Manuals / Multiquip / Lawn and Garden / Portable Generator

Multiquip dca45ssiu4 manual control box ASSY

Models: dca45ssiu4

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control box ASSY.

page 56 — DCA45SSIU4 60 hz Generator • operation and parts manual — rev. #1 (10/24/13)

Page 56

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Multiquip dca45ssiu4 manual control box ASSY

Contents

PARTS LIST NO. M1870301104 Operation and Parts ManualTHIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES MODEL dca45ssiu4proposition 65 warning Diesel engine exhaust and some ofReporting Safety Defects Table of Contents DCA45SSIU4 GeneratorComponent Drawings 6-11Parts Ordering Procedures Ordering parts has never been easier When ordering parts, please supplychoose from three easy options best Deal! Order via Internet Dealers onlySafety Information SaFetY meSSageSSaFetY SYmbolS DANGERgeneral SaFetY GENERATOR SAFETySafety Information „ never disconnect any emergency or safety devicesDANGER ENGINE SAFETySafety Information FUel SaFetY TOWING SAFETySafety Information DANGEReleCtrICal SaFetY power Cord/Cable Safetygrounding Safety BATTERy SAFETyenvIronmental SaFetY/DeCommISSIonIng emISSIonS InFormatIonemission Control label Safety InformationSpecifications Table 1. Generator SpecificationsModel PhaseDimensions Table 3. DimensionsFigure 1. Dimensions Dimension in. mmInstallation Figure 2. Typical Generator Grounding ApplicationOutdoor Installation Indoor InstallationMounting Generator GroundingGeneral Information GeneratorEngine Operating Panel Generator Control PanelITEM NO Major ComponentsTable 4. Generator Major Components Generator Control Panel „„Starter Relay „„Current Transformer „„Voltage Selector SwitchThe Control Box is equipped with the following major components „„Over-Current Relay „„Automatic Voltage Regulator AVRPage ENGINE OPERATING PANEL OFF/RESETFigure 5. Engine Operating Panel AUTOENGINE OPERATING PANEL 8. Fuel Gauge - Indicates amount of diesel fuel availableOUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal FamiliarizationOutput Terminal Panel Terminal legs “O” and “Ground” are considered bonded groundsRemoving the Plastic Face Plate Hard Wire Hookup Panel 120 VAC GFCI ReceptaclesOUTPUT TERMINAL PANEL FAMILIARIZATION Figure 7. G.F.C.I. ReceptacleConnecting Loads Over Current RelayFigure 12. Over Current Relay Figure 11. Connecting Loads OUTPUT TERMINAL PANEL FAMILIARIZATIONSingle Phase Load Three Phase LoadTable 5. Power Factor By Load Load ApplicationVoltage Selector Switch Voltage Selector Switch Locking ButtonGENERATOR OUTPUTS Generator Output VoltagesHow to Read the Output Terminal Gauge GENERATOR OUTPUTS/gauge readingReading Voltage Reading AmperageOUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages3Ø-240/139 UVWO Terminal Output Voltages 3Ø-208V/1Ø-120V UVWO Terminal Output Voltages3Ø-480/277V UVWO Terminal Output Voltages 1Ø-240/120V UVWO Terminal Output VoltagesFigure 24. Voltage Selector Switch 3Ø-480/277V Position Figure 26. Voltage Selector Switch 1Ø-240/120V Positioninspection/SETUP Circuit BreakersLubrication Oil Fuel CheckRefueling Procedure ONLY use #2 diesel fuel when refuelinginspection/SETUP Figure 30. Only Fill on Level GroundCleaning the Radiator Air CleanerCoolant Antifreeze/Summer Coolant/ Water Operation in Freezing WeatherBattery Battery Cable InstallationWiring AlternatorGENERATOR START-UP PROCEDURE Before StartingStarting Starting ManualGENERATOR START-UP PROCEDURE Figure 42. Engine Speed Switch HighFigure 45. Voltage Adjust Control Knob Figure 47. Oil Pressure GaugeGENERATOR SHUT-DOWN PROCEDURES Normal Shutdown ProcedureEmergency Shutdown Procedure OFF/RESET positionMaintenance Air Cleaner with Dust IndicatorGeneral Inspection Air CleanerCleaning Inside the Fuel Tank Fuel AdditionRemoving Water from the Fuel Tank Fuel Tank InspectionRadiator Cleaning Check Oil LevelReplacing Oil Filter Flushing Out Radiator and Replacing CoolantTrailer Maintenance Trailer MaintenanceBrake Adjustment BrakesHydraulic Surge Brakes ActuatorTires/Wheels/Lug Nuts Tire Wear/InflationSuspension Trailer MaintenanceLug Nut Torque Requirements Trailer MaintenanceFigure 60. Wheel Lug Nuts Tightening Sequence Table 18. Tire Torque RequirementsTrailer Wiring Diagram Figure 61. Trailer/Towing Vehicle Wiring DiagramGenerator Wiring Diagram Figure 62. Generator Wiring DiagramEngine Wiring Diagram Figure 63. Engine Wiring Diagramcontroller Wiring Diagram Figure 64. Controller Wiring DiagramTroubleshooting Generator Table 19. Generator TroubleshootingSymptom Possible ProblemTroubleshooting Diagnostic lamp Method of OperationSample partS lISt Explanation of Code in Remarks Columnno. Column part no. ColumnSuggested Spare Parts dca45SSIU4 WHISPERWATT GENERATOR with ISUZU 4JJ1T DIESEL engine1 to 3 units DescriptionGENERATOR ASSY GENERATOR ASSY PART NAMEREMARKS control box ASSY control box ASSY PART NAMEREMARKS AUTOMATIC VOLTAGE REGULATORcontrol box ASSY control box ASSY PART NAMEREMARKS CHANGE-OVER SW., VOLTMETERcontrol box ASSY WIRE HARNESS, GENERATOR WIRE HARNESS, CONTROLLERcontrol box ASSY PART NAMEENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY PART NAMEREMARKS FAN BELT....................................................1.................REPLACES P/NENGINE AND RADIATOR ASSY. continued SWITCH, WARNING OVERHEAT ENGINE AND RADIATOR ASSY. continuedPART NAME GASKET, OIL PRESSURE SENSOROUTPUT TERMINAL ASSY OUTPUT TERMINAL ASSY PART NAMERECEPTACLE, CS6369 250V 50A RECEPTACLE, GF-530EM 125V 20ABATTERY ASSY BATTERY ASSY PART NAMEREMARKS CABLEMuffler Assy Muffler Assy PART NAMEREMARKS REPLACES P/NFUEL TANK ASSY REMARKS FUEL TANK ASSYPART NAME ENCLOSURE ASSY 6-CATERPILLAR YELLOWENCLOSURE ASSY PART NAMEREMARKS INNER COVER, FRONT FRAMEENCLOSURE ASSY. continued ENCLOSURE ASSY. continued PART NAMERUBBER SEALS ASSY PART NAME REMArksRUBBER SEALS ASSY NAMEPLATE AND DECALS ASSY M1550000204 NAMEPLATE AND DECALS ASSYPART NAME Terms and Conditions of Sale - Parts SpeCIal expeDItIng ServICepaYment termS FreIght polICYPage HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLINGService Department Warranty Department