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Multiquip DCA45USI2 manual

Models: DCA45USI2

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DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11) — PAGE 19

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Multiquip DCA45USI2 manual

Contents

MODEL DCA45USI2 PARTS LIST NO. M1870400004OPERATION AND PARTS MANUAL THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMESDiesel engine exhaust and some of PROPOSITION 65 WARNINGREPORTING SAFETY DEFECTS Generator Assembly TABLE OF CONTENTSHow To Read AC Ammeter/AC Voltmeter Gauges Inspection/SetupChoose from three easy options PARTS ORDERING PROCEDURESWhen ordering parts, please supply Ordering parts has never been easierDANGER SAFETY INFORMATIONSAFETY MESSAGES SAFETY SYMBOLSﬁrst aid kit GENERAL SAFETYGENERATOR SAFETY ﬁre extinguisher NEVER operate the engine with heat shields or guards removed ENGINE SAFETYSAFETY INFORMATION DANGERDANGER FUEL SAFETYTOWING SAFETY SAFETY INFORMATIONSAFETY INFORMATION ELECTRICAL SAFETYGrounding Safety Power Cord/Cable SafetyDANGER BATTERY SAFETYENVIRONMENTAL SAFETY SAFETY INFORMATIONPhase SPECIFICATIONSTable 1. Generator Speciﬁcations ModelDimension in. mm DIMENSIONSTable 3. Dimensions Figure 1. DimensionsFigure 2. Typical Generator Grounding Application INSTALLATIONGENERATOR GROUNDING OUTDOOR INSTALLATIONINDOOR INSTALLATION MOUNTINGGENERATOR CONTROL PANEL GENERAL INFORMATIONGENERATOR ENGINE OPERATING PANELFigure 3. Major Components MAJOR COMPONENTSDESCRIPTION Table 4. Generator Major Componentsﬂ owing from the U,V, and W Output Terminal Lugs to the load GENERATOR CONTROL PANELFigure 4. Generator Control Panel Page Figure 5. Engine Operating Panel ENGINE OPERATING PANELOFF/RESET HIGH COOLANT TEMPERATURE6. Fuel Gauge - Indicates amount of diesel fuel available ENGINE OPERATING PANELOUTPUT TERMINAL FAMILIARIZATION OUTPUT TERMINAL PANEL FAMILIARIZATIONOUTPUT TERMINAL PANEL Figure 7. G.F.C.I. Receptacle Removing the Plastic Face Plate Hard Wire Hookup Panel120 VAC GFCI Receptacles OUTPUT TERMINAL PANEL FAMILIARIZATIONOUTPUT TERMINAL PANEL FAMILIARIZATION Connecting LoadsOver Current Relay Figure 11. Connecting LoadsLOAD APPLICATION SINGLE PHASE LOADTHREE PHASE LOAD Table 5. Power Factor By LoadGENERATOR OUTPUT VOLTAGES Voltage Selector SwitchVoltage Selector Switch Locking Button GENERATOR OUTPUTSAC Ammeter Gauge Reading HOW TO READ THE AC AMMETER AND AC VOLTAGE GAUGESGENERATOR OUTPUTS/GAUGE READING AC Voltmeter Gauge Reading3Ø-208V/1Ø-120V UVWO Terminal Output Voltages OUTPUT TERMINAL PANEL CONNECTIONSUVWO TERMINAL OUTPUT VOLTAGES 3Ø-240/139 UVWO Terminal Output VoltagesFigure 26. Voltage Selector Switch 1Ø-240/120V Position 3Ø-480/277V UVWO Terminal Output Voltages1Ø-240/120V UVWO Terminal Output Voltages Figure 24. Voltage Selector Switch 3Ø-480/277V PositionFUEL CHECK INSPECTION/SETUPCIRCUIT BREAKERS LUBRICATION OILFigure 30. Only Fill on Level Ground Refueling ProcedureONLY use #2 diesel fuel when refueling INSPECTION/SETUPOperation in CLEANING THE RADIATORAIR CLEANER COOLANT ANTIFREEZE/SUMMER COOLANT/ WATERALTERNATOR BATTERYBattery Cable Installation WIRINGSTARTING MANUAL GENERATOR START-UP PROCEDUREBEFORE STARTING STARTINGthe problem. If the engine is running smoothly, place the engine speed switch Figure 42 in the HIGH up position GENERATOR START-UP PROCEDUREAUTOMATIC SHUT-DOWN SYSTEM GENERATOR SHUT-DOWN PROCEDURESNORMAL SHUTDOWN PROCEDURE EMERGENCY SHUTDOWN PROCEDUREAIR CLEANER MAINTENANCEAir Cleaner with Dust Indicator GENERAL INSPECTIONFUEL TANK INSPECTION Cleaning Inside the Fuel TankFUEL ADDITION Removing Water from the Fuel TankFLUSHING OUT RADIATOR AND REPLACING COOLANT RADIATOR CLEANINGCHECK OIL LEVEL Replacing Oil FilterTRAILER MAINTENANCE TRAILER MAINTENANCEActuator Brake AdjustmentBRAKES Hydraulic Surge BrakesTRAILER MAINTENANCE TIRES/WHEELS/LUG NUTSTire Wear/Inﬂation SuspensionTable 18. Tire Torque Requirements Lug Nut Torque RequirementsTRAILER MAINTENANCE Figure 61. Wheel Lug Nuts Tightening SequenceFigure 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 DIAGRAMPossible Problem TROUBLESHOOTING GENERATORTable 19. Generator Troubleshooting SymptomMETHOD OF OPERATION TROUBLESHOOTING DIAGNOSTIC LAMPPART NO. Column SAMPLE PARTS LISTEXPLANATION OF CODE IN REMARKS COLUMN 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 CURRENT TRANSFORMER,150/5A REMARKSCONTROL BOX ASSY PART NAMECONTROL BOX ASSY CHANGE-OVER SW, VOLTMETER CONTROL BOX ASSYPART NAME REMARKSCONTROL BOX ASSY PART NAME WIRE HARNESS, GENERATORWIRE HARNESS, CONTROLLER CONTROL BOX ASSYENGINE AND RADIATOR ASSY FAN BELT....................................................1 ................REPLACES P/N ENGINE AND RADIATOR ASSYPART NAME REMARKSENGINE AND RADIATOR ASSY. CONTINUED PART NAME SWITCH, WARNING, OVERHEATSENSOR, WATER TEMPERATURE ENGINE AND RADIATOR ASSY. CONTINUEDOUTPUT TERMINAL ASSY RECEPTACLE GF-530EM, 125V 20A OUTPUT TERMINAL ASSYPART NAME RECEPTACLE CS6369, 250V, 50ABATTERY ASSY REMARKS BATTERY ASSYBATTERY CABLE PART NAMEMUFFLER ASSY REPLACES P/N MUFFLER ASSYPART NAME REMARKSFUEL 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 FREIGHT POLICY TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE PAYMENT TERMSPage Warranty Department HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING Service Department