MQ Power DCA45-circuit-breaker-replacement Operating instructions

DCA45USI — CIRCUIT BREAKER REPLACEMENT KIT INSTRUCTIONS P/N EE55781 — REV. #0 (04/01/11) — PAGE 1

DCA45USI

Circuit Breaker Replacement Kit

The following instructions are intended to assist the user in the installation of the Circuit Breaker Replacement Kit

for use on the DCA45USI generators in the event of a circuit breaker failure. Old-style circuit breakers are no longer

available. Please read all assembly instructions before installing the kit.

REQUIRED TOOLS

PARTS

Verify that all parts are accounted for. See Figure 1 and

Table 1.

Figure 1. Return Fuel Line Kit

1

2

14

12

4

5

6

7

3

8

9

10

11

Hardware

Kit

13

DCA45USI — CIRCUIT BREAKER REPLACEMENT KIT INSTRUCTIONS P/N EE55781 — REV. #0 (04/01/11) — PAGE 1

DCA45USI

Circuit Breaker Replacement Kit

The following instructions are intended to assist the user in the installation of the Circuit Breaker Replacement Kit

for use on the DCA45USI generators in the event of a circuit breaker failure. Old-style circuit breakers are no longer

available. Please read all assembly instructions before installing the kit.

REQUIRED TOOLS

PARTS

Verify that all parts are accounted for. See Figure 1 and

Table 1.

Figure 1. Return Fuel Line Kit

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Fi

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Ret

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PR

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R

AT

I

O

N

1.

Mak

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sure

gen

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at

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s turned

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f

and eng

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2

.

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iv

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cabl

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4

. Open rear cabi

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om

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NOTICE

The Breaker Hard ware Ki t, ite m 3, includes more

hardware than will be used in the procedure.

Hand-Held Rotary Saw

Blue Masking Tape

Phillips Head Screwdriver

Allen Wrench

Ruler

Scribe

Vacuum (Shop Vac)

Wire Cutter

File

Crimp Tool

Black Primer Paint

WORK SAFELY!

Only a qualiﬁed service technician with proper training

should perform this installation. Follow all shop safety rules

when performing this installation.

PREPARATION

1. Make sure generator is turned off and engine is cool.

2. Place the generator in an area free of dir t and debris

Make sure it is on secure level ground with chock blocks

underneath each wheel to prevent the generator from

rolling.

3. Disconnect negative battery cable from the battery.

4. Open rear cabinet door to gain access to control panel.

5. Locate the two knobs at the upp er corn ers of the

control panel door. Twist knobs to unlock door from

frame. See Figure 2. Pull control panel door down to a

horizontal position.

Table 1. Circuit Breaker Replacement Kit

Item

No.

Part No. Description QTY. Remarks

1 BREAKERKIT45USI

Breaker Update

Kit, DCA45USI

1

Includes

Items 2-14

2 0601807521 Circuit Breaker 1

3 RK0001 Breaker Hardware Kit 1

Includes

Items 3-12

4 Screw, Allen Head 6

5 Nut, Square 6

6 Holder, Nut 6

7 Insulating Barrier 1

8 Screw, Phillips Head 3

9 Washer, Lock 3

10 Washer, Flat 3

11 Bracket, Mounting 1

12 Screw, Phillips Head 1

13 Butt Splice 2

14 EE55781

Instructions, DCA45

Breaker Update

NOTICE

The Breaker Hardware Kit, item 3, includes more

hardware than will be used in the procedure.

 Hand-Held Rotary Saw

 Blue Masking Tape

 Phillips Head Screwdriver

 Allen Wrench

 Ruler

 Scribe

 Vacuum (Shop Vac)

 Wire Cutter

 File

 Crimp Tool

 Black Primer Paint

WORK SAFELY!

Only a qualiﬁed service technician with proper training

should perform this installation. Follow all shop safety rules

when performing this installation.

PREPARATION

1. Make sure generator is turned off and engine is cool.

2. Place the generator in an area free of dirt and debris

Make sure it is on secure level ground with chock blocks

underneath each wheel to prevent the generator from

rolling.

3. Disconnect negative battery cable from the battery.

4. Open rear cabinet door to gain access to control panel.

5. Locate the two knobs at the upper corners of the

control panel door. Twist knobs to unlock door from

frame. See Figure 2. Pull control panel door down to a

horizontal position.

Table 1. Circuit Breaker Replacement Kit

Item

No.

Part No. Description QTY. Remarks

1 BREAKERKIT45USI

Breaker Update

Kit, DCA45USI

1

Includes

Items 2-14

2 0601807521 Circuit Breaker 1

3 RK0001 Breaker Hardware Kit 1

Includes

Items 3-12

4 Screw, Allen Head 6

5 Nut, Square 6

6 Holder, Nut 6

7 Insulating Barrier 1

8 Screw, Phillips Head 3

9 Washer, Lock 3

10 Washer, Flat 3

11 Bracket, Mounting 1

12 Screw, Phillips Head 1

13 Butt Splice 2

14 EE55781

Instructions, DCA45

Breaker Update

DCA45USI — CIRCUIT BREAKER REPLACEMENT KIT INSTRUCTIONS P/N EE55781 — REV. #0 (04/01/11) — PAGE 2

6.

Figure 2. Open Control Panel Door

DISCONNECT CIRCUIT BREAKER

1. Locate the two auxiliary wires extending from the rear

of the circuit breaker. Cut wires midway between the

control box and connector. See Figure 3.

Figure 3. Cut Auxiliary Wires

Knob

Pull Down

Control Panel

Door

NOTICE

The auxiliary wires are labeled as “C1” and “C2.” If visible,

mark and tag wires as “C1” and “C2” prior to cutting.

Auxiliary

Wires

Circuit

Breaker

2. Disconnect the wires from the top and bottom of the

circuit breaker. Remove and discard mounting

hardware that secured the wires to the circuit breaker

terminals. See Figure 4.

3. Disconnect the four screws securing the circuit breaker

to the bracket inside the control panel. See Figure 4.

4. Remove and discard circuit breaker.

Figure 4. Disconnect Circuit Breaker

NOTICE

The wires will need to be installed in the same

orientation on the new circuit breaker. Mark and tag

wires as necessary.

4x

6x

Disconnect

Wires

Disconnect

Wires

Circuit

Breaker

DCA45USI — CIRCUIT BREAKER REPLACEMENT KIT INSTRUCTIONS P/N EE55781 — REV. #0 (04/01/11) — PAGE 3

MODIFY CIRCUIT BREAKER CUTOUT

The current circuit breaker cutout on the control panel door

must be modiﬁed to ﬁt the new circuit breaker.

1. Close control panel door.

2. Use a ruler and scribe to mark control panel for cutting.

Refer to Figure 5 and Table 2.

Figure 5. Cutting Guide

3. Overlay scribe marks with blue masking tape.

A

C

D

B

Area to be cut

Table 2. Cutting Dimensions

Reference Letter Dimension

A 1-1/8 in (27.5 mm)

B 13/16 in. (20 mm)

C 2-1/16 in. (51 mm)

D 3-1/4 in. (82 mm)

4. Modify the circuit breaker cutout with a hand-held rotary

saw and metal cutting blade. Use the blue tape as

cutting guide. See Figure 6.

Figure 6. Modify Circuit Breaker Hole

5. De-burr rough edges with a ﬁle.

6. Use a vacuum (shop vac) to clean up all saw dust and

debris on panel door and inside control panel.

7. To prevent rusting, paint exposed edges with black

primer paint.

NOTICE

Cover all gauges on panel door and components inside

control panel to protect against saw dust and debris.

Modify

Circuit Breaker

Cutout

DCA45USI — CIRCUIT BREAKER REPLACEMENT KIT INSTRUCTIONS P/N EE55781 — REV. #0 (04/01/11) — PAGE 4

INSTALL NEW CIRCUIT BREAKER

1. Install square nuts and nut holders (three on top, three

on bottom) in new circuit breaker as referenced in

manufacturer's instructions. See Figure 7.

Figure 7. Install Square Nuts and Nut Holders

2. Install new circuit breaker mounting bracket to existing

bracket inside the control panel. Secure with phillips

head screws, lock washers and ﬂat washers in three

places. See Figure 8.

Figure 8. Install New Mounting Bracket

6x

Square

Nut

Holder

New

Circuit

Breaker

New

Mounting

Bracket

Existing

Bracket

3x

3. Secure the new circuit breaker and insulating barrier

to the new mounting bracket with phillips head screws

in two places. See Figure 9.

Figure 9. Circuit Breaker Mounting Bracket

4. Cut new circuit breaker’s auxiliary wires as required

to allow enough slack when spliced with the existing

auxiliary wires.

5. Strip the insulation back 1/8 in. (3.2 mm) from the cut

ends to expose wire conductor.

6. Place ends of new C1 wire and existing C1 wire into

opposite ends of a butt splice and crimp. Repeat for

C2 wires. See Figure 10.

Figure 10. Splice Auxiliary Wires

New

Circuit

Breaker

New

Insulating

Barrier

New

Mounting

Bracket

2x

C1

C2

Existing

Auxiliary

Wires

Butt

Splice

DCA45USI — CIRCUIT BREAKER REPLACEMENT KIT INSTRUCTIONS P/N EE55781 — REV. #0 (04/01/11) — PAGE 5

7. Connect existing wires to the terminals on the new

circuit breaker. See Figure 11. Use 6mm allen wrench

to tighten screws.

Figure 11. Connect Wires to Terminals

OPERATION

1. Close control panel door.

2. Close rear cabinet door.

3. Reconnect negative battery cable.

4. Start generator as referenced in operation manual.

NOTICE

Make sure to install wires in the same orientation as

on the old circuit breaker.

6x

6mm Allen

Wrench

Existing

Wires

Your Local Dealer is:

HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

United StateS

Multiquip Corporate Ofﬁce MQ Parts Department

18910 Wilmington Ave.

Carson, CA 90746

Contact: mq@multiquip.com

Tel. (800) 421-1244

Fax (800) 537-3927

800-427-1244

310-537-3700

Fax: 800-672-7877

Fax: 310-637-3284

Service Department Warranty Department

800-421-1244

310-537-3700

Fax: 310-537-4259 800-421-1244

310-537-3700

Fax: 310-943-2249

Technical Assistance

800-478-1244 Fax: 310-943-2238

mexico United Kingdom

MQ Cipsa Multiquip (UK) Limited Head Ofﬁce

Carr. Fed. Mexico-Puebla KM 126.5

Momoxpan, Cholula, Puebla 72760 Mexico

Contact: [email protected]

Tel: (52) 222-225-9900

Fax: (52) 222-285-0420

Unit 2, Northpoint Industrial Estate,

Globe Lane,

Dukinﬁeld, Cheshire SK16 4UJ

Contact: sales@multiquip.co.uk

Tel: 0161 339 2223

Fax: 0161 339 3226

Canada

Multiquip

4110 Industriel Boul.

Laval, Quebec, Canada H7L 6V3

Contact: jmartin@multiquip.com

Tel: (450) 625-2244

Tel: (877) 963-4411

Fax: (450) 625-8664

Multiquip Inc

and

the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property

of their respective owners and used with permission.

The information and speciﬁcations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in

this document are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change speciﬁcations, design or the information published

in this publication at any time without notice and without incurring any obligations.

DCA45USI

Circuit Breaker Replacement Kit