MQ Power DCA70USJ 25-150 kVA Single/Three Phase Ultra-Silent Operation Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

ULTRA-SILENT

TM

SERIES

MODEL DCA-70USJ

GENERATOR

PARTS LIST NO. M2870400114

Revision #0 (09/16/04)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-70USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/16/04)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave.

Carson, CA 90746

800-421-1244

FAX: 310-632-2656

Email: [email protected]

Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244

310-537-3700

SERVICE DEPARTMENT

800-835-2551

310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, EXT. 279

310-537-3700, EXT. 279

FAX: 800-672-7877

FAX: 310-637-3284

FAX: 310-638-8046

FAX: 310-638-8046

FAX: 310-638-8046

© COPYRIGHT 2004, MULTIQUIP INC.

MQ Power Inc, Ultra-Silent series, and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of thier respective owners and used with permission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the DCA-70USJ Ultra Silent Generator. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time without notice and without incurring any obligations.

To find the latest revision of this publication, visit our website at: www.mqpower.com

DCA-70USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/16/04) — PAGE 3

1

TABLE OF CONTENTS

UL TRA-SILENT GENERA TOR

California Proposition 65 Warning ..................................... 2

Here's How To Get Help .................................................... 3

Table Of Contents ............................................................. 4

Parts Ordering Procedures ............................................... 5

Specifications ................................................................... 6

Dimensions (Top, Side, Front) ........................................... 7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals ....................................................... 14-15

Installation ................................................................. 16-17

General Information ........................................................ 18

Major Components ......................................................... 19

Generator Control Panel ................................................. 20

Engine Operating Panel ............................................. 22-23

Output Terminal Panel Familiarization ........................ 24-26

Load Application ............................................................. 27

Generator Outputs .......................................................... 28

Gauge Reading ............................................................... 29

Output Terminal Panel Connections ........................... 30-31

Pre Setup .................................................................. 32-35

Generator Start-up Procedure (Manual) ..................... 36-38

Generator Start-up Procedure (Auto Mode) .................... 39

Generator Shut-Down Procedure .................................... 40

Maintenance .............................................................. 41-43

Trailer Maintenance .................................................... 44-47

Trailer Wiring Diagram ..................................................... 48

Generator Wiring Diagram ............................................... 49

Engine Wiring Diagram ................................................... 50

Generator Troubleshooting .............................................. 51

Engine Controller Troubleshooting ................................... 52

COMPONENT DRA WINGS

Explanation of Code in Remarks Column ....................... 54

Suggested Spare Parts .................................................. 55

Generator Assembly .................................................. 56-57

Control Box Assembly ............................................... 58-61

Engine & Radiator Assembly ..................................... 62-65

Output Terminal Assembly ......................................... 66-67

Battery Assembly ...................................................... 68-69

Muffler Assembly ...................................................... 70-71

Fuel Tank Assembly .................................................. 72-73

Enclosure #1 Assembly ............................................ 74-77

Enclosure #2 Assembly ............................................ 78-79

Rubber Seals Assembly ............................................ 80-81

Nameplate and Decals .............................................. 82-83

Terms and Condition of Sale — Parts ............................ 84

NOTE

Specification and part number are subject to change without notice

.


PARTS ORDERING PROCEDURES

❒

❒

When ordering parts, please supply the following information:

❒

❒ ❒ Quantity, part number and description of each part

❒

✓ FedEx or UPS Ground

✓ FedEx or UPS Second Day or Third Day

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will

✓ FedEx or UPS Next Day

✓ Federal Express Priority One ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock ✓ DHL

✓ Truck

Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.



800-421-1244

Carson, CA 90746


FAX: 310-632-2656



800-427-1244

310-537-3700


800-835-2551

310-537-3700

FAX: 800-672-7877

FAX: 310-637-3284

FAX: 310-638-8046


800-835-2551


800-835-2551, EXT. 279

310-537-3700, EXT. 279

FAX: 310-638-8046

FAX: 310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered via

Fax

Standard orders

3%

Web 5%

Special freight allowances when you order 10 or more line items via Web or Fax!**

Stock orders

($750 list and above)

10%

10%

FedEx Ground Service at no charge for freight

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.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254

CARSON, CA 90749

310-537-3700 • 800-421-1244

FAX: 310-632-2656

E-MAIL: [email protected]

INTERNET: www.mqpower.com

Direct TOLL-FREE access to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

1


DCA-70USJ — SPECIFICATIONS

M o d e l

T y p e

A r m a t u r e C o n n e c t i o n

P h a s e

S t a n d b y O u t p u t

P r i m e O u t p u t

V o l t a g e

F r e q u e n c y

S p e e d

P o w e r F a c t o r

A u x .

A C P o w e r

V o l t a g e

O u t p u t

M o d e l

T y p e

N o .

o f C y il n d e r s

B o r e x S t r o k e

R a t e d O u t p u t

D i s p l a c e m e n t

S t a r t i n g

C o o l a n t C a p a c i t y

L u b e O li C a p a c i t y

F u e l T y p e

F u e l T a n k C a p a c i t y

F u e l C o n s u m p t i o n

B a t t e r y

T a b l e 1 .

G e n e r a t o r S p e c i f i c a t i o n s

S t a r w i t h N e u t r a l

D C A 7 0 U S J o p e n p r

R e v o l v i n g o t e c t e d if e t y p e l d , s y s e n fl c h v r o e n n o t u li a t e d , s g e n e r a t o r

Z i g Z a g

3

7 7 K V A ( 6 1 .

6 K W )

7 0 K V A ( 5 6 K W )

2 4 0 V o r 4 8 0 V

S i n g l e

4 4 K W

4 0 K W

2 4 0 / 1 2 0 V

6 0 H z

1 8 0 0 r p m

0 .

8

S i n g l e P h a s e , 6 0 H z

1 2 0 V

4 .

8 K W ( 2 .

4 K W x 2 )

T a b l e 2 .

E n g i n e S p e c i f i c a t i o n s

J O H N D E E R E 4 0 4 5 T F 2 7 5

1

4 c y c l e , w a t e r c o o l e d , d ri e c t i n j e c it o n , t u r b o c h a r g e d

4 c y il n d e r s

4 .

1 9 i n .

x 5 i n .

( 1 0 6 m m x 1 2 7 m m )

1 0 2 H P / 1 8 0 0 r p m

2 7 5 c u .

i n .

( 4 , 5 0 0 c c )

E l e c t r i c 1 2 V D C

3 .

7 g a .l

( 1 4 l ti e r s ) p l u s 2 q u a r t s i n r e t a i n i n g t a n k

3 .

5 g a .l

( 1 3 .

2 l ti e r s )

# 2 D i e s e l F u e l

1 2 7 g a .l

( 4 8 0 l ti e r s )

5 .

0 g a .l

( 1 8 .

9 L ) / h r a t f u ll l o a d 3 .

5 g a .l

( 1 3 .

4 L ) / h r a t 3 / 4 l o a d

2 .

4 g a .l

( 8 .

8 L ) / h r a t 1 / 2 l o a d 1 .

6 g a

1 2 V B C I G r o u p 2 7

.l

( 5 .

9 L ) / h r a t 1 / 4 l o a d


DCA-70USJ — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions


1

DCA85USJ — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the

Safety Messages and Operating Instructions could result in injury to yourself and others.

NOTE

This Owner's Manual has been developed to provide complete instructions for the safe and efficient operation of the

MQ Power Model DCA-70USJ

ULTRA-SILENT™ GENERATOR.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " Hazard Symbols" which appear throughout this manual, and will be referenced in conjunction with Safety " Message Alert Symbols".

WARNING - LETHAL EXHAUST GASES

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH if inhaled. NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The

Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

WARNING - EXPLOSIVE FUEL

Gasoline is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids.

DO NOT fill the fuel tank while the engine is running or hot.

DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of electrocution,

electrical shock or burn, which can cause

severe bodily harm or even DEATH!


DCA85USJ — SAFETY MESSAGE ALERT SYMBOLS

CAUTION - RESPIRATORY HAZARDS WARNING - ROTATING PARTS

NEVER operate equipment with covers, or guards removed. Keep fingers, hands,

hair and clothing away from all moving parts to prevent injury.

ALWAYS wear approved respiratory protection.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the Engine ON/OFF switch in the OFF position and remove the ignition key when the pump is not in use.

CAUTION - SIGHT AND HEARING HAZARDS

ALWAYS wear approved

hearing protection.

eye and

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings of the engine governor or settings.

Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

NOTE

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.


1

DCA-70USJ — RULES FOR SAFE OPERATION

DANGER - READ THIS MANUAL!

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-70USJ Generator:

General Safety:

■ DO NOT operate or service this equipment before reading this entire manual.

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■ This equipment should not be operated by persons under

18 years of age.

■ NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

■ NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■ NEVER operate this equipment under the influence or drugs or alcohol.

■ ALWAYS check the machine for loosened threads or bolts before starting.

■ 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.

■ 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 performing service and maintenance functions. Contact with

hot! components can cause serious burns.

■ 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.

■ DO NOT place hands or fingers inside generator engine compartment when engine is running.

■ NEVER run engine without air filter. Severe engine damage may occur.

■ DO NOT leave the generator running in the manual mode unattended.

■ Refer to the John Deere Engine Owner's Manual for engine technical questions or information.

■ ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

■ 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. Unauthorized equipment modification will void all warranties.

■ Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.



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.

The following safety recommendations should also be followed:

■ ALWAYS make sure generator is properly grounded.

■ NEVER use gas piping as an electrical ground.

■ ALWAYS make sure that electrical circuits are properly

grounded per the National Electrical Code (NEC) and local codes before operating generator. Severe injury or

DEATH! by electrocution can result from operating an ungrounded generator.

■ ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

Electrical Safety

■ ALWAYS have a qualified electrician perform the generator wiring installation.

■ ALWAYS make sure generator installation is accordance with the National Electrical Code (NEC) and local codes before operating generator.

■ NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■ NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■ ALWAYS make certain that proper extension cord has been selected for the job. See Table 5.

■ NEVER power cables or cords lay in water.

■ NEVER stand in water while AC power from the generator is being transfer to a load.


During operation of this generator, there exists the possibility of electrocution,

electrical shock or burn, which can cause

severe bodily harm or even DEATH!

To avoid these hazards:

NEVER use damaged or worn cables when connecting 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 WET

HANDS and electrical shock.

NEVER grab or touch a live power cord with wet hands.

POWER

CORD

(POWER ON)

NEVER touch output terminals during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

Backfeed to a utility system can cause electrocution and or property damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened.

ALWAYS have a licensed electrician perform the installation


1


Maintenance Safety

■ The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits.

Turn all circuit breakers OFF before performing maintenance on the generator.

■ NEVER lubricate components or attempt service on a running machine.

■ ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator.

■ Follow all Battery Safety Guidelines listed in this manual when handleing or servicing the generator.

■ 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.

■ ALWAYS service air cleaner frequently to prevent engine malfunction.

Battery Safety

Use the following guidelines when handling the battery:

■ 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.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid severe injury or DEATH: is the possibility of risk that the battery may explode.

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.


To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations.

Always allow sufficient time for the engine and generator to cool before performing maintenance.

■ 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.

■ Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

■ Engine Oil Drain Plug - Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

charged a buildup of combustible gas will occur.

condition. Repair or replace all worn cables.

environment, to avoid risk of a dangerous concentration of combustible gases.

contact with clothing or skin, rinse skin or clothing immediately with plenty of water.

contact with your EYES, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.



Towing & Transporting Safety

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting Department of

Transportation (DOT) Safety Towing Regulations, before towing your generator.

■ ALWAYS shutdown engine before transporting.

■ Tighten both fuel tank caps securely.

■ If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed Towing & Transporting Safety guidelines for basic towing techniques.

■ Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”

■ 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. Trailer tires should be inflated to 50 psi cold.

Also check the tire tread wear on both vehicles.

■ ALWAYS make sure the trailer is equipped with a "Safety

Chain".

■ ALWAYS attach trailer’s safety chains to towing vehicle properly.

■ ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■ DOT Requirements include the following: z Connect and test electric brake operation.

z Secure portable power cables in cable tray with tie wraps.

■ The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■ Place chock blocks underneath wheel to prevent rolling, while parked.

■ Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■ Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

■ Avoid sharp turns.

■ Trailer should be adjusted to a level position at all times when towing.

■ Raise and lock trailer wheel stand in up position when transporting.

■ The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■ Place support blocks underneath the trailer’s bumper to prevent tipping, while parked.

■ Avoid sharp turns to prevent rolling.

■ DO NOT transport generator with fuel in tank.

Emergencies

■ ALWAYS know the location of the nearest fire extinguisher.

■ ALWAYS know the location of the nearest and first aid kit.

■ ALWAYS know the location of the nearest phone or keep a phone on

the job site, in case of emergencies.

■ ALWAYS have easy access to the phone numbers of the nearest Ambulance, Doctor and Fire Department. This information will be invaluable in the case of an emergency.

1


DCA-70USJ — GENERATOR DECALS

The DCA-70USJ generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

Figure 2. Generator Decals


DCA-70USJ — GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)


1

DCA-70USJ — INSTALLATION

Figure 4. Typical Generator Grounding Application


DCA-70USJ — INSTALLATION

Outdoor Installation

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that 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 engine and alternator parts.

CAUTION - EXHAUST HAZARD

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.

Mounting

The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

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 mm 2 ) or larger.

b. Aluminum - 8 AWG (8.4 mm 2 ) or larger.

2. When grounding the generator (Figure 4) 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 aminimum of 8 ft. into the ground.

NOTE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.


1

DCA-70USJ — GENERAL INFORMATION

DCA-70USJ Series Familiarization

Generator

The MQ Power Model DCA-70USJ is a 56 kW generator

(Figure 5) 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 Operating Panel

The “Engine Operating Panel” is provided with the following:

■

■

■

■

■

■

■

■

■

■

■

■

Tachometer

Water Temperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Fuel Level Gauge

Pre-heat Lamp

Panel Light/Panel Light Switch

Auto ON/OFF Engine Controller (MPEC)

Fuel Leak Detected Alarm Lamp

Generator Control Panel

The “Generator Control Panel” is provided with the following:

■

■

■

■

■

■

■

■

■

■

■

■

■

■

■

■

■

■

■

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Voltage Regulator

3-Pole, 175 amp Main Circuit Breaker

“Control Box” (located behind the Gen. Control Panel)

Automatic Voltage Regulator

Current Transformer

Over-Current Relay

Voltage Rectifer

Starter Relay

Engine Controller (Computer Controlled)

Voltage Selector Switch

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

■

■

■

■

■

■

■

■

■

Three 120/240V output receptacles (CS-6369), 50A

Three auxilliary circuit breakers, 50A

Two 120V output receptacles (GFCI), 20A

Two GFCI circuit breakers, 20A

Five output terminal lugs (3Ø power)

Battery Charger (Optional)

Water Heater (Optional)

Open Delta Excitation System

The DCA-70USJ 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 connections of the open delta A, B, C and D.

During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of 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-70USJ is powered by a 4 cycle, water cooled, direct injection, turbocharged John Deere Model 4045TF275

Diesel Engine. This engine is designed to meet every performance requirement for the generator. Reference Table

1 for engine specifications.

In keeping with MQ Power's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

Electric Governor System

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to

±.25%.

Extension Cables

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 chart (Table 5) as a guide for selecting proper extension cable size.


DCA-70USJ — MAJOR COMPONENTS

T a b l e 3 .

G e n e r a t o r M a j o r C o m p o n e n t s

I T E M N O .

1

2

3

4

5

6

M

G u f e n lf e e r r a t

A s o r s e

A s s

D m b e

E l y m

S b l

C R

E n g i n e A s s e m b l y

E n c l o s u r e A s s e m b l y y

I P T I

O u t p u t T e r m i n a l A s s e m b l y

O N

7

8

9

F u e l T a n k A s s e m b l y

B a tt e r y A s s e m b l y

G e n e r a t o r C o n t r o l P a n e l A s s e m b l y

E n g i n e O p e r a it n g P a n e l A s s e m b l y

Figure 5. Major Components


1

NOTE PAGE


DCA-70USJ — GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel

The definitions below describe the controls and functions of the DCA-70USJ Generator Control Panel (Figure 6).

1.

Main Circuit Breaker – This three-pole, 175A main breaker is provided to protect the the U,V, and W Output

Terminal Lugs from overload.

2.

Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz.

3.

AC Ammeter – Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

4.

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. This switch does not effect the generator output in any fashion, it is for current reading only.

5.

AC Voltmeter – Indicates the output voltage present at the U,V, and W Output Terminal Lugs.

6.

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.

7.

Voltage Regulator Control – Allows ±15% manual adjustment of the generator’s output voltage.

Located behind the generator control panel is the Generator

Control Box. This box contains some of the necessary electronic components required to make the generator function.

The Control Box is equipped with the following major components:

■

■

■

■

■

■

Over-Current Relay

Voltage Rectifer (AVR)

Starter Relay

Current Transformer

Voltage Selector Switch

NOTE

Remember the overcurrent

relay monitors the current flowing from the U,V, and W

Output Terminal Lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the main breaker.

To restore power to the Output Terminal Panel, press the

reset button on the overcurrent relay and place the main circuit breaker in the closed position (ON).

1


DCA-70USJ — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel


DCA-70USJ — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-70USJ Engine Operating Panel (Figure 7).

1.

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.

2.

Panel Light Switch – When activated will turn on control panel light.

3.

Oil Pressure Gauge – During normal operation this gauge be should read between 35 to 65 psi. When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

4.

Water Temperature Gauge – During normal operation this gauge be should read between 180° and 221°F.

5.

Charging Ammeter Gauge – Indicates the current being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

6.

Fuel Gauge - Indicates amount of diesel fuel available.

7.

Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

8.

Pre-Heat Lamp – As the engine cranks, this lamp will illuminate to indicate automatic preheating of the engine.

When the lamp turns off, the engine has been preheated and will start automatically.

9.

Fuel Leak Detected Alarm Lamp – This lamp will illuminate when a leak in the fuel tank containment enclosure is detected.

10. Auto On/Off Engine Controller (MPEC) –

This controller has a vertical row of status LED's (inset), that when lit, indicate that an engine malfunction (fault) has been detected. When a fault has been detected the engine controller will evaluate the fault and all major faults will shutdown the generator.

During cranking cycle , The MPEC will attempt to crank the engine for 10 seconds before disengaging. If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s Over Crank Protection mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the Over Speed Protection mode.

Also the engine controller will shut down the engine in the event of low oil pressure, high coolant temperature, low coolant level, and loss of magnetic pickup. These conditions can be observed by monitoring the LED status indicators on the front of the controller module.

A.

MPEC Control Switch – This switch controls the running of the unit. If this switch is set to the

OFF/RESET position, the unit 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 the switch in the AUTO position. In this position the generator will monitor the AC line output from the building's power source.

B.

Low Oil Pressure – Indicates the engine pressure has fallen below 15 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a major fault.

C.

High Coolant Temperature – Indicates the engine temperature has exceeded 239 °F. The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a major fault.

D.

Overcrank Shutdown – Indicates the unit has attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. It is pre-set at 3 cycles with a 10 second duration. This is considered a major fault.

E.

Overspeed Shutdown – Indicates the engine is running at an unsafe speed. This is considered a major fault.

F. Engine Running – Indicates that engine is running at a safe operating speed.

1


DCA-70USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The Output Terminal Panel (Figure 8) shown below is located on the right-hand side (left from control panel) of the generator.

Lift up on the cover to gain access to receptacles and terminal lugs.

NOTE

Terminal legs “O” and “Ground” are considered bonded grounds.

Output Terminal Familiarization

The “ Output Terminal Panel ” (Figure 8) is provided with the following:

Three (3) 120/240V output receptacles @ 50 amp

Three (3) Circuit Breakers @ 50 amps

Two (2) 120V GFCI receptacles @ 20 amp

Two (2) GFCI Circuit Breakers @ 20 amps

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

Figure 8. Output Terminal Panel



120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These receptacles can be accessed in any voltage selector switch position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both

GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the Test Button (See Figure 9) in the center of the receptacle will check the GFCI function.

Both receptacles should be tested at least once a month.

Each auxilliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the

Output Terminal Lugs.

Turn the voltage regulator control knob (Figure 11) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counterclockwise will decrease the voltage.

Figure 11. Voltage Regulator Control Knob

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxilliary twist-lock

(CS-6369) recepacles (Figure 10) provided on the output terminal panel.These receptacles can only be accessed when the voltage selector switch is placed in the singlephase 240/120 position.

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The Output Terminal Lugs are protected by a plastic face plate cover (Figure 12). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles


1


Connecting Loads

Loads can be connected to the generator by the Ouput

Terminal Lugs or the convienience receptacles. (See Figure

13). Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a

3-pole, 175A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Blower Fan

This unit has an intake fan located at the rear of the machine to draw outside air into the cabinet to cool the engine. The fan has a 10 amp AC fuse located beneath the Voltage

Selector Switch (Figure 15).

Figure 13. Connecting Loads

Over Current Relay

An over current relay (Figure 14) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

Figure 15. Blower Fan Fuse


This fuse has current running through it any time the engine is running. This fuse is NOT connected to the main circuit breaker of the generator. Attempting to replace the fuse with the engine and/or generator operating could result in electrocution and severe

bodily harm. ALWAYS turn the unit completely off before attempting to replace or handle this fuse.

Figure 14. Over Current Relay


Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—

150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and starting system of the equipment.

DCA-70USJ — LOAD APPLICATION

Three Phase Load

When calculating the power requirements for 3-phase power use the following equation:

NOTE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

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

NOTE

Motors and motor-driven equipment draw much greater current for starting than during operation.

The power factor of this generator is 0.8. See Table 4 below when connecting loads.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 5.

T a b l e 4 .

P o w e r F a c t o r B y L o a d

T y p e O f L o a d

S i n g l e p h a s e i n d u c it o n m o t o r s

E l e c t r i c l a m p s h e a t e r s , i n c a n d e s c e n t

F l u o r e s c e n t l a m p s , m e r c u r y l a m p s

E l e c t r o n i c e q u i p m e n t d e v i c e s , c o m m u n i c a it o n

C o m m o n p o w e r t o o l s

P o w e r F a c t o r

0 .

4 0 .

7 5

1 .

0

0 .

4 0 .

9

1 .

0

0 .

8

T a b l e 5 .

C a b l e S e l e c t i o n ( 6 0 H z , S i n g l e P h a s e O p e r a t i o n )

L o a d I n W a t t s

C u r r e n t i n

A m p e r e s A

V o t l t

1 2 s

0 A

V t o l t

2 s

4 0

2 .

5 3 0 0 6 0 0

# 1 0 W i r e

1 0 0 0 f .t

M a x i m u m A ll o w a b l e C a b l e L e n g t h

# 1 2 W i r e

6 0 0 f .t

# 1 4 W i r e

3 7 5 f .t

# 1 6 W i r e

2 5 0 f .t

1 2 5 f .t

1 0 0 f .t

5

7 .

5

1 0

6 0 0

9 0 0

1 2 0 0

1

1

2

2

8

4

0

0

0

0

0

0

5

3

2

0 0

5 0

5 0 f f f

.t

.t

.t

3

2

1

0 0

0 0

5 0 f f f

1 5

2 0

1

2

8

4

0

0

0

0

3

4

6

8

0

0

0

0

1

1

5

2

0

5 f f

.t

.t

1

7

0

5

0

C A U T I O N : E q u i p m e n t d a m a g e c a n r e s u tl f r o m l o w v o tl a g e .

f .t

f .t

.t

.t

.t

2 0 0 f .t

1 2 5 f .t

1 0 0 f .t

6 5 f .t

5 0 f .t

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.

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.

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.

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation

(transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

1


DCA-70USJ — GENERATOR OUTPUTS

Voltage Selector Switch

The voltage selector switch (Figure 16) is located above the output terminal panel’s Hard Wire Hook-up Panel. It has been provided for ease of voltage selection.

Generator Amperage

Table 7 describes the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

D C A 8 U S J

S i n g l e P h a s e

T h r e e P h a s e *

T a b l e 7 .

G e n e r a t o r A m p e r e R a t i n g s k W

4 0

5 6 k V A

N / A

7 0

1 2 0 V

1 6 6 .

7 A x 2

N / A

2 0

N /

8

A

V

1 5 5 A

* P o w e r F a c t o r = 0 .

8

2 4 0 V

1 6 6 .

7 A

1 3 4 A

4 8 0 V

N / A

6 7 A

Figure 16. Voltage Selector Switch

Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect the generator and load from being switched while the engine is running. To lock the voltage selector switch, press and

hold the red button located at the bottom of the switch.

CAUTION - CHANGING VOLTAGES

NEVER change the position of the voltage selector switch while the engine is running. ALWAYS place circuit breaker in the open position before selecting voltage.

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 3 twist lock auxilliary receptacles.

Tables 8 and 9 show what amount of current is available at the GFCI receptacles when the output terminals and twist lock receptacles are in use. Be careful that your load does not to exceed the available current capability at the receptacles.

T a b l e 8 .

1 Ø G F C I R e c e p t a c l e L o a d C a p a b i il t y

T w i s t -

K

L o

W c k i n U

( C s

S e

6 3 6 9 )

1 Ø 2 4 0 / 1 2 0 V

4 0

3 8 .

8

3 7 .

6

3 6 .

4

3 5 .

2

A

C u v a r r e li a b n t l e

( A

L o a d m p s )

G F C I

5 2

D u

0 R p l e x N E M A

1 2 0 V

0

5 a m p s p e r r e c e p t a c l e

1 0 a m p s p e r r e c e p t a c l e



Generator Output Voltages

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the voltage selector switch (Figure 15). To obtain some of the voltages as listed in Table 6 (see below) will require a fine adjustment using the voltage regulator (VR) control

knob located on the control panel.

T a b l e 9 .

3 Ø G F C I

K V A

( U V W O i n

T e r

U s e m i n a l s )

3 Ø 2 4 0 / 4 8 0 V

7 0

6 5 .

8

6 1 .

7

5 7 .

5

5 3 .

4

R e c e p t a c l e L o a d C a p a b i il

A v a

C u r li a b l e r e n t ( A

L o a d m p s )

G F C I D u p

5 2 0 R l e x

1 2

N

0 V

E M A

0

5 a m p s p e r r e c e p t a c l e



2 0 a m p s p e r r e c e p t a c l e t y

T h r e e P h a s e

( S w i t c h a b l e )

S i n g l e P h a s e

( S w i t c h a b l e )

T a b l e 6 .

V o l t a g e s A v a li a b l e

2 0 8 V 2 2 0 V 2 4 0 V 4 1 6 V 4 4 0 V 4 8 0 V

1 2 0 V 1 2 7 V 1 3 9 V 2 4 0 V 2 5 4 V 2 7 7 V


DCA-70USJ — GAUGE READING

How to Read the Output Terminal Gauges.

The gauges and selector switches on the control panel

DO NOT effect the generator output. They are provided to help observe how much power is being supplied at the

Output terminals lugs.

Before taking a reading off either gauge, set the Voltage

Selector Switch (Figure 17) to the position which produces the required voltage (For example, for 3Ø 240V, choose the center 3Ø 240/

139V position on the voltage selector switch.)

Reading Amperage

To determine the amperage at a terminal lug, set the

AC Ammeter Change-Over Switch to the appropriate setting (Figure 20) to activate the AC Ammeter Gauge

(Figure 21) and read the available amperage at the terminal lug.

For example, to measure the amperage at the U terminal lug, set the AC Ammeter Change-Over Switch to

U and read the AC Ammeter Gauge.

Figure 17. Voltage

Selector Switch 240/

139V Three Phase

Position

NOTE

For 3Ø 208V/1Ø,120V, place the Voltage Selector Switch in the 3 Phase 340/139 position.

Reading Voltage

To determine the voltage between two terminal lugs, set the

AC Voltmeter Change-Over Switch to the appropriate setting (Figure 18) to activate the AC Voltmeter Gauge

(Figure 19) and read the available voltage between the two lugs.

For example, to measure the voltage between the W and U terminal lugs, set the AC Voltmeter Change-Over Switch to W-U and read the AC Voltmeter Gauge.

Figure 20. AC Ammeter

Change-Over Switch

Figure 21. AC Ammeter

(Amp reading on U lug)

NOTE

The ammeter gauge will only show a reading when the

Output Terminal Lugs are connected to a load and in use.

Figure 18. AC Voltmeter

Change-Over Switch

Figure 19. AC Voltmeter Gauge

(Volt reading on W-U Lug)


1

DCA-70USJ — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the Output

Terminal Lugs.. The voltages at the terminals are dependent on the position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob.

Remember the voltage selector switch determines the range of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø 240/139 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 22.

3Ø 208V/1Ø120V Output Terminal Lug Voltages


Use this position for

3Ø-208 or 1Ø120V.

Figure 25. Voltage Selector

Switch 3Ø-208V/1Ø-120V

Three-Phase Position

2. Connect the load wires to the Output Terminal Lugs as shown in Figure 26.

Figure 22. Voltage Selector Switch 240/139V



Figure 26. Output Terminal Lugs

3Ø-208V/120V Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Figure 23. Output Terminal Lugs

240/139V Three Phase Connections


NOTE

To achieve a 3Ø 208V output the voltage selector switch must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to

208V.

Figure 24. Voltage Regulator Knob (139V/240V)


DCA-70USJ — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø 480/277 Output Terminal Lug Voltages


1Ø 240V/120V Output Terminal Lug Voltages






Single-Phase Position


Figure 28. UVWO Terminal Lugs

480/277V Three Phase Connections


Figure 30. UVWO Terminal Lugs

1Ø-240V/120V Connections



1

DCA-70USJ — PRE-SETUP

Circuit Breakers

To protect the generator from an overload, a 3-pole, 175 amp,

main circuit breaker is provided to protect the U,V, and W

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 auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level.

and verify that the oil level is maintained between the two notches (Figure 31) on the dipstick. See Table 10 for proper selection of engine oil.

Fuel Check

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a hot engine can cause a fire or explosion.

If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

Refilling the Fuel System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personel who have read and understand this section should refill the fuel tank system.

F

122

104

86

68

50

32

-14

-4

-22

-40

Figure 31. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. 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. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements:

■

■

■

■

■

■

■

API Service Classification CC/SC

API Service Classification CC/SD

API Service Classification CC/SE

API Service Classification CC/SF

Table 10. Recommended Motor Oil

C

20

10

0

-10

-20

-30

-40

50

40

30

OIL: SAE

The generator unit has an internal fuel tank located at the bottom of the cabinet (Figure 32). ALWAYS fill the fuel tank with clean and fresh #2 diesel fuel. DO NOT fill the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel.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.

Figure 32. Internal Fuel Tank System


Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 33).


ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.


3.

Open cabinet doors on the “right side” of the generator

(from generator control panel position). Remove fuel cap and fill tank (Figure 34).

Figure 34. Fueling the Generator

3.

NEVER overfill fuel tank – It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 35).

Figure 33. Only Fill on Level Ground

NOTE

ONLY! use #2 diesel fuel when refueling.

Figure 35. Full Fuel Tank


DO NOT OVER-FILL fuel system. Leave room for fuel expansion. Fuel expands when heated (Figure 36).



Coolant (John Deere Antifreeze/Summer Coolant/Water)

John Deere recommends John Deere Antifreeze/Summer

Coolant for use in thier engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the John Deere Engine Owner's Manual for further details.

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

negative battery terminal disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the John Deere Engine Owner's Manual.


If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See

Table 11 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

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.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 37) when depressed with the thumb as shown below.

T a b l e 1 1 .

C o o l a n t C a p a c i t y

E n g i n e a n d R a d i a t o r

R e s e r v e T a n k

3 .

7 G a .l

( 1 4 l ti e r s )

2 Q u a r t s ( 1 .

9 l ti e r s )

Operation Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 12) has been added.

O

T a b l p e r a e t i

1 2 .

n g

A n t i F r e e z e

T e m p e r a t u r e s

A n t

V

-i o l

F

5 r

0

% e e z e

F r e e z i n g P o i n t

° C

3 7

° F

3 4

Figure 37. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near the belts or fan while the generator set is running.

NOTE

When the antifreeze is mixed with water, the antifreeze 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 are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. 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 an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

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 that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 38) 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 - BATTERY SERVICING SAFETY

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

Figure 38. Battery Connections

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position. ALWAYS make sure that the MPEC

Control Switch is in the OFF/RESET position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTE

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.

CAUTION - BATTERY SERVICING SAFETY

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

Alternator

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrision and damage the alternator.

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.

If any hose ( fuel or oil) lines are defective replace them immediately.

1


Before Starting

DCA-70USJ — GENERATOR START-UP PROCEDURE (MANUAL)

4. Close all engine enclosure doors (Figure 40).

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating.

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER! manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position.

Figure 40. Engine Enclosure Doors

1. Place the main, G.F.C.I., and aux. circuit breakers

(Figure 39) in the OFF position prior to starting the engine.

5. Place the voltage selector switch in the desired voltage position

(Figure 41).

Figure 41. Voltage

Selector Switch

Figure 39. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Connect the load to the receptacles or the Output

Terminal Lugs as shown in Figure 13. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

3. The output terminal lugs are protected by a plastic cover.

Remove this cover to gain access to the terminals.

Tighten terminal nuts securely to prevent load wires from slipping out.



Starting (Manual)

8. Place the MPEC Control Switch in the MANUAL position to start the engine (Figure 42).

9. The generator's frequency meter (Figure 45) should be displaying the 60 cycle output frequency in HERTZ.

Figure 42. MPEC Control Switch

(Manual Position)

In cold weather conditions, placing the MPEC Control

Switch in the MANUAL position will preheat and start the engine AUTOMATICALLY. The Preheat Lamp

(Figure 43) will turn off when the engine has started.

7. Once the engine starts, let the engine run for 1-2 minutes.

Listen for any abnormal noises.

Figure 45. Frequency Meter (Hz)

10. The generator's AC-voltmeter (Figure 46) will display the generator’s output in VOLTS. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 47) to increase or decrease the desired voltage.

Figure 46. Voltmeter

Figure 43. Pre-Heat Lamp

8. Verify that the Engine Running status LED on the MPEC unit

(Figure 44) is ON (lit) after the engine has been started.

Figure 44. Engine

Running LED (ON)

Figure 47. Voltage Adjust Control Knob

11. The ammeter (Figure 48) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 48. Ammeter (No Load)


1


12. The engine oil pressure gauge

(Figure 49) will indicate the oil pressure (kg/ cm 2 ) of the engine.

Under normal operating conditions the oil pressure is approximately

35~65 PSI.

Figure 49. Oil Pressure Gauge

13. The coolant temperature gauge (Figure 50) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between

165 and 215 degrees Fahrenheit ( Green Zone).

15. Place the main, GFCI, and aux. circuit breakers in the

ON position (Figure 52).

Figure 52. Main, Aux. and GFCI

Circuit Breakers (ON)

Figure 50. Coolant Temperature Gauge

14. The tachometer gauge (Figure 51) will indicate the speed of the engine when the generator is operating.

Under normal operating conditions this speed is approximately 1800 RPM’s.

16. Observe the generator's ammeter (Figure 53) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

Figure 51. Engine Tachometer Gauge

Figure 53. Ammeter (Load)

17. The generator will run until manually stopped or an abnormal condition occurs.


DCA-70USJ — GENERATOR START-UP PROCEDURE (AUTO MODE)

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a licensed

electrician must install an isolation

(transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

1. Perform steps 1 through 5 in the Before Starting section as outlined in the Manual Starting Procedure.

2. Place the MPEC Control Switch (Figure 54) in the AUTO position .

Figure 54. MPEC Control Switch (AUTO)

CAUTION - BACKUP GENERATOR USE

When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator's internal battery charger. This will ensure that the engine will not fail due to a dead battery.

3. Continue to follow the steps outlined in the Manual Start-

up procedure (start at step 9).

NOTE

When the generator is set in the

AUTO mode, the generator will

automically start in the event of comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

WARNING - AUTO MODE MAINTENANCE

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.


1

DCA-70USJ — GENERATOR SHUT-DOWN PROCEDURE

WARNING - SHUTTING DOWN THE GENERATOR

NEVER stop the engine suddenly except in an emergency.

DO NOT use the emergency stop switch a as method of shutting down the generator. This switch is ONLY to be used in the event of an emergency.

Emergency Shutdown Procedure

1. To shut-down the engine in the event of an emergency, switch the MAIN, GFCI and LOAD (Figure 39) circuit breakers to OFF position.

2. Place the MPEC Control Switch switch (Figure 55) to the OFF/RESET position.

Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 39 to the OFF position.

3. Let the engine cool by running it for 3-5 minutes with no load applied.

4. Place the MPEC Control Switch (Figure 55) to the

OFF/RESET position.

Figure 55. MPEC Control Switch (Off/Reset)

5. Verify that the all status LED on the MPEC display are OFF (not lit).

6. Remove all loads from the generator.


DCA-70USJ — MAINTENANCE

T A B L E

E N G I N E

G E N E R A T O R

1 3 .

I N S P E C T I O N / M A I N T E N A N C E

1 0

D A I

H r s

L Y

X

2 5 0 H r s 5 0 0 H r s 1 0 0 0 H

C h e c k E n g i n e F l u i d L e v e l s

C h e c k A ri C l e a n e r

C h e c k B a tt e r y A c i d L e v e l

C h e c k F a n B e tl C o n d i it o n

C h e c k f o r L e a k s

C h e c k f o r L o o s e n i n g o f P a r t s

X

X

X

X

X

R e p l a c e E n g i n e O li a n d F i tl e r * 1

C l e a n A ri F i tl e r

C h e c k F u e l F i tl e r / W a t e r S e p e r a t o r B o w l

C l e a n U n i ,t I n s i d e a n d O u t s i d e

C h a n g e F u e l F i tl e r

X

X

X

X

C l e a n R a d i a t o r a n d C h e c k C o o l a n t P r o t e c it o n L e v e l * 2

R e p l a c e A ri F i tl e r E l e m e n t * 3

C h e c k a ll H o s e s a n d C l a m p s * 4

C l e a n I n s i d e o f F u e l T a n k

M e a s u r e I n s u l a it o n R e s i s t a n c e O v e r 3 M o h m s

C h e c k R o t o r R e a r S u p p o r t B e a r i n g

X

X

X

X

X

X

X

* 1 R e p l a c e e n g i n e o li a n f if tl e r a t 1 0 0 h o u r s , f ri s t it m e o n l y .

* 2 A d d " S u p p l e m e n t a l C o o l a n t A d d a it v e s ( S C A ' S ) " t o r e c h a r g e t h e e n g i n e c o o l a n .t

* 3 R e p l a c e p r i m a r y a ri if tl e r e l e m e n t w h e n r e s t r i c it o n i n d i c a t o r s h o w s a v a c c u m o f 6 2 5 m m ( 2 5 i n .

H

2

0 ) .

* 4 fI n o b l o w b y s a g s o r h o s e d i p s n e e d s t h a t c t o o u l b e d c o r e p l a c e d , ll e c t m o i s e n s t u r e u r e a n t h a d / o r t t h e o i .l

s l o p e o f t h e b l o b y h o s e i s a t l e a s t a 1 / 2 i n c h p e r f o o ,t w ti h r s

General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

Service Daily

If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exists.

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the

1 reduced by keeping the tank full with diesel fuel.



Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the John Deere

Engine Manual for details.

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 Figure 33.

Replacing Oil Filter

Flushing Out Radiator and Replacing Coolant the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.

signs of leakage.

radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

manufaturer.

WARNING - BURN HAZARDS will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

Replacing Fuel Filter

Allow engine to cool when flushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.

hours or so.

Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

Generator Storage

For longe term storage of the generator the following is recommended: if necessary.

necessary with fresh oil.

place on blocks so tires do not touch the ground or block and completely remove the tires.



Jacket Water Heater and Internal Battery Charger

120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC,

20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal

battery charger.

These receptacles will ONLY function when commercial power has been supplied to them (Figure 56). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 5).

When using the generator in hot climates there is no reason to apply power to jacket water heater. However, if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using an power cord of adequate size.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger.

Figure 56. DCA-45SIU2 Battery Charger &

Jacket Water Heater Power Connections


1

DCA-70USJ — TRAILER MAINTENANCE

Trailer Maintenance

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with the DCA-70USJ

Ultra-Silent Generator.

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch to the rear bumper (reflector).

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches

(10,12,14, etc.), and the width in millimeters

(175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;

2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.

Always use a torque wrench to tighten down the lug nuts. See Table 17 and Figure 59 for lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed on a particular trailer.



Brakes

Trailer brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Figure 57 displays the major hydraulic surge brake components that will require inspection and maintenance.

Please inspect these components as required using steps 1 through 8 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer to the ground.

8. Repeat steps 1 through 7 on the remaining brakes.

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 57) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 57. Hydraulic Brake Components

Actuator

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying hydraulic pressure to the trailer brakes.

Periodically check and test the surge “ actuator” to make sure that it is functioning correctly. Never use an undersize actuator.

T a b l e 1 4 .

H y d r a u l i c B r a k e T r o u b l e s h o o t i n g

S y m p t o m

N o B r a k e s

W e a k B r a k e s

O n e o r B r a

S i d e k e s P u ll t o

L o c k i n g B r a k e s

N o i s y B r a k e s

D r a g g i n g B r a k e s

P o s s i b l e C a u s e

B r a k e il n e b r o k e n o r k i n k e d ?

B r a k e il n i n g g l a z e d ?

T r a li e r o v e r l o a d e d ?

B r a k e d r u m s s c o r e d o r g r o o v e d ?

T ri e p r e s s u r e c o r r e c t ?

T ri e s u n m a t c h e d o n t h e s a m e a x l e ?

B r a k e c o m p o n e n t s l o o s e , b e n t o r b r o k e n ?

B r a k e d r u m s o u t o f r o u n d ?

S y s t e m l u b r i c a t e d ?

B r a k e c o m p o n e n t s c o r r e c t ?

B r a k e il n i n g t h i c k a d j u s t e d n e s s c o r r i n c o r r e c t e c lt y ?

o r n o t

E n o u g h b r a k e lf u i d o r c o r r e c t lf u i d ?

S o l u t i o n

R e p a ri o r r e p l a c e .

R e b u r n i s h o r r e p l a c e .

C o r r e c t w e i g h .t

M a c h i n e o r r e p l a c e .

I n lf a t e a ll t ri e s e q u a ll y .

M a t c h t ri e s .

R e p l a c e c o m p o n e n t s .

R e p l a c e .

L u b r i c a t e .

R e p l a c e a n d c o r r e c .t

I n s t a ll n e w s h il n i n g s .

o e s a n d

R e p l a c e if ll w ti h r u b b e r d o t 4 p a r t s lf u i d .

1



Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

Suspension

The leaf suspension springs and associated components

(Figure 58) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components as detailed in Table 16.

CAUTION - EYESIGHT HAZARD

ALWAYS wear safety glasses when removing or installing force fitted parts.

Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

DO NOT attempt to repair or modify a wheel. DO NOT install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life.

Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot!. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 15 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

TABLE 15. TIRE WEAR TROUBLESHOOTING

WEAR PATTERN

Center Wear

Edge Wear

Side Wear

Toe Wear

CAUSE

Over Inflation.

Under Inflation.

Loss of camber or overloading.

Incorrect toe-in.

SOLUTION

Adjust pressure to particular load per tire manufacturer.

Adjust pressure to particular load per tire manufacturer.

Make sure load does not exceed axle rating.

Align wheels.

Align wheels.

Cupping

Flat Spots

Out-of-balance.

Wheel lockup & tire skidding.

Check bearing adjustment and balance tires.

Avoid sudden stops when possible and adjust brakes.

Figure 58. Major Suspension Components

T a b l e 1 6 .

S u s p e n s i o n T o r q u e R e q u i r e m e n t s

I t e m

3 / 8 " U B O L T

7 / 1 6 " U B O L T

1 / 2 " U B O L T

SHACKLE BOLT

SPRING EYE BOLT

T o r q

M I N

M I N u e

3 0

4 5

( F t .

L

M A X -

M A X b s .

)

3 5

6 0

M I N 4 5 M A X 6 0

SNUG FIT ONLY

.

PARTS MUST ROTATE FREELY

.

LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

-

BOLT ASSEMBLY

.

SHOULDER TYPE

SHACKLE BOLT

M I N 3 0 M A X 5 0



Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 59). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 17.

3. After first road use, retorque all lug nuts in sequence.

Check all wheel lug nuts periodically.

W h e e l S i z e

1

1

2

3

"

"

T a b l e 1 7 .

T i r e T o r q u e R e q u i r e m e n t s

F i r s t P a

F T L B S

2 0 2 5

2 0 2 5 s s S e c o

3 n

5 d P a s s

F T L B S

3 5 4 0

4 0

T h i r d P a

F T L B S s s

5 0 6 5

5 0 6 5

1 4 "

1 5 "

1 6 "

2

2

2

0

0

0 -

-

-

2

2

2

5

5

5

5

5

5

0

0

0 -

-

-

6

6

6

0

0

0

9

9

9

0 -

0 -

0 -

1 2

1 2

1 2

0

0

0

Figure 59. Wheel Lug Nuts

Tightening Sequence

NOTE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

1


DCA-70USJ — TRAILER WIRING DIAGRAM

Figure 60. Trailer/Towing Vehicle Wiring Diagram


DCA-70USJ — GENERATOR WIRING DIAGRAM


DCA-70USJ — ENGINE WIRING DIAGRAM

Figure 62. Engine Wiring Diagram


DCA-70USJ — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company's business office or service plant.

S Y M P T O M

N o V o tl a g e O u t p u t

L o w V o tl a g e O u t p u t

H i g h V o tl a g e O u t p u t

C ri c u ti B r e a k e r T r i p p e d

T A B L E 1 8 .

G E N E R A T O R T R O U B L E S H O O T I N G

P O S S I B L E P R O B L E M

A C V o tl m e t e r d e f e c it v e ?

I s w ri i n g c o n n e c it o n l o o s e ?

I s A V R d e f e c it v e ?

D e f e c it v e R o t a it n g R e c it if e r ?

D e f e c it v e E x c ti e r F i e l d ?

I s e n g i n e s p e e d c o r r e c t ?

I s w ri i n g c o n n e c it o n s l o o s e ?

D e f e c it v e A V R ?

I s w ri i n g c o n n e c it o n s l o o s e ?

D e f e c it v e A V R ?

S h o r t C ri c u ti i n l o a d ?

O v e r c u r r e n t ?

D e f e c it v e c ri c u ti b r e a k e r ?

O v e r c u r r e n t R e l a y a c t u a t e d ?

S O L U T I O N

C h e c k o u t p u t v o tl a g e u s i n g a v o tl m e t e .r

C h e c k w ri i n g a n d r e p a i .r

R e p l a c e fi n e c e s s a r y .

C h e c k a n d r e p l a c e .

C h e c k f o r 1 7 .

3 o h m s a c r o s s J & K o n C N 1

T u r n e n g i n e t h r o t lt e l e v e r t o " H i g h " .





C h e c k l o a d a n d r e p a i .r

C o n f ri m l o a d r e q u ri e m e n t s a n d r e d u c e .

C h e c k a n d r e p l a c e .

C o n f ri m l o a d r e q u ri e m e n t a n d r e p l a c e .


1

DCA-70USJ — TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor

Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.

T A B L E 1 9 .

E N G I N E C O N T R O L L E R T R O U B L E S H O O T I N G ( M P E C )

S Y M P T O M P O S S I B L E P R O B L E M

L o w o li l e v e l ?

O li p r e s s u r e s e n d i n g u n ti f a li u r e ?

L o w o n .

o li p r e s s u r e il g h t i s

T i m e d e l a y m a fl u n it o n i n C o n t r o ll e r ?

W ri e s h o r t e d ?

L o w c o o l a n t l e v e l ?

L o w o n .

c o

( O p o it l a n t o n a l e ll y v

I e l n s il g t a h t i s ll e d )

S e n d i n g u n ti f a li u r e ?

L o w b a tt e r y v o tl a g e ?

F a n b e tl t e n s i o n i n c o r r e c t ?

A ri lf o w i s n o t c ri c u l a it o n t h r o u g h r a d i a t o r ?

D o o r s o p e n ?

H i g h il g h t c i s o o o l a n t n .

t e m p e r t u r e

E x h a u s t l e a k i n g ?

G e n e r a t o r b e i n g o v e r l o a d e d ?

T h e r m o s t a t f a li u r e ?

A ri i n t a k e b l o c k e d ?

O v e r c r a n k il g h t i s o n .

T e m p e r a t u r e s w ti c h f a li u r e ?

N o o r l o w F u e l ?

C o n t r o ll e r n e e d s t o b e c a il b r a t e d ?

R P M e n g i n e s p e e d t o o h i g h ?

O

L o o v n .

s e s r s p o f e e

M d

P il

U g h il t g i s h t ( s o

) n .

o r

G o v e r n o r a c t u a t o r n e e d s t o b e a d j u s t e d ?

G o v e r n o r c o n t r o ll e r n e e d s t o b e a d j u s t e d ?

E n g i n e C o n t r o ll e r n e e d s t o b e c a il b r a t e d ?

M a g n e it c p i c k u p o u t o f a d j u s t m e n t ?

M a g n e it c p i c k u p d ri t y ?

S O L U T I O N

F i ll o li l e v e .l

R e p l a c e o li p r e s s u r e s e n d i n g u n i .t

R e f e r t o d e a l e .r

I n s p e c /t r e p a ri w ri e .

F i ll c o o l a n t l e v e .l

R e p l a c e s e n d i n g u n i .t

R e p l a c e / c h a r g e b a tt e r y .

T i g h t e n / r e p l a c e f a n b e l .t

C l e a n / r e p a ri r a d i a t o r g r li .l

C l o s e d o o r s .

R e p l a c e / r e p a ri g a s k e t s o r f a u tl y p a r .t

C h e c k / r e d u c e l o a d .

R e p l a c e t h e r m o s t a .t

C l e a r a ll a ri i n t a k e s .

R e p l a c e t e m p e r a t u r e s w ti c h .

F i ll f u e l l e v e .l


A d j u s t R P M .

A d j u s t g o v e r n o r a c t u a t o .r

A d j u s t g o v e r n o r c o n t r o ll e .r


A d j u s t m a g n e it c p i c k u p .

C l e a n m a g n e it c p i c k u p .


NOTE PAGE


1

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 <, 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.

NOTE The contents of this catalog are subject to change without notice.


DCA-70USJ — SUGGESTED SPARE PARTS

DCA-70USJ ULTRA-SILENT GENRATOR

W/JOHN DEERE 4045TF275 DIESEL ENGINE

1 TO 3 UNITS

Qty.

P/N Description

5 ......... 0602041292 ........ FILTER, OIL

5 ......... 0602042594 ........ FILTER, FUEL, PRIMARY

5 ......... 0602042595 ........ FILTER, FUEL, FINAL

3 ......... 0602046377 ........ ELEMENT, AIR

1 ......... 0602011493 ........ BELT, FAN

1 ......... 0605505070 ........ CAP. FUEL TANK

1 ......... 0602122272 ........ UNIT, OIL PRESSURE

1 ......... 0602123261 ........ UNIT, WATER TEMPERATURE

2 ......... 0601802149 ........ FUSE, 10A

1 ......... 0602123282 ........ SENDER, WATER SWITCH (ENGINE SIDE)

1 ......... 0602122281 ........ SENDER, OIL SWITCH (ENGINE SIDE)

NOTE

Part number on this Suggested Spare Parts list may supercede/replace the P/N shown in the text pages of this book.


1

GENERATOR ASSY.

DCA-70USJ — GENERATOR ASSY.


DCA-70USJ — GENERATOR ASSY.

NO.

3

4

1

1-9 *

1-10 *

1-11 *

1-12 *

1-13 *

1-14 *

2

1-15 *

1-16 *

1-1 *

1-2 *

1-3 *

1-4 *

1-5 *

1-6 *

1-7 *

1-8 *

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

21

22

23

24

25

26

27

27A

27B

28

GENERATOR ASSY.

B5130000103

0845041904

8101315202

8101350013

0012110070

0042610000

0041210000

0017110035

8101310014

8131312014

0016906016

8101331003

0016906016

8101333003

0340406040

0041606000

0012810030

8111332014

0340406040

0041606000

0600815000

0605000010

0030012000

0040012000

0041212000

0070506306

PART NO.

B5110100602

8101070033

0012810035

8101611004

PART NAME QTY.

REMARKS

ROTOR ASSY. .............................................. 1 .......... INCLUDES ITEMS W/ *

FIELD ASSY.

1

FAN

BOLT, HEX HEAD

1

8

0012110030

0042510000

8101026013

0601821349

0601822601

8001020004

COUPLING DISK 5

BALANCING PLATE ..................................... 1 .......... MUST PURCHASE ROTOR ASSY.

BOLT, HEX HEAD

SPRING WASHER

8

8

SET PLATE, RECTIFIER ............................. 1 .......... MUST PURCHASE ROTOR ASSY.

RECTIFIER .................................................. 1 .......... PT3610

SURGE ABSORBER .................................... 1 .......... ERZ-M14JK621A

INSULATOR WASHER 1

8001020504

0010110020

0040010000

0601000209

INSULATOR WASHER

BOLT, HEX HEAD

SPRING WASHER

BALANCING WEIGHT KIT

4

1

1

4

0071906311 BEARING ..................................................... 1 .......... 6311DDU C3

M2163400003 COUPLING RING 1

0343204170

0043604000

BOLT, HEX HEAD

SPRING WASHER

8

8

STATOR ASSY. ............................................. 1 .......... B5134000304

GROMMET 2

END BRACKET 1

FIELD ASSY. EXCITER ............................... 1 .......... B5134000304

BOLT, HEX HEAD

SPRING WASHER

PLAIN WASHER

BOLT, HEX HEAD

4

4

4

6

COVER, BEARING

GASKET, BEARING

BOLT, HEX HEAD

COVER, END BRACKET

BOLT, HEX HEAD

COVER, END BRACKET

BOLT, HEX HEAD

PLAIN WASHER

1

1

6

1

4

1

1

1

BOLT, HEX HEAD

COVER, FAN

BOLT, HEX HEAD

PLAIN WASHER

NUT

RUBBER SUSPENSION

HEX, NUT

SPRING WASHER

12

1

1

1

1

2

2

2

PLAIN WASHER 2

BEARING ..................................................... 1 .......... 6306ZZ 1


CONTROL BOX ASSY.

DCA-70USJ — CONTROL BOX ASSY.


CONTROL BOX ASSY.

9

10

11

12

7

8

5

6

NO.

PART NO.

3

4

1

2

M2213000702

0330000180

0601808824

0021005080

0601823863

0027104016

0601820671

0027105016

0601806139

0027106016

0601820845

0601820846

13 0027104016

13A 0207004000

14

15

M3213500013

0016906016

16 M3270100104

16A

17

18

19

20

21

* TBD

M3276600004

M2213600503

0330000330

0027104010

0016906016

22

23

M2213600404

0016906016

24 0016906016

24A 0040506000

25 M2223000403


PART NAME QTY.

REMARKS

CONTROL BOX

EDGING

1

2

CIRCUIT BREAKER ............................................1 ............ KAF361751039 3P 175A

MACHINE SCREW 4

RELAY UNIT ........................................................2 ............. MSA9013A

MACHINE SCREW 4

AUTOMATIC VOLTAGE REGULATOR ..................1 ............. NTA-5A-2DB

MACHINE SCREW 4

CURRENT TRANSFORMER ...............................3 ............. 814-943 150/5A

MACHINE SCREW 6

OVER CURRENT RELAY ....................................1 ............. LR2D1308

OVER CURRENT RELAY ....................................1 ............. LA7D1064

MACHINE SCREW

HEX, NUT

CONTROL BOX COVER

BOLT, HEX HEAD

1

4

2

2

SELECTOR SWITCH ..........................................1 ............. XUSS01574

............................................................................................ INCLUDES ITEMS W/ *

KNOB, SELECTOR SWITCH 1

SPACER 2

SWITCH BRACKET

EDGING

MACHINE SCREW

BOLT, HEX HEAD

SWITCH COVER

BOLT, HEX HEAD

BOLT, HEX HEAD

TOOTHED WASHER

CONTROL PANEL

10

1

1

4

4

6

1

2

1


1

CONTROL BOX ASSY.



CONTROL BOX ASSY.

NO.

PART NO.

26

27

28

29

0601807641

0601808987

0601801040

0601806859

30

31

32

33

0601801041

0601840073

0601840121

0602202593

34

35

0601831340

0021004040

35A 0207004000

36 0602103092

48

49

50

51

44

45

46

47

40

41

42

43

36A 0601810245

37 0602120096

38

39

0602122093

0602123092

0602121080

0602125090

0601810141

0601831330

M1223100004

M3223100004

0027105010

0027105010

M9220100004

0080200007

0602202592

0027106016

57

58

59

60

61

62

52 LY2DUS12VDC

52A PTF08A-E

52B PYCA1

53 0027104020

54

55

0601823240

0602103092

55A 0601810245

56 0602122272

0602123261

M2246701204

M3357201102

M3357200304

0601802149

0601823240


PART NAME QTY.

REMARKS

FREQUENCY METER 1

AC AMMETER ....................................................1 ........ ACF-6 0~150A/300A:5A

CHANGE-OVER SWITCH, AMMETER ...............1 ........ SL-2AS

AC VOLTMETER .................................................1 ........ SCF-6 0~600V

CHANGE-OVER SWITCH, VOLTMETER ............1 ........ SL-2VS

RHEOSTAT (VOLTAGE REGULATOR) .................1 ........ RA20A2SE102BJ 2W 1k OHM

KNOB

CONTROLLER

1

1

SWITCH ..............................................................1 ........ 7562K4

MACHINE SCREW 2

HEX, NUT 2

PREHEAT LAMP .................................................1 ........ PL-05

BULB ...................................................................1 ........ E-10 T-10 DC 18V

TACHOMETER ....................................................1 ........ 111812

OIL PRESSURE GAUGE ....................................1 ........ 100174

WATER TEMPERATURE GAUGE .......................1 ........ 100182

CHARGING AMMETER ......................................1 ........ 100158

FUEL GAUGE ......................................................1 ........ 100176

PANEL LIGHT ......................................................1 ........ 98268-00370

SWITCH, PANEL LIGHT .....................................1 ........ 90-0001

STOPPER

STOPPER

MACHINE SCREW

MACHINE SCREW

4

4

1

1

SET SCREW 2

SNAP RING .........................................................2 ........ S-7

STARTER RELAY ................................................1 ........ AT141011

MACHINE SCREW 2

RELAY .................................................................1 ........ REPLACES 0601827656

BASE ..................................................................1 ........ REPLACES 0601823109

CLIP ....................................................................2 ........ REPLACES 0601824400

MACHINE SCREW 2

RECTIFIER .........................................................1 ........ DE45

ALARM LAMP .....................................................1 ........ PL-05

BULB ...................................................................1 ........ E-10 T-10 DC18V

UNIT, OIL PRESSURE ........................................1 ........ 108497

UNIT, WATER TEMPERATURE ...........................1 ........ 02025-00

WIRE HARNESS, GENERATOR 1

WIRE HARNESS, ENGINE

WIRE HARNESS, FUEL LEAK

1

1

FUSE ...................................................................2 ........ F-1065 10A

RECTIFIER .........................................................1 ........ DE45


1

ENGINE & RADIATOR ASSY.

DCA-70USJ — ENGINE & RADIATOR ASSY.




8

9

6

7

4

5

2

3

NO.

PART NO.

1 M2923200014

1-1 0602041292

1-2 0602042595

1-3 0602011494

0602060004

0602061000

0012110095

0042510000

M2303200303

0010312030

0040012000

0605000009

20

21

22

23

17

18

19

20

13

14

15

16

10

11

0030012000

0040012000

12 C0923200124

12-1 0602011062

M9200100904

0150000016

0016910025

M2313300003

0016910030

M3310500813

M3310500903

0605515148

0605515199

0605515147

B6925200014

0016910030

27

28

29

30

24 0602046582

24A 0602046365

25

26

0602040650

0602040554

31

0016908030

M2373100203

0605515146

0605515197

0602022563

PART NAME QTY.

REMARKS

ENGINE ...............................................................1 ........ JOHN DEERE 4045TF275

CARTRIDGE, OIL FILTER ...................................1 ........ RE504836

CARTRIDGE, FUEL FILTER ...............................1 ........ RE509031

FAN BELT ............................................................1 ........ 240P

BLOWER FAN .....................................................1 ........ RE47518

FAN SPACER ......................................................1 ........ R81911

BOLT, HEX HEAD

SPRING WASHER

4

4

ENGINE FOOT

BOLT, HEX HEAD

SPRING WASHER 6

RUBBER SUSPENSION .....................................2

2

6

HEX, NUT

SPRING WASHER

2

2

RADIATOR ...........................................................1 ........ 232000-3240

CAP .....................................................................1 ........ 102600-0380

PLUG

O RING

BOLT, HEX HEAD

FAN BRACKET

1

1

2

1

BOLT, HEX HEAD

RADIATOR HOSE, UPPER

4

1

RADIATOR HOSE, LOWER 1

HOSE BAND .......................................................3 ........ UP TO S/N 8300040

HOSE BAND .......................................................3 ........ S/N 8300041~

HOSE BAND .......................................................1 ........ 5O32

FAN MOTOR ........................................................1 ........ VP-456SKX

BOLT, HEX HEAD 8

AIR CLEANER ....................................................1 ........ FPG082527

ELEMENT, AIR CLEANER ..................................1 ........ P828889

INDICATOR, AIR CLEANER ................................1 ........ RBX00-2252

BAND, AIR CLEANER .........................................1 ........ P777732

BOLT, HEX HEAD

HOSE, AIR CLEANER

HOSE BAND

HOSE BAND

2

1

1

1

ADAPTER ............................................................1 ........ 10-M18 X 1.5 F80X-S


1






57

58

59

60

53

54

55

56

61

62

63

48

49

51

52

44

45

46

47

40

41

42

43

36

37

38

39

NO.

PART NO.

32

33

34

35

0602022561

0603306590

0603300285

0605511395

0603306395

0602021070

0269200660

M9300000203

0602010900

M3316100303

0016908020

0199102200

0193600700

0193601000

0605515106

M2326000104

0605515149

M3260600104

0602202592

0027106016

0030006000

M2351800004

0021005070

0040005000

0041205000

0017112025

0040512000

M2326200004

0017110030

0602123282

0602122281

PART NAME

90 DEGREE ELBOW

CONNECTOR

ROCKNUT

VALVE

HOSE JOINT

CAP

DRAIN HOSE

RESERVE TANK

CAP, RESERVE TANK

BRACKET, RESERVE TANK

BOLT, HEX HEAD

HOSE

3

1

1

1

1

1

1

1

QTY.

REMARKS

1

1

1

1

HOSE

HOSE

HOSE BAND

BLOWBY HOSE

3

1

1

1

HOSE BAND

RELAY BRACKET

1

1

RELAY .................................................................1 ........ AT141011

MACHINE SCREW 2

HEX, NUT

COLLAR

MACHINE SCREW

SPRING WASHER

PLAIN WASHER

BOLT, HEX HEAD

TOOTHED WASHER

HOSE CLAMPER

2

4

4

4

4

1

1

1

BOLT, HEX HEAD 1

SENDER, WATER SWITCH (ENGINE SIDE) 1

SENDER, OIL SWITCH (ENGINE SIDE) 1


1

OUTPUT TERMINAL ASSY.

DCA-70USJ — OUTPUT TERMINAL ASSY.


DCA-70USJ — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

28

29

30

31

32

33

NO.

PART NO.

3

4

1

2

M2230700113

M2233000004

M2233100004

0039312000

7

8

5

6

0040012000

0041412000

0016908035

M3236100503

9

10

M3236100404

0605010040

11 0027103010

11A 0041203000

16

18

19

20

12

13

14

15

0030003000

0016906020

0016906016

M3236400004

M3236300004

0601808803

0601808804

M1260700304

20-1 0222100150

22 0601812598

23

24

0601812538

0027104016

24A 0207004000

25 M2236100603

26

27

0010112045

0041212000

M9310200004

0030012000

0603306775

0027104016

0601815194

0027104016

PART NAME

TERMINAL PANEL

OUTPUT TERMINAL BOLT

TIE BOLT

HEX, NUT

SPRING WASHER

PLAIN WASHER

BOLT, HEX HEAD

TERMINAL COVER

OUTPUT WINDOW

HINGE

MACHINE SCREW

PLAIN WASHER

8

4

1

2

15

20

5

1

QTY.

REMARKS

5

10

1

5

HEX, NUT

BOLT, HEX HEAD

BOLT, HEX HEAD

CABLE OUTLET COVER

8

10

4

1

SUPPORTER, CABLE OUTLET COVER 1

CIRCUIT BREAKER ............................................2 ........ QOU 120B 1P 20A

CIRCUIT BREAKER ............................................3 ........ QOU 250B 2P 50A

BREAKER FITTING COVER 1

CUSHION RUBBER 1

RECEPTACLE .....................................................2 ........ GF530EM 125V 20A X 2

RECEPTACLE .....................................................3 ........ CS6369 250V 50A

MACHINE SCREW 10

HEX, NUT

TERMINAL COVER

BOLT, HEX HEAD

PLAIN WASHER

10

1

2

2

STAY RUBBER

HEX, NUT

BLIND PLUG

MACHINE SCREW

2

2

2

4

TERMINAL ..........................................................1 ........ 601-GP-02

MACHINE SCREW 2

ADD THE FOLLOWING DIGITS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN

5-BLACK

6-CATERPILLAR YELLOW

7-CATO GOLD

8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

1


BATTERY ASSY.

DCA-70USJ — BATTERY ASSY.


8

9

6

7

10

4

5

2

3

BATTERY ASSY.

NO.

PART NO.

1 0602220187

M9310500014

M9103000304

0602220920

M2346900204

M2346900304

0017112025

0040520000

0040512000

DCA-70USJ — BATTERY ASSY.

PART NAME QTY.

REMARKS

BATTERY ............................................................1 ........ 627MFD

BATTERY SHEET

BATTERY BAND

BATTERY BOLT SET

BATTERY CABLE

1

1

2

1

BATTERY CABLE 1

CABLE ................................................................1 ........ MAKE LOCALLY

BOLT, HEX HEAD

TOOTHED WASHER

1

1

TOOTHED WASHER 1


1

MUFFLER ASSY.

DCA-70USJ — MUFFLER ASSY.


MUFFLER ASSY.

7

8

5

6

9

10

NO.

PART NO.

3

4

1

2

M2330100803

0017112030

M2333000703

M2333200204

0017110040

M3333200204

0017110035

M2333000603

0017110050

0602325066

PART NAME

MUFFLER

BOLT, HEX HEAD

EXHAUST PIPE

GASKET

BOLT, HEX HEAD

GASKET

BOLT, HEX HEAD

EXHAUST PIPE

BOLT, HEX HEAD

CLAMP

DCA-70USJ — MUFFLER ASSY.

4

1

4

1

4

1

QTY.

REMARKS

1

1

1

4


1

FUEL TANK ASSY.

DCA-70USJ — FUEL TANK ASSY.

7


FUEL TANK ASSY.

9

10

11

12

13

7

8

5A

6

4

5

2

3

NO.

PART NO.

1 M2363000902

1-1 0605505070

1-2 0605501073

1-3 0605516090

M2363200404

M9310500104

0016908020

0016908055

0207008000

0191302040

0605515109

0191301000

0191301200

0605515109

0605515189

0602042601

0222101000

DCA-70USJ — FUEL TANK ASSY.

PART NAME

FUEL TANK

FUEL TANK CAP

FUEL SENDER UNIT

GASKET

TANK BAND

SUPPORTER SHEET

BOLT, HEX HEAD

BOLT, HEX HEAD

HEX, NUT

VENT HOSE

HOSE BAND

SUCTION HOSE

QTY.

1

1

1

1

6

6

6

3

9

1

2

1

REMARKS

RETURN HOSE

HOSE BAND

1

3

HOSE BAND 1

RETURN PIPE ....................................................1 ........ RE67050

TANK SHEET 5


1

ENCLOSURE #1 ASSY.

DCA-70USJ — ENCLOSURE #1 ASSY.


ENCLOSURE #1 ASSY.

NO.

PART NO.

3

4

1

2

M2413001502

M2363300203

0016910030

0603306797

5

5A

6

6A

M2423000912

M2493104103

M2423001002

M2493104103

8

9

0601850100

0016908020

10 0016910025

11-1 M3131400103

15

16

17

18

11-2 M3131400004

12 0016908020

13

14

M3423500104

0016906016

M3423200704

0016906020

M3423200804

0016906016

19

20

21

22

M2310300204

M2310300304

0016906020

M2423300004

22A M2493600004

23 0016908020

24 M2423201303

24A M2493103404

25

25

0016908020

0019208020

26 M3433000813

26A M3493201204

27 0010114040

27A 0030014000

27B 0040014000

27C 0041214000


PART NAME

BASE

ENVIRONMENTAL TANK

BOLT, HEX HEAD

PLUG

FRONT FRAME

ACOUSTIC SHEET

FRONT FRAME

ACOUSTIC SHEET

GROMMET

BOLT, HEX HEAD

BOLT, HEX HEAD

HOSE COVER

HOSE COVER

BOLT, HEX HEAD

BRACKET

BOLT, HEX HEAD

DUCT COVER

BOLT, HEX HEAD

DUCT COVER

BOLT, HEX HEAD

FAN SHROUD

FAN SHROUD

BOLT, HEX HEAD

DISCHARGE GUIDE

ACOUSTIC SHEET

BOLT, HEX HEAD

COVER, FRONT FRAME

ACOUSTIC SHEET

QTY.

12

1

1

1

1

1

1

1

1

26

6

1

1

13

1

6

2

14

1

6

1

1

14

1

1

6

1

1

REMARKS

BOLT, HEX HEAD .............................................. 27 ........ S/N 8300001~8300020

BOLT, HEX HEAD .............................................. 27 ........ S/N 8300021~

CENTER FRAME

ACOUSTIC SHEET

1

1

BOLT, HEX HEAD

HEX, NUT

SPRING WASHER

PLAIN WASHER

4

4

4

8

ADD THE FOLLOWING DIGITS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN

5-BLACK


7-CATO GOLD

8-RED


1


ENCLOSURE #1 ASSY.



ENCLOSURE #1 ASSY.

NO.

PART NO.

28 0010120050

28A 0030020000

28B 0040020000

28C 0041220000

29 M2463100102

29A M2493501304

30 M2463200102

30A M2493502203

31

32

M3463200704

0016906016

33 M2463200203

33A M2493502104

42

43

44

45

39

40

41

41

34

35

36

37

0016908020

M2463400003

0016908020

M2423200814

37A M2493102604

38 0016908020

38

39

0019208020

0016910025

0019210025

M3310600004

0016908020

0019208020

0016908020

M2483100004

0016908020

0016908020

45A 004050800

46 0605503062

47

48

M1414800104

0016908020


PART NAME

BOLT, HEX HEAD

HEX, NUT

SPRING WASHER

PLAIN WASHER

ROOF PANEL

ACOUSTIC SHEET

ROOF PANEL

ACOUSTIC SHEET

BACK PLATE

BOLT, HEX HEAD

DUCT

ACOUSTIC SHEET

2

12

1

1

1

1

1

1

QTY.

REMARKS

4

8

4

4

BOLT, HEX HEAD

DUCT COVER

BOLT, HEX HEAD

OVER COVER, FRONT FRAME

10

1

6

1

ACOUSTIC SHEET 1

BOLT, HEX HEAD .............................................. 49 ........ 8300001~8300020

BOLT, HEX HEAD .............................................. 49 ........ S/N 8300021~

BOLT, HEX HEAD ................................................8 ........ S/N 8300001~8300020

BOLT, HEX HEAD ................................................8 ........ S/N 8300021~

COVER, RADIATOR CAP 1

BOLT, HEX HEAD ................................................4 ........ S/N 8300001~8300020

BOLT, HEX HEAD ................................................4 ........ S/N 8300021~

BOLT, HEX HEAD

COVER, EXHAUST PIPE

BOLT, HEX HEAD

BOLT, HEX HEAD

6

1

2

1

TOOTHED WASHER

FUEL LEAK DETECTED SWITCH

BRACKET

BOLT, HEX HEAD

1

2

1

1

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO INDICATE

COLOR OF UNIT:

1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN

5-BLACK


7-CATO GOLD

8-RED


1


ENCLOSURE #2 ASSY.


ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO INDICATE

COLOR OF UNIT:

1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN

5-BLACK


7-CATO GOLD

8-RED



ENCLOSURE #2 ASSY.

7

8

6

6

3

4

5

5A

NO.

PART NO.

1

1A

2

2A

M3443000812

M3493303203

M3443000914

M3493303304

0016908020

0016910025

M2443300903

M2493302204

0016908020

0019208020

M3443200503

M3443600304

9

9A

10

11

0207306000

0041206000

M9113000002

0021806016

11A 0030006000

12 M9110100204

13

14

M9116100004

0016908020

15 M2453200902

15A M2493404614

16

17

0016908065

0016910025

18 M2453001703

18A M2493404704

19 M2453001803

19A M2493405104

28

29

30

24

25

26

27

20 M2453001503

20A M2493404504

21 M2453001603

21A M2493404404

22 M9113000002

22A C9312500004

23 0021806016

23A 0030006000

M9110100804

M9110100904

M9116100004

0016908020

0601850097

0027208025

M9310000004


PART NAME

REAR FRAME

ACOUSTIC SHEET

DUCT

ACOUSTIC SHEET

QTY.

REMARKS

2

2

1

1

BOLT, HEX HEAD

BOLT, HEX HEAD

COVER, REAR FRAME

ACOUSTIC SHEET

26

4

1

1

BOLT, HEX HEAD .............................................. 13 ........ S/N 8300001~8300020

BOLT, HEX HEAD .............................................. 13 ........ S/N 8300021~

DOOR, REAR FRAME

WINDOW PLATE

1

1

HEX, NUT

PLAIN WASHER

DOOR HANDLE ASSY.

MACHINE SCREW

HEX, NUT

HINGE

WASHER

BOLT, HEX HEAD

SPLASHER PANEL

ACOUSTIC SHEET

BOLT, HEX HEAD

BOLT, HEX HEAD

SIDE DOOR

ACOUSTIC SHEET

SIDE DOOR

ACOUSTIC SHEET

8

8

1

4

4

2

2

3

1

1

4

2

1

1

1

1

SIDE DOOR

ACOUSTIC SHEET

SIDE DOOR

ACOUSTIC SHEET

DOOR HANDLE ASSY.

SEAL RUBBER

MACHINE SCREW

HEX, NUT

HINGE

HINGE

WASHER

BOLT, HEX HEAD

STOPPER

MACHINE SCREW

CAP

8

8

13

11

26

6

5

16

16

4

4

1

1

1

1


1

ENCLOSURE #3 ASSY.



ENCLOSURE #3 ASSY.

13

14

15

16

17

18

9

10

11

12

7

8

5

6

NO.

PART NO.

3

4

1

2

0229200870

0229201130

0229201240

0228900660

0229201070

0229200125

0228901165

0228900770

0228901105

0228900565

0228900820

0228800505

0229201200

0228800635

0228800970

0228800595

0228100640

0228100370

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

RUBBER SEAL

RUBBER SEAL


2

1

1

1

2

2

4

1

3

1

3

4

1

4

QTY.

REMARKS

3

2

1

1


1

NAME PLATE ASSY.

DCA-70USJ — NAME PLATE ASSY.


NAME PLATE ASSY.

37

38

39

40

41

33

34

35

36

29

30

31

32

25

26

27

28

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

NO.

PART NO.

3

4

1

2

M1550000204

M1550000703

M2550000304

M2550000603

M3500001803

M3550002003

M9500000004

M9500100004

M9500300004

M9500300104

M9500500004

M9503000004

M9503000103

M9503100004

M9503200004

M9510000004

M9510100004

M9510100304

M9510100403

M9520000004

M9520000104

M9520000204

M9520000504

M9520100004

M9520100204

M9520100304

M9520100404

M9520100503

M9520100603

M9520200003

M9520200104

M9512200004

M9510200304

M3560102004

M2560100603

M3560102204

M2560100903

M2560101003

M3560102504

0600500092

0021106016

DCA-70USJ — NAME PLATE ASSY.

PART NAME QTY.

REMARKS

DECAL, NOTE .............................................................. 1 .......... M15000020

DECAL, AUXILARY OUTPUT ....................................... 1 .......... M15000070

DECAL, NOTE .............................................................. 1 .......... M25000030

DECAL, GENERATOR CONTROL ................................ 1 .......... M25000060

DECAL, OPERATING PROCEDURES ......................... 1 .......... M35000180B

DECAL, ENGINE OPERATING .................................... 1 .......... M35000200

DECAL, OIL DRAIN PLUG ........................................... 1 .......... M90000000

DECAL, WATER ............................................................ 1 .......... M90010000

DECAL, NEGATIVE ...................................................... 1 .......... M90030000

DECAL, POSITIVE ...................................................... 1 .......... M90030010

DECAL, DIESEL FUEL ................................................ 1 .......... M90050000

DECAL, WARNING MOVING PARTS ........................... 2 .......... M90300000

DECAL, WATER - OIL CHECK ..................................... 1 .......... M90300010

DECAL, WARNING HOT COOLANT ............................. 1 .......... M90310000

DECAL, WARNING ENGINE EXHAUST ...................... 1 .......... M90320000

DECAL, FLUID DRAIN ................................................. 1 .......... M91000000

DECAL, CAUTION HOT PARTS ................................... 1 .......... M91010000

DECAL, ENVIRONMENTAL WARNING ........................ 1 .......... M91010030

DECAL, CAUTION ........................................................ 1 .......... M91010040

DECAL, GROUND ........................................................ 1 .......... M92000000

DECAL, AMMETER CHANGE-OVER SW. ................... 1 .......... M92000010

DECAL, VOLTMETER CHANGE-OVER SW. ................ 1 .......... M92000020

DECAL, START CONTACT ........................................... 1 .......... M92000050

DECAL, WARNING ELECTRIC SHOCK HAZARD ....... 2 .......... M92010000

DECAL, CAUTION ........................................................ 1 .......... M92010020A

DECAL, SAFETY INSTRUCTIONS .............................. 1 .......... M92010030

DECAL, DANGER HIGH VOLTAGE .............................. 1 .......... M92010040

DECAL, WARNING ....................................................... 1 .......... M92010050

DECAL, CAUTION ........................................................ 2 .......... M92010060

DECAL, CONNECTION OF OUTPUT CABLE ............. 1 .......... M92020000

DECAL, OVER CURRENT RELAY ............................... 1 .......... M92020010

DECAL, MQ .................................................................. 1 .......... M91220000

DECAL, MQ POWER

STRIPE

STRIPE, WHISPERWATT

STRIPE

2

2

2

2

STRIPE, 70

STRIPE, 70

STRIPE

PLATE, MQ POWER

MACHINE SCREW

1

1

2

1

4


1

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

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.

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.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1.

A Returned Material Authorization must be approved by Multiquip prior to shipment.

2.

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. The parts numbers and descriptions must match the current parts price list.

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. The list must include the name and phone number of the person requesting the RMA.

3.

A copy of the Return Material Authorization must accompany the return shipment.

4.

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 Multiquip part numbers clearly marked.

6.

The following items are not returnable: a. Obsolete parts. (If an item is in the price book and shows 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.

c. Any line item with an extended dealer net price of less than $5.00.

d. Special order items.

e. Electrical components.

f.

Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7.

The sender will be notified of any material received that is not acceptable.

8.

Such material will be held for five working days from notification, pending instructions. If a reply is not received within five 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.

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 $35.00 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.

LIMITATIONS OF SELLER’S LIABILITY

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.

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. Apart 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.


NOTE PAGE


1

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING



800-421-1244

FAX: 310-632-2656 Carson, CA 90746




800-427-1244

310-537-3700


800-835-2551

310-537-3700

FAX: 800-672-7877

FAX: 310-637-3284

FAX: 310-638-8046


800-835-2551


800-835-2551, EXT. 279

310-537-3700, EXT. 279

FAX: 310-638-8046

FAX: 310-638-8046

Your Local Dealer is:

Manufactured for Multiquip Inc.

by

DENYO CO., LTD, JAPAN

MQ POWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254

CARSON, CA 90749

310-537-3700 • 800-421-1244

FAX: 310-632-2656

E-mail: [email protected]


MQ Power DCA70USJ 25-150 kVA Single/Three Phase Ultra-Silent Operation Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

ULTRA-SILENT

SERIES

GENERATOR

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

To find the latest revision of this publication, visit our website at: www.mqpower.com

UL TRA-SILENT GENERA TOR

COMPONENT DRA WINGS

When ordering parts, please supply the following information:

Here’s how to get help...

Place Your Parts Order Via Web or Fax

For Even More Savings!

Extra Discounts!

Special freight allowances when you order 10 or more line items via Web or Fax!**

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

DCA-70USJ — GENERATOR START-UP PROCEDURE (AUTO MODE)

DCA-70USJ ULTRA-SILENT GENRATOR

W/JOHN DEERE 4045TF275 DIESEL ENGINE

1 TO 3 UNITS

Effective: October 1, 2002

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

Related manuals

Table of contents

MQ Power DCA70USJ 25-150 kVA Single/Three Phase Ultra-Silent Operation Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

ULTRA-SILENT

SERIES

GENERATOR

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

To find the latest revision of this publication, visit our website at: www.mqpower.com

UL TRA-SILENT GENERA TOR

COMPONENT DRA WINGS

When ordering parts, please supply the following information:

Here’s how to get help...

Place Your Parts Order Via Web or Fax

For Even More Savings!

Extra Discounts!

Special freight allowances when you order 10 or more line items via Web or Fax!**

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

DCA-70USJ — GENERATOR START-UP PROCEDURE (AUTO MODE)

DCA-70USJ ULTRA-SILENT GENRATOR

W/JOHN DEERE 4045TF275 DIESEL ENGINE

1 TO 3 UNITS

Effective: October 1, 2002

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

Related manuals

MQ Power

DCA70SSJU3

MULTIQUIP

M2870300504

MQ Power

DCA150SSVU

MULTIQUIP

DCA180SSJU WHISPERWATT SERIES

MULTIQUIP

DCA-70SSJU

GA-6RZ2

GA-6RZR2

MQ Power

MQP56

Lionel

Decal Application for Controller - 1994

Steba

OZtrail

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Table of contents