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dca45ssiu4 manual Trailer Wiring Diagram, Trailer/Towing Vehicle Wiring Diagram
Models:
dca45ssiu4
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Troubleshooting
Specifications
Install
Parts list
Trailer Wiring Diagram
Warranty
Dimension
Maintenance
Removing the Plastic Face Plate Hard Wire Hookup Panel
Off/Reset
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Trailer Wiring Diagram
Figure 61. Trailer/Towing Vehicle Wiring Diagram
page 44 — DCA45SSIU4 60 hz Generator • operation and parts manual — rev. #1 (10/24/13)
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Contents
PARTS LIST NO. M1870301104
Operation and Parts Manual
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES
MODEL dca45ssiu4
proposition 65 warning
Diesel engine exhaust and some of
Reporting Safety Defects
Table of Contents
DCA45SSIU4 Generator
Component Drawings
6-11
Parts Ordering Procedures Ordering parts has never been easier
When ordering parts, please supply
choose from three easy options
best Deal! Order via Internet Dealers only
Safety Information
SaFetY meSSageS
SaFetY SYmbolS
DANGER
general SaFetY
GENERATOR SAFETy
Safety Information
never disconnect any emergency or safety devices
DANGER
ENGINE SAFETy
Safety Information
FUel SaFetY
TOWING SAFETy
Safety Information
DANGER
eleCtrICal SaFetY
power Cord/Cable Safety
grounding Safety
BATTERy SAFETy
envIronmental SaFetY/DeCommISSIonIng
emISSIonS InFormatIon
emission Control label
Safety Information
Specifications
Table 1. Generator Specifications
Model
Phase
Dimensions
Table 3. Dimensions
Figure 1. Dimensions
Dimension in. mm
Installation
Figure 2. Typical Generator Grounding Application
Outdoor Installation
Indoor Installation
Mounting
Generator Grounding
General Information
Generator
Engine Operating Panel
Generator Control Panel
ITEM NO
Major Components
Table 4. Generator Major Components
Generator Control Panel
Starter Relay Current Transformer Voltage Selector Switch
The Control Box is equipped with the following major components
Over-Current Relay Automatic Voltage Regulator AVR
Page
ENGINE OPERATING PANEL
OFF/RESET
HIGH COOLANT TEMPERATURE
Figure 5. Engine Operating Panel
ENGINE OPERATING PANEL
8. Fuel Gauge - Indicates amount of diesel fuel available
OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization
Output Terminal Panel
Terminal legs “O” and “Ground” are considered bonded grounds
Removing the Plastic Face Plate Hard Wire Hookup Panel
120 VAC GFCI Receptacles
OUTPUT TERMINAL PANEL FAMILIARIZATION
Figure 7. G.F.C.I. Receptacle
Connecting Loads
Over Current Relay
Figure 12. Over Current Relay Figure 11. Connecting Loads
OUTPUT TERMINAL PANEL FAMILIARIZATION
Single Phase Load
Three Phase Load
Table 5. Power Factor By Load
Load Application
Voltage Selector Switch
Voltage Selector Switch Locking Button
GENERATOR OUTPUTS
Generator Output Voltages
How to Read the Output Terminal Gauge
GENERATOR OUTPUTS/gauge reading
Reading Voltage
Reading Amperage
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø-240/139 UVWO Terminal Output Voltages
3Ø-208V/1Ø-120V UVWO Terminal Output Voltages
3Ø-480/277V UVWO Terminal Output Voltages
1Ø-240/120V UVWO Terminal Output Voltages
Figure 24. Voltage Selector Switch 3Ø-480/277V Position
Figure 26. Voltage Selector Switch 1Ø-240/120V Position
inspection/SETUP
Circuit Breakers
Lubrication Oil
Fuel Check
Refueling Procedure
ONLY use #2 diesel fuel when refueling
inspection/SETUP
Figure 30. Only Fill on Level Ground
Cleaning the Radiator
Air Cleaner
Table 13. Anti-Freeze Operating Temperatures
Coolant Antifreeze/Summer Coolant/ Water
Battery
Battery Cable Installation
Wiring
Alternator
GENERATOR START-UP PROCEDURE
Before Starting
Starting
Starting Manual
GENERATOR START-UP PROCEDURE
Figure 42. Engine Speed Switch High
Figure 48. Coolant Temperature Gauge
Figure 45. Voltage Adjust Control Knob
GENERATOR SHUT-DOWN PROCEDURES
Normal Shutdown Procedure
Emergency Shutdown Procedure
OFF/RESET position
Maintenance
Air Cleaner with Dust Indicator
General Inspection
Air Cleaner
Cleaning Inside the Fuel Tank
Fuel Addition
Removing Water from the Fuel Tank
Fuel Tank Inspection
Radiator Cleaning
Check Oil Level
Replacing Oil Filter
Flushing Out Radiator and Replacing Coolant
Trailer Maintenance
Trailer Maintenance
Brake Adjustment
Brakes
Hydraulic Surge Brakes
Actuator
Tires/Wheels/Lug Nuts
Tire Wear/Inflation
Suspension
Trailer Maintenance
Lug Nut Torque Requirements
Trailer Maintenance
Figure 60. Wheel Lug Nuts Tightening Sequence
Table 18. Tire Torque Requirements
Trailer Wiring Diagram
Figure 61. Trailer/Towing Vehicle Wiring Diagram
Generator Wiring Diagram
Figure 62. Generator Wiring Diagram
Engine Wiring Diagram
Figure 63. Engine Wiring Diagram
controller Wiring Diagram
Figure 64. Controller Wiring Diagram
Troubleshooting Generator
Table 19. Generator Troubleshooting
Symptom
Possible Problem
Troubleshooting Diagnostic lamp
Method of Operation
Sample partS lISt
Explanation of Code in Remarks Column
no. Column
part no. Column
Suggested Spare Parts
dca45SSIU4 WHISPERWATT GENERATOR with ISUZU 4JJ1T DIESEL engine
1 to 3 units
Description
GENERATOR ASSY
GENERATOR ASSY
PART NAME
REMARKS
control box ASSY
SENSOR, INLET AIR TEMPERATURE
control box ASSY
PART NAME
REMARKS
control box ASSY
WATER TEMPERATURE GAUGE
control box ASSY
PART NAME
REMARKS
control box ASSY
WIRE HARNESS, GENERATOR
WIRE HARNESS, CONTROLLER
control box ASSY
PART NAME
ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
PART NAME
REMARKS
FAN BELT....................................................1.................REPLACES P/N
ENGINE AND RADIATOR ASSY. continued
SWITCH, WARNING OVERHEAT
ENGINE AND RADIATOR ASSY. continued
PART NAME
GASKET, OIL PRESSURE SENSOR
OUTPUT TERMINAL ASSY
OUTPUT TERMINAL ASSY
PART NAME
RECEPTACLE, CS6369 250V 50A
RECEPTACLE, GF-530EM 125V 20A
BATTERY ASSY
BATTERY ASSY
PART NAME
REMARKS
CABLE
Muffler Assy
Muffler Assy
PART NAME
REMARKS
REPLACES P/N
FUEL TANK ASSY
REMARKS
FUEL TANK ASSY
PART NAME
ENCLOSURE ASSY
6-CATERPILLAR YELLOW
ENCLOSURE ASSY
PART NAME
REMARKS
INNER COVER, FRONT FRAME
ENCLOSURE ASSY. continued
ENCLOSURE ASSY. continued
PART NAME
RUBBER SEALS ASSY
PART NAME
REMArks
RUBBER SEALS ASSY
NAMEPLATE AND DECALS ASSY
M1550000204
NAMEPLATE AND DECALS ASSY
PART NAME
Terms and Conditions of Sale - Parts
SpeCIal expeDItIng ServICe
paYment termS
FreIght polICY
Page
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
Service Department
Warranty Department