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Multiquip dca45ssiu4 manual Operation and Parts Manual, PARTS LIST NO. M1870301104

Models: dca45ssiu4

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Operation and Parts Manual

Whisperwatt™ Series

MODEL dca45ssiu4

60hz generator

(isuzu 4JJ1t DIESEL ENGINE)

PARTS LIST NO. M1870301104

Revision #1 (10/24/13)

To find the latest revision of this publication, visit our website at: www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Page 1

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Multiquip dca45ssiu4 manual Operation and Parts Manual, This Manual Must Accompany The Equipment At All Times

Contents

Operation and Parts Manual PARTS LIST NO. M1870301104THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES MODEL dca45ssiu4Diesel engine exhaust and some of proposition 65 warningReporting Safety Defects DCA45SSIU4 Generator Table of ContentsComponent Drawings 6-11When ordering parts, please supply Parts Ordering Procedures Ordering parts has never been easierchoose from three easy options best Deal! Order via Internet Dealers onlySaFetY meSSageS Safety InformationSaFetY SYmbolS DANGERGENERATOR SAFETy general SaFetYSafety Information „ never disconnect any emergency or safety devicesSafety Information ENGINE SAFETyDANGER TOWING SAFETy FUel SaFetYSafety Information DANGERpower Cord/Cable Safety eleCtrICal SaFetYgrounding Safety BATTERy SAFETyemISSIonS InFormatIon envIronmental SaFetY/DeCommISSIonIngemission Control label Safety InformationTable 1. Generator Specifications SpecificationsModel PhaseTable 3. Dimensions DimensionsFigure 1. Dimensions Dimension in. mmFigure 2. Typical Generator Grounding Application InstallationIndoor Installation Outdoor InstallationMounting Generator GroundingGenerator General InformationEngine Operating Panel Generator Control PanelTable 4. Generator Major Components Major ComponentsITEM NO „„Starter Relay „„Current Transformer „„Voltage Selector Switch Generator Control PanelThe Control Box is equipped with the following major components „„Over-Current Relay „„Automatic Voltage Regulator AVRPage OFF/RESET ENGINE OPERATING PANELHIGH COOLANT TEMPERATURE Figure 5. Engine Operating Panel8. Fuel Gauge - Indicates amount of diesel fuel available ENGINE OPERATING PANELOutput Terminal Familiarization OUTPUT TERMINAL PANEL FAMILIARIZATIONOutput Terminal Panel Terminal legs “O” and “Ground” are considered bonded grounds120 VAC GFCI Receptacles Removing the Plastic Face Plate Hard Wire Hookup PanelOUTPUT TERMINAL PANEL FAMILIARIZATION Figure 7. G.F.C.I. ReceptacleOver Current Relay Connecting LoadsFigure 12. Over Current Relay Figure 11. Connecting Loads OUTPUT TERMINAL PANEL FAMILIARIZATIONThree Phase Load Single Phase LoadTable 5. Power Factor By Load Load ApplicationVoltage Selector Switch Locking Button Voltage Selector SwitchGENERATOR OUTPUTS Generator Output VoltagesGENERATOR OUTPUTS/gauge reading How to Read the Output Terminal GaugeReading Voltage Reading AmperageUVWO Terminal Output Voltages OUTPUT TERMINAL PANEL CONNECTIONS3Ø-240/139 UVWO Terminal Output Voltages 3Ø-208V/1Ø-120V UVWO Terminal Output Voltages1Ø-240/120V UVWO Terminal Output Voltages 3Ø-480/277V UVWO Terminal Output VoltagesFigure 24. Voltage Selector Switch 3Ø-480/277V Position Figure 26. Voltage Selector Switch 1Ø-240/120V PositionCircuit Breakers inspection/SETUPLubrication Oil Fuel CheckONLY use #2 diesel fuel when refueling Refueling Procedureinspection/SETUP Figure 30. Only Fill on Level GroundAir Cleaner Cleaning the RadiatorTable 13. Anti-Freeze Operating Temperatures Coolant Antifreeze/Summer Coolant/ WaterBattery Cable Installation BatteryWiring AlternatorBefore Starting GENERATOR START-UP PROCEDUREStarting Starting ManualFigure 42. Engine Speed Switch High GENERATOR START-UP PROCEDUREFigure 48. Coolant Temperature Gauge Figure 45. Voltage Adjust Control KnobNormal Shutdown Procedure GENERATOR SHUT-DOWN PROCEDURESEmergency Shutdown Procedure OFF/RESET positionAir Cleaner with Dust Indicator MaintenanceGeneral Inspection Air CleanerFuel Addition Cleaning Inside the Fuel TankRemoving Water from the Fuel Tank Fuel Tank InspectionCheck Oil Level Radiator CleaningReplacing Oil Filter Flushing Out Radiator and Replacing CoolantTrailer Maintenance Trailer MaintenanceBrakes Brake AdjustmentHydraulic Surge Brakes ActuatorTire Wear/Inflation Tires/Wheels/Lug NutsSuspension Trailer MaintenanceTrailer Maintenance Lug Nut Torque RequirementsFigure 60. Wheel Lug Nuts Tightening Sequence Table 18. Tire Torque RequirementsFigure 61. Trailer/Towing Vehicle Wiring Diagram Trailer Wiring DiagramFigure 62. Generator Wiring Diagram Generator Wiring DiagramFigure 63. Engine Wiring Diagram Engine Wiring DiagramFigure 64. Controller Wiring Diagram controller Wiring DiagramTable 19. Generator Troubleshooting Troubleshooting GeneratorSymptom Possible ProblemMethod of Operation Troubleshooting Diagnostic lampExplanation of Code in Remarks Column Sample partS lIStno. Column part no. Columndca45SSIU4 WHISPERWATT GENERATOR with ISUZU 4JJ1T DIESEL engine Suggested Spare Parts1 to 3 units DescriptionGENERATOR ASSY REMARKS PART NAMEGENERATOR ASSY control box ASSY control box ASSY SENSOR, INLET AIR TEMPERATUREPART NAME REMARKScontrol box ASSY control box ASSY WATER TEMPERATURE GAUGEPART NAME REMARKScontrol box ASSY WIRE HARNESS, CONTROLLER WIRE HARNESS, GENERATORcontrol box ASSY PART NAMEENGINE AND RADIATOR ASSY PART NAME ENGINE AND RADIATOR ASSYREMARKS FAN BELT....................................................1.................REPLACES P/NENGINE AND RADIATOR ASSY. continued ENGINE AND RADIATOR ASSY. continued SWITCH, WARNING OVERHEATPART NAME GASKET, OIL PRESSURE SENSOROUTPUT TERMINAL ASSY PART NAME OUTPUT TERMINAL ASSYRECEPTACLE, CS6369 250V 50A RECEPTACLE, GF-530EM 125V 20ABATTERY ASSY PART NAME BATTERY ASSYREMARKS CABLEMuffler Assy PART NAME Muffler AssyREMARKS REPLACES P/NFUEL TANK ASSY PART NAME FUEL TANK ASSYREMARKS 6-CATERPILLAR YELLOW ENCLOSURE ASSYPART NAME ENCLOSURE ASSYREMARKS INNER COVER, FRONT FRAMEENCLOSURE ASSY. continued PART NAME ENCLOSURE ASSY. continuedRUBBER SEALS ASSY RUBBER SEALS ASSY REMArksPART NAME NAMEPLATE AND DECALS ASSY PART NAME NAMEPLATE AND DECALS ASSYM1550000204 SpeCIal expeDItIng ServICe Terms and Conditions of Sale - PartspaYment termS FreIght polICYPage PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING HERE’S HOW TO GET HELPService Department Warranty Department