MQ Power ULTRA-SILENT DCA-45USI Series Guide

PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
PARTS LIST NO. M1871400004B
Revision #2 (04/22/05)
DCA-45USI
ULTRA-SILENTTM SERIES
GENERATOR
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
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PAGE 2 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
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PAGE 4 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
TABLE OF CONTENTS
MQ POWER DCA-45USIMQ POWER DCA-45USI
MQ POWER DCA-45USIMQ POWER DCA-45USI
MQ POWER DCA-45USI
AC GENERAAC GENERA
AC GENERAAC GENERA
AC GENERATORTOR
TORTOR
TOR
Here's How To Get Help ............................................. 3
Table Of Contents ....................................................... 4
Parts Ordering Procedures ........................................ 5
DCA-45USI Specifications .......................................... 6
Dimensions.................................................................. 7
Safety Message Alert Symbols ............................... 8-9
Rules for Safe Operation .....................................10-13
Installation ............................................................14-15
Towing Safety Precautions ....................................... 16
Trailer Specifications................................................. 17
Generator Decals.................................................18-19
General Information .................................................. 20
Major Components ................................................... 21
Generator Control Panel........................................... 22
Engine Operating Panel............................................ 23
Output Terminal Panel Familiarization.................24-26
Load Application........................................................ 27
Generator Outputs...............................................28-29
Gauge Reading......................................................... 30
Output Terminal Panel Connections....................30-31
Pre-setup..............................................................32-35
Generator Start-up Procedure............................36-38
Generator Shut-down Procedure............................. 39
Maintenance.........................................................40-41
Trailer Brakes Maintenance...................................... 42
Trailer Maintenance .............................................43-44
Trailer Wiring Diagram .............................................. 45
Engine Wiring Diagram ........................................46-47
Generator Wiring Diagram ....................................... 48
Generator Troubleshooting....................................... 49
Explanation of Codes in Remarks Column.............. 50
Suggested Spare Parts ............................................ 51
Specificationand partnumber
are subject to change without
notice.
NOTE
COMPONENT DRACOMPONENT DRA
COMPONENT DRACOMPONENT DRA
COMPONENT DRAWINGSWINGS
WINGSWINGS
WINGS
Generator Assembly............................................52-53
Control Box Assembly..........................................54-57
Engine & Radiator Assembly...............................58-61
Output Terminal Assembly...................................62-63
Battery Assembly .................................................64-65
Muffler Assembly .................................................66-67
Fuel Tank Assembly .............................................68-69
Enclosure Assembly ............................................70-75
Rubber Seal Assembly ........................................76-77
Nameplate and Decals ........................................78-79
Terms and Condition of Sale — Parts...................... 80
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PAGE 6 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — SPECIFICATIONS
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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 7
DCA-45USI — DIMENSIONS (SIDE AND FRONT)
Figure 1. Dimensions
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PAGE 8 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — SAFETY MESSAGE ALERT SYMBOLS
This Owner's Manual has been
developed to provide complete
instructions for the safe and efficient
operation of the MQ Power
Model
DCA45USI ULTRA-SILENT™
GENERATOR.
Before using this GENERATOR, ensure that the operating
individual has read and understands all instructions in this
manual.
Safetyprecautions should befollowed at alltimes when operating
this equipment. Failure to read and understand the Safety
Messages and Operating Instructions could result in injury to
yourself and others.
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
theoperator,and are precededbyone ofthree words: DANGER,
WARNING, or CAUTION.
DANGER: You WILL be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
WARNING: You CAN be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
CAUTION: You CAN be injured if you
DO NOT follow directions.
HAZARD SYMBOLS
Engine exhaust gases contain poisonous
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined
area or enclosed structure that does not
provide ample free flow air.
Potential hazards associated with trowel operation will be
referenced with "
Hazard Symbols " which appear throughout
this manual, and will be referenced in conjunction with Safety
"
Message Alert Symbols ".
Diesel fuel is extremely flammable, and its
vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use fuel as a cleaning agent.
Burn Hazards
Enginecomponentscangenerateextremeheat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. NEVER operate the engine with
heat shields or heat guards removed.
Rotating Parts
NEVER operate equipment with covers, or
guards removed. Keep
fingers , hands , hair
and clothing away from all moving parts to
prevent injury.
Explosive Fuel
Lethal Exhaust Gases
NOTE
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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 9
Accidental Starting
ALWAYS place the engine ON/OFF switch
in the OFF position, when the trowel is not
in use.
Over Speed Conditions
NEVER tamperwith the factory settings ofthe
engine governor or settings. Personal injury
and damage to the engine or equipment can
result if operating in speed ranges above
maximum allowable.
Respiratory Hazard
ALWAYS wear approved respiratory protection.
ALWAYS wear approved eye and hearing
protection.
Sight and Hearing hazard
Equipment Damage Messages
Other important messages are provided throughout this manual
to help prevent damage to your trowel, other property, or the
surrounding environment.
This generator , other property, or
the surrounding environment could
be damaged if you do not follow
instructions.
NOTE
DCA-45USI — SAFETY MESSAGE ALERT SYMBOLS
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PAGE 10 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — RULES FOR SAFE OPERATION
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :
Failuretofollowinstructionsinthismanualmay
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is
forindustrial use only.
The following safety guidelines should always be used when
operating the DCA-45USI Generator:
GENERAL SAFETY
■ DONOToperateorservicethisequipmentbefore
readingthis entire manual.
■ Thisequipment shouldnotbe operated bypersons under 18
yearsof age.
■ NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel-
toedbootsand otherprotectivedevices required
bythejob.
■ NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■ NEVER operate this equipment under the
influenceordrugs or alcohol.
■ NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment.Damage to
theequipment and/or injurytouser may result.
■ Manufacturedoesnotassumeresponsibilityfor anyaccident
dueto equipment modifications.
■ Whenever necessary, replace nameplate, operation and
safetydecals whenthey become difficultread.
■ ALWAYS check the machine for loosened threads or bolts
beforestarting.
■ NEVER operatethegenerator inan explosiveatmosphere or
nearcombustible materials. An explosion or firecouldresult
causing severe
bodily harm or even death.
■ High Temperatures – Allow the engine to cool before
performingservice andmaintenancefunctions. Contactwith
hot! components can cause seriousburns.
■ The engine of this
generator requires an
adequate free flow of
cooling air.
NEVER
operatethegenerator in
anyenclosed or narrow
area where free flow of
theairisrestricted.Ifthe
airflowisrestricteditwill
cause serious damage
to the generator or
engineandmaycauseinjury topeople.Thegenerator engine
gives offDEADLY carbon monoxidegas.
■ ALWAYS makesure generator isproperlygrounded.
■ NEVER usegas piping as an electrical ground.
■ DO NOT place hands or fingers inside generator engine
compartmentwhenengineis running.
■ ALWAYS makesuregeneratorinstallationisaccordancewith
national and local electrical codes .
■ ALWAYS have a qualified electrician perform the generator
wiringinstallation.
■ NEVER powercables or cords lay in wate r.
■ NEVER stand in water whileACpowerfromthegenerator
isbeing transfer to a load.
■ NEVER use a defective or frayed power cable. Check the
cablefor cuts in the insulation.
■ NEVERuseaextensioncordthatisfrayedordamagedwhere
theinsulation has been cut.
■ ALWAYS makecertainthat proper extension cordhasbeen
selectedforthe job SeeTable5.
■ The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits.
Turn all circuit breakers OFF before
performing maintenanceon the generator.
■ NEVERtouchthehotexhaustmanifold,
muffler or cylinder. Allow these parts to
coolbeforeservicingengineorgenerator.
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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 11
DCA-45USI — RULES FOR SAFE OPERATION
■ Backfeedto a utilitysystemcan cause electrocution andor
propertydamage. DONOTconnecttoanybuilding'selectrical
system except through an approved device or after building
main switch is opened. ALWAYS have alicensed electrician
performthe installation
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficienttimefortheengineandgenerator
to cool before performing maintenance.
Radiator
1. RadiatorCap-Removingtheradiatorcapwhiletheengine
is hot will result in high pressurized, boiling water to gush
outoftheradiator, causing severescaldingtoanypersons
inthegeneralareaof the generator.
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush out
ofthecoolantdrainplug,thereforecausing severescalding
to any persons in the general area of the generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush out
of the oil drain plug, therefore causing severe scalding to
any persons in the general area of the generator.
DANGERDANGER
DANGERDANGER
DANGER
:
DANGERDANGER
DANGERDANGER
DANGER :
■ NEVER touch output terminals during operation. This is
extremely dangerous. ALWAYS stop the machine and
placethe circuitbreakerinthe “OFF”positionwhen contact
with the output terminals is required. There exists the
possibility of electrocution, electrical shock or burn,
which can cause severe bodily harm or even death !
Never use damaged or worn cables when
connecting equipment to the generator.
Makesurepower
connecting
cables are
securely connected to the
generator’s output terminals,
insufficient tightening of the
terminal connections may cause
damage to the generator and
electrical shock.
.
Maintenance Safety
■ NEVER lubricate components or attempt
serviceon a running machine.
■ ALWAYS allow the machine a proper
amountof time tocool before servicing.
■ Keepthe machinery inproper running condition.
■ Fixdamagetothemachine immediatelyand alwaysreplace
brokenparts.
■ ALWAYS make sure that electrical circuits are properly
grounded perthe NationalElectrical Code (NEC)andlocal
codesbeforeoperatinggenerator.Severe
injury or death! by
electrocution can result from operating an ungrounded
generator.
■ ALWAYS be sure the operator is familiar with proper safety
precautionsand operations techniques beforeusing generator.
■ ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children.
■ ALWAYS read, understand, and follow
procedures in Operator’s Manual before
attempting to operate equipment.
DANGERDANGER
DANGERDANGER
DANGER :
DANGERDANGER
DANGERDANGER
DANGER :
POWER
CORD
(POWER ON)
WET
HANDS
NEVER grab or
touch a live
power cord with
wet hands , the
possibility exists
ofelectricalshock,electrocution,andeven
death!
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PAGE 12 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — RULES FOR SAFE OPERATION
■ NEVERrunenginewithoutair filter.Severeenginedamage
may occur.
■ ALWAYS service air cleaner frequently to prevent engine
malfunction.
■ ALWAYS disconnect the negative battery terminal before
performing service on the generator.
■ ALWAYS besurethe operatorisfamiliarwithpropersafety
precautions when operating the generator set.
■ ALWAYS store equipment properly when not in use.
■ DO NOT leave the generator runninginthe manual mode
unattended.
■ DO NOT allow unauthorized people to operate this
equipment.
■ ALWAYS read, understand, and follow procedures in
Operator’sManualbeforeattemptingtooperateequipment.
■ Refer to the Isuzu Engine Owner's Manual for engine
technical questions or information.
Battery
The battery contains acids that can cause injury to the eyes
andskin.To avoideye irritation, always wearsafetyglasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
2. DO NOT expose the battery to
open flames, sparks, cigarettes
etc. The battery contains
combustible gases and liquids. If
these gases and liquids come in
contact with a flame or spark, an
explosion could occur.
3. ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. ALWAYS keepbatterychargingandcablesingoodworking
condition. Repair or replace all worn cables.
5. ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin , rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contactwithyoureyes,rinseeyes immediatelywithplenty
of water, then contact the nearest doctor or hospital, and
seek medical attention.
Pay close attention to
ventilationwhenoperating
the generator inside
tunnels and caves. The
engineexhaustcontainsnoxiouselements.
Engine exhaust must be routed to a
ventilated area.
DANGER:DANGER:
DANGER:DANGER:
DANGER:
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)providesguidelinesforpropergroundingandspecifies
that the cable ground shall be connected to the grounding
system of the building as close to the point of cable entry
as practical.
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the UVWO output terminals.
Transporting
■ ALWAYS shutdown engine before transporting.
■ Tighten both fuel tank caps securely.
■ If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See next page “ Towing Safety Precautions ” for
basic towing techniques.
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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 13
Emergencies
■ ALWAYS knowthelocationofthenearest fireextinguisher .
■ ALWAYS knowthe locationof thenearest and first aid kit .
■ In emergencies 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.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
Thefollowing list ofsuggestionsshouldbe used whentowing
yourgenerator:
■ Make sure the hitch and coupling of the towing vehicle
areratedequal to,orgreaterthanthe trailer"gross vehicle
weight rating" (GVWR) of 6,000 lbs.
■ ALWAYS inspectthehitchand couplingforwear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■ Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
■ ALWAYS makesurethetrailerisequippedwitha"Safety
Chain".
■ ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ The maximum speed for highway towing is 55 MPH
unlessposted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■ Place chockblocks underneathwheeltopreventrolling,
whileparked.
■ Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
■ Avoidsudden stopsand starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
Towing Safety Precautions
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION:
Conform to Department ofTransportation
(DOT) Safety Towing Regulations before
towinggenerator.
■ Avoid sharp turns.
■ Trailer should be adjusted to a level position at all times
whentowing.
■ Raise and lock trailer wheel stand in up position when
transporting.
■ DOT Requirements include the following:
DCA-45USI — RULES FOR SAFE OPERATION
z Connect and test electric brake operation.
z Secure portable power cables in cable tray with
tie wraps.
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PAGE 14 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
Figure 2. Typical Generator Grounding Application
DCA-45USI — INSTALLATION
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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 15
Outdoor Installation
Installthegenerator in a clear area. Make surethegenerator
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
oftheinsulationandwill resultinshortcircuitsand grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :
Pay close attention to ventilation when
operatingthegenerator inside tunnels and
caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area.
Indoor Installation
Exhaustgasesfromdieselengines areextremelypoisonous.
Whenever an engine is installed indoors the exhaust fumes
mustbeventedto the outside.Theengine shouldbeinstalled
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
Mounting
Thegeneratormust be mounted on a solidfoundation(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
resistdamagetothe 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.
Article250(Grounding)oftheNationalElectricalCode(NEC)
provides guide lines for proper grounding and specifies that
thecable groundshallbeconnectedto thegroundingsystem
of the building as close to the point of cable entry as
practical.
NEC articles 250-64(b) and 250-66 set the following
groundingrequirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
thegeneratorandtightenthenutfully.Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimumof8ft.intotheground.
Whenconnectingthegenerator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.
DCA-45USI — INSTALLATION
NOTE
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PAGE 16 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure3)thatsupports the generatorand the towing vehicle
are in good operating condition and both units are
mechanically sound.
Thefollowing list ofsuggestionsshouldbe used whentowing
yourgenerator:
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :
Towing Safety Precautions
Checkwithyour local county or state safety
towing regulations before towing your
generator.
■ Make sure the hitch and coupling of the towing vehicle
areratedequal to,orgreater thanthetrailer"grossvehicle
weightrating" (GVWR).
■ ALWAYS inspectthe hitch and coupling forwear.NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■ Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
■ ALWAYS makesurethetraileris equipped with a "Safety
Chain".
DCA-45USI —TOWING SAFETY PRECAUTIONS
■ ALWAYS attachtrailer’ssafetychain to bumperof towing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ The maximum speed for highway towing is 55 MPH
unlesspostedotherwise. Recommendedoff-roadtowing
is not to exceed 15 MPH or less depending on type of
terrain.
■ Place chocked blocks underneath wheel to prevent
rolling, while parked.
■ Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
■ Use the trailer’s hand winch to adjust the height of the
trailer,theninsertlockingpinto lockwheelstandinplace,
whileparked.
■ Avoidsuddenstopsandstarts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■ Avoid sharp turns to prevent rolling.
■ Remove wheel stand when transporting.
■ DO NOT transport generator with fuel in tank.
Figure 3. Generator with Trailer
Generatorw/trailer illustrationis
forreferenceonly.
NOTE
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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 17
Explanation of Chart:
This section is to provide the user with trailer service and
maintenance information. The service and maintenance
guidelines referenced in this section apply a wide range of
trailers. Remember periodic inspection of the trailer will en-
sure safe towing of the equipment and will prevent damage
to the equipment and personal injury.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
 Brakes
 Tires
 LugNutTorquing
 Suspension
 Electrical
 BrakeTroubleshootingTables
Use the following definitions when readingTable 2.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipmentinuse. Fuelcellsmustbe empty when trans-
portingequipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
4. Frame Length - Measurement is from the ball hitch to
therear bumper (reflector).
DCA-45USI —TRAILER SPECIFICATIONS
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION
:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
5. FrameWidth - Measurement is from fender to fender
6. Jack Stand - Trailersupportdevicewith maximumpound
requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply,etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Alwaysuseatorquewrenchtotightendownthelugnuts.
See Table 17 and Figure 67 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 2). Please note that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
14. Suspension - Protects the trailer chassis from shocks
transmittedthroughthewheels.Typesofsuspensionused
are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
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PAGE 18 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
TheDCA-45USI generator is equipped with a number of safetydecals. Thesedecals areprovidedfor operator safetyand
maintenance information. The illustration below and on the preceding page show the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-45USI — GENERATOR DECALS
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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 19
DCA-45USI — GENERATOR DECALS
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PAGE 20 — DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05)
DCA-45USI — GENERAL INFORMATION
DCA-45USI FAMILIARIZATION
Generator
The MQ Power Model DCA-45USI (Figure 4) is a 36 kW
generator thatisdesignedasahighqualityportable(requires
atrailerfortransport)powersourcefortelecomsites,lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.
Engine Operating Panel
The“EngineOperatingPanel”is providedwith the following:
z Tachometer
z WaterTemperatureGauge/Alarm Lamp
z Oil Pressure Gauge/ Alarm Lamp
z ChargingAmmeterGauge
z Pre-HeatLamp
z Panel Light
z Panel Light Switch
z Ignition/Preheat Switch
z FuelGauge
z Fuel Filter Water Level Alarm Lamp
Generator Control Panel
The“GeneratorControlPanel”isprovidedwith the following:
z Output Voltage Adjustment Knob
z Frequency Meter (Hz)
z AC Ammeter (Amps)
z AC Voltmeter (Volts)
z AmmeterChange-Over Switch
z Voltmeter Change-Over Switch
z Voltage Regulator
z 3-Pole, 110 amp Main Circuit Breaker
Output Terminal Panel
The “OutputTerminal Panel” is provided with the following:
z Three120/240Voutputreceptacles(CS-6369),50amps
z Three auxilliary circuit breakers, @50 amps
z Two 125 VAC output receptacles, (GFCI), 20 amps
z Two GFCI circuit breakers @ 20amps
z Five output terminal lugs (3Ø power)
Control Box
The “Control Box” is provided with the following:
z AutomaticVoltage Regulator
z CurrentTransformer
z Emergency Relay
z Over-CurrentRelay
OpenDelta Excitation System
The DCA-45USI generator is equipped with the state of the art
"
Open-Delta "excitationsystem.Theopen deltasystemconsistof
an electrically independent winding wound among stationary
windingsoftheACoutputsection.
TherearefourconnectionsoftheopendeltaA,B,CandD.During
steadystateloads,thepowerfromthevoltageregulatorissupplied
fromtheparallelconnectionsofAtoB,AtoD,andCtoD.Thesethree
phasesofthevoltageinputtothevoltageregulatorarethenrectified
andaretheexcitationcurrentfortheexcitersection.
Whenaheavyload,suchasamotorstartingorashortcircuitoccurs,
theautomaticvoltageregulator(AVR)switchestheconfigurationof
theopendeltatotheseriesconnectionofBtoC.Thishastheeffect
ofaddingthevoltagesofeachphasetoprovidehigherexcitationto
the exciter section and thus better voltage response during the
applicationofheavyloads.
The connections of the AVR to the AC output windings are for
sensingonly.Nopowerisrequiredfrom thesewindings.
Theopen-deltadesignprovidesvirtuallyunlimitedexcitationcurrent,
offering maximum motor starting capabilities.The excitation does
nothavea"
fixedceiling "andrespondsaccordingthedemandsof
therequiredload.
Engine
TheDCA-45USIispoweredbya4cycle,watercooled,turbocharged
Isuzu BB-4JG1T
diesel engine.This engine is designed to meet
everyperformancerequirementforthegenerator.ReferenceTable1
forenginespecifications.
InkeepingwithMQPower'spolicyofconstantlyimprovingitsproducts,
thespecificationsquotedhereinaresubjecttochangewithoutprior
notice.
ThebasiccontrolsandindicatorsfortheDCA-45USIgeneratorare
addressedonthefollowingpages.
Mechanical Governor System
ThemechanicalgovernorsystemcontroltheRPMoftheengine.
Whentheenginedemandsincreaseordecrease,themechanical
governorsystemregulatesthefrequencyvariationtowithin±.5%.
Theelectronicgovernoroptiondecreasesthefrequencyvariation
towithin±0.25%.
Extension Cables
When electric power is to be provided to various tools or loads at
some distance from the generator, extension cords are normally
used. Cables should be sized to allow for distance in length and
amperagesothatthevoltagedropbetweenthegeneratorandpoint
of use (load) is held to a minimum.Use the cable selection chart
(Table5 )as a guideforselectingproperextensioncablesize.
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DCA-45USI — OPERATION AND PARTS MANUAL (STD) — REV. #2 (04/22/05) — PAGE 21
DCA-45USI — MAJOR COMPONENTS
Figure 4. Major Components
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