Pre Setup. MQ Power DCA-100SSVU, DCA70USJ, DCA-70USJ

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

PAGE 32 — DCA-70USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/16/04)

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).

CAUTION - REFUELING THE GENERATOR

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.

DCA-70USJ — PRE-SETUP

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

CAUTION - REFUELING THE GENERATOR

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

DCA-70USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/16/04) — PAGE 33

DCA-70USJ — PRE-SETUP

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.

WARNING - BURN HAZARDS

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%.

PAGE 34 — DCA-70USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/16/04)

DCA-70USJ — PRE-SETUP

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

DCA-70USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/16/04) — PAGE 35