MQ POWER MODEL DCA-150SSJU PORTABLE GENERATOR

PARTS AND OPERATION MANUAL
To Table of Contents
© COPYRIGHT 2000, MULTIQUIP INC.
MQ POWER
MODEL DCA-150SSJU
PORTABLE
GENERATOR
Parts List No. M3870300214
Revision #0 (11/09/00)
MULTIQUIP INC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
SERVICE DEPARTMENT:
310-537-3700
800-421-1244
800-835-2551
FAX: 310-537-3927
FAX: 310-638-8046
E-mail:mq@multiquip.com • www:multiquip.com
To Table of Contents
PAGE 2 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Table of Contents
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310 - 537-3927
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 3
TABLE OF CONTENTS
Here's How To Get Help ............................................... 3
Table Of Contents ........................................................ 4
Parts Ordering Procedures .......................................... 5
Rules for Safe Operation .......................................... 6-9
Towing Safety Precaution .......................................... 10
Operation and Safety Decals ................................ 11-12
DCA 150Specifications .............................................. 13
MQPower DCA 150SSJU
AC Generator
General Information ................................................... 14
Major Components .................................................... 16
Dimensions ................................................................ 17
Control Panel Descriptions ................................... 18-19
Engine Operating Panel Descriptions ................... 20-21
Output Terminal Panel Descriptions ...................... 22-23
Installation ............................................................ 24-25
Pre Set-up ............................................................ 26-29
Load Application ........................................................ 30
Generator Start-up Procedure, Manual ................. 31-33
Generator Shut-Down Procedure ............................... 34
Maintenance ......................................................... 36-37
Engine Troubleshooting ......................................... 38-39
Generator/Engine Troubleshooting ............................. 40
MPEC Troubleshooting .............................................. 41
Explaination of Code in Remarks Column ................. 42
Suggested Spare Parts ............................................. 43
Generator Assembly ............................................. 44-45
Control Box Assembly ........................................... 46-47
Engine & Radiator Assembly................................. 48-51
Engine Operating Panel Assembly ........................ 52-53
Output Terminal Assembly ..................................... 54-55
Battery Assembly .................................................. 56-57
Muffler Assembly .................................................. 58-59
Fuel Tank Assembly .............................................. 60-61
Enclosure Assembly ............................................. 62-65
Rubber Seal Assembly .......................................... 66-67
Name Plate And Decals ........................................ 68-69
Terms and Condition of Sale — Parts ....................... 70
NOTE
Specification and part number
are subject to change without
notice.
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PARTS ORDERING PROCEDURES
■
■
■
■
■
■
■
Dealer account number
Dealer name and address
Shipping address (if different than billing address)
Return fax number
Applicable model number
Quantity, part number and description of each part
Specify preferred method of shipment:
•
•
•
•
UPS Ground
UPS Second Day or Third Day*
UPS Next Day*
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
•
Airborne Express*
Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
1-9 items
Additional Discount
3%
10+ items**
5%
Get special freight allowances
when you order 10 or more
line items via FAX!**
■ UPS Ground Service at no charge for freight
■ PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
*DISCOUNTS ARE SUBJECT TO CHANGE*
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Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
Fax order discount and UPS special programs revised June 1, 1995
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 5
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RULES FOR SAFE OPERATION
CAUTION:
Failure to follow instructions in this manual
may lead to serious injury or even death!
This equipment is to be operated by
trained and qualified personnel only! This
equipment is for industrial use only.
The following safety guidelines should always be used when
operating the DCA-150SSJU portable generator:
GENERAL SAFETY
■ DO NOT operate or service this equipment before
reading this entire manual.
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
■ High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with hot components can cause serious
burns.
■ NEVER operate this equipment without proper
protective clothing, shatterproof glasses,
steel-toed boots and other protective devices
required by the job.
■ The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is
restricted it will cause
serious damage to the
generator or engine and
may cause injury to
people. The generator
engine gives off DEADLY
carbon monoxide gas.
■ NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
CAUTION:
■ This equipment should not be operated by
persons under 18 years of age.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ NEVER use accessories or attachments,
which are not recommended by MQ Power for this
equipment. Damage to the equipment and/or injury to user
may result.
■ Manufacturer does not assume responsibility for any
accident due to equipment modifications.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ Always check the machine for loosened threads or bolts
before starting.
■ Always refuel in a well-ventilated area,
away from sparks and open flames.
■
Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool. DO NOT smoke around or near the
machine. Fire or explosion could result
from fuel vapors, or if fuel is spilled on a
hot engine.
■
NEVER operate the generator in an
explosive atmosphere or near combustible materials. An
explosion or fire could result causing severe bodily harm
or even death.
■ Topping-off to filler port is dangerous, as it tends to spill
fuel.
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RULES FOR SAFE OPERATION
CAUTION:
CAUTION:
■ DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
■ NEVER touch output terminals during operation. This is
extremely dangerous. Always stop the machine when
contact with the output terminals.
CAUTION:
■ Never connect the generator to house wiring. This is illegal
and very dangerous. Electrical shock could occur causing
damage to the generator and bodily harm even death.
CAUTION:
Radiator
1. Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
■ Never use damaged or worn cables when connecting
power tools or equipment to the generator. Make sure
power connecting cables are securely connected to the
generator’s output terminals, insufficient tightening of the
terminal connections may cause damage to the generator
and electrical shock.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 7
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RULES FOR SAFE OPERATION
Battery
CAUTION:
■ Never over fill the battery with water above
the upper limit.
The battery contains acids that can cause
injury to the eyes and skin. To avoid eye irritation, always
wear safety glasses. Use well insulated gloves when picking
up the battery. Use the following guidelines when handling
the battery:
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.
■ NEVER Run engine without air filter. Severe engine
damage may occur.
■ Always service air cleaner frequently to prevent carburetor
malfunction.
■ Always disconnect the battery before performing service
on the generator.
■ Always be sure the operator is familiar with proper safety
precaution s and operations techniques before using
generator.
■ Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.
■ DO NOT leave the generator running in the manual mode
unattended.
■ DO NOT allow unauthorized people to operate this
equipment.
■ Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
■ Refer to the John Deere Engine Owner's Manual for
engine technical questions or information.
Loading and Unloading (Crane)
■ Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.
■ Always drain fuel prior to lifting.
■ Always make sure crane or lifting device has been
properly secured to the hook of guard frame on generator.
■ NEVER lift the machine while the engine is running.
■ Use adequate lifting cable (wire or rope) of sufficient
strength.
■ When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.
■ NEVER allow any person or animal to stand underneath
the machine while lifting.
■ When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure the
generator during transport.
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RULES FOR SAFE OPERATION
Transporting
■ Always shutdown engine before transporting.
■ Tighten fuel tank cap securely.
■ Drain fuel when transporting generator over long distances
or bad roads.
■ Always tie-down the generator during transportation by
securing the generator.
■ If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
Emergencies
■ Always know the location of the nearest fire extinguisher
and first aid kit. Know the location of the nearest telephone.
Also know the phone numbers of the nearest ambulance,
doctor and fire department.
Maintenance Safety
■ NEVER lubricate components or attempt service on a
running machine.
■ Always allow the machine a proper amount of time to
cool before servicing.
■ Keep the machinery in proper running condition.
■ Fix damage to the machine immediately and always
replace broken parts.
■ Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
■ DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 9
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DCA-150SSJU — TOWING RULES FOR SAFE OPERATION
Towing Safety Precautions
CAUTION :
Check with your county or state safety
towing regulations department before towing
your generator.
To reduce the possibility of an accident
while transporting the generator on public roads, always
make sure the trailer (Figure 1) that supports the generator
and the towing vehicle are in good operating condition and
both units are mechanically sound.
The following list of suggestions should be used when towing
your generator:
■ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■ ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■ Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ The maximum speed for highway towing is 45 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of
terrain.
■ Place chocked blocks underneath wheel to prevent
rolling, while parked.
■ Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
■ Use the trailer’s hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.
■ Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve gas milage.
■ Avoid sharp turns to prevent rolling.
■ .Remove wheel stand when transporting.
■ DO NOT transport generator with fuel in tank.
■ ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
Figure 1. Generator with Trailer
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DCA-150SSJU — GENERATOR DECALS
The DCA -150SSJU generator is wquipped with a number of safety decals. These decals are provided for operator safety
and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 11
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DCA-150SSJU — GENERATOR DECALS
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DCA-150SSJU — SPECIFICATIONS
Table 1. Specifications
Generator Specifications
Model
DCA-150SSJU
Type
Revolving field, self ventilated, open protected type synchronous generator
Armature Connection
Star with Neutral
Zig Zag
Phase
3
Single
Standby Output
165 KVA (132 KW)
96KW
Prime Output
150 KVA (120 KW)
87KW
Voltage
240V or 480V
240/120V
Frequency
60 Hz
Speed
1800 rpm
Power Factor
0.8
1
Aux. AC Power
Single Phase, 60 Hz
Voltage
120 V
Output
4.8 KW (2.4 KW x 2)
Engine Specifications
Model
JOHN DEERE 6081 TF 001
Type
4-cycle, water-cooled, direct injection, turbo-charged
No. of Cylinders
6 cylinders
Bore x Stroke
4.57 in. x 5.08 in. (116 mm x 129 mm)
Rated Output
190HP/1800 rpm
Displacement
494 cu. in. (8100 cc)
Starting
Electric
Coolant Capacity
10.9 gal. (41 liters)
Lube Oil Capacity
8.5 gal. (32 liters)
9.7 gal. (36.7L)/hr at full load
7.5 gal. (28.3L)/hr at 3/4 load
5.3 gal. (20L)/hr at 1/2 load
3.5 gal. (13.2L)/hr at 1/4 load
Fuel Consumption
Battery
12V- 225AHx1
Fuel
#2 Diesel Fuel
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 13
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DCA-150SSJU — GENERAL INFORMATION
DCA-150SSJU FAMILIARIZATION
Generator
The MQ Power Model DCA-150SSJU is a 120 kW generator
that is designed as a high quality portable (requires a trailer
for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.
Engine Control Panel
The “Engine Control Panel” is provided with the following:
z Tachometer
z Water Temperature Gauge
z Oil Pressure Gauge
z Charging Ammeter Gauge
z Engine Speed Switch
z Microprocessor Engine Controller(if applicable)
z Pre-Heat Button
z Pre-Heat Lamp
z Key Ignition starter
z Fuel Gauge
z Panel Light
z Panel Light Switch
Generator Control Panel
The “Generator Control Panel” is provided with the following:
z Output Voltage Adjustment Knob
z Frequency Meter (Hz)
z AC Ammeter (Amps)
z AC Voltmeter (Volts)
z Ammeter Change-Over Switch
z Voltmeter Change-Over Switch
Open Delta Excitation System
The DCA-150SSJU generator is equipped with the state of
the art "Open-Delta" excitation system. The open delta
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
There are four leads: A, B, C and D. During light loads, the
power to the Automatic Voltage Regulator (AVR) is supplied
from the leads parallel connections of B&C. When loads
increase, the AVR switches and accepts power from leads
A&D. The output of leads A&D increase proportionally with
load. This of adding the voltages to each phase provides
better voltage response during heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "fixed ceiling" and responds
according the demands of the required load.
Engine
The DCA-150SSJU is powered by a 4 cycle, water cooled,
turbocharged John Deere 6081TF001diesel engine. This
engine is designed to meet every performance requirement
for the generator. Reference Table 1, page 13 for engine
specifications.
In keeping with Multiquip's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
The basic controls and indicators for the DCA-150SSJU
generator are addressed on the following pages.
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
z Three 240/139V output receptacles, 50 amp
z Two 120V input receptacles, 20 amp
z 3 Load Circuit Breakers 265V @65 amps
z 2 Load GFCI Circuit Breakers 265V@ 20amps
Mechanical Governor System
The mechanical governor system control the RPM of the
engine. When the engine demands increase or decrease,
the mechanical governor system regulates the frequency
variation to ±1.5%. The electronic governor option increases frequency variation to ±.25%.
Control Box
The “Control Box” is provided with the following:
z Main Circuit Breaker400 amps
z Over-Current Relay
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DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 15
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DCA-150SSJU ___ MAJOR COMPONENTS
Figure 2. Major Components
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DCA-150SSJU — DIMENSIONS
Figure 3. Dimensions
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 17
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DCA-150SSJU — CONTROL PANEL
Figure 4. Control Panel
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DCA-150SSJU — CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-150SSJU " Control Panel " (Figure 4).
1.
Pilot Lamp – Indicates that the generator is working
properly.
2.
Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
3.
Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
AC Ammeter – Indicates the amount of current the
load is drawing from the generator.
4.
5.
AC Voltmeter – Indicates the single phase output
voltage present at the UNV terminals.
6.
Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off.
7.
Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
8.
Panel Light Switch – When activated will turn on control
panel light.
Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage
9.
10. Main Circuit Breaker – This three-pole, 800 amp main
breaker is provided to protect the UNV voltage output
terminals from overload.
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DCA-150SSJU — ENGINE OPERATING PANEL
Figure 5. Engine Operating Panel
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DCA-150SSJU — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of B. Low Oil Pressure – Indicates the engine pressure
the DCA-150SSJU " Engine Operating Panel " (Figure 5).
has fallen below 15 psi. The oil pressure is detected
using variable resistive values from the oil pressure
1. Panel light - Normally used in dark places or at night.
sending unit. This is considered a major fault.
When activated, panel will luminate. When the generator
is not in use, turn the panel light switch to the ‘OFF’ C. High Coolant Temperature – Indicates the engine
position.
temperature has exceeded 215°F. The engine
temperature is detected using variable resistive values
2. Panel light switch- When activiated, will turn on control
from the temperature sending unit. This is considered a
panel light.
major fault.
3. Oil Pressure Gauge – During normal operation this
gauge be should read in the “GREEN” zone. When D. Overcrank Shutdown – Indicates the unit has
attempted to be started a pre- programmed number of
starting the generator the oil pressure mar read a little
times, and has failed to start. The number of cycles
bit higher, but after the engine warms up the oil pressure
and duration are programmable. It is pre-set at 3 cycles
should return to the green zone.
with a 10 second duration. This is considered a major
4. Water Temperature Gauge – During normal operation
fault.
this gauge be should read in the “GREEN” zone.
E. Overspeed Shutdown – Indicates that the engine is
5. Charging Ammeter Gauge – Indicates the current
running at an unsafe speed. This is considered a major
being supplied by the engine’s alternator which provides
fault.
current for generator’s control circuits and battery
F. Engine Running – Indicates that engine is running
charging system.
at a safe operating speed.
6. Fuel Gauge - Indicates amount of diesel fuel available.
9. Throttle Handle - This handle controls the speed of
7. Tachometer – Indicates engine speed in RPM’s for 60
the engine (low or high).
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour 10. Pre-Heat Button – Press hold this button until the preheat lamp is lit (ON).
meter will record the number of operational hours that
the generator has been in use.
11. Water Temperature Indicator - This light indicates the
water temperature is too high and will shut down the
8. Ignition Switch - This switch is used to turn on or off
engine.
the engine with a key.
8a. MPEC – Microprocessor Engine Control Module – 12. Oil Pressure Indicator - This light indicates the oil
pressure is either too high or too low and will shut down
(MPEC) has a vertical row of status LED's (Figure 5),
the engine.
that when lit, indicate that a engine malfunction (fault),
has been detected. When a fault has been detected the
MPEC will evaluate the fault and all major faults will
shutdown the generator.
A. Off/Manual/Auto Switch – This switch controls the
running of the generator. If this switch is left in the "OFF"
position, the generator will not run. When this switch is
set to the manual position, the generator will start
immediately.
If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place
theswitch in the auto position. In this position the
generator will monitor the AC line output from the
building's power source.
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DCA-150SSJU — OUTPUT TERMINAL PANEL
Figure 6.
Output Terminal Panel
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DCA-150SSJU — OUTPUT TERMINAL VOLTAGE SELECTION
Figure 7. Output Terminal Voltage Selection
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 23
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DCA-150SSJU — INSTALLATION
Outdoor Installation
Install the generator in a location where it will not be exposed
to rain or sunshine. Make sure the generator is on secure
level ground so it cannot slide or shift around. Also install
the generator so the exhaust will not be discharged in the
direction of nearby homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to the
engine and alternator parts.
CAUTION :
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
CAUTION :
An electric shock may happen when
vibrators are used. Pay close attention to
handling when operating vibrators and
always use rubber boots and gloves to
insulate the body from electrical shock.
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 8) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
NOTE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
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DCA-150SSJU — INSTALLATION
Figure 8.
Typical Generator Grounding Application
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DCA-150SSJU — PRE-SETUP
General Inspection Prior to Operation
The DCA-150SSJU generator has been thoroughly inspected
and accepted prior to shipment from the factory. However,
be sure to check for damaged parts or components, or loose
nuts and bolts, which could have occurred in transit.
Extension Cable
When electric power is to be provided to various tools or
loads at some distance from the generator, extension
cords are normally used. Cables should be sized to allow
for distance in length and amperage so that the voltage
drop between the generator and point of use (load) is held
to a minimum. Use the Cable Selection Guide (Table 2 )
as a guide for selecting proper cable size.
Circuit Breakers
To protect the generator from an overload, a 3-pole, 400 amp,
main circuit breaker is provided to protect the UNV output
terminals from overload. In addition two single-pole, 20 amp
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload. Three 50 amp load circuit breakers
have also been provided to protect the load side of the
generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
NOTE
ALWAYS consult with a licensed
electrician for correct extension
cord wire size.
Table 2. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Current in
Amperes At 120 At 240
Volts
Volts
Maximum Allowable Cable Length
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
300
600
1000 ft.
600 ft.
375 ft.
250 ft.
5
600
1200
500 ft.
300 ft.
200 ft.
125 ft.
7.5
900
1800
350 ft.
200 ft.
125 ft.
100 ft.
10
1200
2400
250 ft.
150 ft.
100 ft.
15
1800
3600
150 ft.
100 ft.
65 ft.
20
2400
4800
125 ft.
75 ft.
50 ft.
CAUTION: Equipment damage can result from low voltage.
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DCA-150SSJU — PRE-SETUP
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way, but without being screw
into the filler hole, verify that the oil level is maintained
between the two notches (Figure 9) on the dipstick. See
Table 3 for proper selection of engine oil.
Fuel
Fill the fuel tank with clean and fresh diesel fuel. DO NOT
fill the tank beyond capacity.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 13,
Specification Table 1.
The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel. Wipe up any spilled fuel immediately.
CAUTION:
Never fill the fuel tank while the engine is
running or in the dark. Diesel spillage on a
hot engine can cause a fire or explosion.
If diesel spillage occurs, wipe up the spilled
diesel completely to prevent fire hazards.
Coolant
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.
Figure 9. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean and viscous. If the oil is not clean, drain the oil by
removing the oil drain plug, and refill with the specified amount
of oil as outlined in the John Deere Engine Owner's
Manual.
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
Table 3. Recommended Motor Oil
Temperature Range
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
SAE 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
Below 5° C (-15°)
SAE 10W or SAE 10W-30
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 27
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DCA-150SSJU — PRE-SETUP
CAUTION :
When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.
Day-to-day addition of coolant is done from the reserve tank.
When adding coolant to the radiator, DO NOT remove the
radiator cap until the unit has completely cooled. See Table
4 for engine, radiator, and reserve tank coolant capacities.
Make sure the coolant level in the reserve tank is always
between the "H" and the "L" markings.
Cleaning the Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the
battery disconnected.
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the John Deere Engine Owner's Manual.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the John
Deere Engine Owner's Manual.
Table 4. Coolant Capacity
Engine and Radiator
10.3 Gal. (39 Liters)
Reserve Tank
2 Quarts (1.9 Liters)
The fan belt tension is proper if the fan belt bends 7 to 10
mm (Figure 10) when depressed with the thumb as shown
below.
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 5) has been added.
Figure 10. Fan Belt Tension
CAUTION :
Table 5. Anti-Freeze Operating Temperatures
Freezing Point
Boiling Point
°C
°F
°C
°F
40
-24
-12
106
222
50
-37
-34
108
226
Never place hands near the belts or fan while
the generator set is running.
Vol %
Anti-Freeze
NOTE
When the anti-freeze is mixed with
water, the anti-freeze mixing ratio
must be less than 50%.
Battery
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68 F). If the specific gravity
should fall to 1.245 or lower, it indicates the battery is
discharged and needs to be recharged or replaced.
Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions. Always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help inhibit corrosion.
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DCA-150SSJU — PRE-SETUP
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 11) are properly
connected to the battery terminals as shown below. The
RED cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.
CAUTION :
Inadequate battery connections may cause
poor starting of the generator, and create
other malfunctions.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check hoses
for leaks.
Figure 11. Battery Connections
CAUTION :
If the battery cable is connected
incorrectly, electrical damage to the
generator will occur. Pay close attention
to the polarity of the battery when
connecting the battery.
When connecting battery do the following:
1. DO NOT connect the battery cables to the battery
terminals when the Off/Manual/Auto switch is in either
the manual or auto position (ON) if the generator is
installed with a microprossor engine controller. ALWAYS
make sure that the Off/Manual/Auto switch is in the
OFF position when connecting the battery. If the
generator is equipped with an ignition switch, makesure
the key is removed from the switch and is at
2. Place a small amount of grease around both battery
terminals. This will ensure a good connection and will
help prevent corrosion around the battery terminals.
If any hose (fuel or oil) lines are defective replace them
immediately.
Ether Canister Operation
To bleed the ether, crank the engine for at least two
revolutions, then momentarily depress the starting aid button
while the engine is cranking. If the engine does not start,
repeat the cranking process using only short bursts of ether
only while the engine is cranking. Stop injecting the fluid
after then engine starts. If the engine begins to die during
the first few minutes of operation, inject another small shot
of ether.
CAUTION :
Use only ether starting fluid while the
engine is turning or damage may occur.
WARNING :
Ether is hightly flammable. Do not use
near open fires, flames, or sparks.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 29
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DCA-150SSJU — LOAD APPLICATION
Single Phase Load
CAUTION:
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
Motors and motor-driven equipment draw
much greater current for starting than
during operation.
Generally, the wattage listed on the nameplate of the An inadequate size connecting cable which cannot carry
equipment is its rated output. Equipment may require 130— the required load can cause a voltage drop which can burn
150% more wattage than the rating on the nameplate, as out the appliance or tool and overheat the cable.
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
z When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.
NOTE
If wattage is not given on the
equipment's name plate, approximate
wattage may be determined by
multiplying nameplate voltage by the
nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 1.0. See Table 6. below
when connecting loads.
Table 6. Power Factor By Load
Type Of Load
Power Factor
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
Fluorescent lamps, mecury lamps
0.4 - 0.9
Electronic devices, communication
equipment
1.0
Common power tools
0.8
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
z When connecting a fluorescent or mercury lamp,
a capacity of up to the generating set’s rated output
(kW) multiplied by 0.6 can be used.
z When connecting an electric drill or other power
tools, pay close attention to the required starting
current capacity.
When connecting ordinary power tools, a capacity of up
to the generating set’s rated output (kW) multiplied by 0.8
can be used.
CAUTION:
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.
NOTE
If output (kVA) is not given on the
equipment nameplate, approximate
output may be determined by
multiplying voltage by amperage by
.
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DCA-150SSJU — GENERATOR START-UP PROCEDURE
2. Connect the load to the UNV terminals as shown in
Figure 13. These terminals can be found on the output
The engine's exhaust contains harmful
terminal panel, (see page 22 Figure 6). To gain access
emissions. ALWAYS ventilate the
to the output terminals lift the UNV cover. Tighten
exhaust when operating inside tunnels,
terminal nuts securely to prevent load wires from slipping
excavations or buildings. Direct exhaust
out.
away from nearby personnel.
WARNING:
Before Starting
Engine
1. Check the lubricating oil level prior to starting the engine.
Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.
2. When there is not enough lubricating oil, fill the crankcase
with high grade motor oil. Use a high quality detergent
oil classified CC or higher (See Table 3 on page 27).
3. Check the coolant level in the radiator and subtank.
Replenish with antifreeze as necessary. Always maintain
the coolant level between the FULL and LOW markings
on the coolant container. Be sure that the radiator cap is
fastened securely.
4. Check the fuel level on the fuel gauge. If fuel is low, fill
the fuel tank with clean fresh unleaded automotive diesel.
If diesel spillage occurs, completely wipe up the spilled
fuel immediately.
Figure 13. UNV Terminal Lugs (Load)
3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 14).
Before Starting
Generator and Control Panel
CAUTION:
z NEVER start the engine with the
main, GFCI or load circuit breakers
in the ON position.
IVE
ST
PO
1. Be sure to disconnect the electrical load and switch the
main, load and G.F.C.I. circuit breakers (Figure 12) to
the “OFF” position prior to starting the engine.
E
TIV
GA
NE
Y
ER
TT
BA
Figure 14. Battery Connections
Figure 12. Main, GFCI and
Load Circuit Breakers
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 31
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DCA-150SSJU — GENERATOR START-UP PROCEDURE
5. Close all engine enclosure doors (Figure 15).
10. After engine starts, verify that the "Engine Running"
status LED (Figure 20) on the Microprocessor Engine
Control Module (MPEC) display is "ON" (lit)
(if applicable).
Figure 15. Engine Enclosure Doors
6. When starting the generator in COLD weather conditions,
press and hold the engine preheat button (Figure 16).
Figure 20. MPEC Engine Running Status LED
11.
Let the engine warm up for a few minutes. Then
pull and turn the throttle lever to the right to set the
engine speed to ‘high’(Figure 21).
Figure 16. Engine Pre-Heat Button
7. Check the engine throttle lever is in ‘low’ position(Figure
17).
Figure 17. Engine Throttle Lever (low)
8.
Turn the key to ‘Start’ until the engine starts (Figure
18). Then release the key to ‘Run’.
Figure 21. Engine Throttle Lever (high)
12. The generator's frequency meter (Figure 22) displays
the 60 cycle output frequency in HERTZ.
Figure 18. Ignition Switch (Start)
Figure 22. Frequency Meter (Hz)
9. Place the Off/Manual/Auto switch (Figure 19) in the
MANUAL position (down). Observe that the engine begins
to crank (iff applicable).
13. The generator's voltage meter (Figure 23) displays the
120 VAC in VOLTS. If the voltage is not within the
specified frequency tolerance, use the voltage
adjustment control knob (Figure 24) to increase or
decrease the desired voltage.
Figure 19. Off/Manual/Auto Switch (Manual)
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DCA-150SSJU — GENERATOR START-UP PROCEDURE
WATER
Figure 23. Voltage Meter (Volts)
TEMP
Figure 27. Coolant Temperature Gauge
17. The tachometer (Figure 28) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800
RPM’s.
Figure 24. Voltage Adjust Control Knob
14. The ammeter (Figure 25) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator’s alternator.
20
40
0
60
75
A
Figure 28. Engine Tachometer
18. Turn the MAIN, GFCI and LOAD circuit breakers to
their ON position (Figure 29).
Figure 25. Ammeter (No Load)
15. The engine oil pressure gauge (Figure 26) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure is approximately
25 psi.
Figure 29. Main and GFCI Circuit Breakers
19. Observe the generator's ammeter (Figure 30) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if the load is in use.
20
40
0
Figure 26. Oil Pressure Gauge
16. The coolant temperature gauge (Figure 27) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature is between 165 and
215 degrees fahrenheit (Green Zone).
60
75
A
Figure 30. Ammeter (Load)
20. The generator will run until manually stopped or an
abnormal condition occurs.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 33
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DCA-150SSJU — GENERATOR SHUT-DOWN PROCEDURE
With an Engine Controller, starting the generator in the ENGINE SHUTDOWN
"AUTO" mode is similar to starting the generator in the To shutdown the generator, use the following procedure:
"MANUAL" mode, with a few exceptions.
1. Switch both the MAIN, GFCI and LOAD circuit breakers
(Figure 32)to the “OFF” position.
CAUTION:
When running the generator in the AUTO
mode, remember the generator can start
up at any time without warning. NEVER
attempt to perform any maintenance when
the generator is in the auto mode.
When starting generator in Auto mode use the "Manual Startup" procedure except where noted (see below).
1. Perform steps 1 through 7 (Before Starting, page 3132) as outlined in the manual starting procedure.
2. Place the Off/Manual/Auto switch (Figure 31) in the
AUTO position (up).
Figure 32. Main, GFCI and Load
circuit breakers
2.
Set the engine throttle lever to the idle (low) position.
3. Let the engine cool by running it for 3-5 minutes with no
load applied.
4. Turn the starter switch to “OFF” position.
OR
4. Place the Off/Manual/Auto Switch (Figure 33) in the "OFF/
RESET" position (if applicable).
Figure 31. Off/Manual Auto Switch
(AUTO)
5. Continue to follow the steps outline in the manual startup procedure (start at step 11, page 32).
Figure 33. Off/Manual Auto Switch (OFF)
5. Verify that the "Engine Running" status LED (Figure 34)
on the Microprocessor Engine Control Module (MPEC)
display is "OFF" (not lit).
Figure 34. MPEC Engine Running
Status LED (OFF)
6.
Remove the load from the UNV terminal strip.
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DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 35
To Table of Contents
DCA-150SSJU — MAINTENANCE
General Inspection
Prior to each use, the generating set should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for fuel
or oil leaks.
Engine Side, Fuel, Oil and Coolant (Refer to the Engine
Instruction Manual)
Air Cleaner
Every 50 hours: Remove air cleaner element and clean heavy
duty paper element with kerosene, or foam element with
liquid detergent and hot water. Wrap foam element in a cloth
and squeeze dry. For heavy duty paper element, wipe
excess kerosene with towel.
Cleaning the Fuel Strainer
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in diesel. Securely
fasten the fuel strainer cap so that fuel will not leak. Check
the fuel strainer every 200 hours of operation or once a month.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil level
must be between the two notches on the dipstick as shown
in page 27, Figure 9.
Cleaning and Installing Ether Cnnister
Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.
Remove safety cap from ether canister. Remove spray
nezzle from canister. Remove the old cansiter assembly
from the solenoid and properly dispose the old canister.
Install the new canister and canister assembly to the
solenoid.
Removing Water from the Tank
CAUTION:
Fuel Addition
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
cock and drain the contents. During cold weather, the greater
the empty volume inside the tank, the easier it is for water
to condense. This can be reduced by always keeping the
tank as full as possible.
Air Removal
Ether is highly flammable. Do not use near
open fires, flames, or sparks. Do not leave
the canister assembly valve open.
Generator Storage
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or For storage of the generator for over 30 days, the following
after disassembling the fuel system, bleed the system is required:
z Drain the fuel tank completely.
according to the following procedure.
To restart after running out of fuel, turn the key switch to the z Completely drain the oil from the crankcase and refill
with fresh oil.
“START” position for 15-30 seconds. Try again, if needed.
This unit is equipped with an automatic air bleeding system. z Clean all external parts of the generator with a cloth.
Service Daily
If engine is operating in very dusty and dry grass conditions,
a clogged air cleaner will result in high fuel consumption,
loss of power and excessive carbon buildup in the
combustion chamber.
z Cover the generating set and store in a clean, dry place.
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DCA-150SSJU — MAINTENANCE
INSPECTION / MAINTENANCE
10 Hrs
DAILY
Check Engine Fluid Levels
X
Check Air Cleaner
X
Check Battery Acid Level
X
Check Fan Belt Condition
X
Check for Leaks
X
Check for Loosening of Parts
GENERATOR
500 Hrs
1000 Hrs
X
Replace Engine Oil and Filter *
X
Clean Air Filter
X
Drain Bottom of Fuel Tank
X
Clean Unit, Inside and Outside
X
1
ENGINE
250 Hrs
Change Fuel Filter *2
X
Replace Ether Canister
X
Clean Radiator and Check Coolant Protection
Level
X
Replace Air Filter Element
X
Change Corrosion Resistor
X
Check all Hoses and Clamps
X
Clean Inside of Fuel Tank
X
Measure Insulation Resistance Over 3M ohms
X
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Replace fuel filter at 250 Hours, first time only.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 37
To Table of Contents
DCA-150SSJU — TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper
handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for
diagnosis based on the Engine Troubleshooting (Table 7). If
the problem cannot be remedied, consult our company's
business office or service plant.
TABLE 7. ENGINE TROUBLESHOOTING
SYMPTOM
Engine does not start.
POSSIBLE PROBLEM
SOLUTION
No fuel?
Replenish fuel.
Air in the fuel system?
Bleed system.
Water in the fuel system?
Remove water from fuel tank.
Fuel pipe clogged?
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity of fuel
or engine oil at low temperature?
Use the specified fuel or engine oil.
Fuel with low cetane number?
Use the specified fuel.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Incorrect injection timing?
Adjust.
Fuel cam shaft worn?
Replace.
Injection nozzle clogged?
Clean injection nozzle.
Injection pump malfunctioning?
Repair or replace.
Seizure of crankshaft, camshaft,
piston, cylinder liner or bearing?
Repair or replace.
Compression leak from cylinder?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Improper valve timing?
Correct or replace timing gear.
Piston ring and liner worn?
Replace.
Excessive valve clearance?
Adjust.
Battery discharged?
Charge battery.
Starter malfunctioning?
Repair or replace.
Key switch malfunctioning?
Repair or replace.
Wiring disconnected?
Connect wiring.
Starter does not run.
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DCA-150SSJU — TROUBLESHOOTING (ENGINE)
TABLE 7. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
Engine revolution is not smooth.
Either white or blue exhaust gas
is observed.
Either black or dark gray exhaust
gas is observed.
Deficient output.
POSSIBLE PROBLEM
SOLUTION
Fuel filter clogged or dirty?
Clean or change.
Air cleaner clogged?
Clean or change.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Injection pump malfunctioning?
Repair or replace.
Incorrect nozzle opening
pressure?
Adjust.
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe clogged?
Clean.
Governor malfunctioning?
Repair.
Excessive engine oil?
Reduce to the specified level.
Piston ring and liner worn or
stuck?
Repair or replace.
Incorrect injection timing?
Adjust.
Deficient compression?
Adjust top clearance.
Overload?
Lessen the load.
Low grade fuel used?
Use the specified fuel.
Fuel filter clogged?
Clean or change.
Air cleaner clogged?
Clean or change.
Deficient nozzle injection?
Repair or replace the nozzle.
Incorrect injection timing?
Adjust.
Engine's moving parts seem to
be seizing?
Repair or replace.
Uneven fuel injection?
Repair or replace the injection pump.
Deficient nozzle injection?
Repair or replace the nozzle.
Compression leak?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 39
To Table of Contents
DCA-150SSJU — TROUBLESHOOTING (GENERATOR/ENGINE)
Practically all breakdowns can be prevented by proper the Engine and Radiator Troubleshooting (Table8)and MPEC
handling and maintenance inspections, but in the event of a Trouble shooting (iff applicable) (Table 9) . If the problem
breakdown, use the tables shown for diagnosis based on cannot be remedied, consult our company's business office
or service plant.
TABLE 8. ENGINE & GENERATOR TROUBLESHOOTING
SYMPTOM
Engine fails to start and starter
does not rotated.
Engine fails to start and starter
rotates.
Engine starts and remains at low
speed.
Engine speed rises and no
volteage is present n AC power
source.
POSSIBLE PROBLEM
SOLUTION
Dead battery?
Replace battery.
Defective starter switch?
Replace switch.
Fuse F5 burned out?
Replace fuse.
Broken pre-heat circuit?
Check pre-heat circuit.
No fuel?
Add fuel.
Defective wiring?
Check wiring.
Clogged fuel strainer?
Clean or replace.
Clogged air cleaner?
Clean or replace.
Disconnected wiring?
Check and repair wiring.
No voltage present in AC power
source?
Replace rectifier (RE1).
Defective rotor?
Replace rotor.
Defective voltmeter?
Replace voltmeter.
Disconnected wiring?
Check and repair wiring.
Layer short-circuit in armature
winding?
Replace armature.
Engine speed rises and AC power Defective circuit breaker (protector)?
voltage is too low or cannot be
Layer short-circuit, broken wires in
used.
armature winding?
Replace circuit breaker (protector).
Repair or replace armature.
Engine speed rises and battery
discharges too soon.
Defective engine regulator?
Replace regulator.
Defective wiring?
Repair or replace wiring.
Engine speed rises and engine
seems overloaded.
Defective alternator?
Repair or replace alternator.
Damaged alternator bearing?
Replace alternator bearings.
PAGE 40 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Table of Contents
DCA-150SSJU — TROUBLESHOOTING (MPEC)
TABLE 9. MPEC TROUBLESHOOTING
Sympton
Low oil pressure light is
on.
Low coolant level light
is on.
Possible Cause
Solution
Low oil level?
Fill oil level.
Oil pressure sending unit failure?
Replace oil pressure sending unit.
Time delay malfuntion in MPEC?
Refer to dealer.
Wire shorted?
Inspect/repair wire.
Low coolant level?
Fill coolant level.
Sending unit failure?
Replace sending unit.
Low battery voltage?
Replace/charge battery.
Fan belt tension incorrect?
Tighten/replace fan belt.
Air flow is not circulation through radiator?
Clean/repair radiator grill.
Doors open?
Close doors.
High coolant temperture Exhaust leaking?
light is on.
Generator being overloaded?
Replace/repair gaskets or faulty part.
Check/reduce load.
Thermostat failure?
Replace thermostat.
Air intake blocked?
Clear all air intakes.
Temperature switch failure?
Replace temperature switch.
No or low Fuel?
Fill fuel level.
MPEC needs to be calibrated?
Refer to dealer.
RPM engine speed too high?
Adjust RPM.
Governor actuator needs to be adjusted?
Adjust governor actuator.
Governor controller needs to be adjusted?
Adjust governor controller.
MPEC needs to be calibrated?
Refer to dealer.
Magnetic pick up out of adjustment?
Adjust magnetic pick up.
Magnetic pick up dirty?
Clean magnetic pick up.
Overcrank light is on.
Overspeed light is on.
Loss of MPU light(s) or
on.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 41
To Table of Contents
EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.
Items Found In the “Items Number” Column
All parts with same symbol in the number column, , #,
*
+, %, or n, belong to the same assembly or kit.
Note: If more than one of the same reference number is
listed, the last one listed indicates newest (or latest)
part available.
PAGE 42 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Table of Contents
DCA-150SSJU — SUGGESTED SPARE PARTS
DCA-150SSJU W/JOHN DEERE 6081TF001DIESEL ENGINE
1 to 5 Units
Qty.
P/N
Description
10 .............. 0602046379 .....................AIR FILTER
10 .............. 0602042591 .....................FUEL FILTER
10 .............. 0602041291 .....................OIL FILTER
1 ................ 0601808803 .....................CIRCUIT BREAKER
2 ................ 0602011492 .....................ENGINE FAN BELT
1 ................ 0602100056 .....................SWITCH, STARTER
5 ................ AR51481 ..........................KEY SET, STARTER SWITCH (2)
2 ................ 0602122281 .....................OIL SWITCH
1 ................ M3310500203 ..................RADIATOR HOSE (UPPER)
1 ................ M3310500303 ..................RADIATOR HOSE (LOWER)
1 ................ 0605505070 .....................FUEL CAP
1 ................ 0601820671 .....................AUTOMATIC VOLTAGE REGULATOR
1 ................ 0601808815 .....................MAIN CIRCUIT BREAKER
1 ................ 0601808804 .....................CIRCUIT BREAKER
1 ................ 0602103092 .....................PILOT LAMP
2 ................ 0601810245 .....................BULB, PILOT LAMP
1 ................ 0602011068 .....................CAP, RADIATOR
1 ................ 0602122271 .....................UNIT, OIL PRESSURE
1 ................ 0602123261 .....................UNIT, WATER TEMPERATURE
1 ................ 0602121080 .....................CHARGING AMMETER
NOTE
Part number on this Suggested Spare
Parts list may supercede/replace the
P/N shown in the text pages of this
book.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 43
To Table of Contents
DCA-150SSJU — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 44 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Generator Assy.
To Table of Contents
DCA-150SSJU — GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
*1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
2
3
4
5
6
7
8
Full View 9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
PART NO.
C0110000102
8131070013
8131611914
8131015003
0012112035
0042612000
8101026013
0601821349
0601822601
8001020004
8001020504
0010110020
0040010000
0601000209
0076506312
C0130000003
0845041804
8131315202
8101350013
0012110060
0042610000
031110160
0010112035
0040012000
031112230
8131310104
8131312204
8131331003
0105050616
8101333003
0010106030
0040006000
952404470
M3163400303
0013904064
EM923344
0070506306
0012810030
0013904032
EM923344
C0131300004
0605000013
0030016000
0040016000
020106050
PART NAME
QTY.
REMARKS
ROTOR ASS’Y
1
FIELD ASS’Y
1
FAN
1
COUPLING DISK
8
BALANCING PLATE
1
HEX. HEAD BOLT
10
LOCK WASHER
10
SET PLATE RECTIFIER
1
RECTIFIER .................................................. 2 ............. PT 3610
SERGE ABSORBER .................................... 1 ............. ERZ- M14JK621A
INSULATOR WASHER
1
INSULATOR WASHER
1
HEX. HEAD BOLT
4
LOCK WASHER
4
BALANCING WEIGHT KIT
1
CERAMIC BEARING .................................... 1 .............. 6312 SN34 DDU C3
STATOR ASS’Y
1
GROMMET
2
END BRACKET
1
FIELD ASS’Y. EXCITER
1
HEX. HEAD BOLT
4
LOCK WASHER
4
PLAIN WASHER ........................................... 4 ............. REPLACES 0041210000
HEX. HEAD BOLT
6
LOCK WASHER
6
PLAIN WASHER ........................................... 6 ............. REPLACES 0041212000
COVER, BEARING
1
GASKET BEARING
1
COVER, END BRACKET
1
HEX. HEAD BOLT ...................................... 10 ............. REPLACES 0017106012
COVER, END BRACKET
1
HEX. HEAD BOLT
2
LOCK WASHER
2
PLAIN WASHER ........................................... 2 ............. REPLACES 0041206000
COUPLING RING
1
HEX. HEAD BOLT
8
LOCK WASHER ............................................ 8 ............. REPLACES 0043604000
BEARING ..................................................... 1 ............. 6306ZZ
HEX. HEAD BOLT
12
HEX. HEAD BOLT
12
LOCK WASHER .......................................... 12 ............. REPLACES 0043604000
COVER, FAN
1
RUBBER SUSPENSION
2
HEX. NUT
2
LOCK WASHER
2
NUT .............................................................. 1 ............. REPLACES 0600815000
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 45
To Table of Contents
CONTROL BOX ASSY.
DCA-150SSJU —CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 46 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Table of Contents
To Control Box Assy.
DCA-150SSJU — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
PART NAME
25
26
27
28
29
30
31
32
33
34
35
36
37
38
M3246700814
M3213000302
0601808815
0021006080
0601823863
0021304015
0601820671
0027105010
0601806127
011808015
0601820845
0601820846
M1260600004
0021304015
0207004000
0027104010
M3213500013
011106015
M3923100014
M3213600203
0330000370
0027104010
011106015
M3213600304
011106015
0016906015
0040506000
M3223000303
0601807630
0601808954
0601801040
0601806814
0601801041
0601840073
0601840121
M1223100004
0027105015
0027105015
M9220100004
0080200007
0601821370
39
40
41
42
43
44
45
0027104020
0602200478
0027105040
0602202592
011808015
0602202597
0027105015
WIRE HARNESS, GENERATOR
1
CONTROL BOX
1
CIRCUIT BREAKER ...................................................... 1 .......... LAF364001021 3P 400A
MACHINE SCREW
4
RELAY UNIT .................................................................. 2 .......... MSA9013A
MACHINE SCREW
4
REPLACES 0027104015
AUTOMATIC VOLTAGE REGULATOR ........................ 1 ...........NTA- 5A- 2DB
MACHINE SCREW
4
CURRENT TRANSFORMER ........................................ 3 ...........814- 943 300/5A
MACHINE SCREW
6
REPLACES 0027106015
OVER CURRENT RELAY ............................................. 1 .......... LR2D1308
OVER CURRENT RELAY ............................................. 1 .......... LA7D1064
FITTING BRACKET
1
MACHINE SCREW ........................................................ 2 .......... REPLACES 0027104015
HEX. NUT
2
MACHINE SCREW
2
CONTROL BOX COVER
1
HEX. HEAD BOLT .......................................................... 4 .......... REPLACES 0016906015
SELECTOR SWITCH .................................................... 1 .......... VY- 200
SWITCH BRACKET
1
EDGES .......................................................................... 2 .......... REPLACES 0330000370
MACHINE SCREW
4
HEX. HEAD BOLT .......................................................... 8 .......... REPLACES 0016906015
SWITCH COVER
1
HEX. HEAD BOLT .......................................................... 4 .......... REPLACES 0016906015
HEX. HEAD BOLT
13
TOOTHED WASHER
1
CONTROL PANEL
1
FREQUENCY METER .................................................. 1 .......... 264250DJDJ9
AC AMMETER ............................................................... 1 .......... 260240LSLS1JBZ
CHANGE - OVER SWITCH, AMMETER ...................... 1 .......... SL - 2AS
AC VOLTMETER ........................................................... 1 .......... 264230SJSJ9
CHANGE - OVER SWITCH, VOLTMETER .................. 1 .......... SL - 2VS
RHEOSTAT ( VOLTAGE REGULATOR) ....................... 1 .......... RA20A2SE102BJ
KNOB
1
STOPPER
1
MACHINE SCREW
2
MACHINE SCREW
4
SET SCREW
1
SNAP RING
1
RECTIFIER .................................................................... 1 .......... REPLACES 0601823240;
DE 4503
MACHINE SCREW
1
EMERGENCY RELAY ................................................... 1 .......... 10701 - 60603
MACHINE SCREW
2
STARTER RELAY .......................................................... 1 .......... AT141011
MACHINE SCREW ........................................................ 2 .......... REPLACES 0027106015
RELAY ............................................................................ 1 .......... AL81719
MACHINE SCREW
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Full View 24
QTY.
REMARKS
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 47
To Table of Contents
CONTROL BOX ASSY.
DCA-150SSJU —ENGINE AND RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 48 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Engine Assy.
To Table of Contents
DCA-150SSJU —ENGINE AND RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
1
1-1
1-2
2
3
4
5
6
7
8
9
10
11
12
12-1
13
14
15
Full View 16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PART NO.
M3923200024
0602011492
0602041291
0602042591
0602060012
0602061001
0013904178
0043004000
M3303200003
0013907076
0043007000
0605000011
0030016000
0040016000
0602012720
0602011068
0602010691
0602010795
012210025
M3310200604
M3310200504
0013003019
0043003000
0043103000
011008020
M3310500203
M3310500303
0605515148
0605515147
0605512194
7812014003B
M9200200004
0150000018
011206020
0191300730
0605515189
0602046255
0602046379
0602040650
PART NAME
QTY.
REMARKS
ENGINE ............................................................1 .......... JOHN DEERE 6081TF
FAN BELT .........................................................1 .......... 2402
ELEMENT, OIL FILTER ....................................1 .......... RE57394
ELEMENT, FUEL FILTER.................................1 .......... AR86745
BLOWER FAN ..................................................1 .......... REPLACES 0602060002;
RE20967
FAN SPACER ...................................................1 .......... R128767
HEX HEAD BOLT
6
LOCK WASHER
6
ENGINE FOOT
2
HEX HEAD BOLT
8
LOCK WASHER
8
RUBBER SUSPENSION
2
HEX NUT
2
LOCK WASHER
2
RADIATOR ........................................................1 .......... RE65161
CAP
1
SHROUD ..........................................................1 .......... JOHN DEERE R132912
FAN COVER .....................................................1 .......... C281- 004- 4210
HEX HEAD BOLT .............................................8 .......... REPLACES 0016910025
RADIATOR BRACKET
1
RADIATOR BRACKET
1
HEX HEAD BOLT
8
LOCK WASHER
8
PLAIN WASHER
8
HEX HEAD BOLT .............................................8 .......... REPLACES 0016908020
RADIATOR HOSE
1
RADIATOR HOSE
1
HOSE BAND
3
HOSE BAND
1
HOSE JOINT
1
DRAIN JOINT ...................................................1 .......... REPLACES M2320300103
DRAIN BOLT
1
O RING
1
HEX HEAD BOLT .............................................2 .......... REPLACES 0016906020
DRAIN HOSE
1
HOSE BAND
2
AIR CLEANER .................................................1 .......... FWG120063
ELEMENT, AIR CLEANER ...............................1 .......... XLP18- 2035
INDICATOR, AIR CLEANER .............................1 .......... RBX00- 2252
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 49
To Table of Contents
DCA-150SSJU —ENGINE AND RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 50 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Engine Assy.
To Table of Contents
DCA-150SSJU —ENGINE AND RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Full View
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
PART NO.
0602040591
011008020
020108060
M3373100103
0605515200
0602022564
0602021165
0602022562
0602022792
0602021070
0602021572
M9300000203
0802010900
M3316100104
011008020
0193601200
M3313100104
M3493600004
011008020
M3483400104
011008020
0602220911
011008020
0602122281
M9200100704
0602123282
M9200100404
0602014298
011106015
0041216000
M3326200004
0013003019
0043003000
0043103000
PART NAME
QTY.
REMARKS
BAND, AIR CLEANER
2
HEX HEAD BOLT .............................................4 .......... REPLACES 0016908020
HEX NUT ..........................................................4 .......... REPLACES 0207008000
HOSE , AIR CLEANER
1
HOSE BAND
2
ADAPTER
1
O RING
1
UNION
1
SWIVEL
1
CAP
1
DRAIN HOSE
1
RESERVE TANK
1
CAP, RESERVE TANK .....................................1 .......... REPLACES 0602010900
BRACKET, RESERVE TANK
1
HEX HEAD BOLT .............................................2 .......... REPLACES 0016908020
HOSE
1
RADIATOR COVER
1
ACOUSTIC SHEET
1
HEX HEAD BOLT .............................................4 .......... REPLACES 0016908020
ALTERNATOR COVER
1
HEX HEAD BOLT .............................................3 .......... REPLACES 0016908020
CLAMP
1
HEX HEAD BOLT .............................................1 .......... REPLACES 0016908020
OIL SWITCH ....................................................1 .......... 17189- 39011
ADAPTER
1
WATER SWITCH ..............................................1 .......... 15181- 83041
ADAPTER
1
ETHER KIT ......................................................1 .......... AR68492
HEX HEAD BOLT .............................................2 .......... REPLACES 0016906015
PLAIN WASHER
8
HOSE BRACKET
1
HEX HEAD BOLT
1
LOCK WASHER
1
PLAIN WASHER
1
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 51
To Table of Contents
DCA-150SSJU —ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 52 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Table of Contents
To Operating Panel Assy.
DCA-150SSJU —ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Full View 18
19
20
21
22
23
24
25
26
27
28
29
30
PART NO.
M3357200112
M1354300304
0601840190
020108060
M1354200004
020108060
020108060
0605010550
M3354600004
M3354600104
0036203000
M3354300204
M3354300304
020108060
0602180106
020108060
0602180107
020108060
0207006000
952404470
0602100056
0602100028
0602100029
0601831594
0601831584
0602120096
0602122093
0602122272
0602123092
0602123261
0602121080
0602125090
0602103092
0601810245
0601810141
0601831330
PART NAME
QTY.
REMARKS
WIRE HARNESS, ENGINE
1
SLIDE LEVER
1
KNOB ...............................................................1 .......... REPLACES M9320000004
HEX NUT ..........................................................1 .......... REPLACES 0036003000
BRACKET
1
HEX NUT ..........................................................1 .......... REPLACES 0207008000
HEX NUT ..........................................................1 .......... REPLACES 0030008000
SNAP PIN
1
GOVERNOR LEVER
1
GOVERNOR BOLT
1
HEX NUT
1
GOVERNOR ROD
1
GOVERNOR ROD
1
HEX NUT ..........................................................2 .......... REPLACES 0030008000
BALL JOINT
2
HEX NUT ..........................................................2 .......... REPLACES 0030008000
BALL JOINT
2
HEX NUT ..........................................................2 .......... REPLACES 0036508000
HEX NUT
4
PLAIN WASHER ...............................................4 .......... REPLACES 0041206000
STARTER SWITCH ......................................... 1 ........... AR58126
SET NUT ......................................................... 1 ........... R44342
SET WASHER ................................................. 1 ........... A4827R
COLD STARTING BUTTON ............................. 1 ........... R39554
CAP ................................................................. 1 ........... T55585
TACHOMETER ................................................ 1 ........... 103678
OIL PRESSURE GAUGE ................................ 1 ........... 100174
UNIT, OIL PRESSURE .................................... 1 ........... REPLACES 0602122271;
105965
WATER TEMPERATURE GAUGE ................... 1 ........... 100182
UNIT, WATER TEMPERATURE ....................... 1 ........... 02025- 00
CHARGING AMMETER .................................. 1 ........... 100158
FUEL GAUGE ................................................. 1 ........... 100176
ALARM LAMP ................................................. 2 ........... PL- 05
BULB ............................................................... 2 ........... E- 10 T- 10 DC18V
PANEL LIGHT ................................................. 1 ........... 98268- 00370
SWITCH, PANEL LIGHT ................................. 1 ........... 90- 0001
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 53
To Table of Contents
DCA-150SSJU —OUTPUT TERMINAL ASSY.
OUTPUT TERMINAL ASSY.
PAGE 54 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Terminal Assy.
To Table of Contents
DCA-150SSJU —OUTPUT TERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Full View 16
17
18
19
20
20-1
21
22
PART NO.
M3230700003
M9220100304
0801830804
0039316000
0040016000
0041416000
0012108035
M3236100303
M3236100104
0605010040
0027103010
0207003000
58413
0027103010
0207003000
0112206020
011106015
M3236400004
M3236300004
011206020
0601808803
0601808804
M1260700304
0222100150
011206020
0601812597
23
0601811034
24
0021304015
0030004000
M3236100213
012212045
031112230
M9310200004
0030012000
25
26
27
28
29
PART NAME
QTY.
REMARKS
TERMINAL PANEL
1
OUTPUT TERMINAL BOLT
5
TIE BOLT ........................................................ 5 .......... REPLACES M9220100404
HEX NUT
10
LOCK WASHER
15
PLAIN WASHER
20
HEX HEAD BOLT ............................................ 5 .......... REPLACES 0016908035
TERMINAL COVER
1
OUTPUT WINDOW
1
HINGE
2
MACHINE SCREW
4
HEX NUT ......................................................... 4 .......... REPLACES 0030003000
PLAIN WASHER .............................................. 4 .......... REPLACES 0041203000
MACHINE SCREW
4
HEX NUT ......................................................... 4 .......... REPLACES 0030003000
HEX HEAD BOLT ............................................ 2 .......... REPLACES 0016906020
HEX HEAD BOLT ............................................ 4 .......... REPLACES 0016906015
CABLE OUTLET COVER
1
SUPPORTER, CABLE OUTLET COVER
1
HEX HEAD BOLT ............................................ 6 .......... REPLACES 0016906020
CIRCUIT BREAKER ........................................ 2 .......... QOU 120B 1P 20A
CIRCUIT BREAKER ........................................ 3 .......... QOU 250B 2P 50A
BREAKER FITTING COVER
1
CUSHION RUBBER
1
HEX HEAD BOLT ............................................ 2 .......... REPLACES 0016906020
RECEPTACLE ................................................. 2 .......... REPLACES 0601812598;
GF530EM 125V 20A X 2
RECEPTACLE ................................................. 3 .......... REPLACES 0601812538;
CS6369 250V 50A
MACHINE SCREW ........................................ 10 .......... REPLACES 0027104015
HEX NUT ....................................................... 10 .......... REPLACES 0207004000
TERMINAL COVER
1
HEX HEAD BOLT ............................................ 2 .......... REPLACES 0010112045
PLAIN WASHER .............................................. 2 .......... REPLACES 0041212000
STAY RUBBER
2
HEX NUT
2
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 55
To Table of Contents
DCA-150SSJU —BATTERY ASSY.
BATTERY ASSY.
PAGE 56 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Battery Assy.
To Table of Contents
DCA-150SSJU —BATTERY ASSY.
BATTERY ASSY.
NO.
1
2
3
4
5
6
Full View
7
8
9
10
PART NO.
0602220196
M9310500404
M9103000504
0602220921
0040006000
M3346900204
M3346900214
M3346900104
0013007025
0043007000
0043107000
0040516000
012210020
0040510000
PART NAME
QTY.
REMARKS
BATTERY ........................................................ 1 .......... 4D- 2
BATTERY SHEET
1
BATTERY BAND
1
BATTERY BOLT SET
2
LOCK WASHER
2
BATTERY CABLE
1
BATTERY CABLE
1
BATTERY CABLE............................................ 1 .......... REPLACES M3346900304
CABLE
1
HEX HEAD BOLT
1
LOCK WASHER
1
PLAIN WASHER
1
TOOTHED WASHER
1
HEX HEAD BOLT ............................................ 1 .......... REPLACES 0017110020
TOOTHED WASHER
1
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 57
To Table of Contents
DCA-150SSJU —MUFFLER ASSY.
MUFFLER ASSY.
PAGE 58 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Muffler Assy.
To Table of Contents
DCA-150SSJU —MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
Full View
2
3
4
5
6
7
8
9
10
PART NO.
M3330100202
0602300168
012210025
M3333000503
0602325066
M3333200104
0017110050
M3330400804
M3330400903
011008020
0602326062
PART NAME
QTY.
REMARKS
MUFFLER
1
MUFFLER
1
HEX HEAD BOLT ............................................ 4 .......... REPLACES 0016910025
EXHAUST PIPE
1
CLAMP
1
GASKET
1
HEX HEAD BOLT
4
COVER
1
BRACKET
1
HEX HEAD BOLT ............................................ 4 .......... REPLACES 0016908020
U BOLT SET
1
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 59
To Table of Contents
DCA-150SSJU —FUEL TANK ASSY.
FUEL TANK ASSY.
PAGE 60 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Fuel Tank Assy.
To Table of Contents
DCA-150SSJU —FUEL TANK ASSY.
FUEL TANK ASSY.
NO.
1
1-1
2
3
4
5
6
7
8
9
Full View
10
11
12
13
14
15
16
17
18
19
PART NO.
M3363000402
0605505070
M3363200204
M9310500104
011008020
0207308000
0222100660
1502025103C
M9200200004
0150000018
011206020
M1363400104
0605515198
0602042420
0602022793
0602042601
0191300100
0191300900
0191302400
0605515109
PART NAME
QTY.
REMARKS
FUEL TANK
1
CAP, FUEL TANK
1
TANK BAND
2
SUPPORTER SHEET
4
HEX HEAD BOLT ............................................ 2 .......... REPLACES 0016908020
HEX NUT
2
RUBBER SHEET
2
DRAIN JOINT .................................................. 1 .......... REPLACES M9200000003
DRAIN BOLT
1
O RING
1
HEX HEAD BOLT ............................................ 2 .......... REPLACES 0016906020
DRAIN HOSE
1
HOSE BAND
2
FUEL FILTER .................................................. 1 .......... PTG15P
HOSE JOINT ................................................... 1 .......... REPLACES 0605512195
LEAK - OFF LINE............................................ 1 .......... 67050
SUCTION HOSE
1
SUCTION HOSE
1
RETURN HOSE
1
HOSE BAND
6
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 61
To Table of Contents
DCA-150SSJU —ENCLOSURE ASSY.
ENCLOSURE ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 62 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Enclosure Assy.
To Table of Contents
DCA-150SSJU —ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
Full View
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
PART NO.
M3413000402
M1413400004
011008020
M3423000502
M3493101703
012210025
M3423200304
M3493103104
011008020
M3433000312
M3493200304
0010114045
0010114040
020114110
030214350
031114260
M3443000402
M3493301504
012210025
M3443300603
M3493302204
M3443300503
M3493301804
0207006000
011008020
M3443200213
M3443600104
020106050
952404470
B9114000002
0021806015
020106050
M9110100204
M9116100004
011008020
0845031504
M3463100303
M3493501203
M3463200202
M3493501603
M3463500204
011008020
PART NAME
QTY.
REMARKS
BASE
1
UNDER COVER
1
HEX HEAD BOLT ............................................ 2 .......... REPLACES 0016908020
FRONT FRAME
1
ACOUSTIC SHEET
1
HEX HEAD BOLT ............................................ 6 .......... REPLACES 0016910025
COVER, FRONT FRAME
1
ACOUSTIC SHEET
1
HEX HEAD BOLT .......................................... 16 .......... REPLACES 0016908020
CENTER FRAME
1
ACOUSTIC SHEET
1
HEX HEAD BOLT
12
HEX HEAD BOLT
12
HEX NUT ....................................................... 12 .......... REPLACES 0030014000
LOCK WASHER ............................................. 24 .......... REPLACES 0040014000
PLAIN WASHER ............................................ 24 .......... REPLACES 0041214000
REAR FRAME
1
ACOUSTIC SHEET
1
HEX HEAD BOLT ............................................ 4 .......... REPLACES 0016910025
REAR COVER
1
ACOUSTIC SHEET
2
DUCT, REAR COVER
2
ACOUSTIC SHEET
1
HEX NUT
12
HEX HEAD BOLT .......................................... 12 .......... REPLACES 0016908020
REAR DOOR ................................................... 1 .......... REPLACES M3443200203
WINDOW PLATE
1
HEX NUT ....................................................... 10 .......... REPLACES 0207306000
PLAIN WASHER ............................................ 10 .......... REPLACES 0041206000
DOOR HANDLE ASSY .................................... 1 .......... REPLACES M9113000002
MACHINE SCREW .......................................... 4 .......... REPLACES 0021806015
HEX NUT ......................................................... 4 .......... REPLACES 0030006000
HINGE
2
WASHER
2
HEX HEAD BOLT ............................................ 3 .......... REPLACES 0016908020
BLIND PLUG ................................................... 2 .......... REPLACES M9310000004
ROOF PANEL
1
ACOUSTIC SHEET
1
ROOF PANEL
1
ACOUSTIC SHEET
1
OVER COVER, FRONT FRAME
1
HEX HEAD BOLT .......................................... 39 .......... REPLACES 0016908020
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 63
To Table of Contents
DCA-150SSJU —ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 64 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Table of Contents
To Enclosure Assy.
DCA-150SSJU —ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
29
30
31
32
33
34
35
36
37
38
39
Full View
40
41
42
43
44
45
46
47
48
49
50
51
52
53
PART NO.
1625165103
1625165204
M3453200312
M3493405504
011208060
012210025
M3453001103
M3493403804
M3453001003
M3493404404
M3453000903
M3493405204
M3453000803
M3493405304
M3453000803
M3493406303
M3453300603
M3493404804
M3453300203
M3493407003
0207006000
B9114000002
0027106016
020106050
M9110100204
M9110100304
M9116100004
011008020
0601850097
0027208025
0845031504
M3453700004
011106015
011008020
0040508000
PART NAME
QTY.
REMARKS
BONNET CAP ................................................. 1 .......... REPLACES M9310000103
CHAIN ASS’Y .................................................. 1 .......... REPLACES M1483600204
SPLASHER PANEL
1
ACOUSTIC SHEET ......................................... 1 .......... REPLACES M3493405514
HEX HEAD BOLT ............................................ 4 .......... REPLACES 0016908055
HEX HEAD BOLT ............................................ 2 .......... REPLACES 0016910025
SIDE DOOR
1
ACOUSTIC SHEET
1
SIDE DOOR
1
ACOUSTIC SHEET
1
SIDE DOOR
1
ACOUSTIC SHEET
1
SIDE DOOR
1
ACOUSTIC SHEET
1
DUCT
1
ACOUSTIC SHEET
1
DUCT
1
ACOUSTIC SHEET
1
DUCT
1
ACOUSTIC SHEET
1
HEX NUT
25
DOOR HANDLE ASSY .................................... 4 .......... REPLACES M9113000002
MACHINE SCREW ........................................ 16 .......... REPLACES 0021806015
HEX NUT ....................................................... 16 .......... REPLACES 0030006000
HINGE
4
HINGE
4
WASHER
8
HEX HEAD BOLT ............................................ 9 .......... REPLACES 0016908020
DOOR STOPPER
8
MACHINE SCREW
8
BLIND PLUG ................................................... 8 .......... REPLACES M9310000004
DOOR BRACKET
1
HEX HEAD BOLT ............................................ 4 .......... REPLACES 0016906015
HEX HEAD BOLT ............................................ 1 .......... REPLACES 0016908020
TOOTHED WASHER
1
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 65
To Table of Contents
DCA-150SSJU —RUBBER SEAL ASSY.
RUBBER SEALS ASSY.
PAGE 66 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Table of Contents
To Seal Assy.
DCA-150SSJU —RUBBER SEAL ASSY.
RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
Full View
9
10
11
12
13
14
15
16
PART NO.
0228900955
0229200810
0228901120
0228901090
0228900520
0229201200
0229201140
0228801070
0228800680
0228800640
0228100665
0228100370
0228100300
0228100365
0228100280
0228100070
PART NAME
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
QTY.
7
1
2
4
2
4
1
2
1
1
1
1
1
1
1
1
REMARKS
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 67
To Table of Contents
DCA-150SSJU —OPERATION AND SAFETY DECAL ASSY.
NAME PLATE ASSY.
PAGE 68 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
To Decal Assy.
To Table of Contents
DCA-150SSJU —OPERATION AND SAFETY DECAL ASSY.
NAME PLATE ASSY.
Full View
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
PART NO.
M1550000204
M1550000703
M3550000602
M3550000702
M3550000804
M3550000904
M9500000004
M9500100004
M9500100104
M9500300004
M9500300104
M9500500004
M9500500104
M9503000004
M9503000103
M9503100004
M9503200004
M9510100004
M9510200002
M9520000004
M9520000104
M9520000204
M9520100004
M9520100204
M9520100304
M9520100404
M9520100503
M9520200003
M9520200104
M3560100903
M3560101003
M3560101103
M3560101304
M3560101203
M3560101403
M3560101504
0600500090
0021106015
PART NAME
QTY.
REMARKS
DECAL : NOTE ........................................................... 1 ........... M15000020
DECAL : AUXILIARY OUTPUT ................................... 1 ........... M15000070
DECAL : GENERATOR CONTROL ............................. 1 ........... M35000060
DECAL : ENGINE OPERATING .................................. 1 ........... M35000070
DECAL : NOTE ........................................................... 1 ........... M35000080
DECAL : FOR COLD STARTING ................................ 1 ........... M35000090
DECAL : OIL DRAIN PLUG ......................................... 1 ........... M90000000
DECAL : WATER ......................................................... 1 ........... M90010000
DECAL : WATER DRAIN PLUG ................................... 1 ........... M90010010
DECAL : - .................................................................... 1 ........... M90030000
DECAL : + ................................................................... 1 ........... M90030010
DECAL : DIESEL FUEL .............................................. 1 ........... M90050000
DECAL : FUEL DRAIN PLUG ..................................... 1 ........... M90050010
DECAL : WARNING ..................................................... 2 ........... M90300000
DECAL : WATER - OIL CHECK .................................. 1 ........... M90300010
DECAL : WARNING ..................................................... 1 ........... M90310000
DECAL : WARNING ..................................................... 1 ........... M90320000
DECAL : CAUTION ..................................................... 1 ........... M91010000
DECAL : MQ ............................................................... 1 ........... M91020000
DECAL : GROUND ...................................................... 1 ........... M92000000
DECAL : AMMETER CHANGE - OVER SWITCH ....... 1 ........... M92000010
DECAL : VOLTMETER CHANGE - OVER SWITCH .... 1 ........... M92000020
DECAL : WARNING ..................................................... 2 ........... M92010000
DECAL : CAUTION ..................................................... 1 ........... M92010020A
DECAL : SAFETY INSTRUCTIONS ............................ 1 ........... M92010030
DECAL : DANGER ...................................................... 1 ........... M92010040
DECAL : WARNING ..................................................... 1 ........... M92010050
DECAL : CONNECTIONS OF OUTPUT CABLE ......... 1 ........... M92020000
DECAL : OVER CURRENT RELAY ............................. 1 ........... M92020010
STRIPE : WHISPERWATT
1
STRIPE : MQ POWER
2
STRIPE
2
STRIPE
2
STRIPE : 150
1
STRIPE : 150
1
STRIPE
2
EMBLEM
1
MACHINE SCREW
2
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 69
To Table of Contents
TERMS AND CONDITIONS OF SALE — PARTS
Effective: July 1, 2000
PAYMENT TERMS
4.
Terms of payment for parts are net 10 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and the
carrier.
Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
5.
Parts must be in new and resalable
condition, in the original Multiquip package
(if any), and with Muiltiquip part numbers
clearly marked.
6.
The following items are not returnable:
a.
Obsolete parts. (If an item is listed
in the parts price book as being
replaced by another item, it is
obsolete.)
b.
Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
MINIMUM ORDER
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
c.
Any line item with an extended dealer
net price of less than $5.00.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a specific
date and all orders received on or after that date
will be billed at the revised price. Rebates for
price declines and added charges for price
increases will not be made for stock on hand
at the time of any price change.
Multiquip reserves the right to quote and sell
direct to Government agencies, and to Original
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
SPECIAL EXPEDITING SERVICE
A $20.00 to $50.00 surcharge will be added to
the invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
d.
Special order items.
RETURNED GOODS POLICY
e.
Electrical components.
Return shipments will be accepted and credit
will be allowed, subject to the following
provisions:
f.
Paint, chemicals, and lubricants.
LIMITATIONS OF SELLER’S LIABILITY
g.
Decals and paper products.
1.
h.
Items purchased in kits.
Multiquip shall not be liable here under for
damages in excess of the purchase price of the
item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
2.
A Returned Material Authorization must
be approved by Multiquip prior to shipment.
To obtain a Return Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
a.
b.
The list must be typed or computer
generated.
c.
The list must state the reason(s) for
the return.
d.
The list must reference the sales
order(s) or invoice(s) under which
the items were originally purchased.
e.
3.
The parts numbers and descriptions
must match the current parts price
list.
The list must include the name and
phone number of the person
requesting the RMA.
A copy of the Return Material
Authorization must accompany the return
shipment.
7.
The sender will be notified of any material
received that is not acceptable.
8.
Such material will be held for 5 working
days from notification, pending
instructions. If a reply is not received
within 5 days, the material will be returned
to the sender at his expense.
9.
Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.
10. In cases where an item is accepted for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
11. Credit issued will be applied to future
purchases only.
LIMITATION OF WARRANTIES
No warranties, express or implied, are made
in connection with the sale of parts or trade
accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes not
authorizes any person to assume for it any
other obligation or liability whatever in
connection with the sale of its products. A part
from such written statement of warranty, there
are no warranties, express, implied or statutory,
which extend beyond the description of the
products on the face hereof.
PAGE 70 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00)
NOTE PAGE
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #0 (11/09/00) — PAGE 71
To Table of Contents
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310 - 537-3927
MULTIQUIP INC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
SERVICE DEPARTMENT:
310-537-3700
800-421-1244
800-835-2551
FAX: 310-537-3927
FAX: 310-638-8046
E-mail:mq@multiquip.com • www:multiquip.com
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