Manuals / Multiquip / Lawn and Garden / Portable Generator

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ENCLOSURE ASSY. (CONTINUED)

PAGE 74 — DCA45USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (01/12/11)

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Multiquip DCA45USI2 manual Enclosure Assy. Continued

Contents

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES PARTS LIST NO. M1870400004OPERATION AND PARTS MANUAL MODEL DCA45USI2PROPOSITION 65 WARNING Diesel engine exhaust and some ofREPORTING SAFETY DEFECTS Inspection/Setup TABLE OF CONTENTSHow To Read AC Ammeter/AC Voltmeter Gauges Generator AssemblyOrdering parts has never been easier PARTS ORDERING PROCEDURESWhen ordering parts, please supply Choose from three easy optionsSAFETY SYMBOLS SAFETY INFORMATIONSAFETY MESSAGES DANGERﬁre extinguisher GENERAL SAFETYGENERATOR SAFETY ﬁrst aid kitDANGER ENGINE SAFETYSAFETY INFORMATION  NEVER operate the engine with heat shields or guards removedSAFETY INFORMATION FUEL SAFETYTOWING SAFETY DANGERPower Cord/Cable Safety ELECTRICAL SAFETYGrounding Safety SAFETY INFORMATIONSAFETY INFORMATION BATTERY SAFETYENVIRONMENTAL SAFETY DANGERModel SPECIFICATIONSTable 1. Generator Speciﬁcations PhaseFigure 1. Dimensions DIMENSIONSTable 3. Dimensions Dimension in. mmINSTALLATION Figure 2. Typical Generator Grounding ApplicationMOUNTING OUTDOOR INSTALLATIONINDOOR INSTALLATION GENERATOR GROUNDINGENGINE OPERATING PANEL GENERAL INFORMATIONGENERATOR GENERATOR CONTROL PANELTable 4. Generator Major Components MAJOR COMPONENTSDESCRIPTION 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 HIGH COOLANT TEMPERATURE ENGINE OPERATING PANELOFF/RESET Figure 5. Engine Operating PanelENGINE OPERATING PANEL 6. Fuel Gauge - Indicates amount of diesel fuel availableOUTPUT TERMINAL PANEL OUTPUT TERMINAL PANEL FAMILIARIZATIONOUTPUT TERMINAL FAMILIARIZATION OUTPUT TERMINAL PANEL FAMILIARIZATION Removing the Plastic Face Plate Hard Wire Hookup Panel120 VAC GFCI Receptacles Figure 7. G.F.C.I. ReceptacleFigure 11. Connecting Loads Connecting LoadsOver Current Relay OUTPUT TERMINAL PANEL FAMILIARIZATIONTable 5. Power Factor By Load SINGLE PHASE LOADTHREE PHASE LOAD LOAD APPLICATIONGENERATOR OUTPUTS Voltage Selector SwitchVoltage Selector Switch Locking Button GENERATOR OUTPUT VOLTAGESAC Voltmeter Gauge Reading HOW TO READ THE AC AMMETER AND AC VOLTAGE GAUGESGENERATOR OUTPUTS/GAUGE READING AC Ammeter Gauge Reading3Ø-240/139 UVWO Terminal Output Voltages OUTPUT TERMINAL PANEL CONNECTIONSUVWO TERMINAL OUTPUT VOLTAGES 3Ø-208V/1Ø-120V UVWO Terminal Output VoltagesFigure 24. Voltage Selector Switch 3Ø-480/277V Position 3Ø-480/277V UVWO Terminal Output Voltages1Ø-240/120V UVWO Terminal Output Voltages Figure 26. Voltage Selector Switch 1Ø-240/120V PositionLUBRICATION OIL INSPECTION/SETUPCIRCUIT BREAKERS FUEL CHECKINSPECTION/SETUP Refueling ProcedureONLY use #2 diesel fuel when refueling Figure 30. Only Fill on Level GroundCOOLANT ANTIFREEZE/SUMMER COOLANT/ WATER CLEANING THE RADIATORAIR CLEANER Operation inWIRING BATTERYBattery Cable Installation ALTERNATORSTARTING GENERATOR START-UP PROCEDUREBEFORE STARTING STARTING MANUALGENERATOR START-UP PROCEDURE the problem. If the engine is running smoothly, place the engine speed switch Figure 42 in the HIGH up positionEMERGENCY SHUTDOWN PROCEDURE GENERATOR SHUT-DOWN PROCEDURESNORMAL SHUTDOWN PROCEDURE AUTOMATIC SHUT-DOWN SYSTEMGENERAL INSPECTION MAINTENANCEAir Cleaner with Dust Indicator AIR CLEANERRemoving Water from the Fuel Tank Cleaning Inside the Fuel TankFUEL ADDITION FUEL TANK INSPECTIONReplacing Oil Filter RADIATOR CLEANINGCHECK OIL LEVEL FLUSHING OUT RADIATOR AND REPLACING COOLANTTRAILER MAINTENANCE TRAILER MAINTENANCEHydraulic Surge Brakes Brake AdjustmentBRAKES ActuatorSuspension TIRES/WHEELS/LUG NUTSTire Wear/Inﬂation TRAILER MAINTENANCEFigure 61. Wheel Lug Nuts Tightening Sequence Lug Nut Torque RequirementsTRAILER MAINTENANCE 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 ControllerSymptom TROUBLESHOOTING GENERATORTable 19. Generator Troubleshooting Possible ProblemTROUBLESHOOTING DIAGNOSTIC LAMP METHOD OF OPERATIONNO. Column SAMPLE PARTS LISTEXPLANATION OF CODE IN REMARKS 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 PART NAME REMARKSCONTROL BOX ASSY CURRENT TRANSFORMER,150/5ACONTROL BOX ASSY REMARKS CONTROL BOX ASSYPART NAME CHANGE-OVER SW, VOLTMETERCONTROL BOX ASSY CONTROL BOX ASSY WIRE HARNESS, GENERATORWIRE HARNESS, CONTROLLER PART NAMEENGINE AND RADIATOR ASSY REMARKS ENGINE AND RADIATOR ASSYPART NAME FAN BELT....................................................1 ................REPLACES P/NENGINE AND RADIATOR ASSY. CONTINUED ENGINE AND RADIATOR ASSY. CONTINUED SWITCH, WARNING, OVERHEATSENSOR, WATER TEMPERATURE PART NAMEOUTPUT TERMINAL ASSY RECEPTACLE CS6369, 250V, 50A OUTPUT TERMINAL ASSYPART NAME RECEPTACLE GF-530EM, 125V 20ABATTERY ASSY PART NAME BATTERY ASSYBATTERY CABLE REMARKSMUFFLER ASSY REMARKS MUFFLER ASSYPART NAME 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 PAYMENT TERMS TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE FREIGHT POLICYPage Service Department HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING Warranty Department