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dca45ssiu4 manual Engine Wiring Diagram
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dca45ssiu4
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Troubleshooting
Specs
Install
Parts list
Trailer Wiring Diagram
Warranty
Dimension
Maintenance
Removing the Plastic Face Plate Hard Wire Hookup Panel
Off/Reset
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Engine Wiring Diagram
Figure 63. Engine Wiring Diagram
page 46 — DCA45SSIU4 60 hz Generator • operation and parts manual — rev. #1 (10/24/13)
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Contents
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES
PARTS LIST NO. M1870301104
Operation and Parts Manual
MODEL dca45ssiu4
proposition 65 warning
Diesel engine exhaust and some of
Reporting Safety Defects
Component Drawings
Table of Contents
DCA45SSIU4 Generator
6-11
choose from three easy options
Parts Ordering Procedures Ordering parts has never been easier
When ordering parts, please supply
best Deal! Order via Internet Dealers only
SaFetY SYmbolS
Safety Information
SaFetY meSSageS
DANGER
Safety Information
general SaFetY
GENERATOR SAFETy
never disconnect any emergency or safety devices
Safety Information
ENGINE SAFETy
DANGER
Safety Information
FUel SaFetY
TOWING SAFETy
DANGER
grounding Safety
eleCtrICal SaFetY
power Cord/Cable Safety
BATTERy SAFETy
emission Control label
envIronmental SaFetY/DeCommISSIonIng
emISSIonS InFormatIon
Safety Information
Model
Specifications
Table 1. Generator Specifications
Phase
Figure 1. Dimensions
Dimensions
Table 3. Dimensions
Dimension in. mm
Installation
Figure 2. Typical Generator Grounding Application
Mounting
Outdoor Installation
Indoor Installation
Generator Grounding
Engine Operating Panel
General Information
Generator
Generator Control Panel
Table 4. Generator Major Components
Major Components
ITEM NO
The Control Box is equipped with the following major components
Generator Control Panel
Starter Relay Current Transformer Voltage Selector Switch
Over-Current Relay Automatic Voltage Regulator AVR
Page
HIGH COOLANT TEMPERATURE
ENGINE OPERATING PANEL
OFF/RESET
Figure 5. Engine Operating Panel
ENGINE OPERATING PANEL
8. Fuel Gauge - Indicates amount of diesel fuel available
Output Terminal Panel
OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization
Terminal legs “O” and “Ground” are considered bonded grounds
OUTPUT TERMINAL PANEL FAMILIARIZATION
Removing the Plastic Face Plate Hard Wire Hookup Panel
120 VAC GFCI Receptacles
Figure 7. G.F.C.I. Receptacle
Figure 12. Over Current Relay Figure 11. Connecting Loads
Connecting Loads
Over Current Relay
OUTPUT TERMINAL PANEL FAMILIARIZATION
Table 5. Power Factor By Load
Single Phase Load
Three Phase Load
Load Application
GENERATOR OUTPUTS
Voltage Selector Switch
Voltage Selector Switch Locking Button
Generator Output Voltages
Reading Voltage
How to Read the Output Terminal Gauge
GENERATOR OUTPUTS/gauge reading
Reading Amperage
3Ø-240/139 UVWO Terminal Output Voltages
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø-208V/1Ø-120V UVWO Terminal Output Voltages
Figure 24. Voltage Selector Switch 3Ø-480/277V Position
3Ø-480/277V UVWO Terminal Output Voltages
1Ø-240/120V UVWO Terminal Output Voltages
Figure 26. Voltage Selector Switch 1Ø-240/120V Position
Lubrication Oil
inspection/SETUP
Circuit Breakers
Fuel Check
inspection/SETUP
Refueling Procedure
ONLY use #2 diesel fuel when refueling
Figure 30. Only Fill on Level Ground
Table 13. Anti-Freeze Operating Temperatures
Cleaning the Radiator
Air Cleaner
Coolant Antifreeze/Summer Coolant/ Water
Wiring
Battery
Battery Cable Installation
Alternator
Starting
GENERATOR START-UP PROCEDURE
Before Starting
Starting Manual
Figure 48. Coolant Temperature Gauge
GENERATOR START-UP PROCEDURE
Figure 42. Engine Speed Switch High
Figure 45. Voltage Adjust Control Knob
Emergency Shutdown Procedure
GENERATOR SHUT-DOWN PROCEDURES
Normal Shutdown Procedure
OFF/RESET position
General Inspection
Maintenance
Air Cleaner with Dust Indicator
Air Cleaner
Removing Water from the Fuel Tank
Cleaning Inside the Fuel Tank
Fuel Addition
Fuel Tank Inspection
Replacing Oil Filter
Radiator Cleaning
Check Oil Level
Flushing Out Radiator and Replacing Coolant
Trailer Maintenance
Trailer Maintenance
Hydraulic Surge Brakes
Brake Adjustment
Brakes
Actuator
Suspension
Tires/Wheels/Lug Nuts
Tire Wear/Inflation
Trailer Maintenance
Figure 60. Wheel Lug Nuts Tightening Sequence
Lug Nut Torque Requirements
Trailer Maintenance
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
Symptom
Troubleshooting Generator
Table 19. Generator Troubleshooting
Possible Problem
Troubleshooting Diagnostic lamp
Method of Operation
no. Column
Sample partS lISt
Explanation of Code in Remarks Column
part no. Column
1 to 3 units
Suggested Spare Parts
dca45SSIU4 WHISPERWATT GENERATOR with ISUZU 4JJ1T DIESEL engine
Description
GENERATOR ASSY
REMARKS
PART NAME
GENERATOR ASSY
control box ASSY
PART NAME
SENSOR, INLET AIR TEMPERATURE
control box ASSY
REMARKS
control box ASSY
PART NAME
WATER TEMPERATURE GAUGE
control box ASSY
REMARKS
control box ASSY
control box ASSY
WIRE HARNESS, GENERATOR
WIRE HARNESS, CONTROLLER
PART NAME
ENGINE AND RADIATOR ASSY
REMARKS
ENGINE AND RADIATOR ASSY
PART NAME
FAN BELT....................................................1.................REPLACES P/N
ENGINE AND RADIATOR ASSY. continued
PART NAME
SWITCH, WARNING OVERHEAT
ENGINE AND RADIATOR ASSY. continued
GASKET, OIL PRESSURE SENSOR
OUTPUT TERMINAL ASSY
RECEPTACLE, CS6369 250V 50A
OUTPUT TERMINAL ASSY
PART NAME
RECEPTACLE, GF-530EM 125V 20A
BATTERY ASSY
REMARKS
BATTERY ASSY
PART NAME
CABLE
Muffler Assy
REMARKS
Muffler Assy
PART NAME
REPLACES P/N
FUEL TANK ASSY
PART NAME
FUEL TANK ASSY
REMARKS
ENCLOSURE ASSY
6-CATERPILLAR YELLOW
REMARKS
ENCLOSURE ASSY
PART NAME
INNER COVER, FRONT FRAME
ENCLOSURE ASSY. continued
ENCLOSURE ASSY. continued
PART NAME
RUBBER SEALS ASSY
RUBBER SEALS ASSY
REMArks
PART NAME
NAMEPLATE AND DECALS ASSY
PART NAME
NAMEPLATE AND DECALS ASSY
M1550000204
paYment termS
Terms and Conditions of Sale - Parts
SpeCIal expeDItIng ServICe
FreIght polICY
Page
Service Department
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
Warranty Department