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
+DUGZDUH
.LW
D
C
A45USI
—
C
I
R
C
U
I
T
BR
EA
K
ER
R
EPL
AC
EMEN
T
KI
T
I
N
ST
RU
CT
I
O
N
S
P/
N
E
E
5
5
781
—
R
EV
.
#0
(03/0
9
/
11)
—
PA
G
E
1
DCA
45US
I
Circ
u
i
t Br
ea
k
e
r
R
epl
acem
ent Ki
t
T
he
f
o
llo
win
g
inst
ru
c
t
io
n
s are
in
t
e
n
d
e
d
t
o
as
sis
t
th
e
u
se
r
in
t
h
e
in
s
t
a
ll
at
io
n
o
f
t
he
Ci
r
c
u
i
t
Br
e
a
k
er Re
p
la
c
emen
t
Ki
t
f
o
r
us
e
o
n
the DCA45US
I g
e
n
e
rat
o
r
s
in
t
h
e eve
n
t
o
f a
circ
u
it
b
rea
ker f
ailu
re.
O
ld
-s
t
yl
e
c
ircu
i
t
b
r
e
ak
e
r
s
ar
e
n
o
lo
n
g
er
ava
ila
b
l
e.
Ple
a
s
e
r
ea
d
all
as
s
e
mbl
y
in
s
t
r
uc
t
io
n
s be
f
o
r
e
in
s
t
al
lin
g
t
h
e k
it
.
R
EQU
I
R
ED
TO
O
LS
PA
RT
S
Ver
i
fy t
hat
al
l
parts
are ac
counted f
or.
See Fi
gur
e 1 and
T
ab
l
e 1.
Fi
gure 1.
Ret
urn
Fuel
Li
ne
K
i
t
+
D
UG
ZDU
H
.
L
W
N
O
T
IC
E
T
he Breaker H
ardware K
i
t,
it
em 3, incl
udes more
hardw
are
t
han w
i
ll
be used
in t
he pro
c
edure
.
H
and-Hel
d
R
ot
ar
y
Sa
w
B
lue
Mask
ing Tape
P
h
i
ll
i
ps
H
ead
S
c
re
wd
r
i
ve
r
All
en W
renc
h
R
ul
er
Sc
ribe
Vacuum
(
Sho
p
Vac)
W
ire
C
utt
er
Fi
le
C
r
i
m
p T
ool
Bl
ac
k
Pr
imer
P
aint
WORK
SA
F
EL
Y!
O
nl
y
a
q
u
al
i
fi
e
d
servi
ce
t
ec
hni
ci
an
wi
th
pr
oper t
rai
n
ing
shoul
d pe
r
fo
rm
t
h
i
s i
ns
t
al
lat
io
n. Fol
l
ow
al
l
sh
op
safe
t
y
r
u
l
es
w
hen performing
t
hi
s
i
n
s
t
a
l
l
a
ti
o
n.
PR
EPA
R
AT
I
O
N
1.
Mak
e
sure
gen
er
at
o
r
i
s turned
of
f
and eng
i
ne
i
s co
ol
.
2
.
P
l
a
c
e
t
he
generator i
n a
n
a
rea f
ree
of
di
r
t
a
nd
debr
i
s
Mak
e su
re it i
s
on se
cu
r
e
level gro
u
n
d
w
i
th c
ho
c
k
bl
o
c
ks
un
derne
ath each
w
heel
t
o
preven
t
the
generator
f
rom
rolli
ng.
3.
D
i
sco
nnec
t
negat
iv
e battery
cabl
e
f
rom t
he battery
.
4
. Open rear cabi
net d
o
o
r
t
o
gai
n access
to control
panel.
5. L
ocate
th
e t
w
o
kn
ob
s at
th
e
u
p
per
c
o
r
n
er
s
o
f the
c
ontrol
pa
ne
l
door
. T
wi
st
k
nobs
to unl
oc
k
door
f
r
om
fram
e
. S
ee Figure
2. P
ul
l
c
ont
rol
panel
do
or
do
wn
to
a
ho
rizont
al
posi
tion.
T
a
bl
e
1
.
R
e
t
urn F
ue
l L
i
n
e
K
i
t
It
e
m
No
.
P
a
rt
No
.
D
e
s
cr
i
p
t
i
o
nQ
T
Y
.Re
ma
r
ks
1B
RE
A
KERK
I
T
4
5
US
I
Br
ea
ker
U
pd
a
t
e
K
i
t,
D
C
A
45
US
I
1
In
c
l
u
d
e
s
I
te
m
s
2
-
14
2
06018
0
75
21
C
i
rcu
i
t
B
r
e
a
ker
1
3
R
K
000
1B
r
e
ake
r
H
a
r
dwa
r
e
K
i
t1
I
nc
l
u
d
es
I
t
e
ms
3-
1
2
4
S
cre
w,
A
l
l
e
n
H
ea
d6
5
N
u
t,
Sq
uar
e6
6
H
ol
d
er
,
Nu
t
6
7
I
n
s
ul
at
i
n
g Bar
ri
er
1
8
Sc
r
e
w
,
Ph
i
l
l
ips
He
ad
3
9
Wa
s
h
er,
Lo
ck3
1
0
W
ash
er
, F
l
a
t3
1
1
Bracke
t,
M
o
un
t
i
n
g
1
12
S
c
r
ew,
P
hi
l
l
i
p
s
He
a
d
1
1
3
Bu
t
t
S
p
l
i
c
e
2
14
E
E5
57
8
1
I
ns
t
ruc
ti
o
n
s
,
D
CA45
B
r
eak
er
Upd
at
e
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
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
C1
C2
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
© COPYRIGHT 2011, MULTIQUIP INC.
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
/
