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Multiquip DCA45USI2 manual Operation And Parts Manual, PARTS LIST NO. M1870400004

Models: DCA45USI2

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OPERATION AND PARTS MANUAL

MODEL DCA45USI2

60HZ WHISPERWATT™ GENERATOR

(ISUZU BU-4JJ1T DIESEL ENGINE)

PARTS LIST NO. M1870400004

Revision #0 (01/12/11)

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

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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Multiquip DCA45USI2 manual Operation And Parts Manual, This Manual Must Accompany The Equipment At All Times

Contents

OPERATION AND PARTS MANUAL PARTS LIST NO. M1870400004THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES MODEL DCA45USI2Diesel engine exhaust and some of PROPOSITION 65 WARNINGREPORTING SAFETY DEFECTS How To Read AC Ammeter/AC Voltmeter Gauges TABLE OF CONTENTSInspection/Setup Generator AssemblyWhen ordering parts, please supply PARTS ORDERING PROCEDURESOrdering parts has never been easier Choose from three easy optionsSAFETY MESSAGES SAFETY INFORMATIONSAFETY SYMBOLS DANGERGENERATOR SAFETY GENERAL SAFETYﬁre extinguisher ﬁrst aid kitSAFETY INFORMATION ENGINE SAFETYDANGER  NEVER operate the engine with heat shields or guards removedTOWING SAFETY FUEL SAFETYSAFETY INFORMATION DANGERGrounding Safety ELECTRICAL SAFETYPower Cord/Cable Safety SAFETY INFORMATIONENVIRONMENTAL SAFETY BATTERY SAFETYSAFETY INFORMATION DANGERTable 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 PANELDESCRIPTION MAJOR COMPONENTSTable 4. Generator Major Components Figure 3. Major Componentsﬂ owing from the U,V, and W Output Terminal Lugs to the load GENERATOR CONTROL PANELFigure 4. Generator Control Panel Page OFF/RESET ENGINE OPERATING PANELHIGH COOLANT TEMPERATURE Figure 5. Engine Operating Panel6. Fuel Gauge - Indicates amount of diesel fuel available ENGINE OPERATING PANELOUTPUT TERMINAL FAMILIARIZATION OUTPUT TERMINAL PANEL FAMILIARIZATIONOUTPUT TERMINAL PANEL 120 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 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 AC AMMETER AND AC VOLTAGE GAUGESAC Voltmeter Gauge Reading AC Ammeter Gauge ReadingUVWO 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 RADIATORCOOLANT ANTIFREEZE/SUMMER COOLANT/ WATER Operation inBattery Cable Installation BATTERYWIRING ALTERNATORBEFORE STARTING GENERATOR START-UP PROCEDURESTARTING STARTING MANUALthe problem. If the engine is running smoothly, place the engine speed switch Figure 42 in the HIGH up position GENERATOR START-UP PROCEDURENORMAL SHUTDOWN PROCEDURE GENERATOR SHUT-DOWN PROCEDURESEMERGENCY SHUTDOWN PROCEDURE AUTOMATIC SHUT-DOWN SYSTEMAir 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 61. Wheel Lug Nuts Tightening Sequence Table 18. Tire Torque RequirementsFigure 62. Trailer/Towing Vehicle Wiring Diagram TRAILER WIRING DIAGRAMFigure 63. Generator Wiring Diagram GENERATOR WIRING DIAGRAMFigure 64. Engine Wiring Diagram ENGINE WIRING DIAGRAMFigure 65. Engine Controller 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. ColumnDCA45USI2 WHISPERWATT GENERATOR WITH ISUZU BU-4JJ1T DIESEL ENGINE SUGGESTED SPARE PARTS1 to 3 units GENERATOR ASSY QTY. REMARKS PART NAMEGENERATOR ASSY CONTROL BOX ASSY CONTROL BOX ASSY REMARKSPART NAME CURRENT TRANSFORMER,150/5ACONTROL BOX ASSY PART NAME CONTROL BOX ASSYREMARKS CHANGE-OVER SW, VOLTMETERCONTROL 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 SENSOR, WATER TEMPERATURE SWITCH, WARNING, OVERHEATENGINE AND RADIATOR ASSY. CONTINUED PART NAMEOUTPUT TERMINAL ASSY PART NAME OUTPUT TERMINAL ASSYRECEPTACLE CS6369, 250V, 50A RECEPTACLE GF-530EM, 125V 20ABATTERY ASSY BATTERY CABLE BATTERY ASSYPART NAME REMARKSMUFFLER ASSY PART NAME MUFFLER ASSYREMARKS REPLACES P/NFUEL TANK ASSY PART NAME FUEL TANK ASSYREMARKS ENCLOSURE ASSY PART NAME ENCLOSURE ASSYREMARKS ENCLOSURE ASSY. CONTINUED ENCLOSURE ASSY. CONTINUED FUEL LEAK DETECTED SWITCHPART NAME RUBBER SEALS ASSY PART NAME RUBBER SEALS ASSYREMARKS NAMEPLATE AND DECALS ASSY PART NAME NAMEPLATE AND DECALS ASSYM92010020A 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