO CONTROLLER WIRING DIAGRAM CN G 6 MAGNETIC FICK UP WIRING VIEW CAN TERMINATOR 120 OHM TERMINATOR A B BclAcclacca O TERMINAL BOARD TB2 1 2 3 4 AAA MV10 V11 V11 v14 V46 24 fva CN2 CN1 Figure 64 Engine Wiring Diagram PAGE 46 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 CONTROLLER WIRING DIAGRAM en v
41. VOLTMETER CHANGE OVER SW M92000020 26 M9520000504 DECAL START CONTACT M92000050 27 M9520000904 DECAL DIAGNOSTIC SWITCH M92000090 28 M9520001104 DECAL DIAGNOSTIC BUTTON A M92000110 29 M9520100004 DECAL WARNING ELECTRIC SHOCK HAZARD 2 M92010000 30 M9520100204 DECAL CAUTION M92010020 31 M9520100304 DECAL SAFETY INSTRUCTIONS M92010030 32 M9520100404 DECAL DANGER HIGH VOLTAGE AA M92010040 33 M9520100503 M92010050 34 M9520100603 DECAL CAUTION nro E einn M92010060 35 M9520200003 DECAL CONNECTION OF OUTPUT CABLE 92020000 36 9520200404 DECAL OVER CURRENT douche M92020040 37 M1561000004 DECAL MQ POWER 2 38 M1561100004 2 39 1561100103 STRIPE WHISPEPRUWATT 2 40 M1560102204 STRIPE A 1 41 1560102304 iii 1 42 M1561100404 STRIPE _ ____ coa 2 43 0600500092 PLATE MOPOWER rod 1 44 0021106016 MACHINE SCREW naciona ds 4 45 M9520000804 DECAL 1 46 M9503200104 DECAL DANGER ENGINE EXHAUST M90320010 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12
42. X NUT 6 SEAL CLAMP 1 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 69 FUEL TANK ASSY PAGE 70 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NO PART NO 1 M2363000102 1 1 0605505070 1 2 0605501072 1 2A 0605516090 2 M1364200004 3 M1363200404 4 M9310500104 5 0016908020 6 0207008000 T 0222100700 8 0191301300 9 0605515109 10 M1366700214 11 0016910025 12 M1366700304 13 0016908025 14 8980139861 14A 8980088400 15 8980758550 15A 8980758540 16 8973834270 17 1096750951 18 1096300860 PART NAME FUEL TANK FUEL TANK CAP FUEL SENDER UNIT GASKET TANK BAND TANK BAND SUPPORTER SHEET HEX HEAD BOLT HEX NUT TANK SHEET VENT HOSE HOSE BAND FUEL FILTER BRACKET HEX HEAD BOLT FUEL PUMP BRACKET HEX HEAD BOLT FUEL FILTER MAIN ELEMENT FUEL FILTER uu u aaa FUEL FILTER PRE ELEMENT FUEL gt PACKING 1 1 1 1 4 4 8 FUEL TANK ASSY QTY REMARKS 1 1 1 1 2 2 4 4 4 5 1 2 1 4 1 2 AAE REPLACES P N 0602042426 REPLACES P N 0602042515 REPLACES P N 0602042405 REPLACES P N 0602042516 DOT REPLACES P N 0602042661 _ _ REPLACES P N 0602042621 REPLACES P N 0602042641 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL
43. X AND BELOW S N XXXX AND ABOVE S N XXXX TO S N XXX Specific Model Number Use Indicates that the part is used only with the specific model number or model number variant listed It can also be used to show a part is NOT used a specific model or model number variant Indicated by XXXXX ONLY NOT USED ON Make Obtain Locally Indicates that the part can be purchased at any hardware shop or made out of available items Examples include battery cables shims and certain washers and nuts Not Sold Separately Indicates that an item cannot be purchased as a separate item and is either part of an assembly kit that can be purchased or is not available for sale through Multiquip PAGE 50 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL 0 01 12 11 SUGGESTED SPARE PARTS DCA45USI2 WHISPERWATT GENERATOR WITH ISUZU BU 4JJ1T DIESEL ENGINE 1 to 3 units QTY P N DESCRIPTION 8980188580 CARTRIDGE OIL FILTER 8980088400 FILTER FUEL ELEMENT MAIN 8980742880 FILTER FUEL ELEMENT PRE tanda 8980714010 FILTER FUEL FEED PUMP 0602046365 ELEMENT AIR Lanas 8980388550 BELT FAN M131050120 3 RADIATOR HOSE UPPER 1310501303 RADIATOR HOSE LOWER 8121468300 SENSOR WATER TEMP ENGINE SIDE 8971256
44. ade guards in use or a part that has been updated on newer versions of the same machine NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order PART NO Column Numbers Used Part numbers can be indicated by a number a blank entry or TBD TBD To Be Determined is generally used to show a part that has not been assigned a formal part number at the time of publication A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip Other entries will be clarified in the Remarks Column QTY Column Numbers Used Item quantity can be indicated by a number a blank entry or A R As Required is generally used for hoses or other parts that are sold in bulk and cut to length A blank entry generally indicates that the item is not sold separately Other entries will be clarified in the Remarks Column REMARKS Column Some of the most common notes found in the Remarks Column are listed below Other additional notes needed to describe the item can also be shown Assembly Kit All items on the parts list with the same unique symbol will be included when this item is purchased Indicated by INCLUDES ITEMS W unique symbol Serial Number Break Used to list an effective serial number range where a particular part is used Indicated by S N XXXX
45. al combustion engines that use hydrocarbon fuels A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator PAGE 8 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 SAFETY INFORMATION FUEL SAFETY DONOT start the engine near spilled fuel or combustible fluids Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited m ALWAYS refuel in a well ventilated area away from sparks and open flames ALWAYS use extreme caution when working with flammable liquids 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 appropriate containers in well ventilated areas and away from sparks and flames NEVER use fuel as a cleaning agent B DO NOT smoke around or near the equipment Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine TOWING SAFETY M Check with your local county or state safety towing regulations in addition to meeting O Department of Transportation DOT
46. at the earth ground rod should be buried a minimum of 8 ft into the ground NOTICE When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 15 GENERAL INFORMATION GENERATOR This generator Figure 3 is a high quality portable requires a trailer for transport power source for telecom sites lighting facilities power tools submersible pumps and other industrial and construction machinery ENGINE OPERATING PANEL The Engine Operating Panel is provided with the following M Tachometer i Water Temperature Gauge E Warning Lamp B Fuel Leak Detected Alam Lamp E Pre Heat Lamp B Oil Pressure Gauge E Charging Ammeter Gauge B Fuel Level Gauge E Panel Light Panel Light Switch ECU Controller B Engine Speed Switch GENERATOR CONTROL PANEL The Generator Control Panel is provided with the following B Frequency Meter Hz Ammeter Amps MI AC Voltmeter Volts Ammeter Change Over Switch E Voltmeter Change Over Switch E Voltage Regulator 3 Pole 110 amp Main Circuit Breaker Control located behind the Gen Control Panel Automatic Voltage Regulator Current Transformer Over Current Relay e Starter Relay e Voltage Selector Switch OUTPUT TERMINAL PANEL The Output Terminal Panel is provided with the following M Three 120 240V outpu
47. azardous waste are used motor oil fuel and fuel filters DO NOT use food or plastic containers to dispose of hazardous waste DO NOT pour waste oil or fuel directly onto the ground down a drain or into any water source DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 11 SPECIFICATIONS Table 1 Generator Specifications Model DCA 45USI2 Revolving field self ventilated yP open protected type synchronous generator Phase 3 Single 28 6 KW 26 KW 240 or 120V PowerFador 008 1 0 Output S Table 2 Engine Specifications Modl ISUZU BU 4JJ1T Tier 4 Rated Output 57 1 HP 1800 RPM Starting O APA 2 1 gal 8 0 L hr at 3 4 load 0 9 gal 3 4 L hr at 1 4 load Coolant Capacity 3 17 gal 12 liters Lube Oil Capacity 3 83 gal 14 5 liters q PAGE 12 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 DIMENSIONS FRONT VIEW Figure 1 Dimensions Table 3 Dimensions pod Reference Letter Dimension in mm puertos 6 euism p 3016in 766 mm 24 37 in 619 mm DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 13 INSTALLATION GROUND LUG ZW GROUND R
48. cated directly above the GFCI receptacles Remember the load output current of both GFCI receptacles is dependent on the load requirements of the U V and W output terminal lugs Pressing the reset button resets the GFCI receptacle after being tripped Pressing the test button See Figure 7 in the center of the receptacle will check the GFCI function Both receptacles should be tested at least once a month 120 VAC G F C I RECEPTACLE RESET TEST BUTTON Figure 7 G F C l Receptacle Twist Lock Dual Voltage 120 240 VAC Receptacles There are three 120 240V 50 amp auxiliary twist lock CS 6369 receptacles Figure 8 provided on the output terminal panel These receptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position 5 6369 TWIST LOCK RECEPTACLES SINGLE PHASE 120 240 VAC 50 AMP OUTPUT Figure 8 120 240V Twist Lock Auxiliary Receptacles Each auxiliary receptacle is protected by a 50 amp circuit breaker These breakers are located directly above the CLC I receptacles Remember the load output current on all three receptacles is dependent on the load requirements of the output terminal lugs Turn the voltage regulator control knob Figure 9 on the control panel to obtain the desired voltage Turning the knob clockwise will increase the voltage turning the knob counter clockwise will decrease the voltage DECREASE INCREASE
49. censed electrician must install an isolation transfer switch Serious damage to the building s electrical system may occur without this transfer switch DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 25 GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES A wide range of voltages are available to supply voltage for many different applications Voltages are selected by using the voltage selector switch Figure 13 To obtain some of the voltages as listed in Table 7 see below will require a fine adjustment using the voltage regulator VR control knob located on the control panel Voltage Selector Switch The voltage selector switch Figure 13 is located above the output terminal panel s Hard Wire Hook up Panel It has been provided for ease of voltage selection 3 PHASE 240 139 3 PHASE 1 PHASE Figure 13 Voltage Selector Switch Voltage Selector Switch Locking Button To lock the voltage selector switch press and hold the red button located at the bottom of the switch While holding the red button down insert a pad lock into the hole next to the button to retain it in the inward locked position When the lock is removed the red button is spring loaded and will return to its normal outward unlocked position NEVER change the position of the voltage selector switch while the engine is running ALWAYS place circuit breaker in the OFF position before selecting voltage Table
50. d an outage occur the automatic transfer switch ATS will start the generator automatically via the generator s auto start contacts connected to the ATS s start contacts Please refer to your ATS installation manual for further instructions for the correct installation of the auto start contacts of the generator to the ATS Low Oil Pressure Indicates the engine pressure has fallen below 15 psi 103 kPa The oil pressure is detected using variable resistive values from the oil pressure sending unit This is considered a major fault High Coolant Temperature Indicates the engine temperature has exceeded 230 F 110 C The engine temperature is detected using variable resistive values from the temperature sending unit This is considered a major fault Overcrank Shutdown Indicates the unit has attempted to start a pre programmed number of times and has failed to start The number of cycles and duration are programmable It is pre set at 3 cycles with a 10 second duration This is considered a major fault Overspeed Shutdown Indicates the engine is running at an unsafe speed This is considered a major fault Engine Running Indicates that engine is running at safe operating speed DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 21 OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL The Output Terminal Panel Figure 6 shown below is l
51. date 11 Credit issued will be applied to future purchases only PRICING AND REBATES Prices are subject to change without prior notice Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change e 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 hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed and in no event shall Multiquip be liable for loss of profit or good will or for any other special consequential or incidental damages LIMITATION OF WARRANTIES No warranties express or implied are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip Such warranties made in connection with the sale of new complete units are made exclusively by a statement of warranty packaged wi
52. djustment knob whenever fine tuning of the output voltage is required DECREASE INCREASE Figure 21 Voltage Regulator Knob 30 208V 10 120V UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 30 240 139 position as shown in Figure Figure 22 3 PHASE USE THIS POSITION FOR 240 139 30 208V 1 120V 240 120 PRESS TO LOCK Figure 22 Voltage Selector Switch 30 240 139 Position 2 Connect the load wires to the UVWO terminals as shown in Figure 23 GREEN BLUE WHITE GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 23 UVWO Terminal Lugs 30 208 10 120 Connections Connections NOTICE To achieve 30 208V output the voltage selector switch must be in the 30 240 139 position and the voltage regulator must be adjusted to 208V PAGE 28 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 OUTPUT TERMINAL PANEL CONNECTIONS 30 480 277V UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 30 480 277 position as shown in Figure 24 3 PHASE 240 139 3 PHASE 1 PHASE 480 277 PRESS TO LOCK Figure 24 Voltage Selector Switch 30 480 277V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 25 BLUE WHITE GREEN GROUND CONNECTION MUST BE USED ATALL TIMES Figure 25 UVWO Terminal Lugs 30 440 254 Connections Turn the voltage regulator
53. e negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE 4 D gt EE BATTERY Figure 35 Battery Connections When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position ALWAYS make sure that the MPEC Control Switch is in the OFF RESET position when connecting the battery 2 Place a small amount of battery terminal treatment compound around both battery terminals This will ensure a good connection and will help prevent corrosion around the battery terminals NOTICE If the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polarity of the battery when connecting the battery Inadequate battery connections may cause poor starting of the generator and create other malfunctions 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 can cause corrosion and damage the alternator WIRING Inspect the entire generator for bad or worn electrical wiring or connections If any wiring or connections are exposed insulation missing replace wiring immediately PIPING AND HOSE CONNECTION In
54. er may result m ALWAYS know the location of the nearest ps fire extinguisher B ALWAYS know the location of the nearest first aid kit ALWAYS know the location of the nearest phone or keep a phone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency GENERATOR SAFETY DANGER NEVER operate the equipment in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death NEVER disconnect any emergency or safety devices These devices are intended for operator safety Disconnection of these devices can cause severe injury bodily harm or even death Disconnection of any ofthese devices will void all warranties NEVER lubricate components or attempt service on a running machine NOTICE ALWAYS ensure generator is on level ground before use M ALWAYS keep the machine in proper running condition B Fix damage to machine and replace any broken parts immediately M ALWAYS store equipment properly when it is not being used Equipment should be stored in a clean dry location out of the reach of children and unauthorized personnel DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 7 SAFETY INFORMATION ENGINE SAFETY M The engine fuel exhaust gases contain poisonous carbon m
55. f the required load ENGINE This generator unit incorporates an ISUZU BU 4JJ1T diesel engine This engine is designed to meet every performance requirement for the generator Reference Table 2 for engine specifications In keeping with MQ Powers policy of constantly improving its products the specifications quoted herein are subject to change without prior notice ELECTRIC GOVERNOR SYSTEM The electric governor system controls the RPMs of the engine When the engine demand increases or decreases the governor system regulates the frequency variation to 25 EXTENSION CABLES When electric power is to be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to a minimum Use the cable selection chart Table 6 as a guide for selecting proper extension cable size PAGE 16 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 MAJOR COMPONENTS Table 4 Generator Major Components Engine Operating Panel Assembly Battery Assembly Figure 3 Major Components DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PA
56. filter frequently to prevent engine malfunction m NEVER tamper with the factory settings A of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the NS maximum allowable E Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied When a diesel engine operates without sufficient load less than 40 of the rated output it will not operate at its optimum temperature This will allow unburned fuel to accumulate in the exhaust system which can foul the fuel injectors engine valves and exhaust system including turbochargers and reduce the operating performance In order for a diesel engine to operate at peak efficiency it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel Wet stacking does not usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition It can reduce the system performance and increase maintenance Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition This can take several hours to burn off the accumulated unburned fuel State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters must be used on intern
57. iator 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 Table 12 Coolant Capacity Engine and Radiator 3 15 gal 12 liters 2 quarts 1 9 liters Operation in Freezing Weather When operating in freezing weather be certain the proper amount of antifreeze Table 13 has been added Table 13 Anti Freeze Operating Temperatures Vol Freezing Point Anti Boiling Point lt When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 CLEANING THE RADIATOR The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radiator fins with compressed air Cleaning inside the machine is dangerous so clean only with the engine turned off and the negative battery terminal disconnected AIR CLEANER Periodic cleaning replacement is necessary Inspect it in accordance with the ISUZU 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 34 when depressed with the thumb as shown below 10 15 MM DEFL
58. ion manual NOTICE If the engine is cranked while the diagnostic switch is in the position the engine will not be stopped even if the starter switch is turned to the OFF position In such case turn the diagnostic switch to the OFF position DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 49 EXPLANATION OF CODE IN REMARKS COLUMN The following section explains the different symbols and remarks used in the Parts section of this manual Use the help numbers found on the back page of the manual if there are any questions NOTICE The contents and part numbers listed in the parts section are subject to change without notice Multiquip does not guarantee the availability of the parts listed SAMPLE PARTS LIST NO PARTNAME REMARKS 1 12345 22222222 1 INCLUDES ITEMS W 2 WASHER 1 4 IN NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 3 12348 AR MAKE LOCALLY 4 12349 BEARING 1 S N 23458 AND ABOVE NO Column Unique Symbols All items with same unique symbol or gt in the number column belong to the same assembly or kit which is indicated by a note in the Remarks column Duplicate Item Numbers Duplicate numbers indicate multiple part numbers which are in effect for the same general item such as different size saw bl
59. k and replace Check for approximately 17 3 ohms across J amp K on CN1 Turn engine throttle lever to High Low Voltage Output Check wiring and repair Replace if necessary Check wiring and repair Replace if necessary Check load and repair Confirm load requirements and reduce Circuit Breaker Tripped Defective circuit breaker Check and replace Over current Relay actuated Confirm load requirement and replace PAGE 48 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 TROUBLESHOOTING DIAGNOSTIC LAMP The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself Press the diagnostic button Figure 66 on the diagnostic panel to determine if an engine malfunction has occurred DIAGNOSTIC DIAGNOSTIC t ON SWITCH LAMP BUTTON DIAGNOSTIC Y Q y o te O O HicHIDLE abyustT Q SWITCH Figure 66 Diagnostic Panel METHOD OF OPERATION 1 Normally the diagnostic lamp will be dimly lit when the MPEC Control Switch is placed in the MANUAL position 2 f engine trouble occurs the diagnostic lamp will be brightly lit as long as the control switch is left in the manual position 3 The diagnostic lamp will indicate that an engine malfunction has occurred NOTICE For a complete understanding of error codes and troubleshooting procedures refer to the enclosed engine instruct
60. knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required 19 240 120V UVWO Terminal Output Voltages Place the voltage selector switch in the 10 240 120 position as shown in Figure 26 3 PHASE 240 139 3 PHASE 1 PHASE 480 277 240 120 PRESS TO LOCK Figure 26 Voltage Selector Switch 10 240 120V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 27 RED BLUE WHITE GREEN V O O GROUND CONNECTION MUST BE USED AT ALL TIMES Figure 27 UVWO Terminal Lugs 10 240 120V Connections Turn the voltage regulator knob Figure 27 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required NOTICE ALWAYS make sure that the connections to the UVWO terminals are secure and tight The possibility of arcing exists that could cause a fire DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 29 INSPECTION SETUP CIRCUIT BREAKERS To protect the generator from an overload a 3 pole 110 amp main circuit breaker is provided to protect the U V and W Output Terminals from overload In addition two single pole 20 amp GFCI circuit breakers are provided to protect the receptac
61. les from overload Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine LUBRICATION OIL Fill the engine crankcase with lubricating oil through the filler hole but DO NOT overfill Make sure the generator is level and verify that the oil level is maintained between the two notches Figure 28 on the dipstick See Table 11 for proper selection of engine oil ADD FULL OIL LIMIT Figure 28 Engine Oil Dipstick When checking the engine oil be sure to check if the oil is Clean If the oil is not clean drain the oil by removing the oil drain plug and refill with the specified amount of oil as outlined in the ISUZU Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements m API Service Classification CC SC B API Service Classification CC SD API Service Classification CC SE B API Service Classification CC SF Table 11 Recommended Motor Oil OIL SAE 122 50 104 40 86 30 68 20 Mo 10 8 ome Sas 32 0 ONT MT S is m I 4 20 T 22 30 5 40 4 FUEL CHECK Ay DANGER Fuel spillage on a hot engine can cause a fire or explosion If fuel spillage occurs wipe up the spi
62. lled fuel completely to prevent fire hazards NEVER smoke around or near the generator Refilling the Fuel System ONLY properly trained personnel who have read and understand this section should refill the fuel tank system This generator has an internal fuel tank Figure 29 located inside the generator enclosure and may also be equipped with an environmental fuel tank located inside trailer frame ALWAYS fill the fuel tanks with clean fresh 2 diesel fuel DO NOT fill the fuel tanks beyond their capacities Pay attention to the fuel tank capacity when replenishing fuel The fuel tank cap must be closed tightly after filling Handle fuel in a safety container If the container does not have a spout use a funnel Wipe up any spilled fuel immediately EL FUEL TANK Figure 29 Internal Fuel Tank System PAGE 30 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 Refueling Procedure Diesel fuel and its vapors are dangerous to your health and the surrounding environment Avoid skin contact and or inhaling fumes Level Tanks Make sure fuel cells are level with the ground Failure to do so will cause fuel to spill from the tank before reaching full capacity Figure 30 ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank DO NOT fill on unlevel gro
63. ning LED ON The generator s frequency meter Figure 44 should be displaying the 50 cycle output frequency in HERTZ Figure 44 Frequency Meter The generators AC voltmeter Figure 45 will display the generator s output in VOLTS Figure 45 Voltmeter Meter If the voltage is not within the specified tolerance use the voltage adjustment control knob Figure 46 to increase or decrease the desired voltage DECREASE INCREASE N Figure 46 Voltage Adjust Control Knob 9 10 11 12 The ammeter Figure 47 will indicate zero amps with no load applied When a load is applied the ammeter will indicate the amount of current that the load is drawing from the generator Figure 47 Ammeter No Load The engine oil pressure gauge Figure 48 will indicate the oil pressure of the engine Under normal operating conditions the oil pressure is approximately 42 to 71 psi 290 490 kPa Figure 48 Oil Pressure Gauge The coolant temperature gauge Figure 49 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 167 203 F 75 95 C Green Zone Figure 49 Coolant Temperature Gauge The tachometer gauge Figure 50 will indicate the speed of the engine when the generator is operating Under normal operating conditions this speed is approximately 1800 RPM s TACH HOURS 4 fojojo o 4 Figure 50 Engine Tachometer Ga
64. obtain information about motor vehicle safety from http www safecar gov DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 3 DCA45USI2 Generator Proposition 65 Warning 25 2 Reporting Safety 3 Table Of 4 Parts Ordering 5 Safety Information es 6 11 PSCC 12 18 nice 14 gt _ _ 15 General 1 16 Major ComponentS ecos 17 Generator Control 18 Engine Operating Panel 20 21 Output Terminal Panel Familiarization 22 24 Load Appleton 25 Generator 26 How To Read AC Ammeter AC Voltmeter Gauges 27 Output Terminal Panel Connections 28 29 Inspection Setup NN EIE 30 33 Generator Start Up Procedure 34 35 Generator Shut Down Procedures 36 Malin 37 39 Trailer Maintenance 40 43 Trailer Wiring Diagram s 44 Generator Wiring 45 Engine Wiring
65. ocated on the right hand side left from control panel of the generator Lift up on the cover to gain access to receptacles and terminal lugs NOTICE Terminal legs O and Ground are considered bonded grounds 10 AND 30 480 120 OUTPUT TERMINALS NEUTRAL TERMINAL BLACK BLUE WHITE GREEN CIRCUIT BREAKERS FOR GFCI RECEPTACLES 120 VAC 20 AMP GFCI RECEPTACLES RECEPTACLE CIRCUIT BREAKER PANEL AUX POWER RECEPTACLES 120 240V 50 AMPS CIRCUIT BREAKERS FOR CS 6369 TWIST LOCK RECEPTACLES OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel Figure 6 is provided with the following Three 120 240V output receptacles 50 amp B Three Circuit Breakers 50 amps Two 120V receptacles 20 amp M Two GFCI Circuit Breakers 20 amps B Five Output Terminal Lugs U V W O Ground GROUND TERMINAL HARD WIRE HOOKUP PANEL ACCESS DOOR LIFT TO OPEN CS 6369 TWIST LOCK Figure 6 Output Terminal Panel PAGE 22 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles There are two 120 VAC 20 amp GFCI Duplex Nema 5 20R receptacles provided on the output terminal panel These receptacles can be accessed in any voltage selector switch position Each receptacle is protected by a 20 amp circuit breaker These breakers are lo
66. onoxide This gas is colorless and odorless and can cause death if inhaled M The engine of this equipment requires an adequate free flow of cooling air NEVER Operate this equipment in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine M DO NOT place hands or fingers inside engine compartment when engine is running B NEVER operate the engine with heat shields or guards removed M Keep fingers hands hair and clothing away from all moving parts to prevent injury A DO NOT remove the radiator cap while the engine is hot High pressure boiling water will gush out of the radiator and severely W scald any persons in the general area of the generator DO NOT remove the coolant drain plug while the engine is hot Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator DO NOT remove the engine oil drain plug while the engine is hot Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator NEVER touch the hot exhaust manifold Seg muffler or cylinder Allow these parts to cool before servicing equipment NOTICE E NEVER run engine without an air filter or with a dirty air filter Severe engine damage may occur Service air
67. ot be reset the reset button on the over current relay must be pressed The over current relay is located in the control box Figure 12 Over Current Relay PAGE 24 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 LOAD APPLICATION SINGLE PHASE LOAD Always be sure to check the nameplate on the generator and equipment to insure the wattage amperage frequency and voltage requirements are satisfactorily supplied by the generator for operating the equipment Generally the wattage listed on the nameplate of the equipment is its rated output Equipment may require 130 150 more wattage than the rating on the nameplate as the wattage is influenced by the efficiency power factor and starting system of the equipment NOTICE If wattage is not given on the equipment s name plate approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 5 below when connecting loads Table 5 Power Factor By Load Type of Load Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication 10 equipment Common power tools Table 6 Cable Selection 60 Hz Single Phase Operation xm si one ome ems wn _ 26 s s mos zs _ e soon soon aon _
68. other approved device All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes Failure to do so could result in electrical shock or burn causing serious injury or even death Power Cord Cable Safety DANGER NEVER let power cords or cables lay in water B NEVER stand in water while AC power from the generator is being transferred to a load E NEVER use damaged or worn cables or cords when connecting equipment to generator Inspect for cuts in the insulation m NEVER grab or touch live power vos e cord or cable with wet hands The possibility exists of electrical shock SL electrocution or death power POWER ON Make sure power cables are securely connected to the generator s output receptacles Incorrect connections may cause electrical shock and damage to the generator NOTICE M ALWAYS make certain that proper power or extension cord has been selected for the job See Cable Selection Chart in this manual Grounding Safety ALWAYS make sure that electrical circuits are properly grounded to a suitable earth ground ground rod per the National Electrical Code NEC and local codes before operating generator Severe injury or death by electrocution can result from operating an ungrounded generator NEVER use gas piping as an electrical ground PAGE 10 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV
69. own as 2 6000 108 meaning two axles with a total weight capacity of 6000 pounds Suspension Protects the trailer chassis from shocks transmitted through the wheels Types of suspension used are leaf Q flex and air ride Electrical Electrical connectors looms are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle Application Indicates which units can be employed on a particular trailer PAGE 40 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 TRAILER MAINTENANCE BRAKES Trailer brakes should be inspected the first 200 miles of operation This will allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes every 3 000 miles If driving over rough terrain inspect the brakes more frequently Figure 59 displays the major hydraulic surge brake components that will require inspection and maintenance Please inspect these components as required using steps 1 through 8 and Table 15 as listed below Brake Adjustment 1 Place the trailer on jack stands Make sure the jack stands are placed on secure level ground Check the wheel and drum for free rotation 3 Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate 4 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes 5 Adjust the brake
70. re washer stand at least 5 feet 1 5 meters away from the radiator to prevent damage to the fins and tube Figure 58 Radiator Cleaning GENERATOR STORAGE For long term storage of the generator the following is recommended E Drain the fuel tank completely Treat with a fuel stabilizer if necessary Completely drain the oil from the crankcase and refill if necessary with fresh oil E Clean the entire generator internal and external E Cover the generating set and store in a clean dry place Disconnect the battery Make sure engine coolant is at proper level II 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 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 39 TRAILER MAINTENANCE TRAILER MAINTENANCE This section is intended to provide the user with generic trailer service and maintenance information The service and maintenance guidelines referenced in this section refer to a wide range of trailers Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment The definitions below describe some of the major components of a typical trailer that would be used with generator 1 Fuel Cell Provides an adequate amount of fuel for the equipment in use Fuel cells must be empty
71. s Diagrams com E Order Parts To obtain an MQ Account contact your District Sales Manager for more information Print Specification Information uL 1 Goto www multiquip com and click on Use the internet and qualify for 5 Discount Parts to log in and save on Standard orders for all orders which include complete part numbers L Order via Fax Dealers Only Fax your order in and qualify for a 2 Discount All customers are welcome to order parts via Fax on Standard orders for all orders which include Domestic US Customers dial complete part numbers 1 800 6 PARTS 7 800 672 7877 Note Discounts Are Subject To Change Order via Phone Domestic US Dealers Call 1 800 427 1244 a tiquip ceom ee sss Non Dealer Customers Contact your local Multiquip Dealer for International Customers should contact parts or call 800 427 1244 for help in their local Multiquip Representatives for locating a dealer near you Parts Ordering information CEA 4 When ordering parts please supply Dealer Account Number O Specify Preferred Method of Shipment Dealer Name and Address w UPS Fed V DHL Shipping Address if different than billing address Priority One V Truck Return Fax Number Ground B Next Day Applicable Model Number WI Second Third Day Quantity Part
72. se bent or Replace components Locking Brakes Brake drums out of round System lubricated Noisy Brakes Brake components correct Replace and correct Brake lining thickness incorrect or Install new shoes and not adjusted correctly linings Replace rubber parts Enough brake fluid or correct fluid SIN Dragging Brakes DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 41 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 ALWAYS wear safety glasses when aga removing or installing force fitted parts Failure to comply may result in serious injury DO NOT attempt to repair or modify a E 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 Table 16 Tire Wear Troubleshooting will help pinpoint the causes and solutions of tire
73. shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn 6 Adjust rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag 7 Replace the adjusting hole cover and lower the trailer to the ground 8 Repeat steps 1 through 7 on the remaining brakes Hydraulic Surge Brakes Hydraulic surge brakes Figure 59 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 Anchor Post Plate Actuating Pin Hold Down Secondary S Spring gt Primary Shoe Adjuster Spring Adjuster Assembly Figure 59 Hydraulic Brake Components Actuator Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder supplying hydraulic pressure to the trailer brakes Periodically check and test the surge actuator to make sure that it is functioning correctly Never use an undersize actuator Table 15 Hydraulic Brake Troubleshooting Smpom 0 Solution Brake components loo
74. spect all piping oil hose and fuel hose connections for wear and tightness Tighten all hose clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 33 GENERATOR START UP PROCEDURE BEFORE STARTING The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position 1 Place the main G F C I and aux circuit breakers Figure 36 in the OFF position prior to starting the engine MAIN AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER num Figure 36 Main Aux and GFCI Circuit Breakers OFF 2 Make sure the voltage change over board has been configured for the desired output voltage 3 Connect the load to the receptacles or the output terminal lugs as shown in Figure 11 These load connection points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel 4 Tighten terminal nuts securely to prevent load wires from slipping out 5 Close all engine enclosure doors Figure 37 CORRECT INCORRECT Figure 37 Engine Enclosure Doors STARTING 1 Place the voltage selector switch in the desired voltage position Figure 3
75. t 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 61 DO 4 LUG NUTS 6 LUG NUTS NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 18 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically Table 18 Tire Torque Requirements First Pass Second Pass Third Pass FT LBS FT LBS FT LBS 20 25 35 40 50 65 5 LUG NUTS 8 LUG NUTS 20 25 35 40 50 65 PE E aly RU 20 25 50 60 90 120 20 25 50 60 90 120 PNEUMATIC AIR GUN TORQUE WRENCH Figure 61 Wheel Lug Nuts Tightening Sequence NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 43 TRAILER WIRING DIAGRAM TOWING TRAILER SIDE VEHICLE SIDE CONNECTOR CONNECTOR LEFT TAIL LIGHT 1 1 LI i 1 1 1 1 1 1 1 DOUBLE FILAMENT BULB CONNECT TO CHASSIS TAIL LIGHT 1 1 1 1 SINGLE FILAMENT gt BULB GREEN STOP amp TURN LEFT LICENSE TAIL LIGHT i t DOUBLE FILAMENT A BULB FLAT 4 PIN
76. t receptacles CS 6369 50 M Three auxiliary circuit breakers 50 Two 120V output receptacles GFCI 20 Two GFCI circuit breakers 20A E Five output terminal lugs 30 power OPEN DELTA EXCITATION SYSTEM This generator is equipped with the state of the art Open Delta excitation system The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section There are four connections of the open delta A B C and D During steady state loads the power from the voltage regulator is supplied from the parallel connections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section When a heavy load such as a motor starting or a short circuit occurs the automatic voltage regulator AVR switches the configuration of the open delta to the series connection of B to C This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads The connections of the AVR to the AC output windings are for sensing only No power is required from these windings The open delta design provides virtually unlimited excitation current offering maximum motor starting capabilities The excitation does not have a fixed ceiling and responds according the demands o
77. th such units and Multiquip neither assumes nor 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 Effective February 22 2006 PAGE 80 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NOTES DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL 0 01 12 11 PAGE 81 OPERATION AND PARTS MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave Carson CA 90746 Contact O multiquip com Service Department 800 421 1244 310 537 3700 Technical Assistance 800 478 1244 MEXICO MQ Cipsa Tel 800 421 1244 Fax 800 537 3927 Fax 310 537 4259 Fax 310 943 2238 MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537 3700 Fax 310 637 3284 Warranty Department 800 421 1244 Fax 310 537 1173 310 537 3700 UNITED KINGDOM Multiquip UK Limited Head Office Carr Fed Mexico Puebla KM 126 5 Momoxpan Cholula Puebla 72760 Mexico Contact pmastretta cipsa com mx Tel 52 222 225 9900 Fax 52 222 285 0420 Tel 0161 339 2223 Fax 0161 339 3226
78. to the engine Make sure the generator is level The oil level must be between the two notches on the dipstick as shown in Figure 28 Replacing Oil Filter i Remove the old oil filter IM Apply a film of oil to the gasket on the new oil filter E 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 E 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 E Tighten both cocks and replace the overflow tank E Replace with coolant as recommended by the engine manufacturer Close radiator cap tightly Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed DO NOT clean radiator core with any objects such as a screwdriver Allow engine to cool when flushing out IM radiator Flushing the radiator while hot could cause serious burns from water or steam RADIATOR CLEANING The radiator Figure 58 should be sprayed cleaned with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling fins or tube When using a high pressu
79. uge DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 35 GENERATOR SHUT DOWN PROCEDURES 13 Place the main GFCI and aux circuit breakers in the ON position Figure 51 MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Gi Figure 51 Main Aux and Circuit Breakers ON 14 Observe the generators ammeter Figure 52 and verify it reads the anticipated amount of current with respect to the load The ammeter will only display a current reading if a load is in use Figure 52 9Ammeter Load 15 The generator will run until manually stopped or an abnormal condition occurs NEVER stop the engine suddenly except in an emergency NORMAL SHUTDOWN PROCEDURE To shutdown the generator use the following procedure 1 Place both the MAIN GFCI and LOAD circuit breakers as shown in Figure 53 to the OFF position MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Figure 53 Main and Load Circuit Breakers OFF 2 Place the engine speed switch Figure 54 in the LOW down position Q LOW DOWN Figure 54 Engine Speed Switch Low Let the engine cool by running it at low speed for 3 5 minutes with no load applied 4 Place the MPEC Control Switch Figure 55 to the OFF RESET position AUTO MANUAL OFF RESET Figure 55 MPEC Control Switch Off Reset 5 Verify that all status LEDs on the
80. uge Figure 18 This process can be repeated for terminals V and W V Figure 17 AC Ammeter Change Over Switch Figure 18 AC Ammeter Amp Reading on U Lug NOTICE The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load andin use DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL 0 01 12 11 PAGE 27 OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES Various output voltages can be obtained using the UVWO output terminal lugs The voltages at the terminals are dependent on the position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob Remember the voltage selector switch determines the range of the output voltage The voltage regulator VR allows the user to increase or decrease the selected voltage 30 240 139 UVWO Terminal Output Voltages 1 Place the voltage selector switch in the 30 240 139 position as shown in Figure 19 3 PHASE 240 139 1 PHASE 240 120 Figure 19 Voltage Selector Switch 30 240 139 Position 2 Connect the load wires to the UVWO terminals as shown in Figure Figure 20 BLUE WHITE GREEN GROUND CONNECTION MUST BE USED ATALL TIMES Figure 20 UVWO Terminal Lugs 30 240 139V Connections Turn the voltage regulator knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator a
81. unction The Control Box is equipped with the following major components I Over Current Relay B Automatic Voltage Regulator AVR E Starter Relay B Current Transformer E Voltage Selector Switch Main Circuit Breaker NOTICE Remember the overcurrent relay monitors the current flowing from the U V and W Output Terminal Lugs to the load In the event of a short circuit or over current condition it will automatically trip the 110 amp main breaker To restore power to the Output Terminal Panel press the reset button on the overcurrent relay and place the main circuit breaker in the closed position ON PAGE 18 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 NOTES DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 19 ENGINE OPERATING PANEL Figure 5 Engine Operating Panel PAGE 20 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 ENGINE OPERATING PANEL The definitions below describe the controls and functions of the Engine Operating Panel Figure 5 1 10 11 12 Panel Light Normally used in dark areas or at night time When activated panel lights will illuminate When the generator is not in use be sure to turn the panel light switch to the OFF position Panel Light Switch When activated will t
82. und Figure 30 Only Fill on Level Ground NOTICE ONLY use 2 diesel fuel when refueling INSPECTION SETUP 2 Open cabinet doors on the right side of the generator from generator control panel position Remove fuel cap and fill tank Figure 31 Figure 31 Fueling the Generator NEVER overfill fuel tank It is important to read the fuel gauge when filling trailer fuel tank DO NOT wait for fuel to rise in filler neck Figure 32 FUEL GAUGE LOCATED ON CONTROL PANEL MA LM Oh hl llla thls Figure 32 Full Fuel Tank DO NOT OVERFILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 33 Fuel EXPANDS we 2 When Heated Figure 33 Fuel Expansion DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 PAGE 31 INSPECTION SETUP COOLANT ANTIFREEZE SUMMER COOLANT WATER ISUZU recommends ISUZU antifreeze summer coolant for use in their engines which can be purchased in concentrate and mixed with 5096 demineralized water or pre diluted See the ISUZU Engine Owner s Manual for further details If adding coolant antifreeze mix to the ja radiator DO NOT remove the radiator cap until the unit has completely cooled The possibility of hot coolant exists which can cause severe burns Day to day addition of coolant is done from the recovery tank When adding coolantto the radiator DO NOT remove the rad
83. urn on control panel light Oil Pressure Gauge During normal operation this gauge should read between 42 71 psi 290 490 kPa When starting the generator the oil pressure may read a little higher but after the engine warms up the oil pressure should return to the correct pressure range Water Temperature Gauge During normal operation this gauge be should read between 167 2032 75 95 C 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 Fuel Gauge Indicates amount of diesel fuel available 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 Preheat Lamp As the engine cranks this lamp will illuminate to indicate automatic preheating of the engine glow plugs When the lamp turns off this indicates that the preheat cycle is complte and the engine will start automatically Warning Lamp This lamp will illuminate when a critical engine fault has occured Fuel Leak Detected Alarm Lamp This lamp will illuminate when fluids in the containment have reached high levels Engine Speed Switch This switch controls the speed of the engine low high Auto START STOP Engine Controller
84. wear problems Table 16 Tire Wear Troubleshooting Center Wear Over inflation Adjust to particular load per tire manufacturer Edge Wear Under inflation Adjust pressure to particular load per tire manufacturer Make sure load does not Loss of camber Side Wear exceed axle rating or overloading Align wheels Cupping Out of balance Check bearing adjustment 7 and balance tires Flat Spots Wheel lockup and Avoid sudden stops when LV tire skidding possible and adjust brakes Suspension The leaf suspension springs and associated components Figure 60 should be visually inspected every 6 000 miles for signs of excessive wear elongation of bolt holes and loosening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 17 SHACKLE SUPPORT BRACKET IS WELDED TO FRAM SHACKLE NUTS AXLE HANGER SUPPORT BRACKET IS WELDED FRAM SHACKLE BOLTS LEAF FRONT U BOLT HANGER BOLT LOCKING TIE PLATE NUT Figure 60 Major Suspension Components Table 17 Suspension Torque Requirements Torque Fitts Shackle Bolt Snug fit only Parts must freely Locking nuts or cotter pins are Spring Eye Bolt provided to retain nut bolt assembly Shoulder Type Min 30 Max 50 Shackle Bolt PAGE 42 DCA45USI2 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 01 12 11 TRAILER MAINTENANCE Lug Nu
85. when transporting equipment Braking System System employed in stopping the trailer Typical braking systems are electric surge hydraulic hydraulic surge and air GVWR Gross Vehicle Weight Rating GVWR is the maximum number of pounds the trailer can carry including the fuel cell empty Frame Length Measurement is from the ball hitch to the rear bumper reflector Frame Width Measurement is from fender to fender Jack Stand Trailer support device with maximum pound requirement from the tongue of the trailer Coupler Type of hitch used on the trailer for towing 10 11 12 13 14 15 16 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 Tire Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc Wheel Hub The wheel hub is connected to the trailer s axle Tire Rim Tires mounted on a tire rim The tire rim must match the size of the tire Lug Nuts Used to secure the wheel to the wheel hub Always use a torque wrench to tighten down the lug nuts See Table 18 and FigureFigure 61 for lug nut tightening and sequence Axle Indicates the maximum weight the axle can support in pounds and the diameter of the axle expressed in inches Please note that some trailers have a double axle This will be sh
86. zation 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 condition in the original Multiquip package if any and with Multiquip part numbers clearly marked 6 The following items are not returnable 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 Special order items Electrical components Paint chemicals and lubricants Decals and paper products Items purchased in kits 7 The sender will be notified of any material received that is not acceptable 8 Such material will be held for five 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 9 Credit on returned parts will be issued at dealer net price at time of the original purchase less a 15 restocking charge 10 In cases where an item is accepted for 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

Multiquip DCA45USI2 Portable Generator User Manual

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