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Multiquip DCA45USI2 manual Muffler Assy

Models: DCA45USI2

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MUFFLER ASSY.

PAGE 68 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)

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Contents

PARTS LIST NO. M1870400004 OPERATION AND PARTS MANUALTHIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES MODEL DCA45USI2PROPOSITION 65 WARNING Diesel engine exhaust and some ofREPORTING SAFETY DEFECTS TABLE OF CONTENTS How To Read AC Ammeter/AC Voltmeter GaugesInspection/Setup Generator AssemblyPARTS ORDERING PROCEDURES When ordering parts, please supplyOrdering parts has never been easier Choose from three easy optionsSAFETY INFORMATION SAFETY MESSAGESSAFETY SYMBOLS DANGERGENERAL SAFETY GENERATOR SAFETYﬁre extinguisher ﬁrst aid kitENGINE SAFETY SAFETY INFORMATIONDANGER  NEVER operate the engine with heat shields or guards removedFUEL SAFETY TOWING SAFETYSAFETY INFORMATION DANGERELECTRICAL SAFETY Grounding SafetyPower Cord/Cable Safety SAFETY INFORMATIONBATTERY SAFETY ENVIRONMENTAL SAFETYSAFETY INFORMATION DANGERSPECIFICATIONS 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 PANELMAJOR COMPONENTS DESCRIPTIONTable 4. Generator Major Components Figure 3. Major ComponentsFigure 4. Generator Control Panel GENERATOR CONTROL PANELﬂ owing from the U,V, and W Output Terminal Lugs to the load Page ENGINE OPERATING PANEL OFF/RESETHIGH COOLANT TEMPERATURE Figure 5. Engine Operating PanelENGINE OPERATING PANEL 6. Fuel Gauge - Indicates amount of diesel fuel availableOUTPUT TERMINAL PANEL OUTPUT TERMINAL PANEL FAMILIARIZATIONOUTPUT TERMINAL FAMILIARIZATION Removing 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 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 AC AMMETER AND AC VOLTAGE GAUGES GENERATOR OUTPUTS/GAUGE READINGAC Voltmeter Gauge Reading AC Ammeter Gauge ReadingOUTPUT 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 inBATTERY Battery Cable InstallationWIRING ALTERNATORGENERATOR START-UP PROCEDURE BEFORE STARTINGSTARTING STARTING MANUALGENERATOR START-UP PROCEDURE the problem. If the engine is running smoothly, place the engine speed switch Figure 42 in the HIGH up positionGENERATOR SHUT-DOWN PROCEDURES NORMAL SHUTDOWN PROCEDUREEMERGENCY SHUTDOWN PROCEDURE AUTOMATIC SHUT-DOWN SYSTEMMAINTENANCE 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 61. Wheel Lug Nuts Tightening Sequence Table 18. Tire Torque RequirementsTRAILER WIRING DIAGRAM Figure 62. Trailer/Towing Vehicle Wiring DiagramGENERATOR WIRING DIAGRAM Figure 63. Generator Wiring DiagramENGINE WIRING DIAGRAM Figure 64. Engine Wiring DiagramCONTROLLER WIRING DIAGRAM Figure 65. Engine ControllerTROUBLESHOOTING GENERATOR Table 19. Generator TroubleshootingSymptom Possible ProblemTROUBLESHOOTING DIAGNOSTIC LAMP METHOD OF OPERATIONSAMPLE PARTS LIST EXPLANATION OF CODE IN REMARKS COLUMNNO. Column PART NO. Column1 to 3 units SUGGESTED SPARE PARTSDCA45USI2 WHISPERWATT GENERATOR WITH ISUZU BU-4JJ1T DIESEL ENGINE GENERATOR ASSY GENERATOR ASSY PART NAMEQTY. REMARKS CONTROL BOX ASSY REMARKS CONTROL BOX ASSYPART NAME CURRENT TRANSFORMER,150/5ACONTROL 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 SENSOR, WATER TEMPERATUREENGINE AND RADIATOR ASSY. CONTINUED PART NAMEOUTPUT TERMINAL ASSY OUTPUT TERMINAL ASSY PART NAMERECEPTACLE CS6369, 250V, 50A RECEPTACLE GF-530EM, 125V 20ABATTERY ASSY BATTERY ASSY BATTERY CABLEPART NAME REMARKSMUFFLER ASSY MUFFLER ASSY PART NAMEREMARKS REPLACES P/NFUEL TANK ASSY REMARKS FUEL TANK ASSYPART NAME ENCLOSURE ASSY REMARKS ENCLOSURE ASSYPART NAME ENCLOSURE ASSY. CONTINUED PART NAME FUEL LEAK DETECTED SWITCHENCLOSURE ASSY. CONTINUED RUBBER SEALS ASSY REMARKS RUBBER SEALS ASSYPART NAME NAMEPLATE AND DECALS ASSY M92010020A 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